J AC Motor Controller - (08-2005)

AC MOTOR
CONTROLLERS/
DISPLAY PANEL
DESCRIPTION, CHECKS,
ADJUSTMENTS, AND
TROUBLESHOOTING
J1.6-2.0XMT (J30-40ZT) [J160]
PART NO. 1554633 2200 SRM 1087

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 Mainte-
nance 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 condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
AC Motor Controllers/ Display Panel Table of Contents
TABLE OF CONTENTS
Description ........................................................................................................................................................... 1
General ............................................................................................................................................................. 1
Description ....................................................................................................................................................... 1
AC Motors .................................................................................................................................................... 1
ZAPI™ AC Motor Controller ...................................................................................................................... 1
Principles of Operation ............................................................................................................................... 2
Controller Thermal Management............................................................................................................... 3
Controller Area Network (CANbus) ........................................................................................................... 3
Discharging the Capacitors............................................................................................................................. 3
AC Motor Controller Repair ................................................................................................................................ 4
General ............................................................................................................................................................. 4
Special Precautions ..................................................................................................................................... 4
Thermal Sensors .............................................................................................................................................. 5
Motor Controller, Replace ............................................................................................................................... 5
Controller Checks and Adjustments ................................................................................................................... 5
Function Parameters ........................................................................................................................................... 6
General ............................................................................................................................................................. 6
Function Parameter Descriptions ....................................................................................................................... 7
Parameters....................................................................................................................................................... 7
Top Speed Forward...................................................................................................................................... 7
Top Speed Reverse....................................................................................................................................... 7
Acceleration ................................................................................................................................................. 7
Regen Braking ............................................................................................................................................. 7
Auto Deceleration........................................................................................................................................ 7
Extended Shift............................................................................................................................................. 7
Pump Acceleration ...................................................................................................................................... 8
Tilt/Auxiliary Pump Acceleration............................................................................................................... 8
Low Lift Speed............................................................................................................................................. 8
Maximum Lift Speed................................................................................................................................... 8
Maximum Lowering Speed ......................................................................................................................... 8
Tilt Speed ..................................................................................................................................................... 8
3rd Function ................................................................................................................................................ 8
3rd Function Speed ..................................................................................................................................... 8
4th Function ................................................................................................................................................ 8
4th Function Speed ..................................................................................................................................... 9
Battery Voltage............................................................................................................................................ 9
Lift Interrupt ............................................................................................................................................... 9
BDI Adjustment (Early Models) ................................................................................................................. 9
BDI Adjustment (Later Models) ................................................................................................................. 9
BDI Decrement Time .................................................................................................................................. 9
Service Reminder ...................................................................................................................................... 10
Custom ....................................................................................................................................................... 10
Restore Defaults ........................................................................................................................................ 10
Calibration Parameters ..................................................................................................................................... 10
Throttle Calibration ...................................................................................................................................... 10
Steering Calibration ...................................................................................................................................... 10
Display Panel ..................................................................................................................................................... 10
General ........................................................................................................................................................... 10
Premium Display Panel ............................................................................................................................ 10
Standard Display Panel ............................................................................................................................ 10
Display Functions and Features ....................................................................................................................... 11
©2005 HYSTER COMPANY i

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

Key-On Initialization..................................................................................................................................... 11
Standard Display ........................................................................................................................................... 11
Premium Display ........................................................................................................................................... 13
Lift Truck Inspection Function ..................................................................................................................... 13
Access to Service Functions .......................................................................................................................... 14
Service Functions .......................................................................................................................................... 14
Performance Modes ....................................................................................................................................... 15
Battery Discharge Indication (BDI) ............................................................................................................. 16
Hourmeter...................................................................................................................................................... 16
Status Code List ............................................................................................................................................ 16
Dash Display Service Menu Navigation ........................................................................................................... 17
General ........................................................................................................................................................... 17
Moving Through Menu Selections ................................................................................................................ 17
Editing and Adding Information .................................................................................................................. 17
ETACC Test ........................................................................................................................................................ 18
Manual Hydraulics: ....................................................................................................................................... 18
Electro-Hydraulics:........................................................................................................................................ 18
Troubleshooting.................................................................................................................................................. 18
General ........................................................................................................................................................... 18
Status Codes .................................................................................................................................................. 19
Controller Connector Pin Outs ................................................................................................................... 110
Valve Driver Module (Electro-Hydraulic Valve Option) ............................................................................. 111
Hydraulic Lever Console (Electro-Hydraulic Option Only) ...................................................................... 112
Dash Display................................................................................................................................................ 112
System Logic Diagrams............................................................................................................................... 113
This section is for the following models:
J1.6-2.0XMT (J30-40ZT) [J160]
ii
2200 SRM 1087 Description
Description
GENERAL Throughout this section, forward will refer to travel
in the direction of the forks and left and right are
This section describes the ZAPI™ AC motor con- determined by an operator sitting in the seat facing
troller. See Figure 1. Procedures are outlined for forward. See Figure 2.
controller safety, adjustments, troubleshooting, and
repair. This section does not contain information DESCRIPTION
about other electrical components. See the section
Electrical System 2200 SRM 1078 and the sec- AC Motors
tion Electro-Hydraulic Control Valve 2000 SRM
1086. 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 speed is controlled by the controller and can be
changed by the frequency of the AC power presented
to the motor. A speed sensor has been built into
the rear motor bearing, which provides feedback to
the motor controller, allowing software to continually
monitor motor direction and revolutions per minute
(RPMs). Using this software feedback, the AC motor
control system can provide much better vehicle speed
control than is available with DC SEM systems.
The AC motors also have thermal sensors, continu-

ously monitored by the motor controllers, embedded
in the motor windings.
ZAPI™ AC Motor Controller

The ZAPI™ controller comes in two versions. See
Figure 1. AC Controller Figure 3. The first version contains two inverters for
controlling the dual traction motors and a contactor
for the lift function. The second version contains two
inverters for controlling both traction motors and a
transistor controller to control a series DC pump mo-
tor.
The ZAPI™ controller is a solid state AC motor con-

troller utilizing MOSFET technology with micropro-
cessor control. The basic dual motor control is capa-
ble of controlling two asynchronous AC induction mo-
tors simultaneously. The controller has direct control
of the traction system, main contactor, and the elec-
tromagnetic parking brakes.
A. LEFT SIDE C. FORWARD

B. RIGHT SIDE TRAVEL
Figure 2. Truck Orientation
1
Description 2200 SRM 1087
operation of the controller. One microprocessor is

designated the master and controls the right traction
motor and the majority of the logic functions for the
controller. The other microprocessor is designated
the slave and controls the left traction motor and
performs fewer functions than the master. The con-
troller has many programmable features, including
maximum speed, acceleration rate, neutral braking,
and brake current limit. The controller includes a
full range of features, as well as diagnostic and setup
capability.
The controller contains two separate DC to AC in-

verters and the logic cards necessary to process in-
put signals from various truck components. The con-
troller uses these inputs to control the speed and di-
rection of the dual traction motors. These compo-
nents are all contained within a single housing lo-
cated on the inside of the rear compartment cover.
See Figure 4.
Figure 3. AC Controllers
The controller software provides self diagnostics

which are accessed by means of a personal computer
(PC) with specialized ETACC software (see the sec-
tion Troubleshooting and Adjustments Using
the AC Controls Program (ETACC) 2200 SRM
1058 or the on-board Dash Display). The controller
software features a Test Menu for monitoring con-
troller inputs and outputs, a Diagnostic Menu for
viewing fault code information, and a Programming
Menu for customizing the truck performance.
The self diagnostics monitor the traction motor,

brake coil, main contactor coil, controller tempera-
ture, and internal logic functions. Troubleshoot fault
codes generated by the controller self diagnostics
by using the on-board dash display or a properly
configured IBM™ compatible PC.
Principles of Operation
1. LH TRACTION MOTOR
The traction motor controllers convert DC power 2. RH TRACTION MOTOR
from the truck’s battery to three-phase AC power 3. DASH DISPLAY
at the frequencies and current necessary to inde- 4. HYDRAULIC VALVE
5. CONTACTOR AND FUSE PANEL
pendently power each traction motor. Each AC 6. TRACTION CONTROLLER
induction motor provides feedback to the controller 7. HYDRAULIC PUMP AND MOTOR
for speed, rotation direction, and temperature. 8. STEERING PUMP AND MOTOR
The ZAPI™ AC motor controller uses two sophis- Figure 4. Component Location
ticated microprocessors to control the logic and
2
2200 SRM 1087 Description
The controller may also be equipped with an optional

transistor pump motor controller. This transistor WARNING
control is installed in a single housing along with the DO NOT short across the motor controller ter-
two inverters for powering the traction motors. The minals with a screwdriver or jumper wire.
pump controller receives inputs from the hydraulic
valve or the optional valve driver module. The pump NOTE: Some lift trucks are equipped with a premium
motor will run at specific preset motor speeds when controller, which controls the hydraulic motor as well
the manual control valve is installed. Motor speed is as the traction motors.
based on the hydraulic function selected. 1. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2-watt resistor across the
Controller Thermal Management controller’s BT+ and B terminals for 10 seconds
The motor controller is equipped with internal ther- using insulated jumper wires. See Figure 5.
mal sensors to protect the controller from a high tem- 2. On the premium controller, also connect the 200-
perature condition. At a temperature of 80 C (176 F), ohm, 2-watt resistor across the controller’s P+
the controller will begin to reduce current to the trac- and B terminals for 10 seconds using insulated
tion circuit and slow the speed of the lift truck. If jumper wires. See Figure 6.
the controller temperature continues to rise, the trac-
tion current will be further reduced. If the temper- 3. Remove the 200-ohm, 2-watt resistor before re-
ature reaches 100 C (212 F), current to the traction connecting the battery.
circuit will be reduced to zero and the lift truck can-
not travel. As the controller cools, traction will be NOTE: There are no user-serviceable parts in the
restored. When the controller has cooled to 80 C ZAPI™ controller. No attempt should be made to
(176 F), full traction speed will be available. open, repair, or otherwise modify the controller.
Doing so may damage the controller and will void
Controller Area Network (CANbus) the warranty.
The motor controller and the dash display are con-

nected together with a CANbus communication
system. When equipped with the optional elec-
tro-hydraulic valve, the valve, valve driver module,
and the electro-hydraulic lever console also commu-
nicate with the ZAPI™ controller over the CANbus
network. A PC with the appropriate service software
can easily communicate with all system nodes by
simply connecting to the CANbus. A special connec-
tor, located under the dash and next to the display,
is configured specifically for this purpose.
DISCHARGING THE CAPACITORS
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor 1. POSITIVE CONNECTION (BT+)
before inspecting or repairing any component 2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
in the electrical compartment. Wear safety 4. 200-OHM, 2-WATT RESISTOR
glasses. Make certain that the battery has
been disconnected. Figure 5. Discharging the Capacitors -
Economy
3
AC Motor Controller Repair 2200 SRM 1087
Legend for Figure 6

1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. POSITIVE CONNECTION (P+)
Figure 6. Discharging the Capacitors -

Standard and Premium
AC Motor Controller Repair

GENERAL Make sure you disconnect the battery and
separate the connector before you remove any
There are NO internal parts of the controller that can power cables from the power terminals of the
be repaired. The controller must be replaced if an motor controller. The capacitor stores elec-
internal malfunction occurs. trical energy and can cause injury if a person
discharges a capacitor through parts of the
The motor controller, like other electronic devices,
body. AFTER the battery is disconnected and
has temperature limits. These devices can be dam-
the key is in the OFF position, make sure you
aged if they get too hot. Normal maintenance will
discharge the capacitors.
help prevent high-temperature conditions. Always
make sure components are installed using silicon
grease and that all heat sink surfaces are clean. Do CAUTION
not block cooling airflow. To help prevent controller damage:
ALWAYS disconnect the battery when servic-
Special Precautions ing the controller.
ALWAYS discharge the capacitors before
WARNING performing any service.
To avoid injury and prevent electrical shock, NEVER connect power to the motor con-
perform the following steps before trou- troller when any power cable is discon-
bleshooting, adjustments, or repairs: nected.
Turn the key to the OFF position and discon- NEVER make a short circuit at any motor
nect the battery connector. controller terminal to battery (+), battery
Discharge the capacitors in the controller. ( ), or the frame.
Check with the dealer for your lift truck before oper-
WARNING ating in an area with normal temperatures over 40 C
Some checks in this section must be done with (104 F) The lift truck motor controller may not oper-
the battery connected and power applied to the ate at full power under these conditions.
controller. When making these checks, make
sure the drive wheels are raised from the floor.
4
2200 SRM 1087 Controller Checks and Adjustments
MOTOR CONTROLLER, REPLACE

