SEM TRACTION MOTOR

CONTROLLER
N25XMDR3, N30-40XMR3 [C470];
N50XMA3 [C471]; N30XMDR3, N45XMR3 [G138];
N30XMXDR3, N45XMXR3 [B264]

PART NO. 1503627 2200 SRM 977

 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 Mainte-
nance 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!
SEM Traction Motor Controller Table of Contents

TABLE OF CONTENTS

SEM Traction Motor Controller ........................................................................................................................ 1

Description/Features ..................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Test ................................................................................................................................................................. 2
Install ............................................................................................................................................................. 2
1307 Programmer Handset ............................................................................................................................... 3
Description/Features ..................................................................................................................................... 3
SCROLL DISPLAY Keys............................................................................................................................... 4
CHANGE VALUE Keys................................................................................................................................. 4
MORE INFO Key........................................................................................................................................... 4
Operation ....................................................................................................................................................... 4
Connecting Handset to Traction Motor Controller.................................................................................. 4
Disconnecting Handset From Traction Motor Controller ....................................................................... 5
Programmer Self Test ............................................................................................................................... 5
Operating Modes............................................................................................................................................ 6
Program Menu........................................................................................................................................... 6
Test Menu .................................................................................................................................................. 6
Diagnostics Menu ...................................................................................................................................... 7
Diagnostic History..................................................................................................................................... 8
Special Program Menu.............................................................................................................................. 8
Programming the Traction Motor Controller - 1307 Handset ......................................................................... 8
1311 Programmer Handset ............................................................................................................................... 11
Description/Features ..................................................................................................................................... 11
Menu Navigation Key ............................................................................................................................... 11
Data Increase/Decrease Key ..................................................................................................................... 12
Bookmark Keys ......................................................................................................................................... 12
Operation ....................................................................................................................................................... 12
Connecting Handset to Traction Motor Controller.................................................................................. 12
Disconnecting the Handset From the Traction Motor Controller........................................................... 13
Main Menu Selections ................................................................................................................................... 13
Program Menu........................................................................................................................................... 13
Monitor Menu ............................................................................................................................................ 14
Faults Menu .............................................................................................................................................. 14
Functions menu ......................................................................................................................................... 15
Information Menu ..................................................................................................................................... 16
Programmer Setup Menu ......................................................................................................................... 16
Programming the Traction Motor Controller - 1311 Handset ......................................................................... 16
Troubleshooting.................................................................................................................................................. 17
Status LED Diagnostics ................................................................................................................................ 17
Diagnostics Menu .......................................................................................................................................... 18
Test Menu....................................................................................................................................................... 28

This section is for the following models:

N25XMDR3, N30-40XMR3 [C470];

N50XMA3 [C471];
N30XMDR3, N45XMR3 [G138];
N30XMXDR3, N45XMXR3 [B264]

©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 977
SEM Traction Motor Controller
DESCRIPTION/FEATURES
The Curtis Model 1244-4405 SEM Traction Motor
Controller uses a sophisticated microprocessor to
control the logic and operation of the controller, elim-
inating the need for forward and reverse contactors.
See Figure 1. The SEM motor controller operates
on the principle of controlling the motor field circuit
and the motor armature circuit in dependently. The
controller has many programmable features, in-
cluding acceleration rate, maximum speed, braking
current limit, and neutral braking current limit.
The operator can also select from three different
performance modes to customize the operation of
the truck to the application, as required. The SEM
controller includes a full range of features as well
as a diagnostic and setup capability for reliable
operation.
Figure 1. Traction Motor Controller
The Curtis Model 1307 Programmer Handset is used
to program and troubleshoot the traction motor con-
troller. Refer to 1307 Programmer Handset.
The traction motor controller communicates with the
dash display for selection of performance modes and
for diagnostic information. The performance mode
selection feature allows the operator to choose from
three different motor controller performance levels
by pushing a button on the dash display. The rate of
acceleration, maximum top speed, and braking rate
can be specifically assigned for each mode using the
programmer handset.
Simplified diagnostic information is communicated
to the dash display to alert the operator to adverse
SEM Traction Motor Controller
conditions such as controller over temperature, oper-
ator sequence error, or motor controller malfunction.
REMOVE
1. Move the lift truck to a safe, level area. Turn the
key switch to the OFF position and remove the
key. Put a DO NOT OPERATE tag on the con-
trol handle. Put blocks under the drive wheels to
keep the lift truck from moving. See the section
Periodic Maintenance 8000 SRM 578. Refer to
HOW TO PUT THE LIFT TRUCK ON BLOCKS.
WARNING
Disconnect the battery and separate the con-
nector before opening the compartment cover
or inspecting/repairing the electrical system.
If a tool causes a short circuit, the high cur-
rent flow from the battery can cause an injury
or parts damage.
2. Disconnect and separate the battery connector.
Remove the battery. See the section Periodic
Maintenance 8000 SRM 578. Refer to HOW TO
CHANGE THE BATTERY.
3. Remove the front and steer compartment covers
and the front operator cushion. See the section
Frame 100 SRM 975 for the removal procedures.
Refer to COVERS, PANELS, AND PLATES.
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
in the controller by connecting a load (such
as a contactor coil or a horn) across the con-
troller’s B+ and B terminals. DO NOT use a
screwdriver to discharge the traction motor
controller.
4. Discharge the controller by connecting a load
across terminals B+ and B .
1
SEM Traction Motor Controller
5. Unplug the connector from the traction motor
controller. Tag and disconnect the wires to the
power terminals.
6. Remove the capscrews, washers, and nuts re-
taining the controller to the frame. The cap-
screws are accessed from the battery compart-
ment. Carefully remove the traction motor con-
troller from the lift truck.
TEST
Refer to 1307 Programmer Handset for complete
testing and troubleshooting procedures for the Trac-
tion Motor Controller.
The traction motor controller cannot be repaired.
The traction motor controller is sealed and contains
no serviceable parts. If testing has determined the
traction motor controller to be faulty, it must be
replaced.
Figure 2. Traction Motor Controller Pin Arrangement
2
2200 SRM 977
INSTALL
1. Make certain that the mounting surface for the
traction motor controller is clean. There should
be no dirt between the frame and the traction mo-
tor controller. Align the traction motor controller
in the lift truck. Install the capscrews, washers,
and nuts to retain the controller to the frame.
The capscrews must be installed from the battery
compartment up through the controller.
2. Connect the power wires to the terminals. See
Figure 2. Plug the X-3 connector into the J1 re-
ceptacle of the traction motor controller. See the
section Diagrams 8000 SRM 690 for additional
information.
3. Refer to Programming the Traction Motor Con-
troller - 1307 Handset to set up the controller.
2200 SRM 977 1307 Programmer Handset

Legend for Figure 2

X-3 Pin 1: Key Switch Input X-3 Pin 13: Not Used
X-3 Pin 2: Brake Switch X-3 Pin 14: Throttle Reference Voltage
X-3 Pin 3: Drive Mode Select #2 Input X-3 Pin 15: 0-5 Volt Throttle Signal Input
X-3 Pin 4: Drive Mode Select #1 Input X-3 Pin 16: Not Used
X-3 Pin 5: Fault 2 Output X-3 Pin 17: Traction Coil Driver
X-3 Pin 6: Fault 1 Output X-3 Pin 18: Not Used
X-3 Pin 7: Not Used X-3 Pin 19: Not Used
X-3 Pin 8: Not Used X-3 Pin 20: Not Used
X-3 Pin 9: Key Switch Input (Coil Return) X-3 Pin 21: Not Used
X-3 Pin 10: Forward Signal Input X-3 Pin 22: Not Used
X-3 Pin 11: Reverse Signal Input X-3 Pin 23: Not Used
X-3 Pin 12: Not Used X-3 Pin 24: Not Used

1. CONNECT TO J1 2. PROGRAMMER HANDSET CONNECTION

1307 Programmer Handset

DESCRIPTION/FEATURES
The Programmer Handset is a hand-held tool that
allows the user to program, test, and diagnose the
Traction Motor Controller. See Figure 3. It has been
designed for ease of use with eight keys to control all
functions. A MORE INFO key is included to provide
more detail on any display item.

