SX DIAGNOSTIC STATUS CODES

Basic Checks
The biggest mistake technicians can make is to • When you get the 8 888 on the handset push
assume they know the problem before starting to work down on the key pad #1 button to double check
on a truck. Unfortunately while making our life easier the Status Code stored in the memory which
self-diagnostics also make us more susceptible to this should be the same as the dash display (if it
type of mistake. Never start to fix a truck based solely showed one).
on the number on the dash or handset display. Always
follow the basic troubleshooting steps. • Before proceeding check the card’s program-
ming.

• Talk to the operator. Always check each function and write down the
reading.
• Confirm their description of the problem with
an operational check. If the programming fails to match the specifications
reprogram the controller and check the truck opera-
tion before going any further. If repairs are required
• Visually inspect cables, connectors, contactor
turn the key switch off, then push the CONT and ESC
tips, etc.
keys at the same time to enter the History Folder.
These codes should only be zeroed out after the truck
• Perform basic battery cables to frame resistance is repaired and running properly.
tests. You should have at least 20,000 ohms.
Utilize the Status Codes in the following pages to find
the component or area to check for a fault. Status
• Check for any voltage on the frame. Codes can be the result of a defective controller, but
all voltage checks and testing should be performed
• Check the battery condition. before replacing.

Now we are ready to allow the self-diagnostics to give

us a starting point to repair the truck. Turn the key
switch on and check when the display goes through Display Codes
its boot up sequence to be sure all of the LEDs or Note – Shorts to frame may cause false codes.
LCD segments are functional. At this time note the CCCC – No activity detected on communication line
status (fault) code (if any) and then turn the key from display to controller. Check for shorts to
switch off so you can note the hours on the meter. frame by volts.
C– –C – Activity detected on communication line to
• Disconnect the battery and discharge the control, but does not make sense.
capacitor with the 150–25 watt resistor between PC – Pump controller information data cannot be
the Pos & Neg terminals on controller. read. Open in P4.
DC – Drive controller information data cannot be
• Remove the P2 plug which connects the dash read. Open in P2.
display to the card and insert the handset plug “=” – Fault Code Data from controller is outside of
connector. range

• Plug in the battery. Please see Display Section for proper setup of speed
sensor.
• While holding the CONT button down on the
handset turn on the key switch to enter the
programming mode.

6-1
 SX DIAGNOSTIC STATUS CODES
TABLE OF CONTENTS
STATUS DESCRIPTION PAGE
CODE
Blank Segments do not illuminate on the Dash Display and/or the Handset. .6-4
-01 No seat switch input (no voltage to P1-6) . . . . . . . . . . . . . . . . . . . . . . . .6-4
-02 Forward directional switch is closed on initial power up . . . . . . . . . . . . .6-5
-03 Reverse directional switch is closed on initial power up . . . . . . . . . . . . .6-5
-05 Start switch or brake switch fails to close . . . . . . . . . . . . . . . . . . . . . . . .6-6
-06 Accelerator depressed with no direction selected . . . . . . . . . . . . . . . . .6-6
-07 Accelerator input voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
-08 Accelerator input speed too high on power up after initial key switch
closure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
-09 Both the forward and reverse directional switches are closed at the
same time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .6-8
-11 Start switch closed on power up after initial key switch closure . . . . . ..6-8
-15 Battery voltage is too low or control card is mis-adjusted . . . . . . . . . .. .6-9
-16 Battery voltage is too high or control card is mis-adjusted . . . . . . . . . .. 6-9
-21 Accelerator voltage is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
-23 Motor field current is too high on start up in the reverse direction . . . .6-10
-24 Motor field current is too high on start up in the forward direction . . . .6-11
-27 Control’s internal power supply is less than 10 volts DC . . . . . . . . . . .6-11
-28 Motor field current is too high during the run mode . . . . . . . . . . . . . . .6-12
-41 Shorted thermal protector (TP) or armature transistor
over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
-42 Motor armature offset voltage is too high . . . . . . . . . . . . . . . . . . . . . . .6-13
-43 Motor armature offset voltage is too low . . . . . . . . . .. . . . . . . . . . . . .6-13
-44 Armature transistor did not turn off properly . . . . . . . . . . . . . . . . . . . .6-14
-45 Armature transistor did not turn on properly . . . . . . . . . . . . . . . . . . . . .6-14
-46 Look Ahead test for A2 volts less than 12% of battery volts. . . . . . . . .6-15
-49 Motor field current is too low during the run mode. . . . . . . . . . . . . . .. 6-15
-51 Capacitor volts are low before the line contactor closes . . . . . . . . . . ..6-16
-57 Controller “motor current sensor” input too low during running . . . . . ..6-16
-64 The line driver input (P2-17) is less than 12% of battery volts . . . . . ..6-17
-65 The line coil is too high during the run mode . . . . . . . . . . . . . . . . . . .. 6-17
-66 The field current exceeds the current limit on the field transistor . . . .. 6-18
-67 The armature current exceeds the armature transistor limit . . . . . . . .. 6-18
-69 The power steering coil current is too high during the run mode. . . . .6-19
-76 Capacitor (1C) voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-19
-77 Motor current is detected during regenerative braking . . . . . . . . . . . .. 6-20
-82 If the armature motor current is greater than a preset value for
longer than 3.5 sec. The armature motoring current will be turned off . ..6-20

6-2
-83 A switch position is incorrect during the accelerator potentiometer
auto calibration routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-21
-86 Accelerator pot values obtained during the auto calibration routine
were not valid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
-89 Hydraulic lever is activated before the pump is enabled when key
switch is initially enabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
-89 Hydraulic lever is activated when truck is operating . . . . . . . . . . . . . ..6-22
-90 Traction motor temperature has exceeded maximum
temperature limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
-91 Pump motor temperature has exceeded maximum temperature limit. .6-24
-94 Traction motor brush wear indicator had detected a worn brush . . . . .6-25
-94 Traction motor brush wear indicator had detected a worn brush . . . . .6-25
-95 Pump motor brush wear indicator has detected worn brush . . . . . . . .6-26
-95 Pump motor brush wear indicator has detected worn brush . . . . . . . .6-26
-99 Maintenance alert and speed limit . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-27
-117 “Card Type” selection is invalid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-27
-127 Control logic card power supply is less than 10 VDC . . . . . . . . . . . . .6-28
-128 Armature current is too high during the lift mode . . . . . . . . . . . . . . . ..6-28
-141 Shorted thermal protector (TP1) or transistor is over temperature . . . .6-29
-142 Pump Controller “motor current sensor” input is missing . . . . . . . . . . .6-29
-143 Pump Controller “motor current sensor” input is too low . . . . . . . . . . ..6-30
-144 Power Transistor (Q1) did not turn off properly. . . . . . . . . . . . . . . . . . .6-30
-145 Power Transistor (Q1) did not turn on properly. . . . . . . . . . . . . . . . . . ..6-31
-146 “Look Ahead” test for pump motor circuit volts less than 12% of
the battery volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
-150 Capacitor volts are low after the line contactor closes . . . . . . . . . . . . .6-32
-151 Capacitor volts are low before the line contactor closes.
(Internal card function during pre-charge) . . . . . . . . . . . . . . . . . . . . . .6-32
-157 Controller “motor current sensor” input voltage polarity check . . . . . ..6-33
-180 Voltage at capacitor (1C) is less than 14 volts . . . . . . . . . . . . . . . . . . .6-33
-181 Battery voltage is less than 14 volts . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
-189 Input switch closed before pump enable signal is received. . . . . . . . .6-34

6-3
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Segments do not illuminate on the No input voltage to the Logic Card or the display
NONE Dash Display and/or the Handset. unit.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Display screen on Dash Display and/or
Handset is blank.

POSSIBLE CAUSE
Positive or negative control voltage is not present.
• Insure that the key switch is closed and voltage
Circuits valid is present between P1-1 & battery negative.
Also check for voltage between P1-2 and
for control negative.
Traction
Open circuit between control card AND the Dash
Controller Display or Handset.
• Check for an open circuit or loose connection
going from the control and the Dash Display
or Handset.

Defective Dash Display or Handset.

• Replace Dash Display or Handset.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE No seat switch input This status code will be displayed when P1-6 is
-01 (no voltage to P1-6). less than 50% battery volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Mis-adjusted or defective seat or deadman
switch.
• Check to see that the seat switch closes
Circuits valid properly.
for
Open circuit between battery positive and P1-6.
Traction • Check for loose connections or broken wires:
Controller -Between the seat switch and P1-6.
-Between the key switch and the battery
positive side of the seat switch.
-Between the seat switch and P1-2.

• On vehicles without a seat/deadman switch,

check for a loose connection or broken wire
from P1-2 and/or P1-6.

6-4
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Forward directional switch is closed This status code will be displayed when P1-4 is
-02 on initial power up. greater than 60% of battery voltage at initial key
switch on.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate because of Static
Return to Off (SRO) lock out.

POSSIBLE CAUSE
Forward directional switch is closed on initial
start up (i.e. closure of battery, key switch or
Circuits valid seat/deadman switch).
• Return directional switch lever to neutral and
for then return lever to forward position.
Traction
Forward directional switch is welded closed or
Controller mis-adjusted to be held closed.
• Replace or adjust directional switch to insure
that it opens when the directional switch is
returned to neutral.

Defective control.
• Replace the controller unit.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Reverse directional switch is closed This status code will be displayed when P1-5 is
-03 on initial power up. greater than 60% of battery voltage at initial key
switch on.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate because of Static
Return to Off (SRO) lock out.

POSSIBLE CAUSE
Reverse directional switch is closed on initial
start up (i.e. closure of battery, key switch or
Circuits valid seat/deadman switch).
• Return directional switch lever to neutral and
for then return lever to reverse position.
Traction
Reverse directional switch is welded closed or
Controller mis-adjusted to be held closed.
• Replace or adjust directional switch to insure
that it opens when the directional switch is
returned to neutral.

Defective control.
• Replace the controller unit.

6-5
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Start switch or brake switch fails to This status code will be displayed when P1-7 is
-05 close. calling for greater than 40% speed and P1-3 is
less than 60% of battery volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Defective start switch circuit.
• Check start switch to insure closure with
accelerator pedal released.
Circuits valid • Check for open circuit or loose connection in
wiring from key switch to start switch and
for from P1-3 to start switch.
Traction
Controller Defective accelerator switch.
• Check accelerator switch potentiometer for
proper operation and ohmic value.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Accelerator depressed with no This status code will be displayed when P1-4 &
-06 direction selected. P1-5 are less than 60% of battery volts, and P1-7
is calling for greater than 40% speed.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Accelerator pedal is depressed before closing
forward or reverse directional switch.
• Status code will disappear when directional
Circuits valid switch is closed or when accelerator pedal is
released.
for
Traction Defective directional switch.
• Check forward or reverse switch to insure
Controller closure when direction is selected.

Open circuit between directional switch(es) and

battery positive or between directional
switch(es) and P1-4 or P1-5.
• Check all control wires and connections
shown in Trouble Shooting Diagram.

6-6
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Accelerator input voltage too high. This status code will be displayed when the accelerator
input voltage at P1-7 is 0.7 volts less than the zero
-07 speed auto calibration value for the accelerator.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate when accelerator
pedal is depressed or status code -07 is dis-
played then disappears when the vehicle
starts to accelerate.
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
Circuits valid P1-9 P1-7 P1-8
for Open circuit between battery negative and P1-7
in accelerator input circuit. 56 29 28
Traction • Check for broken wires or loose connections
Controller or open potentiometer / voltage supply. P9-4 P9-1
Short circuit from battery positive to wiring in
accelerator input circuit.
P9-3
ACC. POT

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Accelerator input speed too high on This status code will be displayed when the
-08 power up after initial key switch accelerator input voltage at P1-7 is calling for greater
closure. than 20% speed, and any of the following connec-
tions are opened and closed: battery or key switch.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
• Input voltage at P1-7 should be more than
20% speed.. Adjust or replace accelerator unit
Circuits valid to insure that the voltage at P1-7 is calling for
less than 20% before depressing pedal. P1-9 P1-7 P1-8
for
Traction • Repeat the auto calibration routine outlined in 56 29 28
Accelerator Controller Set-up Procedures of
Controller this manual.
P9-4 P9-1
• P1-7 or the accelerator pot negative have an
open circuit.
P9-3
• Defective Control ACC. POT

6-7
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Both the forward and reverse This status code will be displayed when P1-4 and
-09 directional switches are closed at the P1-5 are greater than 60% of battery volts at the
same time. same time.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Forward or reverse directional switch welded
closed or mis-adjusted to be held closed.
• Replace or adjust directional switches to insure
Circuits valid that they open when directional switch is
returned to neutral.
for
Traction Short circuit between battery positive and P1-4
and / or P1-5.
Controller • Disconnect wires from P1-4 and P1-5 and
check wire for short circuit to positive side of
directional switch.

Defective card.
• Disconnect wires and measure voltage at
P1-4 and P1-5. Voltage should be less than
60% of battery volts.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Start switch closed on power up after This status code will be displayed when P3 is
-11 initial key switch closure. greater than 60% of battery voltage when the key
switch is closed.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Start switch input mis-adjusted or defective.
• Input voltage at P1-3 should be less than 60%
of battery volts at key switch closing. Adjust or
Circuits valid replace accelerator unit to insure that the
voltage at P1-3 is less than 60% of battery
for volts before closing the start switch.
Traction
Short circuit between battery positive and P1-3
Controller in start switch input circuit.
• Disconnect wire from P1-3. Check for short
circuit from wire to battery positive.

Defective card.
• Disconnect wire from P1-3. Measure voltage
from P1-3 to negative. Voltage should be zero,
if not, replace card.

6-8
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Battery voltage is too low or control This status code will be displayed when the battery
-15 card is mis-adjusted. volts are less than 1.95 volts per cell at initial key
switch on. See table below.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Discharged battery.
• Check battery for proper open circuit voltage
as shown in “Trouble Shooting Diagram,
Circuits valid charge battery, if required.
for Defective battery.
Traction • Check each battery cell for proper voltage
(greater than 1.95 volts at cell). Replace or
Controller repair battery.

Incorrect control card adjustment.

• Check function 15 for proper adjustment for
battery being used. See Handset instruction
sheet for details. Adjust to proper settings.

Check “minimum” battery volts at P1-1 and

NEG.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Battery voltage is too high or control This status code will be displayed when the bat-
-16 card is mis-adjusted. tery volts are greater than 2.40 volts per cell at ini-
tial key switch on. See table below.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
FU1 15A
Incorrect control card adjustment. 5
• Check function 15 for proper adjustment for
NOMINAL MAXIMUM
battery being used. See Handset instructions LIMIT VOLTS
Circuits valid for details. Adjust to proper setting. BATTERY
VOLTAGE
AT 2.4 VDC
PER CELL
for Battery over-charged or incorrect battery used. 24 28.8
Traction • Check battery for proper open circuit voltage 36 43.2
per table in trouble-shooting diagram. If voltage
Controller excessive, check battery charger for proper
48 57.6
72 86.4
output voltage. +
P1-1 80 100.8

Check “maximum” battery volts at P1-1 and

NEG. -

NEG

Traction
Control N
Terminal

6-9
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Accelerator voltage is too high. This status code will be displayed when the voltage
-21 at P1-7 is greater than 4.5 volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Controller will not operate.

POSSIBLE CAUSE
• Verify wire connection between accelerator pot
to P1-8.

Circuits valid • Verify wire connection between P1-7 to

P1-9 P1-7 P1-8
for accelerator pot.
56 29 28
Traction • Verify that the accelerator pot is adjusted
Controller properly. P9-4 P9-1

P9-3
ACC. POT

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Motor field current is too high on start This status code will be displayed when the cur-
-23 up in the reverse direction. rent draw in the motor field is too high at start up
in the reverse direction.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Defective control
• Replace controller unit.

Circuits valid
for
Traction
Controller

6-10
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Motor field current is too high on This status code will be displayed when the current
-24 start up in the forward direction. draw in the motor field is too high at start up in the
forward direction.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
Control does not operate.
NO
POSSIBLE CAUSE
Defective control.
• Replace controller unit.

Circuits valid
for
Traction
Controller

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Control’s internal power supply is This status code will be displayed when the control’s
-27 less than 10 Volts DC. power supply is less than 10 volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Line contactor opens and closes, then can
only be closed by opening and closing the KEY
key switch. FU2 SWITCH
12

POSSIBLE CAUSE 5
Discharged Battery. FU1
Circuits valid • Check battery to insure proper state of charge. 10
Voltage may be dropping below 10 Volts DC
for under load. + 2
Traction
Loose connection at P1-1.
Controller • Insure that the wire connection at P1-1 is tight. -
P1-1 should be at battery voltage. P1-1 P1-2
NEG
Defective control.
• Replace controller unit.

6-11
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Motor field current is too high dur- This status code will be displayed when the current
-28 ing the run mode. in the motor field is sustained above a preset limit
for longer than 70 seconds.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.

POSSIBLE CAUSE
Continued operation of vehicle in high motor cur-
rent condition.
• Operate vehicle at lower motor current THE PRESENCE OF THIS STATUS CODE
Circuits valid condition for 70 seconds.
IS NOT NECESSARILY INDICATIVE OF A
for Function 7 is mis-adjusted to allow higher than CONTROL ISSUE. IF FUNCTION 7 IS NOT
Traction normal motor filed current.
MIS-ADJUSTED, THE STATUS CODE INDI-
• Adjust function per OEM instructions.
Controller CATES AN APPLICATION ISSUE WHERE A
MOTOR IS BEING STALLED, ETC. DIS-
PLAY OF THIS STATUS CODE SHOULD
NOT TRIGGER THE RETURN OF A CON-
TROL FOR REPAIR OR REPLACEMENT.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Shorted thermal protector (TP) or This status code will be displayed when the voltage
-41 armature transistor over temperature. at the thermal protector is too low.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Reduced or no power to traction motor in
transistor range.

POSSIBLE CAUSE
Control is in thermal cut-back.
• Allow control to cool, status code should THE PRESENCE OF THIS STATUS CODE IS
Circuits valid disappear.
NOT NECESSARILY INDICATIVE OF A CON-
for Defective control. TROL ISSUE. IF FUNCTION 7 IS NOT MIS-
Traction • Replace controller unit. ADJUSTED, THE STATUS CODE INDI-
Controller NOTE: Thermal protector located in control is CATES AN APPLICATION ISSUE WHERE A
not serviceable. MOTOR IS BEING STALLED, ETC. DISPLAY
OF THIS STATUS CODE SHOULD NOT
TRIGGER THE RETURN OF A CONTROL
FOR REPAIR OR REPLACEMENT.

6-12
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Motor armature offset voltage is too This status code will be displayed when the voltage
-42 high. at the current sensor input is greater than 2.6 volts
with no current flowing in the motor circuit.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Defective control.
• Replace controller unit.

Circuits valid
for
Traction
Controller

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Motor armature offset voltage is too This status code will be displayed when the voltage
-43 low. at the current sensor input is less than 2.4 volts
with no current flowing in the motor circuit.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Defective control.
• Replace controller unit.

Circuits valid
for
Traction
Controller

6-13
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Armature transistor did not turn off This status code will be displayed when, during
-44 properly. control operation, the armature transistor fails to
turn off. This will result in a PMT condition.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Line contactor opens and then can only be
closed by opening and closing the key
switch.

POSSIBLE CAUSE
Defective control.
Circuits valid • Replace controller unit.
for
Traction
Controller

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Armature transistor did not turn on This status code will be displayed when, during
-45 properly. control operation, the armature transistor fails to
turn on properly. This will result in a PMT condition.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Truck will not operate.

POSSIBLE CAUSE
Defective control.
• Replace controller unit.

Circuits valid
for
Traction
Controller

6-14
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Look Ahead” test for A2 volts less This status code will be displayed when the volt-
-46 than 12% of battery volts. age at A2 is less than 12% of battery volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Line contactor will open.

POSSIBLE CAUSE
Check for short circuit from the motor armature
to the frame of the vehicle.

Circuits valid Check for welded 1A contactor (if used)

for Defective control.
Traction • Replace controller unit.
Controller

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Motor field current is too low during This status code will be displayed when the current
-49 the run mode. draw in the motor field is too low during the run
mode.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.

POSSIBLE CAUSE
Defective control or connection.

• Replace controller unit.

Circuits valid
• Open motor field winding.
for
Traction
Controller

6-15
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Capacitor volts are low before the line This status code will be displayed during “key on”
-51 contactor closes. when the capacitor volts is less than 85% of battery
volts at initial key switch on.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Line contactor does not close when capaci-
tor does not pre-charge.

POSSIBLE CAUSE
• Welded 1A contactor (if used)
• Check PTC for open circuit on line contactor.
Circuits valid • Check for conductivity across open 1A
contactor.
for
Traction Wiring error
• Insure that there is no device connected to
Controller load side of line contactor.

Defective control.
• Replace controller unit.

1A CTR 740Amp
control only

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage
-57 too low during running. input from the current sensor is too low during run-
ning.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.

POSSIBLE CAUSE
• Line contactor power tips did not close.

• Volt drop across contactor tips.

Circuits valid
Defective control.
for • Replace controller unit.
Traction
Controller

6-16
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE The line driver input (P2-17) is less This status code will be displayed when the control
-64 than 12% of battery volts. detects that the line driver input (P2-17) is less than
12% battery volts when the key switch is turned on.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control does not operate. Line contactor
does not close.

POSSIBLE CAUSE
• Open wire connection to Pin P1-17.
• Shorted line Driver transistor in control.
Circuits valid • Possible open circuit in line contactor coil
for Defective control.
Traction • Replace controller unit.
Controller

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

This status code will be displayed when the current limit in the line
STATUS CODE The line coil is too high during the run coil driver is exceeded during the run mode. The line contactor will
-65 mode. drop out and the key switch will have to be recycled to reset the
control.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control does not operate.

POSSIBLE CAUSE
• Shorted line contactor coil.
• Short between wires connected to line coil.

Circuits valid If line coil resistance is correct:

(59Ω for 36-48)
for (161Ω for 80V)
Traction
Defective control.
Controller • Replace controller unit.

6-17
 SX DIAGNOSTIC STATUS CODES

TRACTION
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
This status code will be displayed when the field transistor
STATUS CODE The field current exceeds the current exceeds its specific current limit. The line contactor will
-66 limit on the field transistor. drop out and the key switch will have to be recycled to
restart the control.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.
• Line contactor opens.

POSSIBLE CAUSE
• Shorted field F1 to F2

Circuits valid • Open FU4 fuse

for • F1 or F2 terminals shorted to battery positive
Traction (B+)
Controller • F1 or F2 Terminals shorted to battery negative
(B-)

(The controller looks for a high change in current

over time to identify a short circuit in the field or
cables.)

TRACTION
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
STATUS CODE The armature current exceeds the This status code will be displayed when the armature tran-
armature transistor limit. sistor exceeds its specific current limit. The control is reset
-67 by recycling the key switch.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.

POSSIBLE CAUSE
• Shorted motor armature A1 to A2

• Power cables may be shorted to each other

Circuits valid (Measure at control terminals)
for • A1 to A2 terminals may be shorted to battery
Traction positive or negative.
Controller

6-18
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE The power steering coil current is too This status code will be displayed when the current in the
high during the run mode. power steering driver circuit exceeds current limit during the
-69 run mode. The control is reset by recycling the key switch.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.

POSSIBLE CAUSE
• Shorted power steering control coil
• Short between wires connecting to the power
steering coil.
Circuits valid • Open FU4 fuse
for
Traction If the power steering coil resistance is correct
(59Ω for 36-48volt)
Controller (161Ω for 80 volt) then:

• Defective control. Replace control unit.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Capacitor (1C) voltage too high. This status code will be displayed when the voltage on
the capacitor goes above limit voltage* during the
-76 regenerative braking cycle.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Line contactor opens and closes, then opens
and can only close by opening and closing the
key switch.

POSSIBLE CAUSE
• Unplugging the battery connector during LINE FU4
Circuits valid regenerative braking.
• Line contactor bouncing open during regen.
for • Main power fuse opening during regen. +
ARMATURE

Traction • Intermittent battery plug connection.

Battery
FIELD

Controller * Limit Voltage: -

POS A1 F1
POWER CONNECTIONS

Limit Batt. NEG A2 F2

50V 36V
70V 48V
96V 72/80V

6-19
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Motor current is detected during This status code will be displayed when motoring
-77 regenerative braking. current is detected during the regenerative braking
cycle.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Truck will not operate.

POSSIBLE CAUSE
Defective control.
• Replace controller unit
LINE FU1
Circuits valid
for +

ARMATURE
Traction Battery ACC POT

FIELD
POS A1 F1
Controller -
POWER CONNECTIONS
NEG A2 F2

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE If the armature motor current is greater than a
This status code will be displayed when the armature
preset value for longer than 3.5 sec the armature
-82 motoring current will be turned off.
motor current exceeds a preset value for 3.5 sec and the
accelerator pedal is calling for maximum performance.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES The Control will not operate, and can only be
reset by cycling the key switch.
*CODE WARNING*
POSSIBLE CAUSE:
• Continued operation of vehicle in high motor
THE PRESENCE OF THIS STATUS CODE
current condition IS NOT NECESSARILY INDICATIVE OF A
Circuits valid • Operating control at stall motor current for
CONTROL ISSUE. IF FUNCTION 16 IS
more than 3.5 seconds.
for • Function 16 is incorrectly adjusted for control NOT MIS-ADJUSTED, THE STATUS
Traction % on time.
CODE INDICATES AN APPLICATION
Adjust function
Controller • Function 16 is adjusted a level of 130 for all ISSUE WHERE A MOTOR IS BEING
controls except the 9"15K-18KL which is set to
120 and the EE’s are all set at 160.
STALLED, ETC. DISPLAY OF THIS STA-
• Possible mechanical resistance to motor TUS CODE SHOULD NOT TRIGGER THE
rotation.
RETURN OF A CONTROL FOR REPAIR
OR REPLACEMENT.

*Continued occurrence of this code could

lead to damage to motor assembly.

6-20
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

This status code will be displayed when the seat switch is
STATUS CODE A switch position is incorrect during the open, or the any of the forward, reverse or start switches
-83 accelerator potentiometer auto calibra- are closed at the beginning of the accelerator potentiome-
tion routine. ter auto calibration routine.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO The auto calibration routine outlined in
Section 8 of this manual will not start.

POSSIBLE CAUSE:
• Seat switch is open
• Confirm switch wiring, or replace
Circuits valid switch, if required.
for • Any of the forward, reverse or start switches
Traction are closed
• Confirm switch wiring, or replace
Controller switch, if required.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Refer to Section 8 of this manual for possible causes of
Accelerator pot values obtained during the
-86 auto calibration routine were not valid. this status code.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Accelerator potentiometer auto calibration
routine was not successfully completed.

POSSIBLE CAUSE:
• Misadjusted or defective accelerator
potentiometer assembly
Circuits valid • Verify the accelerator potentiometer operation.
• Open circuit on the accelerator potentiometer.
for P1-9 P1-7 P1-8
Traction
Controller 56 29 28

P9-4 P9-1

P9-3
ACC. POT

6-21
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Hydraulic lever is activated before the This status code will be displayed when the voltage
-89 pump is enabled when key switch is ini- at P14 is greater than 3 volts at pump enable
tially activated. (10ms).

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO The truck will not run or the pump will not
operate.

POSSIBLE CAUSE:
Shorted or welded hydraulic switch
Circuits valid • Verify connections to hydraulic switches
• Verify mechanical operation of hydraulic
for switches (check adjustment).
Traction
• Check for short between wire 50 and 52.
Controller
• Check for shorted switch.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE This status code will be displayed when the voltage
Hydraulic lever is activated when truck at P14 is greater than 3 volts at pump enable
-89 is operating (10ms).

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Hydraulic functions do not operate.

POSSIBLE CAUSE:
• Battery voltage has dropped to Lift Lockout
conditions.
Circuits valid
for
Traction
Controller

6-22
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Traction motor temperature has This status code will be displayed when the voltage
-90 exceeded maximum temperature limit. at the respective terminal of the Pump Logic Card is
at zero volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status code flashes “on and off”. Action
Light flashes.

POSSIBLE CAUSE
User defined status code is displayed by switch
closure to battery negative.
Circuits valid
• Defective temp switch (shorted). Traction
for motor.
Traction
• Defective TMM card.
Motor
Temperature • Wire 80 shorted to battery NEG.
(Contactor • Battery Neg @ TMM7A terminal 1 P11-5
Hydraulics)

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Traction motor temperature has This status code will be displayed when the voltage
-90 exceeded maximum temperature limit. at the respective terminal of the TMM is at zero
(with pump controller hyd.) volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status code flashes “on and off”. Action light
flashes

POSSIBLE CAUSE
User defined status code is displayed by switch
closure to battery negative.
Circuits valid
• Defective temp switch (shorted). Traction
for motor.
Traction
• Defective pump card.
Motor
Temperature • Wire 80 shorted to battery NEG.
(Pump • Battery Neg @ pump control P5-16
Controller)

6-23
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump motor temperature has This status code will be displayed when the voltage
-91 exceeded maximum temperature limit. at the respective terminal of the TMM is at zero
volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status Code flashes “on and off”. Action
Light flashes

POSSIBLE CAUSE
User defined status code is displayed by switch
closure to battery negative.
Circuits valid
• Battery Neg at TMM7A terminal 3 P11-6.
for
Hydraulic • Wire 82 shorted to battery NEG.

Pump • Defective Temp switch (shorted).

Temperature
• Defective TMM card.
(Contactor
Hydraulics)

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump motor temperature has This status code will be displayed when the voltage
-91 exceeded maximum temperature limit. at the respective terminal of the TMM is at zero
(with pump controller hyd.) volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status Code flashes “on and off”.

POSSIBLE CAUSE
User defined status code is displayed by switch
closure to battery negative.

Circuits valid • Defective temp switch (shorted). Pump

motor.
for
Hydraulic • Defective pump card.

Pump • Wire 82 shorted to battery NEG.

Temperature • Battery Neg at P5-11
(Pump
Controller)

6-24
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Traction motor brush wear indicator This status code will be displayed when the voltage
-93 had detected worn brush. at terminal 8 and 10 of the TMM is at zero volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status Code flashes “on and off”.

POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.

Circuits valid • Worn brushes.

