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 (CANbus)............................................................................................................... 3
Discharging the Capacitors ............................................................................................................................... 3
AC Motor Controller Repair ................................................................................................................................... 4
General ............................................................................................................................................................. 4
Special Precautions ...................................................................................................................................... 4
Thermal Sensors............................................................................................................................................... 5
Motor Controller, Replace ................................................................................................................................. 5
Controller Checks and Adjustments ...................................................................................................................... 5
Function Parameters ............................................................................................................................................. 6
General ............................................................................................................................................................. 6
Function Parameter Descriptions .......................................................................................................................... 7
Parameters........................................................................................................................................................ 7
Top Speed Forward....................................................................................................................................... 7
Top Speed Reverse....................................................................................................................................... 7
Acceleration .................................................................................................................................................. 7
Regen Braking .............................................................................................................................................. 7
Auto Deceleration ......................................................................................................................................... 7
Extended Shift .............................................................................................................................................. 7
Pump Acceleration........................................................................................................................................ 8
Tilt/Auxiliary Pump Acceleration ................................................................................................................... 8
Low Lift Speed .............................................................................................................................................. 8
Maximum Lift Speed ..................................................................................................................................... 8
Maximum Lowering Speed ........................................................................................................................... 8
Tilt Speed...................................................................................................................................................... 8
3rd Function .................................................................................................................................................. 8
3rd Function Speed ...................................................................................................................................... 8
4th Function .................................................................................................................................................. 8
4th Function Speed....................................................................................................................................... 9
Battery Voltage ............................................................................................................................................. 9
Lift Interrupt................................................................................................................................................... 9
BDI Adjustment (Early Models)..................................................................................................................... 9
BDI Adjustment (Later Models)..................................................................................................................... 9
BDI Decrement Time .................................................................................................................................... 9
Service Reminder ....................................................................................................................................... 10
Custom ....................................................................................................................................................... 10
Restore Defaults ......................................................................................................................................... 10
Calibration Parameters ........................................................................................................................................ 10
Throttle Calibration.......................................................................................................................................... 10
Steering Calibration......................................................................................................................................... 10
Display Panel....................................................................................................................................................... 10
General ........................................................................................................................................................... 10
Premium Display Panel............................................................................................................................... 10
Standard Display Panel............................................................................................................................... 10
Display Functions and Features .......................................................................................................................... 11

©2005 Yale Materials Handling Corp. i

Table of Contents AC Motor Controllers/Display Panel

TABLE OF CONTENTS (Continued)

Key-On Initialization ........................................................................................................................................ 11
Standard Display ............................................................................................................................................. 11
Premium Display ............................................................................................................................................. 13
Lift Truck Inspection Function.......................................................................................................................... 13
Access to Service Functions ........................................................................................................................... 14
Service Functions ........................................................................................................................................... 14
Performance Modes ........................................................................................................................................ 15
Battery Discharge Indication (BDI).................................................................................................................. 16
Hourmeter ....................................................................................................................................................... 16
Status Code List.............................................................................................................................................. 16
Dash Display Service Menu Navigation .............................................................................................................. 17
General ........................................................................................................................................................... 17
Moving Through Menu Selections................................................................................................................... 17
Editing and Adding Information ....................................................................................................................... 17
ETACC Test ......................................................................................................................................................... 18
Manual Hydraulics:.......................................................................................................................................... 18
Electro-Hydraulics: .......................................................................................................................................... 18
Troubleshooting ................................................................................................................................................... 18
General ........................................................................................................................................................... 18
Status Codes................................................................................................................................................... 19
Controller Connector Pin Outs ...................................................................................................................... 108
Valve Driver Module (Electro-Hydraulic Valve Option) .................................................................................. 109
Hydraulic Lever Console (Electro-Hydraulic Option Only)............................................................................. 110
Dash Display ................................................................................................................................................. 110
System Logic Diagrams ................................................................................................................................ 111

This section is for the following models:

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

ii
2200 YRM 1087 Description

Description
GENERAL Throughout this section, forward will refer to travel in the
direction of the forks and left and right are determined
This section describes the ZAPI™ AC motor controller. by an operator sitting in the seat facing forward. See
See Figure 1. Procedures are outlined for controller Figure 2.
safety, adjustments, troubleshooting, and repair. This
section does not contain information about other elec- DESCRIPTION
trical components. See the section Electrical System
2200 YRM 1078 and the section Electro-Hydraulic AC Motors
Control Valve 2000 YRM 1086.
The AC motors are three-phase AC induction motors.
They do not include motor brushes or commutators.
An AC induction motor operates on three-phase AC
power provided directly by the motor controller. The
motor speed is controlled by the controller and can be
changed by the frequency of the AC power presented
to the motor. A speed sensor has been built into the
rear motor bearing, which provides feedback to the mo-
tor controller, allowing software to continually monitor
motor direction and revolutions per minute (RPMs). Us-
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.

ZAPI™ AC Motor Controller

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

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

troller utilizing MOSFET technology with microproces-
sor control. The basic dual motor control is capable of
controlling two asynchronous AC induction motors si-
multaneously. The controller has direct control of the
traction system, main contactor, and the electromag-
netic parking brakes.

A. LEFT SIDE C. FORWARD

B. RIGHT SIDE TRAVEL

Figure 2. Truck Orientation

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 (CANbus)
The motor controller and the dash display are con-
nected together with a CANbus communication sys-
tem. 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 CANbus network. A PC
with the appropriate service software can easily com-
municate with all system nodes by simply connecting
to the CANbus. 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 CANbus • Check the hourmeter readings on the traction circuit
via a connector on the main wiring harness near the bot- and hydraulic pump controllers.
tom (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 (Continued)

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
ister is called a parameter. A parameter is a measure- Traction
36V 48V
ment number that defines a lift truck function. A specific
function parameter works with other function parame- BDI Adjustment 35 35
ters to control the operation of the lift truck. Lift Interrupt 1 1
Service Reminder 0 0
WARNING
The parameter for each function has a value range Custom 0 0
so the motor controller can be used on different
models of lift trucks. This variation is needed for Table 2. Transistor Lift With Manual
lift trucks of different sizes and operating voltages. Valve Parameters
Adjustment of a function to the wrong number value
for your lift truck model can cause the truck to oper- Control Settings
ate differently than normal. This different operation
Transistor Lift With Factory Defaults
of the truck can cause an injury.
Manual Valve 36V 48V
NOTE: Table 1, Table 2, and Table 3 show the default
parameter setting for each control function that is ad- Pump Acceleration 1 1
justable by the user. The factory-set default parameters Max Lift Speed 100 100
are the recommended settings for new units. These set-
tings will give satisfactory performance for most appli- Low Lift Speed 40 30
cations. Tilt Speed 58 40

Some functions can be adjusted within the permitted 3rd Function Speed 33 25
range to change the lift truck operation for a specific ap- 4th Function Speed 85 85
plication. Adjustment of a register to a number that is
different than the factory settings is allowed, but follow
Table 3. Transistor Lift With Electro-Hydraulic
the instructions carefully. Adjustments other than the
Valve Parameters
factory settings will cause the lift truck to operate differ-
ently and can cause increased wear of parts.
Control Settings
Table 1. Traction Parameters Factory Defaults
Transistor Lift With
Electro-Hydraulic Valve 36V 48V
Control Settings
Factory Defaults Pump Acceleration 1 1
Traction
36V 48V Max Lift Speed 100 100

Battery Voltage 36 48 Max Lowering Speed 75 75

Extended Shift ON ON Tilt Speed 33 25

Acceleration 5 5 3rd Function Max Speed 33 25

Top Speed Max FWD 128 Hz 140 Hz 4th Function Max Speed 85 85

Top Speed Max REV 128 Hz 140 Hz 3rd Function 0 0

Regen Braking 7 7 4th Function 3 3

Auto Deceleration 6 6 Tilt/Auxiliary Pump 4 4

Acceleration

6
2200 YRM 1087 Function Parameter Descriptions

Function Parameter Descriptions

PARAMETERS Acceleration
(Range 0-9)
WARNING
If any of the parameter values are changed, the op- This parameter setting determines the truck accelera-
erators must be told that the lift truck will operate tion rate. The truck will accelerate at this rate regard-
differently. less of the load on the forks, provided that the motor
and control can deliver the required power.
WARNING To increase the acceleration rate above the factory set-
NEVER adjust any of the following parameters with- ting, the extended shift parameter will need to be dis-
out using the procedures and settings given in this abled.
section.
To reduce the acceleration rate below the factory set-
The following section contains descriptions for the dif- ting, the extended shift parameter may be enabled or
ferent parameters. Access these parameters through disabled.
the SETUP menu in the dash display or with the PC
software. Any increase in performance will decrease the battery
shift life.
Top Speed Forward
Regen Braking
(Range 10-140 Hz)
(Range 0-9)
This parameter setting determines the top speed of the
truck in the forward direction. This parameter setting determines the maximum de-
celeration rate when the accelerator pedal is fully de-
To increase the top speed above the factory setting, the pressed during regen braking.
extended shift parameter will need to be disabled.
NOTE: The deceleration rate is less when the pedal is
To reduce the top speed below the factory setting, not fully depressed.
the extended shift parameter may be enabled or
disabled. Auto Deceleration
For speed limits slower than the normal truck (Range 0-9)
speed, the top speed is the same regardless of
the load on the forks. Acceleration rates are also This parameter setting determines the maximum de-
unaffected by lowering the top speed. celeration rate when the accelerator pedal is released.
The strength of auto deceleration is a percentage of the
Top Speed Reverse regen braking strength.

