Electrical System Os-Ss030be (d826)

Maintenance
ELECTRICAL SYSTEM
OS/SS030BE [D826]
PART NO. 524164050 2200 YRM 956

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Electrical System Table of Contents
TABLE OF CONTENTS
Major Electrical System Features........................................................................................................................ 1

Integrated System ........................................................................................................................................... 1
CAN Bus Advantages ..................................................................................................................................... 1
CAN Bus Communications.............................................................................................................................. 1
Electric Steering.......................................................................................................................................... 1
Traction ....................................................................................................................................................... 1
Master Control Unit ..................................................................................................................................... 1
Input Devices .......................................................................................................................................... 1
Output Devices ....................................................................................................................................... 2
Encoder Integrity ............................................................................................................................................. 2
Test Encoders ................................................................................................................................................. 2
Proximity Switches .......................................................................................................................................... 2
Start Relay ...................................................................................................................................................... 2
Battery Discharge Indicator (BDI) ................................................................................................................... 2
Multifunction Display ....................................................................................................................................... 2
Setup ................................................................................................................................................................... 3
Setup Instructions ........................................................................................................................................... 3
General Diagnostics........................................................................................................................................ 8
Power-On Self-Test.............................................................................................................................................. 8
SEM Traction Motor Controller ............................................................................................................................ 9
Controller Removal.......................................................................................................................................... 9
Install............................................................................................................................................................... 9
Low-Voltage Protection Function..................................................................................................................... 9
Checking Contactor Coils................................................................................................................................ 10
Checking Transistor Controller ............................................................................................................................ 10
Component Repair and Testing....................................................................................................................... 10
Troubleshooting ............................................................................................................................................... 11
Fault Codes and Display Messages ................................................................................................................ 12
Contactor and Electrical Panel Checks ............................................................................................................... 22
Fuses .............................................................................................................................................................. 23
Contactors....................................................................................................................................................... 23
General ....................................................................................................................................................... 23
Test ............................................................................................................................................................. 23
Tips ............................................................................................................................................................. 24
Disassemble and Assemble........................................................................................................................ 24
Traction Throttle Sensor Removal and Installation .............................................................................................. 26
Instrument Panel Removal and Installation ......................................................................................................... 28
Key Switch Removal and Installation................................................................................................................... 28
Remove ........................................................................................................................................................... 28
Install............................................................................................................................................................... 28
Steering Indicator Gauge .................................................................................................................................... 28
Test.................................................................................................................................................................. 28
Remove and Install.......................................................................................................................................... 28
Spy Glass Removal and Installation .................................................................................................................... 29
Foot Switch Removal and Installation.................................................................................................................. 29
Slack Chain Switch Removal and Installation...................................................................................................... 30
Limit Switch Removal and Installation ................................................................................................................. 30
Drive and Hydraulic Pump Motors....................................................................................................................... 31
Routine Preventive Maintenance .................................................................................................................... 31
Preventive Maintenance Checks................................................................................................................. 32
Cleanliness...................................................................................................................................................... 32
©2003 Yale Materials Handling Corp. i

Table of Contents Electrical System
TABLE OF CONTENTS (Continued)

Connections .................................................................................................................................................... 32
Discoloration and Burn Marks ......................................................................................................................... 32
Brushes ........................................................................................................................................................... 32
Short in Armature............................................................................................................................................ 32
Commutator .................................................................................................................................................... 32
Bearings .......................................................................................................................................................... 33
Causes of Motor Failure ...................................................................................................................................... 33
Overload.......................................................................................................................................................... 33
Shock Loading ................................................................................................................................................ 33
Short in Field Coils .......................................................................................................................................... 33
Short Brushes ................................................................................................................................................. 33
High or Low Commutator Bar.......................................................................................................................... 33
Open Circuit .................................................................................................................................................... 33
Low Battery Voltage ........................................................................................................................................ 33
Eccentricity of Commutator ............................................................................................................................. 33
Overspeeding .................................................................................................................................................. 33
Motor Tests .......................................................................................................................................................... 34
Excessive Current Draw.................................................................................................................................. 34
Measuring Current Draw ................................................................................................................................. 34
Excessive Resistance ..................................................................................................................................... 34
Brush Springs ................................................................................................................................................. 34
Drive Motor .......................................................................................................................................................... 35
Inspect............................................................................................................................................................. 35
Preparation of Drive Motor Commutator ......................................................................................................... 35
Fitting Motor Brushes (Motor Removed) ............................................................................................................. 36
Drive Motor Brush and Brush Holder .................................................................................................................. 36
Drive Motor Brush, Remove and Install (Motor Installed)................................................................................ 36
Drive Motor Brush Holder, Remove and Install (Motor Installed) .................................................................... 36
Drive Motor Disassembly and Assembly ............................................................................................................. 37
Hoist Pump Motors .............................................................................................................................................. 39
Maintenance Instructions ................................................................................................................................ 39
General Information ........................................................................................................................................ 39
Brush Replacement......................................................................................................................................... 40
Hoist Motor...................................................................................................................................................... 40
Remove and Install ..................................................................................................................................... 40
Disassemble and Assemble........................................................................................................................ 40
This section is for the following models:
OS/SS030BE [D826]
ii
2200 YRM 956 Major Electrical System Features
Major Electrical System Features

• Keep It Simple philosophy - a simple hardware design NOTE: To make sure CAN bus is working, blow the
with fewer parts - better reliability horn. If it works, the CAN bus is OK from the 1310 to
• Programmable setup of the truck with operator con- 1243 controller.
trols and dash display
• Noncontact encoders that give position of lift, steering Electric Steering
input, and steer drive tire angle
• Variable Hall effect sensor for throttle Steering is provided by the Inmotion gear motor con-
• On-board diagnostics with text display troller. The APS steering uses a brushless DC motor
• Separately Excited Motor (SEM) traction motor and and controller with CAN bus communications. Steering
controller commands are transferred via the CAN bus from the
• Regenerative braking for minimal wear of park brake MCU located under the dash panel.
• Control Area Network (CAN) bus digital data link
• Integrated electrical system Traction
• Reduced wiring complexity Traction is provided by a separately excited motor and
• Over-the-mast wiring reduced to eight conductors a Curtis 1243 Sepex controller. The controller is con-
• Alphanumeric multifunction display nected to the CAN bus communications link over which
• Continuous height sensing (encoder) it receives commands and reports faults and status in-
• Height, steer angle, and travel speed relationships formation. It also has auxiliary transistor outputs that
• Battery discharge indication adjustable for regular or control the traction main contactor, lift pump contactor,
maintenance-free batteries lower solenoid valve, brake coil, and horn. Like other
Curtis controllers, the 1243 has a provision for the 1307
INTEGRATED SYSTEM handset for diagnostics and testing when needed. It
This orderpicker uses a CAN bus, two-wire, twisted pair, also has a blinking light for indicating fault codes at a
serial communications network bus to connect several glance.
electronic subsystems together to form one integrated
NOTE: If a traction controller handset is used for diag-
system.
nostics, start truck in setup menu, then plug handset
in and exit truck setup menu when handset has com-
CAN BUS ADVANTAGES
pleted bootup process. Failure to follow these steps
• Increased reliability may cause the truck to display a height encoder error.
• Substantial reduction in connections and wiring com- To clear the error, unplug handset, lift forks to 762 mm
plexity (30 in.), lower forks fully, then restart truck.
• Extensive function monitoring capability
• Serial bus simplicity (two wires) Master Control Unit
• Easy information exchange between subsystems
Vehicle-control-logic management, diagnostics, and
parameter setup are performed by software in the
CAN BUS COMMUNICATIONS
Curtis 1310. This controller is connected to the CAN
Electronic controllers connected by the CAN bus data bus, is located at the operator platform, and interfaces
link are as follows: with the following input and output devices.
• Curtis 1310 Master Control Unit (MCU)
Input Devices
• Curtis 1243 Traction controller
• Inmotion Advanced Power Steering (APS) • Throttle Hall Sensor - three wires, battery negative,
positive 5 volts, and the variable output having an
The two-wire, twisted pair, CAN bus carries the follow-
approximate range of 1.0 volt (full reverse command)
ing data:
to 4.0 volts (full forward command), with 2.5 volts at
• Traction throttle
neutral.
• Traction direction
• Lift and Lower switches - connect to two digital inputs
• Horn
on the 1310. Both switches are sourced by 15 volts
• Lift/Lower
from the 1310. Used on small chassis trucks, not on
• Steering position and steering rate
large chassis trucks.
• Status information and diagnostic information.
1
Major Electrical System Features 2200 YRM 956
• Lift and Lower Hall effect sensor - used on large chas- encoder very slowly to see if the input goes on/off/on
sis trucks, not on small chassis trucks. (0 then 5 volts) when the encoder is rotated slowly.
• Horn switch - connects to one digital input on the Check the other bit also. If they are both outputting, the
1310. The switch is sourced by 15 volts from the encoder is OK. See Setup.
1310.
• Foot switch - connects to one digital input on the 1310. PROXIMITY SWITCHES
The switch is sourced from B+.
• Side gate switches - both in series, connect to one These are noncontact devices which sense the pres-
digital input on the 1310. These switches are sourced ence of steel. They have three wires going to them:
from B+. battery negative, 15 volts (approximately), and an out-
• Slack chain switches - both in series, connect to one put signal. They also have a built-in indicator light that
digital input on the 1310. The switches are sourced lights the collar where the wires come out. These de-
from B+. vices can be checked by looking at the indicator light
• Steering input encoder - a digital output device with and by testing the output with a voltmeter to see that it
two bits each with 128 pulses per revolution (256 to- changes with and without the steel in front of it.
tal). It is powered by the 5-volt source from the 1310.
• Height encoder - a digital output device with two bits START RELAY
each with 128 pulses per revolution (256 total). It is When the key is rotated to the START position, the
powered by the 5-volt source from the 1310. main contactor coil is energized, powering up the 1310.
• Steer handle center proximity switch (not used with When the 1310 starts up, the start relay driver pulls low
Multiturn Steering). It is powered by the 15-volt at the same time. B+ is supplied to the start relay coil
source from the 1310. through the key switch start circuit and the start relay
Output Devices latches, allowing the key to be turned to the Run posi-
tion. Hold the key in the START position long enough
• Piezo beeper - driven by one 1310 digital output, pull- to hear the beep from the piezo buzzer, then release
down transistor. it. The 1310 has an output that holds the relay coil low
• Start relay - low side driven by 1310 digital output, side, low when it has started. The relay will drop out
pulldown transistor. if the battery disconnect button is depressed or if the
• Curtis 840 display - driven by RS232 serial communi- system recognizes a problem with truck operation that
cation from 1310. It is powered by the 15-volt source is unsafe or uncontrolled.
from the 1310.
BATTERY DISCHARGE INDICATOR (BDI)
ENCODER INTEGRITY
The battery state of charge is determined in the MCU
Steering and height encoders are tested continuously (1310) circuitry and software. The battery voltage is
for current draw. If the total current draw from the two sensed at the 1310. Flooded cell and maintenance-free
encoders and the Hall effect sensor is too high or too battery types can be accommodated by changing the
low, a fault will be generated and truck operation will setup parameters for reset and 80 percent discharge
be inhibited. Additional software continuously checks point (in volts/cell). Check with your battery manufac-
the output bit sequence activity of the steering input en- turer for recommended settings.
coder to ensure that both bits are operating.
MULTIFUNCTION DISPLAY
TEST ENCODERS
The Curtis 840 display is a dumb display, having eight
Conventional means can be used to diagnose the characters alphanumeric LCD and six LEDs. It displays
encoders as follows. Using a voltmeter, determine if BDI percentage Hours, Warnings, and Faults. It is used
5 volts and battery negative are going to each encoder during setup procedures to see menu and parameter
by back-probing the connector. If good, then connect to values.
one output channel and battery negative, and rotate the
2
2200 YRM 956 Setup
Setup
The setup mode is entered by starting the truck with 4. Cycle the throttle handle through a full range of mo-
the horn switch depressed, then releasing and quickly tion while observing the voltage displayed. Voltage
reapplying, then releasing again. This display is multi- should sweep smoothly from 1.2 volts in reverse to
functional with hourmeter, BDI, and the basic operator 3.8 volts in forward (±0.5 volt). If not, check mech-
feedback messages. There is no need for the Curtis anism and Hall effect sensor.
1307 handset. All adjustments are either mechanically
setup or electrically adjusted through the dash display 5. With the traction handle in NEUTRAL (do not move
setup mode. The throttle sensor setup is learned by the handle during this step), depress and release
stroking the handle to full forward and reverse. Me- the foot switch three times to enter the calibration
chanical adjustments are basic adjustments, such as step. The display will change to CyclePot.
mounting the proximity switch at the proper distance
6. Cycle the traction handle twice through its full
from the trip bar on the mast. The software automati-
range of motion within 10 seconds after completing
cally configures some adjustments. For example, it can
Step 5. After 10 seconds, the system will beep.
tell the difference between a Return-to-Center and Mul-
titurn Steering system and configures the truck auto- 7. The traction handle can now be used to navigate
matically. See Setup Instructions. the setup menu, using forward and reverse to scroll
through the parameters and using the lift/lower con-
SETUP INSTRUCTIONS trol to change parameter values. Where noted by
**, setup choices will be automatically set by the
NOTE: For all the display examples shown below, x’s
1310 based on autosensing of components on the
represent numerical values which will vary with param-
truck, but can be manually overridden in the setup
eter adjustments. Menu items requiring pass codes will
menu. Where noted by *, options will only appear in
not be visible if the option is not enabled.
the menu if they have been activated by passcodes.
1. Connect all electrical connections prior to initial Parameters with two choices (e.g., Return-to-Cen-
startup of 1310. If power must be applied (e.g., for ter vs. Multiturn steering) will have one choice se-
raising platform during assembly), do so with 1310 lected by the lowering control and the other se-
power disconnected. During initial startup, the lected by the lifting control. Check and adjust the
1310 senses system devices to determine option following parameters to match the truck configura-
configuration and initial calibrations. Be certain tion.
that the following are connected and/or adjusted
a. Hydraulic Hall effect sensor setup, HydPotSet
during initial startup:
(large chassis only):
a. Steering handle proximity switch (Self-Center-
(1) With the hydraulic knob in NEUTRAL (Do
ing only) connected and adjusted properly.
not move the knob during this step!), de-
b. Steering and Height encoders connected. press and release the foot switch three
times to enter the calibration step. The
c. Traction Hall effect sensor adjusted for center display will change to CyclePot.
and handle in neutral position (preadjust on
bench with 5 volts power supply to achieve 2.5 (2) Cycle the hydraulic knob twice through its
±0.2 volts at neutral). full range of motion within 10 seconds af-
ter completing Step (1). After 10 seconds,
2. Start truck. When starting, the key must be held the system will beep.
in the spring-loaded START position for approxi-
mately 0.5 second (until the system beeps), then b. Restore Defaults (Defaults): To clear memory
released. settings and restore defaults, scroll to this menu
selection then hold down the foot switch for 5
3. Wait for display to show "ThrtVxxx" (xxx equals seconds. The system will continuously beep
throttle Hall effect sensor voltage). The voltage during the clear step and display a countdown
displayed should be between 2.20 and 2.70 volts of the 5 seconds. After the countdown, the
at neutral. If not, loosen setscrews on throttle Hall truck will shut itself off. Restart the truck, then
effect sensor and adjust neutral voltage within this follow these instructions from the beginning.
range.
3
Setup 2200 YRM 956
c. **Small or large chassis truck (SmallBox or Lrg i. Steer adjustments:

