Ac Motor Controller: B60Z (B230) B80Z (B233) B60Z (A262) B80Z (A257)

AC MOTOR
CONTROLLER
B60Z AC [B230];
B80Z AC [B233];
B60Z HD [A262];
B80Z HD [A257]
PART NO. 1640805 2200 SRM 1286

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic 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 Controller Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Discharging the Capacitors............................................................................................................................. 1
Description ........................................................................................................................................................... 2
Electrical System ............................................................................................................................................. 2
AC Traction Motor....................................................................................................................................... 3
Controller..................................................................................................................................................... 3
Service PC Connection ................................................................................................................................ 3
Parameters ........................................................................................................................................................... 3
General ............................................................................................................................................................. 3
Parameter Description......................................................................................................................................... 5
Parameters ....................................................................................................................................................... 5
Extended Shift............................................................................................................................................. 5
Walk Speed (Both Directions) ..................................................................................................................... 5
Hi Speed (FWD)........................................................................................................................................... 5
Hi Speed (REV)............................................................................................................................................ 5
Minimum Acceleration................................................................................................................................ 5
Maximum Acceleration ............................................................................................................................... 5
Plugging ....................................................................................................................................................... 5
ADS-Neutral ................................................................................................................................................ 5
ADS-Throttle ............................................................................................................................................... 5
Pick Acceleration ......................................................................................................................................... 5
Pick Deceleration......................................................................................................................................... 6
Battery Full Voltage .................................................................................................................................... 6
Lift Interrupt ............................................................................................................................................... 6
Troubleshooting ................................................................................................................................................... 6
General ............................................................................................................................................................. 6
Non-Status Code Errors .................................................................................................................................. 7
Powered Black Screen ................................................................................................................................. 7
Tiller Oscillation and Bias (EPAS Option)................................................................................................. 8
Status Codes .................................................................................................................................................... 8
Electrical Checks.............................................................................................................................................. 101
General Electrical System Checks.............................................................................................................. 101
Static Checks on Power and Ground Connections ..................................................................................... 101
Static Checks on CAN Connections ............................................................................................................ 102
Tiller Harness Shorts and Continuity Checks ........................................................................................... 103
Control Card Functional Test.......................................................................................................................... 104
Dash Display .................................................................................................................................................... 107
General ......................................................................................................................................................... 107
Startup ......................................................................................................................................................... 107
Status LED .................................................................................................................................................. 107
Performance Mode Indicator....................................................................................................................... 107
Hourmeter.................................................................................................................................................... 108
Battery Charge Indicator ............................................................................................................................ 108
Fault Log ...................................................................................................................................................... 108
Connector Pin-Outs.......................................................................................................................................... 109
System Logic Diagram..................................................................................................................................... 110
©2011 HYSTER COMPANY i

Table of Contents AC Motor Controller
TABLE OF CONTENTS (Continued)

This section is for the following models:
B60Z AC [B230];
B80Z AC [B233];
B60Z HD [A262];
B80Z HD [A257]
ii
2200 SRM 1286 General
General
This section describes the Iskra® motor controller
and dash display used in B60Z AC, B80Z AC, B60Z HD,
and B80Z HD lift trucks. Procedures are outlined for
controller programming and troubleshooting.
DISCHARGING THE CAPACITORS
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.
1. Move the truck to a safe, level area. Turn the

key switch to the OFF position and disconnect
the battery.
2. Remove the drive unit compartment cover to ac- 1. CONTROLLER

2. POSITIVE CONNECTION
cess the controller. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
3. Discharge the capacitors in the controllers by 5. NEGATIVE CONNECTION
connecting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals. See Figure 1. Figure 1. Discharging the Capacitors
DO NOT short across the motor controller termi-
nals with a screwdriver or jumper wire. Remove
the 200-ohm, 2-watt resistor before reconnecting
the battery.
1
Description 2200 SRM 1286
Description
ELECTRICAL SYSTEM power steering motor. The controller uses CANbus
communication to interact with the dash display and
The Iskra® AC motor controller controls the AC trac- the control handle. See Figure 2.
tion motor and the DC pump motor. The controller
can also be used with the optional brushless DC
1. GRAB RAIL 9. BRAKE

2. AUXILIARY CONTROL BOX 10. STEER MOTOR (POWER STEER ONLY)
3. DASH DISPLAY 11. TRACTION MOTOR
4. POWER FUSE 12. CONTACTOR
5. PC CONNECTOR (ETACC) 13. CONTROLLER
6. KEY SWITCH 14. CONTROL MODULE
7. HORN 15. PROXIMITY SWITCH
8. PUMP MOTOR
Figure 2. Component Location (Power Steer Shown)
2
2200 SRM 1286 Parameters
AC Traction Motor The motor controller receives power through the

main contactor which is controlled by the key
The AC traction motor is a three-phase AC induction switch. The controller receives inputs from the con-
motor. The motor does not include motor brushes or trol handle and the hand rail switches to control lift
a commutator. An AC induction motor operates on truck functions.
three-phase AC power provided directly by the con-
troller. The motor speed is controlled by the motor NOTE: There are no serviceable parts in the motor
controller and can be changed by the frequency of the controller. No attempt should be made to open re-
AC power supplied to the motor. A speed sensor has pair, or otherwise modify the controller. Doing so
been built into one of the motor bearings which pro- may damage the controller and/or lift truck. Remov-
vides feedback to the motor controller allowing soft- ing the cover from the controller will void the war-
ware to continually monitor motor direction and rev- ranty.
olutions per minute (RPM). Using this feedback sys-
tem, the AC motor control can provide much better Service PC Connection
vehicle top speed control than the older DC SEM sys-
tems. The lift truck is equipped with a connection point to
connect a laptop computer with ETACC software in-
Controller stalled. This connection can be used to adjust certain
lift truck parameters and to assist with troubleshoot-
The motor controller converts DC power from the ing the lift truck.
truck battery to three-phase AC power at the fre-
quencies and currents necessary to drive the traction
motor. A bearing in the traction motor provides feed-
back of speed, rotation direction, and temperature di-
rectly to the motor controller.
Parameters
GENERAL Parameters can be adjusted through the dash dis-
play. The factory default values listed in Table 1 are
A parameter is a measurement or a setting that de- the recommended settings for new units. These set-
fines a lift truck function. A specific function param- tings will give satisfactory performance for most ap-
eter works with other function parameters to control plications.
the operation of the lift truck.
WARNING
WARNING If any of the parameter values are changed, the
The parameter for each function has a value operators must be told the lift truck will oper-
range so the motor controller can be used on ate differently.
different models of lift trucks. This variation
is needed for lift trucks of different sized and NEVER adjust any of the following parameters
operation voltages. Adjustment of a function without using the procedures and settings
to the wrong number value for your lift truck given in this section.
model can cause the truck to operate differ-
ently than normal. This different operation of Function Parameter Descriptions in this section
the truck can cause an injury. contains descriptions for the different parameters.
These parameters can also be accessed using the
NOTE: Table 1 shows the factory default setting for ETACC PC software.
each parameter that is adjustable by the user.
3
Parameters 2200 SRM 1286
Table 1. Parameter Default Values
Parameter Default Range

B60Z AC and B80Z AC and Min Max
B60Z HD B80Z HD
Extended Shift OFF OFF ON OFF
Walk Speed (Both 3.8 3.8 0.5 4.0
Directions)
Hi Speed Fwd 9.0 9.0 0.5 9.0
Hi Speed Rev 6.0 6.0 0.5 9.0
Minimum Acceleration 5 5 1 10
Maximum Acceleration 7 7 1 10
Plugging 7 7 1 10
ADS-Neutral 1 1 1 10
ADS-Throttle 1 1 1 10
Pick Acceleration 6 6 1 10
Pick Deceleration 1 1 1 10
1
Battery Full Voltage 25.300 25.300 24.500 26.500
Lift Interrupt 1 23.520 2 23.520 2 18.000 3 24.000
PS Fwd Trav 3 3 1 10
PS Rev Trav 3 3 1 10
PS Max Assist 5 5 1 10
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the Dash Display.
If a parameter value higher than the truck’s ability is entered, the value will revert to the maximum allowed
for that lift truck.
1
Values shown in ETACC format. When viewed through the dash display, values will be rounded and
formatted as three digit numbers without decimals. Example: A value of 23.520 in ETACC will appear as
235 in the dash display.
2
Maintenance-free battery option uses value 24.000.
3
This parameter value should not be set below 20 for normal operations. Contact NMHG Service
Engineering Contact Management for approval before operating trucks below this value.
4
2200 SRM 1286 Parameter Description
Parameter Description
PARAMETERS minimum rate of acceleration. Decreasing the set-
ting will decrease the minimum rate of acceleration.
WARNING
If any of the parameter values are changed, the
Maximum Acceleration
operators must be told the lift truck will oper- This parameter sets the maximum acceleration rate
ate differently. of the lift truck when the truck is traveling at max-
imum throttle. Increasing the setting increases the
NEVER adjust any of the following parameters
maximum rate of acceleration. Decreasing the set-
without using the procedures and settings
ting will decrease the maximum rate of acceleration.
given in this section.
Parameters can be adjusted through the dash display Plugging

LCD. These parameters can also be accessed using
This parameter controls the maximum rate of decel-
the ETACC PC software.
eration when the speed control is fully moved to the
opposite direction from the direction of travel while
Extended Shift
the truck is moving. Increasing this setting will in-
This parameter when on, will reduce traction perfor- crease the rate of deceleration. Decreasing the set-
mance by 15% to provide extended battery shift life. ting will reduce the rate of deceleration.
The parameter may be set to the OFF or ON condi-
tion. ADS-Neutral
This parameter controls the rate of deceleration
Walk Speed (Both Directions)
when the speed control is returned to the neutral po-
This parameter sets the maximum truck speed for sition and the ADS-Throttle parameter is set above
forward and reverse directions when the truck is in 1. Setting the value at 1 will result in no effect on
“Walk” mode. Increasing the setting will increase the rate of deceleration; the truck will coast until it
the truck speed. Decreasing the setting will decrease comes to a stop. Increasing the value will increase
truck speed. the rate of deceleration. Decreasing the value will
decrease the rate of deceleration.
Hi Speed (FWD)
ADS-Throttle
This parameter sets the maximum forward speed of
the lift truck when the truck is in “Ride” mode. In- This parameter controls the rate of deceleration
creasing the setting increases the speed. Decreasing when the speed control is partially reduced and the
the setting will decrease the speed. ADS-Throttle parameter is set above 1. Setting
the value at 1 will result in no effect on the rate of
Hi Speed (REV) deceleration; the truck will coast until it reaches
the lower throttle speed. Increasing the value will
This parameter sets the maximum reverse speed of increase the rate of deceleration. Decreasing the
the lift truck when the truck is in “Ride” mode. In- value will decrease the rate of deceleration.
creasing the setting increases the speed. Decreasing
the setting will decrease the speed. Pick Acceleration
Minimum Acceleration This parameter controls the rate of acceleration
when the coast control switch is activated. Increas-
This parameter sets the minimum acceleration rate ing the value will increase the rate of acceleration.
of the lift truck when the truck is in traveling at the Decreasing the value will decrease the rate of accel-
lowest throttle. Increasing the setting increases the eration.
5
Troubleshooting 2200 SRM 1286
Pick Deceleration setting increases the voltage. Decreasing the setting

reduces the voltage.
This parameter controls the rate of deceleration
when the coast control switch is released. Increas- Lift Interrupt
ing the value will increase the rate of deceleration.
Decreasing the value will decrease the rate of decel- This is the battery voltage in millivolts at which the
eration. Setting the value at 1 will result in no effect battery is considered 80% discharged. Increasing the
on the rate of deceleration; the truck will coast until setting increases the voltage. Decreasing the setting
it comes to a stop. reduces the voltage.
Battery Full Voltage

