Ac Controller and Display Panel - (03-2009) - Us-En

AC MOTOR CONTROLLERS/DISPLAY
PANEL
DESCRIPTION, CHECKS, ADJUSTMENTS, AND
TROUBLESHOOTING
J2.00-3.20XM (J40-65Z) [A416/B416];
V30ZMD [D210/E210]; E1.50-2.00XM
(E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) [D098/E098]
PART NO. 1534735 2200 SRM 1056

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 Maintenance 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 hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
AC Motor Controllers/Display Panel Table of Contents
TABLE OF CONTENTS
Description ......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
AC Motors .................................................................................................................................................. 1
Motor Controllers ...................................................................................................................................... 1
Master Controller ...................................................................................................................................... 1
Dash Display ............................................................................................................................................. 1
Controller Area Network Bus (CANbus).................................................................................................. 1
Master Controller Checks and Adjustments .................................................................................................... 2
Function Settings............................................................................................................................................... 3
General ........................................................................................................................................................... 3
Function Numbers ......................................................................................................................................... 3
Function Descriptions........................................................................................................................................ 6
General ........................................................................................................................................................... 6
Function Number 1 BATTERY VOLTAGE .............................................................................................. 6
Function Number 2 EXTENDED SHIFT ................................................................................................ 6
Function Number 3 ACCELERATION 1 ................................................................................................. 6
Function Number 4 ACCELERATION 2 ................................................................................................. 6
Function Number 5 TOP SPEED LIMIT ................................................................................................. 6
Function Number 6 REGEN BRAKING .................................................................................................. 6
Function Number 7 AUTO DECELERATION ........................................................................................ 7
Function Number 8 BDI ADJUSTMENT ................................................................................................ 7
Function Number 9 LIFT INTERRUPT .................................................................................................. 7
Function Number 10 POWER STEERING TIME DELAY ..................................................................... 7
Function Number 11 SERVICE REMINDER .......................................................................................... 7
Function Number 12 CUSTOM................................................................................................................ 7
Function Number 13 PUMP SPEED 1 .................................................................................................... 7
Function Number 16 PUMP ACCELERATION ...................................................................................... 8
Troubleshooting.................................................................................................................................................. 8
General ........................................................................................................................................................... 8
Controller Status Light Emitting Diodes (LEDs) ........................................................................................ 9
Master Controller ...................................................................................................................................... 9
AC Motor Controllers ................................................................................................................................ 9
Status Codes .................................................................................................................................................. 15
AC Motor Controllers Status Code Charts ....................................................................................................... 17
Troubleshooting When Dash and/or Lift Truck is not Operational ............................................................ 38
Typical Symptoms ..................................................................................................................................... 38
Truck Runs but Dash Display is not Operational, or Only Displays Status Code 55; an
Additional Delay Between Key ON and Line Contactor Closing May Occur ........................................ 38
Truck Does Not Run and Dash is Not Operational or Only Displays Status Code 55 .......................... 39
Hydraulics Operate Normally, Traction Does Not Operate Correctly, and Dash is Operational
but no Status Codes are Present .............................................................................................................. 40
Traction Operates Normally, Hydraulics do Not Operate Correctly, and Dash is Operational
but no Status Codes are Present .............................................................................................................. 40
AC Transistor Motor Controller Replacement ................................................................................................. 40
General ........................................................................................................................................................... 40
General Maintenance Instructions............................................................................................................... 46
Special Precautions ................................................................................................................................... 46
Fuses .............................................................................................................................................................. 47
Fan Test.......................................................................................................................................................... 47
©2009 HYSTER COMPANY i

Table of Contents AC Motor Controllers/Display Panel
TABLE OF CONTENTS (Continued)

Contactors ...................................................................................................................................................... 47
Repair......................................................................................................................................................... 47
Thermal Sensors ............................................................................................................................................ 51
Motor Controller, Replace ............................................................................................................................. 51
Display Panel ..................................................................................................................................................... 52
General ........................................................................................................................................................... 52
Premium Display Panel ............................................................................................................................ 52
Standard Display Panel ............................................................................................................................ 52
Display Functions and Features ....................................................................................................................... 53
Key-On Initialization..................................................................................................................................... 53
Standard Display ........................................................................................................................................... 54
Premium Display ........................................................................................................................................... 54
Lift Truck Inspection Function ..................................................................................................................... 55
Access to Service Functions .......................................................................................................................... 55
Service Functions .......................................................................................................................................... 55
Service Functions .......................................................................................................................................... 56
Performance Modes ....................................................................................................................................... 58
Battery Discharge Indicator (BDI) ............................................................................................................... 58
Hourmeter...................................................................................................................................................... 59
Dash Display Service Menu Navigation ........................................................................................................... 66
General ........................................................................................................................................................... 66
Moving Through Menu Selections ................................................................................................................ 66
Editing and Adding Information .................................................................................................................. 67
This section is for the following models:
J2.00-3.20XM (J40-65Z) [A416/B416];

V30ZMD [D210/E210];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]
ii
2200 SRM 1056 Description
Description
GENERAL Master Controller
The alternating current (AC) system consists of AC The master controller is a general-purpose mi-
motors, motor controller(s), a master controller, and cro-controller for CANbus-based electric vehicles.
a dash display. The major difference between the It contains processing power, memory resources,
AC system and the direct current (DC) system is the analog and digital input/output (I/O) to provide the
master controller performs many of the same func- required full-featured functionality. The master
tions that previously were performed in the motor controller is designed to manage the traction motor
controllers on the DC system. controller and pump motor controller, interface to
the operator controls, auxiliary functions, and to
AC Motors control the vehicle dash display.
The AC motors are three-phase AC induction motors. The master controller also manages the operating
They do not include motor brushes or commutators. truck parameters, status codes, battery discharge
An AC induction motor operates on three-phase AC indicator (BDI) function, hourmeters, password fea-
power provided directly by the motor controller. The ture, and all operator inputs. It also controls the
motor’s speed is controlled by the motor controller contactor, cooling fans, and strobe light relay.
and can be changed by changing the frequency of
the AC power provided to the motor. A speed sensor Dash Display
is built into the rear motor bearing, which provides
RPM and direction feedback to the motor controller. The new AC dash display is similar in appearance
The motor controller continuously monitors motor di- to the SEM dash display and includes the same fea-
rection and speed. Using this feedback, the AC mo- tures. In addition, the AC dash display provides ex-
tor control system can provide much better vehicle panded service capabilities. The dash display has a
top speed control than is available with DC SEM sys- password-accessible service mode that allows a tech-
tems. nician to change control settings and view real-time
RPMs, current, temperature, and switch closure in-
The AC motors also have thermal sensors embedded formation. Previously, a separate handset or com-
in the motor windings that are continuously moni- puter was required for these operations. For a com-
tored by the motor controllers. plete description of the display panel, see the Display
Panel section of this manual.
Motor Controllers
Controller Area Network Bus (CANbus)
The motor controllers receive power from the truck’s
battery and convert it into three-phase AC power at The motor controllers, master controller, and dash
the frequencies and currents necessary to drive the display are connected together with a CANbus
respective pump and/or traction motor. Each AC in- communication system. A personal computer (PC)
duction motor provides feedback of speed, rotation with the appropriate Electric Truck AC Controller
direction, and temperature directly to the motor con- (ETACC) service software and interface cable can
troller. The two motor controllers used to power the easily communicate with all system nodes by simply
traction motor and hydraulic pump motor are very connecting to the CANbus. A diagnostics connector,
similar. The primary motor controller difference is located under the dash and next to the display, is
in the power output rating. configured specifically for this purpose. See Figure 1
and section Troubleshooting and Adjustments
The motor controller logic board receives power from Using the AC Controls Program (ETACC) 2200
the key switch. Power to the motors can be inter- SRM 1058 for procedures to connect a PC to lift
rupted indirectly by the key switch. The motor con- truck.
trollers get motor speed and temperature informa-
tion directly from the motors. The motor controllers
do not get any other input from the truck. The mas-
ter controller relays speed, acceleration, and direc-
tion commands to the motor controllers.
1
Master Controller Checks and Adjustments 2200 SRM 1056
Legend for Figure 1

1. DIAGNOSTIC CONNECTOR
2. DASH DISPLAY
3. DASH WIRE HARNESS
Figure 1. Diagnostic Connector
Master Controller Checks and Adjustments

NOTE: All checks and adjustments to the master The following checks and adjustments may be made
controller can be done with a personal computer (PC) using a PC or the dash display:
that has the ETACC service software installed. See • Check the system status codes history.
Troubleshooting and Adjustments Using the • Check the state of charge of the battery.
AC Controls Program (ETACC) 2200 SRM 1058 • Check the hourmeter readings on the traction cir-
for software installation procedures. A diagnostics cuit and hydraulic pump controllers.
connector in the wiring harness below the display • Monitor or adjust the register values for each func-
panel can connect the PC to the CANbus system to tion as shown in Table 1, Table 2, and Table 3.
communicate to the master controller (see Figure 1).
Many checks can also be done at the display panel
without being connected to a PC.
2
2200 SRM 1056 Function Settings
Function Settings
GENERAL Table 1. Factory Parameters for J2.00-3.20XM
(J40-65Z) (A416/B416)
The master controller has several functions (pa-
rameters) that can be changed to configure differ- Factory Factory
ent lift truck models and voltages. The function set- Function Setting Setting
tings are stored and used by the master controller to 72V 80V
determine lift truck performance or other operation
variables. 1-BATTERY
72 80
VOLTAGE
NOTE: Table 1, Table 2, Table 3, and Table 4 show the
2-EXTENDED SHIFT ENABLED ENABLED
default settings for each control function. The factory
settings are the recommended settings for new units. 3-ACCELERATION 1 40 40
These settings will give satisfactory performance for
4-ACCELERATION 2 7 7
most applications.
5-TOP SPEED LIMIT 94 100
All functions can be adjusted within the permitted
range to change the lift truck operation for a spe- 6-REGEN BRAKING 75 75
cific application. Adjustment of a register to a num- 7-AUTO
ber that is different than the factory setting is al- 70 70
DECELERATION
lowed, but follow the instructions carefully. Adjust-
ments other than the factory settings will cause the 8-BDI ADJUSTMENT 30 30
lift truck performance and energy consumption to 9-LIFT INTERRUPT ENABLED ENABLED
change.
10-PS TIME DELAY 20 20
FUNCTION NUMBERS 11-SERVICE
0 0
REMINDER
WARNING 12-CUSTOM 0 0
NEVER adjust any of the function registers
without using the procedures and settings 13-PUMP SPEED 1 25 25
given in this section. 14-PUMP SPEED 2 50 50
NOTE: Functions 13, 14, and 15 do not apply to lift 15-PUMP SPEED 3 95 95
trucks that are equipped with the e-hydraulics op- 16-PUMP
tion. 25 25
ACCELERATION
The function numbers are code numbers for the dif-
ferent parameters that can be set for the master con-
troller. The PC or the dash display must be used to
adjust the parameters for the master controller.
3
Function Settings 2200 SRM 1056
Table 2. Factory Setting for V30ZMD (D210/E210) and E2.00-3.20XM (E45-65Z) (G108)
Factory Factory Factory Factory

Function
Setting 36V Setting 48V Setting 72V Setting 80V
1-BATTERY VOLTAGE 36 48 72 80
2-EXTENDED SHIFT ENABLED ENABLED ENABLED ENABLED
3-ACCELERATION 1 40 49 46 50
4-ACCELERATION 2 5 8 6 9
5-TOP SPEED LIMIT 85 92 91 98
6-REGEN BRAKING 60 60 60 70
7-AUTO DECELERATION 65 70 70 70
8-BDI ADJUSTMENT 30 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20 20
11-SERVICE REMINDER 0 0 0 0
12-CUSTOM 0 0 0 0
13-PUMP SPEED 1 25 25 25 25
14-PUMP SPEED 2 50 50 50 50
15-PUMP SPEED 3 95 95 95 95
16-PUMP ACCELERATION 25 25 25 25
Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
Factory Setting Factory Setting Factory Setting

