Hyster B199 Service Manual – PDF DOWNLOAD

CURTIS TRANSISTOR MOTOR CONTROLLER W40-60XL, B40-60XL [D135]; N30FR [A217]; R30ES [B174]; R30XMS [C174]; R30XMS2 [D174]; W60-80XT [E135]; B60-80XT [B199]; C60-80XT [B199]; W40XT [A218]; W45XT [A215, B215]; T5XT [E142]; W20/30/40XTA [A453]; W20/25/30/40XTC [A454]; W20/30XTR [A455]

PART NO. 897340

2200 SRM 411

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 condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Curtis Transistor Motor Controller

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Principles of Operation ......................................................................................................................................

General ...........................................................................................................................................................

Transistor Motor Controller ..........................................................................................................................

Basic Controller Operation .......................................................................................................................

Field Effect Transistor (FET)....................................................................................................................

Motor Circuit That Operates With Pulses ...............................................................................................

Induction Current From Motor ................................................................................................................

Plugging .....................................................................................................................................................

Control Circuit...........................................................................................................................................

Static-Return-To-Off (SRO) Function.......................................................................................................

Thermal Protection Function....................................................................................................................

Low Voltage Protection Function..............................................................................................................

Current Limit Protection Function ..........................................................................................................

Power Circuit.............................................................................................................................................

Sequence of Operation .......................................................................................................................................

Key Switch .....................................................................................................................................................

Brake Switch..................................................................................................................................................

Control Circuit ...............................................................................................................................................

FWD/REV Switch Closed ..............................................................................................................................

Forward Contactor Energized.......................................................................................................................

Gate Pulse to FETs ........................................................................................................................................

FETs ON for Time of Gate Pulse ..................................................................................................................

Gate Pulse Removed......................................................................................................................................

Induction Current Flows Through Motor and Flyback Diode.....................................................................

Plugging .........................................................................................................................................................

Checks.................................................................................................................................................................

Checking Contactor Coil................................................................................................................................

Checking Transistor Controller ....................................................................................................................

Checks With Controller Installed .............................................................................................................

Bench Checks ............................................................................................................................................

Accelerator Potentiometer Checks and Adjustments..............................................................................

Adjustments .......................................................................................................................................................

Plugging Adjustment.....................................................................................................................................

Acceleration Adjustment ...............................................................................................................................

Current Limit Adjustment ............................................................................................................................

Repairs................................................................................................................................................................

Contactors ......................................................................................................................................................

Replace .......................................................................................................................................................

Curtis Contactor Parts, Replace ...................................................................................................................

GE Contactor Parts, Replace ........................................................................................................................

Controller, Replace ........................................................................................................................................

Accelerator Potentiometer and Control Switches, Replace and Adjust......................................................

Troubleshooting..................................................................................................................................................

General ...........................................................................................................................................................

General Procedures .......................................................................................................................................

Fault Procedures ................................................................................................................................................

©2004 HYSTER COMPANY

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Table of Contents

Curtis Transistor Motor Controller

TABLE OF CONTENTS (Continued) This section is for the following models: W40-60XL, B40-60XL [D135]; N30FR [A217]; R30ES [B174]; R30XMS [C174]; R30XMS2 [D174]; W60-80XT [E135]; B60-80XT [B199]; C60-80XT [B199]; W40XT [A218]; W45XT [A215, B215]; T5XT [E142]; W20/30/40XTA [A453]; W20/25/30/40XTC [A454]; W20/30XTR [A455]

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2200 SRM 411

General

General This section describes the operation, checks, repairs, and troubleshooting of the Curtis PMC 1204 or 1205 series. It also covers the 1207 series and the new series of the 1243 motor controller. See Figure 1, Figure 2, and Figure 4. This transistor motor controller is used to control the operation of some 24and 36-volt electric lift trucks. The controllers are made for Hyster Company by a division of Curtis Instruments, Inc. The controller for the traction system uses digital logic. Digital logic uses transistors to operate like very fast switches. The transistors are controlled by electrical gate pulses. Electrical noise is also high voltage pulses caused by momentarily operating other electrical devices. Digital logic cannot understand the difference between control pulses and electrical noise. Filter capacitors are connected between the B+ and B terminals in the controller to prevent electrical noise from entering the logic and causing errors.

The logic of the controller also checks the following functions: 1. Checks the temperature and gives both low and high temperature thermal protection to the controller.

2. Electrically checks that an operator follows the correct starting sequence to help prevent unexpected operation. This function has been called Static-Return-To-Off (SRO) in other Hyster motor controller Service Manual sections.

3. Electrically checks the traction circuit for certain malfunctions. This function prevents lift truck operation if a failure is sensed.

4. Checks the current in the motor circuit and automatically decreases the motor voltage to reduce the current and prevent damage. The plugging circuit is also controlled for smoother operation.

NOTE: B60-80XT SHOWN. W45XT, W60-80XT, C60-80XT, AND T5XT MODELS SIMILAR. Figure 1. Transistor Controller on Truck (Early Production)

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Principles of Operation

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Additional information showing how the motor controller is electrically connected in the lift truck is shown in the section Diagrams 8000 SRM 457 for the walkie low lift motorized hand trucks, Diagrams Curtis Transistor 8000 SRM 495

for N30FR units, Diagrams Curtis Transistor 8000 SRM 475 for R30ES units, Diagrams 8000 SRM 653 for the walkie high lift motorized hand trucks, and Diagrams 8000 SRM 923 for the R30XM2/XMA2/XMF2/XMS2 units.

NOTE: B60-80XT SHOWN. W40XT, W45XT, W60-80XT, C60-80XT, AND T5XT MODELS SIMILAR. Figure 2. Transistor Controller on Truck (Late Production)

Principles of Operation GENERAL A motor controller for an electric lift truck controls the speed of the traction motor by making a variation in the applied voltage. This controller uses solid-state electronic devices to permit efficient control of the applied voltage.

The motor controller also generates a high current flow in the traction motor while keeping a low current draw from the battery. A battery is less efficient at a high current draw. A battery will not give all of its electrical power at a high current draw. The

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traction motor is a series wound motor that generates torque. This torque is proportional to the current moving through the motor. The speed of the motor is controlled by the voltage and mechanical load connected to the motor.

The motor will accelerate until the mechanical load equals the torque required. If the torque increases, the current and acceleration will increase.

The two functions look like a problem of opposite needs. How a solid-state electronic controller balances those needs with efficiency is described in this section.

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Principles of Operation

TRANSISTOR MOTOR CONTROLLER The motor controller controls the speed of the traction motor. The direction of rotation of the motor is controlled by the Forward/Reverse switch and contactors. See Figure 3, Figure 4, and Figure 5. The controller is sealed in an aluminum case and has no parts that can be repaired or replaced. The complete unit must be replaced if correct troubleshooting methods show that the unit is damaged.

External contactors are used to control the direction of rotation of the traction motor. Contactors are electrical switches that use an electromagnet to operate

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PMC ELECTRIC BRAKE APS STEERING MOTOR

the power contacts of the switch. A small electric signal is used to energize the electromagnet to close the power contacts and control the large current flow needed for the motor circuit. The electromagnetic field in the coil moves the armature against spring pressure to close the power contacts. When the coil is de-energized, the spring pressure moves the armature and opens the contacts. When a spring holds the contacts of a switch open, the switch is called normally open (NO). If the switch spring holds the contacts of a switch closed, the switch is called normally closed (NC).

5. CONTACTOR PANEL 6. HYDRAULIC PUMP MOTOR 7. DRIVE MOTOR

Figure 3. Transistor Controller on Truck (New Production)

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Principles of Operation

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CONTROLLER LC CONTACTOR POWER FUSE LIFT PUMP CONTACTOR 1A CONTACTOR CONTROL FUSES TIMER FORWARD/REVERSE CONTACTOR Figure 4. Transistor Controller Panel (W/B40-60XL Units)

2200 SRM 411 There are two contactors that control the direction of rotation of the traction motor. Each direction contactor has two sets of contacts on the same plunger assembly. Each contactor has a set of NO contacts and a set of NC contacts. When one set of contacts is closed, the other set of contacts must be open. This arrangement prevents the wrong sequence of closed contacts that could cause an open circuit. This arrangement of contactors also permits current flow through the motor field in either direction. See Figure 5 and Figure 6. One set of contacts causes the motor armature to rotate in one direction. The other set of contacts causes the motor armature to rotate in the opposite direction. See Figure 7. Other contactors used for control functions on the lift truck only have one set of contacts because a forward and reverse operation is not required. An example is the hydraulic pump motor contactor.

Contactors are used to energize and de-energize motors, but cannot control the speed. The transistor motor controller applies battery voltage in short, fast pulses to a DC motor to control the speed. How this circuit controls the speed of a motor with pulses is described in this section.

The direction and speed control operates the FWD/ REV switch to energize the direction contactor. The control also supplies the speed input to the motor controller.

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BATTERY TRACTION MOTOR ARMATURE TRACTION MOTOR FIELD REVERSE CONTACTOR CONTACTS FORWARD CONTACTOR CONTACTS FETS SWITCH Figure 5. Basic Traction Motor Circuit

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Figure 6. Current Flow Through Field in FORWARD Direction

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Principles of Operation voltage. See Figure 8. Electricity flows easily from the input to the output. A FET will only permit current flow when there is a positive voltage at the input, a negative voltage at the output AND a positive voltage applied to the gate. A FET will permit electricity to flow from the input to the source as long as there is the signal voltage at the gate. The FETs ON time is the same as the gate pulse ON time as shown in Figure 9. Current flows as shown in Figure 8. The FET stops conducting when the signal voltage is removed from the gate.

When FETs are used as a switch: a. The FETs are ON when the electric current flows through them (gate voltage applied). b. The FETs are OFF when the electric current cannot flow through them (no gate voltage).

Motor Circuit That Operates With Pulses Figure 7. Current Flow Through Field in REVERSE Direction

Basic Controller Operation This transistor motor controller has a power section and a logic section with solid-state electronic circuits that control the operation of a DC motor. The speed of DC motors is controlled by the average applied voltage. The higher the average applied voltage, the faster the motor will rotate. If a switch is put in the traction motor circuit (see Figure 4) and the switch is changed to OFF and ON quickly (see Figure 9) the traction motor will rotate. The speed of rotation increases as the time the switch is ON increases. The speed of rotation will decrease if the ON time decreases. OFF time will increase at the same time.

The speed of the motor can be controlled using this principle.

This controller uses an electronic device called a Field Effect Transistor (FET) to generate the rapid ON and OFF pulse times. It has no moving parts.

The FETs are turned on and off by the logic circuits in the controller to act as the switch. Several power FETs are connected in parallel to carry the necessary motor current.

Field Effect Transistor (FET) A FET is a solid-state device that operates like a very fast switch. A FET is a transistor that has an element called a gate. FETs are electronic devices that permit electricity to flow as long as there is a gate

A schematic that shows the controller and FETs in a traction circuit is shown in Figure 8. When a signal is applied to the gate of the FETs, the FETs are ON and current flows from the battery through the motor. When the gate signal is removed, the FETs are changed to OFF. The battery voltage is applied to the motor in pulses.

The pulses of energy through the FETs to the motor are very fast (15,000 on/off cycles per second). The motor cannot follow each pulse, but the motor runs smoothly based on the average voltage generated by the ON and OFF times. The average motor voltage applied to the traction motor is shown in Figure 9.

The length of the ON TIME of the pulses changes the average motor voltage. As the ON TIME of each pulse increases (OFF TIME decreases), the average motor voltage increases. This change in the ratio of ON TIME to OFF TIME of the pulses is called pulse width modulation.

The control circuit has an oscillator and a pulse width modulator. The oscillator generates a saw tooth waveform at a constant frequency of 15,000 cycles per second (15 kHz). The pulse width modulator uses this saw tooth waveform to generate a pulse output that can be smoothly changed from a full ON to a full OFF condition. This pulse output is used by the gate driver circuit for the high pulse currents needed to turn the FETs ON and OFF. The pulse width modulator controls the ON and OFF times of the FETs through the gate driver. The ratio of ON TIME to OFF TIME sets the average motor voltage and the motor speed.

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Principles of Operation

2200 SRM 411 Legend for Figure 8 1.

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BATTERY TRACTION MOTOR GATE DRIVE FET INPUT (+) FET OUTPUT ( ) FET GATE (+) POSITIVE SUPPLY THROUGH MOTOR POSITIVE GATE VOLTAGE NO GATE VOLTAGE NO GATE SIGNAL

Figure 9. Average Motor Voltage Figure 8. Transistor Control

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2200 SRM 411

Principles of Operation

The accelerator potentiometer, at the speed control of the lift truck, regulates a voltage that changes as the operator sets the speed of operation. This voltage is an input to the controller and the pulse width modulator. As the voltage changes with the selected speed, a direct change in the ratio of FET ON TIME to FET OFF TIME also occurs. The voltage for maximum speed changes the ratio to pulses with the maximum ON TIME, to produce a maximum average motor voltage. See Figure 9. The pulse rate (15 kHz) stays the same for all speeds.

Induction Current From Motor When a DC motor is controlled by a pulsed circuit, the magnetic field in the armature and field windings is continuously expanding and decreasing. The fields expand when voltage is applied (ON TIME) and decreases when the voltage is removed (OFF

TIME). The voltage causes an increasing current flow through the windings to make the expanding magnetic field. When the voltage is removed, the decreasing magnetic field causes current to flow in the same direction through the windings. See Table 1. This expansion and decrease of the magnetic field is lost energy for doing work unless the controller is designed to use this energy. A Flyback Diode (sometimes called a Freewheel Diode) is in the controller circuit for this purpose.

The Flyback Diode permits the current, from the decreasing magnetic field, to flow through the field and armature again to do work. The torque of a series DC motor is directly proportional to the amount ofcurrent flowing through it. At slower speeds, the OFF times are longer. When the FETs are OFF, the decreasing magnetic field generates a voltage and current in the motor.

Table 1. Inductance Beginning conditions as the switch is closed: 1. Large current flow from battery through inductor.

2. Increasing magnetic field generates reverse voltage within inductor.

3. Reverse voltage decreases current through inductor. Current energy changed to energy in magnetic field.

Constant conditions after switch is closed for a short time period: 1. Voltage and current flow is the same in all parts of the circuit.

2. Magnetic field is constant.

Ending conditions as the switch is opened: 1. Decreasing magnetic field generates voltage within inductor.

2. Decreasing magnetic field generates current flow in original direction.

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Principles of Operation

2200 SRM 411

This current is often called the flyback current. The Flyback Diode permits the current to flow through the field and armature again to do work. At slower speeds, the motor current is part battery current and part flyback current. There is less battery current used for the specific torque requirement.

High current draw from the battery is to be avoided, if possible, because it is less efficient. At higher speeds, the OFF time is less, so that less induction

1. BATTERY 2. MOTOR ARMATURE 3. MOTOR FIELD

current (flyback current) is generated. Most of the motor current must come from the battery at higher speeds. However, the torque and current requirements are also usually less.

The typical induction current during equal ON and OFF times of the FETs is shown in the graph in Figure 10.

4. CONTROLLER 5. FETS (NOT ON) 6. FLYBACK DIODE Figure 10. Induction Motor Current

Plugging The plugging circuit is an added feature of the controller that provides smooth electrical braking when the operator wants to change the truck’s direction of travel. See Figure 11. The plugging feature also saves wear and tear on the drive tires and the drive unit gears.

Plugging occurs when the truck is traveling in one direction but the operator has switched the directional control to the opposite direction. In this instance, the motor armature is rotating in one direction while the magnetic forces of the fields are trying to force the armature the other way. This reaction generates current that is allowed to flow through a loop formed by

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the plugging diode in the controller. This generated current helps to slow the truck’s speed magnetically in the same manner that compression in a gas engine will help to control the speed of an automobile when it is coasting. When a lift truck is in the plugging mode, the pulse rate of the controller must be maintained at a slow rate. To accomplish this the logic section of the controller signals that the truck is in a plugging mode and controls the oscillating rate. The oscillating rate pulses slowly no matter what position the directional control is in on a controller with fixed plugging. Some controllers are furnished with throttle position plugging and the oscillating rate can vary.

2200 SRM 411

Principles of Operation

Control Circuit The control circuit has operator inputs from the key and brake switches as well as the accelerator potentiometer. The circuit also has internal inputs from the power circuit for thermal protection, plugging sensing, low voltage protection and motor current (current limit). The control circuit uses the inputs to regulate the ON TIME pulses to the FETs for speed control, current limit and plugging strength.

Static-Return-To-Off (SRO) Function The control circuit includes a function to prevent the operation of the lift truck if the starting sequence is not correct. The function uses the inputs to the control circuit to make sure the operator is ready to operate the controls. The starting sequence is as follows: 1. Turn the key switch to the ON position. The key switch supplies battery voltage to the brake switch.

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BATTERY MOTOR ARMATURE MOTOR FIELD CONTROLLER PLUG DIODE Figure 11. Plugging Current Circuit

The plugging function of the controller is designed to allow the truck to travel 1 to 2 times the length of the lift truck after the truck is plugged before it reverses direction.

During plugging, the oscillating rate is decreased from 15 kHz to 1 kHz. The controller regulates the pulse widths of the pulses to the motor field for the correct amount of plugging. The accelerator circuit is also set to a low speed so that normal acceleration in the opposite direction will occur. The plugging distance is adjustable. The plugging adjustment on the controller changes the amount of motor field current allowed. The plugging adjustment can be changed as needed for an application. See Adjustments.

Plugging an electric lift truck is not a harmful practice, however, avoid plugging the drive motor when the drive wheel is jacked off the ground.

2. The operator must close the brake switch. Battery voltage is now supplied to the control circuit.

3. Rotate the Direction/Speed control in the desired direction of travel to select travel direction and speed.

If Step 3 is done before both Step 1 and Step 2 are complete, the lift truck will not move in either direction. The control circuit must get battery voltage through both the key and brake switches before it gets a speed signal from the accelerator potentiometer. If the starting sequence is not correct, the control circuit will not send a gate pulse to the FETs for traction motor current.

The SRO function also prevents the lift truck from going to full speed operation because of a malfunction in the accelerator circuit. On the B/W40-60XL units, an open circuit in the accelerator circuit is normally sensed as a full speed signal by the control card. If this malfunction exists, the SRO function will prevent the start of traction pulses. If the malfunction occurs during normal operation, the control circuit senses an accelerator potentiometer input of more than 7000 ohms (open circuit) and stops the traction pulses. The circuit will return to normal operation after the malfunction is repaired.

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Principles of Operation

Thermal Protection Function There is a sensor to sense the heat within the controller housing. If the controller gets too hot or too cold for correct operation, the control circuit will reduce the ON TIME of the pulses to decrease the current to protect the controller. The lift truck will still operate at a slower speed to permit it to be moved to a location out of the work area. The controller can then return to a normal operating temperature. The controller is designed to operate with an internal temperature between 85 C (185 F) and 25 C ( 13 F). Controller performance will be reduced when the controller is in Thermal Protection.

Low Voltage Protection Function This function protects the controller and the battery.

The controller will not operate correctly if there is not a minimum voltage from the battery. The battery current drain increases as the battery voltage decreases. Too large a battery drain will damage the battery. If the battery voltage is low, the control circuit will decrease the ON TIME of the pulses to decrease the current drain. The battery can still operate the lift truck to move it for battery charging or replacement. The controller requires a minimum of

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2200 SRM 411 9 volts on the 12-volt controllers and a minimum of 16 volts on the 24-volt controllers for the system to function properly.

Current Limit Protection Function The control circuit limits the traction motor current to a maximum value to protect the controller, motor and battery. The control circuit will decrease the ON TIME of the motor pulses to keep the motor current less than the maximum value. The maximum value is set by the manufacturer.

Power Circuit The power circuit is controlled by the control circuit.

See Figure 12. The complete power circuit is inside the controller and has the following parts: • Field Effect Transistors • Flyback Diode • Plug Diode • Filter Capacitors The parts in the power circuit cannot be replaced by users. Cables connect the battery and traction motor to the power circuit at the controller power terminals B+, A2, M , and B . All of the traction motor current flows through the power circuit of the controller.

2200 SRM 411

Principles of Operation

Figure 12. N30FR Transistor Controller Circuit Schematic

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Sequence of Operation

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Sequence of Operation The sequence of operation describes a complete cycle of the transistor traction circuit. A sequence of the beginning conditions and the FET cycle is shown in Figure 13.

