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Ac Motor Controller: R30XMF3 (A169) R30XMA3 (A185) R30XMS3 (E174) R30XM3 (H118)

The document provides safety precautions and maintenance guidelines for the AC Motor Controller models R30XMF3, R30XMA3, R30XMS3, and R30XM3. It emphasizes the importance of proper training, safe handling of equipment, and the necessity of using approved parts for repairs. Additionally, it includes instructions for discharging capacitors and adjusting parameters for optimal lift truck operation.

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0% found this document useful (0 votes)

9 views270 pages

Ac Motor Controller: R30XMF3 (A169) R30XMA3 (A185) R30XMS3 (E174) R30XM3 (H118)

Uploaded by

frankj.p117

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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AC MOTOR

CONTROLLER
R30XMF3 [A169]; R30XMA3 [A185];
R30XMS3 [E174]; R30XM3 [H118]

PART NO. 4031796 2200 SRM 1466

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
AC Motor Controller Table of Contents

TABLE OF CONTENTS

General ................................................................................................................................................................. 1
Introduction ..................................................................................................................................................... 1
Discharging the Capacitors............................................................................................................................. 1
Parameters ........................................................................................................................................................... 2
Troubleshooting ................................................................................................................................................. 13
General ........................................................................................................................................................... 13
Status Codes .................................................................................................................................................. 14
Basic Checks ................................................................................................................................................ 259
CANbus Test ................................................................................................................................................ 260
Thermal Management ................................................................................................................................. 262

This section is for the following models:

R30XMF3 [A169];
R30XMA3 [A185];
R30XMS3 [E174];
R30XM3 [H118]

©2012 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1466 General

General
INTRODUCTION is disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor(s)
Procedures are outlined for controller programming before inspecting or repairing any component
and troubleshooting. in the drive unit compartment. Make certain
that the battery has been disconnected.
DISCHARGING THE CAPACITORS
DO NOT short across the motor controller ter-
WARNING minals with a screwdriver or jumper wire.
DO NOT make repairs or adjustments unless 1. To avoid injury and prevent electrical shock, per-
you have been properly trained and authorized form Step 2 through Step 6 to discharge the ca-
to do so. Improper repairs and adjustments pacitors before troubleshooting, making adjust-
can create dangerous operating conditions. ments or repairs, or connecting or disconnecting
DO NOT operate a lift truck that needs re- a PC service tool:
pairs. Report the need for repairs to your
supervisor immediately. If repair is necessary, 2. Turn the key or keyless switch to the OFF po-
attach a DO NOT OPERATE tag on the steering sition and DISCONNECT THE BATTERY by
wheel and disconnect the battery. pushing forward on the battery disconnect lever.
Disconnect the battery and allow the capaci- 3. Block the lift truck so the drive wheels are off the
tors to discharge before opening any compart- floor to prevent lift truck from moving.
ment covers or inspecting or repairing the elec-
trical system. DO NOT place tools on top of the 4. Remove the electrical compartment cover to ac-
battery. If a tool causes a short circuit, the high cess the lift controller.
current flow from the battery can cause per-
sonal injury or property damage. NOTE: The lift and traction controllers are wired
parallel. Connecting the resistor across the lift con-
Some checks and adjustments are performed troller will also discharge capacitors in the traction
with the battery connected. DO NOT connect controllers if they are properly connected. To dis-
the battery until the procedure instructs you charge the capacitors in each controller individually,
to do so. Never wear any metallic items on refer to Periodic Maintenance 8000 SRM 1472.
your fingers, arms, or neck. Metal items can
accidentally make an electrical connection 5. Discharge the capacitors in the controllers by
and cause injury. connecting a 200-ohm, 2-watt resistor across the
lift controller’s negative (B ) and positive (B+)
Before performing any tests or adjustments, terminals. Wait at least 20 seconds to be sure
block the lift truck to prevent unexpected that the capacitors are fully discharged. See
movement. Figure 1.

The capacitor in the transistor controller(s)

can hold an electrical charge after the battery

1
Parameters 2200 SRM 1466

Legend for Figure 1

1. B TERMINAL
2. B+ TERMINAL
3. JUMPER LEADS
4. 200-OHM, 2-WATT RESISTOR

6. Remove the resistor from the controller and rein-

stall the electrical compartment cover before re-
turning the lift truck to service.

There are two controllers used for the Order Selec-

tors. The application of each controller is based on
the truck voltage. The traction controller manages
the CANbus traffic for the truck. In addition the trac-
tion controller has significant I/O responsibility. the
hydraulic coils, horn, back-up alarm, mast prox sen-
sor, parking brake, and the traction motor are man-
aged by the traction controller.

DC Battery AC RMS
Type
Voltage Current Rating
ACE0 24 320
ACE0 36 280
Figure 1. Discharging the Capacitors

Parameters
A parameter is a measurement or a setting that de- Parameters can be adjusted through the dash dis-
fines a lift truck function. A specific function param- play. The factory default values listed in Table 1 are
eter works with other function parameters to control the recommended settings for new units. These set-
the operation of the lift truck. tings will give satisfactory performance for most ap-
plications.
WARNING
The parameter for each function has a value WARNING
range so the motor controller can be used on If any of the parameter values are changed, the
different models of lift trucks. This variation operators must be told the lift truck will oper-
is needed for lift trucks of different capacities ate differently.
and operational needs. Adjustment of a func-
tion to the wrong number value for your lift NEVER adjust any of the following parameters
truck model can cause the truck to operate dif- without using the procedures and settings
ferently than normal. Always test operational given in this section.
characteristics of a lift truck when operating
Parameter Descriptions in this section contain de-
for the first time.
scriptions for the different parameters. These pa-
NOTE: Table 1 shows the factory default setting and rameters can also be accessed using the ZAPI Hand-
total range for each parameter that is adjustable by set tool.
the user.

2
2200 SRM 1466 Parameters

Table 1. Parameter Values

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
Truck Setup
SERIAL NUMBER Truck serial A-Z or 0-9 Serial Number Serial Number
number, 11 digits, assigned at assigned at
alpha-numeric production production
BATTERY TYPE Sets battery type Flooded or Varies depending Varies depending
Maintenance on ordered option on ordered option
Free
BDI MAX ADJUST Adjusts the 0 to 9 3 3
battery voltage
which the
truck software
considers to be
"10" BDI bars. "0
" = lower voltage
to "9" = higher
voltage.
BDI MIN ADJUST Adjusts the 0 to 9 1 1
battery voltage
that would
correspond to
"0" BDI bars. "0
" = lower voltage
to "9" = higher
voltage.
BDI ADJUST STARTUP Used to set the 0 to 9 7 7
number of BDI
bars which the
display will show
immediately after
rekey based on
battery voltage.
"0" = lowest
voltage setting for
a given number
of bars to "9" =
highest voltage
setting for a given
number of bars

3
Parameters 2200 SRM 1466

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
BDI DELTA RESET Adjusts the 0 to 9 4 4
change in battery
state-of-charge
required to reset
the BDI back to
10 bars.
LIFT INTERRUPT Toggle on or ON/OFF ON OFF
off. If on, the
percentage of
battery discharge
(0-10% charge
remaining) is
set. This limit
determines at
what battery
discharge point
the lift function is
prevented. The
lift interrupt
feature is
controlled by the
master CAN I/O
controller and
prevents lift
AUD MOTION ALARM Sets conditions 0 to 15 Varies depending Varies depending
when audible on ordered option on ordered option
alarm will sound
or visual alarm
will flash.
SERVICE REMINDER Sets hour meter 0 to 65535 hours 0 0
increment for
reminder on dash
display, enter
hours 0 hours
will = off
TRUCK INSPECTION Enables the ON/OFF OFF OFF
operator checklist
which is required
to be completed
prior to operating
the truck.

4
2200 SRM 1466 Parameters

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
SPEED UNIT Toggles between MPH/KPH MPH MPH
MPH and KPH.
TEMP UNIT Toggles between °C/°F °F °F
Farenheit and
Celcius.
POWER TIME OUT Sets time period 1 to 60 minutes 10 10
that truck
will remain
operational with
foot pedal switch
not depressed.
WIRE GUIDANCE Enables/disables 1 = ON Varies depending Varies depending
wire guidance 2 = OFF on ordered option on ordered option
functionality. If 0 = OFF
"off", the "WG
Config" menu is
hidden.
RESTORE DEFAULTS Restores all YES/NO NO NO
technician
WARNING modifiable
parameters to
Restore Defaults will
factory default
take all calibration val-
settings.
ues to the factory de-
fault values. Wire guid-
ance and the propor-
tional valve will re-
quire recalibration.
The Traction, Hoist
and RTC Hall sensors
will require recalibra-
tion.

For all Trucks record

SET STEER 0 POS and
for those trucks with
wire guidance record
WG REV OFFSET prior
to selecting Restore De-
faults.

5
Parameters 2200 SRM 1466

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
Traction Setup
TOP SPEED FWD Sets the top 0.1 to 6.5 6 6.5
forward speed
of the truck.
TOP SPEED REV Sets the top 0.1 to 6.5 6 6.5
reverse speed
of the truck.
ACCEL MODE 1 Percent of 0 to 100% 60% 60%
maximum
acceleration.
ACCEL MODE 2 Percent of 0 to 100% 80% 80%
maximum
acceleration.
ACCEL MODE 3 Percent of 0 to 100% 80% 80%
maximum
acceleration.
ACCEL MODE 4 Percent of 0 to 100% 100% 100%
maximum
acceleration.
AUTO DECEL Sets the 0.3 to 10 2.8 2.8
maximum
deceleration rate
when the joystick
is released.
PLUGGING REGEN Determines 0 to 10 1.7 1.7
the maximum
deceleration rate
when plugging.
TRACTION CALIB Starts traction/ ON/OFF OFF OFF
throttle
calibration
routine.

6
2200 SRM 1466 Parameters

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
Steering Setup
MTS GAIN Sensitivity control 0 to 9 2 2
for the steering
stepper motor.
Higher gain
settings make the
steer control more
sensitive, lower
settings make it
less sensitive.
AUTO-CTR STR CAL Activates the ON/OFF OFF OFF
RTC calibration
program by
pressing Right
Arrow key on
display.
SET STEER 0 POS Fine increments 2342 to 2653 2529 2529
to center the in 1mV
WARNING drive wheel to increments
track straight.
If Restore Defaults is
Increasing the
selected from the Dash
value steers truck
menu then SET STEER
more to the right,
0 POS will require re-
decreasing steers
calibration. Record
more to the left.
SET STEER 0 POS
value prior to select-
ing restore defaults.
MAX CW ANGLE C Coarse angle 0 to 9 RTC = 2 RTC = 2
adjustment for
max CW steer
angle: 0=decrease
angle, 9=increase
angle
MAX CW ANGLE F Fine angle 0 to 9 RTC = 8 RTC = 8
adjustment for MTS = 3 MTS = 3
max CW steer
angle: 0=decrease
angle, 9=increase
angle

7
Parameters 2200 SRM 1466

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
MAX CCW ANGLE C Coarse angle 0 to 9 RTC = 2 RTC = 2
adjustment for
max CCW steer
angle: 0=decrease
angle, 9=increase
angle
MAX CCW ANGLE F Fine angle 0 to 9 RTC = 8 RTC = 8
adjustment for MTS = 3 MTS = 3
max CCW steer
angle: 0=decrease
angle, 9=increase
angle
Hydraulic Setup
DC MAX LIFT SPD For DC Hoist 0 to 100% N/A 100
trucks this
parameter setting
determines the
hydraulic pump
motor high speed.
DC LIFT ACCEL For DC Hoist 0 to 100% N/A 6.5
trucks this
parameter setting
determines the
rate of increase
of lifting.
DC LIFT DECEL For DC Hoist 0 to 100% N/A 5
trucks this
parameter setting
determines the
rate of increase
of lowering.
AC MAX LIFT SPD For AC Hoist 0 to 100% N/A 36V
trucks this R30XM3/XMA3
parameter setting
100
determines the
hydraulic pump
motor high speed.