Function
36V 48V 48V (Europe)
1-BATTERY VOLTAGE 36 48 48
2-EXTENDED SHIFT ENABLED ENABLED ENABLED
3-ACCELERATION 1 48 66 62
5-TOP SPEED LIMIT 80 100 100
6-REGEN BRAKING 60 60 75
7-AUTO DECELERATION 65 70 70
8-BDI ADJUSTMENT 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20
11-SERVICE REMINDER 0 0 0
12-CUSTOM 0 0 0
13-PUMP SPEED 1 25 25 25
4
2200 SRM 1056 Function Settings
Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) (Continued)

Function
36V 48V 48V (Europe)
14-PUMP SPEED 2 50 50 50
15-PUMP SPEED 3 95 95 95
16-PUMP ACCELERATION 25 25 25
Table 4. Factory Parameters for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

Function
36V 48V 80V
1-BATTERY VOLTAGE 36V 48V 80V
2-EXTENDED SHIFT ENABLED ENABLED ENABLED
5-TOP SPEED LIMIT 85 100 100
6-REGEN BRAKING 65 65 65
7-AUTO DECELERATION 80 80 80
8-BDI ADJUSTMENT 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20
11-SERVICE REMINDER 0 0 0
12-CUSTOM 0 0 0
13-PUMP SPEED 1 25 25 25
14-PUMP SPEED 2 50 50 50
15-PUMP SPEED 3 95 95 95
16-PUMP ACCELERATION 25 25 25
5
Function Descriptions 2200 SRM 1056
Function Descriptions
GENERAL To increase the acceleration rate above the factory
setting, Function 2 will need to be set to disabled.
WARNING To reduce the acceleration rate below the factory
If any of the register values are changed, the setting, Function 2 may be enabled or disabled.
operators must be told that the lift truck will
operate differently. Any increase in performance will decrease the bat-
tery shift life.
The following section contains descriptions for the
different functions. The register setting for each Function Number 4 ACCELERATION 2
function is specific for each motor controller.
(Range 0-100)
Function Number 1 BATTERY VOLTAGE
Function 4 determines the truck acceleration rate
(36, 48, 72, or 80) when traction motor speed is above 1,500 rpm. The
truck will accelerate at this rate regardless of the
Function 1 is used to inform the master controller load on the forks, provided that the motor and con-
what voltage battery is installed in the truck. The trol can deliver the required power.
battery choices are: 36, 48, 72, or 80.
To increase the acceleration rates above the factory
Function Number 2 EXTENDED SHIFT setting, Function 2 will need to be disabled.
(Enable or Disable) To reduce the acceleration rate below the factory
setting, Function 2 may be enabled or disabled.
Function 2 enables or disables a preset motor per-
formance program in the traction motor controller. Any increase in performance will decrease the bat-
tery shift life.
When enabled, this function provides a balance be-
tween truck performance and battery shift life that Function Number 5 TOP SPEED LIMIT
will meet the requirements of most applications.
Truck acceleration and top speed will vary with the (Range 1-100)
amount of load on the forks.
Function 5 determines the top speed limit of the
When disabled, truck acceleration and top speed are truck.
determined by values set in Functions 3, 4, and 5.
To increase the top speed above the factory setting,
If the motor and controller can deliver the power, Function 2 will need to be disabled.
then the truck performance will not vary with the
amount of load on the forks or the battery state of To reduce the top speed below the factory setting,
charge Function 2 may be enabled or disabled.
Grade climbing speed will also improve because the For speed limits slower than the normal truck speed,
motor controller will deliver maximum current. Any the top speed is the same regardless of the load on
increase in performance will decrease the battery the forks. Acceleration rates are also unaffected by
shift life. lowering the top speed.
Function Number 3 ACCELERATION 1 Any increase in performance will decrease the bat-
tery shift life.
(Range 0-100)
Function Number 6 REGEN BRAKING
Function 3 determines the truck acceleration rate
when traction motor speed is below 1,500 rpm. The (Range 0-100)
truck will accelerate at this rate regardless of the
Function 6 determines the maximum deceleration
load on the forks, provided that the motor and con-
rate when the accelerator pedal is fully depressed
trol can deliver the required power.
during regen braking.
6
2200 SRM 1056 Function Descriptions
NOTE: The deceleration rate is less when the pedal Function Number 11 SERVICE REMINDER
is not fully depressed.
(Set Next Hourmeter)
Function Number 7 AUTO DECELERATION
Function 11 can be used by the service technician
(Range 0-100) to show a Status Code 99 when the truck is due for
service.
Function 7 determines the maximum deceleration
rate when the accelerator pedal is released. The To use this feature, set this function to the hourme-
strength of auto deceleration is a percentage of the ter reading that the service is to occur. When that
regen braking strength determined by Function 6. hourmeter is reached, the dash display will display
Status Code 99 for 10 seconds each time the key is
A Function 7 setting of zero will turn off auto decel- turned ON. After 20 hours of operation, the truck will
eration completely, and a setting of 100 will give auto slow to half speed and the code will display continu-
deceleration the same strength as regen braking. ously until the service is performed. After servicing
the truck, Function 11 should be set to the next ser-
Function Number 8 BDI ADJUSTMENT vice hourmeter reading to regain full performance.
(Range 0-100) NOTE: A setting of zero will disable this feature.
Function 8 allows for adjustment to improve the ac- Function Number 12 CUSTOM
curacy of the Battery Discharge Indicator in the
dash display. Increasing the setting will cause the (Range 0-100)
gage to show empty at a higher specific gravity or
battery voltage. Function 12 is not used except for special func-
tions required for special applications. Normally,
A setting of 30 is the recommended starting point for this function is set to zero.
flooded cell batteries, and a setting of 50 for main-
tenance-free batteries. Further adjustments may be A setting value of 1 will change auto deceleration to
used to fine-tune the BDI accuracy. work even with a partial release of the accelerator
pedal. Normally, auto deceleration only works when
Function Number 9 LIFT INTERRUPT the accelerator pedal is fully released.
(Enable or Disable) A setting value of 2 will cause the maximum lift

speed and pump motor acceleration rate to change
Function 9 enables or disables the lift interrupt with the performance mode selected. Normally, only
feature. The lift interrupt feature stops hoist opera- traction speeds and acceleration rates change with
tion when the BDI reads empty to protect the bat- the performance mode selected.
tery from excessive discharge and possible damage.
A setting value of 3 will combine the changes de-
NOTE: Trucks are shipped from the factory with this scribed for setting values of 1 and 2.
feature enabled.
A setting value of 4 directs the master controller to
Function Number 10 POWER STEERING output forward and reverse signals that are compat-
TIME DELAY ible with wire guided trucks.
(Range 0-100) Function Number 13 PUMP SPEED 1

Function 10 sets the time delay for the power steer- NOTE: This function does not apply for lift trucks
ing contactor to open after the seat switch opens. The that are equipped with the e-hydraulics option.
setting range is 1.5 to 65 seconds. Opening the key
switch will open the power steering contactor with no (Range 0-100)
delay. Function 13 determines the hydraulic pump motor
low speed. Low speed is used for tilt and some
auxiliary operations (sideshift).
7
Troubleshooting 2200 SRM 1056
Any increase in performance will decrease the bat- (Range 0-100)

tery shift life.
Function 15 determines the hydraulic pump motor
Function Number 14 PUMP SPEED 2 high speed. High speed is used for maximum
hoist speed.
NOTE: This function does not apply for lift trucks
that are equipped with the e-hydraulics option. Any increase in performance will decrease the bat-
tery shift life.
(Range 0-100)
Function Number 16 PUMP
Function 14 determines the hydraulic pump motor
ACCELERATION
medium speed. Medium speed is used for slow
hoist and some auxiliary operations. (Range 0-100)
Any increase in performance will decrease the bat- Function 16 determines the hydraulic pump motor
tery shift life. acceleration rate. Higher numbers bring up motor
speed quicker.
Function Number 15 PUMP SPEED 3
Any increase in performance will decrease the bat-
NOTE: This function does not apply for lift trucks tery shift life.
that are equipped with the e-hydraulics option.
Troubleshooting
GENERAL small flat-blade screwdriver into the connec-
tor. After inserting the screwdriver into the
The AC motor and master controllers are sealed connector, attach probes with alligator clips to
units with no serviceable components. Troubleshoot- the shank of the screwdriver to obtain read-
ing is usually limited to accessing status codes and ings. An additional method would be to use a
following the diagnostic procedures listed in the breakout kit, Hyster P/N 1397311.
Status Code Charts.
See Electrical Diagrams, AC Motor Control
Use standard testing procedures to verify inputs and System 8000 SRM 1059 for J2.00-3.20XM (J40-65Z)
outputs when necessary. (A416); V30ZMD (D210/E210); E1.50-2.00XM
(E25-35Z, E40ZS) (E114/F114); and E2.00-3.20XM
CAUTION (E45-65Z) (G108) or Diagrams, AC Motor Con-
trol System 8000 SRM 1203 for E3.50-5.50XL
Never attempt to probe through the back of
(E70-120Z, E100ZS) (D098/E098) or Electrical Di-
the connector plugs of the motor controller.
agrams, AC Motor Control System 8000 SRM
These plugs are special sealed plugs. Probing
1225 for J2.00-3.20XM (J40-65Z) (B416) for addi-
through the back of the plugs will destroy the
tional wiring details.
seal and can cause a short circuit. If a circuit
must be tested for voltage, check for voltage at If the lift truck does not operate correctly, a status
an amp-type plug, a switch, or a component. If code is usually displayed on the display panel. If a
a circuit is suspect, check the circuit for conti- status code is not displayed, see the section Trou-
nuity by disconnecting the P plug and testing bleshooting When Dash and/or Lift Truck is not Op-
continuity from the front (pin end) of the plug. erational.
Standard probes are too large to be inserted Once the status code number is obtained, follow the
into the center of the female pins (sockets) of procedures outlined in the Status Code Charts of this
the special sealed plugs and can expand the manual to determine the problem.
pins. Expanded pins will not provide good con-
nections once the plug is reconnected. The con- NOTE: Due to the interaction of the master controller
nectors are shaped to allow the insertion of a with all lift truck functions, almost any status code
8
2200 SRM 1056 Troubleshooting
or controller fault could be caused by an internal fail- (A416/B416), it is located behind the battery and
ure of the master controller. After all other status can be reached by removing the plastic cover at the
code procedures have been followed and no problem rear of the hood. On the E1.50-2.00XM (E25-35Z,
is found, the master controller should be replaced as E40ZS) (E114/F114), it is located under the frame
the last option to correct the problem. side plate on the right-hand side, and on the
left-hand side for the V30ZMD and E2.00-3.20XM
Tools and test equipment required are: clip leads, (E45-65Z) (D210/E210, G108) line of trucks. A
digital multimeter (20,000 ohms per volt minimum), mirror can be used to view the LED through an ac-
and basic hand tools. cess hole. On E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) lift trucks, the master con-
Check resistance on RX1000 scale from frame to
troller is located under the rear floor plate.
power and controller terminals. Resistance of less
• The LED is located next to the wire harness con-
than 20,000 ohms can cause misleading symptoms.
nector. See Figure 2.
Resistance of less than 1000 ohms should be cor-
• The LED blinking rate is usually twice a second,
rected first.
when the battery is connected and the key switch
Before proceeding, visually check for loose wiring, is in the OFF position.
misaligned linkage to the accelerator switch, signs • The LED blinking rate slows to once every two sec-
of overheating of components, etc. onds when the battery is connected and the key
switch is moved to the ON position.
Prior to troubleshooting systems and components on • If the above conditions are not present, the master
this lift truck, ensure the battery is the correct volt- controller may not be properly connected or may be
age and is fully charged. Make sure the battery con- faulty.
nector contacts are clean of corrosion and the battery • Due to the location of the master controller, a small
polarity within the connector is correct. Inspect to inspection mirror may be needed to view the LED.
ensure all fuses are correct and have not failed. En-
sure the key switch is in the ON position when mak-
ing voltage checks or checking the operation of a com-
ponent. Make sure the floor (reset) switch and the
operator presence switch has been properly closed.
Many faults noted by lift truck systems are the result

