CURTIS TRANSISTOR CONTROLLER SK SLE RMA a BS OAAns ; XM QQ NI 7 ea eens PART NO. 897:SAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables and chains have the capacity to support the weight of the load. Do not lft heavy parts by hand. Use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance orrepair on electriclift 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 and working area clean and in order. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment ‘manufacturer. Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when ‘making repairs or if the unit needs repairs. Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make ‘sure that You 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 has ventilation.CONTENTS INTRODUCTION ........ 1 Bench Checks ........ 2 GENERAL ..... 1 Accelerator Potentiometer Checks And Adjustments. 2B PRINCIPLES OF OPERATION .. 3 ADJUSTMENTS ....... 24 GENERAL ceeeeee sees 3 Plugging Adjustment . + 25 TRANSISTOR MOTOR CONTROLLER... 3 Acceleration Adjustment ot) Basic Controller Operation «.... n Current Limit Adjustment . 225 The Field Effect Transistor (FET) 4 REPAIRS +25 ‘A Motor Circuit Contactors : vise 26 ‘That Operates With Pulses 2.20.02... 5 Contactor Replacement ....... vee 26 Induction Current From The Motor .... 7 Replacing Curtis Contactor Parts ...... 26 8 Replacing GE Contactor Parts. 28 19 Controller Replacement ......2...4.2. 28 9 Accelerator Potentiometer And Control TThenual Protection Fonction ...... 5 Switches Replacement And Adjustment . 28 Gren Lint Pocion ancien, 9 TROUBLESHOOTING 2 Power Circuit .. 10 GENERAL, - . 72 GENERAL PROCEDURES 30 EQUENCE OF OPERATION .. " FAULT PROCEDURES .... CHECKS, ADJUSTMENTS AND REPAIRS .. 20 FAULT NUMBER 1... 31 GENERAL 20 FAULT NUMBER 2 32 CHECKS see vs 20 FAULT NUMBER 3 33 CHECKING CONTACTOR COIL........ 20 FAULT NUMBER 4 .. 34 CHECKING FAULT NUMBER 5 .. 34 TRANSISTOR CONTROLLER .. 20 FAULT CODES Checks With Controller Installed 20 AND DISPLAY MESSAGES ... ‘This section is for the Following models: 'W40-6OXL, B40-60XL, N3OFR, R30ES, R30XMS,R30XMS2 ‘W/BIC60-80XT, W4OXT, W4SXT, TSXT, ‘W20XTA, W30XTA, W40XTA. W2OXTC, W25XTC, W30XTC, W40XTC W20XTR, W30XTR ‘©HYSTER COMPANY 2000“THE QUALITY KEEPERS” HYSTER APPROVED PARTSINTRODUCTION GENERAL ‘This section describes the operation, checks, repairs and troubleshooting of the Curtis PMC 1204 or 1205 series. It also covers the 1207 series and the new series of the 1243 motor controller. See FIGURE 1 and FIGURE 4. ‘This transistor motor controlleris used to control the op- eration of some 24, and 36 volt electric lift trucks. The controllers are made for Hyster Company by a division of Curtis Instruments, Inc. ‘The controller for the traction system uses digital logic. Digital logic uses transistors to operate like very fast switches. The transistors are controlled by electrical gate pulses. Electrical noise is also high voltage pulses caused by momentarily operating other electrical devices. Digital logic can not understand the difference between control pulses and electrical noise. Filter capacitors are connected between the B+ and B- terminals in the controller to prevent electrical noise from entering the logic and causing errors. ‘The logic of the controller also checks the following functions: a. Checks the temperature and gives both low and hhigh temperature thermal protection to the controller. b. Electrically checks that an operator follows the correct starting sequence to help prevent ‘unexpected operation. This function has been. called “Static-Return-To-Off" (SRO) in other Hyster motor controller Service Manual sections. c. Electrically checks the traction circuit for certain malfunctions. This function prevents lift ‘ruck operation if a failure is sensed. d. Checks the current in the motor circuit and automatically decreases the motor voltage to reduce the current and prevent damage. ‘The plugging circuit is also controlled for smoother operation, Additional information showing how the motor controller is electrically connected in the lift truck is shown in the section DIAGRAMS, 8000 SRM 457 for the walkie low lift motorized hand trucks, DIAGRAMS, Curtis Transistor, 8000 SRM 495 for N3OFR units, DIAGRAMS, Curtis Transistor, 8000 SRM 475 for R30ES units, DIAGRAMS, 8000 SRM. 653 for the walkie high lift motorized hand trucks, and DIAGRAMS, 8000 SRM 923. for the R30XM2,/XMA2/XMF2/XMS2 units, B60-80XT SHOWN, W45XT, W60-B0XT, C60-80XT and TSXT MODELS SIMILAR FIGURE 1. ‘TRANSISTOR CONTROLLER ON TRUCK-EARLY PRODUCTION,B60-80XT SHOWN W40XT, W45XT, W60-80XT, C60-80XT and TSXT MODELS SIMILAR PMc. ELECTRIC BRAKE— APS: |——HYDRAULIC jsTEERING—j— S -| [| PUMP ttotor| MOTOR - L a eS —_— = +— 1 —DRWvE WoTOR F Tl | FIGURE 3. TRANSISTOR CONTROLLER ON TRUCK-NEW PRODUCTIONPRINCIPLES OF OPERATION GENERAL A motor controller for an electric lift truck controls the speed of the traction motor by making a variation in the applied voltage. This controller uses solid-state eles tronic devices to permit efficient control of the applied voltage, ‘The motor controller also generates a high current flow in the traction motor while keeping a low current draw from the battery. A battery is less efficient at a high cur- rent draw. A battery will not give all of its electrical power at ahigh current draw. The traction motor is ase- ries wound motor that generates torque. This torque is proportional to the current moving through the motor. The speed of the motor is controlled by the voltage and mechanical load connected to the motor. The motor will accelerate until the mechanical load equals the torque required. If the torque increases, the ‘current and acceleration will increase. ‘The two functions look like a problem of opposite needs. How a solid-state electronic controller balances, those needs with efficiency is described in this section. \W/B40-60XL UNITS CONTROLLER LC CONTACTOR POWER FUSE LIFT PUMP CONTACTOR 1A CONTACTOR CONTROL FUSES: TIMER FORWARD/REVERSE CONTACTOR FIGURE 4. TRANSISTOR CONTROLLER PANEL, TRANSISTOR MOTOR CONTROLLER ‘The motor controller controls the speed of the traction motor. The direction of rotation of the motor is, controlled by the Forward/Reverse switch and contactors. See FIGURE 3 through FIGURE 5. The controllers sealed in an aluminum case and has no parts, that can be repaired or replaced. The complete unit must be replaced if correct troubleshooting methods show that the unit is damaged. External contactors are used to control the direction of rotation of the traction motor. Contactors are electrical switches that use an electromagnet to operate the power ‘contacts of the switch. A small electric signal is used to energize the electromagnet to close the power contacts and control the large current flow needed for the motor circuit. The electromagnetic field in the coil moves the armature against spring pressure to close the power con- tacts. When the coil is de-energized, the spring pressure moves the armature and opens the contacts. When a spring holds the contacts of a switch open, the switch is called normally open (NO). If the switch spring holds the contacts of a switch closed, the switch is called nor- mally closed (NC). 2, TRACTION MOTOR ARMATURE 3. TRACTION MOTOR FIELD 4, REVERSE CONTACTOR CONTACTS. 