CAUTION
Never add any electrical component to the Make sure the battery is disconnected and the capac-
lift truck without approval from your Hys- itors are discharged. Replace the motor controller as
ter dealer. Added electrical components can described in the following procedure.
prevent operation and/or damage the motor
1. Tag and disconnect all wire harness connections
controller.
and power wires from the controller.
Never use steam to clean electronic compo-
2. Remove the mounting screws holding the con-
nents. In dusty areas, blow low pressure air over
troller to the rear compartment cover. Carefully
the controller to remove dust. In oily or greasy areas,
remove the controller from the truck.
a mild solution of detergent or denatured alcohol
can be used to wash off the controller. Then use low
pressure air to completely dry the controller. CAUTION
Do not remove the screws that secure the cover
CAUTION of the controller.
Do NOT operate the traction system at high 3. Ensure there is no dirt between the base of the
speeds or rapidly change the direction of oper- controller and the mounting surface on the rear
ation with the wheels raised. Motor controller compartment cover.
damage can occur.
4. Put an even coat of thermal grease on the base
Do not subject the controller to any high voltage plate of the controller. Ensure there are no air
(hipot or megger) testing. spaces between the plate and the mounting sur-
face of the rear compartment cover. The base
Use a lead acid battery with the voltage and ampere
plate of the controller must make full contact
hour rating specified for the lift truck. Follow nor-
with the mounting surface.
mal battery maintenance procedures, recharging be-
fore 80 percent discharged, with periodic equalizing 5. Install the screws that fasten the controller to the
charges. rear compartment cover.
THERMAL SENSORS 6. Reconnect all power wires and wire harness con-
nections to the controller.
The thermal sensors for the motors are embedded in
the motor end head and are continuously monitored 7. Calibrate steering and throttle inputs. See Cali-
by the motor controller. They are part of the motor bration Parameters in this section.
and cannot be repaired.
Controller Checks and Adjustments

All checks and adjustments to the controller can be • Check the system status codes in history.
done with a PC or through the dash display on the in- • Check the state of charge of the battery.
strument panel. A PC can be connected to the CAN- • Check the hourmeter readings on the traction cir-
bus via a connector on the main wiring harness near cuit and hydraulic pump controllers.
the bottom (backside) of the display panel. • Monitor or adjust the register values for each func-
tion as shown in Function Parameters in this sec-
The following checks and adjustments may be made tion.
using a PC or the dash display:
5
Function Parameters 2200 SRM 1087
Function Parameters
GENERAL Some functions can be adjusted within the permitted
range to change the lift truck operation for a specific
Memory elements within the controller are called application. Adjustment of a register to a number
registers. These registers can have electronic data that is different than the factory settings is allowed,
stored in them to control an operation. The data but follow the instructions carefully. Adjustments
stored in a register is called a parameter. A pa- other than the factory settings will cause the lift
rameter is a measurement number that defines a truck to operate differently and can cause increased
lift truck function. A specific function parameter wear of parts.
works with other function parameters to control the
operation of the lift truck. Table 2. Transistor Lift With Manual
Valve Parameters
WARNING
Control Settings
The parameter for each function has a value
range so the motor controller can be used on Transistor Lift With Factory Defaults
different models of lift trucks. This variation Manual Valve 36V 48V
is needed for lift trucks of different sizes and
operating voltages. Adjustment of a function Pump Acceleration 1 1
to the wrong number value for your lift truck Max Lift Speed 100 100
model can cause the truck to operate differ-
ently than normal. This different operation of Low Lift Speed 40 30
the truck can cause an injury. Tilt Speed 58 40
NOTE: Table 1, Table 2, and Table 3 show the de- 3rd Function Speed 33 25
fault parameter setting for each control function that
4th Function Speed 85 85
is adjustable by the user. The factory-set default
parameters are the recommended settings for new
units. These settings will give satisfactory perfor-
Table 3. Transistor Lift With Electro-Hydraulic
mance for most applications.
Valve Parameters
Table 1. Traction Parameters
Control Settings
Control Settings Factory Defaults
Transistor Lift With
Factory Defaults Electro-Hydraulic Valve 36V 48V
Traction
36V 48V Pump Acceleration 1 1
Battery Voltage 36 48 Max Lift Speed 100 100
Extended Shift ON ON Max Lowering Speed 75 75
Acceleration 5 5 Tilt Speed 33 25
Top Speed Max FWD 128 Hz 140 Hz 3rd Function Max Speed 33 25
Top Speed Max REV 128 Hz 140 Hz 4th Function Max Speed 85 85
Regen Braking 7 7 3rd Function 0 0
Auto Deceleration 6 6 4th Function 3 3
BDI Adjustment 35 35 Tilt/Auxiliary Pump 4 4
Lift Interrupt 1 1 Acceleration
Service Reminder 0 0
Custom 0 0
6
2200 SRM 1087 Function Parameter Descriptions
Function Parameter Descriptions

PARAMETERS the load on the forks. Acceleration rates are
also unaffected by lowering the top speed.
WARNING
If any of the parameter values are changed, the
Acceleration
operators must be told that the lift truck will (Range 0-9)
operate differently.
This parameter setting determines the truck accel-
WARNING eration rate. The truck will accelerate at this rate
regardless of the load on the forks, provided that the
NEVER adjust any of the following parameters
motor and control can deliver the required power.
without using the procedures and settings
given in this section. To increase the acceleration rate above the factory
setting, the extended shift parameter will need to
The following section contains descriptions for the
be disabled.
different parameters. Access these parameters
through the SETUP menu in the dash display or To reduce the acceleration rate below the factory
with the PC software. setting, the extended shift parameter may be en-
abled or disabled.
Top Speed Forward
Any increase in performance will decrease the bat-
(Range 10-140 Hz) tery shift life.
This parameter setting determines the top speed of
Regen Braking
the truck in the forward direction.
(Range 0-9)
To increase the top speed above the factory setting,
the extended shift parameter will need to be dis- This parameter setting determines the maximum de-
abled. celeration rate when the accelerator pedal is fully de-
pressed during regen braking.
To reduce the top speed below the factory setting,
the extended shift parameter may be enabled or NOTE: The deceleration rate is less when the pedal
disabled. is not fully depressed.
For speed limits slower than the normal truck Auto Deceleration
speed, the top speed is the same regardless of
the load on the forks. Acceleration rates are (Range 0-9)
also unaffected by lowering the top speed.
This parameter setting determines the maximum
Top Speed Reverse deceleration rate when the accelerator pedal is
released. The strength of auto deceleration is a
(Range 10-140 Hz) percentage of the regen braking strength.
This parameter setting determines the top speed of A setting of zero will turn off auto deceleration com-
the truck in the reverse direction. pletely and a setting of nine will give auto decelera-
tion the same strength as regen braking.
To increase the top speed above the factory setting,
the extended shift parameter will need to be dis- Extended Shift
abled.
(0 or 1)
To reduce the top speed below the factory setting, (0 = Disable; 1 = Enable)
the extended shift parameter may be enabled or
disabled. This parameter setting enables or disables a pre-
set motor performance program in the traction motor
For speed limits slower than the normal truck controller.
speed, the top speed is the same regardless of
7
Function Parameter Descriptions 2200 SRM 1087
When enabled, this function provides a balance be- Maximum Lowering Speed
tween truck performance and battery shift life that
will meet the requirements of most applications. (Range 0-100%)
Truck acceleration and top speed will vary with the
This parameter setting determines the hydraulic
amount of load on the forks.
pump motor speed during lowering. Increasing the
When disabled, truck acceleration and top speed are setting will increase lowering speed.
determined by values set in the acceleration and top
speed parameters. Tilt Speed
If the motor and controller can deliver the power, (Range 36V = 20-66%)
then the truck performance will not vary with the (Range 48V = 15-50%)
amount of load on the forks or the battery state of
This parameter setting is used to set the hydraulic
charge.
motor speed when the tilt function is selected. In-
Grade climbing speed will also improve be- creasing the setting will increase the speed of the hy-
cause the motor controller will deliver max- draulic pump motor.
imum current. Any increase in performance
will decrease the battery shift life. 3rd Function
(Range 0, 1, or 2)
Pump Acceleration (0 = 3rd Function Without Interlock)
(Range 0-9) (1 = 3rd Function With Interlock)
(2 = 3rd Function With Push/Pull)
pump motor acceleration rate. Increasing the setting This parameter is used to select the operation of the
will increase the speed of the motor. 3rd function mini-lever or joystick roller switch. Use
selection 0 when using the 3rd function to control a
Tilt/Auxiliary Pump Acceleration non-clamping type attachment. Use selection 1 when
using the 3rd function to control a clamping type at-
(Range 0-9) tachment. Use selection 2 when using the 3rd func-
tion to control a push/pull attachment.
pump motor acceleration rate when using the tilt or 3rd Function Speed
auxiliary functions with the electro-hydraulic valve
option. (Range 36V = 20-100%)
(Range 48V = 15-75%)
Low Lift Speed
This parameter setting is used to set the hydraulic
(Range 36V = 25-65%) pump motor speed when the 3rd function hydraulic
(Range 48V = 20-50%) lever is actuated. Increasing the setting increases
the speed of the hydraulic pump motor.
pump motor low speed. This is used with transistor 4th Function
lift and the manual control valve. Increasing the
setting will increase the speed of the hydraulic pump (Range 0, 1, 2, or 3)
motor. (0 = 4th Function Without Interlock)
(1 = 4th Function With Interlock)
Maximum Lift Speed (2 = 4th Function With Push/Pull)
(3 = Default - No 4th Function)
(Range 0-100%)
This parameter is used to select the operation of the
This parameter setting determines the hydraulic 4th function mini-lever or joystick roller switch. Use
pump motor high speed. High speed is used for selection 0 when using the 4th function to control a
maximum lift speed. non-clamping type attachment. Use selection 1 when
8
2200 SRM 1087 Function Parameter Descriptions
using the 4th function to control a clamping type at- BDI Adjustment (Later Models)
tachment. Use selection 2 when using the 4th func-
tion to control a push/pull attachment. (Range - First Digit 1-5)
(Range - Second Digit 3-7)
4th Function Speed
This parameter setting allows for adjustment to im-
(Range 36V = 0-100%) prove the accuracy of the battery discharge indicator
(Range 48V = 0-100%) in the dash display.
This parameter setting is used to set the hydraulic This first digit adjusts the charged setting. Increas-
pump motor speed when the 4th function hydraulic ing the setting will increase the battery voltage or
lever is actuated. Increasing the setting increases specific gravity required for the indicator to show
the speed of the hydraulic pump motor. full. If the indicator consistently reads low with fully
charged batteries, decrease this setting.
Battery Voltage
The second digit adjusts the discharged setting. In-
(36V or 48V) creasing the setting will increase the battery voltage
or specific gravity level required for the indicator to
This parameter setting is used to inform the mas- show empty. If the indicator consistently shows lift
ter controller what voltage battery is installed in the interrupt too soon, decrease this setting.
truck. The battery choices are 36V or 48V.
A setting of 35 is the recommended starting point for
Lift Interrupt flooded batteries. A setting of 37 is the recommended
starting point for maintenance-free batteries. Fur-
(0 or 1) ther adjustments may be used to fine-tune the BDI
(0 = Disable; 1 = Enable) accuracy.
This parameter setting enables or disables the lift BDI Decrement Time
interrupt feature. The lift interrupt feature stops lift
operation when the battery discharge indicator (BDI) This adjustment is used to compensate for duty cy-
reads empty to protect the battery from excessive cles that involve nonstop operation where frequent
discharge and possible damage. pauses of more than 5 seconds do not occur (no drive,
no hydraulic use). When the truck is finally stopped,
NOTE: Trucks are shipped from the factory with this turned OFF, and then restarted, some deviation
feature enabled. in the BDI reading may occur. One of three things
may happen to the BDI reading when the truck is
BDI Adjustment (Early Models) restarted:
(Range - Single Digit 0-9) 1. The BDI gage still reads within plus or minus one
bar as it did when the truck was turned OFF. No
This parameter setting allows for adjustment to im- adjustment is needed.
prove the accuracy of the battery discharge indicator 2. If the BDI gage changed downward more than
in the dash display. Increasing the setting will in- one bar, this parameter should be set to a lower
crease the battery voltage or specific gravity when number.
the gage shows empty. 3. If the BDI gage changed upward more than one
bar, this parameter should be set to a higher
A setting of 2 is the recommended starting number.
point for flooded cell batteries. A setting of 7
is the recommended starting point for main- This adjustment has little or no effect on the BDI
tenance-free batteries. Further adjustments accuracy when the truck is used in intermittent duty
may be used to fine tune the BDI accuracy. cycles that have frequent pauses in truck activity for
greater than 5 seconds each time.
9
Display Panel 2200 SRM 1087
Service Reminder Custom

