Você está na página 1de 67

AC MOTOR

CONTROLLER
T5Z AC [B476]; T7Z AC [B477];
C60Z AC [B478]; C80Z AC [B479]

PART NO. 1687931 2200 SRM 1352


AC Motor Controller Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Description ......................................................................................................................................................... 2
Electrical System ........................................................................................................................................... 2
AC Traction Motor..................................................................................................................................... 4
Controller................................................................................................................................................... 4
Service PC Connection .............................................................................................................................. 4
Parameters ......................................................................................................................................................... 4
General ........................................................................................................................................................... 4
Parameter Description....................................................................................................................................... 5
Parameters..................................................................................................................................................... 5
Extended Shift........................................................................................................................................... 5
Walk Speed (Both Directions) ................................................................................................................... 5
Hi Speed (FWD)......................................................................................................................................... 5
Hi Speed (REV).......................................................................................................................................... 5
Minimum Acceleration.............................................................................................................................. 6
Maximum Acceleration ............................................................................................................................. 6
Plugging ..................................................................................................................................................... 6
ADS-Neutral .............................................................................................................................................. 6
ADS-Throttle ............................................................................................................................................. 6
Pick Acceleration ....................................................................................................................................... 6
Pick Deceleration....................................................................................................................................... 6
Battery Full Voltage .................................................................................................................................. 6
Lift Interrupt ............................................................................................................................................. 6
Service Hour Reminder............................................................................................................................. 6
Troubleshooting.................................................................................................................................................. 7
General ........................................................................................................................................................... 7
Status Codes .................................................................................................................................................. 7
Dash Display ...................................................................................................................................................... 60
General ........................................................................................................................................................... 60
Startup ........................................................................................................................................................... 60
Status LED .................................................................................................................................................... 60
Performance Mode Indicator......................................................................................................................... 60
Hourmeter...................................................................................................................................................... 61
Battery Charge Indicator .............................................................................................................................. 61
Fault Log ........................................................................................................................................................ 61
Connector Pin-Outs............................................................................................................................................ 62
System Logic Diagram....................................................................................................................................... 63

This section is for the following models:

T5Z AC [B476];
T7Z AC [B477];
C60Z AC [B478];
C80Z AC [B479]

2008 HYSTER COMPANY i


2200 SRM 1352 General

General
This section describes the Iskra motor controller
and dash display used in C60Z AC, C80Z AC, T5Z AC,
and T7Z AC lift trucks. Procedures are outlined for
controller programming and troubleshooting.

DISCHARGING THE CAPACITORS

WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.

WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.

CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.

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


key switch to the OFF position and disconnect
the battery.

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


2. POSITIVE CONNECTION
cess the controller. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
3. Discharge the capacitors in the controllers by 5. NEGATIVE CONNECTION
connecting a 200-ohm, 2-watt resistor across the
controllers B+ and B terminals. See Figure 1. Figure 1. Discharging the Capacitors
DO NOT short across the motor controller termi-
nals with a screwdriver or jumper wire. Remove
the 200-ohm, 2-watt resistor before reconnecting
the battery.

1
Description 2200 SRM 1352

Description
ELECTRICAL SYSTEM power steering motor. The controller uses CANbus
communication to interact with the dash display and
The Iskra AC motor controller controls the AC trac- the control handle. See Figure 2 or Figure 3.
tion motor and the DC pump motor. The controller
can also be used with the optional brushless DC

1. KEY SWITCH 8. CONTROL MODULE


2. BATTERY DISCHARGE INDICATOR (BDI) 9. DIAGNOSTIC CONNECTOR
3. PARKING BRAKE SWITCH 10. CONTACTOR
4. PARKING BRAKE 11. CONTROLLER
5. TRACTION MOTOR 12. FUSE
6. HORN 13. BATTERY CONNECTOR
7. LIFT PUMP MOTOR

Figure 2. Electrical Components (C60-80Z AC)

2
2200 SRM 1352 Description

1. KEY SWITCH 7. CONTROL MODULE


2. BATTERY DISCHARGE INDICATOR (BDI) 8. DIAGNOSTIC CONNECTOR
3. PARKING BRAKE SWITCH 9. CONTACTOR
4. PARKING BRAKE 10. CONTROLLER
5. TRACTION MOTOR 11. FUSE
6. HORN 12. BATTERY CONNECTOR

Figure 3. Electrical Components (T5-7Z AC)

3
Parameters 2200 SRM 1352

AC Traction Motor The motor controller receives power through the


main contactor which is controlled by the key
The AC traction motor is a three-phase AC induction switch. The controller receives inputs from the con-
motor. The motor does not include motor brushes or trol handle and the hand rail switches to control lift
a commutator. An AC induction motor operates on truck functions.
three-phase AC power provided directly by the con-
troller. The motor speed is controlled by the motor NOTE: There are no serviceable parts in the motor
controller and can be changed by the frequency of the controller. No attempt should be made to open re-
AC power supplied to the motor. A speed sensor has pair, or otherwise modify the controller. Doing so
been built into one of the motor bearings which pro- may damage the controller and/or lift truck. Remov-
vides feedback to the motor controller allowing soft- ing the cover from the controller will void the war-
ware to continually monitor motor direction and rev- ranty.
olutions per minute (RPM). Using this feedback sys-
tem, the AC motor control can provide much better Service PC Connection
vehicle top speed control than the older DC SEM sys-
tems. The lift truck is equipped with a connection point to
connect a laptop computer with ETACC software in-
Controller stalled. This connection can be used to adjust certain
lift truck parameters and to assist with troubleshoot-
The motor controller converts DC power from the ing the lift truck.
truck battery to three-phase AC power at the fre-
quencies and currents necessary to drive the traction
motor. A bearing in the traction motor provides feed-
back of speed, rotation direction, and temperature di-
rectly to the motor controller.