This is the battery voltage in millivolts at which the
battery is considered fully charged. Increasing the
Troubleshooting
GENERAL If the controller detects an issue, a status code is dis-
played on the display panel.
The controllers are sealed units with no serviceable
components. Troubleshooting is usually limited to Once the status code number is obtained, follow the
accessing status codes and following the diagnostic procedures outlined in the status code charts of this
procedures listed in the status code charts. manual to determine the problem.
Use standard testing procedures to verify inputs and NOTE: Due to the interaction of the controller with
outputs when necessary. all lift truck functions, almost any status code or con-
troller fault could be caused by an internal failure of
the controller. After all other status code procedures
CAUTION
have been followed and no problem is found, the con-
Never attempt to probe through the back of troller should be replaced as the last option to correct
the connector plugs of the motor controller. the problem.
The plugs are special sealed plugs. Probing
through the back of the plugs will destroy the Tools and test equipment required are:
seal and can cause a short circuit. If a circuit • Clip Leads
must be tested for voltage, check for voltage • Digital Multimeter (20,000 ohms per volt)
at an amp-type plug, a switch, or a component. • Basic Hand Tools
If a circuit is suspect, check the circuit for
continuity from the front (pin end) of the plug. Check resistance on the proper scale from frame to
power and controller terminals. Resistance of less
Standard probes are too large to be inserted than 20,000 ohms can cause misleading symptoms.
into the center of the female pins (sockets) of Resistance of less than 1000 ohms indicates a short
the special sealed plugs and can expand the and should be corrected immediately.
pins. Expanded pins will not provide good con-
nections once the plug is reconnected. The con- The on-board diagnostic system employed on this lift
nectors are shaped to allow the insertion of a truck can assist in the troubleshooting process. Read
flat blade screwdriver into the connector. After and be familiar with the instructions for accessing
inserting the screwdriver into the connector, and using the dash display diagnostic system.
attach probes with alligator clips to the shank
of the screwdriver to obtain readings. An addi-
tional method would be to use a breakout kit.
6
2200 SRM 1286 Troubleshooting
Prior to troubleshooting systems and components on No - Proceed to Step 2.

this lift truck, ensure the battery is the correct volt-
age and is fully charged. Make sure the battery con- 2. Measure voltage in CPS_115, pin 1 of the tiller
nector contacts are clean of corrosions and the bat- harness. Is voltage between 12V to 15V?
tery polarity within the connector is correct. Inspect Yes - Proceed to Step 3.
to ensure all fuses are correct and have not failed. No - Proceed to Static Checks on Power and
Ensure the key switch is in the ON position when Ground Connections.
making voltage checks or checking the operator of a
3. Is the voltage between 12 and 15V?
component.
Yes - Check Traction Encoder connector, pin 1
Many faults noted by lift truck systems are the result of CPS03 to have same voltage. Ensure that
of loose wiring connections and/or broken or shorted power is not shorted with ground or signals in
wiring within the lift truck. Begin the troubleshoot- encoder connector. Key off the truck, discon-
ing process by carefully inspecting the wiring involv- nect encoder connector, and measure continu-
ing the device or devices noted by the on-board diag- ity between pin 1 (14V) and pin 2 (encoder sig-
nostics system. nal), pin 3 (encoder signal) and pin 4 (ground).
If wires found shorted, repair connection as
NON-STATUS CODE ERRORS needed. If encoder connector tested good, pro-
ceed to Step 4.
Powered Black Screen No - Then the voltage shall be approximately
same as voltage seen at B+.
- If yes, proceed to Step 4- If not, Check if there
WARNING
is continuity between battery, key switch and
Lift the forklift and block the frame with the pin 1 of controller.
drive tire suspended off the floor for safety - If continuity not found, repair connection as
when performing this check. needed.
NOTE: Use these procedures along with the 4. Measure voltage at pin 5 of tiller harness. Is volt-
schematic and wiring diagrams. age greater than 4.5 volts?
In some instances, the dash display screen may Yes - Proceed to Step 5.
power ON showing only a powered black screen. In No - Test the control card for proper function.
this state, neither hydraulic nor traction functions See Control Card Functional Test in this sec-
will operate. This error can most easily be trou- tion.
bleshot by connecting an ETACC diagnostic system 5. Measure voltage at CPS_05, pin 30 of main har-
(available at you local Hyster lift truck dealer) to the ness. Is voltage between 12 and 15 volts?
lift truck PC Service Tool Connector in the electrical Yes - Check the tiller harness and ensure all
compartment. The ETACC will scan the system and pins in connectors of tiller harness and main
determine the component which is not communicat- harness are properly seated. See Tiller Har-
ing. However, in the absence of an ETACC tool, the ness Shorts and Continuity Checks in this sec-
truck systems can be manually checked by a tech- tion.
nician with a multimeter. Follow the steps below to No - Replace controller.
troubleshoot this error.
6. Was tiller harness verified ok?
NOTE: Ensure the battery if fully charged before you Yes - It is necessary to connect to the ETACC
begin the following tests. diagnostic tool and check the software ver-
1. Do you have access to an ETACC diagnostic tool? sions for control card, dash display, and con-
Yes - Connect ETACC to the forklift PC Ser- troller. Refer to the section Troubleshooting
vice Tool connector following the instructions and Adjustments Using the AC Controls
in the section Troubleshooting and Adjust- Program (ETACC) 2200 SRM 1058.
ments Using the AC Controls Program No - Repair or replace tiller harness.
(ETACC) 2200 SRM 1058. ETACC will indi-
cate the component not communicating.
7
Tiller Oscillation and Bias (EPAS Option) STATUS CODES

Tiller oscillation (Chattering) and Bias of the Elec- Make sure the parameter values are correct for your
tronic Power-Assist Steering Option is not linked to lift truck to ensure the trouble is not just an incorrect
any electrical failure within the End Rider unit. It setting. See function settings to set the correct pa-
is caused by a physical/mechanical issue rather than rameter values. If there is no status code display and
an electrical one. The replacement of EPAS Motor, the lift truck does not operate correctly, there may be
Torque Sensors, or Controller is not necessary in this a fault in the master controller.
occasion. Certain areas of the truck must be visually
and tactically inspected when the oscillation/chatter- The status codes are numbers for malfunction or lift
ing symptoms occur to identify the cause and elimi- truck operation that are not correct and that the mo-
nate the oscillation or bias of the tiller. tor controller can sense. The master controller will
indicate this code number on the LCD screen of the
Inspect the following components to troubleshoot display panel.
chattering or bias in the EPAS (option) system:
1. Casters: adjust casters accordingly to satisfy the NOTE: There are identifiers to determine which de-
currently installed tire size. Using unnecessary vice generated the code:
shims on the casters takes off the weight from Xy = XXXX (Co 23538)
the drive tire making the system susceptible to Co = Controller
chattering. Ep = PAS Unit
2. Drive tire: shall be in good condition. A worn Ti = Steer Handle Card
out tire causes the same effect as having unnec-
The controller senses the following types of malfunc-
essary shims on the casters. The tire must have
tion:
sufficient grip against the floor, and if it does not
• Input voltages that are too high or too low
adjust casters as necessary.
• Input voltages in the wrong sequence or
3. Loose gears: confirm that the gear of the EPAS
• Correct input voltages that occur at the wrong time
motor and the gear mounted on the bracket are
not loose and adjust the bracket as necessary to NOTE: A status code indication does not always mean
minimize the backlash between the EPAS motor that there is a malfunction. A temporary operation
gear and the MDU gear. condition can cause a status code display.
4. Uneven pull rods: this misalignment of the truck
causes unwanted change in the torque signal, These code numbers are only indicators that may
therefore starting the effect of the oscillation. help diagnose a possible malfunction. A short de-
5. Assist level: assist levels 7 through 10 provide scription of the different status codes is shown in Ta-
excessive assistance and cause an increase of the ble 2.
backlash in the system, which is a root caused of
the chattering. Lower assist level as necessary. The Fault Message charts in this section have a more
After ensuring all the aforementioned requirements complete description of the status code, the circuit
are met, the system must be calibrated as mentioned that has generated the input for the status code, the
in the calibration procedure. Refer to Electrical symptom, and the possible cause.
System 2200 SRM 1451 or Electrical System
2200 SRM 1287, Calibration, Power Assist Steer
Sensor.
8
Table 2. Fault Codes
Code Description
To troubleshoot symptoms that do not generate a fault code, refer to Non-Status
Code Errors, in this section.
Check Battery High or low DC link voltage.
High Temp Thermal cut-back due to high motor temperature or high power bridge
temperature.
Overheat Overheated motor or power bridge.
Overload Pump in relief.
Release Coast Coast system engage switch tied down at key ON.
Release Horn Horn switch tied down at key ON.
Release Lift/Lower Lift or lower switch tied down at key ON.
Release Rabbit High speed switch tied down at key ON or activated before throttle.
Reset Handle Tiller was pulled down at key on or throttle was requested before the steer arm
was moved into active region, or open load at regen switch or tiller enable switch.
Stalled Loss of signal from encoder or encoder is disconnected.
Stalled Open load at encoder or brake coil.
9024 Controller failure of the traction motor power circuit.
9088 Pump motor shorted.
9089 Pump motor open.
9090 Pump at relief.
9091 Controller failure of the pump motor power circuit.
12808 Error in steer handle card speed/direction sensor.
12813 Steer handle sensor is out of limits.
12814 Steer handle card signaled that a belly switch error has occurred.
12816 Controller internal voltage over 36 volts.
12819 Incorrect voltage battery connected.
12832 Controller internal voltage less than 16 volts.
12835 Incorrect voltage battery connected.
13316 Pump proportional valve (coil) open load or over current.
13317 Horn open load.
13384 Main contactor bridge (coil) open.
16912 Controller power section is over temperature.
16944 Controller is in thermal cutback - high controller temperature.
16945 Controller internal temperature sensor failure.
17168 Traction motor is over temperature.
17169 Controller is in thermal cutback - high traction motor temperature.
9
Table 2. Fault Codes (Continued)
Code Description
17170 Traction motor temperature sensor failure.
20756 Key switch open.
21024 Steer handle card failure.
21376 Traction Reversing switch closed at startup.
21378 Controller cannot establish contact with steer handle card.
21379 Controller failed to receive Power Steer PDO message within 3 seconds.
21533 Horn circuit is shorted to B+.
21534 Horn circuit is open.
21535 Horn circuit is shorted to B .
21539 Digital output driver failure.
21552 Steer handle inputs incorrect at startup.
21553 Hi Speed switch is closed at startup.
21554 Horn switch is closed at startup.
21555 Lift or lower switch is closed at startup.
21556 Coast engage switch closed at startup.
21568 Main contactor circuit is open.
21569 Main contactor circuit is shorted to B+.
21570 Main contactor circuit is open.
21571 Main contactor circuit is shorted to B .
21588 Internal failure of the power steering unit.
21808 Controller Internal Fault or controller has wrong parameters.
21809 Controller Internal Fault or controller has wrong parameters.
25361 Truck type parameter has not been selected.
28961 Steer assist motor has reached a stop condition.
29445 Traction motor encoder failure.
29448 Steer handle switch closed at startup.
29456 Error in steer handle card speed/direction sensor.
29458 Steer handle sensor is out of limits.
29459 Steer handle card signaled that a belly switch error has occurred.
29472 Failed or maladjusted sensor.
32816 Pump open circuit.
33033 Controller cannot communicate with steer card, dash display, or power steering
motor.
33034 Controller cannot establish communication with steer control card.
10
Table 2. Fault Codes (Continued)
Code Description
33035 Controller cannot establish communication with EPAS.
33056 Controller cannot establish communication with steer handle card.
33057 Controller cannot establish communication the power steering controller.
33072 Controller not responding to Power Steer.
33073 Power Steer not responding to Controller.
33554 Power Steer motor stalled.
36864 Power Steering security line set to LOW.
65280 Controller has detected an abnormal signal from the Position Sensor in the power
steering system.
65281 Controller has detected an abnormal signal from the Torque Sensor in the power
steering system.
65282 Torsion bar broken, reduction gear broken, mechanical connection lost.
11
STATUS DISPLAY MESSAGE LED CIRCUIT

CODE
Check Check Battery Flashing Red Battery
Battery
DESCRIPTION SYMPTOM
Controller has detected a battery with less Traction and hydraulic systems will not operate.
than 16 volts has been connected to the lift
truck. Controller has detected a battery
voltage in excess of 32 volts at startup.
Probable Causes and Test Procedures
1. Check battery voltage at controller B+ terminal.
2. Verify battery voltage matches voltage listed on the lift truck nameplate. If battery is other than speci-
fied, then install correct voltage battery.
3. Check to have battery fully charged, approximately 25.5V ±1V.
4. Condition can be caused by normal operation of the lift truck with a discharged battery. Check battery
state of charge on the dash display and measure voltage across B and B+. Recharge battery if necessary.
Install a fully charged battery.
5. Code may occur on overcharged batteries during regen braking. Verify battery is not overcharged.
6. Check condition (includes proper contacts surface between fuse and fuseholder) of fuse FU 1. Verify
continuity through the fuse. If there is no continuity, then replace fuse.
7. Check for battery voltage continuous across B+ and B terminals when battery is connected and the key
switch is in the ON position.
8. Make sure main contactor is energized and its tips are clean.
12