of loose wiring connections and/or broken or shorted
wiring within the lift truck. Begin the troubleshoot-
ing process by carefully inspecting the wiring involv-
ing the device or devices noted by the onboard diag- 1. LED
nostic system. Faults noted with components located
on the reach attachment may be caused by broken or Figure 2. Master Controller LED
shorted wires in the mast cable. Ensure the integrity
of this cable before troubleshooting attachment-re- AC Motor Controllers
lated faults.
NOTE: In Figure 3 through Figure 7 the terms Gen IV
CONTROLLER STATUS LIGHT EMITTING and Gen V refer to Generation IV and Generation V
respectively. Controller and contactor panels labeled
DIODES (LEDS)
Gen IV are used in early model lift trucks and con-
The AC traction motor controller, AC pump motor troller and contactor panels labeled Gen V are used
controller (optional), and AC master controller each in later model lift trucks.
have a separate LED to indicate its operating status.
This section covers both the AC traction motor con-
Each LED is green in color and may be lit continu-
troller and AC pump motor controller. Remove the
ously or blinking. See each description for the loca-
rear cover to view the motor controllers. See Fig-
tion of each LED.
ure 3, Figure 4, Figure 5, Figure 6, and Figure 7.
Master Controller • The LED is located next to the label on the plastic
• The master controller location varies with cover of the controller. See Figure 3 or Figure 4
the truck model. On J2.00-3.20XM (J40-60Z) Figure 5 or Figure 6.
9
• The LED only turns on when the key switch is in • When a fault condition is detected that has shut
the ON position. down the truck, the LED blinking rate will be at
• The LED will show a steady continuous green color a very rapid rate (too fast to count). A status code
if there is no fault condition detected. should appear on the dash display to reference the
• When a fault condition is detected that is not seri- problem.
ous enough to shut down the truck, the LED blink- • If the above conditions are not present, the AC mo-
ing rate is twice a second. A status code should ap- tor controller may not be getting power from the
pear on the dash display to reference the problem. key switch or may be faulty.
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE 8. LINE CONTACTOR
SOLENOID 9. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (15A) LIGHTS 10. POSITIVE TEMPERATURE COEFFICIENT
4. FUSE 4 (5A) KEY SWITCH RESISTOR (PTC)
5. POWER STEERING CONTACTOR 11. LED INDICATOR
6. FUSE 5 (40 A) POWER STEERING
Figure 3. AC Traction and AC Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for J2.00-3.20XM
(J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models Only and for J2.00-3.20XM
(J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and V30ZMD (D210/E210) Lift Truck
Models
10
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. LINE CONTACTOR

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE 8. POSITIVE TEMPERATURE COEFFICIENT
SOLENOID RESISTOR (PTC)
3. FUSE 3 (15A) LIGHTS 9. AC TRACTION MOTOR CONTROLLER
4. FUSE 4 (5A) KEY SWITCH 10. FUSE (325A) PUMP
5. POWER STEERING CONTACTOR 11. CONTACTOR FOR DC PUMP MOTOR
6. FUSE 5 (40A) POWER STEERING 12. LED INDICATOR
Figure 4. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (Gen V)
(36v/48v or 72v/80v) for J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later
Models Only and for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114);
and V30ZMD (D210/E210) Lift Truck Models
11
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 6 (15A) LIGHTS 8. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (5A) KEY SWITCH 9. LED INDICATOR
4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT
5. FUSE 4 (40A) POWER STEERING RESISTOR (PTC)
6. LINE CONTACTOR
Figure 5. AC Traction and AC Pump Motor Controllers (72v/80v) (Gen IV) for Early Model
J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks
12
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 5 (15A) LIGHTS RESISTOR (PTC)
3. FUSE 3 (5A) KEY SWITCH 8. AC TRACTION MOTOR CONTROLLER
4. POWER STEERING CONTACTOR 9. FUSE 2 (325A) PUMP
5. FUSE 4 (40A) POWER STEERING 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 6. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (72v/80v)
(Gen IV) for Early Model J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift
Trucks
13
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE RESISTOR (PTC)
SOLENOID 8. AC TRACTION MOTOR CONTROLLER
3. FUSE 3 (15A) LIGHTS 9. AC PUMP MOTOR CONTROLLER
4. FUSE 4 (5A) KEY SWITCH 10. FUSE 5 (40A) POWER STEERING
5. POWER STEERING CONTACTOR 11. LED INDICATOR
6. LINE TRACTION CONTACTOR 12. LINE PUMP CONTACTOR
Figure 7. AC Traction and Pump Motor Controllers for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) Lift Truck Models
14
STATUS CODES • Input voltages that are too high or too low
• Input voltages in the wrong sequence or
NOTE: Make sure the parameter values are correct • Correct input voltages that occur at the wrong time
for your lift truck to ensure the trouble is not just an
incorrect setting. See Function Settings to set the NOTE: A status code indication does not always mean
correct parameter values. If there is no status code that there is a malfunction. A temporary operating
display and the lift truck does not operate correctly, condition can cause a status code display.
there can be a fault in the master controller, the
CANbus, or any device on the CANbus. See the sec- These code numbers are only codes to help identify
tion Troubleshooting When Dash and/or Lift Truck a possible malfunction. A short description of the
is not Operational. different status codes is shown in Table 5.
The status codes are code numbers for malfunctions The Status Code Charts in this section have a more
or lift truck operations that are not correct and that complete description of the status code, the circuit
the motor controller can sense. The master controller that has generated the input for the status code, the
will indicate this code number on the LCD screen of symptom, and the possible causes.
the display panel.
The master and motor controllers sense the following

types of malfunctions:
Table 5. List of Status Codes
Status Code Description Status Code Description

BLANK No input voltage to controller or 52 Traction or pump motor speed sensor
display panel. error.
1 No seat switch input. 53 Traction controller does not respond
to master controller.
2 The forward switch is closed before 54 Pump controller does not respond to
the key or seat switch closes. master controller.
3 The reverse switch is closed before 55 Dash display cannot communicate
the key or seat switch closes. with master controller.
4 Park brake applied while the key 56 Mini-lever module or joystick cannot
switch is in the ON position. communicate with master controller.
5 Start switch fails to close. 57 Valve driver module cannot
communicate with master controller.
6 Accelerator depressed, no direction 61 Current to cooling fans is too high
selected. during operation.
7 Acceleration voltage too high when 62 Current to reverse relay is too high
the key switch is first moved to the during operation.
ON position.
8 Acceleration input voltage too low 63 Current to DC pump contactor coil is
when the key switch is first moved too high during operation.
to the ON position.
9 Both the forward and reverse 64 Current to power steering contactor
directional switches are closed at coil is too high during operation.
the same time.
10 Armrest is up. 65 Current to the line contactor coil is
too high during operation.
15
Table 5. List of Status Codes (Continued)
Status Code Description Status Code Description

11 The acceleration start switch 66 Short circuit sensed on power output
closed before the key and/or the to traction motor.
seat switch.
12 Mini-levers or joystick out of 67 Short circuit sensed on power outage
neutral when the key switch is to pump motor.
moved to the ON.
13 Brake pressure is out of range. 68 Current to seat brake controller too
high during operation.
15 Battery voltage is too low or master 69 Current to the pump line contactor
controller is adjusted to the wrong coil is too high during operation.
voltage.
16 Battery voltage is too high or 70 Current to brake light relay is too
master controller is adjusted to the high during operation.
wrong battery voltage.
21 Error in mini-lever module or 76 Capacitor voltage is too high.
joystick input.
22 Coil current to a valve coil is out of 90 Traction motor temperature too high.
range, too low.
23 Coil current to a valve coil is out of 91 Pump motor temperature too high.
range, too high.
41 Traction motor controller 95 Lift pump motor brushes are worn.
overheated.
42 Pump motor controller overheated. 99 Maintenance Alert and Speed Limit.
43 Traction motor temperature sensor
out of range.
44 Pump motor temperature sensor
out of range.
51 Capacitor volts are too low before
line contactor closes.
16
2200 SRM 1056 AC Motor Controllers Status Code Charts
AC Motor Controllers Status Code Charts

Status Code Description Memory Recall Circuit
No seat switch input. No Traction
1
Symptom
Lift truck does not move.
Hydraulic functions are disabled.
Possible Causes and Test Procedures

• Seat switch malfunction.
Check to see that the seat switch operates prop-
erly.
Replace a failed switch.
• Check wiring to the seat switch and from the seat
switch to the master controller

The forward switch is closed before the No Traction
2 key or seat switch closes.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static
Return to Off (SRO) Startup Procedure, move the
directional lever to the neutral position, and then
select a direction.
• A directional switch is failed closed or out of adjust-
ment.
17
AC Motor Controllers Status Code Charts 2200 SRM 1056

The reverse switch is closed before key No Traction
3 or seat switch closes.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static
Return to Off (SRO) Startup Procedure, move the
directional lever to the neutral position, and then
select a direction.
• A directional switch is failed closed or out of adjust-
ment.

Park brake applied while the key switch No Traction
4 is in the ON position.
Symptom

• Park brake is applied.
Truck will not operate with park brake applied.
Release the park break.
• Park brake switch is out of adjustment or is shorted.
18

Start switch fails to close. No Traction
5
Symptom

• Malfunction of start switch circuit.
Check for open circuit or loose connections in
wiring from key switch to start switch and from
P16 to start switch.
• Malfunction of start switch.
Check start switch for correct operation and out-
put.

Accelerator depressed with no direc- No Traction
6 tion selected.
Symptom

• Accelerator pedal is depressed before closing a direc-
tion switch.
Status code will disappear when directional
switch is closed or when accelerator pedal is re-
leased.
• Malfunction of directional switch.
Check forward or reverse switch to make sure
there is continuity when direction is selected.
• Open circuit between directional switch and battery
positive or between directional switch and P4 or P5.
Check all wires and connections shown in trou-
bleshooting diagram.
19

Accelerator input voltage too high when key No Traction
7 is first moved to ON position.
Symptom

• Accelerator unit has a malfunction or is out of adjust-
ment. Maximum accelerator wiper voltage should be
11.00 volts with the pedal fully up.
• Open circuit between accelerator unit and P7.

Accelerator input voltage too low when key No Traction
8 is first moved to the ON position.
Symptom

• Minimum accelerator wiper voltage should be 10.70
volts with the pedal fully up.
• Accelerator unit has malfunction or is out of adjust-
ment.
20

Both the forward and reverse directional No Traction
9 switches are closed at the same time.
Symptom

• Forward or reverse directional switch is failed closed
or out of adjustment (adjusted to be held closed).
Replace or adjust directional switches to make
sure they open when directional switch is re-
turned to neutral.
• Short circuit between battery positive and P4 and/or
P5.
Disconnect wires from P4 and P5 and check wire
for short circuit to positive side of directional
switch.

Armrest is up No E-Hydraulics
10
Symptom

• Put the armrest in the down position and ensure that
it is latched properly.
• Armrest switch malfunction.
Replace a failed switch.
• Check wiring to the armrest switch from the mini-
lever module or joystick.
21

The accelerator start switch closed before No Traction
11 the key and/or the seat switch.
Symptom

• The accelerator pedal was depressed when the key
was turned to the ON position. This violates the
Static Return to Off (SRO) Startup Procedure. To
correct this action, release the accelerator pedal and
resume normal operation.
• The accelerator pedal was depressed when the oper-
ator sat down. This violates the SRO Startup Proce-
dure. To correct this action, release the accelerator
pedal and resume normal operation.
• The accelerator start switch is out of adjustment or
has a short.
22

Mini-levers or joystick out of neutral when No E-Hydraulics
12 the key is moved to the ON position.
Symptom

• One (or more) hydraulic functions are commanded
while the key is turned to the ON position.
Status code will disappear when all hydraulic
commands are returned to neutral.
• Malfunction of joystick, if equipped.
Power-On truck.
Display the diagnostic menu on the dash display
panel.
•Is the joystick input = 128?
•Yes: Go to next step.
•NO: Replace joystick. See Electro-Hy-
draulic Control Valve 2000 SRM 1224.
• Malfunction of mini-lever, if equipped.