(Set Next Hourmeter) (Range 0-100)
This can be used by the service technician to show a This parameter setting is not used except for special
Status Code 99 when the truck is due for service. functions required for special applications. Normally
it is set to zero.
To use this feature, set this function to the hourme-
ter reading at which the service is to occur. When Restore Defaults
that hourmeter is reached, the dash display will dis-
play Status Code 99 for 10 seconds each time the key This function is used to restore all parameter settings
is turned ON. After 20 hours of operation, the truck to the factory default settings shown in Table 1, Ta-
will slow to half speed and the code will display con- ble 2, and Table 3.
tinuously until the service is performed. After ser-
vicing, adjust the service reminder parameter to the
next desired service time.
Calibration Parameters
THROTTLE CALIBRATION STEERING CALIBRATION
Activating this parameter allows the controller to Activating this parameter allows the controller to
“learn” the voltage setting of the throttle assembly. “learn” the voltage setting of the steering feedback
The controller uses this information to control the system. The controller uses this information to con-
lift truck speed. See the section Electrical System trol the traction motors during turning operations.
2200 SRM 1078. See the section Electrical System 2200 SRM 1078.
Display Panel
GENERAL Standard Display Panel
There are two dash display options, Standard and • Allows preassigned service passwords to control ac-
Premium. Both displays look identical. See Figure 7. cess to the service functions available through the
display.
Premium Display Panel • Provides the same comprehensive set of service
functions using the mode buttons and LCD as the
• Allows preassigned user passwords to control Premium Display.
driver access to the vehicle.
• Provides four driving modes that are accessed Standard and Premium display panels are inter-
through the key pad. changeable on the vehicle. Therefore, the display
• Allows preassigned service passwords to control ac- system can be easily upgraded or downgraded by
cess to the service functions available through the changing the display panel.
display.
• Provides a comprehensive set of service functions,
which are accessed through the mode buttons and
liquid crystal display (LCD).
• Allows access to the User Check List function.
10
2200 SRM 1087 Display Functions and Features
Figure 7. Standard and Premium Display Panel
Display Functions and Features

KEY-ON INITIALIZATION STANDARD DISPLAY
Upon turning the key to the ON position, the display Following the sequence given above, and as the seat
sequentially lights the indicators, from left to right, belt light becomes illuminated, the LCD displays the
located along the top of the display. See Figure 8. BDI as a bar. See Figure 9. As the battery is dis-
charged, the bar becomes shorter.
NOTE: The seat belt light will stay on whether the
seat belt is fastened or not fastened. When the key is turned to the OFF position, the
Hourglass indicator becomes illuminated, and the
The indicator lights turn off sequentially, except for following hourmeter information is flashed on the
the seat belt light, which will remain lighted for ap- LCD screen: Traction Hours for 3-4 seconds, followed
proximately 10 seconds. by Pump Hours for 3-4 seconds, after which the dis-
play turns off and appears black. See Figure 10.
11
Display Functions and Features 2200 SRM 1087
1. HOURMETER INDICATOR 8. LCD SCREEN

2. WRENCH INDICATOR 9. STAR PUSH BUTTON
3. BATTERY INDICATOR 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR (BDI) 11. PUSH BUTTON #2
5. BRAKE FLUID LEVEL 12. PUSH BUTTON #3
6. PARKING BRAKE 13. PUSH BUTTON #4
7. FASTEN SEAT BELT 14. PUSH BUTTON #5
Figure 8. Dash Display

Legend for Figure 9
1. 4 SEGMENTS ADJACENT TO RED
2. 4 SEGMENTS ADJACENT TO ORANGE
3. 12 SEGMENTS ADJACENT TO GREEN
4. BDI SHOWS APPROXIMATELY 65-70% CHARGE
Figure 9. Battery Discharge Indicator
12
Figure 12. Display Screen (Premium Display)
LIFT TRUCK INSPECTION FUNCTION

Figure 10. Traction/Pump Hours If this function is turned on, the operator is prompted
to answer a checklist of questions. The operator in-
PREMIUM DISPLAY dicates a 1 for pass or a 4 for fail. If the operator
indicates the vehicle passes the inspection, the dis-
Following the sequence given above, and as the seat play will show the previous information and the op-
belt light becomes illuminated, the LCD displays the erator can drive the vehicle. If the operator indicates
prompt for the operator to enter a password if this that the vehicle fails the inspection, Service Required
function has been enabled. See Figure 11. If the will appear on the display screen, and the vehicle will
password function is disabled, the display will by- only operate in Mode 1 until the required action is
pass the password prompt. To enable the password taken. See Figure 13.
function, see Troubleshooting and Adjustments
Using the AC Controls Program (ETACC) 2200
SRM 1058, Enable/Disable Password and Lift Truck
Inspection Functions.
Figure 13. Inspection Failure Screen
The inspection feature can be enabled with or with-

out the password function enabled, depending upon
Figure 11. Password Prompt Screen the user’s preference. The inspection checklist fea-
ture, as with the password feature, may be set up us-
Until a password is entered that agrees with a pass- ing either the dash display or using a PC. The check-
word stored in the dash display, the lift and traction list must be enabled or disabled by a service techni-
systems are inoperative. Passwords may be entered cian.
directly into the dash display or by using the PC soft-
ware program. The following is the list of checks:
• Check for leaks.
A few seconds after the correct password has been en- • Check service brake.
tered, the BDI and performance mode are displayed • Check park brake.
and the vehicle can be operated. See Figure 12. • Check horn, lights, and reverse alarm.
• Check gauges and warning lights.
• Check tire condition and pressure.
• Check hydraulic oil level.
13
ACCESS TO SERVICE FUNCTIONS SERVICE FUNCTIONS

All service functions are accessible from either Stan- The following submenu functions are accessible from
dard or Premium displays. The following functions the main menu of service functions, described above.
are the same with either display version, except as This includes the following vehicle setup values and
noted in the following sections. control function settings. The control function set-
tings are discussed further in Function Parameter
Once the vehicle is turned ON with the key switch Descriptions.
and the initialization process has been completed, a
service technician can gain access to the service func- • View Hourmeter
tions by pressing the star button (*) twice within 3 Secure Hourmeter
seconds. Set Pump Hours
Set Traction Hours
NOTE: It is suggested that the factory set password, • Software Version
55555, be changed prior to the lift truck being placed Master
into service. Slave
Display
The display will prompt the service technician for a
Valve Driver (Electro-Hydraulic only)
five-digit password. See Figure 14. The default set-
• Password
ting for the password is 55555. When a correct pass-
Add Password
word is entered, the Service Features menu is dis-
Delete Password
played as follows:
Edit Password
• Hourmeters
Operator Password
• Software Versions
Truck Inspection
• Password
• Diagnostics NOTE: All indications in the diagnostic menu are
• Setup shown as ON, OFF, (or a value i.e. volts, amps). ON
is indicated by a one. OFF is indicated by a zero.
• Diagnostic
Error Log
Run Diagnostics
Left Trac Mtr Speed
Left Trac Mtr Crrnt
Left Trac Mtr Temp
Right Trac Mtr Speed
Figure 14. Password Request Right Trac Mtr Crrnt
Right Trac Mtr Temp
If no password is entered, the screen will automati- Steer Position
cally return to the start up screen after 20 seconds. Lift Transistor Control
The screen will also revert to the start up screen if Pump Motor Voltage
an incorrect password is entered. Pump Motor Current
No Run Diagnostics
The technician can scroll through the menu using the Hood Switch
up [1] or down [2] arrows and select the desired func- Seat Belt Switch
tion by pressing the [4] button. Each menu selection Seat Switch
has a list of submenu functions. The submenus are Forward Switch
viewed and items selected by scrolling through the Reverse Switch
menu in the same manner as described above. Accelerator Start
Brake Switch
To exit a selected function and return to the previous
Brake Fluid Level
function, press the [3] button. Pressing the [3] but-
Hydraulic Oil Level
ton multiple times will return the technician to the
Pump Motor Brushes
operator’s driving mode.
Pump Motor Temp
Throttle Pot Volt
14
Steering Enable Truck Settings

Manual with Transistor Control Serial Number
Lo Lift Switch Battery Voltage
Lift Switch Lift Interrupt
Tilt Switch Restore Defaults
3rd Function Switch BDI Adjustment
4th Function Switch BDI Decrement Time
Electro-Hydraulic Service Reminder
Arm Rest Switch Custom
Lift Speed Language
Lower Speed
Tilt Forward Speed PERFORMANCE MODES
Tilt Back Speed
3rd Func In Speed NOTE: Performance modes are not available on the
3rd Func Out Speed Standard Dash display, and the factory configuration
4th Func In Speed is equivalent to Mode 4.
4th Func Out Speed
When equipped with the Premium Dash display,
Manual
the following four operator-selectable performance
Hydraulic Switch
modes are available. These modes are preconfigured
• Setup
from the factory as described below. Mode 4 provides
Traction Settings
the highest performance and Modes 1-3 are percent-
Throttle Calibration
ages of Mode 4. A service technician, using the dash
Max Steer Right
display or connecting with the PC software, can re-
Max Steer Left
vise the control settings and configure the top speed
Max Steer 0
and acceleration of the vehicle. The relationship
Top Speed Forward
between Modes 1-4 remains constant and cannot be
Top Speed Reverse
altered.
Acceleration
Regen Braking With the premium display, the operator can change
Auto Deceleration modes by pressing the numbered keys on the dash
Extended Shift display. Any number can be selected at any time to
Hydraulic Settings change the performance mode. If the mode change
Manual with Transistor Controller is requested while the traction system is in opera-
Lift Pump Accel tion, the requested change will not take effect until
Tilt/Aux Pump Accel the accelerator pedal has been released to the neutral
Lo Lift Speed position. During this operation, the display will indi-
Max Lift Speed cate Mode X Requested until the accelerator is re-
Tilt Speed leased. If the password is enabled, the operator will
3rd Function Speed be limited by the performance level set in the pass-
4th Function Speed word function.
Electro-Hydraulic
4th Function Installed
Lift Pump Accel
Tilt/Aux Pump Accel
Max Lift Speed
Lowering Max Speed
Tilt Max Speed
3rd Function Max Speed
4th Function Max Speed
3rd Function
4th Function
Manual
No Parameters Will Display
15
Mode 4 is the highest level of performance available the battery is 80 percent discharged. Although lift in-
to the operator, regardless of the performance setup terrupt prevents lifting, low speed functions, such as
in the control. For instance, if the control is con- tilt, remain operational to allow the operator to more
figured to limit top speed less than maximum, then easily remove the forks from the load and return to
Mode 4 top speed is equal to the top speed set in the the battery charging area.
control. Three lower performance modes are avail-
able to the operator by using the buttons on the dis- When lift interrupt is initiated, it will remain in ef-
play. These lower performance settings are percent- fect until the battery is disconnected and a recharged
ages of the highest performance available in Mode 4 battery is reconnected to the lift truck. In order to
as described below: reset the BDI function and allow lift truck operation,
• Mode 4 - This is the highest performance mode. the recharged battery must have a state of charge
Other modes are a lower percentage of Mode 4. that is 20 percent above the open cell voltage BDI
• Mode 3 - Top speed is the same as Mode 4. Accel- setting.
eration is 80 percent of Mode 4.
Two BDI adjustment features are provided via the
• Mode 2 - Top speed is 80 percent of Mode 4. Accel-
control setup function, which is accessible via the
dash display (service password required) or with the
• Mode 1 - Top speed is 60 percent of Mode 4. Accel-
PC service software.
HOURMETER
BATTERY DISCHARGE INDICATION (BDI)
There are three different hourmeter functions.
The AC control system includes a Battery Discharge
1. Pump hours - accumulates time only when the
Indicator (BDI) that provides indication of the bat-
pump motor is operating.
tery state of charge. See Figure 15. The BDI feature
2. Traction hours - accumulates time when the seat
is displayed to the operator on the dash display with
switch is closed and the key switch is in the ON
a 20-segment bar that looks and functions the same
position.
as the current BDI. Lift truck operators will not need
3. Secure hours - based on traction hours. The se-
to learn a new BDI system.
cure hours cannot be manually reset. However,
The BDI provides full functionality when used with secure hours will be automatically reset to zero
a full range of batteries including: if both the controller and the dash display are re-
• Flooded cell, standard amp-hour batteries placed at the same time.
• Flooded cell, high amp-hour capacity batteries
The hourmeter data is stored in the master controller
• Valve regulated (absorbed glass mat) maintenance-
during every 6 minutes of operation. If there is a loss
free batteries (VRLA)
of power, data is not lost.
STATUS CODE LIST

The status code list is a stored history of selected sta-
tus codes for malfunctions or incorrect truck use that
have occurred since the list was last cleared of entries
by a technician. These selected status codes are NOT
a list of malfunctions or symptoms that are currently
present, but a list of those that have occurred in the
1. 4 SEGMENTS ADJACENT TO RED past. The list can only be read with the key in the
2. 4 SEGMENTS ADJACENT TO ORANGE OFF position.
3. 12 SEGMENTS ADJACENT TO GREEN
4. BDI SHOWS APPROXIMATELY 65-70% CHARGE To access the status code list, wait until after the
traction and pump hours have been displayed, then
Figure 15. Battery Discharge Indication in push the STAR button. All of the status codes in the
Dash Display LCD Window list will then be shown in sequence. After the last
The lift interrupt feature is controlled by the vehicle status code, END FAULT CODE HISTORY will be
master controller and prevents the lift function when shown.
16
2200 SRM 1087 Dash Display Service Menu Navigation
Dash Display Service Menu Navigation