Box). This parameter is automatically set to
large chassis if the variable valve Hall effect (1) Steer offset adjustment (Self-Centering
sensor is detected by the 1310. If the 1310 or Wire Guidance only) (StOf xxx): Ad-
runs through initial setup and selects the wrong justs tracking for straight-ahead travel
truck type, check voltage at pin J4-7 (should be in 0.01-degree increments. Truck must
0 volts for small chassis, 2.5 volts for large), be restarted after exiting setup mode for
correct any problems, then use Defaults to re- changes to take effect. Positive values
run initial setup. This is necessary for the cor- will offset steering center toward the right.
rect valves to be programmed into the 1243. Range 999 to +999 (±10 ), default 0.
d. 24- or 36-volt selection (large chassis only). (2) Steer gain adjustment (multiturn steering
only) (StrGnxxx): Adjusts how aggres-
e. **Return-to-Center or Multiturn steering: [Han- sively the steering responds to wheel in-
dlStr (RTC), [WheelStr (MTS)]. put (1-5). Defaults to 3.
f. Gear steer or chain steer selection: (Str Gear, j. *Steer maximum speed adjustment (1-5, Only
StrChain). of Self-Centering with wire guidance) (Str-
Max x): Adjusts maximum steer motor speed.
g. Mast type (Small Chassis) or truck type (Large Lower adjustments can be used to simulate
Chassis): performance of EPS II steering. Defaults to 4.
(1) Small Chassis: 2-Stage/3-Stage mast se- k. *Wire guidance, wire guidance-slowdown, or
lection (2-Stage or 3-Stage). This MUST non-guided selection (WG-Setup, WGS-Set, or
be set correctly to achieve the correct Non-Guid) Defaults to standard (Non-Guided).
speed vs. height relationships. Defaults Wire guidance-slowdown sets the truck to run
to 3-Stage. 3.54 km/h (2.2 mph) maximum in manual steer
mode if operating in a guided aisle. This is
(2) Large Chassis: Counterbalanced, strad-
also used to calibrate the wire guidance sen-
dle, or furniture selection (Cntr Bal, Strad-
sors and to force straight-ahead travel on a mul-
dle, or Furnitur). This MUST be set cor-
titurn truck.
rectly to achieve the correct speed vs.
height relationships. Defaults to Counter- To force straight-ahead travel (to check steer
balanced. offset on a multiturn truck):
h. Travel cutout options: (1) While WG-Setup or WGS-Set is dis-
played, depress and hold the foot switch,
(1) *Small Chassis: Travel over 150 inches
then depress the horn button. Steering
option. Will display Cutat150 if the stan-
will be disabled and speed restricted to
dard option is selected, or Trav>150 if
~2.2 mph.
travel over 150 inches is selected. Default
to Cutout at 150 inches. l. To run wire guidance calibration:
(2) *Large Chassis, counterbalanced: Travel (1) Exit the menu (using the horn button)
over 212 inches option. Will display Cu- while WG-Setup or WGS-Set is displayed
tat212 if the standard option is selected, and the wire guidance switch is off.
or Trav>212 if travel over 212 inches is se-
lected. Default to Cutout at 212 inches. (2) Proceed to the wire and center the wire
guidance sensors over the wire [center of
(3) *Large Chassis, Counterbalanced: Travel sensors within 3.175 mm (0.125 in.) of
over 272 inches option. Will display Cu- wire center].
tat272 if the standard option is selected,
or Trav>272 if travel over 272 inches is se- (3) Turn on wire guidance switch. Display
lected. Default to Cutout at 272 inches. should change to WG Calib for a few mo-
ments. If the calibration is successful, the
display will read Success!
4
2200 YRM 956 Setup
(4) Restart the truck (travel will be disabled t. *Lower Limit (LwrLmxxx): The lowering limit
while in calibration). setting in inches. Defaults to 0 inches.
m. *Wire Guidance Lead Distance (WgLd #): This u. Maximum speed limit 1-5 (MaxSpxxx): De-
value (1-20, default 6) is used in the calcula- faults to 5.
tions of steer angle based on wire guidance
sensor position. A shorter lead distance results v. Acceleration aggressiveness (1-5) (Accelxxx):
in the system attempting to steer the truck back Defaults to 4.
onto the wire in a shorter travel distance, re-
w. Neutral braking aggressiveness (1-5) (Nt-
sulting in more aggressive steering. High val-
Brkxxx): Defaults to 3.
ues may result in a slow wandering of the truck
around the center of the wire and low values x. Motion Alarm type (Alarm xx): Alarm types are
may cause the steering to react too quickly to as follows:
sense the wire. 0=no alarm
1=Backup (BU)
n. *Wire Guidance Steering Gain (WG Gn #): This
2=Forward (FWD)
value (1-10, default 4) is used to determine the
3=BU & FWD
responsiveness of the APS to steering com-
4=Lift
mands from the wire guidance unit. Higher
5=BU & Lift
gains may be necessary to overcome friction
6=FWD & Lift
of a large- or soft-drive tire.
7=BU, FWD, & Lift
o. Hydraulic Lift Ramp-in Adjustment [LftRpUp 8=Lower
(large chassis only)]: Ramp-in timing of hy- 9=BU & Lower
draulic lift valve. Affects how quickly full lift 10=FWD & Lower
speed is achieved when applying hoist. Lower 11=BU, FWD, & Lower
numbers yield a softer feel due to the slower 12=Lift & Lower
ramp rate, but slow the lift responsiveness. 13=BU, Lift, & Lower
Defaults to 3, range 1 to 5. 14=FWD, Lift, & Lower
15=BU, FWD, Lift, & Lower
p. Hydraulic Lift Ramp-down Adjustment [(LftR-
pDn) (large chassis only)]: Ramp-down timing y. *Foot Switch Hydraulic Interlock (HydIntOn or
of hydraulic lift valve. Affects how quickly the HydIntOff). If enabled, the operator must de-
platform stops when disengaging hoist. Lower press the foot switch to allow hydraulic func-
numbers yield a softer feel due to the slower tions.
ramp rate, but slow the lift responsiveness. De-
z. *Menu Password Lockout (MenuLkOn or
faults to 3, range 1 to 5.
MenuLkOf). If enabled, this forces the techni-
q. Hydraulic Lower Ramp-in Adjustment [(Lwr- cian to enter a password to access the setup
RpUp) (large chassis only)]: Ramp-in timing of menu.
hydraulic lowering valve. Affects how quickly
aa. *Selection of Menu Password (M# 16000): Use
full lowering speed is achieved. Lower num-
lift/lower control to scroll through the numbers
bers yield a softer feel due to the slower ramp
to the desired password. The password will be
rate, but slow the lowering responsiveness.
saved when the setup menu is exited using the
Defaults to 3, range 1 to 5.
horn button.
r. Hydraulic Lower Ramp-down Adjustment [Lwr-
ab. BDI Reset setting (RsBDIxxx). This is the bat-
RpDn (large chassis only)]: Ramp-down timing
tery level (in volts per cell, 0.01-volt increments)
of hydraulic lowering valve. Affects how quickly
necessary for a charged battery to reset the
the platform stops when disengaging lowering.
BDI to 100 percent. Default setting 2.09 volts,
Lower numbers yield a softer feel due to the
set to 2.19 volts for maintenance-free batteries.
slower ramp rate, but allow more overshoot.
Defaults to 3, range 1 to 5.
s. *Lift Limit (LftLmxxx): The lift limit setting in

inches. Defaults to 380 inches.
5
Setup 2200 YRM 956
ac. BDI Discharge (0%) setting (0%BDIxxx). This truck is restarted. Display items follow, show-
is the battery level (in volts per cell, 0.01-volt in- ing the message choice from the setup menu
crements) for a completely discharged battery. and the format of the value displayed in its run
• Default setting (1.79 volts) is for conventional mode.
(flooded cell) batteries.
• For Douglas™ maintenance-free batteries, (1) No Displ: No diagnostic display (normal
set to 1.98 volts. truck display).
• For GNB™ maintenance-free batteries, set
(2) ThrotVlt: Raw voltage from Hall effect
to 1.86 volts.
throttle pot, in 0.01-volt increments. Run
ad. Voltage Calibrations (Cal xxx): Truck voltage display: Thrtxxxx.
(as measured by the 1310) is displayed in 0.1-
(3) ThrotOut: Processed throttle output sent
volt increments. Connect a digital voltmeter to
to traction controller, 0 to ±100 percent
the 1310 B+ and B terminals. If the displayed
(negative value for reverse). Full throttle
value on the spyglass does not read within 0.3
values will be scaled below 100 percent
volt of the digital voltmeter, adjust using the lift/
for reduced-speed conditions (platform el-
lower controls.
evated or fault condition). Run display:
ae. Diagnostic Switch input display 1: Switch 1 Txxxxxx0.
is displayed for 1.5 seconds, followed by bi-
(4) StrInput: Steer command from the steer-
nary display of switch inputs 1-8 (example:
ing wheel sensor. Self-centering steer-
01100000). If a switch is on, its digit will be 1,
ing is expressed as requested angle in
otherwise 0. Switch inputs from left to right are:
0.01-degree increments, multiturn steer-
0 #1 Steer Handle Switch
ing is expressed as requested steer motor
1 #2 Side Gate Switch
rpm (proportional to steering wheel rpm).
1 #3 Slack Chain Switch
Run display: SxxxxxxI.
0 #4 Wire Guidance Switch
0 #5 Special Option Switch (5) StrPostn: Actual steer tire (MDU) angu-
0 #6 Horn Switch lar position, as reported by steering con-
0 #7 Foot Switch troller, in 0.01- degree increments. Run
0 #8 Lift Limit Override Switch display: SxxxxxxP.
In the display examples above, the Side Gate (6) StrSpeed: Actual steering motor speed
and Slack Chain switches are on and all the as reported by steering controller in rpm.
others are off. Run display: SxxxxxxS.
af. Diagnostic Switch input display 2: Switch 2 is (7) Lift Hgt: Current lift height from ground to
displayed for 1.5 seconds, followed by binary top of forks is measured in inches. Run
display of switch inputs (example: 00000110). display: FrkHtxxx.
If a switch is on, its digit will be 1, otherwise 0.
The only digits used are far right two digits, and (8) Enc Crnt: Measurement of current drawn
other digits may be 0 or 1. The lowering switch from 5-volt power supply by height and
is far right (#8), and the lifting switch is second steer encoders and throttle Hall effect
from right (#7). In the display example above, sensor. This current draw is monitored
the lift switch is on and the lowering switch is by the system to determine if an encoder
off. has become unplugged. During initial
setup of the truck, an initial reading of
ag. Running Diagnostic display: DiagDisp is dis- this current is taken. A fault is triggered
played for 1.5 seconds, followed by No Displ. if the measured current is detected be-
Several display choices (listed below) may then low 80 percent or above 120 percent of
be scrolled through using the lift and lower con- the initial value. Current is displayed in
trol. Select a display choice, then depress the analog-to-digital converter counts (pro-
horn button to exit the menu and return truck to portional to milliampere). Typical value
operating mode. The selected diagnostic dis- 350, minimum initial value 250. Run dis-
play item will be shown until the next time the play: EncCtxxx.
6
2200 YRM 956 Setup
(9) InitEncI: Initial (stored) value of encoder (19) WG Dist: Calculated distance from the
current (see above description of encoder guidance wire in millimeters. Displayed
current). Run display: InitIxxx. value will be from the fork-end sensor if
last traveling in that direction; otherwise
(10) BDI %: Actual percentage value of re- the MDU end sensor output. Run display
maining battery energy available (a pre- Dst xxxx.
cise display of coarse value displayed on
LEDs). Run display: 0000xxx%. (20) WG Dir: Vehicle direction used for calcu-
lating wire guidance steer output. Neutral
(11) Arm PWM: Traction motor armature duty = 0, Forward = 1, Reverse = 2.
cycle in percent. Value is proportional to
voltage applied to armature. Run display: (21) Diagnostic Switch input display 1: Switch
AxxxxxxV. 1 is displayed for 1.5 seconds, followed by
binary display of switch inputs 1-8 (exam-
(12) Arm Crnt: Traction motor armature cur- ple: 01100000). If a switch is on, its digit
rent measured in amperes. Negative val- will be 1, otherwise 0. Switch inputs left
ues shown during regenerative braking. to right are:
Run display: AxxxxxxC. 0 #1 Steer Handle Switch
1 #2 Side Gate Switch
(13) Fld PWM: Traction motor field duty cy-
1 #3 Slack Chain Switch
cle in percent. Value is proportional to
0 #4 Wire Guidance Switch
voltage applied to field. Run display:
0 #5 Special Option Switch
FxxxxxxV.
0 #6 Horn Switch
(14) Fld Crnt: Traction motor field current 0 #7 Foot Switch
measured in amperes. Negative values 0 #8 Lift Limit Override Switch
shown for reverse travel direction. Run
ah. Error Log: Use the lift and lower controls to
display: FxxxxxxC.
scroll through the log. Error codes will be pro-
(15) TrkVolts: Truck voltage as measured at vided in separate troubleshooting instructions.
the 1310 Master controller. Displayed in To clear the error log, hold down the foot switch
0.1-volt increments. Run display: Volt for 5 seconds. The system will continuously
xxx. beep during the clear step and display a count-
down of 5 seconds. Error codes listed in order
(16) 1243Inpt: Inputs into the 1243, displayed will be as follows:
in binary format (see diagnostic switch
display 1 above). Outputs listed (lowering (1) 1 xxxx E, where xxxx equals the most re-
valve, brake, horn) are displayed as a 1 cently stored error code.
if the component is connected but turned
(2) 1ErrCtxxx, where xxx equals the number
off, and displayed as a 0 if it is on or dis-
of occurrences of that error.
connected. Displayed are:
• #1 Lowering valve (3) 1Tmxxxxx, where xxxxx equals the
• #2 Brake hourmeter reading (in 0.1 hr) of the most
• #3 Horn recent occurrence.
• #8 Mast proximity sensor
Run display: xxxx xxx. (4) 1ErNdxx, where xx equals node of con-
troller which sent the error code. 1=1310,
(17) Hyd Volt: Raw voltage from Hall effect 5=1243, 6=Steer Controller, and 7=Wire
hydraulic input sensor in 0.01-volt incre- Guidance Unit.
ments. Run display HyPotxxx.
(5) Step (1) through Step (4) are repeated for
(18) HydValve: Processed signal sent to vari- error codes 2 through 5.
able hydraulic valve in increments of
0-32767. Run display Hydxxxxx. ai. Internal serial number of 1310 (Sr# xxxx), to en-
ter into Passkey program to obtain option en-
abling passcodes.
7
Power-On Self-Test 2200 YRM 956
aj. Erase Memory (EraseMem). To clear all mem- improper password is entered, the truck will
ory settings and restore defaults, scroll to this shut down.
menu selection, then hold down the foot switch
for 5 seconds. The system will continuously GENERAL DIAGNOSTICS
beep during the clear step and display a count-
down of 5 seconds. After the countdown, the Diagnostics are displayed on the 840 dash display.
truck will shut itself off. Restart the truck, then There is no need for a handset; however the Curtis
follow these instructions from the beginning. 1307 can be used in addition to the onboard diagnos-
tics. This is the same handset that the dealers already
ak. Entry of passcode numbers (PC#16000): Use have. No adjustments will be made with the Curtis
lift/lower control to scroll through the numbers handset; it will only be used for diagnostic purposes.
to the proper passcode, then depress the foot
switch to enter. While the foot switch is de- NOTE: If a traction controller handset is used for diag-
pressed, beeper will sound and confirmation nostics, start truck in setup menu. Then plug handset
message for the activated option will be dis- in and exit truck setup menu when handset has com-
played. Multiple passcodes may be entered, pleted bootup process. Failure to follow these steps
but are not saved until menu is exited with horn may cause the truck to display a height encoder error.
button. If an improper passcode is entered, the To clear the error, unplug handset, lift forks to 762 mm
truck will shut down. (30 in.), lower fully, then restart truck.
8. The setup menu can be entered at any time by start- Several levels of diagnostics are utilized. Extensive
ing the truck with the horn button depressed, then tests are completed on every truck startup. Run-time
releasing the horn button and reapplying it within diagnostic displays are available, displaying the oper-
0.5 second, then releasing again. If the Menu Pass- ating information (e.g., armature current) which would
word option is activated, see Step z; the following normally require a traction controller handset. During
applies: truck operations, error or warning conditions detected
by any of the controllers (steering, traction, or master
a. After entering the setup menu using the controllers) are logged in the error log (described below
horn button sequence, the display will show under setup menu diagnostics). Error codes and dis-
(PW#16000); use lift/lower control to scroll play messages are listed in the table for troubleshoot-
through the numbers to the proper password, ing.
then depress the foot switch to enter. If an
Power-On Self-Test
Power-on self-test is completed on every startup of the the truck with the switch/control engaged should result
truck. During startup, the operator must be off the foot in an appropriate message. Releasing the switch/con-
switch, the Return-to-Center handle (if equipped) must trol should turn off the beeper and message.
be in center (neutral) position, the accelerator handle
must be in center (neutral) position, the horn button and Also during power-on self-test, the 1243 traction con-
lift limit switch (optional) must be disengaged, and the troller checks for the presence of the EM brake, the
lift/lower control must not be engaged. If any of these horn, and the lowering solenoid. If any of these items
conditions are not met, the beeper will sound and an are missing or disconnected, an appropriate message
appropriate message (e.g., Foot Sw along with flashing is displayed.
red LED) will be displayed.
This feature may be used as a quick check if any of the

above inputs are suspected to be faulty. Simply starting
8
2200 YRM 956 SEM Traction Motor Controller
SEM Traction Motor Controller

The Curtis 1243 Separately Excited Motor (SEM) con- a short circuit, the high-current flow from the bat-
troller delivers a smooth, silent control of motor speed tery can cause a personal injury or property dam-
and torque. Full-bridge field winding control stage is age.
combined with a half-bridge armature power stage to
provide solid-state motor reversing and full regenera- 1. Disconnect and separate battery connector.
tive braking without additional relays or contactors. See
2. Unplug connector from traction motor controller.
Figure 1. There are no serviceable parts in the 1243
Tag and disconnect wires to terminals.
controller. No attempt should be made to open, repair,
or modify the controller. 3. Remove three capscrews and lockwashers and
carefully remove controller from lift truck.
INSTALL
1. Make certain the mounting surface for controller is
clean. There should be no dirt between the frame
and the controller. Apply heat-conductive grease
to bottom of controller. Align controller in lift truck
with holes on frame and install lockwashers and
capscrews; then tighten capscrews.
2. Connect wires and cables to the same terminals

as identified during the removal procedure. See
Wiring Schematics and Diagrams 8000 YRM
923.
3. See Setup in this section.
LOW-VOLTAGE PROTECTION FUNCTION

Figure 1. Transistor Motor Controller This function protects the controller and the battery.
The controller will not operate correctly if there is not a
The controller checks the following functions:
minimum voltage from the battery. The battery current
Checks the temperature and gives both low- and
drain increases as the battery voltage decreases. Too
high-temperature thermal protection to the controller.
large a battery drain will damage the battery. If the bat-
Electronically checks the traction circuit for malfunc-
tery voltage is low, the control circuit will decrease the
tions and prevents traction motor operation if a failure
ON TIME of the pulses to decrease the current drain.
occurs.
The battery can still operate the lift truck to move it for
Regulates the current in the motor circuit and auto-
battery charging or replacement.
matically decreases the motor voltage to reduce the
current and prevent damage. NOTE: The checks require a voltmeter with a meter
movement. Most digital meters will not operate cor-
CONTROLLER REMOVAL rectly for some of these checks. Specific checks require
additional equipment.
WARNING
Disconnect the battery and separate the connector
before opening the compartment cover or inspect-
ing/repairing the electrical system. If a tool causes
9
Checking Transistor Controller 2200 YRM 956
CHECKING CONTACTOR COILS the Operating Manual or the Periodic Maintenance

section of the Service Manual.
WARNING Check the main contactor coil with an ohmmeter. A
Disconnect the battery and separate the connector suppressor diode is connected across the coil termi-
before opening the drive unit compartment or in- nals. The diode will cause the ohmmeter to indicate
specting or repairing the electrical system. If a tool a difference in resistance in one direction. Reverse the
causes a short circuit, the high-current flow from probes of the ohmmeter to the opposite terminals and
the battery can cause a personal injury or property measure the resistance. Use the highest resistance in-
damage. dication. Replace the coil if the resistance readings are
a short circuit in both directions or if there is an open
WARNING circuit in both directions. Make sure the coil wires are
Some checks require the battery to be connected. connected again to the correct terminals. Refer to Con-
Do not connect the battery until the procedure tells tactors, General within this manual.
you to connect the battery. Make sure the drive
wheel is raised to prevent truck movement and pos-
sible injury. Raise the drive wheel as described in
Checking Transistor Controller

Make sure all checks are done with a fully charged bat- 2. Check for voltage between each terminal of the
tery. connector on the battery and a clean metal con-
nection on the frame of the lift truck. It is normal to
NOTE: The following checks must be done in the order measure some voltage between the battery and the
they are listed due to some steps depending on condi- frame even if the resistance checks are correct. If
tions set in previous steps. a voltage is detected, use an ammeter to measure
current flow. The current must not exceed 100 mil-
COMPONENT REPAIR AND TESTING liamperes. Current in excess of 100 milliamperes
can cause a problem.
1. To check for wire connections to the frame, com-
pletely disconnect the battery and use an ohmme-
ter to check the circuits. Check for 50,000 ohms or WARNING
more between each terminal of the lift truck portion Wear appropriate safety equipment and remove car-
of the battery connector and clean connection point bon dust from motors using dry, compressed air.
on the frame of lift truck. There should be no electri- Compressed air can cause personal injury or prop-
cal connections to the frame of the lift truck. Wires erty damage.
or terminals without insulation can cause electrical
connections to the frame. Isolators used to insulate If voltage is detected at the frame, check to be sure the
circuit boards from the frame that are missing, bro- battery is clean and not defective. Clean the battery and
ken, or installed incorrectly can also cause these battery compartment as required. A buildup of carbon
connections. dust in the electric motors can also cause measurable
voltage at the frame.
10
2200 YRM 956 Checking Transistor Controller
TROUBLESHOOTING 1. Check the specific gravity of the battery. If the spe-

cific gravity is less than 1.260, the battery is not fully
WARNING charged or has a defect. A fully charged battery has
a specific gravity of 1.270-1.290. A discharged bat-
Disconnect the battery and separate the connector
tery has a specific gravity of approximately 1.130.
before opening the drive unit compartment or in-
specting or repairing the electrical system. If a tool 2. The electric lift truck has an isolated electrical sys-
causes a short circuit, the high-current flow from tem. The frame must not be a common electrical
the battery can cause a personal injury or property path. Check for 50,000 ohms or more between
damage. each terminal of the battery connector for the lift
truck and a clean connection on the frame. Re-
WARNING move any circuit paths between the controller and
Some checks require the battery to be connected. the frame of the lift truck. Carbon dust in a motor
Do not connect the battery until the procedure tells or other parts can cause a circuit path. Check for
you to connect the battery. Make sure the drive additional equipment that is causing a circuit path
wheel is raised to prevent truck movement and pos- to the frame.
sible injury. Raise the drive wheel as described in
3. Check for voltage between each terminal of the
the Operating Manual or Periodic Maintenance 8000
connector that fastens to the battery and a clean
YRM 924.
connection on the frame. Normally there is some
small voltage between the battery and the frame
CAUTION even if the resistance is very high. The small volt-
The electrical system on this truck utilizes many age is normally less than 30 percent of the battery
control-level circuits (low voltage and current), voltage. A higher voltage can indicate a dirty bat-
which may be disturbed by contamination, wear, tery or a battery with a defect. Clean the battery
or damage at the electrical connections. When and battery compartment as necessary.
investigating problems or fault codes, it may be
beneficial to check and clean/repair all connections 4. Visually check for parts or wires that are loose or
in the affected circuit first. The use of dielectric damaged.
grease is recommended for all AMP™ and Molex™
NOTE: The correct meter polarity is necessary for the
electrical connectors when operating in adverse
checks. The voltage checks are made between the
environments (freezers or dirty areas).
point indicated in the troubleshooting chart and battery
negative. Connect the meter negative to battery nega-
CAUTION tive.
The fault detection software and circuits of the
NOTE: Make an identification of any wires before you
traction controller (Curtis 1243) are sensitive to
disconnect them. The wires must be connected cor-
abrupt changes in currents and voltages. Con-
rectly after checks or repairs.
troller fault codes may not necessarily indicate
a defective truck component or controller. Fault Table 1 contains a list of fault codes and display mes-
codes may be generated in response to extreme sages. Fault messages listed in the Display column
operating conditions, such as potholes or very low may be displayed while the truck is running. For com-
battery levels. plete instructions on how to retrieve fault codes, refer to
the Setup Instructions in this manual.
This section describes the most common faults that can
occur in the trucks with the Curtis Transistor Controller.
Use the fault procedure that best describes the prob-
lem.
11
FAULT CODES AND DISPLAY MESSAGES