5. FORWARD CONTACTOR CONTACTS 6_FET's SWITCH FIGURE 5. BASIC TRACTION MOTOR CIRCUIT ‘Therearetwocontactorsthat control thedirection ofrota- tion of the traction motor. Each direction contactor has ‘two sets of contacts on the same plunger assembly. Each contactor has a set of NO contacts and a set of NC con- tacts. When one set of contacts is closed, the other set of contacts must be open. This arrangement prevents the ‘wrong sequence of closed contacts that could cause an opencircuit. This arrangement of contactorsalso permits 3current flow through the motor field in either direction. ‘See FIGURE Sand FIGURE 6. One set ofcontactscauses the motor armature to rotate in one direction. The other set of contacts causes the motor armature to rotate in the opposite direction. Other contactors used for control functions on the lift truck only have one set of contacts because a forward and reverse operation is not required. ‘An example is the hydraulic pump motor contactor. Contactors are used to energize and de-energize motors, but cannot control the speed. The transistor motor controller applies battery voltage in short, fast pulses to 4 DC motor to control the speed. How this circuit controls the speed of a motor with pulsesis described in this section ie FORWARD SS Necarve FIGURE 6. CURRENT FLOW THROUGH ‘THE FIELD IN THE FORWARD DIRECTION ‘The direction and speed control operates the FWD/REV. switch to energize the direction contactor. The control also supplies the speed input to the motor controller. Basic Controller Operation ‘This transistor motor controller has a power section and a logic section with solid-state electronic circuits that control the operation of a DC motor. The speed of DC ‘motors is controlled by the average applied voltage. The higher the average applied voltage, the faster the motor will rotate. Ifa switch is put in the traction motor circuit (Gee FIGURE 4.) and the switch is changed to OFF and ON quickly (see FIGURE 9.) the traction motor will rotate. The speed of rotation increases as the time the 4 switch is ON increases. The speed of rotation will decrease if the ON time decreases. OFF time will increase atthe same time. The speed of the moter can be controlled using this principle. This controller uses an electronic device called a Field Effect Transistor (FET) to generate the rapid ON and OFF pulse times. It has no moving parts. The FET’s are tured on and off by the logic circuits in the controllerto act as the switch, Several power FET’s are connected in parallel to carry the necessary motor current. © Posie CS Nesarve FIGURE 7. CURRENT FLOW THROUGH ‘THE FIELD IN THE REVERSE DIRECTION The Field Effect Transistor (FET) AFET is a solid-state device that operates like a very fast switch. A FET is a transistor that has an element called a gate. FET’s are electronic devices that permit electricity to flow as Jong as there is a gate voliage. See FIGURE 8. Electricity flows easily from the input tothe ‘output. A FET will only permit current flow waen there isapositive voltage at the input, anegative voltage atthe output AND a positive voltage applied to the gate. A FET will permit electricity to flow from the input to the source as long as there is the signal voltage atthe gate. ‘The FET’s ON time is the same as the gate pulse ON time as shown in FIGURE 9. Current flows asshown in FIGURE 8. The FET stops conducting when the signal voltage is removed from the gate. ‘When FET’s are used as a switch: a. The FET’s are ON when the electric current flows through them (gate voltage applied). b. The FET’s are OFF when the electric current ‘cannot flow through them (no gate voltage).1. 2 3. 4. 5. 6 7. 8 9. 0. 3 ose NS Necarive FET OFF TRACTION MOTOR GATE DRIVE FET INPUT (+) 10 FET OUTPUT (-) FET GATE (4) POSITIVE SUPPLY THROUGH MOTOR POSITIVE GATE VOLTAGE NO GATE VOLTAGE NO GATE SIGNAL. FIGURE 8. TRANSISTOR CONTROL a er corey Tt ‘| A Motor Circuit That Operates With Pulses ‘A schematic that shows the controller and FET’s in a traction circuit is shown in FIGURE 8. When a signal is applied to the gate of the FET’s, the FET’s are ON and current flows from the battery through the motor. When the gate signal is removed, the FET’s are changed to OFF. ‘The battery voltage is applied to the motorin pulses. The pulses of energy through the FET’s to the motor are very fast (15,000 on/off cycles per second), The motorcannot follow each pulse, but the motor runs smoothly based on the average voltage generated by the ON and OFF times. The average motor voltage applied tothe traction ‘motor is shown in FIGURE 9. The length of the ON TIME of the pulses changes the average motor voltage. As the ON TIME of each pulse increases (OFF TIME decreases), the average motor voltage increases. This change in the ratio of ON TIME to OFF TIME of the pulses is called pulse width modulation. ‘The control circuit has an oscillator and a pulse width modulator. The oscillator generates a saw tooth ‘waveform at a constant frequency of 15,000 cycles per second (15 kHz). The pulse width modulator uses this saw tooth waveform to generate a pulse output that can bbe smoothly changed from a full ON to a full OFF condition. This pulse output is used by the gate driver circuit for the high pulse currents needed to turn the FET’s ON and OFF. The pulse width modulator controls the ON and OFF times of the FETs through the gate driver. The ratio of ON TIME to OFF TIME sets the average motor voltage and the motor speed. ‘The accelerator potentiometer, at the speed control of the lift truck, regulates a voltage that changes as the operator sets the speed of operation. This voltage is an inputto the controller and the pulse width modulator. As the voltage changes with the selected speed, a direct change in the ratio of FET ON TIME to FET OFF TIME also occurs. The voltage for maximum speed changes the ratio to pulses with the maximum ON TIME, to produce a maximum average motor voltage. See FIGURE 9. The pulse rate (15 kHz) stays the same for all speedsa Pane FIGURE 9. AVERAGE MOTOR VOLTAGEFIGURE 10. Induction Current From The Motor ‘When a DC motor is controlled by a pulsed circuit, the magnetic field in the armature and field windings is continuously expanding and decreasing. The fields expand when voltage is applied (ON TIME) and decreases when the voltage is removed (OFF TIME). The voltage causes an increasing current flow through the windings to make the expanding magnetic field. ‘When the voltage is removed, the decreasing magnetic field canses current to flow in the same direction through the windings. See FIGURE 10. This expansion and decrease of the magnetic field is lost energy for doing work unless the controller is designed to use this energy. A Flyback Diode (sometimes called a “Freewheel” Diode) is in the controller circuit for this, purpose. The Flyback Diode permits the current, from the decreasing magnetic field, to flow through the field and BEGINNING CONDITIONS AS THE SWITCH IS CLOSED: 1. LARGE CURRENT FLOW FROM BATTERY THROUGH INDUCTOR, INCREASING MAGNETIC FIELD GENERATES, REVERSE VOLTAGE WITHIN INDUCTOR, REVERSE VOLTAGE DECREASES CURRENT THROUGH INDUCTOR. CURRENT ENERGY CHANGED TO ENERGY IN MAGNETIC FIELD. CONSTANT CONDITIONS AFTER SWITCH IS CLOSED FOR A SHORT TIME PERIOD: 1. VOLTAGE AND CURRENT FLOW IS THE ‘SAME IN ALL PARTS OF THE CIRCUIT. 