How to Use This Chapter

This chapter contains a set of general troubleshooting guidelines, a troubleshooting task flow, and a set of troubleshooting tables for symptoms not accompanied by a fault code.

Use the START TROUBLESHOOTING Chart TS-1 on page 5 - 27 to guide you to the individual symptom chart you need.

Use the Symptom Tables to identify possible causes of problems that are not accompanied by a fault code on the Operator Display.

As you work with a troubleshooting symptom chart, you may be instructed to test various electrical connector pins. Use the Electrical Connector Locator Chart on Page 5 -18.

Every time you complete a troubleshooting procedure, be sure to follow the steps in End of Troubleshooting Chart END1 on Page 5 - 28.

Another troubleshooting resource is the Pinout Matrix on Page 9 - 51 in the Theory of Operation chapter. The pinout matrix chart lists functions and normal voltages of terminals and harness connector pins.

If the troubleshooting symptom charts do not isolate the problem, or if the symptoms are not consistent or repeatable, go to the General Troubleshooting Chart GENl on Page 5 - 28. This chart will help you approach the problem in a systematic and logical manner.

Electrical Troubleshooting Guidelines

Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. See "Battery Exterior Cleaning" on page 7-33. Check the electrolyte level and state of charge.

Jack and block the lift truck whenever a troubleshooting procedure requires turning key switch S1 ON. This prevents accidents caused by unexpected lift truck travel. Opening the Emergency Lowering Valve will prevent unexpected lihing.

Acaution

Unless otherwise directed, disconnect the ba~eryconnector when you check electrical circuits or components with an ohmmeter. Electrical current can damage the ohmmeter. Discharge residual charge in the motor controller by pressing PC and PCP contactors closed simultaneously.

Save time and trouble by looking for simple causes first.

For information on electrical connector location and function, see "Electrical Connector Locator Chart" on page 5- 18.