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AC MOTOR

CONTROLLER
B60Z AC [B230];
B80Z AC [B233]

PART NO. 1640805 2200 SRM 1286


SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.

Wear safety glasses.

DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair


on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
AC Motor Controller Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Description ......................................................................................................................................................... 2
Electrical System ........................................................................................................................................... 2
AC Traction Motor..................................................................................................................................... 3
Controller................................................................................................................................................... 3
Service PC Connection .............................................................................................................................. 3
Parameters ......................................................................................................................................................... 3
General ........................................................................................................................................................... 3
Parameter Description....................................................................................................................................... 4
Parameters..................................................................................................................................................... 4
Extended Shift........................................................................................................................................... 4
Walk Speed (Both Directions) ................................................................................................................... 4
Hi Speed (FWD)......................................................................................................................................... 5
Hi Speed (REV).......................................................................................................................................... 5
Minimum Acceleration.............................................................................................................................. 5
Maximum Acceleration ............................................................................................................................. 5
Plugging ..................................................................................................................................................... 5
ADS-Throttle ............................................................................................................................................. 5
ADS-Neutral .............................................................................................................................................. 5
Pick Acceleration ....................................................................................................................................... 5
Pick Deceleration....................................................................................................................................... 5
Battery Full Voltage .................................................................................................................................. 5
Battery Empty Voltage.............................................................................................................................. 5
Min Steering Assist (High Speed FWD)................................................................................................... 5
Min Steering Assist (High Speed REV) ................................................................................................... 5
Maximum Steering Assist ........................................................................................................................ 6
Troubleshooting.................................................................................................................................................. 6
General ........................................................................................................................................................... 6
Status Codes .................................................................................................................................................. 6
Dash Display ...................................................................................................................................................... 52
General ........................................................................................................................................................... 52
Startup ........................................................................................................................................................... 52
Status LED .................................................................................................................................................... 52
Performance Mode Indicator......................................................................................................................... 52
Hourmeter...................................................................................................................................................... 53
Battery Charge Indicator .............................................................................................................................. 53
Fault Log ........................................................................................................................................................ 53
Connector Pin-Outs............................................................................................................................................ 54
System Logic Diagram....................................................................................................................................... 55

This section is for the following models:

B60Z AC [B230];
B80Z AC [B233]

2007 HYSTER COMPANY i


"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1286 General

General
This section describes the Iskra motor controller
and dash display used in B60Z AC and B80Z AC lift
trucks. Procedures are outlined for controller pro-
gramming and troubleshooting.

DISCHARGING THE CAPACITORS

WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.

WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.

CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.

1. Move the truck to a safe, level area. Turn the


key switch to the OFF position and disconnect
the battery.

2. Remove the drive unit compartment cover to ac- 1. CONTROLLER


2. POSITIVE CONNECTION
cess the controller. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
3. Discharge the capacitors in the controllers by 5. NEGATIVE CONNECTION
connecting a 200-ohm, 2-watt resistor across the
controllers B+ and B terminals. See Figure 1. Figure 1. Discharging Controller - B60Z AC and
DO NOT short across the motor controller termi- B80Z AC
nals with a screwdriver or jumper wire. Remove
the 200-ohm, 2-watt resistor before reconnecting
the battery.

1
Description 2200 SRM 1286

Description
ELECTRICAL SYSTEM power steering motor. The controller uses CANbus
communication to interact with the dash display and
The Iskra AC motor controller controls the AC trac- the control handle. See Figure 2.
tion motor and the DC pump motor. The controller
can also be used with the optional brushless DC

1. GRAB RAIL 8. PUMP MOTOR


2. AUXILIARY CONTROL BOX 9. BRAKE
3. DASH DISPLAY 10. STEER MOTOR (POWER STEER ONLY)
4. BRAKE SWITCH (POWER STEER ONLY) 11. TRACTION MOTOR
5. CONTROL ARM POTENTIOMETER (POWER 12. CONTACTOR
STEER ONLY) 13. CONTROLLER
6. KEY SWITCH 14. POWER FUSE
7. HORN 15. PC CONNECTOR (ETACC)

Figure 2. Component Location (Power Steer Shown)

2
2200 SRM 1286 Parameters

AC Traction Motor The motor controller receives power through the


main contactor which is controlled by the key
The AC traction motor is a three-phase AC induction switch. The controller receives inputs from the con-
motor. The motor does not include motor brushes or trol handle and the hand rail switches to control lift
a commutator. An AC induction motor operates on truck functions.
three-phase AC power provided directly by the con-
troller. The motor speed is controlled by the motor NOTE: There are no serviceable parts in the motor
controller and can be changed by the frequency of the controller. No attempt should be made to open re-
AC power supplied to the motor. A speed sensor has pair, or otherwise modify the controller. Doing so
been built into one of the motor bearings which pro- may damage the controller and/or lift truck. Remov-
vides feedback to the motor controller allowing soft- ing the cover from the controller will void the war-
ware to continually monitor motor direction and rev- ranty.
olutions per minute (RPM). Using this feedback sys-
tem, the AC motor control can provide much better Service PC Connection
vehicle top speed control than the older DC SEM sys-
tems. The lift truck is equipped with a connection point to
connect a laptop computer with ETACC software in-
Controller stalled. This connection can be used to adjust certain
lift truck parameters and to assist with troubleshoot-
The motor controller converts DC power from the ing the lift truck.
truck battery to three-phase AC power at the fre-
quencies and currents necessary to drive the traction
motor. A bearing in the traction motor provides feed-
back of speed, rotation direction, and temperature di-
rectly to the motor controller.

Parameters
GENERAL Parameters can be adjusted through the dash dis-
play. The factory default values listed in Table 1 are
A parameter is a measurement or a setting that de- the recommended settings for new units. These set-
fines a lift truck function. A specific function param- tings will give satisfactory performance for most ap-
eter works with other function parameters to control plications.
the operation of the lift truck.