GENERAL reached. To return to a previous menu item,
press the [1] key. When the last menu item is
To enter the service mode, turn the key to the ON po- reached and the [2] key is pressed again, the first
sition and press the (*) button twice. Enter Password menu item will return to the display.
prompt will appear on the display. See Figure 16. All
lift trucks will have 55555 as the default service pass- 2. To move into a submenu of a main menu item,
word at the time of delivery. This password can be press the [4] key on the dash display numeric key
changed by a service technician. Go to Editing and pad. To move into a sub submenu, as with the
Adding Information. Diagnostics Menu, press the [4] key again.
3. To move up or down within the submenu or the

sub submenu, press the [1] or [2] keys.
4. To move out of the sub submenu and return to

the submenu, press the [3] key.
5. To move out of the submenu and return to the

main menu, press the [3] key.
Figure 16. Password Prompt 6. To exit the service mode, press the [3] key.
Buttons [1], [2], [3], [4], and [*] are used for menu EDITING AND ADDING INFORMATION
navigation and for adding or editing information.
Button [5] is only used if it is part of the password NOTE: The setup and password menus can be used to
required to enter the service mode. The display edit or add information to the truck software. When
has arrows on the buttons to aid in the navigation an item in these menus is selected, the current value
process. See Figure 17. will be displayed. The characters available to be se-
lected from the display are 0-9, A-Z, 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 [4] key and

the cursor will blink on one of the characters.
Keys [3] and [4] are used to move from character
to character in the item being changed.
Figure 17. Dash Display Buttons
2. When a character that is to be changed is blink-
The following list is the numbers on the dash display ing, use keys [1] and [2] to scroll up or down until
and their function: the desired character is found. Use keys [3] or [4]
1. Is up, for scrolling up to move to the next character to be changed. This
2. Is down, for scrolling down is repeated until all changes in the item have
3. Is left, for scrolling left or out of the current menu been made.
4. Is right, for scrolling right or deeper into the next
menu level 3. When all changes have been made, press the [*]
key to store the value. Press the [1] or [2] key to
MOVING THROUGH MENU SELECTIONS access the next item to be changed. Repeat this
procedure for each item that is to be changed.
1. When the service technician’s password is cor-
rectly entered, the first menu item, which is the 4. When all changes have been made, press the [3]
hourmeter, is displayed on the dash display LCD key to exit the menu.
screen. To view the next menu item, press the
[2] key on the dash display numeric key pad. Re-
peat this until the desired menu item has been
17
Troubleshooting 2200 SRM 1087
ETACC Test
If you have access to the ETACC software, the follow- ELECTRO-HYDRAULICS:
ing tests may be conducted.
Connect dongle between the truck and your pc. Turn
MANUAL HYDRAULICS: on the truck, select the proper truck configuration,
and click the connect button. Ensure the "connected"
Connect dongle between the truck and your pc. Turn icon is showing.
on the truck, select the proper truck configuration, • If the red LED on the IFAK dongle is flashing, dis-
and click the connect button. Ensure the "connected" connect the 6 pin connector and the joystick.
icon is showing. If LED stops flashing, the ILM controller may be
• If the red LED on the IFAK dongle is flashing, dis- defective.
connect the dash display connector. If LED continues to flash, go to next step.
If the LED stops flashing, the dash display may • Disconnect the dash display connector and connec-
be defective. tor B at the traction controller.
If the LED continues to flash, go to the next step. If LED stops flashing, the traction controller
• Reconnect the dash display connector and discon- may be defective.
nect connector A from the traction controller. If LED continues to flash, go to next step.
If the LED stops flashing, the traction controller • Reconnect the dash display and connector B.
may be defective. If LED stops flashing, the controller may be de-
If the LED continues to flash, the wiring harness fective.
may be defective. If LED continues to flash, the wiring harness
may be defective.
Troubleshooting
GENERAL pins. Expanded pins will not provide good con-
nections once the plug is reconnected. The con-
The AC motor and master controllers are sealed nectors are shaped to allow the insertion of a
units with no serviceable components. Troubleshoot- small flat blade screwdriver into the connec-
ing is usually limited to accessing status codes and tor. After inserting the screwdriver into the
following the diagnostic procedures listed in the connector attach probes with alligator clips to
Status Code Charts. the shank of the screwdriver to obtain read-
ings. An additional method would be to use a
Use standard testing procedures to verify inputs and
breakout kit Hyster P/N 1397311.
outputs when necessary.
See Diagrams 8000 SRM 1081 for additional wiring
CAUTION details.
Never attempt to probe through the back of If the lift truck does not operate correctly, a status
the connector plugs of the motor controller. code is displayed on the display panel.
These plugs are special sealed plugs. Probing
through the back of the plugs will destroy the Once the status code number is obtained, follow the
seal and can cause a short circuit. If a circuit procedures outlined in the Status Code Charts of this
must be tested for voltage, check for voltage at manual to determine the problem.
an amp-type plug, a switch, or a component. If
a circuit is suspect, check the circuit for conti- NOTE: Due to the interaction of the master controller
nuity by disconnecting the P plug and testing with all lift truck functions, almost any status code
continuity from the front (pin end) of the plug. or controller fault could be caused by an internal fail-
ure of the master controller. After all other status
Standard probes are too large to be inserted code procedures have been followed and no problem
into the center of the female pins (sockets) of is found, the master controller should be replaced as
the special sealed plugs and can expand the the last option to correct the problem.
18
2200 SRM 1087 Troubleshooting
Tools and test equipment required are: clip leads, The status codes are code numbers for malfunctions
volt ohmmeter (20,000 ohms per volt), and basic hand or lift truck operations that are not correct and that
tools. the motor controller can sense. The master controller
will indicate this code number on the LCD screen of
Check resistance on RX1000 scale from frame to the display panel.
power and controller terminals. Resistance of less
than 20,000 ohms can cause misleading symptoms. The master and motor controllers sense the following
Resistance of less than 1000 ohms should be cor- types of malfunctions:
rected first. • Input voltages that are too high or too low
• Input voltages in the wrong sequence or
Before proceeding, visually check for loose wiring, • Correct input voltages that occur at the wrong time
misaligned linkage to the accelerator switch, signs
of overheating of components, etc. NOTE: A status code indication does not always mean
that there is a malfunction. A temporary operating
STATUS CODES condition can cause a status code display.
NOTE: Make sure the parameter values are correct These code numbers are only codes to help identify
for your lift truck to ensure the trouble is not just an a possible malfunction. A short description of the
incorrect setting. See Function Parameters to set the different status codes is shown in Table 4.
correct parameter values. If there is no status code
display and the lift truck does not operate correctly, The Status Code Charts in this section have a more
there can be a fault in the master controller. complete description of the status code, the circuit
that has generated the input for the status code, the
symptom, and the possible causes.
Table 4. List of Status Codes
Status Description
Code
01 Request traction or hydraulic function while seat switch open.
02 Forward switches closed at key on.
03 Reverse switches closed at key on.
05 Start switch not closed when seat switch is closed and either the forward or reverse directional
switch is closed and accelerator voltage shows demand for traction.
06 Request traction function while forward and reverse switches are opened.
07 Accelerator input voltage too high on power up.
08 Accelerator input voltage too low on power up.
09 Forward and reverse direction requested together.
11 Start switch closed before key or seat switch.
12 Steer sensor feedback voltage too low.
13 Steer sensor feedback voltage too high.
14 After steer calibration, controller senses "max right" parameter to be less than "max left"
parameter.
15 Battery voltage lower than the setting in controller.
16 Battery voltage higher than the setting in controller.
41 High temperature in master or slave or both power sections, performance is progressively
reduced as temperature rises.
19
Table 4. List of Status Codes (Continued)
Status Description
Code
42 Pump control temperature too high.
43L Left traction motor temperature out of range.
43R Right traction motor temperature out of range.
51 Capacitor voltage too low.
52L Failure in encoder, in encoder to controller connection, or in controller input circuit, left motor.
52R Failure in encoder, in encoder to controller connection, or in controller input circuit, right motor.
62 Backup alarm driver shorted. Overcurrent protection activated.
65 Main line contactor coil driver shorted.
66L Left traction motor shorted.
66R Right traction motor shorted.
90L Left traction motor high temperature.
90R Right traction motor high temperature.
91 Pump motor high temperature.
95 Pump motor brushes worn.
99 Maintenance required.
142 Controller senses no pump current.
143 Controller senses low pump current.
145 Power transistor did not turn on properly.
201 Request hydraulic or traction function while arm rest switch not closed.
202 Hydraulic oil low.
203 Brake fluid low.
204 Request traction or hydraulic function while hood switch/switches not closed.
207 Lift cutout.
208 Pump incorrect start.
209L Brake coil open, disabling traction.
209R Brake coil open, disabling traction.
210 Internal "watchdog" hardware circuit triggered.
212L Problem with UVW voltage feedback in slave controller.
212R Problem with UVW voltage feedback in master controller.
213 The controller has detected an overvoltage or an undervoltage condition within the controller.
214L Wrong voltage on one phase --> failure in power section (high leg), driver circuit, or motor in
slave controller.
20
Status Description
Code
214R Wrong voltage on one phase --> failure in power section (high leg), driver circuit, or motor
in master controller.
215L Wrong voltage on one phase --> failure in power section (low leg), driver circuit, or motor in
slave controller.
215R Wrong voltage on one phase --> failure in power section (low leg), driver circuit, or motor
in master controller.
222 Controller checks to ensure main contactor coil or brake coil is not shorted at start up.
223 Controller checks main contactor tips and ensures they are open before powering controller.
224 Main contactor not closed.
226 Electric brake driver damaged (shorted or open).
227 Traction controller receives a signal for traction from accelerator potentiometer without start
switch being closed.
238 Internal failure of traction controller hardware.
239 Master controller detected problem in slave controller functionality.
240 Slave controller detected problem in the master controller functionality.
241 Master does not see CAN messages from slave.
242 Master does not see CAN messages from electro-hydraulic lever console.
243 Slave does not see CAN messages from valve driver module.
244 Failure of dash display memory.
245 Master does not see CAN messages from display.
246 Slave does not see CAN messages from display.
247 Valve driver does not see CAN messages from display.
248 Slave does not see CAN messages from master.
249 No communication from slave to EV.
250L Left rotor locked.
250R Right rotor locked.
260 Incorrect voltage on pump motor --> failure in power section, driver section, or motor itself.
270 Error in lift/lower lever.
271 Error in tilt lever.
272 Error in 3rd function lever.
273 Error in 4th function lever.
275 Internal failure of valve driver module.
276 One of the EV drivers of group 1 (lift/lower) is shorted.
277 One of the EV drivers of group 2 (auxiliary in/out) is shorted.
21
Status Description
Code
279 One of the EV drivers of group 3 (tilt up/down) is shorted.
280 One of the EV drivers of group 4 (sideshift R/L) is shorted.
281 Driver of single EV (9th) is shorted.
282 One of the on/off EV drivers is shorted.
283 One of the on/off EV coils is shorted; short-circuit protection is triggered.
289 Voltage supply to the valve driver control module is low.
292 IBattery selection is wrong in valve controller.
294 Interlocked hydraulic function requested without activation of interlock switch.
295 Hi-Lift switch is closed and the Lo-Lift switch is open.
299 CAN wires configuration problem.
Status Premium Display Message Memory Recall Circuit

Code
01 NO SEAT SWITCH INPUT No Traction
Description
Controller is not receiving an input signal from
the seat switch while receiving a traction or
hydraulic function command.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in
the fuse holders.
• Ensure all wiring connections are tight and se-
cure at the fuse panel, key switch, and the bat-
tery disconnect switch.
• Check that the battery disconnect switch, the
key switch, and the main contactor contacts are
in the correct position and properly making con-
tact.
• Seat switch malfunction.
Check to see if the seat switch operates prop-
erly.
Use the dash display diagnostics menu to
check the seat switch operation.
Replace failed switch.
• Check continuity of wiring to and from the seat
switch to the traction controller.
Pin C33 at motor controller to seat switch.
Seat switch to Pin C18 at motor controller.
22

Code
02 FORWARD SWITCH CLOSED No Traction
Description
Forward directional switch is closed before the
key switch closes.
Symptom
the fuse holders.
tact.
• A directional switch is engaged before startup.
Return directional switch to neutral.
• A directional switch is failed, closed, or out of
adjustment.
Use dash display diagnostics menu to check
operation of the directional switches.
Adjust switch for correct operation. See the
section Electrical System 2200 SRM 1078.
• Check for a shorted condition between wire #6
and B+.
Wire #6 will be at battery voltage when the
switch is closed.
Wire #6 will be at 0 volts when the switch is
open.
23

