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AC MOTOR CONTROLLER T5Z AC [B476]; T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]
PART NO. 1687931
2200 SRM 1352
AC Motor Controller
Table of Contents
TABLE OF CONTENTS General ............................................................................................................................................................... Discharging the Capacitors........................................................................................................................... Description ......................................................................................................................................................... Electrical System ........................................................................................................................................... AC Traction Motor..................................................................................................................................... Controller................................................................................................................................................... Service PC Connection .............................................................................................................................. Parameters ......................................................................................................................................................... General ........................................................................................................................................................... Parameter Description....................................................................................................................................... Parameters..................................................................................................................................................... Extended Shift........................................................................................................................................... Walk Speed (Both Directions) ................................................................................................................... Hi Speed (FWD)......................................................................................................................................... Hi Speed (REV).......................................................................................................................................... Minimum Acceleration.............................................................................................................................. Maximum Acceleration ............................................................................................................................. Plugging ..................................................................................................................................................... ADS-Neutral .............................................................................................................................................. ADS-Throttle ............................................................................................................................................. Pick Acceleration ....................................................................................................................................... Pick Deceleration....................................................................................................................................... Battery Full Voltage .................................................................................................................................. Lift Interrupt ............................................................................................................................................. Service Hour Reminder............................................................................................................................. Troubleshooting.................................................................................................................................................. General ........................................................................................................................................................... Status Codes .................................................................................................................................................. Dash Display ...................................................................................................................................................... General ........................................................................................................................................................... Startup ........................................................................................................................................................... Status LED .................................................................................................................................................... Performance Mode Indicator......................................................................................................................... Hourmeter...................................................................................................................................................... Battery Charge Indicator .............................................................................................................................. Fault Log ........................................................................................................................................................ Connector Pin-Outs............................................................................................................................................ System Logic Diagram.......................................................................................................................................
1 1 2 2 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 7 7 7 60 60 60 60 60 61 61 61 62 63
This section is for the following models: T5Z AC [B476]; T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]
©2008 HYSTER COMPANY
i
2200 SRM 1352
General
General This section describes the Iskra® motor controller and dash display used in C60Z AC, C80Z AC, T5Z AC, and T7Z AC lift trucks. Procedures are outlined for controller programming and troubleshooting.
DISCHARGING THE CAPACITORS WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to discharge the traction motor controller.
WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.
CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller. 1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery. 2. Remove the drive unit compartment cover to access the controller. 3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s B+ and B terminals. See Figure 1. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.
1. 2. 3. 4. 5.
CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 1. Discharging the Capacitors
1
Description
2200 SRM 1352
Description ELECTRICAL SYSTEM The Iskra® AC motor controller controls the AC traction motor and the DC pump motor. The controller can also be used with the optional brushless DC
1. 2. 3. 4. 5. 6. 7.
KEY SWITCH BATTERY DISCHARGE INDICATOR (BDI) PARKING BRAKE SWITCH PARKING BRAKE TRACTION MOTOR HORN LIFT PUMP MOTOR
power steering motor. The controller uses CANbus communication to interact with the dash display and the control handle. See Figure 2 or Figure 3.
8. 9. 10. 11. 12. 13.
CONTROL MODULE DIAGNOSTIC CONNECTOR OR CONTROLLER FUSE BATTERY CONNECTOR
Figure 2. Electrical Components (C60-80Z AC)
2
2200 SRM 1352
1. 2. 3. 4. 5. 6.
Description
KEY SWITCH BATTERY DISCHARGE INDICATOR (BDI) PARKING BRAKE SWITCH PARKING BRAKE TRACTION MOTOR HORN
7. 8. 9. 10. 11. 12.
CONTROL MODULE DIAGNOSTIC CONNECTOR OR CONTROLLER FUSE BATTERY CONNECTOR
Figure 3. Electrical Components (T5-7Z AC)
3
Parameters
2200 SRM 1352
AC Traction Motor The AC traction motor is a three-phase AC induction motor. The motor does not include motor brushes or a commutator. An AC induction motor operates on three-phase AC power provided directly by the controller. The motor speed is controlled by the motor controller and can be changed by the frequency of the AC power supplied to the motor. A speed sensor has been built into one of the motor bearings which provides to the motor controller allowing software to continually monitor motor direction and revolutions per minute (RPM). Using this system, the AC motor control can provide much better vehicle top speed control than the older DC SEM systems.
Controller The motor controller converts DC power from the truck battery to three-phase AC power at the frequencies and currents necessary to drive the traction motor. A bearing in the traction motor provides of speed, rotation direction, and temperature directly to the motor controller.
The motor controller receives power through the main or which is controlled by the key switch. The controller receives inputs from the control handle and the hand rail switches to control lift truck functions. NOTE: There are no serviceable parts in the motor controller. No attempt should be made to open repair, or otherwise modify the controller. Doing so may damage the controller and/or lift truck. Removing the cover from the controller will void the warranty.
Service PC Connection The lift truck is equipped with a connection point to connect a laptop computer with ETACC software installed. This connection can be used to adjust certain lift truck parameters and to assist with troubleshooting the lift truck.
Parameters GENERAL A parameter is a measurement or a setting that defines a lift truck function. A specific function parameter works with other function parameters to control the operation of the lift truck.
WARNING The parameter for each function has a value range so the motor controller can be used on different models of lift trucks. This variation is needed for lift trucks of different sized and operation voltages. Adjustment of a function to the wrong number value for your lift truck model can cause the truck to operate differently than normal. This different operation of the truck can cause an injury. NOTE: Table 1 shows the factory default setting for each parameter that is adjustable by the .
4
Parameters can be adjusted through the dash display. The factory default values listed in Table 1 are the recommended settings for new units. These settings will give satisfactory performance for most applications.
WARNING If any of the parameter values are changed, the operators must be told the lift truck will operate differently. NEVER adjust any of the following parameters without using the procedures and settings given in this section. Function Parameter Descriptions in this section contains descriptions for the different parameters. These parameters can also be accessed using the ETACC PC software.
2200 SRM 1352
Parameter Description Table 1. Parameter Default Values
Parameter
Extended Shift Battery Full Voltage Battery Empty Voltage
Range
Default C60Z AC and T5Z AC
C80Z AC and T7Z AC
Min
Max
OFF
OFF
ON
OFF
25.000
27.000
22.800
25.000
25.300 23.520
1
25.300 23.520
1
ADS-Throttle
1
1
1
10
ADS-Neutral
1
1
1
10
Plugging
7
7
1
10
Walk speed (Both Directions)
3.8
3.8
0.5
4.0
Hi Speed (FWD)
9.0
9.0
0.5
9.0
Hi Speed (REV)
6.0
6.0
0.5
7.5
Minimum Acceleration
53
53
0
100
Maximum Acceleration
70
70
0
100
Service Hour Reminder
0
0
0
1000
1
Maintenance-free battery option uses value 24.000.
Parameter Description PARAMETERS WARNING If any of the parameter values are changed, the operators must be told the lift truck will operate differently. NEVER adjust any of the following parameters without using the procedures and settings given in this section. Parameters can be adjusted through the dash display LCD. These parameters can also be accessed using the ETACC PC software.
Extended Shift This parameter when on, will reduce traction performance by 15% to provide extended battery shift life. The parameter may be set to the OFF or ON condition.
Walk Speed (Both Directions) This parameter sets the maximum truck speed for forward and reverse directions when the truck is in “Walk” mode. Increasing the setting will increase the truck speed. Decreasing the setting will decrease truck speed.
Hi Speed (FWD) This parameter sets the maximum forward speed of the lift truck when the truck is in “Ride” mode. Increasing the setting increases the speed. Decreasing the setting will decrease the speed.
Hi Speed (REV) This parameter sets the maximum reverse speed of the lift truck when the truck is in “Ride” mode. Increasing the setting increases the speed. Decreasing the setting will decrease the speed.
5
Parameter Description
Minimum Acceleration This parameter sets the minimum acceleration rate of the lift truck when the truck is in traveling at the lowest throttle. Increasing the setting increases the minimum rate of acceleration. Decreasing the setting will decrease the minimum rate of acceleration.
Maximum Acceleration This parameter sets the maximum acceleration rate of the lift truck when the truck is traveling at maximum throttle. Increasing the setting increases the maximum rate of acceleration. Decreasing the setting will decrease the maximum rate of acceleration.
Plugging This parameter controls the maximum rate of deceleration when the speed control is fully moved to the opposite direction from the direction of travel while the truck is moving. Increasing this setting will increase the rate of deceleration. Decreasing the setting will reduce the rate of deceleration.
ADS-Neutral This parameter controls the rate of deceleration when the speed control is returned to the neutral position and the ADS-Throttle parameter is set above 1. Setting the value at 1 will result in no effect on the rate of deceleration; the truck will coast until it comes to a stop. Increasing the value will increase the rate of deceleration. Decreasing the value will decrease the rate of deceleration.
ADS-Throttle This parameter controls the rate of deceleration when the speed control is partially reduced and the ADS-Throttle parameter is set above 1. Setting the value at 1 will result in no effect on the rate of deceleration; the truck will coast until it reaches the lower throttle speed. Increasing the value will increase the rate of deceleration. Decreasing the value will decrease the rate of deceleration.
Pick Acceleration This parameter controls the rate of acceleration when the coast control switch is activated. Increasing the value will increase the rate of acceleration.
6
2200 SRM 1352 Decreasing the value will decrease the rate of acceleration.
Pick Deceleration This parameter controls the rate of deceleration when the coast control switch is released. Increasing the value will increase the rate of deceleration. Decreasing the value will decrease the rate of deceleration. Setting the value at 1 will result in no effect on the rate of deceleration; the truck will coast until it comes to a stop.
Battery Full Voltage This is the battery voltage in millivolts at which the battery is considered fully charged. Increasing the setting increases the voltage. Decreasing the setting reduces the voltage.