Table 1. Fault Codes and Display Messages
Node
Code Display Description Items to Check If Code Is Displayed
or ND
SlackChn Slack chain circuit open Chains slack (carriage hung up on
lowering)
Slack chain switches functioning
Wiring between 1310 & slack chain
switches
SideGate Side gates up Side gate switches functioning
Wiring between 1310 & side gate
switches
HornOpen Horn disconnected (open circuit) Horn (bench test for function)
Wiring to horn
BrakOpen Brake disconnected (open circuit) Brake coil (bench test)
Wiring to brake
LowrOpen Lowering valve disconnected (open Lowering valve (bench test)
circuit)
Wiring to lowering valve
TractErr Misc. traction error Wiring to 1243
Foot Sw Foot switch off while requesting Use diagnostic display (switches) to
traction, hoist, or foot switch closed confirm switch functionality.
during startup sequence
Check switch function and wiring.
Low Batt Low battery warning, lift cutout, and If lift cutout occurs with true battery
speed reduced conditions too high or low, revise 0%
BDI setting.
LiftLimt Lift limit reached
LowrLimt Lowering limit reached
2041 5 Low Volt Traction-battery undervoltage Check for correct voltage battery.
CAUTION
The electrical system on this truck utilizes many control-level circuits (low voltage and current), which
may be disturbed by contamination, wear, or damage at the electrical connections. When investigating
problems or fault codes, it may be beneficial to first check and clean/repair all connections in the affected
circuit. The use of dielectric grease (Yale part number 580011639) is recommended for all AMP and Molex
electrical connectors when operating in adverse environments (freezers or dirty areas).
CAUTION
The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt
changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck
component or controller. Fault codes may be generated in response to extreme operating conditions,
such as potholes or very low battery levels.
12
Table 1. Fault Codes and Display Messages (Continued)
Node
or ND
2042 5 Hi Volt Traction-battery overvoltage Check for correct voltage battery.
2043 5 TractHot Traction: thermal cutback Check for mechanical resistance
(damaged load wheels, etc.).
Check for improper use conditions
(ramps, pushing loads).
2301 6 Str Crnt High current Mechanical binding of MDU.
2390 1 ChkEncdr Encoder supply current drop Wiring to steer & height encoders.
Steer & height encoders.
Check current draw using diagnostics
Enc Crnt.
2391 1 Enc Off? Encoder supply current too low on Steer & height encoders must be
initialization plugged in during initial setup of a new
1310
2392 1 Enc Crnt Encoder supply current too high Use diagnostic display to display
encoder current draw. Then unplug
individual encoders to determine which
encoder or wiring is drawing high
current.
3101 6 Str Volt High voltage Check voltage to steer controller.
4201 6 Str Temp High temp Check for mechanical resistance in
steering mechanism.
5001 7 Wire guidance unit, no signal from Check front antenna and wiring.
front antenna
5002 7 Wire guidance unit, no signal from rear Check rear antenna and wiring.
antenna
501A 6 MDU Prox Steer feedback sensor error Check MDU proximity sensor and
wiring.
CAUTION
CAUTION
13
Node
or ND
5021 6 StrMotor Steer motor error Check wiring to steer motor.
5022 6 StrSensr Steer Hall effect sensor error Check MDU proximity sensor and
wiring. Sensor gap should be 5 mm
(0.20 in.).
Check wiring for steering Hall effect
sensor.
5090 1 Lift Sw Lift switch shorted Lift switch & wiring.
5091 1 Lower Sw Lower switch shorted Lower switch & wiring.
5092 1 Steer Sw Steer handle proximity switch off Steer handle proximity switch & wiring.
(Self-centering) or steer handle
proximity switch on (Multiturn)
5590 1 MemErr1a Memory read warning-block 1 - unable Repeatedly discharging battery beyond
to start read process normal limits.
5591 1 MemErr1b Memory read warning-block 1 - unable Repeatedly discharging battery beyond
5592 1 MemEr_A3 Memory read warning-block 3 - unable Repeatedly discharging battery beyond
6011 5 TracSnsr Traction-current sensor fault Check cables between controller and
motor. If problem persists, replace
1243.
6013 5 M- Fault Traction M- fault Check cables between controller and
motor. Faults may occasionally occur in
good controllers due to abrupt changes
in wheel speed, such as driving over
breaks in the floor. If problem persists,
replace 1243.
6101 7 Wire guidance unit, software error Check wire guidance unit and wiring.
CAUTION
CAUTION
14
Node
or ND
6102 7 Wire guidance unit, software address Check wire guidance unit and wiring.
error
6103 7 Wire guidance unit, software time-out Check wire guidance unit and wiring.
error
6110 6 StrTmOut Steer initialization time-out Check MDU proximity and wiring.
Check that MDU can rotate freely.
6390 1 MemErr2a Memory read error from block Rerun truck initialization; if problem
3, unable to start read process, persists, replace 1310.
parameter loss
6391 1 MemErr2b Memory read error from block 3, Rerun truck initialization; if problem
unable to complete read process, persists, replace 1310.
parameter loss
parameter loss
parameter loss
parameter loss
parameter loss
6396 1 MemErr6a Memory read error from block 6, Rerun truck initialization; if problem
parameter loss
CAUTION
CAUTION
15
Node
or ND
parameter loss
7305 1 HtEnc Ch Height encoder error channel count Check wiring to encoder.
mismatch
Check both encoder output channels
using voltmeter, should pulse with
encoder rotation.
7306 1 StEnc Ch Steer encoder error channel count Check wiring to encoder.
mismatch
Check both encoder output channels
using voltmeter; voltmeter should pulse
with encoder rotation.
Check for chassis ground in contact
with encoder housing.
Check for wiring problems on external
1243 capacitor.
7307 1 SteerEnc Steer handle proximity sensor shorted Check steer handle proximity function
or steering encoder error using diagnostics switch 1.
Check steer encoder using StrInput in
diagnostics
Check wiring to steer handle proximity
& steering encoder.
7320 1 HtEncOff Height encoder not responding Check mast proximity switch.
(position sensor fault)
Check height encoder, using Lift Hgt
in diagnostics.
7390 1 Throttle Throttle potentiometer out of range Check wiring to throttle Hall effect
potentiometer.
Check throttle output using ThrotOut
in diagnostics.
CAUTION
CAUTION
16
Node
or ND
7391 1 Hyd Pot Hydraulic potentiometer out of range Check wiring to potentiometer.
7392 1 Mast Sw Height proximity not responding Mast proximity switch & wiring.
(encoder functions with lift/lower)
No handset connected.
7393 1 HtEncErr Running height encoder reset error Mast proximity switch & wiring.
Height encoder & wiring.
7394 1 HtEncErr Startup error on 24 in. height proximity Mast proximity switch & wiring.
switch state - switch was on when
truck last turned off, but is now off
No manual hoisting.
Height encoder & wiring.
739A 1 HtEncErr Height encoder error (lift/lower Can be caused by mast being raised
function called for, but encoder not while 1310 is not powered.
incrementing/decrementing)
Can be caused by starting truck with
handset plugged into 1243.
Use DiagDisp (1243Inpt) to confirm
proximity switch functioning when mast
raised/lowered past 24 in.
Check 24 in. proximity switch & wiring.
After verifying correct switch and
encoder function, lift forks above 30 in.,
lower fully, and restart truck to reset
error.
CAUTION
CAUTION
17
Node
or ND
739B 1 HtEncErr Height encoder error: On first proximity Use DiagDisp (Lift Hgt) to confirm
switch transition after truck startup, height incrementing/decrementing
indicated height was >29 in. when mast raised/lowered; if error
in effect, large height value may be
displayed, but it should still change
when lifting/lowering.
If displayed height does not change
with fork height, check height encoder
and wiring.
error.
CAUTION
CAUTION
18
Node
or ND
739C 1 HtEncErr Height encoder error: encoder Can be caused by starting truck with
indicated height <22 in. or >26 in. handset plugged into 1243.
when 24 in. proximity switch passed
Use DiagDisp (1243Inpt) to confirm
proximity switch functioning when mast
raised/lowered past 24 in.
Use DiagDisp (Lift Hgt) to confirm
height incrementing/decrementing
when mast raised/lowered; if error
in effect, large height value may be
displayed, but it should still change
when lifting/lowering.
If displayed height does not change
with fork height, check height encoder
and wiring
error.
739D 1 Throt Lo Throttle voltage too low Throttle mechanism out of adjustment:
check neutral position, calibrate throttle
Throttle Hall effect sensor & wiring.
739E 1 Throt Hi Throttle voltage too high Throttle mechanism out of adjustment:
check neutral position, calibrate
throttle.
Throttle Hall effect sensor & wiring.
CAUTION
CAUTION
19
Node
or ND
73A0 1 Hyd Lo Hydraulic potentiometer out of range - Use diagnostic display (Hyd Volt) to
low voltage confirm voltage output.
Check wiring to hydraulic Hall effect
potentiometer.
73A1 1 Hyd Hi Hydraulic potentiometer out of range Use Diagnostic Display (Hyd Volt) to
- high voltage confirm voltage output.
Check wiring to hydraulic Hall effect
potentiometer.
8012 5 TrctComm Traction-CAN communication fault CAN wiring to traction controller.
8031 5 Cnt Crnt Contactor coil or motor field Wiring shorted to traction contactor.
overcurrent
Contactor coil or suppressor shorted.
Traction motor field or wiring shorted.
8032 5 Cnt Coil Contactor coil open or traction Wiring open to traction contactor.
contactor shorted/welded
Traction contactor contacts welded.
Short from traction armature A2 to B+.
8033 5 Fld Open Field open Wiring from 1243 to motor field.
Motor field winding failure.
8034 5 TracCont Traction contactor missing Traction main fuse blown.
Traction contactor tips bad.
Traction contactor coil wiring
8101 6 Str Comm CAN open time-out CAN wiring to steering controller
CAUTION
CAUTION
20
Node
or ND
8190 1 SteerErr General steering error CAN wiring to steering controller
Wiring & fuse to steering controller
MDU proximity wiring
Wiring between steer controller &
motor.
8191 1 Comm Err Communication error CAN wiring
CAN time-out with multiple nodes
8192 1 TrctComm Communication error Fuse to traction controller.
CAN time-out with traction
CAN wiring to traction controller.
8193 1 Str Comm Communication error CAN wiring to steering controller.
CAN time-out with steering
Fuse to steering controller.
8194 1 SteerErr Steer error after startup CAN bus wiring to steer controller.
Faulty steer controller.
8195 1 SDO response from traction CAN wiring to traction controller.
Faulty traction controller.
8196 1 1243 PDO communication error CAN wiring to traction controller.
Faulty traction controller.
8197 1 TrctComm No communication from traction on Fuse to traction controller.
startup
CAN bus wiring to traction controller.
8198 1 Comm Off CAN system off on startup CAN bus wiring to 1310, steer, traction
controllers.
CAUTION
CAUTION
21
Contactor and Electrical Panel Checks 2200 YRM 956
Node
or ND
8199 1 WGU No communication from wire guidance CAN bus wiring to wire guidance unit.
Comm unit with wire guidance switch on
Power wiring and fuse to wire guidance
unit.
Faulty wire guidance unit.
9090 1 Shutdown due to initial height encoder Welded pump contactor.
movement
9091 1 SteerErr Steered wheel not responding to steer Mechanical binding of MDU.
input
9092 1 LostWire Wire guidance unit indicates truck off See wire guidance setup instructions.
guidepath
CAUTION
CAUTION
NOTE: If a traction controller handset is used for diag- may cause the truck to display a height encoder error.
nostics, start truck in setup menu; then plug handset To clear the error, unplug handset, lift forks to 762 mm
in and exit truck setup menu when handset has com- (30 in.), lower fully; then restart truck.
pleted bootup process. Failure to follow these steps
Contactor and Electrical Panel Checks

make an electrical connection and cause a per-
WARNING sonal injury.
Do not operate a lift truck that needs adjustment
or repairs. Report the need for adjustment or re-
pairs immediately. If adjustment or repair is neces- CAUTION
sary, put a DO NOT OPERATE tag on the instrument Correct multimeter polarity is necessary for some
panel. Remove the key from the key switch. checks. Meter positive is indicated as (+). Meter
negative is indicated as ( ).
WARNING Use a multimeter with a minimum rating of 20,000 ohms
Some of the checks are done with the battery per volt to make measurements. Most digital voltmeters
connected. Never have any metal on your fingers, are acceptable.
arms, or neck. These metal items can accidentally
22
2200 YRM 956 Contactor and Electrical Panel Checks
NOTE: To perform the following component tests or to CONTACTORS

replace any of the components, the drive unit compart-
ment doors must be opened and the drive unit compart- General
ment cover must be removed.
The contactor uses a low-amperage current to energize
FUSES a magnetic coil. This coil then creates a magnetic force
that draws the contact arms together, closing the cir-
All fuses are on the contactor panel. Ratings of the cuit for the high-amperage current, allowing it to flow
fuses are as follows: through the contactor.
Fuses Circuit Rating With the ignition switch turned OFF, the main contactor
has only the battery negative voltage applied. When the
FU-1 Traction 300A
ignition switch is turned ON, battery positive voltage is
FU-2 Pump 300A applied and the contactor is activated.
FU-3 Start Circuit 5A After the ignition switch is turned ON, the traction con-
FU-4 Operator Compartment 15A tactor and the lift pump contactor have battery positive
Light Fan and Flashing voltage applied to their high side. They are activated by
Light a low signal from the controller.
FU-5 APS Power 15A Test

FU-6 APS Power 15A
FU-7 MCU, LS3, WGU and 5A
WARNING
Indicator Parts of this procedure require working on the
truck with full electric current present. To prevent
personal injury or property damage, do not wear
Power for the APS steering motor controller is supplied a watch, rings, or jewelry while working around
by fuses FU-5 and FU-6. They are wired in parallel to the contactor panel. Whenever manually closing a
provide 30 amps to the controller so that if one blows, contactor with the power connected, use a properly
the other may too. Without this current, the controller insulated tool.
will be disabled. The MCU will sense that steering con-
1. Check condition of battery. If it is not fully charged,
troller is disabled and will not allow the drive motor to
recharge or replace battery with a fully charged bat-
work.
tery before continuing.
2. Raise drive wheel of truck so it is clear of the floor.

Block chassis in this position and remove lifting de-
vice.
3. Visually check to see if contactor closes when cir-

cuit is energized. If contactor closes, proceed to
Step 5. If contactor does not close, proceed to
Step 4.
4. Check for battery voltage at contactor coil.

