Ac Motor Controllers/Display Panel: Description, Checks, Adjustments, and Troubleshooting

AC MOTOR
CONTROLLERS/DISPLAY
PANEL
DESCRIPTION, CHECKS,
ADJUSTMENTS, AND
TROUBLESHOOTING
N30ZDRS, N35-40ZRS [A265]
PART NO. 1652263 2200 SRM 1308

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
AC Motor Controllers/Display Panel Table of Contents
TABLE OF CONTENTS
Description ......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
AC Motors .................................................................................................................................................. 1
Motor Controllers ...................................................................................................................................... 1
Master Controller ...................................................................................................................................... 2
Dash Display.............................................................................................................................................. 2
Controller Area Network Bus (CANbus).................................................................................................. 2
AC Transistor Motor Controller Replacement ................................................................................................. 3
General ........................................................................................................................................................... 3
General Maintenance Instructions............................................................................................................... 4
Special Precautions ................................................................................................................................... 5
Fuses .............................................................................................................................................................. 5
Fan.................................................................................................................................................................. 6
Contactors ...................................................................................................................................................... 6
Repair......................................................................................................................................................... 6
Master Controller Checks and Adjustments .................................................................................................... 7
Function Settings............................................................................................................................................... 7
General ........................................................................................................................................................... 7
Troubleshooting ................................................................................................................................................. 9
General ........................................................................................................................................................... 9
Controller Status Light Emitting Diodes (LEDs) ........................................................................................ 10
Master Controller ...................................................................................................................................... 10
AC Motor Controllers ................................................................................................................................ 10
Operator Status Messages ............................................................................................................................ 13
Status Codes .................................................................................................................................................. 18
Checking the Motor Controller ..................................................................................................................... 72
Display Panel ..................................................................................................................................................... 72
General ........................................................................................................................................................... 72
Premium Display Panel ............................................................................................................................ 72
Standard Display Panel ............................................................................................................................ 73
Standard Display Functions and Features....................................................................................................... 73
Key-On Initialization..................................................................................................................................... 73
Passwords....................................................................................................................................................... 74
Performance Modes ....................................................................................................................................... 74
Battery Discharge Indicator (BDI) ............................................................................................................... 74
Hourmeters .................................................................................................................................................... 75
Standard Dash Display Service Menu Navigation .......................................................................................... 75
General ........................................................................................................................................................... 75
Moving Through Menu Selections ................................................................................................................ 75
Editing and Adding Information .................................................................................................................. 76
Access to Service Functions .......................................................................................................................... 76
Service Functions .......................................................................................................................................... 76
Premium Display Functions and Features....................................................................................................... 78
Key-On Initialization..................................................................................................................................... 78
Passwords....................................................................................................................................................... 78
Operator Checklist Function......................................................................................................................... 78
Performance Modes ....................................................................................................................................... 78
Battery Discharge Indicator.......................................................................................................................... 79
Hourmeters .................................................................................................................................................... 79
Shelf Height Selector..................................................................................................................................... 79
Premium Dash Display Service Menu Navigation .......................................................................................... 81
©2010 HYSTER COMPANY i

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

General ........................................................................................................................................................... 81
Moving Through Menu Selections ................................................................................................................ 81
Access to Service Functions .......................................................................................................................... 81
Service Functions .......................................................................................................................................... 82
Connector Pin-Outs............................................................................................................................................ 84
System Logic Diagram....................................................................................................................................... 90
This section is for the following models:
N30ZDRS, N35-40ZRS [A265]
ii
2200 SRM 1308 Description
Description
GENERAL do not get any other input from the truck. The mas-
ter controller relays speed, acceleration, and direc-
The alternating current (AC) system consists of AC tion commands to the motor controllers. See Figure 1
motors, motor controller(s), a master controller, and and Figure 2 for the component locations.
a dash display. The major difference between the
AC system and the direct current (DC) system is the
master controller performs many of the same func-
tions that previously were performed in the motor
controllers on the DC system.
AC Motors
The AC motors are three-phase AC induction motors.
They do not include motor brushes or commutators.
An AC induction motor operates on three-phase AC
power provided directly by the motor controller. The
motor’s speed is controlled by the motor controller
and can be changed by changing the frequency of
the AC power provided to the motor. A speed sensor
is built into the rear motor bearing, which provides
RPM and direction feedback to the motor controller.
The motor controller continuously monitors motor di-
rection and speed. Using this feedback, the AC mo-
tor control system can provide much better vehicle
top speed control than is available with DC SEM sys-
tems.
The AC motors also have thermal sensors embedded

in the motor windings that are continuously moni-
tored by the motor controllers.
Motor Controllers
The motor controllers receive power from the truck’s
battery and convert it into three-phase AC power at 1. TRACTION CONTROLLER
the frequencies and currents necessary to drive the 2. LIFT MOTOR
respective pump and/or traction motor. Each AC in- 3. MAIN CONTROL VALVE
4. MASTER AND STEERING CONTROLLERS
duction motor provides feedback of speed, rotation 5. TRACTION MOTOR
direction, and temperature directly to the motor con- 6. MDU STEER MOTOR
troller. The two motor controllers used to power the 7. CASTER STEER MOTOR (OPTIONAL)
traction motor and hydraulic pump motor are very 8. PUMP MOTOR CONTROLLER
similar. The primary motor controller difference is
Figure 1. Component Locations (Top View) -
in the power output rating.
N30ZDRS, N35-40ZRS
The motor controller logic board receives power from
the key switch. Power to the motors can be inter-
rupted indirectly by the key switch. The motor con-
trollers get motor speed and temperature informa-
tion directly from the motors. The motor controllers
1
Description 2200 SRM 1308
Master Controller
The master controller is a general-purpose mi-
cro-controller for CANbus-based electric vehicles.
It contains processing power, memory resources,
analog and digital input/output (I/O) to provide the
required full-featured functionality. The master
controller is designed to manage the traction motor
controller and pump motor controller, interface to
the operator controls, auxiliary functions, and to
control the vehicle dash display.
The master controller also manages the operating

truck parameters, status codes, battery discharge
indicator (BDI) function, hourmeters, password fea-
ture, and all operator inputs. It also controls the
contactor, cooling fans, and strobe light relay.
Dash Display
The AC dash display provides expanded service ca-
pabilities. The dash display has a password-accessi-
ble service mode that allows a technician to change
control settings and view real-time RPMs, current,
temperature, and switch closure information. Previ-
ously, a separate handset or computer was required
for these operations. For a complete description of
1. CASTER STEER MOTOR (OPTIONAL)
2. MDU STEER MOTOR the display panel, see the Display Panel section of
3. STEERING CONTROLLER this manual.
4. MASTER CONTROLLER
5. LIFT PUMP MOTOR Controller Area Network Bus (CANbus)
6. INTEGRATED FUSE BOARD
7. TRACTION CONTROLLER The motor controllers, master controller, and dash
8. HYDRAULIC CONTROLLER display are connected together with a CANbus
9. SELECTOR VALVE
10. TILT/SIDESHIFT SELECTOR communication system. A personal computer (PC)
11. REMOTE CAN MODULE with the appropriate Electric Truck AC Controller
12. MAIN CONTROL VALVE (ETACC) service software and interface cable can
13. CASTER STEER CONTROLLER (OPTIONAL) easily communicate with all system nodes by simply
14. TRACTION MOTOR connecting to the CANbus. A special connector is
Figure 2. Component Locations (Side View) - located on the right front truck panel cover, adjacent
N30ZDRS, N35-40ZRS to the 12V power supply connector.
2
2200 SRM 1308 AC Transistor Motor Controller Replacement
AC Transistor Motor Controller Replacement

GENERAL controllers that can be repaired. Each of these motor
controllers must be replaced if an internal malfunc-
The AC traction motor controller and AC pump motion occurs.
tor controller assembly is shown in Figure 3 and Fig-
ure 4. There are NO internal parts of these motor
1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

2. AC PUMP MOTOR CONTROLLER 4. STATUS LED
Figure 3. AC Traction and AC Pump Motor Controllers (450A)
3
AC Transistor Motor Controller Replacement 2200 SRM 1308

GENERAL MAINTENANCE help prevent high-temperature conditions. Always

INSTRUCTIONS make sure motor controllers are installed using heat
sink compound and that all heat sink surfaces are
The motor controllers, like other electronic devices, clean. DO NOT block cooling airflow.
have temperature limits. These devices can be dam-
aged if they get too hot. Normal maintenance will
4
2200 SRM 1308 AC Transistor Motor Controller Replacement
Special Precautions
CAUTION
DO NOT operate the traction system at high
WARNING speed or rapidly change direction of operation
To avoid injury and prevent electrical shock, with the wheels raised. Motor controller dam-
perform the following steps before trou- age can occur.
bleshooting, adjustments, or repair:
• Turn the key switch to the OFF position and DO NOT subject the controller to any high voltage
disconnect the battery connector. (hipot or megger) testing.
• Discharge the capacitors in the controllers
by pushing and holding the horn button Use a lead acid battery with the voltage and ampere
down until the horn stops making a sound. hour rating specified for the lift truck. Follow normal
battery maintenance procedures, recharging at 80
percent discharge, with monthly equalizing charges.
CAUTION
To help prevent controller damage: Parts of these assemblies not covered in this manual
• ALWAYS disconnect the battery when servic- cannot be repaired and must be replaced if they mal-
ing the controllers. function. The contactors are serviceable.
• ALWAYS discharge the capacitors before per-
forming any service. WARNING
• NEVER make a short circuit at any motor Some checks in this section must be done with
controller terminal to battery (+), battery ( ), the battery connected and power applied to
or the frame. the controller. When making these checks,
• Remove the motor controllers before per- make sure the drive wheels are raised from
forming any authorized welding procedures. the floor. See procedures given in the Periodic
Maintenance Manual or the Operating Manual
Never add any electrical component to the lift
for your lift truck.
truck without approval from your dealer for
your lift truck. Other electrical components Make sure you disconnect the battery and
can prevent operation and/or damage the mo- separate the connector before you remove any
tor controller. power cables from the power terminals of the
motor controller. The capacitor stores electri-
NEVER USE STEAM TO CLEAN ELECTRONIC
cal energy and can cause injury, if a person
COMPONENTS.
discharges a capacitor, to parts of the body.
In dusty areas, blow low-pressure air over the con- AFTER the battery is disconnected and the
troller to remove dust. In oily or greasy areas, a key switch is in the OFF position, make sure
mild solution of detergent or denatured alcohol can you also discharge the capacitors.
be used to wash off the controller; and then, low-pres-
Discharge the capacitors in the controllers by
sure air should be used to completely dry the con-
pushing and holding the horn button down un-
troller.
til the horn stops making a sound.
For the controller to be most effective, it must be
NOTE: The bolts and screws connected to the elec-
mounted against the finned aluminum heat sink.
tronic components are normally metric sizes.
During installation of the controller, apply a suffi-
cient layer of silicone (heat transfer) grease, Hyster Make sure that you use the correct fastener for the
P/N 1198757, between the controller and the heat part that has been disassembled or removed.
sink to not allow air gaps between the two.
FUSES
Controller wire plugs and other exposed transistor
controller parts should be kept free of dirt and paint The fuses are found on the Integrated Fuse Board.
that might change the effective resistance between See Figure 5. The condition of the fuses can be
points. checked with an ohmmeter.
5
AC Transistor Motor Controller Replacement 2200 SRM 1308
Repair
Tag, identify, and disconnect the wires and cables
from the contactor assembly. Remove the mounting
screws and remove the contactor assembly. See Fig-
ure 7.
1. 7.5 AMP FUSE

2. 10.0 AMP FUSE
3. IDENTIFICATION LABEL
Figure 5. Integrated Fuse Board
FAN
The controller cooling fans operate with battery volt-
age. If battery voltage is present at the fan terminal
strip and the fans do not run, replace the fan. If bat-
tery voltage is not present at the fan terminal strip,
look for problems in the positive circuit from the key
switch or the negative circuit to the master controller.
CONTACTORS
The main (line) contactor is located on the controller
platform beside the pump motor controller. See Fig-
ure 6.
1. TOP COVER
2. FIXED CONTACT SETS
3. MOVABLE CONTACTS
4. SCREW
5. RETURN SPRING
6. INSULATOR
7. COIL ASSEMBLY
Figure 7. Replacement Parts of Line Contactor

1. CONTACTOR 4. MOVABLE
2. POWER CONTACTS Contactor Contacts. The contacts in a contactor
TERMINALS 5. SPRING
3. FIXED CONTACTS 6. PLUNGER are made of special silver alloy. The contacts will look
black and rough from normal operation. This condi-
Figure 6. Main (Line) Contactor tion does not cause problems with the operation of
the lift truck. Cleaning is not necessary. DO NOT
6
2200 SRM 1308 Function Settings
USE A FILE ON THE CONTACTS. DO NOT LU- contact or if there is any transfer of contact ma-
BRICATE THE CONTACTS. terial.
Check the coil with an ohmmeter for an open circuit

CAUTION or a short circuit. Coil resistance should read 32 ±4
ALWAYS replace all of the contacts in a con- ohms at room temperature. Replace the coil if resis-
tactor at the same time. Replace the contacts tances are not within the specification.
when the thickness of any area of a contact is
less than 30 percent of the thickness of a new
Master Controller Checks and Adjustments

NOTE: All checks and adjustments to the master con- • Check the system status codes history.
troller can be done using ETACC software with a per- • Check the state of charge of the battery.
sonal computer (PC). A diagnostics connector is lo- • Check the hourmeter readings on the traction cir-
cated on the right front cover panel next to the 12V cuit and hydraulic pump controllers.
power supply. Many checks can also be done at the • Monitor or adjust the register values for each func-
display panel without being connected to a PC. tion as shown in Table 1.
The following checks and adjustments may be made

using a PC or the dash display:
Function Settings
GENERAL Table 1. Factory Parameter Defaults
The master controller has several functions (pa- Parameter Factory Default
rameters) that can be changed to configure differ-
ent lift truck models and voltages. The function set- Truck Set-Up Parameters
tings are stored and used by the master controller to Truck Serial Number AXXXX12345Z
determine lift truck performance or other operation
variables. Truck Voltage 24 or 36
Truck Capacity 3000, 3500, 4000,
NOTE: Table 1 and Table 2 show the default settings
or 4500
for each control function. The factory settings are the
recommended settings for new units. These settings Battery Type Flooded or
will give satisfactory performance for most applica- Maintenance-Free
tions. 0
BDI Adjust
All functions can be adjusted within the permitted Extended Shift Off
range to change the lift truck operation for a spe-
cific application. Adjustment of a register to a num- LL W/O Override Off*
ber that is different than the factory setting is al- LL W/ Override Off*
lowed, but follow the instructions carefully. Adjust-
ments other than the factory settings will cause the Audible Alarm Off*
lift truck performance and energy consumption to Visible Alarm Off*
change.
Auto Tilt Option Off*
Laser Option Off*
Carry Level Option Beep*
* - Not active on all models
7
Function Settings 2200 SRM 1308
Table 1. Factory Parameter Defaults Table 1. Factory Parameter Defaults