Parameters
GENERAL Parameters can be adjusted through the dash dis-
play. The factory default values listed in Table 1 are
A parameter is a measurement or a setting that de- the recommended settings for new units. These set-
fines a lift truck function. A specific function param- tings will give satisfactory performance for most ap-
eter works with other function parameters to control plications.
the operation of the lift truck.

WARNING
WARNING If any of the parameter values are changed, the
The parameter for each function has a value operators must be told the lift truck will oper-
range so the motor controller can be used on ate differently.
different models of lift trucks. This variation
is needed for lift trucks of different sized and NEVER adjust any of the following parameters
operation voltages. Adjustment of a function without using the procedures and settings
to the wrong number value for your lift truck given in this section.
model can cause the truck to operate differ-
ently than normal. This different operation of Function Parameter Descriptions in this section
the truck can cause an injury. contains descriptions for the different parameters.
These parameters can also be accessed using the
NOTE: Table 1 shows the factory default setting for ETACC PC software.
each parameter that is adjustable by the user.

4
2200 SRM 1352 Parameter Description

Table 1. Parameter Default Values

Parameter Default Range


C60Z AC and C80Z AC and Min Max
T5Z AC T7Z AC
Extended Shift OFF OFF ON OFF
Battery Full Voltage 25.300 25.300 25.000 27.000
1 1
Battery Empty Voltage 23.520 23.520 22.800 25.000
ADS-Throttle 1 1 1 10
ADS-Neutral 1 1 1 10
Plugging 7 7 1 10
Walk speed (Both 3.8 3.8 0.5 4.0
Directions)
Hi Speed (FWD) 9.0 9.0 0.5 9.0
Hi Speed (REV) 6.0 6.0 0.5 7.5
Minimum Acceleration 53 53 0 100
Maximum Acceleration 70 70 0 100
Service Hour Reminder 0 0 0 1000
1
Maintenance-free battery option uses value 24.000.

Parameter Description
PARAMETERS Walk Speed (Both Directions)
This parameter sets the maximum truck speed for
WARNING forward and reverse directions when the truck is in
If any of the parameter values are changed, the Walk mode. Increasing the setting will increase
operators must be told the lift truck will oper- the truck speed. Decreasing the setting will decrease
ate differently. truck speed.
NEVER adjust any of the following parameters
without using the procedures and settings
Hi Speed (FWD)
given in this section. This parameter sets the maximum forward speed of
the lift truck when the truck is in Ride mode. In-
Parameters can be adjusted through the dash display
creasing the setting increases the speed. Decreasing
LCD. These parameters can also be accessed using
the setting will decrease the speed.
the ETACC PC software.

Extended Shift Hi Speed (REV)


This parameter sets the maximum reverse speed of
This parameter when on, will reduce traction perfor-
the lift truck when the truck is in Ride mode. In-
mance by 15% to provide extended battery shift life.
creasing the setting increases the speed. Decreasing
The parameter may be set to the OFF or ON condi-
the setting will decrease the speed.
tion.

5
Parameter Description 2200 SRM 1352

Minimum Acceleration Decreasing the value will decrease the rate of accel-
eration.
This parameter sets the minimum acceleration rate
of the lift truck when the truck is in traveling at the Pick Deceleration
lowest throttle. Increasing the setting increases the
minimum rate of acceleration. Decreasing the set- This parameter controls the rate of deceleration
ting will decrease the minimum rate of acceleration. when the coast control switch is released. Increas-
ing the value will increase the rate of deceleration.
Maximum Acceleration Decreasing the value will decrease the rate of decel-
eration. Setting the value at 1 will result in no effect
This parameter sets the maximum acceleration rate on the rate of deceleration; the truck will coast until
of the lift truck when the truck is traveling at max- it comes to a stop.
imum throttle. Increasing the setting increases the
maximum rate of acceleration. Decreasing the set- Battery Full Voltage
ting will decrease the maximum rate of acceleration.
This is the battery voltage in millivolts at which the
Plugging battery is considered fully charged. Increasing the
setting increases the voltage. Decreasing the setting
This parameter controls the maximum rate of decel- reduces the voltage.
eration when the speed control is fully moved to the
opposite direction from the direction of travel while Lift Interrupt
the truck is moving. Increasing this setting will in-
crease the rate of deceleration. Decreasing the set- This is the battery voltage in millivolts at which the
ting will reduce the rate of deceleration. battery is considered 80% discharged. Increasing the
setting increases the voltage. Decreasing the setting
ADS-Neutral reduces the voltage.

This parameter controls the rate of deceleration Service Hour Reminder


when the speed control is returned to the neutral po-
sition and the ADS-Throttle parameter is set above This parameter initiates a reminder when the
1. Setting the value at 1 will result in no effect on hourmeter reaches a preset point indicating the lift
the rate of deceleration; the truck will coast until it truck is due to be serviced. Within this menu, you
comes to a stop. Increasing the value will increase can reset the Service Hour Reminder, change the
the rate of deceleration. Decreasing the value will service interval hours, and turn the function ON
decrease the rate of deceleration. or OFF. The normal factory default setting for the
Service Hour Reminder is OFF and must be changed
ADS-Throttle to ON for the function to be active.

