Controlador Yale

Maintenance
TRANSISTOR MOTOR
CONTROLLERS
(SR AND SP)
DESCRIPTION, CHECKS, ADJUSTMENTS,
TROUBLESHOOTING, REPAIRS, AND
THEORY OF OPERATION
ERC35-55HG (ERC70-120HG) [A839]
PART NO. 524166843 2200 YRM 808

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!
Transistor Motor Controllers (SR and SP) Table of Contents
TABLE OF CONTENTS
Description .......................................................................................................................................................... 1
Model Number Data for Transistor Motor Controllers (SR and SP)................................................................. 2
Motor Controller Checks and Adjustments .......................................................................................................... 5
Checks and Adjustments Using a Handset ......................................................................................................... 5
General ........................................................................................................................................................... 5
Connect Handset ............................................................................................................................................ 6
Start Sequence ............................................................................................................................................... 6
Check or Delete Stored Status Codes ............................................................................................................ 7
Returning Lift Truck to Normal Operation........................................................................................................ 8
Checks and Adjustments on Workbench ........................................................................................................ 8
How to Check and Adjust Registers................................................................................................................ 8
Function Parameters Adjustments....................................................................................................................... 10
General ........................................................................................................................................................... 10
Function Numbers........................................................................................................................................... 11
When Handset is Connected to Motor Controller in Lift Truck ........................................................................ 11
Function Numbers 1 through 15.............................................................................................................. 11
Function Numbers 16 through 30............................................................................................................ 11
Function Numbers 48 through 63............................................................................................................ 12
Function Number Descriptions ............................................................................................................................ 12
Traction Motor Controller (Label Letter - SR)....................................................................................................... 12
Functions with Premium Display Panel Only................................................................................................... 17
Pump Motor Controller (Label Letter - SP) .......................................................................................................... 19
Functions With Premium Display Panel Only .................................................................................................. 21
Troubleshooting ................................................................................................................................................... 27
General ........................................................................................................................................................... 27
Status Codes................................................................................................................................................... 27
Status Code Charts ............................................................................................................................................. 30
Transistor Motor Controllers Repairs ................................................................................................................... 62
General ........................................................................................................................................................... 62
General Maintenance Instructions .................................................................................................................. 65
Special Precautions .................................................................................................................................... 65
Fuses .............................................................................................................................................................. 65
Contactors....................................................................................................................................................... 66
Repair ......................................................................................................................................................... 66
Contactor Driver Module ................................................................................................................................. 66
Contactor Driver, Replace........................................................................................................................... 66
Motor Controller Plug ...................................................................................................................................... 69
Brush Wear Indicators..................................................................................................................................... 70
Thermal Sensors............................................................................................................................................. 71
Motor Controller, Replace ............................................................................................................................... 71
Parameter Tables................................................................................................................................................. 74
General ........................................................................................................................................................... 74
Function Numbers ...................................................................................................................................... 74
Motor Controller Checks and Adjustments...................................................................................................... 74
Parameter Tables ............................................................................................................................................ 75
Theory of Operation ............................................................................................................................................ 82
General ........................................................................................................................................................... 82
SEM System Description ................................................................................................................................ 83
SEM System Operation (SR Motor Controller) ............................................................................................... 83
Reverse Circuit ........................................................................................................................................... 83
Performance and Efficiency ........................................................................................................................ 84
©2005 Yale Materials Handling Corp. i

Table of Contents Transistor Motor Controllers (SR and SP)
TABLE OF CONTENTS (Continued)

Field Weakening ......................................................................................................................................... 84
Regenerative Braking ................................................................................................................................. 84
Creep Speed............................................................................................................................................... 85
Controlled Acceleration............................................................................................................................... 85
Current Limit ............................................................................................................................................... 85
Braking ............................................................................................................................................................ 85
Regenerative Braking to Zero Speed.......................................................................................................... 85
Pedal Position Braking ................................................................................................................................ 85
Auto Braking ............................................................................................................................................... 85
Auxiliary Speed Control................................................................................................................................... 86
Field Weakening ......................................................................................................................................... 86
Speed Limits ............................................................................................................................................... 86
Ramp Operation.............................................................................................................................................. 86
Ramp Start.................................................................................................................................................. 86
Anti-Rollback............................................................................................................................................... 86
Steer Pump Contactor Time Delay.................................................................................................................. 86
Coil Drivers and Internal Coil Suppression ................................................................................................. 86
System Protective Override............................................................................................................................. 86
SRO (Static Return to Off) .......................................................................................................................... 86
Accelerator Volts Hold Off........................................................................................................................... 86
Pulse Monitor Trip (PMT) ............................................................................................................................ 86
Thermal Protector (TP) ............................................................................................................................... 87
Low Voltage ................................................................................................................................................ 87
SP Pump Motor Controllers ............................................................................................................................ 87
Contactor Driver Module ................................................................................................................................. 87
Diagnostics...................................................................................................................................................... 87
Systems Diagnostics .................................................................................................................................. 87
Standard Status Codes............................................................................................................................... 88
Stored Status Codes................................................................................................................................... 88
Hourmeter Readings................................................................................................................................... 88
Maintenance Management Capability ........................................................................................................ 88
This section is for the following models:
ERC35-55HG (ERC70-120HG) [A839]
ii
2200 YRM 808 Description
Description
This section describes the operation and the functions c. Checks and replacement of the motor controller are
of the Transistor Motor Controllers (SR and SP). The SR described in Repairs.
letters are used to identify the transistor motor controller d. Parameter Tables
that uses the SEM (Separately Excited Motor) technol- e. A basic Theory of Operation on how a transistor
ogy. This motor controller is used to control the opera- motor controller operates using the SEM technol-
tion of the shunt traction motor. The SP motor controller ogy.
is a transistor motor controller that controls the series
lift pump motor and does not use the SEM technology. An electronic diagnostic and adjustment device can
These motor controllers are made by General Electric also be used to check and adjust the motor controllers.
Company. This electronic diagnostic and adjustment device is
• Troubleshooting and Adjustments With a Com- called a handset and is described later in this section.
puter, For EV-100ZX, EV-T100, SR (SEM) and SP A PC, with the control software installed, has access to
Motor Controllers (Windows Version) 2200 YRM function registers of the motor controllers through the
947 SEM display panel. The handset has access to less
• Electrical System, Replacement, Checks, and Ad- function registers of each motor controller and can only
justments Trucks with EV-100/200ZX or SR (SEM) make changes to a limited number of the registers of
and SP Motor Controllers 2200 YRM 560 these SR and SP motor controllers. The handset can
• SEM Display Panel, (Dos Version) 2200 YRM 725 only be connected to a motor controller at the motor
• Display Panel for SEM Controls, (Windows Ver- controller 12-pin connector.
sion) 2200 YRM 942
A short description and the replacement of the display
The motor controllers are similar, but control different panel is in the section SEM Display Panel, (Dos Ver-
types of motors and have some different components. sion) 2200 YRM 725.
Both motor controllers are connected to the display
These transistor motor controllers are covered units
panel on the instrument panel (dash) of the lift truck.
with no serviceable components. This section de-
This display panel provides access to both motor con-
scribes the procedures for using the electronic di-
trollers for adjustments and data display on the Liquid
agnostic and adjustment devices for checking and
Crystal Display (LCD) screen.
adjusting the operation of the motor controller.
The display panel has a connector for a serial cable that
Authorized technicians can adjust the controllers for
will connect to a serial port of a personal computer (PC)
different units or types of operations. Self diagnostics
for checks, adjustments, and troubleshooting.
are provided to monitor internal components as well as
a. A Cable Kit, Display Panel to Computer, is required
to detect problems with certain inputs and outputs. Ad-
(Yale Part No. 580001632). See your dealer for
justable register values and status codes are accessed
Yale lift trucks.
using a handset or a personal computer (PC). See the
b. The SMARTSET™ software for a personal com-
section Troubleshooting and Adjustments With a
puter is available on a 3.5-inch diskette. See your
Computer, For EV-100ZX, EV-T100, SR (SEM) and
dealer for Yale lift trucks.
SP Motor Controllers (Windows Version) 2200 YRM
These motor controllers have logic circuits and func- 947 for information on the use of a PC.
tions that control and keep a record of the operations of
There are electrical components that are not part of the
the motor controller. The registers also store a record
motor controllers but give input signals to them. These
of potential malfunctions or operations that are not cor-
components include the following:
rect. for the motor controller. These malfunctions or
a. Key switch
incorrect operations can indicate possible causes of a
b. Start switch
problem during troubleshooting.
c. Seat switch
This YRM section has the following components: d. Direction (FORWARD and REVERSE) switches
a. A description of the Transistor Motor Controller. e. Accelerator potentiometer
b. A series of Status Codes that describes an indica- f. Lift, tilt, auxiliary, and hydraulic speed switches
tion of a malfunction or operation that is not correct g. Motor brush wear and temperature sensor switches
and its possible causes. These status codes can
be shown on the LCD screen of the display panel.
1
Description 2200 YRM 808
The brake fluid switch and the park brake switch are in- 40 = 400 Amps
puts to the display panel for the attention of the operator.
(06) This number indicates the field current.
Fuses are also located outside the case of the motor
controllers. Checks and replacement of these electri- (07) This letter/number set indicates the revision.
cal components are described in Electrical System,
These motor controllers have signal outputs for the dis-
Replacement, Checks, and Adjustments Trucks
play panel on the dash. The display panel has a serial
with EV-100/200ZX or SR (SEM) and SP Motor Con-
port connector for a serial cable that will connect to a
trollers 2200 YRM 560.
serial port of a personal computer for checks, adjust-
ments, and troubleshooting. All of the control settings
MODEL NUMBER DATA FOR TRANSISTOR
for the motor controllers and the display panel can be
MOTOR CONTROLLERS (SR AND SP) set using a PC through this connector.
The model numbers for the Transistor Motor Controllers A handset with a digital display is also available. The
indicate the following information: handset can be directly connected to a motor controller
Example: to set or check some of the functions and to check the
status codes. This connection uses a different cable
IC3645 SR 4 W 60 6 N6 than the computer or display panel cable.
(01) (02) (03) (04) (05) (06) (07) All of the electronic components of each motor con-
troller are inside the case of the motor controllers and
(01) The first series of letters and numbers indicate the are fastened directly to the lift truck frame. The line con-
basic catalog number of the controller. tactor, fuses, and steering contactor mount to a plate
that is also fastened to the frame of the lift truck. See
(02) The second set of letters indicate the control type. Figure 1. If there is no motor controller for the lift pump,
SP = Series Control (Pump) the lift pump contactor and contactor driver are also on
SR = Separately Excited Control (Regen to Zero) a mount plate. See Figure 2.
(03) The next number indicates the operating voltage. The motor controller has a 12-pin connector, a 23-pin
2 = 24 Volts connector, and four or six power terminals. The 12-pin
3 = 24 to 36 Volts connector is used for handset connection. Jumper
4 = 24 to 48 Volts wires in the plug cover of this connector make connec-
tions to the 23-pin connector. The 23-pin connector is
(04) This letter indicates the housing size. for control signal inputs and outputs. The functions of
(05) These numbers indicate the armature current. each terminal pin are described in Table 5. The power
22 = 220 Amps terminals are for battery positive, battery negative, and
33 = 330 Amps the armature and field terminals of the motor.
2
2200 YRM 808 Description
1. PUMP MOTOR CONTROLLER 8. FUSE

2. PUMP FUSE 9. FUSE
3. TRACTION FUSE 10. 1A CONNECTOR
4. TRACTION MOTOR CONTROLLER 11. LINE CONTACTOR
5. FUSE 12. LINE CONTACTOR
6. FUSE 13. PUMP #2 CONTACTOR
7. POWER STEERING FUSE 14. PUMP #2 FUSE
Figure 1. Traction and Pump Motor Controllers
3
Description 2200 YRM 808
1. CONTACTOR DRIVER CARD 8. FUSE

2. TRACTION FUSE 9. 1A CONTACTOR
5. FUSE 12. PUMP #2 CONTACTOR (DUAL PUMPS ONLY)
6. POWER STEERING FUSE 13. PUMP #2 FUSE (DUAL PUMPS ONLY)
7. FUSE 14. PUMP #1 FUSE
Figure 2. Traction Motor Controller and Contactor Control for Lift Pump Motor
4
2200 YRM 808 Checks and Adjustments Using a Handset
Motor Controller Checks and Adjustments

NOTE: All checks and adjustments to both the trac- • Check system status codes history for both traction
tion AND pump motor controllers can be done with a and hydraulic pump systems.
PC through the display panel on the instrument panel • Check state of charge of battery.
(dash). A connector on the bottom (back side) of the • Check hourmeter readings on traction circuit and hy-
display panel can connect the PC to the panel mem- draulic pump controllers.
ory and the motor controllers. Many checks can also • Monitor or adjust register values for each function as
be done at the display panel without connections to the shown in the Parameter Tables at the end of this sec-
PC. tion.
A personal computer (PC) or a handset is used to permit

Authorized Personnel to make the following checks
and adjustments:
Checks and Adjustments Using a Handset

NOTE: See the section Troubleshooting and Adjust- the handset. The handset can access the registers that
ments With a Computer, For EV-100ZX, EV-T100, control the operation of the lift truck. The values for the
SR (SEM) and SP Motor Controllers (Windows Ver- limits on these motor controller functions can also be
sion) 2200 YRM 947 for information on the use of a PC set with the handset.
to troubleshoot and adjust the motor controllers.
NOTE: The handset is the same for all GE motor con-
GENERAL trollers; however, the cables can be different for some
types of motor controllers.
The GE handset is a tool that can be used with the LX,
ZX, SR, and SP GE solid-state controllers. The handset NOTE: Controllers can also be programmed before in-
has a Light Emitting Diode (LED) display, a keypad for stallation using a 24-volt DC power supply as shown in
data entry, and an adjustment knob for changing func- Figure 6. For instructions, refer to Checks and Adjust-
tion values and for access to stored status codes. See ments on Workbench.
Figure 3. The handset can ONLY be connected directly
This section has the checks and adjustments that can
to a motor controller. The following describes the cor-
be made using the handset. The checks and adjust-
rect procedures.
ments are usually made with the motor controller in-
The handset can be used with the LX, ZX, SR, and SP stalled in the lift truck. Bench checks and adjustments
motor controllers. The handset is used for the following: can also be made with the motor controller connected,
(1) accesses the registers for the traction or pump mo- as shown in Figure 6. The checks show the stored reg-
tor functions; (2) indicates status codes (possible mal- ister values that have been stored for the different func-
functions); and (3) makes adjustments to the operating tions. This section also includes a description of each
limits set in the motor controllers. Some of the regis- of the different functions. Use the adjustment knob on
ters in these motor controllers cannot be accessed with the handset to adjust the function settings as described.
5
Checks and Adjustments Using a Handset 2200 YRM 808
CONNECT HANDSET
WARNING
Prevent movement of the lift truck and possible in-
jury when making checks and adjustments. Before
the handset is connected or disconnected to the
display panel of the lift truck, do the following steps:
1. Raise the drive wheels as described in the Op-
erating Manual or the section Periodic Mainte-
nance for this lift truck.
2. Turn the key to the OFF position, disconnect the
battery, and discharge the capacitor by operat-
ing horn for several seconds. Do NOT make a
short circuit at any of the motor controller ter-
minals.
CAUTION
Prevent damage to the motor controllers. The
motor controllers can be damaged if power is not
correctly connected or disconnected. Always dis-
connect the battery connector before connecting or
disconnecting connectors at the motor controllers.
The plug cover on the small connector of the motor

controller must be installed for correct operation.
Make sure to disconnect the power and replace the
plug cover each time the handset is disconnected.
Connect handset to the small (12-pin) connector on

the motor controller. DO NOT LOSE CONNECTOR
COVER. See Figure 6. Connect handset using the nec-
Plug Wiring essary cables and adapter(s). See Figure 3.
Plug 8-Pin Plug 12-Pin NOTE: The lift truck can be operated with the handset
connected.
1 9
2 6 START SEQUENCE
3 3 NOTE: The term "Push CONT. Key" means to depress
4 4 the control key of the handset for approximately 1 sec-
ond.
5 5
6 8 Connect handset. Connect battery and turn key to ON
position. The display sequence is shown in Figure 4.
7 1
8 2
1. ADJUSTMENT 4. COIL CORD

KNOB 5. PLUG (12-PIN)
2. LED DISPLAY 6. MODULAR PLUG
3. KEYPAD (8-PIN HANDSET)
Figure 3. Handset
6
will be overwritten each time a malfunction or symp-

tom occurs to enter a new status code. The stored sta-
tus codes can be cleared from the register by using the
handset. To access and clear the status code registers
with the handset, use the procedure shown in Figure 5.
Stored status codes can be cleared one at a time by

pushing the ESC key after the hourmeter reading is dis-
played. See Figure 5.
To exit this Check mode, hold the CONT key de-

pressed. The display will scroll through the 16 stored
status codes, battery state-of-charge, and hourmeter
readings, and then will go blank.
Figure 4. Start Sequence for Handset
CHECK OR DELETE STORED STATUS

