Section 5. Troubleshooting Model 8210/8250 Maintenance Manual
Symptom Table: Electrical System
5-16 Publication: 1146945/001, Revised: 25 Sep 2018
Symptom Table: Electrical System
NOTE: Reference electrical schematics.
BDI Does Not Reset to 100% (Lead Acid Battery Only)
Horn Does Not Sound When Horn Button Pushed. No Fault Codes.
Possible Cause Action
Truck not configured correctly Verify the truck is configured for the type of battery installed. Verify
parameter 21 setting.
Incorrect wiring Verify that the wire from the battery connector is attached to the right
terminal of the Main Contactor (MPC), that the Traction System Fuse
(FU1) cable connects to the left MPC terminal, and the Lift Motor Fuse
(FU2) connect the left MPC terminal to the right LPC terminal, and that
the wire from the right terminal of the Traction System Fuse (FU1) is
attached to the Traction Amplifier at the B+ terminal.
Low static voltage If the voltage is below 25.2 volts after a charging cycle, charge the battery
pack 5 times consecutively.
NOTE: The voltage must be at or above 25.2 volts for the truck to reset and stay at 100%. Parameter
settings can also be a factor here. Verify parameter 24 (battery reset voltage) is set higher than 75%.
Low voltage during travel Make sure that the voltage is above 25.2 volts at key ON.
Main contactor wired incorrectly Verify that the wire from the battery connector is attached to the right
terminal of the Main Contactor (MPC), that the Traction System Fuse
(FU1) cable connects to the left MPC terminal, and the Lift Motor Fuse
(FU2) connect the left MPC terminal to the right LPC terminal, and that
the wire from the right terminal of the Traction System Fuse (FU1) is
attached to the Traction Amplifier at the B+ terminal,
Low voltage at key ON If voltage is below 25.2 volts at key ON after charging the battery,
troubleshoot the battery and charger.
Poor wiring connection or bad
VM
1. Check the battery voltage displayed on the VM using the “Service
Display” on page 3-17.
2. Compare the displayed voltage to the voltage read at the battery
using a volt meter.
3. If there is more than a 0.5 volt difference, measure the voltage at
the VM, J11-1 with respect to J11-3.
4. If the voltage is the same as what was read at the battery, replace
the VM.
5. If the voltage is different, troubleshoot the wiring between the VM
and the battery.
6. If no poor connections are found, replace the VM.
Possible Cause Action
Faulty horn switch/wiring in the
handle head
Repair or replace as necessary.
Faulty Horn Replace the horn.
Faulty traction amplifier Replace if necessary.
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