Stroke each lever to full stroke and allow lever
to snap back to center.
Power-On truck.
Display the diagnostics menu on the dash dis-
play panel.
•Is each mini-lever input = 128?
•YES: Go to next step
•NO: Replace the lever. See Electro-Hy-
Operate each lever to full stroke forward and

slowly release (1-2 seconds from full stroke).
Read input when fully released.
•Is each mini-lever input = 128?
•YES: Go to next step.
•NO: Replace lever. See Electro-Hydraulic
Control Valve 2000 SRM 1224.
Operate each lever to full stroke back and slowly

release (1-2 seconds from full stroke). Read input
when fully released.
• Is each mini-lever input = 128?
• YES: Problem resolved.
• NO: Replace lever. See Electro-Hydraulic
23

Brake Pressure is out of range No Traction
13
Symptom
Top speed reduced to half

• Failed sensor
Check wiring for damage. Replace sensor.

Battery voltage is too low or truck is adjusted No Traction
15 to the wrong battery voltage.
Symptom

• Discharged battery.
Check battery for correct open circuit voltage.
Correct voltages are listed on right. Charge bat-
tery if required.
• Battery is damaged.
Check each battery cell for correct voltage (greater
than 1.85 volts each cell). Replace or repair bat-
tery.
• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller for the correct battery volts.
• Check the battery volts on the main power cables at
the motor controllers.
24

Battery voltage is too high or master controller No Traction
16 is adjusted to the wrong battery voltage.
Symptom

• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller for the correct battery volts.
• Battery overcharged or incorrect battery used.
Check battery for correct open circuit voltage.
Correct voltages are listed on right. If voltage is
too high, check battery charger for correct output
voltage.

Error in the mini-lever module or joystick input. No E-Hydraulics
21
Symptom

• Malfunction of joystick, if equipped.
Power-On truck.
Display the diagnostics menu on the dash.
•Is the joystick input = 128?
•NO: Replace joystick. See Electro-Hy-
• Malfunction of mini-lever, if equipped.
Power-On truck.
Display the diagnostics menu on the dash display
panel.
•Is the mini-lever input = 128?
•NO: Replace lever. See Electro-Hydraulic
• Check "No. of functions Setting" in the "E-Hyd Setup
Menu"
25

A valve coil current is out of range, too low. No E-Hydraulics
22
Symptom

• Wiring from the valve driver module to the valve coil
is open.
• Valve coil malfunction.
Check the resistance of the valve coil. The approx-
imate coil resistance at room temperature should
be 8 ohms.

A valve coil current is out of range, too high. No E-Hydraulics
23
Symptom

• Wiring from the valve driver module to the valve coil
is shorted.
• Valve coil malfunction.
Check the resistance of the valve coil. The approx-
imate coil resistance at room temperature should
be 8 ohms.
26

Traction motor controller overheated. Yes Traction
41
Symptom
Truck acceleration is reduced or truck may
stop completely.

• Excessive pushing or stalling of traction motor.
• Check operation of cooling fans.
See Fan Test.
• Check for proper application of thermal grease be-
tween motor controller and heat sink.

Pump motor controller overheated. Yes Traction
42
Symptom
Truck acceleration and travel speed is reduced
and pump motor may stop completely.

• Excessive operation or stalling of the pump motor.
• Check operation of the cooling fans.
See Fan Test.
• Check for proper application of thermal grease be-
tween motor controller and heat sink.
27

Traction motor temperature sensor out of range. No Traction
43
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but traction
motor overtemperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.

Pump motor temperature sensor out of range. No Pump
44
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but pump
motor overtemperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.

Capacitor volts are too low before line No Traction
51 contactor closes.
Symptom
Lift truck does not move and line contac-
tor does not close.

• A Positive Temperature Coefficient (PTC) is discon-
nected or malfunctioning, preventing the capacitors
to charge when the battery is plugged in.
• An accessory or component other than the motor con-
trollers is connected to load side of line contactor.
This will cause the PTC to get hot and not charge
the capacitors.
• Repeated charging/discharging the capacitors dur-
ing troubleshooting may cause a Status Code 51. If
the PTC is hot, allow it to cool.
• Status code will occur if the line contactor does not
close properly and truck operation is attempted.
• Status code will occur if battery voltage drops below
50% nominal voltage.
28

Traction or pump motor speed sensor error. No Traction
52
Symptom
Traction or pump motor operates very slowly and jerky.

• Disconnected or broken sensor wires between motor and motor controller.
• Malfunction of motor encoder bearing.

Traction controller does not respond to No Traction
53 master controller.
Symptom

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working.
Check for loose or broken wires.
• Open connection between motor controller pin 13 (ground) and pin 12 and/or pin 20. See the Electrical
Diagrams manual for your lift truck model. Pins 12 and 20 are truck I.D. pins.
• A code may appear when the master controller does not detect the key turning OFF, but the pump controller
does detect the key turning OFF. This is caused when there is a voltage on the key switch circuit that is
greater that 3 volts and less than 10 volts with the key turned OFF.

Pump controller does not respond to No Pump
Symptom
Hydraulic pump motor does not operate.

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working
• This status code may appear on trucks with contactor controlled DC pump motors. The master controller
senses the presence of a contactor by a voltage on pin 40. If there is no voltage on pin 40, the master con-
troller assumes an AC pump motor controller is present, but not able to communicate.
Check for voltage at the pump contactor coil.
Check wiring from pump contactor coil to master controller, pin 40.
• A code may appear when the master controller does not detect the key turning OFF, but the pump controller
does detect the key turning OFF. This is caused when there is a voltage on the key switch circuit that is
greater that 3 volts and less than 10 volts with the key turned OFF.
29

Dash display cannot communicate with Yes Traction
Symptom
Varies due to problem.

• If truck operates and code is displayed on dash, the CANbus communication is not working between the dash
and the master controller. See the section Troubleshooting When Dash and/or Lift Truck is not Operational.
• If truck does not operate and code is displayed on dash, see the section Troubleshooting When Dash and/or
Lift Truck is not Operational.

Mini-lever module or joystick cannot No E-Hydraulics
56 communicate with the master controller.
Symptom

• Check input to the mini-lever module (or joystick).
Voltage should be in the range 9-16V.
• Check LED status of the valve driver module.
Green LED should be on.
• CANbus communication between mini-lever module and master controller is not working

Valve driver module cannot communicate No E-Hydraulics
57 with master controller.
Symptom

• Check LED status of the valve driver module.
Green LED should be on.
• CANbus communication between mini-lever module and master controller is not working
30

Current to cooling fans is too high No Traction
61 during operation.
Symptom
Lift truck does not move. If fault occurred during
truck operation, status code will not display until the
key switch is cycled to OFF and then to ON again.

• A fan or wiring to fan may have a short.
• Trucks using a fan power supply may have a short in
the power supply.
• If the status code is displayed while fans or power
supply are disconnected, fault is probably in the mas-
ter controller.

Current to reverse relay is too high No Traction
Symptom

• Reverse relay coil or wiring may have a short.
Check the coil resistance with the wires discon-
nected. The approximate resistance is 576 ohms.
• If status code is displayed while relay coil wires are
disconnected, the fault is probably in master con-
troller.
31

Current to DC pump contactor coil is too No Traction
63 high during operation.
Symptom

• DC pump contactor coil or wiring to coil may have a
short.
Check the coil resistance with wires disconnected.
Approximate coil resistance, at room tempera-
ture, should be:
36/48 volt trucks 31 ohms
• If status code is displayed while contactor coil wires
are disconnected, the fault is probably in master con-
troller.

Current to power steering contactor coil No Traction
64 is too high during operation.
Symptom

• Power steering contactor coil or wiring to coil may
have a short.
ture, should be:
troller.
32

Current to the line contactor coil is too No Traction
Symptom

• Line contactor coil or wire to coil has a short.
ture, should be:
troller.

Short circuit sensed on power output No Traction
66 to traction motor.
Symptom

• Short circuit in motor or heavy power wires going to
motor.
• If status code is displayed with motor power wires
disconnected, the short circuit is internal.
Replace motor controller.
33

Short circuit sensed on power output No Pump
67 to pump motor.
Symptom
Hydraulic pump motor does not operate.

• Short circuit in motor or heavy power wires going to
motor
• If status code is displayed with motor power wires
disconnected, short circuit is internal.
Replace motor controller.
Status Code Description Memory Recall

No
Current to seat brake controller too
Symptom
Lift truck does not move, and seat brake
does not release.
If fault occurs during truck operation, status code
does not display until the key switch is turned to the
OFF position and then turned to the ON position.

• Seat brake controller or wire to controller has a short
• If status code is displayed with the wires discon-
nected, the fault is probably in the master controller
34

Current to the pump line contactor coil is No Traction
69 too high during operation.
Symptom

• Pump line contactor coil or wire to coil has a short.
ture, should be:
troller.

Current to brake light relay is too high No Traction
Symptom

• Brake light relay coil or wiring may have a short.
Check the coil resistance with the wires discon-
nected. The approximate resistance is 160 ohms.
• If status code is displayed while relay coil wires are
disconnected, the fault is probably in master con-
troller.

Capacitor voltage too high. No Traction
76
Symptom
Lift truck does not work.

• Regen setting too high.
Combination of a fully charged battery and a high regen setting may cause status code.
35

Traction motor temperature too high. Yes Traction
90
Symptom
Truck acceleration is reduced, or truck may stop completely.

• Excessive pushing or stalling of traction motor.
• Operation may continue at slower duty cycle.
Allow traction motor to cool to regain full performance.
• Comparing the motor temperature through the display panel with a known motor temperature, such as
room temperature, can check the motor temperature sensor.
• A shorted or open temperature sensor will generate a status code 43.

Pump motor temperature is too high. Yes Pump
91
Symptom
Truck acceleration and travel speed reduced. Pump motor may stop completely.

• Excessive operation or stalling of pump motor.
• Operation may continue at slower duty cycle.
Allow pump motor to cool off to regain full performance.
• Comparing the motor temperature through the display panel with a known motor temperature, such as
room temperature, can check the motor temperature sensor.
• A shorted or open temperature sensor will generate a status code 43.
36

DC lift pump motor brushes are worn. Yes Pump
95
Symptom
Status code warning only.

• Pump motor brushes are worn too short.
• Motor brush wear sensor wires to motor controller
may have a short to battery positive.

Maintenance Alert and Speed Limit. No Traction
99
Symptom
Status code is displayed and, after 20 hours, truck speed is reduced to 50% of normal top speed.

