You are on page 1of 82

Maintenance

CONTROLLER
DIAGNOSTICS
MPE060-F [C896];
MPE060-F [D896];
MPE060-VG [B292];
MPE080-VG [B287]

PART NO. 550091264 9000 YRM 1660


SAFETY PRECAUTIONS
TROUBLESHOOTING PROCEDURES
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use 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 re-
move 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 man-
ual:

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

CAUTION
Indicates a condition that can cause property damage!

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Controller Diagnostics Table of Contents

TABLE OF CONTENTS

SECTION 9030 - ELECTRICAL SYSTEM


Group 03 - General Maintenance and Diagnostic Data.....................................................................9030-03-1
Group 20 - Diagnostic Trouble Codes............................................................................................... 9030-20-1

This section is for the following models:

(MPE060-F ) [C896];
(MPE060-F ) [D896];
(MPE060-VG ) [B292];
(MPE080-VG ) [B287]

©2017 Yale Materials Handling Corp. i


How To Use This Troubleshooting Manual Controller Diagnostics

How To Use This Troubleshooting Manual


GENERAL INSTRUCTIONS AND SAFETY Groups: The 9030 Electrical System is divided into
INFORMATION two groups that identify specific electrical trouble-
shooting procedures.
WARNING • 03 – General Maintenance/Diagnostic Data
The General Maintenance and Diagnostic Data
DO NOT add to or modify the lift truck. Any modi-
group includes general troubleshooting, dis-
fication that affects the safe operation of the truck
charging the capacitors, basic electrical trou-
cannot be undertaken without written authoriza-
bleshooting, multiplexing, User Iterface, and
tion of the Yale company.
status codes and descriptions.
Any change to the lift truck, the tires, or its equip- • 20 – Diagnostic Trouble Codes
ment can change the lifting capacity. The lift truck The Diagnostic Trouble Codes group includes
must be rated as equipped and the nameplate all troubleshooting procedures for status codes
must show the new rating capacity. reported by a given Node or system.

For a listing of all Diagnostic Trouble Codes and de-


WARNING
scriptions, see the section of this manual.
The technician must be aware of, and follow, all
general safety precautions that are published in
GENERAL INSTRUCTIONS
the Operating Manual and that are posted as
Safety Decals on and in the lift truck. 1. Become familiar with the content, layout, and
access provisions of data in this manual. This
Before starting, the technician should be familiar with will improve your efficiency and decrease the
certain policies, requirements, and instructions used time required to resolve the problems.
in the troubleshooting procedures. Using the trouble-
shooting procedures correctly helps the technician to 2. Once you begin a troubleshooting procedure,
perform the procedure safely and prevents damage to do not skip steps.
the machine and support equipment. 3. If you reach the end of a procedure without re-
solving the problem and you are not directed to
HOW TO USE DIAGNOSTIC another procedure contact Resident Service
TROUBLESHOOTING MANUAL Engineering through the Contact Management
System.
Manual Layout: 4. Do not limit yourself, remember to apply your
own experience and knowledge to assist in re-
Section: This manual consists of one section which is solving the problems, but do not compromise
further divided into groups. safety in doing so.
• 9030 – Electrical System 5. Most of the cross-reference data in the manual
will be electronically linked for rapid and easy
access. Use the links wherever the cursor
highlights an item as a linkable option.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
ii
SECTION 9030

ELECTRICAL SYSTEM

TABLE OF CONTENTS

Group 03 - General Maintenance and Diagnostic Data


General Troubleshooting.................................................................................................................... 9030-03-1
Discharging the Capacitors.................................................................................................................9030-03-2
Electrical Test Equipment................................................................................................................... 9030-03-3
PC Service Tool..............................................................................................................................9030-03-3
Digital Multimeter (DMM)................................................................................................................9030-03-3
Jumper Wires, Test Leads, and Test Lights................................................................................... 9030-03-3
Basic Electrical Troubleshooting............................................................................................................. 9030-03-4
Electrical Checks................................................................................................................................ 9030-03-4
Voltage Checks.............................................................................................................................. 9030-03-4
Amperage Checks..........................................................................................................................9030-03-4
Resistance Checks.........................................................................................................................9030-03-4
Contactor and Contactor Coil Checks............................................................................................ 9030-03-5
Multiplexing............................................................................................................................................. 9030-03-5
Multiplexing and the CANbus............................................................................................................. 9030-03-5
Troubleshooting the CANbus......................................................................................................... 9030-03-5
User Interface..........................................................................................................................................9030-03-6
User Interface, Setup, and Troubleshooting....................................................................................... 9030-03-6
Button Keypad................................................................................................................................9030-03-6
LED Indicator Lights....................................................................................................................... 9030-03-6
LCD Screen....................................................................................................................................9030-03-6
Dash Display Access......................................................................................................................9030-03-7
Status Code Toggling.....................................................................................................................9030-03-7
Automatic Diagnostics....................................................................................................................9030-03-7
Status Code Indication................................................................................................................... 9030-03-7
Status Codes and Descriptions...............................................................................................................9030-03-7
Status Codes...................................................................................................................................... 9030-03-7
Status Code Descriptions................................................................................................................... 9030-03-8
Group 20 - Diagnostic Trouble Codes
DTC xx100 - CANBus Communications - Combi....................................................................................9030-20-2
DTC xx104 - CANBus Communications - Steer......................................................................................9030-20-5
DTC xx106 - CANBus Communications - Handle...................................................................................9030-20-8
DTC xx109 - CANBus Communications - Display................................................................................ 9030-20-11
Lower Coil:
DTC 32003 - Combination - Lower Coil - Circuit
DTC 32004 - Combination - Lower Coil - Short................................................................................ 9030-20-13
Load Hold Coil:
DTC 32005 - Combi - Load Hold - Circuit
DTC 32006 - Combi - Load Hold - Short.......................................................................................... 9030-20-15
Main Contactor Coil:
DTC 32033 - Combi - Main Cont Coil - Circuit
DTC 32034 - Combi - Main Cont Coil - Short................................................................................... 9030-20-17
Audible Alarm:
DTC 32037 - Combi - Audible Alarm - Circuit
DTC 32038 - Combi - Audible Alarm - Short.................................................................................... 9030-20-19

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-1
Visible Alarm:
DTC 32039 - Combi - Visible Alarm - Circuit
DTC 32040 - Combi - Visible Alarm - Short......................................................................................9030-20-21
ACC Coil:
DTC 32041 - Combi - ACC Coil - Circuit
DTC 32042 - Combi - ACC Coil - Short............................................................................................ 9030-20-23
Traction Motor:
DTC 32060 - Combi - Traction Motor - Circuit
DTC 32061 - Combi - Traction Motor - Open................................................................................... 9030-20-25
DTC 32062 - Combi - Traction Motor - Encoder................................................................................... 9030-20-27
Main Contactor:
DTC 32067 - Combi - Main Contactor - Welded Tips
DTC 32068 - Combi - Main Contactor - Not Closed......................................................................... 9030-20-29
Capacitor Charge:
DTC 32069 - Combi - Capacitor - Charge........................................................................................ 9030-20-31
DTC 32085 - Combi - Key input - Voltage Low..................................................................................... 9030-20-33
DC Bus Voltage:
DTC 32086 - Combi - DC Bus - Voltage Low
DTC 32087 - Combi - DC Bus - Voltage High.................................................................................. 9030-20-35
Lift/Lower Release :
DTC 32200 - Combi - Release - Lift/Lower.......................................................................................9030-20-37
Handle/Throttle Release (Metal Tiller):
DTC 32201 - Combi - Release - Throttle
DTC 32211 - Combi - Handle - Release...........................................................................................9030-20-40
Handle/Throttle Release (Metal Tiller):
DTC 32052 - Combi - Throttle - Sensor
DTC 32201 - Combi - Release - Throttle
DTC 32211 - Combi - Release - Handle...........................................................................................9030-20-43
DTC 32208 - Combi - Release - ACC................................................................................................... 9030-20-46
Belly Switch:
DTC 32050 - Combi - Belly - Mismatch
DTC 32210 - Combi - Belly - Release.............................................................................................. 9030-20-49
Pick Release:
DTC 32212 - Combi - Release - Pick............................................................................................... 9030-20-51
Regen Release :
DTC 32215 - Combi - Release - Regen............................................................................................9030-20-54
Rabbit Release :
DTC 32216 - Combi - Release - Rabbit............................................................................................9030-20-56
DTC 32227 - Traction - Motor - Stalled................................................................................................. 9030-20-58
DTC 40074 - Steer - Motor - Stalled..................................................................................................... 9030-20-61

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-2
Electrical System General Maintenance and Diagnostic Data

Group 03

General Maintenance and Diagnostic Data

GENERAL TROUBLESHOOTING Begin the troubleshooting process by carefully in-


specting the wiring involving the device or devices no-
In the event the lift truck does not operate correctly, a ted by the onboard diagnostic system. .
status code is displayed on the display panel. Once
the status code is obtained, follow the procedures out- The controllers are sealed units with no serviceable
lined in this manual only after reviewing the following components. Troubleshooting is usually limited to ac-
information regarding the truck’s unique electrical sys- cessing status codes and following the diagnostic pro-
tem and troubleshooting procedures. cedure provided for each status code.

NOTE: Due to the interaction of the Combination Use standard testing procedures to verify inputs and
controller with all truck functions, almost any status outputs when necessary.
code or controller fault could be caused by an internal
failure of the Combination controller. After all other
status code procedures have been followed and no CAUTION
problem is found, the Combination controller should Never attempt to probe through the back of the
be tested and replaced as the last option to correct connector plugs of the motor controller. These
the problem. plugs are special sealed plugs. Probing through
the back of the plugs will destroy the seal and can
The onboard diagnostic system employed on the ve- cause a short circuit. If a circuit must be tested for
hicle can assist in the troubleshooting process. Read voltage, check for voltage at an amp-type plug, a
and be familiar with the instructions for accessing and switch, or component. If a circuit is suspect,
using the display's diagnostic system in User Inter- check the circuit for continuity by disconnecting
face Service Technician 2200YRM1659 . the plug and testing continuity from the front (pin
end) of the plug.
Prior to troubleshooting systems and components on
the vehicle, ensure the battery voltage is correct and Standard probes are too large to be inserted into
within specifications. Make sure the battery connector the center of female pins (sockets) of the special
contacts are clean of corrosion and the battery polar- sealed plugs and can damage or expand the pins.
ity within the connector is correct. Inspect that all Expanded pins will not provide good connections
fuses are correct and are not the cause of component once the plug is reconnected. The connectors are
failure. Ensure the key switch is in the ON position shaped to allow the insertion of a small flat-blade
when conducting voltage checks or verifying the oper- screwdriver into the connector. After inserting the
ation of a component. Make sure the brake switch screwdriver into the connector, attach probes
and the operator presence switch, if equipped, are with alligator clips to the shank of the screwdriver
functioning properly and are closed. to obtain readings.

Many faults noted by lift truck’s electrical system may Refer to 8000 YRM 1643 for wiring diagrams and ad-
be the result of loose wiring connections and/or bro- ditional circuit information.
ken or shorted wiring within the lift truck.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-1
General Maintenance and Diagnostic Data Electrical System

DISCHARGING THE CAPACITORS Never short any controller terminal or motor ter-
minal to the battery. Make sure to use proper pro-
When working with the electrical systems of the truck, cedure when servicing the controller.
it is necessary to discharge the internal or external ca-
pacitors of the controllers associated with each circuit 1. Move the lift truck to a safe, level area and com-
affected. pletely lower the forks. Turn the key switch to the
OFF position and attach a DO NOT OPERATE
tag to the control handle. Block the drive wheel to
WARNING prevent unexpected movement.
DO NOT make repairs or adjustments unless you
2. Disconnect the battery power cable connector
have been properly trained and authorized to do
from the truck connector located on the top-left
so. Improper repairs and adjustments can create
side of the frame. Pull the battery cable connector
dangerous operating conditions. DO NOT operate
handle to separate the battery connector from the
a lift truck that needs repairs. Report the need for
truck connector.
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the 3. Remove the operator compartment cover.
control handle and disconnect the battery.
4. Discharge the internal or external capacitors in
Disconnect the battery and discharge the internal the controllers by connecting a 200-ohm, 2-watt
or external capacitors before opening any com- resistor across the controller B(+) and B(-) termi-
partment covers or inspecting or repairing the nals of the combination controller. Remove the re-
electrical system. DO NOT place tools on top of sistor after discharging the capacitors. See Fig-
the battery. If a tool causes a short circuit, the ure 9030-03-1.
high current flow from the battery can cause per-
sonal injury or property damage.

Some checks and adjustments are performed with


the battery connected. DO NOT connect the bat-
tery until the procedure instructs you to do so.
Never wear jewelry or other metallic items on your
fingers, arms, or neck when working near electri-
cal components. Metal items can accidentally
make an electrical connection and cause injury.

Before performing any tests or adjustments, block


the lift truck to prevent unexpected movement.

The capacitors in the transistor controllers can


hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and
personal injury, discharge the internal or external
capacitors before inspecting or repairing any
component in the electrical compartments. Make
certain that the battery has been disconnected.

DO NOT short across the motor controller termi-


nals with a screwdriver or jumper wire.

1. COMBINATION CONTROLLER
CAUTION 2. POSITIVE CONNECTION B(+)
To avoid controller damage, always disconnect 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
the battery, discharge the internal or external ca- 5. NEGATIVE CONNECTION B(-)
pacitors, and never put power to the controller
while any power wires are disconnected. Figure 9030-03-1. Discharging the Internal
Capacitors

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-2
Electrical System General Maintenance and Diagnostic Data

Jumper Wires, Test Leads, and Test Lights


ELECTRICAL TEST EQUIPMENT
When using jumper wires, test leads, and test lights,
Before beginning intrusive circuit checks, verify the take care not to force tips into connector sockets. Use
vehicle battery state of charge. Visually inspect sus- appropriate clips and adapters to prevent damage to
pected connectors for loose, damaged, or corroded connectors. Expanded or damaged sockets can
terminals. Check for blown fuses and inspect circuits cause poor continuity between connections.
for cause of overcurrent conditions. Physically check
mechanical operation to ensure a switch, relay, or sol- Jumper wires allow testing across a suspected open
enoid is not sticking or damaged. in the circuit. Jumper wires can be used for located
opens, shorts, and performing voltage drops. If a cir-
NOTE: Measuring continuity between two terminals cuit operates correctly with the jumper wire in place,
of a switch while operating the switch will determine and is faulty when the jumper wire is removed, a fault
its functionality. can be found in the bypassed location.

Jumper wires can also be used to eliminate sections


PC Service Tool of the circuit to diagnose either power or grounds. Us-
ing the jumper wire to provide a component a known
The PC Service Tool is a Windows based service ap- good ground can help reduce the amount of checks
plication that is used to communicate with the truck’s needed to diagnose a circuit.
electrical control system. It can be used to monitor the
status and condition of various systems. With this ca- Jumper wires can be used to bypass components
pability, the PC Service Tool can be used to monitor such as switches. If a faulty switch is suspected, re-
component operation, or determine if abnormal moving it from the circuit with a jumper wire can deter-
events have occurred in the truck, and assist with di- mine if a switch or component is at fault.
agnostics and troubleshooting.
Jumper wires can be used to check for open or faulty
Digital Multimeter (DMM) relay contacts which are often sealed and can take
additional steps to properly diagnose.
Digital multimeters provide several measurement
functions in one tool. A DMM should be capable of ac- Test lights can be used when quick voltage or ground
curately measuring voltage, amperage, and resist- checks are necessary. Many features operate on
ance. Ensure that the multimeter used in trouble- switched voltage, and using a test light as a load de-
shooting procedures is accurate and that the test vice may be helpful. The test light may also be used
leads do not have excessive resistance. A faulty me- to verify continuity to B-. Discretion should be used
ter or damaged test leads will cause inaccurate read- when troubleshooting a circuit using a test light, as
ings and incorrect electrical diagnoses. the light may illuminate even though there may be an
excessive amount of resistance on the ground circuit
or when a low voltage or amperage situation exists.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-3
General Maintenance and Diagnostic Data Electrical System

Basic Electrical Troubleshooting


ELECTRICAL CHECKS Amperage Checks

The following electrical checks are used to diagnose An ammeter is used to measure amperage or current
circuit and component faults on trucks. Review the fol- flow through a circuit. An ampere is the measurement
lowing information so that it may be applied when di- of electron flow, which can be used to measure the
agnosing a fault or status code. amount of electrons that are flowing through a circuit.
Ohm’s Law states that current flow in a circuit is equal
Voltage Checks to the circuit voltage divided by total circuit resistance,
known as the potential difference. Since amperage is
Voltage is electrical pressure or force that pushes cur- the current in the circuit, increasing voltage also in-
rent through a circuit. The force is measured in volts. creases the current, or amperage levels.

Low voltage to a load device will cause the device to Measuring amperage is always performed by placing
be inoperative or operate poorly. This can be caused the ammeter in series with the device or circuit. This
by a low battery source, high circuit resistance, poor will cause all current to flow through the protected me-
connections, or an open circuit; the resistance of poor ter. The circuit must be operating in order to measure
connections or poor ground acts as an additional load amperage. Never measure amperage on high amper-
in the circuit, causing low voltage pushing current, or age circuits or in parallel to a circuit, this can result in
amperage, through a device. the damage of the meter and the electrical system.

A voltmeter is used to perform: Resistance Checks


• Measurement of force
The ohmmeter is used to measure a circuit or device's
• Presence of voltage resistance in ohms. Ohmmeters use low internal volt-
• Voltage drops age and current which flow through an isolated circuit
or device being tested. The voltage of the meter bat-
When using a voltmeter to determine if voltage is tery and the amount of current flow in the circuit are
present and capable of operating a device, connect used to calculate the circuit’s resistance. It is neces-
the positive meter lead to the power circuit of a de- sary to disconnect or isolate the circuit being test so
vice’s connector and connect the negative meter lead not to damage the vehicle’s electrical system or the
to the negative battery terminal. ohmmeter.

Measuring the voltage drop is performed by connect- An ohmmeter is used to perform:


ing the positive test lead to the positive side of the de- • Resistance of a load device
vice while simultaneously connecting the negative
meter lead to the negative side of the device. The test • Resistance of conductors
can also be performed across a section of wire that is • Value of resistors
faulty and suspected of having excessive resistance. • Operation of variable resistors
A voltage drop must be performed while the device is
operating. In a circuit with a single load device, the • CANbus termination resistors
device will drop the total voltage of the circuit. If the • Continuity
device drops less than battery voltage, it can be as-
sumed that the circuits are using the remaining volt-
age as a source of excessive resistance or a poor
connection exists, assuming the battery state-of-
charge is correct.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-4
Electrical System General Maintenance and Diagnostic Data

Contactor and Contactor Coil Checks Is resistance <1 ohm?

1. Measure voltage between the coil's positive termi- YES- Proceed to Step 3.
nal and B(-).
NO- Inspect ground control circuit. Verify that control-
NOTE: Key in ON position.
ler is receiving device input signal.
Is voltage same as truck's battery voltage?
3. Measure battery voltage between main contac-
tor's battery B(+) terminal and B(-).
YES- Proceed to Step 2.
NOTE: Key in ON position.
NO- Inspect the Coil's battery B(+) input circuit for
open or short. Is voltage same as truck's battery voltage?

2. Disconnect coil's ground control circuit. Measure YES- Repair or replace faulty contactor.
resistance between ground circuit terminal and
B(-). NO- Inspect main contactor battery cable for loose,
damaged, or corroded connections.
NOTE: Actuate coil ground control.

Multiplexing
MULTIPLEXING AND THE CANBUS If both CAN HI and CAN LO have consistent 2.5 volt,
there is no communication on the CANbus.
Controller Area Network (CAN) Bus communication
allows multiple modules to communicate with each If CAN HI is shorted to B(-) or CAN LO is shorted to
other using the same digital data on a shared net- battery voltage, network communication will stop.
work, this method of communication is known as mul-
tiplexing. The CANbus is a pair of twisted insulated If you measure battery voltage on the data link, there
wires that interconnect all the modules on the net- is a short to power in the circuit.
work. The data transmitted is a digital encoded for-
mat. Digital means only two states are used to trans- If you measure 0 volts while the CANBus is active,
mit data, High/On and Low/Off. This eliminates the there is a short to B(-) or an open in the circuit.
need for each module to be hard wired to each sen-
sor. Using Multiplexing, sensor information that may Internal control module failures can stop the entire
be received by one module, can then be shared with network from communicating. If there are no harness
all other modules. The information is sent out over the problems, disconnect control modules one at a time
CANbus in an encoded form and any other module until CANbus communication returns.
that requires the information can pick it out from the
data stream. With both 120 ohm termination resistors connected to
the CANbus, resistance between the two circuits
Troubleshooting the CANbus should read 60 ohms.

NOTE: Refer to the latest Diagram YRM for the most If CANbus resistance is 120 ohms, there is an open
current circuit information. circuit or a termination resistor is missing.

When the CANbus is active and modules are commu- If resistance is 0 ohms, the two circuits are shorted to-
nicating, CAN HI and CAN LO voltage will be approxi- gether.
mately 5 volts when added together.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-5
General Maintenance and Diagnostic Data Electrical System

1. Measure voltage between the diagnostic connec- NO- Inspect the CAN LO circuit for open or short; If
tor, socket A and B(-). voltage is 0 volts, the CAN LO circuit is shorted to
B(-) or open. If voltage is above 5 volts, the CAN
NOTE: Key in ON position. LO is shorted to power.
Is voltage approximately 2.5 volts? 3. Measure resistance between the diagnostic con-
nector, socket A and socket B.
YES- Proceed to Step 2.
Is resistance 60 ± 6 ohms?
NO- Inspect CAN HI circuit for open or short; if volt-
age is 0 volts, the CAN HI circuit is shorted to B(-) YES- CANbus communication is operating cor-
or open. If voltage is above 5 volts, the CAN HI is rectly.
shorted to power.
NO- If resistance is 120 ohms; the CANbus has an
2. Measure voltage between the diagnostic connec- open circuit, missing, or damaged termination re-
tor, socket B and B(-). sistor. If resistance is 0 ohms, the CANbus circuits
are shorted together. If resistance is open; the CAN
NOTE: Key in ON position.
HI and/or CAN LO connection to the diagnostic port
Is voltage approximately 2.5 volts? may be open. Use the wiring diagrams to detect
and correct open circuit.
YES- Disconnect the battery and proceed Step 3.

User Interface
USER INTERFACE, SETUP, AND • Wrench Indicator
TROUBLESHOOTING • Temperature Indicator

The dash display has a LCD screen for displaying • Operator Symbol
truck system information. The display has five indica- • Warning Indicator
tor lights for truck function status. There are five num-
ber keys for password. Number keys 1-4 are also LCD Screen
used for navigating the on-board setup and service
menus. The dash display also contains a battery The LCD screen displays the following when the key
state-of-charge indicator and is equipped to allow op- is in the ON position:
erator selectable drive modes. 1. Indicator symbols will illuminate from left to
right.
Button Keypad
2. The truck horn will beep.
The button keypad is located on the right side of the 3. The battery state-of-charge will illuminate.
display. It consists of four buttons arranged in a circle 4. Performance mode will be displayed.
with a fifth button in the center. The buttons are num-
bered 1 through 5, starting with button 1 at the top 5. Steer angle indicator will be displayed.
and continuing clockwise and ending with button 5 sit- 6. Truck speed indicator will be displayed.
uated in the center of the keypad. 7. Truck hours will be displayed.

LED Indicator Lights

The LED indicator lights are located on the display


below the LCD screen and to the left of the button
keypad. The lights illuminate to notify the operator of
certain conditions. The function of each light (in order
from left to right) is as follows:
• Battery Indicator

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-6
Electrical System General Maintenance and Diagnostic Data

Dash Display Access Status Code Toggling

The operator passwords are a series of five-digit num- This feature allows the operator to toggle the display
bers. Each of the five number digits can be the num- from the normal screen display to the status code
bers 1 through 5. If enabled, the password number screen. Pressing the 2 button will cause the display to
series must be entered into the memory by a techni- switch from the normal display screen to the status
cian or supervisor and assigned to an operator. A cer- code screen. Pressing the 4 button will cause the dis-
tified dealer technician can use a personal computer play to return from the status code screen to the nor-
(PC), connected to the lift truck, to check and assign mal display.
passwords.
Automatic Diagnostics
After the key is moved to the ON position, the LCD
screen will show ENTER PASSWORD, if this function This feature allows for immediate access to diagnos-
is enabled. Use the numbered push buttons to enter tics associated with status codes. To use this feature,
the five-digit password. The password can be entered press the 5 button while viewing the status code
as many times as needed. If the password is entered screen. If diagnostics are available with the code, the
incorrectly, the message PASSWORD ERROR will diagnostics will be immediately entered.
appear and the operator will be prompted to ENTER
PASSWORD again. Status Code Indication

Refer to User Interface manual User Interface Serv- This feature indicates if a status code is available
ice Technician 2200YRM1659 for further information when in the normal screen. If a status code is present,
regarding the User Interface for either Supervisor or the mode indicator will display “!”.
Technician application.

Status Codes and Descriptions


STATUS CODES Status Codes are displayed as four lines. Line one
consist of the Node and Code number. The second
Status codes give an indication to the operator that a line consists of the Node name while lines three and
possible malfunction or incorrect truck use has occur- four contain code descriptions. For example, Status
red. Status codes are a code number of a symptom or Code 32003 is shown in the Status Code Structure
malfunction. The wrench symbol will flash and the sta- Table 9030-03-1. This Status Code is set when a
tus code number will be shown on the LCD screen if lower coil circuit fault is detected by the combination
an incorrect truck use or malfunction occurs during controller.
operation. Have an authorized service person check
and repair the lift truck if a status code number ap- Table 9030-03-1. Status Code Structure
pears. The symptoms for each status code are shown
in this manual. This manual also provides in-depth LINE NUMBER LINE DESCRIPTION
troubleshooting procedures for each fault broken LINE 1 32003
down into the following system or node:
LINE 2 Combi
NODE 10: DISPLAY
LINE 3 Lower Coil
NODE 32: COMBINATION
LINE 4 Circuit
NODE 40: STEER

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-7
General Maintenance and Diagnostic Data Electrical System

STATUS CODE DESCRIPTIONS


Status Codes can be reported by any Node that de-
tects a fault.

Table 9030-03-2. Node 10 Status Codes

NODE STATUS DESCRIPTION


10 099 The Display has detected an Internal Fault.*
10 100 The Display has detected a loss of CAN communication with the Combination Con-
troller
10 104 The Display has detected a loss of CAN communication with the Steer Motor.
10 106 The Display has detected a loss of CAN communication with the Handle.
10 109 The Display is not communicated on the CANbus.
*Any Node or system that detects an internal fault is capable of reporting a 099 Status Code. Refer to the xx099 Status Code
troubleshooting procedures for all Internal Fault Codes regardless of what Node has reported the fault.