(Range 10-140 Hz) A setting of zero will turn off auto deceleration com-
pletely and a setting of nine will give auto deceleration
This parameter setting determines the top speed of the the same strength as regen braking.
truck in the reverse direction.
Extended Shift
To increase the top speed above the factory setting, the
extended shift parameter will need to be disabled. (0 or 1)
(0 = Disable; 1 = Enable)
To reduce the top speed below the factory setting,
the extended shift parameter may be enabled or This parameter setting enables or disables a preset
disabled. motor performance program in the traction motor con-
troller.
For speed limits slower than the normal truck
speed, the top speed is the same regardless of When enabled, this function provides a balance be-
the load on the forks. Acceleration rates are also tween truck performance and battery shift life that will
unaffected by lowering the top speed.

7
Function Parameter Descriptions 2200 YRM 1087

meet the requirements of most applications. Truck ac- Maximum Lowering Speed
celeration and top speed will vary with the amount of
load on the forks. (Range 0-100%)

When disabled, truck acceleration and top speed are This parameter setting determines the hydraulic pump
determined by values set in the acceleration and top motor speed during lowering. Increasing the setting will
speed parameters. increase lowering speed.

If the motor and controller can deliver the power, then Tilt Speed
the truck performance will not vary with the amount of
load on the forks or the battery state of charge. (Range 36V = 20-66%)
(Range 48V = 15-50%)
Grade climbing speed will also improve because
the motor controller will deliver maximum current. This parameter setting is used to set the hydraulic motor
Any increase in performance will decrease the bat- speed when the tilt function is selected. Increasing the
tery shift life. setting will increase the speed of the hydraulic pump
motor.
Pump Acceleration
3rd Function
(Range 0-9)
(Range 0, 1, or 2)
This parameter setting determines the hydraulic pump (0 = 3rd Function Without Interlock)
motor acceleration rate. Increasing the setting will in- (1 = 3rd Function With Interlock)
crease the speed of the motor. (2 = 3rd Function With Push/Pull)

Tilt/Auxiliary Pump Acceleration This parameter is used to select the operation of the
3rd function mini-lever or joystick roller switch. Use
(Range 0-9) selection 0 when using the 3rd function to control a
non-clamping type attachment. Use selection 1 when
This parameter setting determines the hydraulic pump using the 3rd function to control a clamping type attach-
motor acceleration rate when using the tilt or auxiliary ment. Use selection 2 when using the 3rd function to
functions with the electro-hydraulic valve option. control a push/pull attachment.

Low Lift Speed 3rd Function Speed

(Range 36V = 25-65%) (Range 36V = 20-100%)
(Range 48V = 20-50%) (Range 48V = 15-75%)
This parameter setting determines the hydraulic pump This parameter setting is used to set the hydraulic pump
motor low speed. This is used with transistor lift and motor speed when the 3rd function hydraulic lever is
the manual control valve. Increasing the setting will in- actuated. Increasing the setting increases the speed of
crease the speed of the hydraulic pump motor. the hydraulic pump motor.

Maximum Lift Speed 4th Function

(Range 0-100%) (Range 0, 1, 2, or 3)
(0 = 4th Function Without Interlock)
This parameter setting determines the hydraulic pump
(1 = 4th Function With Interlock)
motor high speed. High speed is used for maximum lift
(2 = 4th Function With Push/Pull)
speed.
(3 = Default - No 4th Function)

8
2200 YRM 1087 Function Parameter Descriptions

This parameter is used to select the operation of the batteries. Further adjustments may be used to fine
4th function mini-lever or joystick roller switch. Use tune the BDI accuracy.
selection 0 when using the 4th function to control a
non-clamping type attachment. Use selection 1 when BDI Adjustment (Later Models)
using the 4th function to control a clamping type attach-
ment. Use selection 2 when using the 4th function to (Range - First Digit 1-5)
control a push/pull attachment. (Range - Second Digit 3-7)

This parameter setting allows for adjustment to improve

4th Function Speed
the accuracy of the battery discharge indicator in the
(Range 36V = 0-100%) dash display.
(Range 48V = 0-100%)
This first digit adjusts the charged setting. Increasing
This parameter setting is used to set the hydraulic pump the setting will increase the battery voltage or specific
motor speed when the 4th function hydraulic lever is gravity required for the indicator to show full. If the indi-
actuated. Increasing the setting increases the speed cator consistently reads low with fully charged batteries,
of the hydraulic pump motor. decrease this setting.

The second digit adjusts the discharged setting. In-

Battery Voltage
creasing the setting will increase the battery voltage or
(36V or 48V) specific gravity level required for the indicator to show
empty. If the indicator consistently shows lift interrupt
This parameter setting is used to inform the master con- too soon, decrease this setting.
troller what voltage battery is installed in the truck. The
battery choices are 36V or 48V. A setting of 35 is the recommended starting point for
flooded batteries. A setting of 37 is the recommended
Lift Interrupt starting point for maintenance-free batteries. Further
adjustments may be used to fine-tune the BDI accuracy.
(0 or 1)
(0 = Disable; 1 = Enable) BDI Decrement Time
This parameter setting enables or disables the lift in- This adjustment is used to compensate for duty cycles
terrupt feature. The lift interrupt feature stops lift oper- that involve nonstop operation where frequent pauses
ation when the battery discharge indicator (BDI) reads of more than 5 seconds do not occur (no drive, no hy-
empty to protect the battery from excessive discharge draulic use). When the truck is finally stopped, turned
and possible damage. OFF, and then restarted, some deviation in the BDI
reading may occur. One of three things may happen
NOTE: Trucks are shipped from the factory with this fea- to the BDI reading when the truck is restarted:
ture enabled. 1. The BDI gage still reads within plus or minus one
bar as it did when the truck was turned OFF. No
BDI Adjustment (Early Models) adjustment is needed.
(Range - Single Digit 0-9) 2. If the BDI gage changed downward more than one
bar, this parameter should be set to a lower num-
This parameter setting allows for adjustment to improve ber.
the accuracy of the battery discharge indicator in the 3. If the BDI gage changed upward more than one bar,
dash display. Increasing the setting will increase the this parameter should be set to a higher number.
battery voltage or specific gravity when the gage shows
empty. This adjustment has little or no effect on the BDI accu-
racy when the truck is used in intermittent duty cycles
A setting of 2 is the recommended starting point that have frequent pauses in truck activity for greater
for flooded cell batteries. A setting of 7 is the than 5 seconds each time.
recommended starting point for maintenance-free

9
Display Panel 2200 YRM 1087

Service Reminder Custom

(Set Next Hourmeter) (Range 0-100)

This can be used by the service technician to show a This parameter setting is not used except for special
Status Code 99 when the truck is due for service. functions required for special applications. Normally it
is set to zero.
To use this feature, set this function to the hourmeter
reading at which the service is to occur. When that Restore Defaults
hourmeter is reached, the dash display will display Sta-
tus Code 99 for 10 seconds each time the key is turned This function is used to restore all parameter settings
ON. After 20 hours of operation, the truck will slow to to the factory default settings shown in Table 1, Table 2,
half speed and the code will display continuously un- and Table 3.
til the service is performed. After servicing, adjust the
service reminder parameter to the next desired service
time.

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 access to the User Check List function.

There are two dash display options, Standard and Pre- Standard Display Panel
mium. Both displays look identical. See Figure 7.
• Allows preassigned service passwords to control ac-
Premium Display Panel cess to the service functions available through the
display.
• Allows preassigned user passwords to control driver • Provides the same comprehensive set of service
access to the vehicle. functions using the mode buttons and LCD as the
• Provides four driving modes that are accessed Premium Display.
through the key pad.
• Allows preassigned service passwords to control ac- Standard and Premium display panels are interchange-
cess to the service functions available through the able on the vehicle. Therefore, the display system can
display. be easily upgraded or downgraded by changing the dis-
• Provides a comprehensive set of service functions, play panel.
which are accessed through the mode buttons and
liquid crystal display (LCD).

