Test A100-BSM Comm

Communication level indicator between the iBattery™ Auxiliary Processing Module (APM) and Battery Sensor Module (BSM). This is represented with 0 to 4 bars: 4 bars indicates excellent communication, 0 bars indicates no communication.

Publication: 1089040, Issued: 08 Apr 2016

Input Tests

A Diagnosis and Repair table is provided for most tests. If a test fails, refer to the Diagnosis and Repair table.

Through the process of elimination, these tables provide a step-by-step approach to diagnose a problem and provide the necessary corrective action. See the example below.

Example Diagnosis and Repair Table

Do the testing in this order.

This column identifies any actions required before testing the circuit, such as disconnecting certain connectors. If no instructions are given, all circuits should be connected. Note: If something was disconnected in the prior step, reconnect it before performing the next step.

This column also identifies the required setting on the meter for this step.

Probe point for the positive (+) meter lead.

Probe point for the negative (–) meter lead.

Publication: 1089040, Issued: 08 Apr 2016

The reading required to consider the step a success.

The next action to perform if the Expected Results are met.

The next action to perform if the Expected Results are not met.

Section 6.Electrical Tests

Model 9600/9700 Swing-Reach ® Lift Truck Input TestsTestI00–Dman S23 [Carriage Deadman Switch (S23)]

TestI00–Dman S23 [Carriage Deadman Switch (S23)]

The status of the Carriage Deadman Switch (S23), as seen by the CM, is displayed.

The input is good if these values are displayed:

If these values are not displayed, refer to Diagnosis and Repair.

Diagnosis and Repair

Publication: 1089040, Issued: 08 Apr 2016

Model 9600/9700 Swing-Reach ® Lift Truck

Section 6.Electrical Tests

TestI02–Lift S11 [Lift Reference Prox (S11)] Input Tests

TestI02–Lift S11 [Lift Reference Prox (S11)]

The status of the Lift Reference Prox (S11), as seen by the TM, is displayed.

The display should indicate S11 is below (Belw) when near the mast crosstie and above (Abve) when the telescopic is raised above the switch.

Verify clearance between the switch and telescopic is 0.19 ±0.06 in. (4.8 ±1.5 mm).

The input is good if these values are displayed:

If these values are not displayed, refer to Diagnosis and Repair.

Diagnosis and Repair

Publication: 1089040, Issued: 08 Apr 2016 6-79

Section 6.Electrical Tests

Model 9600/9700 Swing-Reach ® Lift Truck Input TestsTestI04–Bypass S7 [Lift/Lower Inhibit Bypass Switch (S7)]

TestI04–Bypass S7 [Lift/Lower Inhibit Bypass Switch (S7)]

The status of the Lift/Lower Inhibit Bypass Switch (S7), as seen by the CM, is displayed.

The input is good if these values are displayed:

If these values are not displayed, refer to Diagnosis and Repair.

Diagnosis and Repair

Model 9600/9700 Swing-Reach ® Lift Truck

Section 6.Electrical Tests

TestI14–FU1 Sense Input Tests

TestI14–FU1 Sense

The absence or presence of B+ to the load side of the STR contactor is displayed.

The input is good if these values are displayed:

*Allow approx. 7 minutes for voltage to drop below 4V after STR contactor opens.

If these values are not displayed, refer to Diagnosis and Repair.

Code 4B - If >4V is displayed with the contactor open, check for shorts to frame. Remove the sense wire from JPT22-19. If the voltage goes away, locate the cause of the short. If the voltage remains >4V with the sense lead disconnected, replace the TM.

Code 4C - Check FU1 and the STR contactor tips.

Diagnosis and Repair

Publication: 1089040, Issued: 08 Apr 2016

TestI15–Horn S3 [Horn Switch (S3)]

The status of the Horn Switch (S3), as seen by the CM, is displayed.

The input is good if these values are displayed:

If these values are not displayed, refer to Diagnosis and Repair.

Diagnosis and Repair

Publication: 1089040, Issued: 08 Apr 2016

Model 9600/9700 Swing-Reach ® Lift Truck

Section 6.Electrical Tests

TestI19–Trac RPM [Traction Motor RPM] Input Tests

TestI19–Trac RPM [Traction Motor RPM]

The output from the Traction Motor Encoder (TME), as seen by the TPA, is displayed.

The Display shows rpm as measured by the TPA. The rpm reading should show a linear increase to maximum rpm.

If these values are not displayed, refer to Diagnosis and Repair.

Diagnosis and Repair

3 T/S harness 3JPTA2-4Perform step 4

4JPTA1-31

5 JPTA1-32

JPTA1-7 Stationary: >3.5V or <0.5V Running: approx. 2V Replace TPA T/S wiring. If OK, replace TME

Publication: 1089040, Issued: 08 Apr 2016 6-83

Section 6.Electrical Tests

TestI20–Lift RPM [Lift Motor RPM]

The output from the Lift Motor Encoder (LME), as seen by the LPA, is displayed.

The Display shows rpm as measured by the LPA. The rpm reading should show a linear increase to maximum rpm.

If these values are not displayed, refer to Diagnosis and Repair.

Diagnosis and Repair

4JPLA1-32

Stationary: >3.5V or <0.5V Running: approx. 2V step 5T/S wire connections. If OK, replace LME

Publication: 1089040, Issued: 08 Apr 2016

Model 9600/9700 Swing-Reach ® Lift Truck Input TestsTestI20–Lift RPM [Lift Motor RPM] 6-84