This parameter controls the rate of deceleration When the Service Hour Reminder is ON, the dash
when the speed control is partially reduced and the display will display a one-time message to the oper-
ADS-Throttle parameter is set above 1. Setting ator when the preset hourmeter reading has been
the value at 1 will result in no effect on the rate of reached. The lift truck will continue to operate
deceleration; the truck will coast until it reaches normally until the hourmeter reaches 20 hours past
the lower throttle speed. Increasing the value will the preset service interval. At this time the lift truck
increase the rate of deceleration. Decreasing the function speeds will be reduced until the Service
value will decrease the rate of deceleration. Hour Reminder has been reset. The lift truck should
be serviced and the parameter reset to the next
Pick Acceleration hourmeter reading when service is due.

This parameter controls the rate of acceleration


when the coast control switch is activated. Increas-
ing the value will increase the rate of acceleration.

6
2200 SRM 1352 Troubleshooting

Troubleshooting
GENERAL Check resistance on the proper scale from frame to
power and controller terminals. Resistance of less
The controllers are sealed units with no serviceable than 20,000 ohms can cause misleading symptoms.
components. Troubleshooting is usually limited to Resistance of less than 1000 ohms indicates a short
accessing status codes and following the diagnostic and should be corrected immediately.
procedures listed in the status code charts.
The on-board diagnostic system employed on this lift
Use standard testing procedures to verify inputs and truck can assist in the troubleshooting process. Read
outputs when necessary. and be familiar with the instructions for accessing
and using the dash display diagnostic system.
CAUTION Prior to troubleshooting systems and components on
Never attempt to probe through the back of this lift truck, ensure the battery is the correct volt-
the connector plugs of the motor controller. age and is fully charged. Make sure the battery con-
The plugs are special sealed plugs. Probing nector contacts are clean of corrosions and the bat-
through the back of the plugs will destroy the tery polarity within the connector is correct. Inspect
seal and can cause a short circuit. If a circuit to ensure all fuses are correct and have not failed.
must be tested for voltage, check for voltage Ensure the key switch is in the ON position when
at an amp-type plug, a switch, or a component. making voltage checks or checking the operator of a
If a circuit is suspect, check the circuit for component.
continuity from the front (pin end) of the plug.
Many faults noted by lift truck systems are the result
Standard probes are too large to be inserted of loose wiring connections and/or broken or shorted
into the center of the female pins (sockets) of wiring within the lift truck. Begin the troubleshoot-
the special sealed plugs and can expand the ing process by carefully inspecting the wiring involv-
pins. Expanded pins will not provide good con- ing the device or devices noted by the on-board diag-
nections once the plug is reconnected. The con- nostics system.
nectors are shaped to allow the insertion of a
flat blade screwdriver into the connector. After STATUS CODES
inserting the screwdriver into the connector,
attach probes with alligator clips to the shank Make sure the parameter values are correct for your
of the screwdriver to obtain readings. An addi- lift truck to ensure the trouble is not just an incorrect
tional method would be to use a breakout kit. setting. See function settings to set the correct pa-
rameter values. If there is no status code display and
If the controller detects an issue, a status code is dis- the lift truck does not operate correctly, there may be
played on the display panel. a fault in the controller.
Once the status code number is obtained, follow the The status codes are numbers for malfunction or lift
procedures outlined in the status code charts of this truck operation that are not correct and that the con-
manual to determine the problem. troller can sense. The controller will indicate this
code number on the LCD screen of the display panel.
NOTE: Due to the interaction of the controller with
all lift truck functions, almost any status code or con- NOTE: There are identifiers to determine which de-
troller fault could be caused by an internal failure of vice generated the code:
the controller. After all other status code procedures Xy = XXXX (Co 23538)
have been followed and no problem is found, the con- Co = Controller
troller should be replaced as the last option to correct Ti = Control Module
the problem.
The controller senses the following types of malfunc-
Tools and test equipment required are: tion:
Clip Leads Input voltages that are too high or too low
Digital Multimeter (20,000 ohms per volt) Input voltages in the wrong sequence or
Basic Hand Tools Correct input voltages that occur at the wrong time

7
Troubleshooting 2200 SRM 1352

NOTE: A status code indication does not always mean The Fault Message charts in this section have a more
that there is a malfunction. A temporary operation complete description of the status code, the circuit
condition can cause a status code display. that has generated the input for the status code, the
symptom, and the possible cause.
These code numbers are only indicators that may
help diagnose a possible malfunction. A short de-
scription of the different status codes is shown in Ta-
ble 2.