10
2200 YRM 1087 Display Functions and Features

Figure 7. Standard and Premium Display Panel

Display Functions and Features

KEY-ON INITIALIZATION STANDARD DISPLAY
Upon turning the key to the ON position, the display se- Following the sequence given above, and as the seat
quentially lights the indicators, from left to right, located belt light becomes illuminated, the LCD displays the BDI
along the top of the display. See Figure 8. as a bar. See Figure 9. As the battery is discharged,
the bar becomes shorter.
NOTE: The seat belt light will stay on whether the seat
belt is fastened or not fastened. When the key is turned to the OFF position, the Hour-
glass indicator becomes illuminated, and the following
The indicator lights turn off sequentially, except for the hourmeter information is flashed on the LCD screen:
seat belt light, which will remain lighted for approxi- Traction Hours for 3-4 seconds, followed by Pump
mately 10 seconds. Hours for 3-4 seconds, after which the display turns off
and appears black. See Figure 10.

11
Display Functions and Features 2200 YRM 1087

1. HOURMETER INDICATOR 8. LCD SCREEN

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

Figure 8. Dash Display

Legend for Figure 9
1. 4 SEGMENTS ADJACENT TO RED
2. 4 SEGMENTS ADJACENT TO ORANGE
3. 12 SEGMENTS ADJACENT TO GREEN
4. BDI SHOWS APPROXIMATELY 65-70% CHARGE

Figure 9. Battery Discharge Indicator

12
2200 YRM 1087 Display Functions and Features

Figure 12. Display Screen (Premium Display)

LIFT TRUCK INSPECTION FUNCTION

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

Figure 13. Inspection Failure Screen

The inspection feature can be enabled with or without

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

13
Display Functions and Features 2200 YRM 1087

ACCESS TO SERVICE FUNCTIONS SERVICE FUNCTIONS

All service functions are accessible from either Stan- The following submenu functions are accessible from
dard or Premium displays. The following functions are the main menu of service functions, described above.
the same with either display version, except as noted in This includes the following vehicle setup values and
the following sections. control function settings. The control function settings
are discussed further in Function Parameter Descrip-
Once the vehicle is turned ON with the key switch and tions.
the initialization process has been completed, a service
technician can gain access to the service functions by • View Hourmeter
pressing the star button (*) twice within 3 seconds. Secure Hourmeter
Set Pump Hours
NOTE: It is suggested that the factory set password, Set Traction Hours
55555, be changed prior to the lift truck being placed • Software Version
into service. 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
Pump Motor Current
The technician can scroll through the menu using the No Run Diagnostics
up [1] or down [2] arrows and select the desired function Hood Switch
by pressing the [4] button. Each menu selection has a Seat Belt Switch
list of submenu functions. The submenus are viewed Seat Switch
and items selected by scrolling through the menu in the Forward Switch
same manner as described above. Reverse Switch
Accelerator Start
To exit a selected function and return to the previous
Brake Switch
function, press the [3] button. Pressing the [3] button
Brake Fluid Level
multiple times will return the technician to the operator’s
Hydraulic Oil Level
driving mode.
Pump Motor Brushes
Pump Motor Temp
Throttle Pot Volt

14
2200 YRM 1087 Display Functions and Features

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
4th Function Speed Mode 4 is the highest level of performance available to
Electro-Hydraulic the operator, regardless of the performance setup in
4th Function Installed the control. For instance, if the control is configured
Lift Pump Accel to limit top speed less than maximum, then Mode 4 top
Tilt/Aux Pump Accel speed is equal to the top speed set in the control. Three
Max Lift Speed lower performance modes are available to the operator
Lowering Max Speed by using the buttons on the display. These lower perfor-
Tilt Max Speed mance settings are percentages of the highest perfor-
3rd Function Max Speed mance available in Mode 4 as described below:
4th Function Max Speed • Mode 4 - This is the highest performance mode.
3rd Function Other modes are a lower percentage of Mode 4.
4th Function • Mode 3 - Top speed is the same as Mode 4. Acceler-
Manual ation is 80 percent of Mode 4.
No Parameters Will Display

15
Display Functions and Features 2200 YRM 1087

• Mode 2 - Top speed is 80 percent of Mode 4. Accel- When lift interrupt is initiated, it will remain in effect un-
eration is 70 percent of Mode 4. til the battery is disconnected and a recharged battery
• Mode 1 - Top speed is 60 percent of Mode 4. Accel- is reconnected to the lift truck. In order to reset the
eration is 60 percent of Mode 4. BDI function and allow lift truck operation, the recharged
battery must have a state of charge that is 20 percent
BATTERY DISCHARGE INDICATION (BDI) above the open cell voltage BDI setting.

The AC control system includes a Battery Discharge Two BDI adjustment features are provided via the con-
Indicator (BDI) that provides indication of the battery trol setup function, which is accessible via the dash dis-
state of charge. See Figure 15. The BDI feature is play (service password required) or with the PC service
displayed to the operator on the dash display with a software.
20-segment bar that looks and functions the same as
the current BDI. Lift truck operators will not need to learn HOURMETER
a new BDI system.
There are three different hourmeter functions.
The BDI provides full functionality when used with a full 1. Pump hours - accumulates time only when the
range of batteries including: pump motor is operating.
• Flooded cell, standard amp-hour batteries 2. Traction hours - accumulates time when the seat
• Flooded cell, high amp-hour capacity batteries switch is closed and the key switch is in the ON
• Valve regulated (absorbed glass mat) maintenance- position.
free batteries (VRLA) 3. Secure hours - based on traction hours. The secure
hours cannot be manually reset. However, secure
hours will be automatically reset to zero if both the
controller and the dash display are replaced at the
same time.

The hourmeter data is stored in the master controller

during every 6 minutes of operation. If there is a loss of
power, data is not lost.

STATUS CODE LIST

1. 4 SEGMENTS ADJACENT TO RED
2. 4 SEGMENTS ADJACENT TO ORANGE The status code list is a stored history of selected status
3. 12 SEGMENTS ADJACENT TO GREEN codes for malfunctions or incorrect truck use that have
4. BDI SHOWS APPROXIMATELY 65-70% CHARGE
occurred since the list was last cleared of entries by a
Figure 15. Battery Discharge Indication in Dash technician. These selected status codes are NOT a list
Display LCD Window of malfunctions or symptoms that are currently present,
but a list of those that have occurred in the past. The
The lift interrupt feature is controlled by the vehicle mas- list can only be read with the key in the OFF position.
ter controller and prevents the lift function when the bat-
tery is 80 percent discharged. Although lift interrupt pre- To access the status code list, wait until after the traction
vents lifting, low speed functions, such as tilt, remain and pump hours have been displayed, then push the
operational to allow the operator to more easily remove STAR button. All of the status codes in the list will then
the forks from the load and return to the battery charg- be shown in sequence. After the last status code, END
ing area. FAULT CODE HISTORY will be shown.

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

ETACC Test
If you have access to the ETACC software, the following ELECTRO-HYDRAULICS:
tests may be conducted.
Connect dongle between the truck and your pc. Turn
MANUAL HYDRAULICS: on the truck, select the proper truck configuration, and
click the connect button. Ensure the "connected" icon
Connect dongle between the truck and your pc. Turn is showing.
on the truck, select the proper truck configuration, and • If the red LED on the IFAK dongle is flashing, discon-
click the connect button. Ensure the "connected" icon nect the 6 pin connector and the joystick.
is showing. If LED stops flashing, the ILM controller may be
• If the red LED on the IFAK dongle is flashing, discon- defective.
nect the dash display connector. If LED continues to flash, go to next step.
If the LED stops flashing, the dash display may be • Disconnect the dash display connector and connector
defective. B at the traction controller.
If the LED continues to flash, go to the next step. If LED stops flashing, the traction controller may be
• Reconnect the dash display connector and discon- defective.
nect connector A from the traction controller. If LED continues to flash, go to next step.
If the LED stops flashing, the traction controller • Reconnect the dash display and connector B.
may be defective. If LED stops flashing, the controller may be defec-
If the LED continues to flash, the wiring harness tive.
may be defective. If LED continues to flash, the wiring harness may
be defective.