Lift Interrupt This is the battery voltage in millivolts at which the battery is considered 80% discharged. Increasing the setting increases the voltage. Decreasing the setting reduces the voltage.
Service Hour Reminder This parameter initiates a reminder when the hourmeter reaches a preset point indicating the lift truck is due to be serviced. Within this menu, you can reset the Service Hour Reminder, change the service interval hours, and turn the function ON or OFF. The normal factory default setting for the Service Hour Reminder is OFF and must be changed to ON for the function to be active. When the Service Hour Reminder is ON, the dash display will display a one-time message to the operator when the preset hourmeter reading has been reached. The lift truck will continue to operate normally until the hourmeter reaches 20 hours past the preset service interval. At this time the lift truck function speeds will be reduced until the Service Hour Reminder has been reset. The lift truck should be serviced and the parameter reset to the next hourmeter reading when service is due.
2200 SRM 1352
Troubleshooting
Troubleshooting GENERAL The controllers are sealed units with no serviceable components. Troubleshooting is usually limited to accessing status codes and following the diagnostic procedures listed in the status code charts. Use standard testing procedures to inputs and outputs when necessary.
CAUTION Never attempt to probe through the back of the connector plugs of the motor controller. The plugs are special sealed plugs. Probing through the back of the plugs will destroy the seal and can cause a short circuit. If a circuit must be tested for voltage, check for voltage at an amp-type plug, a switch, or a component. If a circuit is suspect, check the circuit for continuity from the front (pin end) of the plug. Standard probes are too large to be inserted into the center of the female pins (sockets) of the special sealed plugs and can expand the pins. Expanded pins will not provide good connections once the plug is reconnected. The connectors are shaped to allow the insertion of a flat blade screwdriver into the connector. After inserting the screwdriver into the connector, attach probes with alligator clips to the shank of the screwdriver to obtain readings. An additional method would be to use a breakout kit. If the controller detects an issue, a status code is displayed on the display . Once the status code number is obtained, follow the procedures outlined in the status code charts of this manual to determine the problem. NOTE: Due to the interaction of the controller with all lift truck functions, almost any status code or controller fault could be caused by an internal failure of the controller. After all other status code procedures have been followed and no problem is found, the controller should be replaced as the last option to correct the problem. Tools and test equipment required are: • Clip Leads • Digital Multimeter (20,000 ohms per volt) • Basic Hand Tools
Check resistance on the proper scale from frame to power and controller terminals. Resistance of less than 20,000 ohms can cause misleading symptoms. Resistance of less than 1000 ohms indicates a short and should be corrected immediately. The on-board diagnostic system employed on this lift truck can assist in the troubleshooting process. Read and be familiar with the instructions for accessing and using the dash display diagnostic system. Prior to troubleshooting systems and components on this lift truck, ensure the battery is the correct voltage and is fully charged. Make sure the battery connector s are clean of corrosions and the battery polarity within the connector is correct. Inspect to ensure all fuses are correct and have not failed. Ensure the key switch is in the ON position when making voltage checks or checking the operator of a component. Many faults noted by lift truck systems are the result of loose wiring connections and/or broken or shorted wiring within the lift truck. Begin the troubleshooting process by carefully inspecting the wiring involving the device or devices noted by the on-board diagnostics system.
STATUS CODES Make sure the parameter values are correct for your lift truck to ensure the trouble is not just an incorrect setting. See function settings to set the correct parameter values. If there is no status code display and the lift truck does not operate correctly, there may be a fault in the controller. The status codes are numbers for malfunction or lift truck operation that are not correct and that the controller can sense. The controller will indicate this code number on the LCD screen of the display . NOTE: There are identifiers to determine which device generated the code: Xy = XXXX (Co 23538) Co = Controller Ti = Control Module The controller senses the following types of malfunction: • Input voltages that are too high or too low • Input voltages in the wrong sequence or • Correct input voltages that occur at the wrong time
7
Troubleshooting
2200 SRM 1352
NOTE: A status code indication does not always mean that there is a malfunction. A temporary operation condition can cause a status code display. These code numbers are only indicators that may help diagnose a possible malfunction. A short description of the different status codes is shown in Table 2.
The Fault Message charts in this section have a more complete description of the status code, the circuit that has generated the input for the status code, the symptom, and the possible cause.
Table 2. Fault Codes Code
8
Description
9024
Controller failure of the traction motor power circuit
9088
Pump motor shorted
9089
Pump motor open
9090
Pump at relief
9091
Controller failure of the pump motor power circuit.
12816
Controller internal voltage over 36 volts
12819
Incorrect voltage battery connected
12832
Controller internal voltage less than 16 volts
12835
Incorrect voltage battery connected
16912
Controller power section is over temperature
16944
Controller is in thermal cutback - high controller temperature
16945
Controller internal temperature sensor failure
17168
Traction motor is over temperature
17169
Controller is in thermal cutback - high traction motor temperature
17170
Traction motor temperature sensor failure
20756
Key switch open
21024
Control module failure
21378
Controller cannot establish with control module
21533
Horn circuit is shorted to B+
21534
Horn circuit is open
21535
Horn circuit is shorted to B
21544
Horn switch is closed at startup
21552
Steer handle inputs incorrect at startup
21553
Hi Speed switch is closed at startup
21555
Lift or lower switch is closed at startup
21568
Main or circuit is open
21569
Main or circuit is shorted to B+
2200 SRM 1352
Troubleshooting
Table 2. Fault Codes (Continued) Code
Description
21570
Main or circuit is open
21571
Main or circuit is shorted to B
21588
Internal failure of the power steering unit
29445
Traction motor encoder failure
29448
Steer handle switch closed at startup
29456
Error in control module speed/direction sensor
29458
Steer handle sensor is out of limits
33056
Controller cannot establish communication with control module
33057
Controller cannot establish communication the power steering controller
9
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9024
Service Required
Solid Red
Traction
DESCRIPTION
SYMPTOM
Traction motor phase U, V, or W shorted to B+ or B .
Truck will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and disconnect the battery connector. 2. Disconnect the motor leads from the controller. 3. Check motor for phase-to-ground or phase-to-B+ shorted condition. a. Motor should measure minimum 1 megohm phase-to-ground. • Replace traction motor. 4. Check U, V, and W terminals of the controller for shorted condition to B+ or B . a. NMHG Service Engineering Management.
10
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9088
Service Required
Solid Red
Pump
DESCRIPTION
SYMPTOM
Pump motor has shorted.
Hydraulics will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and disconnect the battery. 2. Disconnect pump motor leads from controller. a. Check for any burns or evidence of arcing. 3. Visually check motor leads for any damage or evidence of shorting to the truck frame. a. Check for any burns or evidence of arcing. • Repair or replace any damaged wiring. 4. Check for P terminal at the controller shorted to B . a. Resistance should be greater than 50 megohms. • NMHG Service Engineering Management. 5. Replace pump motor.
11
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9089
Service Required
Solid Red
Pump
DESCRIPTION
SYMPTOM
Pump motor has open circuit.
Hydraulics will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and disconnect the battery connector. 2. Disconnect pump motor cables from the controller. 3. continuity through each motor cable. a. Replace any broken wiring. 4. Check for open circuit across the across the motor terminals. a. If greater than 500 ohms, replace the pump motor.
12
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9090
Overload
Flashing Red
Pump
DESCRIPTION
SYMPTOM
Controller has detected the hydraulic system is being operated at relief.
Hydraulics will not operate.
Probable Causes and Test Procedures 1. weight of load does not exceed lift truck capacity on the nameplate. a. Reduce load weight. 2. there is no binding in the lifting mechanism. 3. Install a 24.13 MPa (3500 psi) pressure gauge in the lift cylinder line. a. the relief pressure is correct: • C60Z AC = 18.96 MPa (2750 psi) • C80Z AC = 23.44 MPa (3400 psi) 4. Adjust relief pressure to correct value. a. See Walkie Hydraulic Systems 1900 SRM 964.
13
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9091
Internal Pump Circuit Failure
Solid Red
Pump
DESCRIPTION
SYMPTOM
Controller has detected an internal failure in the pump circuit.
Truck will not operate.
Probable Causes and Test Procedures 1. 24 volts at the controller B+ terminal. a. Ensure battery is connected to the lift truck. b. continuity of fuse FU 1. 2. Turn the key switch to the OFF position. 3. Disconnect cable PM1 at the P controller terminal. a. Check for a shorted condition between P and B • Resistance should be greater than 500 ohms. • NMHG Service Engineering Management. 4. Disconnect cable PM1 at the P controller terminal and reconnect it to the controller B a. Turn the key switch to the ON position and the pump motor operates. b. NMHG Service Engineering Management.
14
terminal.
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
12819
Check Battery
Flashing Red
Battery
DESCRIPTION
SYMPTOM
Controller has detected a battery voltage in excess of 32 volts.
Truck will not operate.
Probable Causes and Test Procedures 1. Check battery voltage at controller B+ terminal. 2. battery voltage matches voltage listed on the lift truck nameplate. a. Install correct voltage battery.
15
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
12832
Check Battery
Flashing Red
Battery
DESCRIPTION
SYMPTOM
The controller has sensed battery voltage to be less than 16 volts.
Truck will not operate.
Probable Causes and Test Procedures 1. Check battery voltage at controller B+ terminal. 2. battery voltage matches voltage listed on the lift truck nameplate. a. Install correct voltage battery. 3. Check for continuity through fuse FU 1. a. Replace fuse. 4. Condition can be caused by normal operation of the lift truck with a discharged battery. a. Check battery state of charge on the dash display. • Recharge battery. • Install a fully charged battery.
16
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
12835
Check Battery
Flashing Red
Battery
DESCRIPTION
SYMPTOM
Controller has detected a battery with less than 16 volts has been connected to the lift truck.
