Controller Sem

Maintenance
SEM TRACTION MOTOR

CONTROLLER
NDR030GB, NR045GB [B861];
NDR030AE, NR035/040/045AE [C815];
NS040AF, NS050AF [C816];
NDR030CB, NR045CB [D829]
PART NO. 524164468 2200 YRM 977

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
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
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............................................................................................................................................. 5
Program Menu ............................................................................................................................................ 5
Test Menu ................................................................................................................................................... 6
Diagnostics Menu ....................................................................................................................................... 7
Diagnostic History....................................................................................................................................... 7
Special Program Menu ............................................................................................................................... 7
Programming the Traction Motor Controller - 1307 Handset ............................................................................... 8
1311 Programmer Handset ................................................................................................................................. 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 ................................................................. 12
Main Menu Selections ..................................................................................................................................... 13
Program Menu ............................................................................................................................................ 13
Monitor Menu .............................................................................................................................................. 13
Faults Menu ................................................................................................................................................ 14
Functions menu .......................................................................................................................................... 14
Information Menu ........................................................................................................................................ 15
Programmer Setup Menu............................................................................................................................ 15
Programming the Traction Motor Controller - 1311 Handset ............................................................................... 15
Troubleshooting ................................................................................................................................................... 16
Status LED Diagnostics .................................................................................................................................. 16
Diagnostics Menu............................................................................................................................................ 17
Test Menu........................................................................................................................................................ 27
This section is for the following models:
NDR030GB, NR045GB [B861];

NDR030AE, NR035/040/045AE [C815];
NS040AF, NS050AF [C816];
NDR030CB, NR045CB [D829]
©2005 Yale Materials Handling Corp. i

2200 YRM 977 SEM Traction Motor Controller
SEM Traction Motor Controller

DESCRIPTION/FEATURES REMOVE
The Curtis Model 1244-4405 SEM Traction Motor Con- 1. Move the lift truck to a safe, level area. Turn the
troller uses a sophisticated microprocessor to control key switch to the OFF position and remove the key.
the logic and operation of the controller, eliminating the Put a DO NOT OPERATE tag on the control handle.
need for forward and reverse contactors. See Figure 1. Put blocks under the drive wheels to keep the lift
The SEM motor controller operates on the principle of truck from moving. See the section Periodic Main-
controlling the motor field circuit and the motor arma- tenance 8000 YRM 970. Refer to HOW TO PUT
ture circuit in dependently. The controller has many pro- THE LIFT TRUCK ON BLOCKS.
grammable features, including acceleration rate, maxi-
mum speed, braking current limit, and neutral braking WARNING
current limit. The operator can also select from three
Disconnect the battery and separate the connector
different performance modes to customize the opera-
before opening the compartment cover or inspect-
tion of the truck to the application, as required. The
ing/repairing the electrical system. If a tool causes
SEM controller includes a full range of features as well
a short circuit, the high current flow from the bat-
as a diagnostic and setup capability for reliable opera-
tery can cause an injury or parts damage.
tion.
2. Disconnect and separate the battery connector.
Remove the battery. See the section Periodic
Maintenance 8000 YRM 970. 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 YRM 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 discon-
nected. To prevent electrical shock and injury, dis-
Figure 1. Traction Motor Controller charge the capacitor before inspecting or repairing
any component. Wear safety glasses. Make cer-
The Curtis Model 1307 Programmer Handset is used to tain the battery has been disconnected. Discharge
program and troubleshoot the traction motor controller. the capacitors in the controller by connecting a load
Refer to 1307 Programmer Handset. (such as a contactor coil or a horn) across the con-
troller’s B+ and B terminals. DO NOT use a screw-
The traction motor controller communicates with the
driver to discharge the traction motor controller.
dash display for selection of performance modes and
for diagnostic information. The performance mode se- 4. Discharge the controller by connecting a load
lection feature allows the operator to choose from three across terminals B+ and B .
different motor controller performance levels by pushing
a button on the dash display. The rate of acceleration, 5. Unplug the connector from the traction motor con-
maximum top speed, and braking rate can be specif- troller. Tag and disconnect the wires to the power
ically assigned for each mode using the programmer terminals.
handset.
6. Remove the capscrews, washers, and nuts retain-
Simplified diagnostic information is communicated to ing the controller to the frame. The capscrews are
the dash display to alert the operator to adverse condi- accessed from the battery compartment. Carefully
tions such as controller over temperature, operator se- remove the traction motor controller from the lift
quence error, or motor controller malfunction. truck.
1
SEM Traction Motor Controller 2200 YRM 977
TEST controller. Align the traction motor controller in the

lift truck. Install the capscrews, washers, and nuts
Refer to 1307 Programmer Handset for complete test- to retain the controller to the frame. The capscrews
ing and troubleshooting procedures for the Traction Mo- must be installed from the battery compartment up
tor Controller. through the controller.
The traction motor controller cannot be repaired. The 2. Connect the power wires to the terminals. See Fig-
traction motor controller is sealed and contains no ser- ure 2. Plug the X-3 connector into the J1 receptacle
viceable parts. If testing has determined the traction of the traction motor controller. See the section Di-
motor controller to be faulty, it must be replaced. agrams 8000 YRM 980 and Diagrams 8000 YRM
982 for additional information.
INSTALL
3. Refer to Programming the Traction Motor Controller
1. Make certain that the mounting surface for the trac- - 1307 Handset to set up the controller.
tion motor controller is clean. There should be
no dirt between the frame and the traction motor
Figure 2. Traction Motor Controller Pin Arrangement
2
2200 YRM 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 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
1. CONNECT TO J1 2. PROGRAMMER HANDSET CONNECTION
1307 Programmer Handset