Troubleshooting
GENERAL allow the insertion of a small flat blade screwdriver
into the connector. After inserting the screwdriver
The AC motor and master controllers are sealed units into the connector attach probes with alligator clips
with no serviceable components. Troubleshooting is to the shank of the screwdriver to obtain readings.
usually limited to accessing status codes and follow- An additional method would be to use a breakout
ing the diagnostic procedures listed in the Status Code kit Yale P/N 580002086.
Charts.
See Diagrams 8000 YRM 1081 for additional wiring de-
Use standard testing procedures to verify inputs and tails.
outputs when necessary.
If the lift truck does not operate correctly, a status code
is displayed on the display panel.
CAUTION
Never attempt to probe through the back of the con- Once the status code number is obtained, follow the
nector plugs of the motor controller. These plugs procedures outlined in the Status Code Charts of this
are special sealed plugs. Probing through the back manual to determine the problem.
of the plugs will destroy the seal and can cause a
short circuit. If a circuit must be tested for voltage, NOTE: Due to the interaction of the master controller
check for voltage at an amp-type plug, a switch, or a with all lift truck functions, almost any status code or
component. If a circuit is suspect, check the circuit controller fault could be caused by an internal failure of
for continuity by disconnecting the P plug and test- the master controller. After all other status code proce-
ing continuity from the front (pin end) of the plug. dures have been followed and no problem is found, the
master controller should be replaced as the last option
Standard probes are too large to be inserted into the to correct the problem.
center of the female pins (sockets) of the special
sealed plugs and can expand the pins. Expanded Tools and test equipment required are: clip leads, volt
pins will not provide good connections once the ohmmeter (20,000 ohms per volt), and basic hand tools.
plug is reconnected. The connectors are shaped to

18
2200 YRM 1087 Troubleshooting

Check resistance on RX1000 scale from frame to indicate this code number on the LCD screen of the
power and controller terminals. Resistance of less than display panel.
20,000 ohms can cause misleading symptoms. Resis-
tance of less than 1000 ohms should be corrected first. The master and motor controllers sense the following
types of malfunctions:
Before proceeding, visually check for loose wiring, mis- • Input voltages that are too high or too low
aligned linkage to the accelerator switch, signs of over- • Input voltages in the wrong sequence or
heating of components, etc. • Correct input voltages that occur at the wrong time

STATUS CODES NOTE: A status code indication does not always mean
that there is a malfunction. A temporary operating con-
NOTE: Make sure the parameter values are correct for dition can cause a status code display.
your lift truck to ensure the trouble is not just an incor-
rect setting. See Function Parameters to set the correct These code numbers are only codes to help identify a
parameter values. If there is no status code display and possible malfunction. A short description of the different
the lift truck does not operate correctly, there can be a status codes is shown in Table 4.
fault in the master controller.
The Status Code Charts in this section have a more
The status codes are code numbers for malfunctions complete description of the status code, the circuit that
or lift truck operations that are not correct and that the has generated the input for the status code, the symp-
motor controller can sense. The master controller will tom, and the possible causes.

Table 4. List of Status Codes

Status Description
Code
01 Request traction or hydraulic function while seat switch open.
02 Forward switches closed at key on.
03 Reverse switches closed at key on.
05 Start switch not closed when seat switch is closed and either the forward or reverse directional switch
is closed and accelerator voltage shows demand for traction.
06 Request traction function while forward and reverse switches are opened.
07 Accelerator input voltage too high on power up.
08 Accelerator input voltage too low on power up.
09 Forward and reverse direction requested together.
11 Start switch closed before key or seat switch.
12 Steer sensor feedback voltage too low.
13 Steer sensor feedback voltage too high.
14 After steer calibration, controller senses "max right" parameter to be less than "max left" parameter.
15 Battery voltage lower than the setting in controller.
16 Battery voltage higher than the setting in controller.
41 High temperature in master or slave or both power sections, performance is progressively reduced
as temperature rises.
42 Pump control temperature too high.
43L Left traction motor temperature out of range.

19
Troubleshooting 2200 YRM 1087

Table 4. List of Status Codes (Continued)

Status Description
Code
43R Right traction motor temperature out of range.
51 Capacitor voltage too low.
52L Failure in encoder, in encoder to controller connection, or in controller input circuit, left motor.
52R Failure in encoder, in encoder to controller connection, or in controller input circuit, right motor.
62 Backup alarm driver shorted. Overcurrent protection activated.
65 Main line contactor coil driver shorted.
66L Left traction motor shorted.
66R Right traction motor shorted.
90L Left traction motor high temperature.
90R Right traction motor high temperature.
91 Pump motor high temperature.
95 Pump motor brushes worn.
99 Maintenance required.
142 Controller senses no pump current.
143 Controller senses low pump current.
145 Power transistor did not turn on properly.
201 Request hydraulic or traction function while arm rest switch not closed.
202 Hydraulic oil low.
203 Brake fluid low.
204 Request traction or hydraulic function while hood switch/switches not closed.
207 Lift cutout.
208 Pump incorrect start.
209L Brake coil open, disabling traction.
209R Brake coil open, disabling traction.
210 Internal "watchdog" hardware circuit triggered.
212L Problem with UVW voltage feedback in slave controller.
212R Problem with UVW voltage feedback in master controller.
213 The controller has detected an overvoltage or an undervoltage condition within the controller.
214L Wrong voltage on one phase --> failure in power section (high leg), driver circuit, or motor in slave
controller.
214R Wrong voltage on one phase --> failure in power section (high leg), driver circuit, or motor in master
controller.
215L Wrong voltage on one phase --> failure in power section (low leg), driver circuit, or motor in slave
controller.

20
2200 YRM 1087 Troubleshooting

Table 4. List of Status Codes (Continued)

Status Description
Code
215R Wrong voltage on one phase --> failure in power section (low leg), driver circuit, or motor in master
controller.
222 Controller checks to ensure main contactor coil or brake coil is not shorted at start up.
223 Controller checks main contactor tips and ensures they are open before powering controller.
224 Main contactor not closed.
226 Electric brake driver damaged (shorted or open).
227 Traction controller receives a signal for traction from accelerator potentiometer without start switch
being closed.
238 Internal failure of traction controller hardware.
239 Master controller detected problem in slave controller functionality.
240 Slave controller detected problem in the master controller functionality.
241 Master does not see CAN messages from slave.
242 Master does not see CAN messages from electro-hydraulic lever console.
243 Slave does not see CAN messages from valve driver module.
244 Failure of dash display memory.
245 Master does not see CAN messages from display.
246 Slave does not see CAN messages from display.
247 Valve driver does not see CAN messages from display.
248 Slave does not see CAN messages from master.
249 No communication from slave to EV.
250L Left rotor locked.
250R Right rotor locked.
260 Incorrect voltage on pump motor --> failure in power section, driver section, or motor itself.
270 Error in lift/lower lever.
271 Error in tilt lever.
272 Error in 3rd function lever.
273 Error in 4th function lever.
275 Internal failure of valve driver module.
276 One of the EV drivers of group 1 (lift/lower) is shorted.
277 One of the EV drivers of group 2 (auxiliary in/out) is shorted.
279 One of the EV drivers of group 3 (tilt up/down) is shorted.
280 One of the EV drivers of group 4 (sideshift R/L) is shorted.
281 Driver of single EV (9th) is shorted.

21
Troubleshooting 2200 YRM 1087

Table 4. List of Status Codes (Continued)

Status Description
Code
282 One of the on/off EV drivers is shorted.
283 One of the on/off EV coils is shorted; short-circuit protection is triggered.
289 Voltage supply to the valve driver control module is low.
292 IBattery selection is wrong in valve controller.
294 Interlocked hydraulic function requested without activation of interlock switch.
295 Hi-Lift switch is closed and the Lo-Lift switch is open.
299 CAN wires configuration problem.

Status Premium Display Message Memory Recall Circuit

Code
01 NO SEAT SWITCH INPUT No Traction
Description
Controller is not receiving an input signal from the
seat switch while receiving a traction or hydraulic
function command.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.

22
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
02 FORWARD SWITCH CLOSED No Traction
Description
Forward directional switch is closed before the key
switch closes.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
Replace failed switch.
Adjust switch for correct operation. See the sec-
tion Electrical System 2200 YRM 1078.
• Check for a shorted condition between wire #6 and
B+.
Wire #6 will be at battery voltage when the switch
is closed.
Wire #6 will be at 0 volts when the switch is open.

23
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
03 REVERSE SWITCH CLOSED No Traction
Description
Reverse directional switch is closed before the key
switch closes.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
Replace failed switch.
Adjust switch for correct operation. See the sec-
tion Electrical System 2200 YRM 1078.
• Check for a shorted condition between wire #8 and
B+.
Wire #8 will be at battery voltage when the switch
is closed
Wire #8 will be at 0 volts when the switch is open.