Code
03 REVERSE SWITCH CLOSED No Traction
Description
Reverse directional switch is closed before the key
switch closes.
Symptom
the fuse holders.
tact.
• A directional switch is engaged before startup.
Return directional switch to neutral.
• A directional switch is failed, closed, or out of
adjustment.
Use dash display diagnostics menu to check
operation of the directional switches.
Adjust switch for correct operation. See the
section Electrical System 2200 SRM 1078.
• Check for a shorted condition between wire #8
and B+.
switch is closed
open.
24

Code
05 START SWITCH NOT CLOSED No Traction
Description
Start switch is open when the seat switch is closed
and either the forward or reverse directional
switch is closed and the accelerator output voltage
shows there is a demand for traction.
Symptom
the fuse holders.
tact.
• Malfunction of the start switch.
Use dash display diagnostics to check opera-
tion of the start switch.
Check for proper switch adjustment.
Replace start switch.
Check for open circuit or loose connections in
wiring from the key switch to the start switch
and from the controller to the start switch.
switch is closed.
open.
25

Code
06 NO DIRECTION SELECTED No Traction
Description
The forward and the reverse switches are both
open and there is a request for traction.
Symptom
the fuse holders.
tact.
tact.
• Accelerator pedal is depressed before closing a
directional switch.
Status code will disappear when the pedal is
released.
• Open circuit between the directional switch and
the controller.
Use dash diagnostics to check the operation of
the switch.
Check wiring from C4 to FWD and REV
switches.
Use ohm meter to ensure proper operation of
direction switches.
Check for continuity between C4 and C6 or
C4 and C7 when each switch closes.
Check wiring from switches to C6 and C7.
Check operation of switch for continuity
through the switch when the switch is closed.
• Malfunction of the directional switch.
Check switch adjustment.
FWD or REV switch is closed when direc-
tion is selected.
• Wire #6 will be at battery voltage when the FWD
switch is closed.
• Wire #8 will be at battery voltage when the REV
switch is closed.
• Wires # 6 & #8 will be at 0 volts when the
switches are open.
26

Code
07 THROTTLE POT ERROR Yes Traction
Description
Accelerator input voltage is too high when the key
is first moved to the ON position.
Symptom
the fuse holders.
tact.
• Accelerator unit has a malfunction or is out of
adjustment.
Maximum accelerator wiper voltage should be
4.6 volts with the pedal fully up at C33.
Check for open circuit between accelerator
and controller.
Recalibrate throttle. See the section Electri-
cal System 2200 SRM 1078.
• Check for 5 volts between wire # 27 and wire #
28 at the throttle potentiometer.
27

Code
08 THROTTLE VOLTAGE LOW No Traction
Description
Accelerator input voltage is lower than threshold
voltage set at throttle calibration.
Symptom
the fuse holders.
tact.
• Accelerator unit has a malfunction or is out of
adjustment.
Check for open circuit between accelerator
and controller.
Minimum accelerator wiper voltage should be
0.5 volt with the pedal fully down at C21.
• Check for 5 volts between wire # 27 and wire #
28 at the throttle potentiometer.
28

Code
09 FWD and REV SWITCHES No Traction
CLOSED AT SAME TIME
Description
Both the forward and reverse directional switches
are closed at the same time.
Symptom
the fuse holders.
tact.
• Either the forward or reverse switch is failed
closed.
Use dash display diagnostic to check operation
of directional switches.
Replace failed or malfunctioning switch.
• Directional switch is out of adjustment.
Switches should be open with directional
switch in neutral.
• Wire #6 will be at battery voltage when the FWD
switch is closed.
• Wire #8 will be at battery voltage when the REV
switch is closed.
• Wires # 6 & #8 will be at 0 volts when the
switches are open.
29

Code
11 START SWITCH CLOSED No Traction
BEFORE KEY
Description
Accelerator start switch is closed before the key
and/or the seat switch.
Symptom
the fuse holders.
tact.
• Accelerator pedal depressed when key is turned
to ON position.
Release pedal and restart.
• Accelerator start switch is out of adjustment.
Switch should be open with accelerator pedal
fully up.
• Accelerator start switch is shorted closed.
Use dash display diagnostic menu to check op-
eration of switch.
• Wire # 15 will be at battery voltage when the
start switch is closed.
• Wire # 15 will be at 0 volts when the start switch
is open.
30

Code
12 STEER SENSOR VOLTAGE LOW Yes Traction
Description
Steer sensor feedback voltage is too low.
Symptom
the fuse holders.
tact.
• Use dash diagnostics to check operation of the
steer sensor.
• Check potentiometer and adjustment. Poten-
tiometer wiper should be set at 5K ohms with
wheels straight ahead.
• Check wiring continuity between steering poten-
tiometer and traction controller.
• Check voltage between C15 and C16.
Voltage should be 5.0 volts.
• Check for 5.0 volts between wire # 70 and Wire
# 72 at the steer potentiometer.
• Recalibrate steering. See the section Electrical
System 2200 SRM 1078.
Check voltage at C17 at the traction con-
troller. Voltage is typically 2.2 volts with the
steer wheel in the straight ahead position.
• Operate the lift truck and recheck the steering
potentiometer voltage to ensure the system will
mechanically remain in calibration.
31

Code
13 STEER SENSOR VOLTAGE HIGH Yes Traction
Description
Steer sensor feedback voltage is too high.
Symptom
the fuse holders.
tact.
• Use dash diagnostics to check operation of the
steer sensor.
• Check potentiometer and adjustment. Poten-
tiometer wiper should be set at 5K ohms with
wheels straight ahead.
• Check wiring continuity between steering poten-
tiometer and traction controller.
• Check voltage between C15 and C16.
Voltage should be 5.0 volts.
• With steer wheel straight ahead, check for 2.2
volts at C17 on the traction controller.
• Recalibrate steering. See the section Electrical
System 2200 SRM 1078.
32

Code
14 WRONG STEER CALIBRATION Yes Traction
Description
After steer calibration, the controller is sensing
the "max right" parameter to be less than the
"max left" parameter.
Symptom
No lift truck operation.
the fuse holders.
tact.
• Recalibrate the steering sensor.
• Check sensor values using the dash diagnostics.
• Check adjustment of the steering potentiometer.
• Check for 5.0 volts between wire # 70 and Wire
# 72 at the steer potentiometer.
• Check voltage at C17 at the traction controller.
Voltage is typically 2.2 volts with the steer wheel
in the straight ahead position.
• Operate the lift truck and recheck the steering
potentiometer voltage to ensure the system will
mechanically remain in calibration.
33

Code
15 BATTERY VOLTAGE LOW Yes Traction
Description
The battery voltage is lower than the setting in the MINIMUM
NOMINAL
controller. LIMIT VOLTS
BATTERY
AT 1.85 VDC
VOLTAGE
PER CELL
Symptom 36 33.3
Lift truck does not move. 48 44.4
• Incorrect battery installed in truck.
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Discharged battery.
Check battery for correct open circuit voltage.
Charge battery.
• Battery is damaged.
Check each cell for correct voltage (greater than
1.85 volts per cell).
Repair or replace battery.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Incorrect controller adjustment.
Use dash display to check battery voltage.
• Check condition of main contactor tips.
34

Code
16 BATTERY VOLTAGE HIGH Yes Traction
Description
The battery voltage is higher than the setting in MAXIMUM
NOMINAL
the controller. LIMIT VOLTS
BATTERY
AT 2.40 VDC
VOLTAGE
PER CELL
Symptom 36 43.2
Lift truck does not move. 48 57.6
the fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Incorrect battery installed in truck.
• Overcharged battery.
Check battery for correct open circuit voltage.
• Incorrect controller adjustment.
Use dash display to check battery voltage.
• Check condition of main contactor tips.
35

Code
41 TRACTION CONTROL Yes Traction
TEMPERATURE HIGH
Description
High temperature in the traction controller power
section. Truck performance is progressively
reduced as temperature rises.
Symptom
Traction performance is reduced.
the fuse holders.
tact.
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, re-
place controller.
• Check for dragging parking brakes or service
brakes.
• Use dash diagnostics to check for correct current
level of the left and right traction motors and the
pump motor.
• Check for mechanical offset of steering poten-
tiometer. Recalibrate as necessary.
36

Code
42 PUMP CONTROL TEMPERATURE Yes Hydraulic
HIGH
Description
Pump controller temperature is too high.
Traction performance is progressively reduced as
temperature increases.
Symptom
the fuse holders.
tact.
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, re-
place controller.
• Check for dragging parking brakes or service
brakes.
• Use dash diagnostics to check for correct current
level of the left and right traction motors and the
pump motor.
37

Code
43L LEFT MOTOR TEMP OUT Yes Traction
OF RANGE
Description
Left traction motor temperature is out of range.
Symptom
the fuse holders.
tact.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor
temperature.
• Check the motor temperature sensor resistance
at the traction controller between C34 and C35.
Resistance should read 500 ohms at24 C (75 F).
• Check for a shorted condition between C34 and
the truck frame and C35 and the truck frame.
Should see a minimum 1 megohm resistance.
38

Code
43R RIGHT MOTOR TEMP OUT Yes Traction
OF RANGE
Description
Right traction motor temperature is out of range.
Symptom
the fuse holders.
tact.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor
temperature.
• Check the motor temperature sensor resistance
at the traction controller between C24 and C25.
Resistance should read 500 ohms at24 C (75 F).
the truck frame and C25 and the truck frame.
Should see a minimum 1 megaohm resistance.
39

Code
51 PRECHARGE Yes Traction
Description
Controller capacitor voltage does not increase at
startup.
Symptom
the fuse holders.
tact.
• Ensure the towing connector near the dash dis-
play is not in place.
• Remove fuse FU3 and turn the key to the ON
position. If the problem remains, perform Test A.
If the problem does not reappear, perform Tests
B.
Test A:
Disconnect the battery and discharge the ca-
pacitors. See Discharging Capacitors in the
front of this section.
Disconnect the B+ cable from the traction con-
troller.
Connect and ohm meter between the B+ and
the B- terminals of the traction controller.
Look for an increasing resistance from 0 to 150
ohms over 10 seconds.
Disconnect the ohm meter and discharge the
capacitors. See Discharging Capacitors in the
front of this section.
Connect the ohm meter negative lead to B-
and ohm meter positive lead to UM. The ohm
meter should read approximately 5K ohms.
Connect the ohm meter negative lead to B-
and the ohm meter positive lead to US. The
ohm meter should read approximately 5K
ohms.
Connect the ohm meter negative lead to UM
and the ohm meter positive lead to B+. The
ohms. (Continued on next page)
40

Code
51 (Cont) PRECHARGE Yes Traction
Description
Controller capacitor voltage does not increase at
startup.
Symptom
• Remove fuse FU3 and turn the key to the ON
position. If the problem remains, perform Test A.
If the problem does not reappear, perform Tests
B (Continued).
Test A: (Continued)
Connect the ohm meter negative lead to US
and the ohm meter positive lead to B+. The
ohms.
If any of these tests is failed, replace the con-
troller.
Tests B:
Check resistance between B+ and B- at the
steering motor. The reading should be several
thousand ohms.
Check for a failed R1 resistor in the steering
circuit.
Install fuse (FU3), disconnect the dash con-
nector, and turn the key to the ON position.
Measure the voltage across B+ and B on the
traction controller. If the value is battery volt-
age, the dash display may be defective.
Check for brake driver continuous on. With
the key switch in the ON position and the seat
switch in the open condition, check that volt-
age between C28 and C29 in less than 2 volts.
Check for welded pump contactor tips.
• Wire #47 should be greater than 5 volts after the
seat switch opens for more than 10 seconds.
• Check the connections of wires #10-6 and #47.
41

Code
52L LEFT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed
sensor.
Symptom
the fuse holders.
tact.
• Use dash diagnostics to check encoder operation.
• Check for 12-volt supply to encoder.
• Ensure wiring to the encoder is correct. See the
section Diagrams 8000 SRM 1081.
• Ensure all wiring connections between the en-
coder and the traction motor are tight.
• Check continuity of the wiring from the con-
troller to the encoder.
• Check for any shorted condition between C1, C2,
C13, or C14 to the truck frame.
• Disconnect the 6 pin connector from the traction
motor and check for pin to pin resistance in the
connector on the motor side. There should be a
minimum 1 megohm resistance from pin to pin.
42

Code
52R RIGHT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed
sensor.
Symptom
the fuse holders.
tact.
• Use dash diagnostics to check encoder operation.
• Check for 12-volt supply to encoder.
• Ensure wiring to the encoder is correct. See the
section Diagrams 8000 SRM 1081.
coder and the traction motor are tight.
• Check continuity of the wiring from the con-
troller to the encoder.
• Check for any shorted condition between C1, C2,
C13, or C14 to the truck frame.
• Disconnect the 6 pin connector from the traction
motor and check for pin to pin resistance in the
connector of the motor side. There should be a
minimum 1 megohm resistance from pin to pin.
43