NOTE: Gray lines on the circuit lines show positive voltage with respect to battery negative. Slash lines show negative voltage with respect to battery positive.

The line codes do not always indicate full battery voltage. The gray tone is used only for the circuits being described. Some parts of the energized circuit are not shown with gray tones or slashes. The thick (bold) lines show the traction power circuit. The thin lines show the control circuits.

NOTE: The following circuit schematics from the W40-60XL and B40-60XL lift trucks are used to describe the sequence of operation. Basic operation of the transistor controller for other lift truck models is similar. See the Diagrams sections for the complete schematics.

NOTE: The N30FR, W40-60XL, and B40-60XL lift trucks have an additional LC contactor that is energized when the key switch closes. The basic circuit operation is the same as described.

KEY SWITCH Key Switch closed by moving key to the ON position.

On N30FR units, the LC contactor is energized. Battery power to brake switch, lift, lower, horn and to optional heater and battery meter. See Figure 14.

BRAKE SWITCH Brake switch must be closed by lowering steering handle (W/B40-60XL, W/B60-80XT, W20-40XTA, W20-40XTC, and W20-30XTR only); operator releasing brake handles (C60-80XT and T5XT); or operator stepping on brake switch (R30ES only) so that the FWD/REV switch, Traction Reverse switch (W/B40-60XL and W/B60-80XT only), Accelerator Potentiometer, and Control Circuit will have battery voltage when key switch is closed. See Figure 15.

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CONTROL CIRCUIT Battery positive to the Control Circuit, Hourmeter, Traction Reverse switch (W/B40-60XL and W/B6080XT only), and Direction switch through the key and brake switches. Hourmeter begins to operate.

Circuit checks that there is no speed signal from the accelerator potentiometer. If there is a speed signal as battery power is applied, the control circuit will prevent the gate signal from going to the FETs. See Figure 15.

FWD/REV SWITCH CLOSED Forward contacts of FWD/REV switch close. Accelerator potentiometer speed signal to control circuit.

Battery positive voltage available to Forward contactor. See Figure 16.

FORWARD CONTACTOR ENERGIZED Normally open contacts of Forward contactor close.

Normally closed contacts open. Battery positive voltage is applied to FETs through traction motor. FETs are still OFF, so there is no current flow and the traction motor does not operate. See Figure 17.

GATE PULSE TO FETS Gate Driver of control circuit sends gate ON pulse to FETs gate. ON TIME (pulse width) set by accelerator potentiometer signal. See Figure 18.

FETS ON FOR TIME OF GATE PULSE FETs conduct to provide power pulse to the traction motor. Traction motor starts to operate. Pulse ON TIME is the same as gate ON TIME. See Figure 18.

GATE PULSE REMOVED FETs stop conducting when gate pulse is removed.

Power pulse is removed from traction motor. Pulse OFF TIME is set by the time remaining for one cycle at 15 kHz. See Figure 19.

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Sequence of Operation

Figure 13. Sequence of Operation

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Sequence of Operation

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NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 14. Sequence of Operation - Key Switch Closed

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2200 SRM 411

Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 15. Sequence of Operation - Power to Control Circuit

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Sequence of Operation

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NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 16. Sequence of Operation - Direction/Speed Control Set for Slow Forward Speed

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2200 SRM 411

Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 17. Sequence of Operation - Forward Contactor Energized

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Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 18. Sequence of Operation - Gate Pulse to FETs, FETs ON

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Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 19. Sequence of Operation - FETs OFF

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Sequence of Operation

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INDUCTION CURRENT FLOWS THROUGH MOTOR AND FLYBACK DIODE Induction current, generated by motor, flows through the flyback (freewheel) diode and returns through the motor. This current is used instead of battery current to keep the motor operating. See Figure 20.

PLUGGING Plugging is a method of stopping an electric lift truck by changing the direction of current flow in the motor field. Figure 21. To actuate the plugging circuit, the operator must change the Direction/Speed control for travel in the opposite direction of present travel.

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 20. Sequence of Operation - Induction Current

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Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR. Figure 21. Sequence of Operation - Plugging The controller prevents motor current flow during the time the FWD/REV contactors change to the reverse direction. The controller senses when the FWD/REV switch goes through neutral and momentarily interrupts the battery positive input from the key and brake switches. This action momentarily turns the FETs OFF when the high current flow can cause an arc and burn the contactor contacts.

The controller senses plugging action by the voltage across the plug diode. The frequency of the oscillator is reduced from 15 kHz to 1 kHz to limit torque.

Current limit is also reduced to prevent the plugging current from becoming too great. This current limit

can be changed by the external plugging adjustment. The controller regulates the pulse widths of the pulses to the motor field for the correct amount of plugging. The controller accelerator circuit is also set to a low speed so that normal acceleration in the opposite direction will occur after the lift truck comes to a stop.

The motion of the lift truck drives the traction motor armature to make the motor operate as a generator. This additional generator current (armature current) adds to the current flow through the field to reverse the motor at an even faster rate. Unless

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Checks

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the control circuit provides a way to slow this change of direction, the lift truck will stop very quickly. The plug diode in the control circuit prevents the lift truck from stopping too quickly. While the motor is acting as a generator, the plug diode prevents this generator

current from adding to the field current. The control circuit lets all of the plugging current flow from the armature through the plug diode, then flow with the battery current through the armature again. This reduces the effect of the induction current.

Checks WARNING Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create a dangerous operating condition. Do not operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, put a DO NOT OPERATE tag on the control handle. Remove the key from the key switch.

There are several checks that can be made that check for correct operation of the system. There are only two external adjustments on early units and three adjustments on later units. There are no internal adjustments for the transistor controller.

NOTE: The checks require a volt-ohmmeter with a meter movement. Most digital meters will not operate correctly for some of the checks. Specific checks require additional equipment.

CHECKING CONTACTOR COIL

B terminals (see Figure 23) of the transistor controller.

Some checks require the battery connected.

Do not connect the battery until the procedure tells you to connect the battery. Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel as described in the Operating Manual or the Periodic Maintenance section of the Service Manual.

Check the Forward or Reverse contactor coil with an ohmmeter. A suppressor diode with a resistor in series is part of the coil. The diode will cause the ohmmeter to indicate a difference in resistance in one direction. Reverse the probes of the ohmmeter to the opposite terminals and measure the resistance. Use the highest resistance indication. Replace the coil if the resistance readings are a short circuit in both directions or if there is an open circuit in both directions. Make sure the coil wires are connected again to the correct terminals.

CHECKING TRANSISTOR CONTROLLER WARNING Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause an injury or parts damage.

The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing components under the hood.

Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then connect an insulated jumper wire between the B+ and

22

These checks are in two sections: checks with the controller installed in the lift truck and checks of the controller out of the lift truck (bench checks).

The controller is protected against operation with a low battery. Controller output is slowly decreased as battery voltage decreases. The battery can be low if an operator notices slower operation or less power.

This operation is not a defect of the transistor controller. Make sure all checks are done with a fully charged battery.

NOTE: The following checks must be done in the order they are listed because some steps depend on conditions set in previous steps.

2200 SRM 411

Checks

Checks With Controller Installed

Resistance Full Speed

Pot P/N

Rotation

Resistance Neutral

2. Make sure the battery is fully charged.

2304385

unidirectional

4.5K to 5.5K

50 to 0

3. Make a physical check to be sure that battery negative is connected to the B terminal of the controller. Connect the negative meter lead to the B terminal.

368034

bi-directional

Infinity

0

826064

bi-directional

0 to 200

4. Check for battery positive voltage at the B+ terminal of the controller (see Figure 23) and the cable P2 terminal of the Reverse contactor. If there is no battery positive voltage, check the cables between battery positive and the two terminals.

If the cables are not damaged, the controller can be damaged.

2302033 bi-directional

1. Raise the drive/steer wheel as described in the Operating Manual or the Periodic Maintenance section of the Service Manual.

5. Tag all wires and cables before they are removed.

Make sure the key switch is in the OFF position and remove the wires from terminals 1 and 2 of the controller. See Figure 22 and Figure 23 for the correct unit. If a resistor is used between terminals 1 and 2, do not disconnect the resistor.

Check for an open circuit (at least 1 megohm) between the wires with the Direction/Speed control in the NEUTRAL position. If there is no open circuit, check to see that the accelerator potentiometer is in the centered position. Check for maximum resistance by moving the control to the full speed position(s). See the following chart. Check for at least one megohm resistance between each wire and the lift truck frame. If any of the resistance readings are wrong, check the wiring to the accelerator potentiometer and check the adjustment of the FWD/REV switch.

Connect wires to terminal 1 and terminal 2. See the sections Diagrams 8000 SRM 457, Diagrams 8000 SRM 475, Diagrams 8000 SRM 495, or Diagrams 8000 SRM 653 for the walkie high lift motorized hand trucks.

3.5K

4.5K to 5K 0

All values ±10%

Figure 22. New Controller

23

Checks

2200 SRM 411

NOTE: SOME CONNECTORS HAVE DIFFERENT FUNCTIONS DEPENDING ON MODEL OF LIFT TRUCK AND MODEL OF CONTROLLER USED. 1.

2.

3.

4.

5.

6.

7.

M POWER TERMINAL TERMINAL 2 TERMINAL 1 B POWER TERMINAL B+ POWER TERMINAL KEY SWITCH INPUT F/R CONTACTOR OUTPUT

8. STATIC-RETURN-TO-OFF, 1A OR NOT USED ON W40XT, W45XT, W/B/C60-80XT, AND T5XT 9. BRAKE OR TRACTION REVERSE (W/B40-60XL, W40XT, W45XT, AND W/B60-80XT ONLY) 10. FORWARD INPUT 11. REVERSE INPUT 12. A2 POWER TERMINAL

Figure 23. Controller Wire (Control) and Cable (Power) Terminals 6. Connect the voltmeter positive lead to the controller B+ terminal. Connect the voltmeter negative lead to the controller M terminal. Move the key to the ON position, lower the control handle (W/B40-60XL, W/B60-80, W40XT, W45XT, W2040XTA, W20-40XTC, W20-30XTR), or step on the brake switch (R30ES, N30FR). Release the brake levers (C60-80XT and T5XT units). Check for zero or near zero volts. Move the Direction/Speed control for full speed travel. Check for full battery voltage.

7. If there is not full battery voltage, the controller is defective. If there is battery voltage and the motor does not operate, disconnect the battery connector and discharge the internal capacitor.

The correct procedure to discharge the capacitor is described in the WARNING at the beginning of this section.

24

8. Disconnect the cable from the controller A2 terminal. Use the ohmmeter to check for a diode between the A2 and B+ terminals. There must be a high resistance in one direction and a low resistance with the meter leads reversed. If there is a low or high resistance in both directions, the diode is damaged. If the readings are correct and the motor does not operate, there is a short circuit in the motor circuit. Check for a short circuit at the motor cables or direction contactors. If there are no short circuits, the motor has a short circuit. Replace any defective item(s).

9. Connect all wires or cables that had been disconnected.

2200 SRM 411

Checks

Bench Checks To test the controller on the bench, you will need the following equipment (see Figure 24): • A power supply with a voltage equal to the lift truck voltage. The power supply can be any of the following: the lift truck battery, automotive batteries connected in series or an AC power supply with a regulated D.C. output of 12 to 48 volts. Only low power tests will be done, so a 10-amp fuse is wired in series with the power supply to protect the operator and controller from accidental short circuits.

Do NOT use a battery charger as a power supply since the no load voltage can be higher than the voltage of the controller.

• A speed control, a 5K ohm potentiometer wired as a 2-terminal rheostat will work fine.

1.

2.

3.

4.

5.

POWER SUPPLY 10-AMP FUSE TOGGLE SWITCH KEY SWITCH CONTACTOR

• A contactor (similar to the pump motor contactor) with a 5-watt, 250-ohm resistor across the contacts.

A toggle switch and key switch connected as shown are also needed.

• A test load of incandescent lamps with a voltage equal to the lift truck voltage. 12-volt lamps wired in series work fine.

• A multimeter or digital voltmeter.

1. Shake the transistor controller to see if any parts are loose inside. If there are loose parts, replace the controller.

2. Connect the controller as shown in Figure 24.

Connect the voltmeter to the B+ and B terminals of the controller.

6.

7.

8.

9.

RESISTOR TRANSISTOR CONTROLLER TEST LOAD SPEED CONTROL

Figure 24. Bench Checks

25

Checks 3. Make sure the key switch is OFF. Turn the power supply and toggle switch ON. Look at the voltmeter. The voltmeter indication must slowly increase to the truck voltage. If the voltage does not increase to the truck voltage, replace the controller.

4. The lamps must not illuminate now. If they illuminate, replace the controller.

5. Move the key switch to the ON position.

6. Move the speed control and look at the lamp brightness. The lamps must slowly increase in brightness as the speed increases.

7. Test the controller’s SRO functions: a. Turn the key switch to the OFF position. b. Move the speed control to the full speed position. c. Turn the key switch to the ON position and check that the lamps do NOT illuminate until the speed control is moved to OFF and returned to ON. 8. Check the controllers fault function by removing a wire from terminal 2 or 3 on the controller. The lamps must NOT illuminate.

9. Disconnect all wires and cables from the controller and use the ohmmeter or diode checker to check the plug diode. Connect the meter between the A2 and B+ terminals. Reverse the meter leads and check the reading. There must be a high resistance in one direction and a low resistance with the meter leads reversed. If there is a low or high resistance in both directions, the diode is damaged. Replace the controller.

10. Check the flyback (freewheel) diode. Connect the meter between the M and B+ terminals.

Reverse the meter leads and check the reading.

There must be a high resistance in one direction and a low resistance with the meter leads reversed. If there is a low or high resistance in both directions, the diode is damaged. Replace the controller.

Accelerator Potentiometer Checks and Adjustments The following procedures are for checking and adjusting the accelerator potentiometer and control

26

2200 SRM 411 switches for the W/B40-60XL units ONLY. different series of lift trucks have their own checks and adjustments. See the sections for the following models: N30FR, N40-50FR, N50FA - Electrical Adjustments 2200 SRM 381 and Diagrams 8000 SRM 495.

R30ES - Electrical System 2200 SRM 420 and Diagrams 8000 SRM 475.

W40XT, W45XT, W/B/C60-80XT, T5XT - Electrical System 2200 SRM 279 and Diagrams 8000 SRM 457.

W20-40XTA, W20-40XTC, W20-30XTR - Electrical System 2200 SRM 279 and Diagrams 8000 SRM 653.

NOTE: The direction switch must be correctly adjusted before the accelerator potentiometer can be checked. The accelerator potentiometer must be adjusted after each installation.

1. Make sure the battery is disconnected and the capacitor in the controller is discharged. The correct procedure to discharge the capacitor is described in the WARNING at the beginning of this section.

2. Adjust the accelerator potentiometer when it is installed with the pulley belt in place and both wires disconnected.

3. Connect an ohmmeter between wires 15 and 16 on the accelerator potentiometer.

4. Rotate the direction and speed control. The ohmmeter will indicate changes of resistance. Loosen the two setscrews in the pulley block. Adjust the potentiometer in the pulley block so that when the control is in the neutral position, the ohmmeter shows maximum resistance. The maximum resistance of the potentiometer will be approximately 4750 ±0%.

5. Tighten the two setscrews on the pulley block. Do not let the pulley or shaft move as the setscrews are tightened.

6. Rotate the direction and speed control to the forward and reverse directions. Check that the resistance of the potentiometer is less than 200 ohms at the maximum speed positions.

7. Connect the wires 14, 15, and 16 from the accelerator potentiometer to the correct wires on the lift truck and the traction reverse switch. Install the cover plate and connect the battery.

2200 SRM 411

Adjustments

Adjustments WARNING Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause a personal injury or property damage.

The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing components under the hood. Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then connect an insulated jumper wire between the B+ and B terminals ( Figure 23) of the transistor controller.

Limit. See Figure 25. The older controllers have two adjustments, Braking and Controlled Acceleration.

The plugging adjustment adjusts how far the lift truck travels before reversing direction. The Direction/Speed control can be moved to the maximum speed position from stop or a slow travel speed. The controlled acceleration adjustment allows adjustment of the maximum rate of acceleration. The Current Limit adjustment controls the motor current to a preset maximum.

Some checks require the battery connected.

Do not connect the battery until the procedure tells you to connect the battery. Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel as described in the Operating Manual or the Periodic Maintenance section of the Service Manual.

WARNING Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create a dangerous operating condition. Do not operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, put a DO NOT OPERATE tag on the control handle. Remove the key from the key switch.

NOTE: The new 1243 controller as no adjustment it is preset and has electronic boxes connected by the Can bus data link system.

NOTE: The SEM motor controller operates on the principle of controlling the motor field circuit and the motor armature circuit independently. The SEM controller includes a full range of built-in safety features and diagnostic and setup capability for safe reliable operation.

The older controller has three adjustments: Braking (plugging), Controlled Acceleration, and Current

A. MIDPOINT ADJUSTMENT 12 O’CLOCK POSITION B. MINIMUM ADJUSTMENT C. MAXIMUM ADJUSTMENT D. ENLARGED VIEW OF ADJUSTING SCREWS (2, 3, AND 4) 1. TRANSISTOR CONTROLLER 2. BRAKING (PLUGGING) ADJUSTMENT SCREW (CW = HARDER BRAKING) 3. CURRENT LIMIT ADJUSTMENT SCREW (CW = HIGHER CURRENT) (NOT USED ON W/B40-60XL CONTROLLERS) 4. CONTROLLED ACCELERATION ADJUSTMENT SCREW (CW = FASTER ACCELERATION) Figure 25. Controller Adjustment Locations

27

Repairs

2200 SRM 411

All adjustments are made with the key switch off and the battery disconnected. Discharge the capacitor. Remove the nylon seal washer and the 3 mm (0.12 in.) socket head screws to access the adjustment screws. Make the adjustments using a small insulated screwdriver. Replace the socket head screws and nylon seal washers after all adjustments are made. Tighten the setscrews to 0.9 N•m (8 lbf in).

PLUGGING ADJUSTMENT

ACCELERATION ADJUSTMENT Turning the controlled acceleration adjustment clockwise will increase the acceleration rate. Turning the adjustment counterclockwise will give a slower rate of acceleration. The traction motor brushes have a faster wear rate when the control is set for an increased acceleration rate. More heat is also generated at this maximum setting. This setting should be set in the twelve o’clock position.

CURRENT LIMIT ADJUSTMENT

Turning the braking (plugging) adjustment clockwise will increase the plugging effect and stop the lift truck in a shorter distance. Turning the adjustment counterclockwise will decrease the plugging effect.

The traction motor brushes have a faster wear rate when the control is set for the shortest stopping distance (maximum plugging). More heat is also generated in the traction motor at this maximum setting. This adjustment should be set in the one o’clock position.

Turning the current limit adjustment clockwise will increase the current limit. This setting is factory set at the maximum 400 amps. The truck will also run at a higher than normal speed especially when it has no load. Lowering this adjustment can cause the truck to have limited starting torque and can cause the truck not to run at top speed when fully loaded.

This setting should be set at the maximum adjustment position.

Repairs CONTACTORS WARNING Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause a personal injury or property damage.

The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing components under the hood. Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then connect an insulated jumper wire between the B+ and B terminals (Figure 23) of the transistor controller.

Some checks require the battery connected.

Do not connect the battery until the procedure tells you to connect the battery. Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel as described in the Operating Manual

28

or the Periodic Maintenance section of the Service Manual.

The FORWARD and REVERSE contactor assembly controls the direction of current flow through the traction motor. See Figure 26. The contactor is a heavy-duty switch that opens and closes the power circuit. The traction circuit has a FORWARD and REVERSE contactor assembly. Each contactor assembly has the following parts: two sets of normally open (NO) contacts, two sets of normally closed (NC) contacts and a coil. The coil is an electromagnet that moves the NO contacts to the closed position against spring pressure. The coil is in the control circuit. The contactor tips are in the traction circuit.

A suppressor is part of each coil.

When a contactor coil is energized, the normally open (NO) contacts close and the normally closed (NC) contacts open. Current flows through the traction motor field in one direction when the FORWARD contactor is energized and in the other direction when the REVERSE contactor is energized. This action gives direction control to the traction motor. The contacts normally have a long service life because the current flow through the contacts is stopped before the contacts open. The FETs are OFF before the contactor coil is de-energized.

2200 SRM 411

Repairs

NOTE: THE POWER CONNECTIONS FOR THE FIXED CONTACTS CAN BE DIFFERENT THAN SHOWN. 1.

2.

3.

4.

5.

6.