24
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Malfunction of the start switch.
Use dash display diagnostics to check operation
of the start switch.
Check for proper switch adjustment.
Replace start switch.
• Malfunction of the 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.
Wire #15 will be at battery voltage when the
switch is closed.
Wire #15 will be at 0 volts when the switch is
open.

25
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
Use ohm meter to ensure proper operation of
direction switches.
Check for continuity between C4 and C6 or
C4 and C7 when each switch closes.
Check wiring from switches to C6 and C7.
Check operation of switch for continuity through
the switch when the switch is closed.
• Malfunction of the directional switch.
Check switch adjustment.
FWD or REV switch is closed when direction
is selected.
• Wire #6 will be at battery voltage when the FWD
switch is closed.
• Wire #8 will be at battery voltage when the REV
switch is closed.
• Wires # 6 & #8 will be at 0 volts when the switches
are open.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Check for 5 volts between wire # 27 and wire # 28
at the throttle potentiometer.

27
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
08 THROTTLE VOLTAGE LOW No Traction
Description
Accelerator input voltage is lower than threshold
voltage set at throttle calibration.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
Recalibrate throttle. See the section Electrical
System 2200 YRM 1078.
• Check for 5 volts between wire # 27 and wire # 28
at the throttle potentiometer.

28
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Either the forward or reverse switch is failed closed.
Use dash display diagnostic to check operation
of directional switches.
Replace failed or malfunctioning switch.
• Directional switch is out of adjustment.
Switches should be open with directional switch
in neutral.
• Wire #6 will be at battery voltage when the FWD
switch is closed.
• Wire #8 will be at battery voltage when the REV
switch is closed.
• Wires # 6 & #8 will be at 0 volts when the switches
are open.

29
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
11 START SWITCH CLOSED No Traction
BEFORE KEY
Description
Accelerator start switch is closed before the key
and/or the seat switch.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
Replace failed switch.
• Wire # 15 will be at battery voltage when the start
switch is closed.
• Wire # 15 will be at 0 volts when the start switch is
open.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
12 STEER SENSOR VOLTAGE LOW Yes Traction
Description
Steer sensor feedback voltage is too low.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Check for 5.0 volts between wire # 70 and Wire #
72 at the steer potentiometer.
• Recalibrate steering. See the section Electrical
System 2200 YRM 1078.
Check voltage at C17 at the traction controller.
Voltage is typically 2.2 volts with the steer wheel
in the straight ahead position.
• Operate the lift truck and recheck the steering po-
tentiometer voltage to ensure the system will me-
chanically remain in calibration.

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Status Premium Display Message Memory Recall Circuit

Code
13 STEER SENSOR VOLTAGE HIGH Yes Traction
Description
Steer sensor feedback voltage is too high.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• With steer wheel straight ahead, check for 2.2 volts
at C17 on the traction controller.
• Recalibrate steering. See the section Electrical
System 2200 YRM 1078.

32
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recalibrate the steering sensor.
• Check sensor values using the dash diagnostics.
• Check adjustment of the steering potentiometer.
• Check for 5.0 volts between wire # 70 and Wire #
72 at the steer potentiometer.
• Check voltage at C17 at the traction controller. Volt-
age is typically 2.2 volts with the steer wheel in the
straight ahead position.
• Operate the lift truck and recheck the steering po-
tentiometer voltage to ensure the system will me-
chanically remain in calibration.

33
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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

34
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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

35
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, replace
controller.
• Check for dragging parking brakes or service
brakes.
• Use dash diagnostics to check for correct current
level of the left and right traction motors and the
pump motor.
• Check for mechanical offset of steering poten-
tiometer. Recalibrate as necessary.

36
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
42 PUMP CONTROL TEMPERATURE Yes Hydraulic
HIGH
Description
Pump controller temperature is too high. Traction
performance is progressively reduced as
temperature increases.
Symptom
Traction performance is reduced.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Reduce duty cycle until temperature is reduced.
• If fault is indicated when controller is cold, replace
controller.
• Check for dragging parking brakes or service
brakes.
• Use dash diagnostics to check for correct current
level of the left and right traction motors and the
pump motor.
• Check for mechanical offset of steering poten-
tiometer. Recalibrate as necessary.

37
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
43L LEFT MOTOR TEMP OUT OF RANGE Yes Traction
Description
Left traction motor temperature is out of range.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor tem-
perature.
• Check the motor temperature sensor resistance at
the traction controller between C34 and C35. Re-
sistance should read 500 ohms at24 C (75 F).
• Check for a shorted condition between C34 and the
truck frame and C35 and the truck frame. Should
see a minimum 1 megohm resistance.

38
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
43R RIGHT MOTOR TEMP OUT Yes Traction
OF RANGE
Description
Right traction motor temperature is out of range.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Failed thermal sensor in traction motor.
Using dash display diagnostic, check motor tem-
perature.
• Check the motor temperature sensor resistance at
the traction controller between C24 and C25. Re-
sistance should read 500 ohms at24 C (75 F).
• Check for a shorted condition between C24 and the
truck frame and C25 and the truck frame.
Should see a minimum 1 megaohm resistance.

39
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
51 PRECHARGE Yes Traction
Description
Controller capacitor voltage does not increase at
startup.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Ensure the towing connector near the dash display
is not in place.
• Remove fuse FU3 and turn the key to the ON posi-
tion. If the problem remains, perform Test A. If the
problem does not reappear, perform Tests B.
Test A:
Disconnect the battery and discharge the capac-
itors. See Discharging Capacitors in the front of
this section.
Disconnect the B+ cable from the traction con-
troller.
Connect and ohm meter between the B+ and the
B- terminals of the traction controller.
Look for an increasing resistance from 0 to 150
ohms over 10 seconds.
Disconnect the ohm meter and discharge the
capacitors. See Discharging Capacitors in the
front of this section.
Connect the ohm meter negative lead to B- and
ohm meter positive lead to UM. The ohm meter
should read approximately 5K ohms.
Connect the ohm meter negative lead to B- and
the ohm meter positive lead to US. The ohm me-
ter should read approximately 5K ohms.
Connect the ohm meter negative lead to UM and
the ohm meter positive lead to B+. The ohm me-
ter should read approximately 5K ohms. (Con-
tinued on next page)

40
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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

41
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
52L LEFT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed sensor.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Check for any shorted condition between C1, C2,
C13, or C14 to the truck frame.
• Disconnect the 6 pin connector from the traction
motor and check for pin to pin resistance in the
connector on the motor side. There should be a
minimum 1 megohm resistance from pin to pin.

42
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
52R RIGHT ENCODER ERROR Yes Traction
Description
Incorrect feedback from traction motor speed sensor.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Check for any shorted condition between C1, C2,
C13, or C14 to the truck frame.
• Disconnect the 6 pin connector from the traction
motor and check for pin to pin resistance in the
connector of the motor side. There should be a
minimum 1 megohm resistance from pin to pin.

43
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Disconnect the dash display A connector and check
for shorted wiring between pin A20 and B- or B+.
• Check wiring for shorts.
• Check for a shorted alarm.
• Check the resistance of R3, R4, D1 and LRC1 for
proper values if equipped with a DC/DC converter.
• Replace dash display.

44
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
65 MAIN CONTACTOR SHORTED Yes Traction
Description
The main contactor coil driver is shortened.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Disconnect C connector from the traction controller
and check the controller for a shorted condition be-
tween C26 and B-.
• Check the harness for a shorted condition between
pin C26 and B+ or B-.
• Check for shorted driver at the controller. Check for
short between terminal C26 and B .
• Check for shorted main contactor coil. Coil should
measure approximately 32 ohms.

45
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
66L LEFT TRACTION MOTOR SHORTED Yes Traction
Description
Left traction motor is shorted.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Ensure all motor connections are tight.
• Ensure motor connections are not shorted to the
truck frame.
• Disconnect all motor leads from the traction mo-
tor. Check line-to-line stator resistance. Resis-
tance should be 10.00 ±0.10 milliohms for 48-volt
truck and 6.10 ±0.10 milliohms for 36-volt truck.

46
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
66R RIGHT TRACTION MOTOR Yes Traction
SHORTED
Description
Right traction motor is shorted.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Ensure all motor connections are tight.
• Ensure motor connections are not shorted to the
truck frame.
• Disconnect all motor leads from the traction mo-
tor. Check line-to-line stator resistance. Resis-
tance should be 10.00 ±0.10 milliohms for 48-volt
truck and 6.10 ±0.10 milliohms for 36-volt truck.