WARNING
WARNING If any of the parameter values are changed, the
The parameter for each function has a value operators must be told the lift truck will oper-
range so the motor controller can be used on ate differently.
different models of lift trucks. This variation
is needed for lift trucks of different sized and NEVER adjust any of the following parameters
operation voltages. Adjustment of a function without using the procedures and settings
to the wrong number value for your lift truck given in this section.
model can cause the truck to operate differ-
ently than normal. This different operation of Function Parameter Descriptions in this section
the truck can cause an injury. contains descriptions for the different parameters.
These parameters can also be accessed using the
NOTE: Table 1 shows the factory default setting for ETACC PC software.
each parameter that is adjustable by the user.

3
Parameter Description 2200 SRM 1286

Table 1. Parameter Default Values

Parameter Default Range


B60Z AC B80Z AC Min Max
Extended Shift OFF OFF ON OFF
Walk speed (Both Directions) 3.8 3.8 1.0 4.0
Hi Speed (FWD) 9.0 9.0 0.5 9.0
Hi Speed (REV) 5.0 5.0 0.5 7.5
Minimum Acceleration 5 5 1 10
Maximum Acceleration 6 6 1 10
Plugging 7 7 1 10
ADS-Neutral 1 1 1 10
ADS-Throttle 1 1 1 10
Pick Acceleration 6 6 1 10
Pick Deceleration 1 1 1 10
Battery Full Voltage 25.300 25.300 24.500 26.500
Battery Empty Voltage 23.520 1 23.520 1 20.000 24.000
Min Steering Assist 3 3 1 10
(High Speed) FWD
Min Steering Assist 3 3 1 10
(High Speed) REV
Maximum Steering Assist 9 9 1 10
1
Maintenance-free battery option uses value 24.000.

Parameter Description
PARAMETERS Extended Shift
This parameter when on, will reduce traction perfor-
WARNING mance by 15% to provide extended battery shift life.
If any of the parameter values are changed, the The parameter may be set to the OFF or ON condi-
operators must be told the lift truck will oper- tion.
ate differently.

NEVER adjust any of the following parameters


Walk Speed (Both Directions)
without using the procedures and settings This parameter sets the maximum truck speed for
given in this section. forward and reverse directions when the truck is in
Walk mode. Increasing the setting will increase
Parameters can be adjusted through the dash display
the truck speed. Decreasing the setting will decrease
LCD. These parameters can also be accessed using
truck speed.
the ETACC PC software.

4
2200 SRM 1286 Parameter Description

Hi Speed (FWD) the rate of deceleration; the truck will coast until it
comes to a stop. Increasing the value will increase
This parameter sets the maximum forward speed of the rate of deceleration. Decreasing the value will
the lift truck when the truck is in Ride mode. In- decrease the rate of deceleration.
creasing the setting increases the speed. Decreasing
the setting will decrease the speed. Pick Acceleration
Hi Speed (REV) This parameter controls the rate of acceleration
when the coast control switch is activated. Increas-
This parameter sets the maximum reverse speed of ing the value will increase the rate of acceleration.
the lift truck when the truck is in Ride mode. In- Decreasing the value will decrease the rate of accel-
creasing the setting increases the speed. Decreasing eration.
the setting will decrease the speed.
Pick Deceleration
Minimum Acceleration
This parameter controls the rate of deceleration
This parameter sets the minimum acceleration rate when the coast control switch is released. Increas-
of the lift truck when the truck is in traveling at the ing the value will increase the rate of deceleration.
lowest throttle. Increasing the setting increases the Decreasing the value will decrease the rate of decel-
minimum rate of acceleration. Decreasing the set- eration. Setting the value at 1 will result in no effect
ting will decrease the minimum rate of acceleration. on the rate of deceleration; the truck will coast until
it comes to a stop.
Maximum Acceleration
Battery Full Voltage
This parameter sets the maximum acceleration rate
of the lift truck when the truck is traveling at max- This is the battery voltage in millivolts at which the
imum throttle. Increasing the setting increases the battery is considered fully charged. Increasing the
maximum rate of acceleration. Decreasing the set- setting increases the voltage. Decreasing the setting
ting will decrease the maximum rate of acceleration. reduces the voltage.

Plugging Battery Empty Voltage


This parameter controls the maximum rate of decel- This is the battery voltage in millivolts at which the
eration when the speed control is fully moved to the battery is considered 80% discharged. Increasing the
opposite direction from the direction of travel while setting increases the voltage. Decreasing the setting
the truck is moving. Increasing this setting will in- reduces the voltage.
crease the rate of deceleration. Decreasing the set-
ting will reduce the rate of deceleration. Min Steering Assist (High Speed FWD)
ADS-Throttle This parameter sets the minimum steer assist pro-
vided by the steering motor when the lift truck is
This parameter controls the rate of deceleration traveling at high speed in the forward direction.
when the speed control is partially reduced and the Increasing the parameter setting will increase the
ADS-Throttle parameter is set above 1. Setting amount of assist. Decreasing the setting will de-
the value at 1 will result in no effect on the rate of crease the amount of assist.
deceleration; the truck will coast until it reaches
the lower throttle speed. Increasing the value will Min Steering Assist (High Speed REV)
increase the rate of deceleration. Decreasing the
value will decrease the rate of deceleration. This parameter sets the minimum steer assist pro-
vided by the steering motor when the lift truck is
ADS-Neutral traveling at high speed in the reverse direction.
Increasing the parameter setting will increase the
This parameter controls the rate of deceleration amount of assist. Decreasing the setting will de-
when the speed control is returned to the neutral po- crease the amount of assist.
sition and the ADS-Throttle parameter is set above
1. Setting the value at 1 will result in no effect on

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Troubleshooting 2200 SRM 1286

Maximum Steering Assist rest or very low speed. Increasing the parameter set-
ting will increase the amount of assist. Decreasing
This parameter sets the maximum steer assist pro- the setting will decrease the amount of assist.
vided by the steering motor when the lift truck is at

