Model 6210 Maintenance Manual Symptom Tables: Wiring System

Section 5.Troubleshooting

Symptom Tables: Wiring System

Truck functions partially, some functions do work when commanded

Possible Cause

Action

Bad wiring in control arm handleWith the Main ON/OFF Switch OFF and the battery connector disconnected, visually inspect the wiring in the handle where the wiring leaves the handle and over the brake. Repair or replace.

Bad wiring in hydraulic control areaWith the Main ON/OFF Switch OFF and the battery connector disconnected, visually inspect the wiring. Repair or replace.

Publication: 1146947, Revised: 12 Jan 2017

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Section 5.Troubleshooting

Symptom Tables: Electrical Problems

Symptom Tables: Electrical Problems

Model 6210 Maintenance Manual

Green and red LEDs on keypad do not light when a button on the keypad is pushed (keypad option only)

Possible Cause Action

Open circuit of wires that power the Vehicle Manager

Bad connectors

F50 Open

Check the control wires, especially wires 1, 20, and 22 (red in the control arm control arm cable) and 40 (black in the control arm cable).

Repair and replace bad connectors (check connector J11 at the control arm base, connector into the Vehicle Manager, and connector J5 to the traction amplifier).

Make sure the control fuse has not tripped.

Key switch jumper not connectedConnect the key switch jumper.

Keypad not connected

Check the connector and ribbon cable between the keypad and the vehicle manager card.

Horn does not sound when horn button is pushed

Possible Cause Action

Bad horn button/wiring in handle head

Bad traction amplifier

Bad horn

Repair/replace as necessary. See page7-50

Check and replace if necessary.

Replace the horn. See page7-50

Battery discharge indicator (BDI) will not reset to 100%

Possible Cause Action

Incorrect contactor wiring

Improperly charged battery or bad battery

Poor wiring connections or bad Vehicle Manager card

Verify that the wire from FU3 goes to MPC-1, same connection as the battery B+ connector, and that the main power fuses FU1 and FU2 are on the same node as MPC-2.

Measure the battery voltage static and traveling. Battery voltage must be at 25.2 volts for 20 seconds while traveling to reset the BDI. If the voltage is low or drops while traveling, verify the battery connections are clean and tight. Equalize charge the battery and retest. If still dropping low, have the battery serviced.

Check the battery voltage using the Service Display. If the voltage is lower than the battery voltage, test the positive wire at J11-1 and the negative wire at J11-3 of the Vehicle Manager for poor connections between the battery and the connector.

Publication: 1146947, Revised: 12 Jan 2017