Model 8210/8250 Maintenance Manual Section 5. Troubleshooting
Symptom Tables: Travel (Forward/Reverse) System
Publication:1146945/001, Revised: 25 Sep 2018 5-23
No Travel Mode. No Fault Codes.
No Travel or Slow Travel. TA Flash Code 2,2, (Thermal Cutback)
Heatsink Temperature Exceeded 185°F (85°C). Operator Display
May Indicate Hot2 (C45)
No Travel, No Lift/Lower. TA Flash Code 3,1. Operator Display
May Indicate Error Code E106
No Travel, No Lift/Lower. TA Flash Code 1,3. Operator Display
Indicates Error Code E202
Possible Cause Action
Arm Angle Proximity Switch
Failure
Check the arm angle proximity switch adjustment, wiring, and the
traction amplifier. See “Arm Angle Proximity Switch” on page 8-2.
Throttle magnet-actuator arm (in
the control handle) out of
adjustment
Check with the service display and repair as needed.
Bad VM. If no other problems are noted but the VM does not detect the
presence of the magnet, replace the VM.
Possible Cause Action
Battery Problem Verify the correct, (24V) fully-charged, battery is installed in truck.
Binding drive unit or dragging
brake
Measure current draw on U, V, and W cables. Traveling at about 1
mph (1.6 km/h) with no load, current should be about 35 to 50 Amps
and the same at each cable. If current is high, inspect the brake for
dragging and the drive unit for binding. If both are OK, replace traction
motor.
Bad TA Examine mounting of TA. It must be mounted securely and in contact
with the truck frame (that acts as a heatsink). If TA is mounted
correctly, replace TA.
Truck does not respond to Keypad
inputs
Enter Parameter 39 Access code. Use FlashWare and change value to
either 3 or 4. Refer to “Programming Service Parameters” on page 3-8.
Possible Cause Action
Short in M1 coil or wiring With the truck OFF and the battery disconnected, remove connector
JP1 from the TA. Measure resistance between JP1-6 and JP1-13.
Resistance should be approx. 22 to 24.2 Ohms for standard contactor
(76.5 to 93.5 Ohms for cold storage contactor). If not, troubleshoot
wires and coil for shorts. If resistance is OK, replace TA.
Possible Cause Action
Bad wiring between TA and traction
motor
With the truck OFF and the battery disconnected, disconnect cables
W, V, and U from TA and traction motor. Check for continuity and
shorts between cables and truck frame.
Bad TA With the truck OFF and the battery disconnected, disconnect the
cables at the TA. Reconnect the battery and turn the truck ON. If
code 1,3 is still displayed, replace the TA. If code 1,3 is not displayed,
replace the traction motor.
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