• Maintenance reminder indicating it is time to service truck. It was set by a technician through the dash
display or with a PC.
• The technician must perform desired maintenance and reset reminder to next hourmeter reading that main-
tenance should occur.
37
TROUBLESHOOTING WHEN DASH • If status code 55 is displayed, proceed to

AND/OR LIFT TRUCK IS NOT Step 2.
OPERATIONAL • If status code 55 is not displayed, check for
battery power between the display connec-
Typical Symptoms tor pins 1 and 2. Power should be detected
between the display connector pins 1 and
There are four typical symptoms that may occur 2, regardless of the key position. If power
when the dash and/or lift truck is not operational: is detected between the display connector
pins 1 and 2, proceed to Step 3.
• The truck runs but the dash display is not opera-
tional, or only displays status code 55. An addi- 2. Check the CANbus as follows:
tional delay between the key ON and the line con-
tactor closing may occur. a. Status code 55 indicates that the display can-
• The lift truck does not run and the dash is not op- not communicate over the CANbus.
erational, or only displays status code 55. • Connect a PC with ETACC installed, and
• The hydraulics operate normally, the traction does proceed to “Report – Devices” to determine
not operate correctly, and the dash is operational if the software article number in the dash
but no status codes are present. software and master controller can be read.
• The traction operates normally, the hydraulics do • If ETACC can read both the dash software
not operate correctly, and the dash is operational article number and master controller arti-
but no status codes are present. cle number, proceed to Step 3.
• If ETACC can only read the article number
Truck Runs but Dash Display is not in the master controller, and not the arti-
Operational, or Only Displays Status Code cle number in the dash software, check the
55; an Additional Delay Between Key ON wiring and connector between the dash and
and Line Contactor Closing May Occur the diagnostic connector. If the wiring and
connector are good, proceed to Step 3.
Possible reasons include: • If ETACC can only read the article num-
• There is no power to the display. ber in the dash software, and not the arti-
• There is no CANbus connection. cle number in the master controller, check
• A software fault has occurred in the display soft- the wiring and connector between the diag-
ware. nostic connector and the master controller.
• An internal hardware fault has occurred in the dis-
play. 3. Check the software as follows:
Troubleshoot as follows: a. On lift trucks equipped with premium dis-

• Check the power to the display. See Step 1. plays, use ETACC to download a standard
• Check the CANbus. See Step 2. display language. If the software appears
• Check the software. See Step 3. to download the standard display language,
• Check the hardware. See Step 4. but the display does not function, proceed to
Step 4.
1. Check the power to the display as follows:
b. On lift trucks equipped with standard dis-
a. When the key switch is turned ON, does the plays, proceed to Step 4.
display back light illuminate?
4. Check the hardware as follows:
• If YES, the display has power. Proceed to
Step 3. a. Replace the display with a new or known
• If NO, turn the key OFF and proceed to good display. Does the display function now?
Step b.
• If YES, the hardware was causing the
b. With the key switch OFF, press the "*" fault.
key twice. An external light source may be • If NO, recheck by performing Step 1
needed to read the display as the display through Step 4.
back light may not illuminate.
38
Truck Does Not Run and Dash is Not 65 ohms. This resistance is the result of the
Operational or Only Displays Status Code 120 ohm termination resistors at the trac-
55 tion control and in the dash display. If the
resistance is not within specification, check
Possible reasons include: the traction control termination resistor and
• The display is bad and the software was not given dash display termination resistor.
enough time to boot up.
• The key switch has no power. b. If the dash and traction control are deter-
• There is no CANbus signal to or from the con- mined not to be the problem, check the har-
trollers due to a faulty control. ness by disconnecting all controls and check-
• There is no CANbus signal to or from the con- ing the resistance between pins A and B, A
trollers due to a faulty harness. and C, and B and C. Also check the resistance
between the truck frame and pins A, B, and
Troubleshoot as follows: C. If the resistance is not greater than 100K
• Make sure that the software has had time to boot ohms, correct the fault in the harness.
up without the dash, and make sure that the truck
is not running. See Step 1. c. If the resistance is greater than 100K ohms,
• Check for power from the key switch. See Step 2. connect the termination resistor at the trac-
• Check to see that the CANbus is physically intact. tion control by connecting the 23 pin connec-
See Step 3. tor. On early model lift trucks, it may be nec-
• Check the CANbus signal to and from the con- essary to connect the external termination
trollers. See Step 4. resistor located next to the 23 pin connector
and check that the resistance between A and
1. Make sure that the software has had time to boot B is 110 to 130 ohms.
up without the dash, and make sure that the
truck is not running by turning the key ON and d. If the resistance in Step c is correct, connect
waiting 30 seconds with the operator in the seat the dash display and check that the resis-
and the park brake released. If the truck runs, tance between A and B is 55 to 65 ohms.
see the section Truck Runs but Dash Display is e. Connect each additional control and check
not Operational, or Only Displays Status Code that the resistance between A and B remains
55; an Additional Delay Between Key ON and between 55 to 65 ohms.
Line Contactor Closing May Occur.
4. Check the CANbus signal to and from the con-
2. Check for power from the key switch by turning trollers by using ETACC to determine if the soft-
the key switch ON and checking the LED on the ware article number can be read for all of the de-
master controller. vices.
a. If the LED blinks two times per second, check a. If all of the devices are being read, use
the key switch circuit. ETACC to determine if all of the switches
b. If the LED blinks once every two seconds, the and sensor outputs are correct.
key switch has power. Proceed to Step 4. b. If no devices are being read, disconnect the
c. If the LED does not illuminate, check the bat- devices one at a time to determine if one par-
tery supply circuit to the master controller. ticular device is disabling the CANbus.
If the supply is good, replace the master con- NOTE: The key switch must be turned ON to read
troller. the traction and pump control.
3. Check to see that the CANbus is physically intact c. If only some devices are being read, check
by measuring the following resistances at the di- the power to the devices that are not being
agnostic connector: read. If available, reload the software to the
a. With the battery disconnected and the con- devices that have power and are not being
trol capacitors discharged, the resistance be- read. Replace the devices as necessary.
tween pins A and B should be between 55 and
39
AC Transistor Motor Controller Replacement 2200 SRM 1056
Hydraulics Operate Normally, Traction • J2.00-3.20XM (J40-65Z) [B416] Only - It the lift
Does Not Operate Correctly, and Dash truck does not have a light harness, locate the main
is Operational but no Status Codes are accessory harness connector and install a 20,000
to 25,000 ohm 1/2 watt or larger resistor between
Present pins 2 (wire 10R) and 5 (wire 84C), and make sure
Possible reasons include: that there is no voltage when the brake pedal is
• The master controller is not detecting input from released.
the accelerator sensor.
• J2.00-3.20XM (J40-65Z) [B416] Only - A brake Traction Operates Normally, Hydraulics
pressure sensor is faulty. do Not Operate Correctly, and Dash is
Operational but no Status Codes are
Troubleshoot as follows:
Present
• Using the dash display or ETACC, check the throt-
tle potentiometer voltage as the accelerator is de- Possible reasons include:
pressed. • There is no switch input from the hand levers.
• J2.00-3.20XM (J40-65Z) [B416] Only - If the lift • The master controller has incorrectly defined the
truck is equipped with brake lights, check that the lift truck due to a corrupt register in the traction
brake lights are OFF when the brake pedal is re- control.
leased. If the brake lights remain ON after the
brake pedal is released, the master controller will Troubleshoot as follows:
not command the traction controller to move. • Using the dash display or ETACC, check that the
• J2.00-3.20XM (J40-65Z) [B416] Only - If the switch inputs as the hydraulic levers are actuated.
lift truck is not equipped with brake lights but is • If the lift truck has contactor hydraulics, connect
equipped with a light wire harness, install relay the pump AC controller connector to the traction
1525827 and suppression module 1520933, if re- control. Turn the key switch ON then OFF, then
quired. Use an ohmmeter across the NO to COM reconnect the traction controller connector. Update
contacts to make sure that the relay releases when the master controller software when the problem
the brake pedal is released. has been corrected.
AC Transistor Motor Controller Replacement

GENERAL in Figure 8, Figure 9, and Figure 10. The assembly
of the AC Traction Motor controller with contactor
NOTE: In Figure 8 through Figure 12, the terms Gen for DC Lift Pump Motor is shown in Figure 11 and
IV and Gen V refer to Generation IV and Genera- Figure 12. There are NO internal parts of these
tion V respectively. Controller and contactor panels motor controllers that can be repaired. Each of these
labeled Gen IV are used in early model lift trucks motor controllers must be replaced if an internal
and controller and contactor panels labeled Gen V malfunction occurs.
are used in later model lift trucks.
The assembly of the AC traction motor controller

with optional AC pump motor controller is shown
40
2200 SRM 1056 AC Transistor Motor Controller Replacement
1. FUSE 1 (15A) 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) (SLOW) 8. LINE CONTACTOR
3. FUSE 3 (15A) 9. AC PUMP MOTOR CONTROLLER
4. FUSE 4 (5A) 10. POSITIVE TEMPERATURE COEFFICIENT
5. POWER STEERING CONTACTOR RESISTOR (PTC)
6. FUSE 4 (POWER STEERING) (40A) 11. LED INDICATOR
Figure 8. AC Traction and AC Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for J2.00-3.20XM
(J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models Only and for J2.00-3.20XM
(J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and V30ZMD (D210/E210) Lift Truck
Models
41

3. FUSE 3 (5A) 9. LED INDICATOR
4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT
5. FUSE 4 (POWER STEERING) (40A) RESISTOR (PTC)
6. LINE CONTACTOR
Figure 9. AC Traction and AC Pump Motor Controllers (72v/80v) (Gen IV) for Early Model
J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks
42

2. FUSE 2 (15A) (SLOW) RESISTOR (PTC)
5. POWER STEERING CONTACTOR 10. POWER STEERING FUSE (40A)
6. LINE TRACTION CONTACTOR 11. LED INDICATOR
12. LINE PUMP CONTACTOR
Figure 10. AC Traction and AC Pump Motor Controllers for E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) Lift Truck Models
43

2. FUSE 2 (15A) (SLOW) RESISTOR (PTC)
4. FUSE 4 (5A) 10. FUSE (PUMP) (325A)
5. POWER STEERING CONTACTOR 11. CONTACTOR FOR DC PUMP MOTOR
6. FUSE 4 (POWER STEERING) (40A) 12. LED INDICATOR
7. LINE CONTACTOR
Figure 11. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (Gen V)
(36v/48v or 72v/80v) for J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later
Models Only and for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114);
and V30ZMD (D210/E210) Lift Truck Models
44

2. FUSE 5 (15A) RESISTOR (PTC)
4. POWER STEERING CONTACTOR 9. FUSE 2 (PUMP) (325A)
5. FUSE 4 (POWER STEERING) (40A) 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 12. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (72v/80v)
(Gen IV) for Early Model J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108)
45
GENERAL MAINTENANCE During installation of the controller, apply a suffi-

INSTRUCTIONS cient layer of silicone (heat transfer) grease, Hyster
P/N 1198757, between the controller and the heat
The motor controllers, like other electronic devices, sink to not allow air gaps between the two.
have temperature limits. These devices can be dam-
aged if they get too hot. Normal maintenance will Controller wire plugs and other exposed transistor
help prevent high-temperature conditions. Always controller parts should be kept free of dirt and paint
make sure motor controllers are installed using heat that might change the effective resistance between
sink compound and that all heat sink surfaces are points.
clean. DO NOT block cooling airflow.
CAUTION
Special Precautions
DO NOT operate the traction system at high
speed or rapidly change direction of operation
WARNING with the wheels raised. Motor controller dam-
To avoid injury and prevent electrical shock, age can occur.
perform the following steps before trou-
bleshooting, adjustments, or repair: DO NOT subject the controller to any high voltage
• Turn the key switch to the OFF position and (hipot or megger) testing.
disconnect the battery connector. Use a lead acid battery with the voltage and ampere
• Discharge the capacitors in the controllers hour rating specified for the lift truck. Follow normal
by pushing and holding the horn button battery maintenance procedures, recharging at 80
down until the horn stops making a sound. percent discharge, with monthly equalizing charges.
CAUTION Parts of these assemblies not covered in this manual