SCREW BUSS BAR COVER SPRING FIXED CONTACTS PLUNGER ASSEMBLIES AND MOVABLE CONTACTS

7.

8.

9.

10.

COVER BASE COIL AND FRAME MOUNT BRACKET ARMATURE CAP

Figure 26. Forward and Reverse Curtis Contactor Assembly

29

Repairs

Replace Make sure the battery is disconnected and the capacitor in the controller is discharged. The correct procedure to discharge the capacitor is described in the WARNING at the beginning of this section. If the lift truck has an EE rating, remove the cover of the contactor box for access to the contactor terminals.

Make an identification of the wires and cables and disconnect them from the contactor assembly. Remove the mounting screws and replace the contactor assembly. Install the wires and cables as removed.

Install the cover of the contactor box on EE units.

CURTIS CONTACTOR PARTS, REPLACE NOTE: If both the contacts and coil of a contactor will be replaced, replace the complete contactor as described in Contactors, Replace. Do only the parts of the procedure necessary to replace the damaged parts you are replacing.

NOTE: All of the contacts for each contactor must be replaced at the same time if any contact needs replacing.

The contactor contacts are made of special silver alloy. The contacts will look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. Replace the contacts when the silver alloy is worn away to the base support metal.

1. Remove the contactor as described in Contactors, Replace. See Figure 26.

2. Make an identification of the buss bars for correct installation. Remove the buss bars and nuts that fasten to the fixed contacts.

3. Remove the two screws that fasten the covers for each contactor. Remove the cover of each contactor. Do NOT lose the plunger springs.

2200 SRM 411 Remove the bushing part of the plunger and the armature cap from the coil. Install these parts on the replacement coil.

7. Install the coil and frame on the mount bracket.

8. Install the cover base, fixed contact bars, and plungers on the coil frame. Make sure both springs are on both plungers.

9. Install the covers and electrical bars on the covers as removed during disassembly.

10. Install the contactor assemblies on the lift truck as described in Contactors, Replace.

GE CONTACTOR PARTS, REPLACE NOTE: If both the contacts and coil of a contactor will be replaced, replace the complete contactor as described in Contactors, Replace. Do only the parts of the procedure necessary to replace the damaged parts you are replacing.

NOTE: All of the contacts for each contactor must be replaced at the same time if any contact needs replacing.

The contactor contacts are made of special silver alloy. The contacts will look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. Replace the contacts when the silver alloy is worn away to the base support metal.

1. Remove the contactor as described in Contactors, Replace.

2. Make an identification of any buss bars for correct installation. Remove the buss bars, spacers, and nuts that fasten to the fixed contacts.

3. Remove the four screws that fasten the contactor parts together.

4. Replace the four fixed contacts in the contactor covers.

4. Carefully remove the upper clamp and the two fixed contact bars.

5. Remove the two plunger assemblies and movable contacts and replace the three fixed contact bars.

Replace the contacts of the plungers.

5. Remove the two lower clamp pieces and the other two fixed contact bars.

6. If a coil will be replaced, remove the cover base.

Remove the screws that fasten the coil frame to the mount bracket. Remove the coil and frame.

30

6. Remove the contact carrier. Then remove the movable contact assembly and armature assembly as a unit. Remove the spring.

2200 SRM 411

Repairs

7. If necessary, carefully disassemble the assemblies as shown in Figure 27. Do not lose any parts

1.

2.

3.

4.

5.

6.

7.

BASE COIL FRAME SPRING (SMALL END UP) ARMATURE ASSEMBLY CONTACT CARRIER FIXED CONTACTS

and make sure to make a note of the shims and their positions for correct assembly.

8.

9.

10.

11.

12.

13.

LOWER CLAMP MOVABLE CONTACT CARRIER SHIM MOVABLE CONTACT ASSEMBLY UPPER CLAMP SCREW (4 EA)

Figure 27. Forward and Reverse GE Contactor Assembly

31

Troubleshooting

2200 SRM 411

8. If necessary, remove the frame and coil.

9. Install the coil on the base. Install the frame over the coil and install the spring with the large coil toward the frame.

10. Assemble the armature assembly and movable contact assembly. Install the assemblies.

11. Install the contact carrier, the lower fixed contact bars, and the lower clamps.

12. Install the upper fixed contact bars. Make sure all contacts on the bars are facing the movable contacts.

13. Install the upper clamp and screws.

14. Install the contactor assemblies on the lift truck as described in Contactors, Replace.

CONTROLLER, REPLACE Make an identification and disconnect the wires and cables from the controller. Remove the mounting screws and remove the controller. Apply a thin coating of silicone grease (Hyster Part Number 1198757) on the bottom of the replacement controller. Install the replacement controller on the lift truck.

Connect the wires and cables to the same terminals as identified during the removal procedure.

If a controller failure has occurred on a R30XM2 (D174) model truck produced prior to serial number D174N02817A, install diode board assembly 2065361 when installing the new controller. This

diode board helps protect the controller from spikes in current caused by operator misuse.

CAUTION Make sure the battery side of the diode board is correctly oriented on the contactor.

To install the diode board, remove the nuts retaining the small wires to the main connector. The board is polarity sensitive. Install the diode board onto the main contactor terminal studs. Install the small wires and tighten nuts, as removed.

ACCELERATOR POTENTIOMETER AND CONTROL SWITCHES, REPLACE AND ADJUST The following SRM sections have the procedures for replacing and adjusting the accelerator potentiometer and control switches of the different series of lift trucks: N30FR, N40-50FR, N50FA - Electrical Adjustments 2200 SRM 381 and Diagrams 8000 SRM 495.

R30ES - Electrical System 2200 SRM 420 and Diagrams 8000 SRM 475.

W40XT, W45XT, W/B40-60XL, W/B/C60-80, and T5XT - Electrical System 2200 SRM 279 and Diagrams 8000 SRM 457.

W20-40XTA, W20-40XTC, W20-30XTR - Electrical System 2200 SRM 279 and Diagrams 8000 SRM 653.

Troubleshooting GENERAL This section describes the most common faults that can occur in trucks with the CURTIS Transistor Controller. Follow the General Procedures to make

32

sure that maintenance problems give the correct troubleshooting results. Follow the General Procedures and then use the fault procedure that best describes the problem.

2200 SRM 411

Fault Procedures

GENERAL PROCEDURES WARNING Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause a personal injury or property damage.

The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing components under the hood. Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then connect an insulated jumper wire between the B+ and B terminals (Figure 23) of the transistor controller.

Some checks require the battery connected.

Do not connect the battery until the procedure tells you to connect the battery. Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel as described in the Operating Manual or the Periodic Maintenance section of the Service Manual.

1. Check the specific gravity of the battery. If the specific gravity is less than 1.260, the battery is not fully charged or is damaged. A fully charged battery has a specific gravity of 1.270-1.290. A discharged battery has a specific gravity of approximately 1.130.

2. The Hyster electric lift truck has a two-wire system. The frame must not be a common electrical path. Check for 50,000 ohms or more between each terminal of the battery connector for the lift truck and a clean connection on the frame.

Remove any circuit paths between the controller and the frame of the lift truck. Carbon dust in a motor or other parts can cause a circuit path.

Check for additional equipment that is causing a circuit path to the frame.

3. Check for voltage between each terminal of the connector that fastens to the battery and a clean connection on the frame. Normally there is some small voltage between the battery and the frame, even if the resistance is very high. The small voltage is normally less than 30% of the battery voltage. A higher voltage can indicate a dirty battery or a battery with damage. Clean the battery and battery compartment as necessary.

4. Visually check for parts or wires that are loose or damaged.

NOTE: The correct meter polarity is necessary for the checks. The voltage checks are made between the point indicated in the troubleshooting chart and battery negative. Connect the meter negative to battery negative.

NOTE: Make an identification of any wires before you disconnect them. The wires must be connected correctly after checks or repairs.

Fault Procedures The following is some common faults of the lift trucks and the procedures for finding the cause. The following SRM sections have the procedures for replacing and adjusting the accelerator potentiometer and control switches of the different series of lift trucks: N30FR, N40-50FR, N50FA - Electrical Adjustments 2200 SRM 381 and Diagrams 8000 SRM 495.

R30ES - Electrical System 2200 SRM 420 and Diagrams 8000 SRM 475.

W/B40-60XL, W40XT, W45XT, W/B/C60-80, and T5XT - Electrical System 2200 SRM 279, Diagrams 8000 SRM 457, and Diagrams 8000 SRM 923. There can be a variation in some of the wire numbers for the different lift truck models.

W20-40XTA, W20-40XTC, W20-30XTR - Electrical System 2200 SRM 279 and Diagrams 8000 SRM 653.

33

Fault Procedures

2200 SRM 411

FAULT NUMBER 1.

ONE DIRECTIONAL CONTACTOR WILL NOT CLOSE.

Possible Causes:

• Damaged (open) wire(s) in control circuit.

• Direction switch is damaged.

• Traction rev. sw. is damaged (W/B40-60XL, W40XT, W45XT, and W/B60-80XT only).

• Contactor coil is damaged.

• Transistor Controller is damage at FWD or REV term.

34

2200 SRM 411

Fault Procedures

FAULT NUMBER 2. DIRECTIONAL CONTACTORS WILL NOT CLOSE FOR OPERATION IN EITHER DIRECTION. Possible Causes:

• Key switch, brake switch, or LC contactor is dam• Battery not connected. aged.

• Control fuse is damaged.

• Pump motor fuse is damaged. • Traction reverse sw. (W/B40-60XL, W40XT, W45XT, and W/B60-80XT only) is damaged.

• Battery voltage is low.

• F/R switch is damaged.

• Wires in circuit are open.

• Transistor controller is damaged.

35

Fault Procedures

2200 SRM 411

FAULT NUMBER 3. LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. THE DIRECTIONAL CONTACTORS CLOSE NORMALLY. NO POWER WHEN DIRECTION/SPEED CONTROL IS MOVED. Possible Causes:

36

• Traction fuse is damaged.

• Open circuit between motor and contactors.

• Power contacts of direction contactor are damaged.

• Accelerator potentiometer is damaged or needs adjustment.

• Traction motor is damaged.

• Damaged (open) traction motor cables.

• Transistor controller is damaged.

2200 SRM 411

Fault Procedures

FAULT NUMBER 4. DIRECTIONAL CONTACTORS CLOSE, LIFT TRUCK ACCELERATES TO FULL SPEED IMMEDIATELY. Possible Causes:

• Accelerator potentiometer is damaged or needs adjustment.

• Transistor controller is damaged.

37

Fault Procedures

2200 SRM 411

FAULT NUMBER 5. NO SPEED CHANGE WHEN FAST SPEED BUTTON IS DEPRESSED. SLOWER SPEED OPERATION IS NORMAL. (B40-60XL, B60-80XT, C60-80XT, T5XT ONLY).

Possible Causes:

38

• Fast speed switch has a short circuit.

• Fast speed switch or wiring is open.

• 3.6K ohm resistor is open.

• Wiring at resistor or switch is open.

2200 SRM 411

Fault Procedures Table 2. Fault Codes and Display Messages for R30XMS2 Only

Code

ND

Display

Description

Items to Check if Code is Displayed

SlackChn

Slack Chain circuit open

*Chains slack (carriage hung up on lowering)? *Slack chain switches functioning *Wiring between 1310 and slack chain switches

SideGate

Side Gates up

*Side Gate switches functioning *Wiring between 1310 and side gate switches

HornOpen

Horn disconnected (Open circuit)

*Horn (bench test for function) *Wiring to horn

BrakOpen

Brake disconnected (Open circuit)

*Brake coil (bench test) *Wiring to brake

LowrOpen

Lowering Valve disconnected (Open circuit)

*Lowering valve (bench test) *Wiring to lowering valve

TractErr

Misc. traction error

*Wiring to 1243

Foot Sw

Foot Switch off while requesting traction or hoist

*Foot switch *Wiring to foot switch

Low Batt

Low Battery warning, lift cutout

LiftLimt

Lift Limit reached

LowrLimt

Lowering limit reached

2041

5

Traction-Battery Undervoltage

2042

5

Traction-Battery Overvoltage

2043

5

TractHot

Traction: Thermal Cutback

*Worn load wheels, pushing loads, operation with low battery

2301

6

Str Crnt

High current

*Mechanical binding of MDU

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to first check and clean/repair all connections in the affected circuit. The use of dielectric grease is recommended for all AMP and Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions such as potholes or very low battery levels.

39

Fault Procedures

2200 SRM 411

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued) Items to Check if Code is Displayed

Code

ND

2390

1

ChkEncdr

Encoder supply current drop

*Wiring to steer and height encoders *Steer and height encoders *Check current draw using diagnostics "Enc Crnt"

2391

1

Enc Off?

Encoder supply current too low on initialization

*Steer and height encoders must be plugged in during initial set up of a new 1310

2392

1

Enc Crnt

Encoder supply current too high

*Use Diagnostic Display to display encoder current draw; then unplug individual encoders to determine which encoder or wiring is drawing high current

3101

6

Str Volt

High Voltage

*Check voltage to steer controller

4201

6

Str Temp

High Temp

*Check for mechanical resistance in steering mechanism

501A

6

MDU Prox

Steer: Feedback sensor error

*Check MDU proximity sensor and wiring

5021

6

StrMotor

Steer motor error

*Check wiring to steer motor

5022

6

StrSensr

Steer: Hall Sensor Error

*Check MDU proximity sensor and wiring *Check wiring for steering Hall sensor

5090

1

Lift Sw

Lift switch shorted

*Lift switch and wiring

5091

1

Lower Sw

Lower switch shorted

*Lower switch and wiring

5092

1

Steer Sw

Steer Handle Proximity switch off

*Steer Handle proximity switch and wiring

5590

1

Memory read warning-block 1-unable to start read process

*Repeatedly discharging battery beyond normal limits

Display

Description

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to first check and clean/repair all connections in the affected circuit. The use of dielectric grease is recommended for all AMP and Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions such as potholes or very low battery levels.

40

2200 SRM 411

Fault Procedures

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued)

Code

ND

5591

1

5592

1

6011

Display

Description

Items to Check if Code is Displayed

Memory read warning-block 1-unable to start read process

*Repeatedly discharging battery beyond normal limits

MemEr_A3

Memory read warning-block 3-unable to start read process

*Repeatedly discharging battery beyond normal limits

5

TracSnsr

Traction-Current sensor fault

*Replace 1243 if problem persists

6013

5

M

Traction M

*Replace 1243 if problem persists

6110

6

Str Comm

Communication time-out

*CAN bus wiring to steer controller

6390

1

MemErr2a

Memory read error from block 2, unable to start read process, parameter loss

*Rerun truck initialization; if problem persists, replace 1310

6391

1

MemErr2b

Memory read error from block 2, unable to complete read process, parameter loss

*Rerun truck initialization; if problem persists, replace 1310

6392

1

MemErr4a

Memory read error from block 4, unable to start read process, parameter loss

*Rerun truck initialization; if problem persists, replace 1310

6393

1

MemErr4b

Memory read error from block 4, unable to complete read process, parameter loss

*Rerun truck initialization; if problem persists, replace 1310

6394

1

MemErr5a

Memory read error from block 5, unable to start read process, parameter loss

*Rerun truck initialization; if problem persists, replace 1310

6395

1

MemErr5b

Memory read error from block 5, unable to complete read process, parameter loss

*Rerun truck initialization; if problem persists, replace 1310

Fault

fault

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to first check and clean/repair all connections in the affected circuit. The use of dielectric grease is recommended for all AMP and Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions such as potholes or very low battery levels.

41

Fault Procedures

2200 SRM 411

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued) Items to Check if Code is Displayed

Code

ND

7305

1

HtEnc Ch

Height Encoder error channel count mismatch

7306

1

StEnc Ch

Steer Encoder error channel count *Check wiring to encoder mismatch *Check both encoder output channels using voltmeter, should pulse with encoder rotation

7307

1

SteerEnc

Steer Handle Proximity Sensor shorted or steering encoder error

*Check Steer Handle proximity function using Switch1 in diagnostics *Check steer encoder using "StrInput" in diagnostics *Check wiring to Steer Handle proximity and steering encoder

7320

1

HtEncOff

Height encoder not responding (Position sensor fault)

*Check mast proximity switch *Check height encoder, using "Lift Hgt" in diagnostics

7390

1

Throttle

Throttle potentiometer out of range

*Check wiring to throttle hall-effect potentiometer *Check throttle output using "ThrotOut" in diagnostics

7391

1

Hyd Pot

Hydraulic potentiometer out of range

*Check wiring to potentiometer

7392

1

Mast Sw

Height proximity not responding (encoder functions with lift/lower)

*Mast proximity switch and wiring *No handset connected

7393

1

HtEncErr

Running Height Encoder reset error

*Mast proximity switch and wiring *No handset connected *Height encoder and wiring

Display

Description

*Check wiring to encoder *Check both encoder output channels using voltmeter, should pulse with encoder rotation

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to first check and clean/repair all connections in the affected circuit. The use of dielectric grease is recommended for all AMP and Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions such as potholes or very low battery levels.

42

2200 SRM 411

Fault Procedures

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued) Items to Check if Code is Displayed

Code

ND

7394

1

HtEncErr

Startup error on Height proximity switch state (Mast lifted while truck off)

*Mast proximity switch and wiring *No handset connected *No manual hoisting *Height encoder and wiring

739A

1

HtEncErr

Height Encoder error (hoist function called for, but encoder not incrementing)

*Mast proximity switch and wiring *No handset connected *Height encoder and wiring

739B

1

HtEncErr

Height Encoder error (startup check)

*Mast proximity switch and wiring *No handset connected *Height encoder and wiring

739C

1

HtEncErr

Height Encoder error: Encoder indicated height <22" or >26" when 24" proximity switch passed

*Mast proximity switch and wiring *No handset connected *Height encoder and wiring

739D

1

Throt Lo

Throttle voltage too low

*Throttle mechanism out of adjustment (check neutral position, calibrate throttle) *Throttle Hall sensor and wiring

739E

1

Throt Hi

Throttle voltage too high

*Throttle mechanism out of adjustment (check neutral position, calibrate throttle) *Throttle Hall sensor and wiring

8012

5

TrctComm

Traction-CAN Communication fault

*CAN wiring to traction controller

8031

5

Cnt Crnt

Contactor over current

*Wiring shorted to traction contactor *Contactor coil or suppressor shorted

Display

Description

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to first check and clean/repair all connections in the affected circuit. The use of dielectric grease is recommended for all AMP and Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions such as potholes or very low battery levels.

43

Fault Procedures

2200 SRM 411

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued) Items to Check if Code is Displayed

Code

ND

8032

5

Cnt Coil

Contactor coil open

*Wiring open to traction contactor *Traction contactor coil failed open

8033

5

Fld Open

Field Open

*Wiring from 1243 to motor field *Motor field winding failure

8034

5

TracCont

Traction-Contactor Missing

*Traction main fuse blown *Traction contactor tips bad *Traction contactor coil wiring

8101

6

Str Comm

CAN open time-out

*CAN Wiring to steering controller

8190

1

SteerErr

General steering error

*CAN Wiring to steering controller *Wiring and fuse to steering controller *MDU proximity wiring *Wiring between steer controller and motor

8191

1

Comm Err

Communication error CAN time-out w/multiple nodes

*CAN Wiring

8192

1

TrctComm

Communication error CAN time-out w/traction

*Fuse to traction controller *CAN wiring to traction controller

8193

1

Str Comm

Communication error CAN time-out w/steering

*CAN Wiring to steering controller *Fuse to steering controller

8194

1

SteerErr

Steer error after startup

*CAN bus wiring to steer controller

8197

1

TrctComm

No communication from traction on startup

*Fuse to traction controller *CAN bus wiring to traction controller

8198

1

Comm Off

CAN system off on startup

*CAN bus wiring to 1310, steer, traction controllers

Display

Description

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to first check and clean/repair all connections in the affected circuit. The use of dielectric grease is recommended for all AMP and Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions such as potholes or very low battery levels.

44

TECHNICAL PUBLICATIONS 2200 SRM 411

6/04 (9/00)(7/99)(5/97)(12/96)(12/93)(7/92)(4/90) Printed in U.S.A.

DIAGRAMS W/B40-60XL [D135]; W40XT [A218]; W45XT [A215, B215]; W/B/C60-80XT [B199]; T5XT [E142]

PART NO. 897401

8000 SRM 457

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 condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Diagrams

Table of Contents

TABLE OF CONTENTS Diagrams, Schematics, or Arrangements .........................................................................................................