(Continued) (Continued)
Parameter Factory Default Parameter Factory Default

Slow Extended Off* Slow Extend Speed 60%
Simultaneous Full Fast Retract Speed 100%
Hydraulics
Slow Retract Speed 60%
Password Option Off
Tilt Up Speed 100%
Shutdown Time Out 15
Tilt Down Speed 100%
Truck Inspection Off*
Side Shift Speed 100%
Impact Sensor*
Reach Cushion On
Impact Action Off
Lift Parameters
Impact Sound 1
Lift Max RPM 100%
Clear Impact --
Lower Max RPM 100%
Hard Duration 0
Steering Parameters
Hard Accel 0
Steer Effort Medium
Soft Duration 0
Steer Mode Auto
Soft Accel 0
Steer Ratio 65
Maintenance Reminder*
Display Parameters
Maint Reminder Off Language English
Maint Interval 200
Aft Control Parameter
Auxiliary Function Parameters
Aft Enable Off*
Fast Extend Speed 100%
Table 2. Traction Parameter Defaults
Model N30ZDRS or N35-40ZRS

Power 24V Std 36V Std
Turtle Mode Speed 60 60
Low Speed 80 80
High Speed 90 90
Rabbit Mode Speed 100 100
Turtle Mode Acceleration 10 15
Low Acceleration 15 20
High Acceleration 20 25
Rabbit Mode Acceleration 20 35
Braking Neutral 0 0
8
2200 SRM 1308 Troubleshooting
Table 2. Traction Parameter Defaults (Continued)
Model N30ZDRS or N35-40ZRS

Power 24V Std 36V Std
Braking Plugging 70 50
Aft Handle Speed Reverse 25 25
Troubleshooting
GENERAL Once the status code number is obtained, follow the
procedures outlined in the Status Code Charts of this
The AC motor and master controllers are sealed manual to determine the problem.
units with no serviceable components. Troubleshoot-
ing is usually limited to accessing status codes and NOTE: Due to the interaction of the master controller
following the diagnostic procedures listed in the with all lift truck functions, almost any status code
Status Code Charts. or controller fault could be caused by an internal fail-
ure of the master controller. After all other status
Use standard testing procedures to verify inputs and code procedures have been followed and no problem
outputs when necessary. is found, the master controller should be replaced as
the last option to correct the problem.
CAUTION
Tools and test equipment required are: clip leads,
Never attempt to probe through the back of digital multimeter (20,000 ohms per volt minimum),
the connector plugs of the motor controller. and basic hand tools.
These plugs are special sealed plugs. Probing
through the back of the plugs will destroy the Check resistance on RX1000 scale from frame to
seal and can cause a short circuit. If a circuit power and controller terminals. Resistance of less
must be tested for voltage, check for voltage at than 20,000 ohms can cause misleading symptoms.
an amp-type plug, a switch, or a component. If Resistance of less than 1000 ohms should be cor-
a circuit is suspect, check the circuit for conti- rected first.
nuity by disconnecting the P plug and testing
continuity from the front (pin end) of the plug. The onboard diagnostic system employed on this lift
truck can assist in the troubleshooting process. Read
Standard probes are too large to be inserted and be familiar with the instructions for accessing
into the center of the female pins (sockets) of and using the dash display diagnostic system found
the special sealed plugs and can expand the in User Interface, Service Technician (Stan-
pins. Expanded pins will not provide good con- dard Display) 2200 SRM 1193 or User Interface,
nections once the plug is reconnected. The con- Service Technician (Premium Display) 2200
nectors are shaped to allow the insertion of a SRM 1241. Reference to these systems will be noted
small flat-blade screwdriver into the connec- in the Troubleshooting instructions found in this
tor. After inserting the screwdriver into the section.
connector, attach probes with alligator clips to
the shank of the screwdriver to obtain read- Prior to troubleshooting systems and components on
ings. An additional method would be to use a this lift truck, ensure the battery is the correct volt-
breakout kit, Hyster P/N 1397311. age and is fully charged. Make sure the battery con-
nector contacts are clean of corrosion and the battery
See Diagrams 8000 SRM 1199 for additional wiring polarity within the connector is correct. Inspect to
details. ensure all fuses are correct and have not failed. En-
sure the key switch is in the ON position when mak-
If the lift truck does not operate correctly, a status ing voltage checks or checking the operation of a com-
code is displayed on the display panel. ponent. Make sure the floor (reset) switch and the
operator presence switch has been properly closed.
9
Troubleshooting 2200 SRM 1308
Many faults noted by lift truck systems are the result

of loose wiring connections and/or broken or shorted
wiring within the lift truck. Begin the troubleshoot-
ing process by carefully inspecting the wiring involv-
ing the device or devices noted by the onboard diag-
nostic system. Faults noted with components located
on the reach attachment may be caused by broken or
shorted wires in the mast cable. Ensure the integrity
of this cable before troubleshooting attachment-re-
lated faults. 1. LED
CONTROLLER STATUS LIGHT EMITTING Figure 8. Master Controller LED

DIODES (LEDS)
AC Motor Controllers
The AC traction motor controller, AC pump motor
controller, and AC master controller each have a sep- This section covers both the AC traction motor con-
arate LED to indicate its operating status. Each LED troller and AC pump motor controller. Remove the
is green in color and may be lit continuously or blink- rear cover to view the motor controllers. See Figure 9
ing. See each description for the location of each and Figure 10.
LED.
• The LED only turns on when the key switch is in
Master Controller the ON position.
• The LED will show a steady continuous green color
• The LED is located next to the wire harness con- if there is no fault condition detected.
nector. See Figure 8. • When a fault condition is detected that is not seri-
• The LED blinking rate is usually twice a second, ous enough to shut down the truck, the LED blink-
when the battery is connected and the key switch ing rate is twice a second. A status code should ap-
is in the OFF position. pear on the dash display to reference the problem.
• The LED blinking rate slows to once every two sec- • When a fault condition is detected that has shut
onds when the battery is connected and the key down the truck, the LED blinking rate will be at
switch is moved to the ON position. a very rapid rate (too fast to count). A status code
• If the above conditions are not present, the master should appear on the dash display to reference the
controller may not be properly connected or may be problem.
faulty. • If the above conditions are not present, the AC mo-
• Due to the location of the master controller, a small tor controller may not be getting power from the
inspection mirror may be needed to view the LED. key switch or may be faulty.
10

11

12
OPERATOR STATUS MESSAGES These messages are only codes to help identify a pos-
sible malfunction. A short description of the different
NOTE: An operator message does not always mean status messages is shown in Table 3.
there is a malfunction. A temporary operating con-
dition can cause a status code display.
Table 3. List of Operator Warning Messages
Message Description Explanation

Brk Ped Message is displayed at key switch ON Normal Operation.
position.
Power On Message is displayed when truck has timed Normal Operation.
out (approximately 15 minutes without
operation). Screen will go blank and display
message. Key switch must be reset to
resume operation.
Foot Sw Message is displayed after brake pedal is Normal Operation.
depressed. Operator must depress foot
switch to activate lift truck controls.
Ready Message is displayed after start-up Normal Operation.
procedure is complete and lift truck is ready
for operation.
Press If Handle Notification to operator that handle control Operator must press the key to activate
Decal Is Correct parameters have been changed. the lift truck controls.
Forward Message is displayed once the forward Normal Operation.
direction has been selected.
Reverse Message is displayed once the reverse Normal Operation.
direction has been selected with the control
handle.
Lift Message is displayed once the lift function Normal Operation.
has been selected with the control handle.
Lower Message is displayed once the lower function Normal Operation.
Extend Message is displayed once the extend Normal Operation.
function has been selected with the control
handle.
Retract Message is displayed once the retract Normal Operation.
function has been selected with the control
handle.
Tilt Up Message is displayed once the tilt up function Normal Operation.
Tilt Down Message is displayed once the tilt down Normal Operation.
function is selected with the control handle.
SS Right Message is displayed once the sideshift right Normal Operation.
13
Table 3. List of Operator Warning Messages (Continued)

SS Left Message is displayed once the sideshift left Normal Operation.
Load "XXXX" lbs Message is displayed when the load weight Normal Operation.
option is activated and there is a load on the
forks.
Enter Password Message is displayed when passwords option Operator must enter correct password to
is activated. activate the lift truck controls.
Traction Low Traction controller senses a battery voltage Make sure battery voltage matches the
Voltage lower than the reference voltage stored in voltage listed on the lift truck nameplate.
the lift truck voltage parameter.
Lift Low Voltage Lift controller senses a battery voltage lower Make sure battery voltage matches the
than the reference voltage stored in the lift voltage listed on the lift truck nameplate.
truck voltage parameter.
Traction High Traction controller senses a battery voltage Make sure battery voltage matches the
Voltage lower than the reference voltage stored in voltage listed on the lift truck nameplate.
Lift High Voltage Lift controller senses a battery voltage Make sure battery voltage matches the
higher than the reference voltage stored in voltage listed on the lift truck nameplate.
Motor Master controller senses a fault in the Sensor is disconnected or damaged.
Temperature traction motor temperature sensor.
Sensor Fault
Password Error Password has been incorrectly entered or Reenter password.
doesn’t match any password stored in the lift
truck memory.
Password Error Password has been incorrectly entered The lift truck cannot be operated until
exceeding the number of attempts allowed the password system has been reset
by the system. using supervisor password.
Lower Forks Hydraulic tank float switch is indicating a Check hydraulic oil level and fill as
low oil level in the tank. needed. Check for leaks.
Cycle Brake Lift truck will not complete start-up Operator must cycle brake pedal to start
Pedal procedure. truck.
Cycle Foot Lift truck will not complete start-up Operator must cycle brake pedal to start
Switch procedure. truck.
Reset Handle Lift truck will not complete start-up Control handle must be in the neutral
procedure. position at truck startup.
Step on Brake Traction is disabled. Brake must be disengaged for traction
to be active.
Step on Foot Lift truck will not complete start-up Operator must engage floor switch to
Switch procedure. complete start-up procedure.
14

Switches Must Lift truck will not complete start-up Operator is holding switch closed. All
Be Released to procedure. control handle switches must be in the
Start neutral position to complete start-up
procedure.
End of Stroke Function has reached end of stroke and Switch is continuing to be held closed
operator is continuing to operate function after function has reached end of stroke,
switch. or a failure of the switch to turn off.
Reduced Lift The master controller has detected a The lift system will operate at reduced
Speed condition that requires the lift speed to be speed until corrected.
reduced.
Mast Up Speed Mast switch has been activated. Traction If message is displayed when mast is
Reduced speed has been reduced by the master lowered, check for a failed mast switch.
controller.
Carriage Extend The extend switch has been activated. Carriage is not in the fully retracted
Traction speed has been reduced by the position. If message is displayed with the
master controller. carriage fully retracted, check for a failed
extend switch.
Steer Temp High Temperature sensor in the steering motor Truck is being used in a high ambient
has reached 140°C (284°F) degrees. The temperature environment. Reduce use of
master controller has reduced the speed of steering function to allow cooling.
the steering motor.
Traction Motor The temperature of the traction motor is Truck is being operated in a low
Temp Low below 20°C ( 4°F) degrees. temperature environment. Move truck
to a higher temperature area or increase
usage of traction function to increase
motor temperature.
Traction Motor The temperature of the traction motor is Truck is being used in a high ambient
Temp High above 145°C (293°F) degrees. The master temperature environment. Move to a
controller has reduced the speed of the lower temperature area or decrease use
traction motor. of traction system to lower temperature
of the traction motor.
Traction The temperature of the traction motor Truck is being used in a low ambient
Controller Temp controller is below 20°C ( 4°F) degrees. temperature environment. Move to a
Low The master controller has reduced the speed higher temperature area or increase use
of the traction motor. of traction system to raise temperature
of the controller.
Traction The temperature of the traction motor Truck is being used in a high ambient
Controller Temp controller is above 85°C (185°F) degrees. temperature environment. Move to a
High The master controller has reduced the speed lower temperature area or decrease use
of the traction motor. of traction system to lower temperature
of the controller.
15

Lift Motor The temperature of the lift motor is below Truck is being used in a low ambient
Temperature 20°C ( 4°F) degrees. temperature environment. Move to a
Low higher temperature area or increase use
of lift system to raise temperature of the
lift motor.
Lift Motor The temperature of the lift motor is above Truck is being used in a high ambient
Temperature 145°C (293°F) degrees. The master controller temperature environment. Move to a
High has reduced the speed of the lift motor. lower temperature area or decrease use
of lift system to lower temperature of the
lift motor.
Lift Controller The temperature of the lift motor controller Truck is being used in a low ambient
Temperature is below 20°C ( 4°F) degrees. The master temperature environment. Move to a
Low controller has reduced the speed of the lift higher temperature area or increase use
motor. of lift system to raise temperature of the
controller.
Lift Controller The temperature of the lift motor controller Truck is being used in a high ambient
Temperature is above 85°C (185°F) degrees. The master temperature environment. Move to a
High controller has reduced the speed of the lift lower temperature area or decrease use
motor. of lift system to lower temperature of the
controller.
Fan Overcurrent The master controller has detected an Check the controller fan for obstructions.
overcurrent condition in the controller fan The fan motor should be receiving 24
circuit. Traction speed has been reduced by volts. Check for broken wiring in the
the master controller. truck wiring harness and make sure all
connections are tight.
Lift Stalled The lift controller has detected a stalled Mast is at end of stroke. Return control
motor condition in the lift motor. handle to neutral. Operator is trying
to lift overcapacity load. Reduce load
weight. Mast movement is obstructed.
Inspect and repair mast. Lift pump
has failed and prevents the motor from
rotating.
Lift Lockout The battery charge is low. The master Install charged battery.
controller has locked out the lifting function
until a properly charged battery is installed
in the lift truck.
Hyd Disabled Hydraulic functions are disabled and cannot The factory disables hydraulic functions
be actuated. for shipment. Before delivery, technician
should reinstall the hydraulic tank
breather then re-enable hydraulic
functions by holding down the #3 and #4
buttons on the display for 2 seconds.
16