CODES
To check or delete stored status codes with the handset,
follow sequence in Figure 5.
Status codes for these functions are stored together Figure 5. Sequence for Access and Clearing of
with the battery charge at the time the malfunction or Status Codes
symptom occurred. The first of the 16 status codes
7
Checks and Adjustments Using a Handset 2200 YRM 808
All stored status codes can also be cleared by using the sure to install connector cover at motor controller each
following procedure. time handset cable is removed.
1. Access the first stored status code. See Figure 5. The handset can also be used to check and adjust the
functions of the motor controller when it is connected to
2. While the first stored status code is being displayed, a bench power supply. The following parts are required:
push and hold the CONT and ESC keys. a. A power source to supply a minimum of 24 DC volts
at 0.5 Amps. Also, a 12-volt battery that can supply
3. Hold the CONT and ESC keys depressed while the
50 milliamperes can be used if a PC is used for
display scrolls through the 16 stored status code
checks and adjustments. A handset requires more
registers.
power for its operation, and a power supply or two
4. When the display goes blank, release the ESC key 12-volt automotive batteries in series must be used.
(continue to hold down the CONT key). A DC power supply to a maximum of 84 volts can
be used.
5. The display will scroll through the 16 stored status
code registers again, and then will go blank. NOTE: The bench supply voltage does not need to
be the same as the voltage of the lift truck.
NOTE: Change function 28 to 0 to make sure that the
next status code that is stored will be stored in the first b. An adapter cable to connect between the small
register. Refer to How to Check and Adjust Registers 12-pin connector of the motor controller and the
in this section. Make sure to install connector cover at handset is necessary. See Figure 3.
motor controller each time handset cable is removed. c. Approximately 45 cm (18 in.) of 18-gage wire for
connecting the power source to the motor controller
RETURNING LIFT TRUCK TO NORMAL
NOTE: A PC can also be used to check and adjust a
OPERATION motor controller on the bench.
CAUTION If batteries are NOT used, the power supply must have
a full bridge rectifier with a filter to give a good quality
The plug cover on the small connector of the motor
DC voltage. Make the connections for the bench checks
and adjustments as shown in Figure 6.
plug cover each time the handset is disconnected. NOTE: The bench checks and adjustments are done
using the same procedures described for the handset
If the lift truck does not operate after the handset is dis-
earlier.
connected, the program in use was not closed correctly.
To correct this, disconnect the battery and discharge the
capacitors by operating the horn for several seconds.
HOW TO CHECK AND ADJUST
After discharging the capacitors, connect battery and REGISTERS
start truck using the normal procedure.
The handset can be used to access many registers that
control the operation of the lift truck. The values for the
CHECKS AND ADJUSTMENTS ON
limits on these motor controller functions can also be
WORKBENCH set with the handset.
CAUTION CAUTION
Prevent damage to the motor controller. The motor Prevent damage to the motor controllers. The
controller can be damaged if power is not correctly motor controllers can be damaged if power is not
connected or disconnected. Always disconnect the correctly connected or disconnected. Always dis-
power supply before connecting or disconnecting connect the battery connector before connecting or
the display panel or motor controller plugs. disconnecting connectors at the motor controllers.
To exit the Setup mode, turn the key to the OFF posi- Connect the handset as previously described. Use the
tion and push the ESC key for at least 1 second. The handset to check or adjust the functions by following the
hourmeter reading will normally be displayed and then procedure as shown in Figure 7.
after a few seconds, the display will go blank. Make
8
NOTE: To check the value of a function, push key(s)

for the function number and wait 1 second. The setting CAUTION
value for that function will appear. The plug cover on the small connector of the motor
WARNING plug cover each time the handset is disconnected.
NEVER attempt to adjust any of the function val-
ues without using the procedures and values given Disconnect handset and return lift truck to normal op-
in this section. Failure to follow these instructions eration as described in Returning Lift Truck to Normal
can cause personal injury or property damage. Operation in this section.
NOTE: ADJUSTMENT CABLES ARE CONNECTED AT THE SMALL CONNECTOR. REMOVE THE COVER TO
MAKE THE CONNECTION AND MAKE SURE TO INSTALL THE COVER AFTER THE CABLE IS REMOVED. DO
NOT LOSE THE CONNECTOR COVER. THERE ARE JUMPER CONNECTIONS IN THE CONNECTOR COVER
FOR CORRECT OPERATION WHEN THE MOTOR CONTROLLER IS INSTALLED IN THE LIFT TRUCK.
1. SMALL CONNECTOR WITH COVER (12-PIN) 4. 24-VOLT DC POWER SUPPLY OR BATTERIES
2. NEGATIVE CONNECTION OF POWER SUPPLY 5. P-PLUG CONNECTOR (23-PIN)
OR BATTERIES 6. MOTOR CONTROLLER
3. POSITIVE CONNECTION OF POWER SUPPLY 7. NEGATIVE POWER TERMINAL
OR BATTERIES 8. POWER SUPPLY PIN P1 (23-PIN)
Figure 6. Bench Checks and Adjustments
9
Function Parameters Adjustments 2200 YRM 808
Figure 7. Set Sequence for Handset
Function Parameters Adjustments

GENERAL NOTE: The Parameter Tables at the end of this section
show the permitted ranges and the default setting for
Memory elements of the motor controller are called reg- each control function. The Factory Set Parameters are
isters. These registers can have electronic data stored the recommended settings for new units. These set-
in them to control an operation. The range of data that tings will give satisfactory performance for most appli-
can be stored in the registers is called a parameter. A cations.
parameter is a measurement number that works with
other measurement numbers (parameters) to define a Some functions can be adjusted within the permitted
system. There are 128 registers. range to change the lift truck operation for a specific
application. Adjustment of a register to a number that
is different than the factory setting is allowed, but follow
WARNING
the instructions carefully and stay within the minimum
The register value for each function has a value and maximum limits. Adjustments other than the factory
range so the motor controller can be used on differ- settings will cause the lift truck to operate differently and
ent models of lift trucks. This variation is needed for can cause increased wear of parts.
lift trucks of different sizes and operating voltages.
Adjustment of a function to the wrong number value
for your lift truck model can cause the truck to oper-
ate differently than normal. This different operation
of the truck can cause an injury.
10
2200 YRM 808 Function Parameters Adjustments
FUNCTION NUMBERS Function Numbers 1 through 15

Push keypad numbers for the desired register. The reg-
WARNING ister and handset numbers are shown in the Parameter
NEVER adjust any of the function registers without Tables.
using the procedures and settings given in this sec-
tion. Function Numbers 16 through 30
The Function Numbers are code numbers for the dif- NOTE: The seat switch must be open.
ferent parameters that can be set for these motor con-
trollers. The personal computer (PC) or the handset 1. Push keypad numbers for the desired function.
must be used to adjust the parameters for the motor Think of the CONT key equaling 15. Push and
controller. There is a description of the code numbers hold the CONT key, plus the additional key
for the different motor controllers in the Parameter Ta- number above 15, to total the required handset
bles. number.
Functions 1-15 are selected by pushing keys 1-15.
Functions 16-30 are selected by pushing the CONT Example: For Function Number 18, push the CONT
key and keys 1-15 (seat switch open). and key 3 (15+3=18). The display will show the
Functions 48-62 are selected by closing the seat selected function. After 1 second, the display will
switch and pushing the CONT key and keys 1-15. show the register value that has been set for this
function.
NOTE: For these functions (48-62), the operator must
also sit on the seat and, if enabled, enter the password 2. Push and hold the CONT key for 1 second. The
on lift trucks that have the Premium Display Panel. Re- register value number on the display will blink.
fer to the Operating Manual for the correct password
3. To change the register value number, check for cor-
procedure.
rect value for that function register in the Parameter
Function Number 63 is selected by closing the seat Tables. Change register value by turning Adjust-
switch and pushing the CONT and ESC keys. ment Knob on handset. The display will continue to
blink as the number value changes.
WHEN HANDSET IS CONNECTED TO
4. Push and hold the STORE key for 1 second. When
MOTOR CONTROLLER IN LIFT TRUCK the new value is set (stored), the display will stop
blinking.
WARNING
Prevent movement and possible injury of the lift 5. Push and hold the ESC key for 1 second. The dis-
truck when making checks and adjustments. Be- play will show 8888. To check or set another reg-
fore the handset is connected or disconnected to ister value number, do Step 1 through Step 3. To
the display panel that is installed in a lift truck, raise return to normal operation (run mode), push and
the drive wheels. Then turn the key to the OFF po- hold ESC again for 1 second or longer. The display
sition, disconnect the battery and discharge the ca- will return to the status code mode or display the
pacitor by operating horn for several seconds. state of battery charge if the operator is in the seat.
The display can also be blank (if there are no status
Make sure the power is off, as described in the WARN- codes or there is no BDI signal).
ING. Remove the cover and connect the handset cable
to the small connector of the motor controller. Connect NOTE: Make sure the motor controller is in the run
the battery and sit on the operator’s seat. mode before disconnecting the handset. If the motor
controller is not in the run mode, the battery must be
The registers can be set when the operator is on the disconnected and connected again to reset the system.
seat or when off the lift truck. Push and hold the CONT It can also be necessary to discharge the capacitors by
button of the handset so that it is depressed when power operating the horn for several seconds with the battery
is applied. Turn the key to the ON position. After the disconnected.
handset screen shows all "8s" (display working check),
the register parameters can be checked or changed.
The handset must be connected to each motor con-
troller in turn to check or set the register values.
11
Traction Motor Controller (Label Letter - SR) 2200 YRM 808
and hold the CONT key, plus the additional key

CAUTION number above 47, to total the required handset
The plug cover on the small connector of the motor number. Close the seat switch and the key switch.
Make sure to disconnect the power and replace the Example: For Function Number 48, push the CONT
plug cover each time the handset is disconnected. and key 1 (47+1=48, 47+2=49, 47+3=50, 47+5=52,
etc.). The display will show the selected function.
The vehicle can now be operated with the handset con- After 1 second, the display will show the register
nected, or the handset can be disconnected. Discon- value that has been set for this function.
nect the handset cable at the small connector on the
motor controller when the battery is disconnected. This 3. Push and hold the CONT key for 1 second. The
will disconnect the handset. Make sure to install the register value number on the display will blink.
plug cover on the connector of the motor controller each
4. To change the register value number, check for cor-
time the handset cable is removed.
rect value for that function register in the Parameter
Function Numbers 48 through 63 Tables. Change register value by turning Adjust-
ment Knob on handset. The display will continue to
NOTE: The seat switch must be closed. The pass- blink as the number value changes.
word must also be entered - if enabled.
5. Push and hold the STORE key for 1 second. When
NOTE: These functions (48 through 63) are the func- the new value is set (stored), the display will stop
tions that are enabled when a Performance Mode (1, blinking.
2, 3, or 4) is selected at the Premium Display Panel.
Each function must be set within the register parame- 6. Push and hold the ESC key for 1 second. The dis-
ters shown in the Parameter Tables. play will show 8888. To check or set another regis-
ter, do Step 1 through Step 3. To return to normal
1. Turn key to ON position after the handset is con- operation (run mode), do Step 5 of the previous pro-
nected to the display panel. cedure.
2. Push handset keypad numbers for the desired func-

tion. Think of the CONT key equaling 47. Push
Function Number Descriptions

The following pages have descriptions for the different motor controller will not operate correctly if the
Function Numbers. The register setting for each func- wrong values are set into the registers.
tion is specific for each motor controller.
The term "regen" is the term used in the following pro-
cedures for Regenerative Braking.
CAUTION
Make sure the Handset is connected to the correct
motor controller. See Figure 1 or Figure 2. The
Traction Motor Controller (Label Letter - SR)

Register values outside the Parameters can cause
WARNING damage to the components of the traction system
If any of the register values are changed, the op- and can cause the lift truck to operate differently
erators must be told that the lift truck will operate than normal. This different operation of the lift
differently. truck can result in personal injury.
Do not adjust the register values outside of the This motor controller controls the speed of the traction
range of numbers shown in the Parameter Tables. motor.
12
2200 YRM 808 Traction Motor Controller (Label Letter - SR)
Function Number 01 Function Number 04

AUTO REGEN ENABLE SPEED ARMATURE CURRENT LIMIT
(Push 1) (Push 4)
This function sets the motor volts or lift truck speed to This function permits the adjustment of the current limit
enable Automatic Regeneration (Auto Regen) opera- of the motor controller. The current rating of a specific
tion. motor AND the motor controller will determine the range
of adjustment for this function. See the Parameter Ta-
A setting of less than 25 will result in a "soft" release bles for the different motors and lift truck models to find
of auto regen and normal regen. Calculate the motor the correct setting.
voltage to enable regen by multiplying the value of the
setting by 0.375. For example, a setting of 16 will be Function Number 05
multiplied by 0.375 to enable auto regen when the motor REGEN RAMP RATE
voltage is above 6 volts (16 × 0.375 = 6). (Push 5)
For a setting value of more than 25, first subtract 25 This function permits the adjustment of the RATE that
from the setting value. Then calculate the motor voltage regen is applied, but does not affect stopping distance.
to enable regen, by multiplying the resulting number by The adjustment sets how smooth regen occurs. Do not
0.375. For example, a setting of 33 (33 25 = 8) will change the setting value unless regen is not smooth.
be multiplied by 0.375. In this example, regen will be 0 - 42 Faster rate of change
enabled when the motor voltage is above 3 volts (8 × 43 - 84 Medium rate of change
0.375 = 3). 85 - 126 Slower rate of change

CREEP SPEED FIELD WEAKENING (FW) RATIO
(Push 2) (Push 6)
This function permits the adjustment of the creep speed

of the lift truck. The range of adjustment is from 0 (2%) WARNING
to 255 (15%) On Time. The percent values are the On Function Number 06 is not normally adjusted in the
Time for the transistors that control the traction motor. field. Adjusting Function Number 06 between the
A constant creep speed frequency will be maintained minimum and maximum values will not change lift
when the accelerator input voltage is between 3.9 and truck performance.
3.3 volts (a potentiometer resistance value between 6K
and 4.0K ohms). This function sets the connection between field and ar-
mature currents when operating below the Field Weak-
Function Number 03 ening Start Point. The actual FW Ratio is the register
CONTROLLED ACCELERATION value without the last digit.
(Push 3)
EXAMPLE: Register value of 45 = FW Ratio of 4
This function permits the adjustment of the maximum
initial rate of acceleration. The register value deter- Field current equals the FW Ratio times the result of
mines the time allowed to reach 100% of battery voltage armature current times 0.024:
to the motor after the accelerator is set for maximum I FIELD = FW Ratio (I ARMATURE × 0.024).
speed from stop. The control will stay in controlled ac- Function Number 07
celeration for between 0.025 second (setting 0) and 6.3 MINIMUM FIELD CURRENT
seconds (setting 255). The numbers in () are the reg- (Push 7)
ister values for the times shown. Do NOT adjust the
register value for this function to LESS THAN the mini-
mum value. WARNING
Function Number 07 is not normally adjusted in the
field.
This function is used to make minor adjustments be-

tween FW Ratio numbers.
13
Function Number 08 available when Speed Limit 3 (SL3) is enabled. SL3

MAXIMUM FIELD CURRENT is activated by status codes 90, 91, or 99.
(Push 8)
Function Number 14
INTERNAL RESISTANCE COMPENSATION
WARNING (Push 14)
field. Adjusting Function Number 08 between the
minimum and maximum values will not change lift CAUTION
truck performance. Adjusting this function setting to the wrong number
can cause battery damage.
This function adjusts the maximum field current that the
motor controller will deliver in normal operation. This function allows improvement in the accuracy of the
BDI. The register value for this function can also be
Function Number 09 changed using the number push buttons on the Pre-
REGENERATIVE BRAKING CURRENT LIMIT (C/L) mium Display Panel. Refer to the procedure following
(Push 9) the Caution. The tables for the Parameter Registers
show the parameters for a battery in average condition.
This function adjusts the maximum armature current
that can be used during regen braking. The higher the For the best use of your battery energy, the function can
value and current, the shorter the stopping distance. be adjusted using the following procedure. However,
setting the value too low for your battery can allow the
Function Number 10 battery to discharge below the minimum specific grav-
FIELD CURRENT FOR REGENERATIVE BRAKING ity value. This minimum specific gravity is the specifica-
(Push 10) tion given by the battery manufacturer to prevent battery
damage.
WARNING
NOTE: It can be necessary to do this procedure again
as a battery gets older.
minimum and maximum values will not change lift Use the following procedure to adjust the function for
truck performance. the correct register value:
a. Operate lift truck on a normal work cycle.
This function adjusts the motor field current that can be
b. When lift interrupt occurs or the bar graph shows
used during regen braking. This function does not affect
"empty," stop lift truck and wait for approximately 10
stopping distance.
minutes.
Function Number 11 c. Check specific gravity of several battery cells. If the
NOT USED specific gravity is between 1.140 and 1.150, the set-
ting is correct for that battery. If the specific grav-
Function Number 12 ity reading is high, adjust register value to a lower
MAXIMUM ARMATURE % ON TIME (Travel Speed number. If the specific gravity reading is low, adjust
Limit) register value to a higher number.
(Push 12)
NOTE: It can be necessary to charge the battery and
This function allows for the adjustment of the maximum do Steps a through c again to get an accurate number
lift truck speed (maximum battery volts to the motor). for your battery.
This function is always active to limit battery volts to the
motor.
CAUTION
Function Number 13 NEVER discharge a battery below a specific gravity
SPEED LIMIT 3 of 1.130. The battery can have permanent damage
(Push 13) if discharged below 1.130.
This function allows for the adjustment of the maximum CHANGE THE REGISTER VALUE USING THE PUSH
lift truck speed (maximum battery volts to the motor) BUTTONS OF THE PREMIUM DISPLAY PANEL (If this
function is enabled).
14
NOTE: The adjustment can only be made with the key Function Numbers GREATER THAN 15
in the OFF position.
The following functions have function numbers larger
1. Press the STAR push button. The first item in the than the numbers on the handset keyboard. To ac-
menu will be shown on the LCD screen. cess these functions, push the CONT key and the num-
ber shown in () with the function "title". Think of the
2. Now press the push button #1 as many times CONT key equaling 15. Push and hold the CONT
as necessary for a display of: BATTERY AD- key, plus the additional key number 1 through 15,
JUSTMENTS NOT ALLOWED or ADJUST BATT. to total the required function number. Example: for
COMPNS DEPRESS 5 NXT 1/4. If ADJUST BATT. Function Number 18, push the CONT key and key 3
COMPNS DEPRESS 5 NXT 1/4 is shown on the (15+3=18). The display will show the selected function.
screen, this feature is enabled. After 1 second, the display will show the setting number
that has been set for that function.
3. Press push button #5 for a display of: CYCLE KEY
OFF/ON BDI NOT RECEIVED or XX % ADJUST NOTE: The Seat Switch must be OPEN for Function
BDI YY=SETTING <1/4> 5 ST. The XX number is Numbers 16 through 30.
the actual bar graph value shown as a number for
better resolution. The YY number is the register Function Number 16
value stored in the motor controller for Function STALL TRIP POINT % ON TIME
Number 14. (Push CONT and 1)
4. Find the correct register value using the procedure This function sets the percent of On Time for the FETs
described in previous Steps a through c. that the motor controller uses to determine a motor
"stall" condition.
5. Use the number push buttons #1 or #4 to increase
or decrease the YY number on the LCD screen to
the new register value. Press push button #5 to CAUTION
store this new number in the register. This function value sets electrical limits to protect
the motor from damage if stall occurs. Increasing
Function Number 15 the setting value can allow motor damage if a stall
BATTERY VOLTAGE SELECTION does occur.
(Push 15)
Percent On Time = (163 - Set Point Value) × 0.892
This function permits adjustment for the operating volt-
age of the lift truck. The adjustment also permits cor- If the Set Point Value is 163 or more, the % On Time is
rect operation of the Battery Discharge Indicator func- zero. If the Set Point Value is 51 or less, the % On Time
tion. For the controller and BDI to operate correctly, the is 100%.
register value shown in the tables for the Register Pa-
Function Number 17
rameters must be entered.
CONTROL TYPE SELECTION
Battery Volts Parameter (Push CONT and 2)
36/48 volts Between 184 and 250

WARNING
NOTE: If the register value is set to a number other than Wrong register values entered for the function in
the number shown for your lift truck in tables for the Reg- Function Number 17 can cause the truck to operate
ister Parameters, a status code of 15 or 16 will occur. differently than normal. This different operation of
Make sure the battery is fully charged and battery con- the truck can cause an injury. NEVER set Function
nector has good connections before making this adjust- Number to a parameter that is not shown for your
ment. This check is especially important when adjust- lift truck.
ing for 36/48 volt operation (numbers 184 to 250). This function permits the selection of the card type used
for your lift truck application. Refer to the tables for the
Register Parameters for your lift truck model and motor
used.
15

SEAT SWITCH TIME DELAY FOR SPECIAL FUNCTIONS
(Push CONT and 3) (Push CONT and 8)
This function permits adjustment of the time delay for This function is not used except for special functions
turning off the line contactor and pump motor control required for special applications.
after the seat switch opens.
NOTE: Set Function Number 23 at 0.
NOTE: There is no delay time for startup after receiving
the input signal from the seat switch. Parameters in Function Number 24
the 0-128 range adjust the delay after the seat switch FIELD WEAKENING START
opens. The time parameters are 1.5 to 65 seconds. (Push CONT and 9)
Adjust the setting to the number shown in tables for the
Register Parameters. WARNING
NOTE: The steering pump has a separate time delay Function Number 24 is not normally adjusted in the
module. field. Adjusting Function Number 02 between the
minimum and maximum values will not change lift
Function Number 19 truck performance.
MAINTENANCE CODE TENS AND UNITS
(Push CONT and 4) This function allows for setting the "change" point be-
tween the Field Weakening ratio (Function Number 6)
This function can be set by the service person to give and the Base Ratio (Function Number 26). This point
a Status Code 99 when scheduled maintenance is re- is determined by the amount of armature current where
quired. Register value range is 0 to 99 hours. A setting this change of ratios occurs.
of 42 will give a Status Code of 99 when the hourmeter
reads XXX42. Setting parameter is 0 to 255. Armature current range
is 0 to 357 amps. Multiply the register value by 1.4 for
Function Number 20 the armature current (90 × 1.4 = 126 Amps).
MAINTENANCE CODE THOUSANDS AND HUN-
DREDS Function Number 25
(Push CONT and 5) MONITOR
(Push CONT and 10)
This function can be set by the service person to give
a Status Code 99 when scheduled maintenance is re- WARNING
quired. Register value range is 0 to 240. The range
for this function is 100 to 24000 hours. A setting of
240 will give a Status Code of 99 when the hourmeter
reads 240XX. The hourmeter will return to 00000 after
truck performance.
it reaches 24099 hours.
Set this function register value at 0.
Function Number 21
AUTO REGEN BRAKING CURRENT LIMIT Function Number 26
(Push CONT and 6) BASE RATIO
(Push CONT and 11)
This function sets the level of auto regen current, which
can never be greater than the regen level set by function
9. The auto regen and regen current levels will be the WARNING
same for settings of 51 or less. The auto regen level will Function Number 26 is not normally adjusted in the
gradually decrease for settings between 51 and 143, field. Adjusting Function Number 26 between the
and is completely disabled with a setting greater than minimum and maximum values will not change lift
143. truck performance.
Function Number 22
NOT USED
16
This function sets the connection between field and ar- Each function must be set within the register parame-
mature currents when operating below the maximum ters shown in the Parameter Tables.
field current and above the Field Weakening Start point
(Function Number 24). The actual Base Ratio is the NOTE: The following functions have function numbers
register value without the last digit. larger than the numbers on the handset keyboard.
Make sure seat switch is CLOSED. To access these
EXAMPLE: Register value of 45 = Base Ratio of 4 functions, push the CONT key and the number shown
in () with the function "title". Think of the CONT key
Field current equals the Base Ratio times the result of equaling 47. Push and hold the CONT key, plus
armature current times 0.024: the additional key number 1 through 15, to total
I FIELD = Base Ratio (I ARMATURE × 0.024). the required function number 48 through 62. For
function number 63, push the CONT key and the
Function Number 27
ESC key.
NOT USED
Function Number 48
Function Number 28
MODE 1 - CONTROLLED ACCELERATION
STORED STATUS CODE COUNT POINTER
(Push CONT and 1)
(Push CONT and 13)
This function contains a coded number that indicates
initial rate of acceleration. The register value deter-
the location of the last stored status code. These stored
mines the time allowed to reach 100% of battery voltage
status codes have caused a PMT controller shutdown
to the motor after the accelerator is set for maximum
and/or caused a change from the normal lift truck oper-
speed from stop. The control will stay in controlled ac-
ation.
celeration for between 0.025 second (setting 0) and 6.3
Set the register value of Function Number 28 to 0 if the seconds (setting 255). The numbers in () are the reg-
stored status codes are cleared (erased) using a hand- ister values for the times shown. Do NOT adjust the
set. If a PC is used to access Function 28, the soft- register value for this function to LESS THAN the mini-
ware program will "ask" the technician if the stored sta- mum value.
tus codes will be cleared (erased). Setting the register
NOTE: This Controlled Acceleration is in effect when
value of Function Number 28 to 0 will erase the stored
mode 1 is selected on the Premium Display Panel.
status codes.
Function Number 49
Refer to HANDSET INSTRUCTIONS, CLEARING THE
MODE 1 FIELD WEAKENING (FW) START
STORED STATUS CODES for instructions on clearing
(Push CONT and 2)
the stored status codes and resetting Function Number
28 to 0 and for additional information. The numbers
always start at status code 1 and scroll to status code WARNING
16. Function Number 49 is not normally adjusted in the
NOTE: Function Numbers 29 through 47 ARE NOT minimum and maximum values will not change lift
USED. Function Numbers 48 through 63 are ONLY truck performance.
used with units that have the Premium Display Panel.
This function allows for setting the "change" point be-
FUNCTIONS WITH PREMIUM DISPLAY tween the Field Weakening ratio (Function Number 6)
PANEL ONLY and the Base Ratio (Function Number 26). This point
is determined by the amount of armature current where
NOTE: The seat switch must be CLOSED to adjust this change of ratios occurs.
Function Numbers 48 through 63.
NOTE: This FW Start is in effect when mode 1 is se-
NOTE: These functions (48 through 63) are the func- lected on the Premium Display Panel.
tions that are enabled when a Performance Mode (1,
2, 3, or 4) is selected at the Premium Display Panel.
17
Function Number 50 Same as Function Number 49.

MODE 1 - FIELD WEAKENING (FW) RATIO
(Push CONT and 3) NOTE: This FW Start is in effect when mode 2 is se-
lected on the Premium Display Panel.
WARNING Function Number 54

Function Number 50 is not normally adjusted in the MODE 2 - FIELD WEAKENING (FW) RATIO
field. Adjusting Function Number 50 between the (Push CONT and 7)
truck performance. WARNING
This function sets the connection between field and ar- Function Number 54 is not normally adjusted in the
mature currents when operating below the Field Weak- field. Adjusting Function Number 54 between the
ening Start Point. The actual FW Ratio is the register minimum and maximum values will not change lift
value without the last digit. truck performance.
EXAMPLE: Register value of 45 = FW Ratio of 4 Same as Function Number 50.
Field current equals the FW Ratio times the result of NOTE: This FW ratio is in effect when mode 2 is se-
armature current times 0.024: lected on the Premium Display Panel.
I FIELD = FW Ratio (I ARMATURE × 0.024).
Function Number 55
NOTE: This FW ratio is in effect when mode 1 is se- MODE 2 - MAXIMUM ARMATURE % ON TIME (MODE
lected on the Premium Display Panel. 2 - TRAVEL SPEED LIMIT)
(Push CONT and 8)
Function 51
MODE 1 - MAXIMUM ARMATURE % ON TIME (MODE Same as Function Number 51.
1 - TRAVEL SPEED LIMIT)
NOTE: This travel speed limit is in effect when mode 2
(Push CONT and 4)
is selected on the Premium Display Panel.
This function allows for the adjustment of the maximum
Function Number 56
lift truck speed (maximum battery volts to the motor).
This function is always active to limit battery volts to the
(Push CONT and 9)
motor.
Same as Function Number 48.
NOTE: This Travel Speed Limit is in effect when mode
1 is selected on the Premium Display Panel. NOTE: This controlled acceleration is in effect when
Function 52
MODE 2 - CONTROLLED ACCELERATION Function Number 57
(Push CONT and 5) MODE 3 - FIELD WEAKENING (FW) START
(Push CONT and 10)
NOTE: This Controlled Acceleration is in effect when WARNING

mode 2 is selected on the Premium Display Panel. Function Number 57 is not normally adjusted in the
Function Number 53 field. Adjusting Function Number 57 between the
MODE 2 - FIELD WEAKENING (FW) START minimum and maximum values will not change lift
(Push CONT and 6) truck performance.

WARNING
NOTE: This FW start is in effect when mode 3 is se-
truck performance.
18
2200 YRM 808 Pump Motor Controller (Label Letter - SP)
Function Number 58
MODE 3 - FIELD WEAKENING (FW) RATIO WARNING
(Push CONT and 11) Function Number 61 is not normally adjusted in the
WARNING truck performance.
field. Adjusting Function Number 58 between the Same as Function Number 49.
truck performance. NOTE: This FW start is in effect when mode 4 is se-
Function Number 62
NOTE: This FW ratio is in effect when mode 3 is se- MODE 4 - FIELD WEAKENING (FW) RATIO
lected on the Premium Display Panel. (Push CONT and 15)
Function Number 59
MODE 3 - MAXIMUM ARMATURE % ON TIME (MODE WARNING
3 - TRAVEL SPEED LIMIT) Function Number 62 is not normally adjusted in the
(Push CONT and 12) field. Adjusting Function Number 62 between the
Same as Function Number 51. truck performance.
NOTE: This travel speed limit is in effect when mode 3 Same as Function Number 50.
NOTE: This FW ratio is in effect when mode 4 is se-
Function Number 60 lected on the Premium Display Panel.
(Push CONT and 13) NOTE: For function number 63, push the CONT key and
the ESC key with the seat switch still closed.
Function Number 63
NOTE: This controlled acceleration is in effect when MODE 4 - MAXIMUM ARMATURE % ON TIME (MODE
mode 4 is selected on the Premium Display Panel. 4 - TRAVEL SPEED LIMIT)
(Push CONT and ESC)
Function Number 61
MODE 4 - FIELD WEAKENING (FW) START Same as Function Number 51.
(Push CONT and 14)
NOTE: This travel speed limit is in effect when mode 4
Pump Motor Controller (Label Letter - SP)

This motor controller controls the speed of the motor for
WARNING the hydraulic lift pump. See Figure 2.
If any of the register values are changed, the op-
erators must be told that the lift truck will operate Function Number 01
differently. STORED STATUS CODE
(Push 1)
Do not adjust the register values outside of the
range of numbers shown in the Parameter Tables. This function contains the last status code of a possible
Register values outside the Parameters can cause malfunction that caused the pump motor to run contin-
damage to the components of the hydraulic system uously. The battery must be disconnected to stop the
and can cause the lift truck to operate differently motor if it runs continuously. This status code will be
than normal. This different operation of the lift replaced with the same status code if another possible
truck can result in personal injury. malfunction occurs. The status code can be cleared
from memory by adjusting the setting number to zero.
19
Pump Motor Controller (Label Letter - SP) 2200 YRM 808
Any new number (including zero) must be stored by EXAMPLE: A setting of 20 (20 units) = 0.032 seconds
pushing the STORE key for 1 second. Adjustment of Voltage added in × time is 0.375 volts. If you had se-
this function does not change operation of the hydraulic lected 2.08 volts from Function Number 16 to be added
system. to the motor, it would take 0.18 seconds to add a total
of 2.08 volts.
Function Number 02 (20 units × 0.0015 sec) + 0.0015 sec. min. = 0.0315
INTERNAL RESISTANCE COMPENSATION START sec
(Push 2) (2.08 V ÷ 0.375 V) × 0.0315 sec = 0.175 or 0.18 sec
This function permits adjustment of the current level re- Function Numbers 08 Through 10 NOT USED
quired to start the internal resistance compensation of
Function Number 16. Multiply the register value by 6.5 Function Number 11
for the current level (72 × 6.5 = 130 Amps). SPEED LIMIT 1 (SL1)
(Slow Speed) - Tilt and Slow Auxiliary
Function Number 03 (Auxiliary and Slow Rotate for N30XMH2)
CONTROLLED ACCELERATION (Push 11)
(Push 3)
This function permits the adjustment of the speed limit
This function permits the adjustment of the maximum (maximum battery volts applied to the motor). When
rate of acceleration of the pump motor. The parame- switch SL-1 is closed, the signal to the pump motor
ter determines the time allowed for the motor controller controller causes it to apply the limit on battery volts to
to apply 100% of battery voltage after a switch for a the pump motor. Multiply the register value by 0.375 to
hydraulic function closes. This parameter determines determine the speed limit voltage (50 × 0.375 = 18.75
how fast the hydraulic functions will begin to operate. volts).
The time can be changed between 0.1 and 5.5 seconds.
Multiply the register value by 0.021, then add 0.1 to de- Function Number 12
termine the time of controlled acceleration (50 × 0.021 SPEED LIMIT 2 (SL2)
+ 0.1 = 1.15 seconds). (Medium Speed) - Slow Lift and Medium Auxiliary
(Slow Lift and Fast Rotate for N30XMH2)
Function Number 04 (Push 12)
CURRENT LIMIT
(Push 4) Same as Function Number 11, except switch SL-2 is
the input to the pump motor controller.
This function permits the adjustment of the current limit
of the control. The current limit is normally set at the Function Number 13
maximum (255). SPEED LIMIT 3 (SL3) Fast Lift
(Push 13)
Function Numbers 05 and 06 NOT USED
Same as Function Number 11, except switch SL-3 is
Function Number 07 the input to the pump motor controller.
INTERNAL RESISTANCE COMPENSATION RATE
(Push 7) Function Numbers 14 and 15 NOT USED
This function allows for the adjustment of the time it Function Numbers Greater Than 15
takes for the controller to add the internal resistance
compensation voltage that is applied to the motor. This For functions greater than 15, push and HOLD the
function will add 0.375 volts to the motor at the rate CONT key and the additional key number above 15 to
of time adjusted until the total internal resistance com- total the required function number. Example: For Func-
pensation voltage has been added. There is 0.0015 tion Number 18, push CONT key and key 3 (15+3=18).
sec/unit starting from a 0.0015 second minimum. The display will show the selected function. After 1
second, the display will show the register value that
NOTE: The internal resistance compensation voltage is has been set in that function.
set by Function Number 16, Speed/Torque Compensa-
tion. NOTE: The Seat Switch must be OPEN for Function
Numbers 16 through 30.
20
Function Number 16 The motor controller for the traction system controls the
SPEED TORQUE COMPENSATION BDI and Lift Interrupt functions. The BDI signal from the
(Push CONT and 1) traction motor controller must be present at the pump
motor controller before it can operate. Refer to Func-
This function is used to give the pump speed better tion Number 17 of the Traction functions for more in-
stability by increasing the pump motor voltage during formation.
heavy loads. This register value adds 0.375 volts to the
motor for each 100 amps increase in pump motor cur- Function Numbers 18 through 27
rent. The voltage is added, starting at the current value TEMPORARY DATA REGISTERS
set for Function Number 02. For example, a register
value of 10 will add 2.28 volts in six steps of 0.375 volts CAUTION
each. See Table 1.
Register 25 must NOT be changed by the user to
Table 1. Speed/Torque Compensation any number above zero.
These register values can be read with the handset, but

Setting Voltage Setting Voltage
the data in them changes during lift truck operation. Do
Drop Drop
not change the values in registers 21 through 27.
2 11.44 17 1.34
Function Number 28
3 7.60 18 1.27 STORED STATUS CODE COUNT POINTER
4 5.72 19 1.20 (Push CONT and 13)
5 4.57 20 1.14 This function contains a coded number that indicates
6 3.81 21 1.09 the location of the last stored status code. These stored
status codes have caused a PMT controller shutdown
7 3.27 22 1.04 and/or a change from the normal lift truck operation.
8 2.86 23 0.99
Set the register value of Function Number 28 to 0 if
9 2.54 24 0.95 the stored status codes are cleared (erased) using a
10 2.28 25 0.91 handset. If stored status codes are cleared using a PC,
Function Number 28 is automatically set to 0.
11 2.08 26 0.88
Refer to HANDSET INSTRUCTIONS, CLEARING THE
12 1.90 27 0.85 STORED STATUS CODES for instructions on clearing
13 1.76 28 0.82 the stored status codes and resetting Function Number
28 to 0 and for additional information. The numbers
14 1.63 29 0.79
always start at status code 1 and scroll to status code
15 1.52 30 0.76 16.
16 1.43 31 0.74 NOTE: Function Numbers 29 through 47 ARE NOT
USED. Function Numbers 48 through 63 are ONLY
Function Number 17 used with units that have the Premium Display Panel.
CONTROL TYPE SELECTION
(Push CONT and 2) FUNCTIONS WITH PREMIUM DISPLAY
PANEL ONLY
WARNING
NOTE: The seat switch must be CLOSED to adjust
Wrong register values entered for Function Number Function Numbers 48 through 63.
17 can cause the truck to operate differently than
normal or cause damage to the controller or motor. NOTE: Functions (48 through 63) are the functions that
This different operation of the truck can result in are enabled when a Performance Mode (1, 2, 3, or 4) is
personal injury. NEVER set Function Number 17 selected at the Premium Display Panel. Each function
to a register value outside the register parameters must be set within the register parameters shown in the
shown for your lift truck. Parameter Tables.
21
NOTE: The following functions have function numbers to less than the register value for Function Number 56.
larger than the numbers on the handset keyboard. To Do not set the number in the function to greater than
access these functions, push the CONT key and the the number in the function for Function Number 48.
number shown in () with the function "title". Think of
the CONT key equaling 47. Push and hold the CONT Function Number 53
key, plus the additional key number 1 through 15, to MODE 2 - SPEED LIMIT 2
total the required function number. (Push CONT and 6 while the key switch and seat
switch are closed)
Function Number 48
MODE 1 - CONTROLLED ACCELERATION This function permits the adjustment of the speed limit
(Push CONT and 1) for the hydraulic pump in MODE 2. Do not set the num-
ber in the function to less than the register value for
This function allows for the adjustment of the time it Function Number 49. Do not set the number in the func-
takes for the controller to accelerate to 100% applied tion to greater than the number in the function for Func-
battery voltage to the motor on hard acceleration. Mul- tion Number 57.
tiply the register value by 0.084 seconds to determine
the time of Controlled Acceleration (120 × 0.084 = 10 Function Number 54
seconds). MODE 2 - SPEED LIMIT 3
(Push CONT and 7 while the key switch and seat
NOTE: This Controlled Acceleration is in effect when switch are closed)
This function permits adjustment of the speed limit
Function Number 49 (maximum battery volts to the motor). The range is 0%
MODE 1 - SPEED LIMIT 2 to 96%. There is no speed limit switch for this function.
(Push CONT and 2 while the key switch and seat This function will be disabled if the register value in
switch are closed) the function is set to zero. Do not set the number in
the function to less than the register value for Function
This function permits the adjustment of the speed limit Number 58. Do not set the number in the function to
for the hydraulic pump in MODE 1. The minimum reg- greater than the number in the function for Function
ister value is zero. Do not set the number in the func- Number 50.
tion greater than the number in the function for Function
Number 53. Function Number 56
Function Number 50 (Push CONT and 9 while the key switch and seat
MODE 1 - SPEED LIMIT 3 switch are closed)
switch are closed) This function permits the adjustment of the maximum
rate of acceleration in MODE 3. The register value
This function permits adjustment of the speed limit determines the time allowed to reach maximum SCR
(maximum battery volts to the motor). The range is 0% speed from stop. Do not set the number in the function
to 96%. There is no speed limit switch for this function. to less than the register value for Function Number 60.
This function will be disabled if the register value in Do not set the number in the function to greater than
the function is set to zero. Do not set the number in the number in the function for Function Number 52.
the function to less than the register value for Function
Number 54. The maximum number in the function is Function Number 57
255. MODE 3 - SPEED LIMIT 2
Function Number 52 switch are closed)
(Push CONT and 5 while the key switch and seat This function permits the adjustment of the speed limit
switch are closed) for the hydraulic pump in MODE 3. Do not set the num-
ber in the function to less than the register value for
This function permits the adjustment of the maximum Function Number 53. Do not set the number in the func-
rate of acceleration in MODE 2. The register value tion to greater than the number in the function for Func-
determines the time allowed to reach maximum SCR tion Number 61.
speed from stop. Do not set the number in the function
22
Function Number 58 This function permits the adjustment of the speed limit
MODE 3 - SPEED LIMIT 3 for the hydraulic pump in MODE 4. Do not set the num-
(Push CONT and 11 while the key switch and seat ber in the function to less than the register value for
switch are closed) Function Number 57. Do not set the number in the func-
tion greater than 70.
(maximum battery volts to the motor). The range is 0% Function Number 62
to 96%. There is no speed limit switch for this function. MODE 4 - SPEED LIMIT 3
This function will be disabled if the register value in the (Push CONT and 14 while the key switch and seat
function is set to zero. The maximum number in the switch are closed)
function is 255.
Function Number 60 (maximum battery volts to the motor). The range is 0%
MODE 4 - CONTROLLED ACCELERATION to 96%. There is no speed limit switch for this function.
(Push CONT and 13 while the key switch and seat This function will be disabled if the register value in the
switch are closed) function is set to zero. The maximum number in the
function is 255.
rate of acceleration in MODE 4 (Rabbit). The register The following tables have the location of each Function
value determines the time allowed to reach maximum Number in the EEPROM of the motor controllers and
SCR speed from stop. Do not set the number in the the PC and handset (HS) Function Numbers. The ta-
function to less than 8. Do not set the number in the bles also show which functions can be accessed by the
function to greater than the number in the function for PC and HS, as well as any restrictions that apply. See
Function Number 56. Table 2 and Table 3. See the Parameter Tables for the
register values and register parameters for each Func-
Function Number 61 tion Number.
MODE 4 - SPEED LIMIT 2
switch are closed)
Table 2. Function Map for Motor Controllers SR (Traction)
EEPROM PC Function Handset Description Access Restrictions

Register Number (HS) By:
Number Number
0 1 1 Auto Regen Enable Speed HS or PC None
1 2 2 Creep Speed HS or PC None
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Armature Current Limit HS or PC None
4 5 5 Regen Ramp Rate HS or PC None
5 6 6 Field Weakening (FW) Ratio HS or PC None
6 7 7 Minimum Field Current HS or PC None
7 8 8 Maximum Field Current HS or PC None
8 9 9 Regenerative Braking Current Limit HS or PC None
9 10 10 Field Current for Regen Braking HS or PC None
10 11 11 NOT USED HS or PC None
11 12 12 Maximum Armature % On Time HS or PC None
12 13 13 Speed Limit 3 HS or PC None
23
Table 2. Function Map for Motor Controllers SR (Traction) (Continued)

Number Number
13 14 14 Internal Resistance Compensation HS or PC None
14 15 15 Battery Voltage Selection HS or PC None
15 16 16 Stall Trip Point % On Time HS or PC None
16 17 17 Control Type Selection HS or PC None
17 18 18 Seat Switch Time Delay HS or PC None
18 19 19 Maintenance Code Tens and Units HS or PC None
19 20 20 Maintenance Code Thousands and HS or PC None
Hundreds
20 21 21 Auto Regen Braking Current Limit HS or PC None
21 22 22 NOT USED HS or PC
22 23 23 For Special Programs HS or PC None
23 24 24 Field Weakening Start HS or PC None
24 25 25 Monitor HS or PC GE Temporary
Storage
25 26 26 Base Ration HS or PC GE Temporary
Storage
26 27 27 NOT USED HS or PC GE Temporary
Storage
27 28 28 Stored Status Code Counter Pointer HS or PC None (Location of
last status code
recorded)
28 - 46 29 - 47 29 - 30 NOT USED HS or PC None
47 48 Mode 1 Controlled Acceleration PC Only Reset to Zero only
48 49 Mode 1 Field Weakening (FW) Start PC Only Reset to Zero only
49 50 Mode 1 Field Weakening (FW) Ratio PC Only Reset to Zero only
50 51 Mode 1 Maximum Armature % On Time PC Only Reset to Zero only
24
Table 2. Function Map for Motor Controllers SR (Traction) (Continued)

Number Number
63 - 127 64 - 128 NOT USED PC Only Reset to Zero only
Table 3. Function Map for Motor Controllers SP (Lift Pump Motor)
EEPROM PC Function Handset Function Access By: Restrictions

Register Number (HS)
Number Function
Number
0 1 1 Stored Status Code HS or PC Erases when
battery is
disconnected
Start
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Current Limit HS or PC None
4 5 5 NOT USED
5 6 6 NOT USED
Rate
7 8 8 NOT USED
8 9 9 NOT USED
9 10 10 NOT USED
10 11 11 Speed Limit 1 (SL1) HS or PC None
14 15 15 NOT USED
15 16 16 Speed Torque Compensation HS or PC None
16 17 17 Control Type Selection HS or PC None
17 - 26 18 - 27 18 - 27 Temporary Data Registers
25
Table 3. Function Map for Motor Controllers SP (Lift Pump Motor) (Continued)
EEPROM PC Function Handset Function Access By: Restrictions

Register Number (HS)
Number Function
Number
27 28 28 Stored Status Code Count Pointer HS or PC None (Location
of last status
code recorded)
28 - 46 29 - 47 29 - 47 NOT USED HS or PC None
47 48 Mode 1 Controlled Acceleration PC Only Reset to Zero
only
48 49 Mode 1 Speed Limit 2 PC Only Reset to Zero
only
49 50 Mode 1 Speed Limit 3
50 51 NOT USED PC Only Reset to Zero
only
only
only
only
only
only
only
only
only
62 - 127 63 - 128 NOT USED PC Only Reset to Zero
only
26
2200 YRM 808 Troubleshooting
Troubleshooting
GENERAL fault could be caused by an internal failure of the con-
troller. After all other status code procedures have been
The SR and SP controllers are sealed units with no ser- followed and no problem is found, the controller should
viceable components. Troubleshooting is usually lim- then be replaced as the last option to correct the prob-
ited to accessing status codes and following the diag- lem.
nostic procedures listed in the Status Code Charts.
Check resistance on R × 1000 scale from frame to
Use standard testing procedures to verify inputs and power and controller terminals. A resistance of less
outputs when necessary. than 20,000 ohms can cause misleading symptoms.
Resistance less than 1000 ohms should be corrected
CAUTION first.
Never attempt to probe through the back of the Before proceeding, visually check for loose wiring, mis-
connector plugs of the motor controller or contac- aligned linkage to the accelerator switch, signs of over-
tor driver module. These plugs are special sealed heating of components, etc.
plugs. Probing through the back of the plugs will
destroy the seal and can cause a short circuit. If a Tools and test equipment required are: clip leads, volt
circuit must be tested for voltage, check for voltage ohmmeter (20,000 ohms per volt), and basic hand tools.
at an "amp" type plug, a switch, or a component. If
a circuit is suspect, check the circuit for continuity STATUS CODES
by disconnecting the P plug and testing continuity
from the front (pin end) of the plug. NOTE: Make sure the register values is correct for each
Function Number of your lift truck to make sure the
Standard probes are too large to be inserted into the trouble is not just a wrong setting. See the Parame-
center of the female pins (sockets) of the special ter Tables at the end of this section. If there is no status
sealed plugs and can expand the pins. Expanded code display and the lift truck does not operate correctly,
pins will not provide good connections once the there can be a fault in the motor controller.
plug is reconnected. To prevent pin damage, only
use probes with a diameter of 1.57 mm (0.062 in.) or The status codes are code numbers for malfunctions
less. or lift truck operation that are not correct and that the
motor controller can sense. The motor controller will
NOTE: A breakout box tool (Yale part number indicate this code number on the LCD screen of the
580002086) is available to use when troubleshoot- display panel or the display on a handset. The motor
ing the transistor controllers. When the breakout tool controller will illuminate the numbers of the status code
is installed between the controller and the harness, on the LCD screen. The status codes are twice illumi-
voltage checks can be made. nated ("flash") on the LCD screen approximately every
2 seconds. Every third "flash" of the LCD screen will
Refer to Table 5 for the SR traction controller connec- indicate the battery charge instead of the status code.
tions. Refer to REPAIRS for the SR lift pump controller
connections. Also refer to REPAIRS for the transistor The control card senses the following types of malfunc-
controller plug pin connections. tions:
• Input voltages that are too high or too low
See the Diagrams manual for your lift truck for addi- • Input voltages that have the wrong polarity
tional wiring details. • Input voltages in the wrong sequence
• Correct input voltages that occur at the wrong time
If the lift truck does not operate correctly, a status code
is displayed on the display panel. NOTE: A status code indication does not always mean
that there is a malfunction. A temporary operating con-
Once the status code number is obtained, follow the
dition can cause a status code display.
procedures outlined in the Status Code Charts of this
manual to determine the problem.
NOTE: Due to the interaction of the controller with all

lift truck functions, almost any status code or controller
27
Troubleshooting 2200 YRM 808
If a status code number is indicated on the LCD screen Table 4. List of Status Codes (Continued)
of the display panel, checks and adjustments cannot
be done. See Table 4 and the following Status Code
Code Description
Charts to find and correct the malfunction. There are
no checks or adjustments for the status codes. These 27 Voltage to logic circuit less than 10 volts.
code numbers are only codes to help identify a possible
28 Motor field current too high for too long
malfunction. A short description of the different status
during operation.
codes is shown in Table 4.
41 Open thermal protector or motor controller
The Status Code Charts in this section have a more temperature too high.
complete description of the status code, the circuit that
has generated the input for the status code, the symp- 42 Motor sensor voltage too high with no
tom, and the possible causes. armature current.
43 Motor sensor voltage too low with no
Table 4. List of Status Codes
armature current.
Code Description 44 Armature transistor did no to OFF
correctly.
Traction Motor Controller (Input
Signals) 45 Armature transistor did not go ON
correctly.
Blank No input voltage to controller or display
panel. 46 A2 voltage too low.
01 No input from seat switch. 49 Motor field current too low during
operation.
02 FWD switch closed on initial start.
51 C1 voltage too low before line contactor
03 REV switch closed on initial start. closes.
05 Start switch did not close. 57 Motor current sensor too low during
06 Accelerator depressed, no direction operation.
selected. 64 Line driver voltage input too low.
07 Accelerator input voltage too high. 66 Field current above transistor current limit.
08 Accelerator input voltage too low. 67 Armature current above transistor current
09 Both FWD and REV switches closed at limit.
same time. 69 Contactor coil current of 1A contactor too
11 The START switch is closed before the high.
key switch is closed. (Regenerative Braking)
15 Battery volts too low. 76 C1 voltage too high during REGEN.
16 Battery volts too high. 77 Motor current during REGEN.
17 Wrong control type selected. (Motor Stall)
23 Motor field current too high on initial start 82 Traction motor stalled for more than 3.5
- REV. seconds.
24 Motor field current too high on initial start
(Motor Conditions and User Defined)*
- FWD.
90 Temperature too high, traction motor*
*Not used on all models of lift trucks. Status Codes
in this group will flash on the LCD screen of display *Not used on all models of lift trucks. Status Codes
panel. in this group will flash on the LCD screen of display
NOTE: Truck speed is decreased when status code 90, panel.
91, or 99 is indicated. NOTE: Truck speed is decreased when status code 90,
91, or 99 is indicated.
28
2200 YRM 808 Troubleshooting
Table 4. List of Status Codes (Continued) Table 4. List of Status Codes (Continued)
Code Description Code Description

91 Temperature too high, hydraulic pump 142 Motor sensor voltage too high with no
motor* armature current.
93 Brush wear, steering pump motor* 143 Motor sensor voltage too low with no
armature current.
93 -
144 Power transistor (Q1) did not go off
94 Brush wear, traction motor*
correctly.
95 Brush wear, hydraulic pump motor*
145 Power transistor (Q1) did not go on
99 Maintenance Required Code. correctly.
Pump Motor Controller 146 T2 Voltage too low.
117 Wrong control type selected. 151 C1 voltage too low before line contactor
closes.
127 Voltage to circuit less than 10 volts.
157 Motor current sensor polarity check.
128 Motor current too high for too long.
180 C1 voltage less than 14 volts.
141 Open thermal protector or motor controller
temperature too high. 181 Battery voltage less than 14 volts.
*Not used on all models of lift trucks. Status Codes *Not used on all models of lift trucks. Status Codes
in this group will flash on the LCD screen of display in this group will flash on the LCD screen of display
panel. panel.
NOTE: Truck speed is decreased when status code 90, NOTE: Truck speed is decreased when status code 90,
91, or 99 is indicated. 91, or 99 is indicated.
29
Status Code Charts 2200 YRM 808
Status Code Charts

Status Code Description Memory Recall Circuit
There is no display on the display panel No Traction and Pump
NONE and the handset.
Symptom
LCD screen of display panel and handset is blank.
Possible Causes and Test Procedures

• Positive or negative motor controller voltage is not
present.
Make sure that the key is in the ON position and
voltage is present between P1 and battery negative
(Power Terminal "NEG"). Also check for voltage be-
tween P2 and motor controller negative (B*).
• Open circuit between motor controller "PY" plug and the
handset or connector cover is missing (no connection
to display panel).
Check for an open circuit or loose connection going
from the "PY" plug to the handset or check that con-
nector cover is installed (no Handset). Cause of Status Indication
• Open circuit between motor controller "P" plug and the No input voltage to the motor controller or the display unit.
display panel.
Check for an open circuit or loose connection going
from the "P" plug to the display panel.

No seat switch input. No Traction
01
Symptom
Lift truck does not move.

• Seat switch malfunction.
Check to see that the seat switch operates properly.
Replace a failed switch.
• Open circuit between battery positive and P6.
Check for loose connections or broken wires:
Between the seat switch and P6.
Between the key switch and the battery positive
side of the seat switch.
Cause of Status Indication

This status code is displayed when P6 is less
than 50% of battery volts.
30
2200 YRM 808 Status Code Charts

Forward directional switch is closed before No Traction
02 key switch closed.
Symptom
Motor controller will not operate because of Static
Return to Off (SRO) circuit.

• Forward directional switch is closed before key switch
closes.
Example: Forward directional switch is closed before
battery is connected or before key and seat switches
close.
Move direction control lever (if installed) to NEU-
TRAL and key to OFF position then operate
switches in correct sequence.
• Forward directional switch is failed closed or out of ad-
justment (adjusted to be held closed).
Replace or adjust directional switch to make sure
This status code is displayed when P4 is greater than
that it opens when the direction control lever is
60% of battery voltage at initial key to the ON position.
returned to NEUTRAL or Foot Directional Control
pedal is released.
• Short circuit between P3 and P4.
Disconnect the wire from P4 and check for a short
circuit between P3 and the wire that was connected
to P4.
• Malfunction of motor controller.
Replace the traction motor controller.
31

Reverse directional switch is closed before No Traction
03 key switch closed.
Symptom
Motor controller will not operate because of Static
Return to Off (SRO) circuit.

• Reverse directional switch is closed before key switch
closes.
Example: Reverse directional switch is closed be-
fore battery is connected or before key and seat
switches close.
Move direction control lever (if installed) to NEU-
TRAL and key to OFF position then operate
switches in correct sequence.
• Reverse directional switch is failed closed or out of ad-
justment (adjusted to be held closed).
Replace or adjust direction control lever is returned
This status code is displayed when P5 is greater than
to NEUTRAL or Foot Directional Control pedal is re-
60% of battery voltage at initial key to the ON position.
leased.
• Short circuit between P3 and P5.
Disconnect the wire from P5 and check for a short
circuit between P3 and the wire that was connected
to P5.

Start switch fails to close. No Traction
05
Symptom

• Malfunction of start switch circuit.
Check for open circuit or loose connections in wiring
from key switch to start switch and from P3 to start
switch.
• Malfunction of start switch.
Check start switch for correct operation and output.
Check adjustment of the accelerator potentiometer.

This status code is displayed when P7 is less than 2.5
volts and P3 is less than 60% of battery volts.
32

Accelerator depressed with no direction selected No Traction
06
Symptom

• Accelerator pedal is depressed before moving direction
control lever.
Status code will disappear when directional switch is
closed or when accelerator pedal is released.
• Malfunction of directional switch.
Check forward or reverse switch to make sure that
there is 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.
This status code is displayed when P4 and P5 are less
than 60% of battery volts, and P7 is less than 2.5 volts.

Accelerator input voltage too high when key No Traction
07 is first moved to the ON position.
Symptom
Motor controller will not operate when accelerator
pedal is depressed or status code 07 is displayed then
disappears when the lift truck starts to accelerate.

• Start switch has a malfunction or is out of adjustment.
Input voltage at P7 must be less than 4.2 volts. Ad-
just or replace start switch to make sure that the volt-
age at P7 will vary from 3.5 volts (pedal up) to less
than 0.5 volts (pedal fully depressed).
• Open circuit between battery negative and P7 in the
accelerator input circuit.
Check for broken wires or loose connections or open
potentiometer/voltage supply.
• Short circuit from battery positive to wiring in the accel- Cause of Status Indication
erator input circuit This status code is displayed when the accelerator
Disconnect wire from P7 and measure voltage at input voltage at P7 is higher than 4.2 volts, and
wire to negative. Should be zero volts for poten- a directional switch is closed.
tiometer type and less than 3.7 volts for solid state
type accelerator input.
33

Accelerator input voltage too low when key No Traction
08 is first moved to the ON position.
Symptom

• Accelerator unit has a malfunction or is out of adjust-
ment.
Input voltage at P7 must be more than 3.0 volts. Ad-
just or replace accelerator unit to make sure that the
voltage at P7 is more than 3.0 volts before depress-
ing 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 must be greater than 3.0
volts for solid state start switch.
• Malfunction of motor controller. Cause of Status Indication
Disconnect wire from P7. Measure voltage from P7 This status code is displayed when the accelerator
to negative. Voltage must be greater than 4.5 volts, input voltage at P7 is less than 3.0 volts, and any of
if not, replace motor controller. the following connections are opened and closed:
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 make sure
that 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.
• Malfunction of motor controller. Cause of Status Indication
Disconnect wires and measure voltage at P4 and P5. This status code is displayed when P4 and P5 are
Voltage must be less than 60% of battery volts. greater than 60% of battery volts at the same time.
34

Start switch closed on power up after key No Traction
11 first moved to the ON position.
Symptom

• Start switch out of adjustment or has a malfunction.
Input voltage at P3 must be less than 60% of bat-
tery volts at key switch closing. Adjust or replace
accelerator unit to make sure that the voltage at P3
is less than 60% of battery volts before closing the
start switch.
• Short circuit between battery positive and P3 in start
switch input circuit.
Disconnect wires at start switch. Disconnect wire Cause of Status Indication
from P3 and check for short circuit from wire to bat- This status code is displayed when P3 is greater than
tery positive. 60% of battery voltage when the key is in the ON position.
Disconnect wire from P3. Measure voltage from P3
to negative. Voltage must be zero, if not, replace
motor controller.

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

• Discharged battery.
Check battery for correct open circuit voltage. Cor-
rect voltages are listed on right. Charge battery, if
required.
• Battery is damaged.
Check each battery cell for correct voltage (greater
than 1.95 volts each cell). Replace or repair battery.
• Incorrect motor controller adjustment.
Check Function Number 15 for correct adjustment
for the battery being used. Adjust to correct settings.
Refer to HANDSET instructions of this manual. See
the section for the correct register value for Function Cause of Status Indication
Number 15 of your lift truck. This status code is displayed when the battery
• Minimum battery volts not present between P1 and volts are less than 1.95 volts per cell when the key
NEG. is first moved to the ON position.
Check for battery volts between P1 and negative
standoff. If battery volts is not present, check for a
voltage drop between battery (+) and P1 and/or be-
tween battery (*) and negative standoff.
35

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

• Incorrect motor controller adjustment.
Check Function Number 16 for correct adjustment
for the battery being used. Adjust to correct setting.
Refer to HANDSET INSTRUCTIONS. See the sec-
tion for the correct register value for Function Num-
ber 16 of your lift truck.
• Battery over charged or incorrect battery used.
Check battery for correct open circuit voltage. Cor-
rect voltages are listed on right. If voltage is too high,
check battery charger for correct output voltage.

This status code is displayed when the battery volts
are greater than 2.4 volts per cell when the key
is first moved to the ON position.

"Controller Type" selection is not correct. No Traction
17
Symptom

• Register value of Function 17 is not correct.
Check the setting of Function Number 17. See the
section for the correct register value for Function
Number 17 of your lift truck.

This status code is displayed when the register
value of Function 17 is not correct.
36

Motor field current is high at start of reverse travel. No Traction
23
Symptom
Maximum travel speed is reduced or lift
truck does not move.

• Confirm that the motor field stud is not shorted to the
hydraulic pump.

This status code is displayed when the current in the
motor field is too high at start of reverse travel.

Motor field current is high at start of forward travel. No Traction
24
Symptom

• Confirm that the motor field stud is not shorted to the
hydraulic pump.

This status code is displayed when the current draw in
the motor field is too high at start of forward travel.
37

Internal power supply is less than 10 volts DC. Yes Traction
27
Symptom
Line contactor closes and opens, then can only be closed
by moving the key switch to the OFF then ON positions.

• Discharged battery.
Check battery to make sure it is charged. Voltage
can be dropping below 10 volts DC under load.
• Loose connection at P1.
Make sure that the wire connection at P1 is tight.

This status code is displayed when the motor controller’s
internal power supply is less than 10 volts.

Drive motor field current is too high for too long. Yes Traction
28
Symptom
The motor controller sees that field current is
too high and stops operation.

• Operation of lift truck in high motor current condition.
Verify that lift truck is being operated correctly. In-
struct operator to avoid stall conditions, pushing
loads, excessive ramp grades, etc.
• Function Number 7 is not correctly adjusted and allows
higher than normal motor field current.
Adjust Function Number 7 to the value listed for your
lift truck. See the section for the correct register
value for Function Number 7 of your lift truck.

This status code is displayed during the run mode
when the motor controller sees that motor field
current is too high for too long.
38

Open thermal protector (TP) or transistor Yes Traction
41 over temperature.
Symptom
NOTE: The controller will store code 41 on the 1st oc-

curence and then store at 20 hour intervals.
• Traction speed reduced because a motor controller is

too hot.
Allow motor controller to cool, status code will disap-
pear.
Insufficient heat transfer may be occurring between
control and mounting surface. See Motor Controller,
Replace.

This status code is displayed when the voltage
of the internal thermal protector of one or more
motor controllers is too high.

Motor armature offset voltage is too high. No Traction
42
Symptom
truck will not move.

• Motor controller has a malfunction.

This status code is displayed when the voltage at the
internal current sensor input is MORE than 2.6 volts
with no current flowing in the motor circuit.
39

Motor armature offset voltage is too low. No Traction
43
Symptom
truck will not move.

• Motor controller has a malfunction.

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 correctly. Yes Traction
44
Symptom
Line contactor can open, close and then open again.

Line contactor can then only be closed by moving
the key to the OFF then ON positions.


This status code is displayed when, during motor
controller operation, the armature transistor fails to
turn off. This will result in a PMT condition.
40

Armature transistor did not turn on correctly. Yes Traction
45
Symptom
Line contactor can open, close and then open

again. Line contactor can then only be closed by
key to the OFF then ON positions.


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

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

• Check for short circuit from the motor armature to the
frame of the lift truck.

This status code is displayed when the voltage at
A2 is less than 12% of battery volts.
41

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

• If the fault code is intermittent, verify that the accelera-
tor potentiometer is adjusted correctly.
Adjust the accelerator potentiometer.
• Check for open motor field coils or loose or intermittent
field connections, or open F1 or F2 connections.
Repair loose or open connections.

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.
Motor controller capacitor does not pre-charge.

• Control fuse open.
Check control fuse for open circuit, replace fuse, if
necessary.
• Faulty PTC.
Replace PTC.
• Verify that the hydraulic pump motor contactor tips are
not welded.
If the contactor tips are welded, replace the contactor
tips. See Contactors.
• Accessory or component other than motor controllers
connected to load side of line contactor.
Verify that the traction and pump motor controllers Cause of Status Indication
are the only components on the load side of the line This status code is displayed when the key is in the ON
contactor. position and the capacitor volts is less than 85% of battery
volts at the time key is first moved to the ON position.
NOTE: Repeated "charging/discharging" the capacitors
during troubleshooting can cause a Status Code 51.
42

Motor controller "motor current sensor" input No Traction
57 too low during operation.
Symptom
pump does not move.


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

The line driver input (at P17) is less than No Traction
64 12% of battery volts.
Symptom
Motor controller will not operate.

• Open or loose connection at P17.
Check for loose or broken wire at plug P17.
• Malfunction of driver transistor in motor controller.
Replace motor controller.

This status code will be displayed when the motor
controller sees that the line driver input (at P17) is less
than 12% of battery volts with key in the ON position.
43

The current for the line contactor coil is Yes Traction
65 too high during operation.
Symptom
Motor controller will not operate.

• Line contactor coil has a short circuit.
Disconnect the wires at the coil terminals of the line
contactor and check for the correct resistance be-
tween the terminals.
• Short circuit of coil wires (10 and 24) of the line contac-
tor.
Make sure is off. Disconnect the wires at the coil
terminals of the line contactor and check for a short
circuit between the wires.

This status code will be displayed when the current
limit for the coil of the line contactor is too high
during operation. The line contactor will drop out
and the key must be moved to the OFF position
to reset the motor controller.
44

Field current is too high (greater than Yes Traction
66 current limit value).
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 a 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 a short circuit between motor terminal F1
and motor case.
Check for a short circuit between motor terminal F2
and motor case.
Check Main Power Fuse.
• Noise Cause of Status Indication
Missing or damaged horn suppressor. This status code will be displayed when the field
Confirm that all inductive loads/accessories are sup- transistor current is greater than it’s current limit setting.
pressed. The line contactor will drop out and the key must be
moved to the OFF position to reset the motor controller.
45

If the armature current is too high (greater Yes Traction
67 than current limit value).
Symptom
Control will not operate (line contactor drops out).

• Short circuit in armature (terminal A1 to A2).
Disconnect power cables from traction motor termi-
nals A1 and A2. Check for a short circuit between
the terminals.
• Short circuit of armature terminal A1 or A2 to battery
positive or battery negative.
nals A1 and A2. Check for a 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 a short circuit between Cause of Status Indication
the power cables. This status code will be displayed when the armature
• Noise transistor current is greater than it’s current limit setting.
Missing or damaged horn suppressor. The line contactor will drop out and the key must be
Confirm that all inductive loads/accessories are sup- moved to the OFF position to reset the motor controller.
pressed.
46

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 steering
contactor. Check for a short circuit between coil ter-
minals. Check for a short circuit between coil wires
10 and 60.

This status code will be displayed when the coil
current of the power steering contactor exceeds
the current limit during operation.
The line and power steering contactors will drop out
and the key must be moved to the OFF position
to reset the motor controller.
47

Capacitor (1C) voltage too high. Yes Traction
76
Symptom
Line contactor opens during operation and can only be
closed by moving the key to the OFF then ON positions.

• Unplugging the battery connector during regenerative
braking.
Do not unplug the battery while the lift truck is in
operation.
• Line contactor bouncing open during regen.
Check line contactor for correct operation.
• Main power fuse opening during regen.
Check fuse and fuse connections.
• Intermittent battery plug connection.
Check connections from battery positive to motor
controller positive. Make sure battery connector is
fully connected.
• Missing or damaged horn suppressor. Cause of Status Indication
Replace horn. This status code is displayed when the voltage
* Limit and Battery Voltages: 50V limit using a 36V on the capacitor goes above limit voltage* during
battery, 70V limit using a 48V battery, and 96V limit the regenerative braking cycle.
using a 72/80V battery.

Motor current is detected during regen- Yes Traction
77 erative braking.
Symptom
Line contactor will open. Line contactor can then only
be closed by key to the OFF then ON positions.


This status code is displayed when motor operating
current is detected during the regenerative braking cycle.
48

Armature stall current has occurred for Yes Traction
82 more than 3.5 seconds.
Symptom
The motor controller will not operate. Key must be moved
to the OFF then ON positions to allow operation again.
CAUTION
If the truck is stalled with partial throttle, this status
code will not appear, and motor damage can occur.
• Accelerator or Foot Directional Control pedal was fully

depressed without lift truck moving for over 3.5 sec-
onds.
To prevent this status code, the operator must oper-
ate the lift truck correctly. Do not attempt to use the
lift truck to push or tow objects beyond the lift truck’s
capabilities.
NOTE: This status code will not appear if Function 16 is This status code will be displayed when the armature
set too high. Motor damage can occur. current is at or above maximum current limit for more
than 3.5 seconds with the accelerator orFoot Directional
Control pedal fully depressed. The key must be moved
to the OFF position to reset the motor controller.
49

Traction motor temperature too high. No Traction and Pump
90
Symptom
Status code flashes "on and off".
Maximum travel speed is reduced.

• Traction motor is too hot.
Allow traction motor to cool.
If problem occurs several times, find reason traction
motor is too hot and correct.
• P16 of pump motor controller or contactor module is
shorted to battery negative.
Locate and repair short.
• Traction motor temperature sensor is shorted or dam-
aged.
Replace temperature sensor.
• Malfunction of pump motor controller (transistor con- Cause of Status Indication
trolled pump motor only). This status code is displayed when the voltage at
Replace the pump motor controller. terminal P16 of the pump motor controller or the
• Malfunction of contactor module (contactor controlled contactor module is at zero volts.
lift pump only).
Replace the contactor module.
NOTE: Function Number 13, speed limit 3 is enabled by

this status code.
50

Temperature of lift pump motor is too high. No Traction and Pump
91
Symptom
Maximum travel speed is reduced.

• Lift pump motor is too hot.
Allow lift pump motor to cool.
If problem occurs several times, find reason lift pump
motor is too hot and correct.
• P11 of pump motor controller or contactor module is
shorted to battery negative.
Locate and repair short.
• Temperature sensor of lift pump motor is shorted or
damaged.
Replace temperature sensor.
• Malfunction of pump motor controller (transistor con- Cause of Status Indication
trolled lift pump only). This status code is displayed when the voltage at
Replace the pump motor controller. terminal P11 of the pump motor controller or the
• Malfunction of contactor module (contactor controlled contactor module is at zero volts.
lift pump only).
Replace the contactor module.

this status code.
51

Brushes of power steering motor are worn. No Traction and Pump
93
Symptom

• Brushes of power steering motor are worn too short.
Sensor of Brush Wear Indicator (BWI) has closed to
battery positive.
Replace the power steering motor brushes.
• P3 and/or P4 of pump motor controller or contactor
module is shorted to battery positive.
Locate and repair the short.
• Brush wear sensor of power steering motor is shorted
or damaged.
Locate and repair the shorted sensor lead or replace
the power steering motor brushes.
• Malfunction of pump motor controller (transistor con-
trolled lift pump only).
Replace the pump motor controller. Cause of Status Indication
• Malfunction of contactor module (contactor controlled This status code is displayed when the voltage at
lift pump only). terminal P3 and/or terminal P4 of the pump motor
Replace the contactor module. controller or the contactor module is at battery volts.
NOTE: Status code 93 is only checked when a neutral sig-
nal is present (open start switch or open forward and re-
verse switches). The status code is then displayed when
the motor controller is returned to the run mode.
52

Brushes of traction motor are worn. No Traction and Pump
94
Symptom

• Brushes traction motor are worn too short.
A sensor has closed to battery positive.
Replace the traction motor brushes.
• A brush wear sensor of the traction motor is shorted or
damaged.
the traction motor brushes.
Replace the pump motor controller.
• Malfunction of contactor module (contactor controlled Cause of Status Indication
lift pump only). This status code is displayed when the voltage at
Replace the contactor module. terminal P5 and/or terminal P6 of the pump motor
controller or the contactor module is at battery volts.
53

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

• Lift pump motor brushes are worn.
A sensor has closed to battery positive.
Replace the pump motor brushes.
• A brush wear sensor of the pump motor is shorted or
damaged.
the pump motor brushes.
Replace the pump motor controller.
• Malfunction of contactor module (contactor controlled Cause of Status Indication
lift pump only). This status code is displayed when the voltage at
Replace the contactor module. terminal P8 and/or terminal P9 of the pump motor
controller or the contactor module is at battery volts.
54

Maintenance Alert and Speed Limit. No Traction
99
Symptom
Status code is displayed for 4 seconds when the
key is first moved to the ON position.
Status code stays on and travel speed is
reduced after 19 hours.

• Status code 99 is displayed when the normal hourmeter
reading exceeds the hour setting of the Maintenance
Codes (Functions 19 and 20).
Functions 19 and 20 are adjusted using the Handset
or PC and command the display of status code 99.
• Technician must perform desired maintenance function
and reset maintenance alert hourmeter after mainte-
nance is performed.
NOTE: Set register value of Functions 19 and 20 to a Cause of Status Indication

value above 250 to disable the maintenance alert and This status code is displayed when the hourmeter
speed limit feature. reading exceeds the hour setting of the Maintenance
Codes (Functions 19 and 20).
this status code.

"Controller Type" selection is not correct. No Pump
117
Symptom
Lift and auxiliary hydraulic functions are disabled
or operate at a reduced rate.

• Register value of Function 117 is not correct.
Check the setting of Function Number 117. See
the section for the correct register value for Function
Number 117 of your lift truck.

This status code is displayed when the register
value of Function 117 is not correct.
55

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

• Discharged Battery.
Check battery to make sure it is charged.
• Loose connection at P1 of pump motor controller.
Make sure that the wire connection at P1 is tight.

This status code is displayed when the internal power
supply of the pump motor controller 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.
Instruct operator to avoid lifting loads that are too
heavy.

This status code is displayed during the run mode
when the motor controller sees that pump motor
current is too high for too long.
56

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

• Motor controller is too hot.
Allow motor controller to cool, status code will disap-
pear.

internal thermal protector is greater than 0.8 volts.

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

• Malfunction of pump motor controller.
Replace pump motor controller.

internal current sensor of pump motor controller is greater
than 0.1 volts with no current flowing in the motor circuit.
57

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


internal current sensor of pump motor controller is greater
than 0.1 volts 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.


This status code is displayed when, during
pump motor controller operation, the power
transistor (Q1) fails to turn off.
58

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


This status code is displayed when during pump
motor controller operation, the power transistor
(Q1) fails to turn on.

"Look Ahead" test for A2 (pump motor) volts Yes Pump
146 less than 12% of battery volts.
Symptom

• Check for short circuit from the motor armature to the
frame of the lift truck.

at power terminal A2 of pump motor controller is
less than 12% of battery volts.
59

Capacitor volts are low before the line No Pump
151 contactor closes. (Internal function of motor
controller during pre-charge).
Symptom
Motor controller capacitor does not pre-charge.
Line contactor cannot close.

• Control fuse open.
Replace control Fuse.
• Faulty PTC.
Replace PTC.
• Verify that the hydraulic pump motor contactor tips are
not welded.
If the contactor tips are welded, replace the tips. See
Contactors
• Accessory or component other than motor controllers
connected to load side of line contactor.
Make sure that the traction and pump motor con-
trollers are the only components on the load side of
This status code is displayed when the key is in
the line contactor.
the ON position and the internal capacitor volts
is less than 85% of battery volts when the key is
first moved to the ON position.
NOTE: Charging and discharging the capacitors several
times during troubleshooting can cause a status code
151.
60

Motor controller "motor current sensor" No Pump
157 input voltage polarity check.
Symptom


input to the internal sensor of the pump motor
controller is of the wrong polarity.

Charge on capacitor of pump motor controller No Pump
180 is less than 14 volts.
Symptom

• Line contactor opens during operation.
Check power connection from battery positive to the
line contactor.
Check for an open control fuse.
Check for dirty contactor tips.

This status code is displayed when the voltage at P1
of the pump motor controller is less than 14 volts.
This normally occurs during operation.
61
Transistor Motor Controllers Repairs 2200 YRM 808

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 the
line contactor.
Check for an open fuse element.
Check for dirty contactor tips.
Verify that there are no traction motor controller faults
causing the line contactor to open during the run
mode.

measured at P1 is less than 14 volts.
Transistor Motor Controllers Repairs

GENERAL internal parts of these motor controllers that can be re-
paired. Each of these motor controllers must be re-
The assembly of the traction motor controller (SR) is placed if an internal malfunction occurs.
shown in Figure 8. The assembly of the pump motor
controller (SP) is shown in Figure 9. There are NO
62
2200 YRM 808 Transistor Motor Controllers Repairs
1. PUMP MOTOR CONTROLLER 8. FUSE

2. PUMP FUSE 9. FUSE
5. FUSE 12. LINE CONTACTOR
7. POWER STEERING FUSE 14. PUMP #2 FUSE
Figure 8. Traction and Pump Motor Controllers
63
1. CONTACTOR DRIVER CARD 8. FUSE

5. FUSE 12. PUMP #2 CONTACTOR (DUAL PUMPS ONLY)
6. POWER STEERING FUSE 13. PUMP #2 FUSE (DUAL PUMPS ONLY)
7. FUSE 14. PUMP #1 FUSE
Figure 9. Traction Motor Controller and Contactor Control for Lift Pump Motor
64
GENERAL MAINTENANCE NEVER USE STEAM TO CLEAN ELECTRONIC COM-

INSTRUCTIONS PONENTS.
The transistor motor controllers, like other electronic de- In dusty areas, blow low pressure air over the controller
vices, have temperature limits. These devices can be to remove dust. In oily or greasy areas, a mild solution
damaged if they get too hot. Normal maintenance will of detergent or denatured alcohol can be used to wash
help prevent high temperature conditions. Always make off the controller, and then low-pressure air should be
sure components are installed using the silicon grease used to completely dry the controller.
and insulating sheet (where applicable) and that all heat
For the controller to be most effective, it must be
sink surfaces are clean. Do not block cooling airflow.
mounted against the frame of the lift truck. The metal
Special Precautions frame, acting as an additional heat sink, will give im-
proved lift truck performance by keeping the controller
package cooler. Apply a thin layer of silicone (heat
WARNING transfer) grease Yale P/N 504223239 between the
To avoid injury and prevent electrical shock, per- controller heat sink and the lift truck frame prior to
form the following steps before troubleshooting, controller installation.
adjustments, or repair:
Controller wire plugs and other exposed transistor con-
Turn the key to the OFF position and disconnect the troller parts should be kept free of dirt and paint that
battery connector. might change the effective resistance between points.
Discharge the capacitors in the controllers using

the horn. Move the key to the OFF position, dis- CAUTION
connect the battery connector, and hold the horn Do NOT operate the traction system at high speed
button until the horn stops making a sound. or rapidly change direction of operation with the
wheels raised. Motor controller damage can occur.
CAUTION Do not subject the controller to any high voltage (hipot
To help prevent controller damage: or megger) testing.
1. ALWAYS disconnect the battery when servicing
the controllers. Use a lead acid battery with the voltage and ampere
2. ALWAYS discharge the capacitors using the hour rating specified for the lift truck. Follow normal bat-
horn before performing any service. tery maintenance procedures, recharging before 80%
3. NEVER connect power to the motor controllers discharged, with periodic equalizing charges.
when any power cable is disconnected.
Other parts of these assemblies also cannot be re-
4. NEVER make a short circuit at any motor con-
paired, and must be replaced if they malfunction. The
troller terminal to battery (+), battery ( ), or the
contactors do have parts that can be replaced.
frame.
Check with the dealer for your lift truck before operating FUSES
in an area with normal temperatures over 40 C (100 F).
The fuses are found on the motor controller assembly
The lift truck motor controllers can be damaged.
or contactor panels. See Figure 8 or Figure 9. The con-
dition of the fuses can normally be checked by looking
CAUTION at them or can be checked with an ohmmeter.
Never add any electrical component to the lift truck
without approval from your dealer for your lift truck.
Other electrical components can prevent operation
and/or damage the motor controller.
65
CONTACTORS Make an identification and disconnect the wires and ca-

bles from the contactor assembly. Remove the mount-
There can be three contactors on these lift trucks. All ing screws and remove the contactor assembly. See
lift trucks have a power steering contactor and a line Figure 11 and Figure 12.
contactor. See Figure 10 and Figure 12. Lift trucks
that do NOT have a pump motor controller (SP) also Contactor Contacts. The contacts in a contactor are
have a contactor to energize the lift pump motor. See made of special silver alloy. The contacts will look
Figure 10. black and rough from normal operation. This condition
does not cause problems with the operation of the lift
truck. Cleaning is not necessary. DO NOT USE A
FILE ON THE CONTACTS. DO NOT LUBRICATE THE
CONTACTS.
Coil. Check the coil with an ohmmeter for an open cir-

cuit or a short circuit. Coil resistance is very low. Re-
place the coil if it is damaged. Make sure the coil wires
are connected again to the correct terminals.
CONTACTOR DRIVER MODULE

Lift trucks that do NOT have a pump motor controller
(SP) have a contactor to energize the lift pump motor.
See Figure 9. The contactor driver module energizes
the pump contactor coil and is controlled by switches at
1. POWER TERMINALS the hydraulic control levers. This module also has in-
2. CONTACTS ternal connections for operation with the traction motor
3. CURRENT LIMITER (LINE CONTACTOR ONLY) controller and input sensors. This part of the contac-
4. COIL TERMINALS
5. MOUNT BRACKET tor driver module "replaces" the necessary interconnec-
6. COIL tions of the pump motor controller.
Figure 10. Line or Pump Motor Contactor Contactor Driver, Replace

Repair Make sure the battery is disconnected and the ca-
pacitor is discharged using the horn as previously
described. Make an identification for correct connec-
CAUTION tion of the wires for the replacement contactor driver
ALWAYS replace all of the contacts in a contactor and disconnect the wires. Disconnect the plug connec-
at the same time. Replace the contacts in the con- tor. See Figure 9. Remove two screws that fasten the
tactor for the hydraulic pump after 1000 hours of contactor driver. Install replacement contactor driver
operation. Replace the contacts in the other con- in the same position and connect wires to the correct
tactors when the thickness of any area of a contact terminals as identified during removal. Connect plug
is less than 30% of the thickness of a new contact, connector.
or if there is any transfer of contact material.
Legend for Figure 11

1. BASE 9. MOVABLE TIP CARRIER
2. COIL 10. PLUNGER BUSHING
3. FRAME 11. MOVABLE CONTACTS
4. FIXED CONTACTS 12. SPRING SEAT
5. BUS CLAMP 13. TIP SPRING
6. RETURN SPRING 14. SPRING CUP
7. ARMATURE 15. WASHER
8. BASE BUS 16. NUT
66
Figure 11. Replace Parts of Line or Pump Motor Contactor
67
Legend for Figure 12

1. TOP COVER
2. FIXED CONTACT SETS
3. FIXED CONTACT SETS
4. SCREW
5. RETURN SPRING
6. INSULATOR
7. COIL ASSEMBLY
Figure 12. Replace Parts of Power Steering

Contactor
68
MOTOR CONTROLLER PLUG

All connections to the motor controller(s) are made at
the 23-pin connector. Do not attempt to replace pins in
23-pin plug. See Table 5 and Table 6.
Table 5. Large (P) Plug (23-Pin) Connections/Descriptions for Motor Controllers
Pin Wire Color Traction Motor Motor Controller for Lift Wire Color
No. or =Wire # Controller Pump Motor or =Wire #
P1 BRN=12B Battery Volts From Battery Positive (BAT) BRN=12C
P2 RED/ BLU-LT=10A Battery Volts At Key Switch RED/ BLU-LT=10G
Battery Volts From
P3 GRN/15=6B Status Code 93 Input BLU/YEL =105
Start Switch
Battery Volts From
P4 WHT-5=8B Status Code 93 Input BLU/YEL =106
Forward Switch
Battery Volts From
P5 BLU-LT=7A Status Code 94 Input BLU/PINK =103
Reverse Switch
Battery Volts From
P6 WHT/PINK =7A Status Code 94 Input BLU/PINK =104
Seat Switch
Accel. Potentiometer
P7 YEL/PINK=29 Not Used -
Input Voltage Signal
P8 Not Used Status Code 95 Input BLU/GRY =108
+5 Volt to Accelerator
P9 GRN/WHT=32 Status Code 95 Input BLU/GRY =107
Potentiometer
P10 BLU-LT=5050 BDI Lift Interrupt Output Pump Enable Signal Input BLU-LT=50
+12 Volt Regen Output
P11 YEL/ GRN-DK =75A Status Code 91 Input ORN/YEL =100
Signal
P12 - Not Used Speed Limit #1 Input GRY=53
P13 - Not Used Brush Wear Indicator Output GRN/YEL =110
Brush Wear Indicator Input Over Temperature Indicator
P14 GRN/YEL =110 GRN/PINK =109
Output
P15 - Not Used Not Used -
P16 - Not Used Status Code 90 Input ORN/PINK =102
Traction Line Contactor
P17 BLK=24 Pump Line Contactor Driver BLK = 80
Driver
P18 - Not Used PM #2 Contactor Driver BLK = 87
+5 Volt Power Supply
P19 GRN/GRY =71 Speed Limit #2 Input BLU/WHT=52
Output
Motor Overtemperature
P20 GRN/PINK =109 Speed Limit #3 Input BLU-DK=51
Indicator Input
P21 BLK=41 1A Contactor Driver +5 Volt Input GRN/GRY =71
69
Table 5. Large (P) Plug (23-Pin) Connections/Descriptions for Motor Controllers (Continued)
Pin Wire Color Traction Motor Motor Controller for Lift Wire Color
No. or =Wire # Controller Pump Motor or =Wire #
Serial Receive - Connects Serial Receive - Connects
P22 GRN-1=74 GRN-2=76
To Display Panel To Display Panel
Serial Transmit - Connects Serial Transmit - Connects
P23 WHT-1=73 WHT-2=75
To Display Panel To Display Panel
Table 6. Small Plug (12-Pin) Connections/Descriptions for Motor Controllers
Pin No. Description Small 12-Pin Connector

1 Clock (Out) (Display Panel - 4)
2 Clock (Out) (Display Panel - 3)
3 Enable (Out) (Display Panel - 1)
4 Negative (Display Panel - 2)
5 +5 Volt Supply (Display Panel - 5)
6 Cont/Store (In) (Handset)
7 External Jumper to Pin 12
8 Value
9 Function
10 External Jumper to Pin 11
11 Serial Receive/Internal Connection to P22
12 Serial Transmit/Internal Connection to P23
BRUSH WEAR INDICATORS wheels as described in the Operating Manual or the

section Periodic Maintenance of the Service Man-
The brush wear indicators illuminate when the motor ual.
brushes must be replaced. When a brush wears to the
point where it needs to be replaced, the brush spring Use a jumper cable so that the battery can be con-
makes an electrical connection to illuminate the indica- nected for operation of the motors. See Figure 13. Dis-
tor. connect the sensor wires, one at a time, from outside
of the motor case. Touch the end of the sensor wire to
The operation of the brush wear indicators can be battery positive. The warning light will illuminate if the
checked during periodic maintenance. The battery circuit is operating correctly. The motor brushes must
must be removed from the lift truck for access to the be replaced when they are worn. If equipped with brush
motors. wear indicators, the condition of the commutator and
the motor brushes must still be checked during periodic
WARNING maintenance.
To help prevent damage or injury raise the drive
wheels before doing these checks. Raise the drive
70
MOTOR CONTROLLER, REPLACE

Make sure the battery is disconnected and the capacitor
is discharged using the horn, as previously described.
Replace the motor controller as described in the follow-
ing procedure. See Figure 8, Figure 9, Figure 14, and
Figure 15.
1. Make an identification for correct connection of the

power cables on the power terminals of the motor
controller. Disconnect the power cables and the
connector plug for the control wires.
2. Remove the eight (traction) or six (pump) mounting

screws that fasten the plate of the motor controller
to the lift truck frame. Carefully remove the motor
controller.
NOTE: CONNECT BATTERY SO MOTOR CAN BE
OPERATED. BATTERY MUST BE REMOVED FOR CAUTION
ACCESS TO MOTOR. USE A JUMPER CABLE TO
Do not remove the small screws that fasten the
CONNECT BATTERY TO LIFT TRUCK. RAISE DRIVE
cover of the motor controller.
WHEELS. SEE HOW TO RAISE DRIVE TIRES IN THE
PERIODIC MAINTENANCE SECTION OR OPERAT- Make sure there is no dirt between the plate of the
ING MANUAL. motor controller and the mount surface of the lift
1. RAISE DRIVE 2. JUMPER truck frame.
WHEELS 3. BATTERY
3. Put a thin, even coat of the silicone compound (Yale
Figure 13. Connect Battery So Motor Can Be Part No. 504223239) or equivalent on the plate of
Operated the motor controller. Make sure there are no air
spaces between the plate and mount surface of the
THERMAL SENSORS lift truck frame. The plate of the motor controller
must make full contact with the lift truck frame. In-
The thermal sensors indicate to the motor controller that stall the mount screws that fasten the motor con-
the motor is too hot. When a motor gets too hot, the troller to the lift truck frame.
sensor makes an electrical connection to send a signal
to the motor controller. 4. Install the power cables at the power terminals of
the motor controller as identified during removal.
WARNING Install the connector plug for the control wires
on the connector of the motor controller. MAKE
To help prevent damage or injury, raise the drive
SURE THE PLUG COVER IS INSTALLED ON
wheels before doing these checks. Raise the drive
THE SMALL CONNECTOR OF THE MOTOR
wheels as described in the Operating Manual or the
CONTROLLER.
section Periodic Maintenance of the Service Man-
ual.
WARNING
Use a jumper cable so that the battery can be con- To help prevent damage or injury, raise the drive
nected for operation of the motors. See Figure 13. Dis- tires before doing these checks. Raise the drive
connect the sensor wires from the outside of the mo- tires as described in the Operating Manual or the
tor case. Touch the ends of the sensor wires together. section Periodic Maintenance of the Service Man-
The warning light will illuminate if the circuit is operat- ual.
ing correctly. The thermal switch can be replaced if it is
damaged. However, the motor must be disassembled 5. Before operating lift truck, raise drive tires and
to replace the thermal switch. check for correct operation.
71
Figure 14. Typical Schematic of Traction Motor Controller
72
Figure 15. Typical Schematic of Pump Motor Controller
73
Parameter Tables 2200 YRM 808
Parameter Tables
GENERAL Function Numbers
This section must be used with the following section of The Function Numbers are code numbers for the differ-
this motor controller: ent parameters that can be set for the SR (SEM) and SP
• SEM Display Panel, (Dos Version) 2200 YRM 725 motor controllers. The personal computer or the hand-
• Troubleshooting and Adjustments With a Com- set must be used to adjust the parameters for these
puter, For EV-100ZX, EV-T100, SR (SEM) and SP motor controllers. There is a description of the code
Motor Controllers (Windows Version) 2200 YRM numbers (functions) in the Parameter Tables. These
947 Parameter Tables have the correct register values for
the functions of each motor controller of the different lift
These motor controllers have an electronic de- trucks.
vice called an EEPROM (Electrically-Erasable-Pro-
grammable-Read-Only-Memory). The EEPROM has a There are parameter tables for the different lift truck
number of memory elements called registers for the models using the different motors or equipment. Do
different functions. These registers can have electronic NOT adjust a register value to a number that is NOT
data stored in them to control an operation. The range SHOWN in the correct table. MAKE SURE YOU USE
of data that can be stored in the registers is called a THE CORRECT TABLE WHEN YOU MAKE ADJUST-
parameter. A register value is a measurement number MENTS. It is a good procedure to check the register
for a specific function that works with other functions to value for a Function Number and compare this register
define a system. The EEPROM in a motor controller is value to the register value in the Parameter Tables be-
a control system for the operation of the lift truck. fore making the adjustment. The factory register value
and the amount (current, time, etc.) for that register
The EEPROM used in these motor controllers has 128 value are shown in the columns indicated as Default.
registers. The parameter values are shown in the columns indi-
cated as Permitted Range.
WARNING
Each register in each motor controller has a range MOTOR CONTROLLER CHECKS AND
of numbers so that the control card can be used ADJUSTMENTS
on different models of lift trucks. This variation is
A personal computer (PC) is used by Authorized Per-
needed for lift trucks of different sizes, motors, and
sonnel to make checks and adjustments. A handset
operating voltages. Adjustment of the register to
can also be used.
the wrong number for your lift truck and compo-
nents can cause the lift truck to operate differently NOTE: The PC can be connected to each separate mo-
than normal. This different operation of the truck tor controller. The PC can also be connected to the
can cause component damage or an injury. SEM Display Panel for computer access to the memory
of the SEM Display Panel AND the motor controllers.
NOTE: These Parameter Tables show the permitted
If the PC is connected to the SEM Display Panel, the
ranges and the default register value for each control
SEM Display Panel must FIRST be programmed by the
function. The Factory-Set Parameters are the recom-
PC as described in the section SEM Display Panel,
mended register values for new units. These values
(Dos Version) 2200 YRM 725. The motor controller
will give satisfactory performance for most applications.
functions can be checked and adjusted as described in
Some functions register values can be adjusted within the section Troubleshooting and Adjustments With
the permitted range to change the lift truck operation a Computer, For EV-100ZX, EV-T100, SR (SEM) and
for a specific application. Adjustment of a register num- SP Motor Controllers (Windows Version) 2200 YRM
ber value to a number that is different than the factory 947.
setting is allowed. Make sure to follow the instructions
carefully and stay within the minimum and maximum
limits.
74
2200 YRM 808 Parameter Tables
The following checks and adjustments can be made: the motor controllers. See Table 7, Table 8, Table 9, and
• Check system status codes history for both traction Table 10. See the information at the beginning of this
and hydraulic pump systems to identify the TYPE of motor controller so that you can
• Check state of charge of battery use the correct table for your lift truck.
• Check hourmeter readings on traction circuit and hy-
draulic pump controllers Make sure to read the WARNINGS and CAUTIONS at
• Monitor or adjust register values for each function as each function description in this section. These WARN-
shown in the Parameter Tables. INGS and CAUTIONS must be read before entering a
register value other than the factory value.
PARAMETER TABLES
NOTE: Make sure you know which motor controller you
are working with before using these tables and adjusting
Table 7. Traction Control - SR Transistor Control Settings, 11-Inch Motor (36/48 Volts)
Function Card Settings

Description
No. Minimum Factory Maximum
1 Auto Regen Enable Speed 0 12 50
2 Creep Speed 0 15 255
3 Controlled Acceleration 30 42 255
4 Armature Current Limit 0 255 255
5 Regen Ramp Rate 39 40 41
6 Field Weakening (FW) Ratio 32 35 38
7 Minimum Field Current 0 51 85
8 Maximum Field Current 253 255 255
9 Regenerative Braking Current Limit 0 85 90
10 Field Current for Regen Braking 197 255 255
11 Speed Limit 1 0 0 0
12 Maximum Armature % On Time 0 0 180
13 Speed Limit 3 51 130 180
14 Internal Resistance Compensation 5 16 23
15 Battery Voltage Selection 184 186 250
16 Stall Trip Point % On Time 113 115 117
17 1 Control Type Selection (With Lift Interrupt) 55 57 59
1
17 Control Type Selection (Without Lift Interrupt) 50 52 54
18 Seat Switch Time Delay 0 25 128
19 Maintenance Code Tens and Units 0 255 255
20 Maintenance Code Thousands and Hundreds 0 255 255
1
A register value setting outside the parameter values can cause the traction system to operate differently than
normal or cause damage to the motor controller or motor. Personal injury can also occur.
75
Table 7. Traction Control - SR Transistor Control Settings, 11-Inch Motor (36/48 Volts) (Continued)

Description
21 Auto Regen Braking Current Limit (With Auto Regen) 51 51 143
21 Auto Regen Braking Current Limit (Without Auto Regen) 143 255 255
22 NOT USED - - -
23 For Special Programs 0 0 255
24 Field Weakening Start 158 170 185
25 Monitor 01 - -
26 Base Ratio 62 65 68
27-47 NOT USED - - -
48 Mode 1 Controlled Acceleration 30 42 255
49 Mode 1 Field Weakening (FW) Start 158 170 185
50 Mode 1 Field Weakening (FW) Ratio 32 35 38
51 Mode 1 Maximum Armature % On Time 50 97 115
64-128 NOT USED
1
76
Table 8. Traction Control - SR Transistor Control Settings, 13-Inch Motors, Standard Speed (36/48 Volts)

Description
13 Speed Limit 3 51 130 180
1
17 Control Type Selection (With Lift Interrupt) 55 57 59
17 1 Control Type Selection (Without Lift Interrupt) 50 52 54
22 NOT USED - - -
25 Monitor 01 - -
1
77
Table 8. Traction Control - SR Transistor Control Settings, 13-Inch Motors,

Standard Speed (36/48 Volts) (Continued)

Description
27-47 NOT USED - - -
64-128 NOT USED
1
78
Table 9. Traction Control - SR Transistor Control Settings, 13-Inch Motors, High Speed (36/48 Volts)

Description
13 Speed Limit 3 51 130 180
1
17 Control Type Selection (With Lift Interrupt) 55 57 59
17 1 Control Type Selection (Without Lift Interrupt) 50 52 54
22 NOT USED - - -
1
79
Table 9. Traction Control - SR Transistor Control Settings, 13-Inch Motors,

High Speed (36/48 Volts) (Continued)

Description
1
25 Monitor 0 - -
27-47 NOT USED - - -
64-128 NOT USED
1
Table 10. Hydraulic Pump - SR Transistor Control Settings (36/48 Volts)

Description
1 Stored Status Code 0 0 255
2 Internal Resistance Comp. Start - 10 -
1
80
Table 10. Hydraulic Pump - SR Transistor Control Settings (36/48 Volts) (Continued)

Description
4 Current Limit (C/L) 255 255 255
5-6 NOT USED - 15 -
7 Controlled Acceleration Compensation 30 35 70
8-10 NOT USED - - -
11 Speed Limit 1 (Tilt and Aux-1) 30 35 70
12 Speed Limit 2 (Slow Lift) 30 55 255
13 Speed Limit 3 (Fast lift) 30 255 255
14 Speed Limit 4 (NOT USED) 30 255 255
15 NOT USED - - -
16 Internal Resistance Compensation 10
17 1 Card Type Selection 63 65 71
18-47 NOT USED - - -
49 Mode 1 Speed Limit 2 30 35 70
51 NOT USED - - -
55 NOT USED - - -
59 NOT USED - - -
1
81
Theory of Operation 2200 YRM 808
Theory of Operation
GENERAL
This section is for lift trucks that have the Separately Ex-
cited Motor (SEM) system. This SEM system controls
a single traction motor. The SEM system has a tran-
sistor motor controller (SR) that controls the shunt trac-
tion motor. Units with this system can have a transistor
motor controller (SP) or a contactor motor controller to
control the lift pump motor. The lift pump motor is a se-
ries motor.
A display panel operates with these motor controllers.

