SR SP Transistor Hanset

Maintenance
SR/SP TRANSISTOR
MOTOR CONTROLLER
AND HANDSET
ALL ELECTRIC LIFT TRUCKS WITH SR/SP
TRANSISTOR MOTOR CONTROLLERS
PART NO. 524164220 2200 YRM 779

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!
SR/SP Transistor Motor Controller and Handset Table of Contents
TABLE OF CONTENTS
Introduction to SEM ............................................................................................................................................. 1

Advantages of Transistorized SEM ................................................................................................................. 1
Features of SEM ............................................................................................................................................. 1
Solid-State Reversing ................................................................................................................................. 1
Performance and Efficiency ........................................................................................................................ 1
Field Weakening ......................................................................................................................................... 1
Regenerative Braking ................................................................................................................................. 1
SR Transistor Traction Motor Controllers ............................................................................................................. 2
Introduction ..................................................................................................................................................... 2
Proportional Operation for Dual-Motor Trucks................................................................................................. 2
General ....................................................................................................................................................... 2
Operation .................................................................................................................................................... 4
Controller Features.......................................................................................................................................... 6
General ....................................................................................................................................................... 6
Creep Speed............................................................................................................................................... 6
Controlled Acceleration............................................................................................................................... 6
Current Limit ............................................................................................................................................... 6
Braking ............................................................................................................................................................ 6
Regenerative Braking to Zero Speed.......................................................................................................... 6
Pedal Position Braking ................................................................................................................................ 6
Auto Regenerative Braking ......................................................................................................................... 7
Conventional Plug Braking.......................................................................................................................... 7
Auxiliary Speed Control................................................................................................................................... 7
Field Weakening ......................................................................................................................................... 7
Speed Limits ............................................................................................................................................... 7
Ramp Operation.............................................................................................................................................. 7
Ramp Start.................................................................................................................................................. 7
Antirollback ................................................................................................................................................. 7
Steer Pump Contactor Time Delay.................................................................................................................. 7
On-Board Coil Drivers and Internal Coil Suppression..................................................................................... 8
System Protective Override............................................................................................................................. 8
SRO (Static Return to Off) .......................................................................................................................... 8
Accelerator Volts Hold Off........................................................................................................................... 8
Pulse Monitor Trip (PMT) ............................................................................................................................ 8
Thermal Protector (TP) ............................................................................................................................... 8
Low Voltage ................................................................................................................................................ 8
SP Lift Pump Controllers ..................................................................................................................................... 8
Sensor Interface/Contactor Driver Module .......................................................................................................... 13
Diagnostic Status Codes and Troubleshooting.................................................................................................... 13
General Maintenance Instructions .................................................................................................................. 13
Special Precautions .................................................................................................................................... 13
Diagnostics...................................................................................................................................................... 14
Systems Diagnostics .................................................................................................................................. 14
Status Codes................................................................................................................................................... 14
Standard Status Codes............................................................................................................................... 14
Stored Status Codes................................................................................................................................... 15
Other Features ................................................................................................................................................ 15
Hourmeter Readings................................................................................................................................... 15
Maintenance Alert and Speed Limit............................................................................................................ 15
Battery Discharge Indication (BDI) ............................................................................................................. 15
Internal Resistance Compensation............................................................................................................. 15
©2005 Yale Materials Handling Corp. i

Table of Contents SR/SP Transistor Motor Controller and Handset
TABLE OF CONTENTS (Continued)

Handset Programmable .............................................................................................................................. 15
RS 232 Communication Ports..................................................................................................................... 15
Circuit Board Coil Driver Modules............................................................................................................... 15
Maintenance Management Capability ........................................................................................................ 16
Interactive Instrument Panel Modes (Premium Only) ................................................................................. 16
General Troubleshooting Instructions.............................................................................................................. 18
Status Code Troubleshooting Tables ................................................................................................................... 19
Description ...................................................................................................................................................... 19
SR/SP Handset Instructions ................................................................................................................................ 58
General Features ............................................................................................................................................ 58
Connecting Handset........................................................................................................................................ 60
Startup Sequence ........................................................................................................................................... 61
Setup Mode..................................................................................................................................................... 61
Stored Status Code Mode............................................................................................................................... 61
Clearing Stored Status Codes......................................................................................................................... 62
Restarting Lift Truck ........................................................................................................................................ 62
SR Traction Controller Function Descriptions...................................................................................................... 63
Premium Instrument Panel Interactive Modes ................................................................................................ 69
SP Pump Controller Function Descriptions ......................................................................................................... 72
Premium Instrument Panel Interactive Modes ................................................................................................ 75
This section is for the following models:
All Electric Lift Trucks With SR/SP Transistor Motor Controllers
ii
2200 YRM 779 Introduction to SEM
Introduction to SEM
ADVANTAGES OF TRANSISTORIZED SEM The line contactor is normally the only contactor re-
quired for the SEM traction circuit. This contactor is
Historically, most electric lift trucks have relied on series used for both precharge of the line capacitors and for
motor designs because of their ability to produce very shutdown of the motor circuit in the event of certain mal-
high levels of torque at low speeds. As the demand functions. The line contactor is energized and de-ener-
for high-efficiency systems increases, shunt motors are gized by the key switch.
now often being considered over series motors. In most
applications, by independently controlling the field and Performance and Efficiency
armature currents in the separately excited motor, the
best attributes of both the series- and the shunt-wound Because the SEM controller has the ability to control
motors can be combined. both the armature and field circuits independently, the
system can normally be adjusted for maximum system
FEATURES OF SEM efficiencies at certain operating parameters. Generally
speaking, with the ability of independent field and arma-
Solid-State Reversing ture control, the motor performance curve can be max-
imized through proper control application.
The direction of armature rotation on a shunt motor
is determined by the direction in which current flows Field Weakening
through the field windings. Because the shunt motor
field only typically requires about 10 percent of the ar- Field weakening of a series-wound motor is accom-
mature current at full torque, it is normally cost effective plished by placing a resistor in parallel with the field
to replace the double-pole, double-throw, reversing con- windings of the motor. Bypassing some of the field
tactor with a low-power transistor H-Bridge circuit. See current into the resistor causes the field current to be
Figure 1. less or weakened, and motor speed can increase. To
change the speed during field weakening, it is nec-
essary to change the resistor value. In a separately
excited motor, independent control of the field current
provides for an infinite adjustment of field-weakened
speeds, between motor base speed and maximum
weak field. The transistorized control also eliminates
the contactor and resistor required for field weakening
with a series motor.
Regenerative Braking
Regenerative braking (braking energy returned to the
battery) may be accomplished completely with solid-
state technology. The main advantage of regenerative
braking is increased motor life. Motor current is reduced
by 50 percent or more during braking while maintain-
Figure 1. Simplified Motor Circuit ing the same braking torque as electrical braking with
a diode clamp around the armature. The lower current
By energizing the transistors in pairs, current can be translates into longer brush life and reduced motor heat-
made to flow in either direction in the field. The field and ing. Solid-state regenerative braking also eliminates a
armature control circuits typically operate at 12 kHz to power diode, current sensor, and contactor from the cir-
15 kHz, a frequency range normally above human hear- cuit.
ing. This high frequency, coupled with the elimination of
directional contactors, provides very quiet lift truck op-
eration.
1
SR Transistor Traction Motor Controllers 2200 YRM 779
SR Transistor Traction Motor Controllers

INTRODUCTION when the steer wheel nears the 90 degree turn angle,
the inside motor is reconnected in the opposite direction
The SR controllers are sealed units with no service- of the outside wheel. At this point, torque is returned to
able components. User-adjustable features allow the the inside wheel, and the speed is the same on both
controllers to be customized for different applications. motors.
Self-diagnostics are provided to monitor internal com-
ponents as well as to detect problems with certain in- With two controllers, the speed of each motor can be
puts and outputs. Adjustable parameters and status regulated independently. The driver controls the speed
codes are accessed using a handset or a personal com- of the outside wheel with the accelerator input signal.
puter. See the section Troubleshooting and Adjust- The inside wheel speed is controlled by the turn angle
ments With a Computer, For EV-100ZX, EV-T100, of the steer tire. A potentiometer attached to the steer
SR (SEM) and SP Motor Controllers (Windows Ver- axle communicates the steer angle to the controllers.
sion) 2200 YRM 947 for information on the use of a PC. See Figure 2.
Handset and cable........... Yale P/N 580001633

SR/SP cable* only ........... Yale P/N 580001634
(*For connecting LX/ZX handset to SX/SR controller)
PC adapter cable kit*....... Yale P/N 580001632
(*Includes PC cable, 9-pin to 20-pin adapter and cord)
The SR controller is a transistorized separately excited

motor (SEM) traction motor controller, providing sepa-
rate control of the motor field and armature currents.
The SR 450 traction controller is rated at 400 amps ar-
mature current and 40 amps field current. Two SR con-
trollers are utilized on dual-drive motor trucks to provide
proportional control of drive motor speeds during turns.
The left control is considered the primary control and
the right control is the secondary control.
PROPORTIONAL OPERATION FOR Figure 2. Steer Angle/Drive Motor Performance

DUAL-MOTOR TRUCKS Profile
General See the section Electrical System 2200 YRM 698 or

Electrical System 2200 YRM 774 for troubleshooting,
A key performance advantage of this controller is the installation, and adjustment procedures for the steer an-
ability to achieve actual proportioning of motor speed on gle potentiometer.
dual-motor trucks. When the lift truck turns, the outside
drive wheel turns in a larger circle than the inside wheel. Refer to Table 1 for the SR traction controller connec-
In a nonproportioning, or single-control system, at some tions.
degree of turn angle, the inside wheel must slow down
to prevent scrubbing of the wheel. This is accomplished Refer to Figure 3 for a typical SR traction controller
on a dual-motor, single-control system by disconnect- schematic. See the section Diagrams 8000 YRM 771
ing the power to the inside motor and letting the wheel or Diagrams 8000 YRM 696 for specific wiring details
roll at whatever speed is dictated by the outside wheel. for your lift truck.
The main disadvantage of this system is that no torque
is available from the inside motor at this time and per-
formance in a turn is reduced. On a dual-motor truck,
2
2200 YRM 779 SR Transistor Traction Motor Controllers
Table 1. SR Traction Controller Connections/Descriptions
Left Traction Controller Right Traction Controller

Pin No. Wire
Description Wire No.
No.
P1 12 Battery Volts From Positive (BAT) Side of Key Switch 12
P2 10 Battery Volts From Negative (IGN) Side of Key Switch 10
P3 15 Battery Volts From Start Switch 15
P4 6 Battery Volts From Forward Switch 6
P5 8 Battery Volts From Reverse Switch 8
P6 7 Battery Volts From Seat Switch 7
P7 29 Accelerator Potentiometer Wiper Voltage Signal Input 29
P8 13 Controller Negative (To Steer Not Used -
Angle Pot)
P9 67 +5 Volt Output (To Steer Angle Pot) Not Used -
P10 50 +12 Volt Enable Signal Output PMT Enable Input (To Left Traction 51
(To Lift Pump Controller) Controller)
P P11 75 +12 Volt Plug/Regen Output Not Used -
(12 Volt=Plug)
P
P12 66 Steer Angle Potentiometer Wiper Voltage Signal Input 66
L
U P13 - Not Used Not Used -
G
P14 110 Brush Wear Indicator Input (From Not Used -
Lift Pump Controller or SICDM)
P15 121 I MOTOR OUT I MOTOR OUT 120
P16 120 Motor Current Compensation Motor Current Compensation 121
P17 24 Line Contactor Coil Driver Not Used -
P18 - Not Used Power Steering Contactor Coil Driver 60
P19 111 +5 Volt Power Supply Output
(To Sensor Interface/Contactor
Driver Module)
P20 109 Motor Overtemperature Input (From Lift Pump Controller or SICDM) 109
P21 51 PMT Enable Output Not Used -
P22 95 Serial Receive - Connects to Instrument Panel 93
P23 94 Serial Transmit - Connects to Instrument Panel 92
3
Table 1. SR Traction Controller Connections/Descriptions (Continued)
Left Traction Controller Right Traction Controller

Pin No. Wire
Description Wire No.
No.
PY1 - Clock (Out) -
PY2 - Data (Out) -
PY3 - Enable (Out) -
PY4 - Negative -
PY PY5 - +5 Volt Supply -
P PY6 - Cont/Store (In) (Handset) -

L PY7 - External Jumper to PY12 -
U
G PY8 - Value -
PY9 - Function -
PY10 - External Jumper to PY11 -
PY11 - Serial Receive/Internal connection to P22 -
PY12 - Serial Transmit/Internal connection to P23 -
Operation wheel, providing a smoother ride throughout the turning

radius of the lift truck.
When the steer tire angle reaches approximately 25 de-
grees, the speed of the inside wheel decreases propor- NOTE: Left and right traction controllers are physically
tionally to the speed of the outside wheel. This pro- identical. Function 17, Controller Type, is used to iden-
portional decline will continue on a linear path until the tify a controller as a right controller or a left controller.
steer tire angle is approximately 65 degrees. At this
point, the inside wheel will stop. As the steer angle is NOTE: Traction motor controller Functions 1 through
increased toward the 90 degrees point, the inside wheel 14, Function 16, and Functions 18 through 63 must
will reverse direction and start to accelerate proportion- have identical values programmed for the right traction
ally in speed. As the steer angle reaches the 90 de- controller and the left traction controller. Never change
grees point, the inside wheel speed will be the same as the value of one of these functions on one traction con-
that of the outside wheel. During this entire turn, ex- troller without changing the value of the same function
cept for several degrees when the motor is stopped to on the opposite controller.
change direction, torque is always present on the inside
4
Figure 3. Typical SR Traction Controller Schematic
5
CONTROLLER FEATURES braking signal has been initiated, the field current is in-
creased. Armature current is regulated to the regener-
General ative braking current limit as set by Function 9. As the
lift truck slows down, the field current continues to in-
The controller has an on-time range of approximately 0 crease, and transistor Q5 begins to turn on and off. See
to 100 percent. The SR and SP controllers operate at Figure 4. The field current will increase until it reaches
a constant frequency, and the percent on time is con- a preset value set by Function 10, and transistor Q5 ON
trolled by the pulse width of the voltage/current applied time will increase until it reaches 100 percent ON time.
to the motor circuits. Once both of the above conditions have been met, and
the regenerative braking current limit can no longer be
Creep Speed maintained, the braking function is canceled. The fields
With the accelerator at maximum volts (approximately will then reverse, and the controller reverts back to mo-
4.2 to 3.5 volts), creep speed can be adjusted by Func- toring.
tion 2. At creep speed, the ON time can decrease
to approximately 5 percent, with the OFF time at ap-
proximately 95 percent. At full transistor operation, this
condition will be reversed (short OFF time, long ON
time). This variation of ON and OFF time of the os-
cillator varies the voltage applied to the motor, thereby
varying the speed of the motor for a given load.
Controlled Acceleration
This feature allows for adjustment of the time it takes
for the controller to accelerate to 100 percent applied
battery voltage to the motor on hard acceleration. Con-
trolled acceleration is adjustable from 0.1 to 22 sec-
onds. Controlled acceleration is adjusted using Func-
tion 3 (standard instrument panel) or Functions 48, 52,
56, and 60 (premium instrument panel).
Current Limit
This circuit monitors motor current by utilizing sensors
in series with the armature and field windings. The infor- Figure 4. Regenerative Braking Circuit
mation is used to maintain maximum currents at a pre-
set value. If heavy load currents are detected, this cir- Part of the energy produced by the motor during regen-
cuit overrides the oscillator and limits the average cur- erative braking is returned to the battery, and part is
rent to a value set by Function 4 and Function 8. The converted to heat in the drive motor.
C/L setting is based on the maximum thermal rating of
the controller. Because of the flyback current, the motor Function 9, Regen Current Limit, is user adjustable and
current is usually greater than battery current, except at will alter the distance the lift truck requires to reach zero
100 percent ON time. speed. Function 10, Regen Field Current, is not nor-
mally adjusted in the field.
BRAKING
Pedal Position Braking
Regenerative Braking to Zero Speed
This feature allows control of the reversing distance
Slowdown is accomplished when reversing direction by based on pedal position when there has been a direc-
providing a small amount of retarding torque for deceler- tional switch change. Pedal position will reduce the
ation. If the lift truck is moving, and the directional lever regenerative braking or plugging current to the value
is moved from one direction to the other, the regener- set by this function as the accelerator is returned to the
ative braking signal is initiated. Once the regenerative creep speed position. Maximum current is obtained
with the accelerator in the top speed position.
6
Auto Regenerative Braking NOTE: Top speed can be reduced by increasing the
value of Maximum Armature Percent On. Maximum Ar-
This feature is enabled by initiating a neutral position mature Percent On must never be adjusted to a value
using either the directional switch or the accelerator less than the factory minimum value. Maximum Arma-
switch. Once activated, auto regenerative braking op- ture Percent On is set using Function 12 (standard in-
erates similar to standard regenerative braking and is strument panel) and Functions 41, 55, 59, and 63 (pre-
adjusted by Function 21. mium instrument panel).
Conventional Plug Braking Speed Limits

Plug braking only occurs when the steer tire is at an This feature provides a means to control speed by limit-
angle of 65 degrees or greater. At steer angles less ing motor volts utilizing three adjustable speed limits.
than 65 degrees, the truck is slowed by regenerative The lower motor volt limit always takes priority when
braking to zero speed. more than one speed limit is activated. This motor volts
limit regulates ON time of the transistor controller, but
During plug braking (when reversing direction), slow-
actual truck speed will vary at any set point depending
down is accomplished by providing a small amount of
on the loading of the lift truck. Each speed limit can be
retarding torque for deceleration. If the lift truck is mov-
adjusted with the handset. Function 11 controls turn
ing, the steer tire is at an angle of 65 degrees or greater,
speed limit. Functions 12, 41, 55, 59, and 63 (Maxi-
and the directional lever is moved from one direction to
mum Armature Percent On) control main speed limit,
the other, the plug signal is initiated. Once the plug sig-
and Function 13 controls maintenance alert speed limit.
nal has been initiated, the field is reversed, and the ar-
mature current is regulated to the plug current limit as
RAMP OPERATION
set by Function 5. Armature current is regulated by in-
creasing the field current as the lift truck slows down. Ramp Start
Once the field current reaches a preset value, set by
Function 10, and armature plug current can no longer This feature provides maximum control torque to restart
be maintained, the braking function is canceled, and the a lift truck on an incline. The memory for this function
controller reverts back to motoring. is the directional switch. When stopping on an incline,
the directional switch must be left in its original or neu-
All energy produced by the motor during plugging is tral position to allow the controller to initiate full power
converted to heat in the drive motor. when restarted. The accelerator potentiometer input
Function 5, Plugging Current Limit, is user adjustable will modulate ramp start current.
and will alter the plugging distance. Function 10, Regen
Field Current, is not normally adjusted in the field. Antirollback
This feature provides retarding torque to limit rollback
AUXILIARY SPEED CONTROL speed in the nontravel direction when the accelerator
pedal is released when stopping on a grade, or when
Field Weakening the brake pedal is released when starting on a grade.
FW Ratio (Function 6) adjusts the field-weakening level This feature forces the lift truck to roll slowly down the
to set the top speed of the motor. The FW Ratio is en- grade when accelerator or brake is released. Because
abled when the armature current is less than the FW the lift truck cannot gain significant speed during roll-
Start Current (Function 24) and the accelerator input back, the torque needed to restart on the ramp is lower
voltage is less than 1 volt. Function 24 is used to opti- than an unrestricted rollback speed.
mize motor and controller performance.
STEER PUMP CONTACTOR TIME DELAY
NOTE: The FW Ratio has been determined by the fac-
tory. Function 6 is not normally adjusted in the field. The steer pump contactor or line contactor will open
when the seat switch opens or the park brake is ap-
NOTE: FW Start, Functions 24, 49, 53, 57, and 61, is plied after the programmed time delay. Function 18 al-
not normally adjusted in the field. lows adjustment of this time delay from 0.5 second to
63 seconds.
7
SP Lift Pump Controllers 2200 YRM 779
ON-BOARD COIL DRIVERS AND • Look again

INTERNAL COIL SUPPRESSION • Automatic look again and reset
The coil drivers for the line contactor and power steering Field or armature field effect transistor (FET) failure that
contactor are internal to the controller. The contactors would cause uncontrolled truck movement is consid-
must have coils rated for the lift truck battery volts. ered a PMT-type fault. The controller monitors both field
and armature FETs at startup and during operation. A
SYSTEM PROTECTIVE OVERRIDE PMT fault will not allow the line contactor to close at
startup, or will open it during operation.
SRO (Static Return to Off)
Thermal Protector (TP)
If the seat switch or key switch is opened, the controller
shuts off and cannot be restarted until the directional This temperature-sensitive device is internal to the
lever is returned to neutral. A time delay of approxi- power transistor (Q1) module. If the transistor’s
mately 2 seconds is built into the seat switch input to temperature begins to exceed the design limits, the
allow momentary opening of the seat switch. thermal protector will lower the maximum current limit
and maintain the transistors within their temperature
Accelerator Volts Hold Off limits. As the controller cools, the thermal protector
will automatically reset, returning the controller to full
This feature checks the voltage level at the accelera- power.
tor input whenever the key switch or seat switch is acti-
vated. If at startup, the voltage is less than 3.0 volts, the Low Voltage
controller will not operate. This feature ensures that the
controller is calling for low-speed operation at startup. Batteries under load, particularly if undersized or more
than 80 percent discharged, will produce low voltages
Pulse Monitor Trip (PMT) at the controller terminals. The SR and SP controllers
are designed for use down to 50 percent of a nominal
The PMT design will disable controller operation if a battery voltage of 36 to 84 volts, and 75 percent of a
fault occurs which would cause a disruption of normal nominal battery voltage of 24 volts. Lower battery volt-
lift truck operation. age may cause the controller to operate improperly, and
the resulting PMT should open the line contactor, in the
The PMT circuit checks for faults three ways: event of a failure.
• Look ahead
SP Lift Pump Controllers

The SP controllers are sealed units with no service- This lift pump motor controller features:
able components. User-adjustable features allow the • Three speeds, adjustable from 0 to 100 percent of
controllers to be customized for different applications. motor volts; the speeds are actuated by connecting
Self-diagnostics are provided to monitor internal com- the appropriate P terminal to battery negative
ponents as well as to detect problems with certain in- • Adjustable current limit and controlled acceleration
puts and outputs. Adjustable parameters and status • Handset and PC programmability
codes are accessed using a handset or a personal com- • Thermal protection
puter. • Low voltage protection
• Systems diagnostics
The SP controller is a transistorized lift pump controller • Premium instrument panel mode select capability
capable of providing multiple lift pump speeds. Many
of the features of the SR traction controller are incorpo-
rated into the lift pump controller.
8
2200 YRM 779 SP Lift Pump Controllers
The three speed limits are activated by the hydraulic The lift pump controller current limit circuit and con-
valve PC board connecting P12, P19, and/or P20 inde- trolled acceleration circuit are adjustable and operate
pendently to battery negative. the same as the traction controller circuits.
The first speed (Speed Limit 1) is activated by connect- The lift interrupt feature will disable the lift pump con-
ing P12 to battery negative. SL1 is set by Function 11. troller when the connection at P10 loses the 12-volt sig-
The specified motor volts will be regulated; however, nal from the traction controller. The battery discharge
motor current will vary, depending on the loading of the feature of the traction controller provides the 12-volt sig-
lift truck. nal to the lift pump controller until the battery is dis-
charged to 10 percent. Lift interrupt can be disabled by
Tilt and auxiliary 1 provide the Speed Limit 1 input. adjusting Function 17 of the traction controller. Do not
adjust function 17 on the pump controller for this pur-
The second speed (Speed Limit 2) is activated by con-
pose.
necting P19 to battery negative. SL2 is set by Function
12. Operation of SL2 is similar to SL1. The handset and PC programmability, thermal protec-
tion, low-voltage protection, systems diagnostics, and
Slow lift and auxiliary 2 provide the Speed Limit 2 input.
premium instrument panel mode select capability oper-
The third speed (Speed Limit 3) is activated by connect- ate similar to the same features of the traction controller.
ing P20 to battery negative. SL3 is set by Function 13.
Refer to Table 2 for the SP lift pump controller connec-
Operation of SL3 is similar to SL1.
tions.
Fast lift provides the Speed Limit 3 Input.
Refer to Figure 5 for a typical SR traction controller
If more than one speed limit is activated, the selected schematic. See the section Wiring Diagrams for spe-
speed with the highest motor volts will override the low cific wiring details for your lift truck.
motor volt speed.
9
Table 2. SP Lift Pump Controller Connections/Descriptions/Status Codes
Wire
Pin Number Description Status Code
Number
P1 Battery Volts From Positive (BAT) Side of Key Switch 12 -
P2 Battery Volts From Negative (IGN) Side of Key Switch 10 -
P3 Power Steering Motor Brush Wear Indicator Input 106 93
P4 Power Steering Motor Brush Wear Indicator Input 105 93
P5 Left Traction Motor Brush Wear Indicator Input 104 94
P6 Right Traction Motor Brush Wear Indicator Input 103 94
P7 NOT USED - -
P8 Lift Pump Motor Brush Wear Indicator Input 107 95
P9 Lift Pump Motor Brush Wear Indicator Input 108 95
P10 +12 Volt Pump Enable Signal Input From Left 50 -
Traction Controller
P
P11 Lift Pump Motor Temperature Input 102 91
P
P12 Speed Limit 1 Input (Tilt and Auxiliary 1) 82 -
L
U P13 Brush Wear Indicator Output to Traction Controller 110 -
G
P14 Motor Overtemperature Output to Traction Controller 109 -
P15 Right Traction Motor Temperature Input 101 92
P16 Left Traction Motor Temperature Input 100 90
P17 NOT USED - -
P18 NOT USED - -
P19 Speed Limit 2 Input (Slow Lift and Auxiliary 2) 81 -
P20 Speed Limit 3 Input (Fast Lift) 84 -
P21 +5 Volt Power Supply From Left Traction Con- 111 -
troller-NOT USED*
P22 Serial Receive - Connects to Instrument Panel 91 -
P23 Serial Transmit - Connects to Instrument Panel 90 -
*Pin is wired, but +5 volt power supply is not used by the SR lift pump controller.
10
2200 YRM 779 SP Lift Pump Controllers
Table 2. SP Lift Pump Controller Connections/Descriptions/Status Codes (Continued)
Wire
Pin Number Description Status Code
Number
PY1 Clock (Out) - -
PY2 Data (Out) - -
PY3 Enable (Out) - -
PY4 Negative - -
PY PY5 +5 Volt Supply - -
P PY6 Cont/Store (In) (Handset) - -

L PY7 External Jumper to PY12 - -
U
G PY8 Value - -
PY9 Function - -
PY10 External Jumper to PY11 - -
PY11 Serial Receive/Internal Connection to P22 - -
PY12 Serial Transmit/Internal Connection to P23 - -
11
Figure 5. Typical SP Lift Pump Controller Schematic
12
2200 YRM 779 Diagnostic Status Codes and Troubleshooting
Sensor Interface/Contactor Driver Module

The Sensor Interface/Contactor Driver Module (SICDM) enables the lift pump circuit. The 12-volt signal is re-
is used with the contactor-controlled lift pump option moved by the traction controller during lift interrupt.
and takes the place of the SP lift pump controller. In-
puts from the hydraulic valve PC board control internal See the section Electrical System 2200 YRM 698 or
drivers, which energize the lift pump contactor(s). A Electrical System 2200 YRM 774 for additional infor-
12-volt output from the traction controller to the SICDM mation on the SICDM.
Diagnostic Status Codes and Troubleshooting

GENERAL MAINTENANCE 2. ALWAYS discharge the capacitors using the
INSTRUCTIONS proper procedure before performing any ser-
vice.
The transistor controller, like all electrical apparatus, 3. NEVER put power to the controller with any
does have some thermal losses. The semiconductor power wire disconnected.
junctions have finite temperature limits, above which 4. NEVER short any controller terminal or motor
these devices may be damaged. For these reasons, terminal to battery (+), battery ( ), or the frame.
normal maintenance should guard against any action
which will expose the components to excessive heat Any controllers that will be applied in ambient tempera-
and/or those conditions which will reduce the heat-dis- tures over 40 C (100 F) should be brought to the atten-
sipating ability of the controller, such as restricting air- tion of the lift truck manufacturer.
flow.
Special Precautions
WARNING
To avoid injury and prevent electrical shock, per-
form the following steps before performing any
troubleshooting, adjustments, or connecting or
disconnecting of a handset or PC:
1. Block the lift truck so that the drive wheels are
off the floor. See the section Periodic Mainte-
nance 8000 YRM 699 or Periodic Maintenance
8000 YRM 772. Refer to How to Put the Lift Truck
on Blocks.
2. Turn the key switch to the OFF position and un-
plug the battery.
3. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across
the controller’s POS and NEG terminals (outer
two power cable terminals). See Figure 6 or Fig-
ure 7. DO NOT short across the motor controller
terminals with a screwdriver or jumper wire. Re- 1. NEGATIVE POWER CABLE CONNECTION
move the 200-ohm, 2-watt resistor before recon- 2. POSITIVE POWER CABLE CONNECTION
necting the battery. 3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
CAUTION Figure 6. Discharging the Capacitors (Earlier

Model)
To avoid controller damage:
1. ALWAYS disconnect the battery when servicing
the controllers.
13
Diagnostic Status Codes and Troubleshooting 2200 YRM 779
create excessive voltages that can be harmful to the

controller.
Do not subject the controller to any high voltage (hipot

or megger) testing.
Use a lead-acid battery with the voltage and ampere

hour rating specified for the lift truck. Follow normal
battery maintenance procedures, recharging before 80
percent discharged, with periodic equalizing charges.
DIAGNOSTICS
Systems Diagnostics
The controller detects the system’s present operating
status and can display that information to either the
premium instrument panel or the handset. There are
currently over 70 status codes that are available with
1. POSITIVE POWER CABLE CONNECTION SR/SP systems using traction and lift pump controllers.
2. NEGATIVE POWER CABLE CONNECTION The SR controller is also capable of reducing the cur-
3. INSULATED JUMPER WIRES
rent to the drive motor to alert the operator of a critical
4. 200-OHM, 2-WATT RESISTOR
fault condition.
Figure 7. Discharging the Capacitors (Latest
NOTE: Lift trucks without the SP pump controller are
Model)
equipped with a SICDM. The SICDM performs some of
Never add unapproved accessories or components to the tasks of the lift pump controller and controls the lift
the lift truck. All external components having inductive pump contactor(s). See the section Electrical System
coils must be filtered. 2200 YRM 698 or Electrical System 2200 YRM 774
for additional information on the SICDM.
The wiring should not be directly steam cleaned. In
dusty areas, blow low-pressure air over the controller to STATUS CODES
remove dust. In oily or greasy areas, a mild detergent
solution or denatured alcohol can be used to wash off Standard Status Codes
the controller, and then low-pressure air should be used
to completely dry the controller. The SR traction controller has over 30 status codes and
the SP lift pump controller has over 20 status codes
For the controller to be most effective, it must be to assist the service technician and operator in trou-
mounted against the frame of the lift truck. The metal bleshooting the lift truck. If a controller or controller cir-
frame, acting as an additional heat sink, will give im- cuit malfunction occurs, a status code is displayed on
proved lift truck performance by keeping the controller the instrument panel of lift trucks.
package cooler. Apply a thin layer of silicone (heat
transfer) grease between the controller heat sink and The instrument panel is capable of displaying sta-
the lift truck frame prior to controller installation. tus codes. The instrument panel will add a "2" pre-
fix to all status codes received from the right trac-
Controller wire plugs and other exposed transistor con- tion controller to enable the operator to quickly de-
troller parts should be kept free of dirt and paint that termine which controller (left or right) is affected.
might change the effective resistance between points.
Use special GE connector grease on controller plug Instrument Panel Status Code Readout:
connections.
Left traction codes ............. no prefix ....... -XX
CAUTION Right traction codes........... 2 prefix.......... -2XX

The lift truck should not be plugged when the lift Pump traction codes .......... 1 prefix.......... -1XX
truck is jacked up and the drive wheels are in a free-
XX = Status Code
wheeling position. The higher motor speeds can
14
Status codes can also be retrieved by using a standard This feature is set with the handset using Functions 19,
GE handset or a PC connected through the PY plug 20, and 13. The operator is alerted that maintenance
of the controller. The handset or PC can only connect on the lift truck is required.
to one controller at a time. To obtain a complete list
of all status codes present, EACH controller (left trac- Battery Discharge Indication (BDI)
tion, right traction, and pump) on the lift truck must be
checked, one at a time, using the handset or PC. The latest in microprocessor technology is used to pro-
vide accurate battery state-of-charge information and
NOTE: The Status Code Instruction Sheets do not to supply passive and active warning signals to the lift
cover all possible causes of a display of a status code. truck operator.
They provide instructions for checking the most direct
inputs that can cause status codes to appear. Features and functions:
• Displays 100 to 0 percent charge.
Procedures are outlined in Diagnostic Status Codes to • Display blinks with 20 percent charge. Disables lift
determine the problem and a solution for each status pump circuit with 10 percent charge. Auto ranging for
code number. 36- to 48-volt operation.
Stored Status Codes Internal Resistance Compensation

This feature records the last 16 stored status codes This feature is used when the battery discharge indica-
that have caused a controller PMT shutdown and/or dis- tor is present. Adjustment of this function will improve
rupted normal lift truck operation. (PMT-type faults are the accuracy of the BDI.
reset by cycling the key switch.) These stored status
codes, along with the corresponding BDI and hourme- Handset Programmable
ter readings, can be accessed with the handset, or by
using the RS 232 communications port and download- This is a multifunctional tool used with the LX, ZX, and
ing the information to a PC. SR series GE solid-state controllers. The handset con-
sists of a Light-Emitting Diode (LED) display and a key-
Stored status codes can also be displayed on the pre- board for data entry.
mium instrument panel. Pushing the status code push
button with the key switch in the OFF position will cause Features and functions:
the status codes in the memory to be shown on the digi- • Monitor existing system status codes for both traction
tal display. When the button is pushed, the status codes and pump controllers. Monitor intermittent random
in memory will be displayed starting with the most re- status codes.
cent problem. The system will go through 16 left traction • Monitor battery state of charge, if available.
motor codes, followed by 16 right traction motor codes, • Monitor hourmeter reading on traction and pump con-
then 16 lift pump motor codes. If the button is pushed trollers. Monitor or adjust the controller functions.
again, the display will start from the beginning. A hand-
set or PC must be used to clear the status codes stored RS 232 Communication Ports
in the register. The P and PY plugs are used as serial communica-
tion ports. Premium instrument panels interface with
OTHER FEATURES the controllers through the P plug. A handset or PC is
connected to the PY plug. This arrangement allows the
Hourmeter Readings use of a handset or a PC without disconnecting the in-
This feature will display the recorded hours of use of the strument panel.
traction controller and pump controller to the instrument
panel each time the key switch is turned OFF. Circuit Board Coil Driver Modules
The line contactor and power steering contactor are
Maintenance Alert and Speed Limit controlled by the traction controller. The controller has
This feature is used to display Status Code 99 and/or internal drivers for the contactors and provides reverse
activate a speed limit when the lift truck operating hours battery protection. If the battery is connected incor-
match the hours set in the maintenance alert register. rectly, the contactors cannot be closed electrically.
15
Maintenance Management Capability control). See the section Electrical System 2200 YRM
698 for additional information on the SICDM.
The SR traction controller has the capability of moni-
toring certain maintenance items. The hourmeter read- Interactive Instrument Panel Modes
ing is monitored and can be used to provide a mainte- (Premium Only)
nance alert when a preprogrammed hourmeter reading
is reached. Brush wear and motor temperature can also Premium instrument panels allow the operator to select
be monitored. Temperature sensors can be present the best lift truck performance for different conditions.
on the traction and lift pump motors. Brush wear sen- There are four modes that can be selected by depress-
sors can be present on the traction, lift pump, and steer ing a push button on the instrument panel.
pump motors.
From the instrument panel, the operator may select any
The traction controller will set a status code and re- of four preset interactive modes.
duce maximum lift truck speed if the maintenance alert
hourmeter reading is reached, or if an optional temper- TRACTION CONTROLLER
ature sensor determines that a motor is overheated. (4) Controlled acceleration levels
(4) Field-weakening levels (FW Start and FW Ratio)
The traction controller will set a status code if an op- (4) Speed limits
tional brush wear indicator detects a worn brush.
LIFT PUMP CONTROLLER
The maintenance alert hourmeter reading is pro- (4) Controlled acceleration levels
grammed into the traction controller using Function 19 (4) Speed Limit 2 levels (Slow Lift, Auxiliary 2)
and Function 20. (4) Speed Limit 3 levels (Fast Lift)
NOTE: The brush wear and motor temperature inputs NOTE: Traction controller Functions 3, 24, 6, and 12 are
to the traction controller are received from the lift pump disregarded when using the premium instrument panel
controller (transistor lift pump control) or the sensor with mode selection. See Table 3.
interface/contactor driver module (contactor lift pump
Table 3. Instrument Panel Function Number Correlation
Standard Dash Function Premium Dash Function Number

Function Description Number (Without mode
Mode 1 Mode 2 Mode 3 Mode 4
selection)
Controlled Acceleration 3 48 52 56 60
FW Start 24 49 53 57 61
Traction
Controller FW Ratio 6 50 54 58 62
Maximum Armature
12 51 55 59 63
Percent On
Controlled Acceleration 3 48 52 56 60
Lift Pump
Speed Limit 2 12 49 53 57 61
Controller
Speed Limit 3 13 50 54 58 62
NOTE: Lift pump controller Functions 3, 12, and 13 are These interactive modes are preset using function num-
disregarded when using the premium instrument panel bers:
with mode selection. See Table 3.
Handset PC
Traction Controller 48 to 63 97 to 112
Lift Pump 48 to 62 97 to 111
Controller
16
Table 4 outlines the normal logic flow for presetting the

interactive traction modes.
Table 4. Traction Function Settings Logic
Mode 1 "Turtle" Mode 2 Mode 3 Mode 4 "Rabbit"

Equal to or greater Equal to or greater
Equal to or greater than Mode 3 than Mode 4 Equal to or less
Controlled than Mode 2 than Mode 3
Equal to or less Equal to or less
Acceleration (C/A)
than Mode 1 than Mode 2
Function 48 Function 52 Function 56 Function 60
Equal to or less than Mode 3 than Mode 4 Equal to or greater
Field Weakening Start than Mode 2 than Mode 3
(FW Start)
WARNING
USE FACTORY
VALUES Field Weakening Start is not normally adjusted in the field. Adjusting Field Weak-
ening Start between the minimum and maximum values will not alter lift truck
performance.
Field Weakening Ratio than Mode 2 than Mode 3
(FW Ratio)
WARNING
USE FACTORY
VALUES Field Weakening Ratio is not normally adjusted in the field. Adjusting Field
Weakening Ratio between the minimum and maximum values will not alter lift
truck performance.
Top Travel Speed than Mode 2 than Mode 3
Limit (SL2)
17
Table 5 outlines the normal logic flow for presetting the

interactive lift pump modes.
Table 5. Lift Pump Function Settings Logic
Mode 1 "Turtle" Mode 2 Mode 3 Mode 4 "Rabbit"

Controlled than Mode 2 than Mode 3
Acceleration (C/A)
Speed Limit 2 (SL2)
Slow Lift, than Mode 2 Equal to or greater Equal to or greater than Mode 3
Auxiliary 2 than Mode 1 than Mode 2
Speed Limit 3 (SL3) than Mode 2 than Mode 3
Fast Lift
GENERAL TROUBLESHOOTING suspect, check the circuit for continuity by discon-

INSTRUCTIONS necting the P plug and testing continuity from the
front (pin end) of the plug.
The SR and SP controllers are sealed units with no
serviceable components. Troubleshooting is usually
limited to accessing status codes and following the
CAUTION
diagnostic procedures listed in the Status Code Trou- Standard probes are too large to be inserted into the
bleshooting Tables. center of the female pins (sockets) of the special
sealed plugs and can expand the pins. Expanded
Use standard testing procedures to verify inputs and pins will not provide good connections once the
outputs when necessary. plug is reconnected. To prevent pin damage, only
use probes with a diameter of 1.57 mm (0.062 in.) or
less.
CAUTION
Never attempt to probe through the back of the con- Refer to Table 1 for the SR traction controller connec-
troller or sensor interface contactor driver module tions. Refer to Table 2 for the SP lift pump controller
plugs. These plugs are special sealed plugs. Prob- connections. Refer to Figure 8 for the transistor con-
ing through the back of the plugs will destroy the troller plug pin out.
seal and can cause a short circuit. If a circuit must
be tested for voltage, check for voltage at an amp- See the section Diagrams 8000 YRM 771 for additional
type plug, a switch, or a component. If a circuit is wiring details.
18
2200 YRM 779 Status Code Troubleshooting Tables
A. WIRE END VIEW, PY PLUG B. WIRE END VIEW, P PLUG
Figure 8. Transistor Controller Plug Pin Out
If misoperation of the lift truck occurs, a status code is Check resistance on R × 1000 scale from frame to
displayed on the instrument panel until the key switch power and controller terminals. A resistance of less
is turned OFF. Status codes may also be accessed by than 20,000 ohms can cause misleading symptoms.
plugging a handset into the PY plug of each controller. Resistance less than 1000 ohms should be corrected
first.
Once the status code number is obtained, follow the
procedures outlined in the Status Code Troubleshooting Before proceeding, visually check for loose wiring, mis-
Tables to determine the problem. aligned linkage to the accelerator switch, signs of over-
heating of components, etc.
NOTE: Due to the interaction of the controller with all
lift truck functions, almost any status code or controller Tools and test equipment required are clip leads, volt-
fault could be caused by an internal failure of the con- ohmmeter (20,000 ohms per volt), and basic hand tools.
troller. After all other status code procedures have been
followed and no problem is found, the controller should
then be replaced as the last option to correct the prob-
lem.
Status Code Troubleshooting Tables

DESCRIPTION The breakout box is avalible through the PDC and con-
sists of the breakout box assembly and the breakout
CAUTION harness. Both are required to form one assembly. The
harness plugs into the SEM controller and the truck har-
Always unplug the battery and discharge the capac-
ness plugs into the breakout box.
itors by blowing the horn, before performing any
task in the electrical panel.
19
Status Code Troubleshooting Tables 2200 YRM 779
Status Code Description Memory Recall Circuit

Segments do not illuminate on the instrument No Traction and Pump
NONE panel and/or the handset.
Symptom
Display screen on instrument panel and/or
handset is blank.
Possible Causes and Test Procedures

• Positive or negative controller voltage is not present.
Ensure key switch is closed and voltage is present
between P1 and battery negative (negative stand-
off). Also, check for voltage between P2 and con-
troller negative (B ).
• Open circuit between controller PY plug and handset.
Check for an open circuit or loose connection going
from PY plug to handset.
• Open circuit between controller P plug and the instru-
ment panel.
Check for an open circuit or loose connection going Cause
from P plug to instrument panel. No input voltage to the controller or the display unit.
• Defective instrument panel or handset.
Replace instrument panel or handset.

No seat switch input. No Traction
-01
Symptom
Traction is disabled.

• Seat switch defective.
Check to see that seat switch operates properly.
Replace a failed switch.
• Open circuit between battery positive and P6.
Check for loose connections or broken wires:
Between seat switch and P6
Between key switch and battery positive side of
seat switch
Cause
This status code is displayed when P6 is less
than 50 percent of battery voltage.
20

Forward directional switch is closed on No Traction
-02 initial powerup.
Symptom
Controller will not operate because of Static
Return to Off (SRO) lockout.

• Forward directional switch is closed on initial startup.
Example: Forward directional switch is closed before
battery is connected or before key or seat switch is
closed.
Return directional switch lever to NEUTRAL and
then return lever to FORWARD position.
• Forward directional switch is failed closed or out of ad-
justment (adjusted to be held closed).
Replace or adjust directional switch to ensure it
opens when directional switch is returned to NEU-
Cause
TRAL.
This status code is displayed when P4 is greater than 60
• Short circuit between P3 and P4.
percent of battery voltage at initial key switch ON.
Disconnect wire from P4 and check for short circuit
between P3 and the wire that was connected to P4.
• Malfunctioning controller.
Replace traction motor controller.

Reverse directional switch is closed on No Traction
-03 initial powerup.
Symptom
Controller will not operate because of Static
Return to Off (SRO) lockout.

• Reverse directional switch is closed on initial startup.
Example: Reverse directional switch is closed be-
fore battery is connected or before key or seat switch
is closed.
Return directional switch lever to NEUTRAL and
then return lever to REVERSE position.
• Reverse directional switch is failed closed or out of ad-
justment (adjusted to be held closed).
Replace or adjust directional switch to ensure it
opens when directional switch is returned to NEU-
Cause
TRAL.
This status code is displayed when P5 is greater than 60
• Short circuit between P3 and P5.
percent of battery voltage at initial key switch ON.
Disconnect wire from P5 and check for short circuit
between P3 and the wire that was connected to P5.
Replace traction controller.
21

Start switch fails to close. No Traction
-05
Symptom

• Defective start switch circuit.
Check for open circuit or loose connections in wiring
from key switch to accelerator speed control unit and
from P3 to accelerator speed control unit.
• Defective accelerator speed control unit.
Check accelerator speed control unit for proper op-
eration and output.
Accelerator speed control unit wiring:
YELLOW - not used
RED - Wire 10 - Battery positive input from key switch
BLACK - Wire 13 - Battery negative
WHITE - Wire 15 - Output from start switch to P3
P3 (PEDAL UP) 0.0 volts Cause
P3 (CREEP to FULLY DEPRESSED) battery volts This status code is displayed when P7 is less than 2.5
GREEN - Wire 29 - Output from speed control to P7 volts and P3 is less than 60 percent of battery voltage.
P7 (PEDAL UP) 3.5 ±0.05 volts
P7 (PEDAL FULLY DEPRESSED) 0.1 volt or less
NOTE: The accelerator speed control unit is not service-

able and must be replaced as an assembly.

Accelerator depressed with no direction selected. No Traction
-06
Symptom

• Accelerator pedal is depressed before closing forward
or reverse directional switch.
Status code will disappear when directional switch is
closed or when accelerator pedal is released.
• Defective directional switch.
Check forward or reverse switch to ensure continuity
when direction is selected.
• Open circuit between directional switch and battery
positive or between directional switch and P4 or P5.
Check all wires and connections shown in trou-
bleshooting diagram.
Cause
This status code is displayed when P4 and P5
are less than 60 percent of battery voltage and
P7 is less than 2.5 volts.
22

Accelerator input voltage too high when No Traction
-07 key switch is initially closed.
Symptom
Controller will not operate when accelerator pedal
is depressed or status code 07 is displayed then
disappears when the lift truck starts to accelerate.

• Accelerator speed control unit out of adjustment or de-
fective.
Input voltage at P7 should be less than 4.2 volts. Ad-
just or replace accelerator speed control unit to en-
sure the voltage at P7 will vary from 3.5 volts (pedal
up) to less than 0.5 volt (pedal fully depressed).
• Open circuit between P7 and accelerator speed control
unit.
Check for broken wires or loose connections.
• Short circuit from battery positive to wiring in accelera-
tor input circuit.
Disconnect wire from P7 and measure voltage at Cause
wire to negative. Should be less than 4.2 volts for This status code is displayed when the accelerator
solid-state accelerator speed control unit. input voltage at P7 is higher than 4.2 volts and
a directional switch is closed.
NOTE: Refer to status code -05 for accelerator speed
control unit voltage specifications.
23

Accelerator input voltage too low when key No Traction
-08 switch is initially closed.
Symptom

• Accelerator speed control unit out of adjustment or de-
fective.
Input voltage at P7 should be more than 3.0 volts.
Adjust or replace accelerator unit to ensure the volt-
age at P7 is more than 3.0 volts before depressing
pedal.
• Short circuit between battery negative and P7 in accel-
erator input circuit.
Disconnect wire from P7 and measure voltage at
wire to negative. Voltage should be greater than 3.0
volts for solid-state accelerator speed control unit.
• Defective controller.
Disconnect wire from P7. Measure voltage from P7
Cause
to negative. Voltage should greater than 4.5 volts. If
This status code is displayed when the accelerator
not, replace controller.
input voltage at P7 is less than 3.0 volts and any of
NOTE: Refer to status code -05 for accelerator speed the following connections are opened and closed:
control unit voltage specifications. battery plug, seat switch, or key switch.

Both the forward and reverse directional switches No Traction
-09 are closed at the same time.
Symptom

• Forward or reverse directional switch is failed closed or
out of adjustment (adjusted to be held closed).
Replace or adjust directional switches to ensure they
open when directional switch is returned to neutral.
• Short circuit between battery positive and P4 and/or P5.
Disconnect wires from P4 and P5 and check wire for
short circuit to positive side of directional switch.
Disconnect wires and measure voltage at P4 and P5. Cause
Voltage should be less than 60 percent of battery This status code is displayed when P4 and P5 are greater
volts. than 60 percent of battery voltage at the same time.
24

Steer angle potentiometer voltage is too high. Yes Traction
-10
Symptom

• Steer angle potentiometer out of adjustment.
Verify that steer angle potentiometer is adjusted
properly. See the section Electrical System for
your lift truck. Refer to Steer Angle Potentiometer
Adjustment.
• Steer angle potentiometer defective.
Check steer angle potentiometer for proper opera-
tion. See the section Electrical System for your lift
truck. Refer to Steer Angle Potentiometer Testing. Cause
• Loose or missing connections at P8, P12, or P9. This status code is displayed when P12 is
Disconnect P plug and potentiometer and check con- greater than 3.9 volts.
tinuity:
Between P8 and pot terminal 1
Replace controller.
NOTE: Input voltage at P12 should be less than 3.9 volts

at all times.
25

Start switch closed on power up after No Traction
-11 initial key switch closure.
Symptom

• Start switch out of adjustment or defective.
Input voltage at P3 should be less than 60 percent
of battery voltage at key switch closing. Adjust or
replace accelerator speed control unit to ensure the
voltage at P3 is less than 60 percent of battery volt-
age before closing the start switch pedal.
• Short circuit between battery positive and P3 in start
switch input circuit.
Disconnect wires at accelerator speed control unit. Cause
Disconnect wire from P3 and check for short circuit This status code is displayed when P3 is greater than 60
from wire to battery positive. percent of battery voltage when the key switch is closed.
Disconnect wire from P3. Measure voltage from P3
to negative. Voltage should be zero. If not, replace
controller.
NOTE: The accelerator speed control unit is not service-

able and must be replaced as an assembly.
NOTE: Refer to status code -05 for accelerator speed

control unit voltage specifications.
26

Steer angle potentiometer voltage is too low. Yes Traction
-12
Symptom

• Steer angle potentiometer out of adjustment.
Verify that steer angle potentiometer is adjusted
properly. See the section Electrical System for
your lift truck. Refer to Steer Angle Potentiometer
Adjustment.
• Steer angle potentiometer defective.
Check steer angle potentiometer for proper opera-
tion. See the section Electrical System for your lift
truck. Refer to Steer Angle Potentiometer Testing. Cause
• Loose or missing connections at P8, P12, or P9. This status code is displayed when P12 is
Disconnect P plug and potentiometer and check con- less than 0.39 volt.
tinuity:
Replace controller.
NOTE: Input voltage at P12 should be greater than 0.39

volt at all times.
27

Battery voltage is too low or controller is adjusted No Traction
-15 to the wrong battery voltage.
Symptom

• Discharged battery.
Check battery for correct open circuit voltage.
Correct voltages are listed on right.
Charge battery, if required.
• Defective battery.
Check each battery cell for correct voltage (greater
than 1.95 volts each cell). Replace or repair battery.
• Incorrect controller adjustment.
Check Function 15 for proper adjustment for bat-
tery being used. Adjust to proper settings. Refer to
SR/SP Handset Instructions. See Capacities and
Specifications for the Function 15 value for your lift Cause
truck. This status code is displayed when the battery volts are
• Minimum battery volts not present between P1 and less than 1.95 volts per cell at initial key switch ON.
NEG.
Check for battery volts between P1 and negative
standoff. If battery volts are not present, check for
a voltage drop between battery (+) and P1 and/or
between battery ( ) and negative standoff.

Battery voltage is too high or controller is No Traction
-16 adjusted to the wrong battery voltage.
Symptom

• Incorrect controller adjustment.
Check Function 16 for proper adjustment for battery
being used. Adjust to proper setting. Refer to SR/SP
Handset Instructions. See Capacities and Specifi-
cations for Function Number 15 value for your lift
truck.
• Battery overcharged or incorrect battery used.
Check battery for correct open circuit voltage.
Correct voltages are listed on right.
If voltage is excessive, check battery charger for
proper output voltage.
Cause
This status code is displayed when the battery volts are
greater than 2.4 volts per cell at key switch ON.
28

"Controller Type" selection is invalid. No Traction
-17
Symptom

• Invalid "controller type" selection.
Check setting of Function 17. Adjust Function 17 to
the value listed for your lift truck as shown in Capac-
ities and Specifications
Cause
This status code is displayed when the "controller type"
selection value is set to an invalid number.

Motor field current is high at startup in No Traction
-23 the reverse direction.
Symptom
Maximum travel speed is reduced or traction is disabled.

Cause
This status code is displayed when the current draw in the
motor field is too high at startup in the reverse direction.
29

Motor field current is high at startup in No Traction
-24 the forward direction.
Symptom

Cause
This status code is displayed when the current draw in the
motor field is too high at startup in the forward direction.

Internal power supply is less than 10 VDC. Yes Traction
-27
Symptom
Line contactor closes and opens, then can only be
closed by opening and closing the key switch.

Check battery to ensure proper state of charge. Volt-
age may be dropping below 10 VDC under load.
• Loose connection at P1.
Ensure wire connection at P1 is tight.
Cause
This status code is displayed when the controller’s
internal power supply is less than 10 volts.
30

Drive motor field current exceeds design Yes Traction
-28 limit for a 70-second period.
Symptom
If one controller detects excessive filed current:
The controller detecting the excessive field current will
shut down. The remaining controller and drive motor
will continue to operate normally for approximately
16 seconds. After 16 seconds, fault code 29 is
set and travel speed is reduced.
If both controllers detect excessive field current:
Both controllers will shut down and traction
will be disabled.

• Operation of lift truck in high motor current condition.
Turn key switch OFF and restart truck normally to
clear status code.
Verify lift truck is being operated properly. Multiple
code 28’s stored in memory can indicate that the lift
truck is frequently being operated improperly. Cause
Instruct operator to avoid stall conditions, pushing This status code is displayed during the run mode
loads, excessive ramp grades, etc. when the controller determines that motor field
• Function 7 is improperly adjusted to allow higher-than- current is above the design limit* for longer than
normal motor field current. approximately 70 seconds.
Adjust Function 7 to the value listed for your lift truck *Design limit for SX 450 controller is 30 amps.
as shown in Capacities and Specifications
NOTE: A status code 28 retained in memory may indicate

that, at some time in the past, the controller has detected
a high current situation and that the code was cleared by
cycling the key switch OFF and ON.
31

Opposite drive motor inoperative. Yes Traction
-29
Symptom
Maximum travel speed is reduced.
Travel speed is limited to the value set by Function 13.

• Opposite controller inoperative or operating in "slow
down" mode.
Verify proper operation of both controllers in the run
mode.
NOTE: A status code 29 retained in memory may indicate

that, at some time in the past, the controller has detected
one inoperative controller and that the code was cleared
by cycling the key switch OFF and ON. A high-current sit-
uation may cause one controller to shut down and would
be indicated by a status code 28 being stored in memory.
NOTE: Function 13, speed limit 3 is enabled by this status Cause

code. This status code is displayed when the current
in one drive motor is greater than 98 amps while
the current in the other drive motor is less than
NOTE: When a controller shuts down and a status code 26 amps for a 16-second period.
29 is set, code 29 is always set in the controller that re-
mains operative.
32

PMT enable signal from auxiliary control to master No Traction
-30 at P21 is missing during SRO check. (Dual motor
proportioning controls only)
Symptom
Auxiliary control shut down

• Check auxiliary control for status codes.
• Verify connection between P21 of master control and
P10 of slave/auxiliary control.
Cause
This status code is displayed when the voltage
at PL21 of the master control is less than 5
volts. This fault is not stored.
33

Open thermal protector (TP) or transistor Yes Traction
-41 overtemperature.
Symptom

• Controller is in thermal cutback.
[Controller heat sink (metal mounting base) tempera-
ture is in excess of 60 C (140 F).]
Allow controller to cool; status code should disap-
pear.
• Internal thermal protector has failed.
Measure the controller heat sink (metal mounting base)
temperature during thermal cutback. Heat sink temper-
atures less than 60 C (140 F) during thermal cutback
indicate a faulty thermal protector.
Cause
This status code is displayed when the voltage at the
internal thermal protector is greater than 0.8 volt.

Motor armature offset voltage is too high. No Traction
-42
Symptom

• Controller is defective.
Cause
internal current sensor input is greater than 2.6 volts
with no current flowing in the motor circuit.
34

Motor armature offset voltage is too low. No Traction
-43
Symptom

• Controller is defective.
Cause
This status code is displayed when the voltage at
the current sensor input is less than 2.4 volts with
no current flowing in the motor circuit.

Armature transistor did not turn off properly. Yes Traction
-44
Symptom
Line contactor may open, close, and then open

again. Line contactor can then only be closed by
opening and closing the key switch.

Cause
This status code is displayed when, during motor
controller operation, the armature transistor fails to
turn off. This will result in a PMT condition.
35

Armature transistor did not turn on properly. Yes Traction
-45
Symptom
Line contactor may open, close, and then open


Cause
This status code is displayed when, during motor
controller operation, the armature transistor fails to turn
on properly. This will result in a PMT condition.

"Look Ahead" test for A2 volts less than 12 No Traction
-46 percent of battery voltage.
Symptom
Line contactor will not close.

• Check for short circuit from the motor armature to the
frame of the lift truck.
Cause
This status code is displayed when the voltage at A2
is less than 12 percent of battery voltage.
36

Motor field current is too low during the run mode. No Traction
-49
Symptom

Cause
This status code is displayed when the current draw in
the motor field is too low during the run mode.

Capacitor volts are low before the line No Traction
-51 contactor closes.
Symptom
Line contactor does not close.
Controller capacitor does not precharge.

• Failed controller fuse.
Check controller fuse for open circuit. Replace fuse,
if necessary.
• Accessory or component other than controllers con-
nected to load side of line contactor.
Verify traction and lift pump controllers are the only
components on the load side of the line contactor.
NOTE: Repeated charging/discharging the capacitors

during troubleshooting can cause a status code 51. Cause
This status code is displayed during key ON when
the capacitor voltage is less than 85 percent of
battery voltage at initial key switch ON.
37

Controller motor current sensor input too No Traction
-57 low during operation.
Symptom

Cause
This status code is displayed when the voltage input
from the current sensor is too low during running.

Line driver input (P2-17) is less than 12 No Traction
Symptom
Motor controller will not operate.

• Open or loose connection to pin P17.
Check for loose or broken wire at plug pin P17.
• Malfunction of driver transistor in motor controller.
Replace motor controller.
Cause
This status code is displayed when the controller detects
that the line driver input (P2-17) is less than 12 percent
of battery voltage with the key switch in the ON position.
38

The line coil current is too high during Yes Traction
-65 the run mode.
Symptom
Motor controller will not operate.

• Line contactor coil has a short circuit.
Disconnect wires at coil terminals of line contactor
and check for correct resistance between terminals.
• Short circuit of coil wires (10 and 24) of the line contac-
tor.
Make sure key switch is OFF. Disconnect wires at
coil terminals of line contactor and check for short
circuit between wires.
• Malfunctions of motor controller.
Replace motor controller.
Cause
This status code is displayed when the current limit
in the line coil is exceeded. The line contactor
will drop out and the key switch must be moved
to OFF to reset the controller.
39

Field current exceeds the current limit Yes Traction
-66 of the field transistor.
Symptom
Motor controller will not operate (line contactor drops out).

• Short circuit in field circuit of traction motor.
Disconnect power leads at traction motor F1 and F2
terminals and check for short circuit between power
leads.
Check for battery positive at both F1 and F2 termi-
nals.
Check for battery negative at both F1 and F2 termi-
nals.
Check for short circuit between motor terminal F1
and motor case.
Check for short circuit between motor terminal F2
and motor case.
Cause
This status code is displayed when the field transistor
current is greater than the current limit setting.
The line contactor will drop out, and the controller
is reset by recycling key switch.

The armature current exceeds the armature Yes Traction
-67 transistor limit.
Symptom
Control will not operate (line contactor drops out).

• Shorted armature A1 to A2.
Disconnect power cables from traction motor termi-
nals A1 and A2. Check for short circuit between ter-
minals.
• Short circuit of armature terminal A1 or A2 to battery
positive or battery negative.
nals A1 and A2. Check for short circuit between
each terminal to battery positive and then each ter-
minal to battery negative.
• Short circuit between power cables to the armature ter-
minals (A1 and A2).
nals A1 and A2. Check for short circuit between Cause
power cables. This status code is displayed when the armature
transistor exceeds its specific current limit. The control
is reset by recycling the key switch.
40

The PMT enable signal from the auxiliary (slave) Yes Traction
-68 control to the master control drops below 5V.
Symptom
Control will not operate.

• Auxiliary control shutdown..
• Check auxiliary control for stored faults.
• Verify the connection between the master control P21
and the auxiliary/slave control P10.
Cause
at master P21 drops below 5V.
41

Coil current of power steering contactor is too high. Yes Traction
-69
Symptom
Control will not operate (line and power steering
contactors drop out).

• Short circuit in coil of power steering contactor or wires
connected to coil.
Disconnect wires connected to coil of power steer-
ing contactor. Check for short circuit between coil
terminals. Check for short circuit between coil wires
10 and 60.
• Malfunction of motor controller.
Replace traction motor controller.
Cause
This status code is displayed when the current in
the power steering driver circuit exceeds current
limit during the run mode. The control is reset
by recycling the key switch.

Capacitor (1C) voltage too high. Yes Traction
-76
Symptom
Line contactor will open, close, and then open

• Unplugging the battery connector during regenerative
braking.
Do not unplug battery while lift truck is in operation.
• Line contactor bouncing open during regen.
Check line contactor for proper operation.
• Main power fuse opening during regen.
Check fuse and fuse connections.
• Intermittent battery plug connection.
Check connections from battery positive to controller
positive.
Cause
on the capacitor goes above 70 volts during the
regenerative braking cycle.
42

Motoring current is detected during Yes Traction
-77 regenerative braking.
Symptom
Line contactor will open, close, and then open

Cause
This status code is displayed when motoring current is
detected during the regenerative braking cycle.

If the armature motor current is at maximum No Traction
-82 for longer than 3.5 seconds, the armature
motoring current will be turned off.
Symptom
The motor controller will not operate and can only
be reset by cycling the key switch.

• Continued operation of vehicle in high motor current
condition.
• Operating control at stall motor current for more than
3.5 seconds.
• Function 16 is incorrectly adjusted for control percent
on time.
Adjust function per OEM instructions. (Motor dam-
age can occur if Function 16 is not set correctly.)
Cause
This status code is displayed when the armature
motor current is at the maximum control limit
(stalled) for 3.5 seconds and the accelerator pedal
is calling for maximum performance.
43

Left traction motor temperature too high. No Traction and Pump
-90
Symptom
Status code flashes on and off.

• Left traction motor is too hot.
Allow traction motor to cool.
If problem recurs, determine reason for overheating
traction motor and correct.
• P16 is shorted to battery negative.
Locate and repair short.
• Left traction motor temperature sensor is shorted or
damaged.
Replace temperature sensor.
• Defective lift pump controller.
(SR transistor-controlled lift pump only.) Cause
Replace lift pump controller. This status code is displayed when the voltage at
• Defective sensor interface/contactor driver module. terminal P16 of the SR lift pump controller or the sensor
(Contactor-controlled lift pump only). interface/contactor driver module is at zero volts.
Replace sensor interface/contactor driver module.
NOTE: Function 13, speed limit 3 is enabled by this status

code.
44

Lift pump motor temperature too high. No Traction and Pump
-91
Symptom

• Lift pump motor is too hot.
Allow lift pump motor to cool.
lift pump motor and correct.
• Lift pump motor temperature sensor is shorted or de-
fective.
(Contactor-controlled lift pump only.) interface/contactor driver module is at zero volts.

code.
45

Right traction motor temperature too high. No Traction and Pump
-92
Symptom

• Right traction motor is too hot.
Allow right traction motor to cool.
traction motor and correct.
• Right traction motor temperature sensor is shorted or
defective.
(Contactor-controlled lift pump only.) interface/contactor driver module is at zero volts.

code.
46

Power steering motor brushes are worn. No Traction and Pump
-93
Symptom

• Power steering motor brushes are worn.
A sensor has closed to battery positive.
Replace power steering motor brushes.
• P3 and/or P4 is shorted to battery positive.
• A power steering motor brush wear sensor is shorted
or defective.
Locate and repair shorted sensor lead or replace
power steering motor brushes.
(SR transistor-controlled lift pump only.)
Replace lift pump controller.
• Defective sensor interface/contactor driver module.
(Contactor-controlled lift pump only.) Cause
Replace sensor interface/contactor driver module. This status code is displayed when the voltage
at terminal P3 and/or terminal P4 of the SR lift
NOTE: Status code 93 is only checked when a neutral sig- pump controller or the sensor interface/contactor
nal is present (open start switch or open forward and re- driver module is at battery volts.
verse switches). The status code is then displayed when
the controller is returned to the run mode.
47

Left or right traction motor brushes are worn. No Traction and Pump
-94
Symptom

• Left or right traction motor brushes are worn.
Replace traction motor brushes.
• A traction motor brush wear sensor is shorted or defec-
tive.
traction motor brushes.
• Defective pump controller.
Replace pump controller.
the controller is returned to the run mode.
48

Lift pump motor brushes are worn. No Traction and Pump
-95
Symptom

• Lift pump motor brushes are worn.
Replace traction motor brushes.
• A lift pump motor brush wear sensor is shorted or de-
fective.
traction motor brushes.
• Defective pump controller.
Replace pump controller.
the motor controller is returned to the run mode.
49

Maintenance Alert and Speed Limit. No Traction
-99
Symptom
Status code is displayed for 4 seconds when the
key switch is first turned ON.

• Status code -99 is displayed when the normal hourme-
ter reading exceeds the programmed maintenance
alert hours setting selected by the user.
Maintenance Code Hourmeter, Functions 19 and 20,
are programmed with the handset and command the
display of status code -99.
• User should perform desired maintenance function.
Reset maintenance alert hourmeter after maintenance
is performed.
NOTE: Program Functions 19 and 20 to a value above 99 Cause

to disable the maintenance alert and speed limit feature. This status code is displayed when the normal
hourmeter reading exceeds the maintenance
alert hours setting for the truck.
NOTE: Function Number 13, speed limit 3 is enabled by
this status code.

"Controller Type" selection is invalid. No Pump
-117
Symptom
Lift and auxiliary hydraulic functions are disabled
or operate at a reduced rate.

• Invalid "controller type" selection.
Check setting of Function Number 17. Adjust Func-
tion 17 to the value listed in Capacities and Speci-
fications
Cause
This status code is displayed when the "controller
type" selection is set to an invalid number.
50

Controller internal power supply is less Yes Pump
-127 than 10 volts.
Symptom
Lift pump will not operate.

Check battery to ensure proper state of charge.
• Loose connection at P1.
Ensure wire connection at P1 is tight.
Cause
This status code is displayed when the controller’s
internal power supply is less than 10 volts.

Motor current is too high during lift. Yes Pump
-128
Symptom
The pump motor controller sees that motor current
is too high for 70 seconds and stops operation.
Lift pump motor will not operate.

• Discharged battery (high motor current due to low volt-
age).
Check battery to make sure it is charged.
• Operation of lift pump in high motor current condition
for too long.
Verify that lift truck is being operated correctly. Mul-
tiple code 128’s stored in memory can indicate that
the lift truck is not being operated correctly.
Instruct operator to avoid lifting loads that are too
heavy.
• Malfunction of pump motor controller.
Replace pump motor controller. Cause
This status code is displayed during the run mode
NOTE: A status code 128 retained in memory can indi- when the motor controller sees that pump motor
cate that, at some time in the past, the motor controller current is too high for too long.
has detected a high-current situation and that the code
was cleared by cycling the key to the OFF and ON posi-
tions.
51

Lift pump controller over temperature. No Pump
-141
Symptom
Lift and auxiliary hydraulic functions are disabled
or operate at a reduced rate.

• Controller is in thermal cutback.
[Controller heat sink (metal mounting base) tempera-
ture is in excess of 60 C (140 F).]
Allow controller to cool; status code should disap-
pear.
• Internal thermal protector has failed.
Measure controller heat sink (metal mounting base)
temperature during thermal cutback. Heat sink temper-
atures less than 60 C (140 F) during thermal cutback
indicate a faulty thermal protector.
Cause
internal thermal protector is greater than 0.8 volt.

Pump controller motor current sensor No Pump
-142 input is missing.
Symptom
Lift and auxiliary hydraulic functions are disabled.

Cause
This status code is displayed when the voltage at the lift
pump controller internal current sensor is greater than
0.1 volt with no current flowing in the motor circuit.
52

Pump controller motor current sensor No Pump
-143 input is too low.
Symptom

Cause
This status code is displayed when the voltage at the lift
pump controller internal current sensor is greater than
0.1 volt with no current flowing in the motor circuit.

Power transistor (Q1) did not turn off correctly. Yes Pump
-144
Symptom
Lift pump motor runs continuously.

Cause
This status code is displayed when, during pump
controller operation, the transistor fails to turn off.
53

Power transistor (Q1) did not turn on properly. Yes Pump
-145
Symptom

Cause
This status code is displayed when, during pump
controller operation, the transistor fails to turn on.

"Look Ahead" test for A2 volts less than 12 Yes Pump
Symptom

• Check for short circuit from the motor armature to the
frame of the lift truck.
Cause
This status code is displayed when the voltage at A2
is less than 12 percent of battery voltage.
54

Capacitor volts are low after the line Yes Pump
-150 contactor closes
This status code will be displayed when the
capacitor voltage is less than 85% of the
battery voltage in the run mode.
Symptom
Pump control will not operate.

• Check for proper operation of main contactor.
• Check for loose or open connections in cables from
battery positive to control positive circuit.
• Check power fuses. Replace as necessary.
• No battery voltage at P1.
Check for battery voltage at POS and P1.
Check for loose connection at P1.
Cause
This status code is displayed during key ON when
the internal capacitor voltage is less than 85 percent
of battery voltage at initial key switch ON.
55

Capacitor volts are low before the line No Pump
-151 contactor closes (internal controller function
during precharge).
Symptom
Controller capacitor does not precharge.
Line contactor may not close.

• Failed key switch fuse.
Replace key switch fuse.
• Open key switch circuit.
Repair key switch circuit.
• Accessory or component other than controllers con-
nected to load side of line contactor.
Verify that the traction and lift pump controllers are
the only components on the load side of the line con-
tactor.
Cause
NOTE: Repeated charging/discharging of the capacitors This status code is displayed during key ON when
during troubleshooting can cause status code 151. the internal capacitor voltage is less than 85 percent
of battery voltage at initial key switch ON.

Controller motor current sensor input No Pump
-157 voltage polarity check.
Symptom

Cause
This status code is displayed when the voltage input to
the internal motor current sensor is of the wrong polarity.
56

Controller capacitor charge is less than 14 volts. No Pump
-180
Symptom

• Line contactor opened up during run.
Check power connection from battery positive to line
contactor.
Check for an open fuse element.
Check for dirty contactor tips.
Cause
at P1 is less than 14 volts. This occurs typically
in the run mode of operation.

Battery voltage is less than 14 volts. No Pump
-181
Symptom

• Line contactor opened up during the run mode.
Check power connection from battery positive to line
contactor.
Check for an open fuse element.
Check for dirty contactor tips.
Verify that there are no traction controller faults caus-
ing the line contactor to open during the run mode.
Cause
measured at P1 is less than 14 volts.
57
SR/SP Handset Instructions 2200 YRM 779
SR/SP Handset Instructions

GENERAL FEATURES
The GE handset is a multifunctional tool used with the
LX, ZX, SR, and SP series GE solid-state controllers.
See Figure 9. The handset consists of a light-emitting
diode (LED) display and a keyboard for data entry. The
handset is used for viewing, adjusting, and storing con-
troller function settings (values) and for accessing sta-
tus codes.
NOTE: The handset is the same for all GE controllers;

however, the cable will change between some control
types.
NOTE: Controllers can be programmed prior to instal-

lation using a 24-VDC power supply. See Figure 10
or Figure 11 for instructions on connecting the 24-VDC
power supply.
See the section Troubleshooting and Adjustments

With a Computer 2200 YRM 597 or Troubleshooting
and Adjustments With a Computer, For EV-100ZX,
EV-T100, SR (SEM) and SP Motor Controllers (Win-
dows Version) 2200 YRM 947 for information on the
use of a PC to troubleshoot and adjust the controllers.
The following outlines the procedures for viewing, ad- Figure 9. LX/ZX/SR/SP Handset
justing, and storing controller function settings (values)
and for accessing status codes.
58
2200 YRM 779 SR/SP Handset Instructions
Figure 10. Connecting Remote Power Supply to Controller (Earlier Model)
59
NOT short across the motor controller termi-

nals with a screwdriver or jumper wire. Remove
the 200-ohm, 2-watt resistor before reconnect-
ing the battery.
At the transistor controller, unplug the blank from the

PY plug or 14-pin plug and plug in the handset. See
Figure 12 or Figure 13.
1. PY PLUG
Figure 12. PY Plug Location, Earlier Model
Figure 11. Connecting Remote Power Supply to

Controller (Latest Model)
CONNECTING HANDSET
WARNING
To avoid injury, perform the following steps before
performing any troubleshooting, adjustments, or
connecting or disconnecting of a handset or PC:
1. Block the lift truck so the drive wheels are off 1. 14 PIN PLUG
the floor. See the section Periodic Maintenance,
Figure 13. 14-Pin Plug Location, Latest Model
for your lift truck. Refer to How to Put Lift Truck
on Blocks. NOTE: The lift truck can be operated with the handset
2. Turn the key switch to the OFF position and un- connected; however, the adjustment knob must be set
plug the battery. fully clockwise to ensure the controller operates at top
3. Discharge the capacitors in the controllers by speed.
connecting a 200-ohm, 2-watt resistor across
the controller’s POS and NEG terminals (outer NOTE: The plug cap or blank covering the PY plug on
two power cable terminals). See Figure 6. DO the controller contains internal jumpers. The plug cap
60
2200 YRM 779 SR/SP Handset Instructions
must be replaced after unplugging the handset for nor- SETUP MODE
mal lift truck operation.
With the handset connected, follow Figure 15 to store
STARTUP SEQUENCE or change function values.
NOTE: The term "push" means to depress key for ap-

WARNING
proximately 1 second.
NEVER attempt to adjust any of the function val-
After installing the handset, plug the battery in and turn ues without using the procedures and values given
key switch ON. Figure 14 shows the startup display se- in this section. Failure to follow these instructions
quence that will occur. can cause personal injury or property damage.

NOTE: To check the value of a function, push the ESC

key after selecting the function.
• Functions 1-15 are selected by pushing keys 1-15.

• Functions 16-30 are selected by pushing the CONT
key and keys 1-15.
• Functions 48-62 are selected by closing the seat
switch and pushing the CONT key and keys 1-15.
• Function 63 is selected by closing the seat switch and
pushing the CONT and ESC keys.
To exit the setup mode, turn the key switch to the OFF
position and push the ESC key for at least 1 second.
The hourmeter reading should be displayed, and then
after a few seconds, the display should go blank. Be
sure to replace the PY plug blank once the handset is
disconnected.
STORED STATUS CODE MODE

The SR/SP family of controllers furnishes a function
register that contains the last 16 stored status codes
that shut down lift truck operation (a PMT-type fault
that is reset by cycling the key switch) and the battery
state-of-charge reading at the time the fault occurred.
See Figure 16. The first of the 16 status codes will be
overwritten each time a new status code occurs. This
stored status code register can be cleared from mem-
ory by using the handset.

To exit the stored status code mode, hold down the

CONT key. The display will scroll through the 16 stored
status codes, battery state of charge, and hourmeter
readings and then go blank.
Figure 14. Handset Startup Sequence
61
5. The display will scroll through the 16 stored status

code registers again and then go blank.
6. Reset function 28 to 0 to ensure that the next sta-

tus code is stored in the first register. Refer to Fig-
ure 15.
RESTARTING LIFT TRUCK

If the lift truck does not operate after the handset is dis-
connected, the program in use may not have been ex-
ited properly. To correct this, disconnect the battery and
discharge the capacitors using the proper procedure.
See WARNING in Connecting Handset. After discharg-
ing the capacitors, connect the battery and restart the
truck using the normal procedure.
Figure 15. Handset Setup Mode
CLEARING STORED STATUS CODES

Stored status codes may be cleared one at a time by
pushing the ESC key after the hourmeter reading is dis-
played. See Figure 16.
All stored status codes may be cleared by using the

following procedure.
1. Access the first stored status code. See Figure 16.
2. While the first stored status code is being displayed,

push and hold the CONT and ESC keys.
3. Hold the CONT and ESC keys depressed while the

display scrolls through the 16 stored status code
registers.
Figure 16. Accessing Stored Status Codes With
4. When the display goes blank, release the ESC key Handset
(continue to hold down the CONT key).
62
2200 YRM 779 SR Traction Controller Function Descriptions
SR Traction Controller Function Descriptions

maximum values will not alter lift truck perfor-
WARNING mance.
NEVER attempt to adjust any of the function val-
ues without using the procedures and values given This setting adjusts the speed, below which the auto
in this section. Failure to follow these instructions regen feature will not be enabled.
can cause personal injury or property damage.
Function 02
Creep Speed
WARNING (Push 2)
Changing a function value will affect lift truck
performance and operation. If function values are This function allows the adjustment of the creep speed
changed, make sure all operators of the lift truck (controller "on time") of the lift truck. Creep speed can
know that the truck can now operate differently. be adjusted when an accelerator input voltage between
Failure to inform all operators can cause personal 3.3 and 3.9 volts is provided to the controller or when
injury or property damage. an accelerator resistance value between 6.0K and 4.0K
ohms is provided to the controller.
WARNING Min. Max. Controller Resolution
Each function of each motor controller has a range On Time On Time Set Range (per set unit)
of setting numbers (minimum/maximum values)
2% 15% 0 to 225 0.05%
so the motor controller can be used on different
models of lift trucks. This variation is needed for Example: Function 02 set at 20 equals 3% on time.
lift trucks of different sizes and operating voltages.
(20 × 0.05%) + 2% = 3%
Adjustment of a function to the wrong value for
your lift truck model can cause the truck to operate • Higher settings increase creep speed.
differently than normal. This different operation of • Lower settings decrease creep speed.
the truck and failure to follow these instructions
can cause injury or damage to the lift truck. Do not Function 03
set a function value outside of the recommended Controlled Acceleration
minimum/maximum range for your model lift truck. (Push 3)
See Capacities and Specifications for the values
for your lift truck. This function allows for the adjustment of the time it
takes for the controller to accelerate to 100 percent ap-
plied battery voltage to the motor on hard acceleration.
CAUTION
The ranges and values given in the following func- NOTE: This controlled acceleration is in effect when the
tion descriptions are the ranges and the minimum standard instrument panel is used.
and maximum values for the Motor Controller. The
motor controller can be used on different models of Min. Max. Controller Resolution
lift trucks. Your lift truck may have specific settings Time Time Set Range (per set unit)
or a different range of settings. Always refer to Ca- 0.025 sec 6.3 secs 0 to 255 0.025 sec
pacities and Specifications for the correct factory
values and the range of allowable settings for your Example: Function 03 set at 20 equals 0.5 seconds.
lift truck. (20 × 0.025 secs) + 0.025 secs = 0.5 secs
Function 01 • Higher settings provide slower acceleration.
Auto Regen Enable Speed • Lower settings provide faster acceleration.
(Push 1)
WARNING
Function 01 is not normally adjusted in the field.
Adjusting Function 01 between the minimum and
63
SR Traction Controller Function Descriptions 2200 YRM 779
Function 04 Function 06
Armature Current Limit FW Ratio
(Push 4) (Push 6)
This function allows for the adjustment of the armature

current limit of the controller. The rating of the controller WARNING
will determine the range of adjustment for this function. Function 06 is not normally adjusted in the field.
See Figure 17 for the current limit curves. See Capaci- Adjusting Function 06 between the minimum and
ties and Specifications for the values for your lift truck. maximum values will not alter lift truck perfor-
mance.
Min. Max. Controller Resolution
Current Current Set Range (per set unit) This setting represents the ratio of field current to arma-
ture current.
* * 0 to 255 -
NOTE: This FW ratio is in effect when the standard in-
*See Figure 17 for the current limit curves.
strument panel is used.
*See Capacities and Specifications for
recommended values. Function 07
• Higher settings increase armature current limit. Minimum Field Current
• Lower settings decrease armature current limit. (Push 7)
This function is used to make minor adjustments be-

Function 05 tween FW Ratio numbers.
Plugging Current Limit
(Push 5) Min. Max. Controller Resolution
Current Current Set Range (per set unit)
WARNING 0 amps 40 amps XX to 255 0.185 amps
Plug settings outside of the recommended values
Example: Function 07 set at 71 equals 3.7 amps.
can cause damage to the traction controller sys-
tem or traction motor. See Capacities and Speci- (71 51) × 0.185 amp = 3.7 amps
fications for recommended values.
• Higher settings can decrease speed.
This function allows for the adjustment of the plugging • Lower settings can increase speed.
distance of the lift truck. NOTE: Settings less than 51 will result in 0 amps.
XX=55 for 36-volt trucks or 51 for 48-volt trucks.
NOTE: Conventional plug braking only occurs when the
steer tire is at an angle of 65 degrees or greater.
Function 08
NOTE: Regenerative braking to zero speed is the nor- Maximum Field Current
mal method of slowing the truck when reversing direc- (Push 8)
tion. Regen braking current limit, Function 9, is ad-
justed to alter the stopping distance at steer angles less WARNING
than 65 degrees.
Min. Max. Controller Resolution Adjusting Function 08 between the minimum and
Current Current Set Range (per set unit) maximum values will not alter lift truck perfor-
mance.
55 amps 455 amps 0 to 255 1.57 amps
Example: Function 05 set at 20 equals 86.4 amps. This function adjusts the maximum field current that the
motor controller will deliver in normal operation.
(20 × 1.57 amps) + 55 amps = 86.4 amps
• Higher settings decrease plugging distance.
• Lower settings increase plugging distance.
64
Figure 17. Explanation of Current Limit Adjustments
65
Function 09 NOTE: This travel speed limit is in effect when the stan-
Regenerative Braking Current Limit dard instrument panel is used.
(Push 9)
Function 13
This function adjusts the regen braking current limit. Speed Limit 3
(Push 13)
Current Current Set Range (per set unit) This function allows for the adjustment of the maximum
lift truck speed (maximum battery volts to the motor)
52 amps 468 amps 0 to 255 1.63 amps
available when speed limit 3 (SL3) is enabled. SL3
Example: Function 09 set at 110 equals 231.3 amps. is activated when fault code 29, 90, 91, 92, or 99 is
present.
(110 × 1.63 amps) + 52 amps = 231.3 amps
• Higher settings decrease stopping distance. Function 14
• Lower settings increase stopping distance. Internal Resistance Compensation
(Push 14)
Function 10 This function is used when the internal battery dis-
Field Current for Regenerative Braking charge indicator feature is utilized. Adjustment of this
(Push 10) function will improve the accuracy of the BDI.
WARNING Use the specific gravity of the battery to determine if the

internal battery discharge indicator feature is accurately
reflecting battery condition.
maximum values will not alter lift truck perfor- 1. Remove the battery from service when the battery
mance. discharge gauge shows empty (discharged). The
battery discharge indicator considers empty to be
This function adjusts the field current to be used during
the point when the gauge first shows the last red
the regen braking mode. Use function 9 to adjust stop-
LED illuminated but not blinking.
ping distance.
NOTE: The lift interrupt point may be used as a mea-
Function 11
suring point for empty, but it is not as accurate. NEVER
Turn Speed Limit
discharge a battery below a specific gravity of 1.130.
(Push 11)
The battery can have permanent damage if discharged
This function allows for the adjustment of the maximum below 1.130.
lift truck speed (maximum battery volts to the motor)
2. Follow the battery manufacturer’s instructions to al-
available when the steer angle potentiometer signal in-
low ample time for the battery to stabilize (if possi-
dicates the steer angle is 32 degrees or greater.
ble).
Max. Min. Controller Resolution
3. Measure the specific gravity of at least several cells
Volts Volts Set Range (per set unit)
of the battery and compare the average specific
100% 0% 51 to 180 0.78% gravity to the chart below.
Example: Function 11 set at 71 equals 84.4% B.V. Battery Specific Gravity
100% [(71 51) × 0.78%] = 84.4% Battery Gauge Shows Empty* At Lift Interrupt
• Higher settings decrease speed. 1.150 1.140
• Lower settings increase speed.
*Battery discharge indicator gauge shows the last red
LED illuminated but not blinking.
Function 12
Maximum Armature Percent On (Travel Speed Limit) • Higher settings increase battery S.G. at lift interrupt.
(Push 12)
• Lower settings decrease battery S.G. at lift interrupt.
Same as Function 11, always active to limit battery volts
to the motor.
66
Battery Volts Stall Trp Point Percent On-Time
(Push 15) (Push CONT 1)
This function sets the percent of on time for the FETs

WARNING that the motor controller uses to determine a motor stall
Function 15 is not normally adjusted in the field. condition.
WARNING
mance.
Function 16 sets electrical limits to protect the mo-
This function allows for the adjustment of voltage range tor from damage if stall occurs. Increasing the set-
for controllers equipped with the battery discharge indi- ting value can allow motor damage if a stall does
cator function. occur.
Factory Values - Function 15 Percent On Time = (163 - Set Point Value) × 0.892
Left Traction If the Set Point Value is 163 or more, the percent On
36/48 volts with BDI 186
Controller Time is zero. If the Set Point Value is 51 or less, the
Right Traction percent On Time is 100 percent.
No BDI 255
Controller Function 17
"Controller Type" Selection
NOTE: The left traction controller is the primary con- (Push CONT 2)
troller and it controls the BDI feature. The left controller
for a dual-motor proportioning system will be set dif-
ferently than the right controller. See Capacities and
WARNING
Specifications for additional information. Function 17 is not normally adjusted in the field.
Controller Set Range - Function 15 maximum values will not alter lift truck perfor-
mance.
Battery Volts Set Units
24 volts Between 0 and 31 This function allows for the selection of the controller
type used for your lift truck’s application. The values
36 volts Between 32 and 44 listed below show the setting required for proper lift truck
48 volts Between 45 and 69 operation.
72 volts Between 70 and 80 Factory Values - Function 17

80 volts Between 81 and 183 W/Lift W/O Lift
Interrupt Interrupt
36/48 volts Between 184 and 250
Left Traction
No BDI feature Between 251 and 255 57 53
Controller
NOTE: The following functions have function numbers Right Traction
121 117
larger than the numbers on the handset keyboard. To Controller
access these functions, push the CONT key and the
number shown in the following instructions at the same NOTE: The left traction controller is the primary con-
time. troller. The left controller for a dual-motor proportioning
system will be set differently than the right controller.
NOTE: The seat switch must be open to access Func- SeeCapacities and Specifications for additional infor-
tions 16 to 28. mation.
67
Steer Pump Time Delay Maintenance Code Thousands and Hundreds
(Push CONT 3) Hours Set
(Push CONT 5)
This function adjusts the steer pump contactor time
delay. The power steering contactor will de-energize This function allows for the adjustment of the thousands
(open) after the seat switch remains open or park brake and hundreds hours of the maintenance code activation
is applied for a period in excess of the programmed time.
steer pump time delay.
NOTE: The power steering contactor is initially ener- Setting Setting Set Range (per set unit)
gized when the seat switch is closed and the key switch
00 255 0 to 255 100 Hours
is turned to the ON position. The power steering con-
tactor will de-energize (open) immediately if the key Example: Function 20 set at 215 equals 215XX hours,
switch opens. where XX is the programmed value of Function 19.

NOTE: Speed limit 3 is enabled once the set hours (as
Time Time Set Range (per set unit)
programmed by Functions 19 and 20) are reached.
1.5 secs 65 secs 0 to 128 0.5 sec
NOTE: The maintenance code alert/speed reduction
Example: Function 18 set at 20 equals 11.5 seconds. can be disabled by setting both Function 19 and Func-
(20 × 0.5 secs) + 1.5 secs = 11.5 secs tion 20 to values above 240.
• Higher settings provide a longer delay. Function 21

• Lower settings provide a shorter delay. Auto Regen Braking Current Limit
(Push CONT 6)
Function 19
This function sets the level of auto regen current, which
Maintenance Code Tens and Units Hours Set
can never be greater than the regen level set by Func-
(Push CONT 4)
tion 9. The auto regen and regen current levels will be
This function allows for the adjustment of the tens and the same for settings of 51 or less. The auto regen level
units hours of the maintenance code activation time. will gradually decrease for settings between 51 and 143
and is completely disabled with a setting greater than
Min. Max. Controller Resolution 143.
Setting Setting Set Range (per set unit)
Function 23
00 99 0 to 99 1 Hour Error Compensation
Example: Function 19 set at 50 equals XXX50 hours, (Push CONT 8)
where XXX is the programmed value of Function 20.
WARNING
NOTE: Speed limit 3 is enabled once the set hours (as Function 23 is not normally adjusted in the field.
programmed by Functions 19 and 20) are reached. Adjusting Function 23 between the minimum and
NOTE: The maintenance code alert/speed reduction
mance.
can be disabled by setting Function 19 and Function
20 to values above 240. The error compensation setting is adjusted by Function
23. This function is used to reduce the ripple in field
current due to the interaction between motor field de-
sign and the digital field current regulation circuit. The
value for this function is defined by the traction motor
controller manufacturer.
NOTE: Function 23 must be set at 6.
68
FW Start Stored Status Code Count Pointer
(Push CONT 9) (Push CONT 13)
This register contains a coded number that indicates

WARNING the location of the last stored status code. These stored
Function 24 is not normally adjusted in the field. status codes have caused a PMT controller shutdown
Adjusting Function 24 between the minimum and and/or disruption of normal lift truck operation.
mance. Function 28 should be set to 0 if the stored status codes
are cleared (erased) using a handset. If stored status
The setting for this function determines the armature codes are cleared using a PC, Function 28 is automat-
current for the transition between the base ratio (Func- ically set to 0.
tion 26) and FW Ratio (Function 6).
Refer to SR/SP Handset Instructions, Clearing Stored
NOTE: This FW start is in effect when the standard in- Status Codes for instructions on clearing the stored sta-
strument panel is used. tus codes and resetting Function 28 to 0.
Function 25 NOTE: When scrolling the stored status code register,
Monitor the register always starts at status code 1 and scrolls
(Push CONT 10) to status code 16. Refer to SR/SP Handset Instruc-
tions, Clearing Stored Status Codes for additional in-
WARNING formation.
PREMIUM INSTRUMENT PANEL
maximum values will not alter lift truck perfor- INTERACTIVE MODES
mance.
NOTE: The following functions (Functions 48 through
See the section Electrical System,for your truck, for 62) are mode settings that are activated using the per-
the adjustment procedures for the steer angle poten- formance level push button on the premium instrument
tiometer. Refer to Steer Angle Potentiometer, Adjust- panel.
ment, Handset Method.
NOTE: Each function should be set using the correct
This function allows the monitoring of certain controller logic. Refer to Table 4 for the correct adjustment logic
functions by looking directly at the RAM of the micro- and sequence guidelines.
processor. Because absolute memory locations need
NOTE: The following functions have function numbers
to be known, the value of this function should not be
larger than the numbers on the handset keyboard. To
changed without detailed instructions from the factory.
access these functions, push the CONT key and the
Function 26 number shown in the following instructions at the same
Base Ratio time.
(Push CONT 11)
NOTE: The seat switch must be closed to access Func-
tion 48 and above.
WARNING
Function 26 is not normally adjusted in the field. Function 48
Adjusting Function 26 between the minimum and Mode 1 - Controlled Acceleration
maximum values will not alter lift truck perfor- (Push CONT 1)
mance. This function allows for the adjustment of the time it
This function sets the ratio between armature and field takes for the controller to accelerate to 100 percent ap-
current when operating below the maximum field cur- plied battery voltage to the motor on hard acceleration.
rent and above the Field Weakening Start point. The
setting represents the quantity of field current changed
for each 1 amp of armature current changed.
69
Min. Max. Controller Resolution Function 51

Time Time Set Range (per set unit) Mode 1 - Maximum Armature Percent On (Mode 1 -
Travel Speed Limit)
0.025 sec 6.3 secs 0 to 255 0. 0.25 sec (Push CONT 4)
Example: Function 48 set at 20 equals 0.5 second.
This function allows for the adjustment of the speed limit
(20 × 0.025 secs) + 0.025 secs = 0.5 secs (maximum battery volts to the motor).
• Higher settings provide slower acceleration. Max. Min. Resolution
Controller
• Lower settings provide faster acceleration. Volts Volts (per set unit)
Set Range
NOTE: This controlled acceleration is in effect when 100% 0% 65 to 130 0.78%

mode 1 is selected on the premium instrument panel. Example: Function 11 set at 71 equals 84.4% B.V.
Function 49 100% [(71 51) × 0.78%] = 84.4 %
Mode 1 FW Start • Higher settings decrease speed.
(Push CONT 2) • Lower settings increase speed.
WARNING NOTE: This travel speed limit is in effect when mode 1

Function 49 is not normally adjusted in the field. is selected on the premium instrument panel.
maximum values will not alter lift truck perfor- Function 52
mance. Mode 2 - Controlled Acceleration
(Push CONT 5)
The setting for this function determines the armature
current for the transition between the base ratio (Func- Same as Function 48.
tion 26) and FW Ratio (Function 6).
NOTE: This controlled acceleration is in effect when
NOTE: This FW start is in effect when mode 1 is se- mode 2 is selected on the premium instrument panel.
lected on the premium instrument panel.
Function 53
Function 50 Mode 2 - FW Start
Mode 1 - FW Ratio (Push CONT 6)
(Push CONT 3)
WARNING
WARNING Function 53 is not normally adjusted in the field.
Function 50 is not normally adjusted in the field. Adjusting Function 53 between the minimum and
Adjusting Function 50 between the minimum and maximum values will not alter lift truck perfor-
maximum values will not alter lift truck performance.
mance.
Same as Function 49.
This function sets the ratio between armature and field
NOTE: This FW start is in effect when mode 2 is se-
current. The setting represents the quantity of field
current changed for each 1 amp of armature current
changed.
NOTE: This FW ratio is in effect when mode 1 is se-

70
Mode 2 - FW Ratio Mode 3 - FW Ratio
WARNING WARNING
Function 54 is not normally adjusted in the field. Function 58 is not normally adjusted in the field.
Adjusting Function 54 between the minimum and Adjusting Function 58 between the minimum and
maximum values will not alter lift truck perfor- maximum values will not alter lift truck perfor-
mance. mance.
Same as Function 50. Same as Function 50.
NOTE: This FW ratio is in effect when mode 2 is se- NOTE: This FW ratio is in effect when mode 3 is se-
lected on the premium instrument panel. lected on the premium instrument panel.
Mode 2 - Maximum Armature Percent On (Mode 2 - Mode 3 - Maximum Armature Percent On (Mode 3 -
Travel Speed Limit) Travel Speed Limit)
NOTE: This travel speed limit is in effect when mode 2 NOTE: This travel speed limit is in effect when mode 3
is selected on the premium instrument panel. is selected on the premium instrument panel.
Mode 3 - Controlled Acceleration Mode 4 - Controlled Acceleration
NOTE: This controlled acceleration is in effect when NOTE: This controlled acceleration is in effect when
mode 3 is selected on the premium instrument panel. mode 4 is selected on the premium instrument panel.
Mode 3 - FW Start Mode 4 - FW Start
WARNING WARNING
Function 57 is not normally adjusted in the field. Function 61 is not normally adjusted in the field.
Adjusting Function 57 between the minimum and Adjusting Function 61 between the minimum and
maximum values will not alter lift truck perfor- maximum values will not alter lift truck perfor-
mance. mance.
NOTE: This FW start is in effect when mode 3 is se- NOTE: This FW start is in effect when mode 4 is se-
lected on the premium instrument panel. lected on the premium instrument panel.
71
SP Pump Controller Function Descriptions 2200 YRM 779
Function 62 NOTE: This FW ratio is in effect when mode 4 is se-