• Terminal 5 or 6 is shorted to positive on the
for TMM7A card.
Traction Motor • Defective input switch (shorted) check for
proper adjustment of the BWI T-bar on brush
Brush Wear holder.
Indicator • Wire 85 or 86 shorted to positive.
• Defective TMM7A card.
(Contactor
Hydraulics)

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Traction motor brush wear indicator This status code will be displayed when the voltage
-94 had detected worn brush. at the respective terminal of the Pump Logic Card is
at zero volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status Code flashes “on and off”.

POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.

Circuits valid • Worn brushes.

• P5-5 or P5-6 is shorted to positive on pump
for control card.
Traction Motor • Defective input switch (shorted) check for
proper adjustment of the BWI T-bar on brush
Brush Wear holder.
(Pump • Wire 85 or 86 shorted to positive.
• Defective pump control card.
Controller)

6-25
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump motor brush wear indicator has This status code will be displayed when the voltage
-94 detected worn brush. at the respective terminal of the TMM is at battery
volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status Code flashes “on and off”.

POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.

Circuits valid • Worn brushes.

NEG
for • Terminal 8 or 10 is shorted to positive on the
Pump TMM7A card.

Motor • Defective input switch (shorted) check for

Brush Wear proper adjustment of the BWI T-bar on brush
holder.
Indicator
(Contactor • Wire 87 or 88 shorted to positive.

Hydraulics)

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump motor brush wear indicator has This status code will be displayed when the voltage
-95 detected worn brush. at the respective terminal of the Pump Logic Card is
at battery volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status Code flashes “on and off”.

POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.

Circuits valid • Worn brushes.

for • P5-8 or 5-9 is shorted to positive.

Pump
• Defective input switch (shorted) check for
Motor proper adjustment of the BWI T-bar on brush
Brush Wear holder.
Indicator • Wire 87 or 88 shorted to positive.
(Pump
• Defective pump control card.
Controller)
NEG

6-26
 SX DIAGNOSTIC STATUS CODES

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Maintenance alert and speed limit. This status code will be displayed when the “normal”
-99 hour meter exceeds the “maintenance alert hours”
setting for the vehicle.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Status code is displayed for 4 seconds when
the key switch is first turned on, and/or the
vehicle may run at a reduced speed.

CUSTOMER SELECTED SETTING WITH THE

HANDSET:
Circuits valid User defined status code is displayed when the
normal hour meter reading exceeds the pro-
for grammed “maintenance alert hours” setting
Traction selected by the user
NO DIAGRAM
• Maintenance Code Hour Meter, Functions 19
Control and 20, are programmed with the Handset and
command the display of status code -99.
USER SHOULD PERFORM THE
• If desired, Maintenance Code Speed Limit, DESIRED MAINTENANCE FUNCTION
Function 13, can be programmed with the
Handset.

User should perform the desired maintenance

function. Re-set maintenance alert hour meter
after maintenance is performed.
.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE “Card Type” selection is invalid. This status code will be displayed when the card
-117 type selection value is set to an invalid number.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Control will not operate.

POSSIBLE CAUSE
Invalid card type selection.
• Review function 17 in the Handset Instruction
sheets. Adjust and set card type value as
Circuits valid instructed by Service Manual.
for
Pump NO
Controller GRAPHIC
FOR THIS
STATUS CODE

6-27
 SX DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Control logic card power supply is less This status code will be displayed when the logic
-127 than 10 VDC. card power supply is less than 10 volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.

POSSIBLE CAUSE
Discharged battery
• Check battery to insure proper state of charge.
• Check control fuse FU 11.
Circuits valid
for Loose connection at P1-1.
• Insure that the wire connection at P1-1 is tight.
Pump • Insure that wire connection at P5-1 is tight.
Controller • Check for Volt drop across wire 12 and wire 2.

Defective logic card..

• Replace control.

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Armature current is too high during the This status code will be displayed when the current
-128 lift mode in the armature circuit is sustained above 400A for
70 sec.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control will not operate.

POSSIBLE CAUSE
Continued operation of vehicle in high motor cur-
rent condition.
• Operate vehicle at lower motor current condi-
Circuits valid tion for 70 seconds.
for • Check hydraulic pressure adjustment. NO
Pump GRAPHIC
Controller
FOR THIS
STATUS CODE

6-28
 SX DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump control is over Temperature This status code is displayed when the voltage at
-141 the thermal protector is less than 3.8 volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Reduced or no power to pump motor in con-
trol range.

POSSIBLE CAUSE
Control is in thermal cut-back.
• Allow control to cool, status code should
Circuits valid disappear.
for • Check wire 23, P5-14 and P2-9
Pump
• Check hydraulic pressure adjustment.
Controller
NOTE: Pump control thermal protection is locat-
ed inside of pump control and is not serviceable

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump Controller “motor current sensor” This status code is displayed when the voltage at
-142 input is missing. the current sensor is greater than 1.6 volts with no
current flowing in the motor circuit.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO No power to pump motor in control range.

POSSIBLE CAUSE
Control is defective.
• Replace controller unit.

Circuits valid • Note: Pump motor current sensor is located

inside of pump control and testing is not possi-
for ble.
Pump
Controller

6-29
 SX DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Pump Controller “motor current sensor” This status code is displayed when the voltage at
-143 input is too low. the current sensor is less than 0.6 volts with no cur-
rent flowing in the motor circuit.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO No power to pump motor in control range.

POSSIBLE CAUSE
Control is defective
• Replace controller unit.

Circuits valid • Note: Pump motor current sensor is located

inside of pump control and testing is not possi-
for ble.
Pump
NOTE: Pump control thermal protection is locat-
Controller ed inside of pump control and is not serviceable

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Power Transistor (Q1) did not turn off This status code is displayed when, during pump
-144 properly. control operation, the transistor fails to turn off.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control may run continuously.

POSSIBLE CAUSE
Control is defective
• Check switch adjustment.
• Check for shorts to Neg on wires 51,52,53,54.
Circuits valid
• Replace controller.
for
Pump
Controller

6-30
 SX DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Power Transistor (Q1) did not turn on This status code is displayed when, during pump
-145 properly. control operation, the transistor fails to turn on.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Control may run continuously.

POSSIBLE CAUSE
Control is defective
• Replace controller unit.

Circuits valid • Check for proper negative voltage at N

for terminal on control.
• Check for shorts to Neg on wires 51,52,53,54.
Pump • Check for proper positive voltage to control at
P5-1. 19-20, 21 and 12
Controller
• Check for proper positive voltage at P5-1

• Check for proper Neg voltage at N terminal on

control

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE “Look Ahead” test for Pump motor cir- This status code will be displayed when the voltage
-146 cuit volts less than 12% of battery in the pump motor is less than 12% of battery volts.
volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Pump contactor will operate. FU6
P
POSSIBLE CAUSE
• Check for short circuit from the motor armature
to the frame of the vehicle.
• Check for open circuit from A1 to A2 on control
Circuits valid through motor.
A1
for Control is defective
Pump • Replace controller.
ARMATURE

A1
Controller
P A1 *
PUMP CONTROL
A2
POWER
CONNECTION
N A2
FIELD

A2

6-31
 SX DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Capacitor volts are low after the line This status code will be displayed when the capacitor
-150 contactor closes. voltage is less than 85% of the battery voltage in the
run mode.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Pump control will not operate.

POSSIBLE CAUSE 325 amps

Defective line contactor. FU6
P
• Check for open line contactor power tips.
• Check for volt drop across line contactor.
Circuits valid • Check for loose or open connections in cables A1
for from battery positive to control positive circuit.

ARMATURE
A1
Pump P A1 *
Defective power fuse.
Controller • Check power fuse for open circuit.
PUMP CONTROL
POWER
CONNECTION
A2

N A2

FIELD
*
No battery voltage at P5-1.
A2
• Check for battery voltage at POS and P5-1.
N
• Check for loose connection at P5-1.

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Capacitor volts are low before the line This status code will be displayed during “key on”
-151 contactor closes. (Internal card func- when the capacitor volts is less than 85% of battery
tion during pre-charge) volts at initial key switch on.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Pump control will not operate.

POSSIBLE CAUSE
Note: Repeated “charging/discharging” the
capacitors during troubleshooting will cause sta-
tus code 51. Also “do not” connect any loads to
Circuits valid the load side of the line contactor.
• Check battery voltage.
for • Check for open PTC resistor.
Pump • Check for battery voltage at P5-1
Controller Defective control.
• Replace controller unit.

Note: PTC resistor is located across the line

contactor that is serviceable.

Note: There is also a PTC resistor that is in the

controller and it is not serviceable.

6-32
 SX DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE “Controller motor current sensor” input This status code will be displayed when the voltage
-157 voltage polarity check. input to motor current sensor is of the wrong polari-
ty.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Pump control will not operate.

POSSIBLE CAUSE
Control is defective
• Replace controller unit.

Circuits valid
for
Pump
Controller

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Voltage at capacitor (1C) is less This status code will be displayed when the voltage
-180 than 14 volts. at P1 is less than 14 volts. This occurs typically in
the run mode of operation.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Pump Control will not operate.

POSSIBLE CAUSE
(Line contactor controlled by traction control).
Line contactor opened up during run.
•Check connection from P5-17 to Line coil (-) for
Circuits valid loose connection.
•Check connection from battery (+) to Line coil
for (+) for loose connection.
Pump •Check for failed power fuse at pump control.
•Check for dirty contactor tips.
Controller

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 SX DIAGNOSTIC STATUS CODES

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Battery voltage is less than 14 volts. This status code will be displayed when the battery
-181 voltage measured at P1 is less than 14 volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
YES Pump control will not operate.

POSSIBLE CAUSE
• Check connection from control fuse to pump
P1 for loose connections.

Circuits valid • Check for low battery volts under load.

for • Check for volt drop between pos. and P5-1.
Pump
Controller

HYDRAULIC DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE Input switch closed before pump This status code will be displayed when pin
-189 enable signal is received. 12,19,20 or 21 is pulled to negative before pin 10 is
greater than 5.0 volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

MEMORY RECALL SYMPTOM
NO Pump Control will not operate.

POSSIBLE CAUSE
• Hydraulic handle pulled before pump enable
signal given.

Circuits valid • Shorted hydraulic switch.

for • Check Hydraulic switch adjustment.
Pump
• Defective control.
Controller

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