Table 9030-03-3. Node 32 Status Codes

NODE STATUS DESCRIPTION


32 003 The Combination Controller has detected a fault in the Lower Coil circuit.
32 004 The Combination Controller has detected a short in the Lower Coil circuit.
32 005 The Combination Controller has detected a fault in the Load Hold Coil circuit.
32 006 The Combination Controller has detected a short in the Load Hold Coil circuit.
32 033 The Combination Controller has detected a fault in the Main Contactor Coil circuit.
32 034 The Combination Controller has detected a short in the Main Contactor Coil circuit.
32 037 The Combination Controller has detected a fault in the Audible Alarm circuit.
32 038 The Combination Controller has detected a short in the Audible Alarm circuit.
32 039 The Combination Controller has detected a fault in the Visible Alarm circuit.
32 040 The Combination Controller has detected a short in the Visible Alarm circuit.
32 041 The Combination Controller has detected a fault in the ACC Coil circuit.
32 042 The Combination Controller has detected a short in the ACC Coil circuit.
32 050 The Combination Controller has detected a Belly Switch mismatch fault.
32 052 The Combination Controller has detected a throttle sensor fault.
32 060 The Combination Controller has detected a fault in the traction motor or traction motor
circuit.
32 061 The Combination Controller has detected a short in the Traction Motor or circuit.
32 062 The Combination Controller has detected a motor encoder fault.
32 067 The Combination Controller has detected that the Main Contactor is stuck closed or
has welded tips.
32 068 The Combination Controller has detected that the Main Contactor is not closed or
stuck open.
32 069 The Combination Controller has detected a fault in Capacitor charge.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-8
Electrical System General Maintenance and Diagnostic Data

Table 9030-03-3. Node 32 Status Codes (Continued)

NODE STATUS DESCRIPTION


32 085 The Combination Controller has detected low key input voltage or a fault in the key
input circuit.
32 086 The Combination Controller has detected Low DC Bus Voltage or a fault in the DC
Bus circuit.
32 087 The Combination Controller has detected High DC Bus Voltage or a fault in the DC
Bus circuit.
32 200 The Combination Controller has detecetd a Lift/Lower Switch release fault.
32 201 The Combination Controller has detected a Throttle release fault.
32 208 The Combination Controller has detected a ACC Switch release fault.
32 210 The Combination Controller has detected a Belly Switch release fault.
32 211 The Combination Controller has detected a Handle release fault.
32 212 The Combination Controller has detected a Pick Switch release fault.
32 215 The Combination Controller has detected a Regen Switch release fault.
32 216 The Combination Controller has detected a Rabbit Switch release fault.
32 227 The Combination Controller has detected that the traction motor has stalled.

Table 9030-03-4. Node 40 Status Codes

NODE STATUS DESCRIPTION


40 074 The steer motor has stalled.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-9
General Maintenance and Diagnostic Data Electrical System

Table 9030-03-5. Warning Codes

CODE NODE STATUS DESCRIPTION SYMPTOM


TYPE
XX 080 Motor Cutback* A controller has begun to reduce power to the motor in
attempt to manage increased temperatures that may
damage the motor. Motor cutback is initiated at
140°C (284°F). Truck performance will be reduced until
temperature lowers to an acceptable level. Motor
temperature input can be monitored in menu D2.32.6.
XX 081 Motor Overheated* Motor cutback (XX080) was unsuccessful. Motor cutback
is initiated at 160°C (320°F). The truck will severely limit
performance until the motor temperature returns to
normal. Motor temperature input can be monitored in
menu D2.32.6
XX 082 Controller Cutback* A controller has begun to reduce power in attempt to
Thermal manage increased temperatures that may damage
internal components. Controller cutback is initiated at
90°C (194°F). Truck performance will be reduced until
temperature lowers to an acceptable level. Controller
temperature input can be monitored in menu D2.32.5.
XX 083 Controller Controller cutback (XX082) was unsuccessful. Controller
Overheated* cutback is initiated at 110°C (230°F). The truck will
severely limit performance until the motor temperature
returns to normal. Motor temperature input can be
monitored in menu D2.32.5.
XX 248 Low Temp* A controller has detected low temperature conditions.
Move truck to a warmer ambient condition an allow
sufficient time to warm.
(XX) Any Node or system that detects a thermal fault is capable of reporting a Status Code.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-03-10
Electrical System Diagnostic Trouble Codes

Group 20

Diagnostic Trouble Codes

DTC xx099
Internal - Fault
POSSIBLE CAUSE

A. INTERNAL FAULT

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM.
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Cause A.
NO: Problem may be intermittent.

CAUSE A - INTERNAL FAULT

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-1
Diagnostic Trouble Codes Electrical System

DTC xx100
CANBus Communications - Combi
POSSIBLE CAUSE

A. CANBUS COMMUNICATION FAULT


B. COMBINATION WIRING FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.10) and verify Combination controller communication (D2.10.32).
Is the Combination controller online?
YES: Fault may be intermittent.
NO: Proceed to Step 4.
4. Using input diagnostics (D2.10), determine if other nodes are offline.
Are other nodes offline?
YES: Suspect short to frame.
NO: Proceed to Cause A.

CAUSE A - CANBUS COMMUNICATION FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Disconnect the Combination controller connector CPS005 and measure voltage between socket 28 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the Combination controller connector CPS005, socket 27 and B(-).
Is CAN LO voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-2
Electrical System Diagnostic Trouble Codes

DTC xx100 (Cont)


CANBus Communications - Combi
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the Combination controller connector CPS005, socket 27 and socket 28.
Is resistance 60 ± 6 ohms?
YES: No communication faults are present, connect battery and proceed to Cause B.
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE B - COMBINATION WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 and Step 3 with key in ON position.

1. Measure voltage between the Combination controller B(+) terminal and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect B(+) cable for damage or loose connections.
2. Measure resistance between the Combination controller B(-) terminal and B(-).
Is resistance ≤ 1 ohm?
YES: Proceed to Step 3.
NO: Inspect B(-) cable for damage or loose connections.
3. Measure voltage between the Combination controller, socket 10 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Cause C.
NO: Inspect circuit 010-A for open or short.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. Replace faulty Combination controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-3
Diagnostic Trouble Codes Electrical System

DTC xx100 (Cont)


CANBus Communications - Combi
DTC XX100 CANBUS COMMUNICATIONS - COMBI DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-4
Electrical System Diagnostic Trouble Codes

DTC xx104
CANBus Communications - Steer
POSSIBLE CAUSE

A. CANBUS COMMUNICATION FAULT


B. STEER MOTOR WIRING FAULT
C. FAULTY STEER MOTOR

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.10) and verify steer motor communication (D2.10.40).
Is the controller online?
YES: Fault may be intermittent.
NO: Proceed to Step 4.
4. Using input diagnostics (D2.10), determine if other nodes are offline.
Are other nodes offline?
YES: Suspect short to frame.
NO: Proceed to Cause A.

CAUSE A - CANBUS COMMUNICATION FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Disconnect the steer motor connector CPS803 and measure voltage between socket 7 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the steer motor connector CPS803, socket 8 and B(-).
Is CAN LO voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-5
Diagnostic Trouble Codes Electrical System

DTC xx104 (Cont)


CANBus Communications - Steer
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the steer motor CPS803, socket 7 and socket 8.
Is resistance 60 ± 6 ohms?
YES: No communication faults are present, connect battery and proceed to Cause B.
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE B - STEER MOTOR WIRING FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the steer motor B(+) terminal and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect power cable for damage and loose connections.
2. Measure resistance between the steer motor B(-) terminal and B(-).
Is resistance ≤ 1 ohm?
YES: Proceed to Cause C.
NO: Inspect ground cable for damage and loose connections.

CAUSE C - FAULTY STEER MOTOR

PROCEDURE OR ACTION:
1. Replace faulty controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-6
Electrical System Diagnostic Trouble Codes

DTC xx104 (Cont)


CANBus Communications - Steer
DTC XX104 CANBUS COMMUNICATIONS - STEER DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-7
Diagnostic Trouble Codes Electrical System

DTC xx106
CANBus Communications - Handle
POSSIBLE CAUSE

A. CANBUS COMMUNICATION FAULT


B. HANDLE WIRING FAULT
C. FAULTY HANDLE

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.10) and verify handle communication (D2.10.60).
Is the handle online?
YES: Fault may be intermittent.
NO: Proceed to Step 4.
4. Using input diagnostics (D2.10), determine if other nodes are offline.
Are other nodes offline?
YES: Suspect short to frame.
NO: Proceed to Cause A.

CAUSE A - CANBUS COMMUNICATION FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Disconnect the control module connector B CRS057 (metal tiller) or tiller card connector CJ2 (composite
tiller). Perform the appropriate voltage check:
• Measure voltage between the control module connector B CRS057, socket 4 and B(-).
• Measure voltage between the tiller card connector CJ2, socket 2 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-8
Electrical System Diagnostic Trouble Codes

DTC xx106 (Cont)


CANBus Communications - Handle
2. Perform the appropriate voltage check:
• Measure voltage between the control module connector B CRS057, socket 1 and B(-).
• Measure voltage between the tiller card connector CJ2, socket 1 and B(-).
Is CAN LO voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Perform the appropriate resistance check:
• Measure resistance between the control module connector B CRS057, socket 1 and socket 4.
• Measure resistance between the tiller card connector CJ2, socket 1 and socket 2.
Is resistance 60 ± 6 ohms?
YES: No communication faults are present, connect battery and proceed to Cause B.
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE B - HANDLE WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 with key in ON position.

1. Disconnect the control module connector B CRS057 (metal tiller) or tiller card connector JP1 (composite
tiller). Perform the appropriate voltage check:
• Measure voltage between the control module connector B CRS057, socket 3 and B(-).
• Measure voltage between the tiller card connector JP1, socket 1 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect the battery and proceed to Step 2.
NO: Inspect circuit 010 (metal tiller) or T/CBL-05 GRY (composite tiller) for open or short.
2. Perform the appropriate resistance check:
• Measure resistance between the control module connector B CRS057, socket 2 and B(-).
• Measure resistance between the tiller card connector JP1, socket 2 and B(-).
Is resistance ≤ 1 ohm?
YES: Proceed to Cause C.
NO: Inspect ground circuit 102-L (metal tiller) or T/CBL-05 GRN (composite tiller) for open or source of exces-
sive resistance.

CAUSE C - FAULTY HANDLE

PROCEDURE OR ACTION:
1. Replace faulty handle. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-9
Diagnostic Trouble Codes Electrical System

DTC xx106 (Cont)


CANBus Communications - Handle
DTC XX106 CANBUS COMMUNICATIONS - HANDLE DIAGRAMS

Metal Tiller Troubleshooting Scenes

Composite Tiller Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-10
Electrical System Diagnostic Trouble Codes

DTC xx109
CANBus Communications - Display
POSSIBLE CAUSE

A. CANBUS COMMUNICATION FAULT


B. DISPLAY WIRING FAULT
C. FAULTY DISPLAY

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: If display diagnostic menu is operational, proceed to Step 3. If display is inoperative, proceed to Cause
A.
NO: Problem may be intermittent.
3. Using input diagnostics (D2.10), determine if other nodes are offline.
Are other nodes offline?
YES: Verify CAN HI and CAN LO voltages of offline node(s).
NO: Proceed to Cause A.

CAUSE A - CANBUS COMMUNICATION FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Disconnect the display connector CRS060 and measure voltage between socket 3 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the display connector CRS060, socket 4 and B(-).
Is CAN LO voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the display connector CRS060, socket 3 and socket 4.
Is resistance 60 ± 6 ohms?

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-11
Diagnostic Trouble Codes Electrical System

DTC xx109 (Cont)


CANBus Communications - Display
YES: No communication faults are present, connect battery and proceed to Cause B.
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE B - DISPLAY WIRING FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the display connector CRS060, socket 6 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 010-B for open or short.
2. Measure voltage between the display connector CRS060, socket 6 and socket 1/2.
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Cause C.
NO: Inspect ground circuit 102-B and 102-C for open or short.

CAUSE C - FAULTY DISPLAY

PROCEDURE OR ACTION:
1. Replace faulty display. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate
problem description leading to controller replacement.

END POSSIBLE CAUSES

DTC XX109 CANBUS COMMUNICATIONS - DISPLAY DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-12
Electrical System Diagnostic Trouble Codes

Lower Coil
CODES

DTC 32003 - Combination - Lower Coil - Circuit


DTC 32004 - Combination - Lower Coil - Short

POSSIBLE CAUSE

A. LOWER COIL WIRING FAULT


B. LOWER COIL FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM ..
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate status menu (D1) and verify that lower coil is enabled (D1.7).
Is lower enabled?
YES: Proceed to Cause A.
NO: Check that all interlocks have been met.

CAUSE A - LOWER COIL WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position

1. Disconnect the lower coil connector CPS088 and measure voltage between socket 2 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect circuit 201-C for open or short.
2. Disconnect the Combination controller connector CPS005 and measure resistance between the Combination
controller connector CPS005, socket 24 and the lower coil connector CPS088, socket 1.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground control circuit 150 for open or short.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-13
Diagnostic Trouble Codes Electrical System

Lower Coil (Cont)


CAUSE B - LOWER COIL FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the lower coil's positive and negative terminals.
Is resistance 40 ± 4.0 ohms?
YES: Proceed to Cause C.
NO: Replace faulty lower coil.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-14
Electrical System Diagnostic Trouble Codes

Load Hold Coil


CODES

DTC 32005 - Combi - Load Hold - Circuit


DTC 32006 - Combi - Load Hold - Short

POSSIBLE CAUSE

A. LOAD HOLD COIL WIRING FAULT


B. LOAD HOLD COIL FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.

NOTE: Operate load hold coil.

3. Locate input diagnostics (D2.32) and verify lower switch activation (D2.32.27).
Does the display indicate ON when the lower is activated?
YES: Proceed to Cause B.
NO: Proceed to Step 4.
4. Locate output diagnostics (D3.32) and actuate load hold coil (D3.32.9).
Does coil energize when actuated?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - LOAD HOLD COIL WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position

1. Disconnect load hold coil connector CPS088 and measure voltage between socket 2 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect circuit 201-C for open or short.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-15
Diagnostic Trouble Codes Electrical System

Load Hold Coil (Cont)


2. Disconnect the Combination controller connector CPS005. Measure resistance between the combination con-
nector CPS005, socket 24 and the load hold coil connector CPS088, socket 1.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground control circuit 150 for open or short.

CAUSE B - LOAD HOLD COIL FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the load hold coil's positive and negative terminals.
Is resistance 40 ± 4.0 ohms?
YES: Proceed to Cause C.
NO: Replace faulty load hold coil.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-16
Electrical System Diagnostic Trouble Codes

Main Contactor Coil


CODES

DTC 32033 - Combi - Main Cont Coil - Circuit


DTC 32034 - Combi - Main Cont Coil - Short

POSSIBLE CAUSE

A. MAIN CONTACTOR COIL WIRING FAULT


B. MAIN CONTACTOR COIL FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D1) and view the main contactor position (D1.2).
Is the main contactor closed at correct time?
YES: Fault may be intermittent.
NO: Proceed to Cause A .

CAUSE A - MAIN CONTACTOR COIL WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Disconnect the main contactor coil's positive socket terminal TS003 and measure voltage between socket ter-
minal TS003 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 010-E for open or short.

NOTE: Key in OFF position.

2. Disconnect combination controller connector CPS005 and the contactor coil's negative socket terminal
TS004. Measure resistance between the main contactor coil negative socket terminal TS004 and the combi-
nation controller connector CPS005, socket 12.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-17
Diagnostic Trouble Codes Electrical System

Main Contactor Coil (Cont)


Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground control circuit 079 for open or source of excessive resistance.

CAUSE B - MAIN CONTACTOR COIL FAULT

PROCEDURE OR ACTION:

NOTE: Key in OFF position.

1. Measure resistance between the main contactor's coil terminals.


Is resistance 32 ± 4.0 ohms?
YES: Proceed to Cause C.
NO: Replace faulty main contactor coil.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-18
Electrical System Diagnostic Trouble Codes

Audible Alarm
CODES

DTC 32037 - Combi - Audible Alarm - Circuit


DTC 32038 - Combi - Audible Alarm - Short

POSSIBLE CAUSE

A. BACKUP ALARM WIRING FAULT


B. BACKUP ALARM FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate output diagnostics (D3.32) and actuate audible alarm (D3.32.10).
Does bakup alarm sound when actuated?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - BACKUP ALARM WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 with key in ON position.

1. Disconnect backup alarm connector CPS014 and measure voltage between socket 1 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect circuit 201-F for open or short.
2. Disconnect the Combination connector CPS005. Measure resistance between the Combination connector
CPS005, socket 8 and the backup alarm connector CPS014, socket 2.
Is resistance <1 ohm?
YES: Connect Combination controller connector CPS005 and proceed to Cause B.
NO: Inspect ground control circuit 603 for open or short.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-19
Diagnostic Trouble Codes Electrical System

Audible Alarm (Cont)


CAUSE B - BACKUP ALARM FAULT

PROCEDURE OR ACTION:

NOTE: Key in ON position.

NOTE: Operate backup alarm.

1. Measure continuity between the backup alarm connector CPS014, socket 2 and B(-).
Is continuity present?
YES: Replace faulty backup alarm.
NO: Proceed to Cause C.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-20
Electrical System Diagnostic Trouble Codes

Visible Alarm
CODES

DTC 32039 - Combi - Visible Alarm - Circuit


DTC 32040 - Combi - Visible Alarm - Short

POSSIBLE CAUSE

A. STROBE WIRING FAULT


B. STROBE LIGHT FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate output diagnostics (D3.32) and actuate strobe (D3.32.11).
Does strobe illuminate when actuated?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - STROBE WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect strobe light connector CRP014 and measure voltage between CRP014, socket 1 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 201-E for open or short.
2. Disconnect the Combination controller connector CPS005 and measure resistance between Combination
connector CPS005, socket 33 and the strobe light connector CRP014, socket 2.
Is resistance ≤ 1 ohm?
YES: Connect the Combination controller connector CPS005 and proceed to Cause B.
NO: Inspect circuit 602 for open or source of excessive resistance.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-21
Diagnostic Trouble Codes Electrical System

Visible Alarm (Cont)


CAUSE B - STROBE LIGHT FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the strobe light connector CRP014, socket 1 and socket 2 while operating strobe
light.
Is voltage 24 ± 2.5 Vdc?
YES: Replace faulty strobe light.
NO: Proceed to Cause C.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-22
Electrical System Diagnostic Trouble Codes

ACC Coil
CODES

DTC 32041 - Combi - ACC Coil - Circuit


DTC 32042 - Combi - ACC Coil - Short

POSSIBLE CAUSE

A. ACC COIL WIRING FAULT


B. ACC COIL FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate output diagnostics (D3.32) and actuat ACC coil (D3.32.8).
Does coil energize when actuated?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - ACC COIL WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the ACC coil connector CPS121 and measure voltage between socket 1 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect circuit 200-B for open or short.
2. Disconnect the Combination controller connector CPS005. Measure resistance between the Combination
controller connector CPS005, socket 4 and the ACC coil connector CPS121, socket 2.
Is resistance <1 ohm?
YES: Proceed to Cause B.
NO: Inspect ground control circuit 730 for open or source of excessive resistance.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-23
Diagnostic Trouble Codes Electrical System

ACC Coil (Cont)


CAUSE B - ACC COIL FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the ACC coil connector CPS121, socket 1 and 2 while operating the ACC switch.
Is voltage 24 ± 2.5 Vdc?
YES: Replace faulty ACC coil.
NO: Proceed to Cause C

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-24
Electrical System Diagnostic Trouble Codes

Traction Motor
CODES

DTC 32060 - Combi - Traction Motor - Circuit


DTC 32061 - Combi - Traction Motor - Open

POSSIBLE CAUSE

A. TRACTION MOTOR CABLE FAULT


B. TRACTION MOTOR FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.

NOTE: The following output diagnostic test will apply 50A DC voltage to each phase cable. The actual current is
then calculated and displayed.

3. Locate output diagnostics (D3.32) and conduct line DC current tests (D3.32.1, D3.32.2, D3.32.3) to diagnose
faults on individual phase cables.
Is DC current present?
YES: No circuit fault present, problem may be intermittent.
NO: Disconnect battery and proceed to Cause A.

CAUSE A - TRACTION MOTOR CABLE FAULT

PROCEDURE OR ACTION:
1. Disconnect the traction motor cables from the Combination controller and traction motor. Measure continuity
of individual cables to isolate fault.
Is continuity present?
YES: Disconnect battery and proceed to Cause B.
NO: Repair or replace faulty phase cable.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-25
Diagnostic Trouble Codes Electrical System

Traction Motor (Cont)


CAUSE B - TRACTION MOTOR FAULT

PROCEDURE OR ACTION:
1. Measure resistance between the traction motor terminals U and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 2.
NO: Repair or replace faulty traction motor.
2. Measure resistance between the traction motor terminals U and W.
Is resistance between .322 and .383 ohms?
YES: Proceed to Step 3.
NO: Repair or replace faulty traction motor.
3. Measure resistance between the traction motor terminals W and V.
Is resistance between .322 and .383 ohms?
YES: Proceed to Cause C.
NO: Repair or replace faulty traction motor.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-26
Electrical System Diagnostic Trouble Codes

DTC 32062
Combi - Traction Motor - Encoder
POSSIBLE CAUSE

A. ENCODER WIRING FAULT


B. ENCODER FAULT
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.32) and view traction motor encoder count (D2.32.3) to verify signal.
Is encoder signal responding to actual motor speed?
YES: Fault may be intermittent. Visually inspect encoder for damage.
NO: Proceed to Cause A.

CAUSE A - ENCODER WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the traction motor encoder connector CPS003 and measure voltage between socket 1 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 250-A and 250-B for open or short.
2. Measure voltage between the encoder connector CPS003, socket 1 and socket 4.
Is voltage 12 ± 1.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect ground circuit 102-H and 102-A for open or short.
3. Disconnect the Combination controller connector CPS005. Measure resistance between socket 14 of the
Combination controller connector and socket 3 of the encoder connector CPS003.
Is resistance <1 ohm?
YES: Proceed to Step 4.
NO: Inspect signal circuit 578 for open or source of excessive resistance.
4. Measure resistance between socket 13 of the Combination controller connector CPS005 and socket 2 of the
encoder connector CPS003.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-27
Diagnostic Trouble Codes Electrical System

DTC 32062 (Cont)


Combi - Traction Motor - Encoder
Is resistance <1 ohm?
YES: Reconnect the encoder connector CPS003, battery, and proceed to Cause B.
NO: Inspect signal circuit 577 for open or source of excessive resistance.

CAUSE B - ENCODER FAULT

PROCEDURE OR ACTION:

NOTE: Connect battery.

NOTE: Operate traction motor while performing this test.

1. Disconnect the Combination controller connector CPS005 and measure voltage between socket 13, 14, and
B(-).
Does voltage signal relate to traction motor movement?
YES: Proceed to Cause C.
NO: Replace faulty encoder.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DTC 32062 COMBI - TRACTION MOTOR - ENCODER DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-28
Electrical System Diagnostic Trouble Codes

Main Contactor
CODES

DTC 32067 - Combi - Main Contactor - Welded Tips


DTC 32068 - Combi - Main Contactor - Not Closed

POSSIBLE CAUSE

A. MAIN CONTACTOR COIL WIRING FAULT


B. MAIN CONTACTOR STUCK CLOSED
C. MAIN CONTACTOR STUCK OPEN
D. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate status tests (D1) and view the main contactor (D1.2) to verify main contactor position.
Does main contactor remain open or closed when coil is energized/de-energized?
YES: Proceed to Cause A.
NO: Fault may be intermittent, inspect main contactor tips for damage or debris.

CAUSE A - MAIN CONTACTOR COIL WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the main contactor coil's positive terminal TS003 and measure voltage between socket TS003
and B(-). Perform test with key in ON position.
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Inspect circuit 010-E for open or short.
2. Disconnect the Combination controller connector CPS005 and the contactor coil negative terminal TS004.
Measure continuity between socket TS004 and socket 12 of the Combination controller connector CPS005.
Is continuity present?
YES: Reconnect battery and all connectors. Proceed to Cause B if contactor is stuck closed or Cause C if
contactor is stuck open.
NO: Inspect ground control circuit 079 for open or short.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-29
Diagnostic Trouble Codes Electrical System

Main Contactor (Cont)


CAUSE B - MAIN CONTACTOR STUCK CLOSED

PROCEDURE OR ACTION:
1. Measure voltage between the main contactor B(+) output terminal and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Replace faulty main contactor.
NO: Proceed to Cause D.

CAUSE C - MAIN CONTACTOR STUCK OPEN

PROCEDURE OR ACTION:

NOTE: Key in ON position.

1. Measure voltage between the main contactor B(+) output terminal and B(-).
Is voltage present?
YES: Proceed to Cause D.
NO: Replace faulty main contactor.

CAUSE D - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-30
Electrical System Diagnostic Trouble Codes

DTC 32069
Combi - Capacitor - Charge
POSSIBLE CAUSE

A. CONTROLLER WIRING FAULT


B. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to perform-
ing Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.32) and view CAP voltage (D2.32.8) to verify capacitor voltages.
Is CAP voltage same as battery voltage?
YES: Verify battery state of charge and recheck condition. If actual voltage does not agree with display, pro-
ceed to Cause B.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER WIRING FAULT

PROCEDURE OR ACTION:
1. Measure voltage between the Combination controller B(+) terminal and B(-).
Is precharge voltage same as battery voltage?
YES: Proceed to Cause B.
NO: Inspect controller B(+) cables for damage or loose connections.

CAUSE B - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-31
Diagnostic Trouble Codes Electrical System

DTC 32069 (Cont)


Combi - Capacitor - Charge

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-32
Electrical System Diagnostic Trouble Codes

DTC 32085
Combi - Key input - Voltage Low
POSSIBLE CAUSE

A. KEY INPUT WIRING FAULT


B. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.32) and view key input voltages (D2.32.11, D2.32.13) to verify actual key voltage
and minimum captured key voltage.
Is key input voltage currently below 24 ± 2.5 Vdc?
YES: Check battery state of charge and proceed to Cause A.
NO: If battery is fully charged and code returns, proceed to Cause B.

CAUSE A - KEY INPUT WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Ensure key is in ON position when performing this test.

1. Disconnect the Combination controller connector CPS005 and measure voltage between socket 10 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Cause B.
NO: Inspect circuit 010-A for open, short, or source of excessive resistance.

CAUSE B - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-33
Diagnostic Trouble Codes Electrical System

DTC 32085 (Cont)


Combi - Key input - Voltage Low
DTC 32085 COMBI - KEY INPUT - VOLTAGE LOW DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-34
Electrical System Diagnostic Trouble Codes

DC Bus Voltage
CODES

DTC 32086 - Combi - DC Bus - Voltage Low


DTC 32087 - Combi - DC Bus - Voltage High

POSSIBLE CAUSE

A. CONTROLLER WIRING FAULT


B. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to perform-
ing Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.32) and view CAP voltage (D.32.8).
Is CAP voltage same as battery voltage?
YES: Verify battery state of charge and recheck condition. If capacitor voltage is within specifications after
retest and code remains, proceed to Cause B.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Key in OFF position.

1. Measure voltage between the Combination controller B(+) terminal and B(-).
Is precharge voltage same as battery voltage?
YES: Proceed to Cause B.
NO: Inspect B(+) cable for damage or loose connections.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-35
Diagnostic Trouble Codes Electrical System

DC Bus Voltage (Cont)


CAUSE B - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-36
Electrical System Diagnostic Trouble Codes

DTC 32200
Combi - Release - Lift/Lower
POSSIBLE CAUSE

A. LIFT/LOWER SWITCH WIRING FAULT


B. FAULTY LIFT/LOWER SWITCH
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Fault may be intermittent.
3. Locate input diagnostics (D2.32) and verify the following switch inputs:
• Lift Switch (D2.32.26)
• Lower Switch (D2.32.27)
Does value follow switch operation?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - LIFT/LOWER SWITCH WIRING FAULT

PROCEDURE OR ACTION:
1. Inspect control box for damage or sticking buttons.
Are controls damaged?
YES: Repair or replace faulty control box.
NO: Proceed to Step 2.
2. Disconnect the handrail harness connector CRP108 and measure voltage between socket 1 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Connect handrail harness connector CRP108 and proceed to Step 3.
NO: Inspect circuit 010-D for open or short.
3. Disconnect Combination controller connector CPS005 and measure voltage between the following sockets
while pressing the lift/lower switches:
• Measure voltage between the Combination controller CPS005, socket 17 and B(-) while pressing/
releasing the lift switch.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-37
Diagnostic Trouble Codes Electrical System

DTC 32200 (Cont)


Combi - Release - Lift/Lower
• Measure voltage between the Combination controller CPS005, socket 31 and B(-) while pressing/
releasing the lower switch.
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Cause C
NO: Inspect lift switch circuit 026 and lower switch circuit 027 for open or short. If no circuit faults are found,
proceed to Cause B.

CAUSE B - FAULTY LIFT/LOWER SWITCH

PROCEDURE OR ACTION:
1. Repair or replace faulty lift/lower switch.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-38
Electrical System Diagnostic Trouble Codes

DTC 32200 (Cont)


Combi - Release - Lift/Lower
DTC 32200 COMBI - RELEASE - LIFT/LOWER DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-39
Diagnostic Trouble Codes Electrical System

Handle/Throttle Release (Metal Tiller)


CODES

DTC 32201 - Combi - Release - Throttle


DTC 32211 - Combi - Handle - Release

POSSIBLE CAUSE

A. THROTTLE WIRING FAULT


B. FAUTLY THROTTLE SENSOR
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Fault may be intermittent.
3. Locate input diagnostics (D2.32) and verify throttle input command (D2.32.1).
Does value follow throttle request?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - THROTTLE WIRING FAULT

PROCEDURE OR ACTION:
1. Inspect throttle controls for damage.
Are controls damaged?
YES: Repair or replace faulty throttle control.
NO: Proceed to Step 2.

NOTE: Perform Step 2 and Step 3 with key in ON position.

2. Disconnect throttle connector CPS145 and measure voltage between socket C, D, and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect supply circuits 357-C, 357-A, and 357-B for open or short.
3. Measure voltage between the throttle connector CPS145, socket C/D and E/F.
Is voltage 5 ± 0.5 Vdc?

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-40
Electrical System Diagnostic Trouble Codes

Handle/Throttle Release (Metal Tiller) (Cont)


YES: Disconnect battery and proceed to Step 4
NO: Inspect ground circuits 103-A and 103-B for open or short.
4. Disconnect control module connector A CRS058. Perform the following resistance checks:
• Measure resistance between the control module connector A CRS058, socket 13 and the throttle con-
nector CPS145, socket A.
• Measure resistance between the control module connector A CRS058, socket 11 and the throttle con-
nector CPS145, socket B.
Is resistance ≤ 1 ohm?
YES: Connect control module connector A CRS058, throttle connector CPS145, battery, and proceed to
Step 5.
NO: Inspect the appropriate return signal circuit for open or source of excessive resistance.
5. Measure voltage between the control module connector A CRS58, sockets 11, 13, and B(-).
Does voltage vary between 0.5 and 4.5 Vdc when throttle is operated?
YES: Proceed to Cause C.
NO: Proceed to Cause B.

CAUSE B - FAUTLY THROTTLE SENSOR

PROCEDURE OR ACTION:
1. Replace faulty throttle hall sensor.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-41
Diagnostic Trouble Codes Electrical System

Handle/Throttle Release (Metal Tiller) (Cont)


DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-42
Electrical System Diagnostic Trouble Codes

Handle/Throttle Release (Metal Tiller)


CODES

DTC 32052 - Combi - Throttle - Sensor


DTC 32201 - Combi - Release - Throttle
DTC 32211 - Combi - Release - Handle

POSSIBLE CAUSE

A. THROTTLE WIRING FAULT


B. FAUTLY THROTTLE SENSOR
C. THROTTLE CALIBRATION
D. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Fault may be intermittent.
3. Locate input diagnostics (D2.32) and verify throttle input command (D2.32.1).
Does value follow throttle request?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - THROTTLE WIRING FAULT

PROCEDURE OR ACTION:
1. Inspect throttle controls for damage.
Are controls damaged?
YES: Repair or replace faulty throttle control.
NO: Proceed to Step 2.

NOTE: Perform Step 2 and Step 3 with key in ON position.

2. Disconnect throttle connector CPS145 and measure voltage between socket C, D, and B(-).
Is voltage 5 ± 0.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect supply circuits 357-C, 357-A, and 357-B for open or short.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-43
Diagnostic Trouble Codes Electrical System

Handle/Throttle Release (Metal Tiller) (Cont)


3. Measure voltage between the throttle connector CPS145, socket C/D and E/F.
Is voltage 5 ± 0.5 Vdc?
YES: Disconnect battery and proceed to Step 4
NO: Inspect ground circuits 103-A and 103-B for open or short.
4. Disconnect control module connector A CRS058. Perform the following resistance checks:
• Measure resistance between the control module connector A CRS058, socket 13 and the throttle con-
nector CPS145, socket A.
• Measure resistance between the control module connector A CRS058, socket 11 and the throttle con-
nector CPS145, socket B.
Is resistance ≤ 1 ohm?
YES: Connect control module connector A CRS058, throttle connector CPS145, battery, and proceed to
Step 5.
NO: Inspect the appropriate return signal circuit for open or source of excessive resistance.
5. Measure voltage between the control module connector A CRS58, sockets 11, 13, and B(-).
Does voltage vary between 0.5 and 4.5 Vdc when throttle is operated?
YES: Proceed to Cause C.
NO: Proceed to Cause B.

CAUSE B - FAUTLY THROTTLE SENSOR

PROCEDURE OR ACTION:
1. Replace faulty throttle hall sensor.

CAUSE C - THROTTLE CALIBRATION

PROCEDURE OR ACTION:
1. Using calibration (C4), perform throttle calibration. See User Interface Service Technician 2200YRM1659.
Was throttle calibration successful?
YES: Calibration successful, rekey and verify operation.
NO: Proceed to Cause D.

CAUSE D - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-44
Electrical System Diagnostic Trouble Codes

Handle/Throttle Release (Metal Tiller) (Cont)


DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-45
Diagnostic Trouble Codes Electrical System

DTC 32208
Combi - Release - ACC
POSSIBLE CAUSE

A. ACC SWITCH WIRING FAULT


B. FAULTY ACC SWITCH
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.32) and verify ACC switch operation (D2.32.22).
Does value follow ACC switch input?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - ACC SWITCH WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Disconnect battery.

1. Disconnect the tiller card connectors JP11 and JP13 (composite tiller) or the control module connector A
CRS058 (metal tiller). Perform the appropriate resistance check.
• Composite tiller - Measure resistance between tiller card connectors JP11/JP13, socket 1 and socket
2. Press and release the appropriate ACC switch.
• Metal tiller - Measure resistance between the control module connector A CRS058, socket 4 and
socket 6. Press and release the appropriate ACC switch.
Is resistance ≤ 1 ohm?
YES: Proceed to Cause C.
NO: Inspect ACC switch harness for open or source of excessive resistance. If no wiring faults are found, pro-
ceed to Cause C.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-46
Electrical System Diagnostic Trouble Codes

DTC 32208 (Cont)


Combi - Release - ACC
CAUSE B - FAULTY ACC SWITCH

PROCEDURE OR ACTION:
1. Replace faulty ACC switch.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-47
Diagnostic Trouble Codes Electrical System

DTC 32208 (Cont)


Combi - Release - ACC
DTC 32208 COMBI - RELEASE - ACC DIAGRAMS

Composite Tiller Troubleshooting Scenes

Metal Tiller Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-48
Electrical System Diagnostic Trouble Codes

Belly Switch
CODES

DTC 32050 - Combi - Belly - Mismatch


DTC 32210 - Combi - Belly - Release

POSSIBLE CAUSE

A. CONTROLLER WIRING FAULT


B. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.32) and view belly switch input (D2.32.25).
Is belly switch operational?
YES: fault may be intermittent. Inspect belly switch for damage.
NO: Proceed to Cause A.

CAUSE A - CONTROLLER WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 with key in ON position.

1. Disconnect the control module connector A CRS058 and measure voltage between pin 15 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Disconnect battery and proceed to Step 2.
NO: Suspect faulty control module.
2. Measure resistance between the control module connector A CRS058, socket 2 and socket 15. Press and
release belly switch.
Is resistance ≤ 1 ohm?
YES: Proceed to Step 3.
NO: Inspect circuits CBL-01BRN and CBL-01ORN for open or short.
3. Disconnect the combination controller connector CPS005 and measure resistance between socket 7 and the
control module connector A CRS058, socket 15. Press and release belly switch.
Is resistance ≤ 1 ohm?

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-49
Diagnostic Trouble Codes Electrical System

Belly Switch (Cont)


YES: Proceed to Cause B.
NO: Inspect circuit 600 for open or source of excessive resistace.

CAUSE B - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-50
Electrical System Diagnostic Trouble Codes

DTC 32212
Combi - Release - Pick
POSSIBLE CAUSE

A. PICK SWITCH WIRING FAULT


B. FAULTY PICK SWITCH
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Cause A.
NO: Fault may be intermittent.

CAUSE A - PICK SWITCH WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Disconnect battery.

1. Disconnect the control module connector A CRS058 (metal tiller) or tiller card connector JP16 (composite
tiller). Perform the appropriate resistance check:
• Metal tiller - Measure resistance between the control module connector A CRS058, socket 15 and
socket 4. Press and release individual pick switch.
• Composite tiller - Measure resistance between the tiller card connector JP16, socket 1 and socket 2.
Press and release individual pick switch.
Is resistance ≤ 1 ohm?
YES: Connect battery and proceed to Step 2.
NO: Inspect pick switch harness for open or source of excessive resistance. if no circuit faults are found, pro-
ceed to Cause B.
2. Perform the appropriate voltage check with key in ON position:
• Metal tiller - Measure voltage between the control module connector A CRS058, pin 15 and B(-).
• Composite tiller - Measure voltage between the tiller card connector JP16, pin 1 and B(-).
Is metal tiller voltage 24 ± 2.5 Vdc or composite tiller voltage 5.0 ± 0.5 Vdc?
YES: Proceed to Cause C.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-51
Diagnostic Trouble Codes Electrical System

DTC 32212 (Cont)


Combi - Release - Pick
NO: Replace faulty tiller card or control module.

CAUSE B - FAULTY PICK SWITCH

PROCEDURE OR ACTION:
1. Replace faulty pick switch.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-52
Electrical System Diagnostic Trouble Codes

DTC 32212 (Cont)


Combi - Release - Pick
DTC 32212 COMBI - RELEASE - PICK DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-53
Diagnostic Trouble Codes Electrical System

DTC 32215
Combi - Release - Regen
POSSIBLE CAUSE

A. REGEN SWITCH WIRING FAULT


B. FAULTY REGEN SWITCH
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Fault may be intermittent.
3. Locate input diagnostics (D2.32) and verify regen switch position (D.32.25).
Does value follow regen switch input?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - REGEN SWITCH WIRING FAULT

PROCEDURE OR ACTION:
1. Perform Step 1 with key in ON position.
2. Disconnect the regen switch connector CRP119 and measure voltage between socket 1 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Step 3.
NO: Inspect circuit 010-G for open or short.

NOTE: Disconnect battery.

3. Disconnect Combination controller connector CPS005, and measure resistance be the combination controller
connector CPS005, socket 6 and the regen switch connector CRP119, socket 2.
Is resistance ≤ 1 ohm?
YES: Connect Combination controller, battery, and proceed to Cause B
NO: Inspect circuits 355-B and 355-A for open or source of excessive resistance.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-54
Electrical System Diagnostic Trouble Codes

DTC 32215 (Cont)


Combi - Release - Regen
CAUSE B - FAULTY REGEN SWITCH

PROCEDURE OR ACTION:
1. Measure continuity between the regen switch connector CRP119, pin 1 and pin 2. Operate regen switch.
Is continuity present?
YES: Proceed to Cause C.
NO: Replace faulty regen switch.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DTC 32215 COMBI - RELEASE - REGEN DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-55
Diagnostic Trouble Codes Electrical System

DTC 32216
Combi - Release - Rabbit
POSSIBLE CAUSE

A. RABBIT SWITCH WIRING FAULT


B. FAULTY RABBIT SWITCH
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 3.
NO: Fault may be intermittent.
3. Locate input diagnostics (D2.32) and verify rabbit switch position (D.32.21).
Does value follow rabbit switch input?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - RABBIT SWITCH WIRING FAULT

PROCEDURE OR ACTION:
1. Disconnect the handrail control box connector CRP108 and measure voltage between pin 1 and B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 010-D for open or short.
2. Disconnect combination controller connector CPS005 and measure resistance between socket 32 and the
handrail control box connector CRP108, socket 5.
Is resistance ≤ 1 ohm?
YES: Proceed to Cause B.
NO: Inspect circuit 342 for open or source of excessive resistance.

CAUSE B - FAULTY RABBIT SWITCH

PROCEDURE OR ACTION:
1. Measure continuity between the handrail control box connector CRP108-A, socket 1 and socket 5. Press and
release rabbit switch.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-56
Electrical System Diagnostic Trouble Codes

DTC 32216 (Cont)


Combi - Release - Rabbit
Is continuity present?
YES: Proceed to Cause C.
NO: Repair or replace faulty rabbit switch.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

DTC 32216 COMBI - RELEASE - RABBIT DIAGRAMS

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-57
Diagnostic Trouble Codes Electrical System

DTC 32227
Traction - Motor - Stalled
POSSIBLE CAUSE

A. ENCODER WIRING FAULT


B. FAULTY TRACTION MOTOR
C. FAULTY COMBINATION CONTROLLER

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 2.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.32) and view motor encoder speed (D2.32.3).
Is encoder signal responding to traction input?
YES: Fault may be intermittent.
NO: Proceed to Cause A.

CAUSE A - ENCODER WIRING FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Disconnect the traction motor encoder connector CPS003 and measure voltage between socket 1 and B(-).
Is voltage 12 ± 1.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect circuit 250-A and 250-B for open or short.
2. Measure voltage between the encoder connector CPS003, socket 1 and socket 4.
Is voltage 12 ± 1.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect ground circuit 102-H and 102-A for open or short.
3. Disconnect the combination controller connector CPS005. Measure resistance between socket 14 of the com-
bination controller connector and socket 3 of the encoder connector CPS003.
Is resistance <1 ohm?
YES: Proceed to Step 4.
NO: Inspect signal circuit 578 for open or source of excessive resistance.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-58
Electrical System Diagnostic Trouble Codes

DTC 32227 (Cont)


Traction - Motor - Stalled
4. Measure resistance between socket 13 of the combination controller connector CPS005 and socket 2 of the
encoder connector CPS003.
Is resistance <1 ohm?
YES: Reconnect the encoder connector CPS003 and proceed to Cause B.
NO: Inspect signal circuit 577 for open or source of excessive resistance.

CAUSE B - FAULTY TRACTION MOTOR

PROCEDURE OR ACTION:

NOTE: Disconnect battery.

1. Measure resistance between the motor terminals U and V.


Is resistance between .322 and .383 ohm?
YES: Proceed to Step 2.
NO: Repair or replace faulty motor.
2. Measure resistance between the motor terminals U and W.
Is resistance between .322 and .383 ohm?
YES: Proceed to Step 3.
NO: Repair or replace faulty motor.
3. Measure resistance between the motor terminals W and V.
Is resistance between .322 and .383 ohm?
YES: Proceed to Cause C.
NO: Repair or replace faulty motor.

CAUSE C - FAULTY COMBINATION CONTROLLER

PROCEDURE OR ACTION:
1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in-
clude an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-59
Diagnostic Trouble Codes Electrical System

DTC 32227 (Cont)


Traction - Motor - Stalled
DTC 32227 TRACTION - MOTOR - STALLED DIAGRAMS

Troubleshooting Scenes

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-60
Electrical System Diagnostic Trouble Codes

DTC 40074
Steer - Motor - Stalled
POSSIBLE CAUSE

A. ENCODER SIGNAL FAULT


B. FAULTY STEER MOTOR CABLES
C. FAULTY STEER MOTOR

NOTE
Please refer to the end of this procedure for supporting diagrams.

COMPONENT OPERATIONAL CHECK

NOTE: Always check battery condition and state of charge before performing electrical troubleshooting. A faulty
or low charged battery will cause electrical features to not operate as designed and give incorrect readings while
performing electrical tests.

PROCEDURE OR ACTION:
1. Conduct a visual inspection of all connectors/wiring associated with the fault code.
Are any faults detected/observed?
YES: Repair/replace connector or wiring associated with faults found. Refer to the appropriate Electrical
System YRM .
NO: Proceed to Step 2.
2. Re-key the vehicle.
Is the code still present?
YES: Proceed to Step 2.
NO: Problem may be intermittent.
3. Locate input diagnostics (D2.40) and view steer motor encoder count (D2.40.3) to verify signal.
Is encoder signal responding to steering input?
YES: Fault may be intermittent. Inspect steer motor for damage or binding.
NO: Proceed to Cause A.

CAUSE A - ENCODER SIGNAL FAULT

PROCEDURE OR ACTION:

NOTE: Perform Step 1 and Step 2 with key in ON position.

1. Disconnect the steer motor connector CPS803 and Measure voltage between socket 7 and B(-).
Is CAN HI voltage approximately 2.5 Vdc?
YES: Proceed to Step 2.
NO: Inspect CAN HI circuit for open or short. If voltage is 0 volts, the CAN HI circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN HI circuit is shorted to power.
2. Measure voltage between the steer motor connector CPS803, socket 8 and B(-).
Is CAN LO voltage approximately 2.5 Vdc?
YES: Disconnect battery and proceed to Step 3.
NO: Inspect CAN LO circuit for open or short. If voltage is 0 volts, the CAN LO circuit is shorted to ground or
open. If voltage is above 5 volts, the CAN LO circuit is shorted to power.
3. Measure resistance between the steer motor connector CPS803, socket 7 and socket 8.
Is resistance 60 ± 6 ohms?
YES: Connect battery and proceed to Cause B.

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-61
Diagnostic Trouble Codes Electrical System

DTC 40074 (Cont)


Steer - Motor - Stalled
NO: If resistance is 120 ohms, the CANbus has an open circuit or a missing or damaged termination resistor.
If resistance is 0 ohms, the CANbus circuits are shorted together.

CAUSE B - FAULTY STEER MOTOR CABLES

PROCEDURE OR ACTION:
1. Disconnect the steer motor B(+) cable and measure voltage to B(-).
Is voltage 24 ± 2.5 Vdc?
YES: Proceed to Step 2.
NO: Repair or replace steer motor B(+) cable.
2. Disconnect the steer motor B(-) cable and measure resistance to B(-).
Is resistance ≤ 1 ohm?
YES: Proceed to Cause C.
NO: Repair or replace steer motor B(-) cable.

CAUSE C - FAULTY STEER MOTOR

PROCEDURE OR ACTION:
1. If no faults are found, replace motor. Make sure to indicate the DTC code(s) on the warranty claim to include
an accurate problem description leading to controller replacement.

END POSSIBLE CAUSES

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-62
Electrical System Diagnostic Trouble Codes

DTC 40074 (Cont)


Steer - Motor - Stalled
DTC 40074 STEER - MOTOR - STALLED DIAGRAMS

Troubleshooting Scenes

Troubleshooting Scenes

END FAULT

Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-20-63
NOTES

9030-20-64
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

9000 YRM 1660 2/17 (5/15)(3/15)(12/13)(10/13)

You might also like