Section 6. Messages and Codes

Transcription

1 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Section 6. Messages and Codes CL398-13, Issued: 6 May

2 Service Manual Change History Description Page # Date Added Service Manual Change 1 History 2 7/15/13 2 Added Information Bulletins 3 7/15/13 3 Added SIB CC /15/13 4 Added SIB CC /31/13 5 Added SIB CE /31/13 6 Added SIB CC /31/13 6 Added SIB CC /15/14

3 Service Information Bulletin 1 SIB BF10-003R Tractor Cover Mounting update kit Section 7 2 SIB BF Fork Crack Repair For Demanding Applications Section 7 3 SIB BR Fixed Handle Adjustable Brake Potentiometer Section 7 4 SIB BR Handle Operating Range Section 7 5 SIB CC Pre-Programmed ETAC Card No Longer Available Section 7 6 SIB CC Software Update Information and Descriptions Section 6 7 SIB CC Power Steering Software Update (V1.9) Section 6 8 SIB CC HBC & 8TB50 Floormatt Switch Operation Section 8 9 SIB CC Power Steering Unit Repair Instructions Section 6 & 7 10 SIB CE C81 Code Steer Potentiometer Section 6 11 SIB CC Vehicle Manager and Traction Amp Software Updates Section 6 12 SIB CE Twist Grip Shimming Section 7 13 SIB CE Power Steer Handle Bezel Update Section 7 14 SIB CE Solid State Steering Potenitomenter Instructions Section 7 Technical News Brief 1 TNB Setting Parameters in ETAC Card Units 2 TNB Change To All Metric Hardware 3 TNB Tandem Load Wheel Block Grease Fitting 4 TNB Excessive Throttle Play In Neutral 5 TNB Steer Bearing Shimming 6 TNB Use of Loctite on Pinion Nut 7 TNB Motor Controller Overtemp Hotline Tech Tips 1 HTT Parameters 2 HTT Pinched Drive Motor Cables 3 HTT Using Loctite on Pinion Nut 4 HTT Truckcomm Software 5 HTT Drive Unit Tightening Sequence 6 HTT Rebuilding Cast style Lift cylinder 7 HTT Water In Grab Rail 8 HTT Gluing of Cushioned Floor Mat 9 HTT Travel Speed And Acceleration Parameters 10 HTT Fix For Loose Keyless Switch 11 HTT Curtis Handset Connection Procedure 12 HTT Static Return To Off; Reducing Steer Effort 13 HTT Parameter 24 Explained 14 HTT Greaseable Steer Bearing 15 HTT Motor Temperature Sensor Replacement 16 HTT Programming ETAC Card; Troubleshooting AMP LED Codes 17 HTT New ETAC Card Installation

4 Section 6. Messages and Codes List of Messages and Codes List of Messages and Codes Traction Amplifier LED Diagnostics Traction Amplifier Flash Codes Caution and Error Codes Caution Codes Code GATE Code SLO Code Sro (C14) Code C Code HPd (C20) Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C36 (Model 8TB50 with Power Steer) Code Lo (C41) Code Hi (C42) Code Hot1 (C44) Code Hot2 (C45) Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Toyota Pallet Truck Service Manual Code C74 (Model 8TB50 with Power Steer) Code C75 (Model 8TB50 with Power Steer) Code C76 (Model 8TB50 with Power Steer) Code C77 (Model 8TB50 with Power Steer) Code C78 (Model 8TB50 with Power Steer) Code C79 (Model 8TB50 with Power Steer) Code C80 (Model 8TB50 with Power Steer) Code C81 (Model 8TB50 with Power Steer) Code C82 (Model 8TB50 with Power Steer) Code C83 (Model 8TB50 with Power Steer) Code C84 (Model 8TB50 with Power Steer) Code C85 (Model 8TB50 with Power Steer) Code C86 (Model 8TB50 with Power Steer) Code C87 (Model 8TB50 with Power Steer) Code C88 (Model 8TB50 with Power Steer) Code C89 (Model 8TB50 with Power Steer) Code C90 (Model 8TB50 with Power Steer) Code C94 (Model 8TB50 with Power Steer) CL398-13, Issued: 6 May 2013

5 Toyota Pallet Truck Service Manual Section 6. Messages and Codes List of Messages and Codes Error Codes Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E CL398-13, Issued: 6 May

6 Section 6. Messages and Codes Toyota Pallet Truck Service Manual List of Messages and Codes This page intentionally left blank CL398-13, Issued: 6 May 2013

7 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Traction Amplifier LED Section 6. Messages and Codes Diagnostics Figure 6-1. P a.jpg Traction Amplifier LED Diagnostics Traction Amplifier Status Indicator LED Error conditions involving the traction amplifier (TA) usually display as fault codes on the. See Caution and Error Codes on page 6-8. The TA also contains two Light Emitting Diodes (LEDs). See Figure 6-1. The two LEDs have five different display modes, indicating the type of information they are providing. See Table 6-1 and Table 6-2. LEDs Table 6-1. Traction Amplifier LED Display Modes Display Neither LED illuminated Orange LED flashing Orange and red LEDs ON solid Red LED ON solid Orange and red LEDs flashing alternately Status Controller is not powered ON or is severely damaged. Controller is operating normally. Controller is in Flash program mode. Watchdog failure. Cycle the truck OFF/ON to restart. Controller has found a fault. See Traction Amplifier Flash Codes on page CL398-13, Issued: 6 May

8 Section 6. Messages and Codes Traction Amplifier Flash Codes Traction Amplifier Flash Codes An internal microcontroller automatically examines the function of the Traction Amplifier (TA). When this microcontroller finds a fault, the LEDs on the bottom of the TA flash the appropriate code. See Table 6-2. Correct faults by following the Caution and Error Codes on page 6-8. NOTE: Toyota Pallet Truck Service Manual When displaying a fault code, the red LED flashes once for the first number, followed by the orange LED for the first number of the code itself. The red LED then flashes twice, followed by the orange LED flashing the second number of the code. Table 6-2. TA Flash Codes TA Flash Code Error Code Description Action 1,2 E201 Overcurrent Fault See Code E201 on page ,3 E202 TA Current Sensor Error See Code E202 on page ,4 E225 Pre-charge Fault See Code E225 on page ,5 E223 TA Severe Under-Temperature Cutback See Code E223 on page ,6 E224 TA Severe Over-Temperature Cutback See Code E224 on page ,7 E221 Severe Battery Undervoltage See Code E221 on page ,8 E222 Severe Battery Overvoltage See Code E222 on page ,2 Hot2 TA in Warm Thermal Cutback See Code Hot2 (C45) on page ,3 Lo Battery Undervoltage Warning See Code Lo (C41) on page ,4 Hi Battery Overvoltage Warning See Code Hi (C42) on page ,5 E233 +5V Supply Failure See Code E233 on page ,6 or C64 Digital Output Overcurrent See Code C64 on page ,7 2,7 C63 Digital Output Open/Shorted - Coast See Code C63 on page ,8 Hot1 Motor Temperature Hot Cutback See Code Hot1 (C44) on page ,9 C70 Motor Temperature Sensor Fault See Code C70 on page ,1 E106 Main Contactor Driver Overcurrent Error See Code E106 on page ,2 C66 Coil 2 Driver Open/Shorted - Brake See Code C66 on page ,3 C60 Coil 3 Driver Open/Shorted - Lift See Code C60 on page ,4 C62 Coil 4 Driver Open/Shorted - Horn See Code C62 on page ,5 C61 PD Driver Open/Shorted - Lower See Code C61 on page ,6 C71 Sensor Bearing Faulty See Code C71 on page ,7 E203 Motor Open See Code E203 on page ,8 E108 Contactor Weld Error See Code E108 on page ,9 E107 Contactor OFF Error See Code E107 on page ,6 E220 Default Parameters DNL See Code E220 on page CL398-13, Issued: 6 May 2013

9 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Traction Amplifier Flash Codes TA Flash Code Error Code 4,9 E228 Parameter Change Fault See Code E228 on page ,1 E150 or blank Initial CAN Message Not Received 5,3 C60 Lift Contactor Coil (M2) Driver Shorted or Open 6,1 E150 CAN Time-out Error or blank 6,3 E150 Ead SDO CAN Message or blank 6,5 E150 Ead Communication Spec or blank See Troubleshooting the CAN Bus on page 5-6. See Code C60 on page See Troubleshooting the CAN Bus on page 5-6. See Troubleshooting the CAN Bus on page 5-6. See Troubleshooting the CAN Bus on page ,8 E232 VCL Runtime See Code E232 on page ,9 E230 External Supply Out-of-Range See Code E230 on page ,1 E150 or blank CAN Time-out, No Truck Functions Active See Table 5-21 on page ,2 E150 or blank Description FDO CAN Message Time-out Action See Troubleshooting the CAN Bus on page ,3 C72 Traction Motor Stalled See Code C72 on page ,2 C67 EM Brake Not Set See Code C67 on page CL398-13, Issued: 6 May

10 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution and Error Codes Caution and Error Codes Figure 6-2. P tif Explanation of Symbols: A = Alpha-Numeric Field B = Hour Meter Indicator C = Parameter Control Indicator D = Battery Indicator E = Error Indicator NOTE: If a Service Key is inserted into the truck, the fault codes do not display on the. The fault is still active, and displays when the Service Key is removed. Caution Codes below 49 are not logged. See the following for how to clear the code and the allowed activity during error. Codes that apply to certain configurations are labeled to assist when servicing trucks. Electric Power Steering is optional equipment on Model 8TB50 tow tractors CL398-13, Issued: 6 May 2013

11 Toyota Pallet Truck Service Manual Caution Codes Section 6. Messages and Codes Caution Codes Code GATE Battery Gate Switch Open 'GATE' Travel limited to 1 MPH (1.6 km/h) Battery gate missing and operator moved handle out-of-neutral. The TA detected that Battery Gate Interlock switch S21 or S22 is open. Troubleshoot wiring to and from switches. See Pinout Matrix on page Make sure the battery gate is installed correctly. Adjust or replace switches. Code SLO Turtle Speed 'SLO' Travel Limited to Turtle Speed The 3-position key switch is in the Turtle Speed Position (normal operation), or broken wire with 2-position key switch. The TA detects IGN2 (High Speed Enable) is missing and limits speed. Test key switch. Test harness to JP10-2. Replace switch or repair harness. Code Sro (C14) SRO (Static Return to Off) 'Sro' Error (E) and Parameter Control (C) Indicators Blinking. See Figure 6-2. Truck is disabled (Emergency Reverse is Active) Control handle out of the brake position when the truck is turned ON. Spring-loaded handle or Power Steer handle is in the brake released range (out of position) or the fixed handle has the hand brake released prior to the system being powered ON. Confirm switch function if brake applied and fault persists. See Table 5-23, No Travel. Static Return to OFF (SRO) Fault. Display may indicate Sro and Error and Parameter Control Indicators Blinking, on page Apply brake CL398-13, Issued: 6 May

12 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C19 Default Parameter Warning C19 No effect on performance New default parameters have been loaded into RAM. None Self clears after timer expires (approximately 5 seconds). Code HPd (C20) HPD Directional/Speed Control Warning (High Pedal Disable) 'HPd' Error (E) and Parameter Control (C) Indicators Blinking. See Figure 6-2. Travel is disabled, all other systems active. Emergency reverse is active. Directional/Speed Control was not in neutral position at power ON, when brake is released, or during auto steer centering. Failure of the Hall Effect sensor in speed control circuit. Jog button controls activated when brake released. Floor Mat Switch: Travel or lift requested with floor mat switch open when in the travel restricted mode. Confirm directional/speed control in neutral, and handle sensors and wiring are correct. Examine function of jog switch and for shorts to related wiring harness. Return directional/speed controls to neutral position. Code C21 Travel request from Directional/Speed Control and Jog Switch at same time C21 Travel is disabled, all other functions are active. Emergency reverse is active. If the Jog Switch is actuated and the directional/speed control is rotated out of neutral, the system ignores the two commands. If commands are not active and code persists, examine sensors and wiring from directional/speed controls and jog switch. See Pinout Matrix on page Return directional/speed control to neutral and release Jog switch CL398-13, Issued: 6 May 2013

13 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code C22 Anti Tie-Down C22 Travel is limited to Jog Pick speed, all other systems perform normally. Rabbit switch pressed ahead of the brake being released or throttle being applied. Confirm Rabbit switch is not stuck or wiring is not shorted. See Pinout Matrix on page Release Rabbit switch. Code C24 Lost High Speed Enable Input C24 Travel is limited to Jog Pick speed. All other systems work normally. During truck operation the coast switch SW18 has stuck OPEN, a lead has come off the switch, or a lead has been damaged between the switch and the controller. Examine wiring to coast switch. Examine continuity of coast switch or open wires to JP10-2 if there is no switch. Repair bad part. Code C25 Jog Pick and Rabbit Requested at the Same Time C25 Turns off Coast (Jog Pick) Solenoid driver output and limits travel to Jog Pick speed. Both Coast Engage/Jog Switch and Rabbit switch are activated at the same time. If fault does not clear on releasing switches and cycling brake, examine for stuck switches or shorted wiring. See Pinout Matrix on page Self clears after both of the switches are released and brake is cycled OFF/ON CL398-13, Issued: 6 May