Truck will not operate.
Probable Causes and Test Procedures 1. Check battery voltage at controller B+ terminal. 2. battery voltage matches voltage listed on the lift truck nameplate. a. Install correct voltage battery.
17
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
16912
Wait to Cool Down
Flashing Red
Battery
DESCRIPTION
SYMPTOM
Controller is over temperature.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position and operate the lift truck briefly. 4. fault does not repeat. a. NMHG Service Engineering Management.
18
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
16944
Performance Reduced
Flashing Red
Controller
DESCRIPTION
SYMPTOM
Truck is in thermal cutback due to high controller temperature.
Traction system is operating at a reduced performance level.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position and operate the lift truck briefly. 4. fault does not repeat. a. NMHG Service Engineering Management.
19
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
16945
Service Required
Solid Red
Controller
DESCRIPTION
SYMPTOM
Controller has detected an internal failure in the power bridge temperature sensor.
Traction system is operating at reduced performance level.
Probable Causes and Test Procedures 1. 2. 3. 4.
20
Turn the key switch to the OFF position and restart the lift truck. the fault has reoccurred on the dash display. Let truck sit for 10 minutes. Restart the lift truck. a. Fault reoccurs. • NMHG Service Engineering Management.
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
17168
Over Temp
Flashing Red
Traction Motor
DESCRIPTION
SYMPTOM
Controller has detected an over temperature condition in the traction motor.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the ON position and operate the lift truck briefly. Check the dash display to fault does not repeat. 4. If fault repeats: a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector. b. Resistance should measure approximately 5.9 ohms ±10% at 25 C (77 F). • Replace sensor.
21
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
17169
No Text Displayed
Solid Green
Traction Motor
DESCRIPTION
SYMPTOM
Controller is in thermal cut back due to high traction motor temperature.
Traction system is operating at a reduced performance level.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the ON position and operate the lift truck briefly. 4. Check the dash display to fault does not repeat. 5. If fault repeats: a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector. b. Resistance should measure approximately 5.9 ohms ±10% at 25 C (77 F). • Replace sensor.
22
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
17170
Service Required
Solid Red
Traction Motor
DESCRIPTION
SYMPTOM
Controller has detected a failure of the traction motor temperature sensor.
Traction system is operating at a reduced performance level.
Probable Causes and Test Procedures 1. Disconnect the traction motor temperature sensor connector at the traction motor. 2. Check for continuity of wire #385 between the connector and pin #25 at the controller. a. Repair any broken wiring or loose connections. 3. Check for continuity of wire #102 from the connector to pin #29 at the controller. a. Repair any broken wiring or loose connections. 4. Measure the resistance across pin #1 and pin #2 of the sensor side of the connector. a. Resistance should measure approximately 5.9 ohms ±10% at 25 C (77 F). 5. If measurement indicates an open or shorted sensor, replace sensor.
23
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
20756
Service Required
Solid Red
Key
DESCRIPTION
SYMPTOM
The controller has sensed the key switch circuit is open.
Truck will not operate.
Probable Causes and Test Procedures 1. the key switch is turned to the ON position. 2. the battery is connected to the lift truck. 3. Check condition of FU 5. a. continuity through the fuse. 4. Check for battery voltage on pin #1 (wire #10) at the controller connector. a. Check for open wire #10 between connector and key switch.
24
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21024
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a failure in the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. battery voltage at pin #6 (X2) at the control module connector. a. Check continuity of wire #10 from key switch to pin #6 (X2) at control module connector. 2. Ensure all wiring connections between the control module and the controller are tight and secure.
25
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21024 (cont)
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a failure in the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 60 ohms. • If resistance is approximately 120 ohms, check wiring for broken or shorted condition. • Repair all damaged wiring.
26
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21024 (cont)
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a failure in the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 60 ohms. • If resistance is approximately 120 ohms, check wiring for broken or shorted condition. • Repair all damaged wiring. 5. Internal failure of the control module. a. Replace control module.
27
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connections between the control module and the controller are tight and secure.
28
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 2. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 40 ohms. • If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
29
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Check for continuity between pin #3 (X2)at the control module connector and pin #28 at the controller connector. a. Repair any broken wiring.
30
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. Check for continuity between pin #4 (X2) at the control module connector and pin #27 at the controller connector. a. Repair any broken wiring.
31
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 5. Check for continuity between pin #2 (X2) at the control module connector and pin #29 at the controller connector. a. Repair any broken wiring.
32
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21521
Service Required
Solid Red
Hydraulics
DESCRIPTION
SYMPTOM
Controller has detected the lower valve shorted to B+.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Disconnect the pump coil connector at the lift pump. 2. Check for a shorted condition across the coil leads at the connector. a. Replace the coil. 3. Check for shorted wiring on wire #150 and wire #86 between the pump coil and the controller. a. Repair any damaged wiring. 4. Check for a shorted condition between pin #22 and pin #23 at the controller and B . a. Resistance should be greater than 1000 ohms. • NMHG Service Engineering Management.
33
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21522
Service Required
Solid Red
Hydraulics
DESCRIPTION
SYMPTOM
Controller has detected an open circuit in the lower valve.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Disconnect the pump coil connector at the lift pump. 2. Measure the resistance across pins from the pump coil. a. Resistance should be approximately 1 ohm. • Replace the coil. 3. Check for open circuit condition in wire #150 and wire #86 from the connector to pin #22 and pin #23 at the controller. a. Repair broken wiring or loose connections.
34
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21533
Service Required
Solid Red
Horn
DESCRIPTION
SYMPTOM
Controller has detected the horn shorted to B+.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Measure the resistance between the red lead and the black lead from the horn at the horn connector. a. The resistance should read approximately 28 ohms. • Replace the horn. 2. Check the horn connector for pin-to-pin shorted condition. a. Repair the connector. 3. Check for pin #20 at the controller shorted to B+. a. NMHG Service Engineering Management.
35
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21534
Service Required
Solid Red
Horn
DESCRIPTION
SYMPTOM
Controller has detected an open circuit in the horn.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Measure the resistance between the red lead and the black lead from the horn at the horn connector. a. The resistance should read approximately 28 ohms. • Replace the horn. 2. Check for battery voltage at wire #10 at the horn connector when the key switch is closed. a. Ensure all connections and connectors are secure and tight. b. Check for open circuits in the harness. • Repair wiring. 3. Check continuity of wire #45 from the horn connector to pin #20 at the controller connector. a. Repair wiring. 4. Internal failure of the controller. a. NMHG Service Engineering Management.
36
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21535
Service Required
Solid Red
Horn
DESCRIPTION
SYMPTOM
The controller has detected the horn shorted to B .
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Measure the resistance between the red lead and the black lead from the horn at the horn connector. a. The resistance should read approximately 28 ohms. • Replace the horn. 2. Check the horn connector for pin-to-pin shorted condition. a. Repair the connector. 3. Check for pin #20 at the controller shorted to B . a. NMHG Service Engineering Management.
37
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21539
Service Required
Solid Red
Controller
DESCRIPTION
SYMPTOM
Controller has detected an internal failure of the output driver.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and restart the lift truck. 2. the fault returns after restart. a. NMHG Service Engineering Management.
38
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. all steer handle switches and controls are in the neutral position. 2. Check for battery voltage at pin #3 at the control module. a. Check for continuity of wire #10 from the key switch to the control module.
39
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552 (cont)
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Check for any mechanical binding in switches or throttle mechanism. a. Clear any binding. b. Repair or replace faulty switches.
40
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552 (cont)
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. there is no shorted wiring between wire #901, wire #902, wire #102, and wire #28 between the control module and the controller. a. Repair any shorted wiring.
41
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552 (cont)
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 5. the continuity of wire #102, wire #900, wire #901 and wire #28 from the control module to the controller. a. Repair any broken wiring or loose connections.
42
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21553
Release Rabbit
Flashing Red
Controls
DESCRIPTION
SYMPTOM
Controller has detected a closed high speed switch at startup.
High speed will not operate.
Probable Causes and Test Procedures 1. Ensure the high speed “Rabbit” switch is not being held closed. a. Eliminate any binding in the handrail handle. 2. Check the switch for a shorted condition. a. Replace faulty switch. 3. Check for wire #342 shorted to B+. a. Repair any faulty wiring.
43
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21554
Improper Start
Flashing Red
Controls
DESCRIPTION
SYMPTOM
Controller has detected a closed auxiliary horn switch at startup.
Horn operates continuously.
Probable Causes and Test Procedures 1. Ensure the handle horn switch is not being held closed. a. Eliminate any binding in the switch. b. Replace switch if necessary. 2. Separate handle connector. a. If horn quits sounding, replace handle horn switch. 3. Check for wire #25 shorted to B+. a. Repair any faulty wiring. 4. Ensure the backrest horn switch is not being held closed. a. Eliminate any binding in the switch. b. Replace switch if necessary. 5. Separate the controller connector. a. If horn continues to sound, check for pin #11 at the controller shorted to B+. • NMHG Service Engineering Management.
44
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21555
Improper Start
Flashing Red
Controls
DESCRIPTION
SYMPTOM
Controller has detected a closed auxiliary lift or lower switch at startup.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Inspect handle lift and lower switches for binding. a. Ensure all parts are free to move. 2. Check each switch for a shorted condition. a. Replace faulty switch. 3. Check wire #25 for a shorted condition to B+. a. Repair any faulty wiring. 4. Ensure the backrest horn switch is not being held closed. a. Eliminate any binding in the switch. b. Replace switch if necessary.
45
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21568
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Main or is open and will not close.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure or tips are free to close. a. Correct any binding in the or. 2. Check for worn or tips. a. Replace or. 3. Ensure there is no foreign material separating the or tips. a. Clean any debris from the or. 4. Replace the or.
46
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21569
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Controller has detected the main or shorted to B+.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Separate the controller connector. 2. Check for a shorted condition between pin #18 at the controller and B+. a. NMHG Service Engineering Management. 3. Check the connector for any pin-to-pin shorts. a. Repair any wiring faults.
47
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21570
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Controller has detected an open circuit in the main or.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connections are secure and tight. 2. Check for battery voltage on wire #10 at the main or. a. Check continuity of wire #10 between the key switch and the main or. • Repair any open wiring. b. Check for continuity through FU 5. • Replace fuse. 3. Check the resistance through the main or coil. a. The resistance should measure approximately 22 ohms ±10%. • Replace the coil. 4. Check continuity of wire #45 from the coil to the controller pin #20. Repair any open wiring. 5. Internal failure of the controller. a. NMHG Service Engineering Management.
48
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21571
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Controller has detected the main or shorted to B .
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure the B+ and B cables from the battery are connected properly. 2. Separate the controller connector. 3. Check for a shorted condition between pin #18 at the controller and B . a. NMHG Service Engineering Management. 4. Check the connector for any pin-to-pin shorts to B . a. Repair any wiring faults.
49
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29445
Service Required
Solid Red
Traction
DESCRIPTION
SYMPTOM
The controller cannot detect the signal from the traction motor encoder.
Traction system will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connection between the encoder and the controller are secure and tight. 2. Check for 12 volts on wire #250. a. Check for 12 volts at controller pin #30. • NMHG Service Engineering Management. 3. Check encoder output between pin #2 and pin #4 at the encoder connector from the traction motor. a. Output should alternate between 12 and 0 volts as the motor rotates. • Change the encoder. 4. Check encoder output between pin #3 and pin #4 at the encoder connector from the traction motor. a. Output should alternate between 12 and 0 volts as the motor rotates.
50
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29448
Improper Start
Flashing Red
Brake
DESCRIPTION
SYMPTOM
Controller has detected a closed brake switch at startup.
Traction system will not operate.
Probable Causes and Test Procedures 1. Ensure the brake switch is in the ON position at truck startup. 2. Ensure the neutral switch is not being held open at truck startup. a. Adjust switch. b. 0 volts at pin #6 at the controller connector with the brake switch in the OFFposition. 3. Measure continuity across pin #1 and pin #2 at the neutral switch connector. a. Switch should be open with no continuity shown. • Replace switch.
51
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29456
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected an error in the control module throttle sensor.
Traction system will not operate.
Probable Causes and Test Procedures 1. Throttle sensor is out of calibration. a. Calibrate throttle sensor. See Electrical System 2200 SRM 1357. 2. Check connection to throttle sensor in handle. a. Check 5V supply to sensor. b. Check ground to sensor.
52
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29456 (cont)
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected an error in the control module throttle sensor (cont).
Traction system will not operate.
Probable Causes and Test Procedures 3. Throttle sensor has failed. a. Replace the sensor.
53
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29458
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected the control module analog sensor to be out of limits.
Traction system will not operate.
Probable Causes and Test Procedures 1. Check connection to throttle sensor in handle. a. Check 5V supply to sensor. b. Check ground to sensor. 2. Measure output @ sensor and ensure 2.5V ±0.5V present in neutral position. 3. Throttle sensor has failed. a. Replace the sensor.
54
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connections between the control module and the controller are tight and secure. 2. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 40 ohms. • If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
55
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Check for continuity between pin #3 (X2) at the control module connector and pin #28 at the controller connector. a. Repair any broken wiring.
56
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. Check for continuity between pin #4 (X2) at the control module connector and pin #27 at the controller connector. a. Repair any broken wiring.
57
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 5. Check for continuity between pin #2 (X2) at the control module connector and pin #29 at the controller connector. a. Repair any broken wiring.
58
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 6. Internal failure in the control module. a. Replace control module. 7. Internal failure of the traction controller. a. NMHG Service Engineering Management.
59
Dash Display
2200 SRM 1352
Dash Display GENERAL The dash display is a multifunction device. It contains a truck status LED and an LCD which displays the performance mode indicator and the battery charge indicator. The menu system can be accessed through the dash display by starting the truck in service mode and entering the proper . See Figure 4.
• When the lift truck is operating normally, the LED will be solid green when the key is in the ON position. • If there is a fault noted by the lift truck controller and the controller has prevented traction and hydraulic functions, the LED will be solid red. • When the battery charge reaches 75% of full charge, the horn will sound and the LED will alternately blink from red to green. • If the controller has noted a condition that require the lift truck to operate at a reduced performance level, the LED will blink red.
PERFORMANCE MODE INDICATOR The performance mode indicator will show the current performance mode setting at truck startup. The indicator is a four bar display with the rabbit or highest performance level on the right and the "Turtle" or lowest performance level on the left. See Figure 5. The performance model level can be changed using the lift and lower buttons on the steer handle as described in the Operating Manual unless the performance mode function has been locked by a supervisor or a technician. Refer to or Interface, Technician Functions On-Board Dash Display 2200 SRM 1354.
Figure 4. Dash Display Screens
STARTUP When the key is turned to the ON position and the handle is in the full upright position, all segments of the display will be illuminated and the horn will beep twice. The LED will flash red, green, and then go blank momentarily. Then the display will show the truck mode setting and the hourmeter reading.
STATUS LED The status LED is located in the top center of the display. When the key switch is in the ON position, the LED is on. The LED can indicate in either red or green depending on the information being communicated. • When the lift truck key is in the OFF position, the LED will be OFF.
60
Figure 5. Performance Mode Screen
2200 SRM 1352
Dash Display
HOURMETER The hourmeter accumulates hours when the key is in the ON position and main or is closed. The hourmeter is capable of showing five digits and displays complete hours. See Figure 6. At truck startup, the display will show the truck hours for 10 seconds after the key has been turned to the ON position. The hourmeter reading will be turned off if the control handle is moved to the operating position any time within the 10 second display period.
Figure 7. Battery Charge Indicator
FAULT LOG The Fault Log menu will list the truck system initiating the fault, the error code associated with the fault, the hourmeter reading when the fault occurred, the number of times the fault has been logged, and the system temperature when the fault occurred. See Figure 8. The Fault Log auto scrolls. The system will retain the last ten faults noted. Figure 6. Hourmeter
BATTERY CHARGE INDICATOR When the truck hourmeter is disabled, it is replaced on the display by the battery charge indicator. The indicator is a five bar graphical indicator with the full indicator bar on the right and the empty indicator bar on the left. See Figure 7. At 100% charge, all bar graph segments will be shaded. As the battery is discharged, fewer of the bars will be shaded. 100% Charge = 5 Solid Bars 80% Charge = 4 Solid Bars 60% Charge = 3 Solid Bars 40% Charge = 2 Solid Bars 30% Charge = 1 Solid Bar During Lifting 20% Charge = 0 Solid Bars, Blinking Red Status LED, Lift Lockout - (Horn Sounds When Lift Switch Is Activated) Figure 8. Fault Log Screen
61
Connector Pin-Outs
2200 SRM 1352
Connector Pin-Outs Controller Connector (S 05)
62
Pin
Wire Number
Function
1
W10 - AC RED
Battery Positive
2
W342 - A
High Speed
3
W26 - A
Aux. Lift Switch
4
W27 - A
Aux. Lower Switch
5
W28 - A
Control Module
6
W98 - AC
Steer Handle Switch
7
-
-
8
-
-
9
-
-
10
-
-
11
W25 - A
Aux. Horn Switch
12
-
-
13
-
-
14
-
-
15
-
-
16
-
-
17
-
-
18
W79 - M RED
Main or Coil
19
-
-
20
W45 - H
Horn
21
-
-
22
W150 - A
Pump Coil (+)
23
W86 - A
Pump Coil ( )
24
-
-
25
W386 - A
Traction Motor Temp Sensor
26
-
-
27
W901/H - WHT
CAN Hi
28
W900/L - BLK
CAN Lo
29
W102/BARE - GRN
Traction Motor Temp Sensor
30
W250 - E
Traction Motor Encoder
31
W577 - E
Traction Motor Encoder
32
W578 - E
Traction Motor Encoder
33
-
-
2200 SRM 1352
System Logic Diagram
System Logic Diagram
Traction Motor
-------CANbus
Traction Encoder
Dash Display
-------CANbus
Temperature Sensor --------
Pump Motor C60/80Z AC
--------
-------- Forward/Reverse Input
Power Steering Motor
--------
--------
Truck Speed Input
Main or
--------
--------
Lift/Lower Input
CANbus CANbus
Horn
--------
-------- Traction Reverse Input
Lower Solenoid
--------
--------
Neutral Input
Cruise Solenoid
--------
--------
Pick Mode Input
Electric Brake Coil
--------
--------
Horn
Control Module
Traction Motor Controller High Speed Switch
--------
Aux. Horn Switch
--------
Aux. Lift Switch
--------
Aux. Lower Switch --------
Tiller Switch
--------
CANbus
PC Service Connection
63
NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________
64
PART NO. 1687931
2200 SRM 1352
AC Motor Controller
Table of Contents
TABLE OF CONTENTS General ............................................................................................................................................................... Discharging the Capacitors........................................................................................................................... Description ......................................................................................................................................................... Electrical System ........................................................................................................................................... AC Traction Motor..................................................................................................................................... Controller................................................................................................................................................... Service PC Connection .............................................................................................................................. Parameters ......................................................................................................................................................... General ........................................................................................................................................................... Parameter Description....................................................................................................................................... Parameters..................................................................................................................................................... Extended Shift........................................................................................................................................... Walk Speed (Both Directions) ................................................................................................................... Hi Speed (FWD)......................................................................................................................................... Hi Speed (REV).......................................................................................................................................... Minimum Acceleration.............................................................................................................................. Maximum Acceleration ............................................................................................................................. Plugging ..................................................................................................................................................... ADS-Neutral .............................................................................................................................................. ADS-Throttle ............................................................................................................................................. Pick Acceleration ....................................................................................................................................... Pick Deceleration....................................................................................................................................... Battery Full Voltage .................................................................................................................................. Lift Interrupt ............................................................................................................................................. Service Hour Reminder............................................................................................................................. Troubleshooting.................................................................................................................................................. General ........................................................................................................................................................... Status Codes .................................................................................................................................................. Dash Display ...................................................................................................................................................... General ........................................................................................................................................................... Startup ........................................................................................................................................................... Status LED .................................................................................................................................................... Performance Mode Indicator......................................................................................................................... Hourmeter...................................................................................................................................................... Battery Charge Indicator .............................................................................................................................. Fault Log ........................................................................................................................................................ Connector Pin-Outs............................................................................................................................................ System Logic Diagram.......................................................................................................................................