2. MAGNETIC FIELD IS CONSTANT. ENDING CONDITIONS AS THE SWITCH IS OPENED: DECREASING MAGNETIC FIELD GENERATES VOLTAGE WITHIN INDUCTOR. DECREASING MAGNETIC FIELD GENERATES. CURRENT FLOW IN ORIGINAL DIRECTION. INDUCTANCE, armature again to do work. The torque of a series DC motor is directly proportional to the amount of current flowing through it. At slower speeds, the OFF times are longer. When the FET’s are OFF, the decreasing magnetic field generates a voltage and current in the motor. This current is often called the “flyback current.” ‘The Flyback Diode permits the current to flow through the field and armature again to do work. At slower speeds, the motor current is part battery current and part “flyback current”. There is less battery current used for the specific torque requirement. High current draw from the battery isto be avoided, if possible, because it is less efficient. At higher speeds, the OFF time is less, so that less induction current (“flyback current”) is generated. Most of the motor current must come from the battery at higher speeds. However, the torque and current requirements are also usually less.INDUCTION CURRENT PEAK MOTOR ‘CURRENT AVERAGE BATTERY CURRENT BATTERY CURRENT 2 Posmve SS necarve FIGURE 11 The typical induction current during equal ON and OFF times of the FET’sis shown in the graph in FIGURE 11. Plugging ‘The plugging circuits an added feature of the controller that provides smooth electrical braking when the opera- tor wants to change the truck’s direction of travel. The plugging feature also saves wear and tear on the drive tires and the drive unit gears. Plugging occurs when the truckii travelingin one direc- ion but the operator has switched the directional control to the opposite direction. In this instance, the motor ar- mature is rotating in one direction while the magnetic forces of the fields are trying to force the armature the other way. This reaction generates current that is al- lowed to flow through a loop formed by the plugging diode in the controller. This generated current helps to slow the truck’s speed magnetically in the same manner that compression ina gas engine will help to control the speed of an automobile when it is coasting. When a lift trucks in the plugging mode, the pulse rate of the con- troller must be maintained ata slow rate. To accomplish this the logic section of the controller signals that the truck is in a plugging mode and controls the oscillating rate. The oscillating rate pulses slowly no matter what 8 BATTERY MOTOR ARMATURE, MOTOR FIELD CONTROLLER FET's (NOT “ON’) FLYBACK DIODE INDUCTION MOTOR CURRENT position the directional control isin on.a controller with fixed plugging, Some controllers are furnished with throttle position plugging and the oscillating rate can vary. SS necarve 4, CONTROLLER, 5. PLUG DIODE 1. BATTERY 2. MOTOR ARMATURE 3. MOTOR FIELD FIGURE 12. PLUGGING CURRENT CIRCUIT‘The plugging function of the controller is designed to al- low the truck to travel 1 to 2 times the length of the lift truck after the truck is plugged before it reverses direc- tion, During plugging, the oscillating rate is decreased from 15 kHz to 1 kHz, The controller regulates the pulse widths of the pulses to the motor field for the correct amount of plugging, The accelerator circuit is also set to a low speed so that normal acceleration in the opposite direction will occur. The plugging distance is adjustable, The plugging adjustment on the controller changes the amount of motor field current allowed. The plugging adjustment can be changed as needed for an application. See ADJUSTMENTS. Plugging an electric lift truck is not a harmful practice, however, avoid plugging the drive motor when the drive wheel is jacked off the ground. Control Circuit ‘The control circuit has operator inputs from the key and brake switches as well as the accelerator potentiometer. The circuit also has internal inputs from the power circuit for thermal protection, plugging sensing, low voltage protection and motor current (current limit). ‘The control circuit uses the inputs to regulate the ON TIME pulses to the FET’s for speed control, current limit and plugging strength. Static-Return-To-Off (SRO) Fun The contol circuit includes afunction to prevent the op- eration of the lft truck f the starting sequence is not cor- rect. The function uses the inputs o the control circuit to make sure the operator is ready to operate the controls. ‘The starting sequence is as follows: a. Tum the key switch to the ON position. The key switch supplies battery voltage to the brake switch b. The operator must close the brake switch. Bat- tery voltage is now supplied to the control cir- cuit ©. Rotate the Direction/Speed control in the de- sired direction of travel to select travel direction and speed. Ifstep cis done before both steps a and b are complete, the lift truck will not move in either direction. The control circuit must get battery voltage through both the key and brake switches before it gets aspeed signal from the accelerator potentiometer. If the starting sequence is not correct, the control circuit will not send a gate pulse to the FETS for traction motor current. ‘The SRO function also prevents the lift truck from going to full speed operation because of a malfunction in the accelerator circuit. On the B/W40-60XL units, an open Circuit in the accelerator circuit is normally sensed as a full speed signal by the control card. Ifthis malfunction exists, the SRO function will prevent the start of traction pulses. If the malfunction occurs during normal operation, the control circuit senses an accelerator potentiometer input of more than 7000 ohms (open Circuit) and stops the traction pulses. The circuit will return to normal operation after the malfunction is repaired Thermal Protection Function ‘There is a sensor to sense the heat within the controller housing. If the controller gets too hot or too cold for correct operation, the control circuit will reduce the ON ‘TIME of the pulses to decrease the current to protect the controller. The lift truck will still operate at a slower speed to permit it to be moved to a location out of the ‘work area, The controller can then return to a normal operating temperature. The controller is designed to operate with an internal temperature between 85°C (85°F) and ~25°C (13°F). Controller performance will be reduced when the controller is in Thermal Protection. Low Voltage Protection Function ‘This function protects the controller and the battery. The controller will not operate correctly if there is not a minimum voltage from the battery. The battery current drain increases as the battery voltage decreases. Too large a battery drain will damage the battery. If the battery voltage is low, the control circuit will decrease the ON TIME of the pulses to decrease the current rain. The battery can still operate the lift truck to move it for battery charging or replacement. The controller requires. minimum of 9 volts on the 12 volt controllers and a minimum of 16 volts on the 24 volt controllers for the system to function properly. Current Limit Protection Function The control circuit limits the traction motor current toa ‘maximum value to protect the controller, motor and battery. The control circuit will decrease the ON TIME, of the motor pulses to keep the motor current less than 9the maximum value. The maximum values set by the + Fyback Diode manufacturer. + Plug Diode _ + Filter Capacitors power Cleat | ‘The parts in the power circuit cannot be replaced by us- ‘The power circuit is controlled by the control circuit. grs. Cables connect the battery and traction motor tothe The complete power cut nid the controlerand per iret tthe contoller ower terminal "B+", BP "42", "M-" and“B - All ofthe traction motor current flows through the power circuit of the controller. + Field Effect Transistors 2». ” FIGURE 13. N30FR TRANSISTOR NTROLLER CIRCUIT SCHEMATICSEQUENCE OF OPERATION ‘The sequence of operation describes a complete cycle of the transistor traction circuit. A sequence of the beginning conditions and the FET cycle is shown in FIGURE 14. NOTE: Gray lines on the circuit lines show positive voltage with respect to battery negative. Slash lines show negative voltage with respect to battery positive ‘The line codes do not always indicate full battery voltage. The gray tone is used only forthe circuits being, described. Some parts of the energized circuit are not shown with gray tones orslashes. The thick (bold) lines Key switch to the ON position. LC contactor energized (NSOFR and oer handle s owered {Wiese 80x1} wzoxr, }W45XT) or operator steps on brake ccs (R005), or operstor releases rate anos (C60-80xT oritsxt) signal Control Circuit has battery Positive. Circuit checks for fo signal from accelerator potentiometer. Direction/Speed Control rotated for slow forward travel FWD/REV switch forward contacts close. Accelera- tor potentiometer signal to Control Circuit Forward contactor ener gized. NO contacts close and NC contacts oper Gate Driver of Control Circuit sends ON pulse to FET's gate. ON TIME (pulse width) set by accelerator potentiometer FET's ON for time of gate ON pulse. Power Pulse to traction motor circuit. show the traction power circuit. The thin lines show the control circuits NOTE: The following circuit schematics from the 'W40-60XL, B40-60X1 lift trucks are used to describe the sequence of operation. Basic eperation of the transistor controller for other lift truck models is similar. See the DIAGRAMS sections for the complete schematics, NOTE: The N30FR and W40-60XL, B40-60XL lift trucks have an additional “LC” contactor that is energized when the key switch closes. The basic circuit operation is the same as described. “Gate Driver sends OFF pulse to FET's gato. OFF TIME (puise width) set by rest of time remaining in one cycle at 15 kz. Power pulse to traction motor circuit ends, Induction current tows through Flyback Diode and traction motor ‘Control Circuit repeats: cycle, FIGURE 14. SEQUENCE OF OPERATION unKey Switch © Key Switch closed by moving key to the ON position. On N30FR units, the LC contactor is energized. Battery power to brake switch, lift, lower, horn and to optional heater and battery meter. contBron ey W/B40-60XL SHOWN. OTHERS SIMILAR. FIGURE 15. SEQUENCE OF OPERATION; KEY SWITCH CLOSED 2Brake Switch © Brake switch must be closed by lowering steering handle (W/B40-60XL, W/B60-80XT, W20-40XTA, W20-40XTC, and W20-30XTR only), operator releasing brake handles (C60-80XT, TSXT) or operator stepping on brake switch (R30ES only) so that the FWD/REV switch, Traction Reverse switch (W/B40-60XL, and W/B60-80XT only), Accelerator Potentiometer and Control Circuit will have battery voltage when Key Switch is closed. Control Circuit © Battery positive to the Control Circuit, Hourmeter, Traction Reverse switch (W/B40-60XL and W/B60-80XT only) and Direction switch through the key and brake switches. Hourmeter begins to operate. Circuit checks that there is no speed signal from the accelerator potentiometer. If there is a speed signal as battery power is applied, the control circuit will prevent the gate signal from going to the FET’s. =e Cee EEE ie © Posmve [SS Negative W/B40-60XL SHOWN. OTHERS SIMILAR. FIGURE 16. SEQUENCE OF OPERATION; POWER TO CONTROL CIRCUITFWD/REV Switch Closed © Forward contacts of FWD/REV switch close. Accelerator potentiometer speed signal to control circuit Battery positive voltage available to Forward contactor. © rosmive C8 necarive ES [=I POSITIVE SIGNAL W/B40-60XL SHOWN. OTHERS SIMILAR. FIGURE 17. SEQUENCE OF OPERATION; DIRECTION/SPEED CONTROL SET FOR SLOW FORWARD SPEED 4Forward Contactor Energized © Normally open contacts of Forward contactor close. Normally closed contacts open. Battery positive voltage is applied to FET’s through traction motor. FET’s are still OFF, so there is no current flow and the traction motor does not operat. thet} Sees [ Posmve SS necatve [=00= POSITIVE SIGNAL W/B40-60XL SHOWN. OTHERS SIMILAR. FIGURE 18. SEQUENCE OF OPERATION; FORWARD CONTACTOR ENERGIZED 15Gate Pulse To FET’s © Gate Driver of control circuit sends gate ON pulse to FET’s gate. ON TIME (pulse width) set by accelerator potentiometer signal. FET's ON For Time Of Gate Pulse ‘© FET’s conduct to provide power pulse to the traction motor. Traction motor starts to operate. Pulse ON TIME is the same as gate ON TIME. SS necarive =00= POSITIVE SIGNAL, W/B40-60XL SHOWN. OTHERS SIMILAR. FIGURE 19. SEQUENCE OF OPERATION; GATE PULSE TO FET's, FET’s ON 16Gate Pulse Removed © FET’s stop conducting when gate pulse is removed. Power pulse is removed from traction motor. Pulse OFF TIME is set by the time remaining for one cycle at 15 kHz. POSITIVE. necarive S=¥ POSITIVE SIGNAL. \W/B40-60XL SHOWN. OTHERS SIMILAR. FIGURE 20. SEQUENCE OF OPERATION, FET’s OFF "7Induction Current Flows Through Motor And Flyback Diode © Induction current, generated by motor, flows through the flyback (freewheel) diode and returns th:oughthe ‘motor. This current is used instead of battery current to keep the motor operating. = Posie Cw NeGarve =0= POSITIVE SIGNAL |W/B40-SOXL SHOWN. OTHERS SIMILAR. FIGURE 21. SEQUENCE OF OPERATION, INDUCTION CURRENT 18Plugging is a method of stopping an electric lit truck by changing the direction of current flow in the ‘motor field, To actuate the plugging circuit, the operator must change the Direction/Speed control for travel in the opposite direction of present travel, The controller prevents motor curent ow during the time the FWO/REV contactors change to the reverse direction. The controller senses when the FWD/ REV switch goes through neutral and momentarily interrupts the battery positive input from the key and brake switches. This action momentarily turns the FET's OFF when the high current flow can cause an arc and burn the contactor contacts. The controller senses plugging action by the voltage across the plug diode. The frequency ofthe oscilator is reduced trom 15 Kz fo 1 kz to limit torque, Current iit is also reduced to prevent the plugging current from becoming too great. This current limit can be changed by the external plugging adjustment. The controller regulates the pulse widths of the pulses to the motor field for the correct amount of plugging. The controller accelerator circuit is also set to a low speed so that normal acceleration in the opposite direction will occur after the lift truck comes to a stop. ‘The motion of the lift truck drives the traction motor armature to make the motor operate as a genera- tor. This additional “generator” current (armature current) adds to the current flow through the field to reverse the motor at an even faster rate. Unless the control circuit provides a way to slow this change of direction, the lift truck will stop very quickly. The plug diode in the control circuit prevents the it truck {rom stopping too quickly. While the motor is acting as a generator, the plug diode prevents this “generator current” from adding to the field current. The control circuit lets all of the plugging current ‘low from the armature through the plug diode, then flow with the battery current through the armature again. This reduces the effect of the induction current. poste “ ( necarve | US SH S00 POSITIVE SIGNAL ‘W/B40-60XL SHOWN. OTHERS SIMILAR. FIGURE 22. SEQUENCE OF OPERATION, PLUGGING 9CHECKS, ADJUSTMENTS AND REPAIRS GENERAL ‘There are several checks that can be made that check for correct operation of the system. There are only two ex ternal adjustments on early units and three adjustments ca later units. These are no internal adjustments for the transistor controller. A warnina Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create a dangerous operating condition. Do not operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, put a “DO NOT OPERATE?” tag on the control handle, Remove the key from the key switch. CHECKS NOTE: The checks require a volt-ohmmeter with ame- ter movement. Most digital meters will not operate cor- rectly for some of the checks. Specific checks require additional equipment. A warnina Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause an injory or parts damage. ‘The capacitor in the transistor controller can hold an electrical charge after the battery is disonnected. ‘Toprevent electrical shock and injury, discharge the capacitor before inspecting or repairing components under the hood. Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then ‘connect an insulated jumper wire between the B+ and B- terminals (see FIGURE 24.) of the transistor control Some checks require the battery connected. Do not ‘connect the battery until the procedure tells you to connect the battery. Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel as described in the OPERATING MANUAL or the Periodic Maintenance section of the SERVICE MANUAL. 20 CHECKING CONTACTOR COIL Check the Forward or Reverse contactor coil with an ‘ohmmeter. A suppressor diode with aresistorin series: part of the coil. The diode will cause the ohmmeter to indicate a difference in resistance in one direction. Re~ verse the probes of the ohmmeter to the opposite termi- nals and measure the resistance. Use the highest resis- tance indication, Replace the coil if the resistance read- ings are a short circuit in both directions or ifthere is an open circuit in both directions. Make sure the coil wires are connected again to the correct terminals. CHECKING TRANSISTOR CONTROLLER ‘These checks are in two sections: checks with the con- troller installed in the lift track and checks of the con- troller out of the lift truck (bench checks). ‘The controller is protected against operation with a low battery. Controller output is slowly decreased as battery voltage decreases. The battery can be low if an operator notices slower operation or less power. This operation is not a defect of the transister controller. Make sure all checks are done with a fully charged battery. NOTE: The following checks must be done in the order they are listed because some steps depend on conditions set in previous steps. Checks With Controller Installed 1. Raise the drive/steer wheel as described in the OPERATING MANUAL or the Periodic ‘Maintenance section of the SERVICE MANUAL, 2. Make sure the battery is fully charged. 3. Make a physical check to be sure that battery negative is connected to the B— terminal of the controller. Connect the negative meter lead to the B— terminal. 4. Check for battery positive voltage at the B+ termi- nal of the controller (see FIGURE 24.) and the cable P2 terminal of the Reverse contactor. If there is no battery positive voltage, check the cables between battery posi- tive and the two terminals. Ifthe cables are not damaged, the controller can be damaged. ‘5. Tag all wires and cables before they are removed. Make sure the key switch is in the OFF position and remove the wires from terminals 1 and 2 of thecontroller. See FIGURE 23. FIGURE 24. for the correct unit. If resistor is used between terminals 1 and 2, do not disconnect the resistor. Check for an open circuit (at least. 1 megohm) between the wires with the Direction/Speed control in the Neutral position. Ifthere is no open circuit, check to see that the accelerator potentiometer is in the centered position. Check for ‘maximum resistance by moving the control to the full speed position(s). See the following chart. Check for at least one megohm resistance between each wire and the lift truck frame. If any of the resistance readings are wrong, check the wiring to the accelerator potentiometer and check the adjustment of the FWD/REV switch. Connect wires to terminal 1 and terminal 2. See the sections DIAGRAMS, 8000 SRM 457, DIAGRAMS, 8000 SRM 475, DIAGRAMS. 8000 SRM 495 or DIAGRAMS, 8000 SRM 653 for the walkie high lift motorized hand trucks. TE [rowron [Mana [Enns Soe wees | ew | Sor faces | tra oma Ser eae | rasp 6 Connect the voltmeter positive lead to the controllerB + terminal. Connectthe voltmeter negative lead to the controller M — terminal. Move the key to the ON position, lower the control _ handle (W/B40-60XL,W/B60-80, W40XT, —_ W4SXT, W20-40XTA, W20-40XTC, W20-30XTR) or step on the brake switch (R30ES, N3OFR). Release the brake levers (C60-80XT and TSXT units) Check for zero or near zero volts. Move the Direction/Speed control for full speed travel. Check for full battery voltage. 7. If there is not full battery voltage, the controller is defective. If there is battery voltage ané the motor does not operate, disconnect the battery connector and dis- charge the internal capacitor. The correct procedure to discharge the capacitor is described in the WARNING at the beginning of this section. 8. Disconnect the cable from the controller A2 termi- nal. Use the ohmmeter to check for a diode between the A2and B+ terminals, There must be high resistance in one direction and a low resistance with the meter leads reversed. If there isa low or high resistance in both directions, the diode is damaged. Ifthe readings are cor- rect and the motor does not operate, there is a short-cit- ‘cuit in the motor circuit. Check for a short-circuit at the motor cables or direction contactors. If there are no short-circuits, the motor has a short-circuit. Replace any defective item(s). 9. Connect all wires or cables that had been discon- nected, FIGURE 23. NEW CONTROLLER 21. M = POWER TERMINAL, 2. TERMINAL 2, 3. TERMINAL 1 4. B — POWER TERMINAL 5. B + POWER TERMINAL 6. KEY SWITCH INPUT 7. FIR CONTACTOR OUTPUT 8. STATIC-RETURN-TO- OFF, 1A OR NOT USED ON ‘W40XT, W45XT, ‘W/B/C60-80XT AND TSXT. 9. BRAKE OR TRACTION REVERSE (W/B40-60XL WaOXT, WA5XT, \W/B60-80XT ONLY) 10. FORWARD INPUT 41. REVERSE INPUT 12. A2 POWER TERMINAL NOTE THAT SOME CONNECTORS HAVE DIFFERENT FUNCTIONS DEPENDING ON MODEL OF LIFT TRUCK AND MODEL OF CONTROLLER USED. FIGURE 24. CONTROLLER WIRE (CONTROL) AND CABLE (POWER) TERMINALS Bench Checks (See FIGURE 25.) To test the controller on the bench, you will need the fol- Jowing equipment: a. A power supply with a voltage equal to the lift truck voltage. The power supply can be any of the following: the lift rack battery, automotive batteries connected in series or an AC power supply with a regulated D.C. output of 12 to 48 volts. Only low power tests will be done, so a 10 amp fuse is wired in series with the power sup- ply to protect the operator and controller from accidental short-circuits. Do NOT use a battery charger as a power supply since the no load volt- age can be higher than the voltage of the control- ler. b. Asspeed control, A SK ohm potentiometer wired as a 2 terminal rheostat will work fine © A contactor (similar to the pump motor contac- tor) with a 5 watt 250 ohm resistor across the 2 contacts. A toggle switch and key switch con- nected as shown are also needed. ©. A test load of incandescent lamps with a voltage equal to the lift truck voltage. 12 volt lamps wired in series work fine. £ A multimeter or digital voltmeter. 1. Shake the transistor controller tosee ifany parts are loose inside. If there are loose parts, replace the control- ler 2. Connect the controller as shown in FIGURE 25. Connect the voltmeter to the B+ and B— terminals of the controller. 3. Make sure the key switch is OFF. Turn the power supply and toggle switch ON. Look at the voltmeter. ‘The voltmeter indication must slowly increase to the truck voltage. If the voltage does not increase to the truck voltage, replace the controller. 4, ‘The lamps must not illuminate now. If they illumi- nate, replace the controller.POWER SUPPLY 10 AMP FUSE, TOGGLE SWITCH KEY SWITCH CONTACTOR RESISTOR TRANSISTOR CONTROLLER TEST LOAD SPEED CONTROL, eonogsena FIGURE 25. 5. Move the key switch to the ON position. 6. Move the speed control and look at the lamp bright- ness. The lamps must slowly increase in brightness as the “speed” increases. 7. Test the controller’s SRO functions: ‘Turn the key switch to the OFF position. b. Move the speed control to the full speed position. €. Tum the key switch to the ON position and ‘check that the lamps do NOT illuminate until the speed control is moved to OFF and returned to ON. 8. Check the controllers fault function by removing a wire from terminal 2 or 3 on the controller. The lamps must NOT illuminate. 9, Disconnect all wires and cables from the controller and use the ohmmeter or diode checker to check the plug, diode. Connect the meter between the A2 and B+ terminals. Reverse the meter leads and check the BENCH CHECKS, reading. There must be a high resistance in one direction and a low resistance with the meter leads reversed. If there is a low or high resistance in both directions, the diode is damaged. Replace the controller. 10. Check the flyback (freewheel) diode. Connect the meter between the M— and B+ terminals. Reverse the meter leads and check the reading. There must be a high resistance in one direction and a low resistance with the meter leads reversed. If there is a low or high resistance in both directions, the diode is damaged. Replace the controller. Accelerator Potentiometer Checks And Adjustments The following procedures are for checking and adjust- ing the accelerator potentiometer and control switches for the W/B40-60XL units ONLY. Different series of lift trucks have their own checks and adjustments. See the sections for the following models: N30FR, N40-S0FR, NSOFA - ELECTRICAL AD- JUSTMENTS, 2200 SRM 381 and DIAGRAMS, 8000 SRM 495. 23R30ES - ELECTRICAL SYSTEM, 2200 SRM. 420 and DIAGRAMS, 8000 SRM 475. W40XT, W45XT, W/B/C60-80XT, TSXT - THE ELECTRICAL SYSTEM, 2200 SRM 279 and DIAGRAMS, 8000 SRM 457. W20-40XTA, W20-40XTC W20-30XTR - THE ELECTRICAL SYSTEM, 2200 SRM 279 and DIAGRAMS, 8000 SRM 653. NOTE: The direction switch must be correctly adjusted before the accelerator potentiometer can be checked. The accelerator potentiometer must be adjusted after each installation 1. Make sure the battery is disconnected and the ca- pacitor in the controller is discharged. The correct pro- cedure to discharge the capacitor is described in the WARNING at the beginning of this section. 2. Adjust the accelerator potentiometer when it is installed with the pulley belt in place and both wires disconnected, 3. Connect an ohmmeter between wires 15 and 16 on the accelerator potentiometer. 4, Rotate the direction and speed control. The ohmmeter will indicate changes of resistance. Loosen the two set screws in the pulley block. Adjust the potentiometer in the pulley block so that when the control is in the neutral position, the ohmmeter shows ‘maximum resistance. The maximum resistance of the potentiometer will be approximately 4750 + 0%. 5. Tighten the 1vo set screws on the pulley block. Do not let the pulley or shaft move as the set screws are tightened. 6. Rotate the direction and speed control to the forward and reverse directions. Check that the resistance of the potentiometer is less than 200 ohms at the maximum speed positions. 7. Conmect the wires 14, 15 and 16 from the accelerator potentiometer to the correct wires on the lift truck and the traction reverse switch. Install the cover plate and connect the battery. 4 ADJUSTMENTS (See FIGURE 26.) A WARNING Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. Ifa tool causes a short circuit, the high current flow from the battery can cause a personal injury or property damage. ‘The capacitor in the transistor controller can hold an electrical charge after the battery is disconnected. ‘To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing components under the hood. Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then connect an insulated jumper wire between the B++ and B- terminals (FIGURE 25.) of the transistor controller. ‘Some checks require the battery connected. Do not connect the battery until the procedure tells you to connect the battery. Make sure the drive wheel is, raised to prevent truck movement and possible injury. Raise the drive wheel as described in the OPERATING MANUAL or the Periodic Maintenance section of the SERVICE MANUAL. A warning Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not corre:t can create a dangerous operating condidon. Do not operate a it truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, put a “DO NOT OPERATE” tag on the control handle. Remove the key from the key switch. NOTE: The new 1243 controller as no adjustment it is preset and has electronic boxes connected by the Can bus data link system, NOTE: The SEM motor controller operateson the prin- ciple of controlling the motor field circuit and the motor armature circuit independently. The SEM controller includes a full range of built-in safety features and diag- nostic and setup capability for safe reliable operation, The older controller has three adjustments: Braking (plugging), Controlled Acceleration and Current Limit. The older controllers have two adjustments, Braking and Controlled Acceleration. The plugging adjustment adjusts how far the lift truck travels before reversing direction. The Direction/Speed control can be moved tothe maximum speed position from stop or a slow travel speed. The controlled acceleration adjustment allows adjustment of the maximum rate of acceleration. The ‘Current Limit adjustment controls the motor current toa preset maximum, All adjustments are made with the key switch off and the battery disconnected. Discharge the capacitor. Remove thenylon seal washer and the 3mm (0.12in) socket head screws to access the adjustment screws. Make the adjustmen's using a small insulated screwdriver. Replace the socket head screws and nylon seal washers after all adjustments are made. Tighten the set screws to 0.9 Nem (@ Ibf in) torque. 2 3 1. TRANSISTOR CONTROLLER 2. BRAKING (PLUGGING) ADJUSTMENT ‘SCREW (CW = HARDER BRAKING) 3. CURRENT LIMIT ADJUSTMENT SCREW. (CW = HIGHER CURRENT) (NOT USED ON ‘W/B40-60XL CONTROLLERS) 4, CONTROLLED ACCELERATION ADJUSTMENT SCREW (CW = FASTER ACCELERATION) MIDPOINT ADJUSTMENT 12 O'CLOCK POSITION MINMUM MAXIMUM ADJUSTMENT ADJUSTMENT ENLARGED VIEW OF ADJUSTING SCREWS (2,3. AND 4 SHOWN ABOVE) FIGURE 26. CONTROLLER ADJUSTMENT LOCATIONS Plugging Adjustment ‘Turning the braking (plugging) adjustment clockwise will increase the plugging effect and stop the lift truck in a shorter distance. Turning the adjustment counter- clockwise will decrease the plugging effect. The trac- tion motor brushes have a faster wear rate when the con- trol is set for the shortest stopping distance (maximum plugging). More heat is also generated in the traction ‘motor at this maximum setting. This adjustment should be set in the one o’clock position. Acceleration Adjustment ‘Tuming the controlled acceleration adjustment clock- ‘wise will increase the acceleration rate. Tuning the ad~ justment counterclockwise will give aslowerrate of ac- celeration. The traction motor brusheshave afaster wear rate when the control is set for an increased acceleration rate, More heat is also generated at this maximum set- ting. This setting should be set in the twelve o’clock position. Current Limit Adjustment ‘Turning the current limit adjustment clockwise will increase the current limit. This setting is factory set at the maximum 400 amps. The truck will also run at a higherthan normal speed especially when ithas no load. Lowering this adjustment can cause the truck to have limited starting torque and can cause the truck not to run at top speed when fully loaded. This setting should be set at the maximum adjustment position, REPAIRS A WARNING Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause a personal injury or property damage. ‘The capacitor in the transistor controller can hold anelectrical charge after the battery isdisconnected. ‘To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing components under the hood. Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then connect an insulated jumper wire between the B+ and B- terminals (FIGURE 25.) of the transistor controller. Some checks require the battery connected. Do not connect the battery until the procedure tells you to 28connect the battery. Make sure the drive wheel is raised to prevent truck movement and possible injury. Raise the drive wheel as described in the OPERATING MANUAL or the Periodic Maintenance section of the SERVICE MANUAL. Contactors (See FIGURE 27.) ‘The “FORWARD” and “REVERSE? contactor assem- bly controls the direction of current flow through the traction motor. The contactor isa heavy-duty switch that ‘opens and closes the power circuit. The traction circuit has a “FORWARD” and “REVERSE? contactor assem- bly. Each contactor assembly has the following parts: ‘two sets of normally open (NO) contacts, two sets of ‘normally closed (NC) contacts and a coil. The coil is an electromagnet that moves the NO contacts to the closed position against spring pressure. The coil is in the con- trol circuit. The contactor tips are in the traction cireuit. A suppressor is part of each coil When a contactor coil is energized, the normally open (NO) contacts close and the normally closed (NC) con- tacts open. Current flows through the traction motor field in one direction when the “FORWARD” contactor is energized and in the other direction when the “RE- VERSE” contactors energized. This action gives direc- tion control tothe traction motor. The contacts normally have a long service life because the current flow through the contacts is stopped before the contacts open. The FET’s are OFF before the contactor coil is deenergized. Contactor Replacement Make sure the battery is disconnected and the capacitor in the controller is discharged. The correct procedure to discharge the capacitor is described in the WARNING at the beginning of this section. Ifthe lift truck has an EE rating, remove the cover of the contactor box for access to the contactor terminals. Make an identification of the wires and cables and disconnect them from the contactor assembly. Remove the mounting screws and replace the ‘contactor assembly. Install the wires and cables as re~ 26 ‘moved. Install the cover of the contactor box on EE, units. Replacing Curtis Contactor Parts (See FIGURE 27.) NOTE: If both the contacts and coil of a contactor will bbe replaced, replace the complete contactor as described in Contactor Replacement. Do only the parts ofthe pro- cedure necessary to replace the damaged parts you are replacing, NOTE: All of the contacts for each contactor must be replaced at the same time ifany contact needs replacing. ‘The contactor contacts are made of special silver alloy. ‘The contacts will look black and rough from normal op- eration. This condition does not cause problems with the ‘operation ofthe lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. Replace the contacts ‘when the silver alloy is worn away to the base support metal. 1. Remove the contactor as described in Contactor Replacement, 2. Make an identification of the buss bars for correct, installation. Remove the buss bars and nuts that fasten to the fixed contacts. 3. Remove the two screws that fasten the covers for each contactor. Remove the cover of each contactor. Do NOT lose the plunger springs. 4, Replace the four fixed contacts in the contactor cov- ers. 5. Remove the two plunger assemblies and movable ‘contacts and replace the three fixed contact bars. Re- place the contacts of the plungers. 6. Ifacoil will be replaced, remove the coverbase. Re- ‘move the screws that fasten the coil frame to the mount bracket. Remove the coil end frame. Remove the bush- ing part of the plunger and the armature cap from the ‘coil. Install these parts on the replacement coil.‘SCREW BUSS BAR COVER SPRING FIXED CONTACTS. PLUNGER ASSEMBLIES AND MOVABLE CONTACTS COVER BASE COIL AND FRAME MOUNT BRACKET ARMATURE CAP NOTE: THE POWER CONNECTIONS FOR THE FIXED CONTACTS CAN BE DIFFERENT THAN SHOWN. FIGURE 27. FORWARD AND REVERSE CURTIS CONTACTOR ASSEMBLY 277. Install the coil and frame on the mount bracket, 8. Install the cover base, fixed contact bars and plung- rs on the coil frame. Make sure both springs are on both plungers. 9. Install the covers and electrical bars on the covers as removed during disassembly, 10. Install the contactor assemblies on the lift truck as described in Contactor Replacement. Replacing GE Contactor Parts (See FIGURE 28.) NOTE: If both the contacts and coil of a contactor will bbe replaced, replace the complete contactor as described in Contactor Replacement. Do only the pars of the pro- cedure necessary to replace the damaged parts you are replacing. NOTE: All of the contacts for each contactor must be replaced at the same time if any contact needs replacing. The contactor contacts are made of special silver alloy. ‘The contacts will look black and rough from normal op- eration. This condition does not cause problems with the operation ofthe lft ruck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS. Replace the contacts when the silver alloy is worn away to the base support ‘metal. 1. Remove the contactor as described in Contactor Replacement. 2. Make an identification of any buss bars for correct installation. Remove the buss bars, spacers and nuts that fasten to the fixed contacts. 3. Remove the four screws that fasten the contactor parts together. 4. Carefully remove the upper clamp and the two fixed contact bars. 5S. Remove the two lower clamp pieces and the other two fixed contact bars. 6. Remove the contact carrier. Then remove the mov- able contact assembly and armature assembly as a unit. Remove the spring. 7. If necessary, carefully disassemble the assemblies as shown in FIGURE 28. Do not lose any parts and 28 make sure to make a note ofthe shims and their positions for correct assembly. 8. If necessary, remove the frame and coil 9. Install the coil on the base. Install the frame over the coil and install the spring with the large coil toward the frame. 10. Assemble the armature assembly and movable contact assembly. Install the assemblies. LL. Install the contact carrier, the lower fixed contact bars and the lower clamps. 12. Install the upper fixed contact bars. Make sure all contacts on the bars are facing the movable contacts. 13, Install the upper clamp and screws. 14, Install the contactor assemblies on the lift truck as described in Contactor Replacement. Controller Replacement Make an identification and disconnect the wires and ca- bles from the controller. Remove the mounting screws and remove the controller. Apply a thin coating of sili- cone grease (Hyster Part Number 1198757) on the bot- tom of the replacement controller. Install the replace- ‘ment controller on the lift truck. Connect the wires and cables to the same terminals as identified during the re- ‘moval procedure. Accelerator Potentiometer And Control Switches Replacement And Adjustment ‘The following SRM sections have the procedures for re- placing and adjusting the accelerator potentiometer and control switches of the different series of lift trucks: N3OFR, N40-5OFR, NSOFA - ELECTRICAL AD- JUSTMENTS, 2200 SRM 381 and DIAGRAMS, 8000 SRM 495, R30ES - ELECTRICAL SYSTEM, 2200 SRM 420 and DIAGRAMS, 8000 SRM 475. W40XT, W45XT, W/B40-60XL, W/B/C60-80, and TSXT - THE ELECTRICAL SYSTEM, 2200 ‘SRM 279 and DIAGRAMS, 8000 SRM 457, W20-40XTA, W20-40XTC W20-30XTR - THE ELECTRICAL SYSTEM, 2200 SRM 279 and DIAGRAMS, 8000 SRM 653.BASE COIL FRAME SPRING (SMALL END UP) ARMATURE ASSEMBLY CONTACT CARRIER FIXED CONTACTS: LOWER CLAMP MOVABLE CONTACT CARRIER SHIM - MOVABLE CONTACT ASSEMBLY UPPER CLAMP ‘SCREW (4 EA) FIGURE 28. FORWARD AND REVERSE GE CONTACTOR ASSEMBLY 29TROUBLESHOOTING GENERAL This section describes the most common faults that can ‘occur in trucks with the CURTIS TRANSISTOR CON- TROLLER. Follow the General Procedures to make sure that maintenance problems give the correct troubleshooting results. Follow the General Procedures and then use the fault procedure that best describes the problem, GENERAL PROCEDURES: A WARNING Disconnect the battery and separate the connector before opening the hood or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause a personal injury or property damage. The capacitor in the transistor controller can hold anelectrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing components under the hood. Wear safety glasses. To discharge the capacitor, first disconnect the battery. Then connect an insulated jumper wire between the B+ and B- terminals (FIGURE 25.) of the transistor controller. Some checks require the battery connected. Do not connect the battery until the procedure tells you to connect the battery. Make sure the drive wheel is raised to prevent truck movement and po: injury. Raise the drive wheel as described OPERATING MANUAL or the Periodic Maintenance section of the SERVICE MANUAL. 1. Check the specific gravity of the battery. Ifthe spe- cific gravity is less than 1.260, the battery is aot fully charged or is damaged. A fully charged battery has a specific gravity of 1.270-1.290. A discharged battery has a specific gravity of approximately 1.130. 2. ‘The Hyster electric lift truck has a two-wire system. ‘The frame must not be a common electrical pati. Check for 50,000 ohms or more between each terminal of the battery connector forthe lift truck and a clean connec- tion on the frame. Remove any circuit paths between the controller and the frame of the lift truck. Carbondust ina ‘motor or other parts can cause a circuit path. Check for additional equipment that is causing a circuit path to the frame. 3. Check for voltage between each terminal of the connector that fastens to the battery and a clear connec- tion on the frame. Normally there is some small voltage between the battery and the frame, even ifthe resistance is very high. The small voltage is normally less than 30% of the battery voltage. A higher voltage can indi- cate a dirty battery or a battery with damage. Clean the battery and battery compartment as necessary. 4, Visually check for parts or wires that are loose or damaged. NOTE: The correct meter polarity is necessary for the checks. The voltage checks are made between the point indicated in the troubleshooting chart and battery nega- fe. Connect the meter negative to battery negative. NOTE: Make an identification of any wires before you disconnect them. The wires must be connectedcorrectly after checks or repairs.FAULT PROCEDURES The following pages have some common faults of the 420 and DIAGRAMS, 8000 SRM 475. lift trucks and the procedures for finding the cause. The W/40-6OXL, W4OXT, WASXT, and, W/B/C60-80, following SRM sections have the procedures forreplac- Ts - THI ELECTRICAL SYSTEM, 2200 ing and adjusting the acceleratorpotentiometerandcon- _§RM 279, and DIAGRAMS, 8000 SRM 457, and trol switches ofthe different series of lift racks: DIAGRAMS, 8000 SRM 923, Therecan be avaria- tion in some ofthe wire numbers forthe different it N3OFR, N40-SOFR, NSOFA-ELECTRICALAD- ——_inuck models seoo eanibe, aD SRMAB1 and DIAGRAMS, Woo.4oxts, W20-40XTC W20-30XTR - THE ELECTRICAL SYSTEM, 2200 SRM 279 and R3OES - ELECTRICAL SYSTEM, 2200 SRM DIAGRAMS, 8000 SRM 653. FAULT NUMBER 1. ONE DIRECTIONAL CONTACTOR WILL NOT CLOSE Possible Causes: Damaged (open) wire(s) in control circuit Direction switch is damaged Traction rev. sw. is damaged (W/B40-60XL, ‘WAOXT, WaSXT, and W/B60-B0XT only) Contactor coil is damaged Transistor Controller is damage at FWD or REV term, 7.0.1 Contacts of direction switch do not close in one direction. Repair or replace the switch. 1.0 Check that the direction switch closes. 1.0.2 The direction switch closes. Check FWD or REV contactor coll and wire 18 (early units) or 27 (later units) at contactors. 1.1.1 Voltage at wire 6. Traction reverse switch or wiring is damaged. No voltage at wire 6. FWD or REV switch, wiring, FWD contactor coil or motor controller is damaged. T11_ Voltage at wire 8, Traction reverse switch or wiring is damaged. 1.4.2 No voltage at wire 8. FWD or REV switch, wiring, REV contactor Coil or motor controller is damaged. 14 Only REV contactor wil lose. Check for battery voltage at wire 6 ‘terminal of traction reverse or direction switch with both switches. in neutral position. 1.1 Only FWD contactor will close. Check for battery voltage at wire 8 terminal of traction reverse or direction switch with both switches in neutral position. 31FAULT NUMBER 2. DIRECTIONAL CONTACTORS WILL NOT CLOSE FOR OPERATION IN EITHER DIRECTION Possible Causes: © Battery not connected ‘© Control fuse is damaged Pump motor fuse is damaged Battery voltage is low Wires in circuit are open Key such, brake switch or LC contactors damaged Traction reverse sw. (W/B40-GOXL, W40XT, W45XT, ‘and W/B60-80XT only) is damaged F/R switch is damaged Transistor controller is damaged 2.0.1 Battery voltage at control fuse. Check for an open control fuse. 2.0 Check for battery voltage on the battery side of control fuse. 2.0.2 No battery voltage at control fuse Connect battery or check wiring between battery and fuse. 21 Check orbattery vlage alcontrolfuse 21.1 Battery volage at key switch. Check Tor terminal of key switch. damaged key switch. 212 No voliage at key switch, Wire to key ‘switch or connections are damaged. Key switch closed. Check for battery’ voltage at key switch terminal of brake switch, Battery voltage at brake switch, Check for damaged brake switch. 222 No vollage at brake switch, Check for damaged wire to brake switch or damaged key switch, Key switch closed (later units only). ‘Check for battery voltage at B+ terminal of transistor controller. 23.1 Battery voltage at B+ terminal Possible damaged transistor controller. 2.3.2 No voltage at B+ terminal. Check for damaged wires 10, 13, 14, or AS. LC contactor or diode between wires 10 and14. 2.4 — W/B40-60 units only. Brake switch closed. Check for battery voltage at brake switch terminal of traction reverse switch. 24.1 Balter voltage attraction reverse switch. Check for damaged traction reverse switch. 2.4.2 No voltage at traction reverse switch. Check for damaged wire to switch or damaged brake switch. 25.1 Voltage at F/R switch. Check for damaged F/R switch or damaged wire to switch, 25 Check for battery voltage at traction reverse switch terminal of F/R switch. 2.5.2 Nobattery voltage at F/R switch. Check for damaged traction reverse switch or damaged wire to F/R switch. 2.6 Check for damaged wire(s) to FWD/ 2.6.1 Wires not damaged. Check for REV contactors. damaged contactor coils. 32FAULT NUMBER 3. LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. THE DIRECTIONAL CONTACTORS CLOSE NORMALLY. NO POWER WHEN DIRECTION/SPEED CONTROL IS MOVED. Possible Causes: Traction fuse is damaged Open circuit between motor and contactors ‘© Power contacts of direction contactor are damaged, ‘© Accelerator potentiometer is damaged or needs adjustment. '® Traction motor is damaged ‘© Damaged (open) traction motor cables ‘© Transistor controller is damaged 3.0.1 Iffuse ig damaged, replace fuse with ‘one of the correct value. 3.0.2 if fuse is not damaged, got 3.1 3.4.1 No battery voltage. Check cables between battery and terminals. 3.1.2 Battery voltage, Goto 32. 321 ‘3.0 Check traction fuse, 3.1 Check for battery voltage between B+ and B — terminals of controll. No battery voltage at A6. Cables to armature of traction motor, motor brushes or motor armature are damaged. Motor brushes or cables are damaged. Replace or repair Motor brushes and cables are not damaged. Armature is open, replace motor. 3.2.2 Battery voltage. Goto 33, 33.4 ‘32 Check for battery voltage at P2 terminal of direction contactors. Check for battery voltage at S2 terminal of traction motor with direction contactor energized. No battery voltage at S2. Check power contact of direction contactor, cable F4 and traction motor field (S1 to $2). Repair or replace damaged contact, cable or motor. 3.3.2 _ Battery voltage. Goto 3.4. 3.4 Check for battery voltage between B+ 3.4.1 No battery voltage at M~. Check and M— terminals of controller. power contact of direction contactor and BUSS BAR. Repair or replace damaged contact or BUSS BAR. ‘3.4.2 Battery voltage. Replace damaged controller. 3.5 Check potentiometer for open circuit 3.5.1. Check for short circuit, open wire or Resistance above 7000 ohms. ‘open switch,