The document provides troubleshooting steps for a machine that failed to power up. It involves 29 steps to test components like batteries, wires, connectors, switches and contactors. The steps instruct the user to check for voltage at key points and replace or repair any faulty components. If the machine still does not power up after following all steps, the user is advised to contact technical support.

1. MACHINE FAILED TO POWER UP
STEP ACTION VALUE(S) YES NO
1 Key Off Position. Reset Circuit Breakers
CB2, CB3 and check that E-Stop is
disengaged.
Were the Circuit
Breakers Tripped or
the E-Stop
Engaged?
Reset and test
power up circuit
operation
Go to Step 2
Go to Step 2
2 Key Off Position. Disconnect and test battery
side Anderson Connector. Attach positive test
lead to Anderson Connector positive terminal
and negative test lead to Anderson Connector
negative terminal.
Is the total battery
voltage greater then
30 VDC?
Go to Step 7 Go to Step 3
3 Key Off Position. Test total battery bank’s
voltage using a voltmeter. Place the positive
test lead on the positive battery post and the
negative test lead on the negative battery post.
Is the total battery
voltage greater then
30 VDC?
Test Terminals
and wires from
Anderson
Connector to
Batteries. Repair
or Replace.
Go to Step 2
Go to Step 4
4 Key Off Position. Test the connections on all
of the batteries. Recharge the batteries with
the correct battery charger and charger profile
if still necessary.
Is the total battery
voltage greater then
30 VDC?
Go to Step 2 Go to Step 5
5 Check the Specific Gravity of the batteries
and replace the batteries if your readings are
low.
Do your readings
indicate to replace
the batteries?
Replace batteries
Go to Step 2
Go to Step 6
6 Key Off Position. Test all of the wires
connected to all of the batteries.
Did you find any
damaged wires?
Replace Wires
Go to Step 2
Go to Step 2
7 Key Off Position. Plug Anderson Connector
in. Attach positive test lead to the input side
of M1B contactor and negative test lead to the
negative standoff.
Is the total battery
voltage greater then
30 VDC?
Go to Step 10 Go to Step 8

2. STEP ACTION VALUE(S) YES NO
8 Key Off Position. Plug Anderson Connector
in. Backprobe with positive test lead to the
M1 side positive Anderson Connector
terminal and backprobe with negative test
lead to Standoff side of the negative
Anderson Connector Terminal.
Is the total battery
voltage greater then
30 VDC?
Repair or
Replace
damaged wire(s)
between M1 and
Anderson
Connector
Go to Step 7
Go to Step 9
9 Key Off Position. Check all Anderson
Connector terminals and connections on both
sides of the Anderson Connector.
Was there damage
to the Anderson
Connector?
Repair or
Replace
Anderson
Connector
Go to Step 7
Go to Step 7
10 Key Off Position. Test Voltage to Terminal
50 (4/YEL) of the Key Switch. Place positive
test lead on Terminal 50 (4/YEL) and
negative test lead on negative battery
terminal.
Is voltage close to
total battery
voltage?
Go to Step 15 Go to Step 11
11 Key Off Position. Test Voltage at Terminal
CB3 (3/ORA). Place positive test lead on
Terminal CB3 (3/ORA). Place negative test
lead on negative battery terminal.
Is voltage close to
total battery
voltage?
Go to Step 13 Go to Step 12
12 Key Off Position. Test Voltage at Terminal
CB3 (1/RED). Place positive test lead on
Terminal CB3 (1/RED). Place negative test
lead on negative battery terminal.
Is voltage close to
total battery
voltage?
Replace Circuit
Breaker CB3
Go to Step 10
Check
Connections,
Repair or Replace
Wire 1/Red
Go to Step 10
13 Key Off Position. Back probe for voltage on
Terminal D-2 (4/YEL). Place positive test
lead on Terminal D-2 (4/YEL). Place negative
test lead on negative battery terminal.
Is voltage close to
total battery
voltage?
Repair or
Replace 4/YEL
wire.
Go to Step 10
Go to Step 14
14 Key Off Position. Back probe for voltage on
Terminal D-2 (3/ORA). Place positive test
lead on Terminal D-2 (3/ORA). Place
negative test lead on negative battery
terminal.
Is voltage close to
total battery
voltage?
Replace Diode
D-2
Go to Step 10
Repair or Replace
Wire 3/ORA
Go to Step 10

