Hyster Yale Error Code 524245-4

DTC 524245-4 – Operator Presence System Sensor Out Of Range Low (OORL)

Possible Cause

A. SENSOR SUPPLY OPEN CIRCUIT
B. SENSOR SIGNAL OPEN CIRCUIT
C. SENSOR SIGNAL SHORTED TO SENSOR GROUND
D. SENSOR SIGNAL SHORTED TO FRAME GROUND
E. SENSOR FAILURE
F. FUNCTIONAL FAILURE IN CONTROLLER

Component Operational Check

PROCEDURE OR ACTION:

1. Turn power to OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
   Does reported DTC reoccur?
   YES: Go to Step 2.
   NO: Problem not verified. Resume operation.
2. Conduct a quick visual inspection of all connectors/wiring associated with the displayed fault code.
   Are any faults detected/observed?
   YES: Repair/replace connector or wiring associated with faults found.
   NO: Go to CAUSE A.

CAUSE A – SENSOR SUPPLY OPEN CIRCUIT

PROCEDURE OR ACTION:

1. Turn truck power ON.
2. Disconnect indicated sensor connector.
3. Change DMM to volts scale.
4. At sensor harness connector, measure voltage across sensor supply pin (+) and sensor ground pin (-).
   Is voltage approximately 5Vdc?
   YES: Sensor supply circuit wiring is OK. Go to CAUSE B.
   NO: Go to Step 5.
5. Move negative (-) meter lead to a clean frame ground.
   Is voltage approximately 5Vdc?
   YES: Sensor return has open circuit. Locate and repair/replace open wire/connection.
   NO: Sensor supply has open circuit. Locate and repair/replace open wire/connection.

CAUSE B – SENSOR SIGNAL OPEN CIRCUIT

PROCEDURE OR ACTION:

1. Ensure truck power is OFF.
2. Disconnect indicated sensor connector.
3. Change DMM to ohms scale. Verify DMM zero reading.
4. At sensor harness connector, measure resistance between sensor signal pin (+) and sensor ground pin (-).
   Is resistance approximately equal to the resistor value shown in applicable schematic?
   YES: Go to CAUSE F.
   NO: If resistance measurement is infinite, sensor signal wire has open circuit. Locate and repair/replace open wire/connection. If resistance measurement is less than 0.5 ohms,
   go to CAUSE C.

CAUSE C – SENSOR SIGNAL SHORTED TO SENSOR GROUND

PROCEDURE OR ACTION:

1. Disconnect indicated sensor connector and VSM/ECU/GCU connector.
2. At the sensor harness connector, measure resistance between sensor signal pin (+) and sensor ground pin (-).
   Is resistance less than 0.5 ohms?
   YES: Sensor signal wire is shorted to sensor ground wire. Locate and repair/replace shorted wire/connector.
   NO: Go to CAUSE D.

CAUSE D – SENSOR SIGNAL SHORTED TO FRAME GROUND

PROCEDURE OR ACTION:

1. At the sensor harness connector, measure resistance between sensor signal pin and a clean frame ground on truck.
   Is resistance less than 0.5 ohms?
   YES: Sensor signal wire is shorted to frame ground. Locate and repair/replace shorted wire/connector.
   NO: Go to CAUSE E.

CAUSE E – SENSOR FAILURE

PROCEDURE OR ACTION:

1. Ensure truck power is OFF.
   NOTE: Do not discard original sensor after removal.
2. Replace sensor.
3. Ensure that all connections are completely inserted.
4. Turn truck power ON.
   Does reported DTC reoccur?
   YES: Reinstall original sensor and go to CAUSE F.
   NO: Problem has been corrected. Resume operation. Discard faulty sensor.

CAUSE F – FUNCTIONAL FAILURE IN CONTROLLER

PROCEDURE OR ACTION:

1. Ensure all previous procedures have been completed.
2. Ensure truck power is OFF.
3. Ensure that all connections to the controller are completely inserted.
4. Ensure truck power is OFF for no less than 30 seconds, and then to ON to clear displayed DTC.
   Does reported DTC reoccur?
   YES: Go to Step 5.
   NO: Problem corrected. Resume operation.
5. At the DSC, press ENTER to access Main Menu.
6. Scroll to VIEW VERSIONS, press ENTER.
7. Scroll to TRUCK SERIAL NUMBER, press ENTER.
8. View the TRUCK SERIAL NUMBER on the display.
   Does the truck serial number on display match serial number on truck nameplate (VSM Only)?
   YES: Go to Step 9.
   NO: Controller has been substituted from another truck. Replace VSM with VSM that has the correct truck serial number or obtain new VSM with correct Serial number/ CDF. See Electrical System 2200SRM1142.
9. Resident Service Approval Required prior to VSM replacement for Trucks under warranty. Make sure to indicate the DTC code(s) on the warranty claim and include an accurate problem description leading to the controller replacement.
10. For other controllers, Replace indicated controller. (ECU-ECM/GCU/TCU).
11. Reinstall all removed components and ensure that all connectors are completely inserted.
12. Repeat Component Operational Check.