CODE
High High Temp Solid Green Motor
Temp
DESCRIPTION SYMPTOM
Thermal cut-back due to high motor Traction system is operating at a reduced
temperature or high power bridge performance level.
temperature.
1. Internal temperature of controller has exceeded 125 C (257 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Service Technician Functions On-Board Dash
Display 2200 SRM 1324.
3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the
ON position and operate the lift truck briefly.
4. Check the dash display to verify fault does not repeat. If fault repeats:
a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector.
b. Resistance should measure approximately 5.9 ohms ±10% at 25°C (77°F).
• Replace sensor.
5. Check for battery voltage on wire #10 at the main contactor.
a. Check continuity of wire #10 between the key switch and the main contactor.
• Repair any open wiring.
b. Check for continuity through FU 5.
• Replace fuse.
13

CODE
Temp
(cont)
DESCRIPTION SYMPTOM
temperature.
6. Check the resistance through the main contactor coil. Refer to the section Electrical System 2200 SRM
1451 or Electrical System 2200 SRM 1287, Contactor Coil Check.
a. The resistance should measure approximately 22 ohms ±10%.
• Replace the coil.
7. Check for shorts with truck frame.
a. Check resistance between the following points for greater than 1Mohm:
• CANH and truck frame
• CANL and truck frame
• B+ and truck frame
• B and truck frame
• UT wire (traction motor) to truck frame
• VT wire (traction motor) to truck frame
• WT wire (traction motor) to truck frame
• PS2 wire (steer motor) to truck frame (if applicable)
• PM2 wire (pump motor) to truck frame
14

CODE
Temp
(cont)
DESCRIPTION SYMPTOM
temperature.
7. Check for shorts with truck frame (Continued).
NOTE: Excessive current draw will cause a component to heat up and this is usually caused by shorts in
the system allowing current to follow paths that are not intended. Sometimes excessive current draw can
be caused by mechanical malfunctions such as worn bearings, misaligned parts, improper lubrication,
and brake adjustments. Other factors include operator misuse such as overloading the truck and pushing
loads.
The condition of the battery can contribute greatly to excessive current draw. When the battery charge
and voltage are low, more current is needed to perform the same task. Since the power required to move
a load is Power = Volts × Amperage, as the battery voltage goes down, the amperage must increase to
maintain power.
15

CODE
Over- Overheat Flashing Red Traction Motor
heat
DESCRIPTION SYMPTOM
Controller has detected an over temperature Traction and hydraulic systems will not operate.
condition in the traction motor or
power bridge.
1. Internal temperature of controller has exceeded 140°C (284°F).
a. Reduce truck usage and allow the controller to cool. System will recover once the truck is able to
achieve a temperature below 125°C (257°F).
2. Clear fault log in dash display. See the section User Interface, Service Technician Functions
On-Board Dash Display 2200 SRM 1324.
4. Check the dash display to verify fault does not repeat.
5. If fault repeats, check resistance between pin #1 and pin #2 at the motor temperature sensor connector.
a. Resistance should measure approximately 5.9 ohms ±10% at 25°C (77°F).
• Replace sensor.
16

CODE
heat
(cont)
DESCRIPTION SYMPTOM
power bridge.
6. Check for shorts with truck frame
a. Check resistance between the following points for greater than 1Mohm:
17

CODE
heat
(cont)
DESCRIPTION SYMPTOM
power bridge.
6. Check for shorts with truck frame (Continued).
NOTE: Excessive current draw will cause a component to heat up and this is usually caused by shorts in
the system allowing current to follow paths that are not intended. Sometimes excessive current draw can
be caused by mechanical malfunctions such as worn bearings, misaligned parts, improper lubrication,
and brake adjustments. Other factors include operator misuse such as overloading the truck and pushing
loads.
The condition of the battery can contribute greatly to excessive current draw. When the battery charge
and voltage are low, more current is needed to perform the same task. Since the power required to move
a load is Power = Volts × Amperage, as the battery voltage goes down, the amperage must increase to
maintain power.
18

CODE
Over- Overload or No Displayed Flashing Red or Pump
load Message Green LED
DESCRIPTION SYMPTOM
Pump in relief. Hydraulics will not operate.
1. Verify weight of load does not exceed lift truck capacity on the nameplate. If it does, reduce load weight.
a. Refer to the section Capacities and Specifications 8000 SRM 1454 or Capacities and Specifi-
cations 8000 SRM 1299.
2. Verify there is no binding in the lifting mechanism.
3. Install a 24.13 MPa (3500 psi) pressure gauge in the lift cylinder line.
a. Verify the relief pressure is correct:
• B60Z AC and B60Z HD = 18.96 MPa (2750 psi)
4. Adjust relief pressure to correct value. Refer to the section Walkie Hydraulic Systems 1900 SRM 964.
19

CODE
Release Release Coast Flashing Red Controls
Coast
DESCRIPTION SYMPTOM
Controller has detected a closed Coast Hydraulic system will not operate.
Control Switch at startup.
1. Verify coast control switches are released.
2. Inspect coast control switches for binding.
a. Ensure all parts are free to move.
3. Check each switch for a shorted condition.
a. Replace faulty switch.
4. Check wire #731-D for a shorted condition.
a. Repair any faulty wiring.
20

CODE
Release Release Horn Flashing Red Controls
Horn
DESCRIPTION SYMPTOM
Horn Switch is held down at key ON. Warning displayed until horn button is released.
1. Ensure the horn switch is not being held closed.
a. Eliminate any binding in the handrail handle.
2. Separate the handrail connector.
a. If the horn stops, replace the auxiliary horn switch.
3. Check wire #25 for shorts to B+.
4. Separate the controller connector.
a. If horn continues to sound, check for shorts from pin #11 at the controller to B+.
• Contact Hyster company Resident Service Engineering through the Contact Management System.
21

CODE
Release Release Lift/Lower Flashing Red Controls
Lift/
Lower
DESCRIPTION SYMPTOM
Controller has detected a closed lift or Hydraulic system will be disabled until
lower switch at startup. switch is released.
1. Verify all lift and lower switches are released.
2. Inspect handrail lift and lower switches for binding.
a. Replace faulty switch(es).
4. Check wire #26 and #27 for a shorted condition to B+.
a. Check for exposed/shorted wire in harness. Repair or replace as necessary.
22

CODE
Release Release Rabbit Flashing Red Controls
Rabbit
DESCRIPTION SYMPTOM
Controller has detected a closed high High speed will not operate.
speed switch at startup.
1. Ensure the high speed "Rabbit" switch is not being held closed at key ON or activated prior to throttle.
2. Check the switch for a shorted condition.
3. Check for wire #342 shorted to B+.
23

CODE
Reset Reset Handle Flashing Red Steer Handle
Handle
DESCRIPTION SYMPTOM
Open load at regen or tiller enable Traction and hydraulic system will not operate.
switch or regen switch. Arm pulled down
prior key on, or throttle applied with
arm out of active region.
1. Ensure tiller arm is within operational region prior to apply throttle.
2. Verify all steer handle switches and controls are in the neutral position.
3. Check for any mechanical binding in switches or throttle mechanism.
a. Clear any binding.
4. Verify battery voltage on wire #355, between pin #7 CPS115 at the steer handle card connector and B .
Lower and rise tiller arm and see for a change in continuity state.
a. If change in continuity is not seen, measure continuity between pin 7 of CPS115 (tiller harness) and
pin 2 of CRP119 (regen switch) and pin 7 of CPS05 (controller).
b. Measure for continuity between pin 1 of CRP119 and pin 1 of CPS05
c. Check not to have shorted condition on regen switch, and ensure that is able to change state every
time the tiller arm is lowered.
d. If in any of the steps continuity is not see, repair wiring; if switch has short or open condition, replace
switch as necessary.
5. Check CRP103 Tiller Enable switch to have B+ voltage. Measure voltage between pin 1 of CRP103 and
ground.
6. Check CRP 105, Electric Brake to have B+ voltage.
a. Ensure continuity between pin 2 of CRP 103 and pin 1 of CRP 105 (Electric Brake).
b. Ensure continuity between pin 2 of CRP105 and TSR45 (Cont_B ).
c. Repair wiring as necessary or replace faulty switch as necessary.
7. On trucks with the potentiometer at the base of tiller arm, check for the vertical angle parameter to be
configured properly. The parameter indicates the operational range for the tiller arm.
24

CODE
Stalled Stalled Flashing Red Traction
DESCRIPTION SYMPTOM
Motor stalled, loss of signal from encoder, Traction system will not operate.
or open load at brake coil.
1. Torque was applied for 10 seconds without any change in horizontal angle position.
a. Check for any objects obstructing movement of the drive tire or MDU.
• Restart the lift truck.
2. Ensure all wiring connection between the encoder and the controller are secure and tight.
a. Check for 12 to 15 volts on wire #250.
b. Check for 12 to 15 volts at controller pin #30.
c. On harness version 8801065 revision 4 and subsequent, check to have 12 to 15 volts in pin 1 of
CRP115 (Tiller Harness).
d. Pin 30 on controller supplies approximately 14 volts to the encoder and tiller card, if not check for
ground (Tiller harness is pin 2 of CRP115 and in encoder is pin 4 of CPS03) not to be shorted with
voltage supply (pin 1 of CRP115 and pin 1 of CPS03).
3. Check on encoder connector (CPS03) not to have the encoder signals switched with encoder power wire.
Pin 2 from encoder connector (wire #578) to be connected to pin 32 (wire #577) on controller, and pin 3
from encoder to have continuity with pin 31 of controller connector.
a. Output should alternate between 12 and 0 volts as the motor rotates.
• Change the encoder.
25

CODE
9024 Service Required Solid Red Traction
DESCRIPTION SYMPTOM
Traction motor phase U, V, or W Truck will not operate.
shorted to B+ or B .
1. Verify 24 volts at the controller B+ terminal.
a. Ensure battery is connected to the lift truck.
b. Verify continuity of fuse FU 1.
2. Turn the key switch to the OFF position and disconnect the battery connector, then the motor leads from
the controller.
3. Check U, V, and W terminals of the controller for shorted condition to B+ or B .
4. If no problem was found, reconnect the phase wires back to controller and proceed to check the hydraulic
motor pump.
5. Disconnect cable PM1 at the P controller terminal. Check for a shorted condition between P and B .
a. Resistance should be greater than 50 megohms; if not replace pump motor.
b. Check for open circuit across the motor terminals. If greater than 500 ohms, replace the pump motor.
6. Disconnect the pump motor leads from the controller.
7. Visually check motor leads for any damage or evidence of shorting to the truck frame. Check for any
burns or evidence of arcing. Repair or replace any damaged wiring.
8. Verify continuity through each motor cable. Replace any broken wiring.
26

CODE
(cont)
DESCRIPTION SYMPTOM
Traction motor phase U, V, or W Truck will not operate.
shorted to B+ or B .
9. Check resistance between the following points for greater than 1Mohm:
27

CODE
9088 Service Required Solid Red Pump
DESCRIPTION SYMPTOM
Pump motor has shorted. Hydraulics will not operate.
1. Turn the key switch to the OFF position and disconnect the battery.
2. Disconnect pump motor leads from controller.
a. Check for any burns or evidence of arcing.
3. Visually check motor leads for any damage or evidence of shorting to the truck frame.
a. Check for any burns or evidence of arcing.
• Repair or replace any damaged wiring.
4. Check for P terminal at the controller shorted to B .
a. Resistance should be greater than 50 megohms.
• Contact Hyster Company Service Engineering through the Contact Management system.
5. Replace pump motor.
28

CODE
DESCRIPTION SYMPTOM
Pump motor has open circuit. Hydraulics will not operate.
1. Turn the key switch to the OFF position and disconnect the battery connector.
2. Disconnect pump motor cables from the controller.
3. Verify continuity through each motor cable.
a. Replace any broken wiring.
4. Check for open circuit across the across the motor terminals.
a. If greater than 500 ohms, replace the pump motor.
29

CODE
9090 Overload Flashing Red Pump
DESCRIPTION SYMPTOM
Controller has detected the hydraulic Hydraulics will not operate.
system is being operated at relief.
1. Verify weight of load does not exceed lift truck capacity on the nameplate.
a. Reduce load weight.
2. Verify there is no binding in the lifting mechanism.
3. Install a 24.13 MPa (3500 psi) pressure gauge in the lift cylinder line.
a. Verify the relief pressure is correct:
4. Adjust relief pressure to correct value.
a. See Walkie Hydraulic Systems 1900 SRM 964.
30