Code
62 REVERSE SIGNAL OUTPUT Yes Auxiliary
SHORTED
Description
Backup alarm driver is shorted. Overcurrent
protection has been activated.
Symptom
Backup alarm does not operate.
the fuse holders.
tact.
• Disconnect the dash display A connector and
check for shorted wiring between pin A20 and
B- or B+.
• Check wiring for shorts.
• Check for a shorted alarm.
• Check the resistance of R3, R4, D1 and LRC1
for proper values if equipped with a DC/DC con-
verter.
• Replace dash display.
44

Code
65 MAIN CONTACTOR SHORTED Yes Traction
Description
The main contactor coil driver is shortened.
Symptom
the fuse holders.
tact.
• Disconnect C connector from the traction con-
troller and check the controller for a shorted con-
dition between C26 and B-.
• Check the harness for a shorted condition be-
tween pin C26 and B+ or B-.
• Check for shorted driver at the controller. Check
for short between terminal C26 and B .
• Check for shorted main contactor coil. Coil
should measure approximately 32 ohms.
45

Code
66L LEFT TRACTION MOTOR Yes Traction
SHORTED
Description
Left traction motor is shorted.
Symptom
the fuse holders.
tact.
• Ensure all motor connections are tight.
• Ensure motor connections are not shorted to the
truck frame.
• Disconnect all motor leads from the traction mo-
tor. Check line-to-line stator resistance. Resis-
tance should be 10.00 ±0.10 milliohms for 48-volt
truck and 6.10 ±0.10 milliohms for 36-volt truck.
46

Code
66R RIGHT TRACTION MOTOR Yes Traction
SHORTED
Description
Right traction motor is shorted.
Symptom
the fuse holders.
tact.
• Ensure all motor connections are tight.
• Ensure motor connections are not shorted to the
truck frame.
tor. Check line-to-line stator resistance. Resis-
tance should be 10.00 ±0.10 milliohms for 48-volt
truck and 6.10 ±0.10 milliohms for 36-volt truck.
47

Code
TEMP HIGH
Description
Left traction motor high temperature.
Temperature sensor in traction motor has
indicated high temperature.
Symptom
the fuse holders.
tact.
• Use dash display diagnostics to verify motor tem-
perature sensor is operating properly.
• Reduce truck operation until motor cools.
• If a fault is signaled with cold motor, disconnect
the C connector from the traction controller and
check the motor temperature sensor resistance
between pin C34 and C35 in the connector. The
resistance should be 555 ohms to 607 ohms at
20 C (68 F). If the resistance is out of range, dis-
connect the 6 pin connector at the left traction
motor and measure the resistance again between
pins 3 and 4 at the motor side of the connector. If
the resistance is within range, check the wiring
harness.
• Check for broken or loose wires.
tor and check line to line stator resistance. The
resistance should read 10.00 +/-0.10 milliohms
for a 48 volt truck and 6/10 +/-0.10 milliohms for
a 36 volt truck.
If the above readings are within in the spec-
ified ranges, compare motor current between
the two traction motors using dash display di-
agnostics. Drive the truck straight ahead and
observe the current level of each traction mo-
tor. If the left traction motor is drawing sig-
nificantly more current than the right traction
motor check for a dragging service or parking
brake. (Continued on next page)
48

Code
(Cont) TEMP HIGH
Description
Left traction motor high temperature.
indicated high temperature.
Symptom
49

Code
TEMP HIGH
Description
Right traction motor high temperature.
indicated high motor temperature.
Symptom
the fuse holders.
tact.
• Use dash display diagnostics to verify motor tem-
perature sensor is operating properly.
• If a fault is signaled with cold motor, disconnect
the C connector from the traction controller and
check the motor temperature sensor resistance
between pin C34 and C35 in the connector. The
resistance should be 555 ohms to 607 ohms at
20 C (68 F). If the resistance is out of range, dis-
connect the 6 pin connector at the left traction
motor and measure the resistance again between
pins 3 and 4 at the motor side of the connector. If
the resistance is within range, check the wiring
harness.
• Check for broken or loose wires.
tor and check line to line stator resistance. The
resistance should read 10.00 +/-0.10 milliohms
for a 48 volt truck and 6/10 +/-0.10 milliohms for
a 36 volt truck.
If the above readings are within in the spec-
ified ranges, compare motor current between
the two traction motors using dash display di-
agnostics. Drive the truck straight ahead and
observe the current level of each traction mo-
tor. If the right traction motor is drawing sig-
nificantly more current than the right traction
motor, check for a dragging service or parking
brake. (Continued on next page)
50

Code
(Cont) TEMP HIGH
Description
Right traction motor high temperature.
indicated high motor temperature.
Symptom
51

Code
91 PUMP MOTOR TEMPERATURE No Lift
HIGH
Description
Pump motor temperature too high. Thermal
switch in pump motor has been activated.
Symptom
Display message.
the fuse holders.
tact.
• Use dash display diagnostics to verify motor
over-temperature switch is activated.
• If fault is signaled with a cold motor, disconnect
the dash display connector and measure the re-
sistance between A2 and A6 at the harness side
of the connector. The resistance should be less
than 10 ohms.
If the resistance is greater than 10 ohms, dis-
connect the 4 pin connector at the pump motor
and measure the resistance between wires 110
and 102 on the motor side of the connector. If
the resistance is less than 10 ohms, check the
wiring harness and connectors.
• Remove all motor leads from the pump motor
and check line to line stator resistance.
• Use the dash display to check for high current
draw during hydraulic operations if equipped.
52

Code
95 PUMP MOTOR BRUSHES No Lift
Description
Pump motor brushes worn. Brush wear indicator
switch in pump motor has been activated.
Symptom
Dash display message.
the fuse holders.
tact.
• Replace pump motor brushes.
• Check wiring and connections.

Code
99 MAINTENANCE REQUIRED No None
Description
Truck maintenance required.
Symptom
Dash display message. Flashing "wrench" icon.
• Truck requires scheduled maintenance.
• Perform required maintenance activity.
53

Code
142 PUMP CURRENT SENSOR Yes Hydraulic
MISSING
Description
Controller senses no pump current.
Symptom
No hydraulic function.
the fuse holders.
tact.
• Check that traction motor windings are not
shorted to the truck frame.
• Check the P+ and P connections at both the
controller and the pump motor.
• Check for shorts from P+ and P to the truck
frame.
• Check to see if the pump motor reverses direction
when a hydraulic function is returned to neu-
tral. If reverse rotation is observed, check the
hydraulic valves for proper operation.
54

Code
143 PUMP CURRENT SENSOR LOW Yes Hydraulic
Description
Controller senses low pump current.
Symptom
No hydraulic function.
the fuse holders.
tact.
• Check the P+ and P connections at both the
controller and the pump motor.
• Check for shorts from P+ and P to the truck
frame.
• Check to see if the pump motor reverses direction
when a hydraulic function is returned to neu-
tral. If reverse rotation is observed, check the
hydraulic valves for proper operation.
55

Code
145 PUMP M- FAULT Yes Hydraulic
Description
Power transistor did not turn on properly.
Symptom
No lift operation.
the fuse holders.
tact.
• Check wiring connections between the controller
and the pump motor.
• Check for open motor windings.
• Check for worn pump motor brushes.
• Check for any shorted condition between P+ or
P- at the pump controller and the truck frame.
56

Code
201 NO ARM REST SWITCH INPUT No Lift
Description
Arm rest switch not closed when requesting
traction or hoist functions.
Symptom
Lift does not operate.
the fuse holders.
tact.
• Ensure arm rest is in full down position.
Arm rest should be in the locked position.
• Use dash diagnostics to check operation of
switch.
Check all wiring connections to switch.
Check switch adjustment. See the section
Electrical System 2200 SRM 1078 for ad-
justment procedure.
57

Code
202 HYDRAULIC OIL LOW No Lift
Description
Hydraulic fluid is low.
Symptom
Dash display message. Flashing icon on display.
the fuse holders.
tact.
• Ensure forks are fully lowered, turn key to the
ON position.
• Check hydraulic fluid level.
Add fluid. See the section Periodic Mainte-
nance 8000 SRM 1079 for correct fluid.
• Check sensor for open condition.
Ensure all wiring connections are secure.
• Check for battery voltage at A9 on the dash dis-
play when the hydraulic oil level is full.
• Disconnect the dash display connector and mea-
sure the resistance between A2 and A9 at the
harness side of the connector. The resistance
should be less than 10 ohms when the hydraulic
oil level is full. If the resistance is greater than
10 ohms, disconnect the 2 pin connector at the
hydraulic oil level sensor and measure the resis-
tance at the sensor. If this resistance is less than
10 ohms, check the condition of the wiring har-
ness.
58

Code
203 BRAKE FLUID LOW No Brake
Description
Brake fluid is low.
Symptom
Dash display message. Flashing icon on display.
the fuse holders.
tact.
• Check brake master cylinder fluid level. Fill as
needed.
• Check for loose or broken wires.
CAUTION
Do not use DOT brake fluid! This truck uses
hydraulic oil in the brake system. See the
section Capacities and Specifications 8000
SRM 1080.
• Check sensor.
Disconnect wiring connector.
Remove fill cap and sensor from reservoir.
Check resistance across the sensor pins.
Resistance is approximately 470 ohms
when float is fully raised.
Resistance is less than 10 ohms when the
float is fully lowered and the switch is
closed.
59

Code
204 NO HOOD SWITCHES INPUT No Traction/Lift
Description
Hood switch or switches are open when requesting
traction or hydraulic functions.
Symptom
No traction or lift operation.
the fuse holders.
tact.
• Check wiring continuity between switches.
There are two switches wired in series.
Check for battery voltage at C5 with both
switches closed.
Check each switch for open condition while op-
erating the switch.
• Replace failed switch.
60

Code
207 LIFT INTERRUPT No Lift
Description
Fault is set when battery is discharged below 20
percent of full charge.
Symptom
the fuse holders.
tact.
• Occurs when battery is 80 percent discharged.
• Discharged battery.
Charge or change battery.
61

Code
208 PUMP REQUEST BEFORE KEY No Lift
Description
Incorrect pump motor starting sequence.
Symptom
the fuse holders.
tact.
Manual Valve
• Recycle key.
• Check for a closed hydraulic function switch at
the manual hydraulic control valve.
Check switch adjustment.
Switches should be open with the hydraulic
function levers in the neutral position.
• Replace failed switch.
NOTE: Lift trucks with transistor hydraulics share

circuitry between the hydraulic and traction cir-
cuits inside the motor controller. This fault code
may sometimes be caused by a problem registered
from the traction motor encoders.
If the lift truck is equipped with transistor hy-

draulics, perform the following tests:
• Disconnect connector “D” from the traction con-

troller.
• Check the status of each function’s switches us-
ing the dash display.
• If the status reading flashes “1” and “0” alter-
nately or if the pump motor runs:
Turn the key switch to the OFF position.
Disconnect the six pin connectors securing
both the left and right traction motor en-
coders to the main wiring harness.
Turn the key switch to the ON position. (Con-
tinued on next page)
62

Code
208 PUMP REQUEST BEFORE KEY No Lift
(Cont)
Description
Incorrect pump motor starting sequence.
Symptom
• If the status reading has stopped flashing “1”
and “0” alternately and if the pump motor has
stopped:
One or both of the encoders is faulty. Check
both encoders by measuring the resistance be-
tween any combination of connector pins 1, 2,
5, and 6 on the motor side. The resistance
should be at least 1 megohm.
Parking brakes that are dragging can damage
the encoders. Inspect the parking brakes for
proper operation when encoders have to be re-
placed. See Brake System 1800 SRM 1076.
Electro-Hydraulic Valve
the fuse holders.
• Cycle key switch from OFF to ON.
• Check for function lever not in neutral. See
the section Electro-Hydraulic Control Valve
2000 SRM 1086.
• Use the dash display diagnostic to view all hy-
draulic functions while all levers are in neutral.
All functions should show 0%.
63

Code
209L BRAKE COIL OPEN No Brake
Description
Brake coil is open, disabling traction.
Symptom
No truck movement, or truck may pull to one side
when starting to accelerate.
the fuse holders.
tact.
• Check the resistance of the brake coil. The coil
resistance should read approximately 32 ohms at
24 C (75 F).
• Recycle key switch.
• Check for voltage at the brake coil.
Should read approximately 36 volts.
If no voltage, check wiring for loose connec-
tions at the dash display connector pins A12
& A13. Also check pins C28 & C29 at the trac-
tion controller. Check for open circuits in the
wiring harness.
• Check brake circuit diodes.
• Check brake circuit diodes D2 and D3 for an open
or shorted condition.
64

Code
209R BRAKE COIL OPEN No Brake
Description
Brake coil is open, disabling traction.
Symptom
No truck movement, or truck may pull to one side
when starting to accelerate.
the fuse holders.
tact.
• Check the resistance of the brake coil. The coil
resistance should read approximately 32 ohms at
24 C (75 F).
• Check for voltage at the brake coil.
Should read approximately 36 volts.
If no voltage, check wiring for loose connec-
tions at the dash display connector pins A12
& A13. Also check pins C28 & C29 at the trac-
tion controller. Check for open circuits in the
wiring harness.
• Check brake circuit diodes.
• Check brake circuit diodes D2 and D3 for an open
or shorted condition.
65

Code
210 WATCHDOG IN TRACTION Yes Traction
CONTROLLER
Description
The internal "watchdog" hardware circuit has
been triggered.
Symptom
the fuse holders.
tact.
• Check resistance between CANL and CANH
wires at the controller.
Resistance should be approximately 60 ohms.
• Ensure CANL, CANH, B+, or B- is not shorted to
the frame of the truck.
• Ensure CANL or CANH is not shorted to B-.
• Ensure CANL and CANH is not shorted to B+.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hy-
draulic levers mounting plate and the truck
frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.
66

Code
212L LEFT U.V.W. VOLTAGE Yes Traction
FEEDBACK
Description
Problem with UVW voltage feedback in slave
controller.
Symptom
No traction.
the fuse holders.
tact.

Code
212R RIGHT U.V.W. VOLTAGE Yes Traction
FEEDBACK
Description
Problem with UVW voltage feedback in master
controller.
Symptom
No traction.
the fuse holders.
tact.
67

Code
213 UNDER/OVER VOLTAGE Yes Internal Controller
Description
The controller has detected an overvoltage or an
undervoltage condition within the controller.
Symptom
the fuse holders.
tact.
• Check that the battery is the proper voltage and
is fully charged. Check the specific gravity of
each cell.
• If a fault occurs at key ON, disconnect the dc-dc
converter if installed on the truck.
• If the fault occurs when a hydraulic or traction
function is activated, check the battery discon-
nect switch condition and the main contactor tip
condition.
68

Code
214L LEFT MOTOR VOLTAGE LOW Yes Traction
Description
Incorrect voltage on one phase of the power
circuit.
Symptom
the fuse holders.
tact.
• Check all wiring connections to motors and con-
troller. All connections should be tight.
• Ensure power wires are connected to correct ter-
minals. See the section Diagrams 8000 SRM
1081.
• Check the resistance of each motor winding.
Each winding should measure approximately
10.00 ±0.10 milliohms (48V) and 6.10 ±0.10
milliohms (36V).
• Ensure each of the motor windings is not shorted
to the truck frame.
69

Code
214R RIGHT MOTOR VOLTAGE LOW Yes Traction
Description
circuit.
Symptom
the fuse holders.
tact.
troller. All connections should be tight.
1081.
10.00 ±0.10 milliohms (48V) and 6.10 ±0.10
milliohms (36V).
to the truck frame.
70

Code
215L LEFT MOTOR VOLTAGE HIGH Yes Traction
Description
circuit.
Symptom
the fuse holders.
tact.
troller. All connections should be tight and clean.
1081.
10.00 ±0.10 milliohms (48V) and 6.10 ±0.10
milliohms (36V).
to the truck frame.
71

Code
215R RIGHT MOTOR VOLTAGE HIGH Yes Traction
Description
circuit.
Symptom
the fuse holders.
tact.
troller. All connections should be tight and clean.
1081.
10.00 ±0.10 milliohms (48V) and 6.10 ±0.10
milliohms (36V).
to the truck frame.
72

Code
222 MAIN OR BRAKE COIL Yes Traction
OVERCURRENT
Description
The controller checks to ensure the main contactor
or brake coils are not shorted at start up.
Symptom
the fuse holders.
tact.
• Check for shorted main contactor coil. Coil
should measure approximately 32 ohms resis-
tance across the coil terminals.
• Check for shorted wiring.
• Check for shorted brake coils. Coil should mea-
sure 32.5 ohms resistance across the coil leads.
• Check for shorted condition between pins C26 &
C27 and between pins C28 & C29 at the traction
controller.
73

Code
223 MAIN CONTACTOR WELDED Yes Traction
Description
The controller checks the main contactor tips
and ensures they are open before powering the
controller.
Symptom
the fuse holders.
tact.
• Check that the main contactor tips are not
welded.
• Open contactor tips and replace if needed.
74

Code
224 MAIN CONTACTOR NOT CLOSED Yes Traction
Description
The controller checks to ensure the main contactor
closes after power has been supplied to the
contactor coil.
Symptom
the fuse holders.
tact.
• Ensure contactor is not stuck in open position.
• Check the contactor coil. Coil should measure
approximately 32 ohms resistance.
• Check wiring from the controller to the contactor
coil. Check for continuity from C26 to coil. Check
for continuity from C27 to coil.
• Check for shorted condition between C26 and the
truck frame.
• Check for shorted condition between C27 and the
truck frame.
75

Code
226 BRAKE DRIVER OPEN OR Yes Traction
SHORTED
Description
Internal check of the parking brake driver in the
controller.
Symptom
the fuse holders.
tact.
• Check for a shorted condition between C28 at
harness side of the connector and B-. If there is
an indication of low resistance while making this
check, check the wire harness for shorts.
B- at the controller side. If there is an indication
of low resistance while making this check, the
controller may be defective.
• Check the brake coil resistance, the brake coil
should measure approximately 31 ohms.
• Check for a shorted condition between pin C28
at the traction controller and the truck frame.
Check for a shorted condition from pin C29 to the
truck frame at the traction controller.
76

Code
227 THROTTLE VOLTAGE HIGH No Traction
Description
The traction controller is receiving a signal for
traction from the accelerator potentiometer
without the start switch being closed.
Symptom
the fuse holders.
tact.
• Accelerator potentiometer is out of adjustment.
Use dash display diagnostics to check opera-
tion of the start switch.
Check for proper switch adjustment.
• Use the dash display diagnostics to check opera-
tion of the throttle sensor.
Replace throttle sensor if necessary.
• Check for a shorted condition between pins C20,
C21 and C33 at the traction controller and the
truck frame.
77

Code
238 TRACTION CONTROLLER FAULT Yes/No Traction
Description
Internal failure of the traction controller
hardware.
Symptom
Lift truck will not operate.
the fuse holders.
tact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• If the truck is equipped with a pump controller,
check all pump motor power connections and ca-
bles.
Check for a shorted condition between P+ and
the truck frame and between P- and the truck
frame.
Check for reverse rotation of the pump motor
when returning a hydraulic function to neu-
tral. If reverse rotation is observed, check hy-
draulic valves for proper operation.
78

Code
239 ALARM IN SLAVE Yes Internal Controller
Description
Master controller has detected a problem with the
slave controller.
Symptom
Lift truck does not operate.
the fuse holders.
tact.
• Check resistance between CANH and CANL
wires at the traction controller. Resistance
should be approximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted
to the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections
or damaged wiring.
frame.
ETACC Test.
79

Code
240 ALARM IN MASTER Yes Internal Controller
Description
Slave controller has detected a problem with the
master controller.
Symptom
Lift truck does not operate.
the fuse holders.
tact.
B+.
or damaged wiring.
frame.
ETACC Test.
80

Code
241 NO COMMUNICATION SLAVE Yes Internal Controller
TO MASTER
Description
Master controller is not receiving CAN messages
from the slave controller.
Symptom
the fuse holders.
tact.
B+.
or damaged wiring.
frame.
ETACC Test.
81

Code
242 NO COMMUNICATION LEVER Yes Lift
TO MASTER
Description
from the electro-hydraulic lever console.
Symptom
the fuse holders.
tact.
B+.
or damaged wiring.
frame.
you have access to the ETACC software. Refer
to ETACC Test.
82

Code
243 NO COMMUNICATION EV Yes Lift
TO SLAVE
Description
Slave controller is not receiving CAN messages
from the electro-hydraulic valve driver module.
Symptom
the fuse holders.
tact.
B+.
or damaged wiring.
frame.
ETACC Test.
EV = Electro-hydraulic valve driver module.
83

Code
244 DASH DISPLAY FAULT No Display
Description
Failure of the dash display memory.
Symptom
Dash display does not operate.
the fuse holders.
tact.
• Check all wiring and pins in the dash display
connector are tight and secure.
84

Code
245 NO COMMUNICATION MASTER Yes Traction
TO DASH
Description
from the dash display.
Symptom
Lift truck does not move or moves very slowly.
the fuse holders.
tact.
• Check termination resistor. Should measure ap-
proximately 60 ohms between A7 and A22 at the
dash display.
B+.
or damaged wiring.
frame.
ETACC Test.
85

Code
246 NO COMMUNICATION SLAVE Yes Traction
TO DASH
Description
from dash display.
Symptom
the fuse holders.
tact.
• Check termination resistor. Should measure ap-
proximately 60 ohms between A7 and A22 at the
dash display.
B+.
or damaged wiring.
frame.
ETACC Test.
86

Code
247 NO COMMUNICATION EV Yes Lift
TO DASH
Description
Electro-hydraulic valve driver module is not
receiving CAN messages from the dash display.
Symptom
the fuse holders.
tact.
• Check continuity of the CANbus wires between
the dash display and the valve driver module.
B+.
or damaged wiring.
frame.
ETACC Test.
87

Code
248 NO COMMUNICATION MASTER Yes Internal Controller
TO SLAVE
Description
from the master controller.
Symptom
the fuse holders.
tact.
• Check continuity of the CANbus wires between
the dash display and the valve driver module.
B+.
frame.
ETACC Test.
88

Code
249 NO COMMUNICATION SLAVE Yes Internal Controller
TO EV
Description
EV controller is not receiving CAN messages from
the slave controller.
Symptom
Truck will not operate.
the fuse holders.
tact.
B+.
or damaged wiring.
frame.
ETACC Test.
89

Code
250L LEFT ROTOR LOCKED Yes Traction
Description
The controller is supplying current to the traction
motors while sensing one or both of the traction
motors is not turning.
Symptom
No truck movement while depressing the
accelerator pedal.
the fuse holders.
tact.
• Wheel is in a hole and the truck cannot move.
• Brake coil has not released the brake disk.
• Mechanical failure of one or both of the traction
motors.
tion of traction motor encoder.
• Check for 12 volts at encoder between wires 75
and 76.
coder harness and the traction motor are tight.
• Check for continuity of all wiring between the
encoder and the traction controller.
• Check for any shorted condition from pins C11,
C12, C22, or C23 at the traction controller to the
truck frame.
•
• Ensure the wiring to the encoder is correct. See
the section Diagrams 8000 SRM 1081.
• Disconnect the 6 pin connector at the traction
motor and measure the resistance between any
combination of pins 1, 2, 5, and 6. The resistance
90

Code
250R RIGHT ROTOR LOCKED Yes Traction
Description
The controller is supplying current to the traction
motors while sensing one or both of the traction
motors is not turning.
Symptom
No truck movement while depressing the
accelerator pedal.
the fuse holders.
tact.
• Wheel is in a hole and the truck cannot move.
• Brake coil has not released the brake disk.
• Mechanical failure of one or both of the traction
motors.
tion of traction motor encoder.
• Check for 12 volts at encoder between wires 83
and 84.
coder harness and the traction motor are tight.
• Check for continuity of all wiring between the
encoder and the traction controller.
• Check for any shorted condition from pins C1,
C2, C13, or C14 at the traction controller to the
truck frame.
•
• Ensure the wiring to the encoder is correct. See
the section Diagrams 8000 SRM 1081.
• Disconnect the 6 pin connector at the traction
motor and measure the resistance between any
combination of pins 1, 2, 5, and 6. The resistance
91

Code
260 PUMP MOTOR VOLTAGE LOW Yes Transistor Lift
Description
Incorrect voltage on pump motor.
Symptom
No lift operation.
the fuse holders.
tact.
• Wrong voltage battery installed in truck.
Ensure battery voltage matches voltage
shown on truck nameplate.
• Wrong voltage parameter selection.
Ensure parameter setting matches voltage
shown on truck nameplate.
Check parameter setting using the dash dis-
play.
• Check for any shorted condition from P+ or P- to
the truck frame.
• Check for any shorted condition between P- and
B-.
• Check P+ and P- connections are tight at the con-
troller and the pump motor.
92

Code
270 LIFT/LOWER LEVER ERROR Yes Electro-hydraulic
Description
Error in signal from the lift/lower lever assembly.
Symptom
No lift/lower operation.
the fuse holders.
tact.
• Check all wiring connections between the hy-
draulic lever console and the hydraulic controller
are tight and secure.
• Check for 12 volts at pin 1 on the hydraulic lever
console.
Check for 12 volts at pin B10 on the valve
driver module.
• Replace the lift/lower lever PC board.
93

Code
271 TILT LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the tilt lever.
Symptom
No mast tilt operation.
the fuse holders.
tact.
console.
driver module.
• Replace the tilt lever PC board.
94

Code
272 3RD FUNCTION LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the sideshift lever.
Symptom
No carriage sideshift operation.
the fuse holders.
tact.
console.
driver module.
• If the truck is not equipped with 3rd. function,
make sure 3rd function parameter is set at 3.
• Replace the sideshift lever PC board.
95

Code
273 4TH FUNCTION LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the auxiliary lever.
Symptom
No operation of the auxiliary hydraulic function.
the fuse holders.
tact.
• If the truck is not equipped with 4th function,
make sure 4th function parameter is set at 3.
console.
driver module.
• Replace the auxiliary lever PC board.
96

Code
275 VALVE CONTROLLER FAULT Yes Electro-hydraulic
Description
Internal failure of the valve driver module.
Symptom
No operation of the electro-hydraulic functions.
the fuse holders.
tact.
• Recycle key switch from OFF to ON.
• Check all pins at the valve controller connector
• Replace the valve driver module.
97

Code
276 LIFT/LOWER EV DRIVER Yes Electro-hydraulic
SHORTED
Description
Lift/lower driver in the valve driver module is
shorted.
Symptom
No lift/lower operation.
the fuse holders.
tact.
• Disconnect connector "C" from EV. Check all
wires for shorts to B-, the truck frame, or be-
tween wires.
• Check resistance of coils:
Resistance should read approximately 19
ohms at 25 C (77 F).
98

Code
277 4TH FUNCTION EV DRIVER Yes Electro-hydraulic
SHORTED
Description
Auxiliary driver in the valve driver module is
shorted.
Symptom
No operation of the auxiliary hydraulic function.
the fuse holders.
tact.
• Recycle key switch to clear fault.
tween wires.
99

Code
279 TILT EV DRIVER SHORTED Yes Electro-hydraulic
Description
Tilt driver in the valve driver module is shorted.
Symptom
No tilt function operation.
the fuse holders.
tact.
tween wires.
100

Code
280 3RD FUNCTION EV DRIVER Yes Electro-hydraulic
SHORTED
Description
The sideshift function driver in the valve driver
module is shorted.
Symptom
No sideshift function operation.
the fuse holders.
tact.
tween wires.
101

Code
281 EV 9 DRIVER SHORTED Yes Electro-hydraulic
Description
Single EVP driver is shorted.
Symptom

This spare output is not used.
the fuse holders.
tact.
tween wires.

EVP = Electro-hydraulic proportional valve driver.
102

Code
282 SELECTOR EV DRIVER SHORTED Yes Electro-hydraulic
Description
On/off EV driver is shorted.
Symptom

the fuse holders.
tact.
tween wires.
103

Code
283 SELECTOR EV COIL SHORTED Yes Electro-hydraulic
Description
One of the electro-hydraulic valve coils is shorted.
Symptom
One of the hydraulic functions will not operate.
the fuse holders.
tact.
tween wires.
104

Code
289 EV CONTROLLER LOW VOLTAGE Yes Electro-hydraulic
Description
Voltage supply to the valve driver control module
is low.
Symptom
No operation of the electro-hydraulic functions.
the fuse holders.
tact.
• Check for battery voltage at pins B1 and B2 with
key switch closed.
• Check that all connections are secure.
105

Code
292 WRONG BATTERY SET IN EV Yes Electro-hydraulic
CONTROLLER
Description
Incorrect battery selection parameter in the valve
driver module.
Symptom
No operation of hydraulic system.
the fuse holders.
tact.
• Ensure battery voltage matches voltage shown
on the lift truck nameplate.
Install correct voltage battery in the lift truck.
• Ensure battery parameter setting matches volt-
age shown on the lift truck nameplate.
Use dash display to change battery parameter.
106

Code
294 INTERLOCK SWITCH No Hydraulic
Description
Message is displayed when an interlocked
hydraulic function is requested without activating
the interlock switch.
Symptom
No operation of the requested interlocked
hydraulic function.
the fuse holders.
tact.
• Check interlock switch on the ILM; replace as
necessary.
107

Code
295 NO LO LIFT SWITCH INPUT Yes Hydraulics
Description
Message is displayed when the hi-lift switch is
closed and the lo-lift switch is open.
Symptom
Lift will only operate at low speed.
the fuse holders.
tact.
• Use dash display diagnostics to check for correct
operation of the lo-lift switch.
• Check switch for correct operation.
• Check for correct switch adjustment. See the sec-
tion Electrical System 2200 SRM 1078 for ad-
justment procedure.
• Check wiring to switch for loose connections or
broken wires.
108

Code
299 WRONG CONFIGURATION Yes Traction
Description
Symptom

the fuse holders.
•
• Check CAN wiring for loose connections at con-
nectors or broken wires.
109
CONTROLLER CONNECTOR PIN OUTS Table 6. Connector C (Continued)

Table 5. Connector A
Pin Wire Function
Pin Wire Function Number
Number C15 70 Steering Potentiometer
A1 CANH High Level CANbus B
A2 C16 72 Steering Potentiometer

Positive (+5V/+12V)
A3
C17 71 Steering Potentiometer
A4 CANL-OUT Low Level CANbus Wiper Input
A5 C18 104 Brake Potentiometer
A6 CANL Low Level CANbus Wipe Input
A7 CANH-OUT High Level CANbus C19 103 B
A8 C20 27 Accelerator
Potentiometer B
C21 29 Traction Potentiometer
Table 6. Connector C Wiper Input
Pin Wire Function C22 77 Left Motor Encoder

Number Phase B
C1 83 Right Motor Encoder C23 78 Left Motor Encoder

Positive (+5V/+12V) Phase A
C2 84 Right Motor Encoder C24 82 Right Motor Temp

B Sensor B
C3 10 B+ from Key Switch C25 81 Right Motor Temp

Sensor Input Signal
C4 110 B+ to Switches
C26 23 Main Contactor B
C5 101 Seat Switch Input
C27 24 Main Contactor B+
C6 6 Forward Switch Input
C28 50 Parking Brake Coil B
C7 8 Reverse Switch Input
C29 51 Parking Brake Coil B+
C8 15 Start Switch Input
C30 88 Auxiliary B+
C9 92 Brake Pedal Switch
Input C31 87 Auxiliary B
C10 94 Hydraulic Function C32 B

Input (Contactor C33 28 Traction Potentiometer
Hydraulic Only) Positive (+5V/+12V)
C11 75 Left Motor Encoder C34 79 Left Traction Motor
Positive (+5V/+12V) Temp Sensor B
C12 76 Left Motor Encoder B C35 80 Left Traction Motor
C13 85 Right Motor Encoder Temp Sensor Input
Phase B Signal
C14 86 Right Motor Encoder

Phase A
110
Table 7. Connector D - Standard Model Table 8. Connector D - Premium

Model (Continued)
Pin Wire Function
Number
Pin Wire Function
D1 Number
D2 113 High Speed Lift Switch D11
Input
D12
D3 98 Low Speed Lift Switch
D13
Input
D14
D4 114 Tilt Speed Prox Switch
Input
VALVE DRIVER MODULE
D5 210 B+ for Hydraulic
Switches (ELECTRO-HYDRAULIC VALVE OPTION)
D6 97 4th Function Speed Table 9. Connector B
Switch Input
Pin Wire Function
D7 93 Sideshift Switch Input
Number
D8 95 Tilt Switch Input
B1 10-1 Key Switch Input B+
D9
B2 10-1 Key Switch Input B+
D10
B3 130 Battery Negative
D11
B4 CANL-2 CAN Low Input Signal
D12
B5 OPEN
D13
B6 OPEN
D14
B7 OPEN
B8 OPEN
Table 8. Connector D - Premium Model
B9 OPEN
Pin Wire Function B10 74 12V Supply to Lever
Number Module
D1 B11 OPEN
D2 B12 OPEN
D3 B13 CANH-2 CAN High Input Signal
D4 114 Tilt Speed Prox Switch B14 OPEN
Input
D5 210 B+ for Hydraulic Table 10. Connector C
Switches
D6 Pin Wire Function
Number
D7
C1 53 Negative for Lowering
D8
Proportional Valve
D9
C2 52 Positive for Lift and
D10 Lower Proportional
Valves
111
Table 10. Connector C (Continued) Table 10. Connector C (Continued)
Pin Wire Function Pin Wire Function

Number Number
C3 54 Negative for Lift C22 OPEN
Proportional Valve
C23 130 Battery Negative
C4 56 Negative for Auxiliary
IN Proportional Valve HYDRAULIC LEVER CONSOLE
C5 55 Positive for Auxiliary (ELECTRO-HYDRAULIC OPTION
Proportional Values ONLY)
C6 57 Negative for Auxiliary
OUT Proportional Pin Wire Function
Valve Number
C7 59 Negative for Tilt UP 1 74 12V Supply from Valve

Proportional Valve Driver Module
C8 58 Positive Voltage Supply 2 CANH_OUT1 CANbus High

for Tilt Proportional 3 130 Battery Negative
Valves
4 CANL_OUT1 CANbus Low
C9 65 Negative for Load Hold
Valve
DASH DISPLAY
C10 67 Negative for Tilt
Auxiliary Selector Pin Wire Function
Valve Number
C11 OPEN A1 10-1B Key Switch Input B+
C12 62 Negative for Sideshift A2 110-1 Positive Supply to
Right Proportional Indicators
Valve A3 130F Battery Negative B
C13 61 Positive for Sideshift A4 130G Battery Negative B
Right and Left
Proportional Valves A5 107 Lift Motor Brush Wear
Indicator Input
C14 63 Negative for Sideshift
Left Proportional Valve A6 102 Negative for Pump
Motor Temp Sensor
C15 60 Negative for Tilt Down
Proportional Valve A7 CANL-1 CANbus Low
C16 64 Positive for Lift Hold A8 OPEN

Valve A9 90 Negative for Hydraulic
C17 66 Positive for Tilt Oil Lever Sensor
Auxiliary Selector A10 91 Positive for Brake Fluid
Valve Level Switch
C18 OPEN A11 96 Negative for Auxiliary
C19 OPEN Switch
C20 OPEN A12 50G Parking Brake Coil

Input
C21 OPEN
112
Pin Wire Function Pin Wire Function

Number Number
A13 50F Parking Brake Coil A21 OPEN
Input
A22 CANH-1 CANbus High
A14 OPEN
A23 OPEN
A15 OPEN
A16 47B Steering Encoder Input SYSTEM LOGIC DIAGRAMS
A17 12A Battery Positive B+ The system logic diagrams for the economy, stan-
A18 130P Battery negative B dard, and premium truck models may be able to as-
sist in troubleshooting. See Figure 18, Figure 19, and
A19 OPEN Figure 20.
A20 26 Positive for Reverse
Alarm
Figure 18. Logic Diagram - Economy
113
Figure 19. Logic Diagram - Standard
114
Figure 20. Logic Diagram - Premium
115
NOTES
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116
TECHNICAL PUBLICATIONS
2200 SRM 1087 8/05 (2/05) Printed in United Kingdom

J AC Motor Controller - (08-2005)

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What safety precautions should be followed when working on lift trucks?

What safety precautions should be followed when working on lift trucks?

What are the main components described in the document?

What are the main components described in the document?

AC MOTOR

PART NO. 1554633 2200 SRM 1087

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• 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.

©2005 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

J1.6-2.0XMT (J30-40ZT) [J160]

The AC motors also have thermal sensors, continu-

ZAPI™ AC Motor Controller

The ZAPI™ controller is a solid state AC motor con-

A. LEFT SIDE C. FORWARD

Figure 2. Truck Orientation

operation of the controller. One microprocessor is

The controller contains two separate DC to AC in-

The controller software provides self diagnostics

The self diagnostics monitor the traction motor,

The controller may also be equipped with an optional

The motor controller and the dash display are con-

DISCHARGING THE CAPACITORS

Legend for Figure 6

Figure 6. Discharging the Capacitors -

AC Motor Controller Repair

MOTOR CONTROLLER, REPLACE

Controller Checks and Adjustments

Function Parameter Descriptions

Service Reminder Custom

Figure 7. Standard and Premium Display Panel

Display Functions and Features

1. HOURMETER INDICATOR 8. LCD SCREEN

Figure 8. Dash Display

Figure 9. Battery Discharge Indicator

Figure 12. Display Screen (Premium Display)

LIFT TRUCK INSPECTION FUNCTION

Figure 13. Inspection Failure Screen

The inspection feature can be enabled with or with-

ACCESS TO SERVICE FUNCTIONS SERVICE FUNCTIONS

Steering Enable Truck Settings

STATUS CODE LIST

Dash Display Service Menu Navigation

3. To move up or down within the submenu or the

4. To move out of the sub submenu and return to

5. To move out of the submenu and return to the

1. If a change is to be made, press the [4] key and

Table 4. List of Status Codes

Table 4. List of Status Codes (Continued)

Table 4. List of Status Codes (Continued)

Table 4. List of Status Codes (Continued)

Status Premium Display Message Memory Recall Circuit

Status Premium Display Message Memory Recall Circuit

Status Premium Display Message Memory Recall Circuit