The programmer is powered by the controller. When

the programmer is plugged into the controller, it will
acquire all the controller function values and display
the model number, date of manufacture, and revision
code. After the initial display, the programmer will
prompt the user with further instructions.

Legend for Figure 3

1. FOUR-LINE LCD DISPLAY WINDOW
2. SELECTS PROGRAM MENU
3. SCROLLS DISPLAY UP AND DOWN
4. SELECTS MORE INFO, SPECIAL PROGRAM,
AND DIAGNOSTICS MENUS
5. SELECTS TEST MENU Figure 3. Curtis Model 1307 Programmer
6. SELECTS DIAGNOSTICS MENU
7. CHANGES VALUE OF SELECTED ITEM Handset

3
1307 Programmer Handset
The display window contains a four-line LCD dis-
play. This display is visible in most lighting condi-
tions. When the programmer is in the PROGRAM,
TEST, or DIAGNOSTICS mode, four lines of a menu
are displayed. The item at the top of the display win-
dow is the selected item (In the PROGRAM menu,
the selected item will be highlighted with a flashing
arrow.).
SCROLL DISPLAY KEYS
To scroll up and down within a menu, use the two
SCROLL DISPLAY arrow keys. The SCROLL DIS-
PLAY arrow keys can be pressed repeatedly or held
down. When a key is held down, the scrolling speed
increases the longer the key is held.
To the left of the PROGRAM, TEST, and DIAGNOS-
TICS menu, a small scroll bar is displayed. The scroll
bar gives a rough indication of the position of the
four displayed items within the entire menu. That is,
when the scroll bar is at the top of the window, the top
of the menu is displayed. When scrolling through the
menu, the bar will move downward. When the bar is
at the bottom, the end of the menu has been reached.
CHANGE VALUE KEYS
The CHANGE VALUE arrow keys increase or de-
crease the value of the selected menu item. There is
an LED on each arrow key to indicate when the key is
active and when a change is permissible. When the
LED is off, the limit setting (maximum or minimum)
of the function has been reached.
The CHANGE VALUE keys may be pressed repeat-
edly or held in the same manner as the SCROLL DIS-
PLAY keys. The longer the key is held, the faster
the value changes. This allows rapid changing of any
functions value.
MORE INFO KEY
The MORE INFO key is used to display additional
information about the selected item and to access the
SPECIAL PROGRAM MENU and the DIAGNOS-
TICS HISTORY MENU. When the programmer is
in any of the operating modes, the MORE INFO key
may be pressed to display additional information
about the selected item. Press the MORE INFO
key again to return to the original list. In the PRO-
GRAM menu, a bar graph is displayed along with
4
2200 SRM 977
the minimum and maximum values available for the
selected item. If the minimum or maximum value
has been programmed, a message replaces the bar
graph and any dependencies are listed.
OPERATION
Connecting Handset to Traction Motor
Controller
NOTE: Each time the programmer handset is
connected to the controller, it acquires all of the
controller function value settings and stores them
in its temporary memory. This allows the user to
revert back to the original settings at any time. The
SPECIAL PROGRAM menu selection RESET ALL
SETTINGS is used to revert to the original settings.
Any inadvertent change made to any of the function
values can be "undone" in this manner, as long as
the programmer has not been unplugged or the key
switch turned OFF (power disconnected).
1. Turn the key switch to the OFF position.
2. Disconnect and separate the battery connector.
3. Remove the front cover. See the section Frame
100 SRM 975 for the removal procedures. Refer
to COVERS, PANELS, AND PLATES.
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
in the controller by connecting a load (such
as a contactor coil or a horn) across the con-
troller’s B+ and B terminals. DO NOT use
a screwdriver to discharge the traction motor
controller.
4. Discharge the capacitors in the traction motor
controller by connecting a load (such as a contac-
tor coil or a horn) across the controller’s B+ and
B terminals.
2200 SRM 977
NOTE: The Programmer Handset should only be con-
nected and disconnected with the key switch in the
OFF position.
5. Connect the Programmer Handset to the 4-pin
Molex connector on the traction motor controller.
See Figure 2.
6. Reconnect the battery.
NOTE: The brake pedal must be released (up posi-
tion).
7. Turn the key switch to the ON position. Ensure
the battery disconnect switch is closed.
Disconnecting Handset From Traction
Motor Controller
1. Turn the key switch to the OFF position.
2. Disconnect and separate the battery connector.
3. Discharge the capacitors in the traction motor
controller by connecting a load (such as a contac-
tor coil or a horn) across the controller’s B+ and
B terminals.
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
Figure 4. Programmer Handset Self Test
1307 Programmer Handset
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
in the controller by connecting a load (such
as a contactor coil or a horn) across the con-
troller’s B+ and B terminals. DO NOT use
a screwdriver to discharge the traction motor
controller.
4. Disconnect the Programmer Handset from the
4-pin Molex connector on the traction motor con-
troller.
NOTE: The Programmer Handset should only be con-
nected and disconnected with the key switch in the
OFF position.
5. Install the front cover.
6. Reconnect the battery.
Programmer Self Test
You can test the programmer by displaying two spe-
cial test screens. Press and hold the MORE INFO
key while the programmer is powering up. During
the SELF TEST, you can toggle between the two test
screens by pressing the SCROLL DISPLAY keys. See
Figure 4. The first screen turns on every LCD ele-
ment, and the second screen displays all the charac-
ters used in the various menus. As part of the SELF
TEST, you can also test the keys by pressing each one
and observing whether its corner LED lights up. To
exit the SELF TEST, unplug the programmer or turn
the key switch to the OFF position.
5
1307 Programmer Handset 2200 SRM 977

OPERATING MODES Table 1. Program Menu (Continued)

Program Menu
Program Menu
Description
Press the PROGRAM key to enter the PROGRAM Display
mode. See Table 1. The LED in the corner of the M2 Max Speed Mode 2 maximum speed, as
PROGRAM key illuminates to indicate that the % of top speed
programmer has been placed in the PROGRAM
mode. All of the adjustable functions and features M1 Max Speed Mode 1 maximum speed, as
are shown in the display window, four at a time, % of top speed
with the corresponding settings. The setting of the
selected item (the item at the top of the display Press the MORE INFO key to display more detailed
with the flashing arrow) can be changed using the information for the setting selected, including a bar
CHANGE VALUE keys. The CHANGE VALUE graph indicating the position of the current setting
keys have LEDs to indicate whether the key can be relative to the range for the setting, the unit of mea-
used to increase or decrease the value any further. sure, and the specific minimum and maximum val-
When the LED is no longer lit, the limit for the key ues for the setting. If the range is limited by the val-
direction has been reached. ues assigned for a different function, the name of the
limiting function is displayed in place of the mini-
Table 1. Program Menu mum and maximum values.