Troubleshooting
GENERAL Tools and test equipment required are:
Clip Leads
The controllers are sealed units with no serviceable Digital Multimeter (20,000 ohms per volt)
components. Troubleshooting is usually limited to Basic Hand Tools
accessing status codes and following the diagnostic
procedures listed in the status code charts. Check resistance on the proper scale from frame to
power and controller terminals. Resistance of less
Use standard testing procedures to verify inputs and than 20,000 ohms can cause misleading symptoms.
outputs when necessary. Resistance of less than 1000 ohms indicates a short
and should be corrected immediately.
CAUTION The on-board diagnostic system employed on this lift
Never attempt to probe through the back of truck can assist in the troubleshooting process. Read
the connector plugs of the motor controller. and be familiar with the instructions for accessing
The plugs are special sealed plugs. Probing and using the dash display diagnostic system.
through the back of the plugs will destroy the
seal and can cause a short circuit. If a circuit Prior to troubleshooting systems and components on
must be tested for voltage, check for voltage this lift truck, ensure the battery is the correct volt-
at an amp-type plug, a switch, or a component. age and is fully charged. Make sure the battery con-
If a circuit is suspect, check the circuit for nector contacts are clean of corrosions and the bat-
continuity from the front (pin end) of the plug. tery polarity within the connector is correct. Inspect
to ensure all fuses are correct and have not failed.
Standard probes are too large to be inserted Ensure the key switch is in the ON position when
into the center of the female pins (sockets) of making voltage checks or checking the operator of a
the special sealed plugs and can expand the component.
pins. Expanded pins will not provide good con-
nections once the plug is reconnected. The con- Many faults noted by lift truck systems are the result
nectors are shaped to allow the insertion of a of loose wiring connections and/or broken or shorted
flat blade screwdriver into the connector. After wiring within the lift truck. Begin the troubleshoot-
inserting the screwdriver into the connector, ing process by carefully inspecting the wiring involv-
attach probes with alligator clips to the shank ing the device or devices noted by the on-board diag-
of the screwdriver to obtain readings. An addi- nostics system.
tional method would be to use a breakout kit.
STATUS CODES
If the controller detects an issue, a status code is dis-
played on the display panel. Make sure the parameter values are correct for your
lift truck to ensure the trouble is not just an incorrect
Once the status code number is obtained, follow the setting. See function settings to set the correct pa-
procedures outlined in the status code charts of this rameter values. If there is no status code display and
manual to determine the problem. the lift truck does not operate correctly, there may be
a fault in the master controller.
NOTE: Due to the interaction of the controller with
all lift truck functions, almost any status code or con- The status codes are numbers for malfunction or lift
troller fault could be caused by an internal failure of truck operation that are not correct and that the mo-
the controller. After all other status code procedures tor controller can sense. The master controller will
have been followed and no problem is found, the con- indicate this code number on the LCD screen of the
troller should be replaced as the last option to correct display panel.
the problem.

6
2200 SRM 1286 Troubleshooting

NOTE: There are identifiers to determine which de- NOTE: A status code indication does not always mean
vice generated the code: that there is a malfunction. A temporary operation
Xy = XXXX (Co 23538) condition can cause a status code display.
Co = Controller
Ep = PAS Unit These code numbers are only indicators that may
Ti = Steer Handle Card help diagnose a possible malfunction. A short de-
scription of the different status codes is shown in Ta-
The controller senses the following types of malfunc- ble 2.
tion:
Input voltages that are too high or too low The Fault Message charts in this section have a more
Input voltages in the wrong sequence or complete description of the status code, the circuit
Correct input voltages that occur at the wrong time that has generated the input for the status code, the
symptom, and the possible cause.

Table 2. Fault Codes

Code Description
9024 Controller failure of the traction motor power circuit
9088 Pump motor shorted
9089 Pump motor open
9090 Pump at relief
9091 Controller failure of the pump motor power circuit.
12816 Controller internal voltage over 36 volts
12819 Incorrect voltage battery connected
12832 Controller internal voltage less than 16 volts
12835 Incorrect voltage battery connected
16912 Controller power section is over temperature

16944 Controller is in thermal cutback - high controller temperature


16945 Controller internal temperature sensor failure
17168 Traction motor is over temperature
17169 Controller is in thermal cutback - high traction motor temperature
17170 Traction motor temperature sensor failure
20756 Key switch open
21024 Steer handle card failure
21376 Traction Reversing switch closed at startup
21378 Controller cannot establish contact with steer handle card
21533 Horn circuit is shorted to B+
21534 Horn circuit is open
21535 Horn circuit is shorted to B
21544 Horn switch is closed at startup
21552 Steer handle inputs incorrect at startup

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Troubleshooting 2200 SRM 1286

Table 2. Fault Codes (Continued)

Code Description
21553 Hi Speed switch is closed at startup
21555 Lift or lower switch is closed at startup
21568 Main contactor circuit is open
21569 Main contactor circuit is shorted to B+
21570 Main contactor circuit is open
21571 Main contactor circuit is shorted to B
21588 Internal failure of the power steering unit
29445 Traction motor encoder failure
29448 Steer handle switch closed at startup
29456 Error in steer handle card speed/direction sensor
29458 Steer handle sensor is out of limits
29472 Failed or maladjusted sensor
33056 Controller cannot establish communication with steer handle card
33057 Controller cannot establish communication the power steering controller
36864 Power Steering security line set to LOW
65281 Power steering torque sensor has failed
65282 Mechanical failure within the power steering system

8
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9024 Service Required Solid Red Traction
DESCRIPTION SYMPTOM
Traction motor phase U, V, or W Truck will not operate.
shorted to B+ or B .
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and disconnect the battery connector.
2. Disconnect the motor leads from the controller.
3. Check motor for phase-to-ground or phase-to-B+ shorted condition.
a. Motor should measure minimum 1 megohm phase-to-ground.
i. Replace traction motor.
4. Check U, V, and W terminals of the controller for shorted condition to B+ or B .
a. Contact NMHG Service Engineering Contact Management.

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Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9088 Service Required Solid Red Pump
DESCRIPTION SYMPTOM
Pump motor has shorted. Hydraulics will not operate.
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and disconnect the battery.
2. Disconnect pump motor leads from controller.
a. Check for any burns or evidence of arcing.
3. Visually check motor leads for any damage or evidence of shorting to the truck frame.
a. Check for any burns or evidence of arcing.
i. Repair or replace any damaged wiring.
4. Check for P terminal at the controller shorted to B .
a. Resistance should be greater than 50 megohms.
i. Contact NMHG Service Engineering Contact Management.
5. Replace pump motor.

10
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9089 Service Required Solid Red Pump
DESCRIPTION SYMPTOM
Pump motor has open circuit. Hydraulics will not operate.
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and disconnect the battery connector.
2. Disconnect pump motor cables from the controller.
3. Verify continuity through each motor cable.
a. Replace any broken wiring.
4. Check for open circuit across the across the motor terminals.
a. If greater than 500 ohms, replace the pump motor.

11
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9090 Overload Flashing Red Pump
DESCRIPTION SYMPTOM
Controller has detected the hydraulic Hydraulics will not operate.
system is being operated at relief.
Probable Causes and Test Procedures
1. Verify weight of load does not exceed lift truck capacity on the nameplate.
a. Reduce load weight.
2. Verify there is no binding in the lifting mechanism.
3. Install a 24.13 MPa (3500 psi) pressure gauge in the lift cylinder line.
a. Verify the relief pressure is correct:
i. B60Z AC = 18.96 MPa (2750 psi)
ii. B80Z AC = 23.44 MPa (3400 psi)
4. Adjust relief pressure to correct value.
a. See Walkie Hydraulic Systems 1900 SRM 964.

12
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9091 Internal Pump Circuit Failure Solid Red Pump
DESCRIPTION SYMPTOM
Controller has detected an internal Truck will not operate.
failure in the pump circuit.
Probable Causes and Test Procedures
1. Verify 24 volts at the controller B+ terminal.
a. Ensure battery is connected to the lift truck.
b. Verify continuity of fuse FU 1.
2. Turn the key switch to the OFF position.
3. Disconnect cable PM1 at the P controller terminal.
a. Check for a shorted condition between P and B
i. Resistance should be greater than 500 ohms.
ii. Contact NMHG Service Engineering Contact Management.
4. Disconnect cable PM1 at the P controller terminal and reconnect it to the controller B terminal.
a. Turn the key switch to the ON position and verify the pump motor operates.
b. Contact NMHG Service Engineering Contact Management.

13
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
12819 Check Battery Flashing Red Battery
DESCRIPTION SYMPTOM
Controller has detected a battery voltage Truck will not operate.
in excess of 32 volts.
Probable Causes and Test Procedures
1. Check battery voltage at controller B+ terminal.
2. Verify battery voltage matches voltage listed on the lift truck nameplate.
a. Install correct voltage battery.

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2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
12832 Check Battery Flashing Red Battery
DESCRIPTION SYMPTOM
The controller has sensed battery voltage Truck will not operate.
to be less than 16 volts.
Probable Causes and Test Procedures
1. Check battery voltage at controller B+ terminal.
2. Verify battery voltage matches voltage listed on the lift truck nameplate.
a. Install correct voltage battery.
3. Condition can be caused by normal operation of the lift truck with a discharged battery.
a. Check battery state of charge on the dash display.
i. Recharge battery.
ii. Install a fully charged battery.
4. Check for continuity through fuse FU 1.
a. Replace fuse.

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Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
12835 Check Battery Flashing Red Battery
DESCRIPTION SYMPTOM
Controller has detected a battery with Truck will not operate.
less than 16 volts has been connected
to the lift truck.
Probable Causes and Test Procedures
1. Check battery voltage at controller B+ terminal.
2. Verify battery voltage matches voltage listed on the lift truck nameplate.
a. Install correct voltage battery.

16
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
16912 Wait to Cool Down Flashing Red Battery
DESCRIPTION SYMPTOM
Controller is over temperature. Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Service Technician Functions On-Board Dash
Display 2200 SRM 1324.
3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position
and operate the lift truck briefly.
4. Verify fault does not repeat.
a. Contact NMHG Service Engineering Contact Management.

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Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
16944 Performance Reduced Flashing Red Controller
DESCRIPTION SYMPTOM
Truck is in thermal cutback due to high Traction system is operating at a reduced
controller temperature. performance level.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Service Technician Functions On-Board Dash
Display 2200 SRM 1324.
3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position
and operate the lift truck briefly.
4. Verify fault does not repeat.
a. Contact NMHG Service Engineering Contact Management.

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2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
16945 Service Required Solid Red Controller
DESCRIPTION SYMPTOM
Controller has detected an internal failure Traction system is operating at reduced
in the power bridge temperature sensor. performance level.
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and restart the lift truck.
2. Verify the fault has reoccurred on the dash display.
3. Let truck sit for 10 minutes.
4. Restart the lift truck.
a. Fault reoccurs.
i. Contact NMHG Service Engineering Contact Management.

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Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
17168 Over Temp Flashing Red Traction Motor
DESCRIPTION SYMPTOM
Controller has detected an over temperature Traction and hydraulic systems will not operate.
condition in the traction motor.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Service Technician Functions On-Board Dash
Display 2200 SRM 1324.
3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the
ON position and operate the lift truck briefly. Check the dash display to verify fault does not repeat.
4. If fault repeats:
a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector.
b. Resistance should measure approximately 5.9 ohms 10% at 25 C (77 F).
i. Replace sensor.
5. Contact NMHG Service Engineering Contact Management.

20
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
17169 No Text Displayed Solid Green Traction Motor
DESCRIPTION SYMPTOM
Controller is in thermal cut back due to Traction system is operating at a reduced
high traction motor temperature. performance level.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Service Technician Functions On-Board Dash
Display 2200 SRM 1324.
3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the
ON position and operate the lift truck briefly.
4. Check the dash display to verify fault does not repeat.
5. If fault repeats:
a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector.
b. Resistance should measure approximately 5.9 ohms 10% at 25 C (77 F).
i. Replace sensor.
6. Contact NMHG Service Engineering Contact Management.

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Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
17170 Service Required Solid Red Traction Motor
DESCRIPTION SYMPTOM

Controller has detected a failure of the Traction system is operating at a reduced


traction motor temperature sensor. performance level.
Probable Causes and Test Procedures
1. Disconnect the traction motor temperature sensor connector at the traction motor.
2. Check for continuity of wire #386 between the connector and pin #25 at the controller.
a. Repair any broken wiring or loose connections.
3. Check for continuity of wire #102 from the connector to pin #29 at the controller.
a. Repair any broken wiring or loose connections.
4. Measure the resistance across pin #1 and pin #2 of the sensor side of the connector.
a. Resistance should measure approximately 5.9 ohms 10% at 25 C (77 F).
5. If measurement indicates an open or shorted sensor, replace sensor.

22
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
20756 Service Required Solid Red Key
DESCRIPTION SYMPTOM
The controller has sensed the key Truck will not operate.
switch circuit is open.
Probable Causes and Test Procedures
1. Verify the key switch is turned to the ON position.
2. Verify the battery is connected to the lift truck.
3. Check condition of FU 5.
a. Verify continuity through the fuse.
4. Check for battery voltage on pin #1 (wire #10) at the controller connector.
a. Check for open wire #10 between connector and key switch.

23
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21024 Service Required Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected a failure in Traction and hydraulic systems will not operate.
the steer handle card.
Probable Causes and Test Procedures
1. Verify battery voltage at pin #7 at the steer handle card connector.
a. Check continuity of wire #10 from key switch to pin #7 at steer handle card connector.
2. Ensure all wiring connections between the steer handle card and the controller are tight and secure.
3. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 60 ohms.
i. If resistance is approximately 120 ohms, check wiring for broken or shorted condition.
ii. Repair all damaged wiring.
4. Internal failure of the steer handle card.
a. Replace steer handle card.

24
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21376 Improper Start Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected the belly switch Traction system will not operate.
being closed at system startup.
Probable Causes and Test Procedures
1. Check that traction reversing switch on the steer handle is not being held closed at startup.
a. Release switch.
2. Verify all steer handle wiring connections are tight and secure.
3. Check resistance across switch terminals for a shorted traction reversing switch.
a. Replace steer handle card.

25
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21378 Service Required Solid Red Controls

DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the steer handle card.
Probable Causes and Test Procedures
1. Ensure all wiring connections between the steer handle card and the controller are tight and secure.
2. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 40 ohms.
i. If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
3. Check for continuity between pin #1 at the steer handle card connector and pin #28 at the controller
connector.
a. Repair any broken wiring.
4. Check for continuity between pin #2 at the steer handle card connector and pin #27 at the controller
connector.
a. Repair any broken wiring.
5. Check for continuity between pin #4 at the steer handle card connector and pin #29 at the controller
connector.
a. Repair any broken wiring.

26
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21521 Service Required Solid Red Hydraulics
DESCRIPTION SYMPTOM
Controller has detected the lower Hydraulic system will not operate.
valve shorted to B+.
Probable Causes and Test Procedures
1. Disconnect the pump coil connector at the lift pump.
2. Check for a shorted condition across the coil leads at the connector.
a. Replace the coil.
3. Check for shorted wiring on wire #150 and wire #86 between the pump coil and the controller.
a. Repair any damaged wiring.
4. Check for a shorted condition between pin #22 and pin #23 at the controller and B .
a. Resistance should be greater than 1000 ohms.
i. Contact NMHG Service Engineering Contact Management.

27
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE

21522 Service Required Solid Red Hydraulics

DESCRIPTION SYMPTOM
Controller has detected an open circuit Hydraulic system will not operate.
in the lower valve.
Probable Causes and Test Procedures
1. Disconnect the pump coil connector at the lift pump.
2. Measure the resistance across pins from the pump coil.
a. Resistance should be approximately 1 ohm.
i. Replace the coil.
3. Check for open circuit condition in wire #150 and wire #86 from the connector to pin #22 and pin #23 at
the controller.
a. Repair broken wiring or loose connections.

28
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21533 Service Required Solid Red Horn
DESCRIPTION SYMPTOM
Controller has detected the horn Hydraulic system will not operate.
shorted to B+.
Probable Causes and Test Procedures
1. Measure the resistance between the red lead and the black lead from the horn at the horn connector.
a. The resistance should read approximately 28 ohms.
i. Replace the horn.
2. Check the horn connector for pin-to-pin shorted condition.
a. Repair the connector.
3. Check for pin #20 at the controller shorted to B+.
a. Contact NMHG Service Engineering Contact Management.

29
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21534 Service Required Solid Red Horn
DESCRIPTION SYMPTOM
Controller has detected an open Hydraulic system will not operate.
circuit in the horn.
Probable Causes and Test Procedures
1. Measure the resistance between the red lead and the black lead from the horn at the horn connector.
a. The resistance should read approximately 28 ohms.
i. Replace the horn.
2. Check for battery voltage at wire #10 at the horn connector when the key switch is closed.
a. Ensure all connections and connectors are secure and tight.
b. Check for open circuits in the harness.
i. Repair wiring.
3. Check continuity of wire #45 from the horn connector to pin #20 at the controller connector.
a. Repair wiring.
4. Internal failure of the controller.
a. Contact NMHG Service Engineering Contact Management.

30
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21535 Service Required Solid Red Horn
DESCRIPTION SYMPTOM
The controller has detected the horn Hydraulic system will not operate.
shorted to B .
Probable Causes and Test Procedures
1. Measure the resistance between the red lead and the black lead from the horn at the horn connector.
a. The resistance should read approximately 28 ohms.
i. Replace the horn.
2. Check the horn connector for pin-to-pin shorted condition.
a. Repair the connector.
3. Check for pin #20 at the controller shorted to B .
a. Contact NMHG Service Engineering Contact Management.

31
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21539 Service Required Solid Red Controller
DESCRIPTION SYMPTOM
Controller has detected an internal Traction and hydraulic systems will not operate.
failure of the output driver.
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and restart the lift truck.
2. Verify the fault returns after restart.
a. Contact NMHG Service Engineering Contact Management.

32
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21552 Improper Start Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected a fault in the signal Traction and hydraulic systems will not operate.
from the steer handle card.
Probable Causes and Test Procedures
1. Verify all steer handle switches and controls are in the neutral position.
2. Check for battery voltage at pin #3 at the steer handle card.
a. Check for continuity of wire #10 from the key switch to the steer handle card.
3. Check for any mechanical binding in switches or throttle mechanism.
a. Clear any binding.
b. Repair or replace faulty switches.
4. Verify there is no shorted wiring between wire #901, wire #902, wire #102, and wire #28 between the
steer handle card and the controller.
a. Repair any shorted wiring.
5. Verify the continuity of wire #102, wire #900, wire #901 and wire #28 from the steer handle card to the
controller.
a. Repair any broken wiring or loose connections.

33
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21553 Release Rabbit Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected a closed high High speed will not operate.
speed switch at startup.
Probable Causes and Test Procedures
1. Ensure the high speed Rabbit switch is not being held closed.
a. Eliminate any binding in the handrail handle.
2. Check the switch for a shorted condition.
a. Replace faulty switch.
3. Check for wire #342 shorted to B+.
a. Repair any faulty wiring.

34
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21554 Improper Start Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected a closed auxiliary Horn operates continuously.
horn switch at startup.
Probable Causes and Test Procedures
1. Ensure the auxiliary horn switch is not being held closed.
a. Eliminate any binding in the handrail handle.
2. Separate handrail connector.
a. If horn quits sounding, replace auxiliary horn switch.
3. Check for wire #25 shorted to B+.
a. Repair any faulty wiring.
4. Separate the controller connector.
a. If horn continues to sound, check for pin #11 at the controller shorted to B+.
i. Contact NMHG Service Engineering Contact Management.

35
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21555 Improper Start Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected a closed auxiliary Hydraulic system will not operate.
lift or lower switch at startup.
Probable Causes and Test Procedures
1. Inspect handrail lift and lower switches for binding.
a. Ensure all parts are free to move.
2. Check each switch for a shorted condition.
a. Replace faulty switch.
3. Check wire #25 for a shorted condition to B+.
a. Repair any faulty wiring.

36
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21568 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Main contactor is open and will not close. Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures
1. Check battery connection, voltage, and charge.
2. Check for power and clean, tight connections to the contactor.
3. Replace the contactor.

37
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21569 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Controller has detected the main Traction and hydraulic systems will not operate.
contactor shorted to B+.
Probable Causes and Test Procedures
1. Separate the controller connector.
2. Check for a shorted condition between pin #18 at the controller and B+.
a. Contact NMHG Service Engineering Contact Management.
3. Check the connector for any pin-to-pin shorts.
a. Repair any wiring faults.

38
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21570 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Controller has detected an open circuit Traction and hydraulic systems will not operate.
in the main contactor.
Probable Causes and Test Procedures
1. Ensure all wiring connections are secure and tight.
2. Check for battery voltage on wire #10 at the main contactor.
a. Check continuity of wire #10 between the key switch and the main contactor.
i. Repair any open wiring.
b. Check for continuity through FU 5.
i. Replace fuse.
3. Check the resistance through the main contactor coil.
a. The resistance should measure approximately 22 ohms 10%.
i. Replace the coil.
4. Check continuity of wire #45 from the coil to the controller pin #20. Repair any open wiring.
5. Internal failure of the controller.
a. Contact NMHG Service Engineering Contact Management.

39
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21571 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Controller has detected the main Traction and hydraulic systems will not operate.
contactor shorted to B .
Probable Causes and Test Procedures
1. Ensure the B+ and B cables from the battery are connected properly.
2. Separate the controller connector.
3. Check for a shorted condition between pin #18 at the controller and B .
a. Contact NMHG Service Engineering Contact Management.
4. Check the connector for any pin-to-pin shorts to B .
a. Repair any wiring faults.

40
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21588 Service Required Solid Red Power Steering
DESCRIPTION SYMPTOM
Controller has detected an internal Traction system will not operate.
failure in the power supply to the
power steering motor.
Probable Causes and Test Procedures
1. Check condition of fuse FU 1.
a. Verify continuity through the fuse.
i. Replace fuse.
2. Verify battery voltage at power steering motor B+ terminal.
a. Check continuity of wire #PS2-1 from FU 1 to power steering motor.
i. Repair damaged wiring.
3. Check continuity of wire #PS1 from power steering motor B terminal to controller terminal B .
a. Repair damaged wiring.
4. Check for failed power steering motor.
a. Check for 24 volts continuous across B+ and B terminals when battery is connected and the key
switch is in the ON position.
i. Contact NMHG Service Engineering Contact Management.
5. Internal failure of the controller.
a. Contact NMHG Service Engineering Contact Management.