14 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C26 Lift Switch Stuck C26 Ignores stuck input. Turns off Lift Contactor. Lift contactor responds to input from alternate switch if equipped. Lift request ON longer than time out value (10 seconds) and the lift cut-out switch SW8 did not open. Either the lift cut-out switch is damaged (or out of adjustment) or the lift system is prevented from lifting (jammed or too heavy a load) to a point of activating the lift cut-out switch. Examine for stuck switch or shorted wiring harness. See Pinout Matrix on page Release Lift switch. Code C27 Lower Switch Stuck C27 System ignores stuck input. Turns off Lower Solenoid. Stuck switch is disabled if truck is equipped with an alternate switch and the alternate switch is still active. Lower solenoid responds to input from alternate switch if equipped. Lower request on longer than time out value (10 seconds). Lower switch is jammed or the operator is holding the switch for longer than is required to lower the forks. Examine for stuck switch or shorted wiring harness. See Pinout Matrix on page Release Lower switch. Code C30 Emergency Reverse has been Activated C30 Normal travel controls are disabled. The truck responds only to activations of the Emergency Reverse switch. The Emergency Reverse switch has been pressed and released. Cycle the brake (deadman) switch by engaging the brake. Clears after the brake is applied CL398-13, Issued: 6 May 2013

15 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code C31 Lost Brake Pot VR1 Input (Brake Pot Out-of-Range) C31 TA Flash Code 3,4 No Travel Brake pot input at JP1-17 is open. See Pinout Matrix on page Troubleshoot wiring to and from the Brake pot. Adjust or replace pot or repair wiring. Cycle the truck OFF/ON. Code C32 Emergency Reverse Before Brake Release C32 Travel is disabled The emergency reverse switch is activated (depressed) prior to the brake being released. Examine for stuck emergency reverse switch. Clears after the Emergency Reverse switch is released. Code C33 Horn Switch Stuck C33 Ignores stuck input. Turns off Horn. Horn responds to input from alternate source if equipped (this does not include the second horn switch on the control handle). Horn request ON longer than time out value (10 seconds). Stuck switch is disabled; if equipped with an alternate switch, the alternate switch is still active. Examine horn switch and related wiring. Examine grab rail switches if provided. See Pinout Matrix on page Release or repair Horn switch CL398-13, Issued: 6 May

16 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C34 Coast Engage Switch Stuck C34 Ignore stuck input. Turn off Coast (Jog Pick) solenoid. Coast solenoid responds to input from the Jog Switch. Jog Pick switch actuated longer than time out value (10 seconds). Stuck switch is disabled. Examine Jog Pick switch. Examine VM. Release Jog Pick switch. Code C35 Brake Switch Error C35 Normal travel controls are disabled. The truck responds only to activations of the Emergency Reverse switch if the traction motor is rotating in tractor-first direction. The brake switch is out of adjustment or damaged. At the same time the traction motor is detected rotating. See Pinout Matrix on page 8-13 and see Brake Potentiometer (VR1) on page 7-76 for brake switch adjustment. Apply brake and have the switch adjusted or replaced. Code C36 (Model 8TB50 with Power Steer) Steering Not Learned at Startup C36 No travel. Operator pushing on the steer tiller at key-on or handle not learned. None Return steering handle to neutral and cycle the truck OFF/ON. If still not clear, re-learn handle CL398-13, Issued: 6 May 2013

17 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code Lo (C41) Battery Undervoltage Warning 'Lo' Error (E) and Battery Indicator (D) Blinking. See Figure 6-2. TA Flash Code 2,3 Travel performance may be limited due to low voltage. Battery voltage below approximately 17V. Battery discharged or excessive load on battery. Measure battery voltage at JP3-1. Refer to Pinout Matrix on page Use service key to read voltage. See Service Input/Output Displays on page Battery needs to be charged. Examine battery and battery connections. The fault is cleared when the battery voltage increases above 17V. Code Hi (C42) Battery Overvoltage Warning 'Hi' Error (E) and Battery Indicator (D) Blinking. See Figure 6-2. TA Flash Code 2,4 Travel performance may be limited. Battery voltage over approximately 32V. This can be caused by wrong type of battery installed in truck or overcharged battery. Measure battery voltage at JP3-1. Refer to Pinout Matrix on page Use service key to read voltage. See Service Input/Output Displays on page Make sure that correct size battery is installed in truck. The fault is cleared when the battery voltage drops below 32V CL398-13, Issued: 6 May

18 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code Hot1 (C44) Motor Temperature Hot Cutback Hot1 TA Flash Code 2,8 Travel performance may be limited. Traction motor temperature above 248 F (120 C). Resistance of temperature sensor should be approximately 91 Ohms at room temperature. Verify the Traction Amp is hot. If it is not, disconnect JP7 at the traction motor and measure continuity. The resistance increases as the temperature increases. At 212 F (100 C), the resistance of the temperature sensor is approximately 100 ohms. At room temperature, the resistance is approximately 91 ohms. If it is, determine the cause by checking for mechanical drag such as brakes dragging, gear box issue, or load wheel binding. Check the current through U, V and W and verify that they are even. See Service Input/Output Displays on page Check for mechanical binding or brake drag. Permit motor to cool down. Replace temperature sensor. Code Hot2 (C45) Traction Power Amp Warm Thermal Cutback Hot2 TA Flash Code 2,2 Travel performance may be limited. TA internal heatsink temperature is above 185 F (85 C). Operation in extreme hot environment, excessive load on vehicle, or incorrect TA mounting. Verify the Traction Amp is hot. If it is, determine the cause by checking for mechanical drag such as brakes dragging, gear box issue, or load wheel binding. Check the current through U, V and W and verify that they are even. See Service Input/Output Displays on page Also see Table 5-22, No Travel or Slow Travel. TA Flash Code 2,2, (Thermal Cutback) Heatsink Temperature Exceeded 185 F (85 C). May Indicate Hot2 (C45), on page Take action to bring heatsink temperature into normal operating range CL398-13, Issued: 6 May 2013

19 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes NOTE: Caution Error Codes above 50 are logged. See the following tables for how to clear the code and the allowed activity during the error. Some codes can be cleared by cycling the truck OFF/ON. Code C50 Lift Switch Active on Power Up C50 Traction performance limited. Outputs available: Main, Horn, and Lower Grab Rail/Load Backrest Lift switch (SW15) active on power up, or pin 12 on TA shorted to B+. TA inputs to JP1-12 are ON. Examine switch and related wiring. Clear input (held switch, stuck switch, or shorted lead). Cycle the truck OFF/ON. Code C51 Lower Switch Active on Power Up C51 Traction performance limited. Grab Rail/Load Backrest Lower switch active on power up or pin 11 on TA shorted to B+. TA inputs to JP1-11 are ON. Examine switch and related wiring. Clear input (held switch, stuck switch, or shorted lead). Cycle the truck OFF/ON. Code C52 Grab Rail/Load Backrest Lift/Lower Switches Active at Same Time C52 Traction performance limited. Grab Rail/Load Backrest Lift and Lower switches active on power up, or pin 11 and 12 shorted to B+. TA inputs to JP1-11 or JP1-12 are ON. Examine Amplifier and related wiring. Clear inputs (held switches, stuck switches, or shorted leads). Cycle the truck OFF/ON CL398-13, Issued: 6 May

20 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C57 Brake Interlock Proximity Switch Input Mismatch C57 Hard Plug to 1 MPH (1.6 km/h) The TA detected that the input from the Brake Switch at JP1-9 and the Redundant Brake Switch input at JP1-24 do not match. Troubleshoot wiring to and from the Brake Switch. Troubleshoot wiring to and from the Redundant Brake Switch. See Pinout Matrix on page Investigate cause of open or short. Code C60 Lift Contactor Coil (M2) Driver Shorted or Open C60 TA Flash Code 3,3 or 5,3 Lift function not available. Lower functions normally. Lift coil driver open or shorted. Verify Parameter 38 is set correctly. See Service Parameters on page Examine lift contactor coil and wiring. Resistance of coil should be approximately 17 Ohms. See Pinout Matrix on page Investigate cause of open or short and repair or replace as needed. Code C61 Lower Solenoid Coil (Sol 1) Driver Shorted or Open C61 TA Flash Code 3,5 Lower function not available. Lift functions normally. Lower coil driver open or shorted. Examine for short or open for lower coil, or related wiring. Resistance of coil should be approximately 39 Ohms. See Pinout Matrix on page Investigate cause of open or short and repair or replace as needed CL398-13, Issued: 6 May 2013

21 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code C62 Horn Coil Driver Shorted or Open C62 TA Flash Code 3,4 Horn function not available. Horn coil driver open or shorted. Examine horn and related wiring. See Pinout Matrix on page Investigate cause of open or short and repair or replace as needed. Code C63 Coast Coil Driver Shorted or Open C63 TA Flash Code 2,7 Jog Pick function not available. Coast coil driver open or shorted. Resistance of coil should be approximately 37 Ohms. Examine for open or shorted Coast Coil driver circuit and related harness. See Pinout Matrix on page Investigate cause of open or short and repair or replace as needed. Code C64 Travel Alarm Inoperable C64 TA Flash Code 2,6 or 2,7 Travel limited to Coast speed. Digital output driver overcurrent Examine for shorted travel alarm, or related wiring. See Service Input/Output Displays on page See also Pinout Matrix on page Investigate cause of short and repair or replace as needed CL398-13, Issued: 6 May

22 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C65 Jog Switch Stuck C65 Turn off Coast Solenoid. Ignore throttle commands from the two jog controls Jog switch active longer than timer (10 seconds). Either the Jog Trigger has been held/pressed for longer than the time out or the switch is jammed in the operating condition. Examine function of jog switch and for shorts to related wiring harness. See Service Input/Output Displays on page See also Pinout Matrix on page Clear input (held switch, stuck switch, or shorted lead). Code C66 Brake Coil Driver Open or Shorted C66 TA Flash Code 3,2 No Travel The TA detected an open or short in the Brake Coil Driver circuit. Troubleshoot wiring to and from the brake and the brake coil for opens or shorts. The brake coil should have approximately 14 ohms resistance. See Pinout Matrix on page Determine cause of short or open circuit and correct. Code C67 EM Brake Not Set C67 TA Flash Code 9,2 No Travel Triggered if the brake switch is open (handle up) and the brake is applied and no motion is detected and then motion is detected without releasing the brake. A weak brake or excessive skidding and then gripping during a deadman braking event could cause this. Troubleshoot wiring to and from the brake and the brake coil for opens or shorts. The brake coil should have approximately 14 ohms resistance. See Pinout Matrix on page Check brake gap. See Checking the Gap on page Return throttle to neutral. Replace the brake or rotor as needed CL398-13, Issued: 6 May 2013

23 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code C68 Brake SelfTest Failed C68 Traction performance limited to 1 MPH (1.6 km/h) Brake did not hold the truck stationary during SelfTest. Check brake gap. See Checking the Gap on page Replace the brake or rotor as needed. Cycle the truck OFF/ON. Code C70 Motor Temperature Sensor Fault C70 TA Flash Code 2,9 Traction performance reduced. Failure of motor temperature sensor. Sensor or wiring to traction motor open or shorted. Resistance of temperature sensor should be 591 Ohms at room temperature. Examine component and related wiring for shorts or open condition. See Service Input/Output Displays on page See also Pinout Matrix on page Determine cause of short or open and correct. Code C71 Failure Detected in Traction Motor Feedback Encoder C71 TA Flash Code 3,6 Traction performance limited. TA detects the loss of traction motor encoder input. Use service key and test the traction motor encoder by scrolling to the RPM display (D) in diagnostic displays and command the motor to rotate. The value displayed is the motor RPM as reported from the TA. Examine wiring to traction motor encoder. See Service Input/Output Displays on page See also Pinout Matrix on page Troubleshoot and repair wiring to Traction Motor Encoder. If still not clear, replace the encoder CL398-13, Issued: 6 May

24 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C72 Traction Motor Stalled C72 TA Flash Code 7,3 Traction performance limited until code cleared. TA detects that the traction motor has stalled. Use service key and test the traction motor encoder by scrolling to the RPM display (D) in diagnostic displays and command the motor to rotate. The value displayed is the motor RPM as reported from the TA. See Service Input/Output Displays on page See also Pinout Matrix on page Cycle the truck OFF/ON. Code C74 (Model 8TB50 with Power Steer) Steer Unit Internal Error - General C74 No steering. Truck plugged to stop. No Travel. Brake applied at 0 mph. Fault internal to steer unit. None Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. If still not clear, replace the PSU controller. Code C75 (Model 8TB50 with Power Steer) Steer Unit Bus Voltage too Low (less than 12V) C75 No steering. Truck plugged to stop. No Travel. Bad wiring or contactor, blown fuse. None Error automatically cleared if possible when truck goes idle. Cycle the truck OFF/ON. If still not clear, replace the PSU controller CL398-13, Issued: 6 May 2013

25 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code C76 (Model 8TB50 with Power Steer) Steer Unit Bus Voltage too High (greater than 39 volts) C76 No steering. Truck plugged to stop. No Travel. Incorrect battery installed or possibly bad steer unit. Check battery voltage to the PSU. Make sure the correct voltage battery is installed. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Replace the PSU controller. Code C77 (Model 8TB50 with Power Steer) Steer Sensor 5V Power Supply Out-of-Range C77 No steering. Truck plugged to stop. No Travel. Short in wiring. Disconnect power steer sensor and check wiring for shorts. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller. Code C78 (Model 8TB50 with Power Steer) Steer Unit Calculated Temperature at 100% of Maximum or Steering is Stalled C78 No steering. Truck plugged to stop. No travel. Excessive loading and/or mechanical binding. 1. Check for mechanical binding. 2. Check motor current draw. Allow steer amplifier to cool. Replace the PSU CL398-13, Issued: 6 May

26 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C79 (Model 8TB50 with Power Steer) Steer Unit Measured Temperature Warning, 80% of Maximum C79 Reduced steering torque. No Travel slowdown. Excessive loading and/or mechanical binding. 1. Check for mechanical binding. 2. Check motor current draw. Allow steer amplifier to cool. Replace the PSU. Code C80 (Model 8TB50 with Power Steer) Steer Unit Calculated Temperature Warning, 80% of Maximum C80 Reduced steering torque. No Travel slowdown. Excessive loading and/or mechanical binding. 1. Check for mechanical binding. 2. Check motor current draw. Allow steer amplifier to cool. Replace the PSU CL398-13, Issued: 6 May 2013

27 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code C81 (Model 8TB50 with Power Steer) Steer Unit Sum of Analog Inputs Out-of-Range C81 No steering. Truck plugged to stop. No Travel. Wiring problem to steering sensor or failed sensor. Open or shorted R2 (carbon potentiometers only). 1. Run Learn on the steering. See Learn Steer on page Check wiring between pots and PSU. For trucks with a carbon potentiometer, the resistance of R2 should be 620 ohms. 3. Verify pot voltages, V1 and V2, per Pinout Matrix on page NOTE: Toyota FlashWare can be used to monitor the voltages of V1 and V2. 4. Verify correct version of software is in the VM and PSU. 5. Check for shorts to frame. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller. Code C82 (Model 8TB50 with Power Steer) Steer Unit Analog Inputs Shorted Together C82 No steering. Truck plugged to stop. No Travel. Wiring problem to steering sensor. Check wiring to V1 and V2. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller. Code C83 (Model 8TB50 with Power Steer) Steer Unit Analog Input V2 Out-of-Range C83 No steering. Truck plugged to stop. No Travel. Wiring problem to steering sensor or failed sensor. 1. Check wiring to V2. 2. Replace Power Steer Sensor. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller CL398-13, Issued: 6 May

28 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C84 (Model 8TB50 with Power Steer) Steer Unit Analog Input V1 Out-of-Range C84 No steering. Truck plugged to stop. No Travel. Wiring problem to steering sensor or failed sensor. 1. Check wiring to V1. 2. Replace Power Steer Sensor. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller. Code C85 (Model 8TB50 with Power Steer) Both Steer Unit Analog Inputs (V1 and V2) Out-of-Range C85 No steering. Truck plugged to stop. No Travel. Wiring problem to steering sensor or failed sensor. 1. Check wiring to V1 and V2. 2. Replace Power Steer Sensor. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller. Code C86 (Model 8TB50 with Power Steer) Steer Unit - Communication Failure C86 No steering. Truck plugged to stop. No Travel. No power to steering unit, broken CAN bus wires, or failed steer unit. 1. Check for B+ at JP9-6 and B at JP9-7 and JP Verify CAN bus wiring. See Troubleshooting the CAN Bus on page Check cable between PSU and steer sensor for shorts. 4. Disconnect sensors. If code changes, replace power steer sensor. Cycle the truck OFF/ON. Replace the PSU controller CL398-13, Issued: 6 May 2013

29 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Caution Codes Code C87 (Model 8TB50 with Power Steer) Home Switch Supply Out-of-Range C87 No steering. Truck plugged to stop. No travel. Bad wiring or failed home switch. Check wiring and voltage to switch. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Replace switch. Code C88 (Model 8TB50 with Power Steer) Reference Run Error C88 No steering. Truck plugged to stop. No Travel. Bad wiring, failed home switch, or failed steer unit. Check wiring and voltage to switch. Cycle the truck OFF/ON. Replace switch. Replace the PSU controller. Code C89 (Model 8TB50 with Power Steer) Steering Response is less than Request C89 Travel limited to 1 MPH (1.6 km/h) Binding drive unit and/or steering gears, failed steering unit. Check for binding in the steer gears and steering unit. Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. Replace the PSU controller CL398-13, Issued: 6 May

30 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Caution Codes Code C90 (Model 8TB50 with Power Steer) Steer Unit Internal Error - Shorted Phase C90 No steering. Truck plugged to stop. No Travel. Fault Internal to Steer Unit. None Error automatically cleared if possible when truck goes idle. If not, cycle the truck OFF/ON. If still not clear, replace the PSU controller. Code C94 (Model 8TB50 with Power Steer) Steer Unit Sum of Analog Inputs Warning Threshold Exceeded C94 Travel Limited to approximately 1.73 MPH (2.8 km/h) and the horn will beep three times in rapid succession. Wiring problem to steering sensor or steer sensor intermittent. 1. Run Learn on the steering. See Learn Steer on page Check wiring between pots and PSU. For trucks with a carbon potentiometer, the resistance of R2 should be 620 ohms. 3. Verify pot voltages, V1 and V2, following the Pinout Matrix on page NOTE: FlashWare can be used to monitor the voltages of V1 and V2. 4. Verify correct version of software is in the VM and PSU. 5. Check for shorts to frame. Error automatically cleared when the analog sum is back within threshold range when the handle is lifted to the brake position. If not, cycle the truck OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller CL398-13, Issued: 6 May 2013

31 Toyota Pallet Truck Service Manual Error Codes Section 6. Messages and Codes Error Codes NOTE: Error Codes are 100 and above. Error codes are logged. No truck activity is allowed during error. Some codes can be cleared when the truck is cycled OFF/ON (unless otherwise noted). Code E101 Traction Amp Type Error E101 No truck function active Incorrect Power Amplifier installed on truck. Determine correct TA P/N. Verify TA and VM software versions. Replace with correct TA. Code E106 Main Contactor Driver Over-current Error E106 TA Flash Code 3,1 No truck function active Short in main contactor coil. Resistance of coil should be approximately 37 Ohms. Examine main contactor for shorts to related wiring harness. See Table 5-13, No Travel, No Lift/Lower. TA Flash Code 3,1. May Indicate Error Code E106, on page Examine for shorted component or related wiring. Repair or replace as needed CL398-13, Issued: 6 May

32 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Error Codes Code E107 Contactor Off Error E107 TA Flash Code 3,9 No truck function active Main contactor did not close. Open in main contactor coil. Examine contactor circuit for opens in related wiring harness. See Table 5-16, No Travel, Main Contactor Does Not Close. TA Flash Code 3,9. Indicates Error Code E107, on page See Service Input/Output Displays on page Examine for open Main Contactor or related wiring. Repair/replace as needed. Code E108 Contactor Weld Error E108 TA Flash Code 3,8 No truck function active Main Contactor welded (detected on start-up). Open in U phase of traction motor. Inspect contact tips for welding. Check for B+ voltage at the B+ connection of the traction amplifier. See Service Input/Output Displays on page NOTE: Check the U cable for correct connection and continuity. An open in only the U circuit causes this code. An open in the V and W circuit causes codes E201 and E203. Examine for welded contact tips. Repair/replace as needed. Code E140 Checksum Error E140 No truck function active Software check sum not the same as the stored value. None May clear on cycling key switch OFF/ON. Reload software in the VM. If not, replace the VM CL398-13, Issued: 6 May 2013

33 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Error Codes Code E141 Software Problem E141 No truck function active VM internal error, or missing or faulty software due to a failure or problem while downloading. VM determined that software files were corrupt. None Reload the software as allowed. Code E150 CAN Bus Communication Error E150 No truck function active. Code may be displayed briefly then goes out. Grab rail (or load backrest) lift or lower switch active at power up. VM has not detected any response from TA to CAN messages. Bad connection or terminal crimp or a damaged wire between TA and VM. Check for low battery voltage. This can be caused by accidental activation (operator pressing the switches) at or during startup or pins 11 and 12 on the TA shorted to B+ (see codes C50, C51 and C52). Examine VM, TA, and related wiring. See Troubleshooting the CAN Bus on page 5-6. Repair/replace as needed. Code E157 CAN Bus Off Error E157 No truck function active TA did not reply to CAN messages. See Troubleshooting the CAN Bus on page 5-6. Examine VM, TA, and related wiring. Repair/replace as needed CL398-13, Issued: 6 May

34 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Error Codes Code E159 CAN Bus Overrun Error E159 No truck function active TA did not reply to CAN messages. See Troubleshooting the CAN Bus on page 5-6. Examine VM, TA, and related wiring. Repair/replace as needed. Code E160 Belly Button/Hall Supply Error E160 No truck function active Faulty hall effect sensor in handle (VM). None The VM is the likely cause. Replace the VM. Code E201 Overcurrent Fault E201 TA Flash Code 1,2 No truck function active TA faulty or motor short circuit. External short of U, V, or W traction motor connections. See Table 5-15, No Travel, No Lift/Lower. TA Flash Code 1,2. Indicates Error Code E201, on page See Service Input/Output Displays on page Investigate cause of apparent short. Start with cables, then replace TA and/or traction motor until problem is isolated CL398-13, Issued: 6 May 2013

35 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Error Codes Code E202 TA Current Sensor Error E202 TA Flash Code 1,3 No truck function active Phase current sensor fault. See Table 5-14, No Travel, No Lift/Lower. TA Flash Code 1,3. Indicates Error Code E202, on page See Service Input/Output Displays on page Investigate cause of apparent short. Start with cables, then replace TA and/or traction motor until problem is isolated. Code E203 Motor Open E203 TA Flash Code 3,7 No truck function active Motor phase V or W detected open. Bad power amplifier. NOTE: An open in the U phase causes a code E108. Examine motor and related wiring for open circuit. See Service Input/Output Displays on page Repair cause of open circuit. Code E220 Default Parameters DNL E220 TA Flash Code 4,6 No truck function active TA default parameters did not load. None Reload software if allowed CL398-13, Issued: 6 May

36 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Error Codes Code E221 Severe Battery Undervoltage E221 TA Flash Code 1,7, Battery icon blinking No truck function active Severe battery undervoltage, under 12V. Measure battery voltage and specific gravity. See Table 5-21, No Truck Functions Active. TA Flash Code 1,7, (Low Battery Voltage). May Indicate E221, on page See Service Input/Output Displays on page NOTE: Check for other codes and, if others are present, troubleshoot following those codes. (Failure of the M1 contactor circuit during operation causes this code to be shown along with E106 and E107.) Replace battery with fully-charged batter. A bad TA or bad wiring could also be the causey. Code E222 Severe Battery Overvoltage E222 TA Flash Code 1,8, Battery icon blinking No truck function active Severe battery overvoltage; over 42V during run time or above 32V at key ON. Measure battery voltage. See Table 5-20, No Truck Functions Active. TA Flash Code 1,8, (Excessive Battery Voltage). May Indicate E222, on page See Service Input/Output Displays on page Install battery of correct voltage. A bad TA or bad wiring could also be the cause. Code E223 TA Severe Undertemperature Cutback E223 TA Flash Code 1,5 No truck function active TA heatsink temperature below minimum operating temperature (below 40 C/ 40 F). Test the temperature sensor. See Service Input/Output Displays on page Warm truck to normal operating temperature and cycle the truck OFF/ON. Investigate to determine the cause of the undertemperature condition CL398-13, Issued: 6 May 2013

37 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Error Codes Code E224 TA Severe Overtemperature Cutback E224 TA Flash Code 1,6 No truck function active TA heatsink temperature over maximum operating temperature (+95 C/203 F). Test temp sensor. See Service Input/Output Displays on page Allow truck to cool. Investigate to determine the cause of the overheating. Code E225 Precharge Fault E225 TA Flash Code 1,4 No truck function active TA precharge circuit failed. None Try cycling the truck OFF/ON. If that does not solve the problem, replace the TA. Code E228 Parameter Change Fault E228 TA Flash Code 4,9 No truck function active TA parameters have changed. Critical TA parameter changed while operating. None Cycle the truck OFF/ON CL398-13, Issued: 6 May

38 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Error Codes Code E230 External Supply Out-Of-Range E230 TA Flash Code 6,9 No truck function active External supply current out-of-range (+12V, +5V). Devices connected to these outputs on the TA are drawing too much current (> 250 ma). Check all wiring and components connected to the 12 volts from the TA for shorts. If OK, check the wiring and encoder connected to JP1-26 for the traction motor for shorts. Cycle the truck OFF/ON. If not cleared by cycling the truck OFF/ON, try to determine what device caused the problem. Code E232 VCL Runtime E232 TA Flash Code 6,8 No truck function active Internal TA software error. None Cycle the truck OFF/ON. Reinstall software if allowed. Code E233 +5V Supply Failure E233 TA Flash Code 2,5 No truck function active Controller +5V supply failed. Check all wiring and components connected to the 12 volts from the TA for shorts. If OK, check the wiring and encoder connected to JP1-26 for the traction motor for shorts. See Code E230. See Pinout Matrix on page Cycle the truck OFF/ON CL398-13, Issued: 6 May 2013

39 Toyota Pallet Truck Service Manual Section 6. Messages and Codes Error Codes Code E235 NVM Reset Error E235 No truck function active TA NVM (Non-Volatile Memory) error. TA Non-volatile memory corrupted, unable to reset. None Try cycling the truck OFF/ON. If that does not solve the problem, replace the TA. Code E252 Not Speed Program E252 No truck function active Detected Inputs/Outputs do not match the selected configuration. None Truck may not be configured to match Sub Model type (Parameter 37). See Programming Service Parameters on page 3-9. Code E253 Invalid Sub Model E253 No truck function active Detected Inputs/Outputs do not match the selected configuration. None Truck may not be configured to match Sub Model type (Parameter 37). See Programming Service Parameters on page CL398-13, Issued: 6 May

40 Section 6. Messages and Codes Toyota Pallet Truck Service Manual Error Codes This page intentionally left blank CL398-13, Issued: 6 May 2013

41 SERVICE INFORMATION BULLETIN Control Circuit CC January 15, 2013 ETAC Software Update Information and Descriptions 8HBW30, 8HBC(E)30-40 and 8TB50 Subject: ETAC Software Update Information and Descriptions Page 1 of 2 MODEL APPLICATION: 8HBW30, 8HBE30-40, 8HBC30-40 and 8TB50 GENERAL INFORMATION: Two new software versions are currently available and are downloadable from the TMHU Portal via TIS (Toyota Information System). REPAIR INFORMATION: This bulletin explains the software version information including a description of changes and additions to each software versions. 1. Error code C88 can be logged with older versions of PSU software. Loading a new version of code with Flashware should correct this issue. If loading the new version does not correct the C88 error code, the PSU must be replaced. 2. A Code C78 now causes the VM to command the truck to plug to a stop on tow tractors with Electric Steer. 3. Previous versions of software would not record or display two error codes that are detected by the power amp, E150 and E235. The traction system would shut down in these cases, but no error would be reported. This version now records and displays the errors. 4. Travel speed will now be consistent when in a slight turn with or without a load. 5. Auto steer center is now enacted any time the main contactor is disabled then re-enabled on an electric steer truck. If the throttle is engaged while an auto steer center is in progress, an HPd will be displayed. Traction is disabled until the throttle is returned to neutral. 6. The maximum steering angle on an Electric Steer tow tractor can be adjusted from 20 degrees through 80 degrees based on direction of travel (default is 80 degrees in both directions). Use parameter #22 for forks-first maximum steer angle and parameter #23 for tractor-first maximum steer angle. 7. Instances of nuisance error codes C74, C86, and C88 have been reduced on trucks equipped with a PSU.

42 Subject: ETAC Software Update Information and Descriptions Page 2 of 2 The following software is being used in current production effective serial numbers: 8HBW , 8HBE , 8HBE , 8HBC , 8HBC and 8TB Added a minimum delay of 400 milliseconds between back to back lifts to prevent contactor chatter. 2. Added more options to Travel Alarm (Parameter 16) so that travel and battery cutout alarm can occur at the same time on 8TB50 trucks. The battery cutout alarm sounds slightly different and takes priority over the travel alarm. 0=No Alarm 1=Tractor-First Travel 2=Forks-First Travel, 3=All Travel 4=Low Battery 5=Low Battery and Tractor-First Travel, 6=Low Battery and Forks-First Travel 7=Low Battery and All Travel 3. Changed the following on electric steer trucks: a. Reduced logging of C88 error codes by increasing the steering speed during auto steer center. b. Made steer centering more accurate. The time allowed for completion was also increased. c. Re-Enabled backlash parameter setting for electric steer tow tractors sent to the PSU from the VM when the key is turned ON to eliminate the clunking sound some tow tractors made when steering. 4. Parameter 11 will now show up on all 8HBC30-40 and 8TB50 trucks. On trucks without electric steer, the parameter must be set to 0 or the travel function will be disabled. 5. Added a drop down for Toyota 8HBC3040/8TB50 Trucks in FlashWare. Changed Truck code to automatically set/clear the Tow bit based on the configured model. Setting the Truck as Model 8HBC30/40 will clear the Tow bit. Setting the Truck as Model 8TB50 will set the Tow bit. 6. Added detection of LOS (Limited Operating Strategy) mode being reported by the Power Amp. This does not change truck functionality because the Amp is already limiting the truck speed, but now an error code will be displayed (Code 72) when the Truck is in LOS mode.

43 SERVICE INFORMATION BULLETIN Control Circuit CC May 31, TB50 Power Steering Software Update (v1.9) 8TB50 with Power Steering Subject: 8TB50 Power Steering Software Update (v1.9) Page 1 of 1 MODEL APPLICATION: 8TB50 with Power Steering GENERAL INFORMATION: This bulletin is being distributed to notify dealers and field personnel of the following changes included in the ETAC software version 1.9 for the 8TB50 with power steering. The update includes: Addition of new Code C94. Changes to Code C81 SERVICE INFORMATION: Flashware software file name is: 915A0019.s19. Install software 915A0019.s19 and PSU (Power Steer Unit) software 915A9160.s19 for the Code C94 to be enabled. If either of the new software versions are combined with an older software version, the C94 code will not be displayed. Code C94 information: Code C94 has been added to identify lower steer unit sum of analog inputs out-of-range conditions. See page 6-28 of the 8 series pallet truck service manual CL issued May 6, 2013 for troubleshooting information. C94 is similar to C81 except C94 attempts to detect the out-of-range condition sooner using a smaller range and where C81 will disable steering and plug the truck to a stop; C94 leaves the steering enabled and slows the truck to 1.7 mph. in the event of a C94: - The horn will beep three times in rapid succession. - Steering remains enabled but travel is de-rated to 1.7 mph. - If the out-of-range condition returns to normal before the handle is lifted to the brake position, the code is cleared when the handle is lifted and normal operation is resumed. Change made to Code C81: - If the out-of-range condition returns to normal while the truck is plugging to a stop, steering will be re-enabled.

44 SERVICE INFORMATION BULLETIN Chassis Electrical CE May 31, 2013 C81 Code Steer Potentiometer 8TB50 with Power Steering Subject: C81 Code Steer Potentiometer Page 1 of 9 MODEL APPLICATION: 8TB50 with Power Steering GENERAL INFORMATION: Some customers have reported code C81 at low hour meter readings. This code may be caused by the carbon steer potentiometer. A solid state potentiometer (P/N ) is now available as a replacement. Follow the instructions on the following pages when replacing a carbon steer potentiometer with a solid state potentiometer. Use FlashWare and install VM software version 1.9 or higher (915A0019.s19) and PSU software version 160 or higher (915A9160.s19). Note: Please be sure to re-learn the steering using Flashware after installation. SERVICE INFORMATION: Steering Potentiometer Replacement instructions for Solid State Potentiometer 1. Remove the Control Handle (P/N ): a. Remove the (4) screws around the bezel.

45 Subject: C81 Code Steer Potentiometer Page 2 of 9 b. Lift the entire assembly out of the handle bracket. c. The cable is retained in the bracket and can be removed by releasing the retainer at bottom of bracket. 2. Remove the (2) screws in the face of the cover. Remove the (2) screws on the side of the cover, then remove the cover. Note: The screws in the plastic on the face are coarse thread, the screws in the side are fine thread. 3. Remove the (2) screws in the cover.

46 Subject: C81 Code Steer Potentiometer Page 3 of 9 4. Remove the cover over the cable, cut the wire tie, and remove. 5. Remove the (4) screws indicated to separate the control handle. Unplug the (2) connectors on the harness, one from the side of the housing, one at the base of the handle. Cut the wire ties at the holders. Note where the cables were tied and length of the service loop left available. Remove the entire cable assembly and potentiometer. These will be replaced with the new Solid State Steering potentiometer/cable. 6. Connect the new potentiometer and cable assembly (P/N ) to the housing and the proximity sensor cable. Use a wire tie to secure the cables to the yellow wire tie pad.

47 Subject: C81 Code Steer Potentiometer Page 4 of 9 7. Rotate the wire tie so the end rests on either side of the cables but not on top for clearance reasons. 8. Reassemble in the upper handle with (4) screws. It is important to torque these screws to 12 in. lbs. (1.35 Nm). CAUTION: Over torqueing can cause throttle to bind. Test operation of the throttle to verify return to center when activated.

48 Subject: C81 Code Steer Potentiometer Page 5 of 9 9. Assemble the upper handle assembly back into the mounting bracket. Push the cable retainer at the end of the new cable into the retainer hole in the bracket before lowering the handle. Route the cable between the front edge of the bracket and post on the lower bearing. 10. Insert the potentiometer into the cavity at the base of the handle. 11. The shaft of the potentiometer must engage the D shaped opening in the bottom bearing. Refer to the picture below to see the indexing feature on the lower bearing for the potentiometer.

49 Subject: C81 Code Steer Potentiometer Page 6 of Replace the two screws that mount the potentiometer with M3 x 16 mm screws (P/N ). Apply thread-locking compound (P/N ) to the screws. Install the cover over the loomed cable with the larger loom opening oriented out away from the handle and the smaller towards the handle. Make sure no wires are caught under the flanges of the cover when assembled. 13. Wire tie cables together as shown. Make sure to maintain a service loop for the handle to rotate up and down.

50 Subject: C81 Code Steer Potentiometer Page 7 of Replace the two lower covers. 15. Install the (4) screws around the perimeter of the top bezel. NOTE: Do Not use thread-locking compound on the bezel screws or near the plastic. 16. Replace the Resistor Module shown below with a jumper (P/N ).

51 Subject: C81 Code Steer Potentiometer Page 8 of Inspect splices SPL11, SPL12, and SPL13 to verify complete crimps were performed. Note: SPL11 can sometimes be buried in the center of the harness. Make sure there is a crimp on both the wire area and the insulation area of the splice. If a crimp is weak or missing, manually crimp and document what needed to be done.

52 Subject: C81 Code Steer Potentiometer Page 9 of 9 Replace any removed cable ties. 18. Install new Vehicle Manager software (version 1.9 or higher) into the truck using Flashware 5.5 or above. 19. Install new Power Steer Unit software (version 160 or higher) into the truck using Flashware 5.5 or above. 20. Relearn steering using Flashware 5.5 or above and test the function of the truck before returning the truck to service.

53 SERVICE INFORMATION BULLETIN Control Circuit CC October 15, 2013 Vehicle Manager and Traction Amp Software Updates 8HBW30, 8HBE30-40, 8HBC30-40, 8TB50 and 8TB50 with Power Steering Subject: Vehicle Manager and Traction Amp Software Updates Page 1 of 2 MODEL APPLICATION: 8HBW30, 8HBE30-40, 8HBC30-40, 8TB50 and 8TB50 with Power Steering GENERAL INFORMATION: This bulletin is being distributed to notify dealers and field personnel of a new software release for the Vehicle Manager (VM) and Traction Power Amplifier (TPA) on the above models. IMPORTANT: To install these software updates you must use Flashware 5.7 or later. On the 8HBC30-40 and 8TB50 with Power Steering if the PSU (Power Steer Unit) software is older than 915A9160.s19, please update accordingly as these software updates are designed to work together. (example of old PSU software: 915A9140 or 9150) Flashware 5.7 and the s19 software files are available for download on TIS. Please remember to uninstall the current version of Flashware on your computer before installing the new version. SERVICE INFORMATION:

54 Subject: Vehicle Manager and Traction Amp Software Updates Page 2 of 2 Summary of Changes included in these software updates: 1) Reduced the occurrence of C81 error codes by increasing some timeouts for the solid state steer potentiometers by a factor of 10 (Changed from 2 ms to 20 ms). 2) Reduced the occurrence of C83 and C84 error codes on trucks with the solid state steer potentiometers when the truck is powered on and the handle is not centered. 3) Reduced the occurrence of C74 error codes when the truck is powered on. 4) Disabled the Lift contactor driver check on Model 8TB50 trucks. 5) Changes were made to improve the reliability of the lift contactor which include a new Traction Amplifier Flash Code, 5,3. It will be shown on the operator display as a Code C60 - Lift Contactor Coil (M2) Driver Shorted or Open. Troubleshooting in the repair manual for the Code C60 remains the same (See page 6-18 of manual CL398-13). This change requires: a) Flashware 5.7 or higher to update the TPA. b) The new VM sofware for the truck being updated (as shown in the table on page 1), and c) the updated Traction Amp sofware version ) Added error code E109 to indicate the failure of a device on the truck to respond to a CAN message sent by the VM. The original code for this was C86. Use the C86 Steer Unit Communication Failure information in the repair manual to troubleshoot a code E109. (See page 6-26 of manual CL398-13) NOTE: Trucks produced after the following model-serial numbers will have these software updates. 8HBW HBE HBE HBC HBC TB

55 SERVICE INFORMATION BULLETIN Control Circuit CC August 15, 2014 Power Steer Unit Controller Repair Instructions 8HBE30-40, 8HBC30-40, 8TB50 Subject: Power Steer Unit Controller Repair Instructions Page 1 of 2 MODEL APPLICATION: Power Steer Models: 8HBE30, 8HBE40, 8HBC30, 8HBC40 and 8TB50 GENERAL INFORMATION: This bulletin is being released to announce that the power steer unit (PSU) controller is now available separately from the motor, gearbox and pinion gear and to provide instructions for how to replace the controller section of the power steer unit assembly. Power Steer Unit Controller individual part (P/N ) Motor, gearbox, and pinion gear without Controller (P/N ) SERVICE INFORMATION: In the Service Manual (00700-CL398-13) the following changes have been made: Change the wording in Codes C74, C75, C76, C86, C88, C89, and C90 in the How to Clear section from Replace the PSU to Replace the PSU Controller. Change the wording in Codes C77, C81, C82, C83, C84, C85, and C94 in the How to Clear section from Replace the PSU to Run Learn Steer. If the code does not clear, then replace the PSU Controller. Added instructions for replacing the power steer unit controller on page 7-13 Please use the following procedures when removing and installing the controller. Removing and Installing the PSU Controller 1. Remove the PSU from the truck. 2. Place the PSU on a Static Mat. Put on the wrist strap and connect the ground cord to the mat. 3. Remove the two screws connecting the controller to the motor. 4. Grab the casing with the bare hand to avoid potential electrical differences between your body and the unit. NOTE: Do not wear gloves.

56 Subject: Power Steer Unit Controller Repair Instructions Page 2 of 2 5. Carefully lift the controller slightly and turn it 90 degrees. See figure 1. Connect the ground cord to the housing of the controller before performing the next step. Figure 1 6. Remove the connector by pressing the locking device to the left. See figure 2. Remove the three flat pin connectors (to the left in the picture). Do NOT pull on the motor cables/wires directly. Grip the connector itself and pull. Figure 2 7. Remove the new controller from its packaging. Connect the ground cord to the housing of the controller. 8. Reconnect the wires as shown in figure 2. From left to right, the three wire colors are Red, Black, and Yellow. Connect the small wires. Make sure the locking tab engages. 9. Place the controller onto the motor. Make sure no cables are pinched between the housing and motor. Apply a drop of thread-locking compound (P/N ) on the screws. Torque the screws to 7 in. lb. (80 Nm). 10. Install the PSU assembly in the truck. Run Learn and test for correct operation. Steering can be learned using FlashWare or the Service Key. See pages 7-13 and 7-14 of the repair manual for instructions.