Yale524183083 2200YRM1056 (03 2003) US

Maintenance
AC MOTOR
CONTROLLERS/DISPLAY
PANEL
DESCRIPTION, CHECKS, ADJUSTMENTS,
AND TROUBLESHOOTING
ERP20-30ALF (ERP040-060DH) [D216]
PART NO. 524183083 2200 YRM 1056

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
AC Motor Controllers/Display Panel Table of Contents
TABLE OF CONTENTS
Description .......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
AC Motors ................................................................................................................................................... 1
Motor Controllers ........................................................................................................................................ 1
Master Controller ........................................................................................................................................ 1
Dash Display............................................................................................................................................... 1
Controller Area Network Bus (CANbus)...................................................................................................... 1
Master Controller Checks and Adjustments ........................................................................................................ 1
Function Parameters ........................................................................................................................................... 2
General ........................................................................................................................................................... 2
Function Numbers........................................................................................................................................... 2
Function Parameter Descriptions ........................................................................................................................ 3
General ........................................................................................................................................................... 3
Function Number 1 BATTERY VOLTAGE ................................................................................................... 3
Function Number 2 EXTENDED SHIFT ..................................................................................................... 3
Function Number 3 ACCELERATION 1...................................................................................................... 3
Function Number 4 ACCELERATION 2...................................................................................................... 3
Function Number 5 TOP SPEED LIMIT...................................................................................................... 3
Function Number 6 REGEN BRAKING ...................................................................................................... 3
Function Number 7 AUTO DECELERATION .............................................................................................. 4
Function Number 8 BDI ADJUSTMENT ..................................................................................................... 4
Function Number 9 LIFT INTERRUPT ....................................................................................................... 4
Function Number 10 POWER STEERING TIME DELAY ........................................................................... 4
Function Number 11 SERVICE REMINDER .............................................................................................. 4
Function Number 12 CUSTOM ................................................................................................................... 4
Function Number 13 PUMP SPEED 1........................................................................................................ 4
Function Number 16 PUMP ACCELERATION ........................................................................................... 4
Troubleshooting ................................................................................................................................................... 5
General ........................................................................................................................................................... 5
Controller Status Light Emitting Diodes (LEDs) .............................................................................................. 5
AC Master Controller .................................................................................................................................. 5
AC Motor Controllers .................................................................................................................................. 5
Status Codes................................................................................................................................................... 8
AC Motor Controllers Status Code Charts .......................................................................................................... 9
AC Transistor Motor Controller Repair................................................................................................................. 23
General ........................................................................................................................................................... 23
General Maintenance Instructions .................................................................................................................. 25
Special Precautions .................................................................................................................................... 26
Fuses .............................................................................................................................................................. 26
Fan Test........................................................................................................................................................... 27
Contactors....................................................................................................................................................... 27
Repair ......................................................................................................................................................... 27
Thermal Sensors............................................................................................................................................. 33
Motor Controller, Replace ............................................................................................................................... 33
Display Panel....................................................................................................................................................... 33
General ........................................................................................................................................................... 33
Premium Display Panel............................................................................................................................... 33
Standard Display Panel............................................................................................................................... 34
Display Functions and Features .......................................................................................................................... 34
©2003 Yale Materials Handling Corp. i

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

Key-ON Initialization........................................................................................................................................ 34
Standard Display ............................................................................................................................................. 35
Premium Display ............................................................................................................................................. 36
Lift Truck Inspection Function.......................................................................................................................... 36
Access to Service Functions ........................................................................................................................... 37
Service Functions ........................................................................................................................................... 37
Performance Modes ........................................................................................................................................ 38
Battery Discharge Indication (BDI).................................................................................................................. 38
Hourmeter ....................................................................................................................................................... 39
Dash Display Service Menu Navigation .............................................................................................................. 39
General ........................................................................................................................................................... 39
Moving Through Menu Selections................................................................................................................... 39
Editing and Adding Information ....................................................................................................................... 39
This section is for the following models:
ERP20-30ALF (ERP040-060DH) [D216]
ii
2200 YRM 1056 Master Controller Checks and Adjustments
Description
GENERAL motor speed and temperature information directly from
the motors. The motor controllers do not get any other
The alternating current (AC) system consists of AC mo- input from the truck. The master controller relays,
tors, motor controller(s), a master controller, and a dash speed, acceleration, and direction commands to the
display. The major difference between the AC system motor controllers.
and the direct current (DC) system is the master con-
troller performs many of the same functions that pre- Master Controller
viously were performed in the motor controllers on the
DC system. The Master Controller is a general-purpose micro-con-
troller for CANbus based electric vehicles. It contains
AC Motors processing power, memory resources, analog and digi-
tal input/output (I/O) to provide the required full-featured
The AC motors are three-phase AC induction motors. functionality. The Master Controller is designed to man-
They do not include motor brushes or commutators. An age the traction motor controller, pump motor controller,
AC induction motor operates on three-phase AC power interface to the operator controls, and control the vehi-
provided directly by the motor controller. The motor’s cle dash display.
speed is controlled by the motor controller and can be
changed by the frequency of the AC power generated to The Master Controller also manages the operating truck
the motor. A speed sensor has been built into the rear parameters, status codes, battery discharge indicator
motor bearing, which provides feedback to the motor (BDI) function, hourmeters, password feature, and all
controller allowing software to continually monitor motor operator inputs. It also supplies power to the line, power
direction and revolutions per minute (RPMs). Using this steering contactor, cooling fans, and reverse light relay.
software feedback, the AC motor control system can
provide much better vehicle top speed control than is Dash Display
available with today’s DC SEM system.
The new AC dash display is similar in appearance to the
The AC motors also have thermal sensors imbedded in SEM dash display and includes the same features. In
the motor windings that are continuously monitored by addition, the AC dash display provides expanded ser-
the motor controllers. vice capabilities. The dash display also has a pass-
word accessible service mode that allows a technician
Motor Controllers to change control settings and view real time RPM, cur-
rent, temperature, and switch closure information. Pre-
The motor controllers converts DC power from the viously, a separate handset was required for these op-
truck’s battery to three-phase AC power at the frequen- erations.
cies and currents necessary to drive the respective
pump and/or traction motor. Each AC induction motor Controller Area Network Bus (CANbus)
provides feedback of speed, rotation direction, and
temperature directly to the Motor Controller. The two The motor controllers, master controller, and dash dis-
motor controllers used to power the traction motor and play are connected together with a CANbus communi-
hydraulic pump motor are very similar. The primary cation system. A personal computer (PC) with the ap-
motor controller difference is in the power output rating. propriate service software can easily communicate with
all system nodes by simply connecting to the CANbus.
The motor controller logic board receives power from A special connector located under the dash and next to
the key switch. Power to the motors can be interrupted the display is configured specifically for this purpose
indirectly by the key switch. The motor controllers get
Master Controller Checks and Adjustments