Figure 1. W/B40-60XL Schematic Diagram ............................................................................................

Figure 2. W/B40-60XL Wiring Diagram ..................................................................................................

Figure 3. W/B40-60XL Cabling Diagram.................................................................................................

Figure 4. W/B40-60XL Wiring Detail - Control Handle Head................................................................

Figure 5. B40-60XL Wiring Detail - Steady Rest Control Panel ............................................................

Figure 6. Wiring Diagram Resistor Control ............................................................................................

Figure 7. Wiring Diagram Transistor Control.........................................................................................

Figure 8. W45XT Schematic Diagram .....................................................................................................

Figure 9. W45XT Wiring Diagram ...........................................................................................................

Figure 10. W40XT/W45XT Wiring Detail - Key Switch and Gauges .....................................................

Figure 11. W40XT/W45XT Wiring Detail - Control Handle Head .........................................................

Figure 12. W40XT/W45XT Transistor Cabling Diagram........................................................................

Figure 13. B60-80XT Schematic Diagram ...............................................................................................

Figure 14. B60-80XT Wiring Diagram.....................................................................................................

Figure 15. W60-80XT Schematic Diagram ..............................................................................................

Figure 16. W60-80XT Wiring Diagram....................................................................................................

Figure 17. C60-80XT Schematic Diagram ...............................................................................................

Figure 18. C60-80XT Wiring Diagram.....................................................................................................

Figure 19. T5XT Schematic Diagram ......................................................................................................

Figure 20. T5XT Wiring Diagram ............................................................................................................

Figure 21. B60-80XT EE Schematic Diagram.........................................................................................

Figure 22. B60-80XT EE Wiring Diagram...............................................................................................

Figure 23. W60-80XT EE Schematic Diagram........................................................................................

Figure 24. W60-80XT EE Wiring Diagram..............................................................................................

Figure 25. B60-80XT/W60-80XT/C60-80XT/T5XT Optional Wiring ......................................................

Figure 26. B60-80XT/W60-80XT Wiring Detail - Key Switch and Gauges............................................

Figure 27. B60-80XT Wiring Detail - Steady Rest Control Panel ..........................................................

Figure 28. B60-80XT/W60-80XT/C60-80XT/T5XT Cabling Diagram ....................................................

Figure 29. B60-80XT/W60-80XT/C60-80XT/T5XT Wiring Detail ..........................................................

Figure 30. B60-80XT/W60-80XT/C60-80XT/T5XT Wiring Detail - Control Handle Head....................

Figure 31. B60-80XT/W60-80XT Wiring Detail EE Contactor Panel ....................................................

2 2 4 6 8 9 10 12 14 16 18 19 20 22 24 26 28 30 32 34 36 38 40 42 44 46 47 48 50 52 54 56

This section is for the following models: W/B40-60XL [D135]; W40XT [A218]; W45XT [A215, B215]; W/B/C60-80XT [B199]; T5XT [E142]

©2003 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 457

Diagrams

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

1

Diagrams, Schematics, or Arrangements

2

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 1. W/B40-60XL Schematic Diagram

3

Diagrams, Schematics, or Arrangements

4

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 2. W/B40-60XL Wiring Diagram

5

Diagrams, Schematics, or Arrangements

6

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 3. W/B40-60XL Cabling Diagram

7

Diagrams, Schematics, or Arrangements

Figure 4. W/B40-60XL Wiring Detail - Control Handle Head

8

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 5. B40-60XL Wiring Detail - Steady Rest Control Panel

9

Diagrams, Schematics, or Arrangements

10

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 6. Wiring Diagram Resistor Control

11

Diagrams, Schematics, or Arrangements

12

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 7. Wiring Diagram Transistor Control

13

Diagrams, Schematics, or Arrangements

14

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 8. W45XT Schematic Diagram

15

Diagrams, Schematics, or Arrangements

16

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 9. W45XT Wiring Diagram

17

Diagrams, Schematics, or Arrangements

Figure 10. W40XT/W45XT Wiring Detail - Key Switch and Gauges

18

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 11. W40XT/W45XT Wiring Detail - Control Handle Head

19

Diagrams, Schematics, or Arrangements

20

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 12. W40XT/W45XT Transistor Cabling Diagram

21

Diagrams, Schematics, or Arrangements

22

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 13. B60-80XT Schematic Diagram

23

Diagrams, Schematics, or Arrangements

24

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 14. B60-80XT Wiring Diagram

25

Diagrams, Schematics, or Arrangements

26

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 15. W60-80XT Schematic Diagram

27

Diagrams, Schematics, or Arrangements

28

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 16. W60-80XT Wiring Diagram

29

Diagrams, Schematics, or Arrangements

30

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 17. C60-80XT Schematic Diagram

31

Diagrams, Schematics, or Arrangements

32

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 18. C60-80XT Wiring Diagram

33

Diagrams, Schematics, or Arrangements

34

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 19. T5XT Schematic Diagram

35

Diagrams, Schematics, or Arrangements

36

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 20. T5XT Wiring Diagram

37

Diagrams, Schematics, or Arrangements

38

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 21. B60-80XT EE Schematic Diagram

39

Diagrams, Schematics, or Arrangements

40

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 22. B60-80XT EE Wiring Diagram

41

Diagrams, Schematics, or Arrangements

42

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 23. W60-80XT EE Schematic Diagram

43

Diagrams, Schematics, or Arrangements

44

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 24. W60-80XT EE Wiring Diagram

45

Diagrams, Schematics, or Arrangements

Figure 25. B60-80XT/W60-80XT/C60-80XT/T5XT Optional Wiring

46

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 26. B60-80XT/W60-80XT Wiring Detail - Key Switch and Gauges

47

Diagrams, Schematics, or Arrangements

Figure 27. B60-80XT Wiring Detail - Steady Rest Control Panel

48

8000 SRM 457

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

49

Diagrams, Schematics, or Arrangements

50

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 28. B60-80XT/W60-80XT/C60-80XT/T5XT Cabling Diagram

51

Diagrams, Schematics, or Arrangements

52

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 29. B60-80XT/W60-80XT/C60-80XT/T5XT Wiring Detail

53

Diagrams, Schematics, or Arrangements

54

8000 SRM 457

8000 SRM 457

Diagrams, Schematics, or Arrangements

Figure 30. B60-80XT/W60-80XT/C60-80XT/T5XT Wiring Detail - Control Handle Head

55

Diagrams, Schematics, or Arrangements

Figure 31. B60-80XT/W60-80XT Wiring Detail EE Contactor Panel

56

8000 SRM 457

TECHNICAL PUBLICATIONS 8000 SRM 457

2/97 (11/96)(11/93)(7/93)(10/92)(11/89) Printed in U.S.A.

DIAGRAMS R30XMS2 [D174]

PART NO. 1490102

8000 SRM 923

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 condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Diagrams

Table of Contents

TABLE OF CONTENTS Diagrams, Schematics, or Arrangements .........................................................................................................

Figure 1. Schematic Diagram 24V STD/Guidance CAN Bus EPS IV SEM...........................................

Figure 2. Schematic Diagram 24V STD/Guidance CAN Bus EPS IV SEM...........................................

Figure 3. Schematic Diagram Optional Equipment................................................................................

Figure 4. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM ................................................

Figure 5. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM ................................................

Figure 6. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM ................................................

Figure 7. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM ................................................

Figure 8. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM ................................................

Figure 9. Wiring Diagram Optional Equipment .....................................................................................

1 1 2 3 4 5 6 7 8 9

This section is for the following models: R30XMS2 [D174]

©2004 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 923

Diagrams, Schematics, or Arrangements

Figure 1. Schematic Diagram 24V STD/Guidance CAN Bus EPS IV SEM

1

Diagrams, Schematics, or Arrangements

Figure 2. Schematic Diagram 24V STD/Guidance CAN Bus EPS IV SEM

2

8000 SRM 923

8000 SRM 923

Diagrams, Schematics, or Arrangements

Figure 3. Schematic Diagram Optional Equipment

3

Diagrams, Schematics, or Arrangements

Figure 4. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM

4

8000 SRM 923

8000 SRM 923

Diagrams, Schematics, or Arrangements

Figure 5. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM

5

Diagrams, Schematics, or Arrangements

Figure 6. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM

6

8000 SRM 923

8000 SRM 923

Diagrams, Schematics, or Arrangements

Figure 7. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM

7

Diagrams, Schematics, or Arrangements

Figure 8. Wiring Diagram 24V STD/Guidance CAN Bus EPS IV SEM

8

8000 SRM 923

8000 SRM 923

Diagrams, Schematics, or Arrangements

Figure 9. Wiring Diagram Optional Equipment

9

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

10

TECHNICAL PUBLICATIONS 8000 SRM 923

11/04 (9/00) Printed in U.S.A.

ELECTRICAL SYSTEM R30XMS2 [D174]

PART NO. 1493912

2200 SRM 933

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 condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Electrical System

Table of Contents

TABLE OF CONTENTS Major Electrical System Features.....................................................................................................................

Integrated System .........................................................................................................................................

CAN Bus Advantages ....................................................................................................................................

CAN Bus Communications ...........................................................................................................................

Electric Steering ........................................................................................................................................

Traction ......................................................................................................................................................

Master Control Unit..................................................................................................................................

Input Devices.........................................................................................................................................

Output Devices......................................................................................................................................

Encoder Integrity...........................................................................................................................................

Test Encoders .................................................................................................................................................

Proximity Switches........................................................................................................................................

Start Relay .....................................................................................................................................................

Battery Discharge Indicator (BDI) ...............................................................................................................

Multifunction Display ...................................................................................................................................

Setup...................................................................................................................................................................

Setup Instructions .........................................................................................................................................

General Diagnostics.......................................................................................................................................

Power-On Self-Test ............................................................................................................................................

SEM Traction Motor Controller ........................................................................................................................

Controller Removal........................................................................................................................................

Install .............................................................................................................................................................

Low-Voltage Protection Function..................................................................................................................

Checking Contactor Coils ..............................................................................................................................

Checking Transistor Controller.........................................................................................................................

Component Repair and Testing ....................................................................................................................

Troubleshooting .............................................................................................................................................

Fault Codes and Display Messages ..............................................................................................................

Contactor and Electrical Panel Checks ............................................................................................................

Fuses ..............................................................................................................................................................

Contactors ......................................................................................................................................................

General.......................................................................................................................................................

Test .............................................................................................................................................................

Tips.............................................................................................................................................................

Disassemble and Assemble .......................................................................................................................

Traction Throttle Sensor Removal and Installation ........................................................................................

Instrument Panel Removal and Installation....................................................................................................

Key Switch Removal and Installation ..............................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Steering Indicator Gauge ..................................................................................................................................

Test .................................................................................................................................................................

Remove and Install........................................................................................................................................

Spy Glass Removal and Installation.................................................................................................................

Foot Switch Removal and Installation .............................................................................................................

Slack Chain Switch Removal and Installation.................................................................................................

Limit Switch Removal and Installation............................................................................................................

Drive and Hydraulic Pump Motors...................................................................................................................

Routine Preventive Maintenance .................................................................................................................

Preventive Maintenance Checks ..............................................................................................................

Cleanliness .....................................................................................................................................................

©2005 HYSTER COMPANY

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i

Table of Contents

Electrical System

TABLE OF CONTENTS (Continued) Connections....................................................................................................................................................

Discoloration and Burn Marks .....................................................................................................................

Brushes ..........................................................................................................................................................

Short in Armature .........................................................................................................................................

Commutator ...................................................................................................................................................

Bearings .........................................................................................................................................................

Causes of Motor Failure ....................................................................................................................................

Overload .........................................................................................................................................................

Shock Loading................................................................................................................................................

Short in Field Coils........................................................................................................................................

Short Brushes ................................................................................................................................................

High or Low Commutator Bar ......................................................................................................................

Open Circuit...................................................................................................................................................

Low Battery Voltage ......................................................................................................................................

Eccentricity of Commutator ..........................................................................................................................

Overspeeding .................................................................................................................................................

Motor Tests .........................................................................................................................................................

Excessive Current Draw ...............................................................................................................................

Measuring Current Draw..............................................................................................................................

Excessive Resistance .....................................................................................................................................

Brush Springs ................................................................................................................................................

Drive Motor ........................................................................................................................................................

Inspect ............................................................................................................................................................

Preparation of Drive Motor Commutator.....................................................................................................

Fitting Motor Brushes (Motor Removed)..........................................................................................................

Drive Motor Brush and Brush Holder ..............................................................................................................

Drive Motor Brush, Remove and Install (Motor Installed) .........................................................................

Drive Motor Brush Holder, Remove and Install (Motor Installed) .............................................................

Drive Motor Disassembly and Assembly ..........................................................................................................

Hoist Pump Motors ............................................................................................................................................

Maintenance Instructions .............................................................................................................................

General Information......................................................................................................................................

Brush Replacement .......................................................................................................................................

Hoist Motor ....................................................................................................................................................

Remove and Install ...................................................................................................................................

Disassemble and Assemble .......................................................................................................................

Height Encoder Troubleshooting.......................................................................................................................

Description .....................................................................................................................................................

Symptoms.......................................................................................................................................................

24" Mast Proximity Switch Diagnostics .......................................................................................................

Height Encoder Diagnostics..........................................................................................................................

Symptoms and Recommendations ................................................................................................................

Travel Speed Reduction.................................................................................................................................

Additional Encoder Check.............................................................................................................................

Steer Encoder Troubleshooting .........................................................................................................................

Description .....................................................................................................................................................

MDU Proximity Switch Issues......................................................................................................................

Steering System Issues .................................................................................................................................

How to Check the Steer Encoder ..................................................................................................................

ii

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Electrical System

Table of Contents

TABLE OF CONTENTS (Continued) This section is for the following models: R30XMS2 [D174]

iii

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

2200 SRM 933

Major Electrical System Features

Major Electrical System Features • Keep It Simple philosophy - a simple hardware design with fewer parts - better reliability • Programmable setup of the truck with operator controls and dash display • Noncontact encoders that give position of lift, steering input, and steer drive tire angle • Variable Hall effect sensor for throttle • On-board diagnostics with text display • Separately Excited Motor (SEM) traction motor and controller • Regenerative braking for minimal wear of park brake • Control Area Network (CAN) bus digital data link • Integrated electrical system • Reduced wiring complexity • Over-the-mast wiring reduced to eight conductors • Alphanumeric multifunction display • Continuous height sensing (encoder) • Height, steer angle, and travel speed relationships • Battery discharge indication adjustable for regular or maintenance-free batteries

INTEGRATED SYSTEM This orderpicker uses a CAN bus, two-wire, twisted pair, serial communications network bus to connect several electronic subsystems together to form one integrated system.

CAN BUS ADVANTAGES • Increased reliability • Substantial reduction in connections and wiring complexity • Extensive function monitoring capability • Serial bus simplicity (two wires) • Easy information exchange between subsystems

CAN BUS COMMUNICATIONS Electronic controllers connected by the CAN bus data link are as follows: • Curtis 1310 Master Control Unit (MCU) • Curtis 1243 Traction controller • In-motion Advanced Power Steering (APS) The two-wire, twisted pair, CAN bus carries the following data: • Traction throttle • Traction direction • Horn • Lift/Lower • Steering position and steering rate

• Status information and diagnostic information.

NOTE: To make sure CAN bus is working, blow the horn. If it works, the CAN bus is OK from the 1310 to 1243 controller.

Electric Steering Steering is provided by the In-motion gear motor controller. The APS steering uses a brushless DC motor and controller with CAN bus communications. Steering commands are transferred via the CAN bus from the MCU located under the dash panel.

Traction Traction is provided by a separately excited motor and a Curtis 1243 Sepex controller. The controller is connected to the CAN bus communications link over which it receives commands and reports faults and status information. It also has auxiliary transistor outputs that control the traction main contactor, lift pump contactor, lower solenoid valve, brake coil, and horn. Like other Curtis controllers, the 1243 has a provision for the 1307 handset for diagnostics and testing when needed. It also has a blinking light for indicating fault codes at a glance.

NOTE: If a traction controller handset is used for diagnostics, start truck in setup menu, then plug handset in and exit truck setup menu when handset has completed boot-up process. Failure to follow these steps may cause the truck to display a height encoder error. To clear the error, unplug handset, lift forks to 762 mm (30 in.), lower forks fully, then restart truck.

Master Control Unit Vehicle-control-logic management, diagnostics, and parameter setup are performed by software in the Curtis 1310. This controller is connected to the CAN bus, is located at the operator platform, and interfaces with the following input and output devices.

Input Devices • Throttle Hall Sensor - three wires, battery negative, positive 5 volts, and the variable output having an approximate range of 1.0 volt (full reverse command) to 4.0 volts (full forward command), with 2.5 volts at neutral.

• Lift and Lower switches - connect to two digital inputs on the 1310. Both switches are sourced by

1

Major Electrical System Features 15 volts from the 1310. Used on small chassis trucks, not on large chassis trucks.

• Lift and Lower Hall effect sensor - used on large chassis trucks, not on small chassis trucks.

• Horn switch - connects to one digital input on the 1310. The switch is sourced by 15 volts from the 1310.

• Foot switch - connects to one digital input on the 1310. The switch is sourced from B+.

• Side gate switches - both in series, connect to one digital input on the 1310. These switches are sourced from B+.

• Slack chain switches - both in series, connect to one digital input on the 1310. The switches are sourced from B+.

• Steering input encoder - a digital output device with two bits each with 128 pulses per revolution (256 total). It is powered by the 5-volt source from the 1310.

• Height encoder - a digital output device with two bits each with 128 pulses per revolution (256 total).

It is powered by the 5-volt source from the 1310.

• Steer handle center proximity switch (not used with Multiturn Steering). It is powered by the 15-volt source from the 1310.

Output Devices • Piezo beeper - driven by one 1310 digital output, pull-down transistor.

• Start relay - low side driven by 1310 digital output, pull-down transistor.

• Curtis 840 display - driven by RS232 serial communication from 1310. It is powered by the 15-volt source from the 1310.

ENCODER INTEGRITY Steering and height encoders are tested continuously for current draw. If the total current draw from the two encoders and the Hall effect sensor is too high or too low, a fault will be generated and truck operation will be inhibited. Additional software continuously checks the output bit sequence activity of the steering input encoder to ensure that both bits are operating.

TEST ENCODERS Conventional means can be used to diagnose the encoders as follows. Using a voltmeter, determine if 5 volts and battery negative are going to each encoder by back-probing the connector. If good, then connect to one output channel and battery negative, and rotate the encoder very slowly to see if the input goes

2

2200 SRM 933 on/off/on (0 then 5 volts) when the encoder is rotated slowly. Check the other bit also. If they are both outputting, the encoder is OK. See Setup.

PROXIMITY SWITCHES These are noncontact devices which sense the presence of steel. They have three wires going to them: battery negative, 15 volts (approximately), and an output signal. They also have a built-in indicator light that lights the collar where the wires come out.

These devices can be checked by looking at the indicator light and by testing the output with a voltmeter to see that it changes with and without the steel in front of it.

START RELAY When the key is rotated to the START position, the main contactor coil is energized, powering up the 1310. When the 1310 starts up, the start relay driver pulls low at the same time. B+ is supplied to the start relay coil through the key switch start circuit and the start relay latches, allowing the key to be turned to the Run position. Hold the key in the START position long enough to hear the beep from the piezo buzzer, then release it. The 1310 has an output that holds the relay coil low side, low when it has started. The relay will drop out if the battery disconnect button is depressed or if the system recognizes a problem with truck operation that is unsafe or uncontrolled.

BATTERY DISCHARGE INDICATOR (BDI) The battery state of charge is determined in the MCU (1310) circuitry and software. The battery voltage is sensed at the 1310. Flooded cell and maintenancefree battery types can be accommodated by changing the setup parameters for reset and 80 percent discharge point (in volts/cell). Check with your battery manufacturer for recommended settings.

The BDI calculations are performed in the Curtis 1310 controller not in the spyglass display unit.

If the discharge indicator is not reading correctly, changing the display on the spyglass will not solve the problem.

If adjustments to the 1310 controller are required, see Setup Instructions.

NOTE: It may take a little time for the gauge to reset after a fresh battery is plugged in.

2200 SRM 933

Setup

Changing the settings may be necessary to accommodate local conditions. If the display does not register a full charge after a fully charged battery is put into the truck, the reset voltage may need to be reduced slightly.

If the display is suspected to have a dead center, segment, or LED, it can be checked by observing it when the truck is turned on. All segments and LEDs are momentarily illuminated during the power-on self test to verify their operation.

