Hyster A099, Troubleshooting Manual

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d. Probing the back of connectors for obtaining in-
line voltage measurements requires a special
probe extension for the meter probes. Failure
to use this tool can result in damage to the in-
tegrity of the connector seal and may cause a
failure in the harness/connector assembly. See
Wire Harness Repair 2200SRM1128.
5. Most electrical problems will be harness related:
• Connectors not fully engaged and locked
• Connector pins not fully inserted
• Circuit repairs incorrectly wired at connec-
tors
• Damaged connector pins
6. Major component service tips:
a. Vehicle System Manager (VSM):
• Connectors are keyed and color coded
• Non-serviceable part
• Last replaceable item in troubleshooting
procedures
• Do not transfer VSMs or Display Panel
from other trucks
• Always confirm VSM/Display Panel and
lift truck serial numbers match before
doing any servicing
7. When troubleshooting electrical/electronic faults
and symptoms:
a. Verify that the connector is properly engaged
and that connector security clips, tabs, and
other locking devices are properly attached.
b. Visually examine the connectors and harness
termination points for “pushed” or “recessed”
pins or sockets.
c. The Electric Truck Battery Negative and Posi-
tive are isolated from the Vehicle Frame. Un-
less directed in a Procedure, no measurements
will be made using the vehicle frame as an
electrical path.
d. Before opening any connector or removing any
wires from their termination point, disconnect
the circuits from the battery as directed in the
procedure. Trucks are equipped with a Emer-
gency Disconnect Switch. Pushing the emer-
gency disconnect switch in until it clicks, dis-
connects the power supply to the lift truck.
NOTE: The Electrical System Schematic referenced
in this manual will be supplied in Diagrams. Verify that
this data is current and the revisions are up to date
before making any changes or alterations to the truck
wiring.
Prior to making any corrections or changes to
the wiring, verify that the wire number and color
coincide with the information on the referenced
schematics, wiring diagrams, or special instruc-
tions, if any.
NOTE: There may be customer options and equip-
ment installed on the lift trucks by third-party services
that do not comply with the standard wiring specifica-
tions and standards. Suppliers are encouraged to fol-
low these standards for circuits when possible.
8. The chassis wiring used in these vehicles con-
forms to the electrical circuit identification stand-
ard ES-1359 and in addition to surface marked ID
circuit numbers, generally utilizes the colors that
are indicated below.
a. Red = Battery level power circuits
b. Black = Heavy current grounds
c. Green = Signal Grounds
d. White = Other circuits
e. Twisted Pair (preferred CAN option)
• Yellow = CANbus Hi
• Green = CANbus Lo
f. Twisted Pair (non-preferred CAN option)
• White = CAN-Hi
• White = CAN-Lo
g. Orange = 5 volt
h. Pink = 12 volt
9. Connectors used on schematics and reference
drawings are identified as follows: See Fig-
ure 9030-03-1 in this section.
a. CPSXXX -- Connector Plug Socket (CPS) ,
with XXX being the identity number.
b. CRPXXX -- Connector Receptacle Pin
(CRP) , with XXX being the identity number.
10. At the completion of a Troubleshooting Proce-
dure, verify the following:
General Maintenance and Diagnostic Data Electrical System
Check the Service Manual section in Hypass Online for possible updates and check pertinent Grams
9030-03-2 Confidential/Proprietary - Do Not Copy or Duplicate