47
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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
Traction performance is reduced.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Use dash display diagnostics to verify motor tem-
perature sensor is operating properly.
• Reduce truck operation until motor cools.
• If a fault is signaled with cold motor, disconnect the
C connector from the traction controller and check
the motor temperature sensor resistance between
pin C34 and C35 in the connector. The resistance
should be 555 ohms to 607 ohms at 20 C (68 F). If
the resistance is out of range, disconnect the 6 pin
connector at the left traction motor and measure
the resistance again between pins 3 and 4 at the
motor side of the connector. If the resistance is
within range, check the wiring harness.
• Check for broken or loose wires.
• Disconnect all motor leads from the traction motor
and check line to line stator resistance. The resis-
tance should read 10.00 +/-0.10 milliohms for a 48
volt truck and 6/10 +/-0.10 milliohms for a 36 volt
truck.
If the above readings are within in the speci-
fied ranges, compare motor current between the
two traction motors using dash display diagnos-
tics. Drive the truck straight ahead and observe
the current level of each traction motor. If the
left traction motor is drawing significantly more
current than the right traction motor check for a
dragging service or parking brake.
• Check for mechanical offset of steering poten-
tiometer. Recalibrate as necessary.

48
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Traction performance is reduced.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Use dash display diagnostics to verify motor tem-
perature sensor is operating properly.
• Reduce truck operation until motor cools.
• If a fault is signaled with cold motor, disconnect the
C connector from the traction controller and check
the motor temperature sensor resistance between
pin C34 and C35 in the connector. The resistance
should be 555 ohms to 607 ohms at 20 C (68 F). If
the resistance is out of range, disconnect the 6 pin
connector at the left traction motor and measure
the resistance again between pins 3 and 4 at the
motor side of the connector. If the resistance is
within range, check the wiring harness.
• Check for broken or loose wires.
• Disconnect all motor leads from the traction motor
and check line to line stator resistance. The resis-
tance should read 10.00 +/-0.10 milliohms for a 48
volt truck and 6/10 +/-0.10 milliohms for a 36 volt
truck.
If the above readings are within in the specified
ranges, compare motor current between the two
traction motors using dash display diagnostics.
Drive the truck straight ahead and observe the
current level of each traction motor. If the right
traction motor is drawing significantly more cur-
rent than the right traction motor, check for a
dragging service or parking brake.
• Check for mechanical offset of steering poten-
tiometer. Recalibrate as necessary.

49
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Use dash display diagnostics to verify motor over-
temperature switch is activated.
• Reduce truck operation until motor cools.
• If fault is signaled with a cold motor, disconnect
the dash display connector and measure the resis-
tance between A2 and A6 at the harness side of
the connector. The resistance should be less than
10 ohms.
If the resistance is greater than 10 ohms, discon-
nect the 4 pin connector at the pump motor and
measure the resistance between wires 110 and
102 on the motor side of the connector. If the re-
sistance is less than 10 ohms, check the wiring
harness and connectors.
• Remove all motor leads from the pump motor and
check line to line stator resistance.
• Use the dash display to check for high current draw
during hydraulic operations if equipped.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Replace pump motor brushes.
• Check wiring and connections.

Status Premium Display Message Memory Recall Circuit

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

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
142 PUMP CURRENT SENSOR MISSING Yes Hydraulic
Description
Controller senses no pump current.
Symptom
No hydraulic function.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check that traction motor windings are not shorted
to the truck frame.
• Check the P+ and P connections at both the con-
troller and the pump motor.
• Check for shorts from P+ and P to the truck frame.
• Check to see if the pump motor reverses direction
when a hydraulic function is returned to neutral. If
reverse rotation is observed, check the hydraulic
valves for proper operation.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
143 PUMP CURRENT SENSOR LOW Yes Hydraulic
Description
Controller senses low pump current.
Symptom
No hydraulic function.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check that traction motor windings are not shorted
to the truck frame.
• Check the P+ and P connections at both the con-
troller and the pump motor.
• Check for shorts from P+ and P to the truck frame.
• Check to see if the pump motor reverses direction
when a hydraulic function is returned to neutral. If
reverse rotation is observed, check the hydraulic
valves for proper operation.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
145 PUMP M- FAULT Yes Hydraulic
Description
Power transistor did not turn on properly.
Symptom
No lift operation.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check wiring connections between the controller
and the pump motor.
• Check for open motor windings.
• Check for worn pump motor brushes.
• Check for any shorted condition between P+ or P-
at the pump controller and the truck frame.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
202 HYDRAULIC OIL LOW No Lift
Description
Hydraulic fluid is low.
Symptom
Dash display message. Flashing icon on display.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Check for battery voltage at A9 on the dash display
when the hydraulic oil level is full.
• Disconnect the dash display connector and mea-
sure the resistance between A2 and A9 at the har-
ness side of the connector. The resistance should
be less than 10 ohms when the hydraulic oil level is
full. If the resistance is greater than 10 ohms, dis-
connect the 2 pin connector at the hydraulic oil level
sensor and measure the resistance at the sensor.
If this resistance is less than 10 ohms, check the
condition of the wiring harness.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
203 BRAKE FLUID LOW No Brake
Description
Brake fluid is low.
Symptom
Dash display message. Flashing icon on display.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check wiring continuity between switches.
There are two switches wired in series.
Check for battery voltage at C5 with both
switches closed.
Check each switch for open condition while op-
erating the switch.
• Replace failed switch.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
207 LIFT INTERRUPT No Lift
Description
Fault is set when battery is discharged below 20
percent of full charge.
Symptom
Lift does not operate.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Occurs when battery is 80 percent discharged.
• Discharged battery.
Charge or change battery.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
208 PUMP REQUEST BEFORE KEY No Lift
Description
Incorrect pump motor starting sequence.
Symptom
Lift does not operate.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
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.

NOTE: Lift trucks with transistor hydraulics share cir-

cuitry between the hydraulic and traction circuits in-
side the motor controller. This fault code may some-
times be caused by a problem registered from the
traction motor encoders.

If the lift truck is equipped with transistor hydraulics,

perform the following tests:

• Disconnect connector “D” from the traction con-

troller.
• Check the status of each function’s switches using
the dash display.
• If the status reading flashes “1” and “0” alternately
or if the pump motor runs:
Turn the key switch to the OFF position.
Disconnect the six pin connectors securing both
the left and right traction motor encoders to the
main wiring harness.
Turn the key switch to the ON position. (Contin-
ued on next page)

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
208 (Cont) PUMP REQUEST BEFORE KEY No Lift
Description
Incorrect pump motor starting sequence.
Symptom
Lift does not operate.
Probable Causes and Test Procedures
• If the status reading has stopped flashing “1” and
“0” alternately and if the pump motor has stopped:
One or both of the encoders is faulty. Check both
encoders by measuring the resistance between
any combination of connector pins 1, 2, 5, and 6
on the motor side. The resistance should be at
least 1 megohm.
Parking brakes that are dragging can damage
the encoders. Inspect the parking brakes for
proper operation when encoders have to be re-
placed. See Brake System 1800 YRM 1076.
Electro-Hydraulic Valve
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• 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.
• Use the dash display diagnostic to view all hydraulic
functions while all levers are in neutral. All functions
should show 0%.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the resistance of the brake coil. The coil
resistance should read approximately 32 ohms at
24 C (75 F).
• Recycle key switch.
• Check for voltage at the brake coil.
Should read approximately 36 volts.
If no voltage, check wiring for loose connections
at the dash display connector pins A12 & A13.
Also check pins C28 & C29 at the traction con-
troller. Check for open circuits in the wiring har-
ness.
• Check brake circuit diodes.
• Check brake circuit diodes D2 and D3 for an open
or shorted condition.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the resistance of the brake coil. The coil
resistance should read approximately 32 ohms at
24 C (75 F).
• Recycle key switch.
• Check for voltage at the brake coil.
Should read approximately 36 volts.
If no voltage, check wiring for loose connections
at the dash display connector pins A12 & A13.
Also check pins C28 & C29 at the traction con-
troller. Check for open circuits in the wiring har-
ness.
• Check brake circuit diodes.
• Check brake circuit diodes D2 and D3 for an open
or shorted condition.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
210 WATCHDOG IN TRACTION Yes Traction
CONTROLLER
Description
The internal "watchdog" hardware circuit has been
triggered.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Cycle key switch from OFF to ON.
• Check resistance between CANL and CANH wires
at the controller.
Resistance should be approximately 60 ohms.
• Ensure CANL, CANH, B+, or B- is not shorted to
the frame of the truck.
• Ensure CANL or CANH is not shorted to B-.
• Ensure CANL and CANH is not shorted to B+.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
212L LEFT U.V.W. VOLTAGE FEEDBACK Yes Traction
Description
Problem with UVW voltage feedback in slave
controller.
Symptom
No traction.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check that traction motor windings are not shorted
to the truck frame.

Status Premium Display Message Memory Recall Circuit

Code
212R RIGHT U.V.W. VOLTAGE FEEDBACK Yes Traction
Description
Problem with UVW voltage feedback in master
controller.
Symptom
No traction.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check that traction motor windings are not shorted
to the truck frame.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
213 UNDER/OVER VOLTAGE Yes Internal Controller
Description
The controller has detected an overvoltage or an
undervoltage condition within the controller.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Cycle key switch from OFF to ON.
• Check that the battery is the proper voltage and is
fully charged. Check the specific gravity of each
cell.
• If a fault occurs at key ON, disconnect the dc-dc
converter if installed on the truck.
• If the fault occurs when a hydraulic or traction
function is activated, check the battery disconnect
switch condition and the main contactor tip condi-
tion.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
214L LEFT MOTOR VOLTAGE LOW Yes Traction
Description
Incorrect voltage on one phase of the power circuit.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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 the resistance of each motor winding. Each
winding should measure approximately 10.00
±0.10 milliohms (48V) and 6.10 ±0.10 milliohms
(36V).
• Ensure each of the motor windings is not shorted
to the truck frame.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
214R RIGHT MOTOR VOLTAGE LOW Yes Traction
Description
Incorrect voltage on one phase of the power circuit.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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 the resistance of each motor winding. Each
winding should measure approximately 10.00
±0.10 milliohms (48V) and 6.10 ±0.10 milliohms
(36V).
• Ensure each of the motor windings is not shorted
to the truck frame.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
215L LEFT MOTOR VOLTAGE HIGH Yes Traction
Description
Incorrect voltage on one phase of the power circuit.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check all wiring connections to motors and con-
troller. All connections should be tight and clean.
• Ensure power wires are connected to correct termi-
nals. See the section Diagrams 8000 YRM 1081.
• Check the resistance of each motor winding. Each
winding should measure approximately 10.00
±0.10 milliohms (48V) and 6.10 ±0.10 milliohms
(36V).
• Ensure each of the motor windings is not shorted
to the truck frame.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
215R RIGHT MOTOR VOLTAGE HIGH Yes Traction
Description
Incorrect voltage on one phase of the power circuit.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check all wiring connections to motors and con-
troller. All connections should be tight and clean.
• Ensure power wires are connected to correct termi-
nals. See the section Diagrams 8000 YRM 1081.
• Check the resistance of each motor winding. Each
winding should measure approximately 10.00
±0.10 milliohms (48V) and 6.10 ±0.10 milliohms
(36V).
• Ensure each of the motor windings is not shorted
to the truck frame.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check for shorted main contactor coil. Coil should
measure approximately 32 ohms resistance across
the coil terminals.
• Check for shorted wiring.
• Check for shorted brake coils. Coil should measure
32.5 ohms resistance across the coil leads.
• Check for shorted condition between pins C26 &
C27 and between pins C28 & C29 at the traction
controller.

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Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check that the main contactor tips are not welded.
• Open contactor tips and replace if needed.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Ensure contactor is not stuck in open position.
• Check the contactor coil. Coil should measure ap-
proximately 32 ohms resistance.
• Check wiring from the controller to the contactor
coil. Check for continuity from C26 to coil. Check
for continuity from C27 to coil.
• Check for shorted condition between C26 and the
truck frame.
• Check for shorted condition between C27 and the
truck frame.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
226 BRAKE DRIVER OPEN OR Yes Traction
SHORTED
Description
Internal check of the parking brake driver in the
controller.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check for a shorted condition between C28 at har-
ness side of the connector and B-. If there is an in-
dication of low resistance while making this check,
check the wire harness for shorts.
• Check for a shorted condition between C28 and B-
at the controller side. If there is an indication of low
resistance while making this check, the controller
may be defective.
• Check the brake coil resistance, the brake coil
should measure approximately 31 ohms.
• Check for a shorted condition between pin C28 at
the traction controller and the truck frame. Check
for a shorted condition from pin C29 to the truck
frame at the traction controller.

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Status Premium Display Message Memory Recall Circuit

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
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Accelerator potentiometer is out of adjustment.
Recalibrate throttle. See the section Electrical
System 2200 YRM 1078.
• Malfunction of the start switch.
Use dash display diagnostics to check operation
of the start switch.
Check for proper switch adjustment.
• Use the dash display diagnostics to check opera-
tion of the throttle sensor.
Replace throttle sensor if necessary.
• Check for a shorted condition between pins C20,
C21 and C33 at the traction controller and the truck
frame.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
238 TRACTION CONTROLLER FAULT Yes/No Traction
Description
Internal failure of the traction controller hardware.
Symptom
Lift truck will not operate.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• If the truck is equipped with a pump controller,
check all pump motor power connections and
cables.
Check for a shorted condition between P+ and
the truck frame and between P- and the truck
frame.
Check for reverse rotation of the pump motor
when returning a hydraulic function to neutral.
If reverse rotation is observed, check hydraulic
valves for proper operation.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

77
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
241 NO COMMUNICATION SLAVE Yes Internal Controller
TO MASTER
Description
Master controller is not receiving CAN messages
from the slave controller.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
242 NO COMMUNICATION LEVER Yes Lift
TO MASTER
Description
Master controller is not receiving CAN messages
from the electro-hydraulic lever console.
Symptom
Lift does not operate.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in
the fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted
to the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Lift does not operate.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

EV = Electro-hydraulic valve driver module.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
244 DASH DISPLAY FAULT No Display
Description
Failure of the dash display memory.
Symptom
Dash display does not operate.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key from OFF to ON.
• Check all wiring and pins in the dash display con-
nector are tight and secure.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
245 NO COMMUNICATION MASTER Yes Traction
TO DASH
Description
Master controller is not receiving CAN messages
from the dash display.
Symptom
Lift truck does not move or moves very slowly.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check termination resistor. Should measure ap-
proximately 60 ohms between A7 and A22 at the
dash display.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
246 NO COMMUNICATION SLAVE Yes Traction
TO DASH
Description
Slave controller is not receiving CAN messages
from dash display.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check termination resistor. Should measure ap-
proximately 60 ohms between A7 and A22 at the
dash display.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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
Lift does not operate.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check continuity of the CANbus wires between the
dash display and the valve driver module.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

EV = Electro-hydraulic valve driver module.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
248 NO COMMUNICATION MASTER Yes Internal Controller
TO SLAVE
Description
Slave controller is not receiving CAN messages
from the master controller.
Symptom
Lift truck does not move.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check continuity of the CANbus wires between the
dash display and the valve driver module.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check the condition of the main contactor and
pump contactor (if equipped) tips.
• Recycle key from OFF to ON.
• Check resistance between CANH and CANL wires
at the traction controller. Resistance should be ap-
proximately 60 ohms.
• Check CANL, CANH, B+, and B- are not shorted to
the frame of the truck.
• Check CANL and CANH are not shorted to B- or
B+.
• Check all CANbus wiring for loose connections or
damaged wiring.
• If the truck is equipped with electro-hydraulics
option, check for continuity between the hydraulic
levers mounting plate and the truck frame.
• ETACC tests may be conducted on the system if
you have access to the ETACC software. Refer to
ETACC Test.

EV = Electro-hydraulic valve driver module.

87
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Use the dash display diagnostics to check opera-
tion of traction motor encoder.
• Check for 12 volts at encoder between wires 75 and
76.
• Ensure all wiring connections between the encoder
harness and the traction motor are tight.
• Check for continuity of all wiring between the en-
coder and the traction controller.
• Check for any shorted condition from pins C11,
C12, C22, or C23 at the traction controller to the
truck frame.
•
• Ensure the wiring to the encoder is correct. See
the section Diagrams 8000 YRM 1081.
• Disconnect the 6 pin connector at the traction motor
and measure the resistance between any combina-
tion of pins 1, 2, 5, and 6. The resistance should
be at least 1 megohm.

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2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Use the dash display diagnostics to check opera-
tion of traction motor encoder.
• Check for 12 volts at encoder between wires 83 and
84.
• Ensure all wiring connections between the encoder
harness and the traction motor are tight.
• Check for continuity of all wiring between the en-
coder and the traction controller.
• Check for any shorted condition from pins C1, C2,
C13, or C14 at the traction controller to the truck
frame.
•
• Ensure the wiring to the encoder is correct. See
the section Diagrams 8000 YRM 1081.
• Disconnect the 6 pin connector at the traction motor
and measure the resistance between any combina-
tion of pins 1, 2, 5, and 6. The resistance should
be at least 1 megohm.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
260 PUMP MOTOR VOLTAGE LOW Yes Transistor Lift
Description
Incorrect voltage on pump motor.
Symptom
No lift operation.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.
• Check for any shorted condition from P+ or P- to
the truck frame.
• Check for any shorted condition between P- and B-.
• Check P+ and P- connections are tight at the con-
troller and the pump motor.