DESCRIPTION/FEATURES
The Programmer Handset is a hand-held tool that al-
lows the user to program, test, and diagnose the Trac-
tion Motor Controller. See Figure 3. It has been de-
signed for ease of use with eight keys to control all func-
tions. 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 Handset
6. SELECTS DIAGNOSTICS MENU
7. CHANGES VALUE OF SELECTED ITEM
3
1307 Programmer Handset 2200 YRM 977
The display window contains a four-line LCD display. OPERATION

This display is visible in most lighting conditions. When
the programmer is in the PROGRAM, TEST, or DIAG- Connecting Handset to Traction Motor
NOSTICS mode, four lines of a menu are displayed. Controller
The item at the top of the display window is the selected
item (In the PROGRAM menu, the selected item will be NOTE: Each time the programmer handset is con-
highlighted with a flashing arrow.). nected to the controller, it acquires all of the controller
function value settings and stores them in its temporary
SCROLL DISPLAY KEYS memory. This allows the user to revert back to the
original settings at any time. The SPECIAL PROGRAM
To scroll up and down within a menu, use the two menu selection RESET ALL SETTINGS is used to
SCROLL DISPLAY arrow keys. The SCROLL DIS- revert to the original settings. Any inadvertent change
PLAY arrow keys can be pressed repeatedly or held made to any of the function values can be "undone"
down. When a key is held down, the scrolling speed in this manner, as long as the programmer has not
increases the longer the key is held. been unplugged or the key switch turned OFF (power
disconnected).
To the left of the PROGRAM, TEST, and DIAGNOS-
TICS menu, a small scroll bar is displayed. The scroll 1. Turn the key switch to the OFF position.
bar gives a rough indication of the position of the four
displayed items within the entire menu. That is, when 2. Disconnect and separate the battery connector.
the scroll bar is at the top of the window, the top of the
menu is displayed. When scrolling through the menu, 3. Remove the front cover. See the section Frame
the bar will move downward. When the bar is at the bot- 100 YRM 975 for the removal procedures. Refer to
tom, the end of the menu has been reached. COVERS, PANELS, AND PLATES.
CHANGE VALUE KEYS WARNING

The CHANGE VALUE arrow keys increase or decrease
the value of the selected menu item. There is an LED
on each arrow key to indicate when the key is active and
charge the capacitor before inspecting or repairing
when a change is permissible. When the LED is off, the
limit setting (maximum or minimum) of the function has
tain the battery has been disconnected. Discharge
been reached.
the capacitors in the controller by connecting a load
The CHANGE VALUE keys may be pressed repeatedly (such as a contactor coil or a horn) across the con-
or held in the same manner as the SCROLL DISPLAY troller’s B+ and B terminals. DO NOT use a screw-
keys. The longer the key is held, the faster the value driver to discharge the traction motor controller.
changes. This allows rapid changing of any functions
4. Discharge the capacitors in the traction motor con-
value.
troller by connecting a load (such as a contactor coil
MORE INFO KEY or a horn) across the controller’s B+ and B termi-
nals.
The MORE INFO key is used to display additional infor-
mation about the selected item and to access the SPE- NOTE: The Programmer Handset should only be con-
CIAL PROGRAM MENU and the DIAGNOSTICS HIS- nected and disconnected with the key switch in the OFF
TORY MENU. When the programmer is in any of the op- position.
erating modes, the MORE INFO key may be pressed to 5. Connect the Programmer Handset to the 4-pin
display additional information about the selected item. Molex connector on the traction motor controller.
Press the MORE INFO key again to return to the orig- See Figure 2.
inal list. In the PROGRAM menu, a bar graph is dis-
played along with the minimum and maximum values 6. Reconnect the battery.
available for the selected item. If the minimum or maxi-
mum value has been programmed, a message replaces NOTE: The brake pedal must be released (up position).
the bar graph and any dependencies are listed.
7. Turn the key switch to the ON position. Ensure the
battery disconnect switch is closed.
4
Disconnecting Handset From Traction 4. Disconnect the Programmer Handset from the
Motor Controller 4-pin Molex connector on the traction motor con-
troller.
1. Turn the key switch to the OFF position.
NOTE: The Programmer Handset should only be con-
2. Disconnect and separate the battery connector. nected and disconnected with the key switch in the OFF
position.
troller by connecting a load (such as a contactor coil 5. Install the front cover.
or a horn) across the controller’s B+ and B termi-
nals. 6. Reconnect the battery.
Programmer Self Test

WARNING
The capacitor in the traction motor controller can You can test the programmer by displaying two spe-
hold an electrical charge after the battery is discon- cial test screens. Press and hold the MORE INFO key
nected. To prevent electrical shock and injury, dis- while the programmer is powering up. During the SELF
charge the capacitor before inspecting or repairing TEST, you can toggle between the two test screens by
any component. Wear safety glasses. Make cer- pressing the SCROLL DISPLAY keys. See Figure 4.
tain the battery has been disconnected. Discharge The first screen turns on every LCD element, and the
the capacitors in the controller by connecting a load second screen displays all the characters used in the
(such as a contactor coil or a horn) across the con- various menus. As part of the SELF TEST, you can
troller’s B+ and B terminals. DO NOT use a screw- also test the keys by pressing each one and observ-
driver to discharge the traction motor controller. ing whether its corner LED lights up. To exit the SELF
TEST, unplug the programmer or turn the key switch to
the OFF position.
Figure 4. Programmer Handset Self Test
OPERATING MODES display window, four at a time, with the corresponding