No voltage: Open circuit in control circuit wiring
to contactor.
Low voltage: High resistance in control circuit
wiring to contactor.
Full battery voltage: No problem with control cir-
cuit. Problem is probably in contactor. Proceed
with test.
5. Check at the contactor for loose, broken, or cor-

roded connections.
Figure 2. Fuse Locations
23
Contactor and Electrical Panel Checks 2200 YRM 956
6. Visually check the condition of the tips for pitting, Tips

burning, or wear.
When replacing tips, make sure the new tips have the
7. Check ohm value of contactor coil. Disconnect same ampere carrying capacity and are direct replace-
leads from one side of the coil and connect an ments for the original tips.
ohmmeter across coil. Reverse ohmmeter leads
and check in the opposite polarity (since spike A high-voltage drop (2 volts or more) across the tips
suppressors on some coils make them polarity indicates poor contact or high resistance. Check for
sensitive). Compare ohm reading against ohm burned or worn tips, incorrect size or mismatched tips,
value for the type contactor. Use the highest rating. and proper gap settings when open.
See Coil Resistance.
Disassemble and Assemble
Table 2. Coil Resistance
WARNING
24v Coil 36v Coil Disconnect the battery and separate the connector
Resis- Resis- before opening the drive unit and compartment
Loca-
Device tance tance Notes and inspecting or repairing the electrical system.
tion
@ 21 C @ 21 C If a tool causes a short circuit, the high-current
(70 F) (70 F) flow from the battery can cause a personal injury
Truck Contac- 44 ohms 103 Test coil or property damage.
main tor panel ±8 ohms ohms ±8 both
contac- ohms ways. NOTE: If both the contacts and coil of a contactor will be
tor Use replaced, replace the complete contactor as described
highest in Replacing the Contactor. Do only the parts of the pro-
reading. cedure necessary to replace the defective parts being
replaced.
Traction Contac- 44 ohms 103 Test coil
contactor panel ±8 ohms ohms ±8 both NOTE: All of the contacts for each contactor must be
tor ohms ways. replaced at the same time if any contact requires re-
Use placement.
highest
reading. The contactor contacts are made of special silver alloy.
The contacts may look black and rough from normal
Lift Contac- 17 ohms 35 ohms Test coil operation. This condition does not cause problems with
pump tor panel ±4 ohms ±4 ohms both the operation of the lift truck. Cleaning is not necessary.
contac- ways. DO NOT USE A FILE ON THE CONTACTS. DO NOT
tor Use LUBRICATE THE CONTACTS. Replace contacts when
highest the silver alloy is worn away to the base support metal.
reading. Replace contactor parts as follows:
Lower On 40 ohms 64 ohms Test coil 1. Make an identification of the buss bars for correct
solenoid pump ±10 ±10 both installation. Remove nuts that fasten fixed contacts.
valve assem- ohms ohms ways.
bly Use 2. Remove two screws that fasten covers for each
highest contactor. See Figure 3. Remove cover of each
reading. contactor. Do NOT lose plunger springs.
Start Under 360 360 Termi-
3. Replace two fixed contacts in contactor covers.
relay dash ohms ohms nals 85
cover ±65 ±65 and 86 4. Remove plunger assembly and movable contact
near key ohms ohms are the and replace fixed contact bar. Replace contact of
switch coil. plungers.
Brake On top 17 ohms 27 ohms
of drive ±4 ohms ±4 ohms
motor
24
2200 YRM 956 Contactor and Electrical Panel Checks
5. If a coil will be replaced, remove cover base.

Remove screws that fasten coil frame to mount
bracket. Remove coil and frame. Remove bushing
part of plunger and armature cap from coil. Install
these parts on the replacement coil.
6. Install coil and frame on mount bracket.
7. Install cover base, fixed contact bar, and plunger on

coil frame. Make sure spring is on plunger.
8. Install covers and electrical bars on covers as re-

moved during disassembly.
9. Install contactor assemblies on the lift truck.
1. FIXED CONTACT 5. RETURN SPRING

2. MOVING CONTACT 6. COIL AND FRAME
3. TOP COVER 7. END CAP
4. SCREW - TOP
COVER
Figure 3. Contactor
25
Traction Throttle Sensor Removal and Installation 2200 YRM 956
Traction Throttle Sensor Removal and Installation

1. Disconnect battery.
WARNING
The operator platform can move abruptly and can 2. Remove four capscrews that fasten console panel
cause personal injury when any lift or lower but- cover.
tons are accidently pushed. Fully lower the op-
erator platform and remove the key from the key 3. Disconnect electrical plug.
switch, disconnect the battery, and install a DO NOT
4. Remove nut that holds sensor on bracket. See Fig-
OPERATE tag on the instrument panel.
ure 4.
WARNING 5. Install new sensor into opening of bracket support.

Align sensor on bracket and tighten nut.
The traction throttle sensor is a Hall effect device.
The sensor provides a voltage output ratio (typi- 6. Connect electrical plug.
cally 5 volts) as a function of mechanical angle to
the shaft as it rotates. The sensor operates on low 7. Install instrument panel cover on cowl.
supply voltage and is limited to short mechanical
angles, requiring less than 180-degree rotation. 8. Reconnect the battery.
9. Go to the Setup Instructions.

WARNING
Disconnect the battery connector to prevent opera-
tion of the hydraulic system or electrical shock and
possible injury.
26
2200 YRM 956 Traction Throttle Sensor Removal and Installation
1. SUPPORT BRACKET 9. RETURN SPRING 17. HALL EFFECT SENSOR

2. BRACKET ASSEMBLY 10. THREADED STANDOFF BRACKET
3. BUTTON HEAD SCREW 11. SCREW 18. SCREW
4. NYLON BEARING 12. WASHER 19. RUBBER GROMMET
5. SHAFT CONTROL HANDLE 13. HALL EFFECT SENSOR 20. NUT
6. WASHER 14. CAM ASSEMBLY 21. SETSCREW
7. SPACER 15. CAPSCREW 22. HANDLE BODY
8. ROLL PIN 16. BUSHING
Figure 4. Control Handle Mechanism
27
Steering Indicator Gauge 2200 YRM 956
Instrument Panel Removal and Installation

3. Remove four screws that fasten instrument panel to
WARNING console.
Always disconnect the battery ground cable before
making repairs to prevent possible damage and in- 4. Align instrument panel on console and install cap-
jury. Install a tag on the battery terminal so that no screws.
one connects the cable on the terminal.
5. Install instrument panel cover.
6. Connect battery.
2. Remove four capscrews that fasten console panel
cover.
Key Switch Removal and Installation

REMOVE 9. Identify and disconnect electrical wires to switch.
1. Move lift truck to a safe area. INSTALL

2. Block drive wheel to prevent truck from rolling. 1. Connect wires to proper terminals.
3. Disconnect battery connectors and turn key switch 2. Mount key switch in bracket.
to OFF position.
3. Install nut to retain key switch. Make certain switch
4. Remove instrument panel. See Instrument Panel is properly aligned before tightening retaining nut.
Removal and Installation.
4. Install instrument panel. See Instrument Panel Re-
5. Remove cover. moval and Installation.
6. Discharge the capacitors inside the controller. 5. Connect battery connectors.
7. Remove nut retaining key switch to bracket. 6. Test key switch by turning it ON and OFF.
8. Remove key switch. 7. Install cover.
Steering Indicator Gauge

TEST 3. Remove nuts and lockwashers retaining indicator
gauge to instrument panel.
The steering indicator gauge can be tested using
the schematics. See Wiring Schematics and Dia- 4. Install gauge on instrument panel. Make certain
grams 8000 YRM 958. gauge is properly aligned.
REMOVE AND INSTALL 5. Install wires on proper terminals.
1. Remove instrument panel. See Instrument Panel 6. Install instrument panel. See Instrument Panel Re-
Removal and Installation. moval and Installation.
2. Identify and disconnect wires.
28
2200 YRM 956 Foot Switch Removal and Installation
Spy Glass Removal and Installation

1. Disconnect 8-pin plug. 3. Install gauge in instrument panel by reversing the
order of removal.
2. Remove hex nuts and washers holding retaining
bracket. Remove bracket and gauge from instru- 4. Reconnect 8-pin plug.
ment panel.
Foot Switch Removal and Installation

1. Remove nut from bottom of foot switch assembly. 3. Remove screws that fasten switch in housing and
See Figure 5. remove switch.
2. Unplug Molex™ switch so wires can be removed 4. Install new switch and wire connector. Install screw
and connected during installation. at bottom of plate and connect connector.
1. FOOT SWITCH ASSEMBLY 2. MOLEX™ CONNECTOR
Figure 5. Foot Switch
29
Limit Switch Removal and Installation 2200 YRM 956
Slack Chain Switch Removal and Installation

5. Install replacement switch on bracket. Attach
WARNING switch to switch bracket. Adjust switch to provide
To replace the loose chain switches, the operator proper contact of cam to chain anchor. Repeat
platform must be raised to provide access. The operation for second switch.
lowering of the operator platform can cause an in-
jury. The operator platform must have a support or 6. Connect wires to switch terminals as marked during
a chain to prevent the operator platform from low- removal.
ering.
The loose chain switches are at the chain anchors on

the mast side of the operator platform. See Figure 6.
1. Raise operator platform for access to loose chain

switches. Block operator platform or use chains
to prevent operator platform from lowering. The
chains must be fastened to the operator platform
and to a part of the mast that cannot move.
WARNING
making repairs to prevent possible damage and in-
jury. Install a tag on the battery terminal so that no
3. Install labels on wires for correct connection during

installation. Remove wires from switch terminals. 1. SWITCH BRACKET 3. CHAIN ANCHOR
2. SWITCH
4. Remove nuts that fasten switches to bracket and
remove switches. Figure 6. Loose Chain Switch
Limit Switch Removal and Installation

WARNING WARNING
The operator platform can move abruptly and cause Always disconnect the battery ground cable before
an injury when any lift or lower buttons are acciden- making repairs to prevent possible damage and in-
tally pushed. Fully lower the operator platform, Re- jury. Install a tag on the battery terminal so that no
move the key from the key switch and install a DO one connects the cable on the terminal.
NOT OPERATE tag on the instrument panel.
3. Disconnect battery. Disconnect limit switch con-
1. Raise and block mast and operator platform high nector.
enough to gain access to the 24-inch limit switch
located on a bracket welded to the bottom of the 4. Loosen and remove nut retaining switch on front of
mast. See Figure 7. bracket. Remove switch from bracket.
2. Remove top cover and open compartment doors. 5. Reverse above procedure to assemble and install.
6. When installing limit switch, the distance between

target and sensor should be 14 mm (0.55 in.).
30
2200 YRM 956 Drive and Hydraulic Pump Motors
Figure 7. 24-Inch Limit Switch
Drive and Hydraulic Pump Motors

ROUTINE PREVENTIVE MAINTENANCE 3. Check bearings for retention of lubricant.
4. Check to make sure pole pieces are tight.