8
2200 SRM 1466 Parameters

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

9
Parameters 2200 SRM 1466

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
LOWER DECEL This parameter 0 to 100% N/A 24V/36V
setting R30XM3/XMA3
determines the
AC = 5
rate of decrease
DC = 8
of lowering.
24V
R30XMF3
DC = 8
36V
R30XMF3
DC = 8
LIFT LIMIT Sets lift limit 0 to 300 100 100
height in inches
(measured at top
of forks).
LIFT LIMIT ENABLE Turns lift limit ON/OFF Varies depending Varies depending
functionality on on ordered option on ordered option
or off.
LOWER LIMIT Sets lower limit 0 to 300 26 26
height in inches
(measured at top
of forks).
LOWER LIMIT ENABLE Turns lower limit ON/OFF Varies depending Varies depending
functionality on on ordered option on ordered option
or off.
HOIST CALIB Starts hoist ON/OFF N/A OFF
calibration
routine.
PROP VALVE CALIB Starts ON/OFF N/A OFF
proportional
valve calibration
routine
Wire Guidance Setup (Not applicable for the R30XMF3)
FWD ANT FREQ 0=5.2kHz 0 to 4 Varies depending Varies depending
1=6.2kHz on ordered option on ordered option
2=7.0kHz
3=9.1kHz
4=10.0kHz

10
2200 SRM 1466 Parameters

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
REV ANT FREQ 0=5.2kHz 0 to 4 Varies depending Varies depending
1=6.2kHz on ordered option on ordered option
2=7.0kHz
3=9.1kHz
4=10.0kHz
WG SLOW SET Toggles between ON/OFF OFF OFF
full speed
wire approach
or automatic
slowdown once
antenna detects
wire is near.
WG REV OFFSET Adjusts the device 0 to 5000mV 2540 2540
wheel angle to in 20mV
WARNING maintain straight increments
travel, when
If Restore Defaults is
traveling forks
selected from the Dash
leading (reverse
menu then wire guid-
direction).
ance will require recal-
ibration. Record WG
REV OFFSET value
prior to selecting re-
store defaults.
FWD ANT LAG 0=no lag 0 to 9 4 4
correction
9=max lag
correction
FWD ANT LEAD 0=no lead 0 to 9 1 1
correction
9=max lead
correction
FWD ANT ACQ AREA 0=least sensitive 0 to 9 6 6
9=most sensitive
REV ANT LAG 0=no lag 0 to 9 4 4
correction
9=max lag
correction

11
Parameters 2200 SRM 1466

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

(R30XMS3) (R30XM3/XMA3/
XMF3)
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the
Dash Display. If a parameter value higher than the truck’s ability is entered, the value will revert
to the maximum allowed for that lift truck.
REV ANT LEAD 0=no lead 0 to 9 1 1
correction
9=max lead
correction
REV ANT ACQ AREA 0=least sensitive 0 to 9 6 6
9=most sensitive
FREQUENCY CALIB Toggle switch ON/OFF OFF OFF
used during
wire guidance
setup to use the
antennas to detect
non-standard
line driver
frequencies.
FIELD STR CALIB Toggle switch ON/OFF OFF OFF
used during setup
to calibrate the
antennas.
WIRE DEPTH FWD Measurement (in 0 to 9 8 R30XM3
5mm increments)
8
from the center
of the line driver R30XMA3
wire to the center 6
of the coil within
the antenna. Coil
is 12mm from
the bottom of
the antenna.
0=30mm and
9=75mm

12
2200 SRM 1466 Troubleshooting

Table 1. Parameter Values (Continued)

Parameter Function Range 24V Default 24V/36V Default

Troubleshooting
GENERAL inserting the screwdriver into the connector,
attach probes with alligator clips to the shank
The controllers are sealed units with no serviceable of the screwdriver to obtain readings. An addi-
components. Troubleshooting is usually limited to tional method would be to use a breakout kit.
accessing status codes and following the diagnostic
procedures listed in the status code charts. If the controller detects an issue, a status code is dis-
played on the display panel.
Use standard testing procedures to verify inputs and
outputs when necessary. Once the status code number is obtained, follow the
procedures outlined in the status code charts of this
manual to determine the problem.
CAUTION
Never attempt to probe through the back of NOTE: Due to the interaction of the controller with
the connector plugs of the motor controller. all lift truck functions, almost any status code or con-
The plugs are special sealed plugs. Probing troller fault could be caused by an internal failure of
through the back of the plugs will destroy the the controller. After all other status code procedures
seal and can cause a short circuit. If a circuit have been followed and no problem is found, the con-
must be tested for voltage, check for voltage troller should be replaced as the last option to correct
at an amp-type plug, a switch, or a component. the problem. A Node shall be given, indicating which
If a circuit is suspect, check the circuit for device generated the fault.
continuity from the front (pin end) of the plug.
Tools and test equipment required are:
Standard probes are too large to be inserted • Clip Leads
into the center of the female pins (sockets) of • Digital Multimeter (20,000 ohms per volt)
the special sealed plugs and can expand the • Basic Hand Tools
pins. Expanded pins will not provide good con-
nections once the plug is reconnected. The con- Check resistance on the proper scale from frame to
nectors are shaped to allow the insertion of a power and controller terminals. Resistance of less
flat blade screwdriver into the connector. After than 50,000 ohms can cause misleading symptoms.

13
Troubleshooting 2200 SRM 1466

The on-board diagnostic system employed on this lift Node X = XXXX (12544 Node 3)
truck can assist in the troubleshooting process. Read Node 2 = Traction
and be familiar with the instructions for accessing Node 5 = Pump
and using the dash display diagnostic system. Node 6 = Steer Master
Node 7 = CAN I/O Master
Prior to troubleshooting systems and components on Node 8 = CAN I/O Slave
this lift truck, ensure the battery is the correct volt- Node 11 = Forward Antenna
age and is fully charged. Make sure the battery con- Node 12 = Reverse Antenna
nector contacts are clean of corrosions and the bat- Node 16 = Display
tery polarity within the connector is correct. Inspect
to ensure all fuses are correct and have not failed. There is a Steer Master Node and a Steer Slave Node
Ensure the key switch is in the ON position when similar to the CAN I/O unit. The software revision
making voltage checks or checking the operator of a level is noted in the Display menu structure for the
component. Steer Master and the Steer Slave Nodes. The Steer
Master Node reports the fault codes for the EPS unit.
Many faults noted by lift truck systems are the result
of loose wiring connections and/or broken or shorted The controller senses the following types of malfunc-
wiring within the lift truck. Begin the troubleshoot- tion:
ing process by carefully inspecting the wiring involv- • Input voltages that are too high or too low
ing the device or devices noted by the on-board diag- • Input voltages in the wrong sequence or
nostics system. • Correct input voltages that occur at the wrong time
• Internal software checksum errors
STATUS CODES
NOTE: A status code indication does not always mean
Make sure the parameter values are correct for your that there is a malfunction. A temporary operation
lift truck to ensure the trouble is not just an incor- condition can cause a status code display.
rect setting. See function settings to set the correct
parameter values. These code numbers are only indicators that may
help diagnose a possible malfunction. A short de-
The status codes are numbers for malfunction or lift scription of the different status codes is shown in Ta-
truck operation that are not correct and that the mo- ble 3.
tor controller can sense. The display will indicate
this code number on the LCD screen. The Fault Message charts in this section have a more
complete description of the status code, the circuit
NOTE: There are identifiers to determine which de- that has generated the input for the status code, the
vice generated the code: symptom, and the possible cause.

Table 2. Warning Messages

Display
Message Description
Steer controller has indicated internal temperature is lower
STEER UNDERTEMP
than 40°C ( 40°F).
Steer controller has indicated internal temperature exceeds
STEER OVERTEMP
78°C (172°F).
Hoist controller has indicated internal temperature is lower
HOIST CONTROL UNDERTEMP
than 40°C ( 40°F).
Hoist controller has indicated internal temperature exceeds
HOIST CONTROL OVERTEMP
92°C (198°F).
Traction controller has indicated internal temperature is lower
TRACT UNDERTEMP
than 40°C ( 40°F).

14
2200 SRM 1466 Troubleshooting

Table 2. Warning Messages (Continued)

Display
Message Description
Traction controller has indicated internal temperature exceeds
TRACT OVERTEMP
92°C (198°F).
FOOT SW OPEN The system has detected that the foot switch on pedal is open.
FOOT SW CLOSED The system has detected that the foot switch on pedal is closed.
The system has detected that the lowering switch on control
LOWER SW CLOSED
handle is closed.
The system has detected that the lifting switch on control handle
LIFT SW CLOSED
is closed.
The system has detected that at least one of the switches that
SLACK CHAIN SW OPEN
detect slack chain condition are open.
The system has detected that at least one of the side gate
SIDE GATE SW OPEN
switches on the platform circuit are open.
The system has detected that the traction hall sensor is not in
TRACT THROT NOT NEUTRAL
neutral position.
System is not detecting battery voltage at pin 17 of the AC
SERVICE KEY SW OPEN
traction controller.
OVERRIDE SW CLOSED The system has detected that the override switch is closed.
System has detected that the hydraulic throttle located on the
HYD THROT NOT NEUTRAL
control handle is not in neutral position.
System has detected that Auto Center steering control handle is
AUTO-CTR STEER NOT NEUTRAL
not in neutral position.

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

STEER UNDERTEMP Re-key only Steer

DESCRIPTION BEHAVIOR
Steer controller has indicated internal No traction, no steer.
temperature is lower than 40°C ( 40°F).
Probable Causes and Test Procedures
1. Remove truck from cold or freezer environment.
2. Verify for reasonable controller temperature by using another accurate method to measure the tempera-
ture of the controller heat sink and compare with the reading from the display diagnostic. If the difference
is greater than 4°C (40°F), then use Field Service tool to download software and parameters. If warning
message does not clear up, possible faulty controller, contact Service Engineer to confirm failure.
3. Ensure truck is operating within its operating specification.

15
Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

STEER OVERTEMP Re-key only Steer

DESCRIPTION BEHAVIOR
Steer controller has indicated internal No traction, no steer.
temperature exceeds 78°C (172°F).
Probable Causes and Test Procedures
1. Perform basic checks.
2. Verify steer controller temperature by using another accurate method to measure the temperature of the
controller heat sink and compare with the reading from the display diagnostic. If the difference is greater
than 4°C (40°F) it may be a faulty controller, contact Service Engineer to confirm failure.
3. Ensure truck is operating within its capacity.
4. Power cables and NEG (battery connector) checks:
a. Check the cables for proper crimping, seating and torque value.
b. Ensure the lug contact surfaces are clean.
5. Steer controller studs checks:
a. Ensure the U, V, W, B+ and B contact surfaces are clean and secure.
6. Mechanical checks:
a. Ensure truck has correct tire type on the drive wheel.
b. Lift drive wheel off the ground and remove ONLY the steer unit assembly from truck. Rotate the
MDU with hand to ensure there is no binding in the turn table bearing.
c. Place back the steer unit assembly and lift drive wheel off the ground, turn steer wheel from one
extreme to the other while observing the steer motor current from RUN DIAGNOSTIC. If the current
constantly stays above 60 amps there may be possible binding in the turn table bearing.
7. If the following checks do not fix/identify the issue a new steer controller may be needed.

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

HOIST CONTROL UNDERTEMP Re-key only Hoist

DESCRIPTION BEHAVIOR
Hoist controller has indicated internal Limping traction, no lifting.
temperature is lower than 40°C ( 40°F).
Probable Causes and Test Procedures
1. Remove truck from cold or freezer environment.
2. Verify steer controller temperature by using another accurate method to measure the temperature of the
controller heat sink and compare with the reading from the display diagnostic. If the difference is greater
than 4°C (40°F) it may be a faulty controller, contact Service Engineer to confirm failure.

