SENB8604-02

Circuit Tests
Test A: Internal Circuitry
Connect the battery and turn the key switch ON.
Display = blank See Troubleshooting Problems
1, 2, or 3.
Display = FF Logics failure. Replace logics. You
may also bypass this failure by toggling the
DIAG/RUN/SETUP switch to RUN and back to
DIAG.
NOTE: This test does not check all the logics
circuits, so the logics may pass this test and
still have a failure.
Display = dd Line fuse not disconnected or head
capacitors not discharged below 5 volts.
Return to Step 2.

Test B: Line (drive) Fuse Out

This test will take place automatically if Test A is
completed successfully.
Display = 01 Line (drive) fuse is out and head
capacitors are discharged, as they should be f
or these tests. The 01 display indicates a pass
for this test.
Display = dd Line fuse not disconnected or
head capacitors not discharged below 5 volts.
Return to Step 2.

Test C: Seat Switch Circuit

Press and release seat to close and open seat
switch.
Display = 01 Seat switch circuit defect. Move
hand around on seat and press again. If still
01, see Troubleshooting Problem 37.
Display = 02 Seat switch circuit OK.

Test D: Direction Switch Circuit

Cycle the direction lever from neutral to reverse to
neutral again and then to forward.
Display = 02 Direction switch circuit defect.
See Troubleshooting Problem 38.
Display = 03 Direction switch circuit OK.

Test E: Park Brake Circuit

Engage and release the park brake.
NOTE: The Park Brake action light may come on.
This does not indicate a problem.
Display = 03 Park brake circuit defect.
See Troubleshooting Problem 40.
Display = 04 Park brake circuit OK.

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Test F: Service Brake Circuit

NOTE: It is not necessary for the park brake to be
released for this test.
Depress and release the service brake.
Display = 04 Service brake circuit defect.
See Troubleshooting Problem 41.
Display = 05 Service brake switch circuit OK.

Test G: Accelerator Circuit

Fully depress and release the accelerator.
Display = 05 Accelerator circuit defect.
See Troubleshooting Problem 42.
Display = Flashing 00 Accelerator circuit OK,
ready to perform the accelerator speed test.

Test H: Accelerator Speed Check

Depress the accelerator again.
Display shows flashing accelerator position, 00 - 15.
If some speeds are missing, at the beginning or the
end of travel, for example, then the pedal probably
needs to be adjusted. To bypass the flashing speed
number and proceed to the next test, toggle the
DIAG/RUN/SETUP switch from DIAG to RUN and
back to DIAG.

Test I: BDI Circuit

This test is performed automatically after the
DIAG/RUN/SETUP switch is toggled in the preceding test. The BDI test happens quickly; in fact, if the
BDI is OK, 06 (indicating a pass for Test H) may be
bypassed too quickly to be seen.
Display = 06 BDI circuit failure.
See Troubleshooting Problem 43.
Display = 07 BDI circuit OK.

SENB8604-02

Test J: Lift Switch Circuit

Pull the lift lever back to maximum and release.
Display = 07 Lift switch circuit defect.
See Troubleshooting Problem 44.
Display = 08 Lift switch circuit OK.

Test K: Tilt Switch Circuit

Test M: Aux2 Switch Circuit

NOTE: If AUX2 does not exist on the test truck,
bypass by toggling the DIAG/RUN/SETUP switch.
Pull the aux2 lever back to maximum and release.
Display = 10 Aux1 switch circuit defect.
See Troubleshooting Problem 47.
Display = Flashing 00 Aux2 switch circuit OK.

Pull the tilt lever back to maximum and release.

Display = 08 Tilt switch circuit defect.
See Troubleshooting Problem 45.
Display = 09 Tilt switch circuit OK.

Test L: Aux1 Switch Circuit

Pull the aux1 lever back to maximum and release.
Display = 09 Aux1 switch circuit defect.
See Troubleshooting Problem 46.
Display = 10 Aux1 switch circuit OK.