Table 2. Fault Codes

Code Description
9024 Controller failure of the traction motor power circuit
9088 Pump motor shorted
9089 Pump motor open
9090 Pump at relief
9091 Controller failure of the pump motor power circuit.
12816 Controller internal voltage over 36 volts
12819 Incorrect voltage battery connected
12832 Controller internal voltage less than 16 volts
12835 Incorrect voltage battery connected
16912 Controller power section is over temperature
16944 Controller is in thermal cutback - high controller temperature
16945 Controller internal temperature sensor failure
17168 Traction motor is over temperature
17169 Controller is in thermal cutback - high traction motor temperature
17170 Traction motor temperature sensor failure
20756 Key switch open
21024 Control module failure
21378 Controller cannot establish contact with control module
21533 Horn circuit is shorted to B+
21534 Horn circuit is open
21535 Horn circuit is shorted to B
21544 Horn switch is closed at startup
21552 Steer handle inputs incorrect at startup
21553 Hi Speed switch is closed at startup
21555 Lift or lower switch is closed at startup
21568 Main contactor circuit is open
21569 Main contactor circuit is shorted to B+

8
2200 SRM 1352 Troubleshooting

Table 2. Fault Codes (Continued)

Code Description
21570 Main contactor circuit is open
21571 Main contactor circuit is shorted to B
21588 Internal failure of the power steering unit
29445 Traction motor encoder failure
29448 Steer handle switch closed at startup
29456 Error in control module speed/direction sensor
29458 Steer handle sensor is out of limits
33056 Controller cannot establish communication with control module
33057 Controller cannot establish communication the power steering controller

9
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9024 Service Required Solid Red Traction
DESCRIPTION SYMPTOM
Traction motor phase U, V, or W Truck will not operate.
shorted to B+ or B .
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and disconnect the battery connector.
2. Disconnect the motor leads from the controller.
3. Check motor for phase-to-ground or phase-to-B+ shorted condition.
a. Motor should measure minimum 1 megohm phase-to-ground.
Replace traction motor.
4. Check U, V, and W terminals of the controller for shorted condition to B+ or B .
a. Contact NMHG Service Engineering Contact Management.

10
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


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

11
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9089 Service Required Solid Red Pump
DESCRIPTION SYMPTOM
Pump motor has open circuit. Hydraulics will not operate.
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and disconnect the battery connector.
2. Disconnect pump motor cables from the controller.
3. Verify continuity through each motor cable.
a. Replace any broken wiring.
4. Check for open circuit across the across the motor terminals.
a. If greater than 500 ohms, replace the pump motor.

12
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9090 Overload Flashing Red Pump
DESCRIPTION SYMPTOM
Controller has detected the hydraulic Hydraulics will not operate.
system is being operated at relief.
Probable Causes and Test Procedures
1. Verify weight of load does not exceed lift truck capacity on the nameplate.
a. Reduce load weight.
2. Verify there is no binding in the lifting mechanism.
3. Install a 24.13 MPa (3500 psi) pressure gauge in the lift cylinder line.
a. Verify the relief pressure is correct:
C60Z AC = 18.96 MPa (2750 psi)
C80Z AC = 23.44 MPa (3400 psi)
4. Adjust relief pressure to correct value.
a. See Walkie Hydraulic Systems 1900 SRM 964.

13
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
9091 Internal Pump Circuit Failure Solid Red Pump
DESCRIPTION SYMPTOM
Controller has detected an internal Truck will not operate.
failure in the pump circuit.
Probable Causes and Test Procedures
1. Verify 24 volts at the controller B+ terminal.
a. Ensure battery is connected to the lift truck.
b. Verify continuity of fuse FU 1.
2. Turn the key switch to the OFF position.
3. Disconnect cable PM1 at the P controller terminal.
a. Check for a shorted condition between P and B
Resistance should be greater than 500 ohms.
Contact NMHG Service Engineering Contact Management.
4. Disconnect cable PM1 at the P controller terminal and reconnect it to the controller B terminal.
a. Turn the key switch to the ON position and verify the pump motor operates.
b. Contact NMHG Service Engineering Contact Management.

14
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
12819 Check Battery Flashing Red Battery
DESCRIPTION SYMPTOM
Controller has detected a battery voltage Truck will not operate.
in excess of 32 volts.
Probable Causes and Test Procedures
1. Check battery voltage at controller B+ terminal.
2. Verify battery voltage matches voltage listed on the lift truck nameplate.
a. Install correct voltage battery.

15
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
12832 Check Battery Flashing Red Battery
DESCRIPTION SYMPTOM
The controller has sensed battery voltage Truck will not operate.
to be less than 16 volts.
Probable Causes and Test Procedures
1. Check battery voltage at controller B+ terminal.
2. Verify battery voltage matches voltage listed on the lift truck nameplate.
a. Install correct voltage battery.
3. Check for continuity through fuse FU 1.
a. Replace fuse.
4. Condition can be caused by normal operation of the lift truck with a discharged battery.
a. Check battery state of charge on the dash display.
Recharge battery.
Install a fully charged battery.

16
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
12835 Check Battery Flashing Red Battery
DESCRIPTION SYMPTOM
Controller has detected a battery with Truck will not operate.
less than 16 volts has been connected
to the lift truck.
Probable Causes and Test Procedures
1. Check battery voltage at controller B+ terminal.
2. Verify battery voltage matches voltage listed on the lift truck nameplate.
a. Install correct voltage battery.

17
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
16912 Wait to Cool Down Flashing Red Battery
DESCRIPTION SYMPTOM
Controller is over temperature. Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Technician Functions On-Board Dash Display
2200 SRM 1354.
3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position
and operate the lift truck briefly.
4. Verify fault does not repeat.
a. Contact NMHG Service Engineering Contact Management.

18
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
16944 Performance Reduced Flashing Red Controller
DESCRIPTION SYMPTOM
Truck is in thermal cutback due to high Traction system is operating at a reduced
controller temperature. performance level.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Technician Functions On-Board Dash Display
2200 SRM 1354.
3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position
and operate the lift truck briefly.
4. Verify fault does not repeat.
a. Contact NMHG Service Engineering Contact Management.

19
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


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

20
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
17168 Over Temp Flashing Red Traction Motor
DESCRIPTION SYMPTOM
Controller has detected an over temperature Traction and hydraulic systems will not operate.
condition in the traction motor.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Technician Functions On-Board Dash Display
2200 SRM 1354.
3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the
ON position and operate the lift truck briefly. Check the dash display to verify fault does not repeat.
4. If fault repeats:
a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector.
b. Resistance should measure approximately 5.9 ohms 10% at 25 C (77 F).
Replace sensor.

21
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
17169 No Text Displayed Solid Green Traction Motor
DESCRIPTION SYMPTOM
Controller is in thermal cut back due to Traction system is operating at a reduced
high traction motor temperature. performance level.
Probable Causes and Test Procedures
1. Internal temperature of controller has exceeded 165 C (329 F).
a. Reduce truck usage and allow the controller to cool.
2. Clear fault log in dash display. See User Interface, Technician Functions On-Board Dash Display
2200 SRM 1354.
3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the
ON position and operate the lift truck briefly.
4. Check the dash display to verify fault does not repeat.
5. If fault repeats:
a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector.
b. Resistance should measure approximately 5.9 ohms 10% at 25 C (77 F).
Replace sensor.

22
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
17170 Service Required Solid Red Traction Motor
DESCRIPTION SYMPTOM

Controller has detected a failure of the Traction system is operating at a reduced


traction motor temperature sensor. performance level.
Probable Causes and Test Procedures
1. Disconnect the traction motor temperature sensor connector at the traction motor.
2. Check for continuity of wire #385 between the connector and pin #25 at the controller.
a. Repair any broken wiring or loose connections.
3. Check for continuity of wire #102 from the connector to pin #29 at the controller.
a. Repair any broken wiring or loose connections.
4. Measure the resistance across pin #1 and pin #2 of the sensor side of the connector.
a. Resistance should measure approximately 5.9 ohms 10% at 25 C (77 F).
5. If measurement indicates an open or shorted sensor, replace sensor.

23
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


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

24
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21024 Service Required Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected a failure in Traction and hydraulic systems will not operate.
the control module.
Probable Causes and Test Procedures
1. Verify battery voltage at pin #6 (X2) at the control module connector.
a. Check continuity of wire #10 from key switch to pin #6 (X2) at control module connector.
2. Ensure all wiring connections between the control module and the controller are tight and secure.

25
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21024 Service Required Solid Red Steer Handle
(cont)
DESCRIPTION SYMPTOM
Controller has detected a failure in the Traction and hydraulic systems will not operate.
control module (cont).
Probable Causes and Test Procedures
3. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 60 ohms.
If resistance is approximately 120 ohms, check wiring for broken or shorted condition.
Repair all damaged wiring.

26
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21024 Service Required Solid Red Steer Handle
(cont)
DESCRIPTION SYMPTOM
Controller has detected a failure in the Traction and hydraulic systems will not operate.
control module (cont).
Probable Causes and Test Procedures
4. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 60 ohms.
If resistance is approximately 120 ohms, check wiring for broken or shorted condition.
Repair all damaged wiring.
5. Internal failure of the control module.
a. Replace control module.

27
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21378 Service Required Solid Red Controls

DESCRIPTION SYMPTOM
Controller has lost communication Traction and hydraulic systems will not operate.
with the control module.
Probable Causes and Test Procedures
1. Ensure all wiring connections between the control module and the controller are tight and secure.

28
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21378 Service Required Solid Red Controls
(cont)

DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
2. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 40 ohms.
If resistance is greater than 90 ohms, check wiring for broken or shorted condition.

29
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21378 Service Required Solid Red Controls
(cont)

DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
3. Check for continuity between pin #3 (X2)at the control module connector and pin #28 at the controller
connector.
a. Repair any broken wiring.

30
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21378 Service Required Solid Red Controls
(cont)

DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
4. Check for continuity between pin #4 (X2) at the control module connector and pin #27 at the controller
connector.
a. Repair any broken wiring.

31
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21378 Service Required Solid Red Controls
(cont)

DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the control module (cont).
Probable Causes and Test Procedures
5. Check for continuity between pin #2 (X2) at the control module connector and pin #29 at the controller
connector.
a. Repair any broken wiring.

32
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21521 Service Required Solid Red Hydraulics
DESCRIPTION SYMPTOM
Controller has detected the lower Hydraulic system will not operate.
valve shorted to B+.
Probable Causes and Test Procedures
1. Disconnect the pump coil connector at the lift pump.
2. Check for a shorted condition across the coil leads at the connector.
a. Replace the coil.
3. Check for shorted wiring on wire #150 and wire #86 between the pump coil and the controller.
a. Repair any damaged wiring.
4. Check for a shorted condition between pin #22 and pin #23 at the controller and B .
a. Resistance should be greater than 1000 ohms.
Contact NMHG Service Engineering Contact Management.

33
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE

21522 Service Required Solid Red Hydraulics

DESCRIPTION SYMPTOM
Controller has detected an open circuit Hydraulic system will not operate.
in the lower valve.
Probable Causes and Test Procedures
1. Disconnect the pump coil connector at the lift pump.
2. Measure the resistance across pins from the pump coil.
a. Resistance should be approximately 1 ohm.
Replace the coil.
3. Check for open circuit condition in wire #150 and wire #86 from the connector to pin #22 and pin #23 at
the controller.
a. Repair broken wiring or loose connections.