settings. The setting of the selected item (the item
Program Menu at the top of the display with the flashing arrow) can
be changed using the CHANGE VALUE keys. The
Press the PROGRAM key to enter the PROGRAM CHANGE VALUE keys have LEDs to indicate whether
mode. See Table 1. The LED in the corner of the PRO- the key can be used to increase or decrease the value
GRAM key illuminates to indicate that the programmer any further. When the LED is no longer lit, the limit for
has been placed in the PROGRAM mode. All of the the key direction has been reached.
adjustable functions and features are shown in the
5
Table 1. Program Menu Test Menu
Program Menu Press the TEST key to enter the TEST mode. See Ta-
Description ble 2. The LED in the corner of the TEST key illumi-
Display
nates to indicate that the programmer has been placed
M3 Brake C/L Mode 3 braking current, in in the TEST mode. The TEST menu displays real time
amps information about the status of the inputs, outputs, and
M2 Brake C/L Mode 2 braking current, in controller temperature. In the TEST mode, the item of
amps interest does not need to be the top item in the window;
it only needs to be one of the four items displayed in
M1 Brake C/L Mode 1 braking current, in the window. The TEST mode is useful for checking out
amps the operation of the controller during initial installation.
M3 Neut Brk % Mode 3 neutral braking, as % The MORE INFO key, when used in the TEST mode,
of brake C/L displays additional information about the top item in the
window.
M2 Neut Brk % Mode 2 neutral braking, as %
of brake C/L Table 2. Test Menu
M1 Neut Brk % Mode 1 neutral braking, as %
of brake C/L Test Menu
Description
Display
M3 Accel Rate Mode 3 acceleration rate, in
seconds THROTTLE % Throttle reading, as % of full
throttle
seconds ARM CURRENT Motor armature current, in
amps
seconds FIELD CURRENT Motor field current, in amps
Taper Rate Regen braking decrease rate, BATT VOLTAGE Battery voltage across the
when transitioning to plug, in capacitors
1/32 seconds HEATSINK C Heatsink temperature in C
M3 Max Speed Mode 3 maximum speed, as FORWARD INPUT Forward signal input from MIB:
% of top speed ON or OFF
M2 Max Speed Mode 2 maximum speed, as REVERSE INPUT Reverse signal input from MIB:
% of top speed ON or OFF
M1 Max Speed Mode 1 maximum speed, as INTERLOCK Brake switch input:
% of top speed INPUT ON or OFF
MAIN CONT Traction contactor:
Press the MORE INFO key to display more detailed in- OPEN or CLOSED
formation for the setting selected, including a bar graph
indicating the position of the current setting relative to FAULT 1 OUTPUT Fault 1 driver status:
the range for the setting, the unit of measure, and the ON (low) or OFF (high)
specific minimum and maximum values for the setting. FAULT 2 OUTPUT Fault 2 driver status:
If the range is limited by the values assigned for a dif- ON (low) or OFF (high)
ferent function, the name of the limiting function is dis-
played in place of the minimum and maximum values. MODSEL 1 Mode select inputs 1 and 2
together define the operating
MODSEL 2 mode from the dash display to
the controller. Refer to Table 3.
6
Table 3. Dash Display Drive Mode Inputs Table 4. Diagnostics and Diagnostic History
Display (Continued)
Drive Mode
Test Menu
Turtle Middle Rabbit Diagnostics Menu
Definition
Display
Mode Select Input 1 OFF ON OFF
MISSING Missing Contactor
Mode Select ON OFF ON
CONTACTOR
Diagnostics Menu NO KNOWN No known faults have occurred

FAULTS
Press the DIAGNOSTIC key to enter the DIAGNOSTIC OVERVOLTAGE Battery voltage too high
mode. The LED in the corner of the DIAGNOSTIC key
illuminates to indicate that the programmer has been SRO Static Return to Off activated
placed in the DIAGNOSTIC mode. The DIAGNOSTICS THERMAL Cutback, due to
menu displays all currently active faults detected by the CUTBACK over/undertemperature
controller. It is capable of displaying 19 different faults,
four at a time. THROTTLE FAULT Throttle out of range
1
NOTE: The DIAGNOSTICS and DIAGNOSTIC HIS-
THROTTLE FAULT Throttle low fault
TORY display shown in Table 4 is not a menu as
2
such, but simply a list of the possible messages
displayed when the programmer is operating in the
DIAGNOSTICS or DIAGNOSTIC HISTORY modes. Diagnostic History
The messages are listed in alphabetical order for easy
reference. Press the DIAGNOSTICS key and the MORE INFO
key simultaneously to enter the DIAGNOSTIC HIS-
Table 4. Diagnostics and Diagnostic TORY menu. The DIAGNOSTIC HISTORY lists all
History Display of the faults observed and recorded by the controller
since the history was last cleared. Press the SCROLL
Diagnostics Menu DOWN key to display any recorded faults. Each fault
Definition
Display will be listed only once, regardless of the number of
times the fault may have occurred.
ARM SENSOR Armature sensor fault
CONT DRVR OC Contactor driver overcurrent The diagnostic history can be cleared from the con-
troller using the SPECIAL PROGRAM MENU function,
Field winding open or CLEAR DIAG HISTORY. Press the PROGRAM key
FIELD OPEN
disconnected while holding the MORE INFO key. Press the SCROLL
FLD SENSOR Field sensor fault DOWN key until CLEAR DIAG HISTORY appears in
the top line of the display. Press the MORE INFO
HPD High Pedal Disable activated key again, and then press the VALUE UP key to clear
HW FAILSAFE 1 Power-on self test fault the history or the VALUE DOWN key to cancel the
operation.
HW FAILSAFE 2 External watchdog fault
HW FAILSAFE 3 Internal watchdog fault Special Program Menu
LOW BATTERY Battery voltage too low Press and hold the MORE INFO key, then press the
VOLTAGE PROGRAM key to enter the SPECIAL PROGRAM
menu. See Table 5. The SPECIAL PROGRAM menu
M output (Controller M
M SHORTED allows the user to: revert the controller to previous
Terminal) shorted to B
settings, save controller settings to the programmer
Traction contactor did not memory, load controller settings from the programmer
MAIN CONT DNC
close memory, clear diagnostic history, adjust the contrast of
the programmer display, select language, and display
MAIN CONT Traction contactor welded
basic controller and programmer information. Press the
WELDED
7
Programming the Traction Motor Controller - 1307 Handset 2200 YRM 977
SCROLL DISPLAY key until the desired function is on Table 5. Special Program Menu (Continued)
the top line. Press the MORE INFO key for information
on how to make the desired adjustment.
Special Program
Definition
The SPECIAL PROGRAM menu also allows the user to Menu Display
"clone" controllers. After one controller is programmed PROG SET- Load programmer settings
with all of the desired values, the values can be saved TINGS→CONT to controller
to the programmer handset memory. The programmer
handset can then be used to load the saved values to CLEAR DIAG Clear DIAGNOSTIC
other similar controllers (same model number). HISTORY HISTORY memory
CONTRAST Adjust programmer display
Table 5. Special Program Menu
ADJUSTMENT contrast
Special Program LANGUAGE Select displayed language
Definition
Menu Display SELECTION
RESET ALL Revert to previous settings PROGRAMMER Display programmer
SETTINGS INFO information
CONT SET- Save controller settings to CONTROLLER INFO Display controller
TINGS→PROG programmer information
Programming the Traction Motor Controller - 1307 Handset

WARNING (such as a contactor coil or a horn) across the con-
NEVER adjust function settings outside the range troller’s B+ and B terminals. DO NOT use a screw-
recommended for the specific truck model. See Ta- driver to discharge the traction motor controller.
ble 6.
WARNING troller by connecting a load (such as a contactor coil
or a horn) across the controller’s B+ and B termi-
Program changes affect lift truck performance and
nals.
operation. If function settings are changed, make
sure all operators of the lift truck know that the truck 5. Connect the PROGRAMMER HANDSET to the
has been changed and may operate differently. traction motor controller. Connect the cord of the
handset plug into the 4-pin Molex, Mini-Fit Jr. re-
ceptacle on the front of the controller.
2. Disconnect and separate the battery connector.
NOTE: Each time the programmer handset is con-
3. Remove the front cover. See the section Frame nected to the controller, it acquires all of the controller
100 YRM 975 for the removal procedure. Refer to function value settings and stores them in its temporary
Covers, Panels, and Plates. 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
WARNING revert to the original settings. Any inadvertent change
The capacitor in the traction motor controller can made to any of the function values can be "undone"
hold an electrical charge after the battery is discon- in this manner, as long as the programmer has not
nected. To prevent electrical shock and injury, dis- been unplugged or the key switch turned OFF (power
charge the capacitor before inspecting or repairing disconnected).
tain the battery has been disconnected. Discharge 6. Reconnect the battery.
8
2200 YRM 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 Allowed Measure
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
24- and 36-volt
End Regen trucks except 25 1 to 64
TAPER RATE B861 and D829 1/32 second
Taper Rate
B861 and D829 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 SPEED M3 Speed Limit % of Throttle
only EE 75 0 to 75

only EE 85 0 to 85
only EE 75 0 to 75

only EE 65 0 to 65
only EE 65 0 to 65
9
Programming the Traction Motor Controller - 1307 Handset 2200 YRM 977
NOTE: The brake pedal must be released (up position)

during Step 7. WARNING
7. Turn the key switch to the ON position. Ensure bat- operation. If function settings are changed, make
tery disconnect switch is closed. sure all operators of the lift truck know that the truck
has been changed and may operate differently.
8. Press the PROGRAM button on the PROGRAM-
MER HANDSET. The green LED in the corner of the 12. Press the MORE INFO button to return to the PRO-
PROGRAM button lights to indicate that the HAND- GRAM menu, if the MORE INFO screen had been
SET has been placed in the PROGRAM mode. selected.
9. Press the SCROLL DISPLAY buttons, as required, 13. Repeat Step 9 through Step 12 as required, until all
until the desired function is shown on the top line of of the functions are set to the desired values.
the display.
NOTE: Any inadvertent change made to any of the func-
10. Press the MORE INFO button to display additional tion values can be "undone" using the SPECIAL PRO-
information, if desired, on the selected function. GRAM menu selection RESET ALL SETTINGS, as long
The green LED in the corner of the MORE INFO as the programmer has not been unplugged or the key
button lights to indicate that the MORE INFO op- switch turned OFF (power disconnected).
tion has been selected.
NOTE: Some function values are limited by values set
for other functions. For example, the value for M2 AC- 15. Disconnect and separate the battery connector.
CELERATION RATE (Mid Mode) must be equal to or
less than the value for M1 ACCELERATION RATE (Tur- WARNING
tle 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 maxi-
mum values normally displayed.
any component. Wear safety glasses. Make certain
the battery has been disconnected. DO NOT use
WARNING a screwdriver to discharge the traction motor con-
NEVER adjust function settings outside the range troller.
recommended for the specific truck model.
16. Discharge the capacitors in the controller by con-
11. Press the CHANGE VALUE buttons to change the necting a load (such as a contactor coil or a horn)
function value higher or lower, as required. A green across the controller’s B+ and B terminals.
LED on each CHANGE VALUE button lights to indi-
cate that the function value can be changed in the 17. Disconnect the programmer handset cord from the
corresponding direction. If the green LED on one traction motor controller.
of the CHANGE VALUE buttons is not illuminated, 18. Install the front cover.
the value has reached the limit for the correspond-
ing direction.
10
1311 Programmer Handset

DESCRIPTION/FEATURES Menu Navigation Key
The programmer handset is a handheld tool that allows The navigation key is a four-position switch that allows
the user to program, test, and diagnose the traction mo- you to move up and down a menu list using the top or
tor controller. See Figure 5. It has been designed for bottom arrows or you can open and close sub-menus
ease of use with a navigation key, data increase/de- using the right and left arrows. Use the navigation key to
crease key, and three bookmark keys to control all pro- move up or down through the main menu items. There
grammer functions. is a blinking square on the left side of the programmer
that indicates the current menu selection. See Figure 6.
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 visible in most
lighting conditions and can be adjusted using the pro-
grammer 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 program-
mer to generate menu items that will be displayed by
the programmer. Figure 6. Menu Selection
After selection of a main menu item, submenus for the

main selection can be opened using the right arrow.
See Figure 7. As submenus are opened, a new series
of indicator boxes will appear with a blinking square to
indicate the current submenu selection. You can move
up and down within the submenus using the up and
down arrows. Pressing the left arrow will return the
programmer to the main menu. Pressing the right ar-
row while in a submenu will bring up an additional infor-
mation screen about the submenu item previously se-
lected. See Figure 8.
Figure 5. Curtis Model 1311 Programmer Handset
Figure 7. Menu Selection
11
revert to the original settings. 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).
1. Turn the key to the OFF position.
2. Disconnect the battery.
3. Remove drive unit compartment cover.
WARNING
Figure 8. Menu Selection charge the capacitor before inspecting or repairing
Data Increase/Decrease Key tain the battery has been disconnected. Discharge
The date increase/decrease key allows the adjustment
(such as a contactor coil or a horn) across the con-
of various parameter setting by pressing the + side of
troller’s B+ and B terminals. DO NOT use a screw-
the switch to increase a value or by pressing the side
driver to discharge the traction motor controller.
of the switch to decrease a value. See Figure 5.
4. Discharge the capacitors in the controller.
Bookmark Keys
5. Connect programmer handset to the four-pin
There are three bookmark keys that can be set by the Molex™ connector on the traction motor controller.
user. These keys allow you to bookmark your position
within the menu structure to allow the user to quickly re- 6. Reconnect the battery.
turn to a selection without having to re-navigate the en-
tire menu structure. While you are positioned at a menu 7. Turn the key to the ON position.
item you want to bookmark, press one of the bookmark
buttons and hold it down for four seconds until the book- Disconnecting the Handset From the
mark set screen appears. You can return to this preset Traction Motor Controller
menu item at any time by pressing the bookmark but-
ton you assigned to this item. Bookmarks are perma- 1. Turn the key to the OFF position.
nently retained in the programmer memory. Once the
2. Disconnect the battery.
programmer has been unplugged or power to the con-
troller has been interrupted, the bookmarks are cleared
from the programmer memory. See Figure 5. WARNING
OPERATION hold an electrical charge after the battery is discon-
Connecting Handset to Traction Motor charge the capacitor before inspecting or repairing
Controller any component. Wear safety glasses. Make cer-
NOTE: Each time the programmer handset is con- the capacitors in the controller by connecting a load
nected to the controller, it acquires all of the controller (such as a contactor coil or a horn) across the con-
function value settings and stores them in its temporary troller’s B+ and B terminals. DO NOT use a screw-
memory. This allows the user to revert back to the driver to discharge the traction motor controller.
original settings at any time. The special program
menu selection RESET ALL SETTINGS is used to 3. Discharge the capacitors in the controller.
12
4. Disconnect programmer handset from the four-pin

Molex™ connector on the traction motor controller.
NOTE: The programmer handset should only be con-

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 adjustable
parameters downloaded to the programmer from the
Monitor Menu
motor controller. The motor controller can be setup for
specific operating conditions by changing the parame- The monitor menu will contain a list of all truck func-
ters that can be accessed through the program menu tions that can be read and displayed by the program-
selections. Those parameters that can be adjusted by mer. Using the menu navigation key, scroll up or down
the handset will be shown as submenu items under the to select a parameter from the list. See Figure 11.
program menu. Each menu item is constantly monitored and displayed
to show real-time information about the selected func-
Use the up or down arrow on the navigation key to select
tion.
a parameter. See Figure 9. Press the right arrow key
to access the detail screen for the selected parameter. To view a single function in real time, press the right
See Figure 10. The detail screen will show the mea- arrow on the menu navigation key and a detail screen
surement units, min/max range for the parameter, and a about the selected parameter will appear. See Fig-
bar graph indicating the current parameter setting. The ure 12.
setting may be changed using the Increase/Decrease
key. Press the (+) to increase the value or press ( ) to To return to the monitor menu or the main menu, press
decrease the value. the left arrow on the menu navigation key.
To return to the program menu or the main menu, press