Program Menu Test Menu

Description
Display
Press the TEST key to enter the TEST mode. See
M3 Brake C/L Mode 3 braking current, in
Table 2. The LED in the corner of the TEST key il-
amps
luminates to indicate that the programmer has been
M2 Brake C/L Mode 2 braking current, in placed in the TEST mode. The TEST menu displays
amps real time information about the status of the inputs,
outputs, and controller temperature. In the TEST
M1 Brake C/L Mode 1 braking current, in
mode, the item of interest does not need to be the top
amps
item in the window; it only needs to be one of the
M3 Neut Brk % Mode 3 neutral braking, as four items displayed in the window. The TEST mode
% of brake C/L is useful for checking out the operation of the con-
troller during initial installation. The MORE INFO
M2 Neut Brk % Mode 2 neutral braking, as
key, when used in the TEST mode, displays addi-
% of brake C/L
tional information about the top item in the window.
M1 Neut Brk % Mode 1 neutral braking, as
% of brake C/L Table 2. Test Menu

M3 Accel Rate Mode 3 acceleration rate, in Test Menu

seconds Description
Display
M2 Accel Rate Mode 2 acceleration rate, in THROTTLE % Throttle reading, as % of full
seconds throttle
M1 Accel Rate Mode 1 acceleration rate, in ARM CURRENT Motor armature current, in
seconds amps
Taper Rate Regen braking decrease rate, FIELD Motor field current, in amps
when transitioning to plug, CURRENT
in 1/32 seconds
BATT VOLTAGE Battery voltage across the
M3 Max Speed Mode 3 maximum speed, as capacitors
% of top speed
HEATSINK C Heatsink temperature in C

6
2200 SRM 977 1307 Programmer Handset

Table 2. Test Menu (Continued) but simply a list of the possible messages displayed
when the programmer is operating in the DIAGNOS-
TICS or DIAGNOSTIC HISTORY modes. The mes-
Test Menu
Description sages are listed in alphabetical order for easy refer-
Display
ence.
FORWARD Forward signal input from
INPUT MIB: Table 4. Diagnostics and Diagnostic
ON or OFF History Display

REVERSE Reverse signal input from Diagnostics

INPUT MIB: Definition
Menu Display
ON or OFF
ARM SENSOR Armature sensor fault
INTERLOCK Brake switch input:
INPUT ON or OFF CONT DRVR OC Contactor driver overcurrent

MAIN CONT Traction contactor: Field winding open or

FIELD OPEN
OPEN or CLOSED disconnected

FAULT 1 Fault 1 driver status: FLD SENSOR Field sensor fault

OUTPUT ON (low) or OFF (high) HPD High Pedal Disable activated
FAULT 2 Fault 2 driver status: HW FAILSAFE 1 Power-on self test fault
OUTPUT ON (low) or OFF (high)
HW FAILSAFE 2 External watchdog fault
MODSEL 1 Mode select inputs 1 and 2
together define the operating HW FAILSAFE 3 Internal watchdog fault
mode from the dash display LOW BATTERY Battery voltage too low
MODSEL 2 to the controller. Refer to VOLTAGE
Table 3.
M output (Controller M
M SHORTED
Terminal) shorted to B
Table 3. Dash Display Drive Mode Inputs Traction contactor did not
MAIN CONT DNC
close
Drive Mode
Test Menu MAIN CONT Traction contactor welded
Turtle Middle Rabbit WELDED
Mode Select MISSING Missing Contactor
OFF ON OFF
Input 1 CONTACTOR
Mode Select ON OFF ON NO KNOWN No known faults have
FAULTS occurred
Diagnostics Menu OVERVOLTAGE Battery voltage too high
Press the DIAGNOSTIC key to enter the DIAGNOS- SRO Static Return to Off activated
TIC mode. The LED in the corner of the DIAGNOS-
THERMAL Cutback, due to
TIC key illuminates to indicate that the programmer
CUTBACK over/undertemperature
has been placed in the DIAGNOSTIC mode. The
DIAGNOSTICS menu displays all currently active THROTTLE Throttle out of range
faults detected by the controller. It is capable of dis- FAULT 1
playing 19 different faults, four at a time.
THROTTLE Throttle low fault
NOTE: The DIAGNOSTICS and DIAGNOSTIC HIS- FAULT 2
TORY display shown in Table 4 is not a menu as such,

7
Programming the Traction Motor Controller - 1307 Handset 2200 SRM 977

Diagnostic History The SPECIAL PROGRAM menu also allows the user
to "clone" controllers. After one controller is pro-
Press the DIAGNOSTICS key and the MORE INFO grammed with all of the desired values, the values
key simultaneously to enter the DIAGNOSTIC HIS- can be saved to the programmer handset memory.
TORY menu. The DIAGNOSTIC HISTORY lists all The programmer handset can then be used to load
of the faults observed and recorded by the controller the saved values to other similar controllers (same
since the history was last cleared. Press the SCROLL model number).
DOWN key to display any recorded faults. Each fault
will be listed only once, regardless of the number of Table 5. Special Program Menu
times the fault may have occurred.
Special Program
The diagnostic history can be cleared from the Definition
Menu Display
controller using the SPECIAL PROGRAM MENU
function, CLEAR DIAG HISTORY. Press the PRO- RESET ALL Revert to previous settings
GRAM key while holding the MORE INFO key. SETTINGS
Press the SCROLL DOWN key until CLEAR DIAG CONT SET- Save controller settings to
HISTORY appears in the top line of the display. TINGS→PROG programmer
Press the MORE INFO key again, and then press
the VALUE UP key to clear the history or the VALUE PROG SET- Load programmer settings
DOWN key to cancel the operation. TINGS→CONT to controller
CLEAR DIAG Clear DIAGNOSTIC
Special Program Menu HISTORY HISTORY memory
Press and hold the MORE INFO key, then press the CONTRAST Adjust programmer
PROGRAM key to enter the SPECIAL PROGRAM ADJUSTMENT display contrast
menu. See Table 5. The SPECIAL PROGRAM menu
LANGUAGE Select displayed language
allows the user to: revert the controller to previous
SELECTION
settings, save controller settings to the programmer
memory, load controller settings from the program- PROGRAMMER Display programmer
mer memory, clear diagnostic history, adjust the INFO information
contrast of the programmer display, select language,
CONTROLLER Display controller
and display basic controller and programmer in-
INFO information
formation. Press the SCROLL DISPLAY key until
the desired function is on the top line. Press the
MORE INFO key for information on how to make
the desired adjustment.