CODE
9091 Internal Pump Circuit Failure Solid Red Pump
DESCRIPTION SYMPTOM
Controller has detected an internal Truck will not operate.
failure in the pump circuit.
2. Turn the key switch to the OFF position.
3. Disconnect cable PM1 at the P controller terminal.
a. Check for a shorted condition between P and B :
• Resistance should be greater than 500 ohms.
• Contact Hyster Company Service Engineering through the Contact Management System.
4. Disconnect cable PM1 at the P controller terminal and reconnect it to the controller B terminal.
a. Turn the key switch to the ON position and verify the pump motor operates.
b. Contact Hyster Company Service Engineering through the Contact Management System.
31

CODE
12808 Service Required Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected an error in the Traction system will not operate.
steer handle card throttle sensor.
1. Throttle sensor is out of calibration.
a. Calibrate throttle sensor. See the section Electrical System 2200 SRM 1451 or Electrical System
2200 SRM 1287.
b. Make sure “Hall Hysteresis” parameter is set to 100. This can be verified or edited from ETACC,
“Control Handle Inputs” menu.
c. If during calibration the indicator bar in DDI is just moving between center and one of the ends,
check for proper alignment of the Hall Effect sensors in the plastic thumbwheel switch (magnetic
holder). Edge of thumbwheel switch shall be aligned with opening mark located in thumbwheel
switch protective cover, as shown in illustration below.
d. If during calibration the indicator bar in DDI cannot center to neutral,
i. Check the square interface on the plastic thumbwheel switch is not broken.
ii. Check the spring control return mechanism on butterfly.
iii. Check for butterfly screws to be tightened. Apply thread locker adhesive.
32

CODE
DESCRIPTION SYMPTOM
Steer card has sensed vertical Traction system will not operate
position sensor to be positioned out "Reset Handle" may be displayed
of calibration limits.
1. Ensure tiller arm is within operational region prior to applying throttle.
2. Ensure sensor is properly mounted to swivel casting.
3. Attempt to re-calibrate position sensor through DDI. (Review procedure)
Note 1: Bar movement should be smooth and not skip, if no movement is present verify electrical con-
nections. This only applies to truck built prior to May 09. Note 2: for trucks after May 09, there will be
no bar movement but the calibration still required.
4. Verify electrical connections to sensor:
a. Remove connector and measure total sensor resistance between pin 1 and 3 of the sensor, it should
be 5k ±10% Ohms, and not infinite (open) or 0 Ohms (shorted) If either of the later, replace sensor. If
proper resistance is present, sensor is working properly.
b. Verify 4.5 to 5.5V is present between pin 1 (Wire 354-C) and pin 3 (Wire 13-C). If 5V not present, verify
wire integrity back to main controller pin 26 (CPS05) and verify continuity of ground connection from
pin 3 (Wire 13-C) to B .
c. Verify voltage output on pin 2 (Wire 355A) changes between 0.25 to 4.5 (Decreasing as steer handle
very slowly moves from vertical 90 to 0).
Note 1: If voltage goes through 0V during any part of the vertical steer handle motion, the sensor is
positioned incorrectly, and must be rotated 180 degrees by rotating its key. Note 2: This can also be
verified by monitoring the vertical angle in Ctrl Handle Input View (Output) is in degrees of angle,
and should move from 0 (up) to ~90 (down) position.
d. Verify continuity from pin 2 to pin 3 of steer handle card (CPS114).
33

CODE
(cont)
DESCRIPTION SYMPTOM
5. If after successful calibrations, the vehicle continues to have reoccurrences, then check the following:
a. Verify steer handle pivot pin is tight and is properly mounted.
b. Verify Loctite is present on the threads.
6. Verify the handle is not slamming into steer stop upon release. If so, replace gas spring.
34

CODE
DESCRIPTION SYMPTOM
Controller has detected a belly switch error. Traction system will not operate.
1. Control handle wire #28 is damaged or bad connection.
a. Inspect wire #28 between steer card (connector JP1, pin 6) to the controller (pin #5). Repair as nec-
essary.
2. Belly switch has failed. Disconnect and test switch for proper operation using an ohmmeter.
a. On tiller control card, check for continuity between pin 5 of JP1 and belly switch. Refer to Control
Card Functional Test in this section.
3. Contact Hyster Company Service Engineering through the Contact Management System.
35

CODE
12816 Check Battery Flashing Red Battery
DESCRIPTION SYMPTOM
Controller has detected a battery voltage Truck will not operate.
in excess of 32 volts during operation.
2. Verify battery voltage matches voltage listed on the lift truck nameplate.
a. Install correct voltage battery.
3. Code may occur on overcharged batteries during regen braking.
a. Verify battery is not overcharged.
4. Verify traction speeds and regenerative braking is operational.
a. If regen is not operating consistently, overvoltage may occur. Replace controller.
36

CODE
DESCRIPTION SYMPTOM
Controller has detected a battery voltage Truck will not operate.
in excess of 32 volts at startup.
37

CODE
DESCRIPTION SYMPTOM
The controller has sensed battery voltage Truck will not operate.
to be less than 16 volts.
3. Condition can be caused by normal operation of the lift truck with a discharged battery.
a. Check battery state of charge on the dash display.
• Recharge battery.
• Install a fully charged battery.
4. Check for continuity through fuse FU 1.
a. Replace fuse.
38

CODE
DESCRIPTION SYMPTOM
Controller has detected a battery with Truck will not operate.
less than 16 volts has been connected
to the lift truck.
39

CODE
DESCRIPTION SYMPTOM
Proportional valve (pump coil) has an Lowering hydraulic system will not operate.
open load or over current.
2. Verify continuity of fuse FU 1 and FU 5, check for clean and tight connections.
3. Verify all coils are not shorted (measure across disconnected coil terminals with ohmmeter should produce
resistance greater than 5 ohms). Refer to the section Electrical System 2200 SRM 1451 or Electrical
System 2200 SRM 1287, Contactor Coil Check.
a. Pump Coil
b. Contactor
c. Coast Control Solenoid
4. Verify for proper, tight and clean connections between controller and coils.
a. Pump Coil
b. Contactor
5. Verify continuity of wire W150-A between CPS05 pin 22 and CPS88 pin 1. Repair connections as neces-
sary.
6. Verify continuity of wire W86-A between CPS05 pin 23 and CPS88 pin 2. Repair connections as neces-
sary.
40

CODE
(cont)
DESCRIPTION SYMPTOM
Proportional valve (pump coil) has an Lowering hydraulic system will not operate.
open load or over current.
7. Check for a shorted condition between pin #18 at the controller and B.
41

CODE
13317 Service Required Solid Red Horn
DESCRIPTION SYMPTOM
Horn Open Load No traction or hydraulic system.
1. Check for battery voltage at wire #10 at the horn connector when the key switch is closed.
a. Ensure all connections and connectors are secure and tight.
b. Check for open circuits in the harness.
• Repair wiring.
2. Ensure Horn Connector TSM01 (horn’s red lead) is connected tight to main harness horn connector
TSF01.
3. Check continuity of wire #W10-F from the horn connector TSF01 (red) to pin #1 at the controller connec-
tor CPS05.
4. Ensure Horn Connector TSM02 (horn’s black lead) is connected tight to main harness horn connector
TSF02.
5. Check continuity of wire #45-H between horn connector TSF02 and pin 20 of contronller CPS05.
a. Repair wiring.
6. Measure the resistance between the red lead and the black lead from the horn at the horn connector.
a. The resistance should read approximately 28 ohms.
• Replace the horn.
7. Internal failure of the controller.
a. Contact Hyster Company Service Engineering through the Contact Management System.
42

CODE
13384 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Main contactor bridge (coil) open. Traction and hydraulic systems will not operate.
1. Check battery connection, voltage, and charge.
2. Check for power and clean, tight connections to the contactor.
• Replace fuse.
4. Check the resistance through the main contactor coil. Refer to the section Electrical System 2200 SRM
1451 or Electrical System 2200 SRM 1287, Contactor Coil section.
5. Check continuity of wire #45 from the coil to the controller pin #20 on CPS05. Repair any open wiring.
6. If fault persist, then internal failure of the controller.
43

CODE
16912 Service Required Flashing Red Battery
DESCRIPTION SYMPTOM
Controller is over temperature. Traction and hydraulic systems will not operate.
3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position
and operate the lift truck briefly.
4. Verify fault does not repeat.
44

CODE
16944 Performance Reduced Flashing Red Controller
DESCRIPTION SYMPTOM
Truck is in thermal cutback due to high Traction system is operating at a reduced
controller temperature. performance level.
3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position
and operate the lift truck briefly.
4. Verify fault does not repeat.
45

CODE
16945 Service Required Solid Red Controller
DESCRIPTION SYMPTOM
Controller has detected an internal failure Traction system is operating at reduced
in the power bridge temperature sensor. performance level.
1. Turn the key switch to the OFF position and restart the lift truck.
2. Verify the fault has reoccurred on the dash display.
3. Let truck sit for 10 minutes.
4. Restart the lift truck.
a. Fault reoccurs.
46

CODE
17168 Over Temp Flashing Red Traction Motor
DESCRIPTION SYMPTOM
condition in the traction motor.
ON position and operate the lift truck briefly. Check the dash display to verify fault does not repeat.
4. If fault repeats:
• Replace sensor.
47

CODE
17169 No Text Displayed Solid Green Traction Motor
DESCRIPTION SYMPTOM
Controller is in thermal cut back due to Traction system is operating at a reduced
high traction motor temperature. performance level.
4. Check the dash display to verify fault does not repeat.
5. If fault repeats:
• Replace sensor.
48

CODE
17170 Service Required Solid Red Traction Motor
DESCRIPTION SYMPTOM
Controller has detected a failure of the Traction system is operating at a reduced

traction motor temperature sensor. performance level.
1. Disconnect the traction motor temperature sensor connector at the traction motor.
2. Check for continuity of wire #386 between the connector and pin #25 at the controller.
a. Repair any broken wiring or loose connections.
3. Check for continuity of wire #102 from the connector to pin #29 at the controller.
4. Measure the resistance across pin #1 and pin #2 of the sensor side of the connector.
a. Resistance should measure approximately 5.9 ohms ±10% at 25°C (77°F).
5. If measurement indicates an open or shorted sensor, replace sensor.
49

CODE
20756 Service Required Solid Red Key
DESCRIPTION SYMPTOM
The controller has sensed the key Truck will not operate.
switch circuit is open.
1. Verify the key switch is turned to the ON position.
2. Verify the battery is connected to the lift truck.
3. Check condition of FU 5.
a. Verify continuity through the fuse.
4. Check for battery voltage on pin #1 (wire #10) at the controller connector.
a. Check for open wire #10 between connector and key switch.
50

CODE
DESCRIPTION SYMPTOM
Controller has detected a failure in Traction and hydraulic systems will not operate.
the steer handle card.
1. Verify battery voltage at pin #7 at the steer handle card connector.
a. Check continuity of wire #10 from key switch to pin #7 at steer handle card connector.
2. Ensure all wiring connections between the steer handle card and the controller are tight and secure.
3. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 60 ohms.
• If resistance is approximately 120 ohms, check wiring for broken or shorted condition.
• Repair all damaged wiring.
4. Internal failure of the steer handle card.
a. Refer to Control Card Functional Test in this section.
51

CODE
21376 Improper Start Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected the belly switch Traction system will not operate.
being closed at system startup.
1. Ensure tiller arm is within operational region prior to applying throttle.
2. Check that traction reversing switch on the steer handle is not being held closed at startup.
a. Release switch.
3. Verify all steer handle wiring connections are tight and secure.
4. Check resistance across switch terminals for a shorted traction reversing switch.
52

CODE
21378 Service Required Solid Red Controls
DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
Apply dielectric grease on K3 and all pin Molex connectors of tiller harness.
a. Resistance should be approximately 50 ohms for power steer truck and 60 ohms for manual steer.
• If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
3. Check for continuity between pin #1 at the steer handle card connector and pin #28 at the controller
connector.
a. Repair any broken wiring.
connector.
connector.
53

CODE
(cont)
DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
6. Perform static checks as follows:
Note: Before performing static checks, the battery must disconnected, the capacitors must be discharged
completely, and key must be in the ON position.
a. Check for approximately 60 ohms for manual steer and 50 ohms for power steer between CANH and
CANL at PC connector.
b. Check resistance between the following circuit for greater than 1Kohm:
• CANH and B+
• CANH and B
• CANL and B+
• CANL and B
c. Check resistance between the following points for greater than 1Mohm:
7. Disconnect all switches from Tiller Card, check resistance across pin 1 and pin 4 on K4 switch connector
on the tiller card, resistance should be greater than 200 ohms.
54

CODE
DESCRIPTION SYMPTOM
Controller has lost communication Traction system will not operate.
with the steer unit.
3. Check for continuity between pin #1 at the steer unit connector and pin #28 at the controller connector.
4. Check for continuity between pin #2 at the steer unit connector and pin #27 at the controller connector.
5. Replace power steer motor if cycling the key does not resolve.
55

CODE
DESCRIPTION SYMPTOM
Controller has detected the horn Hydraulic system will not operate.
shorted to B+.
2. Check the horn connector for pin-to-pin shorted condition.
a. Repair the connector.
3. Check for pin #20 at the controller shorted to B+.
56

CODE
DESCRIPTION SYMPTOM
Controller has detected an open Hydraulic system will not operate.
circuit in the horn.
2. Check for battery voltage at wire #10 at the horn connector when the key switch is closed.
a. Ensure all connections and connectors are secure and tight.
b. Check for open circuits in the harness.
• Repair wiring.
3. Check continuity of wire #45 from the horn connector to pin #20 at the controller connector.
a. Repair wiring.
57

CODE
DESCRIPTION SYMPTOM
The controller has detected the horn Hydraulic system will not operate.
shorted to B .
2. Check the horn connector for pin-to-pin shorted condition.
a. Repair the connector.
3. Check for pin #20 at the controller shorted to B .
58

CODE
DESCRIPTION SYMPTOM
Controller has detected an internal Traction and hydraulic systems will not operate.
failure of the output driver.
1. Turn the key switch to the OFF position and restart the lift truck.
Note: Due to the tolerance of components in the system, this code may appear in the error log. If this
code does not affect the operation of the truck, no action is required.
2. Verify the fault returns after restart.
3. Verify all coils are not shorted (measure across disconnected coil terminals with ohmmeter should pro-
duce resistance greater than 5 ohms).
a. Pump Coil
b. Contactor
4. Verify for proper connections between controller and coils.
a. Pump Coil
b. Contactor
59

CODE
21552 Improper Start Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected a fault in the signal Traction and hydraulic systems will not operate.
from the steer handle card.
1. Verify all steer handle switches and controls are in the neutral position.
2. Check for battery voltage at pin #3 at the steer handle card.
a. Check for continuity of wire #10 from the key switch to the steer handle card.
3. Check for any mechanical binding in switches or throttle mechanism.
a. Clear any binding.
b. Repair or replace faulty switches.
4. Verify there is no shorted wiring between wire #901, wire #902, wire #102, and wire #28 between the
steer handle card and the controller.
a. Repair any shorted wiring.
5. Verify the continuity of wire #102, wire #900, wire #901 and wire #28 from the steer handle card to the
controller.
6. Refer to Control Card Functional Test in this section.
60

CODE
21553 Release Rabbit Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected a closed high High speed will not operate.
speed switch at startup.
1. Ensure the high speed “Rabbit” switch is not being held closed.
2. Check the switch for a shorted condition.
61

CODE
DESCRIPTION SYMPTOM
Controller has detected a closed auxiliary Horn operates continuously.
horn switch at startup.
1. Ensure the auxiliary horn switch is not being held closed.
2. Separate handrail connector.
a. If horn quits sounding, replace auxiliary horn switch.
a. If horn continues to sound, check for pin #11 at the controller shorted to B+.
62

CODE
DESCRIPTION SYMPTOM
Controller has detected a closed auxiliary Hydraulic system will not operate.
lift or lower switch at startup.
1. Inspect handrail lift and lower switches for binding.
3. Check wires #26 and #27 for a shorted condition to B+.
a. Check for exposed/shorted wire in harness. Repair or replace as necessary.
63

CODE
DESCRIPTION SYMPTOM
Controller has detected a closed Coast Hydraulic system will not operate.
Control Switch at startup.
1. Inspect coast control switches for binding.
3. Check wire #731-D for a shorted condition to B+.
64

CODE
DESCRIPTION SYMPTOM
Main contactor is open and will not close. Traction and hydraulic systems will not operate.
1. Check battery connection, voltage, and charge.
2. Check for power and clean, tight connections to the contactor.
3. Replace the contactor.
65

CODE
DESCRIPTION SYMPTOM
Controller has detected the main Traction and hydraulic systems will not operate.
contactor shorted to B+.
2. Check for a shorted condition between pin #18 at the controller and B+.
3. Check the connector for any pin-to-pin shorts.
a. Repair any wiring faults.
66

CODE
DESCRIPTION SYMPTOM
Controller has detected an open circuit Traction and hydraulic systems will not operate.
in the main contactor.
1. Ensure all wiring connections are secure and tight.
• Replace fuse.
3. Check the resistance through the main contactor coil.
4. Check continuity of wire #45 from the coil to the controller pin #20. Repair any open wiring.
67

CODE
DESCRIPTION SYMPTOM
Controller has detected the main Traction and hydraulic systems will not operate.
contactor shorted to B .
1. Ensure the B+ and B cables from the battery are connected properly.
3. Check for a shorted condition between pin #18 at the controller and B .
4. Check the connector for any pin-to-pin shorts to B .
a. Repair any wiring faults.
68

CODE
21588 Service Required Solid Red Power Steering
DESCRIPTION SYMPTOM
Controller has detected B+ power missing. Traction system will not operate.
1. Check condition (includes proper contacts surface between fuse and fuseholder) of fuse FU 1. Verify
continuity through the fuse.
a. Replace fuse.
2. Verify battery voltage at power steering motor B+ terminal.
3. Check continuity of wire #PS2-1 from FU 1 to power steering motor.
a. Repair damaged wiring.
4. Check continuity of wire #PS1 from power steering motor B terminal to controller terminal B .
a. Repair damaged wiring.
5. Check for battery voltage continuous across B+ and B terminals when battery is connected and the key
switch is in the ON position.
6. Make sure main contactor is energized and its tips are clean.
69

CODE
DESCRIPTION SYMPTOM
P lead always conducting or Controller No traction or hydraulic, main contactor open.
Internal Fault or controller has
wrong parameters.
1. P lead always conducting or Controller Internal Fault or controller has wrong parameters.
2. Set truck parameters using display.
a. The parameter for each function has a value range so the motor controller can be used on different
models of lift trucks. This variation is needed for lift trucks of different sized and operation voltages.
Adjustment of a function to the wrong number value for your lift truck model can cause the truck to
operate differently than normal or present a status code.
3. If parameters cannot be download and horn is always on, replace the controller.
70

CODE
DESCRIPTION SYMPTOM
EEPROM error No traction or hydraulic, main contactor open.
1. Troubleshoot the control handle steer card (refer to Control Card Functional Test in this section).
2. Attempt to download the parameters for the controller. If parameters cannot be download and horn is
always on, replace the controller.

CODE
25361 Select Truck Flashing Red Control
DESCRIPTION SYMPTOM
Truck type parameter missing. Traction and hydraulic systems disabled
1. Set truck parameters using display.
71

CODE
28961 Service Required Flashing Red Power Steering
DESCRIPTION SYMPTOM
Stall Condition Motor has reached a stop condition.
1. Torque was applied for 10 seconds without any change in horizontal angle position.
b. Check for continuous oscillation of motor.
• Lower power steering gain (level of assist) parameter.
• Replace power steer motor.
72

CODE
DESCRIPTION SYMPTOM
The controller cannot detect the signal Traction system will not operate.
from the traction motor encoder.
1. Ensure all wiring connection between the encoder and the controller are secure and tight.
2. Check for 12 volts on wire #250.
a. Check for 12 volts at controller pin #30.
3. Check encoder output between pin #2 and pin #4 at the encoder connector from the traction motor.
• Change the encoder.
4. Check encoder output between pin #3 and pin #4 at the encoder connector from the traction motor.
73

CODE
29448 Improper Start Flashing Red Brake
DESCRIPTION SYMPTOM
Controller has detected a closed brake Traction system will not operate.
switch at startup.
1. Ensure the steer handle is in the full vertical position at truck startup.
2. Ensure the steer handle enable switch is not being held closed at truck startup.
a. Adjust switch.
b. Verify 0 volts at pin #6 at the controller connector with the steer handle in the vertical position.
3. Measure continuity across pin #1 and pin #2 at the steer handle enable connector.
a. Switch should be open with no continuity shown.
• Replace switch.
74

CODE
DESCRIPTION SYMPTOM
Controller has detected an error in the Traction system will not operate.
steer handle card throttle sensor.
1. Throttle sensor is out of calibration.
a. Calibrate throttle sensor. See the section Electrical System 2200 SRM 1451 or Electrical System
2200 SRM 1287.
b. Make sure “Hall Hysteresis” parameter is set to 100. This can be verified or edited from ETACC,
“Control Handle Inputs” menu.
c. If during calibration the indicator bar in Dash Display is just moving between center and one of the
ends, check for proper alignment of the Hall Effect sensors in the plastic thumbwheel switch (mag-
netic holder). Edge of thumbwheel switch shall be aligned with opening mark located in thumbwheel
switch protective cover, as shown in illustration below.
d. If during calibration the indicator bar in Dash Display cannot center to neutral,
iv. Check the square interface on the plastic thumbwheel switch is not broken.
v. Check the spring control return mechanism on butterfly.
vi. Check for butterfly screws to be tightened. Apply thread locker adhesive.
75

CODE
DESCRIPTION SYMPTOM
1. Ensure sensor is properly mounted to swivel casting.
2. Attempt to re-calibrate position sensor through DDI. (Review procedure)
Note 1: Bar movement should be smooth and not skip, if no movement is present verify electrical con-
nections. This only applies to truck built prior to May 09. Note 2: for trucks after May 09, there will be
no bar movement but the calibration still required.
3. Verify electrical connections to sensor:
a. Remove connector and measure total sensor resistance between pin 1 and 3 of the sensor, it should
be 5k ±10% Ohms, and not infinite (open) or 0 Ohms (shorted) If either of the later, replace sensor. If
proper resistance is present, sensor is working properly.
b. Verify 4.5 to 5.5V is present between pin 1 (Wire 354-C) and pin 3 (Wire 13-C). If 5V not present verify
wire integrity back to main controller pin 26 (CPS05) and verify continuity of ground connection from
pin 3 (Wire 13-C) to B .
c. Verify voltage output on pin 2 (Wire 355A) changes between 0.25 to 4.5 (Decreasing as steer handle
very slowly moves from vertical 90 to 0).
Note 1: If voltage goes through 0V during any part of the vertical steer handle motion, the sensor is
positioned incorrectly, and must be rotated 180 degrees by rotating its key. Note 2: This can also be
verified by monitoring the vertical angle in Ctrl Handle Input View (Output) is in degrees of angle,
and should move from 0 (up) to ~90 (down) position.
d. Verify continuity from pin 2 to pin 3 of steer handle card (CPS114).
4. If after successful calibrations, the vehicle continues to have reoccurrences, then check the following:
a. Verify steer handle pivot pin is tight and is properly mounted.
b. Verify Loctite is present on the threads.
5. Verify the handle is not slamming into steer stop upon release. If so, replace gas spring.
76

CODE
DESCRIPTION SYMPTOM
Controller has detected a belly switch error. Traction system will not operate.
1. Control handle wire #28 is damaged or bad connection.
a. Inspect wire #28 between pin #2 on steer card to pin #5 on controller. Repair as necessary.
2. Belly switch has failed. Disconnect and test switch for proper operation using an ohmmeter.
77

CODE
DESCRIPTION SYMPTOM
Controller has detected a failure in the Traction system will not operate.
steering sensor circuit.
Bad electrical connection, not properly mounted (distance between sensor and metal surface too small
or too big)
1. Measure the voltage at pin #1, wire #19 at the torque sensor connector. Voltage should read 3.3 ±0.5
volts.
a. Replace the steering sensor.
2. Measure the voltage between pin #2 and pin #3 at the torque sensor connector. Voltage should measure
1.7 volts with the steer handle arm stationary.
a. Replace the torque sensor.
3. Measure the voltage between pin #2 and pin #3 while moving the steer handle arm side to side. Voltage
should alternate between 0 volts and 3.3 volts while moving the steer handle arm side to side.
4. Measure the voltage between pin #5 and pin #6 at the torque sensor connector. Voltage should alternate
between 0 volts and 3.3 volts while moving the steer handle arm side to side.
78

CODE
DESCRIPTION SYMPTOM
Pump Open Load Hydraulics will not operate.
2. Turn the key switch to the OFF position and disconnect the battery connector.
3. Check for power and clean, tight connections between pump motor and -P connection at the controller.
4. Disconnect cable PM1 at the P controller terminal.
a. Check for a shorted condition between P and B. Resistance should be greater than 500 ohms.
5. Verify continuity through each motor cable.
a. Replace any broken wiring.
79

CODE
33033 33033 or Lighted Black Screen Solid Red Control Card
DESCRIPTION SYMPTOM
Controller cannot communicate with steer Traction and hydraulic systems will not operate.
card, dash display, or power steering motor.
1. Note:Refer to the section Diagrams 8000 SRM 1288 for comprehensive wiring information.
Ensure all wiring connections between the steer handle card and the controller are tight and secure.
• CANH and B+
• CANH and B
• CANL and B+
• CANL and B
80

CODE
(cont)
DESCRIPTION SYMPTOM
3. Perform static checks as follows (continued):
connector.
81

CODE
(cont)
DESCRIPTION SYMPTOM
connector.
connector.
7. Check to have more than 12 volts at pin 1 of CRP115. On harness version 8801065 revision 4 and sub-
sequent the power to tiller cards come from pin 30 (14V supply) of controller CPS05. For prior harness
versions, power to the tiller card comes from pin 1 (24V) of the controller CPS05.
8. If on earlier version harnesses you find no power, check on encoder connector (CPS03) not to have the
encoder signals switched with encoder power wire. Pin 1 on encoder connector goes to pin 30 of controller
connector, Pin 4 on encoder connector goes to ground, Pin 2 from encoder connector (wire #578) to be
connected to pin 32 (wire #577) on controller, and pin 3 from encoder to have continuity with pin 31 of
controller connector.
9. Open tiller head, disconnect JP10 switch connector (4 pin Molex connector on control card where the
lift/lower switches connect) from tiller card and measure resistance between pin 1 and 4. It should be
greater than 300 ohms.
10. For further troubleshooting on control handle steer card, refer to Control Card Functional Test in this
section.
82

CODE
33034 CO 33034 or Lighted Black Solid Red Control Card
Screen
DESCRIPTION SYMPTOM
Steer handle card has lost communication Traction and hydraulic systems will not operate.
with Controller or Dash Display.
3. Note: Before performing static checks, the battery must disconnected, the capacitors must be discharged
Perform static checks as follows:
• CANH and B+
• CANH and B
• CANL and B+
• CANL and B
83

CODE
(cont) Screen
DESCRIPTION SYMPTOM
3. Note: Before performing static checks, the battery must disconnected, the capacitors must be discharged
completely, and key must be in the ON position (continued).
Perform static checks as follows (continued):
c. Check resistance between the following circuit for greater than 1Mohm:
connector.
84

CODE
(cont) Screen
DESCRIPTION SYMPTOM
connector.
connector.
7. Check to have more than 12 volts at pin 1 of CRP115. On later version wiring harnesses the power to
tiller cards come from pin 30 (14V supply) of controller CPS05. For prior harness versions, power to the
tiller card comes from pin 1 (24V) of the controller CPS05.
8. If on later version wiring harnesses you find no power, check on encoder connector (CPS03) not to have
the encoder signals switched with encoder power wire. Pin 1 on encoder connector goes to pin 30 of
controller connector, Pin 4 on encoder connector goes to ground, Pin 2 from encoder connector (wire #578)
to be connected to pin 32 (wire #577) on controller, and pin 3 from encoder to have continuity with pin
31 of controller connector.
9. Open tiller head, disconnect JP10 switch connector (4 pin Molex connector on control card where the
lift/lower switches connect) from tiller card and measure resistance between pin 1 nd 4. It should be
10. For further troubleshooting on control handle steer card, refer to Control Card Functional Test in this
section.
85

CODE
33035 CO 33035 or Lighted Black Solid Red Power Steering
Screen
DESCRIPTION SYMPTOM
Controller cannot establish communication Traction and hydraulic systems will not
with EPAS. operate; or Traction system is operating at
a reduced performance level.
1. NOTE:Refer to the section Diagrams 8000 SRM 1288 for comprehensive wiring information.
Ensure all wiring connections between the power steering unit and the controller are tight and secure.
3. NOTE: Before performing static checks, the battery must be disconnected, the capacitors must be dis-
charged completely, and key must be in the ON position.
Perform static checks as follows:
• CANH and B+
• CANH and B
• CANL and B+
• CANL and B
86

CODE
(cont) Screen
DESCRIPTION SYMPTOM
3. NOTE: Before performing static checks, the battery must be disconnected, the capacitors must be dis-
charged completely, and key must be in the ON position (continued).
4. Ensure battery voltage at the red PS2-1 wire at the controller.
a. Ensure contactor is engaging.
b. Check proper terminal connection on power steer motor.
87

CODE
(cont) Screen
DESCRIPTION SYMPTOM
5. Note:Fuses may not exist on newer production models.
Check for proper connection between B of steer assembly and B of battery connector.
7. Check for continuity between pin #2 at the power steering connector and pin #28 at the controller con-
nector. Repair any broken wiring.
9. Check for continuity between pin #4 at the power steering connector and pin #10 at the traction controller.
10. Check for battery voltage at pin #3 at power steering connector.
11. Check for continuity between pin #2 at the power steering connector and pin #4 at the steer handle con-
88

CODE
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the steer handle card.
Measure resistance between pin #A and pin #B at the Service PC Connection. Resistance should be
approximately 50 ohms for power steer truck and 60 ohms for manual steer.
a. If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
connector.
connector.
connector.
Note: Steer handle harness should be inspected first (check for pinched/cut areas in wiring).
5. Disconnect JP10 connector from tiller card and measure resistance between pin 1and 4. It should be
6. Measure for battery voltage between green and purple wires at the tiller card.
89

CODE
(cont)
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the steer handle card.
• CANH and B+
• CANH and B
• CANL and B+
• CANL and B
90

CODE
DESCRIPTION SYMPTOM
Controller cannot establish CAN Operator will lose speed reduction at steer angles.
communication with the power steering unit.
NOTE: If code exists and Power Steering continues to operate, skip to step 3.
1. Ensure all wiring connections between the power steering unit and the controller are tight and secure.
a. Ensure contactor is engaging.
b. Ensure power steer 30A fuse and fuse holder is not open
c. Check proper terminal connection on power steer motor.
Note: Fuses may not exist on newer production models.
nector.
nector.
8. Check for proper connection between B of steer assembly and B of battery connector.
91

CODE
(cont)
DESCRIPTION SYMPTOM
Controller cannot establish CAN Operator will lose speed reduction at steer angles.
• CANH and B+
• CANH and B
• CANL and B+
• CANL and B
92

CODE
DESCRIPTION SYMPTOM
Steer card cannot establish CAN Traction and hydraulic systems will not operate.
communication with the controller.
1. Ensure all wiring connections between the steer handle and the controller are tight and secure.
4. Check for continuity between pin #3 at the steer handle connector and pin #28 at the controller connector.
5. Check for continuity between pin #4 at the steer handle connector and pin #27 at the controller connector.
6. Internal Failure of the steer handle card.
7. Internal failure of the traction controller.
93

CODE
DESCRIPTION SYMPTOM
Steer handle cannot establish CAN Traction and hydraulic systems will not operate.
1. Ensure all wiring connections between the power steering unit and the controller are tight and secure.
nector.
nector.
8. Check for proper connection between B of steer assembly and B of battery connector.
94

CODE
(cont)
DESCRIPTION SYMPTOM
Steer handle cannot establish CAN Traction and hydraulic systems will not operate.
• CANH and B+
• CANH and B
• CANL and B+
• CANL and B
95

CODE
DESCRIPTION SYMPTOM
Traction motor stalled. Traction systems will not operate.
1. Torque was applied for 10 seconds without any change in motor position.
b. Check for internal damage to MDU.
• Repair as necessary.
c. Check for continuous oscillation of motor.
• Adjust traction parameters.
• Replace traction motor.
96

CODE
DESCRIPTION SYMPTOM
Power steering security line has been Traction system will not operate.
set to LOW.
NOTE: This is a master level fault code, and simply indicates a steering failure has occurred. See subsequent
EP codes for troubleshooting root cause. If no additional EP codes are present, check the following:
1. Check continuity of wire #574 between pin #4 at the power steering connector and pin #10 at the traction
controller.
a. Repair any damaged wiring.
97

CODE
DESCRIPTION SYMPTOM
Controller has detected an abnormal Traction system will not operate.
signal from the position sensor in the
power steering system.
Monitor the signal output using the DDI display or ETACC.
Output should vary from +76° to 0° to 76° (degrees of angle) with steer moved horizontally from one side
to the other. Value should increase smoothly and consistently as steer handle moves.
NOTE: This sensor reads horizontal position of the control arm, not the wheel, which is geared to have
+90° to 90°.
1. If the signal transitions suddenly, reporting rapid changes in angle, sensor should be replaced.
Value should increase smoothly and consistently as steer handle moves.
2. If output goes remains static in any location or greater than ±76°, replace sensor.
3. If there is 0 output for sensor, verify electrical connections:
a. Measure from pin #1 & Pin #4 of (VCRP19) and verify 3.3V (±10%) exists.
b. If no power exists, verify continuity back to Power Steer motor. (Verify all pins fully seated and
properly crimped).
4. If ETACC or DDI unavailable, verify torque output by measuring the signals directly.
a. Voltage of pin #5 (YEL) at the steering torque sensor connector should measure 1.7V (± 0%) volts
with the steer handle at 0°. (Verify)
• If successful, verify increase of voltage as torque is applied. Should be smooth and consistent up to
maximum position and should read 3.3V ±10% (Verify)
• If not consistent, static, or out of range then replace torque sensor.
b. Repeat for pin #6 (White).
NOTE: This signal will be on an inverted slope compared to pin #5 (complimentary).
98

CODE
DESCRIPTION SYMPTOM
Controller has detected an abnormal Power assist system will not operate.
signal from the torque sensor in the
power steering system.
Monitor the torque signal output using the DDI display or ETACC. Output should vary from
13.6 N•m (120.0 lbf in) with steer handle in static up position.
1. Value should increase smoothly and consistently as torque effort is placed on steer handle. Value should
not exceed 80.
2. If the signal transitions suddenly between high and low torque values, particularly in specific positions,
sensor should be replaced.
3. If output goes remains static (but positive) or greater than 80, replace sensor.
4. If there is 0 output for sensor, verify all electrical connections between torque sensor and steer assembly,
such as bad crimp, broken wire and pins not proper installed.
a. Measure from pin #1 & Pin #4 of (VCRP19) and verify 3.3V (±10%) on units built through 5/09 or
verify 5.0V (±10%) on units built after 5/09.
b. If no power exists, verify continuity back to power steer motor. (Verify all pins fully seated and prop-
erly crimped).
5. If ETACC or DDI unavailable, verify torque output by measuring the signals directly.
a. Voltage should measure 1.7V (±10%) on units built through 5/09 or 2.5V (±10%) on units built after
5/09 with the steer handle stationary. (Verify) If successful, verify increase of voltage as torque is ap-
plied. Should be smooth and consistent up to maximum torque and should read 3.3V (±10%) (Verify)
on units built through 5/09 or 5.0V (±10%) on units built after 5/09.
• If not consistent, static, or out of range then replace torque sensor.
b. Repeat for pin #3 (Violet).
NOTE: For consistent results it is best to lock the MDU & Power Steer movement, so that the steer
handle torque is proportional to handle movement.
NOTE: Movement of steer handle will not move beyond 9 degrees from center (Verify) to attain max-
imum torque output.
99

CODE
65282 Service Required Flashing Red Power Steering
DESCRIPTION SYMPTOM
Torsion bar broken, reduction gear broken, Mechanical failure or connection lost.
mechanical connection lost.
1. Check all mechanical steering components for damage.
a. Repair or replace any damaged components.
2. Check for foreign material binding the gearing.
a. Remove any material found.
3. Check that all steering torque sensor linkage with the steer handle arm is intact.
a. Repair linkage.
4. Verify all electrical connections between torque sensor and steer assembly, such as bad crimp, broken
wire and pins not proper installed.
a. Measure from pin #1 and pin #4 of (VCRP19) and verify 3.3V (±10%) on units built through 5/09.
b. If no power exists, verify continuity back to power steer motor. (Verify all pins fully seated and prop-
erly crimped).
100
2200 SRM 1286 Electrical Checks
Electrical Checks
GENERAL ELECTRICAL SYSTEM battery terminal). If not, charge the battery or
CHECKS replace battery with a proper type, fully charged
battery.
1. Turn the key to the OFF position, disconnect
the battery, and discharge the capacitors (refer NOTE: The following test would be performed with
to Discharging the Capacitors in this section). the truck powered on. Key off prior disconnecting or
Make the following electrical checks: reconnecting any connector.
a. Check the continuity of fuses and open load 2. Measure battery voltage at B+ and B connec-
connections. tions at the controller. Is the voltage the same as
the properly charged battery voltage?
b. Check for batter voltage on wire #10 at the Yes - Go to Step 3.
main contactor. No - Go to General Electrical System Checks.
c. Ensure contactor is engaging has continuity 3. Check the voltage between pin C of CPS15/
across the contacts, and all connection are PC_Service connector, pin 3 of CPS60/BDI_Dash,
tight. Pin 6 of CRP115/Tiller Harness, pin 3 of CPS
800/Proximity Switch, pin2 of CRP105/Electric
d. Disconnect coil wires. Test the contactor coil Brake and B . Is the voltage difference between
using an ohmmeter to measure the resis- B- and pin C of CPS15/PC Service Connection
tance. Measure resistance between TBF03 greater than 0.25 V?
and TBF04. The coil should read 22 ohms Yes - Go to Step 4.
±10%. If resistance readings indicate a short No - Go to Static Checks on CAN Connections.
circuit in both directions or if there is an
open circuit in both terminals, replace the 4. Disconnect CPS_05 controller connector. Check
contactor. Make sure coil wires are con- the voltage between CPS_05, pin 29 (at con-
nected to the proper terminals. troller) and B . Is voltage difference between
B- and pin C of CPS15/PC Service Connection
e. Disconnect cable PM1 at the P controller greater than 0.25 V?
terminal. Check for a shorted condition be- Yes - If voltage is greater than 0.25 V, replace
tween P and B . Resistance should be the controller.
greater than 500 ohms. No - Go to Step 5.
STATIC CHECKS ON POWER AND 5. Reconnect CPS_05 (harness connector) to con-
GROUND CONNECTIONS troller. difference between B- and pin C of
CPS15/PC Service Connection and disconnect:
NOTE: Pin 1 on Molex connectors is identified with Traction Encoder, Tiller harness and Proximity
a notch (top side of connector), sequence will be fol- Switch (if Power Assisted Steering equipped),
lowed from pin 1 to the bottom of that column and Electric Brake. Check the voltage between
will continue on top side of second column up to the CPS_60, pin 3 (dash display) and B . Is voltage
bottom. difference between B- and pin C of CPS15/PC
Service Connection greater than 0.25 V?
Pin 2 of Deutsche connectors would be identify with Yes - Go to Step 6.
a number 1 at the back of pin connector where the No - Go to Step 7.
wires are inserted or will have numbers embossed
at front of female connector. Would have clockwise 6. The harness is either shorted internally or has a
sequence. bad connection at dash display.
Superseal connectors would have the numbers em- a. Check for continuity between dash display
bossed on connector. power and key switch.
1. Verify battery is the proper type (per the name- b. Check for continuity between dash display
plate), is fully charged and not damaged, and is ground and B .
producing 24.5 V or more (measured from the
101
Electrical Checks 2200 SRM 1286
c. Check for continuity between dash display 13. If static checks did not pass, check for harness
CAN lines and controller CAN lines. locations that may be shorting to truck frame.
Repair or replace harness as necessary.
d. Check software on dash display, connector
connections, or repair dash display if pins are STATIC CHECKS ON CAN CONNECTIONS
damaged.
NOTE: If ground continuity is seen between CPS_60, WARNING

pin 3 (dash display) and B then reconnect dash dis- The capacitor in the controller can hold an
play connector to main harness. There is no voltage electrical charge after the battery is discon-
differential induced by dash nected. To prevent electrical shock and per-
sonal injury, discharge the capacitor before
7. Leave BDI Dash Display connected and leave all repairing or inspecting any component. Refer
prior mentioned connectors disconnected. Check to Discharging the Capacitors at the beginning
voltage between CRP_115, pin 6 (tiller harness of this section.
connector, main harness side) and CPS_05, pin
29 (controller connector). Is voltage difference 1. Turn the key switch to the OFF position, discon-
between B- and pin C of CPS15/PC Service Con- nect the battery, and discharge the capacitor. See
nection greater than 0.25 V? Discharging the Capacitors at the beginning of
Yes - Go to Step 13. this section.
No - Go to Step 8.
2. Turn the key to the ON position, but leave
8. Leave the tiller harness and EPAS connectors the battery disconnected. Measure CAN lines
disconnected if equipped. Check voltage between impedance. Resistance should be approximately
CPS_115, pin 6 (tiller harness) and B at con- 50 ohms (on trucks equipped with Power Assist
troller. Is the voltage more than 0.25 V? Steering) or 65 ohms (on manual steer trucks).
Yes - Check the tiller harness. Refer to Tiller Measure resistance between pin #A and pin #B
Harness Shorts and Continuity Checks. at the Service PC Connector. Is the resistance
No - Go to Step 13. reading correct for your truck ±10%?
9. Check between pin 4 of CPS03 / TRC_Encoder Yes - Go to Step 4.

not to be shorted with pin 1, pin 2 or pin 3 of same No - Go to Step 3.
connector.
If is shorted, repair as needed. NOTE: If tests indicated that the control card may be
at fault, test the control card before replacement. See
10. Reconnect Proximity Switch. Measure voltage Control Card Functional Test in this section.
between pin C of PC Service connector and B-.
Is the voltage greater than 0.25V? 3. If resistance is not within specification, check
Yes - Check leads of proximity switch for pos- wiring for broken or shorted condition. Remove
sible shorts. tiller, dash display, and power steering con-
No - Proceed to next step nectors and perform the general checks to the
electrical system. See General Electrical System
11. If no voltage differential was seen between Checks in this section. Repair as necessary.
ground connections, proceed to Static Check on
CAN Communication lines. 4. Disconnect the tiller harness and check resis-
tance between the following circuits for greater
12. Reconect the Electric Brake. Measure voltage be- than 1 Kohm resistance. Repair open circuits or
tween pin C of PC Service connector and B-. Is shorts as necessary.
the voltage greater than 0.25V? • CANH and B+
Yes - Check leads of Electric Brake for possi- • CANH and B
ble shorts. Refer to Electrical System 2200 • CANL and B+
SRM 1287 or Electrical System 2200 SRM • CANL and B
1451.
No - All ground connections are good. Proceed
to Static Checks on CAN Connections.
102
2200 SRM 1286 Electrical Checks
5. Check resistance between the following points TILLER HARNESS SHORTS AND
for greater than 1 Mohm: CONTINUITY CHECKS
• B+ and Truck Frame
• B and Truck Frame NOTE: The following wires on the tiller card circuit
• CANH and Truck Frame are responsible for no communication, lighted black
• CANL and Truck Frame screen conditions, loss of traction and hydraulics:
• CPS_115, pin 1 - Power to Tiller Card
a. If resistance is lower than 1 Mohm, check • CPS_115, pin 3 - CAN HI communication Line
for shorted conditions between components • CPS_115, pin 4 - CAN LO communication Line
harness, and the truck. • CPS_115, pin 6 - CAN Ground to Tiller Card
b. Check for connections between B and B+ at 1. Raise lift truck frame and position on blocks so
controller, battery, and truck frame. Ensure the drive tire is suspended off the floor. Turn the
connections are tight and secure. key switch to the OFF position and disconnect
the battery.
c. Check for tight connections at U, V, and W
terminals of the controller and for shorted NOTE: This check looks for open circuits in the tiller
condition between terminals to B+ or B . harness. If no open circuits are found with this check,
other problems with the tiller harness may still exist.
NOTE: When performing the following tests, check
each connector for CAN HI shorts to CAN LO or CAN 2. Open the tiller head to access the tiller card and
LO shorts to ground, or CAN HI and CAN LO shorts tiller harness. Disconnect the tiller harness from
to Ground. the main wiring harness. Check that the connec-
tor pins are securely anchored in the connector.
6. Verify for appropriate CAN connections between
If the pins become loose in their settings they can
Combi Controller, Tiller Control Card, Dash Dis-
slide backwards out of position when the connec-
play, and Power Steering (EPAS)(if equipped).
tors are connected resulting in an open connec-
a. Check continuity on CAN HI connections, tion. Repair or replace as necessary. Check to
wire #901 from PC Service tool connector verify continuity from each pin of the connector
CPS_15, pin A to: to its corresponding connection in the tiller head.
Was continuity present on every wire?
• Connector CRP_115, Pin 3 of Tiller Card Yes - Proceed to Step 3.
• Connector CPS_60, Pin 2 of Dash Display No - Repair or replace the wiring.
• Connector CPS_18, Pin 2 of Power Steer
Unit (EPAS) NOTE: Earlier revision wiring harnesses were con-
figured differently than later versions. The voltage
b. Check continuity on CAN LO connections, supplied to CPS_115, pin 1 should read either 14V
wire #900 from PC Service tool connector (±10%) on the latest version main wiring harnesses
CPS_15, pin B to: or 24V (±10%) on earlier version main wiring har-
• Connector CRP_115, Pin 1 of Tiller Card nesses used.
• Connector CPS_60, Pin 4 of Dash Display
• Connector CPS_18, Pin 1 of Power Steer 3. Reconnect the connectors and wiring. Connect
Unit (EPAS) the battery and turn the key switch to the ON
position. Position the tiller arm in the full up-
c. Check continuity on CAN ground connec- right position, open the tiller head and discon-
tions, wire #102 from PC Service tool connect JP1 from tiller card and measure voltage
nector CPS_15, pin C to: seen between pin 1 and pin 2 of Tiller Harness
• Connector CRP_115, Pin 6 of Tiller Card connector that attach to JP1. Does voltage read
• Connector CPS_60, Pin 4 of Dash Display either 14V (±10%) or 24V (±10%)?
• Connector CPS_800, Pin 3 of Proximity Yes - Go to Step 5.
Switch No - Check for continuity and good connec-
tions on power wire and ground wire:
• Current Version Power Wire (#250) - runs
from CPS_05, pin 30 to CPS_115, pin 1 (and
continues into tiller card at JP1, pin 1).
103
Control Card Functional Test 2200 SRM 1286
• Earlier Version Power Wire (#10) - runs from of CPS03. If is the main harness on the truck
CPS_05, pin 1 to CPS_115, pin 1 (and contin- was installed prior 2010, then there could be an
ues to the tiller card at JP1, pin 1). open or loose connection on splice S10-03 located
• Ground Wire- runs from CPS_05, pin 29 to on the main harness at the right side of the tiller
CPS_115, pin 6 (and continues into tiller harness break out (right side is facing the main
card at JP1, pin 2). harness)
Repair or replace wiring as necessary. If
no wiring problems were found, continue to 5. Check across JP16, pin1 and pin 2 on tiller card.
Step 4. Are there 5 volts present?
Yes - Tiller card is responding.
4. If the truck’s main harness was manufactured No - Go to Control Card Functional Test in this
on 2010 and after, the power to the tiller card section.
would be shared with the encoder of the traction
motor. In the case that the leads of the traction NOTE: Reset Handle, is not related to communica-
encoder are shorted, the tiller card power would tion failures, but relates to tiller harness could be
be routed to ground. To ensure encoder leads are generated by not receiving B+ voltage at tiller card
correct check for short to ground between pin 1 or pin 7 of controller. Refer to Control Card Func-
to pin 4 of CPS 03, and short to encoder digital tional Test, step 5 (g).
signals between pin 1 (14.3V) to pin 2 and pin 3
Control Card Functional Test

can be damaged or it can fall, causing serious
WARNING injury. Attach the chain or sling to a support
Make sure the drive wheel is raised to prevent structure of the lift truck frame.
truck movement and possible injury. Raise the
drive wheel. The blocks must prevent the lift NOTE: Tools and test equipment required:
truck from falling and causing personal injury • Clip Leads
or property damage. Refer to the section Elec- • Digital Multimeter (20,000 ohms per volt)
trical System 2200 SRM 1451 or Electrical Sys- • Various Standard Hand Tools
tem 2200 SRM 1287.
1. Check for proper power supply:
Block lift truck so the drive tire is raised
slightly off the floor to prevent unexpected a. Ensure battery is properly charged. Voltage
movement when making checks DO NOT put should read 25 ±0.5V across battery termi-
the lift truck on blocks unless the surface nals.
is solid, even, and level. Make sure that all
b. Verify battery voltage present between B+
blocks used to support the lift truck are solid,
and B controller terminals.
one-piece units. Put a block in front and back
of the tire or wheels touching the ground to c. Verify continuity between battery negative
prevent unexpected movement of the lift truck. (at battery) and B controller terminal. Ver-
ify continuity between battery positive (at
WARNING battery) and B+ controller terminal. Repair
DO NOT raise the lift truck by attaching an as necessary. Refer to the section Electrical
overhead crane to areas that will be damaged. System 2200 SRM 1451 or Electrical Sys-
Some of these points are not designed to sup- tem 2200 SRM 1287 for troubleshooting the
port the weight of the lift truck. The lift truck electrical system.
104
2200 SRM 1286 Control Card Functional Test
2. Static Checks: The following step is to check re- c. If resistance is greater than 90 ohms, check
sistance on the proper scale from frame to power wiring for broken or shorted condition.
and controller terminals. Resistance of less than
20,000 ohms can cause misleading symptoms. 4. Access Service Technician Menu through the
Resistance of less than 1000 ohms indicates a Dash Display (refer to the section User In-
short and should be corrected immediately. terface, Service Technician Functions
On-Board Dash Display 2200 SRM 1324).
NOTE: Before performing static checks, the battery Check the Control Handle functionality of
must be disconnected, the capacitors must be dis- lift/lower, belly, regen brake, and horn switches
charged completely, and key must be in the ON po- through the dash display. If test is successfully
sition. Refer to Discharging the Capacitors, in this passed, control card is functioning properly. DO
section. NOT replace the control card.
a. Check resistance between the following cir- 5. If functionality test was not achieved through
cuit for greater than 1000 ohms: dash display test; then check for loose or dam-
aged electrical connections between control card
(1) CANH and B+ and controller.
(2) CANH and B Verify connection at the controller and control
card. Use along with the section Diagrams 8000
(3) CANL and B+
SRM 1288 to follow traces from control card to
(4) CANL and B the controller to check for continuity:
b. Check resistance between the following a. Power connection between Control Card to
points for greater than 1Mohm: Controller (Trucks manufactured up to De-
cember 2009)
(1) CANH and truck frame
(1) Wire 10 connected from pin 1 of CPS05
(2) CANL and truck frame AC Controller and pin 1 of CPS115
Tiller harness connector (24V)
(3) B+ and truck frame
(2) Wire 10 connected from B+ of AC Con-
(4) B and truck frame troller and pin 1 of CPS115 Tiller har-
ness connector (24V)
(5) UT wire (traction motor) to truck frame
(3) Voltage across pin 1 of CPS 115 and B-
(6) VT wire (traction motor) to truck frame
shall be equal to B+.
(7) WT wire (traction motor) to truck frame
(4) On all trucks, power lines go to pin 1 in
(8) PS2 wire (steer motor) to truck frame (if JP2 (look for the notch on Molex connec-
applicable) tor to identify pin 1) on control card.
(9) PM2 wire (pump motor) to truck frame b. Power connection between Control Card to
Controller (Trucks manufactured on/or later
(10) PM1 wire (pump motor) to truck frame January 2010 or any truck using main har-
ness manufactured on 2010 and after).
3. Ensure all wiring connections between the con-
trol card and the controller are tight and secure. (1) Wire 250 connected from pin 30 of
CPS05 AC Controller and pin 1 of
a. Measure resistance between pin #A and pin CPS115 Tiller harness connector
#B at the Service PC Connection. (12-15V)
b. Resistance should be approximately 45±15% (2) Voltage across pin 1 of CPS 115 and B-
ohms for power steer truck and 60±15% ohms shall range between 12 and 15V.
for manual steer.
(3) On all trucks power lines end up in JP2
- pin 1 on control card
105
Control Card Functional Test 2200 SRM 1286
c. GROUND wire # W102 –TH GRN (2) Voltage across pin 7 of CPS05 and B-
shall range between 12 and 24V, de-
(1) Check connections between pin 29 pending on voltage source used in Con-
of CPS05 AC Controller and pin 6 trol Card Power Line.
of CPS115 Tiller harness connector
(which goes to JP2 - pin 2 on control (3) Ensure connection between Regen
card) Switch (or potentiometer, as used on
models built prior June 2009) and pin
d. CAN LO wire # W900/ LO BLK between 7 of CPS 05 and pin 7 of CPS115 on
control card side.
(1) Check connections between pin 28
of CPS05 AC Controller and pin 4 h. TORQUE SENSOR wire # W357
of CPS115 Tiller harness connector
(which goes to CJ2 - pin 2 on control (1) Between pin 1 of CPS801 TORQUE
card) - CAN HI wire # W901/HI WHT SEN and pin 7 of CPS115 Tiller har-
ness connector (which goes to JP17 -
e. CAN HI wire # W901/HI WHT pin 1 on control card)
(1) Check connections between pin 27 (2) Voltage across pin 1 of CPS801 and B-
of CPS05 AC Controller and pin 3 shall be approximately 5V.
of CPS115 - Tiller harness connector
(which goes to CJ2 - pin 1 on control 6. With harness connected into control card
card) and forklift powered on, disconnect lift/lower
switches and check for voltage across pin 1 of
f. BELLY SW wire # W28-TH switches and pin 2 of JP1 (GND) to be 5.00V. If
voltage is below 4.75V, replace control card.
(1) Check connections between pin 5
of CPS05 AC Controller and pin 2 7. Power off the forklift, disconnect tiller harness
of CPS115 Tiller harness connector connectors that go into control card, leave lift/
(which goes to JP2 - pin 5 on control lower switches disconnected and check to have
card) more than 300 ohms between pin 1 and pin 4 of
JP10 connector on the control card. If impedance
(2) Voltage across pin 5 of CPS05 and B-
is below 300 ohms with all switches disconnected,
shall range between 12 and 24V, de-
replace control card.
pending on voltage source used in Con-
trol Card Power Line. a. Remove the control card from the control
handle. Refer to Electrical System 2200
(3) If continuity is not found; check for con-
SRM 1451 or Electrical System 2200 SRM
tinuity on control card between pin 2 of
1287, Control Handle.
S1 Belly Switch and pin 5 of JP1. If
no continuity is found, replace control 8. If the forklift inspected is a Power Assisted
card. forklift and at any time the tiller handle move
slowly in one direction during start-up; it is
g. SNAIL/TILLER ARM SW wire # wire W355
likely Power Assist Steering Motor calibration
AC
that needs to be performed. Refer to Electrical
(1) Check connections between pin 7 of System 2200 SRM 1451 or Electrical System
CPS05 AC Controller and pin 7 of 2200 SRM 1287, Power Assist Steering Sensor.
CPS115 Tiller harness connector.
106
2200 SRM 1286 Dash Display
Dash Display
GENERAL • If there is a fault noted by the lift truck controller
and the controller has prevented traction and hy-
The dash display is a multifunction device. It con- draulic functions, the LED will be solid red.
tains a truck status LED and an LCD which dis- • When the battery charge reaches 75% of full
plays the performance mode indicator and the bat- charge, the horn will sound and the LED will
tery charge indicator. The menu system can be ac- alternately blink from red to green.
cessed through the dash display by starting the truck • If the controller has noted a condition that require
in service mode and entering the proper password. the lift truck to operate at a reduced performance
See Figure 3. level, the LED will blink red.
PERFORMANCE MODE INDICATOR

The performance mode indicator will show the cur-
rent performance mode setting at truck startup. The
indicator is a four bar display with the rabbit or high-
est performance level on the right and the "Turtle"
or lowest performance level on the left. See Figure 4.
The performance model level can be changed using
the lift and lower buttons on the steer handle as de-
scribed in the Operating Manual unless the per-
formance mode function has been locked by a su-
pervisor or a technician. Refer to User Interface,
Supervisor Functions On-Board Dash Display
2200 SRM 1323 or User Interface, Service Tech-
nician Functions On-Board Dash Display 2200
SRM 1324.
Figure 3. Dash Display Screens
STARTUP
When the key is turned to the ON position and the
handle is in the full upright position, all segments
of the display will be illuminated and the horn will
beep twice. The LED will flash red, green, and then
go blank momentarily. Then the display will show
the truck mode setting and the hourmeter reading.
STATUS LED
The status LED is located in the top center of the dis-
play. When the key switch is in the ON position, the
LED is on. The LED can indicate in either red or
green depending on the information being communi-
cated. Figure 4. Performance Mode Screen
• When the lift truck key is in the OFF position, the
LED will be OFF.
• When the lift truck is operating normally, the LED
will be solid green when the key is in the ON posi-
tion.
107
Dash Display 2200 SRM 1286
HOURMETER
The hourmeter accumulates hours when the key is
in the ON position and main contactor is closed. The
hourmeter is capable of showing five digits and dis-
plays complete hours. See Figure 5. At truck startup,
the display will show the truck hours for 10 seconds
after the key has been turned to the ON position. The
hourmeter reading will be turned off if the control
handle is moved to the operating position any time
within the 10 second display period.
Figure 6. Battery Charge Indicator
FAULT LOG
The Fault Log menu will list the truck system initiat-
ing the fault, the error code associated with the fault,
the hourmeter reading when the fault occurred, the
number of times the fault has been logged, and the
system temperature when the fault occurred. See
Figure 7. The Fault Log auto scrolls. The system
will retain the last ten faults noted.
Figure 5. Hourmeter
BATTERY CHARGE INDICATOR

When the truck hourmeter is disabled, it is replaced
on the display by the battery charge indicator. The
indicator is a five bar graphical indicator with the full
indicator bar on the right and the empty indicator
bar on the left. See Figure 6. At 100% charge, all
bar graph segments will be shaded. As the battery is
discharged, fewer of the bars will be shaded.
100% Charge = 5 Solid Bars
30% Charge = 1 Solid Bar During Lifting
20% Charge = 0 Solid Bars, Blinking Red Status
LED,
Lift Lockout - (Horn Sounds When Lift Switch
Is Activated)
Figure 7. Fault Log Screen
108
2200 SRM 1286 Connector Pin-Outs
Connector Pin-Outs
Controller Connector (CPS 05)
Pin Wire Number Function
1 W10 - AC RED Battery Positive

Proximity Sensor (Optional)
2 W342 - A High Speed
3 W26 - A Aux. Lift Switch
4 W27 - A Aux. Lower Switch
5 W28 - A Steer Handle Card
6 W98 - AC Steer Handle Switch
7 W99 - C RED Coast Switch (Optional)
10 W574 - PS Power Steer Encoder (Optional)
11 W25 - A Aux. Horn Switch
12
13
14 W730 - A RED Cruise Solenoid (Optional)
15
16
17
18 W79 - M RED Main Contactor Coil
19
20 W45 - H Horn
21
22 W150 - A Pump Coil (+)
23 W86 - A Pump Coil ( )
24
25 W386 - A Traction Motor Temp Sensor
26 W354 - TS RED Steer Handle Switches

Steer Handle Sensor (Optional)
27 W901/H - WHT CAN Hi
28 W900/L - BLK CAN Lo
29 W102/BARE - GRN Traction Motor Temp Sensor
30 W250 - E Traction Motor Encoder
33
34
35
109
System Logic Diagram 2200 SRM 1286
System Logic Diagram
Traction Motor --------

CANbus Dash Display
Traction Encoder --------

CANbus
Temperature Sensor --------
Pump Motor -------- -------- Forward/Reverse Input
Power Steering Motor -------- -------- Truck Speed Input
Main Contactor -------- CANbus -------- Lift/Lower Input
CANbus
Horn -------- -------- Traction Reverse Input

Steer Handle Card
Lower Solenoid -------- -------- Neutral Input
Cruise Solenoid -------- -------- Pick Mode Input
Electric Brake Coil -------- -------- Horn

Traction Motor
Controller
High Speed Switch -------- -------- Steer Handle Switches
Aux. Horn Switch -------- -------- PS Motor Encoder
CANbus
▲
|
Power Assist Steer
Aux. Lift Switch -------- Torque Sensor
Aux. Lower Switch -------- -------- Proximity Switch
Coast Switch --------
Brake Switch --------
Service
CANbus
PC Connection
110
TECHNICAL PUBLICATIONS
2200 SRM 1286 4/11 (10/10)(12/09)(9/09)(6/09)(5/07)(2/07)(12/06)(11/06) Printed in U.S.A.

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AC MOTOR

PART NO. 1640805 2200 SRM 1286

• 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.

©2011 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

DISCHARGING THE CAPACITORS

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

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

1. GRAB RAIL 9. BRAKE

Figure 2. Component Location (Power Steer Shown)

AC Traction Motor The motor controller receives power through the

Table 1. Parameter Default Values

Parameter Default Range

Parameters can be adjusted through the dash display Plugging

Pick Deceleration setting increases the voltage. Decreasing the setting

Battery Full Voltage

Prior to troubleshooting systems and components on No - Proceed to Step 2.

Tiller Oscillation and Bias (EPAS Option) STATUS CODES

Table 2. Fault Codes

Table 2. Fault Codes (Continued)

Table 2. Fault Codes (Continued)

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT

STATUS DISPLAY MESSAGE LED CIRCUIT