Electrical System Troubleshooting
PS S5.4 5460
F-code Section C-code
Version no T-code
001 OE35
199
Service Manual 1996-10-15
© BT Products
Electrical Syste
Troubleshooting
Troubleshooting can be broken down into Control Circuits
and Power Circuits. By knowing the exact symptoms of the
truck operation, many hours of troubleshooting time can be
saved. If the proper contactor operates for the chosen
direction and speed then the problem can be found in the
Power Circuits troubleshooting procedures. If a particular
contactor does not operate when a function is chosen then
the problem can be found in the Control Circuits
troubleshooting procedures.
To use this troubleshooting guide go to the appropriate
section, and locate the symptom that best describes the truck
operation. Follow the instructions for the tests that are
outlined. All tests, unless otherwise specified, instruct the
technician to test for battery voltage at a particular point. If the
proper voltage is present, continue with the next point in the
testing procedure. If the voltage is not present, or if the
voltage is too low, perform the repairs listed directly below the
test procedure.
Voltage tests are made with the negative lead of the volt
meter connected to battery negative. If the negative lead is
connected to a negative terminal on the electrical panel you
must verify the negative connection to the battery by touching
the positive meter lead to the positive battery post. The
battery voltage must be at least 25.2 volts for a 24 volt
system, 37.8 for a 36 volt system. If the battery voltage is
below 22 volts (24 volt system) and 33 volts (36 volt system)
(with no load) then the controller may not operate properly.
You will then have to charge the battery before starting the
troubleshooting procedure.
When testing voltage the “positive side” of any component
refers to the terminal on that component that is closest
electrically to the to the battery positive terminal. The
“negative side” of any component refers to the terminal on
that component that is farthest electrically from the battery. It
is possible, and in many cases desirable, to measure battery
voltage on the negative side of a component.
“Forward” direction refers to travel with forks trailing.
“Reverse” direction refers to travel in the fork direction.
To Next Page
Loading...