NOTE: All checks and adjustments to the master con- the display panel can connect the PC to the CANbus
trollers can be done with a Personal Computer (PC) system to communicate to the controller. Many checks
through the display panel on the instrument panel can also be done at the display panel without being
(dash). A connector on the bottom (back side) of connected to a PC.
1
Function Parameters 2200 YRM 1056
The following checks and adjustments may be made • Check the hourmeter readings on the traction circuit
using a personal computer or the dash display: and hydraulic pump controllers.
• Check the system status codes history. • Monitor or adjust the register values for each function
• Check the state of charge of the battery. as shown in Table 1.
Function Parameters
GENERAL The Function Numbers are code numbers for the differ-
ent parameters that can be set for the master controller.
Memory elements of the master controller are called The personal computer (PC) or the dash display must
registers. These registers can have electronic data be used to adjust the parameters for the master con-
stored in them to control an operation. The range of troller.
data that can be stored in the registers is called a pa-
rameter. A parameter is a measurement number that Table 1. Factory Parameter Table
works with other measurement numbers (parameters)
to define a system. There are 16 registers. Factory Factory
Control Settings
72V 80V
WARNING 1-BATTERY VOLTAGE 72 80
The register value for each function has a value 2-EXTENDED SHIFT EN-
range so that the motor controller can be used ENABLED
ABLED
on different models of lift trucks. This variation is
needed for lift trucks of different sizes and operat- 3-ACCELERATION 1 40 40
ing voltages. Adjustment of a function to the wrong 4-ACCELERATION 2 7 7
number value for your lift truck model can cause
the truck to operate differently than normal. This 5-TOP SPEED LIMIT 90 90
different operation of the truck can cause an injury. 6-REGEN BRAKING 75 75
NOTE: The Table 1 shows the default setting for each 7-AUTO DECELERATION 70 70
control function. The Factory Set Parameters are the
8-BDI ADJUSTMENT 30 30
recommended settings for new units. These settings
will give satisfactory performance for most applications. 9-LIFT INTERRUPT EN-
ENABLED
ABLED
Some functions can be adjusted within the permitted
range to change the lift truck operation for a specific 10-PS TIME DELAY 20 20
application. Adjustment of a register to a number that 11-SERVICE REMINDER 0 0
is different than the factory setting is allowed, but follow
the instructions carefully. Adjustments other than the 12-CUSTOM 0 0
factory settings will cause the lift truck to operate differ- 13-PUMP SPEED 1 25 25
ently and can cause increased wear of parts.
14-PUMP SPEED 2 50 50
FUNCTION NUMBERS 15-PUMP SPEED 3 95 95
16-PUMP
WARNING ACCELERATION
25 25
NEVER adjust any of the function registers without
using the procedures and settings given in this sec-
tion.
2
2200 YRM 1056 Function Parameter Descriptions
Function Parameter Descriptions

GENERAL To increase the acceleration rate above the factory set-
ting, Function 2 will need to be disabled.
WARNING To reduce the acceleration rate below the factory set-
If any of the register values are changed, the op- ting, Function 2 may be enabled or disabled.
erators must be told that the lift truck will operate
differently. Any increase in performance will decrease the battery
shift life.
The following section contains descriptions for the dif-
ferent Function Numbers. The register setting for each Function Number 4 ACCELERATION 2
function is specific for each motor controller.
(Scale 0-100)
Function Number 1 BATTERY VOLTAGE
Function 4 determines the truck acceleration rate when
(36, 48, 72, or 80) traction motor speed is above 1,500 rpm. The truck
will accelerate at this rate regardless of the load on the
Function 1 is used to inform the master controller what forks, provided that the motor and control can deliver
voltage battery is installed in the truck. The battery the required power.
choices are: 36, 48, 72, or 80.
To increase the acceleration rates above the factory
Function Number 2 EXTENDED SHIFT setting, Function 2 will need to be disabled.
(Enable or Disable) To reduce the acceleration rate below the factory set-
ting, Function 2 may be enabled or disabled.
Function 2 enables or disables a preset motor perfor-
mance program in the traction motor controller. Any increase in performance will decrease the battery
shift life.
When enabled, this function provides a balance be-
tween truck performance and battery shift life that will Function Number 5 TOP SPEED LIMIT
meet the requirements of most applications. Truck ac-
celeration and top speed will vary with the amount of (Scale 1-100)
load on the forks.
Function 5 determines the top speed limit of the truck.
When disabled, truck acceleration and top speed are
determined by values set in Functions 3, 4, and 5. To increase the top speed above the factory setting,
Function 2 will need to be disabled.
If the motor and controller can deliver the power, then
the truck performance will not vary with the amount of To reduce the top speed below the factory setting,
load on the forks or the battery state of charge Function 2 may be enabled or disabled.
Grade climbing speed will also improve because the For speed limits slower than the normal truck speed, the
motor controller will deliver maximum current. Any in- Top Speed is the same regardless of the load on the
crease in performance will decrease the battery shift forks. Acceleration rates are also unaffected by lower-
life. ing the top speed.
Function Number 3 ACCELERATION 1 Function Number 6 REGEN BRAKING

(Scale 0-100) (Scale 0-100)
Function 3 determines the truck acceleration rate when Function 6 determines the maximum deceleration rate
traction motor speed is below 1,500 rpm. The truck when the accelerator pedal is fully depressed during
will accelerate at this rate regardless of the load on the regen braking.
forks, provided that the motor and control can deliver
NOTE: The deceleration rate is less when the pedal is
the required power.
not fully depressed.
3
Function Parameter Descriptions 2200 YRM 1056
Function Number 7 AUTO DECELERATION To use this feature, set this function to the hourmeter
reading that the service is to occur. When that hourme-
(Scale 0-100) ter is reached, the dash display will display Status
Code 99 for 10 seconds each time the key is turned
Function 7 determines the maximum deceleration rate
ON. After 20 hours of operation, the truck will slow to
when the accelerator pedal is released. The strength of
half speed and the code will display continuously until
auto deceleration is a percentage of the regen braking
the service is performed. After servicing the truck,
strength determined by Function 6.
Function 11 should be set to the next service hourme-
A Function 7 setting of zero will turn off auto decel- ter reading to regain full performance.
eration completely, and a setting of 100 will give auto
NOTE: A setting of zero will disable this feature.
deceleration the same strength as regen breaking.
Function Number 12 CUSTOM
Function Number 8 BDI ADJUSTMENT
(Scale 0-100)
(Scale 0-100)
Function 12 is not used except for special functions
Function 8 allows for adjustment to improve the accu-
required for special applications. Normally, this function
racy of the Battery Discharge Indicator in the dash
is set to zero.
display. Increasing the setting will increase the battery
voltage or specific gravity when the gage shows empty.
Function Number 13 PUMP SPEED 1
A setting of 30 is the recommended starting point for
(Scale 0-100)
flooded cell batteries, and a setting of 50 for mainte-
nance free batteries. Further adjustments may be used Function 13 determines the hydraulic pump motor low
to fine tune the BDI accuracy. speed. Low speed is used for tilt and some auxiliary
operations (slide shift).
Function Number 9 LIFT INTERRUPT
Function Number 14 PUMP SPEED 2
(Enable or Disable)
(Scale 0-100)
Function 9 enables or disables the lift interrupt feature.
The lift interrupt feature stops hoist operation when the Function 14 determines the hydraulic pump motor
BDI reads empty to protect the battery from excessive medium speed. Medium speed is used for slow hoist
discharge and possible damage. and some auxiliary operations.
NOTE: Trucks are shipped from the factory with this fea- Function Number 15 PUMP SPEED 3
ture enabled.
(Scale 0-100)
Function Number 10 POWER STEERING
TIME DELAY Function 15 determines the hydraulic pump motor high
speed. High speed is used for maximum hoist speed.
(Scale 0-100)
Function Number 16 PUMP
Function 10 sets the time delay for the power steering ACCELERATION
contactor to open after the seat switch opens. The set-
ting range is 1.5 to 65 seconds. Opening the key switch (Scale 0-100
will open the power steering contactor with no delay.
Function 16 determines the hydraulic pump motor ac-
Function Number 11 SERVICE REMINDER celeration rate. Higher numbers bring up motor speed
quicker.
(Set Next Hour Meter)
Function 11 can be used by the service technician to

show a Status Code 99 when the truck is due for ser-
vice.
4
2200 YRM 1056 Troubleshooting
Troubleshooting
GENERAL Resistance less than 1000 ohms should be corrected
first.
The AC motor and master controllers are sealed units
with no serviceable components. Troubleshooting is Before proceeding, visually check for loose wiring, mis-
usually limited to accessing status codes and follow- aligned linkage to the accelerator switch, signs of over-
ing the diagnostic procedures listed in the Status Code heating of components, etc.
Charts.
CONTROLLER STATUS LIGHT EMITTING
Use standard testing procedures to verify inputs and DIODES (LEDS)
outputs when necessary.
The AC traction motor controllers, AC pump motor con-
CAUTION trollers, and AC master controllers each have a sepa-
rate LED to indicate its operating status. Each LED is
Never attempt to probe through the back of the
green in color and may be lit continuously or blinking.
connector plugs of the motor controller or contac-
See each description for the location of each LED.
tor driver module. These plugs are special sealed
plugs. Probing through the back of the plugs will
AC Master Controller
destroy the seal and can cause a short circuit. If a
circuit must be tested for voltage, check for voltage • The LED is located next to the wire harness connec-
at an amp-type plug, a switch, or a component. If tor. See Figure 1.
a circuit is suspect, check the circuit for continuity • The LED-blinking rate is usually twice a second, when
by disconnecting the P plug and testing continuity the battery is connected and the key is in the OFF
from the front (pin end) of the plug. position.
• The LED-blinking rate slows to once every two sec-
Standard probes are too large to be inserted into the
onds when the battery is connected and the key is
center of the female pins (sockets) of the special
moved to the ON position.
sealed plugs and can expand the pins. Expanded
• If the above conditions are not present, the master
pins will not provide good connections once the
controller may not be properly connected or may be
plug is reconnected.
faulty.
See the section Diagrams for your lift truck model for • Due to the location of the master controller, a small
additional wiring details. inspection mirror may be needed to view the LED.
If the lift truck does not operate correctly, a status code

is displayed on the display panel.
Once the status code number is obtained, follow the

procedures outlined in the Status Code Charts of this
manual to determine the problem.
NOTE: Due to the interaction of the controller with all

lift truck functions, almost any status code or controller
fault could be caused by an internal failure of the con-
1. LED
troller. After all other status code procedures have been
followed and no problem is found, the controller should Figure 1. AC Master Controller LED
then be replaced as the last option to correct the prob-
lem. AC Motor Controllers
Tools and test equipment required are: clip leads, volt This section covers both the AC traction motor con-
ohmmeter (20,000 ohms per volt), and basic hand tools. trollers and AC pump motor controllers.
Check resistance on RX1000 scale from frame to • The LED is located next to the label on the plastic
power and controller terminals. A resistance of less cover of the controller. See Figure 2 or Figure 3.
than 20,000 ohms can cause misleading symptoms.
5
Troubleshooting 2200 YRM 1056
• The LED only turns on when the key is in the ON • When a fault condition is detected that has shut down
position. the truck, the LED-blinking rate will be at a very rapid
• The LED will show a steady continuous green color if rate (too fast to count). A status code should appear
there is no fault condition detected. on the dash display to reference the problem.
• When a fault condition is detected that is not serious • If the above conditions are not present, the AC mo-
enough to shut down the truck, the LED-blinking rate tor controller may not be getting power from the key
is twice a second. A status code should appear on switch or may be faulty.
the dash display to reference the problem.
1. FUSE 7 (15A) 6. LINE CONTACTOR

2. FUSE 6 (15A) 7. AC TRACTION MOTOR CONTROLLER
3. FUSE 3 (15A) 8. AC PUMP MOTOR CONTROLLER
4. POWER STEERING CONTACTOR 9. LED INDICATOR
5. FUSE 4 (POWER STEERING) (40A)
6
2200 YRM 1056 Troubleshooting
10. POSITIVE TEMPERATURE COEFFICIENT

RESISTOR (PTC)
Figure 2. AC Traction and AC Pump Motor Controllers
1. FUSE 7 (15A) 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 5 (15A) RESISTOR (PTC)
4. POWER STEERING CONTACTOR 9. FUSE 2 (PUMP) (325A)
5. FUSE 4 (POWER STEERING) (40A) 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 3. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor
7
Troubleshooting 2200 YRM 1056
STATUS CODES • Input voltages that are too high or too low
• Input voltages in the wrong sequence or
NOTE: Make sure the register values are correct for • Correct input voltages that occur at the wrong time
each Function Number of your lift truck to make sure the
trouble is not just a wrong setting. See Function Param- NOTE: A status code indication does not always mean
eters to set the correct parameter values. If there is no that there is a malfunction. A temporary operating con-
status code display and the lift truck does not operate dition can cause a status code display.
correctly, there can be a fault in the master controller.
These code numbers are only codes to help identify a
The status codes are code numbers for malfunctions or possible malfunction. A short description of the different
lift truck operation that is not correct that the motor con- status codes is shown in Table 2.
troller can sense. The master controller will indicate this
code number on the LCD screen of the display panel. The Status Code Charts in this section have a more
complete description of the status code, the circuit that
The master and motor controllers sense the following has generated the input for the status code, the symp-
types of malfunctions: tom, and the possible causes
Table 2. Table 1. List of Status Codes
Status Description Status Code Description

Code
BLANK No input voltage to controller 51 Capacitor volts are too low before
or display panel. line contactor closes.
01 No seat switch input. 54 Pump controller does not respond to
master controller.
02 A directional switch is closed before 55 Dash display cannot communicate with
the key or seat switch closes. This is master controller.
forward direction on DBB trucks and
reverse direction on CBB trucks.
03 A directional switch is closed before 61 Current to cooling fans is too high during
the key or seat switch closes. This is operation.
forward direction on DBB trucks and
reverse direction on CBB trucks.
04 Park brake applied while the key 62 Current to reverse relay is too high
switch is in the ON position. during operation.
05 Start switch fails to close. 63 Current to DC pump contactor coil is too
high during operation.
06 Accelerator depressed, no 64 Current to power steering contactor coil
direction selected. is too high during operation.
07 Acceleration Voltage too high when 65 Current to the line contactor coil is too
key is first moved to the ON.position. high during operation.
08 Acceleration input voltage too 66 Short circuit sensed on power output to
low when key is first moved to traction motor.
the ON position.
09 Both the forward and reverse 67 Short circuit sensed on power outage
directional switches are closed to pump motor.
at the same time.
11 The acceleration start switch closed 76 Capacitor voltage is too high.
before key and/or the seat switch.
8
2200 YRM 1056 AC Motor Controllers Status Code Charts
Table 2. Table 1. List of Status Codes (Continued)
15 Battery voltage is too low or 90 Traction motor temperature too high.

master controller is adjusted to
the wrong voltage.
16 Battery voltage is too high or 91 Pump motor temperature too high.
master controller is adjusted to the
wrong battery voltage.
41 Traction motor controller overheated. 93 Power steering brushes are worn.
42 Pump motor controller overheated. 95 Lift pump motor brushes are worn.
43 Traction motor temperature sensor 99 Maintenance Alert and Speed Limit.
out of range.
44 Pump motor temperature sensor
out of range.
AC Motor Controllers Status Code Charts

Status Code Description Memory Recall Circuit
No seat switch input. No Traction
01
Symptom
Lift truck does not move.
Possible Causes and Test Procedures

• Seat switch malfunction.
Check to see that the seat switch operates properly.
Replace a failed switch.
• Check wiring to the seat switch and from the seat switch
to the master controller
9
AC Motor Controllers Status Code Charts 2200 YRM 1056

A directional switch is closed before the key or No Traction
02 seat switch closes. This is forward direction on
DBB trucks and reverse direction on CBB trucks.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static Re-
turn to Off (SRO) Startup Procedure, move the direc-
tional lever to the neutral position, and then select a
direction.
• A directional switch is failed closed or out of adjustment.

A directional switch is closed before key or seat No Traction
03 switch closes. This is reverse direction on DBB
trucks and forward direction on CBB trucks.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static Re-
turn to Off (SRO) Startup Procedure, move the direc-
tional lever to the neutral position, and then select a
direction.
• A directional switch is failed closed or out of adjustment.
10

Park brake applied while the key switch No Traction
04 is in the ON position.
Symptom

• Park brake is applied.
Truck will not operate with park brake applied. Re-
lease the park break.
• Park brake switch is out of adjustment or is shorted.

Start switch fails to close. No Traction
05
Symptom

• Malfunction of start switch circuit.
Check for open circuit or loose connections in wiring
from key switch to start switch and from P16 to start
switch.
• Malfunction of start switch.
Check start switch for correct operation and output.
11

Accelerator depressed with no direction selected. No Traction
06
Symptom

• Accelerator pedal is depressed before closing a direc-
tion switch.
Status code will disappear when directional switch is
closed or when accelerator pedal is released.
• Malfunction of directional switch.
Check forward or reverse switch to make sure there
is continuity when direction is selected.
• Open circuit between directional switch and battery
positive or between directional switch and P4 or P5.
Check all wires and connections shown in trou-
bleshooting diagram.

Accelerator input voltage too high when key No Traction
07 is first moved to ON position.
Symptom

• Accelerator unit has a malfunction or is out of adjust-
ment. Maximum accelerator wiper voltage should be
11.00 volts with the pedal fully up.
• Open circuit between accelerator unit and P7.
12

Accelerator input voltage too low when key No Traction
08 is first moved to the ON position.
Symptom

• Minimum accelerator wiper voltage should be 10.70
volts with the pedal fully up.

Both the forward and reverse directional switches No Traction
09 are closed at the same time.
Symptom

• Forward or reverse directional switch is failed closed or
out of adjustment (adjusted to be held closed).
Replace or adjust directional switches to make sure
they open when directional switch is returned to neu-
tral.
• Short circuit between battery positive and P4 and/or P5.
Disconnect wires from P4 and P5 and check wire for
short circuit to positive side of directional switch.
13

The accelerator start switch closed before No Traction
11 key and/or the seat switch.
Symptom

• The accelerator pedal was depressed when the key
was turned to ON. This violates the Static Return to
Off (SRO) Startup Procedure. To correct this action,
release the accelerator pedal and resume normal op-
eration.
• The accelerator pedal was depressed when the opera-
tor sat down. This violates the SRO Startup Procedure.
To correct this action, release the accelerator pedal and
resume normal operation.
• The accelerator start switch is out of adjustment or has
a short.

Battery voltage is too low or master controller is No Traction
15 adjusted to the wrong battery voltage.
Symptom

• Discharged battery.
Check battery for correct open circuit voltage. Cor-
rect voltages are listed on right. Charge battery if
required.
• Battery is damaged.
Check each battery cell for correct voltage (greater
than 1.85 volts each cell). Replace or repair battery.
• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller is for the correct battery volts.
• Check the battery volts at motor controllers.
14

Battery voltage is too high or master controller No Traction
16 is adjusted to the wrong battery voltage.
Symptom

• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller is for the correct battery volts.
• Battery over charged or incorrect battery used.
Check battery for correct open circuit voltage. Cor-
rect voltages are listed on right. If voltage is too high,
check battery charger for correct output voltage.

Traction motor controller overheated. Yes Traction
41
Symptom
Truck acceleration is reduced or truck may
stop completely.

• Excessive pushing or stalling of traction motor.
• Check operation of cooling fans.
See Fan Test.
• Check for proper application of thermal grease between
motor controller and heat sink.
15

Pump motor controller overheated. Yes Traction
42
Symptom
Truck acceleration and travel speed is reduced and
pump motor may stop completely.

• Excessive operation or stalling of the pump motor.
• Check operation of the cooling fans.
See Fan Test.
• Check for proper application of thermal grease between
motor controller and heat sink.

Traction motor temperature sensor out of range. No Traction
43
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but traction
motor over temperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.

Pump motor temperature sensor out of range. No Pump
44
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but pump motor
over temperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.
16

Capacitor volts are too low before line No Traction
51 contactor closes.
Symptom
Lift truck does not move and line contactor does not close.

• A Positive Temperature Coefficient (PTC) is discon-
nected or malfunctioning, preventing the capacitors to
charge when the battery is plugged in.
• An accessory or component other than the motor con-
trollers is connected to load side of line contactor. This
will cause the PTC to get hot and not charge the capac-
itors.
• Repeated charging/discharging the capacitors during
troubleshooting may cause a Status Code 51. If the
PTC is hot, allow it to cool.

Traction or pump motor speed sensor error. No Traction
52
Symptom
Traction or pump motor operates very slowly and jerky.

• Disconnected or broken sensor wires between motor and motor controller.
• Malfunction of motor encoder bearing.

Traction controller does not respond to No Traction
53 master controller.
Symptom

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working.
Check for loose or broken wires.
17

Pump controller does not respond to No Traction
Symptom
Hydraulic pump motor does not operate.

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working

Dash display cannot communicate with Yes Traction
Symptom
Varies due to problem.

• If truck operates and code is displayed on dash, the CANbus communication is not working.
• If truck does not operate and code is displayed on dash, fault may be in master controller.

Current to cooling fans is too high during operation. No Traction
61
Symptom
Lift truck does not move. If fault occurred during truck
operation, status code will not display until the key
switch is cycled to OFF and then to ON again.

• A fan or wiring to fan may have a short.
• Trucks using a fan power supply may have a short in
the power supply.
• If the status code is displayed while fans or power sup-
ply are disconnected, fault is probably in the master
controller.
18

Current to reverse relay is too high No Traction
62 during operation.
Symptom

• Reverse relay coil or wiring coil may have a short.
Check the coil resistance with the wires discon-
nected.
• If status code is displayed while relay coil wires are
disconnected, the fault is probably in master controller.

Current to DC pump contactor coil is too No Traction
63 high during operation.
Symptom

• DC Pump contactor coil or wiring to coil may have a
short.
Check the coil resistance with wires disconnected.
• If status code is displayed while contactor coil wires are
19

Current to power steering contactor coil is No Traction
64 too high during operation.
Symptom

• Power steering contactor coil or wiring to coil may have
a short.
Check the coil resistance with the wires discon-
nected.

Current to the line contactor coil is too No Traction
65 high during operation.
Symptom

• Line contactor coil or wire to coil has a short.
Check coil resistance with the wires disconnected.
20

Short circuit sensed on power output No Traction
66 to traction motor.
Symptom

• Short circuit in motor or heavy power wires going to
motor.
• If status code is displayed with motor power wires dis-
connected, the short circuit is internal.
Replace motor controller.

Short circuit sensed on power output No Traction
67 to pump motor.
Symptom
Hydraulic pump motor does not operate.

• Short circuit in motor or heavy power wires going to
motor
• If status code is displayed with motor power wires dis-
connected, short circuit is internal.
Replace motor controller.

Capacitor voltage too high. No Traction
76
Symptom
Lift truck does not work.

• Regen setting too high.
Combination of a fully charged battery and a high regen setting may cause status code.
21

Traction motor temperature too high. Yes Traction
90
Symptom
Truck acceleration is reduced, or truck may stop completely.

• Excessive pushing or stalling of traction motor.
• Operation may continue at slower duty cycle.
Allow traction motor to cool to regain full performance.

Pump motor temperature is too high. Yes Pump
91
Symptom
Truck acceleration and travel speed reduced. Pump motor may stop completely.

• Excessive operation or stalling of pump motor.
• Operation may continue at slower duty cycle.
Allow pump motor to cool off to regain full performance.

Power steering motor brushes are worn. Yes
93
Symptom
Status code warning only.

• Pump motor brushes are worn too short.
• Motor brush wear sensor wires to motor controller may have a short to battery positive.
22
2200 YRM 1056 AC Transistor Motor Controller Repair

DC lift pump motor brushes are worn. Yes Pump
95
Symptom
Status code warning only.

• Pump motor brushes are worn too short.
• Motor brush wear sensor wires to motor controller may
have a short to battery positive.

Maintenance Alert and Speed Limit. No Traction
99
Symptom
Status code is displayed and after 20 hours, truck speed is reduced to 50% of normal top speed.

• Maintenance reminder indicating it is time to service truck. It was set by a technician through the dash display or
with a PC.
• The technician must perform desired maintenance and reset reminder to next hour meter reading that mainte-
nance should occur.
AC Transistor Motor Controller Repair

GENERAL Pump Motor is shown in Figure 5. There are NO inter-
nal parts of these motor controllers that can be repaired.
The assembly of the AC Traction Motor Controller with Each of these motor controllers must be replaced if an
AC Pump Motor controller is shown in Figure 4. The as- internal malfunction occurs.
sembly of the AC Traction Motor controller with DC Lift
23
AC Transistor Motor Controller Repair 2200 YRM 1056
1. FUSE 7 (15A) 6. LINE CONTACTOR

3. FUSE 3 (15A) 8. AC PUMP MOTOR CONTROLLER
4. POWER STEERING CONTACTOR 9. LED INDICATOR
5. FUSE 4 (POWER STEERING) (40A) 10. POSITIVE TEMPERATURE COEFFICIENT
RESISTOR (PTC)
Figure 4. AC Traction and AC Pump Motor Controllers
24
1. FUSE 7 (15A) 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 5 (15A) RESISTOR (PTC)
4. POWER STEERING CONTACTOR 9. FUSE 2 (PUMP) (325A)
5. FUSE 4 (POWER STEERING) (40A) 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 5. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor
GENERAL MAINTENANCE prevent high-temperature conditions. Always make

INSTRUCTIONS sure components are installed using silicon grease
and that all heat sink surfaces are clean. Do not block
The motor controllers, like other electronic devices, cooling airflow.
have temperature limits. These devices can be dam-
aged if they get too hot. Normal maintenance will help
25
Special Precautions Controller wire plugs and other exposed transistor con-
troller parts should be kept free of dirt and paint that
might change the effective resistance between points.
WARNING
To avoid injury and prevent electrical shock, per-
form the following steps before troubleshooting, CAUTION
adjustments or repair: Do NOT operate the traction system at high speed
• Turn the key to the OFF position and disconnect or rapidly change direction of operation with the
the battery connector. wheels raised. Motor controller damage can occur.
• Discharge the capacitors in the controllers using
the horn. Move the key to the OFF position, dis- Do not subject the controller to any high voltage (hipot
connect the battery connector, and hold the horn or megger) testing.
button until the horn stops making a sound.
Use a lead acid battery with the voltage and ampere
hour rating specified for the lift truck. Follow normal bat-
CAUTION tery maintenance procedures, recharging before 80%
To help prevent controller damage: discharged, with periodic equalizing charges.
• ALWAYS disconnect the battery when servicing
the controllers. Other parts of these assemblies also cannot be re-
• ALWAYS discharge the capacitors using the horn paired and must be replaced if they malfunction. The
before performing any service. contactors do have parts that can be replaced.
• NEVER connect power to the motor controllers
when any power cable is disconnected. WARNING
• NEVER make a short circuit at any motor con- Some checks in this section must be done with the
troller terminal to battery (+), battery ( ), or the battery connected and power applied to the con-
frame. troller. When making these checks, make sure the
drive wheels are raised from the floor.
Check with the dealer for your lift truck before operating
in an area with normal temperatures over 40 C (104 F). Make sure you disconnect the battery and sepa-
The lift truck motor controllers may not operate at full rate the connector before you remove any power
power. cables from the power terminals of the motor con-
troller. The capacitor stores electrical energy and
CAUTION can cause injury if a person discharges a capaci-
tor through parts of the body. AFTER the battery
Never add any electrical component to the lift truck
is disconnected and the key in the OFF position,
without approval from your dealer for your lift truck.
make sure you also discharge the capacitors. Dis-
Other electrical components can prevent operation
charge the capacitors by pushing and holding the
and/or damage the motor controller.
horn button until the horn stops making a sound.
NEVER USE STEAM TO CLEAN ELECTRONIC COM- The capacitors discharges through the horn.
PONENTS.
NOTE: The bolts and screws connected to the elec-
In dusty areas, blow low pressure air over the controller tronic components are normally metric sizes.
to remove dust. In oily or greasy areas, a mild solution
Make sure that you use the correct fastener for the part
of detergent or denatured alcohol can be used to wash
that has been disassembled or removed.
off the controller; and then, low pressure air should be
used to completely dry the controller.
FUSES
For the controller to be most effective, it must be
The fuses are found on the contactor panels. See Fig-
mounted against the finned aluminum heat sink. This
ure 4 or Figure 5. The condition of the fuses can nor-
additional heat sink will give improved lift truck perfor-
mally be checked by looking at them or can be checked
mance by keeping the controller package cooler. Apply
with an ohmmeter.
a sufficient layer of silicone (heat transfer) grease Yale
P/N 504223239 between the controller heat sink to fill
all gaps.
26
FAN TEST Repair

To determine if the fans are operating correctly, go to the Make an identification and disconnect the wires and ca-
Access to Service Functions section of this SRM. Using bles from the contactor assembly. Remove the mount-
the procedures in that section, go to "Diagnostics Menu" ing screws and remove the contactor assembly. See
and select "No Run Diagnostics." From there, go to "Fan Figure 7.
On" which is the last menu item. As soon as "Fan On"
is selected, the fans should start running. If only one
fan is running, replace the fan that is not running. If nei-
ther fan is running, check for 48VDC between the FAN
+ and FAN terminals of the fan power supply located
between the fans. If the voltage is present, replace both
fans. If voltage is not present, check for 80 VDC be-
tween pins 14 and 15 of the 42-pin connector at the
Master Controller wiring harness. If voltage is present,
check for damage to the wiring harness between the
Master Controller and fan power supply. Repair or re-
place wiring harness as necessary. If the wiring har-
ness is not damaged, replace the fan power supply.
CONTACTORS
There can be three contactors on these lift trucks. All
lift trucks have a power steering contactor and a line
contactor. See Figure 6. Also see Figure 7. Lift trucks
that do NOT have a pump motor controller also have a
contactor to energize the lift pump motor. See Figure 6.
1. TOP COVER
1. CONTACTOR 2. FIXED CONTACT SETS
2. POWER TERMINALS 3. MOVABLE CONTACTS
3. FIXED CONTACTS 4. SCREW
4. MOVABLE CONTACTS 5. RETURN SPRING
5. SPRING 6. INSULATOR
6. PLUNGER 7. COIL ASSEMBLY
Figure 6. Pump Motor Contactor Figure 7. Replacement Parts of Power Steering

Contactor
Contactor Contacts. The contacts in a contactor are

made of special silver alloy. The contacts will look
black and rough from normal operation. This condition
does not cause problems with the operation of the lift
27
truck. Cleaning is not necessary. DO NOT USE A is less than 30% of the thickness of a new contact
FILE ON THE CONTACTS. DO NOT LUBRICATE THE or if there is any transfer of contact material.
CONTACTS.
Coil. Check the coil with an ohmmeter for an open cir-
cuit or a short circuit. Coil resistance is very low. Re-
CAUTION place the coil if it is damaged. Make sure the coil wires
ALWAYS replace all of the contacts in a contactor are connected again to the correct terminals.
at the same time. Replace the contacts in the con-
tactor for the hydraulic pump after 1000 hours of
operation. Replace the contacts in the other con-
tactors when the thickness of any area of a contact
Table 3. 42-Pin Connections/Descriptions for Master Controller
Pin No. Wire Number Function

1
2 7 SEAT SWITCH
3 10P KEY SWITCH
4 8 REVERSE SWITCH
5 6 FORWARD SWITCH
6 32 +12 V
7 13G ANALOG GROUND
8 72B CANBUS GROUND
9 51 PUMP HIGH SPEED
10
11
12 6A FORWARD SIGNAL
13 24 LINE CONTACTOR
14 3C BATTERY POSITIVE
15 65 FAN
16 15 ACC START SWITCH
17 107A PUMP MOTOR BRUSH WEAR
18 108A PUMP MOTOR BRUSH WEAR
19 44 PARK BRAKE
20
21
22 74B CANBUS HIGH
23 73B CANBUS LOW
24
25
26
28
Table 3. 42-Pin Connections/Descriptions for Master Controller (Continued)

27
28 13B BATTERY NEGATIVE
29
30
31 45 BRAKE FLUID LEVEL
32 100A D.C. PUMP MOTOR TEMPERATURE
33 53 PUMP LOW SPEED
34
35
36 29 ACCELERATOR PEDAL POSITION
37
38 52 PUMP MEDIUM SPEED
39
40 54 D.C. PUMP CONTACTOR
41 8A REVERSE SIGNAL
42 60D POWER STEERING CONTACTOR
Table 4. 13-Pin Connections/Descriptions for Traction Controller

1 10 KEY SWITCH
2
3 33 SENSOR VOLTAGE SUPPLY
4 13S BATTERY NEGATIVE
5 104 SENSOR BEARING SIGNAL
7 102 MOTOR TEMPERATURE
8
9 13V CONTROLLER ID PIN
10 74A CANBUS HIGH
11 73A CANBUS LOW
12 74F CANBUS TERMINATION RESISTANCE
13 72A CANBUS GROUND
29
Table 5. 13-Pin Connections/Descriptions for Pump Motor Controller

1 10 KEY SWITCH
2
3 33P SENSOR VOLTAGE SUPPLY
4 13M BATTERY NEGATIVE
7 100 TEMPERATURE MOTOR
8 CONTROLLER ID PIN
9 CONTROLLER ID PIN
10 74A CANBUS HIGH
11 73A CANBUS LOW
12
13 72A CANBUS GROUND
30
Figure 8. AC Traction Motor Controller Typical Schematic
31
Figure 9. AC Pump Motor Controller Typical Schematic
32
2200 YRM 1056 Display Panel
THERMAL SENSORS
CAUTION
The thermal sensors for AC motors are embedded in Do not remove the small screws that fasten the
the motor windings and are continuously monitored by cover of the motor controller.
the motor controllers. They are part of the motor and
cannot be replaced or repaired. Make sure there is no dirt between the plate of the
motor controller and the mount surface of the lift
MOTOR CONTROLLER, REPLACE truck heat sink.
Make sure the battery is disconnected and the capacitor 3. Put an even coat of the silicone compound (Hyster
is discharged using the horn as previously described. Part No. 1198757) or equivalent on the plate of
Replace the motor controller as described in the follow- the motor controller. Make sure there are no air
ing procedure. See Figure 4 or Figure 5. spaces between the plate and mount surface of the
lift truck heat sink. The plate of the motor controller
1. Make an identification for correct connection of the must make full contact with the heat sink. Install the
power cables on the power terminals of the motor mount screws that fasten the motor controller to the
controller. Disconnect the power cables and the heat sink.
connector plug for the control wires.
4. Install the power cables at the power terminals of
2. Remove the eight (traction) or six (pump) mounting the motor controller as identified during removal.
screws that fasten the plate of the motor controller Install the connector plug for the control wires on
to the lift truck heat sink. Carefully remove the mo- the connector of the motor controller.
tor controller.
Display Panel
GENERAL • Allows pre-assigned service passwords to control ac-
cess to the service functions available through the
There are two dash display options, Standard and Pre- display
mium. Both displays look identical. See Figure 10. • Provides a comprehensive set of Service Functions
which are accessed through the Mode buttons and
Premium Display Panel LCD display
• Allows access to the User "Check List" function
• Allows pre-assigned user passwords to control driver
access to the vehicle
• Provides four driving Modes that are accessed
through the key pad
33
Display Functions and Features 2200 YRM 1056
Figure 10. Standard and Premium Display Panel
Standard Display Panel Standard and Premium display panels are interchange-
able on the vehicle. Therefore, the display system can
• Allows pre-assigned service passwords to control ac- be easily upgraded or downgraded by changing the dis-
cess to the service functions available through the play panel.
display
• Provides the same comprehensive set of Service
Functions using the Mode buttons and LCD display
as the Premium Display
Display Functions and Features

KEY-ON INITIALIZATION NOTE: The Seat Belt light will stay on whether the seat
belt is fastened or not fastened.
Upon turning the key to the ON position, the display se-
quentially lights the indicators from left to right located The indicator lights turn off sequentially, except for the
along the top of the display. See Figure 11. Seat Belt light which will remain lighted for approxi-
mately 10 seconds.
34
2200 YRM 1056 Display Functions and Features
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 11. Dash Display
STANDARD DISPLAY
Following the sequence given above, and as the Seat
Belt light becomes illuminated, the liquid crystal display
(LCD) displays the Battery Discharge Indicator (BDI) as
a bar. See Figure 12. As the battery is discharged, the
bar becomes shorter.
Figure 12. Battery Discharge Indicator
When the key is turned to the OFF position, the Hour-

glass indicator becomes illuminated, and the following
hourmeter information is flashed on the LCD screen:
Traction Hours for 3-4 seconds, followed by Pump
Hours for 3-4 seconds, after which the display turns off
and appears black. See Figure 13.
35
display (see Dash Display Service Menu Navigation) or

by using the PC software (see Troubleshooting and
Adjustment With a Computer With AC Controller
2200 YRM 1058.
A few seconds after the correct password has been en-

tered, the BDI and Performance Mode are displayed
and the vehicle can be operated. See Figure 16
Figure 13. Traction/Pump Hours
PREMIUM DISPLAY
Following the sequence given above, and as the Seat
Belt light becomes illuminated, the LCD displays the Figure 16. Display Screen (Premium Display)
prompt for the Operator to enter a password if this func-
tion has been enabled. See Figure 14. If the password LIFT TRUCK INSPECTION FUNCTION
function is disabled, the display will bypass the pass-
word prompt. To enable the password function, see If this function is turned on, the operator is prompted to
password function. answer a checklist of questions. The operator indicates
a 1 for a Pass or a 4 for Fail. If the operator indicates
the vehicle passes the inspection, the display will show
the previous information and the operator can drive the
vehicle. If the operator indicates that the vehicle fails the
inspection "Service Required" will appear on the display
screen, and the vehicle will only operate in Mode 1 until
the required action is taken. See Figure 17.
Figure 14. Password Prompt Screen
If the password is not entered within 5-8 seconds, a re-

minder screen is shown on the LCD display. See Fig-
ure 15.
Figure 17. Inspection Failure Screen
The inspection feature can be enabled with or without

the password function enabled, depending upon the
user’s preference. The inspection checklist feature, as
with the password feature, may be setup using either
the dash display or using a PC. For the PC instructions,
go to Troubleshooting and Adjustment With a Com-
Figure 15. Password Reminder Screen puter With AC Controller 2200 YRM 1058. The check-
list must be enabled or disabled by a service technician.
Until a password is entered that agrees with a pass-
word stored in the vehicle master controller, the hoist The following is the list of checks:
and traction systems are inoperative. Passwords may • Check for leaks
be entered in the master controller using either the dash • Check service brake
36
2200 YRM 1056 Display Functions and Features
• Check park brake and 16 control function settings. The 16 control function
• Check horn, lights, and reverse alarm settings are discussed further in Function Parameter
• Check gauges and warning lights Descriptions.
• Check tire condition and pressure • Setup Menu
• Check hydraulic oil level Serial Number
Set Traction Hours
ACCESS TO SERVICE FUNCTIONS Set Pump Hours
Control Function Settings
All service functions are accessible from either Stan- 1. Battery voltage
dard or Premium displays. The following functions are 2. Extended Shift
the same with either display version, except as noted in 3. Acceleration 1
the following sections. 4. Acceleration 2
5. Top speed limit
Once the vehicle is turned on with the key switch and
6. Regen braking
the initialization process has been completed, a service
7. Auto deceleration
technician can gain access to the service functions by
8. BDI adjustment
pressing the asterisk button (*) twice.
9. Lift interrupt
The display will prompt the service technician for a five- 10. PS time delay
digit password. See Figure 18. The default setting for 11. Service reminder
the password is 55555. When a correct password is 12. Custom
entered, the Service Features menu is displayed as fol- 13. Pump speed 1
lows: 14. Pump speed 2
• Setup Menu 15. Pump speed 3
• Password Menu (Operator Passwords are only avail- 16. Pump acceleration
able with Premium Display) • Password Menu
• Diagnostic Menu Enter Password
• View Hourmeter Truck Inspection
Add Password
Delete Password
Edit Password
NOTE: All indications in the diagnostic menu are

shown as on, off, or a value (i.e. Throttle Pot Volt).
On is indicated by a 1. Off is indicated by a 0.
• Diagnostic Menu
No Run Diagnostics
Figure 18. Password Request Direction switch
Accelerator start
The technician can scroll through the menu using the up
Throttle pot volt
(1) or down (2) arrows and select the desired function
Seat switch
by pressing the 4-button. Each menu selection has a
Park brake
list of sub-menu functions. The sub menus are viewed
Pump switch #1
and items selected by scrolling through the menu in the
Pump switch #2
same manner as described above.
Pump switch #3
To exit a selected function and return to the previous Steering brush #1
function, press the 3 button. Pressing the 3 button mul- Steering brush #2
tiple times will return the technician to the operator’s DC pump brush #1
driving mode. DC pump brush #2
DC pump motor temp
SERVICE FUNCTIONS Fan on
Run Diagnostics:
The following sub-menu functions are accessible from Traction motor speed
the Main Menu of Service Functions, described above. Traction motor amps
This includes the following three vehicle setup values
37
Traction motor temp BATTERY DISCHARGE INDICATION (BDI)