cannot be repaired and must be replaced if they mal-
To help prevent controller damage:
function. The contactors are serviceable.
• ALWAYS disconnect the battery when servic-
ing the controllers.
• ALWAYS discharge the capacitors before per- WARNING
forming any service. Some checks in this section must be done with
• NEVER make a short circuit at any motor the battery connected and power applied to
controller terminal to battery (+), battery ( ), the controller. When making these checks,
or the frame. make sure the drive wheels are raised from
• Remove the motor controllers before per- the floor. See procedures given in the Periodic
forming any authorized welding procedures. Maintenance Manual or the Operating Manual
for your lift truck.
Never add any electrical component to the lift
truck without approval from your dealer for Make sure you disconnect the battery and
your lift truck. Other electrical components separate the connector before you remove any
can prevent operation and/or damage the mo- power cables from the power terminals of the
tor controller. motor controller. The capacitor stores electri-
cal energy and can cause injury, if a person
NEVER USE STEAM TO CLEAN ELECTRONIC discharges a capacitor, to parts of the body.
COMPONENTS. AFTER the battery is disconnected and the
key switch is in the OFF position, make sure
In dusty areas, blow low-pressure air over the con- you also discharge the capacitors.
troller to remove dust. In oily or greasy areas, a
mild solution of detergent or denatured alcohol can Discharge the capacitors in the controllers by
be used to wash off the controller; and then, low-pres- pushing and holding the horn button down un-
sure air should be used to completely dry the con- til the horn stops making a sound.
troller.
NOTE: The bolts and screws connected to the elec-
For the controller to be most effective, it must be tronic components are normally metric sizes.
mounted against the finned aluminum heat sink.
46
Make sure that you use the correct fastener for the
part that has been disassembled or removed.
FUSES
The fuses are found on the contactor panels. See Fig-
ure 8, Figure 9, Figure 10, Figure 11, and Figure 12.
The condition of the fuses can normally be checked
by looking at them. Some fuses do not change in ap-
pearance and must be checked with an ohmmeter.
FAN TEST
To determine if the fans are operating correctly, go
to the Access to Service Functions section of this
SRM. Using the procedures in that section, go to 1. CONTACTOR 4. MOVABLE
Diagnostics Menu and select No Run Diagnostics. 2. POWER CONTACTS
From there, go to Fan On, which is the last menu TERMINALS 5. SPRING
item. As soon as Fan On is selected, the fans should 3. FIXED CONTACTS 6. PLUNGER
start running.
Figure 13. Pump Motor Contactor
On 36/48 volt trucks, the fans operate at battery volt-
age. If battery voltage is present at the fan terminal Repair
strip and the fan(s) doesn’t run, replace the fan(s).
Tag, identify, and disconnect the wires and cables
If battery voltage is not present at the fan terminal
from the contactor assembly. Remove the mounting
strip, look for problems in the positive circuit from
screws and remove the contactor assembly. See Fig-
the key switch or the negative circuit to pin 15 on
ure 14.
the master controller.
Contactor Contacts. The contacts in a contactor
On 72/80 volt trucks, the fans operate with a fan
are made of special silver alloy. The contacts will look
power supply. If the power supply voltage (48 volts) is
black and rough from normal operation. This condi-
present and the fan(s) doesn’t run, then replace the
tion does not cause problems with the operation of
fan(s). If there is battery voltage to the fan power
the lift truck. Cleaning is not necessary. DO NOT
supply and there is no output voltage, then replace
USE A FILE ON THE CONTACTS. DO NOT LU-
the fan power supply. If battery voltage is not present
BRICATE THE CONTACTS.
at the power supply, look for problems in the positive
circuit from the key switch or the negative circuit to
pin 15 on the master controller. CAUTION
ALWAYS replace all of the contacts in a con-
CONTACTORS tactor at the same time. Replace the contacts
when the thickness of any area of a contact is
There can be three contactors on these lift trucks. less than 30 percent of the thickness of a new
All lift trucks have a power steering contactor and contact or if there is any transfer of contact ma-
a line contactor. See Figure 13 and Figure 14. Lift terial.
truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) have a separate line contactor Coil. Check the coil with an ohmmeter for an open
for the pump motor controller. Lift trucks that do not circuit or a short circuit. Coil resistance is very low.
have a pump motor controller also have a contactor Approximate coil resistance, at room temperature,
to energize the lift pump motor. See Figure 13. can be determined by looking at Status Codes 63,
64, 65, and 69. Replace the coil if it is damaged.
Make sure the coil wires are connected again to the
correct terminals.
47
NOTE: Some wire numbers found in Table 6, Table 7, Legend for Figure 14
and Table 8 may or may not be followed by a letter,
depending on the lift truck model. 1. TOP COVER
2. FIXED CONTACT SETS
3. MOVABLE CONTACTS
4. SCREW
5. RETURN SPRING
6. INSULATOR
7. COIL ASSEMBLY
Figure 14. Replacement Parts of Power

Steering Contactor
48
Table 6. 42-Pin Connections/Descriptions for Master Controller
Pin No. Wire Number Function

1
2 7 SEAT SWITCH
3 10 KEY SWITCH
4 8 REVERSE SWITCH
5 6 FORWARD SWITCH
6 32 +12 V
7 13 ANALOG GROUND
8 72 CANbus GROUND
9 51 PUMP HIGH SPEED
10 84D BRAKE LIGHT RELAY COIL
11* 24A PUMP LINE CONTACTOR
12 6 FORWARD SIGNAL
13 24 LINE CONTACTOR
14 3 BATTERY POSITIVE
15 65 FAN
16 15 ACC START SWITCH
17 107 PUMP MOTOR BRUSH WEAR
18 108 PUMP MOTOR BRUSH WEAR
19 44 PARK BRAKE
20
21
22 74 CANbus HIGH
23 73 CANbus LOW
24
25
26
27
28 13 BATTERY NEGATIVE
29 46 SEAT BRAKE
30
31 45 BRAKE FLUID LEVEL
32 100 DC PUMP MOTOR TEMPERATURE
33 53 PUMP LOW SPEED
34
49
Table 6. 42-Pin Connections/Descriptions for Master Controller (Continued)
Pin No. Wire Number Function

35
36 29 ACCELERATOR PEDAL POSITION
37 359 BRAKE FLUID PRESSURE
38 52 PUMP MEDIUM SPEED
39
40 54 DC PUMP CONTACTOR
41 8 REVERSE SIGNAL
42 60 POWER STEERING CONTACTOR
*E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) LIFT TRUCK MODELS ONLY
Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Motor Controllers
Wire Number
Pin No. Traction Pump Function
1 10 10 KEY SWITCH
2
3 33 33 SENSOR VOLTAGE SUPPLY
4 13 13 BATTERY NEGATIVE
5 104 110 SENSOR BEARING SIGNAL
7 102 100 MOTOR TEMPERATURE
8
9 CONTROLLER ID PIN
10 74 74 CANbus HIGH
11 73 73 CANbus LOW
12 74 CANbus TERMINATION RESISTANCE
13 72 72 CANbus GROUND
Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen V) Volt Motor Controllers
Wire Number
1 10 10 KEY SWITCH
2
3 33 33 SENSOR VOLTAGE SUPPLY
50
Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen V)

Volt Motor Controllers (Continued)
Wire Number
4 13 13 BATTERY NEGATIVE
7 72 72 CANbus GROUND
12 CONTROLLER ID PIN
13 13 CONTROLLER ID PIN GROUND
14 73 73 CANbus LOW
15 73 CANbus LOW
16 102 100 MOTOR TEMPERATURE
17 13 13 MOTOR TEMPERATURE GROUND
20 CONTROLLER ID PIN
22 74 74 CANbus HIGH
23 74 CANbus HIGH
THERMAL SENSORS CAUTION

The thermal sensors for AC motors are embedded in DO NOT remove the small screws that fasten
the motor windings and are continuously monitored the cover of the motor controller.
by the motor controllers. They are part of the motor
Make sure there is no dirt between the plate of
and cannot be replaced or repaired.
the motor controller and the mount surface of
MOTOR CONTROLLER, REPLACE the lift truck heat sink.
Make sure the battery is disconnected and the capac- 3. Put an even coat of the silicone compound (Hys-
itor is discharged. Discharge the capacitor by holding ter P/N 1198757) or equivalent on the plate of
down the horn button until the horn stops making a the motor controller. Make sure there are no air
sound. Put a DO NOT CONNECT tag on the bat- spaces between the plate and mount surface of
tery connector. Replace the motor controller as de- the lift truck heat sink. The plate of the motor
scribed in the following procedure. controller must make full contact with the heat
sink. Install the mount screws that fasten the
1. Make an identification for correct connection of motor controller to the heat sink.
the power cables on the power terminals of the
motor controller. Disconnect the power cables 4. Install the power cables at the power terminals
and the connector plug for the control wires. of the motor controller as identified during re-
moval. Install the connector plug for the control
2. Remove the eight (traction) or six (pump) mount- wires on the connector of the motor controller.
ing screws that fasten the plate of the motor con-
troller to the lift truck heat sink. Carefully re- 5. Remove the DO NOT CONNECT tag from bat-
move the motor controller. tery connector and reconnect the battery.
51
Display Panel 2200 SRM 1056
Display Panel
GENERAL • Allows access to the User Check List function.
There are two dash display options, Standard and Standard Display Panel
Premium.Both displays look identical. See Fig-
ure 15. • Allows preassigned service passwords to control ac-
cess to the service functions available through the
Premium Display Panel display.
• Provides the same comprehensive set of service
• Allows preassigned user passwords to control functions using the mode keys and LCD as the
driver access to the vehicle. Premium Display.
• Provides four driving modes that are accessed
through the keypad. Standard and Premium display panels are inter-
• Allows preassigned service passwords to control ac- changeable on the vehicle. Therefore, the display
cess to the service functions available through the system can be easily upgraded or downgraded by
display. changing the display panel.
• Provides a comprehensive set of service functions,
which are accessed through the mode keys and liq-
uid crystal display (LCD).
Figure 15. Standard and Premium Display Panel
52
2200 SRM 1056 Display Functions and Features
Display Functions and Features

KEY-ON INITIALIZATION The indicator lights turn off sequentially, except for
the seat belt light, which will remain lighted for ap-
Upon turning the key to the ON position, the display proximately 10 seconds.
sequentially lights the indicators, from left to right,
located along the top of the display. See Figure 16.
NOTE: The seat belt light will stay on whether the

seat belt is fastened or not fastened.
1. HOURMETER INDICATOR 8. LCD SCREEN

2. WRENCH INDICATOR 9. STAR PUSH BUTTON
3. BATTERY INDICATOR 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR (BDI) 11. PUSH BUTTON #2
5. BRAKE FLUID LEVEL 12. PUSH BUTTON #3
6. PARKING BRAKE 13. PUSH BUTTON #4
7. FASTEN SEAT BELT 14. PUSH BUTTON #5
Figure 16. Dash Display
53
Display Functions and Features 2200 SRM 1056
STANDARD DISPLAY SRM 1058, Enable/Disable Password and Lift Truck

Inspection Functions.
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the
BDI as a bar. See Figure 17. As the battery is dis-
charged, the bar becomes shorter.
Figure 19. Password Prompt Screen
If the password is not entered within 5 to 8 seconds,

a reminder screen is shown on the LCD display. See
Figure 20.
Figure 17. Battery Discharge Indicator
When the key is turned to the OFF position, the