16
2200 SRM 1466 Troubleshooting

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

HOIST CONTROL OVERTEMP Re-key only Hoist

DESCRIPTION BEHAVIOR
Hoist Controller has indicated internal No lifting, traction limited to limp home mode.
temperature exceeds 92°C (198°F).
Probable Causes and Test Procedures
1. Perform basic checks.
2. Ensure the controller temperature is below 90°C (194°F).
3. Verify steer controller temperature by using another accurate method to measure the temperature of the
controller heat sink and compare with the reading from the display diagnostic. If the difference is greater
than 4°C (40°F) it may be a faulty controller, contact Service Engineer to confirm failure.
4. Ensure truck is operating within its capacity.
5. Power cables and NEG (battery connector) checks:
a. Check the cables for proper crimping, seating and torque value.
b. Ensure the lug contact surfaces are clean.
6. Hoist controller studs checks:
a. Ensure the U, V, W, B+ and B contact surfaces are clean and secure.
7. If the following checks do not fix/identify the issue a new steer controller may be needed.

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

TRACT UNDER TEMP Re-key only Traction

DESCRIPTION BEHAVIOR
Traction controller has indicated internal Maximum current limit will be linearly reduced
temperature is lower than 40°C ( 40°F). until temperature returns above 40°C ( 40°F).
Lift, lower and steer enabled.
Probable Causes and Test Procedures
1. Remove truck from cold or freezer environment.
2. Verify for reasonable controller temperature by using another accurate method to measure the tempera-
ture of the controller heat sink and compare with the reading from the display diagnostic. If the difference
is greater than 4°C (40°F), then use Field Service tool to download software and parameters. If warning
message does not clear up, possible faulty controller, contact Service Engineer to confirm failure.
3. Ensure truck is operating within its operating specification.

17
Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

TRACT OVER TEMP Re-key only Traction

DESCRIPTION BEHAVIOR
Traction controller has indicated internal Maximum current limit will be linearly reduced
temperature exceeds 92°C (198°F). until temperature drops below 90°C (194°F).
Lift, lower, and steer enabled.
Probable Causes and Test Procedures
1. Ensure truck is operating within its capacity.
2. Perform basic checks.
3. Verify for reasonable controller temperature by using another accurate method to measure the tempera-
ture of the controller heat sink and compare with the reading from the display diagnostic. If the difference
is greater than 4°C (40°F), then use Field Service tool to download software and parameters. If warning
message does not clear up, possible faulty controller, contact Service Engineer to confirm failure.
4. Main contactor checks:
a. Plunger freely moved.
b. Tips are clean and making proper contacts.
c. Coil has proper connection.
d. Coil resistance approximately 44 ohms for 24V truck and 103 ohms for 36V truck.
e. Coil voltage should be 24V for 24V truck and 36V for 36V truck.
5. Power cables U, V, W, NEG 1, POS 1, POS and NEG (battery connector) checks:
a. Properly crimped, seated and torqued.
b. Lugs contact surfaces are clean.
6. Traction controller stud checks:
a. B+, B contact surface are clean.
7. Wire harness checks (key off and disconnect traction controller connector):
a. Check CPS100 pin 2 and 4 for spread socket and socket properly seated.
b. Check pins and socket of CPS60/CPS61 and brake connector (brake side) for proper connection, seated
and sockets are not spread.
c. Check for shorts between CPS100 pin 4 (harness side) and traction controller B .
d. Check continuity between:
• CPS100 pin 2 and CPS60/CPS61 pin 1
• CPS100 pin 4 and CPS60/CPS61 pin 2
8. Parking Electric Brake check:
a. Disconnect the brake and measure its coil resistance, should be approximately 12 ohms.
b. Check for proper air gap, according Brake System 1800 SRM 1463.
c. Check for dragging of the brake.
9. Mechanical checks:
a. Check for binding in drive and load wheels.

18
2200 SRM 1466 Troubleshooting

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

FOOT SW OPEN Re-key only Platform

DESCRIPTION BEHAVIOR
The system has detected that the foot No traction, no lifting, no lowering.
switch on pedal is open.
Probable Causes and Test Procedures
1. Check connections on Lower Platform Circuit between:
a. CPS40 pin 13 to CRP/CPS 18 pin 3
b. CRP/CPS 18 to Foot SW CPS11 pin 2
c. CPS 11 pin 1 and CPS/CRP18 pin 2
2. Check for battery voltage between CPS/CPR 18 (platform harness side) pin 2 and B . If battery voltage
is not seen, then check continuity between CPS/CRP 18 pin 2 and CPS40 pin 9.
3. Check shorts between:
a. CPS40 pin 13 to B
4. If harness connections checked good, then check the switch itself.
a. Measure resistance between CPS11 pin 1 and pin 2 with the foot switch closed, measured value shall
be less than 10 ohms. If value is higher, then replace foot switch.
b. Check for continuity between the two leads of the switch if the foot switch is closed and check for a
change of state when switch is pressed and released. If no change in state is seen, then replace foot
switch.

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Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

FOOT SW CLOSED Re-key only Platform

DESCRIPTION BEHAVIOR
The system has detected that the foot No Traction, no lifting, no lowering.
switch on pedal is closed.
Probable Causes and Test Procedures
1. Check for shorts between CPS40 pin 13 to key switch and between CPS40 pin 13 and pin 9.
2. If no shorts were seen, then check the switch itself.
a. Check for continuity between the two leads of the switch if the foot switch is closed and check for a
change of state when switch is pressed and released. If no change in state is seen, then replace foot
switch.

20
2200 SRM 1466 Troubleshooting

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

LOWER SW CLOSED Re-key only CAN I/O

DESCRIPTION BEHAVIOR
The system has detected that the lowering If happens at key on system will have no
switch on control handle is closed. traction, no lifting, and no lowering.
Probable Causes and Test Procedures
1. Check for shorts between:
a. CPS50 pin 13 to key switch
b. CPS93 pin 2 and pin 9
c. CPS93 pin 2 and pin 1
2. Check for continuity between:
a. CRP93 pin 2 and pin 9, when the lower switch is pressed and released there shall be a change of state
in continuity. If not, switch must be replaced.
3. With the truck in off position, while keeping the lower switch activated measure for lower switch resis-
tance between CRP93 pin 2 and pin 9, resistance shall be below 10 ohms (ideally less than 1 ohm). If
resistance is beyond 10 ohms, replace switch.

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Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

LIFT SW CLOSED Re-key only CAN I/O

DESCRIPTION BEHAVIOR
The system has detected that the lifting If happens at key on system will have no
switch on control handle is closed. traction, no lifting, and no lowering.
Probable Causes and Test Procedures
1. Check for shorts between:
a. CPS50 pin 8 to key switch
b. CPS93 pin 3 and pin 9
c. CPS93 pin 3 and pin 1
2. Check for continuity between:
a. CRP93 pin 3 and pin 9, when the lower switch is pressed and release there shall be a change of state
in continuity. If not, switch must be replaced.
3. With the truck in off position, while keeping the lower switch activated measure for lower switch resis-
tance between CRP93 pin 3 and pin 9, resistance shall be below 10 ohms (ideally less than 1 ohm). If
resistance is beyond 10 ohms, replace switch.

22
2200 SRM 1466 Troubleshooting

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

SLACK CHAIN SW OPEN Re-key only Platform

DESCRIPTION BEHAVIOR
The system has detected that at least No traction, no lowering.
one of the switches that detect slack
chain condition are open.
Probable Causes and Test Procedures
1. Check for any object that is obstructing the movement of the forks and preventing the platform from
lowering.
2. Check for shorts between CPS40 pin 4 and ground.
3. Check for voltage at CRP18 pin 2 and B- stud. It should be approximately battery voltage, if not seen,
check wiring according schematic.
4. Check for continuity on lower platform harness connector, between CRP18 pin 1 and CRP18 pin 2, if
there is no obstruction and there is no continuity, then possible faulty slack chain switches which are
located at lower part of mast.

23
Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

SIDE GATE SW OPEN Re-key only Platform

DESCRIPTION BEHAVIOR
The system has detected that at least No traction, no lifting, and no lowering.
one of the side gate switches on the
platform circuit are open.
Probable Causes and Test Procedures
1. On truck with retractable side gates:
a. The system needs both gates to be lowered in order to operate.
b. Check the gate switches using NO RUN DIAGNOSTIC menu to check status of switch. Ensure that
when you lift and release the gate there will be a change of state (ON/OFF) on NO RUN DIAGNOS-
TIC menu.
c. With retractable side gates down, disconnect CPS18 only and measure approximately battery voltage
between CPS18 pin 2 and B- negative stud. If no voltage is seen, check wire connection at CPS40 pin
9 to be properly seeded and not spread.
d. With the retractable side gates down, check for continuity between CPS40 pin 3 and CPS40 pin 9.
e. Check for switch adjustment or faulty switches.
f. If continuity is not achieved on system with mechanical gates option and both gates are lowered,
check for faulty switches.
2. On system with fixed hoop side rails:
a. Ensure connection between platform harness between:
• Right gate switch TS43 to gates jumper TP42
• Gates jumper TP41 to left gate switch TS40
• Those fast on terminals are located under the dash, on the upper right corner and upper left corner.

24
2200 SRM 1466 Troubleshooting

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

TRACT THROT NOT NEUTRAL Re-key only CAN I/O

DESCRIPTION BEHAVIOR
The system has detected that the Traction No traction.
hall sensor is not in neutral position.
Probable Causes and Test Procedures
1. Return traction control handle to neutral position. Before command for traction, foot pedal switch shall
be pressed, and then traction can be commanded.
2. Use the latest version of Field Service Tool to update truck.
3. Check the traction control handle using NO RUN DIAGNOSTIC menu to check status of traction hall sen-
sor. Ensure that when you move the traction control handle in forward and reverse there will be change
on the voltage displayed on NO RUN DIAGNOSTIC menu. voltage seen at neutral position should be
close to 2.5V ±2V, otherwise traction throttle hall sensor installation.
4. Traction throttle hall sensor installation checks:
a. Connect CPS270 if it’s not connected, remove pin 2 from traction hall sensor connector, turn the key
switch on and do the following:
• Measure the voltage between B and the removed wire, should be 2.5V ±0.2V when handle is at
neutral. If it is not within range, adjust sensor as needed.
• Use Electrical System 2200 SRM 1467 or Electrical System 2200 SRM 1468 to check for proper
installation
• Recalibrate traction throttle hall sensor through the dash menu.

25
Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

TRACT THROT NOT NEUTRAL Re-key only CAN I/O

DESCRIPTION BEHAVIOR
The system has detected that the Traction No traction.
hall sensor is not in neutral position.
Probable Causes and Test Procedures
5. Wire harness checks (turn key switch to the OFF position):
a. Check for correct wires connected to the following components per schematic: CPS50 (CAN I/O) pin
6, 7, 10; CPS270 (traction hall sensor) pin 1, 2,3.
b. Check CPS50 pin 6, 7, 10 and CPS270 pin 1, 2, 3 for spread socket and socket properly seated.
c. Disconnect CPS270 (traction sensor), check for shorts on traction sensor side between:
• Pin 1 and 2
• Pin 1 and 3
• Pin 2 and 3
d. Check continuity between:
• CPS50 pin 6 and CPS270 pin 3
• CPS50 pin 7 and CPS270 pin 1
• CPS50 pin 10 and CPS270 pin 2
6. 5V supply checks (turn key to the ON position):
a. Measure the voltage at CPS270 pin 1 and 3 (approximately 5V ±0.5V) if the voltage is less than 4.5V,
do the following:
• Disconnect CPS270 (traction sensor) and measure the voltage again. If the voltage is within range,
traction throttle hall sensor is faulty.

26
2200 SRM 1466 Troubleshooting

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

SERVICE KEY SW OPEN Re-key only Traction

DESCRIPTION BEHAVIOR
System is not detecting battery voltage at No traction, no steering, no lifting, no
pin 17 of the AC traction controller. lowering, no horn.
Probable Causes and Test Procedures
1. If service key switch option is available, locate the service key switch on the traction motor compartment
and ensure service key toggle switch to be closed.
a. Disconnect TS33-A and TS33-B from service key switch and measure resistance across terminal tabs
with the key switch close, if resistance is more than 10 ohms, key switch is faulty.
2. If service key switch option is not available on truck, then verify that TS33-B and TS33-A are connected
together.
3. If circuit is connected correctly, then verify continuity between FU3 TS30 and CPS100 pin 17.
4. Verify for CPS100 pin 17 not to be spread or deformed.
5. Verify crimping connections of TS33-B and TS33-A.
6. If service key switch option is available on truck, then check service key toggle switch, located on the
traction compartment. Measure continuity on service key switch tabs, ensure to have a change of conti-
nuity state when switch is closed and open. If continuity not seen then key switch is faulty.

27
Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

OVERRIDE SW CLOSED Re-key only CAN I/O

DESCRIPTION BEHAVIOR
The system has detected that the No traction, no lifting, no lowering.
override switch is closed.
Probable Causes and Test Procedures
1. Check for shorts between:
a. CPS40 pin 19 and pin 9
b. CPS40 pin 19 and pin 1
2. If limit override switch option is available on the truck, ensure switch is not closed.
3. Check for continuity between CPS40 pin 9 and pin 19, when the lift limit switch is pressed and released.
There shall be a change of state in continuity. If not, switch must be replaced.
4. Measure switch resistance, shall be below 10 ohms. If resistance is above 10 ohms, replace switch.

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2200 SRM 1466 Troubleshooting

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

HDY THROT NOT NEUTRAL Re-key only CAN I/O

DESCRIPTION BEHAVIOR
System has detected that the Hydraulic No traction, no steering, no lifting, no lowering.
throttle located on the control handle
is not in neutral position.
Probable Causes and Test Procedures
1. Check for connector CPS 93 and CRP 93 pins to be properly seeded and not spread.
2. Check for shorts on both sides CPS93 and CRP93 between:
a. Pin 7 and pin 9
b. Pin 7 and pin 6
c. Pin 7 and pin 4
d. Pin 7 and pin 1
3. Check to have 5V between CPS 93 pin 1 and pin 6.
4. Ensure circuit is connected appropriately per schematic, following connections between hydraulic hall
sensor, through CPS93, into CAN I/O.
5. Check the control handle to be in neutral position. Use NO RUN DIAGNOSTIC menu to check status of
LIFT/LOWER JOY.
6. Check LIFT/LOWER JOY should have a voltage reading in dash display of 2.5V ±0.2V when in neutral.
Recalibrate hydraulic hall sensor.

29
Troubleshooting 2200 SRM 1466

DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

AUTO-CTR STEER NOT NEUTRAL Re-key only CAN I/O

DESCRIPTION BEHAVIOR
System has detected that Auto Center No traction, no steering, no lifting, no lowering.
Steering handle is not in neutral position.
Probable Causes and Test Procedures
1. Check for connector CPS 280 and CRP 280 pins to be properly seeded and not spread.
2. Check for shorts on both sides between:
a. CPS280 and CRP280
b. Pin 4 to pin 1
c. Pin 4 to pin 3
d. Pin 2 to pin 1
e. Pin 2 to pin 3.
3. Check to have 5V between CPS280 pin 2 and pin 4.
4. Ensure that Auto Center Steer is at neutral position and that all other traction/hydraulic inputs are in
neutral condition. Re-key and verify.
5. Check AUTO-CTR CW Signal and AUTO-CTR CCW Signal in NO RUN DIAGNOSTIC from dash display
for 2.5V ±0.2V when in neutral. If the voltage is not within the range, check Auto-Center Steering Dual
hall sensor (CPS280) installation and adjust voltage level until 2.5V is reached. Recalibrate Auto-Center
dual hall sensor.
6. Use Steering System 1600 SRM 1462 to check for proper installation.
7. Use latest version of Field Service Tool.

30
2200 SRM 1466 Troubleshooting

Table 3. Fault Codes

AC Motor Controller
Code Description
4096 Drive wheel angle is not valid.
Node 2
4097 The traction controller has detected an alarm in the CAN I/O
Node 2
4128 Steer motor controller (EPS) determines there is an alarm condition in the forward
or reverse antenna.
Node 6

4129 Drive wheel does not center within six seconds.

Node 6
4130 Steer (EPS) controller detects CAN I/O has an error.
Node 6
8480 When in wire guidance mode, one or both antennas are not sensing the magnetic
field from the wire.
Node 6
8481 When in wire guidance mode, the truck has moved too far laterally from the wire.
Node 6
8482 When in wire guidance mode, steer wheel angle is outside the limiting threshold
between truck angle and wire.
Node 6
8961 The traction controller has noted an incorrect output voltage for the proportional
valve control.
Node 2
8962 The traction controller has noted an incorrect output voltage for the load hold
valve control.
Node 2
8963 Overcurrent detected from outputs on traction controller connector CPS100 pins
8, 11, and 33.
Node 2
8964 The RELAY1 coil driver is shorted or RELAY1 coil open.
Node 2
8965 The Pump contactor driver is shorted or the HYD PUMP COIL circuit is open.
Node 2
8966 The back-up alarm driver shorted or open load circuit.
Node 2
8967 Main contactor output driver shorted to battery negative (B ) or open main
contactor coil circuit detected.
Node 2
8968 No positive supply to electric brake.
Node 2

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Troubleshooting 2200 SRM 1466

Table 3. Fault Codes (Continued)

AC Motor Controller
Code Description
8969 The high side driver of the parking brake coil is shorted (24V system only).
Node 2
8970 Low side driver of the electric brake is shorted or open brake coil.
Node 2
8971 One of the traction motor phases has an open circuit.
Node 2
8972 The main line contactor coil or the parking brake coil has detected an overcurrent
condition.
Node 2
8973 The lift /lower proportional valve coil circuit is open or shorted.
Node 2
8974 The load hold valve coil circuit is open.
Node 2
8992 Steer (EPS) power failure motor phase W or problems with steer speed encoder.
Node 6
8993 Steer (EPS) power failure motor phase V or problems with steer speed encoder.
Node 6
8994 Steer (EPS) power failure motor phase U or problems with steer speed encoder.
Node 6
8996 Steer (EPS) motor in a locked rotor condition.
Node 6
12289 Traction throttle voltage is out of range.
Node 2
12290 Lift throttle voltage is out of range (R30XM3/XMA3/XMF3 only).
Node 2
12291 A traction motor speed encoder fault has been detected.
Node 2
12292 A traction motor stall condition has been detected.
Node 2
12293 Lift and lower commands are being requested simultaneously (R30XMS3 only).
Node 2
12321 Steer (EPS) motor power phases output mismatch between EPS slave and EPS
master.
Node 6

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2200 SRM 1466 Troubleshooting

Table 3. Fault Codes (Continued)

AC Motor Controller
Code Description
12322 Steer motor encoder mismatch between steer (EPS) master controller and steer
(EPS) slave controller microprocessor.
Node 6
12323 Steer EPS controller has detected a position mismatch between the centering
prox switch and the steer motor encoder.
Node 6
12324 EPS motor encoder error between commanded and actual frequency.
Node 6
12325 Command and encoder feedback direction not matched..
Node 6
12352 Auto center steer sensor inputs out of range.
Node 7 & 8
12544 The battery voltage has been detected as too high or too low.
Node 2
12545 Pin 3 of the traction controller connector is not connected to battery positive or
there is a difference between the voltage at pin 3 and the voltage at pin 10, the
Node 2 controller key switch input voltage (24V truck only).
12546 Pin 3 of the traction controller connector is not connected to the battery positive or
there is a difference between the voltage at pin 3 and the voltage ay pin 10, the
Node 2 controller key switch input (36V truck only).
12547 A traction controller under voltage or over voltage condition has been detected.
Node 2
12548 Traction controller DC bus capacitor voltage is too low or capacitor pre-charge is
not complete.
Node 2
12549 The main line contactor has been detected as closed.
Node 2
12550 The main line contactor remains open after power is applied to the coil.
Node 2
12554 Hoist Controller detects incorrect battery voltage.
Node 5
12705 The voltage between the B+ and B of the ACE2 hoist controller has been detected
too low.
Node 5
12706 Hoist controller is not receiving CAN messages from ACE0 traction controller.
Node 5
13056 The traction motor voltage is lower than expected at initial start-up.
Node 2

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Troubleshooting 2200 SRM 1466

Table 3. Fault Codes (Continued)

AC Motor Controller
Code Description
13057 The traction motor voltage is higher than expected at initial start-up.
Node 2
13058 The traction controller has detected an alarm condition in the steer controller.
Node 2
13059 The traction controller detects STEER STATUS is ON at key on.
Node 2
13088 Wrong voltage on steer security line.
Node 6
13089 EPS connector CPS120 pin 5 not receiving battery voltage from key switch..
Node 6
13216 Hoist controller internal failure, harness issue or shorted power connections to the
hoist motor.
Node 5
13217 Hoist controller capacitor charging circuit failure.
Node 5
13218 Hoist controller over or under voltage detected
Node 5
13219 AC hoist motor encoder error.
Node 5
20480 Traction controller has indicated an internal failure of the controller.
Node 2
20512 The steer controller has indicated an internal failure of the controller.
Node 6
20544 Multiturn steering or internal controller failure.
Node 7 & 8
20576 Antenna forward - Internal failure
Node 11
20608 Antenna reverse - Internal failure
Node 11
20640 Hoist controller - Internal failure
Node 5
20672 Display - Internal failure
Node 16

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2200 SRM 1466 Troubleshooting

Table 3. Fault Codes (Continued)

AC Motor Controller
Code Description
25345 The performance mode parameter values have been entered incorrectly.
Node 2
25346 The height versus traction speed map parameters have been entered incorrectly.
Node 2
25347 The slip map parameters are set incorrectly.
Node 2
25348 The traction controller configuration voltage is set incorrectly.
Node 2
25349 There is a mismatch condition with the traction motor speed encoder pulses per
revolution.
Node 2
25350 There is a mismatch condition between the mast prox switch and the height
encoder.
Node 2
25351 No height encoder counts detected when platform is lifting or lowering.
Node 2
25376 Parameter mismatch between CAN I/O and EPS controller.
Node 6
25408 Stepper motor signals shorted to B .
Node 7 & 8
25409 Stepper motor Q signal (wire 400) not connected.
Node 7 & 8
25410 Stepper motor D signal (wire 401) not connected.
Node 7 & 8
33024 The traction controller has noted no CAN communication with the CAN I/O master
microprocessor.
Node 2
33025 The traction controller has noted no CAN communication with the CAN I/O slave
microprocessor.
Node 2
33026 The traction controller has noted no CAN communication with the steer controller.
Node 2
33027 The traction controller has noted no CAN communication with the hoist controller.
Node 2
33028 The traction controller has noted no CAN communication with the display.
Node 2

CODE
8480 8480 Set Wire Guidance Steer, Wire Guidance
Switch Off, Re-key
Node 6

DESCRIPTION BEHAVIOR
When in wire guidance mode, one or both Truck brakes to a stop. Wire guidance is disabled.
antennas are not sensing the magnetic
field from the wire.
Probable Causes and Test Procedures

NOTE: This alarm occurs in wire guidance mode when the truck is locked onto the wire and at least one
antenna loses the magnetic field generated by the wire.

1. Perform basic checks.

2. Verify that the truck is still located over the wire. This code can be generated by driving off the end of
the guide wire with WG switch activated.
3. Verify that the antennas are working correctly.
a. Enter the dash display top level menu structure.
b. Through the dash display, scroll to SOFTWARE VERSIONS and verify that the antennas are report-
ing their respective software version.
c. Drive the truck over the guide wire such that the forward and reverse antennas are aligned over the
wire.

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2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
8480 8480 Set Wire Guidance Steer, Wire Guidance
Switch Off, Re-key
Node 6

NOTE: This alarm occurs in wire guidance mode when the truck is locked onto the wire and at least one
antenna loses the magnetic field generated by the wire.

3. Verify that the antennas are working correctly.

d. Through the dash display, enter the DIAGNOSTICS - WG DIAGNOSTICS menu. Verify that the
dash display is receiving information concerning the following menu items.
• FIELD STR FWD - Detected field strength, which is a percentage based off of the maximum value
that the forward antenna can pick up in a given setup.
• FIELD STR RR - Detected field strength, which is a percentage based off of the maximum value
that the rear antenna can pick up in a given setup.
• PATH FWD ON/OFF - Indicates whether the forward antenna is on the wire.
• PATH RR ON/OFF - Indicates whether the rear antenna is on the wire.
• FREQ IN RANGE YES/NO - Indicates whether or not the system is properly calibrated to the wire
frequency (can the antenna detect the wire).

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
8480 8480 Set Wire Guidance Steer, Wire Guidance
Switch Off, Re-key
Node 6

NOTE: This alarm occurs in wire guidance mode when the truck is locked onto the wire and at least one
antenna loses the magnetic field generated by the wire.

4. If either antenna field strength value reads less than 40%, then check connections or possible faulty
antenna.
5. If the readings noted in 3 indicate no signal, then verify that there is current in the guide wire.

46
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
8481 8481 Set Wire Guidance Steer, Wire Guidance
Switch Off, Re-key
Node 6

DESCRIPTION BEHAVIOR
When in wire guidance mode, the truck has Truck brakes to a stop. Wire guidance is disabled.
moved too far laterally from the wire.
Probable Causes and Test Procedures

NOTE: This alarm occurs in WG mode if the truck is locked on the guide wire and at least one antenna’s
lateral error overtakes the alarm thresholds. The truck will oscillate laterally left and right of the wire as
the truck travels along the wire. In the steered wheel direction, that is forks trailing, only the error in the
FWD antenna is used to raise this alarm.

1. The factory settings have been set to minimize oscillation about the guide wire. To get back to the default
settings select RESTORE DEFAULTS located in the dash display menu structure.
a. From the top level menu scroll to SETUP. Press 2 to enter.
b. Then scroll to TRUCK SETTINGS. Press 2 to enter.
c. Scroll to RESTORE DEFAULTS.
d. Select 5 to RESTORE DEFAULTS.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
8481 8481 Set Wire Guidance Steer, Wire Guidance
Switch Off, Re-key
Node 6

DESCRIPTION BEHAVIOR
When in wire guidance mode, the truck has Truck brakes to a stop. Wire guidance is disabled.
moved too far laterally from the wire.
Probable Causes and Test Procedures

2. Rerun the truck on the guide wire. If the fault code persists, perform the wire guidance setup procedure.
It is important to follow wire guidance procedure exactly as stated in Wire Guidance 2200 SRM 1471.
3. Through the dash display, enter the DIAGNOSTICS - WG DIAGNOSTICS menu. Verify that the dash
display is receiving information concerning the following menu items. Verify FIELD STR FWD and
FIELD STR REV on antennas to have a value of 60% or more. If the difference between the antennas
field strength is higher than 10%, probably the antenna with lowest value is faulty.

48
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
8482 8482 Set Wire, Guidance Steer, Wire Guidance
Switch Off, Re-key
Node 6

DESCRIPTION BEHAVIOR
When in wire guidance mode, steer wheel Truck brakes to a stop. Wire guidance is disabled.
angle is outside the limiting threshold
between truck angle and wire.
Probable Causes and Test Procedures

NOTE: Control system parameters are set to prevent the truck from striking the adjacent racks when locked
onto the guide wire. The maximum angle of the drive wheel is maintained by a closed loop control system.
The angle alarm can occur if there is an oscillation of the drive wheel angle, outside of the maximum angle
allowed, for more than 0.10 seconds.

1. Perform basic checks.

2. Perform wire harness checks (disconnect CPS110, CPS120, and CPS200):
a. Check for spread sockets or deformed pins on following connectors:
• CPS110 (Steer EPS controller) pins 4, 7 and 8
• CPS120 (Steer EPS controller) pin 11
• CPS200 (Steer speed encoder) pin 1, 2, 3, and 4

49
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
8482 8482 Set Wire, Guidance Steer, Wire Guidance
Switch Off, Re-key
Node 6

2. Perform wire harness checks (disconnect CPS110, CPS120, and CPS200):

b. Check for continuity on following connections:
• CPS200 pin 1 and CPS110 pin 4
• CPS200 pin 3 and CPS110 pin 8
• CPS200 pin 4 and CPS110 pin 7
• CPS200 pin 2 and CPS120 pin 11
c. Check for shorts between:
• B and each one of the phases of Steer EPS controller U, V, W.

50
2200 SRM 1466 Troubleshooting

CODE
12289 12289 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
Traction throttle voltage is out of range. Disable traction, disable lift. Lower
and steer enabled.
Probable Causes and Test Procedures

CODE
12352 12352 Re-key and calibrate CAN I/O Auto Center
Steer
Node 7 or 8

DESCRIPTION BEHAVIOR
Auto center steer sensor inputs out of range. Traction disabled.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Disconnect the battery and discharge the controller capacitors.
3. Check for continuity from connector CPS50 pin 2 to the NEG Stud. (Use schematic to follow continuity
on wire 113)
4. Check connector pin connections and continuity:
a. Disconnect CAN I/O connectors CPS50 and auto center steering CPS280.
b. Check the following pins and associated wires. Repair/replace faulty connections with properly
crimped connections. All pins must seat properly and must not be deformed.
c. Continuity Checks:
• CPS50 Pin 12 to harness side of CPS280 Pin 1
• CPS50 Pin 9 to harness side of CPS280 Pin 3
• CPS50 Pin 6 to harness side of CPS280 Pin 4
• CPS50 Pin 7 to harness side of CPS280 Pin 2
5. Connect CPS50 and then connect the battery and then turn the key switch to the ON position.
6. Measure the voltage between pins 4 & 2 on the harness side of CPS280.
a. Voltage measured between pins 2 and 4 on CPS280 should be 5V ±0.5V, if not possible faulty CAN
I/O.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12352 12352 Re-key and calibrate CAN I/O Auto Center
Steer
Node 7 or 8

DESCRIPTION BEHAVIOR
Auto center steer sensor inputs out of range. Traction disabled.
Probable Causes and Test Procedures
7. Connect CPS50 and CPS280. Battery to be connected and the key switch in the ON position. Auto-Center
control in the neutral position.
8. Measure the voltage on Hall Sensor output Pins 1 and 3 referenced to ground Pin 2.
a. Voltage measured between pins 1 and 2 or pins 2 and 3 on CPS280 should be 2.5V ±0.2V, if not
possible faulty CAN I/O.
9. If the fault code persists then replace the CAN I/O.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12544 12544 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The battery voltage has been detected Disable traction, disable lift, disable
as too high or too low. lower, disable steer.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Ensure the battery voltage is within 20V and 28V for 24V truck, 30V and 43V for 36V truck.
3. Ensure correct traction controller installed.
4. Wire harness checks - disconnect battery connector, turn key to the OFF position and disconnect ONLY
CPS100 (at traction controller):
a. Ensure socket of CPS100 pin 10 not spread and properly seated.
b. Check for proper connections at battery disconnect switch (TP11, TP12) and key switch (TS14, TS15).
• Turn key to the ON position and measure resistance across the key switch, should be less than 2
ohms.
c. Verify the battery disconnect to be normal operating condition and measure resistance across the
battery disconnect switch, should be less than 2 ohms.
d. Check wire 001 (at contactor panel) to ensure it is properly crimped and torqued, has proper contact
surface.
e. Check fuse FU1 to ensure it is properly seated.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12544 12544 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The battery voltage has been detected Disable traction, disable Lift, disable
as too high or too low. lower, disable Steer.
Probable Causes and Test Procedures
4. Wire harness checks - disconnect battery connector, turn key to the OFF position and disconnect ONLY
CPS100 (at traction controller):
f. Check for wire 001 and 004 at FU1 are proper contact and properly tighten.
g. Check continuity between:
• Positive stud of line contactor and FU1
• FU1 and battery disconnect switch
• Battery disconnect switch and BAT tab of key switch
• IGN tab of key switch and CPS100 pin 10
5. Use latest version of Field Service Tool to update truck.
6. Circuit connections checks (key in the OFF position):
a. Check for correct wires connected to the following components per schematic:
• Key switch
• CPS100 pin 10
• FU1

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12545 12545 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
Pin 3 of the traction controller connector is Traction in limp mode. Disable lift, disable
not connected to battery positive or there lower, steer enabled.
is a difference between the voltage at pin 3
and the voltage at pin 10, the controller key
switch input voltage. (24V truck only)
Probable Causes and Test Procedures
1. Perform basic checks.
2. If alarm 12548 exists, troubleshoot this alarm first.
3. Harness checks - disconnect the battery connector, turn the key switch to the ON position, and disconnect
CPS100:
a. Check CPS100 pin 3 and pin 10 for spread socket and to ensure that the socket is properly seated.
b. Check fuse FU3 for good condition and proper connection.
c. Check wire 002 terminals (at contactor panel) to ensure they are properly crimped, torqued and have
proper contact surface.
d. Check continuity between:
• CPS100 pin 3 and fuse FU3
• Fuse FU3 and negative post of line contactor.
• CPS100 pin 10 and fuse FU1 terminal TS10 (use schematic to follow circuit wire 004 and wire 10)

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12545 12545 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
Pin 3 of the traction controller connector is Traction in limp mode. Disable lift, disable
not connected to battery positive or there lower, steer enabled.
is a difference between the voltage at pin 3
and the voltage at pin 10, the controller key
switch input voltage. (24V truck only)
Probable Causes and Test Procedures
4. Main contactor checks:
a. Plunger freely moved.
b. Tips shall be clean and making proper contacts.
c. Coil has proper connection.
d. Coil resistance approximately 44 ohms for 24V truck and 103 ohms for 36V truck
e. Coil voltage should be 24V for 24V truck and 36V for 36V truck.
f. Continuity between traction controller pin 12 and negative side of coil.
g. Continuity between traction controller pin 10 and positive side of the coil.
5. Power cables NEG 1, POS 1, POS and NEG (battery connector) checks:
a. Properly crimped, seated and torqued.
b. Lugs contact surfaces are clean.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12545 12545 Re-key only Traction

Node 2

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12546 12546 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
Pin 3 of the traction controller connector is Traction in limp mode. disable lift, disable
not connected to battery positive or there lower, steer enabled.
is a difference between the voltage at pin 3
and the voltage at pin 10, the controller key
switch input voltage. (36V truck only)
Probable Causes and Test Procedures
1. Perform basic checks.
2. If alarm 12548 exists, troubleshoot this alarm first.
3. Harness checks - disconnect the battery connector, turn the key switch to the ON position, and disconnect
CPS100:
a. Check CPS100 pin 3 and pin 10 for spread socket and to ensure that the socket is properly seated.
b. Check fuse FU3 for good condition and proper connection.
c. Check wire 002 terminals (at contactor panel) to ensure they are properly crimped, torqued and have
proper contact surface.
d. Check continuity between:
• CPS100 pin 3 and fuse FU3
• Fuse FU3 and negative post of line contactor.
• CPS100 pin 10 and fuse FU1 terminal TS10 (use schematic to follow circuit wire 004 and wire 10)

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2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
12546 12546 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
Pin 3 of the traction controller connector is Traction in limp mode. disable lift, disable
not connected to battery positive or there lower, steer enabled.
is a difference between the voltage at pin 3
and the voltage at pin 10, the controller key
switch input voltage. (36V truck only)
Probable Causes and Test Procedures
4. Main contactor checks:
a. Plunger freely moved.
b. Tips shall be clean and making proper contacts.
c. Coil has proper connection.
d. Coil resistance approximately 44 ohms for 24V truck and 103 ohms for 36V truck
e. Coil voltage should be 24V for 24V truck and 36V for 36V truck.
f. Continuity between traction controller pin 12 and negative side of coil.
g. Continuity between traction controller pin 10 and positive side of the coil.
5. Power cables NEG 1, POS 1, POS and NEG (battery connector) checks:
a. Properly crimped, seated and torqued.
b. Lugs contact surfaces are clean.

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Troubleshooting 2200 SRM 1466

CODE
12554 12554 Re-key only Hoist

Node 5

DESCRIPTION BEHAVIOR
Hoist controller detects incorrect No traction, no steer, no lift, no lower.
battery voltage.
Probable Causes and Test Procedures

NOTE: At start-up, the controller checks the battery voltage and verify it is within ±20% of the battery nom-
inal value.

1. Perform basic checks.

2. Ensure 36V battery is completely charged.
3. Sockets on CPS150 pin 1 to be properly seated and not spread.
4. Wire circuit checks (use schematic for verification of circuit wire 10) for continuity between:
a. Ensure B and B+ terminal studs on AC hoist controller are clean and secured.
b. Key switch, ignition side TS15 and TS31-B (main line contactor coil connection)
c. TS31-B (main line contactor coil connection) and hoist controller CPS150 pin 1
d. Turn the key to the ON position, and check for battery voltage between B and CPS150 pin 1.
e. If battery voltage is seen and code still active, contact Service Engineering for possible failure of AC
hoist controller.
5. Use Field Service Tool to perform updates.

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2200 SRM 1466 Troubleshooting

CODE
13058 13058 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The traction controller has detected an Disable traction, disable lift, disable
alarm condition in the steer controller. lower, steer enabled.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Troubleshoot alarm code from the steer controller first if any.
3. Wire harness checks - turn key to the OFF position, disconnect ONLY CPS120 (steer EPS controller) and
CPS100 (ACE0 traction controller):
a. Check sockets of CPS120 pin 4, 5 and sockets of CPS100 pin 1 for properly seated and not spread.
b. Check continuity between:
• CPS120 pin 7 and 5
• CPS120 pin 4 and CPS100 pin 1
• TS15 (key switch) and CPS120 pin 7
4. Circuit connections checks:
a. Check for correct wires connected to the following components per schematic:
• CPS120 pins 4, 5, 7
• CPS100 pin 1
• TS15 (key switch)
b. Use the latest version of Field Service Tool to update truck.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
13059 13059 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The traction controller detects STEER Disable traction, disable lift, disable
STATUS is ON at key on. lower, disable steer.
Probable Causes and Test Procedures

NOTE: The traction controller detects STEER STATUS is ON at key on.

CODE
13219 13219 Re-key only Hoist

Node 5

DESCRIPTION BEHAVIOR
AC hoist motor encoder error. No lift.
Probable Causes and Test Procedures
4. Check for shorted conditions on the encoder side:
a. Pin 1 to pin 2
b. Pin 1 to pin 3
c. Pin 1 to pin 4
d. Pin 2 to pin 3
e. Pin 2 to pin 4
f. Pin 3 to pin 4

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20480 20480 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
Traction controller has indicated an Enabled/disabled functions depend
internal failure of the controller. on failure mode.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Are there any other codes than 20480, specifically those relating to power? If YES, troubleshoot those
codes first, before troubleshoot 20480.
3. Use the latest Field Service Tool to update the truck. If problem persists after updating, possible faulty
traction controller. Contact Service Engineer to confirm finding.

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2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20512 20512 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller has indicated an internal No traction, no steer.
failure of the controller.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Use the latest field service tool to update the truck. if problem persists after updating possible faulty
steer controller..
3. If the reprogramming does not fix the issue replace the steer controller.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20544 20544 Re-key only CAN I/O

Node 7 or 8

DESCRIPTION BEHAVIOR
Multiturn steering or internal No traction, no steer, no lift, no lower.
controller failure.
Probable Causes and Test Procedures
1. Perform basic checks.
2. If the truck has Multiturn steering, check connector CPS92.
a. Check for correct wires connected to the following components per schematic: CPS40 (CAN I/O) pin
10, 11, 12, 18; CPS92 (stepper motor) pin 1, 2, 4, 5 (both harness side and stepper motor side) repair/
replace faulty connections with properly crimped connectors.
b. Measure the resistance between pins 1 and 2 and also between pins 4 and 5 of the stepper motor.
The resistance should be in the range of 30 ohms ±5 ohms. Replace the stepper motor if there is an
open circuit.

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2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20544 20544 Re-key only CAN I/O

Node 7 or 8

DESCRIPTION BEHAVIOR
Multiturn steering or internal No traction, no steer, no lift, no lower.
controller failure.
Probable Causes and Test Procedures
2. If the truck has Multiturn steering, check connector CPS92.
c. On the harness side of connector CPS92 check for shorts to B or B+ on pins 1,2,4 and 5.
d. Check for continuity between the harness side of CPS270, traction hall sensor pins 1 and 3, and
CPS50 pins 6 and 7 respectively. Reference CAN I/O schematic diagram.
e. Check for a short to B at pin 9 of CPS50.
3. Check for loose or faulty connection on the number 10 wire between key switch and CPS 40 pin 1.
4. Repair faulty connections with properly crimped connections. This would include checking connections
to PTC1. PTC1 is located in the harness bundle. If fault code persists update the software with the Field
Tool.
5. If fault code persists, possible faulty CAN I/O controller.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20576 20576 Re-key only Antenna

Node 11

DESCRIPTION BEHAVIOR
Antenna Forward - Internal Failure No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Internal fault, use latest version of Field Service Tool, if this doesn’t fix the issue then change the an-
tenna.

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2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20608 20608 Re-key only Antenna

Node 11

DESCRIPTION BEHAVIOR
Antenna Reverse - Internal Failure No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Internal fault, use latest version of Field Service Tool, if this doesn’t fix the issue then change the an-
tenna.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20640 20640 Re-key only Hoist

Node 5

DESCRIPTION BEHAVIOR
Hoist controller internal failure. No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Use Field Service Tool to perform updates in software and parameters.
3. If all above checks OK, possible faulty AC hoist controller.

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2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
20672 20672 Re-key only Display

Node 16

DESCRIPTION BEHAVIOR
Display internal failure. No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Use Field Service Tool to perform updates in software and parameters.
3. If all above checks OK, possible faulty display.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25345 25345 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The performance mode parameter values Traction enabled, lift enabled, lower
have been entered incorrectly. enabled, steer enabled.
Probable Causes and Test Procedures
1. Check ACCEL MODE 1 (lowest), 2, 3, 4 (highest) parameters to ensure that higher mode value is greater
than lower mode value. If lower mode has higher value than higher mode, use the display to change to
appropriate value.
2. If no problem found in step above and alarm persists, then go to Truck Setup through the dash display
and perform a "RESTORE DEFAULTS".
a. Notice that if RESTORE DEFAULTS is performed, all other previous adjustable parameters will also
be reset to default.
3. Use Field Service Tool to perform updates.
4. Possible faulty traction controller. Contact Service Engineer to confirm the failure.

176
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25346 25346 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The height versus traction speed map No traction, no lift, no lower, steer enabled.
parameters have been entered incorrectly.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Use Field Service Tool to perform updates.
3. If all above checks OK, possible faulty traction controller. Contact Service Engineer to confirm the find-
ing.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25347 25347 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The slip map parameters are set incorrectly. No traction, no lift, no lower, steer enabled.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Use latest version of Field Service Tool to update trucks.
3. If all above checks OK, possible faulty traction controller. Contact Service Engineer to confirm the find-
ing.

178
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25348 25348 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The traction controller configuration No lower.
voltage is set incorrectly.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Check for correct traction controller installed.
3. Use latest version of Field Service Tool to update trucks.
4. If all above checks OK, possible faulty traction controller. Contact Service Engineer to confirm the find-
ing.

179
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25349 25349 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
There is a mismatch condition with No traction, no lift, no lower, no steer.
the traction motor speed encoder
pulses per revolution.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Ensure correct traction motor installed.
3. Check for correct traction controller installed.
4. Use latest version of Field Service Tool to update trucks.
5. If all above checks OK, possible faulty traction controller. Contact Service Engineer to confirm the find-
ing.

180
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25350 25350 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
There is a mismatch condition between the Reduced traction, lift enabled, lower enabled.
mast prox switch and the height encoder.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Mast prox switch checks:
a. Lower the platform to ground and check for proper gap between prox sensor and target.
b. Lift platform to 24 inches and check for proper gap between prox sensor and target.
c. With prox sensor connected to the harness, measure the voltage across CPS90 (mast prox) pin 2 and
3. It should be approximately same as battery voltage. If the voltage checked OK, target within
range and the LED on the prox sensor not illuminated, possible faulty prox sensor.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25350 25350 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
There is a mismatch condition between the Reduced traction, lift enabled, lower enabled.
mast prox switch and the height encoder.
Probable Causes and Test Procedures
3. Platform wire harness checks:
a. Check all pins in CPS3B (mast encoder) and its mating connector for spread sockets, deformed pins
and to ensure it is properly seated.
b. Check all pins in CPS3A (sheave cable) and its mating connector for spread sockets, deformed pins
and to ensure it is properly seated.
c. Check all pins in CPS3B (mast encoder) and its mating connector for spread sockets, deformed pins
and to ensure it is properly seated.
d. Check CPS40 (CAN I/O) pins 14, 15 and CPS50 (CAN I/O) pins 6, 7 for spread sockets and to ensure
they are properly seated.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25350 25350 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
There is a mismatch condition between the Reduced traction, lift enabled, lower enabled.
mast prox switch and the height encoder.
Probable Causes and Test Procedures
3. Platform wire harness checks:
e. Check continuity between:
• CPS3B (height encoder) pin 1 and CPS40 (CAN I/O) pin 14
• CPS3B pin 4 and CPS40 pin 15
• CPS3B pin 2 and CPS50 (CAN I/O) pin 7
• CPS3B pin 3 and CPS50 (CAN I/O) pin 6
4. Mast encoder checks:
a. Ensure height encoder is properly installed.
b. With the height encoder connected, measure the voltage across CPS3B pins 2 and 3, the voltage
should be approximately 5V.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25350 25350 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
There is a mismatch condition between the Reduced traction, lift enabled, lower enabled.
mast prox switch and the height encoder.
Probable Causes and Test Procedures
5. If the platform wire harness, the height encoder installation and the 5V measurement above checked
OK, do the following:
a. Access the FORK HEIGHT in RUN DIAGNOSTIC menu, command lift. FORK HEIGHT needs to
increase when platform is lifted and needs to decrease if platform is lowered. If the value of FORK
HEIGHT does not change, possible faulty height encoder.
6. Chassis wire harness checks - disconnect the battery connector and check the following:
a. Check CPS90 (mast prox switch) pins 1, 2, 3 and CPS100 (traction controller) pin 6 for spread sockets
and to ensure sockets are properly seated.
b. Check mast prox sensor connector for pins deformed and to ensure they are properly seated.

184
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

185
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25350 25350 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
There is a mismatch condition between the Reduced traction, lift enabled, lower enabled.
mast prox switch and the height encoder.
Probable Causes and Test Procedures
7. 5V supply checks (turn the key switch to the ON position):
a. Measure the voltage at CPS280 (Auto Center steering connector) pin 2 and 4 (approximately 5V
±0.5V) if the voltage is less than 4.5V, do the following:
• Disconnect CPS270 (traction throttle) and measure the voltage again. If the voltage is within range,
traction throttle hall sensor is faulty.
• Disconnect CPS93 (control handle) and measure the voltage again. If the voltage is within range,
lift/lower hall sensor is faulty. (Large Chassis Only)

186
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25350 25350 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
There is a mismatch condition between the Reduced traction, lift enabled, lower enabled.
mast prox switch and the height encoder.
Probable Causes and Test Procedures
7. 5V supply checks (turn the key switch to the ON position):
a. Measure the voltage at CPS280 (Auto Center steering connector) pin 2 and 4 (approximately 5V
±0.5V) if the voltage is less than 4.5V, do the following:
• Disconnect CPS260 (height encoder sheave cable) and measure the voltage again. If the voltage is
within range, disconnect the height encoder at the mast and check for shorts at CPS260 (sheave
cable side) between fallowing pins:
– 1 and 2
– 1 and 3
– 1 and 4
– 2 and 3
– 2 and 4
– 3 and 4
– If no shorts found, the height encoder is faulty.

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Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

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2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25351 25351 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
No height encoder counts detected when Reduced traction, lift enabled, lower enabled.
platform is lifting or lowering.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Platform wire harness checks:
a. Check all pins in CPS3B (mast encoder) and its mating connector for spread sockets, deformed pins
and to ensure it is properly seated.
b. Check all pins in CPS3A (sheave cable) and its mating connector for spread sockets, deformed pins
and to ensure it is properly seated.
c. Check all pins in CPS3B (mast encoder) and its mating connector for spread sockets, deformed pins
and to ensure it is properly seated.
d. Check CPS40 (CAN I/O) pins 14, 15 and CPS50 (CAN I/O) pins 6, 7 for spread sockets and to ensure
they are properly seated.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25351 25351 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
No height encoder counts detected when Reduced traction, lift enabled, lower enabled
platform is lifting or lowering.
Probable Causes and Test Procedures
2. Platform wire harness checks:
e. Check continuity between:
• CPS3B (height encoder) pin 1 and CPS40 (CAN I/O) pin 14
• CPS3B pin 4 and CPS40 pin 15
• CPS3B pin 2 and CPS50 (CAN I/O) pin 7
• CPS3B pin 3 and CPS50 (CAN I/O) pin 6
3. Mast encoder checks:
a. Ensure height encoder is properly installed.
b. With the height encoder connected, measure the voltage across CPS3B pins 2 and 3, the voltage
should be approximately 5V.

190
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
25351 25351 Lift platform above 30" Traction
then lower platform
Node 2 to ground.
DESCRIPTION BEHAVIOR
No height encoder counts detected when Reduced traction, lift enabled, lower enabled
platform is lifting or lowering.
Probable Causes and Test Procedures
4. If the platform wire harness, the height encoder installation and the 5V measurement above checked
OK, do the following:
a. Access the FORK HEIGHT in RUN DIAGNOSTIC menu, command lift. FORK HEIGHT needs to
increase when platform is lifted and needs to decrease if platform is lowered. If the value of FORK
HEIGHT does not change, possible faulty height encoder.
5. 5V supply checks (turn the key switch to the ON position):
a. Measure the voltage at CPS280 (Auto Center steering connector) pin 2 and 4 (approximately 5V
±0.5V) if the voltage is less than 4.5V, do the following:
• Disconnect CPS270 (traction throttle) and measure the voltage again. If the voltage is within range,
traction throttle hall sensor is faulty.

191
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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

211
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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33028 33028 Re-key only Traction

Node 2

DESCRIPTION BEHAVIOR
The traction controller has noted no CAN Reduced traction, no lift, no steer. Lower enabled.
communication with the display.
Probable Causes and Test Procedures
3. Display check:
a. With CPS290 (display) connected, measure the voltage between CPS290 pin 1 and CPS290 pin 6. It
should be approximately same as battery voltage. If it is not, repeat Wire Harness Checks procedure.
b. If traction is in limp mode, lift disabled, lower allowed and TRACTION, CAN IO MASTER, CAN
IO SLAVE, STEER MASTER, STEER SLAVE in SOFTWARE VERSION menu in the display shows
NOT AVAILABLE, possible faulty display.
4. Perform the Field Service Tool update. If the voltage between CPS290 (display) pin 1 and CPS290 pin
6 is approximately same as battery voltage and the Field Service Tool fails to update display, possible
faulty display.
5. If problem is intermittent, perform CANbus test.

212
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33056 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Forward antenna is not present on the CAN. No traction, no steering.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Circuit connections checks:
a. Check pins and sockets at forward or reverse antenna and ensure that they are properly seated and
not deformed:
• CPS220 pin 2 (Forward antenna)
• CPS220 pin 3 (Forward antenna)
• CPS220 pin 4 (Forward antenna)
• CPS230 pin2 (Reverse antenna)
• CPS230 pin 3 (Reverse antenna)
• CPS230 pin 4 (Reverse antenna)

213
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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33056 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Forward antenna is not present on the CAN. No traction, no steering.
Probable Causes and Test Procedures
2. Circuit connections checks:
b. Check for continuity between the following:
• CPS220 pin 1 and CPS110 pin 5
• CPS220 pin 2 and CPS120 pin 14
• CPS220 pin 3 and CPS120 pin 6
• CPS220 pin 4 and CPS105 Pin p
• CPS220 pin 5 and CPS110 pin 5
• CPS230 pin 1 and CPS110 pin 5
• CPS230 pin 2 and CPS120 pin 14
• CPS230 pin 3 and CPS120 pin 6
• CPS230 pin 4 and CPS105 Pin p

214
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33056 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Forward antenna is not present on the CAN. No traction, no steering.
Probable Causes and Test Procedures
2. Circuit connections checks:
c. Check sockets and pins for each one of the following connectors and ensure that they are properly
seated and are not spread:
• CPS/CRP106 - CAN Port
• CPS/CRP105 - CAN Port
• CPS20
• CPS22
• Mast sheave cable
• Retractable coil cord
• CPS40
• CPS120
• CPS91 - CAN Port
d. Check for 12 to 15 volts on CPS 220 pin 4 and pin 1, if voltage is not seen check wiring.

215
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33056 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Forward antenna is not present on the CAN. No traction, no steering.
Probable Causes and Test Procedures
3. If all above tests passed, and ANTENNA FORWARD in SOFTWARE VERSION menu in the display
shows NOT AVAILABLE while other modules DO NOT show NOT AVAILABLE, possible faulty forward
antenna.
4. Perform the Field Service Tool update. If the voltage measurement in above step checked OK and the
Field Service Tool fails to update steer controller, possible faulty steer controller.
5. If problem is intermittent, perform CANbus test.
6. Use latest Field Service Tool to update truck.

216
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33057 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Reverse antenna is not present on the CAN. No traction, no steer.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Circuit connections checks:
a. Check pins and sockets at forward or reverse antenna and ensure that they are properly seated and
not deformed:
• CPS220 pin 2 (Forward antenna)
• CPS220 pin 3 (Forward antenna)
• CPS220 pin 4 (Forward antenna)
• CPS230 pin 2 (Reverse antenna)
• CPS230 pin 3 (Reverse antenna)
• CPS230 pin 4 (Reverse antenna)

217
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33057 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Reverse antenna is not present on the CAN. No traction, no steer.
Probable Causes and Test Procedures
2. Circuit connections checks:
b. Check for continuity between the following:
• CPS220 pin 1 and CPS110 pin 5
• CPS220 pin 2 and CPS120 pin 14
• CPS220 pin 3 and CPS120 pin 6
• CPS220 pin 4 and CPS105 pin p
• CPS220 pin 5 and CPS110 pin 5
• CPS230 pin 1 and CPS110 pin 5
• CPS230 pin 2 and CPS120 pin 14
• CPS230 pin 3 and CPS120 pin 6
• CPS230 pin 4 and CPS105 pin p

218
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33057 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Reverse antenna is not present on the CAN. No traction, no steer.
Probable Causes and Test Procedures
2. Circuit connections checks:
c. Check sockets and pins for each one of the following connectors and ensure that they are properly
seated and are not spread:
• CPS/CRP106 - CAN Port
• CPS/CRP105 - CAN Port
• CPS20
• CPS22
• Mast sheave cable
• Retractable coil cord
• CPS40
• CPS120
• CPS91 - CAN Port
d. Check for 12 to 15 volts on CPS 220 pin 4 and pin 1, if voltage is not seen check wiring.

219
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33057 WG Not Calib When antenna(s) is Steer
connected on the
Node 6 CANbus.
DESCRIPTION BEHAVIOR
Reverse antenna is not present on the CAN. No traction, no steer.
Probable Causes and Test Procedures
3. If all above tests passed, and ANTENNA REVERSE in SOFTWARE VERSION menu in the display
shows NOT AVAILABLE while other modules DO NOT show NOT AVAILABLE, possible faulty reverse
antenna.
4. Perform the Field Service Tool update. If the voltage measurement in above step checked OK and the
Field Service Tool fails to update steer controller, possible faulty steer controller.
5. If problem is intermittent, perform CANbus test.
6. Use latest Field Service Tool to update truck.

220
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33059 33059 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
No communication with CAN I/O slave. No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
1. Circuit connections checks:
a. Check for correctness in CAN HI circuit 901 and CAN LO circuit 900 wires connected to the following
components per schematic:
• CAN I/O CPS40 pin 16 (CAN HI) and pin 17 (CAN LO)
• Traction controller CPS100 pin 27 (CAN LO) and pin 28 (CAN HI)
• Steer controller CPS120 pin 6 (CAN LO) and pin 14 (CAN HI)
• Hoist controller CPS150 pin 21 (CAN HI) and CPS150 pin 20 (CAN LO)
• Dash display CPS290 pin 3 (CAN HI) and pin 4 (CAN LO)

221
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33059 33059 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
No communication with CAN I/O slave. No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
1. Circuit connections checks:
b. Check for continuity between:
• Key Switch and CPS100 pin 10
• Key Switch and CPS40 pin 1
• CPS40 pin 17 and CPS100 pin 27
• CPS40 pin 17 and CPS150 pin 20
• CPS40 pin 17 and CPS120 pin 6
• CPS40 pin 17 and CPS290 pin 4
• CPS40 pin 16 and CPS100 pin 28
• CPS40 pin 16 and CPS150 pin 21
• CPS40 pin 16 and CPS290 pin 3
• CPS40 pin 16 and CPS120 pin 14

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33059 33059 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
No communication with CAN I/O slave. No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
1. Circuit connections checks:
c. Check sockets and pins for each one of the following connectors and ensure that they are properly
seated and are not spread:
• CPS/CRP106 - CAN Port
• CPS/CRP105 - CAN Port
• CPS20
• CPS22
• Mast sheave cable
• Retractable coil cord
• CPS40
• CPS120
• CPS91 - CAN Port
d. Check for battery voltage between CPS40 pin 1 and pin 2, if voltage is not seen check wiring.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33059 33059 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
No communication with CAN I/O slave. No traction, no steer, no lift, no lower.
Probable Causes and Test Procedures
2. If all above tests passed, and CAN I/O SLAVE in SOFTWARE VERSION menu in the display shows
“NOT AVAILABLE” while other modules DO NOT show “NOT AVAILABLE”, possible faulty CAN I/O.
3. Perform the Field Service Tool update. If the voltage measurement in above step checked OK and the
Field Service Tool fails to update CAN I/O SLAVE, possible faulty CAN I/O controller.
4. If problem is intermittent, perform CANbus test.

224
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33060 33060 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller EPS has lost CANbus No traction, no steering, no lift, no lower.
communication with the traction controller.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Circuit connections checks:
a. Check for correctness in CAN HI circuit 901 and CAN LO circuit 900 wires connected to the following
components per schematic:
• CAN I/O CPS40 pin 16 (CAN HI) and pin 17 (CAN LO)
• Traction controller CPS100 pin 27 (CAN LO) and pin 28 (CAN HI)
• Steer controller CPS120 pin 6 (CAN LO) and pin 14 (CAN HI)
• Hoist controller CPS150 pin 21 (CAN HI) and CPS150 pin 20 (CAN LO)
• Dash display CPS290 pin 3 (CAN HI) and pin 4 (CAN LO)

225
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33060 33060 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller EPS has lost CANbus No traction, no steering, no lift, no lower.
communication with the traction controller.
Probable Causes and Test Procedures
2. Circuit connections checks:
b. Check for continuity between:
• Key switch and CPS100 pin 10
• Key switch and CPS40 pin 1
• CPS40 pin 17 and CPS100 pin 27
• CPS40 pin 17 and CPS150 pin 20
• CPS40 pin 16 and CPS100 pin 28
• CPS40 pin 16 and CPS150 pin 2
c. Check for shorts between:
• B on the traction controller and CPS70 pin 1
• B negative stud and CPS100 pin 25
d. Measure resistance of CAN circuit on CAN port.

226
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33060 33060 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller EPS has lost CANbus No traction, no steering, no lift, no lower.
communication with the traction controller.
Probable Causes and Test Procedures
3. Wire harness checks:
a. Check pins and sockets of the following connectors and ensure that they are properly seated, are not
spread and are not deformed:
• CPS/CRP106 - CAN Port
• CPS/CRP105 - CAN Port,
• CPS20
• CPS22
• Mast sheave cable
• Retractable coil cord
• CPS50
• CPS91 - CAN Port
b. Check for battery voltage between CPS100 pin 10 and B of traction controller, if voltage is not seen
check wiring.

227
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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33060 33060 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller EPS has lost CANbus No traction, no steering, no lift, no lower.
communication with the traction controller.
Probable Causes and Test Procedures
4. If all above tests passed, and TRACTION in SOFTWARE VERSION menu in the display shows “NOT
AVAILABLE” while other modules DO NOT show “NOT AVAILABLE”, possible faulty traction controller.
5. Perform the Field Service Tool update. If the voltage measurement in above step checked OK and the
Field Service Tool fails to update traction controller, possible faulty traction controller. Contact Service
Engineering to confirm failure.
6. If problem is intermittent, perform CANbus test.

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STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33061 33061 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller (EPS) master No traction, no steer, no lift, no lower.
microprocessor has lost CANbus
communication with the CAN I/O.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Circuit connections checks:
a. Check for steer motor controller B and B+ stud terminal to be clean.
b. If AC hoist controller is available, check B and B+ stud terminal to be clean.
c. Check for ground wire circuit 113 on traction controller B terminal to be clean.
d. Check for continuity between:
• Circuit 113 and B terminal stud
• CAN LO in CAN port B and CPS40 pin 17
• CPS290 pin 4 and CPS100 pin 27
• CAN HI in CAN port A and CPS40 pin 16
• CPS290 pin 3 and CPS100 pin 28

229
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33061 33061 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller (EPS) master No traction, no steer, no lift, no lower.
microprocessor has lost CANbus
communication with the CAN I/O.
Probable Causes and Test Procedures
2. Circuit connections checks:
e. Check for continuity between:
• Key switch (ignition side) TS15 and CPS40 pin 1
• B and CPS40 pin 2 (If necessary disconnect CPS 40, turn truck on and measure for battery voltage
between B negative stud and CPS 40 pin 1)
• B and CPS40 pin 2
• B and CPS50 pin 2
f. Check for correctness in CAN HI circuit 901 and CAN LO circuit 900 wires connected to the following
components per schematic:
• CAN I/O CPS40 pin 16 (CAN HI) and pin 17 (CAN LO)
• Traction controller CPS100 pin 27 (CAN LO) and pin 28 (CAN HI)
• Steer controller CPS120 pin 6 (CAN LO) and pin 14 (CAN HI)
• Hoist controller CPS150 pin 21 (CAN HI) and CPS150 pin 20 (CAN LO)
• Dash display CPS290 pin 3 (CAN HI) and pin 4 (CAN LO)

230
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33061 33061 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller (EPS) master No traction, no steer, no lift, no lower.
microprocessor has lost CANbus
communication with the CAN I/O.
Probable Causes and Test Procedures
3. If problem is intermittent, perform CANbus test.
4. Wire harness checks:
a. Check pins and sockets for each one of the following connectors and ensure that they are properly
seated, are not spread and are not deformed:
• CPS/CRP106 - CAN Port
• CPS/CRP105 - CAN Port
• CPS20
• CPS22
• Mast sheave cable
• Retractable coil cord
• CPS50
• CPS91 - CAN Port
• CPS290
• CPS50
• CPS40

231
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33061 33061 Re-key only Steer

Node 6

DESCRIPTION BEHAVIOR
Steer controller (EPS) master No traction, no steer, no lift, no lower.
microprocessor has lost CANbus
communication with the CAN I/O.
Probable Causes and Test Procedures
5. Check for battery voltage between CPS40 pin 1 and pin 2, if voltage is not seen check wiring.
6. If all above tests passed, and CAN I/O MASTER in SOFTWARE VERSION menu in the display shows
“NOT AVAILABLE” while other modules DO NOT show “NOT AVAILABLE”, possible faulty CAN I/O
controller.
7. Perform the Field Service Tool update. If the voltage measurement in above step checked OK and the
Field Service Tool fails to update CAN I/O controller, possible faulty CAN I/O controller. Contact Service
Engineering to confirm failure.
8. If problem is intermittent, perform CANbus test.

232
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33088 33088 Re-key only CANbus

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from CAN I/O slave No traction, no steer, no lift, no lower.
to CAN I/O master.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Check the software version in the display for the CAN I/O master and CAN I/O slave. The CAN I/O
master and slave software versions must be at the same revision level.
a. If either version is not shown, upgrade software with the latest version of Field Tool.
b. If software versions are not at the same level, update software with the latest version of Field Tool.
c. If either version of software cannot be updated, possible faulty CAN I/O controller.
3. Connection Checks:
a. Check the B connections to the traction controller and EPS Controller.
b. Check the NEG stud and correct faulty connections as necessary.
c. Check continuity between following pins:
• CPS40 Pin 2 and B
• CPS50 Pin 2 and B
• CPS40 Pin 1 and key switch TS15

233
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33088 33088 Re-key only CANbus

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from CAN I/O slave No traction, no steer, no lift, no lower.
to CAN I/O master.
Probable Causes and Test Procedures
4. Disconnect battery and discharge controller capacitor.
a. Check for shorted CANH and CANL wires.
• CANH to truck frame - > 50K ohms
• CANL to truck frame - > 50K ohms
• CANH to B stud - > 25K ohms
• CANL to B stud - > 25K ohms
b. Check for shorted power connections.
• B+ to truck frame - >50K ohms
• B to truck frame - >50K ohms
• Traction motor U,V,W terminals to truck frame - >50K ohms
• Steer motor U,V,W terminals to truck frame - >50K ohms
• Hoist motor U,V,W terminals to truck frame - >50K ohms
5. Update software with the latest version Field Tool.
6. If fault code persists, possibly faulty CAN I/O.

234
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33089 33089 Re-key only CANbus

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from traction controller No traction, no steer, no lift, no lower.
to CAN I/O master.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Wire harness checks - disconnect the battery connector and check the following:
a. Check resistance between CAN LO and CAN HI wires at PC connector, should be approximately 60
ohms.
b. Check continuity between:
• CPS100 pin 28 and CPS40 pin 16 (CAN I/O)
• CPS100 pin 27 and CPS40 pin 17 (CAN I/O)
• CPS40 pin 2 and B stud
• CPS50 pin 2 and B stud
• NEG Stud and B of traction controller
• CPS100 pin 10 and TS15 (key switch)
• Ensure sockets at following connectors are not spread and are properly seated:
– CPS10 pin 10
– CPS100 pins 27 and 28
– CPS40 pins 2, 16, and 17
– CPS50 pin 2

235
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33089 33089 Re-key only CANbus

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from traction controller No traction, no steer, no lift, no lower.
to CAN I/O master.
Probable Causes and Test Procedures
3. Traction controller checks:
a. With CPS100 connected, measure the voltage across CPS100 pin 10 and B . It should be approxi-
mately same as battery voltage.
• If the voltage is shown correctly, check the software version in the Display. If the version is shown
as “NOT AVAILABLE” while other modules DO NOT show “NOT AVAILABLE”, then possibly a
faulty traction controller. Contact Service Engineering to confirm failures.
• If the voltage measurement in above step has not checked out OK, then repeat wire harness Checks
procedure.
• Perform the Field Service Tool update. If the voltage measurement in the above step checked out
OK and the Field Service Tool fails to update the traction controller then possibly a faulty traction
controller. Contact Service Engineering to confirm failures.
4. If problem is intermittent, perform CANbus test.

236
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33090 33090 Re-key only Internal CANbus

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from CAN I/O master No traction, no steer, no lift, no lower.
to CAN I/O slave.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Check the software version in the display for the CAN I/O master and CAN I/O slave. The CAN I/O
master and slave software versions must be at the same revision level.
a. If either version is not shown, upgrade software with the latest version of Field Tool.
b. If software versions are not at the same level, update software with the latest version of Field Tool.
c. If either version of software cannot be updated, possible faulty CAN I/O controller.
3. Connection Checks:
a. Check the B connections to the traction controller and EPS Controller.
b. Check the NEG Stud and correct faulty connections as necessary.
c. Check continuity between following pins:
• CPS40 Pin 2 and B
• CPS50 Pin 2 and B
• CPS40 Pin 1 and key switch TS15

237
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33090 33090 Re-key only Internal CANbus

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from CAN I/O master No traction, no steer, no lift, no lower.
to CAN I/O slave.
Probable Causes and Test Procedures
4. Disconnect battery and discharge controller capacitor.
a. Check for shorted CANH and CANL wires.
• CANH to truck frame - > 50K ohms
• CANL to truck frame - > 50K ohms
• CANH to B Stud - > 25K ohms
• CANL to B Stud - > 25K ohms
b. Check for shorted power connections.
• B+ to truck frame - >50K ohms
• B to truck frame - >50K ohms
• Traction Motor U,V,W terminals to truck frame - >50K ohms
• Steer Motor U,V,W terminals to Truck frame - >50K ohms
• Hoist Motor U,V,W terminals to Truck frame - >50K ohms
5. Update software with the latest version Field Tool.
6. If fault code persists, possibly faulty CAN I/O.

238
2200 SRM 1466 Troubleshooting

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33091 33091 Re-key only CAN I/O

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from traction controller No traction, no steer, no lift, no lower.
to CAN I/O slave.
Probable Causes and Test Procedures
1. Perform basic checks.
2. Wire harness checks - disconnect the battery connector and check the following:
a. Check resistance between CAN LO and CAN HI wires at PC connector, should be approximately 60
ohms.
b. Check continuity between:
• CPS100 pin 28 and CPS40 pin 16 (CAN I/O)
• CPS100 pin 27 and CPS40 pin 17 (CAN I/O)
• CPS40 pin 2 and B stud
• CPS50 pin 2 and B stud
• NEG Stud and B of traction controller
• CPS100 pin 10 and TS15 (key switch)
• Ensure sockets at following connectors are not spread and are properly seated:
– CPS10 pin 10
– CPS100s pin 27 and 28
– CPS40 pins 2, 16, and 17
– CPS50 pin 2

239
Troubleshooting 2200 SRM 1466

STATUS DISPLAY MESSAGE RECOVERY METHOD CIRCUIT

CODE
33091 33091 Re-key only CAN I/O

Node 7 or 8

DESCRIPTION BEHAVIOR
No communication from traction controller No traction, no steer, no lift, no lower.
to CAN I/O slave.
Probable Causes and Test Procedures
3. Traction controller checks:
a. With CPS100 connected, measure the voltage across CPS100 pin 10 and B . It should be approxi-
mately same as battery voltage.
• If the voltage is shown correctly, check the software version in the display. If the version is shown
as “NOT AVAILABLE” while other modules DO NOT show “NOT AVAILABLE”, then possibly a
faulty traction controller. Contact Service Engineering to confirm failures.
• If the voltage measurement in above step has not checked out OK, then repeat wire harness Checks
procedure.
• Perform the Field Service Tool update. If the voltage measurement in the above step checked out
OK and the Field Service Tool fails to update the traction controller then possibly a faulty traction
controller. Contact Service Engineering to confirm failures.
4. If problem is intermittent, perform CANbus test.

240
2200 SRM 1466 Troubleshooting