34
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21533 Service Required Solid Red Horn
DESCRIPTION SYMPTOM
Controller has detected the horn Hydraulic system will not operate.
shorted to B+.
Probable Causes and Test Procedures
1. Measure the resistance between the red lead and the black lead from the horn at the horn connector.
a. The resistance should read approximately 28 ohms.
Replace the horn.
2. Check the horn connector for pin-to-pin shorted condition.
a. Repair the connector.
3. Check for pin #20 at the controller shorted to B+.
a. Contact NMHG Service Engineering Contact Management.

35
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21534 Service Required Solid Red Horn
DESCRIPTION SYMPTOM
Controller has detected an open Hydraulic system will not operate.
circuit in the horn.
Probable Causes and Test Procedures
1. Measure the resistance between the red lead and the black lead from the horn at the horn connector.
a. The resistance should read approximately 28 ohms.
Replace the horn.
2. Check for battery voltage at wire #10 at the horn connector when the key switch is closed.
a. Ensure all connections and connectors are secure and tight.
b. Check for open circuits in the harness.
Repair wiring.
3. Check continuity of wire #45 from the horn connector to pin #20 at the controller connector.
a. Repair wiring.
4. Internal failure of the controller.
a. Contact NMHG Service Engineering Contact Management.

36
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21535 Service Required Solid Red Horn
DESCRIPTION SYMPTOM
The controller has detected the horn Hydraulic system will not operate.
shorted to B .
Probable Causes and Test Procedures
1. Measure the resistance between the red lead and the black lead from the horn at the horn connector.
a. The resistance should read approximately 28 ohms.
Replace the horn.
2. Check the horn connector for pin-to-pin shorted condition.
a. Repair the connector.
3. Check for pin #20 at the controller shorted to B .
a. Contact NMHG Service Engineering Contact Management.

37
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21539 Service Required Solid Red Controller
DESCRIPTION SYMPTOM
Controller has detected an internal Traction and hydraulic systems will not operate.
failure of the output driver.
Probable Causes and Test Procedures
1. Turn the key switch to the OFF position and restart the lift truck.
2. Verify the fault returns after restart.
a. Contact NMHG Service Engineering Contact Management.

38
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21552 Improper Start Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected a fault in the Traction and hydraulic systems will not operate.
signal from the control module.
Probable Causes and Test Procedures
1. Verify all steer handle switches and controls are in the neutral position.
2. Check for battery voltage at pin #3 at the control module.
a. Check for continuity of wire #10 from the key switch to the control module.

39
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21552 Improper Start Solid Red Steer Handle
(cont)
DESCRIPTION SYMPTOM
Controller has detected a fault in the signal Traction and hydraulic systems will not operate.
from the control module (cont).
Probable Causes and Test Procedures
3. Check for any mechanical binding in switches or throttle mechanism.
a. Clear any binding.
b. Repair or replace faulty switches.

40
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21552 Improper Start Solid Red Steer Handle
(cont)
DESCRIPTION SYMPTOM
Controller has detected a fault in the signal Traction and hydraulic systems will not operate.
from the control module (cont).
Probable Causes and Test Procedures
4. Verify there is no shorted wiring between wire #901, wire #902, wire #102, and wire #28 between the
control module and the controller.
a. Repair any shorted wiring.

41
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21552 Improper Start Solid Red Steer Handle
(cont)
DESCRIPTION SYMPTOM
Controller has detected a fault in the signal Traction and hydraulic systems will not operate.
from the control module (cont).
Probable Causes and Test Procedures
5. Verify the continuity of wire #102, wire #900, wire #901 and wire #28 from the control module to the
controller.
a. Repair any broken wiring or loose connections.

42
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21553 Release Rabbit Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected a closed high High speed will not operate.
speed switch at startup.
Probable Causes and Test Procedures
1. Ensure the high speed Rabbit switch is not being held closed.
a. Eliminate any binding in the handrail handle.
2. Check the switch for a shorted condition.
a. Replace faulty switch.
3. Check for wire #342 shorted to B+.
a. Repair any faulty wiring.

43
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21554 Improper Start Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected a closed auxiliary Horn operates continuously.
horn switch at startup.
Probable Causes and Test Procedures
1. Ensure the handle horn switch is not being held closed.
a. Eliminate any binding in the switch.
b. Replace switch if necessary.
2. Separate handle connector.
a. If horn quits sounding, replace handle horn switch.
3. Check for wire #25 shorted to B+.
a. Repair any faulty wiring.
4. Ensure the backrest horn switch is not being held closed.
a. Eliminate any binding in the switch.
b. Replace switch if necessary.
5. Separate the controller connector.
a. If horn continues to sound, check for pin #11 at the controller shorted to B+.
Contact NMHG Service Engineering Contact Management.

44
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21555 Improper Start Flashing Red Controls
DESCRIPTION SYMPTOM
Controller has detected a closed auxiliary Hydraulic system will not operate.
lift or lower switch at startup.
Probable Causes and Test Procedures
1. Inspect handle lift and lower switches for binding.
a. Ensure all parts are free to move.
2. Check each switch for a shorted condition.
a. Replace faulty switch.
3. Check wire #25 for a shorted condition to B+.
a. Repair any faulty wiring.
4. Ensure the backrest horn switch is not being held closed.
a. Eliminate any binding in the switch.
b. Replace switch if necessary.