Hourglass indicator becomes illuminated, and the
following hourmeter information is flashed on the
LCD screen: Traction Hours for 3-4 seconds, followed
by Pump Hours for 3-4 seconds, after which the dis-
play turns off and appears black. See Figure 18.
Figure 20. Password Reminder Screen
Until a password is entered that matches a pass-

word stored in the vehicle master controller, the lift
and traction systems are inoperative. Passwords
may be entered in the master controller using either
the dash display (see Dash Display Service Menu
Navigation) or by using the ETACC PC service
software. See the section Troubleshooting and
Adjustments Using the AC Controls Program
(ETACC) 2200 SRM 1058.
A few seconds after the correct password has been en-

tered, the BDI and performance mode are displayed
and the vehicle can be operated. See Figure 21.
Figure 18. Traction/Pump Hours
PREMIUM DISPLAY
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the
prompt for the operator to enter a password if this
function has been enabled. See Figure 19. If the
password function is disabled, the display will by-
pass the password prompt. To enable the password
function, see Troubleshooting and Adjustments
Using the AC Controls Program (ETACC) 2200 Figure 21. Display Screen (Premium Display)
54
LIFT TRUCK INSPECTION FUNCTION NOTE: It is suggested that the factory set password,
55555, be changed prior to the lift truck being placed
If this function is turned on, the operator is prompted into service.
to answer a checklist of questions. The operator in-
dicates a 1 for pass or a 4 for fail. If the operator The display will prompt the service technician for a
indicates the vehicle passes the inspection, the dis- five-digit password. See Figure 23. The default set-
play will show the previous information and the op- ting for the password is 55555. When a correct pass-
erator can drive the vehicle. If the operator indicates word is entered, the Service Features menu is dis-
that the vehicle fails the inspection, Service Required played as follows:
will appear on the display screen, and the vehicle will • Setup Menu
only operate in Mode 1 until the required action is • Password Menu (Operator passwords are only
taken. See Figure 22. available with Premium Display)
• Diagnostic Menu
• View Hourmeter
Figure 22. Inspection Failure Screen
The inspection feature can be enabled with or with- Figure 23. Password Request
out the password function enabled, depending upon
the user’s preference. The inspection checklist fea- The technician can scroll through the menu using the
ture, as with the password feature, may be set up up [1] or down [2] arrows and select the desired func-
using either the dash display or using a PC. For the tion by pressing the [4] button. Each menu selection
PC instructions, go to the section Troubleshooting has a list of submenu functions. The submenus are
and Adjustments Using the AC Controls Pro- viewed and items selected by scrolling through the
gram (ETACC) 2200 SRM 1058. The checklist must menu in the same manner as described above.
be enabled or disabled by a service technician.
To exit a selected function and return to the previous
The following is the list of checks: function, press the [3] button. Pressing the [3] but-
• Check for leaks. ton multiple times will return the technician to the
• Check service brake. operator’s driving mode.
• Check park brake.
• Check horn, lights, and reverse alarm. SERVICE FUNCTIONS
• Check gauges and warning lights.
The following submenu functions are accessible
• Check tire condition and pressure.
from the Main Menu of Service Functions, described
• Check hydraulic oil level.
above. This includes the following three vehicle
setup values and 16 control function settings. The
ACCESS TO SERVICE FUNCTIONS
16 control function settings are discussed further in
All service functions are accessible from either Stan- Function Descriptions.
dard or Premium displays. The following functions • Setup Menu
are the same with either display version, except as Serial Number
noted in the following sections. Set Traction Hours
Set Pump Hours
Once the vehicle is turned ON with the key switch Control Function Settings
and the initialization process has been completed, a 1. Battery voltage
service technician can gain access to the service func- 2. Extended Shift
tions by pressing the star button ( ) twice. 3. Acceleration 1
55
4. Acceleration 2 SERVICE FUNCTIONS

5. Top speed limit
6. Regen braking NOTE: The following service functions apply only
7. Auto deceleration to J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM
8. BDI adjustment (E25-35Z, E40ZS) (F114); V30ZMD (E210); and
9. Lift interrupt E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
10. PS time delay (E098). In addition these functions also apply to
11. Service reminder E2.00-3.20XM (E45-65Z) (G108) lift trucks produced
12. Custom after January 1, 2006.
13. Pump speed 1
The following submenu functions are accessible
14. Pump speed 2
from the Main Menu of Service Functions, described
15. Pump speed 3
above. This includes the following three vehicle
16. Pump acceleration
setup values and 16 control function settings. The
• Password Menu
16 control function settings are discussed further in
Enter Password
Function Descriptions.
Truck Inspection
• Setup Menu
Add Password
Serial Number
Delete Password
Set Traction Hours
Edit Password
Set Pump Hours
NOTE: All indications in the diagnostic menu are Control Function Settings
shown as On, Off, or a value (i.e., Throttle Pot Volt). 1. Battery voltage
On is indicated by a 1. Off is indicated by a 0. 2. Extended Shift
3. Acceleration 1
• Diagnostic Menu 4. Acceleration 2
No Run Diagnostics 5. Top speed limit
Direction switch 6. Regen braking
Accelerator start 7. Auto deceleration
Throttle pot volt 8. BDI adjustment
Seat switch 9. Lift interrupt
Park brake 10. PS time delay
Pump switch #1 11. Service reminder
Pump switch #2 12. Custom
Pump switch #3 13. PUMP SPEED 1 (NOT USED WITH
Steering brush #1 E-HYD)
Steering brush #2 14. PUMP SPEED 2 (NOT USED WITH
DC pump brush #1 E-HYD)
DC pump brush #2 15. PUMP SPEED 3 (NOT USED WITH
DC pump motor temp E-HYD)
Fan on 16. Pump acceleration
Run Diagnostics • E-HYD SETUP
Traction motor speed LIFT SPEED
Traction motor amps Setting 0 to 100: This function determines the
Traction motor temp top speed of the pump motor when lift is used
AC pump motor speed by the operator. Factory default is 100
AC pump motor amps TILT SPEED
AC pump motor temp Setting 0 to 25: This function determines the
• View Hourmeter top speed of the pump motor when tilt is used
Traction Hourmeter by the operator. Factory default is 25.
Pump Hourmeter AUX 1 SPEED
Secure Hourmeter Setting 0 to 30 (standard flow) or 0 to 50 (high
flow option), see Figure 25, Figure 26, Fig-
ure 27, and Figure 28. This function deter-
mines the top speed of the pump motor when
56
1 is used by the operator. Factory default is until there is creep in the function. A num-
25. ber from 0 to 15 will be displayed on the
AUX 2 SPEED Dash Display which corresponds to a crack-
Setting 0 to 30 (standard flow) or 0 to 50 (high ing current off set value. objective is to find
flow option), see Figure 25, Figure 26, Fig- the value of cracking current that produces
ure 27, and Figure 28. This function deter- the slowest creep speed. Press the key to
mines the top speed of the pump motor when save.
auxiliary 2 is used by the operator. Factory 4. Once the calibration is saved, the pump will
default is 25. stop and the Dash Display will return to the
AUX 3 SPEED calibration menu. Repeat the above proce-
Setting 0 to 30 (standard flow) or 0 to 50 (high dure to calibrate the next function.
flow option), see Figure 25, Figure 26, Fig- 5. No calibration is required for the lowering
ure 27, and Figure 28. This function deter- function.
mines the top speed of the pump motor when • PASSWORD MENU
auxiliary 3 is used by the operator. Factory ENTER PASSWORD
default is 25. TRUCK INSPECTION
NO OF FUNCTIONS ADD PASSWORD
Setting 3 or 4: For hydraulic valves with a DELETE PASSWORD
single auxiliary function, the number of auxil- EDIT PASSWORD
iary functions is set to 3. For hydraulic valves • NO RUN DIAGNOSTICS
with double auxiliary functions, the number DIRECTION SWITCH
of auxiliary functions is set to 4. ACCELERATOR LOCK
CLAMP INSTALLED? THROTTLE POT VOLT
Setting Yes or No: If a clamp attachment is in- SEAT SWITCH
stalled, then the setting is yes. If the number PARK BRAKE
of functions is 3, then the clamp is assumed to PUMP SWITCH #1
be aux 1 position. If the number of functions PUMP SWITCH #2
is 4, then the clamp is assumed to be aux 2. PUMP SWITCH #3
HI FLOW AUX INSTLD? DC PUMP BRUSH #1
Setting Yes or No: If the E-hydraulic valve DC PUMP BRUSH #2
has the optional High Flow Auxiliary block in- DC PUMP MOTOR
stalled, then set this to Yes. If it is a standard FAN ON
flow auxiliary block, then the setting is No. • RUN DIAGNOSTICS
See Figure 25, Figure 26 and Figure 28. TRACTION MOTOR SPEED
• E-HYD CALIBRATION TRACTION MOTOR AMPS
CALIBRATE LIFT TRACTION MOTOR TEMP
CALIBRATE TILT FW TRACTION CNTRL TEMP
CALIBRATE TILE BK AC PUMP MOTOR SPEED
CALIBRATE AUX1 DIR A AC PUMP MOTOR AMPS
CALIBRATE AUX1 DIR B AC PUMP MOTOR TEMP
CALIBRATE AUX2 DIR A AC PUMP CNTRL TEMP
CALIBRATE AUX2 DIR B • E-HYD DIAGNOSTICS
Calibration procedure is as follows: LIFT/LOWER INPUT
1. The operator must be on the seat, and the The four inputs are displayed on a scale from
armrest down and latched in order to cali- 0 to 255. The value ranges from 0 when the
brate the valve. lever is moved to the full back position to 255
2. Press the or keys to select the function when the lever is moved to the full forward
for which calibration is desired. Press the position. The value 128 must be displayed
key to start calibration of that function. when the lever is in the neutral position.
3. The master controller will run the pump at a TILT INPUT
slow speed and will command cracking cur- AUX1 INPUT
rent to that function. Use the or keys AUX2 INPUT
to increase or decrease the cracking current
57
CLAMP INTERLOCK control. Three lower performance modes are avail-

When the clamp interlock switch on the mini- able to the operator by using the buttons on the dis-
lever module is pressed, 1 will be displayed on play. These lower performance settings are percent-
the Dash Display. ages of the highest performance available in Mode 4
DUAL FUNCTION SW as described below:
If the truck is equipped with a third auxiliary • Mode 4 - This is the highest performance mode.
function then the dual function switch will Other modes are a lower percentage of Mode 4.
indicate whether it is pressed (1) or released • Mode 3 - Top speed is the same as Mode 4. Accel-
(0). eration is 80 percent of Mode 4.
LIFT COIL CURRENT • Mode 2 - Top speed is 80 percent of Mode 4. Accel-
The coil currents, as measured by the Valve eration is 70 percent of Mode 4.
Driver, is displayed in mA/10. The maximum • Mode 1 - Top speed is 60 percent of Mode 4. Accel-
value 255 corresponds with 2550 mA (or 2.55 eration is 60 percent of Mode 4.
amps).
TILT COIL CURRENT BATTERY DISCHARGE INDICATOR (BDI)
AUX1 COIL CURRENT
AUX2 COIL CURRENT The AC control system includes a Battery Discharge
• VIEW HOURMETER Indicator (BDI) that provides indication of the bat-
TRACTION HOURMETER tery state of charge. See Figure 24. The BDI feature
PUMP HOURMETER is displayed to the operator on the dash display with
SECURE HOURMETER a 20-segment bar. For information on how the BDI
system works, see the Operating Manual for your
PERFORMANCE MODES lift truck.
NOTE: Performance modes are not available on the The BDI provides full functionality when used with
Standard Dash display, and the factory configuration a full range of batteries including:
is equivalent to Mode 4. • Flooded cell, standard amp-hour batteries
• Flooded cell, high amp-hour capacity batteries
When equipped with the Premium Dash display, • Valve regulated (absorbed glass mat) maintenance-
the following four operator-selectable performance free batteries (VRLA)
modes are available. These modes are preconfigured
from the factory as described below. Mode 4 pro-
vides the highest performance and Modes 1-3 are
percentages of Mode 4. A service technician, using
the dash display or connecting with the PC software,
can revise the control settings and configure the top
speed and acceleration of the vehicle. The relation-
ship between Modes 1 through 4 remains constant
and cannot be altered.
With the premium display, the operator can change

modes by pressing the numbered keys on the dash
display. Any number can be selected at any time to
change the performance mode. The change does not Figure 24. Battery Discharge Indication in
take effect until the operator releases the accelerator Dash Display LCD Window
pedal. If the password is enabled, the operator will be
limited by the performance level set in the password
function. The lift interrupt feature is controlled by the vehicle
master controller and prevents the lift function when
Mode 4 is the highest level of performance available the battery is 80 percent discharged. Although lift
to the operator, regardless of the performance setup interrupt prevents lifting, low speed functions, such
in the control. For instance, if the control is con- as tilt and sideshift, remain operational to allow the
figured to limit top speed less than maximum, then operator to more easily remove the forks from the
Mode 4 top speed is equal to the top speed set in the load and return to the battery charging area.
58
When lift interrupt is initiated, it will remain in ef- If a maintenance-free battery is installed, the BDI
fect until the battery is disconnected and a recharged adjustment should be increased to a value of about
battery is reconnected to the vehicle. When a bat- 50 as a starting point. Fine-tuning can be done from
tery is replaced or recharged, the new state of charge that value.
must be at least 25 percent greater than the previ-
ous state of charge. This prevents the BDI from be- HOURMETER
ing activated by a battery that has recovered slightly
during an idle period. There are three different hourmeter functions.
1. Pump hours - accumulates time only when the
A BDI adjustment feature is provided through the pump motor is operating.
control setup function, which is accessible using ei- 2. Traction hours - accumulates time when the seat
ther the dash display or the PC service software. The switch is closed and the key switch is in the ON
adjustment scale is 0-100, with a value of 30 for the position.
factory setting. The setting of 30 is the starting point 3. Secure hours - based on traction hours. The se-
for flooded cell-type batteries of all voltages and amp- cure hours cannot be reset.
hour capacities. The adjustment can then be used to
fine-tune the BDI lift interrupt feature. For example, The hourmeter data is stored in the master controller
if it is desired to have the lift interrupt to occur at a during every 6 minutes of operation. If there is a loss
higher battery specific gravity, then the value would of power, data is not lost.
be increased. The value is decreased if a lower spe-
cific gravity is desired for the lift interrupt point.
59
Figure 25. Electro-Hydraulic Control Valve Schematic (Standard Flow) for Lift Truck Models
J2.00-3.20XM (J40-65Z) (B416), E1.50-2.00XM (E25-35Z, E40ZS) (F114), E2.00-3.20XM (E45-65Z)
(G108)
60
Legend for Figure 25