41
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29445 Service Required Solid Red Traction
DESCRIPTION SYMPTOM
The controller cannot detect the signal Traction system will not operate.
from the traction motor encoder.
Probable Causes and Test Procedures
1. Ensure all wiring connection between the encoder and the controller are secure and tight.
2. Check for 12 volts on wire #250.
a. Check for 12 volts at controller pin #30.
i. Contact NMHG Service Engineering Contact Management.
3. Check encoder output between pin #2 and pin #4 at the encoder connector from the traction motor.
a. Output should alternate between 12 and 0 volts as the motor rotates.
i. Change the encoder.
4. Check encoder output between pin #3 and pin #4 at the encoder connector from the traction motor.
a. Output should alternate between 12 and 0 volts as the motor rotates.

42
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29448 Improper Start Flashing Red Brake
DESCRIPTION SYMPTOM
Controller has detected a closed brake Traction system will not operate.
switch at startup.
Probable Causes and Test Procedures
1. Ensure the steer handle is in the full vertical position at truck startup.
2. Ensure the steer handle enable switch is not being held closed at truck startup.
a. Adjust switch.
b. Verify 0 volts at pin #6 at the controller connector with the steer handle in the vertical position.
3. Measure continuity across pin #1 and pin #2 at the steer handle enable connector.
a. Switch should be open with no continuity shown.
i. Replace switch.

43
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29456 Service Required Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected an error in the Traction system will not operate.
steer handle card throttle sensor.
Probable Causes and Test Procedures
1. Throttle sensor is out of calibration.
a. Calibrate throttle sensor. See Electrical System 2200 SRM 1287.
2. Throttle sensor has failed.
a. Replace the steer handle card.

44
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29458 Service Required Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected the steer handle Traction system will not operate.
card analog sensor to be out of limits.
Probable Causes and Test Procedures
1. Throttle sensor has failed.
a. Replace the steer handle card.

45
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29472 Service Required Solid Red Power Steering
DESCRIPTION SYMPTOM
Controller has detected a failure in Traction system will not operate.
the steering sensor.
Probable Causes and Test Procedures
1. Measure the voltage at pin #1, wire #19 at the torque sensor connector.
a. Voltage should read 3.3 0.5 volts.
i. Replace the steering sensor.
2. Measure the voltage between pin #2 and pin #3 at the torque sensor connector.
a. Voltage should measure 1.7 volts with the steer handle arm stationary.
i. Replace the torque sensor.
3. Measure the voltage between pin #2 and pin #3 while moving the steer handle arm side to side.
a. Voltage should increase up to a maximum of 3.3 volts.
i. Replace the torque sensor.
4. Measure the voltage between pin #5 and pin #6 at the torque sensor connector.
a. Voltage should alternate between 0 volts and 3.3 volts while moving the steer handle arm side to side.
i. Replace the torque sensor.

46
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
33056 Service Required Solid Red Controls
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the steer handle card.
Probable Causes and Test Procedures
1. Ensure all wiring connections between the steer handle card and the controller are tight and secure.
2. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 40 ohms.
i. If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
3. Check for continuity between pin #1 at the steer handle card connector and pin #28 at the controller
connector.
a. Repair any broken wiring.
4. Check for continuity between pin #2 at the steer handle card connector and pin #27 at the controller
connector.
a. Repair any broken wiring.
5. Check for continuity between pin #4 at the steer handle card connector and pin #29 at the controller
connector.
a. Repair any broken wiring.
6. Internal failure in the steer handle card.
a. Replace steer handle card.
7. Internal failure of the traction controller.
a. Contact NMHG Service Engineering Contact Management.

47
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
33057 Service Required Solid Red Power Steering
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the power steering unit.
Probable Causes and Test Procedures
1. Ensure all wiring connections between the power steering unit and the controller are tight and secure.
2. Ensure battery voltage at the red PS2-1 wire at the controller.
3. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 40 ohms.
i. If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
4. Check for continuity between pin #2 at the power steering connector and pin #28 at the controller con-
nector.
a. Repair any broken wiring.
5. Check for continuity between pin #1 at the power steering connector and pin #27 at the controller con-
nector.
a. Repair any broken wiring.
6. Check for continuity between pin #4 at the power steering connector and pin #10 at the traction controller.
7. Check for battery voltage at pin #3 at power steering connector.
8. Internal Failure of the power steering unit.
a. Contact NMHG Service Engineering Contact Management.
9. Internal failure of the traction controller.
a. Contact NMHG Service Engineering Contact Management.

48
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
36864 Service Required Solid Red Power Steering
DESCRIPTION SYMPTOM
Power steering security line has Traction system will not operate.
been set to LOW.
Probable Causes and Test Procedures
1. Check continuity of wire #574 between pin #4 at the power steering connector and pin #10 at the traction
controller.
a. Repair any damaged wiring.
2. Check continuity of fuse FU 6.
a. Replace fuse.
3. Check continuity of wire #PS2 and wire #PS2-1 from controller fuse to steering motor.
a. Repair any faulty wiring.
4. Check for battery voltage at the PS2-1 connection at the steering motor.
5. Internal failure of the traction controller.
a. Contact NMHG Service Engineering Contact Management.

49
Troubleshooting 2200 SRM 1286

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
65281 Service Required Solid Red Power Steering
DESCRIPTION SYMPTOM
Controller has detected a fault with the Traction system will not operate.
torque sensor in the power steering system.
Probable Causes and Test Procedures
1. Measure voltage between pin #2 and pin #3 (blue and black wires) at the steering torque sensor connector.
a. Voltage should measure 1.7 volts with the steer handle stationary.
i. Replace torque sensor.
b. Voltage should measure 3.3 volts while moving the steer handle arm side to side.
i. Replace torque sensor.

50
2200 SRM 1286 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
65282 Service Required Solid Red Power Steering
DESCRIPTION SYMPTOM
Controller has detected a failure in Traction system will not operate.
the steering system.
Probable Causes and Test Procedures
1. Check all mechanical steering components for damage.
a. Repair or replace any damaged components.
2. Check for foreign material binding the gearing.
a. Remove any material found.
3. Check that all steering torque sensor linkage with the steer handle arm is intact.
a. Repair linkage.

51
Dash Display 2200 SRM 1286

Dash Display
GENERAL If there is a fault noted by the lift truck controller
and the controller has prevented traction and hy-
The dash display is a multifunction device. It con- draulic functions, the LED will be solid red.
tains a truck status LED and an LCD which dis- When the battery charge reaches 75% of full
plays the performance mode indicator and the bat- charge, the horn will sound and the LED will
tery charge indicator. The menu system can be ac- alternately blink from red to green.
cessed through the dash display by starting the truck If the controller has noted a condition that require
in service mode and entering the proper password. the lift truck to operate at a reduced performance
See Figure 3. level, the LED will blink red.

PERFORMANCE MODE INDICATOR


The performance mode indicator will show the cur-
rent performance mode setting at truck startup. The
indicator is a four bar display with the rabbit or high-
est performance level on the right and the "Turtle" or
lowest performance level on the left. See Figure 4.
The performance model level can be changed using
the lift and lower buttons on the steer handle as de-
scribed in the Operating Manual unless the per-
formance mode function has been locked by a su-
pervisor or a technician. Refer to User Interface,
Supervisor Functions On-Board Dash Display
2200 SRM 1323 or User Interface, Service Tech-
nician Functions On-Board Dash Display 2200
SRM 1324.

Figure 3. Dash Display Screens

STARTUP
When the key is turned to the ON position and the
handle is in the full upright position, all segments
of the display will be illuminated and the horn will
beep twice. The LED will flash red, green, and then
go blank momentarily. Then the display will show
the truck mode setting and the hourmeter reading.

STATUS LED
The status LED is located in the top center of the dis-
play. When the key switch is in the ON position, the
LED is on. The LED can indicate in either red or
green depending on the information being communi-
cated. Figure 4. Performance Mode Screen
When the lift truck key is in the OFF position, the
LED will be OFF.
When the lift truck is operating normally, the LED
will be solid green when the key is in the ON posi-
tion.

52
2200 SRM 1286 Dash Display

HOURMETER
The hourmeter accumulates hours when the key is
in the ON position and main contactor is closed. The
hourmeter is capable of showing five digits and dis-
plays complete hours. See Figure 5. At truck startup,
the display will show the truck hours for 10 seconds
after the key has been turned to the ON position. The
hourmeter reading will be turned off if the control
handle is moved to the operating position any time
within the 10 second display period.

Figure 6. Battery Charge Indicator

FAULT LOG
The Fault Log menu will list the truck system initiat-
ing the fault, the error code associated with the fault,
the hourmeter reading when the fault occurred, the
number of times the fault has been logged, and the
system temperature when the fault occurred. See
Figure 7. The Fault Log auto scrolls. The system
will retain the last ten faults noted.

Figure 5. Hourmeter

BATTERY CHARGE INDICATOR


When the truck hourmeter is disabled, it is replaced
on the display by the battery charge indicator. The
indicator is a five bar graphical indicator with the full
indicator bar on the right and the empty indicator
bar on the left. See Figure 6. At 100% charge, all
bar graph segments will be shaded. As the battery is
discharged, fewer of the bars will be shaded.
100% Charge = 5 Solid Bars
80% Charge = 4 Solid Bars
60% Charge = 3 Solid Bars
40% Charge = 2 Solid Bars
30% Charge = 1 Solid Bar During Lifting
20% Charge = 0 Solid Bars, Blinking Red Status
LED,
Lift Lockout - (Horn Sounds When Lift Switch
Is Activated)
Figure 7. Fault Log Screen

53
Connector Pin-Outs 2200 SRM 1286

Connector Pin-Outs
Controller Connector (CPS 05)
Pin Wire Number Function
1 W10 - AC RED Battery Positive
2 W342 - A High Speed
3 W26 - A Aux. Lift Switch
4 W27 - A Aux. Lower Switch
5 W28 - A Steer Handle Card
6 W98 - AC Steer Handle Switch
7 W99 - C RED Coast Switch (Optional)
8
9
10 W574 - PS Power Steer Encoder (Optional)
11 W25 - A Aux. Horn Switch
12
13
14 W730 - A RED Cruise Solenoid (Optional)
15
16
17
18 W79 - M RED Main Contactor Coil
19
20 W45 - H Horn
21
22 W150 - A Pump Coil (+)
23 W86 - A Pump Coil ( )
24
25 W386 - A Traction Motor Temp Sensor
26 W354 - TS RED Steer Handle Sensor (Optional)
27 W901/H - WHT CAN Hi
28 W900/L - BLK CAN Lo
29 W102/BARE - GRN Traction Motor Temp Sensor
30 W250 - E Traction Motor Encoder
31 W577 - E Traction Motor Encoder
32 W578 - E Traction Motor Encoder
33
34
35

54
2200 SRM 1286 System Logic Diagram

System Logic Diagram

Traction Motor --------


CANbus Dash Display

Traction Encoder --------


CANbus

Temperature Sensor --------

Pump Motor -------- -------- Forward/Reverse Input

Power Steering Motor -------- -------- Truck Speed Input

Main Contactor -------- CANbus -------- Lift/Lower Input

CANbus

Horn -------- -------- Traction Reverse Input


Steer Handle Card

Lower Solenoid -------- -------- Neutral Input

Cruise Solenoid -------- -------- Pick Mode Input

Electric Brake Coil -------- -------- Horn


Traction Motor
Controller
High Speed Switch -------- -------- Tiller Sensor

Aux. Horn Switch -------- -------- PS Motor Encoder

CANbus
PAS |

Aux. Lift Switch -------- Torque Sensor

Aux. Lower Switch --------

Coast Switch --------

Brake Switch --------

Service
CANbus
PC Connection

55
NOTES

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56
TECHNICAL PUBLICATIONS

2200 SRM 1286 5/07 (2/07)(12/06)(11/06) Printed in U.S.A.