45
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21568 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Main contactor is open and will not close. Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures
1. Ensure contactor tips are free to close.
a. Correct any binding in the contactor.
2. Check for worn contactor tips.
a. Replace contactor.
3. Ensure there is no foreign material separating the contactor tips.
a. Clean any debris from the contactor.
4. Replace the contactor.

46
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21569 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Controller has detected the main Traction and hydraulic systems will not operate.
contactor shorted to B+.
Probable Causes and Test Procedures
1. Separate the controller connector.
2. Check for a shorted condition between pin #18 at the controller and B+.
a. Contact NMHG Service Engineering Contact Management.
3. Check the connector for any pin-to-pin shorts.
a. Repair any wiring faults.

47
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21570 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Controller has detected an open circuit Traction and hydraulic systems will not operate.
in the main contactor.
Probable Causes and Test Procedures
1. Ensure all wiring connections are secure and tight.
2. Check for battery voltage on wire #10 at the main contactor.
a. Check continuity of wire #10 between the key switch and the main contactor.
Repair any open wiring.
b. Check for continuity through FU 5.
Replace fuse.
3. Check the resistance through the main contactor coil.
a. The resistance should measure approximately 22 ohms 10%.
Replace the coil.
4. Check continuity of wire #45 from the coil to the controller pin #20. Repair any open wiring.
5. Internal failure of the controller.
a. Contact NMHG Service Engineering Contact Management.

48
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
21571 Service Required Solid Red Main Contactor
DESCRIPTION SYMPTOM
Controller has detected the main Traction and hydraulic systems will not operate.
contactor shorted to B .
Probable Causes and Test Procedures
1. Ensure the B+ and B cables from the battery are connected properly.
2. Separate the controller connector.
3. Check for a shorted condition between pin #18 at the controller and B .
a. Contact NMHG Service Engineering Contact Management.
4. Check the connector for any pin-to-pin shorts to B .
a. Repair any wiring faults.

49
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29445 Service Required Solid Red Traction
DESCRIPTION SYMPTOM
The controller cannot detect the signal Traction system will not operate.
from the traction motor encoder.
Probable Causes and Test Procedures
1. Ensure all wiring connection between the encoder and the controller are secure and tight.
2. Check for 12 volts on wire #250.
a. Check for 12 volts at controller pin #30.
Contact NMHG Service Engineering Contact Management.
3. Check encoder output between pin #2 and pin #4 at the encoder connector from the traction motor.
a. Output should alternate between 12 and 0 volts as the motor rotates.
Change the encoder.
4. Check encoder output between pin #3 and pin #4 at the encoder connector from the traction motor.
a. Output should alternate between 12 and 0 volts as the motor rotates.

50
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


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

51
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29456 Service Required Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected an error in the Traction system will not operate.
control module throttle sensor.
Probable Causes and Test Procedures
1. Throttle sensor is out of calibration.
a. Calibrate throttle sensor. See Electrical System 2200 SRM 1357.
2. Check connection to throttle sensor in handle.
a. Check 5V supply to sensor.
b. Check ground to sensor.

52
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29456 Service Required Solid Red Steer Handle
(cont)
DESCRIPTION SYMPTOM
Controller has detected an error in the Traction system will not operate.
control module throttle sensor (cont).
Probable Causes and Test Procedures
3. Throttle sensor has failed.
a. Replace the sensor.

53
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
29458 Service Required Solid Red Steer Handle
DESCRIPTION SYMPTOM
Controller has detected the control module Traction system will not operate.
analog sensor to be out of limits.
Probable Causes and Test Procedures
1. Check connection to throttle sensor in handle.
a. Check 5V supply to sensor.
b. Check ground to sensor.
2. Measure output @ sensor and ensure 2.5V 0.5V present in neutral position.
3. Throttle sensor has failed.
a. Replace the sensor.

54
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
33056 Service Required Solid Red Controls
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the control module.
Probable Causes and Test Procedures
1. Ensure all wiring connections between the control module and the controller are tight and secure.
2. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 40 ohms.
If resistance is greater than 90 ohms, check wiring for broken or shorted condition.

55
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
33056 Service Required Solid Red Controls
(cont)
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the control
module (cont).
Probable Causes and Test Procedures
3. Check for continuity between pin #3 (X2) at the control module connector and pin #28 at the controller
connector.
a. Repair any broken wiring.

56
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
33056 Service Required Solid Red Controls
(cont)
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the control
module (cont).
Probable Causes and Test Procedures
4. Check for continuity between pin #4 (X2) at the control module connector and pin #27 at the controller
connector.
a. Repair any broken wiring.

57
Troubleshooting 2200 SRM 1352

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
33056 Service Required Solid Red Controls
(cont)
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the control
module (cont).
Probable Causes and Test Procedures
5. Check for continuity between pin #2 (X2) at the control module connector and pin #29 at the controller
connector.
a. Repair any broken wiring.

58
2200 SRM 1352 Troubleshooting

STATUS DISPLAY MESSAGE LED CIRCUIT


CODE
33056 Service Required Solid Red Controls
(cont)
DESCRIPTION SYMPTOM
Controller cannot establish CAN Traction and hydraulic systems will not operate.
communication with the control
module (cont).
Probable Causes and Test Procedures
6. Internal failure in the control module.
a. Replace control module.
7. Internal failure of the traction controller.
a. Contact NMHG Service Engineering Contact Management.

59
Dash Display 2200 SRM 1352

Dash Display
GENERAL When the lift truck is operating normally, the LED
will be solid green when the key is in the ON posi-
The dash display is a multifunction device. It con- tion.
tains a truck status LED and an LCD which dis- If there is a fault noted by the lift truck controller
plays the performance mode indicator and the bat- and the controller has prevented traction and hy-
tery charge indicator. The menu system can be ac- draulic functions, the LED will be solid red.
cessed through the dash display by starting the truck When the battery charge reaches 75% of full
in service mode and entering the proper password. charge, the horn will sound and the LED will
See Figure 4. alternately blink from red to green.
If the controller has noted a condition that require
the lift truck to operate at a reduced performance
level, the LED will blink red.

PERFORMANCE MODE INDICATOR


The performance mode indicator will show the cur-
rent performance mode setting at truck startup. The
indicator is a four bar display with the rabbit or high-
est performance level on the right and the "Turtle" or
lowest performance level on the left. See Figure 5.
The performance model level can be changed using
the lift and lower buttons on the steer handle as de-
scribed in the Operating Manual unless the perfor-
mance mode function has been locked by a supervisor
or a technician. Refer to or User Interface, Tech-
nician Functions On-Board Dash Display 2200
SRM 1354.

Figure 4. Dash Display Screens

STARTUP
When the key is turned to the ON position and the
handle is in the full upright position, all segments
of the display will be illuminated and the horn will
beep twice. The LED will flash red, green, and then
go blank momentarily. Then the display will show
the truck mode setting and the hourmeter reading.

STATUS LED
The status LED is located in the top center of the dis-
play. When the key switch is in the ON position, the
LED is on. The LED can indicate in either red or
green depending on the information being communi-
cated.
When the lift truck key is in the OFF position, the Figure 5. Performance Mode Screen
LED will be OFF.

60
2200 SRM 1352 Dash Display

HOURMETER
The hourmeter accumulates hours when the key is
in the ON position and main contactor is closed. The
hourmeter is capable of showing five digits and dis-
plays complete hours. See Figure 6. At truck startup,
the display will show the truck hours for 10 seconds
after the key has been turned to the ON position. The
hourmeter reading will be turned off if the control
handle is moved to the operating position any time
within the 10 second display period.

Figure 7. Battery Charge Indicator

FAULT LOG
The Fault Log menu will list the truck system initiat-
ing the fault, the error code associated with the fault,
the hourmeter reading when the fault occurred, the
number of times the fault has been logged, and the
system temperature when the fault occurred. See
Figure 8. The Fault Log auto scrolls. The system
will retain the last ten faults noted.

Figure 6. Hourmeter

BATTERY CHARGE INDICATOR


When the truck hourmeter is disabled, it is replaced
on the display by the battery charge indicator. The
indicator is a five bar graphical indicator with the full
indicator bar on the right and the empty indicator
bar on the left. See Figure 7. At 100% charge, all
bar graph segments will be shaded. As the battery is
discharged, fewer of the bars will be shaded.
100% Charge = 5 Solid Bars
80% Charge = 4 Solid Bars
60% Charge = 3 Solid Bars
40% Charge = 2 Solid Bars
30% Charge = 1 Solid Bar During Lifting
20% Charge = 0 Solid Bars, Blinking Red Status
LED,
Lift Lockout - (Horn Sounds When Lift Switch
Is Activated)
Figure 8. Fault Log Screen

61
Connector Pin-Outs 2200 SRM 1352

Connector Pin-Outs
Controller Connector (CPS 05)
Pin Wire Number Function
1 W10 - AC RED Battery Positive
2 W342 - A High Speed
3 W26 - A Aux. Lift Switch
4 W27 - A Aux. Lower Switch
5 W28 - A Control Module
6 W98 - AC Steer Handle Switch
7 - -
8 - -
9 - -
10 - -
11 W25 - A Aux. Horn Switch
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 W79 - M RED Main Contactor Coil
19 - -
20 W45 - H Horn
21 - -
22 W150 - A Pump Coil (+)
23 W86 - A Pump Coil ( )
24 - -
25 W386 - A Traction Motor Temp Sensor
26 - -
27 W901/H - WHT CAN Hi
28 W900/L - BLK CAN Lo
29 W102/BARE - GRN Traction Motor Temp Sensor
30 W250 - E Traction Motor Encoder
31 W577 - E Traction Motor Encoder
32 W578 - E Traction Motor Encoder
33 - -

62
2200 SRM 1352 System Logic Diagram

System Logic Diagram

Traction Motor --------


CANbus Dash Display

Traction Encoder --------


CANbus

Temperature Sensor --------

Pump Motor C60/80Z AC -------- -------- Forward/Reverse Input

Power Steering Motor -------- -------- Truck Speed Input

Main Contactor -------- CANbus -------- Lift/Lower Input

CANbus

Horn -------- -------- Traction Reverse Input


Control Module

Lower Solenoid -------- -------- Neutral Input

Cruise Solenoid -------- -------- Pick Mode Input

Electric Brake Coil -------- -------- Horn


Traction Motor
Controller
High Speed Switch --------

Aux. Horn Switch --------

Aux. Lift Switch --------

Aux. Lower Switch --------

Tiller Switch --------

CANbus PC Service Connection

63
NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

64