1 1 2 2 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 7 7 7 60 60 60 60 60 61 61 61 62 63
This section is for the following models: T5Z AC [B476]; T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]
©2008 HYSTER COMPANY
i
2200 SRM 1352
General
General This section describes the Iskra® motor controller and dash display used in C60Z AC, C80Z AC, T5Z AC, and T7Z AC lift trucks. Procedures are outlined for controller programming and troubleshooting.
DISCHARGING THE CAPACITORS WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to discharge the traction motor controller.
WARNING To avoid personal injury and prevent electrical shock, perform the following steps before performing any troubleshooting or adjustments, and connecting or disconnecting a handset or PC.
CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller. 1. Move the truck to a safe, level area. Turn the key switch to the OFF position and disconnect the battery. 2. Remove the drive unit compartment cover to access the controller. 3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s B+ and B terminals. See Figure 1. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.
1. 2. 3. 4. 5.
CONTROLLER POSITIVE CONNECTION INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR NEGATIVE CONNECTION Figure 1. Discharging the Capacitors
1
Description
2200 SRM 1352
Description ELECTRICAL SYSTEM The Iskra® AC motor controller controls the AC traction motor and the DC pump motor. The controller can also be used with the optional brushless DC
1. 2. 3. 4. 5. 6. 7.
KEY SWITCH BATTERY DISCHARGE INDICATOR (BDI) PARKING BRAKE SWITCH PARKING BRAKE TRACTION MOTOR HORN LIFT PUMP MOTOR
power steering motor. The controller uses CANbus communication to interact with the dash display and the control handle. See Figure 2 or Figure 3.
8. 9. 10. 11. 12. 13.
CONTROL MODULE DIAGNOSTIC CONNECTOR OR CONTROLLER FUSE BATTERY CONNECTOR
Figure 2. Electrical Components (C60-80Z AC)
2
2200 SRM 1352
1. 2. 3. 4. 5. 6.
Description
KEY SWITCH BATTERY DISCHARGE INDICATOR (BDI) PARKING BRAKE SWITCH PARKING BRAKE TRACTION MOTOR HORN
7. 8. 9. 10. 11. 12.
CONTROL MODULE DIAGNOSTIC CONNECTOR OR CONTROLLER FUSE BATTERY CONNECTOR
Figure 3. Electrical Components (T5-7Z AC)
3
Parameters
2200 SRM 1352
AC Traction Motor The AC traction motor is a three-phase AC induction motor. The motor does not include motor brushes or a commutator. An AC induction motor operates on three-phase AC power provided directly by the controller. The motor speed is controlled by the motor controller and can be changed by the frequency of the AC power supplied to the motor. A speed sensor has been built into one of the motor bearings which provides to the motor controller allowing software to continually monitor motor direction and revolutions per minute (RPM). Using this system, the AC motor control can provide much better vehicle top speed control than the older DC SEM systems.
Controller The motor controller converts DC power from the truck battery to three-phase AC power at the frequencies and currents necessary to drive the traction motor. A bearing in the traction motor provides of speed, rotation direction, and temperature directly to the motor controller.
The motor controller receives power through the main or which is controlled by the key switch. The controller receives inputs from the control handle and the hand rail switches to control lift truck functions. NOTE: There are no serviceable parts in the motor controller. No attempt should be made to open repair, or otherwise modify the controller. Doing so may damage the controller and/or lift truck. Removing the cover from the controller will void the warranty.
Service PC Connection The lift truck is equipped with a connection point to connect a laptop computer with ETACC software installed. This connection can be used to adjust certain lift truck parameters and to assist with troubleshooting the lift truck.
Parameters GENERAL A parameter is a measurement or a setting that defines a lift truck function. A specific function parameter works with other function parameters to control the operation of the lift truck.
WARNING The parameter for each function has a value range so the motor controller can be used on different models of lift trucks. This variation is needed for lift trucks of different sized and operation voltages. Adjustment of a function to the wrong number value for your lift truck model can cause the truck to operate differently than normal. This different operation of the truck can cause an injury. NOTE: Table 1 shows the factory default setting for each parameter that is adjustable by the .
4
Parameters can be adjusted through the dash display. The factory default values listed in Table 1 are the recommended settings for new units. These settings will give satisfactory performance for most applications.
WARNING If any of the parameter values are changed, the operators must be told the lift truck will operate differently. NEVER adjust any of the following parameters without using the procedures and settings given in this section. Function Parameter Descriptions in this section contains descriptions for the different parameters. These parameters can also be accessed using the ETACC PC software.
2200 SRM 1352
Parameter Description Table 1. Parameter Default Values
Parameter
Extended Shift Battery Full Voltage Battery Empty Voltage
Range
Default C60Z AC and T5Z AC
C80Z AC and T7Z AC
Min
Max
OFF
OFF
ON
OFF
25.000
27.000
22.800
25.000
25.300 23.520
1
25.300 23.520
1
ADS-Throttle
1
1
1
10
ADS-Neutral
1
1
1
10
Plugging
7
7
1
10
Walk speed (Both Directions)
3.8
3.8
0.5
4.0
Hi Speed (FWD)
9.0
9.0
0.5
9.0
Hi Speed (REV)
6.0
6.0
0.5
7.5
Minimum Acceleration
53
53
0
100
Maximum Acceleration
70
70
0
100
Service Hour Reminder
0
0
0
1000
1
Maintenance-free battery option uses value 24.000.
Parameter Description PARAMETERS WARNING If any of the parameter values are changed, the operators must be told the lift truck will operate differently. NEVER adjust any of the following parameters without using the procedures and settings given in this section. Parameters can be adjusted through the dash display LCD. These parameters can also be accessed using the ETACC PC software.
Extended Shift This parameter when on, will reduce traction performance by 15% to provide extended battery shift life. The parameter may be set to the OFF or ON condition.
Walk Speed (Both Directions) This parameter sets the maximum truck speed for forward and reverse directions when the truck is in “Walk” mode. Increasing the setting will increase the truck speed. Decreasing the setting will decrease truck speed.
Hi Speed (FWD) This parameter sets the maximum forward speed of the lift truck when the truck is in “Ride” mode. Increasing the setting increases the speed. Decreasing the setting will decrease the speed.
Hi Speed (REV) This parameter sets the maximum reverse speed of the lift truck when the truck is in “Ride” mode. Increasing the setting increases the speed. Decreasing the setting will decrease the speed.
5
Parameter Description
Minimum Acceleration This parameter sets the minimum acceleration rate of the lift truck when the truck is in traveling at the lowest throttle. Increasing the setting increases the minimum rate of acceleration. Decreasing the setting will decrease the minimum rate of acceleration.
Maximum Acceleration This parameter sets the maximum acceleration rate of the lift truck when the truck is traveling at maximum throttle. Increasing the setting increases the maximum rate of acceleration. Decreasing the setting will decrease the maximum rate of acceleration.
Plugging This parameter controls the maximum rate of deceleration when the speed control is fully moved to the opposite direction from the direction of travel while the truck is moving. Increasing this setting will increase the rate of deceleration. Decreasing the setting will reduce the rate of deceleration.
ADS-Neutral This parameter controls the rate of deceleration when the speed control is returned to the neutral position and the ADS-Throttle parameter is set above 1. Setting the value at 1 will result in no effect on the rate of deceleration; the truck will coast until it comes to a stop. Increasing the value will increase the rate of deceleration. Decreasing the value will decrease the rate of deceleration.
ADS-Throttle This parameter controls the rate of deceleration when the speed control is partially reduced and the ADS-Throttle parameter is set above 1. Setting the value at 1 will result in no effect on the rate of deceleration; the truck will coast until it reaches the lower throttle speed. Increasing the value will increase the rate of deceleration. Decreasing the value will decrease the rate of deceleration.
Pick Acceleration This parameter controls the rate of acceleration when the coast control switch is activated. Increasing the value will increase the rate of acceleration.
6
2200 SRM 1352 Decreasing the value will decrease the rate of acceleration.
Pick Deceleration This parameter controls the rate of deceleration when the coast control switch is released. Increasing the value will increase the rate of deceleration. Decreasing the value will decrease the rate of deceleration. Setting the value at 1 will result in no effect on the rate of deceleration; the truck will coast until it comes to a stop.
Battery Full Voltage This is the battery voltage in millivolts at which the battery is considered fully charged. Increasing the setting increases the voltage. Decreasing the setting reduces the voltage.
Lift Interrupt This is the battery voltage in millivolts at which the battery is considered 80% discharged. Increasing the setting increases the voltage. Decreasing the setting reduces the voltage.
Service Hour Reminder This parameter initiates a reminder when the hourmeter reaches a preset point indicating the lift truck is due to be serviced. Within this menu, you can reset the Service Hour Reminder, change the service interval hours, and turn the function ON or OFF. The normal factory default setting for the Service Hour Reminder is OFF and must be changed to ON for the function to be active. When the Service Hour Reminder is ON, the dash display will display a one-time message to the operator when the preset hourmeter reading has been reached. The lift truck will continue to operate normally until the hourmeter reaches 20 hours past the preset service interval. At this time the lift truck function speeds will be reduced until the Service Hour Reminder has been reset. The lift truck should be serviced and the parameter reset to the next hourmeter reading when service is due.
2200 SRM 1352
Troubleshooting
Troubleshooting GENERAL The controllers are sealed units with no serviceable components. Troubleshooting is usually limited to accessing status codes and following the diagnostic procedures listed in the status code charts. Use standard testing procedures to inputs and outputs when necessary.
CAUTION Never attempt to probe through the back of the connector plugs of the motor controller. The plugs are special sealed plugs. Probing through the back of the plugs will destroy the seal and can cause a short circuit. If a circuit must be tested for voltage, check for voltage at an amp-type plug, a switch, or a component. If a circuit is suspect, check the circuit for continuity from the front (pin end) of the plug. Standard probes are too large to be inserted into the center of the female pins (sockets) of the special sealed plugs and can expand the pins. Expanded pins will not provide good connections once the plug is reconnected. The connectors are shaped to allow the insertion of a flat blade screwdriver into the connector. After inserting the screwdriver into the connector, attach probes with alligator clips to the shank of the screwdriver to obtain readings. An additional method would be to use a breakout kit. If the controller detects an issue, a status code is displayed on the display . Once the status code number is obtained, follow the procedures outlined in the status code charts of this manual to determine the problem. NOTE: Due to the interaction of the controller with all lift truck functions, almost any status code or controller fault could be caused by an internal failure of the controller. After all other status code procedures have been followed and no problem is found, the controller should be replaced as the last option to correct the problem. Tools and test equipment required are: • Clip Leads • Digital Multimeter (20,000 ohms per volt) • Basic Hand Tools
Check resistance on the proper scale from frame to power and controller terminals. Resistance of less than 20,000 ohms can cause misleading symptoms. Resistance of less than 1000 ohms indicates a short and should be corrected immediately. The on-board diagnostic system employed on this lift truck can assist in the troubleshooting process. Read and be familiar with the instructions for accessing and using the dash display diagnostic system. Prior to troubleshooting systems and components on this lift truck, ensure the battery is the correct voltage and is fully charged. Make sure the battery connector s are clean of corrosions and the battery polarity within the connector is correct. Inspect to ensure all fuses are correct and have not failed. Ensure the key switch is in the ON position when making voltage checks or checking the operator of a component. Many faults noted by lift truck systems are the result of loose wiring connections and/or broken or shorted wiring within the lift truck. Begin the troubleshooting process by carefully inspecting the wiring involving the device or devices noted by the on-board diagnostics system.
STATUS CODES Make sure the parameter values are correct for your lift truck to ensure the trouble is not just an incorrect setting. See function settings to set the correct parameter values. If there is no status code display and the lift truck does not operate correctly, there may be a fault in the controller. The status codes are numbers for malfunction or lift truck operation that are not correct and that the controller can sense. The controller will indicate this code number on the LCD screen of the display . NOTE: There are identifiers to determine which device generated the code: Xy = XXXX (Co 23538) Co = Controller Ti = Control Module The controller senses the following types of malfunction: • Input voltages that are too high or too low • Input voltages in the wrong sequence or • Correct input voltages that occur at the wrong time
7
Troubleshooting
2200 SRM 1352
NOTE: A status code indication does not always mean that there is a malfunction. A temporary operation condition can cause a status code display. These code numbers are only indicators that may help diagnose a possible malfunction. A short description of the different status codes is shown in Table 2.
The Fault Message charts in this section have a more complete description of the status code, the circuit that has generated the input for the status code, the symptom, and the possible cause.
Table 2. Fault Codes Code
8
Description
9024
Controller failure of the traction motor power circuit
9088
Pump motor shorted
9089
Pump motor open
9090
Pump at relief
9091
Controller failure of the pump motor power circuit.
12816
Controller internal voltage over 36 volts
12819
Incorrect voltage battery connected
12832
Controller internal voltage less than 16 volts
12835
Incorrect voltage battery connected
16912
Controller power section is over temperature
16944
Controller is in thermal cutback - high controller temperature
16945
Controller internal temperature sensor failure
17168
Traction motor is over temperature
17169
Controller is in thermal cutback - high traction motor temperature
17170
Traction motor temperature sensor failure
20756
Key switch open
21024
Control module failure
21378
Controller cannot establish with control module
21533
Horn circuit is shorted to B+
21534
Horn circuit is open
21535
Horn circuit is shorted to B
21544
Horn switch is closed at startup
21552
Steer handle inputs incorrect at startup
21553
Hi Speed switch is closed at startup
21555
Lift or lower switch is closed at startup
21568
Main or circuit is open
21569
Main or circuit is shorted to B+
2200 SRM 1352
Troubleshooting
Table 2. Fault Codes (Continued) Code
Description
21570
Main or circuit is open
21571
Main or circuit is shorted to B
21588
Internal failure of the power steering unit
29445
Traction motor encoder failure
29448
Steer handle switch closed at startup
29456
Error in control module speed/direction sensor
29458
Steer handle sensor is out of limits
33056
Controller cannot establish communication with control module
33057
Controller cannot establish communication the power steering controller
9
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9024
Service Required
Solid Red
Traction
DESCRIPTION
SYMPTOM
Traction motor phase U, V, or W shorted to B+ or B .
Truck will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and disconnect the battery connector. 2. Disconnect the motor leads from the controller. 3. Check motor for phase-to-ground or phase-to-B+ shorted condition. a. Motor should measure minimum 1 megohm phase-to-ground. • Replace traction motor. 4. Check U, V, and W terminals of the controller for shorted condition to B+ or B . a. NMHG Service Engineering Management.
10
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9088
Service Required
Solid Red
Pump
DESCRIPTION
SYMPTOM
Pump motor has shorted.
Hydraulics will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and disconnect the battery. 2. Disconnect pump motor leads from controller. a. Check for any burns or evidence of arcing. 3. Visually check motor leads for any damage or evidence of shorting to the truck frame. a. Check for any burns or evidence of arcing. • Repair or replace any damaged wiring. 4. Check for P terminal at the controller shorted to B . a. Resistance should be greater than 50 megohms. • NMHG Service Engineering Management. 5. Replace pump motor.
11
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9089
Service Required
Solid Red
Pump
DESCRIPTION
SYMPTOM
Pump motor has open circuit.
Hydraulics will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and disconnect the battery connector. 2. Disconnect pump motor cables from the controller. 3. continuity through each motor cable. a. Replace any broken wiring. 4. Check for open circuit across the across the motor terminals. a. If greater than 500 ohms, replace the pump motor.
12
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9090
Overload
Flashing Red
Pump
DESCRIPTION
SYMPTOM
Controller has detected the hydraulic system is being operated at relief.
Hydraulics will not operate.
Probable Causes and Test Procedures 1. weight of load does not exceed lift truck capacity on the nameplate. a. Reduce load weight. 2. there is no binding in the lifting mechanism. 3. Install a 24.13 MPa (3500 psi) pressure gauge in the lift cylinder line. a. the relief pressure is correct: • C60Z AC = 18.96 MPa (2750 psi) • C80Z AC = 23.44 MPa (3400 psi) 4. Adjust relief pressure to correct value. a. See Walkie Hydraulic Systems 1900 SRM 964.
13
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
9091
Internal Pump Circuit Failure
Solid Red
Pump
DESCRIPTION
SYMPTOM
Controller has detected an internal failure in the pump circuit.
Truck will not operate.
Probable Causes and Test Procedures 1. 24 volts at the controller B+ terminal. a. Ensure battery is connected to the lift truck. b. continuity of fuse FU 1. 2. Turn the key switch to the OFF position. 3. Disconnect cable PM1 at the P controller terminal. a. Check for a shorted condition between P and B • Resistance should be greater than 500 ohms. • NMHG Service Engineering Management. 4. Disconnect cable PM1 at the P controller terminal and reconnect it to the controller B a. Turn the key switch to the ON position and the pump motor operates. b. NMHG Service Engineering Management.
14
terminal.
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
12819
Check Battery
Flashing Red
Battery
DESCRIPTION
SYMPTOM
Controller has detected a battery voltage in excess of 32 volts.
Truck will not operate.
Probable Causes and Test Procedures 1. Check battery voltage at controller B+ terminal. 2. battery voltage matches voltage listed on the lift truck nameplate. a. Install correct voltage battery.
15
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
12832
Check Battery
Flashing Red
Battery
DESCRIPTION
SYMPTOM
The controller has sensed battery voltage to be less than 16 volts.
Truck will not operate.
Probable Causes and Test Procedures 1. Check battery voltage at controller B+ terminal. 2. battery voltage matches voltage listed on the lift truck nameplate. a. Install correct voltage battery. 3. Check for continuity through fuse FU 1. a. Replace fuse. 4. Condition can be caused by normal operation of the lift truck with a discharged battery. a. Check battery state of charge on the dash display. • Recharge battery. • Install a fully charged battery.
16
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
12835
Check Battery
Flashing Red
Battery
DESCRIPTION
SYMPTOM
Controller has detected a battery with less than 16 volts has been connected to the lift truck.
Truck will not operate.
Probable Causes and Test Procedures 1. Check battery voltage at controller B+ terminal. 2. battery voltage matches voltage listed on the lift truck nameplate. a. Install correct voltage battery.
17
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
16912
Wait to Cool Down
Flashing Red
Battery
DESCRIPTION
SYMPTOM
Controller is over temperature.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position and operate the lift truck briefly. 4. fault does not repeat. a. NMHG Service Engineering Management.
18
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
16944
Performance Reduced
Flashing Red
Controller
DESCRIPTION
SYMPTOM
Truck is in thermal cutback due to high controller temperature.
Traction system is operating at a reduced performance level.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the controller at room temperature, turn the key switch to the OFF then back to the ON position and operate the lift truck briefly. 4. fault does not repeat. a. NMHG Service Engineering Management.
19
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
16945
Service Required
Solid Red
Controller
DESCRIPTION
SYMPTOM
Controller has detected an internal failure in the power bridge temperature sensor.
Traction system is operating at reduced performance level.
Probable Causes and Test Procedures 1. 2. 3. 4.
20
Turn the key switch to the OFF position and restart the lift truck. the fault has reoccurred on the dash display. Let truck sit for 10 minutes. Restart the lift truck. a. Fault reoccurs. • NMHG Service Engineering Management.
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
17168
Over Temp
Flashing Red
Traction Motor
DESCRIPTION
SYMPTOM
Controller has detected an over temperature condition in the traction motor.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the ON position and operate the lift truck briefly. Check the dash display to fault does not repeat. 4. If fault repeats: a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector. b. Resistance should measure approximately 5.9 ohms ±10% at 25 C (77 F). • Replace sensor.
21
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
17169
No Text Displayed
Solid Green
Traction Motor
DESCRIPTION
SYMPTOM
Controller is in thermal cut back due to high traction motor temperature.
Traction system is operating at a reduced performance level.
Probable Causes and Test Procedures 1. Internal temperature of controller has exceeded 165 C (329 F). a. Reduce truck usage and allow the controller to cool. 2. Clear fault dash display. See Interface, Technician Functions On-Board Dash Display 2200 SRM 1354. 3. With the traction motor at room temperature, turn the key switch to the OFF position then back to the ON position and operate the lift truck briefly. 4. Check the dash display to fault does not repeat. 5. If fault repeats: a. Check resistance between pin #1 and pin #2 at the motor temperature sensor connector. b. Resistance should measure approximately 5.9 ohms ±10% at 25 C (77 F). • Replace sensor.
22
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
17170
Service Required
Solid Red
Traction Motor
DESCRIPTION
SYMPTOM
Controller has detected a failure of the traction motor temperature sensor.
Traction system is operating at a reduced performance level.
Probable Causes and Test Procedures 1. Disconnect the traction motor temperature sensor connector at the traction motor. 2. Check for continuity of wire #385 between the connector and pin #25 at the controller. a. Repair any broken wiring or loose connections. 3. Check for continuity of wire #102 from the connector to pin #29 at the controller. a. Repair any broken wiring or loose connections. 4. Measure the resistance across pin #1 and pin #2 of the sensor side of the connector. a. Resistance should measure approximately 5.9 ohms ±10% at 25 C (77 F). 5. If measurement indicates an open or shorted sensor, replace sensor.
23
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
20756
Service Required
Solid Red
Key
DESCRIPTION
SYMPTOM
The controller has sensed the key switch circuit is open.
Truck will not operate.
Probable Causes and Test Procedures 1. the key switch is turned to the ON position. 2. the battery is connected to the lift truck. 3. Check condition of FU 5. a. continuity through the fuse. 4. Check for battery voltage on pin #1 (wire #10) at the controller connector. a. Check for open wire #10 between connector and key switch.
24
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21024
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a failure in the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. battery voltage at pin #6 (X2) at the control module connector. a. Check continuity of wire #10 from key switch to pin #6 (X2) at control module connector. 2. Ensure all wiring connections between the control module and the controller are tight and secure.
25
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21024 (cont)
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a failure in the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 60 ohms. • If resistance is approximately 120 ohms, check wiring for broken or shorted condition. • Repair all damaged wiring.
26
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21024 (cont)
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a failure in the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 60 ohms. • If resistance is approximately 120 ohms, check wiring for broken or shorted condition. • Repair all damaged wiring. 5. Internal failure of the control module. a. Replace control module.
27
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connections between the control module and the controller are tight and secure.
28
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 2. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 40 ohms. • If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
29
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Check for continuity between pin #3 (X2)at the control module connector and pin #28 at the controller connector. a. Repair any broken wiring.
30
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. Check for continuity between pin #4 (X2) at the control module connector and pin #27 at the controller connector. a. Repair any broken wiring.
31
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21378 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller has lost communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 5. Check for continuity between pin #2 (X2) at the control module connector and pin #29 at the controller connector. a. Repair any broken wiring.
32
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21521
Service Required
Solid Red
Hydraulics
DESCRIPTION
SYMPTOM
Controller has detected the lower valve shorted to B+.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Disconnect the pump coil connector at the lift pump. 2. Check for a shorted condition across the coil leads at the connector. a. Replace the coil. 3. Check for shorted wiring on wire #150 and wire #86 between the pump coil and the controller. a. Repair any damaged wiring. 4. Check for a shorted condition between pin #22 and pin #23 at the controller and B . a. Resistance should be greater than 1000 ohms. • NMHG Service Engineering Management.
33
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21522
Service Required
Solid Red
Hydraulics
DESCRIPTION
SYMPTOM
Controller has detected an open circuit in the lower valve.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Disconnect the pump coil connector at the lift pump. 2. Measure the resistance across pins from the pump coil. a. Resistance should be approximately 1 ohm. • Replace the coil. 3. Check for open circuit condition in wire #150 and wire #86 from the connector to pin #22 and pin #23 at the controller. a. Repair broken wiring or loose connections.
34
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21533
Service Required
Solid Red
Horn
DESCRIPTION
SYMPTOM
Controller has detected the horn shorted to B+.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Measure the resistance between the red lead and the black lead from the horn at the horn connector. a. The resistance should read approximately 28 ohms. • Replace the horn. 2. Check the horn connector for pin-to-pin shorted condition. a. Repair the connector. 3. Check for pin #20 at the controller shorted to B+. a. NMHG Service Engineering Management.
35
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21534
Service Required
Solid Red
Horn
DESCRIPTION
SYMPTOM
Controller has detected an open circuit in the horn.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Measure the resistance between the red lead and the black lead from the horn at the horn connector. a. The resistance should read approximately 28 ohms. • Replace the horn. 2. Check for battery voltage at wire #10 at the horn connector when the key switch is closed. a. Ensure all connections and connectors are secure and tight. b. Check for open circuits in the harness. • Repair wiring. 3. Check continuity of wire #45 from the horn connector to pin #20 at the controller connector. a. Repair wiring. 4. Internal failure of the controller. a. NMHG Service Engineering Management.
36
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21535
Service Required
Solid Red
Horn
DESCRIPTION
SYMPTOM
The controller has detected the horn shorted to B .
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Measure the resistance between the red lead and the black lead from the horn at the horn connector. a. The resistance should read approximately 28 ohms. • Replace the horn. 2. Check the horn connector for pin-to-pin shorted condition. a. Repair the connector. 3. Check for pin #20 at the controller shorted to B . a. NMHG Service Engineering Management.
37
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21539
Service Required
Solid Red
Controller
DESCRIPTION
SYMPTOM
Controller has detected an internal failure of the output driver.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Turn the key switch to the OFF position and restart the lift truck. 2. the fault returns after restart. a. NMHG Service Engineering Management.
38
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. all steer handle switches and controls are in the neutral position. 2. Check for battery voltage at pin #3 at the control module. a. Check for continuity of wire #10 from the key switch to the control module.
39
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552 (cont)
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Check for any mechanical binding in switches or throttle mechanism. a. Clear any binding. b. Repair or replace faulty switches.
40
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552 (cont)
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. there is no shorted wiring between wire #901, wire #902, wire #102, and wire #28 between the control module and the controller. a. Repair any shorted wiring.
41
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21552 (cont)
Improper Start
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected a fault in the signal from the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 5. the continuity of wire #102, wire #900, wire #901 and wire #28 from the control module to the controller. a. Repair any broken wiring or loose connections.
42
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21553
Release Rabbit
Flashing Red
Controls
DESCRIPTION
SYMPTOM
Controller has detected a closed high speed switch at startup.
High speed will not operate.
Probable Causes and Test Procedures 1. Ensure the high speed “Rabbit” switch is not being held closed. a. Eliminate any binding in the handrail handle. 2. Check the switch for a shorted condition. a. Replace faulty switch. 3. Check for wire #342 shorted to B+. a. Repair any faulty wiring.
43
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21554
Improper Start
Flashing Red
Controls
DESCRIPTION
SYMPTOM
Controller has detected a closed auxiliary horn switch at startup.
Horn operates continuously.
Probable Causes and Test Procedures 1. Ensure the handle horn switch is not being held closed. a. Eliminate any binding in the switch. b. Replace switch if necessary. 2. Separate handle connector. a. If horn quits sounding, replace handle horn switch. 3. Check for wire #25 shorted to B+. a. Repair any faulty wiring. 4. Ensure the backrest horn switch is not being held closed. a. Eliminate any binding in the switch. b. Replace switch if necessary. 5. Separate the controller connector. a. If horn continues to sound, check for pin #11 at the controller shorted to B+. • NMHG Service Engineering Management.
44
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21555
Improper Start
Flashing Red
Controls
DESCRIPTION
SYMPTOM
Controller has detected a closed auxiliary lift or lower switch at startup.
Hydraulic system will not operate.
Probable Causes and Test Procedures 1. Inspect handle lift and lower switches for binding. a. Ensure all parts are free to move. 2. Check each switch for a shorted condition. a. Replace faulty switch. 3. Check wire #25 for a shorted condition to B+. a. Repair any faulty wiring. 4. Ensure the backrest horn switch is not being held closed. a. Eliminate any binding in the switch. b. Replace switch if necessary.
45
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21568
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Main or is open and will not close.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure or tips are free to close. a. Correct any binding in the or. 2. Check for worn or tips. a. Replace or. 3. Ensure there is no foreign material separating the or tips. a. Clean any debris from the or. 4. Replace the or.
46
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21569
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Controller has detected the main or shorted to B+.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Separate the controller connector. 2. Check for a shorted condition between pin #18 at the controller and B+. a. NMHG Service Engineering Management. 3. Check the connector for any pin-to-pin shorts. a. Repair any wiring faults.
47
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21570
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Controller has detected an open circuit in the main or.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connections are secure and tight. 2. Check for battery voltage on wire #10 at the main or. a. Check continuity of wire #10 between the key switch and the main or. • Repair any open wiring. b. Check for continuity through FU 5. • Replace fuse. 3. Check the resistance through the main or coil. a. The resistance should measure approximately 22 ohms ±10%. • Replace the coil. 4. Check continuity of wire #45 from the coil to the controller pin #20. Repair any open wiring. 5. Internal failure of the controller. a. NMHG Service Engineering Management.
48
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
21571
Service Required
Solid Red
Main or
DESCRIPTION
SYMPTOM
Controller has detected the main or shorted to B .
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure the B+ and B cables from the battery are connected properly. 2. Separate the controller connector. 3. Check for a shorted condition between pin #18 at the controller and B . a. NMHG Service Engineering Management. 4. Check the connector for any pin-to-pin shorts to B . a. Repair any wiring faults.
49
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29445
Service Required
Solid Red
Traction
DESCRIPTION
SYMPTOM
The controller cannot detect the signal from the traction motor encoder.
Traction system will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connection between the encoder and the controller are secure and tight. 2. Check for 12 volts on wire #250. a. Check for 12 volts at controller pin #30. • NMHG Service Engineering Management. 3. Check encoder output between pin #2 and pin #4 at the encoder connector from the traction motor. a. Output should alternate between 12 and 0 volts as the motor rotates. • Change the encoder. 4. Check encoder output between pin #3 and pin #4 at the encoder connector from the traction motor. a. Output should alternate between 12 and 0 volts as the motor rotates.
50
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29448
Improper Start
Flashing Red
Brake
DESCRIPTION
SYMPTOM
Controller has detected a closed brake switch at startup.
Traction system will not operate.
Probable Causes and Test Procedures 1. Ensure the brake switch is in the ON position at truck startup. 2. Ensure the neutral switch is not being held open at truck startup. a. Adjust switch. b. 0 volts at pin #6 at the controller connector with the brake switch in the OFFposition. 3. Measure continuity across pin #1 and pin #2 at the neutral switch connector. a. Switch should be open with no continuity shown. • Replace switch.
51
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29456
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected an error in the control module throttle sensor.
Traction system will not operate.
Probable Causes and Test Procedures 1. Throttle sensor is out of calibration. a. Calibrate throttle sensor. See Electrical System 2200 SRM 1357. 2. Check connection to throttle sensor in handle. a. Check 5V supply to sensor. b. Check ground to sensor.
52
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29456 (cont)
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected an error in the control module throttle sensor (cont).
Traction system will not operate.
Probable Causes and Test Procedures 3. Throttle sensor has failed. a. Replace the sensor.
53
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
29458
Service Required
Solid Red
Steer Handle
DESCRIPTION
SYMPTOM
Controller has detected the control module analog sensor to be out of limits.
Traction system will not operate.
Probable Causes and Test Procedures 1. Check connection to throttle sensor in handle. a. Check 5V supply to sensor. b. Check ground to sensor. 2. Measure output @ sensor and ensure 2.5V ±0.5V present in neutral position. 3. Throttle sensor has failed. a. Replace the sensor.
54
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module.
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 1. Ensure all wiring connections between the control module and the controller are tight and secure. 2. Measure resistance between pin #A and pin #B at the Service PC Connection. a. Resistance should be approximately 40 ohms. • If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
55
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 3. Check for continuity between pin #3 (X2) at the control module connector and pin #28 at the controller connector. a. Repair any broken wiring.
56
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 4. Check for continuity between pin #4 (X2) at the control module connector and pin #27 at the controller connector. a. Repair any broken wiring.
57
Troubleshooting
2200 SRM 1352
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 5. Check for continuity between pin #2 (X2) at the control module connector and pin #29 at the controller connector. a. Repair any broken wiring.
58
2200 SRM 1352
Troubleshooting
STATUS CODE
DISPLAY MESSAGE
LED
CIRCUIT
33056 (cont)
Service Required
Solid Red
Controls
DESCRIPTION
SYMPTOM
Controller cannot establish CAN communication with the control module (cont).
Traction and hydraulic systems will not operate.
Probable Causes and Test Procedures 6. Internal failure in the control module. a. Replace control module. 7. Internal failure of the traction controller. a. NMHG Service Engineering Management.
59
Dash Display
2200 SRM 1352
Dash Display GENERAL The dash display is a multifunction device. It contains a truck status LED and an LCD which displays the performance mode indicator and the battery charge indicator. The menu system can be accessed through the dash display by starting the truck in service mode and entering the proper . See Figure 4.
• When the lift truck is operating normally, the LED will be solid green when the key is in the ON position. • If there is a fault noted by the lift truck controller and the controller has prevented traction and hydraulic functions, the LED will be solid red. • When the battery charge reaches 75% of full charge, the horn will sound and the LED will alternately blink from red to green. • If the controller has noted a condition that require the lift truck to operate at a reduced performance level, the LED will blink red.
PERFORMANCE MODE INDICATOR The performance mode indicator will show the current performance mode setting at truck startup. The indicator is a four bar display with the rabbit or highest performance level on the right and the "Turtle" or lowest performance level on the left. See Figure 5. The performance model level can be changed using the lift and lower buttons on the steer handle as described in the Operating Manual unless the performance mode function has been locked by a supervisor or a technician. Refer to or Interface, Technician Functions On-Board Dash Display 2200 SRM 1354.
Figure 4. Dash Display Screens
STARTUP When the key is turned to the ON position and the handle is in the full upright position, all segments of the display will be illuminated and the horn will beep twice. The LED will flash red, green, and then go blank momentarily. Then the display will show the truck mode setting and the hourmeter reading.
STATUS LED The status LED is located in the top center of the display. When the key switch is in the ON position, the LED is on. The LED can indicate in either red or green depending on the information being communicated. • When the lift truck key is in the OFF position, the LED will be OFF.
60
Figure 5. Performance Mode Screen
2200 SRM 1352
Dash Display
HOURMETER The hourmeter accumulates hours when the key is in the ON position and main or is closed. The hourmeter is capable of showing five digits and displays complete hours. See Figure 6. At truck startup, the display will show the truck hours for 10 seconds after the key has been turned to the ON position. The hourmeter reading will be turned off if the control handle is moved to the operating position any time within the 10 second display period.
Figure 7. Battery Charge Indicator
FAULT LOG The Fault Log menu will list the truck system initiating the fault, the error code associated with the fault, the hourmeter reading when the fault occurred, the number of times the fault has been logged, and the system temperature when the fault occurred. See Figure 8. The Fault Log auto scrolls. The system will retain the last ten faults noted. Figure 6. Hourmeter
BATTERY CHARGE INDICATOR When the truck hourmeter is disabled, it is replaced on the display by the battery charge indicator. The indicator is a five bar graphical indicator with the full indicator bar on the right and the empty indicator bar on the left. See Figure 7. At 100% charge, all bar graph segments will be shaded. As the battery is discharged, fewer of the bars will be shaded. 100% Charge = 5 Solid Bars 80% Charge = 4 Solid Bars 60% Charge = 3 Solid Bars 40% Charge = 2 Solid Bars 30% Charge = 1 Solid Bar During Lifting 20% Charge = 0 Solid Bars, Blinking Red Status LED, Lift Lockout - (Horn Sounds When Lift Switch Is Activated) Figure 8. Fault Log Screen
61
Connector Pin-Outs
2200 SRM 1352
Connector Pin-Outs Controller Connector (S 05)
62
Pin
Wire Number
Function
1
W10 - AC RED
Battery Positive
2
W342 - A
High Speed
3
W26 - A
Aux. Lift Switch
4
W27 - A
Aux. Lower Switch
5
W28 - A
Control Module
6
W98 - AC
Steer Handle Switch
7
-
-
8
-
-
9
-
-
10
-
-
11
W25 - A
Aux. Horn Switch
12
-
-
13
-
-
14
-
-
15
-
-
16
-
-
17
-
-
18
W79 - M RED
Main or Coil
19
-
-
20
W45 - H
Horn
21
-
-
22
W150 - A
Pump Coil (+)
23
W86 - A
Pump Coil ( )
24
-
-
25
W386 - A
Traction Motor Temp Sensor
26
-
-
27
W901/H - WHT
CAN Hi
28
W900/L - BLK
CAN Lo
29
W102/BARE - GRN
Traction Motor Temp Sensor
30
W250 - E
Traction Motor Encoder
31
W577 - E
Traction Motor Encoder
32
W578 - E
Traction Motor Encoder
33
-
-
2200 SRM 1352
System Logic Diagram
System Logic Diagram
Traction Motor
-------CANbus
Traction Encoder
Dash Display
-------CANbus
Temperature Sensor --------
Pump Motor C60/80Z AC
--------
-------- Forward/Reverse Input
Power Steering Motor
--------
--------
Truck Speed Input
Main or
--------
--------
Lift/Lower Input
CANbus CANbus
Horn
--------
-------- Traction Reverse Input
Lower Solenoid
--------
--------
Neutral Input
Cruise Solenoid
--------
--------
Pick Mode Input
Electric Brake Coil
--------
--------
Horn
Control Module
Traction Motor Controller High Speed Switch
--------
Aux. Horn Switch
--------
Aux. Lift Switch
--------
Aux. Lower Switch --------
Tiller Switch
--------
CANbus
PC Service Connection
63
NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________
64
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