Model 6210 Maintenance Manual

Section 5.Troubleshooting

Symptom Tables: Travel Sy stem (Forward/Reverse)

Slow or no travel (Code C43, Traction Amplifier thermal cutback)

Possible Cause Action

Battery problems

Binding load wheel(s)

Bad drive wheel assembly

Binding brake disc

Binding traction motor

Verify a correct, fully-charged good battery (24V) is installed in the truck.

Make sure the load wheels rotate freely. If not, repair or replace. See page7-88

Jack and block the truck. See page2-8. Place the Main ON/OFF Switch in the ON position. Pull the control arm down to release the brake. Check the drive wheel to see if it spins freely. If not, repair or replace. See page7-28 .

Jack and block the truck. See page2-8. Place the Main ON/OFF Switch in the ON position. Pull the control arm down to release the brake. Check the brake disc to see if it spins freely. If not, adjust, repair, or replace. See page7-31.

Jack and block the truck. See page2-8. Place the Main ON/OFF Switch in the ON position. Pull the control arm down to release the brake. Check the brake disc to see if it spins freely. Turn the Main ON/OFF Switch OFF. Remove the brake disc and check the armature shaft. Remove the motor and repair or replace the drive unit or traction motor. See page7-22 or page7-62

Bad drive motor (may test ok with no load, but fail under load)

Truck overloaded or operating in extreme conditions

Bad traction amplifier

Repair or replace the traction motor. See page7-62

Operate and load the truck within specifications.

Check the mounting of the traction amplifier. Check to make sure the traction amplifier is secure and in contact with the truck frame (acts as a heatsink). If the traction amplifier is mounted correctly, replace the traction amplifier.

Bad wire or connector

Jack and block the truck. See page2-8. With the Main ON/OFF Switch ON and the battery connected, while attempting to travel, measure the voltage between B– and the traction amplifier TA B+, TA B–, and J1-1. If not 24V, repair or replace the wiring.

No travel (Code C42, Battery over-voltage warning)

Possible Cause Action

Battery problem

Verify a correct, fully-charged good battery is installed in the truck. Verify battery charger is not plugged into truck Disconnect the battery charger immediately.

Bad traction amplifier

Verify a correct battery is installed. Replace the traction amplifier.

Publication: 1146947, Revised: 12 Jan 2017 5-13

Section 5.Troubleshooting

Symptom Tables: Travel System (Forward/Reverse)

Truck does not accelerate correctly

Possible Cause Action

Battery problems

Traction amplifier or Vehicle Manager programming not correct

Bad traction motor

Model 6210 Maintenance Manual

Verify a correct, fully-charged good battery (24V) is installed in the truck.

Verify the programming.

With the Main ON/OFF Switch OFF and the battery connector disconnected, check the traction motor (see page7-62 ).

Bad traction amplifier If all possible causes check out, replace the traction amplifier.

Battery problems

Traction amplifier or Vehicle Manager programming not correct

Verify a correct, fully-charged good battery (24V) is installed in the truck.

Verify the programming.

No Travel or Slow Travel. TA Flash Code 2,2, (Thermal Cutback)

Heatsink Temperature Exceeded 185°F (85°C). Operator Display May Indicate Hot2 (C45)

Possible Cause Action

Battery Problem

Binding drive unit or dragging brake

Verify the correct, (24V) fully-charged, battery is installed in truck.

Measure current draw on U, V, and W cables. Traveling at about 1 mph (1.6 km/h) with no load, current should be about 35 to 50 Amps and the same at each cable. If current is high, inspect the brake for dragging and the drive unit for binding. If both are OK, replace traction motor.

Bad TA

Truck does not respond to Keypad inputs

Examine mounting of TA. It must be mounted securely and in contact with the truck frame (that acts as a heatsink). If TA is mounted correctly, replace TA.

Enter Parameter 39 Access code. Use FlashWare and change value to either 3 or 4. Refer to “Programming Service Parameters” on page3-12 .

No Travel, No Lift/Lower. TA Flash Code 3,1. Operator Display

May Indicate Error Code E106

Possible Cause Action

Short in M1 coil or wiring

5-14

With the truck OFF and the battery disconnected, remove connector JP1 from the TA. Measure resistance between JP1-6 and JP1-13. Resistance should be approx. 22 to 24.2 Ohms for standard contactor (76.5 to 93.5 Ohms for cold storage contactor). If not, troubleshoot wires and coil for shorts. If resistance is OK, replace TA.

Publication: 1146947, Revised: 12 Jan 2017

Section 5.Troubleshooting

Symptom Tables: Travel Sy stem (Forward/Reverse)

No Travel, Main Contactor Does Not Close. TA Flash Code 3,9. Operator Display Indicates Error Code E107

Possible Cause Action

Loss of B+ at the TA

Open in M1 coil or wiring

Troubleshoot B+ from the battery to B+ at the TA. Check the wiring, connections, and fuses.

With the truck OFF and the battery disconnected, remove connector JP1 from the TA. Measure resistance between JP1-6 and JP1-13. Resistance should be approx. 22 to 24.2 Ohms for standard contactor (76.5 to 93.5 Ohms for cold storage contactor). If not, troubleshoot wires and coil for opens. If resistance is OK, replace TA.

No Travel, No Lift/Lower. TA Flash Code 1,2. Operator Display Indicates Error Code E201

Possible Cause Action

Bad wiring between TA and traction motor

Bad TA

With the truck OFF and the battery disconnected, disconnect cables W, V, and U from TA and traction motor. Measure for continuity and shorts between cables and to truck frame.

With the truck OFF and the battery disconnected, disconnect motor cables at TA. Reconnect the battery and turn the truck ON. If code is still displayed, replace the TA. If code goes away, replace the traction motor.

No Travel, No Lift/Lower. TA Flash Code 1,3. Operator Display Indicates Error Code E202

Possible Cause Action

Bad wiring between TA and traction motor

Bad TA

With the truck OFF and the battery disconnected, disconnect cables W, V, and U from TA and traction motor. Check for continuity and shorts between cables and truck frame.

With the truck OFF and the battery disconnected, disconnect the cables at the TA. Reconnect the battery and turn the truck ON. If code 1,3 is still displayed, replace the TA. If code 1,3 is not displayed, replace the traction motor.

No Truck Functions Active. TA Flash Code 1,7, (Low Battery Voltage). Operator Display May Indicate E221

Possible Cause Action

Battery Problem

Verify the correct, (24V) fully-charged, battery is installed in truck. Bad traction amplifier Verify battery voltage at key switch input. Measure voltage at JP1-1 wire with JP1 disconnected. If 24V, replace TA.

Publication: 1146947, Revised: 12 Jan 2017 5-15

Section 5.Troubleshooting

Symptom Tables: Travel System (Forward/Reverse)

Model 6210 Maintenance Manual

No Truck Functions Active. TA Flas h Code 1,8, (Excessive Battery Voltage). Operator Display May Indicate E222

Possible Cause Action

Battery Problem Verify the correct, (24V) fully-charged, battery is installed in truck.

Bad traction amplifier Verify battery voltage at key switch input. Measure voltage at JP1-1 wire with JP1 disconnected. If 24V, replace TA.

5-16

Publication: 1146947, Revised: 12 Jan 2017