90
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
270 LIFT/LOWER LEVER ERROR Yes Electro-hydraulic
Description
Error in signal from the lift/lower lever assembly.
Symptom
No lift/lower operation.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check all wiring connections between the hydraulic
lever console and the hydraulic controller are tight
and secure.
• Check for 12 volts at pin 1 on the hydraulic lever
console.
Check for 12 volts at pin B10 on the valve driver
module.
• Replace the lift/lower lever PC board.

91
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
271 TILT LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the tilt lever.
Symptom
No mast tilt operation.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check all wiring connections between the hydraulic
lever console and the hydraulic controller are tight
and secure.
• Check for 12 volts at pin 1 on the hydraulic lever
console.
Check for 12 volts at pin B10 on the valve driver
module.
• Replace the tilt lever PC board.

92
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
272 3RD FUNCTION LEVER ERROR Yes Electro-hydraulic
Description
Error in the signal from the sideshift lever.
Symptom
No carriage sideshift operation.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check all wiring connections between the hydraulic
lever console and the hydraulic controller are tight
and secure.
• Check for 12 volts at pin 1 on the hydraulic lever
console.
Check for 12 volts at pin B10 on the valve driver
module.
• If the truck is not equipped with 3rd. function, make
sure 3rd function parameter is set at 3.
• Replace the sideshift lever PC board.

93
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check all wiring connections between the hydraulic
lever console and the hydraulic controller are tight
and secure.
• If the truck is not equipped with 4th function, make
sure 4th function parameter is set at 3.
• 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 auxiliary lever PC board.

94
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
275 VALVE CONTROLLER FAULT Yes Electro-hydraulic
Description
Internal failure of the valve driver module.
Symptom
No operation of the electro-hydraulic functions.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch from OFF to ON.
• Check all pins at the valve controller connector are
tight and secure.
• Replace the valve driver module.

95
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch.
• Disconnect connector "C" from EV. Check all wires
for shorts to B-, the truck frame, or between wires.
• Check resistance of coils:
Resistance should read approximately 19 ohms
at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

96
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch to clear fault.
• Disconnect connector "C" from EV. Check all wires
for shorts to B-, the truck frame, or between wires.
• Check resistance of coils:
Resistance should read approximately 19 ohms
at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

Code
279 TILT EV DRIVER SHORTED Yes Electro-hydraulic
Description
Tilt driver in the valve driver module is shorted.
Symptom
No tilt function operation.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch to clear fault.
• Disconnect connector "C" from EV. Check all wires
for shorts to B-, the truck frame, or between wires.
• Check resistance of coils:
Resistance should read approximately 19 ohms
at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

98
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch to clear fault.
• Disconnect connector "C" from EV. Check all wires
for shorts to B-, the truck frame, or between wires.
• Check resistance of coils:
Resistance should read approximately 19 ohms
at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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

Probable Causes and Test Procedures

This spare output is not used.
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch to clear fault.
• Disconnect connector "C" from EV. Check all wires
for shorts to B-, the truck frame, or between wires.

EV = Electro-hydraulic valve driver module.

EVP = Electro-hydraulic proportional valve driver.

100
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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

Probable Causes and Test Procedures

• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch to clear fault.
• Disconnect connector "C" from EV. Check all wires
for shorts to B-, the truck frame, or between wires.
• Check resistance of coils:
Resistance should read approximately 19 ohms
at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

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Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Recycle key switch to clear fault.
• Disconnect connector "C" from EV. Check all wires
for shorts to B-, the truck frame, or between wires.
• Check resistance of coils:
Resistance should read approximately 19 ohms
at 25 C (77 F).

EV = Electro-hydraulic valve driver module.

102
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check for battery voltage at pins B1 and B2 with
key switch closed.
• Check that all connections are secure.

EV = Electro-hydraulic valve driver module.

103
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.

EV = Electro-hydraulic valve driver module.

104
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• Check interlock switch on the ILM; replace as nec-
essary.

105
Troubleshooting 2200 YRM 1087

Status Premium Display Message Memory Recall Circuit

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.
Probable Causes and Test Procedures
• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
• Check that the battery disconnect switch, the key
switch, and the main contactor contacts are in the
correct position and properly making contact.
• 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.

106
2200 YRM 1087 Troubleshooting

Status Premium Display Message Memory Recall Circuit

Code
299 WRONG CONFIGURATION Yes Traction
Description

Symptom

Probable Causes and Test Procedures

• Ensure all fuses are properly seated and tight in the
fuse holders.
• Ensure all wiring connections are tight and secure
at the fuse panel, key switch, and the battery dis-
connect switch.
•
• Recycle key switch.
• Check CAN wiring for loose connections at connec-
tors or broken wires.

107
Troubleshooting 2200 YRM 1087

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 CANbus B

A2 C16 72 Steering Potentiometer

Positive (+5V/+12V)
A3
C17 71 Steering Potentiometer
A4 CANL-OUT Low Level CANbus Wiper Input
A5 C18 104 Brake Potentiometer
A6 CANL Low Level CANbus Wipe Input

A7 CANH-OUT High Level CANbus C19 103 B

A8 C20 27 Accelerator
Potentiometer B
C21 29 Traction Potentiometer
Table 6. Connector C Wiper Input

Pin Wire 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
C13 85 Right Motor Encoder
Phase B C35 80 Left Traction Motor Temp
Sensor Input Signal
C14 86 Right Motor Encoder
Phase A

108
2200 YRM 1087 Troubleshooting

Table 7. Connector D - Standard Model Table 8. Connector D - Premium Model (Continued)

Pin Wire Number Function

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

109
Troubleshooting 2200 YRM 1087

Table 10. Connector C Table 10. Connector C (Continued)

Pin Wire Number Function

Pin Wire Number Function
C1 53 Negative for Lowering
C22 OPEN
Proportional Valve
C23 130 Battery Negative
C2 52 Positive for Lift and
Lower Proportional
Valves HYDRAULIC LEVER CONSOLE
C3 54 Negative for Lift (ELECTRO-HYDRAULIC OPTION
Proportional Valve ONLY)
C4 56 Negative for Auxiliary IN Pin Wire Number Function
Proportional Valve
1 74 12V Supply from Valve
C5 55 Positive for Auxiliary Driver Module
Proportional Values
2 CANH_OUT1 CANbus High
C6 57 Negative for Auxiliary
3 130 Battery Negative
OUT Proportional Valve
59 4 CANL_OUT1 CANbus Low
C7 Negative for Tilt UP
Proportional Valve
C8 58 Positive Voltage Supply
DASH DISPLAY
for Tilt Proportional Pin Wire Number Function
Valves
A1 10-1B Key Switch Input B+
C9 65 Negative for Load Hold
Valve A2 110-1 Positive Supply to
Indicators
C10 67 Negative for Tilt Auxiliary
Selector Valve A3 130F Battery Negative B

C11 OPEN A4 130G Battery Negative B

C12 62 Negative for Sideshift A5 107 Lift Motor Brush Wear

Right Proportional Valve Indicator Input

C13 61 Positive for Sideshift A6 102 Negative for Pump Motor

Right and Left Temp Sensor
Proportional Valves A7 CANL-1 CANbus Low
C14 63 Negative for Sideshift A8 OPEN
Left Proportional Valve
A9 90 Negative for Hydraulic
C15 60 Negative for Tilt Down Oil Lever Sensor
Proportional Valve
A10 91 Positive for Brake Fluid
C16 64 Positive for Lift Hold Level Switch
Valve
A11 96 Negative for Auxiliary
C17 66 Positive for Tilt Auxiliary Switch
Selector Valve
A12 50G Parking Brake Coil Input
C18 OPEN
A13 50F Parking Brake Coil Input
C19 OPEN
A14 OPEN
C20 OPEN
A15 OPEN
C21 OPEN
A16 47B Steering Encoder Input

110
2200 YRM 1087 Troubleshooting

Pin Wire Number Function Pin Wire Number Function

A17 12A Battery Positive B+ A22 CANH-1 CANbus 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

111
Troubleshooting 2200 YRM 1087

Figure 19. Logic Diagram - Standard

112
2200 YRM 1087 Troubleshooting

Figure 20. Logic Diagram - Premium

113
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114
 Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom

2200 YRM 1087 8/05 (2/05) Printed in the United Kingdom