SECTION 9030

ELECTRICAL SYSTEM

TABLE OF CONTENTS

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

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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

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Section 9030 Electrical System

TABLE OF CONTENTS (Continued)

Display Internal Failure:
DTC 22032 - Display EEPROM Checksum Error
DTC 22033 - Display Cell Write Error
DTC 33056 - Display Internal CAN Failure
DTC 33057 - Display Communications Error with VSM
DTC 8704 - Display Internal LCD Backlight
DTC 12934 - Display Internal LCD Backlight
DTC 12935 - Display Internal LCD Backlight
DTC 8705 - Display Internal LCD Heater
DTC 12936 - Display Internal LCD Heater
DTC 12937 - Display Internal LCD Heater
DTC 22528 - Display Button *
DTC 22529 - Display Button #
DTC 22530 - Display \ Arrow
DTC 22531 - Display ] Arrow
DTC 22532 - Display Button 1
DTC 22533 - Display Button 2
DTC 22534 - Display Button 3
DTC 22535 - Display Button 4
DTC 22536 - Display Button 5
DTC 22537 - Display Button 6
DTC 22538 - Display Button 7
DTC 22539 - Display Button 8
DTC 22540 - Display Button 9
DTC 22541 - Display Button 0......................................................................................................... 9030-20-178
Display Failure – Keyswitch Relay Output:
DTC 9041 - Display Keyswitch Output
DTC 12940 - Display Keyswitch Output
DTC 12941 - Display Keyswitch Output .......................................................................................... 9030-20-184
VSM Controller Check:
DTC 21760 - VSM BOOT_BLOCK
Checksum failure
DTC 21761 - CDF_Checksum_failure
DTC 21762 - VSM APPLICATION_SOFTWARE Checksum failure/Error
DTC 21764 - VSM EEPROM Checksum
failure/Error
DTC 21766 - VSM EEPROM Cell failure
Write Error
DTC 21792 - VSM Serial Number Error.......................................................................................... 9030-20-196
Display Failure – Temperature/Buzzer:
DTC 12928 - Display Temperature Sensor (Freezer Option Only)
DTC 12929 - Display Temperature Sensor (Freezer Option Only)
DTC 9040 - Display Buzzer Output
DTC 12938 - Display Buzzer Output
DTC 12939 - Display Buzzer Output ............................................................................................... 9030-20-202

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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

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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