If the display does not register a full discharge after the battery has been discharged, the discharge settings may need to be increased.

MULTIFUNCTION DISPLAY

The 1310 controller must be calibrated correctly for the discharge indicator to work properly.

The Curtis 840 display is a dumb display, having eight characters alphanumeric LCD and six LEDs. It displays BDI percentage Hours, Warnings, and Faults. It is used during setup procedures to see menu and parameter values.

Setup The setup mode is entered by starting the truck with the horn switch depressed, then releasing and quickly reapplying, then releasing again. This display is multifunctional with hourmeter, BDI, and the basic operator feedback messages. There is no need for the Curtis 1307 handset. All adjustments are either mechanically setup or electrically adjusted through the dash display setup mode. The throttle sensor setup is learned by stroking the handle to full forward and reverse. Mechanical adjustments are basic adjustments, such as mounting the proximity switch at the proper distance from the trip bar on the mast. The software automatically configures some adjustments. For example, it can tell the difference between a Return-to-Center and Multiturn Steering system and configures the truck automatically. See Setup Instructions.

SETUP INSTRUCTIONS NOTE: For all the display examples shown below, x’s represent numerical values which will vary with parameter adjustments. Menu items requiring pass codes will not be visible if the option is not enabled.

1. Connect all electrical connections prior to initial startup of 1310. If power must be applied (e.g., for raising platform during assembly), do so with 1310 power disconnected. During initial startup, the 1310 senses system devices to determine option configuration and initial calibrations. Be certain that the following are connected and/or adjusted during initial startup: a. Steering handle proximity switch (Self-Centering only) connected and adjusted properly. b. Steering and Height encoders connected.

c. Traction Hall effect sensor adjusted for center and handle in neutral position (pre-adjust on bench with 5 volts power supply to achieve 2.5 ±0.2 volts at neutral).

2. Start truck. When starting, the key must be held in the spring-loaded START position for approximately 0.5 second (until the system beeps), then released.

3. Wait for display to show "ThrtVxxx" (xxx equals throttle Hall effect sensor voltage). The voltage displayed should be between 2.20 and 2.70 volts at neutral. If not, loosen setscrews on throttle Hall effect sensor and adjust neutral voltage within this range.

4. Cycle the throttle handle through a full range of motion while observing the voltage displayed.

Voltage should sweep smoothly from 1.2 volts in reverse to 3.8 volts in forward (±0.5 volt). If not, check mechanism and Hall effect sensor.

5. With the traction handle in NEUTRAL (do not move the handle during this step), depress and release the foot switch three times to enter the calibration step. The display will change to CyclePot. 6. Cycle the traction handle twice through its full range of motion within 10 seconds after completing Step 5. After 10 seconds, the system will beep.

7. The traction handle can now be used to navigate the setup menu, using forward and reverse to scroll through the parameters and using the lift/ lower control to change parameter values. Where noted by **, setup choices will be automatically

3

Setup

2200 SRM 933

set by the 1310 based on autosensing of components on the truck, but can be manually overridden in the setup menu. Where noted by *, options will only appear in the menu if they have been activated by passcodes. Parameters with two choices (e.g., Return-to-Center vs. Multiturn steering) will have one choice selected by the lowering control and the other selected by the lifting control. Check and adjust the following parameters to match the truck configuration.

g. Mast type (Small Chassis) or truck type (Large Chassis): (1)

Small Chassis: 2-Stage/3-Stage mast selection (2-Stage or 3-Stage). This MUST be set correctly to achieve the correct speed vs. height relationships.

Defaults to 3-Stage.

(2)

Large Chassis: Counterbalanced, straddle, or furniture selection (Cntr Bal, Straddle, or Furniture).

This MUST be set correctly to achieve the correct speed vs. height relationships.

Defaults to Counterbalanced.

a. Hydraulic Hall effect sensor setup, HydPotSet (large chassis only): (1)

(2)

With the hydraulic knob in NEUTRAL (Do not move the knob during this step!), depress and release the foot switch three times to enter the calibration step. The display will change to CyclePot.

h. Travel cutout options:

Cycle the hydraulic knob twice through its full range of motion within 10 seconds after completing Step (1). After 10 seconds, the system will beep.

b. Restore Defaults (Defaults): To clear memory settings and restore defaults, scroll to this menu selection then hold down the foot switch for 5 seconds. The system will continuously beep during the clear step and display a countdown of the 5 seconds. After the countdown, the truck will shut itself off.

Restart the truck, then follow these instructions from the beginning. c. **Small or large chassis truck (SmallBox or Lrg Box). This parameter is automatically set to large chassis if the variable valve Hall effect sensor is detected by the 1310. If the 1310 runs through initial setup and selects the wrong truck type, check voltage at pin J4-7 (should be 0 volts for small chassis, ≈2.5 volts for large), correct any problems, then use Defaults to rerun initial setup. This is necessary for the correct valves to be programmed into the 1243.

i.

(1)

*Small Chassis: Travel over 150 inches option. Will display Cutat150 if the standard option is selected, or Trav>150 if travel over 150 inches is selected. Default to Cutout at 150 inches.

(2)

*Large Chassis, counterbalanced: Travel over 212 inches option. Will display Cutat212 if the standard option is selected, or Trav>212 if travel over 212 inches is selected. Default to Cutout at 212 inches.

(3)

*Large Chassis, Counterbalanced: Travel over 272 inches option. Will display Cutat272 if the standard option is selected, or Trav>272 if travel over 272 inches is selected. Default to Cutout at 272 inches.

Steer adjustments: (1)

Steer offset adjustment (Self-Centering or Wire Guidance only) (StOf xxx): Adjusts tracking for straight-ahead travel in 0.01-degree increments. Truck must be restarted after exiting setup mode for changes to take effect. Positive values will offset steering center toward the right. Range 999 to +999 (±10 ), default 0.

(2)

Steer gain adjustment (multiturn steering only) (StrGnxxx): Adjusts how aggressively the steering responds to wheel input (1-5). Defaults to 3.

d. 24- or 36-volt selection (large chassis only). e. **Return-to-Center or Multiturn steering: [HandlStr (RTC), [WheelStr (MTS)]. f.

4

Gear steer or chain steer selection: (Str Gear, StrChain).

2200 SRM 933 j.

*Steer maximum speed adjustment (1-5, Only of Self-Centering with wire guidance) (StrMax x): Adjusts maximum steer motor speed. Lower adjustments can be used to simulate performance of EPS II steering.

Defaults to 4.

k. *Wire guidance, wire guidance-slowdown, or non-guided selection (WG-Setup, WGS-Set, or Non-Guid) Defaults to standard (Non-Guided). Wire guidance-slowdown sets the truck to run 3.54 km/h (2.2 mph) maximum in manual steer mode if operating in a guided aisle. This is also used to calibrate the wire guidance sensors and to force straight-ahead travel on a multi-turn truck.

To force straight-ahead travel (to check steer offset on a multi-turn truck): (1)

l.

While WG-Setup or WGS-Set is displayed, depress and hold the foot switch, then depress the horn button.

Steering will be disabled and speed restricted to ~2.2 mph.

To run wire guidance calibration: (1)

Exit the menu (using the horn button) while WG-Setup or WGS-Set is displayed and the wire guidance switch is off.

(2)

Proceed to the wire and center the wire guidance sensors over the wire [center of sensors within 3.175 mm (0.125 in.) of wire center].

(3)

Turn on wire guidance switch. Display should change to WG Calib for a few moments. If the calibration is successful, the display will read Success!

(4)

Restart the truck (travel will be disabled while in calibration).

m. *Wire Guidance Lead Distance (WgLd #): This value (1-20, default 6) is used in the calculations of steer angle based on wire guidance sensor position. A shorter lead distance results in the system attempting to steer the truck back onto the wire in a shorter travel distance, resulting in more aggressive steering. High values may result in a slow wandering of the truck around the

Setup center of the wire and low values may cause the steering to react too quickly to sense the wire. n. *Wire Guidance Steering Gain (WG Gn #): This value (1-10, default 4) is used to determine the responsiveness of the APS to steering commands from the wire guidance unit.

Higher gains may be necessary to overcome friction of a large- or soft-drive tire. o. Hydraulic Lift Ramp-in Adjustment [LftRpUp (large chassis only)]: Ramp-in timing of hydraulic lift valve. Affects how quickly full lift speed is achieved when applying hoist.

Lower numbers yield a softer feel due to the slower ramp rate, but slow the lift responsiveness. Defaults to 3, range 1 to 5. p. Hydraulic Lift Ramp-down Adjustment [(LftRpDn) (large chassis only)]: Ramp-down timing of hydraulic lift valve. Affects how quickly the platform stops when disengaging hoist. Lower numbers yield a softer feel due to the slower ramp rate, but slow the lift responsiveness. Defaults to 3, range 1 to 5. q. Hydraulic Lower Ramp-in Adjustment [(LwrRpUp) (large chassis only)]: Ramp-in timing of hydraulic lowering valve. Affects how quickly full lowering speed is achieved.

Lower numbers yield a softer feel due to the slower ramp rate, but slow the lowering responsiveness. Defaults to 3, range 1 to 5. r.

Hydraulic Lower Ramp-down Adjustment [LwrRpDn (large chassis only)]: Ramp-down timing of hydraulic lowering valve. Affects how quickly the platform stops when disengaging lowering. Lower numbers yield a softer feel due to the slower ramp rate, but allow more overshoot. Defaults to 3, range 1 to 5.

s.

*Lift Limit (LftLmxxx): The lift limit setting in inches. Defaults to 380 inches.

t.

*Lower Limit (LwrLmxxx): The lowering limit setting in inches. Defaults to 0 inches.

u. Maximum speed limit 1-5 (MaxSpxxx): Defaults to 5. v.

Acceleration aggressiveness (1-5) (Accelxxx): Defaults to 4.

5

Setup

2200 SRM 933

w. Neutral braking aggressiveness (1-5) (NtBrkxxx): Defaults to 3. x. Motion Alarm type (Alarm xx): Alarm types are as follows: 0=no alarm 1=Backup (BU) 2=Forward (FWD) 3=BU & FWD 4=Lift 5=BU & Lift 6=FWD & Lift 7=BU, FWD, & Lift 8=Lower 9=BU & Lower 10=FWD & Lower 11=BU, FWD, & Lower 12=Lift & Lower 13=BU, Lift, & Lower 14=FWD, Lift, & Lower 15=BU, FWD, Lift, & Lower y.

*Foot Switch Hydraulic Interlock (HydIntOn or HydIntOff). If enabled, the operator must depress the foot switch to allow hydraulic functions.

z. *Menu Password Lockout (MenuLkOn or MenuLkOf). If enabled, this forces the technician to enter a password to access the setup menu. aa. *Selection of Menu Password (M# 16000): Use lift/lower control to scroll through the numbers to the desired password. The password will be saved when the setup menu is exited using the horn button. ab. BDI Reset setting (RsBDIxxx). This is the battery level (in volts per cell, 0.01-volt increments) necessary for a charged battery to reset the BDI to 100 percent. Default setting 2.09 volts, set to 2.19 volts for maintenance-free batteries. ac. BDI Discharge (0%) setting (0%BDIxxx).

This is the battery level (in volts per cell, 0.01-volt increments) for a completely discharged battery.

• Default setting (1.79 volts) is for conventional (flooded cell) batteries.

• For Douglas™ maintenance-free batteries, set to 1.98 volts.

• For GNB™ maintenance-free batteries, set to 1.86 volts.

6

ad. Voltage Calibrations (Cal xxx): Truck voltage (as measured by the 1310) is displayed in 0.1-volt increments. Connect a digital voltmeter to the 1310 B+ and B terminals. If the displayed value on the spyglass does not read within 0.3 volt of the digital voltmeter, adjust using the lift/lower controls. ae. Diagnostic Switch input display 1: Switch 1 is displayed for 1.5 seconds, followed by binary display of switch inputs 1-8 (example: 01100000). If a switch is on, its digit will be 1, otherwise 0. Switch inputs from left to right are: 0 #1 Steer Handle Switch 1 #2 Side Gate Switch 1 #3 Slack Chain Switch 0 #4 Wire Guidance Switch 0 #5 Special Option Switch 0 #6 Horn Switch 0 #7 Foot Switch 0 #8 Lift Limit Override Switch In the display examples above, the Side Gate and Slack Chain switches are on and all the others are off. af. Diagnostic Switch input display 2: Switch 2 is displayed for 1.5 seconds, followed by binary display of switch inputs (example: 00000110). If a switch is on, its digit will be 1, otherwise 0. The only digits used are far right two digits, and other digits may be 0 or 1. The lowering switch is far right (#8), and the lifting switch is second from right (#7).

In the display example above, the lift switch is on and the lowering switch is off. ag. Running Diagnostic display: DiagDisp is displayed for 1.5 seconds, followed by No Displ.

Several display choices (listed below) may then be scrolled through using the lift and lower control. Select a display choice, then depress the horn button to exit the menu and return truck to operating mode. The selected diagnostic display item will be shown until the next time the truck is restarted.

Display items follow, showing the message choice from the setup menu and the format of the value displayed in its run mode.

(1)

No Displ: No diagnostic display (normal truck display).

2200 SRM 933 (2)

ThrotVlt: Raw voltage from Hall effect throttle pot, in 0.01-volt increments.

Run display: Thrtxxxx.

(3)

ThrotOut: Processed throttle output sent to traction controller, 0 to ±100 percent (negative value for reverse). Full throttle values will be scaled below 100 percent for reduced-speed conditions (platform elevated or fault condition).

Run display: Txxxxxx0.

(4)

StrInput: Steer command from the steering wheel sensor. Self-centering steering is expressed as requested angle in 0.01-degree increments, multiturn steering is expressed as requested steer motor rpm (proportional to steering wheel rpm). Run display: SxxxxxxI.

(5)

StrPostn: Actual steer tire (MDU) angular position, as reported by steering controller, in 0.01- degree increments.

Run display: SxxxxxxP.

(6)

StrSpeed: Actual steering motor speed as reported by steering controller in rpm. Run display: SxxxxxxS.

(7)

Lift Hgt: Current lift height from ground to top of forks is measured in inches. Run display: FrkHtxxx.

(8)

(9)

Enc Crnt: Measurement of current drawn from 5-volt power supply by height and steer encoders and throttle Hall effect sensor. This current draw is monitored by the system to determine if an encoder has become unplugged.

During initial setup of the truck, an initial reading of this current is taken.

A fault is triggered if the measured current is detected below 80 percent or above 120 percent of the initial value.

Current is displayed in analog-to-digital converter counts (proportional to milliampere). Typical value 350, minimum initial value 250. Run display: EncCtxxx.

InitEncI: Initial (stored) value of encoder current (see above description of encoder current). Run display: InitIxxx.

Setup (10) BDI %: Actual percentage value of remaining battery energy available (a precise display of coarse value displayed on LEDs).

Run display: 0000xxx%.

(11) Arm PWM: Traction motor armature duty cycle in percent. Value is proportional to voltage applied to armature.

Run display: AxxxxxxV. (12) Arm Crnt: Traction motor armature current measured in amperes. Negative values shown during regenerative braking. Run display: AxxxxxxC. (13) Fld PWM: Traction motor field duty cycle in percent. Value is proportional to voltage applied to field. Run display: FxxxxxxV. (14) Fld Crnt: Traction motor field current measured in amperes. Negative values shown for reverse travel direction. Run display: FxxxxxxC. (15) TrkVolts: Truck voltage as measured at the 1310 Master controller. Displayed in 0.1-volt increments. Run display: Volt xxx.

(16) 1243Inpt: Inputs into the 1243, displayed in binary format (see diagnostic switch display 1 above). Outputs listed (lowering valve, brake, horn) are displayed as a 1 if the component is connected but turned off, and displayed as a 0 if it is on or disconnected. Displayed are: • #1 Lowering valve • #2 Brake • #3 Horn • #8 Mast proximity sensor Run display: xxxx xxx.

(17) Hyd Volt: Raw voltage from Hall effect hydraulic input sensor in 0.01-volt increments. Run display HyPotxxx.

(18) HydValve: Processed signal sent to variable hydraulic valve in increments of 0-32767. Run display Hydxxxxx.

(19) WG Dist: Calculated distance from the guidance wire in millimeters. Displayed value will be from the fork-end

7

Setup

2200 SRM 933 sensor if last traveling in that direction; otherwise the MDU end sensor output.

Run display Dst xxxx.

(20) WG Dir: Vehicle direction used for calculating wire guidance steer output.

Neutral = 0, Forward = 1, Reverse = 2.

(21) Diagnostic Switch input display 1: Switch 1 is displayed for 1.5 seconds, followed by binary display of switch inputs 1-8 (example: 01100000). If a switch is on, its digit will be 1, otherwise 0. Switch inputs left to right are: 0 #1 Steer Handle Switch 1 #2 Side Gate Switch 1 #3 Slack Chain Switch 0 #4 Wire Guidance Switch 0 #5 Special Option Switch 0 #6 Horn Switch 0 #7 Foot Switch 0 #8 Lift Limit Override Switch

ah. Error Log: Use the lift and lower controls to scroll through the log. Error codes will be provided in separate troubleshooting instructions. To clear the error log, hold down the foot switch for 5 seconds. The system will continuously beep during the clear step and display a countdown of 5 seconds. Error codes listed in order will be as follows: (1)

1 xxxx E, where xxxx equals the most recently stored error code.

(2)

1ErrCtxxx, where xxx equals the number of occurrences of that error.

(3)

1Tmxxxxx, where xxxxx equals the hourmeter reading (in 0.1 hr) of the most recent occurrence.

(4)

1ErNdxx, where xx equals node of controller which sent the error code.

1=1310, 5=1243, 6=Steer Controller, and 7=Wire Guidance Unit.

ak. Entry of passcode numbers (PC#16000): Use lift/lower control to scroll through the numbers to the proper passcode, then depress the foot switch to enter. While the foot switch is depressed, beeper will sound and confirmation message for the activated option will be displayed. Multiple passcodes may be entered, but are not saved until menu is exited with horn button. If an improper passcode is entered, the truck will shut down.

8. The setup menu can be entered at any time by starting the truck with the horn button depressed, then releasing the horn button and reapplying it within 0.5 second, then releasing again. If the Menu Password option is activated, see Step z; the following applies: a. After entering the setup menu using the horn button sequence, the display will show (PW#16000); use lift/lower control to scroll through the numbers to the proper password, then depress the foot switch to enter. If an improper password is entered, the truck will shut down.

GENERAL DIAGNOSTICS Diagnostics are displayed on the 840 dash display.

There is no need for a handset; however the Curtis 1307 can be used in addition to the onboard diagnostics. This is the same handset that the dealers already have. No adjustments will be made with the Curtis handset; it will only be used for diagnostic purposes.

ai. Internal serial number of 1310 (Sr# xxxx), to enter into Passkey program to obtain option enabling passcodes.

NOTE: If a traction controller handset is used for diagnostics, start truck in setup menu. Then plug handset in and exit truck setup menu when handset has completed boot-up process. Failure to follow these steps may cause the truck to display a height encoder error. To clear the error, unplug handset, lift forks to 762 mm (30 in.), lower fully, then restart truck.

aj. Erase Memory (EraseMem). To clear all memory settings and restore defaults, scroll

Several levels of diagnostics are utilized. Extensive tests are completed on every truck startup. Run-time

(5)

8

to this menu selection, then hold down the foot switch for 5 seconds. The system will continuously beep during the clear step and display a countdown of 5 seconds. After the countdown, the truck will shut itself off.

Restart the truck, then follow these instructions from the beginning.

Step (1) through Step (4) are repeated for error codes 2 through 5.

2200 SRM 933

SEM Traction Motor Controller

diagnostic displays are available, displaying the operating information (e.g., armature current) which would normally require a traction controller handset.

During truck operations, error or warning conditions detected by any of the controllers (steering, traction,

or master controllers) are logged in the error log (described below under setup menu diagnostics). Error codes and display messages are listed in the table for troubleshooting.

Power-On Self-Test Power-on self-test is completed on every startup of the truck. During startup, the operator must be off the foot switch, the Return-to-Center handle (if equipped) must be in center (neutral) position, the accelerator handle must be in center (neutral) position, the horn button and lift limit switch (optional) must be disengaged, and the lift/lower control must not be engaged. If any of these conditions are not met, the beeper will sound and an appropriate message (e.g., Foot Sw along with flashing red LED) will be displayed.

starting the truck with the switch/control engaged should result in an appropriate message. Releasing the switch/control should turn off the beeper and message.

Also during power-on self-test, the 1243 traction controller checks for the presence of the EM brake, the horn, and the lowering solenoid. If any of these items are missing or disconnected, an appropriate message is displayed.

This feature may be used as a quick check if any of the above inputs are suspected to be faulty. Simply

SEM Traction Motor Controller The Curtis 1243 Separately Excited Motor (SEM) controller delivers a smooth, silent control of motor speed and torque. Full-bridge field winding control stage is combined with a half-bridge armature power stage to provide solid-state motor reversing and full regenerative braking without additional relays or contactors. See Figure 1. There are no serviceable parts in the 1243 controller. No attempt should be made to open, repair, or modify the controller.

If a controller failure has occurred on a R30XMS2 (D174) model truck produced prior to serial number D174N02817A, install diode board assembly 2065361 when installing the new controller. This diode board helps protect the controller from damage caused by operator misuse.

Figure 1. Transistor Motor Controller

9

SEM Traction Motor Controller

CAUTION Make sure the battery side of the diode board is correctly oriented on the contactor.

To install the diode board, remove the nuts retaining the small wires to the main connector. The board is polarity sensitive. Install the diode board onto the main contactor terminal studs. Install the small wires and tighten nuts, as removed.

The controller checks the following functions: Checks the temperature and gives both low- and high-temperature thermal protection to the controller.

Electronically checks the traction circuit for malfunctions and prevents traction motor operation if a failure occurs.

Regulates the current in the motor circuit and automatically decreases the motor voltage to reduce the current and prevent damage.

Additional information showing how the motor controller is electrically connected is shown in the Diagrams 8000 SRM 923.

CONTROLLER REMOVAL Before replacing the traction controller, you will have to perform an erase memory procedure on the 1310 controller. If the memory is not erased, you could have slow speed issues.

Using the setup instructions, scroll to the erase memory message "Erase Mem", and follow the instructions to erase the memory. Reestablish the unit’s parameters by using the setup instructions.

The 1310 controller will be reconfigured with the correct data for the new traction controller.

1. Move lift truck to a safe, level area. Turn key switch to OFF position and remove key. Put a DO NOT OPERATE tag on the multifunction control handle. Put blocks under drive wheels to keep lift truck from moving. See HOW TO PUT A LIFT TRUCK ON BLOCKS, Periodic Maintenance 8000 SRM 924.

WARNING Disconnect the battery and separate the connector before opening the compartment cover

10

2200 SRM 933 or inspecting/repairing the electrical system.

If a tool causes a short circuit, the high-current flow from the battery can cause a personal injury or property damage.

2. Disconnect and separate battery connector.

3. Remove fasteners retaining chassis cover, unplug flashing light, and remove cover.

4. Unplug connector from traction motor controller.

Tag and disconnect wires to terminals.

5. Remove three capscrews and lockwashers and carefully remove controller from lift truck.

INSTALL 1. Make certain the mounting surface for controller is clean. There should be no dirt between the frame and the controller. Apply heat-conductive grease to bottom of controller. Align controller in lift truck with holes on frame and install lockwashers and capscrews; then tighten capscrews.

2. Connect wires and cables to the same terminals as identified during the removal procedure. See Diagrams 8000 SRM 923.

3. See Setup in this section.

LOW-VOLTAGE PROTECTION FUNCTION This function protects the controller and the battery.

The controller will not operate correctly if there is not a minimum voltage from the battery. The battery current drain increases as the battery voltage decreases. Too large a battery drain will damage the battery. If the battery voltage is low, the control circuit will decrease the ON TIME of the pulses to decrease the current drain. The battery can still operate the lift truck to move it for battery charging or replacement.

NOTE: The checks require a voltmeter with a meter movement. Most digital meters will not operate correctly for some of these checks. Specific checks require additional equipment.

2200 SRM 933

Checking Transistor Controller

CHECKING CONTACTOR COILS WARNING Disconnect the battery and separate the connector before opening the drive unit compartment or inspecting or repairing the electrical system. If a tool causes a short circuit, the highcurrent flow from the battery can cause a personal injury or property damage.

WARNING Some checks require the battery to be connected. Do not connect the battery until the procedure tells you to connect the battery.

Make sure the drive wheel is raised to prevent

truck movement and possible injury. Raise the drive wheel as described in the Operating Manual or the Periodic Maintenance section of the Service Manual.

Check the main contactor coil with an ohmmeter. A suppressor diode is connected across the coil terminals. The diode will cause the ohmmeter to indicate a difference in resistance in one direction. Reverse the probes of the ohmmeter to the opposite terminals and measure the resistance. Use the highest resistance indication. Replace the coil if the resistance readings are a short circuit in both directions or if there is an open circuit in both directions. Make sure the coil wires are connected again to the correct terminals.

Refer to Contactors, General within this manual.

Checking Transistor Controller Make sure all checks are done with a fully charged battery.

NOTE: The following checks must be done in the order they are listed due to some steps depending on conditions set in previous steps.

COMPONENT REPAIR AND TESTING 1. To check for wire connections to the frame, completely disconnect the battery and use an ohmmeter to check the circuits. Check for 50,000 ohms or more between each terminal of the lift truck portion of the battery connector and clean connection point on the frame of lift truck. There should be no electrical connections to the frame of the lift truck. Wires or terminals without insulation can cause electrical connections to the frame.

Isolators used to insulate circuit boards from the frame that are missing, broken, or installed incorrectly can also cause these connections.

2. Check for voltage between each terminal of the connector on the battery and a clean metal connection on the frame of the lift truck. It is normal to measure some voltage between the battery and the frame even if the resistance checks are correct. If a voltage is detected, use an ammeter to measure current flow. The current must not exceed 100 milliamperes. Current in excess of 100 milliamperes can cause a problem.

WARNING Wear appropriate safety equipment and remove carbon dust from motors using dry, compressed air. Compressed air can cause personal injury or property damage.

If voltage is detected at the frame, check to be sure the battery is clean and not defective. Clean the battery and battery compartment as required. A buildup of carbon dust in the electric motors can also cause measurable voltage at the frame.

11

Checking Transistor Controller

TROUBLESHOOTING WARNING Disconnect the battery and separate the connector before opening the drive unit compartment or inspecting or repairing the electrical system. If a tool causes a short circuit, the highcurrent flow from the battery can cause a personal injury or property damage.

WARNING Some checks require the battery to be connected. Do not connect the battery until the procedure tells you to connect the battery.

Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel as described in the Operating Manual or Periodic Maintenance 8000 SRM 924.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on Molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

This section describes the most common faults that can occur in the trucks with the Curtis Transistor

12

2200 SRM 933 Controller. Use the fault procedure that best describes the problem.

1. Check the specific gravity of the battery. If the specific gravity is less than 1.260, the battery is not fully charged or has a defect. A fully charged battery has a specific gravity of 1.270-1.290. A discharged battery has a specific gravity of approximately 1.130.

2. The electric lift truck has an isolated electrical system. The frame must not be a common electrical path. Check for 50,000 ohms or more between each terminal of the battery connector for the lift truck and a clean connection on the frame.

Remove any circuit paths between the controller and the frame of the lift truck. Carbon dust in a motor or other parts can cause a circuit path.

Check for additional equipment that is causing a circuit path to the frame.

3. Check for voltage between each terminal of the connector that fastens to the battery and a clean connection on the frame. Normally there is some small voltage between the battery and the frame even if the resistance is very high. The small voltage is normally less than 30 percent of the battery voltage. A higher voltage can indicate a dirty battery or a battery with a defect. Clean the battery and battery compartment as necessary.

4. Visually check for parts or wires that are loose or damaged.

NOTE: The correct meter polarity is necessary for the checks. The voltage checks are made between the point indicated in the troubleshooting chart and battery negative. Connect the meter negative to battery negative.

NOTE: Make an identification of any wires before you disconnect them. The wires must be connected correctly after checks or repairs.

Table 1 contains a list of fault codes and display messages. Fault messages listed in the Display column may be displayed while the truck is running. For complete instructions on how to retrieve fault codes, refer to the Setup Instructions in this manual.

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Checking Transistor Controller

FAULT CODES AND DISPLAY MESSAGES Table 1. Fault Codes and Display Messages Code

Node or ND

Display

Description

Items to Check If Code Is Displayed

********

1310 is damaged

Replace 1310 Unplug and check steering and height encoders prior to installing new 1310

SlackChn

Slack chain circuit open

Chains slack (carriage hung up on lowering) Slack chain switches functioning Wiring between 1310 & slack chain switches

SideGate

Side gates up

Side gate switches functioning Wiring between 1310 & side gate switches

HornOpen

Horn disconnected (open circuit)

Horn (bench test for function) Wiring to horn

BrakOpen

Brake disconnected (open circuit)

Brake coil (bench test) Wiring to brake

LowrOpen

Lowering valve disconnected (open circuit)

Lowering valve (bench test)

TractErr

Misc. traction error

Wiring to 1243

Foot Sw

Foot switch off while requesting traction, hoist, or foot switch closed during startup sequence

Use diagnostic display (switches) to confirm switch functionality.

Wiring to lowering valve

Check switch function and wiring.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

13

Checking Transistor Controller

2200 SRM 933

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

Display

Description

Low Batt

Low battery warning, lift cutout, and speed reduced

LiftLimt

Lift limit reached

LowrLimt

Lowering limit reached

Items to Check If Code Is Displayed If lift cutout occurs with true battery conditions too high or low, revise 0% BDI setting.

2041

5

Low Volt

Traction-battery undervoltage

Check for correct voltage battery.

2042

5

Hi Volt

Traction-battery overvoltage

Check for correct voltage battery.

2043

5

TractHot

Traction: thermal cutback

Check for mechanical resistance (damaged load wheels, etc.).

Check for improper use conditions (ramps, pushing loads).

2301

6

Str Crnt

High current

Mechanical binding of MDU.

2390

1

ChkEncdr

Encoder supply current drop

Wiring to steer & height encoders.

Steer & height encoders.

Check current draw using diagnostics Enc Crnt.

2391

1

Enc Off?

Encoder supply current too low on initialization

Steer & height encoders must be plugged in during initial setup of a new 1310

2392

1

Enc Crnt

Encoder supply current too high

Use diagnostic display to display encoder current draw. Then unplug individual encoders to determine which encoder or wiring is drawing high current.

3101

6

Str Volt

High voltage

Check voltage to steer controller.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

14

2200 SRM 933

Checking Transistor Controller

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

4201

6

5001

Display Str Temp

Description

Items to Check If Code Is Displayed

High temp

Check for mechanical resistance in steering mechanism.

7

Wire guidance unit, no signal from front antenna

Check front antenna and wiring.

5002

7

Wire guidance unit, no signal from rear antenna

Check rear antenna and wiring.

501A

6

MDU Prox

Steer feedback sensor error

Check MDU proximity sensor and wiring.

5021

6

StrMotor

Steer motor error

Check wiring to steer motor.

5022

6

StrSensr

Steer Hall effect sensor error

Check MDU proximity sensor and wiring. Sensor gap should be 10 mm (0.40 in.).

Check wiring for steering Hall effect sensor.

5090

1

Lift Sw

Lift switch shorted

Lift switch & wiring.

5091

1

Lower Sw

Lower switch shorted

Lower switch & wiring.

5092

1

Steer Sw

Steer handle proximity switch off (Self-centering) or steer handle proximity switch on (Multiturn)

Steer handle proximity switch & wiring.

5590

1

MemErr1a

Memory read warning-block 1 unable to start read process

Repeatedly discharging battery beyond normal limits.

5591

1

MemErr1b

Memory read warning-block 1 unable to start read process

Repeatedly discharging battery beyond normal limits.

5592

1

MemEr_A3

Memory read warning-block 3 unable to start read process

Repeatedly discharging battery beyond normal limits.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

15

Checking Transistor Controller

2200 SRM 933

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

6011

5

TracSnsr

Traction-current sensor fault

Check cables between controller and motor. If problem persists, replace 1243.

6013

5

M- Fault

Traction M- fault

Check cables between controller and motor. Faults may occasionally occur in good controllers due to abrupt changes in wheel speed, such as driving over breaks in the floor. If problem persists, replace 1243.

6101

7

Wire guidance unit, software error

Check wire guidance unit and wiring.

6102

7

Wire guidance unit, software address error

Check wire guidance unit and wiring.

6103

7

Wire guidance unit, software time-out error

Check wire guidance unit and wiring.

6110

6

Steer initialization time-out

Check MDU proximity and wiring.

Display

StrTmOut

Description

Items to Check If Code Is Displayed

Check that MDU can rotate freely.

6390

1

MemErr2a

Memory read error from block 3, unable to start read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

6391

1

MemErr2b

Memory read error from block 3, unable to complete read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

6392

1

MemErr4a

Memory read error from block 4, unable to start read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

6393

1

MemErr4b

Memory read error from block 4, unable to complete read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

16

2200 SRM 933

Checking Transistor Controller

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

6394

1

MemErr5a

Memory read error from block 5, unable to start read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

6395

1

MemErr5b

Memory read error from block 5, unable to complete read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

6396

1

MemErr6a

Memory read error from block 6, unable to start read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

6397

1

MemErr6b

Memory read error from block 6, unable to complete read process, parameter loss

Rerun truck initialization; if problem persists, replace 1310.

7305

1

HtEnc Ch

Height encoder error channel count mismatch

Check wiring to encoder.

Steer encoder error channel count mismatch

Check wiring to encoder.

7306

1

Display

StEnc Ch

Description

Items to Check If Code Is Displayed

Check both encoder output channels using voltmeter, should pulse with encoder rotation.

Check both encoder output channels using voltmeter; voltmeter should pulse with encoder rotation.

Check for chassis ground in contact with encoder housing.

Check for wiring problems on external 1243 capacitor.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

17

Checking Transistor Controller

2200 SRM 933

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

7307

1

Display SteerEnc

Description Steer handle proximity sensor shorted or steering encoder error

Items to Check If Code Is Displayed Check steer handle proximity function using diagnostics switch 1.

Check steer encoder using StrInput in diagnostics Check wiring to steer handle proximity & steering encoder.

7320

7390

1

1

HtEncOff

Throttle

Height encoder not responding (position sensor fault)

Check mast proximity switch.

Throttle potentiometer out of range

Check wiring to throttle Hall effect potentiometer.

Check height encoder, using Lift Hgt in diagnostics.

Check throttle output using ThrotOut in diagnostics.

7391

1

Hyd Pot

Hydraulic potentiometer out of range

Check wiring to potentiometer.

7392

1

Mast Sw

Height proximity not responding (encoder functions with lift/lower, but no proximity)

Mast proximity switch & wiring.

Running height encoder reset error

Mast proximity switch & wiring.

7393

1

HtEncErr

Handset connected.

Use DiagDisp (1243Inpt) to confirm proximity switch functioning when mast raised/lowered past 24 in.

After verifying correct switch and encoder function, lift forks above 30 in., lower fully, and restart truck to reset error.

No handset connected.

Height encoder & wiring.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

18

2200 SRM 933

Checking Transistor Controller

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

7394

1

Display HtEncErr

Description Startup error on 24 in. height proximity switch state - switch was on when truck last turned off, but is now off

Items to Check If Code Is Displayed Can be caused by mast being raised while 1310 is not powered.

Can be caused by starting truck with handset plugged into 1243.

Use DiagDisp (1243Inpt) to confirm proximity switch functioning when mast raised/lowered past 24 in.

Check 24 in. proximity switch & wiring. If a wire has been pulled out of the switch at the plug, replace the switch assembly.

After verifying correct switch and encoder function, lift forks above 30 in., lower fully, and restart truck to reset error.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

19

Checking Transistor Controller

2200 SRM 933

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

739A

1

Display HtEncErr

Description

Items to Check If Code Is Displayed

Height encoder error (lift/lower Use DiagDisp (Lift Hgt) to confirm function called for, but encoder not height incrementing/decrementing incrementing/decrementing) when mast raised/lowered; if error in effect, large height value may be displayed, but it should still change when lifting/lowering.

If displayed height does not change with fork height, check height encoder and wiring.

Use DiagDisp (1243Inpt) to confirm proximity switch functioning when mast raised/lowered past 24 in.

Check 24 in. proximity switch & wiring. If a wire has been pulled out of the switch at the plug, replace the switch assembly.

After verifying correct switch and encoder function, lift forks above 30 in., lower fully, and restart truck to reset error.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

20

2200 SRM 933

Checking Transistor Controller

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

739B

1

Display HtEncErr

Description Height encoder error: On first proximity switch transition after truck startup, indicated height was >29 in.

Items to Check If Code Is Displayed Can be caused by starting truck with handset plugged into 1243.

Use DiagDisp (1243Inpt) to confirm proximity switch functioning when mast raised/lowered past 24 in.

Use DiagDisp (Lift Hgt) to confirm height incrementing/decrementing when mast raised/lowered; if error in effect, large height value may be displayed, but it should still change when lifting/lowering.

If displayed height does not change with fork height, check height encoder and wiring.

Check 24 in. proximity switch & wiring. If a wire has been pulled out of the switch at the plug, replace the switch assembly.

After verifying correct switch and encoder function, lift forks above 30 in., lower fully, and restart truck to reset error.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

21

Checking Transistor Controller

2200 SRM 933

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

739C

1

Display HtEncErr

Description Height encoder error: encoder indicated height <22 in. or >26 in. when 24 in. proximity switch passed

Items to Check If Code Is Displayed Can be caused by starting truck with handset plugged into 1243.

Use DiagDisp (1243Inpt) to confirm proximity switch functioning when mast raised/lowered past 24 in.

Use DiagDisp (Lift Hgt) to confirm height incrementing/decrementing when mast raised/lowered; if error in effect, large height value may be displayed, but it should still change when lifting/lowering.

If displayed height does not change with fork height, check height encoder and wiring Check 24 in. proximity switch & wiring. If a wire has been pulled out of the switch at the plug, replace the switch assembly.

After verifying correct switch and encoder function, lift forks above 30 in., lower fully, and restart truck to reset error.

739D

1

Throt Lo

Throttle voltage too low

Throttle mechanism out of adjustment: check neutral position, calibrate throttle Throttle Hall effect sensor & wiring.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

22

2200 SRM 933

Checking Transistor Controller

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

739E

1

Display Throt Hi

Description Throttle voltage too high

Items to Check If Code Is Displayed Throttle mechanism out of adjustment: check neutral position, calibrate throttle.

Throttle Hall effect sensor & wiring.

73A0

1

Hyd Lo

Hydraulic potentiometer out of range - low voltage

Use diagnostic display (Hyd Volt) to confirm voltage output.

Check wiring to hydraulic Hall effect potentiometer.

73A1

1

Hyd Hi

Hydraulic potentiometer out of range - high voltage

Use Diagnostic Display (Hyd Volt) to confirm voltage output.

Check wiring to hydraulic Hall effect potentiometer.

8012

5

TrctComm

Traction-CAN communication fault

CAN wiring to traction controller.

8031

5

Cnt Crnt

Contactor coil or motor field overcurrent

Wiring shorted to traction contactor.

Contactor coil or suppressor shorted.

Traction motor field or wiring shorted.

8032

5

Cnt Coil

Contactor coil open or traction contactor shorted/welded

Wiring open to traction contactor.

Traction contactor contacts welded.

Short from traction armature A2 to B+.

8033

5

Fld Open

Field open

Wiring from 1243 to motor field.

Motor field winding failure.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

23

Checking Transistor Controller

2200 SRM 933

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

8034

5

Display TracCont

Description Traction contactor missing

Items to Check If Code Is Displayed Traction main fuse blown.

Traction contactor tips bad.

Traction contactor coil wiring

8101

6

Str Comm

CAN open time-out

CAN wiring to steering controller

8190

1

SteerErr

General steering error

CAN wiring to steering controller Wiring & fuse to steering controller MDU proximity wiring Wiring between steer controller & motor.

8191

1

Comm Err

Communication error CAN time-out with multiple nodes

CAN wiring

8192

1

TrctComm

Communication error CAN time-out with traction

Fuse to traction controller.

Communication error CAN time-out with steering

CAN wiring to steering controller.

Steer error after startup

CAN bus wiring to steer controller.

8193

8194

1

1

Str Comm

SteerErr

CAN wiring to traction controller.

Fuse to steering controller.

Faulty steer controller.

8195

1

SDO response from traction

CAN wiring to traction controller.

Faulty traction controller.

8196

1

1243 PDO communication error

CAN wiring to traction controller.

Faulty traction controller.

8197

1

TrctComm

No communication from traction on startup

Fuse to traction controller.

CAN bus wiring to traction controller.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

24

2200 SRM 933

Checking Transistor Controller

Table 1. Fault Codes and Display Messages (Continued)

Code

Node or ND

8198

1

Comm Off

CAN system off on startup

CAN bus wiring to 1310, steer, traction controllers.

8199

1

WGU Comm

No communication from wire guidance unit with wire guidance switch on

CAN bus wiring to wire guidance unit.

Display

Description

Items to Check If Code Is Displayed

Power wiring and fuse to wire guidance unit.

Faulty wire guidance unit.

9090

1

9091

1

9092

1

Shutdown due to initial height encoder movement

Welded pump contactor.

SteerErr

Steered wheel not responding to steer input

Mechanical binding of MDU.

LostWire

Wire guidance unit indicates truck off guidepath

See wire guidance setup instructions.

CAUTION The electrical system on this truck utilizes many control-level circuits (low voltage and current), which may be disturbed by contamination, wear, or damage at the electrical connections. When investigating problems or fault codes, it may be beneficial to check and clean/repair all connections in the affected circuit first. The use of dielectric grease is recommended for all AMP™ and Molex™ electrical connectors. Dielectric grease must be applied to each terminal opening to a depth of 3 mm (0.12 in.) on all AMP connectors and to 4 mm (0.16 in.) on molex connectors. Apply lubricant to mating end only.

CAUTION The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a defective truck component or controller. Fault codes may be generated in response to extreme operating conditions, such as potholes or very low battery levels.

NOTE: If a traction controller handset is used for diagnostics, start truck in setup menu; then plug handset in and exit truck setup menu when handset has completed bootup process. Failure to follow these

steps may cause the truck to display a height encoder error. To clear the error, unplug handset, lift forks to 762 mm (30 in.), lower fully; then restart truck.

25

Contactor and Electrical Panel Checks

2200 SRM 933

Contactor and Electrical Panel Checks WARNING Do not operate a lift truck that needs adjustment or repairs. Report the need for adjustment or repairs immediately. If adjustment or repair is necessary, put a DO NOT OPERATE tag on the instrument panel. Remove the key from the key switch.

WARNING Some of the checks are done with the battery connected. Never have any metal on your fingers, arms, or neck. These metal items can accidentally make an electrical connection and cause a personal injury.

Fuses

Circuit

Rating

FU-5

APS Power

15A

FU-6

APS Power

15A

FU-7

MCU, LS3, WGU and Indicator

5A

Power for the APS steering motor controller is supplied by fuses FU-5 and FU-6. They are wired in parallel to provide 30 amps to the controller so that if one blows, the other may too. Without this current, the controller will be disabled. The MCU will sense that steering controller is disabled and will not allow the drive motor to work.

CAUTION Correct multimeter polarity is necessary for some checks. Meter positive is indicated as (+).

Meter negative is indicated as ( ).

Use a multimeter with a minimum rating of 20,000 ohms per volt to make measurements. Most digital voltmeters are acceptable.

NOTE: To perform the following component tests or to replace any of the components, the drive unit compartment doors must be opened and the drive unit compartment cover must be removed.

FUSES All the fuses are located in the electrical compartment. See Figure 2. Remove cover over electrical compartment for access. The condition of some fuses can be checked by looking at them. Other fuses do not change in looks and must be checked with an ohmmeter to determine continuity. Disconnect battery before checking fuses.

All fuses are on the contactor panel. Ratings of the fuses are as follows: Fuses

Circuit

Rating

FU-1

Traction

300A

FU-2

Pump

300A

FU-3

Start Circuit

5A

FU-4

Operator Compartment Light Fan and Flashing Light

15A

26

Figure 2. Fuse Locations

CONTACTORS General The contactor uses a low-amperage current to energize a magnetic coil. This coil then creates a magnetic force that draws the contact arms together, closing the circuit for the high-amperage current, allowing it to flow through the contactor.

With the ignition switch turned OFF, the main contactor has only the battery negative voltage applied.

When the ignition switch is turned ON, battery positive voltage is applied and the contactor is activated.

2200 SRM 933 After the ignition switch is turned ON, the traction contactor and the lift pump contactor have battery positive voltage applied to their high side. They are activated by a low signal from the controller.

Contactor and Electrical Panel Checks sensitive). Compare ohm reading against ohm value for the type contactor. Use the highest rating. See Coil Resistance.

Table 2. Coil Resistance

Test WARNING Parts of this procedure require working on the truck with full electric current present.

To prevent personal injury or property damage, do not wear a watch, rings, or jewelry while working around the contactor panel.

Whenever manually closing a contactor with the power connected, use a properly insulated tool.

Device

Location

24v Coil Resistance @ 21 C (70 F)

36v Coil Resistance @ 21 C (70 F)

Notes

Truck main contactor

Contactor panel

44 ohms ±8 ohms

103 ohms ±8 ohms

Test coil both ways.

Use highest reading.

Traction contactor

Contactor panel

44 ohms ±8 ohms

103 ohms ±8 ohms

Test coil both ways.

Use highest reading.

Lift pump contactor

Contactor panel

17 ohms ±4 ohms

35 ohms ±4 ohms

4. Check for battery voltage at contactor coil.

No voltage: Open circuit in control circuit wiring to contactor.

Low voltage: High resistance in control circuit wiring to contactor.

Full battery voltage: No problem with control circuit. Problem is probably in contactor. Proceed with test.

Test coil both ways.

Use highest reading.

Lower solenoid valve

On pump assembly

40 ohms ±10 ohms

64 ohms ±10 ohms

Test coil both ways.

Use highest reading.

5. Check at the contactor for loose, broken, or corroded connections.

Start relay

Under dash cover near key switch

360 ohms ±65 ohms

360 ohms ±65 ohms

Terminals 85 and 86 are the coil.

Brake

On top of drive motor

17 ohms ±4 ohms

27 ohms ±4 ohms

1. Check condition of battery. If it is not fully charged, recharge or replace battery with a fully charged battery before continuing.

2. Raise drive wheel of truck so it is clear of the floor. Block chassis in this position and remove lifting device.

3. Visually check to see if contactor closes when circuit is energized. If contactor closes, proceed to Step 5. If contactor does not close, proceed to Step 4.

6. Visually check the condition of the tips for pitting, burning, or wear.

7. Check ohm value of contactor coil. Disconnect leads from one side of the coil and connect an ohmmeter across coil. Reverse ohmmeter leads and check in the opposite polarity (since spike suppressors on some coils make them polarity

27

Contactor and Electrical Panel Checks

2200 SRM 933

Tips When replacing tips, make sure the new tips have the same ampere carrying capacity and are direct replacements for the original tips.

A high-voltage drop (2 volts or more) across the tips indicates poor contact or high resistance. Check for burned or worn tips, incorrect size or mismatched tips, and proper gap settings when open.

Disassemble and Assemble WARNING Disconnect the battery and separate the connector before opening the drive unit and compartment and inspecting or repairing the electrical system. If a tool causes a short circuit, the high-current flow from the battery can cause a personal injury or property damage.

NOTE: If both the contacts and coil of a contactor will be replaced, replace the complete contactor as described in Replacing the Contactor. Do only the parts of the procedure necessary to replace the defective parts being replaced.

NOTE: All of the contacts for each contactor must be replaced at the same time if any contact requires replacement.

The contactor contacts are made of special silver alloy. The contacts may look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. Replace contacts when the silver alloy is worn away to the base support metal. Replace contactor parts as follows: 1. Make an identification of the buss bars for correct installation. Remove nuts that fasten fixed contacts.

2. Remove two screws that fasten covers for each contactor. See Figure 3. Remove cover of each contactor. Do NOT lose plunger springs.

1.

2.

3.

4.

FIXED CONTACT MOVING CONTACT TOP COVER SCREW - TOP COVER

5. RETURN SPRING 6. COIL AND FRAME 7. END CAP

3. Replace two fixed contacts in contactor covers.

Figure 3. Contactor

28

2200 SRM 933 4. Remove plunger assembly and movable contact and replace fixed contact bar. Replace contact of plungers.

5. If a coil will be replaced, remove cover base.

Remove screws that fasten coil frame to mount bracket. Remove coil and frame. Remove bushing part of plunger and armature cap from coil.

Install these parts on the replacement coil.

Traction Throttle Sensor Removal and Installation 6. Install coil and frame on mount bracket.

7. Install cover base, fixed contact bar, and plunger on coil frame. Make sure spring is on plunger.

8. Install covers and electrical bars on covers as removed during disassembly.

9. Install contactor assemblies on the lift truck.

Traction Throttle Sensor Removal and Installation WARNING The operator platform can move abruptly and can cause personal injury when any lift or lower buttons are accidently pushed. Fully lower the operator platform and remove the key from the key switch, disconnect the battery, and install a DO NOT OPERATE tag on the instrument panel.

WARNING The traction throttle sensor is a Hall effect device. The sensor provides a voltage output ratio (typically 5 volts) as a function of mechanical angle to the shaft as it rotates. The sensor operates on low supply voltage and is limited to short mechanical angles, requiring less than 180-degree rotation.

1. Disconnect battery.

2. Remove four capscrews that fasten console panel cover.

3. Disconnect electrical plug.

4. Remove nut that holds sensor on bracket. See Figure 4.

5. Install new sensor into opening of bracket support. Align sensor on bracket and tighten nut.

6. Connect electrical plug.

7. Install instrument panel cover on cowl.

8. Reconnect the battery.

9. Go to the Setup Instructions.

WARNING Disconnect the battery connector to prevent operation of the hydraulic system or electrical shock and possible injury.

29

Traction Throttle Sensor Removal and Installation

1.

2.

3.

4.

5.

6.

7.

8.

SUPPORT BRACKET BRACKET ASSEMBLY BUTTON HEAD SCREW NYLON BEARING SHAFT CONTROL HANDLE WASHER SPACER ROLL PIN

9.

10.

11.

12.

13.

14.

15.

16.

RETURN SPRING THREADED STANDOFF SCREW WASHER HALL EFFECT SENSOR CAM ASSEMBLY CAPSCREW BUSHING

2200 SRM 933

17. HALL EFFECT SENSOR BRACKET 18. SCREW 19. RUBBER GROMMET 20. NUT 21. SETSCREW 22. HANDLE BODY

Figure 4. Control Handle Mechanism

30

2200 SRM 933

Steering Indicator Gauge

Instrument Panel Removal and Installation 3. Remove four screws that fasten instrument panel to console.

WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

4. Align instrument panel on console and install capscrews.

5. Install instrument panel cover.

6. Connect battery.

1. Disconnect battery.

2. Remove four capscrews that fasten console panel cover.

Key Switch Removal and Installation REMOVE

INSTALL

1. Move lift truck to a safe area.

1. Connect wires to proper terminals.

2. Block drive wheel to prevent truck from rolling.

2. Mount key switch in bracket.

3. Disconnect battery connectors and turn key switch to OFF position.

3. Install nut to retain key switch. Make certain switch is properly aligned before tightening retaining nut.

See Instrument 4. Remove instrument panel.

Panel Removal and Installation.

5. Remove cover.

6. Discharge the capacitors inside the controller.

7. Remove nut retaining key switch to bracket.

4. Install instrument panel. See Instrument Panel Removal and Installation.

5. Connect battery connectors.

6. Test key switch by turning it ON and OFF. 7. Install cover.

8. Remove key switch.

9. Identify and disconnect electrical wires to switch.

Steering Indicator Gauge TEST The steering indicator gauge can be tested using the schematics. See Diagrams 8000 SRM 923.

REMOVE AND INSTALL 1. Remove instrument panel. See Panel Removal and Installation.

3. Remove nuts and lockwashers retaining indicator gauge to instrument panel.

4. Install gauge on instrument panel. Make certain gauge is properly aligned.

5. Install wires on proper terminals.

Instrument 6. Install instrument panel. See Instrument Panel Removal and Installation.

2. Identify and disconnect wires.

31

Foot Switch Removal and Installation

2200 SRM 933

Spy Glass Removal and Installation 1. Disconnect 8-pin plug.

2. Remove hex nuts and washers holding retaining bracket. Remove bracket and gauge from instrument panel.

3. Install gauge in instrument panel by reversing the order of removal.

4. Reconnect 8-pin plug.

Foot Switch Removal and Installation 1. Remove nut from bottom of foot switch assembly.

See Figure 5.

3. Remove screws that fasten switch in housing and remove switch.

2. Unplug Molex™ switch so wires can be removed and connected during installation.

4. Install new switch and wire connector. Install screw at bottom of plate and connect connector.

1. FOOT SWITCH ASSEMBLY

2. MOLEX™ CONNECTOR Figure 5. Foot Switch

32

2200 SRM 933

Slack Chain Switch Removal and Installation

Slack Chain Switch Removal and Installation WARNING To replace the loose chain switches, the operator platform must be raised to provide access. The lowering of the operator platform can cause an injury. The operator platform must have a support or a chain to prevent the operator platform from lowering.

5. Install replacement switch on bracket. Attach switch to switch bracket. Adjust switch to provide proper contact of cam to chain anchor. Repeat operation for second switch.

6. Connect wires to switch terminals as marked during removal.

The loose chain switches are at the chain anchors on the mast side of the operator platform. See Figure 6.

1. Raise operator platform for access to loose chain switches. Block operator platform or use chains to prevent operator platform from lowering. The chains must be fastened to the operator platform and to a part of the mast that cannot move.

WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

2. Disconnect battery.

3. Install labels on wires for correct connection during installation. Remove wires from switch terminals.

1. SWITCH BRACKET 2. SWITCH

3. CHAIN ANCHOR

Figure 6. Loose Chain Switch

4. Remove nuts that fasten switches to bracket and remove switches.

33

Drive and Hydraulic Pump Motors

2200 SRM 933

Limit Switch Removal and Installation WARNING The operator platform can move abruptly and cause an injury when any lift or lower buttons are accidentally pushed. Fully lower the operator platform, Remove the key from the key switch and install a DO NOT OPERATE tag on the instrument panel.

6. When installing limit switch, the distance between target and sensor should be 14 mm (0.55 in.).

1. Raise and block mast and operator platform high enough to gain access to the 24-inch limit switch located on a bracket welded to the bottom of the mast. See Figure 7.

2. Remove top cover and open compartment doors.

WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

3. Disconnect battery. Disconnect limit switch connector.

4. Loosen and remove nut retaining switch on front of bracket. Remove switch from bracket.

5. Reverse above procedure to assemble and install.

Figure 7. 24-Inch Limit Switch

Drive and Hydraulic Pump Motors ROUTINE PREVENTIVE MAINTENANCE WARNING Compressed air can move particles and cause injury to the user or to other personnel. Make sure compressed air path is away from all personnel. Wear eye protection.

CAUTION

3. Check bearings for retention of lubricant.

4. Check to make sure pole pieces are tight.

5. Inspect brushes. Brushes must be replaced when they are worn to one-half their original length. When replacing brushes, make certain ALL brushes are changed and properly seated.

Brushes must be able to move freely. Make sure they are not too tight in the brush holders.

Make sure motor covers, if used, are replaced before operating truck.

6. Visually inspect the commutator. Commutator should be smooth, with a chocolate brown color.

1. Periodically blow out all motors with clean, dry compressed air.

7. When ordering motor parts, be sure to state both model and serial numbers of truck, model number of motor, and voltage.

2. Check for oil or dirt in motor.

34

2200 SRM 933

Drive and Hydraulic Pump Motors

Preventive maintenance on electric motors is recommended to be performed at 200-hour intervals under normal operating conditions.

present, the motor should be disassembled and the individual parts washed in a suitable cleaning solvent.

Under heavy-duty, dusty, and dirty conditions, preventive maintenance on electric motors must be performed more frequently, depending on the conditions and the environment in which the electric truck is running.

CONNECTIONS

Proper electric motor preventive maintenance will aid in detecting many problems before they become serious.

Maximum performance from electric motors and reduced maintenance costs can be obtained by performing the following periodic preventive maintenance checks on motors that are in the truck.

Preventive Maintenance Checks WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

1. Disconnect battery while checking electrical connection.

2. Open cover for access to drive motor.

Check every screw, bolt, and nut for tightness. Especially check pigtails of the brushes, brush holders, power lead connections, and field jumper connections.

DISCOLORATION AND BURN MARKS Discoloration and burn marks usually indicate the motor or certain components of the motor have been overheated, normally due to stalled conditions, loose connections, insulation breakdown, or contamination. If signs of overheating are present, determine the cause and perform necessary repairs. The commutator should be smooth, free of burn marks, and have a chocolate brown color. Inspect brushes, brush holders, brush springs, and insulation for discoloration.

BRUSHES Brushes should be inspected to make certain they are not worn to less than one-half original length; see DC Motor Maintenance 620 SRM 294. The brushes must be free to move in the brush holders and should not have too much clearance. Check brush springs for proper tension. If brushes have to be replaced, use only specified brushes for a specific motor.

3. Open cover for access to hydraulic pump motor.

CLEANLINESS WARNING Compressed air can move particles and cause injury to the user or to other personnel. Make sure compressed air path is away from all personnel. Wear eye protection.

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions.

Electric motors must be kept clean and dry internally and externally and must be free of dust, dirt, grease, oil, chemicals, moisture, water, carbon dust, and metallic chips. Blow off contamination with compressed air. If internal oil or grease contamination is

SHORT IN ARMATURE A shorted armature or coils will increase the current draw. A visual inspection of the commutator will show burn marks on the commutator bars connected to the shorted coil or coils.

COMMUTATOR Check that carbon dust and other foreign matter is not caked on the undercut mica between the copper bars.

The mica separators should be below the segment face. There should not be any thrown solder from the armature risers. Check that brazed connections are not loose.

35

Causes of Motor Failure

2200 SRM 933

If grease, oil, or corrosive materials are present, wipe clean with a cloth, wash with soap and water, and dry or blow dry surface. Clean up the surface of the commutator with a commercially available commutator stone if necessary. Take the necessary steps to prevent reappearance.

seals. Only original equipment sealed bearings with high-temperature lubricants should be used if replacement is required. Do not be misled by identifying numbers on the bearings. The high-temperature lubricant is not specified in the identification number.

BEARINGS Check bearings for noise and rough spots while armature is rotating. Inspect bearings for damaged

Causes of Motor Failure OVERLOAD Motors have a specific rating of voltage and current at which they are designed to operate. Should a motor be subjected to a severe overload for substantial periods of time, overheating will result. Pushing loads, working on ramps of too steep a grade, and attempting to lift loads greater than the capacity of the truck are just a few overload conditions. The end result of this overheating is the throwing out of solder in the commutator riser and bearing failure due to excessive heat. Also, thrown or lifted commutator bars or insulation breakdown may occur.

SHOCK LOADING Shock loading can result from severe (stiff) plugging of the drive motor. This will cause excessive current draw, as the motor at the time of plugging is at stall point. Breaking of the armature shaft could result from severe plugging.

SHORT IN FIELD COILS A short in the field coil or coils causes excessive current draw, again resulting in too much heat. When the truck runs faster than normal, but with little or no torque, it is an indication of a short in the field coils.

SHORT BRUSHES Short brushes cause arcing on the commutator and excessive heat. In addition to brush replacement, turning and undercutting of the commutator may be

36

all that is required, provided the damage is not too great. Check for damage from shunts hitting the commutator.

HIGH OR LOW COMMUTATOR BAR When one of the bars is protruding above or lying below the normal diameter of the commutator, the result is excessive brush wear and arcing of the brushes. Usually a clicking sound will be heard when the armature is rotating.

OPEN CIRCUIT An open circuit in the field or armature coils of the motor.

LOW BATTERY VOLTAGE Low voltage causes excessive current draw and increased heating. Also, accelerated brush wear may occur.

ECCENTRICITY OF COMMUTATOR Eccentricity of commutator causes rapid brush wear, excessive sparking of brushes, and increased heating.

OVERSPEEDING Overspeeding of the motor by pushing or towing of the truck at more than 5 mph will result in failure of the armature.

2200 SRM 933

Motor Tests

Motor Tests When testing electric motors for grounds and shorts in the truck, disconnect all armature and field leads from the motor. Use an ohmmeter, RX 10 or RX 100 scale, to check for grounds or shorts in the motor.

The ohmmeter should indicate: 1. A closed circuit between armature terminals.