WARNING
Compressed air can move particles and cause in- 5. Inspect brushes. Brushes must be replaced
jury to the user or to other personnel. Make sure when they are worn to one-half their original
compressed air path is away from all personnel. length. When replacing brushes, make certain
Wear eye protection. ALL brushes are changed and properly seated.
Brushes must be able to move freely. Make sure
they are not too tight in the brush holders.
CAUTION
Make sure motor covers, if used, are replaced be- 6. Visually inspect the commutator. Commutator
fore operating truck. should be smooth, with a chocolate brown color.
1. Periodically blow out all motors with clean, dry com- 7. When ordering motor parts, be sure to state both
pressed air. model and serial numbers of truck, model number
of motor, and voltage.
2. Check for oil or dirt in motor.
31
Drive and Hydraulic Pump Motors 2200 YRM 956
Preventive maintenance on electric motors is recom- CONNECTIONS

mended to be performed at 200-hour intervals under
normal operating conditions. Check every screw, bolt, and nut for tightness. Es-
pecially check pigtails of the brushes, brush holders,
Under heavy-duty, dusty, and dirty conditions, preven- power lead connections, and field jumper connections.
tive maintenance on electric motors must be performed
more frequently, depending on the conditions and the DISCOLORATION AND BURN MARKS
environment in which the electric truck is running.
Discoloration and burn marks usually indicate the
Proper electric motor preventive maintenance will aid in motor or certain components of the motor have been
detecting many problems before they become serious. overheated, normally due to stalled conditions, loose
connections, insulation breakdown, or contamination.
Maximum performance from electric motors and If signs of overheating are present, determine the
reduced maintenance costs can be obtained by per- cause and perform necessary repairs. The commuta-
forming the following periodic preventive maintenance tor should be smooth, free of burn marks, and have a
checks on motors that are in the truck. chocolate brown color. Inspect brushes, brush holders,
brush springs, and insulation for discoloration.
Preventive Maintenance Checks
BRUSHES
WARNING
Brushes should be inspected to make certain they are
not worn to less than one-half original length; see DC
Motors 620 YRM 294. The brushes must be free to
jury. Install a tag on the battery terminal so that no
move in the brush holders and should not have too
much clearance. Check brush springs for proper ten-
1. Disconnect battery while checking electrical con- sion. If brushes have to be replaced, use only specified
nection. brushes for a specific motor.
2. Open cover for access to drive motor. SHORT IN ARMATURE

3. Open cover for access to hydraulic pump motor. A shorted armature or coils will increase the current
draw. A visual inspection of the commutator will show
CLEANLINESS burn marks on the commutator bars connected to the
shorted coil or coils.
WARNING
Compressed air can move particles and cause in-
COMMUTATOR
jury to the user or to other personnel. Make sure Check that carbon dust and other foreign matter is not
compressed air path is away from all personnel. caked on the undercut mica between the copper bars.
Wear eye protection.
The mica separators should be below the segment face.
Cleaning solvents can be flammable and toxic and There should not be any thrown solder from the ar-
can cause skin irritation. When using cleaning mature risers. Check that brazed connections are not
solvents, always follow the solvent manufacturer’s loose.
recommended safety precautions.
If grease, oil, or corrosive materials are present, wipe
Electric motors must be kept clean and dry internally clean with a cloth, wash with soap and water, and dry
and externally and must be free of dust, dirt, grease, or blow dry surface. Clean up the surface of the commu-
oil, chemicals, moisture, water, carbon dust, and metal- tator with a commercially available commutator stone if
lic chips. Blow off contamination with compressed air. necessary. Take the necessary steps to prevent reap-
If internal oil or grease contamination is present, the pearance.
motor should be disassembled and the individual parts
washed in a suitable cleaning solvent.
32
2200 YRM 956 Causes of Motor Failure
BEARINGS high-temperature lubricants should be used if replace-

ment is required. Do not be misled by identifying
Check bearings for noise and rough spots while ar- numbers on the bearings. The high-temperature lubri-
mature is rotating. Inspect bearings for damaged cant is not specified in the identification number.
seals. Only original equipment sealed bearings with
Causes of Motor Failure

OVERLOAD and undercutting of the commutator may be all that is
required, provided the damage is not too great. Check
Motors have a specific rating of voltage and current at for damage from shunts hitting the commutator.
which they are designed to operate. Should a motor be
subjected to a severe overload for substantial periods HIGH OR LOW COMMUTATOR BAR
of time, overheating will result. Pushing loads, working
on ramps of too steep a grade, and attempting to lift When one of the bars is protruding above or lying be-
loads greater than the capacity of the truck are just a few low the normal diameter of the commutator, the result is
overload conditions. The end result of this overheating excessive brush wear and arcing of the brushes. Usu-
is the throwing out of solder in the commutator riser ally a clicking sound will be heard when the armature is
and bearing failure due to excessive heat. Also, thrown rotating.
or lifted commutator bars or insulation breakdown may
occur. OPEN CIRCUIT
SHOCK LOADING An open circuit in the field or armature coils of the motor.
Shock loading can result from severe (stiff) plugging of LOW BATTERY VOLTAGE
the drive motor. This will cause excessive current draw,
as the motor at the time of plugging is at stall point. Low voltage causes excessive current draw and in-
Breaking of the armature shaft could result from severe creased heating. Also, accelerated brush wear may
plugging. occur.
SHORT IN FIELD COILS ECCENTRICITY OF COMMUTATOR
A short in the field coil or coils causes excessive current Eccentricity of commutator causes rapid brush wear,
draw, again resulting in too much heat. When the truck excessive sparking of brushes, and increased heating.
runs faster than normal, but with little or no torque, it is
an indication of a short in the field coils. OVERSPEEDING
Overspeeding of the motor by pushing or towing of the
SHORT BRUSHES truck at more than 5 mph will result in failure of the ar-
Short brushes cause arcing on the commutator and ex- mature.
cessive heat. In addition to brush replacement, turning
33
Motor Tests 2200 YRM 956
Motor Tests
When testing electric motors for grounds and shorts in A motor drawing excessive current can usually be iden-
the truck, disconnect all armature and field leads from tified by two dark burn marks on the commutator 90
the motor. Use an ohmmeter, RX 10 or RX 100 scale, degrees or 180 degrees apart. If a motor draws too
to check for grounds or shorts in the motor. much current due to excessive ramp operation, push-
ing loads, or being stalled, heat damage will occur.
The ohmmeter should indicate:
Current draw is measured with a shunt-type ammeter
1. A closed circuit between armature terminals. in series with the motor. The meter should be capa-
ble of reading 600 amps. A 600-ampere shunt meter
2. A closed circuit between field terminals.
suitable for this purpose is available through your Yale
3. Infinity between motor housing and armature termi- dealer. Since current draw is measured with the shunt
nals, with meter on high-resistance scale. meter wired in series with the motor circuit, you must
break the circuit to insert the meter. This will require
4. Infinity between armature and field terminals. disconnecting the main power cable to the motor and
connecting the meter in line at this point. In most cases,
EXCESSIVE CURRENT DRAW this will require the use of a jumper cable between the
meter and the truck terminal post. This jumper should
Excessive current draw is usually caused by shorts be made from the same type and gauge cable as the
in the system allowing current to follow paths that are power cable it is replacing and should be kept as short
not intended. Sometimes excessive current draw can as practical.
be caused by mechanical malfunctions such as worn
bearings, misaligned parts, improper lubrication, and Current draw may also be measured using the on-board
brake adjustments. Other factors include operator mis- diagnostics. Refer to Setup Instructions.
use such as operating on steep grades, overloading the
truck, and pushing loads. The condition of the battery EXCESSIVE RESISTANCE
can contribute greatly to excessive current draw. When
the battery charge and voltage are low, more current Excessive resistance is usually caused by loose or cor-
is needed to perform the same task. Since the power roded terminal connections, poor solder joints, and dirty
required to move a load is Power = Volts × Amperage, or corroded contacts. Incorrectly sized wiring and poor
as the battery voltage goes down, the amperage must crimp connections of terminals can also cause exces-
increase to maintain power. sive resistance.
When too much resistance exists in a circuit, overheat-

MEASURING CURRENT DRAW
ing and sluggish or erratic operation will occur.
When troubleshooting the electrical system of a bat-
tery-powered industrial truck, you will need to know the BRUSH SPRINGS
specified current draw of the motor being tested as well
The brush springs should be inspected. If the springs
as the actual current draw during the test. If a motor
are found to be broken or discolored, they must be re-
draws too much current, excessive heat is created, re-
placed. Be certain to replace the springs with the rec-
sulting in damage to the commutator, brushes, arma-
ommended spring listed in the parts manual.
ture, and related components.
34
2200 YRM 956 Drive Motor
Drive Motor
INSPECT 3. Undercut the mica using one of the several types
of undercutting tools available on the market. See
1. Check commutator for grounds, shorts, or uneven Figure 8. Undercutting is usually done to a depth
wear. of 1.1938 mm (0.047 in.). It is recommended to
slightly bevel the segment corners.
2. Check bearings; replace if worn or damaged.
3. Check field coils. WARNING

4. Check brush holder/assembly. Compressed air can move particles and cause in-
jury to the user or to other personnel. Make sure
5. Replace lock nut on commutator end of armature compressed air path is away from all personnel.
shaft. Wear eye protection.
PREPARATION OF DRIVE MOTOR 4. A commutator that is badly grooved should be

ground or turned the same as for roughness or
COMMUTATOR eccentricity. After the commutator has been con-
To ensure the best possible operation from newly fitted ditioned, make sure it is completely cleaned out
brushes, the commutator should be in good condition. by suction (preferred) or by blowing out with clean,
dry compressed air.
Check commutator for:
• Dirt or other foreign matter
• Eccentricity:
0.05 mm (0.002 in.) max runout from shaft - motors
up to 185.7 mm (7.311 in.) diameter
0.08 mm (0.003 in.) max runout from shaft - motors
larger than 185.7 mm (7.311 in.) diameter
• High or low bars, roughness, or burning
• High mica
• Grooving of commutator
If any of the above conditions exist, they should be

remedied as follows:
1. Clean commutator by holding a piece of dry canvas

or other hard nonlinting material, which is wound
around and securely fastened to a piece of wood,
against the commutator. A. RIGHT WAY
USING UNDERCUTTING TOOL
2. If the eccentricity or roughness is not too great, it REMOVES ALL TRACES OF INSULATOR
may be possible to polish the commutator with one ALONG THE CONDUCTING SLOTS.
of several varieties of dressing stones available on B. WRONG WAY
USING HACKSAW MAY LEAVE
the market. Before stoning, clean grease and oil RIDGES OF INSULATOR ALONG THE EDGES
from commutator using a cloth saturated with a suit- OF THE CONDUCTING SLOTS, CAUSING
able solution. After stoning, the commutator should ARCING, CHATTER, AND RAPID BRUSH WEAR.
be smoothed with a very fine grade of sandpaper,
1. CONDUCTOR 2. INSULATOR
and then polished by using the back of the paper.
When the commutator is too rough or eccentric to Figure 8. Undercutting Commutator
be stoned, it is advisable to turn the commutator on
a lathe.
35
Drive Motor Brush and Brush Holder 2200 YRM 956
Fitting Motor Brushes (Motor Removed)

1. Care taken to ensure the best possible commuta- against brush). Use several strokes of the sandpa-
tor and brush running conditions, mechanical and per, pulled in the direction the commutator rotates
otherwise, will pay dividends along improved com- with the forward direction of the truck (drive motor),
mutation. and in the direction in which the commutator rotates
while hoisting (hoist pump motor). Only the pres-
2. Brushes of different qualities should never be run sure of the brush should be on the sandpaper when
together on the same commutator. Using brushes it is fitted in this matter. Make sure that the com-
of improper compound, or brushes other than those plete surface of the brush rides on the cleaned-up
originally specified and manufactured for a specific surface of the commutator.
motor, will cause commutator damage.
3. Before installing brushes, inspect the brush holders WARNING

inside and out for burned spots. Make sure the Compressed air can move particles and cause in-
brush pigtails are properly secured in the brushes jury to the user or to other personnel. Make sure
and the brushes move freely in the brush holders. compressed air path is away from all personnel.
Wear eye protection.
4. Fit new brushes to the commutator surface by us-
ing a strip of fine sandpaper placed between the 5. Following the installation of new brushes, the motor
face of the brush and the commutator (sand surface should be blown out with clean, dry compressed air.
Drive Motor Brush and Brush Holder