Test N: Hydraulic Speed Check

After a successful aux2 circuit test, the flashing
number in the display can show the speed associated
with each hydraulic function. For example, if you
pull back on the tilt lever, you will see the tilt speed
on the display. Only one lever should be tested
(pulled back) at a time. Exception: If you are using
only the lift0 and lift1 switches, you can test them
both at the same time. The speed displayed represents the second lift speed.
To exit the hydraulic speed check (bypass the flashing 00), toggle the DIAG/RUN/SETUP switch from
DIAG to RUN and back to DIAG.
Display = 11 Ready for the next test.

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SENB8604-02

Test R: Forward Contactor Circuit

Tests O Through T

Move the DIAG/RUN/SETUP switch to RUN.

Display = 15 and the forward contactor (4) does
not close. Circuit is defective.
See Troubleshooting Problem 50.
Display = 15 and forward contactor (4) closes.
Forward contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG.
Display = 16 and the forward contactor (4) opens.

The remaining tests check contactor operation. You

will toggle the DIAG/RUN/SETUP switch from DIAG
to RUN to activate the contactor being tested, then
toggle the switch back to DIAG to deactivate it. You
must visually observe the contactors for proper
operation during these tests.

Test S: Reverse Contactor Circuit

Move the DIAG/RUN/SETUP switch to RUN.
Display = 16 and the reverse contactor (5) does
not close. Circuit is defective.
See Troubleshooting Problem 50.
Display = 16 and reverse contactor (5) closes.
Reverse contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG. If the
panel does not have regen, the display will =
donE. The self diagnostics are complete for nonregen (plug only) panels. If the panel has regen,
the display = 17 and the reverse contactor (5)
opens. Go to Test T.

1
2

Contactor Locations. Panel with regen is shown.

Plug-only panels will not have regen contactor (6).
(1) Line contactor. (2) Pump bypass contactor. (3) Drive bypass contactor.
(4) Forward contactor. (5) Reverse contactor. (6) Regen contactor.

Test T: Regen Contactor Circuit

Move the DIAG/RUN/SETUP switch to RUN.
Display = 17 and the regen contactor (6) does
not close. Circuit is defective.
See Troubleshooting Problem 50.
Display = 17 and regen contactor (6) closes.
Regen contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG.
Display = donE and the regen contactor (6) opens.

Test O: Line Contactor Circuit

Move the DIAG/RUN/SETUP switch to RUN.
Display = 12 and the line contactor (1) does not
close. Circuit is defective.
See Troubleshooting Problem 50.
Display = 12 and line contactor (1) closes. Line
contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG.
Display = 13 and the line contactor (1) opens.

Test P: Pump Bypass Contactor Circuit

Move the DIAG/RUN/SETUP switch to RUN.
Display = 13 and the pump bypass contactor (2)
does not close. Circuit is defective.
See Troubleshooting Problem 50.
Display = 13 and pump bypass contactor (2)
closes. Pump bypass contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG.
Display = 14 and the pump bypass contactor (2)
opens.

Test Q: Drive Bypass Contactor Circuit

Move the DIAG/RUN/SETUP switch to RUN.
Display = 14 and the drive bypass contactor (3)
does not close. Circuit is defective.
See Troubleshooting Problem 50.
Display = 14 and drive bypass contactor (3)
closes. Drive bypass contactor circuit OK.
Move the DIAG/RUN/SETUP switch to DIAG.
Display = 15 and the drive bypass contactor (3)
opens.
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Location of components: 1.Line Fuse 2.Screws 3.Logics Cover

This completes the self-diagnostics tests. The contactor tests may be repeated by moving the
DIAG/RUN/SETUP switch to RUN and back to DIAG.
If you are finished with self diagnostics, do the following:
1. Disconnect the battery and install the line fuse (1).
2. Move the DIAG/RUN/SETUP switch to the RUN
position.
3. Install the logics cover (3) and tighten screws (2).