Programming the Traction Motor Controller - 1307 Handset

WARNING
NEVER adjust function settings outside the
range recommended for the specific truck
model. See Table 6.
WARNING
Program changes affect lift truck perfor-
mance and operation. If function settings are
changed, make sure all operators of the lift
truck know that the truck has been changed
and may operate differently.
1. Turn the key switch to the OFF position.
2. Disconnect and separate the battery connector.
3. Remove the front cover. See the section Frame
100 SRM 975 for the removal procedure. Refer to
Covers, Panels, and Plates.

8
2200 SRM 977 Programming the Traction Motor Controller - 1307 Handset

Table 6. Program Menu Range and Default Values

Min./Max.
Units of
Menu Display Function Description Factory Value Values
Measure
Allowed
M3 BRAKE C/L 24-volt trucks
320 100 to 450
M2 BRAKE C/L Brake Current only
M1 BRAKE C/L Amps
Limit 36-volt trucks
280 100 to 450
only
NOTE: Changes made to the BRAKE C/L settings may necessitate changes to the TAPER RATE setting below
to ensure smooth operation when plugging to a stop or transitioning from one direction to the other.
M3 NEUT BRK
%
M2 NEUT BRK
Neutral Braking Level 30 0 to 50 % of Regen C/L
%
M1 NEUT BRK
%
M3 ACCEL M3 Acceleration 24- and 36-volt
1.3 0.1 to 5.0 Seconds
RATE Ramp Rate trucks only
M2 ACCEL M2 Acceleration 24- and 36-volt
2.3 0.1 to 5.0 Seconds
RATE Ramp Rate trucks only
M1 ACCEL M1 Acceleration 24- and 36-volt
3.5 0.1 to 5.0 Seconds
RATE Ramp Rate trucks only
24- and 36-volt
End Regen trucks except 25 1 to 64
TAPER RATE B264 and G138 1/32 second
Taper Rate
B264 and G138 10 1 to 64
NOTE: Changes made to the TAPER RATE setting may necessitate changes to the BRAKE C/L settings above
to ensure smooth operation when plugging to a stop or transitioning from one direction to the other.

24-volt trucks Standard 100 0 to 100

only EE 85 0 to 85
M3 MAX
M3 Speed Limit % of Throttle
SPEED Standard 100 0 to 100
36-volt trucks
only EE 75 0 to 75

24-volt trucks Standard 100 0 to 100

only EE 85 0 to 85
M2 MAX
M2 Speed Limit % of Throttle
SPEED Standard 100 0 to 100
36-volt trucks
only EE 75 0 to 75

24-volt trucks Standard 65 0 to 65

only EE 65 0 to 65
M1 MAX
M1 Speed Limit % of Throttle
SPEED Standard 65 0 to 65
36-volt trucks
only EE 65 0 to 65

9
Programming the Traction Motor Controller - 1307 Handset
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
in the controller by connecting a load (such
as a contactor coil or a horn) across the con-
troller’s B+ and B terminals. DO NOT use
a screwdriver to discharge the traction motor
controller.
4. Discharge the capacitors in the traction motor
controller by connecting a load (such as a contac-
tor coil or a horn) across the controller’s B+ and
B terminals.
5. Connect the PROGRAMMER HANDSET to the
traction motor controller. Connect the cord of the
handset plug into the 4-pin Molex, Mini-Fit Jr.
receptacle on the front of the controller.
NOTE: Each time the programmer handset is
connected to the controller, it acquires all of the
controller function value settings and stores them
in its temporary memory. This allows the user to
revert back to the original settings at any time. The
SPECIAL PROGRAM menu selection RESET ALL
SETTINGS is used to revert to the original settings.
Any inadvertent change made to any of the function
values can be "undone" in this manner, as long as
the programmer has not been unplugged or the key
switch turned OFF (power disconnected).
6. Reconnect the battery.
NOTE: The brake pedal must be released (up posi-
tion) during Step 7.
7. Turn the key switch to the ON position. Ensure
battery disconnect switch is closed.
8. Press the PROGRAM button on the PROGRAM-
MER HANDSET. The green LED in the corner of
the PROGRAM button lights to indicate that the
HANDSET has been placed in the PROGRAM
mode.
9. Press the SCROLL DISPLAY buttons, as re-
quired, until the desired function is shown on
the top line of the display.
10
2200 SRM 977
10. Press the MORE INFO button to display addi-
tional information, if desired, on the selected
function. The green LED in the corner of the
MORE INFO button lights to indicate that the
MORE INFO option has been selected.
NOTE: Some function values are limited by values set
for other functions. For example, the value for M2
ACCELERATION RATE (Mid Mode) must be equal
to or less than the value for M1 ACCELERATION
RATE (Turtle Mode) and equal to or greater than the
value for M3 ACCELERATION RATE (Rabbit Mode).
Press the MORE INFO key to display the limiting
function, shown on the bottom line in place of the
minimum and maximum values normally displayed.
WARNING
NEVER adjust function settings outside the
range recommended for the specific truck
model.
11. Press the CHANGE VALUE buttons to change
the function value higher or lower, as required.
A green LED on each CHANGE VALUE button
lights to indicate that the function value can be
changed in the corresponding direction. If the
green LED on one of the CHANGE VALUE but-
tons is not illuminated, the value has reached the
limit for the corresponding direction.
WARNING
Program changes affect lift truck perfor-
mance and operation. If function settings are
changed, make sure all operators of the lift
truck know that the truck has been changed
and may operate differently.
12. Press the MORE INFO button to return to the
PROGRAM menu, if the MORE INFO screen had
been selected.
13. Repeat Step 9 through Step 12 as required, until
all of the functions are set to the desired values.
NOTE: Any inadvertent change made to any of the
function values can be "undone" using the SPECIAL
PROGRAM menu selection RESET ALL SETTINGS,
as long as the programmer has not been unplugged
or the key switch turned OFF (power disconnected).
14. Turn the key switch to the OFF position.
15. Disconnect and separate the battery connector.
2200 SRM 977 1311 Programmer Handset

16. Discharge the capacitors in the controller by con-

WARNING necting a load (such as a contactor coil or a horn)
The capacitor in the traction motor controller across the controller’s B+ and B terminals.
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock 17. Disconnect the programmer handset cord from
and injury, discharge the capacitor before the traction motor controller.
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has 18. Install the front cover.
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.

1311 Programmer Handset

DESCRIPTION/FEATURES
The programmer handset is a handheld tool that al-
lows the user to program, test, and diagnose the trac-
tion motor controller. See Figure 5. It has been de-
signed for ease of use with a navigation key, data in-
crease/decrease key, and three bookmark keys to con-
trol all programmer functions.

The display window contains a seven line 128 × 64

pixel LCD screen that is capable of displaying both
text and graphics simultaneously. The window is vis-
ible in most lighting conditions and can be adjusted
using the programmer setup menu.

The programmer is menu driven and accesses sub-

menus by pressing the navigation key.

When the programmer is connected to the motor

controller, all current motor controller information
is up-loaded into the 1311 programmer handset
and ready for viewing. This up-load is used by the
programmer to generate menu items that will be
displayed by the programmer.
Figure 5. Curtis Model 1311 Programmer
Menu Navigation Key Handset
The navigation key is a four-position switch that al-
lows you to move up and down a menu list using
the top or bottom arrows or you can open and close
sub-menus using the right and left arrows. Use the
navigation key to move up or down through the main
menu items. There is a blinking square on the left
side of the programmer that indicates the current
menu selection. See Figure 6.

