WENB 8632 Circuit Tests Test A: Internal Circuitry Connect the battery and turn the key switch ON. Display = “blank” See Troubleshooting Problems 4,2,0°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 stil 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. 54 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. Ht 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 |: BDI Circuit This test is performed automatically after the DIAG/RUN/SETUP switch is toggled in the preced- ing test. The BDI test happens quickiy; in fact, ifthe 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.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 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 auxt lever back to maximum and release. Display = 09 Aux1 switch circuit defect. See Troubleshooting Problem 46, Display = 10 Aux1 switch circuit OK. 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 Auxt switch circuit defect. See Troubleshooting Problem 47. Display = Flashing 00 Aux? 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 liftO and lift! switches, you can test them both at the same time. The speed displayed repre- sents the second lift speed. To exit the hydraulic speed check (bypass the flash- ing 00), toggle the DIAG/RUN/SETUP switch from DIAG to RUN and back to DIAG. Display = 11 Ready for the next test. WENB 8632 55WENB 8632 SORES Tests “O” Through “T” 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. ‘ug only panes wil not have regen contactor). (1 Line contactor) Pump bypass cotactor () Drive bypass sontactor (@ Forward contactor fs) Roverse contactor (@) Regen contactor 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. splay = 14 and drive bypass contactor (3) closes. Drive bypass contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. isplay = 15 and the drive bypass contactor (3) opens. 56 Test R: Forward Contactor Circuit 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. Test S: Reverse Contactor Circuit Move the DIAG/RUN/SETUP switch to FUN. Display = 16 and the reverse contactor (5) does Not close. Circuit is defective See Troubleshooting Problem 50. Display = 16 and reverse contactor (6) closes. Reverse contactor circuit OK. Move the DIAG/RUN/SETUP switch to DIAG. If the panel does not have regen, the display will = don€. The self diagnostics are complete for non- regen (plug only) panels. if the panel has regen, the display = 17 and the reverse contactor (6) ‘opens. Go to Test T. ‘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. {cation of componeris Line Fuse 2.Screws & Logics Cover ‘This completes the self-diagnostics tests. The contac- tor tests may be repeated by moving the DIAG/RUN/SETUP switch to RUN and back to DIAG. IF you are finished with seif 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)