2. A closed circuit between field terminals.

3. Infinity between motor housing and armature terminals, with meter on high-resistance scale.

4. Infinity between armature and field terminals.

EXCESSIVE CURRENT DRAW Excessive current draw is usually caused by shorts in the system allowing current to follow paths that are not intended. Sometimes excessive current draw can be caused by mechanical malfunctions such as worn bearings, misaligned parts, improper lubrication, and brake adjustments. Other factors include operator misuse such as operating on steep grades, overloading the truck, and pushing loads. The condition of the battery can contribute greatly to excessive current draw. When the battery charge and voltage are low, more current is needed to perform the same task. Since the power required to move a load is Power = Volts × Amperage, as the battery voltage goes down, the amperage must increase to maintain power.

MEASURING CURRENT DRAW When troubleshooting the electrical system of a battery-powered industrial truck, you will need to know the specified current draw of the motor being tested as well as the actual current draw during the test.

If a motor draws too much current, excessive heat is created, resulting in damage to the commutator, brushes, armature, and related components.

A motor drawing excessive current can usually be identified by two dark burn marks on the commutator 90 degrees or 180 degrees apart. If a motor draws too much current due to excessive ramp operation, pushing loads, or being stalled, heat damage will occur.

Current draw is measured with a shunt-type ammeter in series with the motor. The meter should be capable of reading 600 amps. A 600-ampere shunt meter suitable for this purpose is available through your Hyster dealer. Since current draw is measured with the shunt meter wired in series with the motor circuit, you must break the circuit to insert the meter. This will require disconnecting the main power cable to the motor and connecting the meter in line at this point. In most cases, this will require the use of a jumper cable between the meter and the truck terminal post. This jumper should be made from the same type and gauge cable as the power cable it is replacing and should be kept as short as practical.

Current draw may also be measured using the on-board diagnostics. Refer to Setup Instructions.

EXCESSIVE RESISTANCE Excessive resistance is usually caused by loose or corroded terminal connections, poor solder joints, and dirty or corroded contacts. Incorrectly sized wiring and poor crimp connections of terminals can also cause excessive resistance.

When too much resistance exists in a circuit, overheating and sluggish or erratic operation will occur.

BRUSH SPRINGS The brush springs should be inspected. If the springs are found to be broken or discolored, they must be replaced. Be certain to replace the springs with the recommended spring listed in the parts manual.

37

Drive Motor

2200 SRM 933

Drive Motor INSPECT 1. Check commutator for grounds, shorts, or uneven wear.

2. Check bearings; replace if worn or damaged.

3. Check field coils.

4. Check brush holder/assembly.

5. Replace lock nut on commutator end of armature shaft.

PREPARATION OF DRIVE MOTOR COMMUTATOR To ensure the best possible operation from newly fitted brushes, the commutator should be in good condition.

3. Undercut the mica using one of the several types of undercutting tools available on the market.

See Figure 8. Undercutting is usually done to a depth of 1.1938 mm (0.047 in.). It is recommended to slightly bevel the segment corners.

WARNING Compressed air can move particles and cause injury to the user or to other personnel. Make sure compressed air path is away from all personnel. Wear eye protection.

4. A commutator that is badly grooved should be ground or turned the same as for roughness or eccentricity. After the commutator has been conditioned, make sure it is completely cleaned out by suction (preferred) or by blowing out with clean, dry compressed air.

Check commutator for: • Dirt or other foreign matter • Eccentricity: 0.05 mm (0.002 in.) max runout from shaft motors up to 185.7 mm (7.311 in.) diameter 0.08 mm (0.003 in.) max runout from shaft - motors larger than 185.7 mm (7.311 in.) diameter • High or low bars, roughness, or burning • High mica • Grooving of commutator If any of the above conditions exist, they should be remedied as follows: 1. Clean commutator by holding a piece of dry canvas or other hard nonlinting material, which is wound around and securely fastened to a piece of wood, against the commutator.

2. If the eccentricity or roughness is not too great, it may be possible to polish the commutator with one of several varieties of dressing stones available on the market. Before stoning, clean grease and oil from commutator using a cloth saturated with a suitable solution. After stoning, the commutator should be smoothed with a very fine grade of sandpaper, and then polished by using the back of the paper. When the commutator is too rough or eccentric to be stoned, it is advisable to turn the commutator on a lathe.

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A. RIGHT WAY USING UNDERCUTTING TOOL REMOVES ALL TRACES OF INSULATOR ALONG THE CONDUCTING SLOTS. B. WRONG WAY USING HACKSAW MAY LEAVE RIDGES OF INSULATOR ALONG THE EDGES OF THE CONDUCTING SLOTS, CAUSING ARCING, CHATTER, AND RAPID BRUSH WEAR. 1. CONDUCTOR

2. INSULATOR

Figure 8. Undercutting Commutator

2200 SRM 933

Drive Motor Brush and Brush Holder

Fitting Motor Brushes (Motor Removed) 1. Care taken to ensure the best possible commutator and brush running conditions, mechanical and otherwise, will pay dividends along improved commutation.

2. Brushes of different qualities should never be run together on the same commutator. Using brushes of improper compound, or brushes other than those originally specified and manufactured for a specific motor, will cause commutator damage.

3. Before installing brushes, inspect the brush holders inside and out for burned spots. Make sure the brush pigtails are properly secured in the brushes and the brushes move freely in the brush holders.

4. Fit new brushes to the commutator surface by using a strip of fine sandpaper placed between the face of the brush and the commutator (sand surface against brush). Use several strokes of the

sandpaper, pulled in the direction the commutator rotates with the forward direction of the truck (drive motor), and in the direction in which the commutator rotates while hoisting (hoist pump motor). Only the pressure of the brush should be on the sandpaper when it is fitted in this matter.

Make sure that the complete surface of the brush rides on the cleaned-up surface of the commutator.

WARNING Compressed air can move particles and cause injury to the user or to other personnel. Make sure compressed air path is away from all personnel. Wear eye protection.

5. Following the installation of new brushes, the motor should be blown out with clean, dry compressed air.

Drive Motor Brush and Brush Holder DRIVE MOTOR BRUSH, REMOVE AND INSTALL (MOTOR INSTALLED) WARNING

DRIVE MOTOR BRUSH HOLDER, REMOVE AND INSTALL (MOTOR INSTALLED) WARNING

Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

1. Disconnect battery and open drive unit compartment door.

1. Disconnect battery and open drive unit compartment door.

2. Remove screws securing motor cover plates, if equipped.

2. Remove brush assemblies. Refer to Drive Motor Brush, Remove and Install (Motor Installed).

3. Note position of brush and wire assemblies before removing. When installing brush set, be certain to place brush set and wires in same position as removed.

3. Scribe motor field ring housing and commutator end head to make certain end head is installed in same position as removed.

4. Loosen screw and washer securing brush wire to terminal. Remove brush springs and brush set.

5. Reverse above to install. Refer to Fitting Motor Brushes (Motor Removed).

4. Tag and disconnect drive motor wires from terminals on end head.

5. Remove hex head screws securing end head to field ring.

6. Remove end head assembly.

39

Drive Motor Disassembly and Assembly

2200 SRM 933

NOTE: It may be necessary to use a puller to start the end head off the bearing when removing. Do not force, or damage to the end head may result.

8. Reverse above to install. Be sure the new brush holders are rigid, not sloppy, and there are no loose rivets.

7. Remove screws securing brush holder assembly to end head. Inspect all parts for wear or damage and replace when necessary.

NOTE: Do not force end head on when installing.

Lightly tap using a plastic hammer.

Drive Motor Disassembly and Assembly WARNING

WARNING

Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

CAUTION Be sure to cover the drive unit opening so debris does not enter it.

1. Disconnect battery.

2. Open drive unit compartment.

3. Tag and disconnect power cables to motor and wires to electric brake and drive motor.

4. Remove bolts mounting motor to drive unit.

To prevent serious personal injury and possible damage to components, be very careful when using lifting devices during service and maintenance procedures • Inspect to make sure that neither lifting strap is damaged • Do not subject lifting loops or lifting straps to any shock or drop loading 5. Remove drive motor with brake assembly in place using a sling and proper lifting equipment.

Refer to manual for brake disassembly. See Electric Brake 1800 SRM 761.

6. Clean and punch-mark (or scribe) brake assembly, drive and commutator end heads, and motor field ring housing to simplify assembly of the motor.

7. Remove brushes and brush spring assemblies.

See Figure 9.

Legend for Figure 9 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

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FIELD RING FIELD COIL FIELD COIL FIELD COIL FIELD COIL SPLICE CONNECTOR SCREW POLE PIECE COMMUTATOR END HEAD BRUSH HOLDER SCREW SCREW

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

TERMINAL LEAD INSULATOR TERMINAL INSULATOR TERMINAL LOCKWASHER WASHER NUT BRUSH ASSEMBLY SCREW NUT WASHER WASHER INSULATOR TERMINAL

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

ARMATURE ASSEMBLY PINION END HEAD RETAINING RING BEARING LOCKWASHER LOCKWASHER SPRING SCREW WAVE SPRING BEARING SNAP RING OIL SEAL

2200 SRM 933

Drive Motor Disassembly and Assembly

Figure 9. Drive Motor

41

Hoist Pump Motors

2200 SRM 933

8. Remove elastic stopnut and gear and shims, if necessary, using a socket and impact wrench.

NOTE: When same motor pinion or gear is used, replace shim or shims in same position as removed.

When a new gear set is used, refer to Drive Unit for gear setting. See Master Drive Unit 630 SRM 283.

9. Remove screws securing commutator end head.

Remove end head. It may be necessary to use a puller to remove the end head. Do not apply force, or damage to the end head may result.

10. Remove screws securing drive end head. Tap end head loose using a plastic hammer and remove, complete with armature.

CAUTION

CAUTION Do not force, or damage to the end head may result.

12. Separate drive end head from armature. The bearing end head will come off with the bearing.

It may be necessary to use a puller to remove.

13. Remove screws securing brush holder assembly to commutator end head. Remove brush holder assembly.

14. Remove bearings from end heads if necessary.

15. Replace field coils when necessary. Refer to Drive Motor, Inspect.

16. Install bearing on shaft.

Be extremely careful not to damage the field coils, pole pieces, or armature when removing.

11. Remove oil seal and outer snap ring retaining armature shaft. Remove inner snap ring retaining end head.

17. Install snap ring into slot provided in armature shaft.

18. Continue to assemble motor in the reverse steps of the disassembly. Install new elastic stopnut to secure motor pinion gear.

19. Reverse the procedure to install the drive motor.

Hoist Pump Motors MAINTENANCE INSTRUCTIONS Vendor-supplied pump motors are generally used where smaller pump requirements are found. Typical vendor-supplied motors include those from General Electric™, Ohio Motor™, etc. Service requirements are similar for all DC motors, but several differences should be observed.

1. Some vendor-supplied motors require removal of the commutator end head to replace the brushes (see following procedure).

2. Many vendor-supplied motors have an integral cooling fan on the armature shaft. This means that the armature can only be removed through the drive end of the motor, since the fan would interfere with the field coils if you try to remove it through the commutator end.

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CAUTION Do not attempt to press the armature shaft out of the armature on vendor-supplied motors without first checking your service parts manual.

3. Some motors do not have a separate serviceable armature shaft, and attempting to press the shaft out will destroy the armature.

CAUTION Never run a pump motor for more than a few seconds without the pump attached and connected.

4. Series-wound DC motors, without a load, may accelerate beyond their designed maximum rpm, at which point they will self-destruct.

2200 SRM 933

Hoist Pump Motors

GENERAL INFORMATION

HOIST MOTOR

1. Lubrication - Prelubricated ball bearings are supplied. Replace only with original equipment.

Press only on the inner race when installing bearings on the shaft.

Remove and Install

2. Motor brushes need periodic inspection and replacement. Brush wear is greatly influenced by individual application, so it is recommended the brush wear be checked often to determine future required inspections. When the brushes are worn to half their original length, they should be replaced.

3. If mechanical or electrical failure occurs, first check for proper electrical connections, fusing, or unusual binding of the shaft. Starting and accelerating torques of DC motors are considerably higher than the full load torque of the motor. Care should be taken to prevent damage to driven machinery as a result of the higher starting and accelerating torques. Perform motor tests as outlined in this section.

BRUSH REPLACEMENT WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

1. Disconnect battery. Open drive unit compartment doors. Remove drive unit compartment top cover.

2. Remove cover from commutator end head.

3. Remove brush springs and brushes.

4. Inspect brushes for excessive wear.

WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

1. Disconnect battery.

2. Remove pump mounting bolts.

3. Move hoist pump away from motor.

4. Identify and remove power cables.

5. Remove four hex head screws securing hoist motor to truck frame.

6. Reverse the above steps to install motor.

Disassemble and Assemble 1. Punch-mark end heads and frame to ensure correct placement of end heads when reassembling motor.

2. Loosen screw securing cover band and slide off band.

3. Remove brush springs and brushes. See Figure 10.

4. Remove two screws and nuts securing stator and commutator end head together. Remove capscrews and nuts retaining drive end head and commutator end head to stator. Carefully remove commutator end head. Remove brush ring and brushes.

5. Remove drive end head. Remove armature from stator.

5. Reverse above steps to assemble.

CAUTION Be extremely careful not to damage the field coils, pole pieces, or armature when removing.

6. If the field coil must be replaced, remove pole shoe screws and terminal screws, if necessary, and remove field coils.

43

Hoist Pump Motors

2200 SRM 933

7. Inspect all components and brushes. Replace as necessary. Refer to Brush Replacement in this section.

WARNING

sure compressed air path is away from all personnel. Wear eye protection.

8. Using compressed air, blow out motor. Thoroughly clean and replace any worn parts.

Compressed air can move particles and cause injury to the user or to other personnel. Make

9. Reverse steps above to assemble. Make sure armature turns freely.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

DRIVE END HEAD BEARING SNAP RING FIELD COIL KIT FAN ARMATURE ASSEMBLY BRUSH

BRUSH SPRING BRUSH BOX AND PLATE LEAD ARM KIT BEARING WAVY WASHER COMMUTATOR END HEAD BRUSH COVER PLATE

Figure 10. Hoist Pump Motor Parts

44

2200 SRM 933

Height Encoder Troubleshooting

Height Encoder Troubleshooting DESCRIPTION

HEIGHT ENCODER DIAGNOSTICS

This section is to help the technician to accurately and quickly diagnose height encoder problems and to return the truck to service as quickly as possible.

1. Go to Diagnostics Display - Enc Crnt. Unplug the encoder at pin-4 connector 20 on the operator’s console. The reading should drop approximately 150 units for square shaped encoders and approximately 100 units for round shaped encoders. If there is no drop, ensure the violet and tan wires on the encoder is getting 5 volts.

The height encoder operates in conjunction with other components to reduce speed in the truck when the platform is raised and/or the MDU (Master Drive Unit) is turned 10 degrees to one side. Speed reduction problems can result from faulty or mis-adjusted components other than the height encoder.

SYMPTOMS 1. Truck operates at low speed only.

NOTE: When normally operating the truck, the speed reduction system gradually reduces the speed when the forks are raised above 60 inches and the MDU is straight ahead.

2. No speed reduction at elevated heights.

3. Truck shuts down giving codes 7392, 7394, 739A, 739B, or 739C. 4. Truck shuts down when operating.

2. Go to Diagnostics Display - Lift Hgt. The system will display what it thinks is the height of forks above the floor in inches. This value resets to 24 inches when the mast proximity switch is crossed. When the platform is raised or lowered, the display will read higher or lower.

SYMPTOMS AND RECOMMENDATIONS Symptom

Recommendations

Faulty wiring between the 1310 controller and the height encoder.

Check all pins for open or intermittent faults.

Encoder shaft not attached to the chain sheave bracket.

Install the encoder shaft to the chain sheave bracket with two capscrews. Apply Loctite to capscrews after they are tight.

No voltage to the encoder.

Check the wiring.

Dead encoder channel(s).

Check for bad wiring and connections.

Low battery.

Replace battery if indicator shows low battery. If indicator shows charged battery, the 1310 controller needs to be calibrated.

24" MAST PROXIMITY SWITCH DIAGNOSTICS Go to Diagnostics Display - 1243Inpt. The section at the far right represents the mast proximity switch. It should change from 1 to 0 when the proximity switch is crossed at a fork height of about 24 inches. The LED on the back of the switch can also be observed. If the switch does not change when the 24 inch height is crossed, the proximity switch may be adjusted to far from the target. It must be within 3.10 mm (0.12 in.).

45

Steer Encoder Troubleshooting

TRAVEL SPEED REDUCTION The travel speed reduction system uses information from the encoder and the 24" proximity switch to reduce maximum speed when the platform is raised and/or the MDU is turned 10 degrees in either direction. When the MDU is straight ahead, maximum speed is gradually reduced above a fork height of 60 inches. The following is a way to check for proper functioning of the speed reduction system: NOTE: There is no speed reduction if the platform is below 24 inches and the MDU is turned beyond 10 degrees. Travel speed is cut in half if the MDU is turned and the platform is between 24 and 60 inches.

Travel will be disabled if the platform is above 60 inches and the MDU is turned.

1. Lower the platform fully, and go to Diagnostic Display - Lift Hgt. The display will read approximately 4 inches.

2. Raise the platform above the travel cut-out height.

• 150 inches for small chassis order pickers • 212 inches for large chassis order pickers • 272 inches for straddle and furniture trucks

2200 SRM 933 3. The reading on the display will indicate the approximate height of the forks.

4. If the reading is accurate, move the truck forward or backward. Travel should be deactivated.

5. Lower the platform to just below the travel cutout height and try to move the truck again. The truck should move at a very slow speed.

6. Lower the platform to the following height: • 100 inches for small chassis order pickers • 135 inches for large chassis order pickers • 160 inches for straddle and furniture trucks 7. To restore full speed, lower the platform below 60 inches with the MDU straight ahead.

ADDITIONAL ENCODER CHECK The height encoder can be further checked by removing it from the mast and plugging it into the steer encoder and trying to turn the MDU with the height encoder and stepping on the foot switch. If the MDU will not turn, then the height encoder is the problem.

Steer Encoder Troubleshooting DESCRIPTION This section is to help the technician to accurately and quickly diagnose steering problems and to return the truck to service as quickly as possible.

46

The steer encoder operates in conjunction with other components in the steering system and also the truck’s control system. Steering problems can result from faulty or misadjusted components other than the steer encoder.

2200 SRM 933

Steer Encoder Troubleshooting

MDU PROXIMITY SWITCH ISSUES Symptom

Possible Cause

Action

MDU turns full right or full left on truck start up.

The steer centering proximity switch is not sensing the metal flag.

If LED on the back of proximity switch does not light when the switch detects the flag, either the wiring is defective or the proximity switch is defective.

The truck operates at reduced speed and displays "SteerErr" on the display when the MDU is turned to the full right position.

The steer centering proximity switch is sensing the MDU casting.

If the LED comes on when the MDU is turned to the full right position, the switch needs to be moved away from the MDU casting until the light no longer comes on. The proximity switch needs to be at least 0.25 in. from the MDU casting.

The truck operates at reduced speed and displays "SteerErr" on the display or shuts down completely when driving or turning left.

The steer centering proximity switch is not close enough to the flag.

The tip of the proximity switch must be within 0.12 in. of the flag.

STEERING SYSTEM ISSUES Symptom

Possible Cause

Action

Truck shuts down when driving and lifting.

Low battery

Replace battery if indicator shows low battery. If indicator shows charged battery, the 1310 controller needs to be calibrated.

Truck shuts down and displays code 5022 or the steer encoder is suspected to be bad.

Code 5022 is only for the APS’s steer motor encoder, which is integral to the steer motor. It will not be related to steer encoder in any way.

Check the wiring from the APS to the steer encoder (5 wires in a 6-pin AMP connector, between the steer motor and the APS). If code 5022 is repeated, replace APS.

HOW TO CHECK THE STEER ENCODER Go to Diagnostic Display - Enc Crnt. Unplug the encoder. If the reading does not drop by 150 to 175 units, check the red and black encoder wires for 5 volts. If the wires are receiving 5 volts, check the green and white encoder wires for 0 or 5 volts. Rotating the encoder shaft will alternate from 0 to 5 volts.

On Return to Center Steering systems, check that the proximity switch :LED is illuminating when the knob is in the centered position. If the LED is not lighting, the switch may not be adjusted properly or there is a wiring problem.

47

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

48

TECHNICAL PUBLICATIONS 2200 SRM 933

8/05 (9/04)(6/04)(2/04)(8/03)(3/02)(11/00) Printed in U.S.A.