Group 03 - General Maintenance and Diagnostic Data
Troubleshooting Guidelines and Procedures......................................................................................... 9030-03-1 Troubleshooting Guidelines ................................................................................................................. 9030-03-1 Troubleshooting Procedures ............................................................................................................... 9030-03-4 Troubleshooting Procedures, Identification ....................................................................................... 9030-03-4 Troubleshooting Procedures, Location.............................................................................................. 9030-03-4 Troubleshooting Procedures, Structure............................................................................................. 9030-03-4 Troubleshooting Procedures, Performance ....................................................................................... 9030-03-5 Troubleshooting Procedures, Final.................................................................................................... 9030-03-5 Diagnostic Trouble Codes ..................................................................................................................... 9030-03-6 Diagnostic Trouble Code (DTC) Chart............................................................................................. 9030-03-6 Wiring Reference Data ........................................................................................................................ 9030-03-10 Harness Assembly Data...................................................................................................................... 9030-03-13 Group 10 - Principles of Operation Electrical System................................................................................................................................... 9030-10-1 General Description ............................................................................................................................ 9030-10-1 Battery............................................................................................................................................... 9030-10-6 Power Distribution Module (PDM) ..................................................................................................... 9030-10-6 Contactor ........................................................................................................................................ 9030-10-6 Fuses .............................................................................................................................................. 9030-10-6 Relays ............................................................................................................................................. 9030-10-6 Wire Harnesses .............................................................................................................................. 9030-10-7 Operator Interface ............................................................................................................................. 9030-10-7 Display ............................................................................................................................................ 9030-10-7 Controllers......................................................................................................................................... 9030-10-7 Vehicle System Manager (VSM) ..................................................................................................... 9030-10-7 Motor Controllers ............................................................................................................................ 9030-10-8 E-Hydraulics Mini Levers Module (MLM) ........................................................................................ 9030-10-9 System Controlled Outputs ............................................................................................................. 9030-10-10 Valve Coils .................................................................................................................................... 9030-10-10 Lights and Backup Alarm .............................................................................................................. 9030-10-11 Cab options................................................................................................................................... 9030-10-11 PRINCIPLES OF OPERATION, COMPONENTS ............................................................................. 9030-10-12 Power Distribution ........................................................................................................................... 9030-10-12 Contactor ...................................................................................................................................... 9030-10-12 Positive Temperature Coefficient (PTC)........................................................................................ 9030-10-12 Fuses ............................................................................................................................................ 9030-10-12 Relays ........................................................................................................................................... 9030-10-13 Operator Interface ........................................................................................................................... 9030-10-14 Display .......................................................................................................................................... 9030-10-14 Controllers....................................................................................................................................... 9030-10-15 Vehicle System Manager (VSM): .................................................................................................. 9030-10-15 Motor Controller ............................................................................................................................ 9030-10-17 E-Hydraulics Mini Levers Module (MLM) ...................................................................................... 9030-10-18 PRINCIPLES OF OPERATION, SYSTEM ........................................................................................ 9030-10-19
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Section 9030 Electrical System
TABLE OF CONTENTS (Continued)
Battery (Plug-In).............................................................................................................................. 9030-10-19 Key ON and Operation .................................................................................................................... 9030-10-19 Sensors........................................................................................................................................... 9030-10-19 Switches.......................................................................................................................................... 9030-10-23 Outputs ........................................................................................................................................... 9030-10-23 Relays ........................................................................................................................................... 9030-10-23 Hydraulic Valve ............................................................................................................................. 9030-10-23 Cab Devices.................................................................................................................................. 9030-10-25 Lights and Backup Alarm .............................................................................................................. 9030-10-25 Group 20 - Diagnostic Trouble Codes Load Weigh/Service Brake Pressure Sensor Out of Range Low (OORL): DTC 12844 - Load Weigh Pressure DTC 12836 - Service Brake Pressure................................................................................................. 9030-20-1 Load Weigh/Service Brake Pressure Sensor Out of Range High (OORH): DTC 12845 - Load Weigh Pressure DTC 12837 - Service Brake Pressure................................................................................................. 9030-20-6 Accelerator Pedal Position A/B Out of Range Low (OORL): DTC 12808 - Accelerator Pedal Position A DTC 12810 - Accelerator Pedal Position B ....................................................................................... 9030-20-11 Accelerator Pedal Position A/B Out of Range High (OORH): DTC 12809 - Accelerator Pedal Position A DTC 12811 - Accelerator Pedal Position B .......................................................................................................................................... 9030-20-15 Accelerator Pedal Position A/B Data Incorrect: DTC 12812 - Accelerator Pedal Position A to B ................................................................................ 9030-20-20 Steering Wheel/Steering Axle Position Sensor Out of Range Low (OORL): DTC 12820 - Steering Wheel Position DTC 12824 - Steering Axle Position.................................................................................................. 9030-20-26 Steering Wheel/Steering Axle Position Sensor Out of Range High (OORH): DTC 12821 - Steering Wheel Position DTC 12825 - Steering Axle Position.................................................................................................. 9030-20-30 Steer Axle Calibration Required: DTC 4098 - Steer Axle Calibration .................................................................................................... 9030-20-35 Hydraulic Temperature Sensor Out of Range High (OORL) : DTC 12852 - Hydraulic Temperature................................................................................................. 9030-20-39 Hydraulic Temperature Sensor Out of Range High (OORH) : DTC 12853 - Hydraulic Temperature................................................................................................. 9030-20-43 Hydraulic Fluid Level Sensor Out Of Range Low (OORL): DTC 12872 - Hydraulic Fluid Level ................................................................................................... 9030-20-48 Hydraulic Fluid Level Sensor Out Of Range High (OORH): DTC 12873 - Hydraulic Fluid Level ................................................................................................... 9030-20-53 Park Brake/Mast Tilt Position Sensor Out of Range Low (OORL): DTC 12832 - Park Brake Position DTC 12840 - Mast Tilt Position ......................................................................................................... 9030-20-57 Park Brake/Mast Tilt Position Sensor Out of Range High (OORH): DTC 12831 - Park Brake Position DTC 12841 - Mast Tilt Position ......................................................................................................... 9030-20-61 Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range Low (OORL): DTC 12800 - Directional Select A DTC 12804 - Directional Select B ..................................................................................................... 9030-20-66
9030-2 Confidential/Proprietary - Do Not Copy or Duplicate
Section 9030 Electrical System
TABLE OF CONTENTS (Continued)
Travel Direction Select - Foot Pedal/Manual Hydraulic Out of Range High (OORH): DTC 12801 - Directional Select A DTC 12805 - Directional Select B ..................................................................................................... 9030-20-70 Seat Sensor Out of Range Low (OORL): DTC 12816 - Seat Sensor................................................................................................................. 9030-20-75 Seat Sensor Out of Range High (OORH): DTC 12819 - Seat Sensor................................................................................................................. 9030-20-79 Battery OORH/OORL: DTC 12545 - Battery OORH DTC 12546 - Battery OORL .............................................................................................................. 9030-20-83 VSM 5 Volt Supply (OORL) (OORH): DTC 13056 - 5V OORL DTC 13057 - 5V OORH .................................................................................................................... 9030-20-90 Manual Hydraulic Position Sensors Out Of Range Low (OORL): DTC 12856 - Manual Hyd 1 DTC 12860 - Manual Hyd 2 DTC 12864 - Manual Hyd 3 DTC 12868 - Manual Hyd 4 .............................................................................................................. 9030-20-97 Manual Hydraulic Position Sensor Out Of Range High (OORH): DTC 12857 - Manual Hyd 1 DTC 12861 - Manual Hyd 2 DTC 12865 - Manual Hyd 3 DTC 12869 - Manual Hyd 4 ............................................................................................................ 9030-20-101 E-Hydraulic Enable System Data Incorrect: DTC 12332 - Data Incorrect ............................................................................................................ 9030-20-106 E-Hydraulic Coils Short To Battery Positive (STBP): DTC 8960 - Lift DTC 8964 - Lower DTC 8968 - Tilt Forward DTC 8972 - Tilt Back DTC 8978 - Aux 1A DTC 8980 - Aux 1B DTC 8984 - Aux 2A DTC 8988 - Aux 2B ......................................................................................................................... 9030-20-111 E-Hydraulic Coils Short To Battery Negative (STBN)/Open Circuit (OC): DTC 13312 - Lift DTC 13316 - Lower DTC 13320 - Tilt Forward DTC 13324 - Tilt Back DTC 13328 - Aux 1A DTC 13332 - Aux 1B DTC 13336 - Aux 2A DTC 13340 - Aux 2B ....................................................................................................................... 9030-20-116
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Section 9030 Electrical System
TABLE OF CONTENTS (Continued)
A935 – K160 CAN Communication Failure: DTC 33025 - VSM to Display DTC 33026 - VSM to Traction 1 (Right) DTC 33027 - VSM to Traction 2 (Left) DTC 33029 - VSM to Pump DTC 33034 - VSM to MLM (DCS) DTC 33035 - VSM to Impact DTC 33036 - VSM to CAN Reserved 1 DTC 33037 - VSM to CAN Reserved 2 DTC 33038 - VSM to CAN Reserved 3 DTC 33057 - Display to VSM .......................................................................................................... 9030-20-121 CBB 4 Wheel CAN Communication: DTC 33025 - VSM to Display DTC 33026 - VSM to Traction 1 (Right) DTC 33027 - VSM to Traction 2 (Left) DTC 33029 - VSM to Pump DTC 33034 - VSM to MLM (DCS) DTC 33035 - VSM to Impact DTC 33036 - VSM to CAN Reserved 1 DTC 33037 - VSM to CAN Reserved 2 DTC 33038 - VSM to CAN Reserved 3 DTC 33057 - Display to VSM .......................................................................................................... 9030-20-133 DBB 4 Wheel CAN Communication: DTC 33025 - VSM to Display DTC 33026 - VSM to Traction 1 (Right) DTC 33027 - VSM to Traction 2 (Left) DTC 33029 - VSM to Pump DTC 33034 - VSM to MLM (DCS) DTC 33035 - VSM to Impact DTC 33036 - VSM to CAN Reserved 1 DTC 33037 - VSM to CAN Reserved 2 DTC 33038 - VSM to CAN Reserved 3 DTC 33057 - Display to VSM .......................................................................................................... 9030-20-148 MLM Failure: DTC 21830 - MLM EEPROM Write Error DTC 21834 - MLM Sensor 1 Out of Range DTC 21835 - MLM Sensor 2 Out of Range DTC 21836 - MLM Sensor 3 Out of Range DTC 21837 - MLM Sensor 4 Out of Range DTC 25344 - MLM Checksum Error................................................................................................ 9030-20-160 MLM Incorrect Lever Installed: DTC 4112 - Incorrect Lever 1 Installed DTC 4113 - Incorrect Lever 2 Installed DTC 4114 - Incorrect Lever 3 Installed DTC 4115 - Incorrect Lever 4 Installed DTC 4116 - Incorrect Lever 5 Installed ........................................................................................... 9030-20-166 VSM 12 Volts Supply OORL/OORH: DTC 13060 - VSM 12V OORL DTC 13061 - VSM 12V OORH........................................................................................................ 9030-20-169
9030-4 Confidential/Proprietary - Do Not Copy or Duplicate
Confidential/Proprietary - Do Not Copy or Duplicate 9030-5
Section 9030 Electrical System
TABLE OF CONTENTS (Continued)