1. AUXILIARY 2 VALVE (SP5) 15. STEERING RELIEF VALVE
2. AUXILIARY 1 VALVE (SP4) 16. HYDRAULIC TANK
3. TILT CYLINDERS 17. HYDRAULIC FILTER
4. LIFT CYLINDER 18. HYDRAULIC PUMP
5. SECONDARY LOWERING CONTROL INTEGRAL 19. PRIMARY RELIEF VALVE (RV1)
WITH LIFT CYLINDERS 20. SECONDARY RELIEF VALVE (RV2)
6. PRIMARY LOWERING CONTROL (MOUNTED 21. TILT SOLENOID VALVE (SP3)
ON MAST) 22. LIFT SOLENOID VALVE (SP1)
7. STEERING CYLINDER 23. PRIORITY COMPENSATOR VALVE (EC1)
8. STEERING WHEEL 24. LOWERING COMPENSATOR VALVE (EC2)
9. STEERING CHECK PORT 25. TILT COUNTERBALANCE VALVE (CB1)
10. STEERING CONTROL UNIT 26. CHECK VALVE LIFT CIRCUIT (CV1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP 29. GAUGE PORT
61
Figure 26. Electro-Hydraulic Control Valve Schematic (High Flow) for Lift Truck Models
J2.00-3.20XM (J40-65Z) (B416), E1.50-2.00XM (E25-35Z, E40ZS) (F114), E2.00-3.20XM (E45-65Z)
(G108)
62

1. PILOT-OPERATED SPOOL VALVE (PE1) 16. HYDRAULIC TANK
2. PILOT-OPERATED SPOOL VALVE (PE2) 17. HYDRAULIC FILTER
3. TILT CYLINDERS 18. HYDRAULIC PUMP
4. LIFT CYLINDER 19. PRIMARY RELIEF VALVE (RV1)
5. SECONDARY LOWERING CONTROL INTEGRAL 20. SECONDARY RELIEF VALVE (RV2)
WITH LIFT CYLINDERS 21. TILT SOLENOID VALVE (SP3)
6. PRIMARY LOWERING CONTROL (MOUNTED 22. LIFT SOLENOID VALVE (SP1)
ON MAST) 23. PRIORITY COMPENSATOR VALVE (EC1)
7. STEERING CYLINDER 24. LOWERING COMPENSATOR VALVE (EC2)
8. STEERING WHEEL 25. PILOT-OPERATED SOLENOID VALVE (EHPR1
9. STEERING CHECK PORT THROUGH 4)
10. STEERING CONTROL UNIT 26. TILT COUNTERBALANCE VALVE (CB1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP 29. CHECK VALVE LIFT CIRCUIT (CV1)
15. STEERING RELIEF VALVE 30. GAUGE PORT
63
1. PILOT OPERATED SPOOL VALVE (PE1) 16. HYDRAULIC TANK

2. PILOT OPERATED SPOOL VALVE (PE2) 17. HYDRAULIC FILTER
3. TILT CYLINDERS 18. HYDRAULIC PUMP
4. LIFT CYLINDERS 19. PRIMARY RELIEF VALVE (RV1)
5. SECONDARY LOWERING CONTROL INTEGRAL 20. SECONDARY RELIEF VALVE (RV2)
WITH LIFT CYLINDERS 21. PROPORTIONAL SOLENOID VALVE (LIFT) (SP1)
6. PRIMARY LOWERING CONTROL MOUNTED 22. PROPORTIONAL SOLENOID VALVE
ON THE MAST (LOWERING) (SP2)
7. STEERING CYLINDER 23. PRIORITY COMPENSATOR VALVE (EC1)
8. STEERING WHEEL 24. LOWERING COMPENSATOR VALVE (EC2)
9. STEERING CHECKPORT 25. PILOT OPERATED SOLENOID VALVE (EHPR 1
10. STEERING CONTROL UNIT THROUGH 6)
11. HAND PUMP 26. TILT COUNTER BALANCED VALVE (CB1)
12. STEERING VALVE 27. FLOW REGULATOR VALVE (FR1)
13. MAIN CONTROL VALVE 28. MANUAL LOWERING VALVE (NV1)
14. STEERING PUMP 29. LIFT CIRCUIT CHECK VALVE (CU1)
15. STEERING RELIEF VALVE 30. GAUGE PORT
Figure 27. Electro-Hydraulic Control Valve Schematic for Lift Truck Models E3.50-5.50XL
(E70-120Z) (E098)
64
Figure 28. Hydraulic Schematic With Electro-Hydraulics for Lift Trucks Model V30ZMD (E210)
65
Dash Display Service Menu Navigation 2200 SRM 1056

1. SINGLE ACTING PIVOT CYLINDER 19. LOWERING COMPENSATOR VALVE (EC2)
2. ADJUSTABLE FLOW RESTRICTOR 20. LOWERING SOLENOID VALVE WITH MANUAL
3. LOCK/CROSS OVER RELIEF VALVE OVERRIDE (SP2)
4. TRAVERSE HYDRAULIC MOTOR 21. PRIORITY COMPENSATOR VALVE (EC1)
5. SIDESHIFT CYLINDER 22. LIFT SOLENOID VALVE (SP1)
6. LIFT CYLINDERS 23. STEERING VALVE
7. SECONDARY LOWERING CONTROL 24. PRIMARY RELIEF VALVE (RV1)
8. PRIMARY LOWERING CONTROL 25. SECONDARY RELIEF VALVE (RV2)
9. STEERING CYLINDER 26. FLOW REGULATOR VALVE (FR1)
10. HAND PUMP 27. TILT CYLINDER VALVE (SP3)
11. STEERING WHEEL 28. TILT COUNTERBALANCE VALVE (CB1)
12. LINE PRESSURE TAP 29. CHECK VALVE LIFT CIRCUIT (CV1)
13. CHECK PORT 30. GAUGE PORT
14. STEERING PUMP 31. PILOT OPERATED SOLENOID VALVE (EHPR 1
15. HYDRAULIC TANK THROUGH 4)
16. HYDRAULIC FILTER 32. PILOT OPERATED SPOOL VALVE (PE1)
17. HYDRAULIC PUMP 33. PILOT OPERATED SPOOL VALVE (PE2)
18. MAIN CONTROL VALVE
Dash Display Service Menu Navigation

GENERAL
To enter the service mode, turn the key to the ON po-
sition and press the (enter) key twice. Enter Pass-
word prompt will appear on the display. See Fig-
ure 29. All lift trucks will have 55555 as the default
service password at the time of delivery. This pass-
Figure 30. Dash Display Keys
word can be changed by a service technician. Go to
Editing and Adding Information.
MOVING THROUGH MENU SELECTIONS
1. When the service technician’s password has been
correctly entered, the first menu item, which is
the Setup menu, is displayed on the dash dis-
play LCD screen. To view the next menu item,
press the ↓ (down arrow) key on the dash dis-
play numeric key pad. Repeat this until the de-
sired menu item has been reached. To return to a
previous menu item, press the ↑ (up arrow) key.
Figure 29. Password Prompt When the last menu item is reached and the ↓
(down arrow) key is pressed again, the first menu
The ↑ (up arrow) and the ↓ (down arrow) keys allow item will return to the display.
you to move up and down within a menu. The ← (left
arrow) key and the → (right arrow) key allow you to 2. To move into a submenu of a main menu item,
move from menu to menu. The (enter) key allows press the → (right arrow) key on the dash display
you to enter or save a parameter. The 5 (five) key numeric key pad. To move into a sub submenu,
is only used if it is part of the password required to as with the Diagnostics menu, press the → (right
enter the service mode. See Figure 30. arrow) key again.
66
2200 SRM 1056 Dash Display Service Menu Navigation
3. To move up or down within the submenu or the characters. The ← (left arrow) key and → (right
sub submenu, press the ↑ (up arrow) or ↓ (down arrow) key are used to move from character to
arrow) keys. character in the item being changed.
4. To move out of the sub submenu and return to 2. When a character that is to be changed is blink-
the submenu, press the ← (left arrow) key. ing, use the ↑ (up arrow) and ↓ (down arrow)
keys to scroll up or down until the desired char-
5. To move out of the submenu and return to the acter is found. Use the ← (left arrow) or → (right
Main Menu, press the ← (left arrow) key. arrow) keys to move to the next character to be
changed. This is repeated until all changes in the
6. To exit the service mode, press the ← (left arrow)
item have been made.
key.
3. When all changes have been made, press the
EDITING AND ADDING INFORMATION (enter) key to store the value. Press the ↑ (up ar-
row) key or the ↓ (down arrow) key to access the
NOTE: The setup and password menus can be used to
next item to be changed. Repeat this procedure
edit or add information to the truck software. When
for each item that is to be changed.
an item in these menus is selected, the current value
will be displayed. The characters available to be se- 4. When all changes have been made, press the ←
lected from the display are 0 through 9, A through Z, (left arrow) key to exit the menu.
blank, and dash. Each line in the display can have
no more than 20 characters including blanks.
1. If a change is to be made, press the → (right ar-

row) key and the cursor will blink on one of the
67
NOTES
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68
TECHNICAL PUBLICATIONS
2200 SRM 1056 3/09 (4/08)(6/07)(11/06)(3/06)(1/06)(7/05)(3/05)(5/04)(3/04)(1/04)(12/03) Printed in U.S.A.

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AC MOTOR CONTROLLERS/DISPLAY

PART NO. 1534735 2200 SRM 1056

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2009 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

J2.00-3.20XM (J40-65Z) [A416/B416];

Legend for Figure 1

Figure 1. Diagnostic Connector

Master Controller Checks and Adjustments

Factory Factory Factory Factory

Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)

Factory Setting Factory Setting Factory Setting

Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) (Continued)

Factory Setting Factory Setting Factory Setting

Table 4. Factory Parameters for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

Factory Setting Factory Setting Factory Setting

(Enable or Disable) A setting value of 2 will cause the maximum lift

(Range 0-100) Function Number 13 PUMP SPEED 1

Any increase in performance will decrease the bat- (Range 0-100)

Many faults noted by lift truck systems are the result

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. LINE CONTACTOR

1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

The master and motor controllers sense the following

Table 5. List of Status Codes

Status Code Description Status Code Description

Table 5. List of Status Codes (Continued)

Status Code Description Status Code Description

AC Motor Controllers Status Code Charts

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

• Malfunction of mini-lever, if equipped.

Operate each lever to full stroke forward and

Operate each lever to full stroke back and slowly

Status Code Description Memory Recall Circuit