3. STEP ACTION VALUE(S) YES NO
15 Key Start Position. Place positive test lead on
E-Stop Switch (7/PUR) Terminal and
negative test lead on negative battery
terminal. (Hold key in Fully Clockwise
Position)
Is the voltage close
to the total battery
voltage?
Go to Step 18 Go to Step 16
16 Key Start Position. Place positive test lead on
E-Stop Switch (6/BLU) Terminal and
negative test lead on negative battery
terminal. (Hold key in Fully Clockwise
Position)
Is the voltage close
to the total battery
voltage?
Replace E-Stop
Switch
Go to Step 15
Go to Step 17
17 Key Start Position. Place positive test lead on
Terminal 15 (6/BLU) of the key switch and
negative test lead on negative battery
terminal. (Hold key in Fully Clockwise
Position)
Is the voltage close
to the total battery
voltage?
Repair or
Replace Wire
6/BLU
Go to Step 15
Replace Key
Switch
Go to Step 15
18 Key Start Position. Place positive test lead on
Charger Interlock (8/GRY) Terminal and
negative test lead on negative battery
terminal. (Hold key in Fully Clockwise
Position)
Is the voltage close
to the total battery
voltage?
Go to Step 21 Go to Step 19
19 Key Start Position. Place positive test lead on
Charger Interlock (7/PUR) Terminal and
negative test lead on negative battery
terminal. (Hold key in Fully Clockwise
Position)
Is the voltage close
to the total battery
voltage?
Go to Step 20 Repair or Replace
Wire 7/PUR
Go to Step 18
20 Check the Charger Interlock Switch to make
sure that the wire 7/PUR is plugged into the
common terminal of the switch and that wire
8/GRY is plugged into the Normally Closed
terminal of the switch.
Is the charger
interlock switch
plugged in
correctly?
Replace Switch
Go to Step 18
Plug Charger
Interlock Switch in
Correctly
Go to Step 18
21 Key Start Position. Place positive test lead on
M1A (8/GRY) Terminal and negative test
lead on negative battery terminal. (Hold key
in Fully Clockwise Position)
Is the voltage close
to the total battery
voltage?
Go to Step 22 Repair or Replace
Wire 8/GRY
Go to Step 22

4. STEP ACTION VALUE(S) YES NO
22 Key Start Position. Place positive test lead on
M1A (8/GRY) Terminal and negative test
lead M1A (13/BLK) Terminal. (Hold key in
Fully Clockwise Position)
Is the voltage close
to the total battery
voltage?
Replace M1
Contactor
Go to Step 23
Repair or Replace
Negative Wire
13/BLK
Go to Step 23
23 Key Start Position. Observe if M1 contactor is
energized. Place positive test lead on M1B
contactor output and negative test lead on
negative battery terminal. (Hold key in Fully
Clockwise Position)
Is the voltage close
to the total battery
voltage?
Go to Step 24 Replace M1
Contactor
Go to Step 24
24 Key Start Position. Place positive test lead on
Terminal 30 (5/GRN) and negative test lead
on negative battery terminal. (Hold key in
Fully Clockwise Position)
Is the voltage close
to the total battery
voltage?
Go to Step 29. Go to Step 25.
25 Key Start Position. Place positive test lead on
Terminal CB2 (10/Tan) and negative test lead
on negative battery terminal. (Hold key in
Fully Clockwise Position)
Is the voltage close
to the total battery
voltage?
Go to Step 27. Go to Step 26.
26 Key Start Position. Place positive test lead on
Terminal CB2 (2/BRN) and negative test lead
on negative battery terminal. (Hold key in
Fully Clockwise Position)
Is the voltage close
to the total battery
voltage?
Replace Circuit
Breaker CB-2.
Go to Step 24.
Repair or Replace
Wire 2/BRN Go to
Step 24.
27 Key Start Position. Place positive test lead on
Terminal D-1 (5/GRN) and negative test lead
on negative battery terminal. (Hold key in
Fully Clockwise Position)
Is the voltage close
to the total battery
voltage?
Repair or
Replace Wire
5/GRN
Go to Step 24
Go to Step 28
28 Key Start Position. Place positive test lead on
Terminal D-1 (10/TAN) and negative test lead
on negative battery terminal. (Hold key in
Fully Clockwise Position)
Is the voltage close
to the total battery
voltage?
Replace
Diode D-1
Go to Step 24
Repair or Replace
Wire 10/TAN Go
to Step 24

5. STEP ACTION VALUE(S) YES NO
29 Key Start Position listen for click of Contactor
M1. Let key go to Key Run(On) Position.
Does Machine
Power up correctly?
Run a Self test to
determine if any
other systems
have faults.
Finish up and
close out.
Contact Tech
Support who will
assist you with
difficult problems.
 VDC = Volts Direct Current
 After Replacing a Component, Fixing a Wire, or repairing a problem. Check for Machine Power Up.
 Key Start Position = Holding key in fully clockwise position like starting a car.
 Key Run(On) Position = Vehicle is running and key has been let go of.
 30 VDC is a bottom reference voltage for a T12 being able to function.
 If a new part does not function after installing it, take the new part out and test it.
 Ladder diagrams show electrical components in their electrical sequence of operation not in their
physical locations.
 As a general rule ladder diagrams are read from left to right and top to bottom.
 M1 Contactor = The Entire Solenoid (The Coil and the Contacts)
 Contacts with the same letter or number as the coil are controlled by that coil.
(Example M1A = The Coil and M1B = The Contacts)
 Dashed lines between components mean that they are mechanically connected.
(Example Terminal 50 (4/YEL) ------- Terminal 15 (6/BLU) and Terminal 30 (5/GRN) ------- Terminal 15 (6/BLU) )