Contactor/Relay/Valve Coil Short to Battery Positive (STBP): DTC 9000 - Diverter Valve DTC 9004 - E Hyd Enable DTC 9008 - Clamp Solenoid (Optional) DTC 9012 - Acc 2 Relay DTC 9016 - Forward Relay DTC 9020 - Reverse Relay DTC 9026 - Spare 1 Relay DTC 9028 - Spare 2 Relay DTC 9032 - Main Contactor DTC 9036 - 2nd Contactor .............................................................................................................. 9030-20-208 Contactor/Relay/Valve Coil Short to Battery Negative (STBN)/Open Circuit (OC): DTC 13352 - Diverter Valve DTC 13356 - E Hyd Enable DTC 13360 - Acc 1 Relay DTC 13364 - Acc 2 Relay DTC 13368 - Motion Relay DTC 13372 - Reverse Relay DTC 13376 - Spare 1 Relay DTC 13380 - Spare 2 Relay DTC 13384 - Main Contactor DTC 13388 - 2nd Contactor ............................................................................................................ 9030-20-213 A935 – K160 Motor Controller Contactor Failure: DTC 21569 - Contactor Open DTC 21570 - Contactor Closed....................................................................................................... 9030-20-219 A935 – K160 Motor Controller Capacitor Failure: DTC 12592 - Capacitor Charge ...................................................................................................... 9030-20-230 A935 – K160 Motor Speed Sensor Failure: DTC 29456 - Sensor Fault .............................................................................................................. 9030-20-237 CBB/DBB Motor Speed Sensor Failure: DTC 25104 - Sensor Fault DTC 29456 - Sensor Fault .............................................................................................................. 9030-20-248 A935 – K160 Motor Auto Brake Failure: DTC 8786 - Brake Coil Shorted DTC 12834 - Aux Driver Short to Bat (-) Brake Coil Open Circuit DTC 12835 - Aux Driver Open Circuit Excess Current ................................................................... 9030-20-260 A935 – K160 Motor Controller Power Mosfet Failure : DTC 65513 - Power MOS Shorted.................................................................................................. 9030-20-269 A935 – K160 Motor/Motor Controller Failure: DTC 12576 - Motor Voltage Not OK................................................................................................ 9030-20-277 A935 – K160 Motor Controller Failure: DTC 65280 - Controller Failure ....................................................................................................... 9030-20-287 CBB/DBB Motor/Motor Controller Failure: DTC 8976 - AC Current – Over Current DTC 9024 - AC Current – Short Circuit........................................................................................... 9030-20-294 A935 – K160 Motor Controller CAN Communication Failure: DTC 65527 - No CAN Communication ........................................................................................... 9030-20-305 CBB/DBB Motor Controller CAN Communication Failure: DTC 33024 - CAN Communication Failure ..................................................................................... 9030-20-313
9030-6 Confidential/Proprietary - Do Not Copy or Duplicate
Section 9030 Electrical System
TABLE OF CONTENTS (Continued)
Travel Direction Select Incorrect: DTC 12802 - Direction Select Data Incorrect – Direction Signals Incorrect .............................................................................................................. 9030-20-322 Travel Direction Select Data Incorrect – 2 Sources: DTC 12806 - Direction Select – Data Incorrect 2 + Direction Devices Installed........................................................................................................ 9030-20-329 Direction Select Data Incorrect - No DCS Source: DTC 12807 - Direction Select Data Incorrect - No DCS Source ..................................................... 9030-20-333 CBB/DBB Motor/Motor Controller Temperature Sensor Failure: DTC 16912 - Motor Temperature High DTC 17168 - Controller/Heatsink Temperature High DTC 25105 - Temperature Sensor Failure ...................................................................................... 9030-20-341 CBB/DBB Motor Controller Current Sensor Failure : DTC 21008 - Current Sensor Offset Calibration Error .................................................................... 9030-20-354 Hydraulic Calibration Required: DTC 4096 - Hydraulic Calibration Required .................................................................................... 9030-20-360 CBB/DBB Motor Controller 15 – 5 Volt Internal Failure: DTC 20753 - 15 Volt Supply Low Voltage DTC 20755 - 5 Volt Supply Low/High Voltage................................................................................. 9030-20-365 CBB/DBB Motor Controller DC Bus Low/High: DTC 12576 - DC Bus Charging Timeout DTC 12817 - DC Bus Hi – Software Detected DTC 12818 - DC Bus Hi – Hardware Detected DTC 12833 - DC Bus Low – Hardware/Software ............................................................................ 9030-20-371 CBB/DBB Motor Aux Driver Failure: DTC 21520 - Aux Driver Current High............................................................................................. 9030-20-388 Group 30 - Observed Symptoms No Display/No Truck Operation: DTC None - No Display/No Truck Operation....................................................................................... 9030-30-1 A935 – K160 Motor Controller Fan Failure: DTC None - A935 – K160 Motor Controller Fan Failure...................................................................... 9030-30-9 A935 – K160 Motor/Motor Controller Temperature Sensor Failure: DTC None - A935 – K160 Motor/Motor Controller Temperature Sensor Failure ............................... 9030-30-22 Horn Failure......................................................................................................................................... 9030-30-33 Group 55 - Icons and Graphics Icon Glossary ........................................................................................................................................ 9030-55-1 Introduction to Icons............................................................................................................................ 9030-55-1
Confidential/Proprietary - Do Not Copy or Duplicate 9030-7