DRIVE MOTOR BRUSH, REMOVE AND DRIVE MOTOR BRUSH HOLDER, REMOVE
INSTALL (MOTOR INSTALLED) AND INSTALL (MOTOR INSTALLED)
WARNING WARNING
Always disconnect the battery ground cable before Always disconnect the battery ground cable before
making repairs to prevent possible damage and in- making repairs to prevent possible damage and in-
jury. Install a tag on the battery terminal so that no jury. Install a tag on the battery terminal so that no
one connects the cable on the terminal. one connects the cable on the terminal.
1. Disconnect battery and open drive unit compart- 1. Disconnect battery and open drive unit compart-
ment door. ment door.
2. Remove screws securing motor cover plates, if 2. Remove brush assemblies. Refer to Drive Motor
equipped. Brush, Remove and Install (Motor Installed).
3. Note position of brush and wire assemblies before 3. Scribe motor field ring housing and commutator
removing. When installing brush set, be certain end head to make certain end head is installed in
to place brush set and wires in same position as same position as removed.
removed.
4. Tag and disconnect drive motor wires from termi-
4. Loosen screw and washer securing brush wire to nals on end head.
terminal. Remove brush springs and brush set.
5. Remove hex head screws securing end head to
5. Reverse above to install. Refer to Fitting Motor field ring.
Brushes (Motor Removed).
6. Remove end head assembly.
36
2200 YRM 956 Drive Motor Disassembly and Assembly
NOTE: It may be necessary to use a puller to start the 8. Reverse above to install. Be sure the new brush
end head off the bearing when removing. Do not force, holders are rigid, not sloppy, and there are no loose
or damage to the end head may result. rivets.
7. Remove screws securing brush holder assembly to NOTE: Do not force end head on when installing.
end head. Inspect all parts for wear or damage and Lightly tap using a plastic hammer.
replace when necessary.
Drive Motor Disassembly and Assembly

8. Remove elastic stopnut and gear and shims, if nec-
WARNING essary, using a socket and impact wrench.
making repairs to prevent possible damage and in- NOTE: When same motor pinion or gear is used,
jury. Install a tag on the battery terminal so that no replace shim or shims in same position as removed.
one connects the cable on the terminal. When a new gear set is used, refer to Drive Unit for
gear setting. See Master Drive Unit 630 YRM 1021.
CAUTION 9. Remove screws securing commutator end head.
Be sure to cover the drive unit opening so debris Remove end head. It may be necessary to use a
does not enter it. puller to remove the end head. Do not apply force,
or damage to the end head may result.
10. Remove screws securing drive end head. Tap end
2. Open drive unit compartment. head loose using a plastic hammer and remove,
3. Tag and disconnect power cables to motor and complete with armature.
wires to electric brake and drive motor.
CAUTION
4. Remove bolts mounting motor to drive unit.
Be extremely careful not to damage the field coils,
pole pieces, or armature when removing.
WARNING
To prevent serious personal injury and possible 11. Remove oil seal and outer snap ring retaining ar-
damage to components, be very careful when us- mature shaft. Remove inner snap ring retaining end
ing lifting devices during service and maintenance head.
procedures
• Inspect to make sure that neither lifting strap is CAUTION
damaged Do not force, or damage to the end head may result.
• Do not subject lifting loops or lifting straps to any
shock or drop loading 12. Separate drive end head from armature. The bear-
ing end head will come off with the bearing. It may
5. Remove drive motor with brake assembly in place be necessary to use a puller to remove.
using a sling and proper lifting equipment. Refer to
manual for brake disassembly. See Electric Brake 13. Remove screws securing brush holder assembly
System 1800 YRM 761. to commutator end head. Remove brush holder
assembly.
6. Clean and punch-mark (or scribe) brake assembly,
drive and commutator end heads, and motor field 14. Remove bearings from end heads if necessary.
ring housing to simplify assembly of the motor.
7. Remove brushes and brush spring assemblies.

See Figure 9.
37
Drive Motor Disassembly and Assembly 2200 YRM 956
Figure 9. Drive Motor
38
2200 YRM 956 Hoist Pump Motors
Legend for Figure 9

1. TOLERANCE RING 14. LOCKWASHER 27. SCREW
2. FAN 15. NUT 28. BRUSH
3. DRIVE BEARING RING 16. NUT 29. BRUSH SPRING
4. ARMATURE 17. SPRING RING 30. BALL BEARING
5. HOUSING 18. WASHER 31. SCREW
6. SCREW 19. WASHER 32. WASHER
7. LOCKWASHER 20. ISOLATION DISK 33. CAPSCREW
8. ISOLATION DISK 21. SCREW 34. NUT
9. SPRING RING 22. SNAP RING 35. POLE PIECE
10. NUT 23. COMMUTATOR 36. CAPSCREW
11. WASHER 24. COMMUTATOR 37. FIELD COIL
12. DISK 25. SNAP RING 38. CAPSCREW
13. NUT 26. PLATE
15. Replace field coils when necessary. Refer to Drive 18. Continue to assemble motor in the reverse steps
Motor, Inspect. of the disassembly. Install new elastic stopnut to
secure motor pinion gear.
16. Install bearing on shaft.
19. Reverse the procedure to install the drive motor.
17. Install snap ring into slot provided in armature shaft.
Hoist Pump Motors

MAINTENANCE INSTRUCTIONS CAUTION
Vendor-supplied pump motors are generally used Never run a pump motor for more than a few sec-
where smaller pump requirements are found. Typical onds without the pump attached and connected.
vendor-supplied motors include those from General
4. Series-wound DC motors, without a load, may ac-
Electric™, Ohio Motor™, etc. Service requirements
celerate beyond their designed maximum rpm, at
are similar for all DC motors, but several differences
which point they will self-destruct.
should be observed.
1. Some vendor-supplied motors require removal of GENERAL INFORMATION

the commutator end head to replace the brushes
1. Lubrication - Prelubricated ball bearings are sup-
(see following procedure).
plied. Replace only with original equipment. Press
2. Many vendor-supplied motors have an integral only on the inner race when installing bearings on
cooling fan on the armature shaft. This means the shaft.
that the armature can only be removed through the
2. Motor brushes need periodic inspection and re-
drive end of the motor, since the fan would interfere
placement. Brush wear is greatly influenced by
with the field coils if you try to remove it through
individual application, so it is recommended the
the commutator end.
brush wear be checked often to determine future
required inspections. When the brushes are worn
CAUTION to half their original length, they should be replaced.
Do not attempt to press the armature shaft out of
the armature on vendor-supplied motors without 3. If mechanical or electrical failure occurs, first
first checking your service parts manual. check for proper electrical connections, fusing, or
unusual binding of the shaft. Starting and acceler-
3. Some motors do not have a separate serviceable ating torques of DC motors are considerably higher
armature shaft, and attempting to press the shaft than the full load torque of the motor. Care should
out will destroy the armature. be taken to prevent damage to driven machinery
as a result of the higher starting and accelerating
torques. Perform motor tests as outlined in this
section.
39
Hoist Pump Motors 2200 YRM 956
BRUSH REPLACEMENT 2. Loosen screw securing cover band and slide off
band.
WARNING 3. Remove brush springs and brushes. See Fig-
Always disconnect the battery ground cable before ure 10.
jury. Install a tag on the battery terminal so that no 4. Remove two screws and nuts securing stator and
one connects the cable on the terminal. commutator end head together. Remove cap-
screws and nuts retaining drive end head and
1. Disconnect battery. Open drive unit compartment commutator end head to stator. Carefully remove
doors. Remove drive unit compartment top cover. commutator end head. Remove brush ring and
brushes.
2. Remove cover from commutator end head.
5. Remove drive end head. Remove armature from
3. Remove brush springs and brushes.
stator.
4. Inspect brushes for excessive wear.
CAUTION
5. Reverse above steps to assemble.
Be extremely careful not to damage the field coils,
HOIST MOTOR pole pieces, or armature when removing.
6. If the field coil must be replaced, remove pole shoe

Remove and Install screws and terminal screws, if necessary, and re-
move field coils.
WARNING
Always disconnect the battery ground cable before 7. Inspect all components and brushes. Replace as
making repairs to prevent possible damage and in- necessary. Refer to Brush Replacement in this sec-
jury. Install a tag on the battery terminal so that no tion.
WARNING
Compressed air can move particles and cause in-
2. Remove pump mounting bolts. jury to the user or to other personnel. Make sure
compressed air path is away from all personnel.
3. Move hoist pump away from motor. Wear eye protection.
4. Identify and remove power cables. 8. Using compressed air, blow out motor. Thoroughly
clean and replace any worn parts.
5. Remove four hex head screws securing hoist motor
to truck frame. 9. Reverse steps above to assemble. Make sure ar-
mature turns freely.
6. Reverse the above steps to install motor.
Disassemble and Assemble

1. Punch-mark end heads and frame to ensure correct
placement of end heads when reassembling motor.
40
2200 YRM 956 Hoist Pump Motors
1. ARMATURE ASSEMBLY 15. NUT

2. FRAME 16. DISC (SPRING)
3. SCREW 17. BUSHING
4. BALL BEARING 18. BRUSH HOLDER
5. WASHER 19. LOCKWASHER
6. BEARING 20. WASHER
7. COVER 21. SCREW
8. BEARING 22. BRUSH
9. BALL BEARING 23. LOCKRING
10. SCREW 24. SCREW
11. BRUSH CONNECTION 25. LOCKWASHER
12. WASHER (TOOTH) 26. LOCKWASHER
13. NUT 27. SPRING
14. LOCKWASHER
Figure 10. Hoist Pump Motor Parts
41
NOTES
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42
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 956 8/03 (7/03)(7/02) Printed in U.S.A.

Electrical System Os-Ss030be (d826)

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Maintenance

PART NO. 524164050 2200 YRM 956

• 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

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

• 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.

Major Electrical System Features........................................................................................................................ 1

©2003 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

Major Electrical System Features

c. **Small or large chassis truck (SmallBox or Lrg i. Steer adjustments:

s. *Lift Limit (LftLmxxx): The lift limit setting in

This feature may be used as a quick check if any of the

SEM Traction Motor Controller

2. Connect wires and cables to the same terminals

3. See Setup in this section.

LOW-VOLTAGE PROTECTION FUNCTION

CHECKING CONTACTOR COILS the Operating Manual or the Periodic Maintenance

Checking Transistor Controller

TROUBLESHOOTING 1. Check the specific gravity of the battery. If the spe-

FAULT CODES AND DISPLAY MESSAGES

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Table 1. Fault Codes and Display Messages (Continued)

Contactor and Electrical Panel Checks

NOTE: To perform the following component tests or to CONTACTORS

FU-5 APS Power 15A Test

2. Raise drive wheel of truck so it is clear of the floor.

3. Visually check to see if contactor closes when cir-

4. Check for battery voltage at contactor coil.

5. Check at the contactor for loose, broken, or cor-

6. Visually check the condition of the tips for pitting, Tips

5. If a coil will be replaced, remove cover base.

6. Install coil and frame on mount bracket.

7. Install cover base, fixed contact bar, and plunger on

8. Install covers and electrical bars on covers as re-

9. Install contactor assemblies on the lift truck.

1. FIXED CONTACT 5. RETURN SPRING

Traction Throttle Sensor Removal and Installation

WARNING 5. Install new sensor into opening of bracket support.

9. Go to the Setup Instructions.

1. SUPPORT BRACKET 9. RETURN SPRING 17. HALL EFFECT SENSOR

Figure 4. Control Handle Mechanism

Instrument Panel Removal and Installation

Key Switch Removal and Installation

1. Move lift truck to a safe area. INSTALL

Steering Indicator Gauge

REMOVE AND INSTALL 5. Install wires on proper terminals.

2. Identify and disconnect wires.

Spy Glass Removal and Installation

Foot Switch Removal and Installation

1. FOOT SWITCH ASSEMBLY 2. MOLEX™ CONNECTOR