the left arrow on the menu navigation key.
13

Faults Menu
The faults menu will provide the present status of the
motor controller and access to past fault history. The
fault history is up-loaded to the programmer when the
programmer is connected to the motor controller. Use
the menu navigation key to access system faults, fault
history, or to clear the fault history. See Figure 13.
Functions menu
The functions menu is used to copy data between motor
controllers or reset the data in a controller to the orig-
inal settings. Use the menu navigation key to select
Figure 13. Menu Selection the functions menu to access the settings menu. See
Figure 16. From this menu you can upload the param-
System faults will show the current state of the motor eter block from an existing controller and download that
controller. See Figure 14. parameter block into another motor controller. See Fig-
ure 17.
Fault history will list the faults that have been stored in
the motor controller memory. These faults will be shown Each time the programmer is connected to a motor con-
as descriptive text of the fault. Scroll through the faults troller, it uploads the present data from the controller
using the up and down arrows on the menu navigation into the programmer. Using the settings menu, this orig-
key. See Figure 15. inal information can be downloaded into the controller at
any time to restore the controller with the original data.
Clear Fault History is used to remove faults from the
Any inadvertent change in controller parameters can be
controller memory after review. Use the increment (+)
undone using this feature as long as the programmer
arrow on the increase/decrease switch to delete the
has not been disconnected from the controller or the
faults from memory.
power has not been removed from the controller.
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.
14
2200 YRM 977 Programming the Traction Motor Controller - 1311 Handset

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.
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 information
will be displayed on the screen. See Figure 18. Figure 19. Menu Selection
Programming the Traction Motor Controller - 1311 Handset

WARNING WARNING
NEVER adjust function settings outside the range The capacitor in the traction motor controller can
recommended for the specific truck model. See Ta- hold an electrical charge after the battery is discon-
ble 6. nected. To prevent electrical shock and injury, dis-
WARNING any component. Wear safety glasses. Make cer-
the capacitors using the recommended procedures
and never by any other method.
sure all operators of the lift truck know that the truck
has been changed and may operate differently. 4. Discharge the capacitors in the traction motor
controller by connecting a 200-ohm, 2-watt resistor
1. Turn key switch to the OFF position.
across the controller’s B+ and B terminals using
2. Disconnect and separate battery connector. two insulated jumper wires.
3. Remove drive unit compartment cover.
15
Troubleshooting 2200 YRM 977
5. Connect programmer handset to traction motor sure all operators of the lift truck know that the truck
controller. The cord of the handset plugs into the has been changed and may operate differently.
J-3 connector on the front of the controller.
12. Press the LEFT arrow on the menu navigation key
NOTE: Each time the programmer handset is con- to return to the parameters menu.
nected to the controller, it acquires all of the controller
function value settings and stores them in temporary 13. Repeat Step 8 through Step 12, as required, until
memory. This allows the user to return to the original all of the functions are set to the desired value.
settings at any time. Any unwanted change made
NOTE: Any unwanted change made to any of the func-
to any of the function values can be undone in this
tion values can be undone using the RESET ALL SET-
manner, as long as the programmer has not been
TINGS from the FUNCTIONS menu as long as the pro-
unplugged or the key switch turned OFF (power dis-
grammer has not been unplugged or the key switch
connected).
turned OFF (power disconnected).
6. Reconnect battery.
7. Turn key switch to the ON position.
15. Disconnect the battery connector.
8. Select the PROGRAM menu on the programmer
handset. WARNING
9. Use the menu navigation key UP or DOWN arrows The capacitor in the traction motor controller can
to scroll until the desired function is reached. hold an electrical charge after the battery is discon-
10. Press the RIGHT arrow on the menu navigation key charge the capacitor before inspecting or repairing
to enter the function being changed. any component. Wear safety glasses. Make cer-
the capacitors using the recommended procedures
WARNING and never by any other method.
NEVER adjust function settings outside the range
recommended for the specific truck model. See Ta- 16. Discharge the capacitors in the traction motor
ble 6. controller by connecting a 200-ohm, 2-watt resistor
across the controller’s B+ and B terminals using
11. Using the DATA INCREASE/DECREASE key, two insulated jumper wires.
change the function setting to the new setting.
Pressing the (+) will increase the parameter value. 17. Disconnect the programmer handset from the con-
Pressing the ( ) will decrease the parameter set- troller.
ting.
18. Install the drive unit compartment covers.
WARNING 19. Reconnect the battery.

Troubleshooting
The traction motor controller provides diagnostic infor- 3. Test the circuitry (inputs/outputs) using the pro-
mation to the programmer handset, the dash display, grammer handset.
and the status LED on the controller. The following
four-step process is recommended for diagnosing and 4. Correct the problem.
troubleshooting an inoperative vehicle:
STATUS LED DIAGNOSTICS
1. Visually inspect the truck for obvious problems.
A status LED is built into the traction motor controller.
2. Diagnose the problem using the programmer hand- See Table 7. It is visible through a window in the label
set. on the top of the controller. The status LED displays
fault codes when there is a problem with the controller
16
2200 YRM 977 Troubleshooting
or with the inputs to the controller. During normal op- Table 7. Status LED Fault Codes (Continued)
eration, with no faults present, the status LED flashes
steadily on and off. If the controller detects a fault, a
LED Code Explanation
2-digit fault identification code is flashed continuously
until the fault is corrected. For example: code "3,2" - 2,1 Throttle fault
welded traction contactor - appears as three flashes,
2,2 Static return to off (SRO) fault
pause, two flashes, long pause, three flashes, pause,
two flashes, long pause . . . and so on, continuously 2,3 High pedal disable (HPD) fault
until the problem is corrected.
3,1 Contactor driver overcurrent
Table 7. Status LED Fault Codes 3,2 Welded contactor
LED Code Explanation 3,4 Missing contactor, or traction

contactor did not close
OFF (no flashes) No Power or defective
controller 4,1 Low battery voltage
ON (continuously) Controller or microprocessor 4,2 Overvoltage

fault 4,3 Thermal cutback;
0,1 Controller operational, no over/undertemperature
faults
NOTE: Only one LED fault code is indicated at a time,
1,2 Hardware failsafe fault and faults are not queued up. Operational faults, such
1,3 M , current sensor, or motor as a fault in SRO sequencing, are cleared by cycling the
fault key switch.
DIAGNOSTICS MENU
LED Code Dash Display Message Programmer Handset Display Message
COMMUNICATION ERROR WITH CONTROLLER.
0, 1 "Any Message" PRESS SCROLL DOWN TO 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.
17

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.

• No faults that are diagnosable by the traction motor
controller exist.
Logic
Displayed when no known faults are present.

"Any LED PROGRAMMER FAULT
"Any Message"
Code"
Condition
Truck Response
Traction may or may not function normally.

• 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.
18
DRIVE CTRL LIMIT SPEED THERMAL CUTBACK

4, 3
REDUCED THERMAL CUTBACK DUE TO OVER/UNDERTEMP
Condition
Truck Response
Traction speed is reduced.

• 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 tempera-
ture and correct (low battery, overloading, etc.). Logic
Can be caused by excessive load on vehicle, oper- Displayed when the internal temperature of the traction
ation in extreme environments, or improper mount- motor controller is beyond the operating range of 25
ing of controller. When the internal temperature of to +85C. The internal temperature can be read by
the controller returns to the operating range of 25 accessing the test menu on the handset.
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 nor-
mal 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 replaced.
19
DRIVE CONTROL ERROR SRO

2, 2
CHECK ERROR CODE STATIC RETURN TO OFF ACTIVATED
Condition
Truck Response
Traction is disabled until fault condition is corrected.

• 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 potentiometer
to MIB for proper operation. Logic
A shorted traction potentiometer, a traction poten- Displayed when battery volts is simultaneously supplied
tiometer out of adjustment, or a defective MIB can to terminals 2 and 10 or terminals 2 and 11.
also cause the fault.
NOTE: The brake can be released while traveling. If

the operator presses the brake pedal within 3 seconds,
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.
20
DRIVE CONTROL ERROR HPD

2, 3
CHECK ERROR CODE HIGH PEDAL DISABLE ACTIVATED
Condition
Truck Response
Traction is disabled until fault condition is
corrected. (The HPD function has a 3-second
delay during normal operation.)

• Throttle greater than 25% before the brake pedal is
pressed.
Check control handle to ensure it is in the neutral
position.
Check for approximately 0.2 volts at pin 14 and pin Logic
15 at the traction motor controller, with the control Displayed when pin 2 goes to battery voltage if pin 14
handle in neutral. 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 to 25% = 1.25 volts]
Traction Potentiometer Setup.
• MIB failed.
Check the MIB for proper operation. The MIB pro-
vides the throttle position signal to the traction mo-
tor 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.
21

DRIVE CTRL FAULT M FAULT
1, 3
CHECK FAULT CODE
Condition
Truck Response

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

4, 2
REDUCED OVERVOLTAGE
Condition
Truck Response

• Truck voltage greater than 45 volts.
Check to ensure proper battery is in the truck.
• Plugging the charger into the truck instead of the bat-
tery 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.
22

CONT DRVR OC
3, 1 DRIVE CTRL FAULT
CONTACTOR DRIVER OVERCURRENT
Condition
Truck Response

• 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.

HW FAILSAFE
HARDWARE FAILSAFE ACTIVATED
Condition
Truck Response

• 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.
23
DRIVE CTRL LIMIT SPEED LOW BATTERY VOLTAGE

4, 1
REDUCED LOW BATTERY VOLTAGE
Condition
Truck Response

• 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.
"Any or No PROC/WIRING FAULT

DRIVE CTRL FAULT
LED Code" PROCEDURE OR WIRING FAULT
Condition
Truck Response

• Traction motor controller is not wired properly or is
missing required inputs.
Check controller connections. See the section Di- Logic
agrams 8000 YRM 980 and Diagrams 8000 YRM Displayed when internal logic of the traction motor
982. controller detects improper inputs.
24

MISSING CONTACTOR
MISSING CONTACTOR
Condition
Truck Response

• 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 and
sensed in the traction controller coil.
the contactor coil.
Check for continuity between pin 17 at the traction
motor controller and wire #14 at the contactor coil.
Check for continuity between pin 9 at the traction
motor controller and wire #15 at the contactor coil.
These checks should read near 0 ohms. If they do
not, locate the open and repair it.
25

THROTTLE FAULT 1
2, 1 DRIVE CTRL FAULT THROTTLE INPUT FAULT
(OUT OF RANGE)
Condition
Truck Response