For more information on this display panel. See the
section SEM Display Panel, (Dos Version) 2200 YRM
725.
NOTE: The description of the current flow in the electri-

cal circuits in this section uses the "Conventional The-
ory of Current Flow." This theory describes the current
as flowing from positive to negative. An electric lift truck
uses a two-wire electrical system. There is no common
ground through the frame. Both the positive supply and
the negative return current flow through wires and ca-
bles. There must be a minimum resistance of 50,000
ohms between the electrical circuits and the frame of
the lift truck.
These motor controllers have solid-state electronic cir-

cuits that control the operation of a DC motor. They
use Field Effect Transistors (FET) as power transistors
to control motor armature and field voltages and cur-
rents. The speed of DC motors is primarily controlled
by the average applied voltage. Generally, the higher
the average applied voltage to the armature, the faster
the motor will rotate. If a switch is put in the armature
and field circuits, the average voltage of each circuit can
be changed. The switches are changed to OFF and ON
quickly to change the average voltages. See Figure 16.
By controlling the average voltage, the current can also
be controlled. The average voltage increases as the
time the switch is ON increases. The average voltage
decreases if the switch is OFF for a longer time than it is
ON. The speed and characteristics of the motor can be Figure 16. Average Voltage
controlled by separately changing the average voltages
of both the armature and the field of a shunt motor.
82
2200 YRM 808 Theory of Operation
SEM SYSTEM DESCRIPTION

Most electric lift trucks have used series motor designs
because of their ability to produce very high levels of
torque at low speeds. Higher efficiency shunt motors
are now often being considered over series motors. By
separately controlling the field and armature currents
the SEM system, the best attributes of both the series
and the shunt wound motors can be combined.
SEM SYSTEM OPERATION (SR MOTOR

CONTROLLER)
Reverse Circuit
The direction of armature rotation on a shunt motor
is determined by the direction in which current flows
through the field windings. A shunt motor field usu-
ally requires about 10% of the armature current at full
torque. The lower current makes it possible to replace
the reversing contactors of a series motor system with
a transistor circuit. See Figure 17.
Energizing transistors Q3 and Q4 or Q2 and Q5 can

make field current flow in either direction through the
field as shown in Figure 17. The field control circuit
operates at 2KHZ. The armature current is controlled
by transistor Q1. See Figure 18. The armature control
circuit operates at 12KHZ to 15KHZ, a frequency range
normally above human hearing.
The line contactor is the only contactor used for the

SEM traction circuit. This contactor is used for both
precharge of the line capacitors and for shut down of the
motor circuit in the event of certain malfunctions. The
line contactor is energized and de-energized by the key
switch.
Figure 17. Current Flow Through Power Circuit for

Direction Control
83
Figure 18. Simplified Motor Circuit
Performance and Efficiency for field weakening with a series motor is not needed
with the transistorized controller.
The SEM system has the ability to control both the ar-
mature and field circuits independently. The system can Regenerative Braking
usually be adjusted for maximum efficiency. Generally
speaking, with the ability of independent field and arma- Regenerative braking uses the energy of lift truck move-
ture control, the motor performance curve can be max- ment during slowing to drive the traction motor and help
imized through proper control application. slow the lift truck. The motor can then become an elec-
trical generator. The electrical energy is returned to
Field Weakening the battery. The main advantage of regenerative brak-
ing is increased motor life. Motor current is reduced by
Field weakening of a series wound motor uses a re- 50% or more during braking while maintaining the same
sistor in parallel with the field windings of the motor. braking torque. Regenerative braking with a series mo-
Current through the resistor makes less current through tor uses a diode connected in parallel with the armature.
the field. Less field current makes the field weaker so
motor speed increases. To change the speed during A power diode, current sensor, and contactor are used
field weakening, the resistor value must change. A con- for regenerative braking with a series motor. The lower
tactor and resistor are usually used to change speed motor current increases brush life and reduces motor
during field weakening with a series motor. In a sep- heating. This motor controller reduces the motor cur-
arately excited motor, independent control of the field rent using the power transistors.
current provides for an infinite adjustment of field weak-
ened speeds, between motor base speed and maxi- The controller has an on-time range of approximately
mum weak field. The contactor and resistor required 0 to 100%. The SR and SP controllers operate at a
84
constant frequency and the percent on time is controlled conditions have been met, and the regenerative braking
by the pulse width of the voltage/current applied to the current limit can no longer be maintained, the braking
motor circuits. function is canceled. The fields will then reverse, and
the controller reverts back to normal operation.
Creep Speed
Part of the energy produced by the motor during regen-
With the accelerator at maximum volts (approximately erative braking is returned to the battery, and part is
4.2 to 3.5 volts), Creep Speed can be adjusted by Func- converted to heat in the drive motor.
tion 2. At creep speed, the ON time can decrease to
approximately 5%, with the OFF time at approximately Function 9, Regen Current Limit is adjustable and will
95%. At full transistor operation, this condition will be change the distance the lift truck requires to reach zero
reversed (short OFF time, long ON time). This variation speed. Function 10, Regen Field Current is not nor-
of oscillator ON and OFF time varies the average volt- mally adjusted in the field.
age applied to the motor, to vary 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% applied battery
voltage to the motor on hard acceleration. Controlled
acceleration is adjustable from 0.1 to 22 seconds.
Current Limit
This circuit monitors motor current by utilizing sensors
in series with the armature and field windings. The infor-
mation is used to maintain maximum currents at a pre-
set value. If heavy load currents are detected, this cir-
cuit overrides the oscillator and limits the average cur-
rent to a value set by Function 4 and Function 8. The
C/L setting is based on the maximum thermal rating of
the controller. Because of the flyback current, the motor
current is usually greater than battery current, except at
100% ON time. Figure 19. Regenerative Braking Circuit
BRAKING Pedal Position Braking

Regenerative Braking to Zero Speed This feature allows control of the reversing distance
based on pedal position when there has been a "direc-
Slow down is accomplished when reversing direction by tional switch" change. Pedal position will reduce the
providing a small amount of retarding torque for deceler- regenerative braking current to the "value set by this
ation. If the lift truck is moving, and the directional lever function" as the accelerator is returned to the creep
or Foot Directional Control pedal is moved from one speed position. Maximum current is obtained with the
direction to the other, the regenerative braking signal accelerator in the top speed position. This feature is
is initiated. Once the regenerative braking signal has adjustable by using Function 16 on the handset.
been initiated, the field current is increased. Armature
current is regulated to the regenerative braking current Auto Braking
limit as set by Function 9. As the lift truck slows down,
the field current continues to increase, and transistor This feature is enabled by initiating a "neutral position"
Q5 begins to turn on and off. See Figure 19. The field using either the directional switch or the accelerator
current will increase until it reaches a preset value set switch. Once activated, Auto Braking operates similar
by Function 10, and transistor Q5 on time will increase to Pedal Position Braking and is adjusted by using Func-
until it reaches 100% on time. Once both of the above tion 21.
85
AUXILIARY SPEED CONTROL significant speed during rollback, the torque needed to
restart on the ramp is lower than an unrestricted roll-
Field Weakening back speed.
The Field Weakening (FW) ratio (Function 6) adjusts the STEER PUMP CONTACTOR TIME DELAY
field weakening level in order to set the top speed of the
motor. The FW ratio is enabled when the armature cur- The steer pump contactor will open when the seat
rent is less than the FW Start Current (Function 24) and switch opens after the programmed time delay. Func-
the accelerator input voltage is less than 1 volt. Func- tion 18 allows adjustment of this time delay from 0.5
tion 24 is used to optimize motor and controller perfor- second to 63 seconds.
mance.
Coil Drivers and Internal Coil Suppression
NOTE: The FW ratio has been determined by the fac-
tory. Function 6 is not normally adjusted in the field. The coil drivers for the line contactor and 1A contactors
are internal to the controller. The contactors must have
NOTE: FW Start, Functions 24, 49, 53, 57, and 61, is coils rated for the lift truck battery volts.
not normally adjusted in the field.
The coil driver for the lift pump contactors are internal
NOTE: Top speed can be reduced by increasing the to the contactor driver module. The lift pump contactors
value of Maximum Armature % On Time. Maximum Ar- must also have coils rated for the lift truck battery volts.
mature % On Time is set using Function 12 (standard
instrument panel) or Functions 41, 55, 59, and 63 (pre- Suppressors for contactor coils are internal to the motor
mium instrument panel). controller or contactor driver module.
Speed Limits SYSTEM PROTECTIVE OVERRIDE

This feature provides a means to control speed by limit- SRO (Static Return to Off)
ing motor volts utilizing two adjustable speed limits. The
lower motor volt limit always takes priority when more If the seat switch or key switch is opened, the controller
than one speed limit is activated. This motor volts limit shuts off and cannot be restarted until the directional
regulates "on time" of the transistor controller, but ac- lever is returned to neutral. A time delay of approxi-
tual truck speed will vary at any set point depending on mately 2 seconds is built into the seat switch input to
the loading of the lift truck. Each speed limit can be ad- allow momentary opening of the seat switch.
justed with the handset.
Accelerator Volts Hold Off
RAMP OPERATION
This feature checks the voltage level at the accelera-
Ramp Start tor input whenever the key switch or seat switch is acti-
vated. If at startup, the voltage is less than 3.0 volts, the
This feature provides maximum control torque to restart controller will not operate. This feature assures that the
a lift truck on an incline. The memory for this function controller is calling for low-speed operation at startup.
is the directional switch. When stopping on an incline,
the directional switch must be left in its original or neu- Pulse Monitor Trip (PMT)
tral position to allow the controller to initiate full power
when restarted. The accelerator potentiometer input The PMT design will disable controller operation if a
will modulate ramp start current. fault occurs which would cause a disruption of normal
lift truck operation.
Anti-Rollback The PMT circuit checks for faults three ways:
This feature provides retarding torque to limit rollback • Look ahead
speed in the nontravel direction when the accelerator or • Look again
Foot Directional Control pedal is released when stop- • Automatic look again and reset
ping on a grade, or when the brake pedal is released
Field or armature FET (field effect transistor) failure
when starting on a grade. This feature forces the lift
which would cause uncontrolled truck movement is
truck to roll slowly down the grade when accelerator or
considered a PMT-type fault. The controller monitors
brake is released. Because the lift truck cannot gain
86
both field and armature FETs at startup and during The first speed (Speed Limit 1) is activated by connect-
operation. A PMT fault will not allow the line contactor ing P12 to battery negative. SLl is set by Function 11.
to close at startup, or will open it during operation. The specified motor volts will be regulated, however
motor current will vary depending on the loading of the
Thermal Protector (TP) lift truck.
This temperature sensitive device is internal to the Tilt and auxiliary 1 provide the Speed Limit 1 input.
power transistor (Q1) module. If the transistor’s
temperature begins to exceed the design limits, the The second speed (Speed Limit 2) is activated by con-
thermal protector will lower the maximum current limit necting P19 to battery negative. SL2 is set by Function
and maintain the transistors within their temperature 12. Operation of SL2 is similar to SL1.
limits. As the controller cools, the thermal protector
The third speed (Speed Limit 3) is activated by connect-
will automatically reset, returning the controller to full
ing P20 to battery negative. SL3 is set by Function 13.
power.
Operation of SL3 is similar to SL1.
Low Voltage Fast lift provides the Speed Limit 3 Input.
Batteries under load, particularly if undersized or more If more than one speed limit is activated, the selected
than 80% discharged, will produce low voltages at the speed with the highest motor volts will override the low
controller terminals. The SR and SP controllers are de- motor volt speed.
signed for use down to 50% of a nominal battery voltage
of 36 to 84 volts, and 75% of a nominal battery volt- The lift pump controller current limit circuit and con-
age of 24 volts. Lower battery voltage can cause the trolled acceleration circuit are adjustable and operate
controller to operate improperly and the resulting PMT the same as the traction controller circuits.
should open the line contactor, in the event of a failure.
The lift interrupt feature will disable the lift pump con-
SP PUMP MOTOR CONTROLLERS troller when the connection at P10 loses the 12-volt sig-
nal from the traction controller. The battery discharge
The SP controllers are sealed units with no service- feature of the traction controller provides the 12-volt sig-
able components. User adjustable features allow the nal to the lift pump controller until the battery is dis-
controllers to be customized for different applications. charged to 10%. Lift interrupt can be disabled by ad-
Self diagnostics are provided to monitor internal com- justing Function 17 of the traction motor controller.
ponents as well as detect problems with certain inputs
and outputs. Adjustable registers and status codes are CONTACTOR DRIVER MODULE
accessed using a handset or a personal computer.
The Contactor Driver Module is used with the contac-
The SP controller is a transistorized lift pump controller tor-controlled lift pump option and takes the place of
capable of providing multiple lift pump speeds. Many the SP lift pump controller. Inputs from the hydraulic
of the features of the SR traction controller are incorpo- valve PC board control internal drivers which energize
rated into the lift pump controller. the lift pump contactor. A 12-volt output from the trac-
tion controller to the contactor driver module enables
This lift pump motor controller features: the lift pump circuit. The 12-volt signal is removed by
• Three speeds, adjustable from 0 to 100% of motor the traction controller during lift interrupt. Lift interrupt
volts. The speeds are actuated by connecting the can be disabled by adjusting Function 17 of the traction
appropriate "P" terminal to battery negative. motor controller.
• Adjustable current limit and controlled acceleration.
• Lift interrupt capability. DIAGNOSTICS
• Handset and PC programmability.
• Thermal protection. Systems Diagnostics
• Low-voltage protection.
• Systems diagnostics. The controller detects the system’s present operating
• Premium instrument panel mode select capability. status and can display that information to either the Dis-
play Panel or the handset. There are currently over 70
The three speed limits are activated by the hydraulic status codes that are available with SR/SP systems us-
valve PC board connecting P12, P19, and/or P20 inde- ing traction and lift pump controllers. The SR controller
pendently to battery negative.
87
is also able to reduce the current to the drive motor to Stored status codes can also be displayed on the Pre-
alert the operator of a critical fault condition. mium Display Panel. Refer to the Operating Manual or
the section SEM Display Panel, (Dos Version) 2200
NOTE: Lift trucks without the SP pump controller are YRM 725. A handset or PC must be used to clear the
equipped with a Contactor Driver Module. The contac- stored status codes.
tor driver module does some of the same jobs of the
pump motor controller. The module also controls the lift Hourmeter Readings
pump contactor.
This feature will display the recorded hours of use of
Standard Status Codes the traction and pump motor controllers. The hours are
shown on the display panel each time the key is turned
The traction motor controller (SR) has over 30 status to the OFF position.
codes and the pump motor controller has over 20 status
codes to assist the service technician and operator in Maintenance Management Capability
troubleshooting the lift truck. If a controller or circuit
malfunction occurs, a status code is displayed on the The traction motor controller (SR) has the capability of
display panel. monitoring some maintenance items. The hourmeter
reading is monitored and can be used to provide a main-
Stored status codes can be retrieved on lift trucks with- tenance status code 99 when a set hourmeter reading
out a Premium Display Panel by using a standard GE is reached. Brush wear and motor temperature are also
handset or a PC connected through the small plug of the monitored. Temperature sensors can be present on the
controller. The handset can only connect to one motor traction and lift pump motors. Brush wear sensors can
controller at a time. A PC can connect to the display be present on the traction, lift pump, and steer pump
panel for access to checks and adjustments of each motors.
motor controller. To obtain a complete list of all status
codes present, EACH controller (traction and pump) on The traction controller will set a status code and re-
the lift truck must be checked, one at a time, using the duce maximum lift truck speed if the maintenance alert
handset, or with a PC through the display panel. hourmeter reading is reached or if an optional temper-
ature sensor determines that a motor is overheated.
NOTE: The STATUS CODES tables of this manual do
not cover all possible causes of a display of a "status The traction controller will set a status code if an op-
code." They provide instructions for checking the most tional brush wear indicator detects a worn brush.
direct inputs that can cause status codes to appear.
The maintenance alert hourmeter reading is pro-
Stored Status Codes grammed into the traction controller using Function
Number 19 and Function Number 20.
This feature records the last 16 "Stored Status Codes"
that have caused a controller PMT shutdown and/or dis- NOTE: The brush wear and motor temperature inputs to
rupted normal lift truck operation. PMT-type faults are the traction controller are received from the pump motor
reset by moving the key to the OFF and ON positions. controller or contactor driver module.
These stored status codes, along with the correspond-
ing BDI and hourmeter readings, can be accessed with
the handset, or by using the RS 232 communications
port and downloading the information to a PC.
88
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 808 6/05 (4/05)(8/03)(4/03)(8/02)(5/02) Printed in U.S.A.

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Maintenance

PART NO. 524166843 2200 YRM 808

• 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.

©2005 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

ERC35-55HG (ERC70-120HG) [A839]

1. PUMP MOTOR CONTROLLER 8. FUSE

Figure 1. Traction and Pump Motor Controllers

1. CONTACTOR DRIVER CARD 8. FUSE

Motor Controller Checks and Adjustments

A personal computer (PC) or a handset is used to permit

Checks and Adjustments Using a Handset

The plug cover on the small connector of the motor

Connect handset to the small (12-pin) connector on

1. ADJUSTMENT 4. COIL CORD

will be overwritten each time a malfunction or symp-

Stored status codes can be cleared one at a time by

To exit this Check mode, hold the CONT key de-

Figure 4. Start Sequence for Handset

CHECK OR DELETE STORED STATUS

NOTE: To check the value of a function, push key(s)

Figure 6. Bench Checks and Adjustments

Figure 7. Set Sequence for Handset

Function Parameters Adjustments

FUNCTION NUMBERS Function Numbers 1 through 15

and hold the CONT key, plus the additional key

2. Push handset keypad numbers for the desired func-

Function Number Descriptions

Traction Motor Controller (Label Letter - SR)

Function Number 01 Function Number 04

Function Number 02 Function Number 06

This function permits the adjustment of the creep speed

This function is used to make minor adjustments be-

Function Number 08 available when Speed Limit 3 (SL3) is enabled. SL3

36/48 volts Between 184 and 250

Function Number 18 Function Number 23

Function Number 50 Same as Function Number 49.

WARNING Function Number 54

EXAMPLE: Register value of 45 = FW Ratio of 4 Same as Function Number 50.

NOTE: This Controlled Acceleration is in effect when WARNING

Same as Function Number 49.

Pump Motor Controller (Label Letter - SP)

These register values can be read with the handset, but

Table 2. Function Map for Motor Controllers SR (Traction)

EEPROM PC Function Handset Description Access Restrictions

Table 2. Function Map for Motor Controllers SR (Traction) (Continued)

EEPROM PC Function Handset Description Access Restrictions

Table 2. Function Map for Motor Controllers SR (Traction) (Continued)

EEPROM PC Function Handset Description Access Restrictions

Table 3. Function Map for Motor Controllers SP (Lift Pump Motor)

EEPROM PC Function Handset Function Access By: Restrictions

EEPROM PC Function Handset Function Access By: Restrictions

NOTE: Due to the interaction of the controller with all

Code Description Code Description

Status Code Charts

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit