2200YRM1087

Maintenance
AC MOTOR
CONTROLLERS/DISPLAY
PANEL
DESCRIPTION, CHECKS,
ADJUSTMENTS, AND
TROUBLESHOOTING
ERP1.6-1.8-2.0ATF (ERP030-040TH) [F807]
PART NO. 524204504 2200 YRM 1087

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
Description ...................................................................................................................................................... 1
AC Motors ................................................................................................................................................... 1
ZAPI™ AC Motor Controller........................................................................................................................ 1
Principles of Operation ............................................................................................................................... 2
Controller Thermal Management ................................................................................................................ 3
Controller Area Network (CAN Bus) ........................................................................................................... 3
Discharging the Capacitors ............................................................................................................................. 3
AC Motor Controller Repair ................................................................................................................................. 4
General ........................................................................................................................................................... 4
Special Precautions .................................................................................................................................... 4
Thermal Sensors............................................................................................................................................. 5
Motor Controller, Replace ............................................................................................................................... 5
Controller Checks and Adjustments .................................................................................................................... 5
Function Parameters ........................................................................................................................................... 6
General ........................................................................................................................................................... 6
Function Parameter Descriptions ........................................................................................................................ 7
Parameters...................................................................................................................................................... 7
Top Speed Forward..................................................................................................................................... 7
Top Speed Reverse..................................................................................................................................... 7
Acceleration ................................................................................................................................................ 7
Regen Braking ............................................................................................................................................ 8
Auto Deceleration ....................................................................................................................................... 8
Extended Shift ............................................................................................................................................ 8
Pump Acceleration...................................................................................................................................... 8
Tilt/Auxiliary Pump Acceleration ................................................................................................................. 8
Low Lift Speed ............................................................................................................................................ 8
Maximum Lift Speed ................................................................................................................................... 8
Maximum Lowering Speed ......................................................................................................................... 8
Tilt Speed.................................................................................................................................................... 8
3rd Function ................................................................................................................................................ 9
3rd Function Speed .................................................................................................................................... 9
4th Function ................................................................................................................................................ 9
4th Function Speed..................................................................................................................................... 9
Battery Voltage ........................................................................................................................................... 9
Lift Interrupt................................................................................................................................................. 9
BDI Adjustment ........................................................................................................................................... 9
BDI Decrement Time .................................................................................................................................. 10
Service Reminder ....................................................................................................................................... 10
Custom ....................................................................................................................................................... 10
Restore Defaults ......................................................................................................................................... 10
Calibration Parameters ........................................................................................................................................ 10
Throttle Calibration.......................................................................................................................................... 10
Steering Calibration......................................................................................................................................... 10
Display Panel....................................................................................................................................................... 10
General ........................................................................................................................................................... 10
Premium Display Panel............................................................................................................................... 10
Standard Display Panel............................................................................................................................... 11
Display Functions and Features .......................................................................................................................... 12
Key-On Initialization ........................................................................................................................................ 12
©2005 Yale Materials Handling Corp. i

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

Standard Display ............................................................................................................................................. 13
Premium Display ............................................................................................................................................. 13
Lift Truck Inspection Function.......................................................................................................................... 13
Access to Service Functions ........................................................................................................................... 14
Service Functions ........................................................................................................................................... 14
Performance Modes ........................................................................................................................................ 15
Battery Discharge Indication (BDI).................................................................................................................. 16
Hourmeter ....................................................................................................................................................... 16
Status Code List.............................................................................................................................................. 16
Dash Display Service Menu Navigation .............................................................................................................. 17
General ........................................................................................................................................................... 17
Moving Through Menu Selections................................................................................................................... 17
Editing and Adding Information ....................................................................................................................... 17
Troubleshooting ................................................................................................................................................... 18
General ........................................................................................................................................................... 18
Status Codes................................................................................................................................................... 18
Controller Connector Pin Outs ........................................................................................................................ 78
Valve Driver Module (Electro-Hydraulic Valve Option) .................................................................................... 79
Hydraulic Lever Console (Electro-Hydraulic Option Only)............................................................................... 80
Dash Display ................................................................................................................................................... 80
System Logic Diagrams .................................................................................................................................. 81
This section is for the following models:
ERP1.6-1.8-2.0ATF (ERP030-040TH) [F807]
ii
2200 YRM 1087 Description
Description
GENERAL rear motor bearing, which provides feedback to the mo-
tor controller, allowing software to continually monitor
This section describes the ZAPI™ AC motor controller. motor direction and revolutions per minute (RPMs). Us-
See Figure 1. ing this software feedback, the AC motor control system
can provide much better vehicle speed control than is
available with DC SEM systems.
The AC motors also have thermal sensors, continuously

monitored by the motor controllers, embedded in the
motor windings.
Figure 1. AC Controller
Procedures are outlined for controller safety, adjust-

ments, troubleshooting, and repair. This section does A. LEFT SIDE C. FORWARD
B. RIGHT SIDE TRAVEL
not contain information about other electrical compo-
nents. See the section Electrical System 2200 YRM Figure 2. Truck Orientation
1078 and the section Electro-Hydraulic Control Valve
2000 YRM 1086. ZAPI™ AC Motor Controller
Throughout this section, forward will refer to travel in the The ZAPI™ controller comes in two versions. See Fig-
direction of the forks and left and right are determined ure 3. The first version contains two inverters for con-
by an operator sitting in the seat facing forward. See trolling the dual traction motors and a contactor for the
Figure 2. lift function. The second version contains two inverters
for controlling both traction motors and a transistor con-
DESCRIPTION troller to control a series DC pump motor.
AC Motors The ZAPI™ controller is a solid state AC motor con-
troller utilizing MOSFET technology with microproces-
The AC motors are three-phase AC induction motors. sor control. The basic dual motor control is capable of
They do not include motor brushes or commutators. controlling two asynchronous AC induction motors si-
An AC induction motor operates on three-phase AC multaneously. The controller has direct control of the
power provided directly by the motor controller. The traction system, main contactor, and the electromag-
motor’s speed is controlled by the controller and can be netic parking brakes.
changed by the frequency of the AC power presented
to the motor. A speed sensor has been built into the
1
Description 2200 YRM 1087
the controller. One microprocessor is designated the

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

and the logic cards necessary to process input signals
from various truck components. The controller uses
these inputs to control the speed and direction of the
dual traction motors. These components are all con-
tained within a single housing located on the inside of
the rear compartment cover. See Figure 4.
Figure 3. AC Controllers
The controller software provides self diagnostics which

are accessed by means of a personal computer (PC)
with specialized ETACC software (see the section Trou-
bleshooting and Adjustments Using the AC Con-
trols Program 2200 YRM 1058 or the on-board Dash
Display). The controller software features a Test Menu
for monitoring controller inputs and outputs, a Diagnos-
tic Menu for viewing fault code information, and a Pro-
gramming Menu for customizing the truck performance.
The self diagnostics monitor the traction motor, brake

coil, main contactor coil, controller temperature, and in-
ternal logic functions. Troubleshoot fault codes gen-
erated by the controller self diagnostics by using the
on-board dash display or a properly configured IBM™
compatible PC.
Principles of Operation 1. LH TRACTION MOTOR

2. RH TRACTION MOTOR
The traction motor controllers convert DC power from 3. DASH DISPLAY
the truck’s battery to three-phase AC power at the 4. HYDRAULIC VALVE
5. CONTACTOR AND FUSE PANEL
frequencies and current necessary to independently 6. TRACTION CONTROLLER
power each traction motor. Each AC induction motor 7. HYDRAULIC PUMP AND MOTOR
provides feedback to the controller for speed, rotation 8. STEERING PUMP AND MOTOR
direction, and temperature.
Figure 4. Component Location
The ZAPI™ AC motor controller uses two sophisticated
microprocessors to control the logic and operation of
2
2200 YRM 1087 Description
The controller may also be equipped with an optional

transistor pump motor controller. This transistor con- WARNING
trol is installed in a single housing along with the two DO NOT short across the motor controller terminals
inverters for powering the traction motors. The pump with a screwdriver or jumper wire.
controller receives inputs from the hydraulic valve or the
optional valve driver module. The pump motor will run NOTE: Some lift trucks are equipped with a premium
at specific preset motor speeds when the manual con- controller, which controls the hydraulic motor as well as
trol valve is installed. Motor speed is based on the hy- the traction motors.
draulic function selected. 1. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2-watt resistor across the con-
Controller Thermal Management troller’s BT+ and B terminals for 10 seconds using
The motor controller is equipped with internal thermal insulated jumper wires. See Figure 5.
sensors to protect the controller from a high tempera- 2. On the premium controller, also connect the 200-
ture condition. At a temperature of 80 C (176 F), the ohm, 2-watt resistor across the controller’s P+ and
controller will begin to reduce current to the traction cir- B terminals for 10 seconds using insulated jumper
cuit and slow the speed of the lift truck. If the controller wires. See Figure 6.
temperature continues to rise, the traction current will
be further reduced. If the temperature reaches 100 C 3. Remove the 200-ohm, 2-watt resistor before recon-
(212 F), current to the traction circuit will be reduced to necting the battery.
zero and the lift truck cannot travel. As the controller
cools, traction will be restored. When the controller has NOTE: There are no user-serviceable parts in the
cooled to 80 C (176 F), full traction speed will be avail- ZAPI™ controller. No attempt should be made to open,
able. repair, or otherwise modify the controller. Doing so
may damage the controller and will void the warranty.
Controller Area Network (CAN Bus)
The motor controller and the dash display are con-
nected together with a CAN bus communication
system. When equipped with the optional electro-hy-
draulic valve, the valve, valve driver module, and the
electro-hydraulic lever console also communicate with
the ZAPI™ controller over the CAN bus network. A PC
with the appropriate service software can easily com-
municate with all system nodes by simply connecting
to the CAN bus. A special connector, located under the
dash and next to the display, is configured specifically
for this purpose.
DISCHARGING THE CAPACITORS
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and 1. POSITIVE CONNECTION (BT+)
personal injury, discharge the capacitor before 2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
inspecting or repairing any component in the elec- 4. 200-OHM, 2-WATT RESISTOR
trical compartment. Wear safety glasses. Make
certain that the battery has been disconnected. Figure 5. Discharging the Capacitors - Economy
3
AC Motor Controller Repair 2200 YRM 1087
Legend for Figure 6

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

and Premium
AC Motor Controller Repair

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

CAUTION
Never add any electrical component to the lift truck Make sure the battery is disconnected and the capac-
without approval from your Yale dealer. Added elec- itors are discharged. Replace the motor controller as
trical components can prevent operation and/or described in the following procedure.
damage the motor controller.
1. Tag and disconnect all wire harness connections
Never use steam to clean electronic components. In and power wires from the controller.
dusty areas, blow low pressure air over the controller to
2. Remove the mounting screws holding the controller
remove dust. In oily or greasy areas, a mild solution of
to the rear compartment cover. Carefully remove
detergent or denatured alcohol can be used to wash off
the controller from the truck.
the controller. Then use low pressure air to completely
dry the controller.
CAUTION
CAUTION Do not remove the screws that secure the cover of
the controller.
Do NOT operate the traction system at high speeds
or rapidly change the direction of operation with the 3. Ensure there is no dirt between the base of the con-
wheels raised. Motor controller damage can occur. troller and the mounting surface on the rear com-
partment cover.
Do not subject the controller to any high voltage (hipot
or megger) testing. 4. Put an even coat of thermal grease on the base
plate of the controller. Ensure there are no air
Use a lead acid battery with the voltage and ampere
spaces between the plate and the mounting sur-
hour rating specified for the lift truck. Follow normal
face of the rear compartment cover. The base plate
battery maintenance procedures, recharging before 80
of the controller must make full contact with the
percent discharged, with periodic equalizing charges.
mounting surface.
THERMAL SENSORS 5. Install the screws that fasten the controller to the
rear compartment cover.
The thermal sensors for the motors are embedded in
the motor end head and are continuously monitored by 6. Reconnect all power wires and wire harness con-
the motor controller. They are part of the motor and nections to the controller.
cannot be repaired.
7. Calibrate steering and throttle inputs. See Calibra-
tion Parameters in this section.
Controller Checks and Adjustments

All checks and adjustments to the controller can be • Check the system status codes in history.
done with a PC or through the dash display on the in- • Check the state of charge of the battery.
strument panel. A PC can be connected to the CAN • Check the hourmeter readings on the traction circuit
bus via a connector on the main wiring harness near and hydraulic pump controllers.
the bottom (backside) of the display panel. • Monitor or adjust the register values for each function
as shown in Function Parameters in this section.
The following checks and adjustments may be made
using a PC or the dash display:
5
Function Parameters 2200 YRM 1087
Function Parameters
GENERAL Table 1. Traction Parameters
Memory elements within the controller are called regis- Control Settings
ters. These registers can have electronic data stored in
them to control an operation. The data stored in a reg- Factory Defaults
Traction
ister is called a parameter. A parameter is a measure- 36V 48V
ment number that defines a lift truck function. A specific
function parameter works with other function parame- Battery Voltage 36 48
ters to control the operation of the lift truck. Extended Shift ON ON
Acceleration 0 0
WARNING
Top Speed Max FWD 128 Hz 140 Hz
The parameter for each function has a value range
so the motor controller can be used on different Top Speed Max REV 128 Hz 140 Hz
models of lift trucks. This variation is needed for
Regen Braking 9 9
lift trucks of different sizes and operating voltages.
Adjustment of a function to the wrong number value Auto Deceleration 6 6
for your lift truck model can cause the truck to oper-
BDI Adjustment 35 35
ate differently than normal. This different operation
of the truck can cause an injury. Lift Interrupt 1 1
NOTE: Table 1, Table 2, and Table 3 show the default Service Reminder 0 0
parameter setting for each control function that is ad- Custom 0 0
justable by the user. The factory-set default parameters
are the recommended settings for new units. These set-
tings will give satisfactory performance for most appli- Table 2. Transistor Lift With Manual
cations. Valve Parameters
Some functions can be adjusted within the permitted
Control Settings
range to change the lift truck operation for a specific ap-
plication. Adjustment of a register to a number that is Transistor Lift With Factory Defaults
different than the factory settings is allowed, but follow Manual Valve 36V 48V
the instructions carefully. Adjustments other than the
factory settings will cause the lift truck to operate differ- Pump Acceleration 1 1
ently and can cause increased wear of parts. Max Lift Speed 100 100
Low Lift Speed 40 30
Tilt Speed 58 40
3rd Function Speed 33 25
4th Function Speed 85 85
6
2200 YRM 1087 Function Parameter Descriptions
Table 3. Transistor Lift With Electro-Hydraulic Table 3. Transistor Lift With Electro-Hydraulic
Valve Parameters Valve Parameters (Continued)
Control Settings
Control Settings
Transistor Lift With Factory Defaults
Transistor Lift With Factory Defaults
Electro-Hydraulic Valve 36V 48V Electro-Hydraulic Valve 36V 48V
Pump Acceleration 1 1
4th Function Max Speed 85 85
Max Lift Speed 100 100
3rd Function 0 0
Max Lowering Speed 75 75
4th Function 3 3
Tilt Speed 33 25
Tilt/Auxiliary Pump 4 4
3rd Function Max Speed 33 25 Acceleration
Function Parameter Descriptions

PARAMETERS Top Speed Reverse
(Scale 10-140 Hz)
WARNING
If any of the parameter values are changed, the op- This parameter setting determines the top speed of the
erators must be told that the lift truck will operate truck in the reverse direction.
differently.
To increase the top speed above the factory setting, the
extended shift parameter will need to be disabled.
WARNING
NEVER adjust any of the following parameters with- To reduce the top speed below the factory setting,
out using the procedures and settings given in this the extended shift parameter may be enabled or
section. disabled.
The following section contains descriptions for the dif- For speed limits slower than the normal truck
ferent parameters. Access these parameters through speed, the top speed is the same regardless of
the SETUP menu in the dash display or with the PC the load on the forks. Acceleration rates are also
software. unaffected by lowering the top speed.
Top Speed Forward Acceleration

(Scale 10-140 Hz) (Scale 0-9)
This parameter setting determines the top speed of the This parameter setting determines the truck accelera-
truck in the forward direction. tion rate. The truck will accelerate at this rate regard-
less of the load on the forks, provided that the motor
To increase the top speed above the factory setting, the and control can deliver the required power.
extended shift parameter will need to be disabled.
To increase the acceleration rate above the factory set-
To reduce the top speed below the factory setting, ting, the extended shift parameter will need to be dis-
the extended shift parameter may be enabled or abled.
disabled.
To reduce the acceleration rate below the factory set-
For speed limits slower than the normal truck ting, the extended shift parameter may be enabled or
speed, the top speed is the same regardless of disabled.
the load on the forks. Acceleration rates are also
unaffected by lowering the top speed.
7
Function Parameter Descriptions 2200 YRM 1087
Any increase in performance will decrease the battery Pump Acceleration

shift life.
(Scale 0-9)
Regen Braking
This parameter setting determines the hydraulic pump
(Scale 0-9) motor acceleration rate. Increasing the setting will in-
crease the speed of the motor.
This parameter setting determines the maximum de-
celeration rate when the accelerator pedal is fully de- Tilt/Auxiliary Pump Acceleration
pressed during regen braking.
(Scale 0-9)
NOTE: The deceleration rate is less when the pedal is
not fully depressed. This parameter setting determines the hydraulic pump
motor acceleration rate when using the tilt or auxiliary
Auto Deceleration functions with the electro-hydraulic valve option.
(Scale 0-9) Low Lift Speed

This parameter setting determines the maximum de- (Scale 36V = 25-65%)
celeration rate when the accelerator pedal is released. (Scale 48V = 20-50%)
The strength of auto deceleration is a percentage of the
regen braking strength. This parameter setting determines the hydraulic pump
motor low speed. This is used with transistor lift and
A setting of zero will turn off auto deceleration com- the manual control valve. Increasing the setting will in-
pletely and a setting of nine will give auto deceleration crease the speed of the hydraulic pump motor.
the same strength as regen braking.
Maximum Lift Speed
Extended Shift
(Scale 0-100%)
(0 or 1)
(0 = Disable; 1 = Enable) This parameter setting determines the hydraulic pump
motor high speed. High speed is used for maximum lift
This parameter setting enables or disables a preset speed.
motor performance program in the traction motor con-
troller. Maximum Lowering Speed
When enabled, this function provides a balance be- (Scale 0-100%)
tween truck performance and battery shift life that will
meet the requirements of most applications. Truck ac- This parameter setting determines the hydraulic pump
celeration and top speed will vary with the amount of motor speed during lowering. Increasing the setting will
load on the forks. increase lowering speed.
When disabled, truck acceleration and top speed are Tilt Speed
determined by values set in the acceleration and top
speed parameters. (Scale 36V = 20-66%)
(Scale 48V = 15-50%)
If the motor and controller can deliver the power, then
the truck performance will not vary with the amount of This parameter setting is used to set the hydraulic motor
load on the forks or the battery state of charge. speed when the tilt function is selected. Increasing the
setting will increase the speed of the hydraulic pump
Grade climbing speed will also improve because motor.
the motor controller will deliver maximum current.
Any increase in performance will decrease the bat-
tery shift life.
8
2200 YRM 1087 Function Parameter Descriptions
3rd Function Battery Voltage

(Scale 0, 1, or 2) (36V or 48V)
(0 = 3rd Function Without Interlock)
(1 = 3rd Function With Interlock) This parameter setting is used to inform the master con-
(2 = 3rd Function With Push/Pull) troller what voltage battery is installed in the truck. The
battery choices are 36V or 48V.
This parameter is used to select the operation of the
3rd function mini-lever or joystick roller switch. Use Lift Interrupt
selection 0 when using the 3rd function to control a
non-clamping type attachment. Use selection 1 when (0 or 1)
using the 3rd function to control a clamping type attach- (0 = Disable; 1 = Enable)
ment. Use selection 2 when using the 3rd function to
This parameter setting enables or disables the lift in-
control a push/pull attachment.
terrupt feature. The lift interrupt feature stops lift oper-
ation when the battery discharge indicator (BDI) reads
3rd Function Speed
empty to protect the battery from excessive discharge
(Scale 36V = 20-100%) and possible damage.
(Scale 48V = 15-75%)
NOTE: Trucks are shipped from the factory with this fea-
This parameter setting is used to set the hydraulic pump ture enabled.
motor speed when the 3rd function hydraulic lever is
actuated. Increasing the setting increases the speed of BDI Adjustment
the hydraulic pump motor.
(Scale - First Digit 1-5)
(Scale - Second Digit 3-7)
4th Function
This parameter setting allows for adjustment to improve
(Scale 0, 1, 2, or 3)
the accuracy of the battery discharge indicator in the
(0 = 4th Function Without Interlock)
dash display.
(1 = 4th Function With Interlock)
(2 = 4th Function With Push/Pull) This first digit adjusts the charged setting. Increasing
(3 = Default - No 4th Function) the setting will increase the battery voltage or specific
gravity required for the indicator to show full. If the indi-
This parameter is used to select the operation of the
cator consistently reads low with fully charged batteries,
4th function mini-lever or joystick roller switch. Use
decrease this setting.
selection 0 when using the 4th function to control a
non-clamping type attachment. Use selection 1 when The second digit adjusts the discharged setting. In-
using the 4th function to control a clamping type attach- creasing the setting will increase the battery voltage or
ment. Use selection 2 when using the 4th function to specific gravity level required for the indicator to show
control a push/pull attachment. empty. If the indicator consistently shows lift interrupt
too soon, decrease this setting.
4th Function Speed
A setting of 35 is the recommended starting point for
(Scale 36V = 0-100%) flooded batteries. A setting of 45 is the recommended
(Scale 48V = 0-100%) starting point for maintenance-free batteries. Further
adjustments may be used to fine-tune the BDI accuracy.
This parameter setting is used to set the hydraulic pump
motor speed when the 4th function hydraulic lever is
actuated. Increasing the setting increases the speed
of the hydraulic pump motor.
9
Display Panel 2200 YRM 1087
BDI Decrement Time This can be used by the service technician to show a
Status Code 99 when the truck is due for service.
This adjustment is used to compensate for duty cycles
that involve nonstop operation where frequent pauses To use this feature, set this function to the hourmeter
of more than 5 seconds do not occur (no drive, no hy- reading at which the service is to occur. When that
draulic use). When the truck is finally stopped, turned hourmeter is reached, the dash display will display Sta-
OFF, and then restarted, some deviation in the BDI tus Code 99 for 10 seconds each time the key is turned
reading may occur. One of three things may happen ON. After 20 hours of operation, the truck will slow to
to the BDI reading when the truck is restarted: half speed and the code will display continuously un-
1. The BDI gage still reads within plus or minus one til the service is performed. After servicing, adjust the
bar as it did when the truck was turned OFF. No service reminder parameter to the next desired service
adjustment is needed. time.
2. If the BDI gage changed downward more than one
bar, this parameter should be set to a lower num- Custom
ber.
3. If the BDI gage changed upward more than one bar, (Scale 0-100)
this parameter should be set to a higher number.
This parameter setting is not used except for special
This adjustment has little or no effect on the BDI accu- functions required for special applications. Normally it
racy when the truck is used in intermittent duty cycles is set to zero.
that have frequent pauses in truck activity for greater
than 5 seconds each time. Restore Defaults
This function is used to restore all parameter settings
Service Reminder to the factory default settings shown in Table 1, Table 2,
(Set Next Hourmeter) and Table 3.
Calibration Parameters
THROTTLE CALIBRATION STEERING CALIBRATION
Activating this parameter allows the controller to “learn” Activating this parameter allows the controller to “learn”
the voltage setting of the throttle assembly. The con- the voltage setting of the steering feedback system.
troller uses this information to control the lift truck The controller uses this information to control the trac-
speed. See the section Electrical System 2200 YRM tion motors during turning operations. See the section
1078. Electrical System 2200 YRM 1078.
Display Panel
GENERAL • Allows preassigned service passwords to control ac-
cess to the service functions available through the
There are two dash display options, Standard and Pre- display.
mium. Both displays look identical. See Figure 7. • Provides a comprehensive set of service functions,
which are accessed through the mode buttons and
Premium Display Panel liquid crystal display (LCD).
• Allows access to the User Check List function.
• Allows preassigned user passwords to control driver
access to the vehicle.
• Provides four driving modes that are accessed
through the key pad.
10
2200 YRM 1087 Display Panel
Standard Display Panel Standard and Premium display panels are interchange-
able on the vehicle. Therefore, the display system can
• Allows preassigned 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 as the
Premium Display.
Figure 7. Standard and Premium Display Panel
11
Display Functions and Features 2200 YRM 1087
Display Functions and Features

KEY-ON INITIALIZATION The indicator lights turn off sequentially, except for the
seat belt light, which will remain lighted for approxi-
Upon turning the key to the ON position, the display se- mately 10 seconds.
quentially lights the indicators, from left to right, located
along the top of the display. See Figure 8.
NOTE: The seat belt light will stay on whether the seat
belt is fastened or not fastened.
1. HOURMETER INDICATOR 8. LCD SCREEN

2. WRENCH INDICATOR 9. STAR PUSH BUTTON
3. BATTERY INDICATOR 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR (BDI) 11. PUSH BUTTON #2
5. BRAKE FLUID LEVEL 12. PUSH BUTTON #3
6. PARKING BRAKE 13. PUSH BUTTON #4
7. FASTEN SEAT BELT 14. PUSH BUTTON #5
Figure 8. Dash Display
12
2200 YRM 1087 Display Functions and Features
STANDARD DISPLAY
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the BDI
as a bar. See Figure 9. As the battery is discharged,
the bar becomes shorter.
Figure 11. Password Prompt Screen
Until a password is entered that agrees with a password

stored in the dash display, the lift and traction systems
are inoperative. Passwords may be entered directly into
the dash display or by using the PC software program.
A few seconds after the correct password has been en-

1. 4 SEGMENTS ADJACENT TO RED tered, the BDI and performance mode are displayed
2. 4 SEGMENTS ADJACENT TO ORANGE
3. 12 SEGMENTS ADJACENT TO GREEN and the vehicle can be operated. See Figure 12.
4. BDI SHOWS APPROXIMATELY 65-70% CHARGE
Figure 9. 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 10.
Figure 12. Display Screen (Premium Display)
LIFT TRUCK INSPECTION FUNCTION

If this function is turned on, the operator is prompted to
answer a checklist of questions. The operator indicates
a 1 for 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 13.
Figure 10. Traction/Pump Hours
PREMIUM DISPLAY
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the
prompt for the operator to enter a password if this func-
tion has been enabled. See Figure 11. If the password
function is disabled, the display will bypass the pass-
word prompt. To enable the password function, see the Figure 13. Inspection Failure Screen
password menu.
13
The inspection feature can be enabled with or without The technician can scroll through the menu using the
the password function enabled, depending upon the up [1] or down [2] arrows and select the desired function
user’s preference. The inspection checklist feature, as by pressing the [4] button. Each menu selection has a
with the password feature, may be set up using either list of submenu functions. The submenus are viewed
the dash display or using a PC. The checklist must be and items selected by scrolling through the menu in the
enabled or disabled by a service technician. same manner as described above.
The following is the list of checks: To exit a selected function and return to the previous
• Check for leaks. function, press the [3] button. Pressing the [3] button
• Check service brake. multiple times will return the technician to the operator’s
• Check park brake. driving mode.
• Check horn, lights, and reverse alarm.
• Check gauges and warning lights. SERVICE FUNCTIONS
• Check tire condition and pressure.
• Check hydraulic oil level. The following submenu functions are accessible from
the main menu of service functions, described above.
ACCESS TO SERVICE FUNCTIONS This includes the following vehicle setup values and
control function settings. The control function settings
All service functions are accessible from either Stan- are discussed further in Function Parameter Descrip-
dard or Premium displays. The following functions are tions.
the same with either display version, except as noted in
the following sections. • View Hourmeter
Secure Hourmeter
Once the vehicle is turned ON with the key switch and Set Pump Hours
the initialization process has been completed, a service Set Traction Hours
technician can gain access to the service functions by • Software Version
pressing the star button (*) twice within 3 seconds. Master
Slave
The display will prompt the service technician for a five- Display
digit password. See Figure 14. The default setting for Valve Driver (Electro-Hydraulic only)
the password is 55555. When a correct password is • Password
entered, the Service Features menu is displayed as fol- Add Password
lows: Delete Password
• Hourmeters Edit Password
• Software Versions Operator Password
• Password Truck Inspection
• Diagnostics
• Setup NOTE: All indications in the diagnostic menu are shown
as ON, OFF, (or a value i.e. volts, amps). ON is indi-
cated by a one. OFF is indicated by a zero.
• Diagnostic
Error Log
Run Diagnostics
Left Trac Mtr Speed
Left Trac Mtr Crrnt
Left Trac Mtr Temp
Figure 14. Password Request Right Trac Mtr Speed
Right Trac Mtr Crrnt
If no password is entered, the screen will automatically Right Trac Mtr Temp
return to the start up screen after 20 seconds. The Steer Position
screen will also revert to the start up screen if an in- Lift Transistor Control
correct password is entered. Pump Motor Voltage
14
2200 YRM 1087 Display Functions and Features
Pump Motor Current 4th Function Speed

No Run Diagnostics Electro-Hydraulic
Hood Switch 4th Function Installed
Seat Belt Switch Lift Pump Accel
Seat Switch Tilt/Aux Pump Accel
Forward Switch Max Lift Speed
Reverse Switch Lowering Max Speed
Accelerator Start Tilt Max Speed
Brake Switch 3rd Function Max Speed
Brake Fluid Level 4th Function Max Speed
Hydraulic Oil Level 3rd Function
Pump Motor Brushes 4th Function
Pump Motor Temp Manual
Throttle Pot Volt No Parameters Will Display
Steering Enable Truck Settings
Manual with Transistor Control Serial Number
Lo Lift Switch Battery Voltage
Lift Switch Lift Interrupt
Tilt Switch Restore Defaults
3rd Function Switch BDI Adjustment
4th Function Switch BDI Decrement Time
Electro-Hydraulic Service Reminder
Arm Rest Switch Custom
Lift Speed Language
Lower Speed
Tilt Forward Speed PERFORMANCE MODES
Tilt Back Speed
3rd Func In Speed NOTE: Performance modes are not available on the
3rd Func Out Speed Standard Dash display, and the factory configuration is
4th Func In Speed equivalent to Mode 4.
4th Func Out Speed
When equipped with the Premium Dash display, the fol-
Manual
lowing four operator-selectable performance modes are
Hydraulic Switch
available. These modes are preconfigured from the fac-
• Setup
tory as described below. Mode 4 provides the highest
Traction Settings
performance and Modes 1-3 are percentages of Mode
Throttle Calibration
4. A service technician, using the dash display or con-
Max Steer Right
necting with the PC software, can revise the control set-
Max Steer Left
tings and configure the top speed and acceleration of
Max Steer 0
the vehicle. The relationship between Modes 1-4 re-
Top Speed Forward
mains constant and cannot be altered.
Top Speed Reverse
Acceleration With the premium display, the operator can change
Regen Braking modes by pressing the numbered keys on the dash
Auto Deceleration display. Any number can be selected at any time to
Extended Shift change the performance mode. If the mode change is
Hydraulic Settings requested while the traction system is in operation, the
Manual with Transistor Controller requested change will not take effect until the acceler-
Lift Pump Accel ator pedal has been released to the neutral position.
Tilt/Aux Pump Accel During this operation, the display will indicate Mode
Lo Lift Speed X Requested until the accelerator is released. If the
Max Lift Speed password is enabled, the operator will be limited by the
Tilt Speed performance level set in the password function.
3rd Function Speed
15
Mode 4 is the highest level of performance available to battery is 80 percent discharged. Although lift interrupt
the operator, regardless of the performance setup in prevents lifting, low speed functions, such as tilt, remain
the control. For instance, if the control is configured operational to allow the operator to more easily remove
to limit top speed less than maximum, then Mode 4 top the forks from the load and return to the battery charg-
speed is equal to the top speed set in the control. Three ing 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 un-
mance settings are percentages of the highest perfor- til the battery is disconnected and a recharged battery
mance available in Mode 4 as described below: is reconnected to the lift truck. In order to reset the
• Mode 4 - This is the highest performance mode. BDI function and allow lift truck operation, the recharged
Other modes are a lower percentage of Mode 4. battery must have a state of charge that is 20 percent
• Mode 3 - Top speed is the same as Mode 4. Acceler- above the open cell voltage BDI setting.
ation is 80 percent of Mode 4.
Two BDI adjustment features are provided via the con-
• Mode 2 - Top speed is 80 percent of Mode 4. Accel-
trol setup function, which is accessible via the dash dis-
eration is 70 percent of Mode 4.
play (service password required) or with the PC service
• Mode 1 - Top speed is 60 percent of Mode 4. Accel-
software.
eration is 60 percent of Mode 4.
HOURMETER
BATTERY DISCHARGE INDICATION (BDI)
There are three different hourmeter functions.
The AC control system includes a Battery Discharge
1. Pump hours - accumulates time only when the
Indicator (BDI) that provides indication of the battery
pump motor is operating.
state of charge. See Figure 15. The BDI feature is
2. Traction hours - accumulates time when the seat
displayed to the operator on the dash display with a
switch is closed and the key switch is in the ON
20-segment bar that looks and functions the same as
position.
the current BDI. Lift truck operators will not need to learn
3. Secure hours - based on traction hours. The secure
a new BDI system.
hours cannot be manually reset. However, secure
The BDI provides full functionality when used with a full hours will be automatically reset to zero if both the
range of batteries including: controller and the dash display are replaced at the
• Flooded cell, standard amp-hour batteries same time.
• Flooded cell, high amp-hour capacity batteries
The hourmeter data is stored in the master controller
• Valve regulated (absorbed glass mat) maintenance-
during every 6 minutes of operation. If there is a loss of
free batteries (VRLA)
power, data is not lost.
STATUS CODE LIST

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

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

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

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

menu, press the [3] key.
Figure 16. Password Prompt 6. To exit the service mode, press the [3] key.
Buttons [1], [2], [3], [4], and [*] are used for menu navi- EDITING AND ADDING INFORMATION
gation and for adding or editing information. Button [5]
is only used if it is part of the password required to enter NOTE: The setup and password menus can be used to
the service mode. The display has arrows on the but- edit or add information to the truck software. When an
tons to aid in the navigation process. See Figure 17. item in these menus is selected, the current value will
be displayed. The characters available to be selected
from the display are 0-9, A-Z, blank, and dash. Each
line in the display can have no more than 20 characters
including blanks.
1. If a change is to be made, press the [4] key and the

cursor will blink on one of the characters. Keys [3]
and [4] are used to move from character to charac-
Figure 17. Dash Display Buttons ter in the item being changed.
The following list is the numbers on the dash display 2. When a character that is to be changed is blinking,
and their function: use keys [1] and [2] to scroll up or down until the
1. Is up, for scrolling up desired character is found. Use keys [3] or [4] to
2. Is down, for scrolling down move to the next character to be changed. This
3. Is left, for scrolling left or out of the current menu is repeated until all changes in the item have been
4. Is right, for scrolling right or deeper into the next made.
menu level
3. When all changes have been made, press the [*]
MOVING THROUGH MENU SELECTIONS key to store the value. Press the [1] or [2] key to
access the next item to be changed. Repeat this
1. When the service technician’s password is correctly procedure for each item that is to be changed.
entered, the first menu item, which is the hourme-
ter, is displayed on the dash display LCD screen. To 4. When all changes have been made, press the [3]
view the next menu item, press the [2] key on the key to exit the menu.
dash display numeric key pad. Repeat this until the
17
Troubleshooting 2200 YRM 1087
Troubleshooting
GENERAL Tools and test equipment required are: clip leads, volt
ohmmeter (20,000 ohms per volt), and basic hand tools.
The AC motor and master controllers are sealed units
with no serviceable components. Troubleshooting is Check resistance on RX1000 scale from frame to
usually limited to accessing status codes and follow- power and controller terminals. Resistance of less than
ing the diagnostic procedures listed in the Status Code 20,000 ohms can cause misleading symptoms. Resis-
Charts. tance of less than 1000 ohms should be corrected first.
Use standard testing procedures to verify inputs and Before proceeding, visually check for loose wiring, mis-
outputs when necessary. aligned linkage to the accelerator switch, signs of over-
heating of components, etc.
CAUTION STATUS CODES
Never attempt to probe through the back of the con-
nector plugs of the motor controller. These plugs NOTE: Make sure the parameter values are correct for
are special sealed plugs. Probing through the back your lift truck to ensure the trouble is not just an incor-
of the plugs will destroy the seal and can cause a rect setting. See Function Parameters to set the correct
short circuit. If a circuit must be tested for voltage, parameter values. If there is no status code display and
check for voltage at an amp-type plug, a switch, or a the lift truck does not operate correctly, there can be a
component. If a circuit is suspect, check the circuit fault in the master controller.
for continuity by disconnecting the P plug and test-
ing continuity from the front (pin end) of the plug. The status codes are code numbers for malfunctions
or lift truck operations that are not correct and that the
Standard probes are too large to be inserted into the motor controller can sense. The master controller will
center of the female pins (sockets) of the special indicate this code number on the LCD screen of the
sealed plugs and can expand the pins. Expanded display panel.
pins will not provide good connections once the
plug is reconnected. The master and motor controllers sense the following
types of malfunctions:
See the section Diagrams for your lift truck model for • Input voltages that are too high or too low
additional wiring details. • Input voltages in the wrong sequence or
• Correct input voltages that occur at the wrong time
If the lift truck does not operate correctly, a status code
is displayed on the display panel. NOTE: A status code indication does not always mean
that there is a malfunction. A temporary operating con-
Once the status code number is obtained, follow the dition can cause a status code display.
procedures outlined in the Status Code Charts of this
manual to determine the problem. These code numbers are only codes to help identify a
possible malfunction. A short description of the different
NOTE: Due to the interaction of the controller with all status codes is shown in Table 4.
lift truck functions, almost any status code or controller
fault could be caused by an internal failure of the con- The Status Code Charts in this section have a more
troller. After all other status code procedures have been complete description of the status code, the circuit that
followed and no problem is found, the controller should has generated the input for the status code, the symp-
be replaced as the last option to correct the problem. tom, and the possible causes.
18
2200 YRM 1087 Troubleshooting
Table 4. List of Status Codes
Status Code Description Status Code Description

01 Request traction or hydraulic function 214L Wrong voltage on one phase --> failure
while seat switch open. in power section (high leg), driver
circuit, or motor in slave controller.
02 Forward switches closed at key on. 214R Wrong voltage on one phase --> failure
in power section (high leg), driver
circuit, or motor in master controller.
03 Reverse switches closed at key on. 215L Wrong voltage on one phase --> failure
in power section (low leg), driver circuit,
or motor in slave controller.
05 Start switch not closed when seat 215R Wrong voltage on one phase --> failure
switch is closed and either the in power section (low leg), driver circuit,
forward or reverse directional switch or motor in master controller.
is closed and accelerator voltage
shows demand for traction.
06 Request traction function while 222 Controller checks to ensure main
forward and reverse switches are contactor coil or brake coil is not
opened. shorted at start up.
07 Accelerator input voltage too high on 223 Controller checks main contactor tips
power up. and ensures they are open before
powering controller.
08 Accelerator input voltage too low on 224 Main contactor not closed.
power up.
09 Forward and reverse direction 226 Electric brake driver damaged (shorted
requested together. or open).
10 Steer sensor feedback voltage too 227 Traction controller receives a signal for
high. traction from accelerator potentiometer
without start switch being closed.
11 Start switch closed before key or 228 Pump contactor not connected or coil
seat switch. opened.
12 Steer sensor feedback voltage too 238 Internal failure of traction controller
low. hardware.
14 After steer calibration, controller 239 Master controller detected problem in
senses "max right" parameter to be slave controller functionality.
less than "max left" parameter.
15 Battery voltage lower than the setting 240 Slave controller detected problem in the
in controller. master controller functionality.
16 Battery voltage higher than the 241 Master does not see CAN messages
setting in controller. from slave.
41 High temperature in master or 242 Master does not see CAN messages
slave or both power sections, from electro-hydraulic lever console.
performance is progressively
reduced as temperature rises.
19
Table 4. List of Status Codes (Continued)

42 Pump control temperature too high. 243 Slave does not see CAN messages
from valve driver module.
43L Left traction motor temperature out 244 Failure of dash display memory.
of range.
43R Right traction motor temperature out 245 Master does not see CAN messages
of range. from display.
51 Capacitor voltage too low. 246 Slave does not see CAN messages
from display.
52L Failure in encoder, in encoder to 247 Valve driver does not see CAN
controller connection, or in controller messages from display.
input circuit, left motor.
52R Failure in encoder, in encoder to 248 Slave does not see CAN messages
controller connection, or in controller from master.
input circuit, right motor.
62 Backup alarm driver shorted. 249 No communication from slave to EV.
Overcurrent protection activated.
65 Main line contactor coil driver 250L Left rotor locked.
shorted.
66L Left traction motor shorted. 250R Right rotor locked.
66R Right traction motor shorted. 260 Incorrect voltage on pump motor -->
failure in power section, driver section,
or motor itself.
90L Left traction motor high temperature. 270 Error in lift/lower lever.
90R Right traction motor high 271 Error in tilt lever.
temperature.
91 Pump motor high temperature. 272 Error in 3rd function lever.
95 Pump motor brushes worn. 273 Error in 4th function lever.
99 Maintenance required. 275 Internal failure of valve driver module.
145 Power transistor did not turn on 276 One of the EV drivers of group 1
properly. (lift/lower) is shorted.
201 Request hydraulic or traction function 277 One of the EV drivers of group 2
while arm rest switch not closed. (auxiliary in/out) is shorted.
202 Hydraulic oil low. 279 One of the EV drivers of group 3 (tilt
up/down) is shorted.
203 Brake fluid low. 280 One of the EV drivers of group 4
(sideshift R/L) is shorted.
204 Request traction or hydraulic function 281 Driver of single EV (9th) is shorted.
while hood switch/switches not
closed.
20
Table 4. List of Status Codes (Continued)

207 Lift cutout. 282 One of the on/off EV drivers is shorted.
208 Pump incorrect start. 283 One of the on/off EV coils is shorted;
short-circuit protection is triggered.
209L Brake coil open, disabling traction. 289 Voltage supply to the valve driver
control module is low.
209R Brake coil open, disabling traction. 292 Battery selection is wrong in valve
controller.
210 Internal "watchdog" hardware circuit 294 Interlocked hydraulic function requested
triggered. without activation of interlock switch.
213 The controller has detected an 295 Hi-Lift switch is closed and the Lo-Lift
overvoltage or an undervoltage switch is open.
condition within the controller.
Status Premium Display Message Memory Recall Circuit

Code
01 NO SEAT SWITCH INPUT No Traction
Description
Controller is not receiving an input signal from the
seat switch while receiving a traction or hydraulic
function command.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Seat switch malfunction.
Check to see if the seat switch operates properly.
Use the dash display diagnostics menu to
check the seat switch operation.
Replace failed switch.
• Check continuity of wiring to and from the seat
switch to the traction controller.
Pin C33 at motor controller to seat switch.
Seat switch to Pin C18 at motor controller.
21

Code
02 FORWARD SWITCH CLOSED No Traction
Description
Forward directional switch is closed before the key
switch closes.
Symptom
• A directional switch is engaged before startup.
Return directional switch to neutral.
• A directional switch is failed, closed, or out of ad-
justment.
Use dash display diagnostics menu to check op-
eration of the directional switches.
Adjust switch for correct operation. See the sec-
tion Electrical System 2200 YRM 1078.
22

Code
03 REVERSE SWITCH CLOSED No Traction
Description
Reverse directional switch is closed before the key
switch closes.
Symptom
• A directional switch is engaged before startup.
Return directional switch to neutral.
• A directional switch is failed, closed, or out of ad-
justment.
Use dash display diagnostics menu to check op-
eration of the directional switches.
Adjust switch for correct operation. See the sec-
tion Electrical System 2200 YRM 1078.
23

Code
05 START SWITCH NOT CLOSED No Traction
Description
Start switch is open when the seat switch is closed
and either the forward or reverse directional switch
is closed and the accelerator output voltage shows
there is a demand for traction.
Symptom
• Malfunction of the start switch.
Use dash display diagnostics to check operation
of the start switch.
Check for proper switch adjustment.
Replace start switch.
Check for open circuit or loose connections in
wiring from the key switch to the start switch and
from the controller to the start switch.
24

Code
06 NO DIRECTION SELECTED No Traction
Description
The forward and the reverse switches are both open
and there is a request for traction.
Symptom
• Accelerator pedal is depressed before closing a di-
rectional switch.
Status code will disappear when the pedal is re-
leased.
• Open circuit between the directional switch and the
controller.
Use dash diagnostics to check the operation of
the switch.
Check wiring from C4 to FWD and REV
switches.
Check wiring from switches to C6 and C7.
Check operation of switch for continuity through
the switch when the switch is closed.
• Malfunction of the directional switch.
Check switch adjustment.
FWD or REV switch is closed when direction
is selected.
25

Code
07 THROTTLE POT ERROR Yes Traction
Description
Accelerator input voltage is too high when the key
is first moved to the ON position.
Symptom
• Accelerator unit has a malfunction or is out of ad-
justment.
Maximum accelerator wiper voltage should be
4.6 volts with the pedal fully up at C33.
Check for open circuit between accelerator and
controller.
Recalibrate throttle. See the section Electrical
System 2200 YRM 1078.

Code
08 THROTTLE VOLTAGE LOW No Traction
Description
Accelerator input voltage is too low when the key is
first moved to the ON position.
Symptom
• Accelerator unit has a malfunction or is out of ad-
justment.
Check for open circuit between accelerator and
controller.
Minimum accelerator wiper voltage should be
0.5 volt with the pedal fully down at C21.
26

Code
09 FWD and REV SWITCHES CLOSED No Traction
AT SAME TIME
Description
Both the forward and reverse directional switches
are closed at the same time.
Symptom
• Either the forward or reverse switch is failed closed.
Use dash display diagnostic to check operation
of directional switches.
Replace failed or malfunctioning switch.
• Directional switch is out of adjustment.
Switches should be open with directional switch
in neutral.
27

Code
10 STEER SENSOR VOLTAGE HIGH Yes Traction
Description
Steer sensor feedback voltage is too high.
Symptom
• Use dash diagnostics to check operation of the
steer sensor.
• Check potentiometer and adjustment. Potentiome-
ter wiper should be set at 5K ohms with wheels
straight ahead.
• Check wiring continuity between steering poten-
tiometer and traction controller.
• Check voltage between C15 and C16.
Voltage should be 5.0 volts.
• Recalibrate steering. See the section Electrical
28

Code
11 START SWITCH CLOSED No Traction
BEFORE KEY
Description
Accelerator start switch is closed before the key
and/or the seat switch.
Symptom
• Accelerator pedal depressed when key is turned to
ON position.
Release pedal and restart.
• Accelerator start switch is out of adjustment.
Switch should be open with accelerator pedal
fully up.
• Accelerator start switch is shorted closed.
Use dash display diagnostic menu to check op-
eration of switch.
29

Code
12 STEER SENSOR VOLTAGE LOW Yes Traction
Description
Steer sensor feedback voltage is too low.
Symptom
• Use dash diagnostics to check operation of the
steer sensor.
• Check potentiometer and adjustment. Potentiome-
ter wiper should be set at 5K ohms with wheels
straight ahead.
• Check wiring continuity between steering poten-
tiometer and traction controller.
• Check voltage between C15 and C16.
Voltage should be 5.0 volts.
• Recalibrate steering. See the section Electrical

Code
14 WRONG STEER CALIBRATION Yes Traction
Description
After steer calibration, the controller is sensing the
"max right" parameter to be less than the "max left"
parameter.
Symptom
No lift truck operation.
• Recalibrate the steering sensor.
• Check sensor values using the dash diagnostics.
• Check adjustment of the steering potentiometer.
• Check for 5.0-volt supply voltage at the steering
potentiometer.
30

Code
15 BATTERY VOLTAGE LOW Yes Traction
Description
The battery voltage is lower than the setting in the
controller.
Symptom
• Discharged battery.
Check battery for correct open circuit voltage.
Charge battery.
• Battery is damaged.
Check each cell for correct voltage (greater than
1.85 volts per cell).
Repair or replace battery.
• Incorrect controller adjustment.
Use dash display to check battery voltage.
• Incorrect battery installed in truck.

Code
16 BATTERY VOLTAGE HIGH Yes Traction
Description
The battery voltage is higher than the setting in the
controller.
Symptom
• Overcharged battery.
Check battery for correct open circuit voltage.
• Incorrect controller adjustment.
Use dash display to check battery voltage.
• Incorrect battery installed in truck.
31

Code
41 TRACTION CONTROL Yes Traction
TEMPERATURE HIGH
Description
High temperature in the traction controller power
section. Truck performance is progressively reduced
as temperature rises.
Symptom
Traction performance is reduced.
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, replace
controller.

Code
42 PUMP CONTROL TEMPERATURE Yes Hydraulic
HIGH
Description
Pump controller temperature is too high. Traction
performance is progressively reduced as
temperature increases.
Symptom
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, replace
controller.
32

Code
43L LEFT MOTOR TEMP OUT OF RANGE Yes Traction
Description
Left traction motor temperature is out of range.
Symptom
• Ensure all wiring connections are tight.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor tem-
perature.

Code
43R RIGHT MOTOR TEMP OUT Yes Traction
OF RANGE
Description
Right traction motor temperature is out of range.
Symptom
• Ensure all wiring connections are tight.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor tem-
perature.
33

Code
51 PRECHARGE Yes Traction
Description
Controller capacitor voltage does not increase at
startup.
Symptom
• Remove fuse FU3 and turn key to the ON position.
If problem remains, replace controller.
• Ensure towing jumper has been disconnected near
dash display.
• Ensure dash display is operating properly.
• Failed R1 resistor in the steering circuit.
• Check for brake driver continuous ON.
With the key in the ON position, check for voltage
between pins C28 and C29.
Replace controller.
• Failure of the controller logic card.
Replace controller.

Code
52L LEFT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed sensor.
Symptom
• Use dash diagnostics to check encoder operation.
• Check for 12-volt supply to encoder.
• Ensure wiring to the encoder is correct. See the
section Diagrams 8000 YRM 1081.
• Ensure all wiring connections between the encoder
and the traction motor are tight.
• Check continuity of the wiring from the controller to
the encoder.
• Replace traction motor end head.
34

Code
52R RIGHT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed sensor.
Symptom
• Use dash diagnostics to check encoder operation.
• Check for 12-volt supply to encoder.
• Ensure wiring to the encoder is correct. See the
section Diagrams 8000 YRM 1081.
• Ensure all wiring connections between the encoder
and the traction motor are tight.
• Check continuity of the wiring from the controller to
the encoder.
• Replace traction motor end head.
35

Code
62 REVERSE SIGNAL OUTPUT Yes Auxiliary
SHORTED
Description
Backup alarm driver is shorted. Overcurrent
protection has been activated.
Symptom
Backup alarm does not operate.
• Ensure all wiring is secure.
• Check wiring for shorts.
• Check for a shorted alarm.
• Replace dash display.
36

Code
65 MAIN CONTACTOR SHORTED Yes Traction
Description
The main contactor coil driver is shortened.
Symptom
• Check for shorted driver at the controller. Check for
short between terminal C26 and B .
• Check for shorted main contactor coil. Coil should
measure approximately 32 ohms.
• Failure of the controller logic card. Replace the
controller.
37

Code
66L LEFT TRACTION MOTOR SHORTED Yes Traction
Description
Left traction motor is shorted.
Symptom
• Disconnect all motor leads from the traction motor.
• Check line-to-line stator resistance. Resistance
should be 10.00 ±0.10 milliohms for 48-volt truck
and 6.10 ±0.10 milliohms for 36-volt truck.
• Replace traction motor if readings are not correct.
38

Code
66R RIGHT TRACTION MOTOR Yes Traction
SHORTED
Description
Right traction motor is shorted.
Symptom
• Disconnect all motor leads from the traction motor.
• Check line-to-line stator resistance. Resistance
should be 10.00 ±0.10 milliohms for 48-volt truck
and 6.10 ±0.10 milliohms for 36-volt truck.
• Replace traction motor if readings are not correct.
39

Code
90L LEFT TRACTION MOTOR Yes Traction
TEMP HIGH
Description
Left traction motor high temperature. Temperature
sensor in traction motor has indicated high
temperature.
Symptom
• Use dash display diagnostics to verify motor over-
temperature switch is activated.
Reduce truck operation until motor cools.
• If a fault is signaled with cold motor, check the
motor temperature sensor resistance. Resistance
should be 555 ohms to 607 ohms at 20 C (68 F).
• Check for broken or loose wires.

Code
90R RIGHT TRACTION MOTOR Yes Traction
TEMP HIGH
Description
Right traction motor high temperature. Temperature
sensor in traction motor has indicated high motor
temperature.
Symptom
Reduce truck operation until motor cools.
• If a fault is signaled with cold motors, check the
motor temperature sensor resistance. Resistance
should be 555 ohms to 607 ohms at 20 C (68 F).
• Check for broken or loose wires.
40

Code
91 PUMP MOTOR TEMPERATURE HIGH No Lift
Description
Pump motor temperature too high. Thermal switch
in pump motor has been activated.
Symptom
Display message.
• Reduce truck operation until motor cools.
• If fault is signaled with cold motor, use dash display
diagnostic to verify motor temperature.
Replace motor temperature sensor.
Replace dash display.
41

Code
95 PUMP MOTOR BRUSHES No Lift
Description
Pump motor brushes worn. Brush wear indicator
switch in pump motor has been activated.
Symptom
Dash display message.
• Replace pump motor brushes.
• Check wiring.
• If brushes are OK, replace dash display.

Code
99 MAINTENANCE REQUIRED No None
Description
Truck maintenance required.
Symptom
Dash display message. Flashing "wrench" icon.
• Truck requires scheduled maintenance.
• Perform required maintenance activity.
42

Code
145 PUMP M- FAULT Yes Hydraulic
Description
Power transistor did not turn on properly.
Symptom
No lift operation.
• Check wiring connections between the controller
and the pump motor.
• Check for open motor windings.
• Check for worn pump motor brushes.

Code
201 NO ARM REST SWITCH INPUT No Lift
Description
Arm rest switch not closed when requesting traction
or hoist functions.
Symptom
Lift does not operate.
• Ensure arm rest is in full down position.
Arm rest should be in the locked position.
• Use dash diagnostics to check operation of switch.
Check all wiring connections to switch.
Check switch adjustment. See the section Elec-
trical System 2200 YRM 1078 for adjustment
procedure.
43

Code
202 HYDRAULIC OIL LOW No Lift
Description
Hydraulic fluid is low.
Symptom
Dash display message. Flashing icon on display.
• Ensure forks are fully lowered, turn key to the ON
position.
• Check hydraulic fluid level.
Add fluid. See the section Periodic Mainte-
nance 8000 YRM 1079 for correct fluid.
• Check sensor for open condition.
Ensure all wiring connections are secure.
Replace sensor.
Replace dash display.
44

Code
203 BRAKE FLUID LOW No Brake
Description
Brake fluid is low.
Symptom
Dash display message. Flashing icon on display.
• Check brake master cylinder fluid level. Fill as
needed.
• Check for loose or broken wires.
CAUTION
Do not use DOT brake fluid! This truck uses hy-
draulic oil in the brake system. See the section
Capacities and Specifications 8000 YRM 1080.
• Check sensor.
Disconnect wiring connector.
Remove fill cap and sensor from reservoir.
Check resistance across the sensor pins.
Resistance is approximately 470 ohms when
float is fully raised.
Resistance is less than 10 ohms when the
float is fully lowered and the switch is closed.
45

Code
204 NO HOOD SWITCHES INPUT No Traction/Lift
Description
Hood switch or switches are open when requesting
traction or hydraulic functions.
Symptom
No traction or lift operation.
• Ensure all wiring connections are secure.
• Check wiring continuity between switches.
There are two switches wired in series.
Check for voltage at C5 with both switches
closed.
Check each switch for open condition while op-
erating the switch.
• Replace failed switch.
46

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

Code
208 PUMP REQUEST BEFORE KEY No Lift
Description
Incorrect pump motor starting sequence.
Symptom
Manual Valve
• Recycle key.
• Check for a closed hydraulic function switch at the
manual hydraulic control valve.
Check switch adjustment.
Switches should be open with the hydraulic func-
tion levers in the neutral position.
• Replace failed switch.
Electro-Hydraulic Valve
• Cycle key switch from OFF to ON.
• Check for function lever not in neutral. See the sec-
tion Electro-Hydraulic Control Valve 2000 YRM
1086.
• Replace failed function lever.
47

Code
209L BRAKE COIL OPEN No Brake
Description
Brake coil is open, disabling traction.
Symptom
No truck movement, or truck may pull to one side
when starting to accelerate.
• Electric brake will not release.
Recycle key switch.
• Check for voltage at the brake coil.
Should read approximately 36 volts.
• If no voltage, check wiring for loose connection or
broken wire.
• Check motor encoder. See Status Code 52.
• Check brake circuit diodes.
48

Code
209R BRAKE COIL OPEN No Brake
Description
Brake coil is open, disabling traction.
Symptom
No truck movement, or truck may pull to one side
when starting to accelerate.
• Electric brake will not release.
Recycle key switch.
• Check for voltage at the brake coil.
Should read approximately 36 volts.
• If no voltage, check wiring for loose connection or
broken wire.
• Check motor encoder. See Status Code 52.
• Check brake circuit diodes.
49

Code
210 WATCHDOG IN TRACTION Yes Traction
CONTROLLER
Description
The internal "watchdog" hardware circuit has been
triggered.
Symptom
• Check resistance between CANL and CANH wires
at the controller.
Resistance should be approximately 60 ohms.
• Replace the controller.

Code
213 UNDER/OVER VOLTAGE Yes Internal Controller
Description
The controller has detected an overvoltage or an
undervoltage condition within the controller.
Symptom
• Fault in the hardware section of the logic card.
• Replace the controller.
50

Code
214L LEFT MOTOR VOLTAGE LOW Yes Traction
Description
Incorrect voltage on one phase of the power circuit.
Symptom
• Check all wiring connections to motors and con-
troller. All connections should be tight.
• Ensure power wires are connected to correct termi-
nals. See the section Diagrams 8000 YRM 1081.
• Check for traction motor grounded to frame.
• Fault in the inverter section of the controller.
Replace the controller.

Code
214R RIGHT MOTOR VOLTAGE LOW Yes Traction
Description
Symptom
51

Code
215L LEFT MOTOR VOLTAGE HIGH Yes Traction
Description
Symptom

Code
215R RIGHT MOTOR VOLTAGE HIGH Yes Traction
Description
Symptom
52

Code
222 MAIN OR BRAKE COIL Yes Traction
OVERCURRENT
Description
The controller checks to ensure the main contactor
or brake coils are not shorted at start up.
Symptom
• Check for shorted main contactor coil. Coil should
measure approximately 32 ohms resistance across
the coil terminals.
• Check for shorted wiring.
• Failure of the controller logic card. Replace the
controller.
• Check for shorted brake coils. Coil should measure
32.5 ohms resistance across the coil leads.

Code
223 MAIN CONTACTOR WELDED Yes Traction
Description
The controller checks the main contactor tips
and ensures they are open before powering the
controller.
Symptom
• Check that the main contactor tips are not welded.
• Open contactor tips and replace if needed.
53

Code
224 MAIN CONTACTOR NOT CLOSED Yes Traction
Description
The controller checks to ensure the main contactor
closes after power has been supplied to the
contactor coil.
Symptom
• Ensure contactor is not stuck in open position.
• Open contactor coil. Check the contactor coil.
Coil should measure approximately 32 ohms re-
sistance.
• Check wiring from the controller to the contactor
coil. Check for continuity from C26 to coil. Check
for continuity from C27 to coil.
54

Code
226 BRAKE DRIVER OPEN OR Yes Traction
SHORTED
Description
Internal check of the parking brake driver in the
controller.
Symptom
• Disconnect connector C from controller.
Check for short between B and C28.
The brake coil resistance is approximately 31
ohms.
55

Code
227 THROTTLE VOLTAGE HIGH No Traction
Description
The traction controller is receiving a signal for
traction from the accelerator potentiometer without
the start switch being closed.
Symptom
• Accelerator potentiometer is out of adjustment.
Use dash display diagnostics to check operation
of the start switch.
Check for proper switch adjustment.
• Replace throttle sensor.

Code
228 PUMP CONTACTOR OPENED No Lift
Description
Lift contactor is not connected or coil is open.
Symptom
Lift does not operate on trucks equipped with
contactor lift.
• Ensure all wiring is secure.
• Check for continuity between C30 and contactor
coil.
• Check for continuity between C31 and contactor
coil.
• Check coil resistance. Resistance should measure
approximately 15 ohms.
• Replace contactor coil.
56

Code
238 TRACTION CONTROLLER FAULT Yes/No Traction
Description
Internal failure of the traction controller hardware.
Symptom
Lift truck will not operate.
• Recycle key from OFF to ON.
If fault repeats, replace controller.

Code
239 ALARM IN SLAVE Yes Internal Controller
Description
Master controller has detected a problem with the
slave controller.
Symptom
Lift truck does not operate.
• Internal failure of the traction controller. Replace
controller.
57

Code
240 ALARM IN MASTER Yes Internal Controller
Description
Slave controller has detected a problem with the
master controller.
Symptom
Lift truck does not operate.
controller.

Code
241 NO COMMUNICATION SLAVE Yes Internal Controller
TO MASTER
Description
Master controller is not receiving CAN messages
from the slave controller.
Symptom
controller.
58

Code
242 NO COMMUNICATION LEVER Yes Lift
TO MASTER
Description
from the electro-hydraulic lever console.
Symptom
• Ensure all wiring connections to the lever console
are secure.
• Check continuity of the CAN bus wires between the
dash display and the controller.
• Check for 12 volts between wire 74 and wire 130
at the lever console.
Check for 12 volts between B10 and B3 at the
valve driver module.
• Check for 60 ohms resistance between
CANH_OUT and CANL_OUT.
• Replace lever console.
59

Code
243 NO COMMUNICATION EV TO SLAVE Yes Lift
Description
Slave controller is not receiving CAN messages from
the electro-hydraulic valve driver module.
Symptom
• Ensure all wiring connections to the lever console
are secure.
• Check for 60 ohms resistance between
CANH_OUT and CANL_OUT.
• Replace the valve driver module.
EV = Electro-hydraulic valve driver module.

Code
244 DASH DISPLAY FAULT No Display
Description
Failure of the dash display memory.
Symptom
Dash display does not operate.
• Ensure battery is connected to the truck.
• Turn key to the ON position.
• Replace dash display.
60

Code
245 NO COMMUNICATION MASTER Yes Traction
TO DASH
Description
from the dash display.
Symptom
Lift truck does not move or moves very slowly.
• Check termination resistor. Should measure ap-
proximately 60 ohms between A7 and A22 at the
dash display.
61

Code
246 NO COMMUNICATION SLAVE Yes Traction
TO DASH
Description
Slave controller is not receiving CAN messages
from dash display.
Symptom
dash display.
62

Code
247 NO COMMUNICATION EV TO DASH Yes Lift
Description
Electro-hydraulic valve driver module is not receiving
CAN messages from the dash display.
Symptom
dash display and the valve driver module.
dash display.

Code
248 NO COMMUNICATION MASTER Yes Internal Controller
TO SLAVE
Description
Slave controller is not receiving CAN messages
from the master controller.
Symptom
• Reset key to the ON position.
• Replace controller.
63

Code
249 NO COMMUNICATION SLAVE TO EV Yes Internal Controller
Description
EV controller is not receiving CAN messages from
the slave controller.
Symptom
Truck will not operate.
• Reset key to the ON position.
• Replace controller.

Code
250L LEFT ROTOR LOCKED Yes Traction
Description
The controller is supplying current to the traction
motors while sensing one or both of the traction
motors is not turning.
Symptom
No truck movement while depressing the accelerator
pedal.
• Wheel is in a hole and the truck cannot move.
• Brake coil has not released the brake disk.
• Mechanical failure of one or both of the traction mo-
tors.
64

Code
250R RIGHT ROTOR LOCKED Yes Traction
Description
The controller is supplying current to the traction
motors while sensing one or both of the traction
motors is not turning.
Symptom
No truck movement while depressing the accelerator
pedal.
• Wheel is in a hole and the truck cannot move.
• Brake coil has not released the brake disk.
• Mechanical failure of one or both of the traction mo-
tors.

Code
260 PUMP MOTOR VOLTAGE LOW Yes Transistor Lift
Description
Incorrect voltage on pump motor.
Symptom
No lift operation.
• Wrong voltage battery installed in truck.
Ensure battery voltage matches voltage shown
on truck nameplate.
• Wrong voltage parameter selection.
Ensure parameter setting matches voltage
shown on truck nameplate.
Check parameter setting using the dash display.
65

Code
270 LIFT/LOWER LEVER ERROR Yes Electro-hydraulic
Description
Error in signal from the lift/lower lever assembly.
Symptom
No lift/lower operation.
• Check for 12 volts at pin 1 on the hydraulic lever
console.
Check for 12 volts at pin B10 on the valve driver
module.
Replace the valve driver module.
• Replace the lift/lower lever PC board.

Code
271 TILT LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the tilt lever.
Symptom
No mast tilt operation.
console.
module.
• Replace the tilt lever PC board.
66

Code
272 3RD FUNCTION LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the sideshift lever.
Symptom
No carriage sideshift operation.
console.
module.
• Replace the sideshift lever PC board.

Code
273 4TH FUNCTION LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the auxiliary lever.
Symptom
No operation of the auxiliary hydraulic function.
console.
module.
• Replace the auxiliary lever PC board.