Mode 4 - FW Ratio lected on the premium instrument panel.
(Push CONT 15)
Function 63
Mode 4 - Maximum Armature Percent On (Mode 4 -
WARNING Travel Speed Limit)
Function 62 is not normally adjusted in the field. (Push CONT ESC)
maximum values will not alter lift truck perfor- Same as Function 51.
mance.
NOTE: This travel speed limit is in effect when mode 4
Same as Function 50. is selected on the premium instrument panel.
SP Pump Controller Function Descriptions

on different models of lift trucks. Your lift truck
WARNING may have specific settings or a different range of
NEVER attempt to adjust any of the function val- settings. Always refer to Capacities and Specifica-
ues without using the procedures and values given tions for the correct factory values and the range
in this section. Failure to follow these instructions of allowable settings for your lift truck.
can cause personal injury or property damage.
NOTE: For complete information on controller settings.
See Capacities and Specifications for your lift truck.
WARNING
Changing a function value will affect lift truck Function 01
performance and operation. If function values are Stored Fault Code
changed, make sure all operators of the lift truck (Push 1)
know that the truck can now operate differently.
Failure to inform all operators can cause personal This function register contains the last status code that
injury or property damage. shut down lift truck operation (PMT-type fault that is re-
set by cycling the key switch). This status code will be
overwritten each time a new fault occurs and can be
WARNING cleared from memory by adjusting the value to zero.
Each function of each motor controller has a range This register will be cleared when the battery is un-
of setting numbers (minimum/maximum values) so plugged.
that the motor controller can be used on different
models of lift trucks. This variation is needed for Function 02
lift trucks of different sizes and operating voltages. Internal Resistance Compensation Start
Adjustment of function to the wrong value for your (Push 2)
lift truck model can cause the truck to operate dif-
ferently than normal. This different operation of the This function allows for the adjustment of the current
truck and failure to follow these instructions can level at which the internal resistance compensation fea-
cause injury or damage to the lift truck. Do not ture (Function 16) will take effect.
set a function value outside of the recommended
minimum/maximum range for your model lift truck.
Level Level Set Range (per set unit)
See Capacities and Specifications for the values for
your lift truck. 0 amps 1325 amps 52 to 255 6.5 amps
Example: Function 02 set at 72 equals 130 amps.
CAUTION (72 52) × 6.5 amps = 130 amps
The ranges and values given in the following
function descriptions are the ranges and the • Higher settings = Function 16 at a higher current.
minimum and maximum values for the MOTOR • Lower settings = Function 16 at a lower current.
CONTROLLER. The motor controller can be used
72
2200 YRM 779 SP Pump Controller Function Descriptions
Function 03 Min. Max. Controller Resolution

Controlled Acceleration Time Time Set Range (per set unit)
(Push 3)
0.0015 sec 0.383 sec 0 to 255 0.0015 sec
This function allows for the adjustment of the time it Example: Function 07 set at 20 equals 0.032 second.
takes for the controller to accelerate to 96 percent ap-
plied battery voltage to the motor on hard acceleration. (20 × 0.0015 secs) + 0.0015 secs = 0.032 secs
Min. Max. Resolution • Higher settings provide a slower compensation.

Controller
Time Time (per set unit) • Lower settings provide a faster compensation.
Set Range
0.1 sec 5.5 secs 0 to 255 0.021 sec For example, if you had selected 2.08 volts from Func-
Example: Function 03 set at 20 equals 0.52 second. tion 16 to be added to the motor, it would take 0.18 sec-
ond to add a total of 2.08 volts.
(20 × 0.021 secs) + 0.1 secs = 0.52 secs (2.08 ÷ 0.375) × 0.032 = 0.18 seconds
• Higher settings provide slower acceleration.
• Lower settings provide faster acceleration. Function 11
Speed Limit 1 (SL1)
(Push 11)
NOTE: This controlled acceleration is in effect when the
standard instrument panel is used. This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL1 limit
Function 04
switch input signal is received by the controller. SL1
Current Limit
limit switch is a normally open switch connected to bat-
(Push 4)
tery negative; the switch closing enables speed limit.
WARNING Min. Max. Controller Resolution

Function 04 is not normally adjusted in the field. Volts Volts Set Range (per set unit)
Adjusting Function 04 between the minimum and 0% 100% 30 to 70 0.375 volt
Example: Function 11 set at 50 equals 18.75 volts.
mance.
0.375 volts × 50 = 18.75 volts
This function sets the adjustment of the current limit of
the controller. The rating of the controller will determine • Higher settings increase speed.
the range of adjustment for this function. • Lower settings decrease speed.
Min. Max. Controller Resolution Function 12

Current Current Set Range (per set unit) Speed Limit 2 (SL2)
* * 255 to 255 - (Push 12)
• Higher settings increase current limit. Same as Function 11 except using SL2 limit switch for
• Lower settings decrease current limit. input.
NOTE: This speed limit 2 is in effect when the standard

Function 07
instrument panel is used.
Internal Resistance Compensation Rate
(Push 7) Function 13
Speed Limit 3 (SL3)
This function allows for the adjustment of the time it
(Push 13)
takes for the controller to add the internal resistance
compensation voltage that is applied to the motor. This Same as Function 11 except using SL3 limit switch for
function will add 0.375 volt to the motor at the rate of input.
time adjusted until the total internal resistance compen-
sation voltage has been added. NOTE: This speed limit 3 is in effect when the standard
instrument panel is used.
NOTE: The internal resistance compensation voltage is
set by Function 16, Speed/Torque Compensation.
73
Function 14 Table 6. Speed/Torque Compensation (Continued)

Speed Limit 4 (SL4)
(Push 14)
Voltage Voltage
Setting Setting
Same as Function 11 except using SL4 limit switch for Drop Drop
input. 13 1.76 28 0.82
NOTE: Speed Limit 4 is not used on this model. 14 1.63 29 0.79
NOTE: The following functions have function numbers 15 1.52 30 0.76

larger than the numbers on the handset keyboard. To 16 1.43 31 0.74
access these functions. Push the CONT key and the
number shown in the following instructions at the same Function 17
time. "Controller Type" Selection
(Push CONT 2)
NOTE: The key switch must be in the open OFF position
to access Functions 16 to 28.
WARNING
Function 16
Speed/Torque Compensation
(Push CONT 1)
This function is used to stabilize lift pump speed at mance.
heavy loads. The voltage selected will be added to the
This function allows for the selection of the controller
motor at each 100-amp increment, starting at the value
type used for your lift truck’s application.
set in Function 2. The voltage compensation selected
will be added in increments of 0.375 volt until the entire Refer to Capacities and Specifications for the factory
voltage is added. For example, a setting of 2 will be value for your truck.
added in 30 steps of 0.375 volt each, whereas a setting
of 4 will be added in 15 steps of 0.375 volt each. Function 28
Stored Status Code Count Pointer
Table 6. Speed/Torque Compensation (Push CONT 13)
Voltage Voltage This register contains a coded number that indicates

Setting Setting the location of the last stored status code. These stored
Drop Drop
status codes have caused a PMT controller shutdown
2 11.44 17 1.34
and/or disruption of normal lift truck operation.
3 7.60 18 1.27
Function 28 should be set to 0 if the stored status codes
4 5.72 19 1.20 are cleared (erased) using a handset. If stored status
5 4.57 20 1.14 codes are cleared using a PC, Function 28 is automat-
ically set to 0.
6 3.81 21 1.09
7 3.27 22 1.04 Refer to SR/SP Handset Instructions, Clearing Stored
Status Codes for instructions on clearing the stored sta-
8 2.86 23 0.99 tus codes and resetting Function 28 to 0.
9 2.54 24 0.95
NOTE: When scrolling the stored status code register,
10 2.28 25 0.91 the register always starts at status code 1 and scrolls
to status code 16. Refer to SR/SP Handset Instruc-
11 2.08 26 0.88
tions, Clearing Stored Status Codes for additional in-
12 1.90 27 0.85 formation.
74
2200 YRM 779 SP Pump Controller Function Descriptions
PREMIUM INSTRUMENT PANEL Min. Max. Controller Resolution

INTERACTIVE MODES Volts Volts Set Range (per set unit)
NOTE: The following functions (Functions 48 through 0% 100% 30 to 70 0.375 volt

62) are mode settings that are activated using the per- Example: Function 50 set at 50 equals 18.75 volts.
formance level push button on the premium instrument
panel. 50 × 0.375 volt = 18.75 volts
• Higher settings increase speed.
NOTE: Each function should be set using the correct
• Lower settings decrease speed.
logic. Refer to Table 5 for the correct adjustment logic
and sequence guidelines.
NOTE: This speed limit 2 is in effect when mode 1 is
NOTE: The following functions have function numbers selected on the premium instrument panel.
larger than the numbers on the handset keyboard. To
access these functions, push the CONT key and the Function 50
number shown in the following instructions at the same Mode 1 - Speed Limit 3 (SL3)
time. (Push CONT 3)
NOTE: The key switch must be in the ON position to This function allows for the adjustment of the speed limit
access Functions 48 to 62. (maximum battery volts to the motor) when the SL3 limit
switch input signal is received by the controller. SL3
Function 48 limit switch is a normally open switch connected to bat-
Mode 1 - Controlled Acceleration tery negative; the switch closing enables speed limit.
(Push CONT 1)
This function allows for the adjustment of the time it Volts Volts Set Range (per set unit)
takes for the controller to accelerate to 96 percent ap- 0% 100% 30 to 255 0.375 volt
plied battery voltage to the motor on hard acceleration.
Example: Function 50 set at 50 equals 18.75 volts.
Time Time Set Range (per set unit) 50 × 0.375 volt = 18.75 volts
0.1 sec 5.5 secs 25 to 150 0.021 sec • Higher settings increase speed.
• Lower settings decrease speed.
Example: Function 48 set at 20 equals 0.52 seconds.
(20 × 0.021 secs) + 0.1 secs = 0.52 secs NOTE: This speed limit 3 is in effect when mode 1 is
selected on the premium instrument panel.
• Higher settings provide slower acceleration.
• Lower settings provide faster acceleration. Function 52
Mode 2 - Controlled Acceleration
NOTE: This controlled acceleration is in effect when (Push CONT 5)
mode 1 is selected on the premium instrument panel.
Function 49
Mode 1 - Speed Limit 2 (SL2) NOTE: This controlled acceleration is in effect when
(Push CONT 1) mode 2 is selected on the premium instrument panel.
This function allows for the adjustment of the speed limit Function 53
(maximum battery volts to the motor) when the SL2 limit Mode 2 - Speed Limit 2 (SL2)
switch input signal is received by the controller. SL2 (Push CONT 6)
limit switch is a normally open switch connected to bat-
tery negative; the switch closing enables speed limit.
selected on the premium instrument panel.
75
Function 54 NOTE: This speed limit 3 is in effect when mode 3 is

Mode 2 - Speed Limit 3 (SL3) selected on the premium instrument panel.
(Push CONT 7)
Function 60
Same as Function 50. Mode 4 - Controlled Acceleration
(Push CONT 13)
selected on the premium instrument panel. Same as Function 48.
Function 56 NOTE: This controlled acceleration is in effect when

Mode 3 - Controlled Acceleration mode 4 is selected on the premium instrument panel.
(Push CONT 9)
Function 61
Same as Function 48. Mode 4 - Speed Limit 2 (SL2)
(Push CONT 14)
NOTE: This controlled acceleration is in effect when
mode 3 is selected on the premium instrument panel. Same as Function 49.

(Push CONT 10)
Function 62
Same as Function 49. Mode 4 - Speed Limit 3 (SL3)
(Push CONT 15)
selected on the premium instrument panel. Same as Function 50.

(Push CONT 11)
76
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 779 8/05 (6/05)(4/05)(9/03)(8/03)(11/02)(4/02) Printed in U.S.A.

SR SP Transistor Hanset

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Maintenance

PART NO. 524164220 2200 YRM 779

• 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.

Introduction to SEM ............................................................................................................................................. 1

©2005 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

All Electric Lift Trucks With SR/SP Transistor Motor Controllers

SR Transistor Traction Motor Controllers

Handset and cable........... Yale P/N 580001633

The SR controller is a transistorized separately excited

PROPORTIONAL OPERATION FOR Figure 2. Steer Angle/Drive Motor Performance

General See the section Electrical System 2200 YRM 698 or

Table 1. SR Traction Controller Connections/Descriptions

Left Traction Controller Right Traction Controller

Table 1. SR Traction Controller Connections/Descriptions (Continued)

Left Traction Controller Right Traction Controller

P PY6 - Cont/Store (In) (Handset) -

Operation wheel, providing a smoother ride throughout the turning

Figure 3. Typical SR Traction Controller Schematic

Conventional Plug Braking Speed Limits

ON-BOARD COIL DRIVERS AND • Look again

SP Lift Pump Controllers

Table 2. SP Lift Pump Controller Connections/Descriptions/Status Codes

Table 2. SP Lift Pump Controller Connections/Descriptions/Status Codes (Continued)

P PY6 Cont/Store (In) (Handset) - -

Figure 5. Typical SP Lift Pump Controller Schematic

Sensor Interface/Contactor Driver Module

Diagnostic Status Codes and Troubleshooting

CAUTION Figure 6. Discharging the Capacitors (Earlier

create excessive voltages that can be harmful to the

Do not subject the controller to any high voltage (hipot

Use a lead-acid battery with the voltage and ampere

CAUTION Right traction codes........... 2 prefix.......... -2XX

Stored Status Codes Internal Resistance Compensation

Table 3. Instrument Panel Function Number Correlation

Standard Dash Function Premium Dash Function Number

Table 4 outlines the normal logic flow for presetting the

Table 4. Traction Function Settings Logic

Mode 1 "Turtle" Mode 2 Mode 3 Mode 4 "Rabbit"

Table 5 outlines the normal logic flow for presetting the

Table 5. Lift Pump Function Settings Logic

Mode 1 "Turtle" Mode 2 Mode 3 Mode 4 "Rabbit"

GENERAL TROUBLESHOOTING suspect, check the circuit for continuity by discon-

A. WIRE END VIEW, PY PLUG B. WIRE END VIEW, P PLUG

Figure 8. Transistor Controller Plug Pin Out

Status Code Troubleshooting Tables

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

NOTE: The accelerator speed control unit is not service-