Figure 6. Menu Selection

11
1311 Programmer Handset
After selection of a main menu item, submenus for
the main selection can be opened using the right ar-
row. See Figure 7. As submenus are opened, a new
series of indicator boxes will appear with a blink-
ing square to indicate the current submenu selection.
You can move up and down within the submenus us-
ing the up and down arrows. Pressing the left ar-
row will return the programmer to the main menu.
Pressing the right arrow while in a submenu will
bring up an additional information screen about the
submenu item previously selected. See Figure 8.
Figure 7. Menu Selection
Figure 8. Menu Selection
12
2200 SRM 977
Data Increase/Decrease Key
The date increase/decrease key allows the adjust-
ment of various parameter setting by pressing the +
side of the switch to increase a value or by pressing
the side of the switch to decrease a value. See
Figure 5.
Bookmark Keys
There are three bookmark keys that can be set by
the user. These keys allow you to bookmark your po-
sition within the menu structure to allow the user
to quickly return to a selection without having to
re-navigate the entire menu structure. While you
are positioned at a menu item you want to bookmark,
press one of the bookmark buttons and hold it down
for four seconds until the bookmark set screen ap-
pears. You can return to this preset menu item at any
time by pressing the bookmark button you assigned
to this item. Bookmarks are permanently retained in
the programmer memory. Once the programmer has
been unplugged or power to the controller has been
interrupted, the bookmarks are cleared from the pro-
grammer memory. See Figure 5.
OPERATION
Connecting Handset to Traction Motor
Controller
NOTE: Each time the programmer handset is con-
nected to the controller, it acquires all of the con-
troller function value settings and stores them in its
temporary memory. This allows the user to revert
back to the original settings at any time. The special
program menu selection RESET ALL SETTINGS is
used to revert to the original settings. Any unwanted
change made to any of the function values can be un-
done in this manner, as long as the programmer has
not been unplugged or the key switch turned OFF
(power disconnected).
1. Turn the key to the OFF position.
2. Disconnect the battery.
3. Remove drive unit compartment cover.
2200 SRM 977 1311 Programmer Handset

NOTE: The programmer handset should only be con-

WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
in the controller by connecting a load (such
as a contactor coil or a horn) across the con-
troller’s B+ and B terminals. DO NOT use a
screwdriver to discharge the traction motor
controller.
4. Discharge the capacitors in the controller.
5. Connect programmer handset to the four-pin
Molex™ connector on the traction motor con-
troller.
nected and disconnected with the key switch in the
OFF position.
5. Install drive unit compartment cover.
6. Reconnect battery.
MAIN MENU SELECTIONS
Program Menu
The program menu will contain submenus of ad-
justable parameters downloaded to the programmer
from the motor controller. The motor controller can
be setup for specific operating conditions by chang-
ing the parameters that can be accessed through the
program menu selections. Those parameters that
can be adjusted by the handset will be shown as
submenu items under the program menu.

6. Reconnect the battery. Use the up or down arrow on the navigation key to se-
lect a parameter. See Figure 9. Press the right arrow
7. Turn the key to the ON position. key to access the detail screen for the selected param-
eter. See Figure 10. The detail screen will show the
Disconnecting the Handset From the measurement units, min/max range for the param-
Traction Motor Controller eter, and a bar graph indicating the current param-
eter setting. The setting may be changed using the
1. Turn the key to the OFF position. Increase/Decrease key. Press the (+) to increase the
value or press ( ) to decrease the value.
2. Disconnect the battery.
To return to the program menu or the main menu,
WARNING press the left arrow on the menu navigation key.
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
in the controller by connecting a load (such
as a contactor coil or a horn) across the con-
troller’s B+ and B terminals. DO NOT use a
screwdriver to discharge the traction motor
controller.

3. Discharge the capacitors in the controller.

Figure 9. Menu Selection
4. Disconnect programmer handset from the four-
pin Molex™ connector on the traction motor con-
troller.

13
1311 Programmer Handset 2200 SRM 977

Figure 12. Menu Selection

Figure 10. Menu Selection

Monitor Menu Faults Menu

The faults menu will provide the present status of the
The monitor menu will contain a list of all truck func-
motor controller and access to past fault history. The
tions that can be read and displayed by the program-
fault history is up-loaded to the programmer when
mer. Using the menu navigation key, scroll up or
the programmer is connected to the motor controller.
down to select a parameter from the list. See Fig-
Use the menu navigation key to access system faults,
ure 11. Each menu item is constantly monitored and
fault history, or to clear the fault history. See Fig-
displayed to show real-time information about the se-
ure 13.
lected function.

To view a single function in real time, press the right

arrow on the menu navigation key and a detail screen
about the selected parameter will appear. See Fig-
ure 12.

To return to the monitor menu or the main menu,

press the left arrow on the menu navigation key.

Figure 13. Menu Selection

System faults will show the current state of the motor

controller. See Figure 14.

Figure 11. Menu Selection
Fault history will list the faults that have been stored
in the motor controller memory. These faults will be
shown as descriptive text of the fault. Scroll through
the faults using the up and down arrows on the menu
navigation key. See Figure 15.

14
2200 SRM 977 1311 Programmer Handset

to select the functions menu to access the settings

menu. See Figure 16. From this menu you can up-
load the parameter block from an existing controller
and download that parameter block into another mo-
tor controller. See Figure 17.

Each time the programmer is connected to a motor

controller, it uploads the present data from the
controller into the programmer. Using the settings
menu, this original information can be downloaded
into the controller at any time to restore the con-
troller with the original data. Any inadvertent
change in controller parameters can be undone us-
ing this feature as long as the programmer has not
Figure 14. Menu Selection
been disconnected from the controller or the power
has not been removed from the controller.

Figure 16. Menu Selection

Figure 15. Menu Selection

Clear Fault History is used to remove faults from the

controller memory after review. Use the increment
(+) arrow on the increase/decrease switch to delete
the faults from memory.

NOTE: You will be asked to confirm that you do want

to clear the fault history. Use the decrease ( ) arrow
to cancel any action and not clear the fault history.

Functions menu
The functions menu is used to copy data between
motor controllers or reset the data in a controller to
the original settings. Use the menu navigation key Figure 17. Menu Selection

15
Programming the Traction Motor Controller - 1311 Handset
Information Menu
The information menu will display information about
the controller. Use the menu navigation key to select
the information menu and all specific controller in-
formation will be displayed on the screen. See Fig-
ure 18.
Figure 18. Menu Selection
Programming the Traction Motor Controller - 1311 Handset
WARNING
NEVER adjust function settings outside the
range recommended for the specific truck
model. See Table 6.
WARNING
Program changes affect lift truck perfor-
mance and operation. If function settings are
changed, make sure all operators of the lift
truck know that the truck has been changed
and may operate differently.
1. Turn key switch to the OFF position.
2. Disconnect and separate battery connector.
3. Remove drive unit compartment cover.
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
using the recommended procedures and never
by any other method.
16
2200 SRM 977
Programmer Setup Menu
The programmer setup menu contains several items
that can be viewed, setup, or customized to the user’s
preference. See Figure 19.
Figure 19. Menu Selection
4. Discharge the capacitors in the traction motor
controller by connecting a 200-ohm, 2-watt resis-
tor across the controller’s B+ and B terminals
using two insulated jumper wires.
5. Connect programmer handset to traction motor
controller. The cord of the handset plugs into the
J-3 connector on the front of the controller.
NOTE: Each time the programmer handset is
connected to the controller, it acquires all of the
controller function value settings and stores them in
temporary memory. This allows the user to return
to the original settings at any time. Any unwanted
change made to any of the function values can be
undone in this manner, as long as the programmer
has not been unplugged or the key switch turned
OFF (power disconnected).
6. Reconnect battery.
7. Turn key switch to the ON position.
8. Select the PROGRAM menu on the programmer
handset.
9. Use the menu navigation key UP or DOWN
arrows to scroll until the desired function is
reached.
2200 SRM 977
10. Press the RIGHT arrow on the menu navigation
key to enter the function being changed.
WARNING
NEVER adjust function settings outside the
range recommended for the specific truck
model. See Table 6.
11. Using the DATA INCREASE/DECREASE key,
change the function setting to the new setting.
Pressing the (+) will increase the parameter
value. Pressing the ( ) will decrease the param-
eter setting.
WARNING
Program changes affect lift truck perfor-
mance and operation. If function settings are
changed, make sure all operators of the lift
truck know that the truck has been changed
and may operate differently.
12. Press the LEFT arrow on the menu navigation
key to return to the parameters menu.
13. Repeat Step 8 through Step 12, as required, until
all of the functions are set to the desired value.
NOTE: Any unwanted change made to any of the
function values can be undone using the RESET
Troubleshooting
The traction motor controller provides diagnostic in-
formation to the programmer handset, the dash dis-
play, and the status LED on the controller. The fol-
lowing four-step process is recommended for diagnos-
ing and troubleshooting an inoperative vehicle:
1. Visually inspect the truck for obvious problems.
2. Diagnose the problem using the programmer
handset.
3. Test the circuitry (inputs/outputs) using the pro-
grammer handset.
4. Correct the problem.
Troubleshooting
ALL SETTINGS from the FUNCTIONS menu as
long as the programmer has not been unplugged or
the key switch turned OFF (power disconnected).
14. Turn the key switch to the OFF position.
15. Disconnect the battery connector.
WARNING
The capacitor in the traction motor controller
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
and injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. Discharge the capacitors
using the recommended procedures and never
by any other method.
16. Discharge the capacitors in the traction motor
controller by connecting a 200-ohm, 2-watt resis-
tor across the controller’s B+ and B terminals
using two insulated jumper wires.
17. Disconnect the programmer handset from the
controller.
18. Install the drive unit compartment covers.
19. Reconnect the battery.
STATUS LED DIAGNOSTICS
A status LED is built into the traction motor con-
troller. See Table 7. It is visible through a window in
the label on the top of the controller. The status LED
displays fault codes when there is a problem with
the controller or with the inputs to the controller.
During normal operation, with no faults present, the
status LED flashes steadily on and off. If the con-
troller detects a fault, a 2-digit fault identification
code is flashed continuously until the fault is cor-
rected. For example: code "3,2" - welded traction con-
tactor - appears as three flashes, pause, two flashes,
long pause, three flashes, pause, two flashes, long
pause . . . and so on, continuously until the prob-
lem is corrected.
17
Troubleshooting 2200 SRM 977

Table 7. Status LED Fault Codes Table 7. Status LED Fault Codes (Continued)

LED Code Explanation

LED Code Explanation
OFF (no flashes) No Power or defective
3,2 Welded contactor
controller
3,4 Missing contactor, or
ON (continuously) Controller or microprocessor
traction contactor did not
fault
close
0,1 Controller operational, no
4,1 Low battery voltage
faults
4,2 Overvoltage
1,2 Hardware failsafe fault
4,3 Thermal cutback;
1,3 M , current sensor, or motor
over/undertemperature
fault
2,1 Throttle fault NOTE: Only one LED fault code is indicated at a time,
2,2 Static return to off (SRO) and faults are not queued up. Operational faults,
fault such as a fault in SRO sequencing, are cleared by
cycling the key switch.
2,3 High pedal disable (HPD)
fault
3,1 Contactor driver overcurrent

DIAGNOSTICS MENU
LED Code Dash Display Message Programmer Handset Display Message
COMMUNICATION ERROR WITH CON-
TROLLER. PRESS SCROLL DOWN TO
0, 1 "Any Message" ATTEMPT TO RESTART.
PROGRAMMER FAULT
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.

Truck Response
Traction may or may not function properly.

Possible Causes and Test Procedures

• Brake pedal is pressed when programmer handset
is connected.
Turn key switch to the OFF position. Release
the brake pedal. Turn the key switch to the ON
position.
• Interface cable between traction motor controller
and programmer handset is defective.
Replace the interface cable. Logic
Initial communication between the traction motor
controller and the programmer handset is not valid.

18
2200 SRM 977 Troubleshooting

LED Code Dash Display Message Programmer Handset Display Message

NO KNOWN FAULTS
0, 1 "Any Message"
NO KNOWN FAULTS HAVE OCCURRED
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction functions normally.

Possible Causes and Test Procedures

• No faults that are diagnosable by the traction mo-
tor controller exist.

Logic
Displayed when no known faults are present.

LED Code Dash Display Message Programmer Handset Display Message

"Any LED PROGRAMMER FAULT
"Any Message"
Code"
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction may or may not function normally.

Possible Causes and Test Procedures

• Caused by a defective handset.
Replace the handset.

Logic
Displayed when the internal check logic of the
traction motor controller does not get the correct
communication from the programmer handset.

19
Troubleshooting 2200 SRM 977

LED Code Dash Display Message Programmer Handset Display Message

THERMAL CUTBACK
DRIVE CTRL LIMIT SPEED
4, 3 THERMAL CUTBACK DUE TO OVER/UN-
REDUCED
DERTEMP
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction speed is reduced.

Possible Causes and Test Procedures

• Temperature of the traction motor controller is
greater than 85 C (185 F) or less than 25 C
( 13 F).
Determine the cause of the out-of-range temper- Logic
ature and correct (low battery, overloading, etc.). Displayed when the internal temperature of the
Can be caused by excessive load on vehicle, op- traction motor controller is beyond the operating
eration in extreme environments, or improper range of 25 to +85C. The internal temperature can
mounting of controller. When the internal tem- be read by accessing the test menu on the handset.
perature of the controller returns to the operat-
ing range of 25 to +85C, normal operation will
resume.
If the controller is improperly mounted, remount
the controller according to specifications. Refer
to SEM Traction Motor Controller, Install.
If the motor temperature does not return to the
normal operating range 25 to +85 C ( 13 to
+185 F) after the truck has been turned off for
at least 1 hour, the motor controller must be re-
placed.

20
2200 SRM 977 Troubleshooting

LED Code Dash Display Message Programmer Handset Display Message

DRIVE CONTROL ERROR SRO

2, 2
CHECK ERROR CODE STATIC RETURN TO OFF ACTIVATED
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Forward or reverse direction is selected before the
brake is released (operator is on the truck, initial
startup only).
Check brake switch for proper operation; an
open brake switch can cause this fault.
Check direction inputs from traction poten-
tiometer to MIB for proper operation.
Logic
A shorted traction potentiometer, a traction
Displayed when battery volts is simultaneously
potentiometer out of adjustment, or a defective
supplied to terminals 2 and 10 or terminals 2 and 11.
MIB can also cause the fault.

NOTE: The brake can be released while traveling. If

the operator presses the brake pedal within 3 sec-
onds, SRO will not be activated. If the operator waits
more than 3 seconds, SRO will be activated and the
handle will have to be returned to neutral to resume
normal operation of the truck.

21
Troubleshooting 2200 SRM 977

LED Code Dash Display Message Programmer Handset Display Message

DRIVE CONTROL ERROR HPD

2, 3
CHECK ERROR CODE HIGH PEDAL DISABLE ACTIVATED
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is
corrected. (The HPD function has a 3-second
delay during normal operation.)

Possible Causes and Test Procedures

• Throttle greater than 25% before the brake pedal
is pressed.
Check control handle to ensure it is in the neu-
tral position.
Check for approximately 0.2 volts at pin 14 and Logic
pin 15 at the traction motor controller, with the Displayed when pin 2 goes to battery voltage if pin
control handle in neutral. 14 and pin 15 are not less than about 1.25 volts.
• Traction potentiometer out of adjustment. [5.00 volts (full speed throttle voltage) ×
Check traction potentiometer adjustment. Refer 25% = 1.25 volts]
to Traction Potentiometer Setup.
• MIB failed.
Check the MIB for proper operation. The MIB
provides the throttle position signal to the trac-
tion motor controller via wire #29 (J1-20) and a
throttle reference voltage via wire #30 (J1-16).
With the control handle in neutral, pin 15 and
pin 14 should measure approximately 0.2 volts.

22
2200 SRM 977 Troubleshooting

LED Code Dash Display Message Programmer Handset Display Message

DRIVE CTRL FAULT M FAULT
1, 3
CHECK FAULT CODE
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• M output shorted or internal short in the traction
motor.
Verify voltage between battery and M to be
10% less than battery volts with the control han-
dle in neutral. Logic
• Traction motor shorted. M bus bar should measure approximately
Check traction motor for shorted condition. 10% less than battery volts. Pin 10 and pin
• Forward or reverse circuitry shorted. 11 should measure near zero volts with control
Pin 10 and pin 11 should measure near zero volts handle in neutral. Pin 10 (forward) or pin 11
with control handle in neutral. Pin 10 (forward) (reverse) should measure near battery voltage
or pin 11 (reverse) should measure near battery with corresponding direction selected.
voltage with corresponding direction selected.

LED Code Dash Display Message Programmer Handset Display Message

DRIVE CTRL LIMIT SPEED OVERVOLTAGE

4, 2
REDUCED OVERVOLTAGE
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Truck voltage greater than 45 volts.
Check to ensure proper battery is in the truck.
• Plugging the charger into the truck instead of the
battery can also cause this fault.
Check to ensure the proper battery charging pro-
cedure is followed.

Logic
Traction controller is designed to operate with
24- and 36-volt batteries only.

23
Troubleshooting 2200 SRM 977

LED Code Dash Display Message Programmer Handset Display Message

CONT DRVR OC
3, 1 DRIVE CTRL FAULT
CONTACTOR DRIVER OVERCURRENT
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Traction contactor coil shorted.
Check traction contactor coil for a shorted condi-
tion.
Logic
Contactor coil should measure approximately 17
Displayed when higher-than-normal current is
±1 ohms.
sensed in the traction contactor coil.
• Shorted wire between the traction motor controller
and the contactor coil.

LED Code Dash Display Message Programmer Handset Display Message

HW FAILSAFE
1, 2 DRIVE CTRL FAULT
HARDWARE FAILSAFE ACTIVATED
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Defective traction motor controller.
Replace traction motor controller.

Logic
Displayed when the internal check logic of the
traction motor controller determines an internal
failure of the traction motor controller.

24
2200 SRM 977 Troubleshooting

LED Code Dash Display Message Programmer Handset Display Message

DRIVE CTRL LIMIT SPEED LOW BATTERY VOLTAGE

4, 1
REDUCED LOW BATTERY VOLTAGE
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Battery voltage less than 16 volts.
Check battery voltage to ensure proper voltage
for truck.
Check for loose or corroded connections between
the battery and the traction motor controller.

Logic
B+ bus bar on traction motor controller should
measure near truck battery voltage. Connections
should be tight and corrosion-free.

LED Code Dash Display Message Programmer Handset Display Message

"Any or No PROC/WIRING FAULT

DRIVE CTRL FAULT
LED Code" PROCEDURE OR WIRING FAULT
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Traction motor controller is not wired properly or
is missing required inputs.
Check controller connections. See the section
Diagrams 8000 SRM 690.
Logic
Displayed when internal logic of the traction motor
controller detects improper inputs.

25
Troubleshooting 2200 SRM 977

LED Code Dash Display Message Programmer Handset Display Message

MISSING CONTACTOR
3, 4 DRIVE CTRL FAULT
MISSING CONTACTOR
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Traction contactor missing or contactor coil open.
Check traction contactor coil for open condition.
Contactor coil should measure approximately 17
Logic
±1 ohms. If contactor coil is open, replace it.
Displayed when lower-than-normal current is
• Open wire between the traction motor controller
sensed in the traction controller coil.
and the contactor coil.
Check for continuity between pin 17 at the trac-
tion motor controller and wire #14 at the contac-
tor coil.
Check for continuity between pin 9 at the trac-
tion motor controller and wire #15 at the contac-
tor coil.
These checks should read near 0 ohms. If they
do not, locate the open and repair it.

26
2200 SRM 977 Troubleshooting

LED Code Dash Display Message Programmer Handset Display Message

THROTTLE FAULT 1
2, 1 DRIVE CTRL FAULT THROTTLE INPUT FAULT
(OUT OF RANGE)
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Throttle input voltage (pin 15, wire #29) out of Logic
range. Pin 15 at the traction motor controller is above
Check wire #29 for short to B or B+. (approximately) 5.0 volts (full speed reference
Check for continuity between J1-20 (wire #29) voltage) or below (approximately) 0.2 volts
at the MIB and pin 15 (wire #29) at the traction (neutral reference voltage).
motor controller. You should read near 0 ohms.
If this wire is open, find the open and repair it.
• MIB failed.
Check the MIB for proper operation. The MIB
provides the throttle position signal to the trac-
tion motor controller via wire #29 (J1-20). With
control handle in neutral, pin 15 (wire #29)
should measure approximately 0.2 volts. As the
handle is moved in a FORWARD or REVERSE
direction, the voltage should increase to near 5
volts.

27
Troubleshooting 2200 SRM 977

LED Code Dash Display Message Programmer Handset Display Message

THROTTLE FAULT 2
2, 4 DRIVE CTRL FAULT
THROTTLE LOW INPUT FAULT
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Diagnostic menu is selected.

Truck Response
Traction is disabled until fault condition is corrected.

Possible Causes and Test Procedures

• Throttle reference voltage (pin 14, wire #30) open Logic
or shorted. Pin 14 at the traction motor controller is above or
Check wire #30 (pin 14 at the traction motor con- below (approximately) 0.2 volts (reference voltage).
troller) for a short to B or B+.
Check continuity between pin 14 (wire #30) at
the traction motor controller and J1-16 (wire
#30) at the MIB. You should read near 0 ohms.
If the wire is open, find the open and repair it.
Wire #30 (pin 14 at the traction motor controller)
should measure approximately 0.2 volts.
• MIB failed.
Check the MIB for proper operation. The MIB
provides the throttle reference signal to the trac-
tion motor controller via wire #30 (J1-16). With
the key switch ON, pin 14 should measure ap-
proximately 0.2 volts. As the handle is moved in
a FORWARD or REVERSE direction, the voltage
should remain at approximately 0.2 volts.

TEST MENU
Menu Test Menu
Operating Range
Item (Neutral position shown)
Scroll display until 0% to 100%
For Additional
THROTTLE % 0 with control handle in neutral.
Information:
is shown on the 100* with control handle positioned for full-speed
Press MORE INFO
1 top line travel (forward or reverse).
Throttle % should gradually increase as the control
THROTTLE % 0 THROTTLE
handle is moved from the neutral position to the
INPUT,
full-speed position (forward and reverse).
% 0
*Maximum value may be less than 100 and is dependant on truck model, direction of travel, battery
voltage, and type (E or EE).
Throttle signal is generated by the MIB and dependant on the throttle pot position.
Displays throttle reading in percent of full as seen by the traction motor controller.

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2200 SRM 977 Troubleshooting

Menu
Test Menu Operating Range
Item
Scroll display until 0 to 450*
For Additional
ARM CURRENT
Information:
is shown on the *Approximate values.
Press MORE INFO
2 top line Displayed value dependant on lift truck model, load,
travel conditions, etc.
ARM CURRENT ARM
CURRENT,
AMPS 0
Indicates traction motor armature current.

Menu
Test Menu Operating Range
Item
Scroll display until 0 to 45*
For Additional
FIELD CURRENT
Information:
is shown on the *Approximate values.
3 Press MORE INFO
top line Displayed value dependant on lift truck model, load,
travel conditions, etc.
FIELD CURRENT FIELD
CURRENT 0
Indicates traction motor field current.

Menu Test Menu

Operating Range
Item (24-volt truck shown)
Scroll display until Approximately 20.76 to 26.4 . . . 24-volt truck
For Additional
BATT VOLTAGE
Information:
is shown on the Approximately 31.14 to 39.6 . . . 36-volt truck
Press MORE INFO
4 top line
(average 1.73 volts per cell discharged)
BATT VOLTAGE 24 BATTERY
(average 2.2 volts per cell charged)
VOLTAGE,
VOLTS 24
Indicates actual battery voltage to the traction motor controller.

Menu Test Menu

Operating Range
Item 22 C (71.5 F) shown
Scroll display until Between 25 C ( 13 F) and 85 C (185 F)
For Additional
HEATSINK C
Information:
is shown on the
Press MORE INFO
5 top line
HEATSINK C 22 HEATSINK
TEMPERA-
TURE C 22
Indicates traction motor controller heatsink temperature.

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Troubleshooting 2200 SRM 977

Test Menu
Menu
(Control handle positioned for Operating Range
Item
forward travel.)
Scroll display until Control Handle in NEUTRAL . . . OFF
For Additional
FORWARD INPUT
Information:
is shown on the FORWARD selected . . . ON
6 Press MORE INFO
top line
FORWARD ON FORWARD
INPUT INPUT IS ON
Shows status of forward signal input at traction motor controller. Output of MIB.

Test Menu
Menu
(Control handle positioned for Operating Range
Item
reverse travel.)
Scroll display until Control handle in NEUTRAL . . . OFF
For Additional
REVERSE INPUT
Information:
is shown on the REVERSE selected . . . ON
7 Press MORE INFO
top line
REVERSE ON REVERSE
INPUT INPUT IS ON
Shows status of reverse signal input at traction motor controller. Output of MIB.

Menu Test Menu

Operating Range
Item (Brake switch closed.)
Scroll display until Brake pedal DEPRESSED . . . ON
For Additional
INTRLCK INPUT
Information:
is shown on the Brake pedal UP . . . OFF
8 Press MORE INFO
top line
INTRLCK ON INTERLOCK
INPUT INPUT ON
Shows status of interlock (brake) switch input at traction motor controller.

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2200 SRM 977 Troubleshooting

Menu Test Menu

Operating Range
Item (Traction contactor energized.)
Scroll display until Traction contactor OPEN . . . OFF
For Additional
MAIN CONT is
Information: Press
shown on the Traction contactor CLOSED . . . ON
MORE INFO
9 top line
MAIN CONT OPEN MAIN
CONTACTOR
DRIVER IS OFF
Shows status of main* (traction) contactor driver.
*Internal to the traction motor controller.

Menu Test Menu

Operating Range
Item (No faults, normal condition shown.)
Scroll display until Normal . . . OFF
For Additional
FAULT 1 OUTPUT
Information: Press
is shown on the Throttle Fault . . . OFF
MORE INFO
10 top line
Drive Controller Hot . . . ON
FAULT 1 ON FAULT 1
OUTPUT OUTPUT
OFF Drive Controller Fault . . . ON
Shows status of fault 1 output. Used by dash display in conjunction with fault 2 output to determine
traction motor controller status.

Menu Test Menu

Operating Range
Item (No faults, normal condition shown.)
Scroll display until Normal . . . OFF
For Additional
FAULT 2 OUTPUT
Information: Press
is shown on the Throttle Fault . . . ON
MORE INFO
11 top line
Drive Controller Hot . . . OFF
FAULT 2 ON FAULT 2
OUTPUT OUTPUT
OFF Drive Controller Fault . . . ON
Shows status of fault 2 output. Used by dash display in conjunction with fault 1 output to determine
traction motor controller status.

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Troubleshooting 2200 SRM 977

Menu Test Menu

Operating Range
Item (Rabbit mode shown)
Scroll display Turtle Mode . . . ON
For Additional
until MODSEL 1
Information: Press
is shown on the Mid Mode . . . OFF
12 MORE INFO
top line
Rabbit Mode . . . OFF
MODSEL 1 MODSEL 1
IS OFF
Shows status of model select 1 input.
Used in conjunction with model select 2 input to select 1 of 3 traction motor controller drive modes.
Controlled by the drive mode switch on the dash display.

Menu Test Menu

Operating Range
Item (Rabbit mode shown)
Scroll display Turtle Mode . . . OFF
For Additional
until MODSEL 2
Information: Press
13 is shown on the Mid Mode . . . ON
MORE INFO
top line
Rabbit Mode . . . OFF
MODSEL 2 MODSEL 2 IS OFF
Shows status of model select 2 input.
Used in conjunction with model select 1 input to select 1 of 3 traction motor controller drive modes.
Controlled by the drive mode switch on the dash display.

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 TECHNICAL PUBLICATIONS

2200 SRM 977 8/05 (5/05)(3/05)(1/04)(5/01) Printed in U.S.A.