Code
275 VALVE CONTROLLER FAULT Yes Electro-hydraulic
Description
Internal failure of the valve driver module.
Symptom
No operation of the electro-hydraulic functions.
• Recycle key switch from OFF to ON.
• Replace the valve driver module.
67

Code
276 LIFT/LOWER EV DRIVER SHORTED Yes Electro-hydraulic
Description
Lift/lower driver in the valve driver module is shorted.
Symptom
No lift/lower operation.
• Recycle key switch to clear fault.
• Disconnect connector from EV. Check wires for
shorts to B- or between wires.
• Check resistance of coils:
Resistance should read approximately 19 ohms
at 25 C (77 F).
• Replace valve driver module.
68

Code
277 4TH FUNCTION EV DRIVER Yes Electro-hydraulic
SHORTED
Description
Auxiliary driver in the valve driver module is shorted.
Symptom
No operation of the auxiliary hydraulic function.
at 25 C (77 F).
69

Code
279 TILT EV DRIVER SHORTED Yes Electro-hydraulic
Description
Tilt driver in the valve driver module is shorted.
Symptom
No tilt function operation.
at 25 C (77 F).
70

Code
280 3RD FUNCTION EV DRIVER Yes Electro-hydraulic
SHORTED
Description
The sideshift function driver in the valve driver
module is shorted.
Symptom
No sideshift function operation.
at 25 C (77 F).
71

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

This spare output is not used.
• Check the connector wiring.
• Replace EV if unable to clear fault.

EVP = Electro-hydraulic proportional valve driver.
72

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

at 25 C (77 F).
73

Code
283 SELECTOR EV COIL SHORTED Yes Electro-hydraulic
Description
One of the electro-hydraulic valve coils is shorted.
Symptom
One of the hydraulic functions will not operate.
at 25 C (77 F).
74

Code
289 EV CONTROLLER LOW VOLTAGE Yes Electro-hydraulic
Description
Voltage supply to the valve driver control module
is low.
Symptom
No operation of the electro-hydraulic functions.
• Check for battery voltage at pins B1 and B2 with
key switch closed.
• Check that all connections are secure.
75

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

Code
294 INTERLOCK SWITCH No Hydraulic
Description
Message is displayed when an interlocked hydraulic
function is requested without activating the interlock
switch.
Symptom
No operation of the requested interlocked hydraulic
function.
• Use the dash display diagnostics to turn off the
lever interlock parameter. If function now operates,
replace interlock switch.
76

Code
295 NO LO LIFT SWITCH INPUT Yes Hydraulics
Description
Message is displayed when the hi-lift switch is
closed and the lo-lift switch is open.
Symptom
Lift will only operate at low speed.
• Use dash display diagnostics to check for correct
operation of the lo-lift switch.
• Check switch for correct operation.
• Check for correct switch adjustment. See the sec-
tion Electrical System 2200 YRM 1078 for adjust-
ment procedure.
• Check wiring to switch for loose connections or bro-
ken wires.
77
CONTROLLER CONNECTOR PIN OUTS Table 6. Connector C (Continued)

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

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

Phase B
C1 83 Right Motor Encoder
Positive (+5V/+12V) C23 78 Left Motor Encoder
Phase A
C2 84 Right Motor Encoder B
C24 82 Right Motor Temp
C3 10 B+ from Key Switch Sensor B
C4 110 B+ to Switches C25 81 Right Motor Temp
C5 101 Seat Switch Input Sensor Input Signal
C6 6 Forward Switch Input C26 23 Main Contactor B
C7 8 Reverse Switch Input C27 24 Main Contactor B+
C8 15 Start Switch Input C28 50 Parking Brake Coil B
C9 92 Brake Pedal Switch C29 51 Parking Brake Coil B+

Input C30 88 Auxiliary B+
C10 94 Hydraulic Function Input C31 87 Auxiliary B
(Contactor Hydraulic
Only) C32 B
C11 75 Left Motor Encoder C33 28 Traction Potentiometer

Positive (+5V/+12V) Positive (+5V/+12V)
C12 76 Left Motor Encoder B C34 79 Left Traction Motor

Temp Sensor B
Phase B C35 80 Left Traction Motor Temp
Sensor Input Signal
Phase A
78
Table 7. Connector D - Standard Model Table 8. Connector D - Premium Model (Continued)

D1
D13
D2 113 High Speed Lift Switch
D14
Input
D3 98 Low Speed Lift Switch
VALVE DRIVER MODULE
Input
(ELECTRO-HYDRAULIC VALVE OPTION)
D4 114 Tilt Speed Prox Switch
Input Table 9. Connector B
D5 210 B+ for Hydraulic
Switches
B1 10-1 Key Switch Input B+
D6 97 4th Function Speed
Switch Input B2 10-1 Key Switch Input B+
D7 93 Sideshift Switch Input B3 130 Battery Negative
D8 95 Tilt Switch Input B4 CANL-2 CAN Low Input Signal
D9 B5 OPEN
D10 B6 OPEN
D11 B7 OPEN
D12 B8 OPEN
D13 B9 OPEN
D14 B10 74 12V Supply to Lever
Module
B11 OPEN
Table 8. Connector D - Premium Model
B12 OPEN
Pin Wire Number Function B13 CANH-2 CAN High Input Signal
D1 B14 OPEN
D2
D3 Table 10. Connector C
D4 114 Tilt Speed Prox Switch
Input Pin Wire Number Function
D5 210 B+ for Hydraulic C1 53 Negative for Lowering
Switches Proportional Valve
D6 C2 52 Positive for Lift and
Lower Proportional
D7
Valves
D8 54
C3 Negative for Lift
D9 Proportional Valve
D10 C4 56 Negative for Auxiliary IN
Proportional Valve
D11
D12
79
Table 10. Connector C (Continued) HYDRAULIC LEVER CONSOLE

(ELECTRO-HYDRAULIC OPTION
Pin Wire Number Function ONLY)
C5 55 Positive for Auxiliary Pin Wire Number Function
Proportional Values
1 74 12V Supply from Valve
C6 57 Negative for Auxiliary Driver Module
OUT Proportional Valve
2 CANH_OUT1 CAN bus High
C7 59 Negative for Tilt UP
Proportional Valve 3 130 Battery Negative
C8 58 Positive Voltage Supply 4 CANL_OUT1 CAN bus Low

for Tilt Proportional
Valves DASH DISPLAY
C9 65 Negative for Load Hold Pin Wire Number Function
Valve
A1 10-1B Key Switch Input B+
C10 67 Negative for Tilt Auxiliary
Selector Valve A2 110-1 Positive Supply to
Indicators
C11 OPEN
A3 130F Battery Negative B
C12 62 Negative for Sideshift
Right Proportional Valve A4 130G Battery Negative B
C13 61 Positive for Sideshift A5 107 Lift Motor Brush Wear

Right and Left Indicator Input
Proportional Valves A6 102 Negative for Pump Motor
C14 63 Negative for Sideshift Temp Sensor
Left Proportional Valve A7 CANL-1 CAN bus Low
C15 60 Negative for Tilt Down A8 OPEN
Proportional Valve
A9 90 Negative for Hydraulic
C16 64 Positive for Lift Hold Oil Lever Sensor
Valve
A10 91 Positive for Brake Fluid
C17 66 Positive for Tilt Auxiliary Level Switch
Selector Valve
A11 96 Negative for Auxiliary
C18 OPEN Switch
C19 OPEN A12 50G Parking Brake Coil Input
C20 OPEN A13 50F Parking Brake Coil Input
C21 OPEN A14 OPEN
C22 OPEN A15 OPEN
C23 130 Battery Negative A16 47B Steering Encoder Input
80
Pin Wire Number Function Pin Wire Number Function

A17 12A Battery Positive B+ A22 CANH-1 CAN bus High
A18 130P Battery negative B A23 OPEN
A19 OPEN
SYSTEM LOGIC DIAGRAMS
A20 26 Positive for Reverse
Alarm The system logic diagrams for the economy, standard,
A21 OPEN and premium truck models may be able to assist in trou-
bleshooting. See Figure 18, Figure 19, and Figure 20.
Figure 18. Logic Diagram - Economy
81
Figure 19. Logic Diagram - Standard
82
Figure 20. Logic Diagram - Premium
83
NOTES
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84
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 1087 2/05 Printed in U.S.A.

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2200YRM1087

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Maintenance

PART NO. 524204504 2200 YRM 1087

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

• Wear safety glasses.

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2005 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

ERP1.6-1.8-2.0ATF (ERP030-040TH) [F807]

The AC motors also have thermal sensors, continuously

Procedures are outlined for controller safety, adjust-

the controller. One microprocessor is designated the

The controller contains two separate DC to AC inverters

The controller software provides self diagnostics which

The self diagnostics monitor the traction motor, brake

Principles of Operation 1. LH TRACTION MOTOR

The controller may also be equipped with an optional

DISCHARGING THE CAPACITORS

Legend for Figure 6

Figure 6. Discharging the Capacitors - Standard

AC Motor Controller Repair

MOTOR CONTROLLER, REPLACE

Controller Checks and Adjustments

Function Parameter Descriptions

Top Speed Forward Acceleration

Any increase in performance will decrease the battery Pump Acceleration

(Scale 0-9) Low Lift Speed

3rd Function Battery Voltage

Figure 7. Standard and Premium Display Panel

Display Functions and Features

1. HOURMETER INDICATOR 8. LCD SCREEN

Figure 8. Dash Display

Figure 11. Password Prompt Screen

Until a password is entered that agrees with a password

A few seconds after the correct password has been en-

Figure 9. Battery Discharge Indicator

When the key is turned to the OFF position, the Hour-

Figure 12. Display Screen (Premium Display)

LIFT TRUCK INSPECTION FUNCTION

Pump Motor Current 4th Function Speed

STATUS CODE LIST

Dash Display Service Menu Navigation

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

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

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

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

Table 4. List of Status Codes

Status Code Description Status Code Description

Table 4. List of Status Codes (Continued)

Status Code Description Status Code Description

Table 4. List of Status Codes (Continued)

Status Code Description Status Code Description

Status Premium Display Message Memory Recall Circuit

Status Premium Display Message Memory Recall Circuit

Status Premium Display Message Memory Recall Circuit

Status Premium Display Message Memory Recall Circuit

Status Premium Display Message Memory Recall Circuit