• Throttle input voltage (pin 15, wire #29) out of range. Logic
Check wire #29 for short to B or B+. Pin 15 at the traction motor controller is above
Check for continuity between J1-20 (wire #29) at (approximately) 5.0 volts (full speed reference
the MIB and pin 15 (wire #29) at the traction motor voltage) or below (approximately) 0.2 volts
controller. You should read near 0 ohms. If this (neutral reference voltage).
wire is open, find the open and repair it.
• MIB failed.
vides the throttle position signal to the traction mo-
tor 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.
26

THROTTLE FAULT 2
THROTTLE LOW INPUT FAULT
Condition
Truck Response

• Throttle reference voltage (pin 14, wire #30) open or Logic
shorted. Pin 14 at the traction motor controller is above or below
Check wire #30 (pin 14 at the traction motor con- (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.
vides the throttle reference signal to the traction
motor controller via wire #30 (J1-16). With the key
switch ON, pin 14 should measure approximately
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 % is 0 with control handle in neutral.
Information: Press
shown on the 100* with control handle positioned for full-speed travel
MORE INFO
1 top line (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.
27
Menu
Test Menu Operating Range
Item
Scroll display until 0 to 450*
For Additional
ARM CURRENT
Information: Press
is shown on the *Approximate values.
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: Press
is shown on the *Approximate values.
3 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: Press
is shown on the Approximately 31.14 to 39.6 . . . 36-volt truck
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 is
Information: Press
shown on the
MORE INFO
5 top line
HEATSINK C 22 HEATSINK
TEMPERA-
TURE C 22
Indicates traction motor controller heatsink temperature.
28
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: Press
is shown on the FORWARD selected . . . ON
6 MORE INFO
top line
FORWARD INPUT ON FORWARD
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: Press
is shown on the REVERSE selected . . . ON
7 MORE INFO
top line
REVERSE INPUT ON REVERSE
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: Press
is shown on the Brake pedal UP . . . OFF
8 MORE INFO
top line
INTRLCK INPUT ON INTERLOCK
INPUT ON
Shows status of interlock (brake) switch input at traction motor controller.
Menu Test Menu

Operating Range
Item (Traction contactor energized.)
Scroll display until For Additional Traction contactor OPEN . . . OFF
MAIN CONT is shown Information: Press
on the top line MORE INFO Traction contactor CLOSED . . . ON
9
MAIN CONT OPEN MAIN
CONTACTOR
DRIVER IS OFF
Shows status of main* (traction) contactor driver.
*Internal to the traction motor controller.
29
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 OUTPUT ON FAULT 1
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 OUTPUT ON FAULT 2
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.
Menu Test Menu

Operating Range
Item (Rabbit mode shown)
Scroll display until For Additional Turtle Mode . . . ON
MODSEL 1 is shown Information: Press
12 on the top line MORE INFO Mid Mode . . . OFF
MODSEL 1 MODSEL 1 IS
OFF Rabbit Mode . . . 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 until For Additional Turtle Mode . . . OFF
MODSEL 2 is shown Information: Press
13 on the top line MORE INFO Mid Mode . . . ON
MODSEL 2 MODSEL 2 IS
OFF Rabbit Mode . . . 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.
30
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 977 8/05 (5/05)(1/04)(7/02) Printed in U.S.A.

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Maintenance

SEM TRACTION MOTOR

PART NO. 524164468 2200 YRM 977

• 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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

This section is for the following models:

NDR030GB, NR045GB [B861];

©2005 Yale Materials Handling Corp. i

SEM Traction Motor Controller

3. Remove the front and steer compartment covers

TEST controller. Align the traction motor controller in the

Figure 2. Traction Motor Controller Pin Arrangement

Legend for Figure 2

1. CONNECT TO J1 2. PROGRAMMER HANDSET CONNECTION

1307 Programmer Handset

The programmer is powered by the controller. When the

Legend for Figure 3

The display window contains a four-line LCD display. OPERATION

CHANGE VALUE KEYS WARNING

Programmer Self Test

Figure 4. Programmer Handset Self Test

OPERATING MODES display window, four at a time, with the corresponding

Table 1. Program Menu Test Menu

Diagnostics Menu NO KNOWN No known faults have occurred

Programming the Traction Motor Controller - 1307 Handset

Table 6. Program Menu Range and Default Values

24-volt trucks Standard 100 0 to 100

24-volt trucks Standard 100 0 to 100

24-volt trucks Standard 65 0 to 65

NOTE: The brake pedal must be released (up position)

1311 Programmer Handset

The programmer is menu driven and accesses sub-

When the programmer is connected to the motor

After selection of a main menu item, submenus for the

Figure 5. Curtis Model 1311 Programmer Handset

Figure 7. Menu Selection

revert to the original settings. Any unwanted change

1. Turn the key to the OFF position.

2. Disconnect the battery.

3. Remove drive unit compartment cover.

4. Disconnect programmer handset from the four-pin

NOTE: The programmer handset should only be con-

5. Install drive unit compartment cover.

MAIN MENU SELECTIONS

To return to the program menu or the main menu, press

Figure 11. Menu Selection

Figure 9. Menu Selection

Figure 12. Menu Selection

Figure 15. Menu Selection

Figure 16. Menu Selection

Programmer Setup Menu

Figure 17. Menu Selection

Programming the Traction Motor Controller - 1311 Handset

3. Remove drive unit compartment cover.

WARNING 19. Reconnect the battery.

LED Code Explanation 3,4 Missing contactor, or traction

ON (continuously) Controller or microprocessor 4,2 Overvoltage

Possible Causes and Test Procedures