AC pump motor speed
AC pump motor amps The AC control system includes a newly developed Bat-
AC pump motor temp tery Discharge Indicator (BDI) that provides accurate
• View Hourmeter and reliable indication of the battery state of charge.
Traction Hourmeter See Figure 19. The BDI feature is displayed to the op-
Pump Hourmeter erator on the dash display with a 20 segment bar that
Secure Hourmeter looks and functions the same as the current BDI. Lift
truck operators will not need to learn a new BDI sys-
PERFORMANCE MODES tem.
NOTE: Performance modes are not available on the The BDI provides full functionality when used with a full
Standard Dash display, and the factory configuration is range of batteries including:
equivalent to Mode 4. • Flooded cell, standard amp hour batteries
• Flooded cell, high amp hour capacity batteries
When equipped with the Premium Dash display, the • Valve regulated (absorbed glass mat) maintenance-
following four operator selectable performance modes free batteries (VRLA)
are available. These modes are pre configured from
the factory as described below. Mode 4 provides the
highest performance and modes 1-3 are percentages
of Mode 4. A service technician using the dash dis-
play or connecting with the PC software, can revise the
control settings and configure the top speed and accel-
eration of the vehicle. The relationship between mode
1-4 remains constant and cannot be altered.
With the premium display the operator can change

modes by pressing the numbered keys on the dash
display. Any number can be selected at anytime to
change the performance mode. The change does not
take effect until the operator releases the accelerator Figure 19. Battery Discharge Indication in Dash
pedal. If the password is enabled, the operator will be Display LCD Window
limited by the performance level set in the password
function. The lift interrupt feature is controlled by the vehicle
master controller and prevents the hoist function when
Mode 4 is the highest level of performance available to the battery is 80% discharged. Although lift interrupt
the operator, regardless of the performance setup in prevents hoisting, low speed functions such as tilt and
the control. For instance, if the control is configured sideshift remain operational to allow the operator to
to limit top speed less than maximum, then Mode 4 top more easily remove the forks from the load and return
speed is equal to the top speed set in the control. Three to the battery charging area.
lower performance modes are available to the operator
by using the buttons on the display. These lower perfor- When lift interrupt is initiated, it will remain in effect until
mance settings are percentages of the highest perfor- the battery is disconnected and a recharged battery is
mance available in Mode 4 as described below: reconnected to the vehicle. When a battery is replaced
• Mode 4 - This is the highest performance mode. or recharged, the new state of charge must be at least
Other modes are a lower percentage of Mode 4. 25% greater than the previous state of charge. This
• Mode 3 - Top speed is the same as mode 4. Acceler- prevents the BDI from being activated by a battery that
ation is 80% of mode 4. has recovered slightly during an idle period.
• Mode 2 - Top speed is 80% of mode 4. Acceleration
A BDI adjustment feature is provided through the con-
is 70% of mode 4.
trol setup function, which is accessible using either the
• Top speed is 60% of mode 4. Acceleration is 60% of
dash display or PC Service Software. The adjustment
mode 4.
scale is 0-100, with a value of 30 for the factory setting.
The setting of 30 is the starting point for flooded cell
type batteries of all voltages and amp hour capacities.
The adjustment can then be used to fine tune the BDI lift
38
2200 YRM 1056 Dash Display Service Menu Navigation
interrupt feature. For example, it is desired to have the 1. Pump hours - accumulates time only when the
lift interrupt to occur at a higher battery specific gravity, pump motor is operating.
then the value would be increased. The value is de- 2. Traction hours - accumulates time when the seat
creased if a lower specific gravity is desired for the lift switch is closed and the key switch is in the ON
interrupt point. position.
3. Secure hours - based on traction hours. The secure
If a maintenance-free battery is installed, the BDI ad- hours cannot be reset.
justment should be increased to a value of about 50
as a starting point. Fine tuning can be done from that The hourmeter data is stored in the Master Controller
value. during every 6 minutes of operation. If there is a loss of
power, data is not lost.
HOURMETER
There are three different hourmeter functions.
Dash Display Service Menu Navigation

GENERAL 3. is left, for scrolling left, or out of the current menu
4. is right, for scrolling right, or deeper into the next
To enter the service mode, turn the key to the ON po- menu level
sition and press the [*] button twice. Enter password
prompt will appear on the display.See Figure 20. All lift MOVING THROUGH MENU SELECTIONS
trucks will have 55555 as the default service password
at the time of delivery. This password can be changed 1. When the service technician’s password has been
by a service technician. Go to Editing and Adding Infor- correctly entered, the first menu item, which is the
mation. Setup menu, will appear on the dash display LCD
screen. To view the next menu item, press the [2]
key on the dash display numeric key pad. Repeat
this until the desired menu item has been reached.
If it is desired to go back to a previous menu item,
press the [1] key. When the last item in the menu
has been reached and the [2] key is pressed again,
the menu will wrap to the first item.
2. To move into a sub menu of a main menu item,

Figure 20. Password Prompt press the [4] key on the dash display numeric key
pad. To move into a sub-sub menu, as with the
Buttons [1], [2], [3], [4], and [*] are used for menu navi- Diagnostics menu, press the [4] key again.
gation and for adding or editing information. Button [5]
is only used if it is part of the password required to enter 3. To move up or down within the sub menu or the
the service mode. The display has arrows on the but- sub-sub menu press the [1] or [2] keys.
tons to aid in the navigation process. See Figure 21
4. To move out of the sub-sub menu, press the [3] key.
This will go back to the sub menu.
5. To move out of the sub menu, press the [3] key. This
will go back to the main menu.
6. To exit the service mode, press the [3] key.
Figure 21. Dash Display Buttons EDITING AND ADDING INFORMATION

The following list is the numbers on the dash display NOTE: The setup and password menus can be used to
and their function: edit or add information to the truck software. When an
1. is up, for scrolling up item in these menus is selected, the current value will
2. is down, for scrolling down be displayed. The characters available to be selected
39
Dash Display Service Menu Navigation 2200 YRM 1056
from the display are 0-9, A-Z, Blank, and dash. Each move to the next character to be changed. This
line in the display can have no more than 20 characters is repeated until all changes in the item have been
including blanks. made.
1. If a change is to be made, press the [4] key and the 3. When all changes have been made, press the [*]
cursor will blink on one of the characters. Keys [3] key to store the value. Press the [1] or [2] key to
and [4] are used to move from character to charac- access the next item to be changed. Repeat this
ter in the item being changed. procedure for each item that is to be changed.
2. When a character that is to be changed is blinking, 4. When all changes have been made, press the [3]
use keys [1] and [2] to scroll up or down until the key to exit the menu.
desired character is found. Use keys [3] or [4] to
40
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 1056 3/03 Printed in U.S.A.

Yale524183083 2200YRM1056 (03 2003) US

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Maintenance

PART NO. 524183083 2200 YRM 1056

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2003 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

ERP20-30ALF (ERP040-060DH) [D216]

Master Controller Checks and Adjustments

Function Parameter Descriptions

Function Number 3 ACCELERATION 1 Function Number 6 REGEN BRAKING

Function 11 can be used by the service technician to

If the lift truck does not operate correctly, a status code

Once the status code number is obtained, follow the

NOTE: Due to the interaction of the controller with all

1. FUSE 7 (15A) 6. LINE CONTACTOR

10. POSITIVE TEMPERATURE COEFFICIENT

Figure 2. AC Traction and AC Pump Motor Controllers

1. FUSE 7 (15A) 7. POSITIVE TEMPERATURE COEFFICIENT

Table 2. Table 1. List of Status Codes

Status Description Status Code Description

Table 2. Table 1. List of Status Codes (Continued)

15 Battery voltage is too low or 90 Traction motor temperature too high.

AC Motor Controllers Status Code Charts

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit