43Service Manual – SC5000 04 - Control System
1-003 K1 KSI Contact Weld
Description
The controller has detected that the KSI relay output power is active after the
controller has de-energized the relay coil.
Setting
Conditions
Power is detected at contacts J1-12 and J1-13 when the KSI
relay is not commanded to be energized.
When Monitored
Always
Possible Causes
• Fused relay contacts.
• Short to B+ in relay output
• Short to B- in relay coil control.
Initial Action None
Troubleshooting Steps
1. Disconnect the spade lugs from the relay coil, and check if the
error persists.
− If the error clears, the relay is functioning correctly. Proceed to
step 2 to isolate the cause as either a short or control board
failure.
− If the error persists, proceed to step 3 to isolate the cause as
either a short or relay contact weld.
2. Isolate the cause between control wire short to ground, or main
control board.
a. Shut down the machine, and disconnect the main battery
disconnect.
b. Disconnect the J1 connector from the main control board.
c. Disconnect the spade lugs from the KSI relay coil.
d. Check for continuity between J1-15 (or Org/Brn at the relay) and the main grounding terminal in the
electrical bay.
– If the resistance is at or near zero ohms (continuity), repair or replace the Org/Brn wire between
the relay and the main controller.
– If the resistance is not near zero (no continuity), make one more conrmation check of the
controller. Continue to next step.
e. Leave the KSI realy coil terminals disconnected, but reconnect the J1 connector to the main control
board, and re-connect the battery disconnect.
f. Re-power the machine, verify that the KSI relay is NOT commanded to be on, and verify that the
error persists.
g. Check the voltage between J1-16 and J1-15 at the main control board.
– If the voltage is at or near 36 volts, replace the main control board.
3. Isolate the cause between a short to power or the relay contacts welded.
a. With the error still being reported, disconnect the output terminal from contact 4 of the KSI relay.
– If the error clears, replace the KSI relay.
– If the error persists, trace the gray wire emanating from the KSI relay, to repair a short to battery
positive.
0
1
Org/Brn
Yel/Brn
4
2
Org
Gry
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