Carriage Truck performs like turtle mode. This is Check position of retract sensor, if
Extended / Speed normal if retract sensor option is installed, equipped. Verify sensor is connected to
Reduced carriage is not fully retracted, and slow wire #803 and not #13. The LED and
extend option is set. signal (wire # 815) are only valid when
retracting or extending or if a jumper is
connected from wire #803 to B .
No Message Truck does not lift, but pump turns. Check the lift valve, coil, and wiring to
the coil. If lift functions after startup,
but not after trying to lower, check for a
shorted lower coil.
No Message Truck does not lower. Check the lower valve, coil, and wiring to
the coil. If lower functions after startup,
but not after trying to lift, check for a
shorted lift coil.
No Message Truck does not extend, sideshift right, or tilt Check aux reverse valve. If these
up but the pump turns. functions work after startup, but not
after attempting opposite function, check
for a shorted aux forward coil.
No Message Truck does not retract, sideshift left, or tilt Check the aux forward valve. If these
down but pump turns. functions work after startup, but not
after attempting an opposite function,
check for a shorted aux reverse coil.
No Message Truck does not extend or retract, but the Check the extend valve. If these
pump turns. functions work after startup, but not
after attempting sideshift, check for a
shorted sideshift coil.
No Message Truck does not sideshift, but the pump turns. Check the sideshift valve. If this works
after startup, but not after attempting
to extend or retract, check for a shorted
extend coil.
No Message Truck does not tilt, but the pump turns. Check the tilt valve. If this works after
startup, but not after attempting extend
or retract, check for a shorted strobe
relay coil.
17
STATUS CODES • Correct input voltages that occur at the wrong time
NOTE: Make sure the parameter values are correct NOTE: A status code indication does not always mean
for your lift truck to ensure the trouble is not just that there is a malfunction. A temporary operating
an incorrect setting. See Function Settings to set the condition can cause a status code display.
correct parameter values. If there is no status code
display and the lift truck does not operate correctly, These code numbers are only codes to help identify
there can be a fault in the master controller. a possible malfunction. A short description of the
different status codes is shown in Table 4.
The status codes are code numbers for malfunctions
or lift truck operations that are not correct and that NOTE: If a "C" appears at the end of a fault code,
the motor controller can sense. The master controller it indicates that the fault is in the caster steering
will indicate this code number on the LCD screen of system.
the display panel.
The Fault Message charts in this section have a more
The master and motor controllers sense the following complete description of the status code, the circuit
types of malfunctions: that has generated the input for the status code, the
• Input voltages that are too high or too low symptom, and the possible causes.
• Input voltages in the wrong sequence or
Table 4. List of Fault Messages
Fault Message Description

Blank Blank Screen No Power to Unit
10/10C STEER FEEDBACK FAULT Steer Feedback Fault
14/14C STR CENTER FAULT Steer Centering Fault
16/16C STEER HIGH VOLT Steer High Voltage
28 LD HOLD CI OPEN Load Hold Coil Open
42 LIFT DRV TMP HIGH Lift Drive Temperature High
52 STR ENCODER FAULT Steer Encoder Fault (Tiller)
62 HORN SHORTED Horn Shorted
65 MAIN COIL SHORTED Main Coil Shorted
66 TRACTION SHORTED Traction Shorted
90 TRAC MTR TEMP HI Traction Motor Temperature High
91 LIFT MTR TMP HIGH Lift Motor Temperature High
214 LIFT SHORT CIRC Lift Short Circuit
222 BRAKE COIL SHORT Brake Coil Shorted
223 MAIN COIL OPEN Main Coil Open
230 FAN OVER CURRENT Fan Over Current (Traction)
238 TRACTION CONTROL FLT Traction Control Fault
239/239C STEER CONT FAULT Steer Control Fault
241/241C STEER COMM ERR Steer Communication Error
348 TRAC COMM ERROR Traction Communication Error
242 HANDLE COMM ERR Handle Communication Error
18
Table 4. List of Fault Messages (Continued)
Fault Message Description

243 PRES SENS FLT Pressure Sensor Fault
247 REMOTE COMM ERR Remote Communication Error
260 LIFT LOW VOLTAGE Lift Low Voltage
271 HANDLE FAULT Handle Fault (Forward/Reverse)
271 HANDLE FAULT Handle Fault (Lift/Lower)
272 AFT HANDLE FAULT Aft Throttle or Sensor Fault
273 HANDLE FAULT Handle Fault (Hall-Error)
310 LIFT CONTROL FAULT Lift Control Fault
311 LIFT COMM ERROR Lift Communication Error
313 LIFT OVER CURRENT Lift Overcurrent
314 NO CHARGE DC BUS No Charge DC Bus
316 LIFT HIGH VOLTAGE Lift High Voltage
320/320C STR MTR HI CUR Steer Motor High Current
321/321C STEER HIGH TMP Steer High Voltage
322/322C STR CONT HI CUR Steer Continuously High Current
330 FAN OVER CURRENT Fan Over Current (Lift)
341 TRAC DRVE TMP HI Traction Drive Temperature High
342 TRACTION OVERCUR Traction Overcurrent
343 NO CHARGE DC BUS No Charge DC Bus
344 TRACTION LOW VOLT Traction Low Voltage
345 TRACTION HIGH VOLT Traction High Voltage
347 TRAC SPD SENS ER Traction Speed Sensor Error
348 TRAC COMM ERROR Traction Communication Error
- SOFT IMPACT Soft Impact
- HARD IMPACT Hard Impact
- IMPACT SENSOR FAULT Impact Sensor Fault
19
Status Display Message Circuit

Code
Blank Blank Blank
Description
Dead Truck
Symptom
No power to the lift truck; blank screen on display.
Probable Causes and Test Procedures
– Verify battery is plugged into the battery connec-
tor.
– Verify condition of FU 10.
– Verify Battery disconnect switch is closed.
– Verify key switch is in the ON position.
– Verify battery voltage at pin #10 at the inte-
grated fuse board.
• Check for battery voltage at run terminal of the
key switch.
• Check continuity of wire #5 from key switch to
integrated fuse board.
– Verify battery voltage at all fuses on integrated
fuse board.
• Check condition of all fuses.
• Replace integrated fuse board.
– Verify battery voltage at pin #1 at the integrated
fuse board.
– Verify 24 volts at pin #4 at the integrated fuse
board connector.
• Replace integrated fuse board.
– Check dash display for fault codes or messages.
• Enter the Diagnostics - Error Log menu for
stored error codes. Clear any errors.
– Verify operation of the main contactor.
• Contactor should close.
– Check for a steady illuminated LED on all con-
trollers. Blinking LED indicates a fault in the
controllers.
• Enter the Diagnostics - Error Log menu.
Check for stored error codes. Clear any errors.
• Replace controller.
– Turn the key switch to the OFF position and
check the resistance between pin #A and pin #B
at the service PC connection.
• Resistance should read between 50 and 70
ohms.
• Check wiring for damage.
20

Code
10/10C 10 STEER FEEDBACK FAULT Steering
CALL SERVICE
Description
The steer controller or caster controller has
sensed either an open or short in the steer motor
or caster motor feedback circuit.
Symptom
Truck is disabled; does not center on startup.
– Check wiring for any loose or shorted connec-
tions in the MDU or caster steering circuit.
– Ensure the connectors in these circuits are tight.
– Check the MDU proximity switch and steering
proximity switch (if equipped) for proper adjust-
ment (1.50 mm (0.06 in.) of the drive gear or tar-
get plate.
– Check proximity switch face for damage.
– Steer the truck to determine which steering mo-
tor is causing the fault.
• Trucks without a steered caster: If the MDU
steering motor fails to operate, the MDU steer-
ing motor is causing the fault.
• Trucks with a steered caster: If the MDU steer-
ing motor operates and the caster steering mo-
tor fails to operate, the caster steering motor is
causing the fault.
– Check for continuity in the wiring between the
steering controller and the steering. Repair as
necessary.
– Check for 5 volts at terminal #3 on the steering
controller and on the red wire at the steering mo-
tor.
• If there is no voltage at terminal #3 of the steer-
ing controller, the steering controller may be
bad.
• If there is voltage at terminal #3 and no voltage
at the red wire, ensure there is contact within
the connector between the steering controller
and the steer motor.
– If no wiring faults are found, the problem is in
the steering motor. Replace the steering motor.
21

Code
14/14C 14 STR CENTER FAULT Steering
CALL SERVICE
Description
The steering controller or caster controller has
sensed a fault in the steer centering operation.
The truck has not centered the steering on system
startup. Drive wheel moves to mechanical stop.
Symptom
Truck is disabled.
– Enter the Diagnostic - Static Diagnostic - Str
Ctr Prox Switch1 and verify the operation of the
MDU steering proximity switch as the steering
system is operated from lock to lock. The dash
display should change from 0 to 1 and back to 0
as the steering system passes through the center
position.
• Check that the MDU proximity switch and
steering proximity switch (if equipped) is ad-
justed within 1.50 mm (0.06 in.) of the drive
gear or target plate.
• Check that the indicator light on the end of the
proximity switch illuminates when the tire is
in the straight-ahead position. Refer to Steer-
ing System 1600 SRM 1187 for instructions
on adjusting the steering proximity sensors.
• Check proximity switch face for damage.
– If the truck is equipped with a steered caster as-
sembly, enter the Diagnostics - Static Diagnostic
- Str Ctr Prox Switch2 and verify the operation of
the caster steering proximity switch as the steer-
ing system is operated lock to lock. The dash dis-
play should change from 0 to 1 and back to 0 as
the system passes thought the center position.
• Check that the proximity sensor is adjusted
within 1.50 mm (0.06 in.) of the drive gear or
target plate.
• Check that the indicator light on the end of the
proximity switch illuminates when the tire is
in the straight-ahead position. Refer to Steer-
ing System 1600 SRM 1187 for instructions
on adjusting the steering proximity sensors.
22

Code
14/14C 14 STR CENTER FAULT Steering
(cont) CALL SERVICE
Description
The steering controller or caster controller has
sensed a fault in the steer centering operation.
The truck has not centered the steering on system
startup. Drive wheel moves to mechanical stop.
Symptom
Truck is disabled.
– Check continuity of all wiring to the proximity
switches from the steering controller to the MDU
or caster assembly.
– Check for 24 volts at terminal #19 on the steering
controller.
– Check for 24 volts at pin #4 or wire #285 on the
integrated fuse board connector.
• Check FU 11 for continuity and replace as nec-
essary.
• Check for battery voltage at FU 11.
– Replace the proximity switch.
23

Code
16/16C 16 STEER HIGH VOLT Steering
CALL SERVICE
Description
The steer controller or caster controller has sensed
a high voltage condition of its power connection.
Symptom
Truck is disabled.
– Check that the MDU proximity switch and steer-
ing proximity switch (if equipped) is adjusted
within 1.50 mm (0.06 in.) of the drive gear or
target plate.
– Check that the indicator light on the end of the
proximity switch illuminates when the tire is in
the straight-ahead position. Refer to Steering
System 1600 SRM 1187 for instructions on ad-
justing the steering proximity sensors.
– Check proximity switch face for damage.
– Enter the Setup - Truck Settings - Voltage menu
and ensure the battery voltage matches the volt-
age setting shown on the dash display.
• Install the correct voltage battery.
– Check to ensure the battery polarity is correct at
the battery connector.
– Check voltage at B+ terminal of the steering con-
troller. Voltage should not exceed 42 volts.
– Replace steering controller.
24

Code
28 28 LD HOLD CI OPEN Lift
CALL SERVICE
Description
The controller has sensed an open condition in
the load hold coil.
Symptom
Lifting is disabled.
– Enter the Diagnostics - Hydraulic System - Load
Hold Coil and check the operation of the load
hold coil.
• The dash display should change from 0 to 1 as
the hoist system is operated and then returned
to neutral.
– Check for loose wiring connections at the load
hold coil.
– Check for battery voltage at terminal #1 of the
load hold coil.
• Check for battery voltage at pin #1 on the in-
tegrated fuse board.
• Check wiring continuity between pin #1 on the
integrated fuse board connector and terminal
#1 on the load hold coil.
– Check wiring continuity between terminal #2 of
the load hold coil and pin #39 at the master con-
troller.
– Disconnect the wires from the terminals of the
load hold coil and check the coil for continuity.
Coil should show continuity and should measure
approximately 30 ohms resistance.
• Replace the coil
– Connect an external ground to terminal #2 of the
load hold coil.
• If coil operates, the problem is internal in the
master controller. Replace the master con-
troller.
25

Code
42 42 LIFT DRV TMP HIGH Lift
CALL SERVICE
Description
The lift controller temperature sensor has sensed
a controller temperature in excess of 85°C (185°F).
Normal system operation will resume when the
lift controller has cooled.
Symptom
The lift motor is operating at a reduced speed.
– Enter the Diagnostics - Hydraulic System -
Pump Control Temp to verify the pump motor
controller has exceeded 85°C (185°F).
– Check the operation of the cooling fan.
• The fan should be operating if the controller
temperature is above 50°C (122°F).
• Check for airflow through the cooling fins at
the base of the motor controllers and that the
cooling fins are not clogged.
• Check that the fan is not blocked and is free to
rotate.
• Check for 24 volts on the red wire at the fan.
• Check for 24 volts at terminal #4 on the inte-
grated fuse board.
• Check the condition of FU 11 on the integrated
fuse board. If FU 11 is good and there is no
voltage at terminal #4, replace the integrated
fuse board.
• If there is 24 volts at the red wire, connect a
jumper from the black wire from the fan to a
system ground.
• If the fan operates, and the controller temper-
ature is above 50°C (122°F), the problem is in
pump motor controller.
• If the fan does not operate, replace the fan.
– Reduce lift system use to allow the controller to
cool and remain below 85°C (185°F).
26

Code
52 52 STR ENCODER FAULT Steering
CALL SERVICE
Description
The steer controller or caster controller has
sensed a fault in the tiller encoder.
Symptom
If moving, the speed command is set to zero,
the electric brake is enabled, and the truck is
disabled. If the fault is sensed at truck startup,
vehicle systems will not be engaged.
– Verify 5 volts on pin #3 of the steering controller.
If voltage is not present, check the steer con-
troller for B+ voltage at the B+ terminal. Check
the LED for solid light.
– If voltage is good on pin #3, check voltage at pin
#1 to the steer encoder unit, pin #B to th epres-
sure transducer (if equipped), and pin #1 (wire
250A) to the steer motor.
– If any circuit is open, check the wiring harness
for continuity. Inspect for loose or damaged pin
connectors and for broken or damaged wires.
– If voltage is less than 5 volts at any point, check
for a grounded circuit by disconnecting the fol-
lowing components one at a time:
• Steer Motor Connection
• Pressure Transducer Connection (if equipped)
• Steer Encoder Connection
Any voltage drop should be determined and the
affected part replaced as necessary.
– Check the continuity of all wiring from the
steering encoder connections to the steering
controller, steering pressure transducer (if
equipped) and the steer motor.
– Check voltage on wire #573, wire #574, wire
#575, and wire #576.
• Voltage on each wire should switch back and
forth between 5 volts and 0 volts as the steer-
ing encoder is slowly rotated.
• If voltage on all wires stays at 5 volts and 0
volts as the steering encoder is rotated, replace
the steering encoder.
27

Code
62 62 HORN SHORTED Horn
CALL SERVICE
Description
The master controller has detected a shorted
condition in the horn circuit.
Symptom
Horn does not operate.
– The horn should be receiving 24 volts when the
horn button is depressed. Check for broken
wiring in the truck wiring harness and make
sure all connections are tight.
• Replace the horn.
– Enter the Diagnostics - Static Diagnostics - Horn
Switch menu to check the operation of the horn
switch.
• The value on the display should switch from 0
to 1 as the horn switch is operated. If the value
does not change, check the horn switch.
• Replace handle.
– Check for 24 volts at terminal #1 at the horn.
• Check for 24 volts at terminal #4 on the inte-
grated fuse board (wire #285).
• Check condition of FU 11 on the integrated
fuse board. Replace as necessary.
– Connect an external ground to terminal #2 on the
horn.
• If the horn now operates, the problem is in
the master controller. Replace the master con-
troller.
28

Code
65 65 MAIN COIL SHORTED Traction
CALL SERVICE
Description
The master controller has sensed the main
contactor coil is shorted at system startup.
Symptom
Truck is disabled.
– Remove the wires from the terminals on the
main contactor.
– Check the contactor coil for a shorted condition.
The coil should measure approximately 32 ±4
ohms resistance.
• Replace the contactor coil.
– Check harness wiring from the contactor nega-
tive terminal to terminal #40 at the master con-
troller for any shorted wires.
– Ensure there is 24 volts at the positive terminal
of the main contactor when the truck is on.
– Connect an external wire from the main contac-
tor negative terminal to terminal #40 at the mas-
ter controller.
• If contactor works properly and fault clears,
the problem is in the wiring.
• If the contactor fails to operate, the problem is
in the master controller. Replace the master
controller.
29

Code
66 66 TRACTION SHORTED Traction
CALL SERVICE
Description
The controller has sensed a shorted condition in
the traction motor.
Symptom
Traction is disabled.
– Restart lift truck to see if the fault reoccurs.
Overcurrent condition may occur during periods
of high use.
– Check battery condition and state of charge.
– Check wiring from traction controller to traction
motor for any loose connections, burned wiring,
or shorted wiring.
• Replace or repair any damaged or shorted
wiring.
• Tighten any loose connections.
– Check the motor controller for shorts. See
Checking the Motor Controller.
• Replace motor controller if any shorts are
found in the controller FET’s and internal
diodes.
– Checking for a shorted motor is possible but re-
quires a low ohm reading meter (milliohms) and
a low cost resistance bridge. The reading for each
phase should be around 0.0032 ohms.
• Replace the traction motor.
30

Code
90 90 TRAC MTR TEMP HI Traction
CALL SERVICE
Description
The traction motor temperature sensor has
sensed a high temperature condition in the
traction motor. The traction motor temperature
has exceeded 145°C (293°F).
Symptom
Traction performance is reduced. If motor
temperature continues to rise above 165°C
(329°F), traction will be disabled.
– Truck is being operated in high ambient tem-
peratures or the truck is being used in a very
high-duty cycle application.
• Reduce the duty cycle to return to normal trac-
tion system operation.
• Enter the Diagnostics - Traction System - Trac-
tion Motor Temp menu to verify the high tem-
perature condition via the dash display.
– If equipped, ensure the compartment fan is op-
erating.
• Clear the fan of any debris.
– Check the drive train to ensure there is no bind-
ing or excessive tightness in the drive unit.
– Check the temperature sensor.
• Allow the motor to cool and measure resistance
between pin #1 and pin #2 at the temperature
sensor connector. Resistance should be approx-
imately 650 ohms at 27°C (80°F).
31

Code
91 91 LIFT MTR TMP HIGH Lift
CALL SERVICE
Description
The temperature sensor in the lift motor has
sensed a temperature exceeding 145°C (293°F)
degrees. Normal system operation will resume
when motor has cooled.
Symptom
The lift motor is operating at a reduced speed.
– Truck is being operated in high ambient tem-
peratures or the truck is being used in a very
high-duty cycle application.
• Reduce the duty cycle to return to normal trac-
tion system operation.
• Enter the Diagnostics - Hydraulic System -
Pump Motor Temp menu to verify the high
temperature condition via the dash display.
– If equipped, ensure the compartment fan is op-
erating.
• Clear the fan of any debris.
– Check the mast to ensure there is no binding or
excessive tightness in the mast.
– Check the temperature sensor.
• Allow the motor to cool and measure resistance
between pin #1 and pin #2 at the temperature
sensor connector. Resistance should be approx-
imately 650 ohms at 27°C (80°F).
32

Code
214 214 LIFT SHORT CIRC Lift
CALL SERVICE
Description
The lift motor controller has sensed a short circuit
condition in the lift motor.
Symptom
Lift is disabled.
– Restart the lift truck to see if the fault reoccurs.
– Check wiring from pump controller to the lift mo-
tor for any loose connections, burned wiring, or
shorted wiring.
wiring.
– Check the lift motor for phase-to-phase or phase-
to-ground shorts.
• Replace lift motor if shorted or resistance is
not within ±10% of the acceptable resistance
value. Refer to section AC Motor Repair 620
SRM 1186 for phase-to-phase resistance val-
ues and replacement instructions.
– If no fault is found with the lift motor or wiring
and problem reoccurs, the problem may be an
internal fault within the pump controller.
• Replace the pump controller.
33

Code
222 222 BRAKE COIL SHORT Brake
CALL SERVICE
Description
The master controller has sensed a shorted coil
condition in the brake circuit.
Symptom
Truck is disabled. If fault is detected while
moving, the speed command is set to zero and the
truck will come to a stop. If fault is detected at
startup, truck is disabled.
– Check the brake coil.
• Remove the wires from the brake coil termi-
nals and check the resistance across the termi-
nals. The coil should measure approximately
12 ohms resistance across the terminals.
• If the resistance is not correct, replace the coil.
– Verify the wiring.
• Check all wiring between the integrated fuse
board and the brake coil (wire #206) and be-
tween the brake coil and terminal #24 at the
master controller (wire #96).
• Verify that all connections are tight and con-
nectors are secure. Repair any broken or
shorted wires.
• Verify there are no shorted wires within con-
nector at the brake coil.
– Verify battery voltage at the positive (wire #206)
terminal of the brake coil.
• Verify battery voltage at terminal #1 at the in-
• Verify the condition of fuse #13 at the inte-
grated fuse board.
– Disconnect wire #96 at the brake coil. Connect
an external ground to the negative terminal of
the main contactor coil.
• If the brake operates as the key switch is op-
erated, the problem may be an internal fault
within the master controller. Replace the mas-
ter controller.
34

Code
223 223 MAIN COIL OPEN Traction
CALL SERVICE
Description
The master controller has sensed the main
contactor coil is open at system startup.
Symptom
Truck is disabled, may give other codes, such as
No Charge DC bus.
– Check the main contactor coil.
• Remove the wires from the main contactor coil
terminals and check for continuity across the
terminals. The coil should measure approxi-
mately 32 ±4 ohms resistance across the ter-
minals.
• If no continuity or the resistance is not correct,
replace the coil.
– Check all wiring for continuity between the inte-
grated fuse board (pin #1) and the main contactor
(wire #206) and between the main contactor and
terminal #40 at the master controller (wire #24).
• Repair any broken or shorted wires.
• Check that all connections are tight and con-
nectors are secure.
– Verify battery voltage at the positive (wire #206)
terminal of the main contactor coil.
• Verify the condition of FU 13 at the integrated
fuse board.
– Verify the CANbus wiring - main contactor will
not close if a CANbus fault is present.
• Turn the key switch to the OFF position
• Check the resistance between pin #A and pin
#B at the service PC connection.
• Resistance should read between 50 and 70
ohms. If resistance of 120 ohms is present,
check CANbus wiring for damage.
– Disconnect wire #24 at the main contactor coil.
Connect an external ground to the negative ter-
minal of the main contactor coil.
• If the main contactor closes as the key switch
is operated, the problem may be an internal
fault within the master controller. Replace the
master controller.
35

Code
230 230 FAN OVER CURRENT Traction
CALL SERVICE
Description
The master controller has sensed an overcurrent
condition in the motor controller (traction) fan
circuit.
Symptom
Truck is disabled.
– Check fan:
• Verify fan is not prevented from rotating.
• Clean any debris from fan.
– Check fan motor for a shorted condition.
• Measure resistance between pin #1 and pin #2
at the fan connector. Resistance should mea-
sure approximately 1.2 ohms.
• Replace fan.
– Check for 24 volts at pin #1 of the fan connector.
• Check for 24 volts at pin #1 of the fan connec-
tor.
36

Code
238 238 TRACTION CONTROL FLT Traction
CALL SERVICE
Description
The master controller has sensed a fault in the
traction controller.
Symptom
restart the lift truck.
– Check all CANbus wiring between the traction
motor controller and the master controller.
• Ensure all connectors are tight and pins are in
good condition.
• Check all CANbus wiring between terminals
for continuity.
– Wire #113 between pin #8 at the master con-
troller connector and pin #7 at the traction
controller connector.
– Wire #900 between pin #23 at the master
controller connector and pin #14 at the trac-
tion controller connector.
controller connector and pin #22 at the steer-
ing controller connector.
– Replace any defective wiring.
– Verify condition of the traction motor controller.
• Verify steady green LED at the traction motor
controller - controller is OK.
• No illuminated LED at the traction motor con-
troller.
– Verify battery voltage at the B+ terminal of
the traction motor controller.
– Verify battery is connected to the truck.
– Verify battery is charged and is correct volt-
age for the lift truck.
• Flashing LED at the traction motor controller
- Internal Fault. Replace the traction motor
controller.
37

Code
239/239C 239 STEER CONT FAULT Steering
CALL SERVICE
Description
The master controller or caster controller has
sensed a fault in the controller. The controller
has an internal fault. This error is usually
accompanied by a more detailed fault code.
Symptom
Truck is disabled. If the truck is moving, the
speed command is set to zero, the electric brake is
engaged, and the truck systems are disabled.
– If the lift truck is equipped with caster steering,
determine which steering controller is producing
the fault.
• Operate the steering system.
• If only the drive unit turns, the caster con-
troller is producing the fault.
• If neither the drive unit nor the caster turns,
the drive unit controller is at fault.
38

Code
(cont) CALL SERVICE
Description
Symptom
– Enter the Diagnostics - Error Log menu of the
dash display and note any other steering system
fault error codes.
• Refer to the procedures for any other error code
listed in the menu.
– Check all CANbus wiring between the steering
good condition.
for continuity.
troller connector and pin #8 at the steering
Note: If the lift truck is equipped with the
steered caster option, there will be no con-
nection to pin #14 at the steering controller
for the MDU steering motor.
– Wire #901 between pin #23 at the steering
39

Code
(cont) CALL SERVICE
Description
Symptom
– Verify condition of the steering motor controller.
• Verify steady green LED at the steering motor
• No illuminated LED at the steering motor con-
troller.
the steering motor controller.
• Flashing LED at the steering motor controller -
internal fault. Replace the steering motor con-
troller.
40

Code
241/241C 241 STEER COMM ERR Steering
CALL SERVICE
Description
The master controller cannot establish or has lost
CANbus communication with the steering motor
controller or caster controller.
Symptom
Truck is disabled.
– If the lift truck is equipped with caster steering,
determine which steering controller is producing
the fault.
• Operate the steering system.
• If only the drive unit turns, the caster con-
troller is producing the fault.
• If neither the drive unit nor the caster turns,
the drive unit controller is at fault.
– Enter the Diagnostics - Error Log menu of the
dash display and note any other steering system
fault error codes.
• Refer to the procedures for any other error code
listed in the menu.
41

Code
241/241C 241 STEER COMM ERR Steering
(cont) CALL SERVICE
Description
CANbus communication with the steering motor
controller or caster controller.
Symptom
Truck is disabled.
– Check all CANbus wiring between the steering
good condition.
for continuity.
troller connector and pin #8 at the steering
– Wire #901 between pin #23 at the steering
ing controller connector. Note: If the lift
truck is equipped with the steered caster op-
tion, there will be no connection to pin #14 at
the steering controller for the MDU steering
motor.
– Verify condition of the steering motor controller.
• Verify steady green LED at the steering motor
• No illuminated LED at the steering motor con-
troller.
the steering motor controller.
• Flashing LED at the steering motor controller
- Internal Fault. Replace the steering motor
controller.
42

Code
242 242 HANDLE COMM ERR Controls
CALL SERVICE
Description
CANbus communication with the control handle.
Handle must establish communication with the
master controller within four seconds at startup.
Symptom
Truck is disabled. Main contactor will not pull in.
– Check for 24 volts at pin #1 of the handle connec-
tor, wire #1285.
• Check for 24 volts at pin #5 at the IFB connec-
tor.
• Check FU 11 on the IFB.
– Check continuity of wire #1285 from pin #5 of the
IFB connector to pin #1 of the handle connector.
• Check FU 11 on the IFB.
– Verify all CANbus wiring between the steering
good condition.
for continuity. Replace any defective wiring.
– Wire #113 between ground and pin #4 at the
multifunction handle connector.
controller connector and pin #2 at the mul-
tifunction handle connector.
– Control handle is defective.
• Replace the control handle.
43

Code
243 243 PRES SENS FAULT STEER
CALL SERVICE
Description
The Master Controller has sensed an out of range

fault with the pressure transducer.
Symptom
The truck does not limit or always limits, for
weighted speed reduction.
– Ensure the sensor has power (5V ±15% on wire
#250A Red).
• If power not present at sensor, trace #250 wire
back to steer controller pin 3.
– If connection is good, including pins, unplug
sensor and measure again.
– If connection is good, including pins, unplug
sensor and measure again.
– If 5V still not present, and connection is good
check ground wire #105-Grn, should have
continuity to B .
– If good continuity, but 5V & Gnd reference
still show no power then replace steer con-
troller.
• If power is present, move on to the next check:
– Check the pressure sensor: With the forks sitting
on the ground the output should be ~2.5V on wire
#62.
• If output shows > 4.5 or < 0.25V, replace sensor.
• If output within 2.2 to 2.7V, then check conti-
nuity in harness to pin 7 of steer controller.
• If continuity OK, check pressure variability:
– Lift forks in air, no load, and check value
– Repeat with a 2000lb load and check value
– Value should have increased > 2.7V
– If no change found replace sensor.
– If sensor changes output, then replace steer
controller
44

Code
247 247 REMOTE COMM ERR REMOTE
CALL SERVICE
Description
The Master Controller has lost communication

with the Remote Module.
Symptom
The auxiliary hydraulic functions do not operate.
– Ensure the remote module has power (24V ±15%
on wire #285C).
• If power not present at aft handle, trace wire
#285C back to the over-the-mast cable.
– If connection is good, but still no power, check
over the mast cable connection to main har-
ness.
– If connection is bad, replace reach harness.
– If mast connection is good, but no power,
check wire #285 from IFB.
– If main harness connection is good, check
FU13 on IFB.
– If fuse is good, replace IFB.
• If power is present, move onto the next check:
– Measure CANbus impedance with truck off and
battery disconnected.
• CAN should be 60 Ohms between wire #900
and #901 at diagnostic connector.
• If CAN impedance is 110 Ohms or greater,
there is a broken CAN line to the remote:
– Check wire #900 and #901 on the over the
mast wire.
– if either have no continuity.
– Replace reach harness if continuity bad or
shorted to B+ or GND.
– If a good connection exists, check wires #900 and
#901 on reach harness through mechanism.
• If connections have been good, check harness
& connector pins for continuity. Repair as nec-
essary
• If no faults in harness found, replace remote
module.
– NOTE: Usually a bad harness or lack of power to
module is the cause.
45

Code
260 260 LIFT LOW VOLTAGE Lift
CALL SERVICE
Description
The lift motor controller has sensed a low voltage
condition in the lift motor circuit.
Symptom
Lift is disabled.
– Verify correct lift truck voltage.
• Enter the Setup - Truck Settings - Voltage and
verify correct voltage.
• Ensure this matches the voltage on the lift
truck nameplate.
– Verify correct voltage battery is installed in the
lift truck.
– Check the battery indicator on the dash display
to verify the battery is sufficiently charged.
– If the battery voltage and the state of charge are
correct, turn the lift truck off for 10 seconds.
• Turn the key switch to the ON position to
– If the status code reoccurs, the problem is inter-
nal to the pump controller.
• Check the status LED on the controller. See
Controller Status Light Emitting Diodes
(LEDs).
• Replace the pump motor controller.
46

Code
271 271 HANDLE FAULT Controls
CALL SERVICE (Forward/Reverse)
Description
control handle operation. The forward/reverse
signal is out of range.
Symptom
If the truck is moving, the speed command is set
to zero, the electric brake is engaged, and the
truck systems are disabled.
– Enter the Diagnostics – Static Diagnostics -
Reach/Retract Switch menu through the dash
display.
• Switch output should vary from greater than
95% forward throttle to greater than 95% re-
verse throttle as the Control Handle is moved
from full forward to full reverse.
– Using ETACC, verify that the control select
parameter is correct for the type of control
present on the truck.
– Check wiring for loose connections or broken
wires between the control handle and the mas-
ter controller.
– Verify all CANbus wiring and connections are se-
cure.
good condition.
• Check all CANbus wiring between the steering
controller and the master controller for conti-
nuity.
– Pin #2 & pin #3 at the handle connector and
pin #22 and pin #23 at the master controller
connector.
– Replace the control handle.
47

Code
271 271 HANDLE FAULT Controls
CALL SERVICE (Lift/Lower)
Description
The controller has sensed the handle output
voltage is out of range when requesting a lift or
lower operation.
Symptom
Lifting and lowering are disabled. Traction
operates at turtle speed.
– Enter the Diagnostics - Static Diagnostics - Hy-
draulic Throttle menu through the dash display.
95% Lift to greater than 95% Lower as the
Control Handle is moved from full Lift to full
Lower.
• Using ETACC, verify that the handle parame-
ters are correct.
– Check wiring for loose connections or broken
wires between the control handle and the mas-
ter controller.
– Ensure all connectors are tight and pins are in
good condition.
• Check all CANbus wiring between the control
handle and the master controller for continu-
ity. Replace any defective wiring.
troller connector and pin #4 at the multifunc-
tion handle connector.
• Verify all CANbus wiring and connections are
secure.
– Replace the control handle.
48

Code
272 272 AFT HANDLE FAULT TRACTION
CALL SERVICE
Description
The Master Controller has sensed a fault in the

Aft Handle Throttle or Sensor.
Symptom
The aft handle does not work, and the truck will
operate in limp mode.
– Ensure the aft handle assembly has power (24V
±15% on wire #285).
• If power not present at aft handle, trace #285
wire back to IFB pin 4.
– If connection is good, check FU13 fuse on
IFB.
• If power present, move onto the next check:
– Using Static Dash Diagnostics, check the aft
throttle:
95% forward throttle to greater than 95% re-
verse throttle as the Aft Throttle is moved from
full forward to full reverse.
– If throttle does not vary, replace aft handle.
– Using Static Dash Diagnostics, check the aft sen-
sor:
• The status of “aft sensor” will change to “1”
when hand is inserted, and “0” when removed.
– If no transition occurs, replace Aft Handle.
– With no faults are found with above, re-key the
truck, and ensure no object is in the aft handle
area.
• NOTE: The truck WILL produce this fault code
if any object is within aft handle sensor area
upon key ON.
49

Code
273 273 HANDLE FAULT CONTROLS
CALL SERVICE
Description
The handle has detected an internal fault.

Symptom
The primary handle does not function or operate
the truck to some degree. Some functions may
still exist.
– Internal diagnostics has already pointed to the
problem. No troubleshooting is possible.
– Replace handle.
50

Code
310 310 LIFT CONTROL FAULT Lift
CALL SERVICE
Description
lift controller.
Symptom
Lift is disabled.
– Ensure all wiring connections at the lift con-
troller are secure and connector is tight.
– Check the lift controller LED.
• LED is illuminated and not flashing. Con-
troller is OK.
• LED is flashing. There is an error with the
controller.
• LED is not illuminated.
Check for battery voltage at the B+ terminal
of the lift controller.
Check that main contactor is closed.
Check for continuity across the contactor tips
when closed. Replace contactor tips.
– Enter the Diagnostics – Error Log menu at the
dash display.
• Correct any errors noted in the Error Log.
• If problem returns, replace the lift controller.
51

Code
311 311 LIFT COMM ERROR Lift
CALL SERVICE
Description
CANbus communication with the lift controller.
Symptom
Lift is disabled.
– Check the lift controller LED.
troller is OK.
controller.
Check for continuity across the contactor tips
when closed. Replace contactor tips.
– Check the CANbus wiring between the lift con-
troller and the master controller.
• Check continuity of wire #900 and wire #901.
• Ensure the harness connectors at the pump
controller and the master controller are tight
and secure.
• Problem returns. Replace the lift controller.
52

Code
313 313 LIFT OVER CURRENT Lift
CALL SERVICE
Description
The lift motor controller has sensed an overcurrent
condition in the lift motor.
Symptom
Lift is disabled.
restart the lift truck to verify the error.
– Ensure wiring between the lift pump controller
and the lift pump motor is tight and secure.
• Check wiring for a short to ground condition.
– Check the lift pump motor for phase-to-phase
shorts or phase-to-ground shorts.
• Repair or replace the lift pump motor.
53

Code
314 314 NO CHARGE DC BUS Lift
CALL SERVICE
Description
The integrated fuse board has detected a fault in
the lift controller precharge circuit.
Symptom
Lift is disabled. Main contactor will not pull in.
– Check power on circuit:
• Verify the main contactor is closing at the key
switch ON position.
• Verify the battery is charged, properly con-
nected to the lift truck and cables and connec-
tors are in good working order.
• Check the key switch and E-Stop for proper
connections and operation.
• Ensure the accessory light connections are not
mistakenly connected to the key switch (these
connectors are normally tied to the wiring har-
ness when not used).
• Recycle the key switch and check to see if the
fault clears.
– Check the main contactor and power circuits.
• Check main contactor coil: Remove the wires
from the main contactor coil terminals and
check for continuity across the terminals. The
coil should measure approximately 32 ±4 ohms
resistance across the terminals.
– If no continuity or the resistance is not cor-
rect, replace the coil.
• Check all wiring for continuity between the in-
tegrated fuse board (pin #1) and the main con-
tactor (wire #206) and between the main con-
tactor (wire #24) and terminal #40 at the mas-
ter controller.
nectors are secure.
• Verify battery voltage at the positive (wire
#206) terminal of the main contactor coil.
fuse board.
54

Code
314 (cont) 314 NO CHARGE DC BUS Lift
CALL SERVICE
Description
Symptom
– Verify the CANbus wiring – Main contactor will
not close if a CANbus fault is present. Turn the
key switch to the OFF position and disconnect
the battery.
#B at the service PC connection. Resistance
should read between 50 and 70 ohms.
• If resistance of 120 ohms is seen, check CAN-
bus wiring for shorts, loose connections, or
damaged wiring.
• Verify the 120 ohm resistor is present in the
main harness.
• Use ETACC software to verify all devices are
present and communicating on the CANbus.
Use the menu bar "reports’ then "devices re-
port" to view the communication of the compo-
nents.
– Check the Precharge Status LED on the inte-
grated fuse board to verify the fault.
• LED is off. Check the condition of FU 10. Re-
place the fuse.
55

Code
314 (cont) 314 NO CHARGE DC BUS Lift
CALL SERVICE
Description
Symptom
– Check for battery voltage at pin #7 at the inte-
grated fuse board connector with the key switch
in the ON position.
• Verify battery is connected.
• Verify battery disconnect switch is closed.
• Verify the key switch is in the ONposition.
• Check continuity of the wiring between the key
switch and the integrated fuse board.
in the ON position.
• If the problem persists, replace the integrated
fuse board.
– Check the Master Controller:
• Disconnect wire #24 at the main contactor coil.
Connect an external ground to the negative
– If the main contactor closes as the key switch
fault within the master controller.
– Replace the master controller.
56

Code
316 316 LIFT HIGH VOLTAGE Lift
CALL SERVICE
Description
The lift motor controller has sensed a high voltage
condition in the lift motor circuit.
Symptom
Lift is disabled.
– Enter the Setup - Truck Settings - Voltage menu

at the dash display.
• Verify battery installed in lift truck is the same
voltage as listed on the dash display and the
lift truck nameplate. Install correct battery.
– Verify the battery state of charge. Install cor-
rectly charged battery.
– Turn the key switch to the OFF position. Wait 10
seconds. Turn the key switch to the ON position
and restart the lift truck.
57

Code
320/320C 320 STEER MTR HI CURR Steering
CALL SERVICE
Description
The controller has sensed a high current condition
in the steer motor drive or caster motor circuit.
Symptom
Truck is disabled.
– Enter the Diagnostics – Steer System – Steer
Motor Temp menu at the dash display.
• Verify the reading on the dash exceeds 125°C
(257°F) while the fault is being displayed.
• Trucks without a steered caster:
If the MDU steering motor fails to oper-
ate, the MDU steering motor is causing the
fault.
• Trucks with a steered caster:
If the MDU steering motor operates and the
caster steering motor fails to operate, the
caster steering motor is causing the fault.
If both steering motors fail to operate, the
MDU steering motor is causing the fault.
– Elevate the rear of the lift truck to allow the drive
and/or caster wheels to be slightly off the floor.
• Verify there is no binding in the steering sys-
tem. Wheels should rotate freely during opera-
tion of the steering system. Repair the steering
system.
– Verify operation of the steer motor temperature
sensor.
• Check for voltage at pin #16 of the motor con-
troller identified in the above step while the
fault is being displayed. Replace faulty steer-
ing controller.
• Allow motor to cool.
– Measure resistance between pin #1 and pin
#2 at the temperature sensor connector. Re-
sistance should be approximately 650 ohms
at 27°C (80°F).
– Allow the steering motor to cool and check for no
voltage at pin #16 of the motor controller.
• Replace the steer motor.
58

Code
321/321C 321 STEER HIGH TMP Steering
CALL SERVICE
Description
The controller has sensed a high temperature in
the steer motor drive or caster motor circuit.
Symptom
Truck is disabled.
Motor Temp menu at the dash display.
• Verify the reading on the dash exceeds 125°C
(257°F) while the fault is being displayed.
fault.
tion of the steering system. Repair the steering
system.
– Verify operation of the steer motor temperature
sensor.
• Check for voltage at pin #16 of the motor con-
troller identified in the above step while the
fault is being displayed. Replace faulty steer-
ing controller.
• Allow motor to cool.
– Measure resistance between pin #4 and pin
#6 at the temperature sensor connector. Re-
sistance should measure 610 ohms ±10% at
27°C (80°F).
– Allow the steering motor to cool and check for no
voltage at pin #16 of the motor controller.
• Replace the steer motor.
59

Code
322/322C 322 STR CONT HI CUR Steering
CALL SERVICE
Description
The master controller has sensed a continuous
overcurrent condition in the steering or caster
actuator.
Symptom
Truck is disabled.
Motor Current menu at the dash display.
• Verify the reading on the dash exceeds 25 amps
for a 24-volt truck or 35 amps for a 36-volt
truck while operating the steering system on
a smooth level floor.
fault.
tion of the steering system Repair steering sys-
tem.
– Check the motor wiring for a shorted condition.
• Remove the power leads from the motor at the
steering controller. Check the motor for phase-
to-phase or phase-to-ground shorts. Replace
the steering motor.
• Replace the steering controller.
60

Code
323/323C 323 STEER POS ERR Steering
CALL SERVICE
Description
The deviation between the calculated steering
position and the measured steering position is too
large.
Symptom
Truck is disabled.
– If the MDU steering motor fails to operate,
the MDU steering motor is causing the fault.
– If the MDU steering motor operates and the
– Inspect all wiring from the steering proximity
switch (either SW-1 or SW-2) of the faulty motor
to the steering controller.
• Check for loose connections or damaged wiring.
Repair as necessary.
Rotate the drive wheel or the caster wheels.
• Verify the steering proximity switch indicator
light illuminates as the wheel is rotated.
• Check for 24 volts at pin #1 at the steering
proximity switch connector.
• Check for 24 volts at pin #4 at the integrated
fuse board.
• Check condition of FU 11.
• Check for battery voltage at FU 11.
– Verify the steering proximity switch spacing is
not greater than 1.5 mm (0.06 in.).
• Adjust proximity switch.
– Inspect the sensor for any damage to the sensor.
• Replace proximity switch.
61

Code
330 330 FAN OVER CURRENT Lift
CALL SERVICE
Description
The master controller has sensed an overcurrent
condition in the motor controller (lift) fan circuit.
Symptom
Truck is disabled.
– Check fan:
• Verify fan is not prevented from rotating.
• Clean any debris from fan.
– Check fan motor for a shorted condition.
• Measure resistance between pin #1 and pin #2
at the fan connector. Resistance should mea-
sure approximately 1.2 ohms.
• Replace fan.
– Check for 24 volts at pin #1 of the fan connector.
• Check for 24 volts at pin #1 of the fan connec-
tor.
62

Code
341 341 TRAC DRVE TMP HI Traction
CALL SERVICE
Description
The temperature controller temperature sensor
has sensed a controller temperature in excess
of 85°C (185°F). Normal system operation will
resume when the traction controller has cooled.
Symptom
Traction performance is reduced. If motor
temperature continues to rise above 165°C
(329°F), traction will be disabled.
– Enter the Diagnostics – Traction System – Trac-
tion Control Temp to verify the traction motor
controller has exceeded 85°C (185°F).
– Check the operation of the cooling fan.
• The fan should be operating if the controller
temperature is above 50°C (122°F).
• Check for airflow through the cooling fins at
the base of the motor controllers. Check the
cooling fins are not obstructed. Check the fan
is not blocked and is free to rotate.
• Check for 24 volts on the red wire at the fan.
Check for 24 volts at terminal #4 on the
integrated fuse board.
Check the condition of FU 11 on the inte-
grated fuse board.
If FU 11 is good and there is no voltage
at terminal #4, replace the integrated fuse
board.
If there is 24 volts at the red wire, connect
a jumper from the black wire from the fan
to a system ground. If the fan operates,
and the controller temperature is above
50°C (122°F), the problem is in traction
motor controller.
If the fan does not operate, replace the fan.
– Reduce traction system use to allow the con-
troller to cool and remain below 85°C (185°F).
63

Code
342 342 TRACTION OVERCUR Traction
CALL SERVICE
Description
The controller has sensed an overcurrent
condition in the traction circuit.
Symptom
– Restart lift truck to see if the fault reoccurs.
– Check wiring from traction controller to traction
motor for any loose connections, burned wiring,
or shorted wiring.
wiring.
– Check the traction motor for phase-to-phase or
phase-to-ground shorts.
• Replace traction motor.
– If no fault is found with the traction motor or
wiring and problem reoccurs, the problem may
be an internal fault within the traction con-
troller.
• Replace the traction controller.
64

Code
343 343 NO CHARGE DC BUS Traction
CALL SERVICE
Description
the traction controller precharge circuit.
Symptom
– Check power on circuit:
• Verify the main contactor is closing at the key
switch ON position.
• Verify the battery is charged, properly con-
nected to the lift truck and cables and connec-
tors are in good working order.
• Check the key switch and E-Stop for proper
connections and operation.
• Ensure the accessory light connections are not
mistakenly connected to the key switch (these
connectors are normally tied to the wiring har-
ness when not used).
• Recycle the key switch and check to see if the
fault clears.
– Check the main contactor and power circuits.
• Check main contactor coil: Remove the wires
from the main contactor coil terminals and
check for continuity across the terminals. The
coil should measure approximately 32 ±4 ohms
resistance across the terminals.
– If no continuity or the resistance is not cor-
rect, replace the coil.
• Check all wiring for continuity between the in-
tegrated fuse board (pin #1) and the main con-
tactor (wire #206) and between the main con-
tactor (wire #24) and terminal #40 at the mas-
ter controller.
nectors are secure.
• Verify battery voltage at the positive (wire
#206) terminal of the main contactor coil.
fuse board.
65

Code
343 (cont) 343 NO CHARGE DC BUS Traction
CALL SERVICE
Description
Symptom
– Verify the CANbus wiring – Main contactor will
not close if a CANbus fault is present. Turn the
key switch to the OFF position and disconnect
the battery.
#B at the service PC connection. Resistance
should read between 50 and 70 ohms.
• If resistance of 120 ohms is seen, check CAN-
bus wiring for shorts, loose connections, or
damaged wiring.
• Verify the 120 ohm resistor is present in the
main harness.
• Use ETACC software to verify all devices are
present and communicating on the CANbus.
Use the menu bar "reports’ then "devices re-
port" to view the communication of the compo-
nents.
– Check the Precharge Status LED on the inte-
grated fuse board to verify the fault.
• LED is off. Check the condition of FU 10. Re-
place the fuse.
66

Code
343 (cont) 343 NO CHARGE DC BUS Traction
CALL SERVICE
Description
Symptom
in the ON position.
• Verify battery is connected.
• Verify battery disconnect switch is closed.
• Verify the key switch is in the ONposition.
in the ON position.
• If the problem persists, replace the integrated
fuse board.
– Check the Master Controller:
• Disconnect wire #24 at the main contactor coil.
Connect an external ground to the negative
– If the main contactor closes as the key switch
fault within the master controller.
– Replace the master controller.
67

Code
344 344 TRACTION LOW VOLT Traction
CALL SERVICE
Description
The controller has sensed a low voltage condition
in the traction circuit.
Symptom
– Enter the Setup – Truck Settings – Voltage and
verify correct voltage.
• Ensure this matches the voltage on the lift
truck nameplate.
– Verify correct voltage battery is installed in the
lift truck.
– Verify the battery is sufficiently charged.
– If the battery voltage and the state of charge are
correct, turn the lift truck off for 10 seconds.
• Turn the key switch to the ON position to
– If the status code reoccurs, the problem is inter-
nal to the traction controller.
• Replace the traction motor controller.
68

Code
345 345 TRACTION HIGH VOLT Traction
CALL SERVICE
Description
The controller has sensed a high voltage condition
in the traction circuit.
Symptom
– Enter the Setup – Truck Settings – Voltage menu
at the dash display.
• Verify battery installed in lift truck is the same
voltage as listed on the dash display and the
lift truck nameplate.
– Verify the battery state of charge.
– Turn the key switch to the OFF position. Wait 10
seconds. Turn the key switch to the ON position
and restart the lift truck.
• If problem returns, replace the traction con-
troller.
69

Code
347 347 TRAC SPD SENS ER Traction
CALL SERVICE
Description
traction motor speed sensor.
Symptom
– Enter the Diagnostics – Traction System – Trac-
tion Motor Speed menu at the dash display.
– Operate the traction system and observe the
RPM value. If no RPM value is displayed or
reading is erratic:
• Check all wiring connections are tight and se-
cure.
• Check continuity of wire #104, wire #281, wire
#577, and wire #578 from the traction motor
encoder to the traction motor controller.
– Check continuity of wire #104, wire #281, wire
#577, and wire #578 from the traction motor en-
coder to the traction motor controller.
– Check for 12 volts on wire #281 at the traction
motor encoder connector.
• Check for 12 volts between pin #3 and pin #4
at the traction motor controller.
• Check for battery voltage at B+ terminal of the
controller.
• Replace controller.
– Check for voltage between pin #2 and pin #4 at
the connector from the traction motor encoder.
• Voltage should be between 0.0 volts and 10.8
volts.
• Replace traction motor encoder.
– Check for voltage between pin #3 and pin #4 at
the connector from the traction motor encoder.
• Voltage should be between 0.0 volts and 10.8
volts.
• Replace traction motor encoder.
70

Code
348 348 TRAC COMM ERROR Traction
CALL SERVICE
Description
The master controller has lost communication

with the traction motor controller.
Symptom
– Check the traction controller LED.
troller is OK.
controller.
Check for continuity across the contactor
tips when closed. Replace contactor tips.
– Check the CANbus wiring between the traction
controller and the master controller.
• Check continuity of wire #900 and wire #901.
• Check all connectors are secure.
• If the problem returns, replace the traction
controller.
71
Display Panel 2200 SRM 1308
CHECKING THE MOTOR CONTROLLER a. Each phase should measure equal readings.
Check the traction motor controller for shorts to the 4. Using a multi-meter set to diode check, measure
internal FET’s; from B to each phase’s terminal on the con-
troller (U,V,W).
1. Disconnecting the motor U,V,W leads from the
controller. a. Each phase should measure open (OL).
2. Using a multi-meter set to diode check, measure 5. Reverse the leads and check each phase again.
from B+ to each phase’s terminal on the con-
troller (U,V,W). a. Each phase should measure equal readings.
a. Each phase should measure open (OL). 6. Replace the motor controller if any shorts are
found in the controller FET’s and internal diodes.
3. Reverse the leads and check each phase again.
Display Panel
GENERAL • Allows preassigned service passwords to control ac-
cess to the service functions available through the
There are two dash display options, Standard and display.
Premium. See Figure 11 and Figure 12. • Provides a comprehensive set of service functions,
which are accessed through the mode keys and liq-
Premium Display Panel uid crystal display (LCD).
• Allows use of an operator checklist, so the operator
• Allows preassigned user passwords to control
verifies truck function prior to vehicle startup.
driver access to the vehicle.
• Provides four driving modes that are accessed
through the keypad.
Figure 11. Premium Display Panel
72
2200 SRM 1308 Standard Display Functions and Features
Standard Display Panel • Provides the same comprehensive set of service

functions using the mode keys and LCD as the
• Allows preassigned service passwords to control ac- Premium Display.
cess to the service functions available through the • Provides four driving modes that are accessed
display. through the keypad.
Figure 12. Standard Display Panel
Standard Display Functions and Features

KEY-ON INITIALIZATION
Upon turning the key to the ON position, the display
sequentially lights the indicators, from left to right,
located along the top of the display. See Figure 13.
1. INDICATOR LIGHTS
Figure 13. Dash Display
73
Standard Display Functions and Features 2200 SRM 1308
PASSWORDS lift truck. The relationship between the modes re-

mains constant and cannot be altered.
Following the initialization sequence given above,
the LCD displays the prompt for the operator to The operator can change performance modes by
enter a password if this function has been enabled. pressing the performance key on the dash display to
See Table 5. If the password function is disabled, the cycle through the four modes. An arrow on the dash
display will bypass the password prompt. To enable display indicates the selected performance mode.
the password function, see User Interface, Super- Any change to the performance mode does not take
visor Password Functions (Standard Display) effect until the operator releases the control handle.
2200 SRM 1192 or User Interface, Supervisor If the password function is enabled, the operator
Password Functions (Premium Display) 2200 will be limited by the performance level set in the
SRM 1240. password function.
Table 5. Password Prompt Screen BATTERY DISCHARGE INDICATOR (BDI)

The AC control system includes a Battery Discharge
Indicator (BDI) that provides indication of the bat-
Enter Password tery state of charge. See Figure 14. The BDI feature
is displayed to the operator on the dash display with
XXXXX a 20-segment bar.
The BDI provides full functionality when used with

a full range of batteries including:
A few seconds after the correct password has been en- • Flooded cell, standard amp-hour batteries
tered, the BDI and performance mode are displayed • Flooded cell, high amp-hour capacity batteries
and the vehicle can be operated. See Figure 14. • Valve regulated (absorbed glass mat) maintenance-
free batteries (VRLA)
The lift interrupt feature is controlled by the vehicle

master controller and prevents the lift function when
the battery is 80 percent discharged. Although lift
interrupt prevents lifting, low speed functions, such
as tilt and sideshift, remain operational to allow the
operator to more easily remove the forks from the
load and return to the battery charging area.
When lift interrupt is initiated, it will remain in ef-

fect until the battery is disconnected and a recharged
battery is reconnected to the vehicle. When a bat-
tery is replaced or recharged, the new state of charge
1. BATTERY DISCHARGE INDICATOR (BDI) must be at least 25 percent greater than the previ-
2. PERFORMANCE MODE SELECTION ous state of charge. This prevents the BDI from be-
ing activated by a battery that has recovered slightly
Figure 14. Battery Discharge Indication in during an idle period.
Standard Dash Display LCD Window
A BDI adjustment feature is provided through the
PERFORMANCE MODES control setup function, which is accessible using ei-
ther the dash display or the PC service software. The
The following four operator selectable performance adjustment scale is 0-100, with a value of 30 for the
modes are available. These modes are preconfigured factory setting. The setting of 30 is the starting point
from the factory as described below. Rabbit mode for flooded cell-type batteries of all voltages and amp-
provides the highest performance. The other three hour capacities. The adjustment can then be used to
modes are a percentage of the rabbit performance. A fine-tune the BDI lift interrupt feature. For example,
service technician, using either the dash display or if it is desired to have the lift interrupt to occur at a
the PC service tool, can revise the control settings higher battery specific gravity, then the value would
and configure the top speed and acceleration of the
74
2200 SRM 1308 Standard Dash Display Service Menu Navigation
be increased. The value is decreased if a lower spe- • Traction - accumulates time when the traction mo-
cific gravity is desired for the lift interrupt point. tor is activated.
• Lift - accumulates time when the lift motor is acti-
If a maintenance-free battery is installed, the BDI vated.
adjustment should be increased to a value of about • Auxiliary - accumulates time when the auxiliary
50 as a starting point. Fine-tuning can be done from motor is activated.
that value.
The hourmeter data is stored in the master controller
HOURMETERS during every six minutes of operation. If there is a
loss of power, data is not lost.
There are four hourmeter functions:
• Truck - accumulates time when the operator pres-
ence switch is activated.
Standard Dash Display Service Menu Navigation

GENERAL MOVING THROUGH MENU SELECTIONS
To enter the service mode, turn the key to the ON po- 1. When the service technician’s password has been
sition and press the (enter) key twice. Enter Pass- correctly entered, the first menu item, which is
word prompt will appear on the display. See Table 6. the Setup menu, is displayed on the dash dis-
All lift trucks will have 55555 as the default service play LCD screen. To view the next menu item,
password at the time of delivery. This password can press the ↓ (down arrow) key on the dash dis-
be changed by a service technician. Go to Editing and play numeric key pad. Repeat this until the de-
Adding Information. sired menu item has been reached. To return to a
previous menu item, press the ↑ (up arrow) key.
Table 6. Password Prompt Screen When the last menu item is reached and the ↓
(down arrow) key is pressed again, the first menu
item will return to the display.
Enter Password 2. To move into a submenu of a main menu item,
press the → (right arrow) key on the dash display
XXXXX numeric key pad. To move into a sub submenu,
as with the Diagnostics menu, press the → (right
arrow) key again.
The ↑ (up arrow) and the ↓ (down arrow) keys allow 3. To move up or down within the submenu or the
you to move up and down within a menu. The ← (left sub submenu, press the ↑ (up arrow) or ↓ (down
arrow) key and the → (right arrow) key allow you to arrow) keys.
move from menu to menu. The (enter) key allows
you to enter or save a parameter. The 5 (five) key 4. To move out of the sub submenu and return to
is only used if it is part of the password required to the submenu, press the ← (left arrow) key.
enter the service mode. See Figure 15. 5. To move out of the submenu and return to the
Main Menu, press the ← (left arrow) key.
6. To exit the service mode, press the ← (left arrow)

key.
Figure 15. Dash Display Keys
75
Standard Dash Display Service Menu Navigation 2200 SRM 1308
EDITING AND ADDING INFORMATION Table 7. Password Prompt Screen
NOTE: The setup and password menus can be used to

edit or add information to the truck software. When
an item in these menus is selected, the current value Enter Password
will be displayed. The characters available to be se-
lected from the display are 0 through 9, A through Z, XXXXX
blank, and dash. Each line in the display can have
no more than 20 characters including blanks.
1. If a change is to be made, press the → (right ar- The technician can scroll through the menu using the
row) key and the cursor will blink on one of the ← (left arrow) and the → (right arrow) keys to move
characters. The ← (left arrow) key and → (right up and down within a menu and the ↑ (up arrow) or
arrow) key are used to move from character to ↓ (down arrow) keys to move from menu to menu.
character in the item being changed. Use the (enter) key to enter a menu selection. Each
menu selection has a list of submenu functions. The
2. When a character that is to be changed is blink- submenus are viewed and items selected by scrolling
ing, use the ↑ (up arrow) and ↓ (down arrow) through the menu in the same manner as described
keys to scroll up or down until the desired char- above.
acter is found. Use the ← (left arrow) or → (right
arrow) keys to move to the next character to be To exit a selected function and return to the previ-
changed. This is repeated until all changes in the ous function, press the ↑ (up arrow) key. Continue to
item have been made. press the ↑ (up arrow) key until you are returned to
the Main Menu.
3. When all changes have been made, press the
(enter) key to store the value. Press the ↑ (up ar- SERVICE FUNCTIONS
row) key or the ↓ (down arrow) key to access the
The following submenu functions are accessible from
next item to be changed. Repeat this procedure
the Main Menu described above.
for each item that is to be changed.
1. Diagnostic Menu
4. When all changes have been made, press the ←
Static Diagnostics
(left arrow) key to exit the menu.
Brake Pedal Switch
ACCESS TO SERVICE FUNCTIONS Operator Sensing Switch
Steer OK?
All service functions are accessible from either Stan- Steer Centering Proximity Switch 1
dard or Premium displays. The following functions Steer Centering Proximity Switch 2
are the same with either display version, except as Free Lift Proximity Switch
noted in the following sections. Tilt Sensor
Hydraulic Level Switch
Once the vehicle is turned ON with the key switch Tilt Up Switch
and the initialization process has been completed, a Tilt Down Switch
service technician can gain access to the service func- Extend Switch
tions by pressing the (enter) key twice. Retract Switch
Sideshift Right Switch
The display will prompt the service technician for a Sideshift Left Switch
five-digit password. See Table 7. The default setting Horn Switch
for the password is 55555. When a correct password Traction Throttle
is entered, the Main Menu is displayed as follows: Hydraulic Throttle
• Diagnostics Menu Reach Throttle
• View Hourmeters Aft Throttle
• Setup Menu Aft Sensor
• View Software Versions Aft Horn
• Passwords Menu Traction System
• Impact Sensor Menu Traction Motor Speed
Traction Motor Current
76
2200 SRM 1308 Standard Dash Display Service Menu Navigation
Traction Motor Temperature Auxiliary Settings

Traction Controller Temperature Fast Extend Speed
Traction Throttle Slow Extend Speed
Aft Throttle Fast Retract Speed
Brake Coil Slow Retract Speed
Hydraulic System Tilt Up Speed
Pump Motor Speed Tilt Down Speed
Pump Motor Current Sideshift Speed
Pump Motor Temperature Reach Cushioning
Pump Controller Temperature Steer Settings
Pump Throttle Steer Mode
Load Hold Coil Steer Effort
Pressure Transducer Steer Ratio
Auxiliary Motor Speed Truck Settings
Auxiliary Motor Current Serial Number
Auxiliary Motor Temperature Voltage
Auxiliary Forward Coil Capacity
Reverse Coil Carriage Type
Reach Coil BDI Adjust
Tilt Coil Extended Shift
Sideshift Coil Lift Limit Without Override
Reach Direction Lift Limit With Override
Reach Sensor Audible Alarm
Tilt Sensor Visible Alarm
Lift PV Autotilt Option
Lower PV Laser Option
Steer System Carry Level Option
Steering Motor Speed Slow Extended
Steer Motor Temperature Simultaneous Hydraulics
Steer Controller Temperature Password Option
Steer OK? Shutdown Timeout
Steer Motor Angle Traction Settings
General Truck Rabbit Speed
Height Sensor Rabbit Acceleration
Cal Fork Tare (Free Lift) High Speed
Cal Fork Tare (Above Free Lift) High Acceleration
Cal Cush Inpoint Mid Speed
Cal Cush Outpoint Mid Acceleration
Cal Mast Slow Down Turtle Speed
Error Log Turtle Acceleration
Error # Neutral Braking
Last Time Plug Braking
First Time Aft Speed Reverse
Count 4. View Software Versions
2. View Hourmeters Master Controller Software Version
Truck Hourmeter Display Software Version
Traction Hourmeter Traction Controller Software Version
Pump Hourmeter Hydraulic Controller Software Version
Auxiliary Hourmeter Control Handle Software Version
3. Setup Menu Remote CAN Module Software Version
Lift Settings Steer Controller Software Version
Lift Maximum Speed Caster Controller Software Version
Lower Maximum Speed Aux Pump Software Version
77
Premium Display Functions and Features 2200 SRM 1308
5. Impact Sensor Menu Soft Duration

Impact Action Soft Accel
Impact Sound 6. Password Menu
Clear Impact Add Password
Hard Duration Delete Password
Hard Accel Edit Password
Premium Display Functions and Features

KEY-ON INITIALIZATION A few seconds after the correct password has been en-
tered, the BDI and performance mode are displayed
Upon entering the key to the ON position, the display and the vehicle can be operated.
will illuminate and display the POWER ON screen.
See Figure 16. Table 9. Password Screen
Password Invalid
Disabled in ## X
Enter Password
OPERATOR CHECKLIST FUNCTION

Figure 16. Power On Screen If this function is enabled in the premium display, the
operator is prompted to answer a checklist of ques-
PASSWORDS tions. The operator indicates a 1 for pass or a 4 for
fail. If the operator indicates the vehicle passes the
Following the initialization sequence given above, inspection, the display will show the previous infor-
the LCD displays the prompt for the operator to mation and the operator can drive the lift truck. If
enter a password if this function has been enabled. the operator indicates that the vehicle fails the in-
See Table 8. If the password function is disabled, the spection, Service Required will appear on the display
display will bypass the password prompt. To enable screen, and the vehicle will only operate in turtle
the password function, see the password menu. mode until the required action is taken.
Table 8. Password Prompt Screen The checklist feature can be enabled with or with-
out the password function enabled, depending upon
the user’s preference. The checklist feature, as with
the password feature, may be setup using either the
Enter Password XXXXX dash display or using the PC service tool. For the
PC instruction, go to the section Troubleshooting
and Adjustments Using the AC Controls Pro-
gram (ETACC) 2200 SRM 1058. The checklist must
If the password is not entered within 5 to 8 seconds, be enabled or disabled by a service technician.
a screen is shown on the LCD display. See Table 9.
PERFORMANCE MODES
Until a password is entered that agrees with a pass-
word stored in the vehicle master controller, the lift Four different performance modes of operation can
and traction systems are inoperative. Passwords be selected. Each mode can change acceleration and
may be entered in the master controller using either top speed. The factory settings increase operating
the dash display or by using the PC software. speeds from slowest, turtle, to the fastest, rabbit.
78
2200 SRM 1308 Premium Display Functions and Features
Upon startup, either the rabbit symbol or one of the The hourmeter data is stored in the master controller
bars beneath the rabbit symbol will be illuminated. during every six minutes of operation. If there is a
If the top performance level is selected, the rabbit loss of power, data is not lost.
symbol is illuminated. To change the performance
mode, the operator must activate the lift truck with SHELF HEIGHT SELECTOR
the key switch and be positioned on the floor switch,
and the brake pedal must be depressed. To change If your lift truck is equipped with the shelf height se-
performance modes, press the performance mode lector option, the free-lift height and a required load
key until the correct performance indicator is illu- offset must be set using the PC Service Tool (ETACC)
minated. Any change to the performance mode does before entering any shelf height settings into the lift
not take effect until the operator releases the control truck. Free-lift should be preset at the factory and
handle. If the password function is enabled, the offset will be set at the default value of 3.00 inches.
operator will be limited by the performance level set
NOTE: All heights must be input in tenths of an inch
in the password function.
and must be in whole number format.
BATTERY DISCHARGE INDICATOR If the lift truck is not equipped with the shelf height
selector option, contact your local Hyster® dealer for
The Battery Discharge Indicator (BDI) uses a bar
installation information.
graph and a color chart as a fuel gauge for the bat-
tery state of charge. As the battery discharges, the Input the shelf PICK height (no load condition) into
bar gets shorter to show less fuel. The green band the lift truck operating system using the dash dis-
near the bar graph shows the normal operating range play. The system then calculates the PLACE height
for the battery. The yellow band shows the range in (loaded condition) using the offset dimension loaded
which the battery can still be operated without dam- with the PC Service Tool. The PLACE height must
age. This band indicates that the battery is nearing be slightly above the PICK height to allow for deflec-
the point of discharge where it can be damaged with tion of the mast and forks when the truck is in the
continued hard use. The red band indicates the dis- loaded condition.
charge condition where battery damage can occur. At
this point, the battery should be charged very soon The dash display allows direct input of the shelf
to prevent battery damage. When the battery is dis- height or the forks can be elevated to the correct
charged approximately 75%, segments 1 and 2 al- height and the system can be instructed to remem-
ternately flash on and off, and the battery symbol ber that elevation. Up to 10 heights may be stored in
flashes. Continued operation will cause lift interrupt the dash display. Each height is assigned a number
(if enabled) to occur to help prevent battery damage. from 1 to 0. These numbers are used by the shelf
Lift interrupt prevents the operator from lifting loads height selector to access the preprogrammed shelf
and saves enough battery power for operator to move heights.
the lift truck to a battery charger. At lift interrupt,
there are no segments (bars) displayed, and the bat- After setting a shelf height in the dash display, se-
tery symbol is flashing. lect the desired shelf height number using the num-
ber keys on the dash display and activate the lift or
HOURMETERS lower control to move the forks to the desired eleva-
tion. The shelf height selector system will automati-
There are five hourmeter functions: cally slow the forks as the forks approach the selected
• Truck – accumulates time when the operator pres- height and will stop the forks at the desired height
ence switch is activated. regardless of control handle position.
• Traction – accumulates time when the traction mo-
tor is activated. To input a shelf height directly into the dash display,
• Lift – accumulates time when the lift motor is ac- enter the Main Menu. If the shelf height selector
tivated. option is enabled, scroll to Setup Shelf Height. See
• Auxiliary – accumulates time when the auxiliary Figure 17.
motor is activated.
• Steer – accumulates time when the steer motor is
activated.
79
Premium Display Functions and Features 2200 SRM 1308
Input the correct height in tenths of an inch (the de-

sired height in inches and add a zero at the end) using
the number keys. Press the (enter) key to save the
value or press the left arrow key to cancel the entry
and return to the Main Menu. You can edit any shelf
height by repeating the above procedure.
To allow the system to “learn” a shelf height, enter

the Main Menu and move to the Learn Shelf Height
menu. Press the right arrow key to enter the Learn
Shelf Height menu. See Figure 20.
Figure 17. Main Menu
Press the right arrow key to enter the Setup Shelf

Height menu. See Figure 18.
Figure 20. Learn Shelf Height
Scroll down to highlight the learn height number you

want to associate with the shelf height you are learn-
ing. Move the forks to the correct PICK (no load con-
Figure 18. Setup Shelf Height dition) elevation and press the (enter) key to save
the shelf height in the dash display.
Scroll down the screen to highlight the pick height
number you want to associate with the shelf height NOTE: Entering a shelf height in either the Setup
you are entering. Press the (pencil) key, and the Shelf Height or the Learn Shelf Height menu will
cursor will move to allow the height to be input. See save and display the value in the other menu. Edit-
Figure 19. ing a value in either menu will also make the change
and display the new value within the other menu.
Figure 19. Selecting Pick Height
80
2200 SRM 1308 Premium Dash Display Service Menu Navigation
Premium Dash Display Service Menu Navigation

GENERAL
To enter the service mode, turn the key to the ON po-
sition and press the (enter) key twice. Enter Pass-
word prompt will appear on the display. See Table 10.
All lift trucks will have 55555 as the default service
password at the time of delivery. This password can
be changed by a service technician.
Table 10. Password Prompt Screen
Figure 21. Menu Navigation Action Symbols

Enter Password XXXXX
ACCESS TO SERVICE FUNCTIONS
All service functions are accessible from either Stan-
MOVING THROUGH MENU SELECTIONS dard or Premium displays. The following functions
are the same with either display version, except as
Upon successful entry of your supervisor password, noted in the following sections.
the Main Menu screen will appear on the LCD
screen, and the four menu navigation keys on the Once the vehicle is turned ON with the key switch
right side of the display will be activated. Action and the initialization process has been completed, a
symbols will appear on the LCD screen just to the service technician can gain access to the service func-
left of the menu navigation keys. See Figure 21. tions by pressing the (enter) key twice.
These symbols indicate the action that will be taken
when that key is pressed. The ↑ (up arrow) key and The display will prompt the service technician for a
the ↓ (down arrow) key are used to move up and five-digit password. See Table 11. The default set-
down within a selected menu. The → (right arrow) ting for the password is 55555. When a correct pass-
key is used to select a menu item. The ← (left arrow) word is entered, the Main Menu is displayed as fol-
key is used to return to the previous menu. The lows:
(door indicator) key is used to exit the Main Menu • Diagnostics
and return to the truck operation screen. • View Hourmeters
• Setup
When a menu item is available for editing, the • View Software Versions
(pencil) key will appear in place of the → (right ar- • Passwords
row) key, and is used to edit a menu selection. The • Setup Shelf Height
(enter) key is used to save a value or menu choice • Learn Shelf Height
when in the edit mode. When in edit mode, use the ↑ • Impact Sensor
(up arrow) and ↓ (down arrow) keys to scroll through • Maintenance Reminder
the options available for that menu selection. Use
the (enter) key to save the chosen value. Press the Table 11. Password Prompt Screen
←(left arrow) key repeatedly to return to the Main
Menu. Push the (door indicator) key to return to
normal truck operation.
Enter Password XXXXX
81
Premium Dash Display Service Menu Navigation 2200 SRM 1308
The technician can scroll through the menu using the Pump Controller Temperature
→ (right arrow) key and the ← (left arrow) key to Pump Throttle
move from menu to menu, and the ↑ (up arrow) key Pressure Transducer
and the ↓ (down arrow) key to scroll within a menu. Auxiliary Motor Speed
Use the (enter) key to enter a menu selection. Each Auxiliary Motor Current
menu selection has a list of submenu functions. The Auxiliary Motor Temperature
submenus are viewed and items selected by scrolling Auxiliary Forward Coil
through the menu in the same manner as described Reverse Coil
above. Reach Coil
Tilt Coil
To exit a selected function and return to the previous Sideshift Coil
function, press the ←(left arrow) key. Continue to Reach Direction
press the ←(left arrow) key until you are returned to Reach Sensor
the Main Menu. Tilt Sensor
Lift PV
SERVICE FUNCTIONS Lower PV
Steer System
The following submenu functions are accessible from
Steering Motor Speed
the Main Menu described above.
Steer Motor Temperature
1. Diagnostic Menu Steer Controller Temperature
Static Diagnostics Steer OK?
Brake Pedal Switch Steer Motor Angle
Operator Sensing Switch General Truck
Steer OK? Height Sensor
Steer Centering Proximity Switch 1 Cal Fork Tare (Free Lift)
Steer Centering Proximity Switch 2 Cal Fork Tare (Above Free Lift)
Free Lift Proximity switch Cal Cush Inpoint
Tilt Sensor Cal Cush Outpoint
Hydraulic Level Switch Cal Mast Slow Down
Tilt Up Switch Error Log
Tilt Down Switch Error #
Extend Switch Last Time
Retract Switch Count
Sideshift Right Switch First Time
Sideshift Left Switch Last Date
Horn Switch Time
Traction Throttle 2. View Hourmeters
Hydraulic Throttle Truck Hours
Aft Throttle Traction Hours
Aft Sensor Pump Hours
Aft Horn Auxiliary Hours
Traction System 3. Setup Menu
Traction Motor Speed Lift Settings
Traction Motor Current Lift Maximum Speed
Traction Motor Temperature Lower Maximum Speed
Traction Controller Temperature Auxiliary Settings
Traction Throttle Fast Extend Speed
Travel Direction Slow Extend Speed
Brake Coil Fast Retract Speed
Aft Throttle Slow Retract Speed
Hydraulic System Tilt Up Speed
Pump Motor Speed Tilt Down Speed
Pump Motor Current Sideshift Speed
Pump Motor Temperature Reach Cushioning
82
2200 SRM 1308 Premium Dash Display Service Menu Navigation
Steer Settings Master Controller Software Version

Steer Mode Display Software Version
Steer Effort Traction Controller Software Version
Steer Ratio Hydraulic Controller Software Version
Display Settings Control Handle Software Version
Display Language Remote CAN Module Software Version
Year Steer Controller Software Version
Month Caster Controller Software Version
Day Aux Pump Software Version
Hour 5. Password Menu
Minute View Password Log
Second Add Password
Truck Settings Delete Password
Serial Number Edit Password
Voltage 6. Setup Shelf Height
Capacity Pick Height 1
Carriage Type Pick Height 2
BDI Adjust Pick Height 3
Extended Shift Pick Height 4
Shelf Height Selection Pick Height 5
Load Weight Option Pick Height 6
Lift Limit Without Override Pick Height 7
Lift Limit With Override Pick Height 8
Audible Alarm Pick Height 9
Visible Alarm Pick Height 10
Fork Height Display 7. Learn Shelf Height
Autotilt Option Learn Height 1
Laser Option Learn Height 2
Carry Level Option Learn Height 3
Slow Extended Learn Height 4
Simultaneous Hydraulics Learn Height 5
Password Option Learn Height 6
Shutdown Timeout Learn Height 7
Truck Inspection Learn Height 8
Traction Settings Learn Height 9
Rabbit Speed Learn Height 10
Rabbit Acceleration 8. Impact Sensor
High Speed Impact Action
High Acceleration Impact Sound
Mid Speed Clear Impact
Mid Acceleration Hard Duration
Turtle Speed Hard Accel
Turtle Acceleration Soft Duration
Neutral Braking Soft Accel
Plug Braking 9. Maintenance Reminder
Aft Speed Reverse Maintenance Reminder
4. View Software Versions Maintenance Interval
83
Connector Pin-Outs 2200 SRM 1308
Connector Pin-Outs
Traction Controller (Connector CPS 11)
Pin Wire Number Function
1 W206-G-RED IFB Battery Pos Input
2 W765-A-WHT Compartment Fan Input
3 W281-A-WHT 12V B+ Traction Motor Encoder Output
4 W104-A-GRN Traction Motor Encoder Ground
5 W577-A-WHT Traction Motor Encoder Phase A
6 W578-A-WHT Traction Motor Encoder Phase B
7 W-CT-01 / BAR CANbus Bare
8 W-CTP-01 / BAR CANbus Bare
9 BLANK -
10 BLANK -
11 BLANK -
12 W-JUMPER -
13 W-JUMPER -
14 W-CT-01 / BLK CANbus Low
15 W-CTP-01 / BLK CANbus Low
16 W386-A-WHT Traction Motor Temp Sensor Output
17 W102-A-WHT Traction Motor Temp Sensor Input
18 BLANK -
19 BLANK -
20 BLANK -
21 BLANK -
22 W-CT-01 / WHT CANbus Hi
23 W-CTP-01 / WHT CANbus Hi
24 BLANK -
Hydraulic Controller (Connector CPS 12)

1 W206-F-RED IFB Battery Pos Input
2 W701-A-WHT Compartment Fan Input
3 W280-A-WHT 12V B+ Hydraulic Motor Encoder Output
4 W103-A-GRN Hydraulic Motor Encoder Ground
5 W580-A-WHT Hydraulic Motor Encoder Phase A
6 W579-A-WHT Hydraulic Motor Encoder Phase B
84
2200 SRM 1308 Connector Pin-Outs
Hydraulic Controller (Connector CPS 12)

7 W-CP-01 / BAR CANbus Bare
8 W-CTP-01 / BAR CANbus Bare
9 BLANK -
10 BLANK -
11 BLANK -
12 BLANK -
13 BLANK -
14 W-CP-01 / BLK CANbus Low
15 W-CTP-01 / BLK CANbus Low
16 W100-A-WHT Hydraulic Motor Temp Sensor Output
17 W101-A-WHT Hydraulic Motor Temp Sensor Input
18 BLANK -
19 BLANK -
20 BLANK -
21 BLANK -
22 W-CP-01 / WHT CANbus Hi
23 W-CTP-01 / WHT CANbus Hi
24 BLANK -
Master Controller (Connector CPS 31)

1 W910-A-WHT IFB Input
2 W7-A-WHT Operator Sensor Input
3 W10-D-RED Key Switch Input B+
4 BLANK -
5 W503-A-WHT Spare Digital Input
6 815-A Retract Prox Sensor (Optional)
7 W106 Aft Handle Return
8 W-CT-02-BAR CANbus Spare
9 W30-A-WHT Height Encoder Input
10 X801-ZA Lower Coil
11 BLANK -
12 X804-ZC Aux. Straight Coil
13 W830-A-WHT Strobe Light Relay Coil Input
85
Master Controller (Connector CPS 31)

14 W206-J-RED IFB Battery Pos Input
15 W724-A-WHT Motion Alarm Input
16 W98-A-WHT Foot Switch Input
17 W25-A WHT Aft Handle Horn Switch Input
18 W571-A-WHT Freelift Prox Sensor Input
19 W504-A-WHT Lift Limit Sensor Input
20 BLANK -
21 BLANK -
22 W-CT-02-WHT CANbus Hi
23 W-CT-02-BLK CANbus Lo
24 W96-A-WHT Electric Brake Coil Input
25 W27-A-WHT Steering Unit Input
26 BLANK -
27 BLANK -
28 W13-V-GRN Battery Neg
29 W45-A-WHT Horn Input
30 BLANK -
31 W30-A BRN Aft Handle Sensor Input
32 W90-2A-WHT Hyd. Fluid Level Sensor #2 Input
33 W90-1A-WHT Hyd. Fluid Level Sensor #1 Input
34 BLANK -
35 BLANK -
36 W62-A-WHT Pressure Transducer Input
37 W29-A GRN Aft Handle Throttle Input
38 W572-A-WHT Height Encoder Input
39 W811-S Lift Coil Input
40 W24-A-WHT Main Contactor Coil Input
41 X805-ZB Aux. Rev. Coil
42 X803-A Ext / Ret Coil
Integrated Fuse Board (Connector CPS 1)

1 W-206-A-RED B+ Fused Output
2 BLANK -
86
Integrated Fuse Board (Connector CPS 1)

3 W33-A-WHT 12V Pos Output
4 W285-A-WHT 24V Pos Output
5 W1285-A-WHT 24V power to Control Handle
6 W2-A-RED Main Contactor B+ Input
7 W10-A-RED Key Switch B+ Input
8 W35-A-RED B+ Output to Power Disconnect Switch
9 BLANK -
10 W-5-A-RED Key Switch B+ Input
11 BLANK -
12 W-205-A-RED Spare B+ Output
Dash Display (Connector CPS 22)

1 W285-S-WHT 24V Battery Pos
4 BLANK -
Steering Unit (Connector CPS 45)

1 W250-B-RED 5V Input From Steering Controller
2 W573-A-WHT CH1 Output to Steering Controller
3 W574-A-WHT CH2 Output to Steering Controller
4 W13-E-GRN Battery Negative
5 W576-A-WHT CB1 Output to Steering Controller
6 W575-A-WHT CB2 Output to Steering Controller
7 W27-A-WHT Master Controller Input
8 W206-N-RED B+ Power to Lord® Coil
87
Steering Controller (Connector CPS 59)

1 W206-P-RED Battery Pos Input
2 BLANK -
3 W-RED 5V Pos Output
4 W-C-APS1 / BAR Steering Motor Encoder Ground
5 W-C-APS1 / NAT Steering Motor Encoder Input
6 W-C-APS1 / GRN Steering Motor Encoder Input
7 BLANK -
9 BLANK -
10 W573-A-WHT Steering Unit CH1 Input
11 W574-A-WHT Steering Unit CH2 Input
12 BLANK -
13 BLANK -
14 W-CT-06A-WHT CANbus Hi (Blank if Power Caster Equipped)
15 W-CT-06-BLK CANbus Low
16 W-C-APS1 / BLK Steering Motor Temp Input
17 W576-A-WHT Steering Unit CB1 Input
18 BLANK -
19 W515-A-WHT Steering Centering Sensor Input
20 W575-A WHT Steering Unit CB2 Input

21 BLANK -
22 BLANK -
23 W-CT-06-WHT CANbus Hi
24 BLANK -
Caster Controller (Connector CPS 82)

1 W260-EC-RED Battery Pos Input
2 BLANK -
3 W-C-APS2 / RED 5V Pos Output
4 W-C-APS2 / BAR Steering Motor Encoder Ground
5 W-C-APS2 / NAT Steering Motor Encoder Input
6 W-C-APS2 / GRN Steering Motor Encoder Input
88
Caster Controller (Connector CPS 82)

7 BLANK -
9 BLANK -
10 BLANK -
11 BLANK -
12 BLANK -
13 BLANK -
14 W-CT-08B-WHT CANbus Hi
15 W-CT-08 / WHT CANbus Low
16 W-C-APS2 / BLK Steering Motor Temp Input
17 BLANK -
18 BLANK -
19 W1515-A-WHT Caster Centering Sensor Input
20 BLANK -
21 BLANK -
22 BLANK -
23 W-CT-08B-WHT CANbus Hi
24 BLANK -
89
System Logic Diagram 2200 SRM 1308
System Logic Diagram

The following diagram may be able to assist in troubleshooting.
Traction Motor -------

------- Shelf Selector
Speed Encoder -------

Traction Dash Display ------- Mode Selection
Motor
Temperature Sensor ------- Controller
------- Truck Parameter Input
Compartment Fan ------- C
N ------- Forward/Reverse Input
B ------- Truck Speed Input
Pump Motor ------- U
S ------- Lift/Lower Input
Compartment Fan -------

Multifunction
Pump Control
------- Reach/Retract Input
Motor Handle
Speed Encoder ------- Controller
CAN Bus ------- Tilt Up/Tilt Down Input
Temperature Sensor -------

Sideshift Left/
C ------- Sideshift Right Input
N ------- Horn
Horn ------- B
U ------- MDU Steering Motor
Operator Sensing
Switch
------- S
MDU Steering Motor

------- Encoder
Free-Lift Prox. Sensor ------- Master

MDU
Controller
Steering MDU Centering Prox.
Controller
------- Switch
Pressure Transducer ------- CAN Bus
------- Steering Unit Encoder
Lift Limit Prox.

Sensor
-------
------- Pressure Transducer
90
2200 SRM 1308 System Logic Diagram
Foot Switch ------- C
Main Contactor ------- N
Lift Coil ------- B
Lower Coil ------- S ------- Caster Steering Motor
Caster Steering Motor

Electric Brake Coil ------- CAN Bus Optional - Caster ------- Encoder
Steering Controller
Caster Centering Prox.

Motion Alarm ------- ------- Switch
Strobe Light Relay

Coil
------- A
Optional - Height
Encoder
------- CAN Bus
Master
Controller B
Hydraulic Fluid Level

Switch #1
------- U
Hydraulic Fluid Level

Switch #2
------- CAN Bus PC Connection
Key Switch -------
Tilt Select Coil ------- CAN Bus Impact Sensor
Aux. Straight Coil ------- A
Sideshift Select Coil -------

B
Aux. Rev. Coil ------- U
Extend/Retract Select
Coil
-------
91
NOTES
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92
TECHNICAL PUBLICATIONS
2200 SRM 1308 10/10 (8/09)(11/08)(5/08)(10/07)(2/07)(11/06) Printed in U.S.A.

Ac Motor Controllers/Display Panel: Description, Checks, Adjustments, and Troubleshooting

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Ac Motor Controllers/Display Panel: Description, Checks, Adjustments, and Troubleshooting

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AC MOTOR

PART NO. 1652263 2200 SRM 1308

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2010 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

N30ZDRS, N35-40ZRS [A265]

The AC motors also have thermal sensors embedded

The master controller also manages the operating

AC Transistor Motor Controller Replacement

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 3. AC Traction and AC Pump Motor Controllers (450A)

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 4. AC Traction and AC Pump Motor Controllers (675A)

GENERAL MAINTENANCE help prevent high-temperature conditions. Always

1. 7.5 AMP FUSE

Figure 5. Integrated Fuse Board

Figure 7. Replacement Parts of Line Contactor

Check the coil with an ohmmeter for an open circuit

Master Controller Checks and Adjustments

The following checks and adjustments may be made

Table 1. Factory Parameter Defaults Table 1. Factory Parameter Defaults

Parameter Factory Default Parameter Factory Default

Table 2. Traction Parameter Defaults

Model N30ZDRS or N35-40ZRS

Table 2. Traction Parameter Defaults (Continued)

Model N30ZDRS or N35-40ZRS

Many faults noted by lift truck systems are the result

CONTROLLER STATUS LIGHT EMITTING Figure 8. Master Controller LED

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 9. AC Traction and AC Pump Motor Controllers (450A)

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 10. AC Traction and AC Pump Motor Controllers (675A)

Table 3. List of Operator Warning Messages

Message Description Explanation

Table 3. List of Operator Warning Messages (Continued)

Message Description Explanation

Table 3. List of Operator Warning Messages (Continued)

Message Description Explanation

Table 3. List of Operator Warning Messages (Continued)

Message Description Explanation

Table 3. List of Operator Warning Messages (Continued)

Message Description Explanation

Table 4. List of Fault Messages

Fault Message Description

Table 4. List of Fault Messages (Continued)

Fault Message Description

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit