Hyster 1503628 07 02 srm0978

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N30-40XMR3 [C470]; N25XMDR3 [C470];

N50XMA3 [C471]; N30XMXDR3 [G138];
N45XMXR3 [B264]
PART NO. 1503628 2200 SRM 978

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

on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Electrical System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Component Repair and Testing - General ........................................................................................................ 2
Contactor Panel Assembly................................................................................................................................. 2
Description/Features ..................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 3
Contactors .......................................................................................................................................................... 4
Auxiliary Switch ............................................................................................................................................ 4
Testing ............................................................................................................................................................ 4
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
EE Contactors ................................................................................................................................................ 6
Fuses................................................................................................................................................................... 7
Relays ................................................................................................................................................................. 8
Enable Relay .................................................................................................................................................. 8
Hourmeter Relay ........................................................................................................................................... 8
Coil Testing .................................................................................................................................................... 8
Contact Testing .............................................................................................................................................. 8
Remove and Install........................................................................................................................................ 8
Height Proximity Switch ................................................................................................................................... 9
Remove ........................................................................................................................................................... 9
Test ................................................................................................................................................................. 10
Install ............................................................................................................................................................. 10
Key Switch.......................................................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Install ............................................................................................................................................................. 10
Battery Disconnect Switch ................................................................................................................................ 11
Remove ........................................................................................................................................................... 11
Install ............................................................................................................................................................. 11
Proportional Electro-Hydraulic Control Valves ............................................................................................... 12
Manual Lowering........................................................................................................................................... 12
Trucks built before 15 July, 2002.............................................................................................................. 12
Trucks built after 15 July, 2002................................................................................................................ 12
Operation ....................................................................................................................................................... 13
Selector Valves ................................................................................................................................................... 13
Test/Remove/Install ....................................................................................................................................... 13
Multifunction Control Handle........................................................................................................................... 13
Remove ........................................................................................................................................................... 14
Install ............................................................................................................................................................. 14
Main Interface Board (MIB).............................................................................................................................. 15
Operation ....................................................................................................................................................... 15
LED Display................................................................................................................................................... 15
MIB, Remove.................................................................................................................................................. 16
MIB, Install.................................................................................................................................................... 17
Main Interface Board (MIB) Setup Procedures................................................................................................ 18
General ........................................................................................................................................................... 18
Default Values................................................................................................................................................ 18
©2002 HYSTER COMPANY i

Table of Contents Electrical System
TABLE OF CONTENTS (Continued)

Checking Model Code and Setup Status ...................................................................................................... 18
MIB Generation II Setup Procedure............................................................................................................. 18
Entering the Setup Mode.......................................................................................................................... 18
Editing Settings......................................................................................................................................... 19
Changing the Setting Values .................................................................................................................... 19
Entering Text............................................................................................................................................. 19
System Information and Fault Log .......................................................................................................... 19
Passwords .................................................................................................................................................. 19
Defaults...................................................................................................................................................... 19
Exit and Save............................................................................................................................................. 20
Parameters ................................................................................................................................................ 20
Top Level Menu Items............................................................................................................................... 20
Options .................................................................................................................................................. 20
Handle Dead Band................................................................................................................................ 20
Lift/Lower .............................................................................................................................................. 20
Speeds .................................................................................................................................................... 21
Auxiliary ................................................................................................................................................ 21
Customizing MIB Functions ......................................................................................................................... 21
MIB Status, Warning, and Fault Codes ........................................................................................................... 29
General ........................................................................................................................................................... 29
Troubleshooting Charts ................................................................................................................................. 30
Blank or Undefined Code Conditions ............................................................................................................... 31
Status Codes....................................................................................................................................................... 35
Warning Codes ................................................................................................................................................... 40
Fault Codes ........................................................................................................................................................ 44
SEM Traction Motor Controller ........................................................................................................................ 52
Remove ........................................................................................................................................................... 53
Test ................................................................................................................................................................. 54
Install ............................................................................................................................................................. 54
Programmer Handset ........................................................................................................................................ 55
SCROLL DISPLAY Keys............................................................................................................................... 55
CHANGE VALUE Keys................................................................................................................................. 56
MORE INFO Key........................................................................................................................................... 56
Operation ....................................................................................................................................................... 56
Connecting Handset to Traction Motor Controller.................................................................................. 56
Disconnecting Handset from Traction Motor Controller......................................................................... 57
Programmer Self Test ............................................................................................................................... 57
Operating Modes............................................................................................................................................ 57
Program Menu........................................................................................................................................... 57
Test Menu .................................................................................................................................................. 58
Diagnostics Menu ...................................................................................................................................... 59
Diagnostic History..................................................................................................................................... 59
Special Program Menu.............................................................................................................................. 60
Programming the Traction Motor Controller ................................................................................................... 61
Troubleshooting.................................................................................................................................................. 64
Status LED Diagnostics ................................................................................................................................ 64
Programmer Diagnostics............................................................................................................................... 65
Diagnostics Menu .......................................................................................................................................... 65
Test Menu....................................................................................................................................................... 73
ii
Electrical System Table of Contents
TABLE OF CONTENTS (Continued)

This section is for the following models:
N30-40XMR3 [C470];
N25XMDR3 [C470];
N50XMA3 [C471];
N30XMXDR3 [G138];
N45XMXR3 [B264]
iii
2200 SRM 978 General
General
The electrical control system consists of the following See the section Diagrams 8000 SRM 980 or 8000
major components (see Figure 1): SRM 982 for additional information.
• Main Interface Board (MIB)
• Proportional Electro-Hydraulic Valve NOTE: Throughout this manual, the terms right,
• SEM Traction Motor Controller left, front, and rear relate to the viewpoint of an op-
• Dash Display Assembly erator standing in the truck facing the forks.
• Control Handle Assembly
• Contactor Panel Assembly
Figure 1. Logic Diagram
1
Contactor Panel Assembly 2200 SRM 978
Component Repair and Testing - General

1. To check for wire connections to the frame, and frame even if the resistance checks are cor-
disconnect the battery connector completely and rect. If voltage is detected, use an ammeter to
use an ohmmeter to check the circuits. Check measure current flow. The current must not ex-
for resistance of 50,000 ohms or more between ceed 100 milliamperes. Current in excess of 100
each terminal of the lift truck portion of the milliamperes can cause a problem.
battery connector and a clean connection point
on the frame of the lift truck. There should be If voltage is detected at the frame, check to be sure
no electrical connections to the frame of the lift the battery is clean and is not defective. Clean the
truck. Wires or terminals without insulation battery and battery compartment as required. A
can cause electrical connections to the frame. buildup of carbon dust in the electric motors can
Isolators used to insulate circuit boards from also cause measurable voltage at the frame. Wear
the frame that are missing, broken, or installed appropriate safety equipment and remove carbon
incorrectly can also cause these connections. dust from motors using dry, compressed air.
2. Check for voltage between each terminal of the

connector on the battery and a clean metal con-
nection on the frame of the lift truck. It is nor-
mal to measure some voltage between the battery
Contactor Panel Assembly

DESCRIPTION/FEATURES REMOVE
The contactor panel assembly is located in the front
compartment. The contactor panel assembly con-
WARNING
tains the following major components: Disconnect the battery by separating the con-
• Traction Contactor nector before opening the compartment cover
• Lift Pump Contactor or inspecting/repairing the electrical system.
• Steer/Auxiliary Pump Contactor If a tool causes a short circuit, the high-cur-
• 3 Power Fuses rent flow from the battery can cause an injury
• 4 Control Fuses or parts damage.
• ER (Enable Relay)
1. Move the lift truck to a safe, level area. Turn
• HR (Hourmeter Relay)
the key switch OFF and remove the key. Put a
• EE trucks only
DO NOT OPERATE tag on the control handle.
• 6-Amp Diode (for reverse polarity protection)
Put blocks under the drive wheels to keep the lift
Components used in the contactor panel assembly truck from moving. See Periodic Maintenance
are common to both the 24-volt truck and the 36-volt 8000 SRM 970 .
truck options.
2. Disconnect the battery and separate the connec-
tors.
3. Lift off the battery compartment cover for access

to the contactor panel.
2
2200 SRM 978 Contactor Panel Assembly
steps listed above must be done to service any item

WARNING that is attached to the contactor panel assembly.
The capacitor in the traction motor controller
can hold an electrical charge after the battery 5. To remove the panel assembly, tag and discon-
is disconnected. To prevent electrical shock nect the power wires to the contactors and the
and injury, discharge the capacitor before fuses.
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has 6. Unplug the control wires from the main wire har-
been disconnected. Discharge the capacitors ness at the P-1 connector.
in the controller by connecting a load (such 7. Remove the capscrews, flat washer, lockwasher,
as a contactor coil or a horn) across the con- and nut retaining the top of the panel assembly
troller’s B+ and B− terminals. DO NOT use a to the frame. Remove the two nuts, lockwash-
screwdriver to discharge the traction motor ers, and flat washers retaining the bottom of the
controller. panel assembly to the frame. Remove the contac-
4. Discharge the controller by connecting a load tor panel assembly.
across terminals B+ and B−. See Figure 2. 8. (B264) Remove the three nuts, lockwashers, and
flat washers retaining the panel assembly to the
frame. Remove the contactor panel assembly.
INSTALL
1. Align the contactor panel with the mounting
holes in the frame. Install the two flat washers,
lockwashers, and nuts on the bottom of the panel
assembly. Install the capscrew, flat washer, lock-
washer, and nut to retain the top of the panel
assembly.
2. (B264) Replace the contactor panel on the three

mounting capscrews. Install the flat washers,
lockwashers, and nuts to retain the panel assem-
bly.
3. Install the power wires and fuses. See the man-

ual Diagrams 8000 SRM 980 or 8000 SRM 982
or for additional information.
4. Reconnect the control wires.
5. Connect the battery.

1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION 6. Remove the blocks from under the drive wheels,
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR remove the DO NOT OPERATE tag, and install
the key.
Figure 2. Discharging the Capacitors
NOTE: The contactor panel assembly does not nor-

mally have to be removed from the lift truck. The
3
Contactors 2200 SRM 978
Contactors
DESCRIPTION/FEATURES AUXILIARY SWITCH
Contactors are switches, controlled by electromag- On non EE-rated trucks, there is an auxiliary switch
nets (coils), that close and open a power circuit. The mounted on the lift pump contactor. A mechanical
MIB and traction motor controller have internal elec- connection between the lift pump contactor and the
tronic drivers to control the current to the coils of auxiliary switch causes the contacts of the auxiliary
the contactors. The electromagnetic field in the coil switch to close when the lift pump contactor is closed.
moves the armature against spring pressure to close
the contact. When the coil is de-energized, the spring The lift pump contactor auxiliary switch is used to
pressure moves the armature and opens the contacts. send a signal to the dash display whenever the lift
When a spring holds the contacts of a switch open, pump is activated. When the signal is present, pump
the switch is called normally open (NO). If a spring hours accumulate on the dash display hourmeter.
holds the contacts of a switch closed, the switch is
NOTE: The lift pump contactor auxiliary switch is
called normally closed (NC).
not present on EE-rated trucks. On EE-rated trucks,
The contactor contacts are made of special silver a hourmeter relay is used to send a signal to the dash
alloy. The contacts will normally look black and display. Refer to RELAYS for additional information
rough from normal operation. This condition does on the hourmeter relay.
not cause problems with the operation of the lift
truck. Cleaning is not necessary. DO NOT USE A TESTING
FILE ON THE CONTACTS. DO NOT LUBRICATE
THE CONTACTS. Replace the contacts when the WARNING
silver alloy is worn away to the base support metal. Parts of this procedure requires working
on the lift truck with full electrical current
The traction, lift pump, and steer pump contactors present. Do not wear any rings, watches, or
are SPNO (single-pole, normally open) contactors. any other jewelry while working around the
SPNO contactors have one set of normally open contactor panel assembly. When manually
contacts. See Figure 3. closing a contactor with the power connected,
use a properly insulated tool.
1. Check the condition of the battery. If it is not

fully charged, charge or replace the battery with
a fully charged battery before continuing.
2. Lift off the battery compartment cover for access

to the contactor.
3. Visually check to see if the contactor closes when

the circuit is energized. If the contactor closes,
skip to Step 9. If the contactor does not close,
proceed to Step 4.
4. Connect a voltmeter across the coil terminals.

Verify that the correct voltage is being applied to
the coil with the circuit energized. See Table 1.
5. Check the contactor for loose, broken, or corroded

connections at the contactor.
Figure 3. Typical SPNO Contactor Assembly
4
2200 SRM 978 Contactors
Table 1. Contactor Coil Voltages A voltage drop of 2 volts or more across the closed tips
indicates a poor contact or high resistance. Check for
Pull In Holding burned or worn tips, incorrect size, or mismatched
Contactor Coil Approxi- Approxi- tips. Also check for an incorrect gap setting on con-
mate mate tactors with adjustable point gaps.
Traction 24 Volts 12 Volts
REMOVE
Lift Pump 24 Volts 12 Volts
Power Steering/ 24 Volts 24 Volts tors.
Aux. Pump
NOTE: Pull in voltage occurs for only approx- WARNING
imately 1 second. Some voltmeters may not The capacitor in the traction motor controller
display this voltage. can hold an electrical charge after the battery
is disconnected. To prevent electrical shock
6. Check the mechanical function of the contactor. and injury, discharge the capacitor before
Use an insulated tool, such as an electrician’s inspecting or repairing any component. Wear
screwdriver, to manually close the contactor tips. safety glasses. Make certain the battery has
Check for looseness or binding of the moving been disconnected. Discharge the capacitors
parts of the contactor. The parts should move in the controller by connecting a load (such
freely, but the parts must not be so loose that as a contactor coil or a horn) across the con-
the movement is sloppy. troller’s B+ and B− terminals. DO NOT use a
screwdriver to discharge the traction motor
7. Visually check the tips for pitting, burning, or controller.
wear.
2. Discharge the controller by connecting a load
8. If an external suppressor is attached to the coil, across terminals B+ and B−. See Figure 2.
remove the suppressor. Check the resistance of
the contactor coil. Compare the reading against 3. Refer to Contactor Panel Assembly, Remove for
the values for the type of contactor being tested. access to the contactors.
See Table 3 for coil resistance values. Readings
not within the listed limits indicate the following: 4. Tag and disconnect the wires and/or bus bars to
High Resistance - Corrosion or an open coil the contactor.
Low Resistance - Shorted or a burnt coil
5. Remove the capscrews, flat washers, and lock-
NOTE: No external suppressors are used on contactor washers retaining the contactor to the contac-
coils which are controlled by the MIB or the traction tor panel assembly. For the pump contactor, re-
motor controller. The MIB and traction motor con- move the capscrews, lockwashers, flat washers,
troller have internal suppressors for these contactor and nuts.
coils.
INSTALL
9. If the contactor closes but the truck does not
work properly, check the electrical function of 1. Align the contactor to the contactor panel assem-
the high current section of the contactor (the bly. Install the contactor using the capscrews,
tips and buss bars). With the lift truck battery flat washers, and lockwashers.
connected and all switches closed, connect a volt 2. Connect the wires and/or buss bars to the con-
ohmmeter across the high current terminals of tactor. See the section Diagrams for additional
the contactor. information.
Check the voltage drop across the contactor tips. Set 3. Install the cover on the battery compartment.
the voltage scale of the meter to the lowest range,
higher than battery voltage (50 volts for a 36-volt 4. Connect the battery and test the operation of the
battery, etc.). On SPNO contactors, read the voltage truck.
across the contactor with the tips open. Battery volt-
age should drop to zero or near zero as the tips close.
5
Contactors 2200 SRM 978
EE CONTACTORS
When EE contactors are used, additional steps are
required to service the contactors, as the contactors
are covered by an enclosure shroud. See Figure 4.
1. Remove the capscrews retaining the enclosure

shroud to the contactor. Remove the shroud.
2. Remove the insulator.
3. Service the contactor.
4. Install the insulator.
5. Position the enclosure shroud over the contactor

and fasten the shroud to the coil and frame as-
sembly.
1. ENCLOSURE 7. RETURN SPRING

SHROUD 8. MOVING CONTACT
2. CAPSCREW 9. BASE
3. INSULATOR 10. PLUNGER
4. FIXED CONTACT 11. COIL AND FRAME
5. CAPSCREW
6. COVER
Figure 4. Typical EE Contactor
6
2200 SRM 978 Fuses
Fuses
The fuses are located on the contactor panel assem- certain to replace any failed fuse with one of the same
bly. Lift off the cover for access to the contactor panel amperage. See Table 2.
assembly.
Table 2. Fuses
WARNING Fuse Circuit Rating

Disconnect the battery and separate the con-
nector before opening the compartment cover FU1 Traction 325 Amp
or inspecting/repairing the electrical system. FU2 Lift Pump 400 Amp
If a tool causes a short circuit, the high-cur-
rent flow from the battery can cause an injury FU3 Power Steering/Auxiliary 100 Amp
or parts damage. Pump
FU4 Battery Input to Dash 1 Amp
When the lift truck has the provision for EE, the Display
fuses FU1, FU2, and FU3 are enclosed in a fuse box
on the contactor panel assembly. For access to the FU5 Key Switch to Control 10 Amp
fuses, see Figure 5. Remove the capscrews and lock- Wiring Circuits
washers retaining the floor insulator, wall insulator, FU6 Horn 10 Amp
and the fuse box enclosure to the base plate to test or
remove the fuses. FU7 Operator Compartment 10 Amp
Lamp and Fan
The fuses may be checked for continuity if it cannot
FU8 RF/Accessories Terminal 10 Amp
be determined visually that a fuse has failed. Make
1. INSULATOR - TERMINAL 8. SCREW 15. NUT

2. ENCLOSURE - FUSE BOX 9. WASHER 16. FUSE 400 AMPS
3. NUT 10. TERMINAL POST 17. FUSE 325 AMPS
4. LOCKWASHER 11. CAPSCREW 18. INSULATOR - WALL
5. SPACER 12. INSULATOR - FLOOR 19. LOCKWASHER
6. LOCK NUT 13. SPACER 20. CAPSCREW
7. FUSE 100 AMPS 14. WASHER
Figure 5. Enclosed Fuse Box EE Application
7
Relays 2200 SRM 978
Relays
DESCRIPTION/FEATURES CONTACT TESTING
The ER (enable relay) is found on all narrow aisle The normally open contacts of the ER and HMR re-
model lift trucks. The HMR (hourmeter relay) is lays are checked at terminals 30 and 87. Check for
present only on EE-rated trucks. Both relays are a voltage drop across the NO contacts with the re-
mounted on the contactor panel assembly. lay energized. Replace any relay which has a voltage
drop exceeding 2 volts. See Figure 6 for test point lo-
ENABLE RELAY cations.
The enable relay is controlled by the MIB. The enable REMOVE AND INSTALL
relay supplies battery volts to the lift pump contactor
coil, the power steering contactor coil, the hydraulic To remove the relays, tag and disconnect the wires.
control valve coils, and the selector valve coils when Remove the capscrews and lockwashers retaining the
the truck is in the "ready" mode. relay to the contactor panel assembly or the mount-
ing bracket.
HOURMETER RELAY
Replace the relays by aligning the relay with the
The HMR (hourmeter relay) is used to send a signal mounting holes in the contactor panel assembly or
to the dash display whenever the lift pump is acti- mounting bracket and installing the capscrews and
vated. When the signal is present, pump hours ac- lockwashers.
cumulate on the dash display hourmeter. The HMR
(hourmeter relay) is present only on EE-rated trucks.
NOTE: On non-EE-rated trucks, there is an auxil-

iary switch mounted on the lift pump contactor. Re-
fer to Contactors, Auxiliary Switch for additional in-
formation.
COIL TESTING
The ER and HMR relay coils can be tested for resis-
tance across terminals 85 and 86. See Figure 6 for
test point locations. Replace any relay which has a
coil resistance value outside of specifications. See Ta-
ble 3 for coil resistance values. NOTE: BOSCH AND POTTER BRUMFIELD RELAYS.
A. PIN B. SCHEMATIC
NOTE: The ER and HMR are both single-pole, ARRANGEMENT
double-throw (SPDT) type relays. They are manu-
factured by either The Bosch Company or Potter & Figure 6. ER and HMR Relays
Brumfield. When testing these relays, it is impor-
tant to identify the manufacturer due to different
coil resistance values. The name of the manufac-
turer is stamped on the relay.
8
2200 SRM 978 Height Proximity Switch
Table 3. Hydraulic Control Valve/Relay Coil Resistance Values
Coil Resistance
Coil Location Manufacturer Test Points
@ 21 C (70 F)
LIFT/LOWER coil 20 ±4 ohms Coil leads
LOWER Holding
29 ±4 ohms Coil leads
coil
Aux metering coil Hydraulic Control 22 ±4 ohms Coil leads
HydraForce, Inc.
Valve
AUX UP (auxiliary
up) and AUX
39 ±4 ohms Coil leads
DOWN (auxiliary
down) coils
Robert Bosch Corp. 305 ±15 ohms
ER (enable relay) Terminals 85
Contactor Panel Potter & Brumfield 360 ±35 ohms
coil and 86
Co.
HMR (hourmeter Robert Bosch Corp. 305 ±15 ohms

Drive Unit Terminals 85
relay) coil (EE Potter & Brumfield 360 ±35 ohms
Compartment and 86
trucks only) Co.
SS (sideshift) coil Extend Assembly HydraForce, Inc. 39 ±4 ohms Coil leads
EX (reach) coil Extend Assembly HydraForce, Inc. 39 ±4 ohms Coil leads
Tilt coil Extend Assembly HydraForce, Inc. 39 ±4 ohms Coil leads
Drive Unit
P (lift pump) Albright 15 ±2 ohms Coil leads
Compartment
PS (power steering) Contactor Panel Albright 52 ±4 ohms Coil leads
Traction Contactor Panel Albright 17 ±2 ohms Coil leads
Height Proximity Switch

REMOVE 1. Move the lift truck to a safe, level area. Raise the
mast high enough to obtain access to the height
WARNING limit switch. SAFETY CHAIN THE MAST. See
Periodic Maintenance 8000 SRM 970 . Refer
Do not raise the frame of the truck with the
to Safety Procedures When Working Near The
forks raised. The stability of the truck is re-
Mast.
duced. Raising the frame of the truck with the
forks raised could cause it to tip over. Tipping 2. Turn the key switch OFF and remove the key.
of the truck can cause personal injury or prop- Put a DO NOT OPERATE tag on the control han-
erty damage. dle. Put blocks under the drive wheels to keep
the lift truck from moving. See Periodic Main-
WARNING tenance 8000 SRM 970 . Refer to How To Put
Disconnect the battery and separate the con- The Lift Truck On Blocks.
nector before opening the compartment cover
or inspecting/repairing the electrical system.
tors.
rent flow from the battery can cause an injury 4. Disconnect the height proximity switch plug.
or parts damage.
9
Key Switch 2200 SRM 978
5. Remove the two capscrews retaining the cover to 3. Install the cover using the two capscrews.
the switch body. Pry the cover from the switch.
4. Connect the height proximity plug.
6. Tag and disconnect the wires.
5. Remove the safety chains from the mast. Con-
7. Remove the switch by removing the mounting nect the battery, install the key, and check the
capscrews, lockwashers, and nuts. mast for proper operation.
TEST 6. Connect the battery, install the key and turn the
key ON.
1. Remove wires #15 and #74 from the switch and
check the resistance between switch terminals 7 7. Check the mast for proper operation.
and 8.
8. Remove the blocks from under the drive wheels.
2. Replace any switch that does not read continuity Remove the DO NOT OPERATE tag from the
between switch terminals 7 and 8 with the switch control handle.
activated and no continuity with the switch not
9. Verify that the switch is activated with the in-
activated.
ner mast lowered and not activated with the in-
NOTE: The switch is not activated (switch arm out) ner mast elevated. Check wire #74 at the plug.
when the inner mast is elevated. The switch is acti- Battery volts should be present at wire #74 with
vated (switch arm depressed) when the inner mast is the inner mast lowered. Near 0 volts should be
lowered. present at wire #74 with the inner mast elevated.
INSTALL 10. Check the truck for proper operation. Maximum

travel speed must be limited with the mast ele-
1. Position the new switch on the bracket. Install vated above free lift.
the mounting capscrews, lockwashers, and nuts.
2. Connect wire #15 to terminal 8 and wire #74 to

terminal 7.
Key Switch
REMOVE 3. Remove the battery compartment cover for ac-
cess to the wiring to the key switch.
WARNING 4. Tag and disconnect the electrical wires to the key
Disconnect the battery and separate the con- switch.
or inspecting/repairing the electrical system. 5. Remove the nut retaining the key switch to the
If a tool causes a short circuit, the high-cur- mounting bracket and remove the key switch.
rent flow from the battery can cause an injury
or parts damage. INSTALL
1. Move the lift truck to a safe level area. Turn 1. Position the new switch in the mounting bracket.
the key switch OFF and remove the key. Put a Install the nut to retain the key switch.
Put blocks under the drive wheels to keep the lift 2. Install the electrical wires to the key switch. See
truck from moving. See Periodic Maintenance the section Diagrams 8000 SRM 980 or 8000
8000 SRM 970 . Refer to How To Put The Lift SRM 982 for additional information.
Truck On Blocks.

tors.
10
2200 SRM 978 Battery Disconnect Switch
3. Install the battery compartment cover. 5. Remove the blocks from under the drive wheels,
remove the DO NOT OPERATE tag, install the
4. Connect the battery. key, and test the key switch.
Battery Disconnect Switch

REMOVE 8. Rotate the red knob counterclockwise to remove
it.
WARNING 9. Remove the two screws retaining the battery dis-
Disconnect the battery, and separate the con- connect switch to the mounting bracket and re-
nector before opening the compartment cover move the switch.
If a tool causes a short circuit, the high-cur- INSTALL
or parts damage. 1. Ensure the replacement battery disconnect
switch is in the ON (up) position and that the
1. Move the lift truck to a safe, level area. Turn red knob is removed.
DO NOT OPERATE tag on the control handle. 2. Position the new battery disconnect switch in the
Put blocks under the drive wheels to keep the lift mounting bracket. Install the two screws retain-
truck from moving. See Periodic Maintenance ing the battery disconnect switch to the mount-
8000 SRM 970 . Refer to How To Put The Lift ing bracket.
Truck On Blocks.
3. Install the red knob by threading it clockwise. In-
2. Disconnect the battery and separate the connec- sert a 4.0 mm (0.15 in.) diameter rod through
tors. the hole in the housing and into the hole in the
shaft to prevent the shaft from rotating while in-
3. Remove the battery compartment cover for stalling the knob. Remove the rod from the hous-
access to the wiring to the battery disconnect ing once the red knob is tightened securely.
switch.
4. Install the electrical wires to the battery discon-
4. Tag and disconnect the electrical wires to the bat- nect switch.
tery disconnect switch.
5. Install the battery compartment cover.
5. Pull the battery disconnect switch up to the ON
position. 6. Connect the battery.
6. Rotate the red knob to align the hole in the hous- 7. Install the key and test the battery disconnect
ing with the hole in the shaft. switch.
7. Insert a 4.0 mm (0.15 in.) diameter rod through 8. Remove the blocks from under the drive wheels,
the hole in the housing and into the hole in the remove the DO NOT OPERATE tag.
shaft to prevent the shaft from rotating.
11
Proportional Electro-Hydraulic Control Valves 2200 SRM 978
Proportional Electro-Hydraulic Control Valves

There are four electrically operated proportional
valves located on the main hydraulic control
valve. These proportional valves are controlled by
solenoids. Valve openings are controlled by varying
the electrical current in the valve coils.
See the section Hydraulic System 1900 SRM 973

for instructions for testing, removal, and replace-
ment of the proportional valves.
MANUAL LOWERING
WARNING
Always verify that no one is under or near
the lift mechanism or load during the manual
lowering procedure. Verify that there are no
obstructions beneath the lift mechanism or
load. If the mast does not lower when the man-
ual lowering valve is activated, deactivate the
A. LOAD HOLDING CHECK VALVE BUTTON
valve immediately and determine the cause. B. MANUAL OVERRIDE THUMB SCREW
WARNING Figure 7. Hydraulic Control Valve

Failure to return the manual lowering screw or
knob to the full counterclockwise position will
cause the forks to lower unexpectedly.
A provision is provided on the lowering valve to allow

manual lowering of the forks if necessary. Refer to
Trucks built before 15 July, 2002 or Trucks built after
15 July, 2002.
Trucks built before 15 July, 2002

Manual lowering is accomplished by first pushing
in the Load Holding check valve button (button A),
turning it counterclockwise 180 , and releasing it. In
this position, the valve will remain open and but-
ton A is popped out. This button is found on the
side of the control valve next to the frame wall of Figure 8. Manual Lowering Buttons
the truck. Turn the manual override thumb screw
(button B) slowly clockwise until the forks begin to Trucks built after 15 July, 2002
lower. See Figure 7 and Figure 8. Be sure to return
Manual lowering is accomplished by turning the
the manual override thumb screw to the original po-
setscrew in a counterclockwise direction using a
sition once the manual lowering process is complete
hex driver. Always return the setscrew to the full
by slowly turning the screw counterclockwise until it
clockwise position prior to operating the lift truck.
stops. Push in the Load Holding check valve button
See Figure 9.
(button A), and turn it clockwise 180 to close it.
12
2200 SRM 978 Multifunction Control Handle
OPERATION
The four electrically operated proportional valves lo-
cated on the main hydraulic control valve are con-
trolled by solenoids. These solenoids can be checked
for resistance by removing the leads to the solenoids
and tested using a volt ohmmeter. See Table 3 for coil
resistance values.
If a reading other than those listed are obtained, re-

place the solenoid. See the section Hydraulic Sys-
tem 1900 SRM 973 for information on removing and
installing the solenoids.
Figure 9. Manual Lowering Setscrew
Selector Valves
The carriage of the REACH model trucks has an ad- TEST/REMOVE/INSTALL
ditional valve assembly to enable the tilt, sideshift,
and reach functions of the carriage. Each function is Solenoids can be checked for resistance by remov-
controlled by a solenoid which manipulates a selec- ing the leads to the solenoids and tested using a volt
tor valve. For example, when reach is selected, the ohmmeter. See Table 3 for coil resistance values. If
coil is energized on the reach selector valve. When a reading other than those listed are obtained, re-
tilt is selected, the coil is energized on the tilt selec- place the solenoid. See the section Hydraulic Sys-
tor valve. When sideshift is selected, the coil on the tem 1900 SRM 973 for additional information.
sideshift selector valve is energized.
NOTE: Sideshift is an option not found on all trucks.
Multifunction Control Handle

DESCRIPTION/FEATURES lift truck will decelerate or accelerate. If the control
handle is released, it will return to neutral and the
The multifunction control handle controls the di- truck will coast to a stop.
rection and speed of the lift truck. See Figure 10.
Travel is activated by moving the entire control The multifunction control handle controls the direc-
handle in the desired direction of travel. Pushing tion and speed at which the carriage moves vertically
the control handle toward the forks makes the lift on the mast. Lift/lower is activated by moving the en-
truck travel toward the forks. To change direction, tire control handle toward the left or right side of the
move the control handle in the opposite direction lift truck. If the control handle is moved to the right,
of lift truck travel, regardless of travel speed. The the carriage lifts; if the control handle is moved to
lift truck will come to a stop, then accelerate in the the left, the carriage lowers. This control is also pro-
opposite direction. This action is called plugging. portional. The farther the lever is moved, the faster
The plugging control is proportional; therefore, the the carriage lifts or lowers.
farther the control handle is pushed, the faster the
13
Multifunction Control Handle 2200 SRM 978
been disconnected. Discharge the capacitors

in the controller by connecting a load (such
as a contactor coil or a horn) across the con-
troller’s B+ and B− terminals. DO NOT use a
screwdriver to discharge the traction motor
controller. See Figure 11.
4. Remove the multifunction control handle by dis-

connecting the two plugs from the connectors and
removing the four capscrews retaining the han-
dle to the frame.
5. The multifunction control handle has no re-

pairable parts and can only be replaced as a
whole unit.
1. TILT/SIDESHIFT DISK
2. HORN BUTTON INSTALL
3. EXTEND/RETRACT BUTTONS ARE ON THE
UNDERSIDE OF THE HANDLE 1. Install the multifunction control handle by re-
versing the steps above.
Figure 10. Control Handle
2. Install the battery compartment cover.
REMOVE
WARNING
or parts damage.
1. Move the lift truck to a safe level area. Turn the

key switch OFF and remove the key. Put blocks
under the drive wheels to keep the lift truck from
moving. See Periodic Maintenance 8000 SRM
970 . Refer to How To Put The Lift Truck On
Blocks.

tors.
3. Remove the battery compartment cover.
WARNING 1. NEGATIVE CONNECTION

The capacitor in the traction motor controller 2. POSITIVE CONNECTION
can hold an electrical charge after the battery 3. INSULATED JUMPER WIRES
is disconnected. To prevent electrical shock 4. 200-OHM, 2-WATT RESISTOR
and injury, discharge the capacitor before
Figure 11. Electrical Compartment
safety glasses. Make certain the battery has
14
2200 SRM 978 Main Interface Board (MIB)
Main Interface Board (MIB)

DESCRIPTION/FEATURES OPERATION
Pushbuttons on the MIB provide for factory-level di- The dash display is used in conjunction with the con-
agnostics and setup capability only, and should not trol handle to program the MIB and change various
be used for operator or service level diagnostics and operating functions of the MIB. Refer to Main Inter-
repair. Diagnostics and setup are to be performed us- face Board (MIB) Setup Procedures. The display is
ing the dash display and the control handle only. also the primary means of troubleshooting the truck.
The display will detect any fault and warning condi-
The Main Interface Board (MIB) is a printed circuit tions and will display them in standard text on the
board that directs communication between the elec- display window.
trical components of the truck. See Figure 12. The
MIB controls inputs and outputs to the control han- When the key switch is in the ON position and the
dle, variable valves, solenoid valves, contactor coils, operator is not on the truck, the MIB should display
relay coils, throttle, speed limit switch, brake switch, 0200 and the dash display should read POWER ON.
operator sensing switch, and the dash display. Setup If the operator is present on the truck and the brake
operations of the MIB is accomplished using the con- pedal is pressed (operator sensing switch and brake
trol handle, brake pedal, horn button, and the dash switch closed), the MIB should display 0300 and the
display. Removing the cover or accessing the dash display should read READY.
MIB is not required for setting up the MIB or
programming the MIB functions. The MIB dis- NOTE: When the operator enters the operator’s com-
plays real-time STATUS, WARNINGS, and FAULTS partment, the operator sensing switch (under right
directly on the dash display menu screen and dis- foot) and the brake switch (under left foot) must both
plays the fault code on the LED readout on the MIB. be closed to change the MIB display to 0300 and the
See MIB troubleshooting and fault description. dash display to READY. Afterward, either of the two
switches may be opened at any one time as long as
both switches are not opened simultaneously.
If the operator steps off the truck, and the key switch
remains in the ON position, the MIB will display
0200 and the dash display will read POWER ON (af-
ter a 3 second delay).
LED DISPLAY
The four-digit LED display is capable of displaying
truck function status, warning, or fault codes si-
multaneously. See Figure 13. Refer to MIB Status,
Warning, and Fault Codes for a comprehensive
explanation of each code. One code is displayed by
the left two digits and the other code is displayed by
the right two digits. It is important to read the left
Figure 12. Main Interface Board (MIB) two digits as one code and the right two digits as a
separate code.
15
Main Interface Board (MIB) 2200 SRM 978
Figure 13. MIB LED Display
During normal operation, the left two digits show or inspecting/repairing the electrical system.
the STATUS code of the truck and the right two dig- If a tool causes a short circuit, the high-cur-
its show 00. Whenever a truck function is selected, rent flow from the battery can cause an injury
the left two digits are updated to display the selected or parts damage.
function.
The two digits on the right side of the display are the key switch OFF and remove the key. Put a
used to display either a WARNING code or a FAULT DO NOT OPERATE tag on the control handle.
code. If neither a WARNING code nor a FAULT code Put blocks under the drive wheels to keep the lift
is present, the right two digits continue to display truck from moving. See Periodic Maintenance
00. If multiple faults are present, the highest priority 8000 SRM 970 . Refer to How To Put The Lift
FAULT code is displayed. After the highest priority Truck On Blocks.
fault is repaired, the next highest priority FAULT
code will be displayed. 2. Disconnect the battery and separate the connec-
tors.
If a WARNING code and a FAULT code are received
at the same time, the left two digits will display the 3. Remove the battery compartment cover for ac-
WARNING code, the right two digits will display the cess to the MIB.
FAULT code, and the STATUS code will not be dis-
played. Always troubleshoot the code shown on the WARNING
right side of the display first. The capacitor in the traction motor controller
can hold an electrical charge after the battery
Codes are displayed as follows:
• STATUS codes → numbers 01 to 16.
• WARNING codes → numbers 34 to 38.
• FAULT codes → all others.
been disconnected. Discharge the capacitors
MIB, REMOVE in the controller by connecting a load (such
The main interface board (MIB) is located in the front as a contactor coil or a horn) across the con-
compartment. The MIB is not a repairable item and troller’s B+ and B− terminals. DO NOT use a
must be replaced if troubleshooting determines the screwdriver to discharge the traction motor
MIB to be faulty. controller.

WARNING across terminals B+ and B−. See Figure 14. Dis-
Disconnect the battery and separate the con- connect the two plugs from the main interface
nector before opening the compartment cover board (MIB).
16
2200 SRM 978 Main Interface Board (MIB)

or parts damage.

Put blocks under the drive wheels to keep the lift
truck from moving. See Periodic Maintenance
8000 SRM 970 . Refer to How To Put The Lift
Truck On Blocks.

tors.
3. Align the plugs with the connectors located on

the bottom of the MIB. Connect the two plugs, J1
(white) and J2 (black), to the bottom of the main
interface board. Make certain that the lock on
each plug is engaged with the latch.
4. Align the new main interface board with the

1. NEGATIVE CONNECTION holes in the MIB bracket and install the screws.
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES 5. Align the MIB bracket with the lift truck frame.
4. 200-OHM, 2-WATT RESISTOR Install the capscrews and lockwashers.
5. Remove the screws retaining the MIB to the MIB

bracket.
6. Remove the capscrews and lockwashers retain-

ing the MIB bracket to the lift truck frame.
7. Use a screwdriver in the slot of the lock on the

connector to release the male plug. Pull and hold
the lock away from the latch while pulling the J
plugs from the MIB. See Figure 15. Disconnect
both the J1 (white) and J2 (black) plugs from the
MIB.
8. Lift the MIB bracket high enough to allow re-

moval of the MIB.
NOTE: The MIB is not a repairable item and must

be replaced if there is a problem with the board itself.
NOTE: PULL LOCK AWAY FROM THE CONNECTOR
MIB, INSTALL TO DISCONNECT.
A. PULL
WARNING 1. INSERT SCREWDRIVER INTO SLOT
nector before opening the compartment cover Figure 15. MIB J Connector
17
Main Interface Board (MIB) Setup Procedures 2200 SRM 978
6. After installing the cover, the MIB must be pro- 8. Remove the blocks from under the drive wheels,
grammed for the lift truck that it is being in- remove the DO NOT OPERATE tag, and install
stalled in. Refer to MIB Generation II Setup Pro- the key.
cedure.
9. Test lift truck for proper operation.
7. Install the cover and connect the battery.
Main Interface Board (MIB) Setup Procedures

GENERAL Table 4. Truck Unit and Model Codes
The term "Setup" is used in this manual to explain Unit Code Truck Model
the set of selections that the operator is allowed to
make with the MIB. N45XMXR3
B264
N30XMXDR3
CAUTION N30XMR3
Turning the key switch OFF or disconnecting
the battery when the MIB is being Setup will re- C470 N40XMR3
sult in the MIB returning to the run mode with- N25XMDR3
out saving any new values.
C471 N50XMA3
The MIB Setup procedure must be performed when- N45XMR3
ever a new MIB is installed or a MIB is transferred G138
from one truck to another. N30XMDR3
DEFAULT VALUES MIB GENERATION II SETUP PROCEDURE

Every MIB installed in a new truck by the factory is
programmed with the recommended factory default
Entering the Setup Mode
values for that model truck. A newly replaced MIB will enter the setup mode on
initial power up. Normal operation is not possible
Whenever a replacement MIB is installed in a truck,
until the truck model is set and the parameters are
the appropriate unit code and model must be Setup
saved.
into the MIB. This automatically sets the recom-
mended factory default values for all functions. To enter the setup mode on a newly replaced MIB:
CHECKING MODEL CODE AND SETUP 1. Turn off the truck.
STATUS
2. Press the horn button as you turn the key switch
Unit and Model code shown should correspond to one to ON.
of the truck models in Table 4. Refer to MIB Gener-
ation II Setup Procedure. 3. Hold the horn button until the dash display says
MIB SETUP MODE.
NOTE: Pushbuttons on the MIB provide for FAC-
TORY-level diagnostics and setup capability only, 4. Release the horn button. The MIB will prompt
and should not be used for operator or service level for a password entry or display FOR-REV
diagnostics and repair. Diagnostics and Setup are SCROLL, LIFT-LOWR CHANGE.
to be done using the dash display and the control
handle only.
18
2200 SRM 978 Main Interface Board (MIB) Setup Procedures
Editing Settings history was cleared. The first fault is for the most re-
cent. Use forward and reverse to scroll through other
The handle is used to change settings. Settings and faults and their number of occurrences. After the
values will appear on the dash display. Generally the first fault, any other faults are displayed in any par-
display will have a description of the setting on the ticular order. Only the faults that have been detected
left and the setting value on the right. Moving the are reported. If a fault has not been detected since
handle in the throttle forward direction will advance the MIB was last cleared, it will not be displayed. If
to the next setting. Moving the handle in the throttle the fault log is empty, NO STORED FAULTS is dis-
reverse direction will revert to the previous setting. played. After the last fault, CLR FAULTS: HORN
Selecting throttle reverse from the unit code (the first is displayed. Pressing the horn button will clear the
setting) goes to the system information and the fault fault history. NO STORED FAULTS will then be dis-
log. played.
Changing the Setting Values Passwords

The setting values are changed using the control There are two optional passwords: Operating and
handle in the lift direction to increase the value, or Setup. A MIB password is not required to operate
in the lower direction to decrease the value. Placing the truck if it has never been programmed for one.
the handle in the full lift or full lower position causes
some values to be skipped to allow faster scrolling Setup Password:
through the settings. The setup password is optional. Once programmed
in the MIB, it is required before any operational fea-
Entering Text tures allowed by the MIB can be changed. The user
will be prompted to enter it after entering the setup
Text is entered by using lift or lower to scroll to the mode.
desired letter, and throttle forward to scroll to the
next letter. The characters start with the numbers Operating Password:
0 through 9, then a blank space is allowed, then the The operating password is optional, but once pro-
letters A through Z are available. Only upper case grammed into the MIB, it is required before the truck
letters are used. can be operated. The user will be prompted to enter
it before the normal operating mode. Note: The op-
NOTE: Only the letters A through G are used for unit erating password is also used as the setup password
codes. After the desired text is entered press and if the setup password is blank.
release the horn button.
To Enter Passwords:
Some items are multiple choice, such as the truck The dash display will say ENTER PASSWORD for
model number. Use lift or lower to display the next several seconds. It will then display PASSW _. Scroll
item on the list. to the correct letter or number using lift or lower. Se-
lect the next character using throttle forward. Pass-
System Information and Fault Log words can be up to eight characters with any com-
When the first setting (the unit code) is displayed, bination of uppercase letters, numbers, or embedded
throttle reverse will take the user to the system in- blanks. If the first character is blank, the password
formation section. The dash display will show the is treated as blank.
software version date. After the date is displayed,
moving the handle in the forward direction will dis-
Defaults
play the MIB serial number. Moving the handle for- After the unit code, model, voltage, and E or EE sta-
ward again will display the fault log. tus are established or changed, the dash display will
say SETTING DEFAULTS. The other settings will be
NOTE: The MIB fault log does not include motor con-
set to established defaults.
troller faults. See motor controller faults and trou-
bleshooting.
The MIB fault log displays the fault messages and

the number of occurrences (up to 254) since the fault
19
Exit and Save Top Level Menu Items

The changes are not recorded until the save proce- Options
dure is completed. If the truck is turned off, it will
revert to the previous settings before the setup mode OPERATING PASSWD
was entered. If you wish to establish or change the operating pass-
word, move the handle to lift. The dash display will
To save changes: then say OP PW _ and you can input a password.
1. Apply forward throttle until the dash displays SET UP PASSWORD

EXIT & SAVE. Note: If the horn is pressed with If you wish to establish or change the setup pass-
throttle forward, parameter displays will be word, move the handle to lift. The dash display will
skipped and you will get to EXIT & SAVE faster. then say S UP PW _ and you can input a password.
2. Move the handle to lift until the dash displays Handle Dead Band
CYCLE BRAKE. Return the handle to neutral
and cycle the brake. The MIB will save the DRIVE DBAND1
changes and exit the setup mode. This is the first or narrow traction deadband. If the
handle is in neutral, it must be moved this distance
Parameters before the MIB will send a forward or reverse signal
to the motor controller.
UNIT CODE
Enter the four-character unit code. This is the first DRIVE DBAND2
part of the serial number. If an unrecognized unit This is the second or wide traction deadband. If the
code is entered, it will be blanked out and the user handle is in lift or lower, it must be moved this dis-
will not have access to subsequent parameters. tance before the MIB will send a forward or reverse
signal to the motor controller.
MODEL
This is a multiple choice list of the models for the HYD DBAND 1
applicable unit code. This is the first or narrow hydraulic deadband. If the
handle is in neutral, it must be moved this distance
E OR EE before the MIB will go to lift or lower.
This defaults to E. Use lift or lower to change to EE
if the truck has an EE rating. HYD DBAND 2
This is the second or wide hydraulic deadband. If
24 OR 36 VOLT driving, the handle must be moved this distance be-
The default is determined by measurement, but can fore the MIB will go to lift or lower.
be changed with lift or lower.
Lift/Lower
NO EXTEND
This is only displayed if the extend coil is not de- LIFT MIN
tected. If this is due to a wiring problem, use lift to Increasing this will increase the valve opening when
change it to EXTEND INSTALLED. the handle first moves from neutral to lift.
NO SIDESHIFT LIFT MAX

This is only displayed if the sideshift coil is not de- Increasing this will increase the current to the valve
tected. If this is due to a wiring problem, use lift to at maximum lift. Note that increasing this beyond
change it to SS INSTALLED. the full open current will not cause it to lift faster,
but will cause full lift earlier in the handle travel.
NO TILT
This is only displayed if the tilt coil is not detected. LOWER MIN
If this is due to a wiring problem, use lift to change Increasing this will increase the valve opening when
it to TILT INSTALLED. the handle first moves from neutral to lower.
LOWER MAX
Increasing this will increase the current to the valve
at maximum lower.
20
NEUTRAL MIN SLOW RETRACT

Increasing this will increase the pause when quickly Increasing this will increase the slow retract speed.
going from lift to lower. At this point, reach and retract are functional if the
handle is in neutral and the user is on the brake. The
setting can therefore be tested without exiting setup.
WARNING
Decreasing this too much may cause the valve FAST RETRACT
to hang up and not lower after a fast transition Increasing this will increase the fast retract speed.
from lift to lower. At this point, reach and retract are functional if the
handle is in neutral and the user is on the brake. The
HYD RAMP setting can therefore be tested without exiting setup.
This is the maximum rate of change for lift and lower.
TILT DOWN
Speeds Increasing this will increase the tilt down speed. At
REVERSE MAX this point, tilt is functional if the handle is in neutral
Increasing this will increase the maximum speed in and the user is on the brake. The setting can there-
reverse. fore be tested without exiting setup.
FORWARD MAX TILT UP

Increasing this will increase the maximum forward Increasing this will increase the tilt up speed. At this
speed. point, tilt is functional if the handle is in neutral and
the user is on the brake. The setting can therefore be
MAST UP SPD tested without exiting setup.
Increasing this will increase the maximum speed
when the speed is reduced due to a elevated forks. SS RIGHT
Increasing this will increase the sideshift right
LOAD 100S speed. At this point, sideshift is functional if the
This should be 255 for trucks not equipped with pres- handle is in neutral and the user is on the brake.
sure transducers. For trucks with pressure trans- The setting can therefore be tested without exiting
ducers, it is the load in hundreds of pounds, when the setup.
maximum speed of the truck begins to ramp down.
SS LEFT
LOADED SPEED Increasing this will increase the sideshift left speed.
This should be 255 for trucks not equipped with pres- At this point, sideshift is functional if the handle is
sure transducers. For trucks with pressure trans- in neutral and the user is on the brake. The setting
ducers, it is the speed setting below which the maxi- can therefore be tested without exiting setup.
mum speed will not be reduced due to load.
CUSTOMIZING MIB FUNCTIONS
Auxiliary
Certain function values can be customized, as re-
SLOW REACH quired. The following contains detailed descriptions
Increasing this will increase the slow reach speed. of each function number.
At this point, reach and retract are functional if the
handle is in neutral and the user is on the brake. The Refer to Table 5, Table 6, Table 7, Table 8, Table 9,
setting can therefore be tested without exiting setup. Table 10, Table 11, Table 12, Table 13, and Table 14
for specific minimum and maximum values available
FAST REACH for each function, corresponding to the specific truck
Increasing this will increase the fast reach speed. At model.
this point, reach and retract are functional if the han-
dle is in neutral and the user is on the brake. The set-
ting can therefore be tested without exiting setup.
21
Table 5. MIB Function Code Values for

WARNING
N30XMR3 (Continued)
Program changes will affect lift truck perfor-
mance and operation. If function values are
changed, make sure all operators of the lift Description Default Min./Max.
truck know that the truck may now operate Value
differently. Hydraulic Ramp 70 40/120
Slow Reach (SRCH) 95 80/FRCH
WARNING
Fast Reach (FRCH) 160 SRCH/200
Each function has a range of values (mini-
mum/maximum), specific to each model truck. Slow Retract (SRT) 80 70/FRT
Adjustment of functions to a value outside the
Fast Retract (FRT) 130 SRT/160
specific range for the truck model can cause
the truck to operate differently than normal. Tilt Down 95 0/105
Do not set any function to a value outside the
Tilt Up 120 0/150
minimum/maximum range for the truck. Func-
tion values set incorrectly can cause personal Sideshift Right 95 0/110
injury or damage to the truck.
Sideshift Left 95 0/110
Settings can be returned to the existing values by ex- 24 Volt
iting without saving the new values. To exit without
saving new values, turn the key switch to the OFF Lift-Minimum 40 30/80
position. The settings can be returned to the factory Lift-Maximum 170 80/200
default values by setting Function 01 to the correct
value for the specific lift truck model. Refer to MIB Lower-Minimum 50 25/80
Generation II Setup Procedure. Lower-Maximum 200 80/220
Table 5. MIB Function Code Values Lift Neutral 20 20/40
for N30XMR3 Lower Neutral 20 10/30
Description Default Min./Max. 24 Volt E

Value Reverse-Maximum* 227 0/+247
Drive Dead Band 1 32 16/DDB2 Forward-Maximum* 219 0/+239
(DDB1)
Mast Up Speed* 181 0/+194
Drive Dead Band 2 64 DDB1/130
(DDB2) 24 Volt EE
Hydraulic Dead Band 1 32 16/HDB2 Reverse-Maximum* 219 0/+239

(HDB1) Forward-Maximum* 219 0/+239
Hydraulic Dead Band 2 64 HDB1/130 Mast Up Speed* 181 0/+194
(HDB2)
NOTE: *Not more than 255.
22
Table 6. MIB Function Code Values Table 6. MIB Function Code Values for
for N40XMR3 N40XMR3 (Continued)
Description Default Min./Max.

Value
Value
Drive Dead Band 1 32 16/DDB2
Reverse-Maximum* 235 0/+255
(DDB1)
Forward-Maximum* 206 0/+226
(DDB2) Mast Up Speed* 181 0/+194
Hydraulic Dead Band 1 32 16/HDB2 24 Volt EE
(HDB1)
Hydraulic Dead Band 2 64 HDB1/130
(HDB2)
Hydraulic Ramp 70 40/120
36 Volt
Lift-Minimum 25 10/80
Lift-Maximum 190 80/210
Slow Retract (SRT) 80 70/FRT
Lower-Minimum 30 10/80
Lower-Maximum 170 80/190
Tilt Down 95 0/105
Lift Neutral 15 15/30
Tilt Up 120 0/150
Lower Neutral 20 10/30
Sideshift Right 95 0/110
36 Volt E
24 Volt
36 Volt EE
24 Volt E
23
for N25XMDR3 N25XMDR3 (Continued)

Value
Value
(DDB1)
Hydraulic Dead Band 1 32 16/HDB2 24 Volt EE
(HDB1)
Hydraulic Dead Band 2 64 HDB1/130
(HDB2)
36 Volt
Tilt Down 95 0/105
Tilt Up 120 0/150
36 Volt E
24 Volt
36 Volt EE
24 Volt E
24
for N50XMA3 N50XMA3 (Continued)

Value
Value
(DDB1)
Hydraulic Dead Band 32 16/HDB2 24 Volt EE
1 (HDB1)
Hydraulic Dead Band 64 HDB1/130
2 (HDB2)
36 Volt
Tilt Down 95 0/105
Tilt Up 120 0/150
36 Volt E
24 Volt
36 Volt EE
24 Volt E
25
Table 9. MIB Function Code Values Table 10. MIB Function Code Values
for N45XMR3 for N30XMDR3
Description Default Min./Max. Description Default Min./Max.

Value Value
Drive Dead Band 1 32 16/DDB2 Drive Dead Band 1 32 16/DDB2
(DDB1) (DDB1)
Drive Dead Band 2 64 DDB1/130 Drive Dead Band 2 64 DDB1/130
(DDB2) (DDB2)
Hydraulic Dead Band 32 16/HDB2 Hydraulic Dead Band 32 16/HDB2
1 (HDB1) 1 (HDB1)
Hydraulic Dead Band 64 HDB1/130 Hydraulic Dead Band 64 HDB1/130
2 (HDB2) 2 (HDB2)
Hydraulic Ramp 70 40/120 Hydraulic Ramp 70 40/120
Slow Reach (SRCH) 95 80/FRCH Slow Reach (SRCH) 95 80/FRCH
Fast Reach (FRCH) 160 SRCH/200 Fast Reach (FRCH) 115 SRCH/200
Slow Retract (SRT) 80 70/FRT Slow Retract (SRT) 80 70/FRT
Fast Retract (FRT) 130 SRT/160 Fast Retract (FRT) 100 SRT/160
Tilt Down 95 0/105 Tilt Down 95 0/105
Tilt Up 120 0/150 Tilt Up 120 0/150
Sideshift Right 95 0/110 Sideshift Right 95 0/110
Sideshift Left 95 0/110 Sideshift Left 95 0/110
36 Volt 36 Volt
Lift-Minimum 25 10/80 Lift-Minimum 25 10/80
Lift-Maximum 190 80/210 Lift-Maximum 190 80/210
Lower-Minimum 30 10/80 Lower-Minimum 30 10/80
Lower-Maximum 170 80/190 Lower-Maximum 170 80/190
Lift Neutral 15 15/30 Lift Neutral 15 15/30
Lower Neutral 20 10/30 Lower Neutral 20 10/30
36 Volt E 36 Volt E
Reverse-Maximum* 227 0/+247 Reverse-Maximum* 229 0/+249
Forward-Maximum* 194 0/+214 Forward-Maximum* 232 0/+252
Mast Up Speed* 130 0/+143 Mast Up Speed* 130 0/+143
36 Volt EE 36 Volt EE
Reverse-Maximum* 206 0/+226 Reverse-Maximum* 219 0/+239
Forward-Maximum* 194 0/+214 NOTE: *Not more than 255.
26
Table 10. MIB Function Code Values for Table 11. MIB Function Code Values for
N30XMDR3 (Continued) N45XMXR3 Mast Full Height less than
333 Inches (Continued)
Value Description Default Min./Max.
Value
Table 11. MIB Function Code Values NOTE: *Not more than 255.
for N45XMXR3 Mast Full Height less
than 333 Inches
N45XMXR3 Mast Full Height Greater
Than 333 Inches
Value
Drive Dead Band 1 32 16/DDB2 Description Default Min./Max.
(DDB1) Value
Drive Dead Band 2 64 DDB1/130 Drive Dead Band 1 32 16/DDB2
(DDB2) (DDB1)
Hydraulic Dead Band 32 16/HDB2 Drive Dead Band 2 64 DDB1/130
1 (HDB1) (DDB2)
Hydraulic Dead Band 64 HDB1/130 Hydraulic Dead Band 32 16/HDB2
2 (HDB2) 1 (HDB1)
Hydraulic Ramp 70 40/120 Hydraulic Dead Band 64 HDB1/130
2 (HDB2)
Tilt Down 95 0/105
Tilt Up 120 0/150
Tilt Down 95 0/105
Tilt Up 120 0/150
36 Volt
36 Volt
36 Volt E
27
N45XMXR3 Mast Full Height Greater Than N30XMXDR Mast Full Height less than
333 Inches (Continued) 333 Inches (Continued)

Value Value
Lower Neutral 20 10/30 Lower-Maximum 170 80/190
36 Volt E Lift Neutral 15 15/30
Reverse-Maximum* 232 0/+252 Lower Neutral 20 10/30
Forward-Maximum* 232 0/+252 36 Volt E
Mast Up Speed* 130 0/+143 Reverse-Maximum* 255 0/+255
NOTE: *Not more than 255. Forward-Maximum* 255 0/+255
Table 13. MIB Function Code Values
for N30XMXDR Mast Full Height less NOTE: *Not more than 255.
than 333 Inches
Description Default Min./Max. N30XMXDR Mast Full Height greater
Value than 333 Inches
(DDB1)
Value
(DDB2)
(DDB1)
Hydraulic Dead Band 32 16/HDB2
1 (HDB1)
(DDB2)
Hydraulic Dead Band 32 16/HDB2
2 (HDB2)
1 (HDB1)
Slow Reach (SRCH) 95 80/FRCH 2 (HDB2)
Fast Reach (FRCH) 115 SRCH/200 Hydraulic Ramp 70 40/120
Slow Retract (SRT) 80 70/FRT Slow Reach (SRCH) 95 80/FRCH
Fast Retract (FRT) 100 SRT/160 Fast Reach (FRCH) 115 SRCH/200
Tilt Down 95 0/105 Slow Retract (SRT) 80 70/FRT
Tilt Up 120 0/150 Fast Retract (FRT) 100 SRT/160
Sideshift Right 95 0/110 Tilt Down 95 0/105
Sideshift Left 95 0/110 Tilt Up 120 0/150
36 Volt Sideshift Right 95 0/110
Lift-Minimum 25 10/80 Sideshift Left 95 0/110
Lift-Maximum 190 80/210 36 Volt
Lower-Minimum 30 10/80 Lift-Minimum 25 10/80
NOTE: *Not more than 255. NOTE: *Not more than 255.
28
2200 SRM 978 MIB Status, Warning, and Fault Codes
N30XMXDR Mast Full Height greater than N30XMXDR Mast Full Height greater than
333 Inches (Continued) 333 Inches (Continued)

Value Value
Lift-Maximum 190 80/210 36 Volt E
Lower-Minimum 30 10/80 Reverse-Maximum* 232 0/+252
Lower-Maximum 170 80/190 Forward-Maximum* 232 0/+252
Lift Neutral 15 15/30 Mast Up Speed* 130 0/+143
Lower Neutral 20 10/30 NOTE: *Not more than 255.
MIB Status, Warning, and Fault Codes

GENERAL Codes are displayed as follows:
During normal operation, the left two digits show • STATUS codes → numbers 01 to 16.
the STATUS code of the truck and the right two dig-
its show 00. Whenever a truck function is selected, • WARNING codes → numbers 34 to 38.
the left two digits are updated to display the selected
function. • FAULT codes → numbers 40 to 85.
The two digits on the right side of the display are NOTE: Not all codes are used on all models.
used to display either a WARNING code or a FAULT
code. If neither a WARNING code nor a FAULT code For example, if an operator tries to use the sideshift
is present, the right two digits continue to display and there is an open sideshift solenoid on the mast,
00. If multiple faults are present, the highest priority the red fault icon on the dash will light and CHECK
FAULT code is displayed. After the highest priority FAULT CODE, NO SIDESHIFT will be displayed.
fault is repaired, the next highest priority FAULT
code will be displayed. To repair the problem, remove the cover for access to
the MIB and perform the function (sideshift) which
If a WARNING code and a FAULT code are received caused the fault to occur. Fault code 43 would be
at the same time, the left two digits will display the displayed on the right two digits of the MIB when the
WARNING code, the right two digits will display the sideshift function was attempted. The service person
FAULT code, and the STATUS code will not be dis- would refer to MIB Code 43 on the following pages to
played. Always troubleshoot the code shown on the diagnose and repair the cause of the problem.
right side of the display first.
NOTE: The fault code, fault message, and fault icon
for most faults are displayed only when the operator
attempts to perform the affected function.
29
MIB Status, Warning, and Fault Codes 2200 SRM 978
TROUBLESHOOTING CHARTS sealed plugs. Probing through the back of the

J1 or J2 MIB plugs will destroy the seal and can
The sample chart that follows explains the format cause a short circuit. If a circuit must be tested
for the information provided on the following pages. for voltage, check for voltage at an amp type
Note that an X in the MIB CODE section represents plug, a switch, or a component. If the circuit to
a placeholder character and can be any number. The the MIB is suspect, check the circuit by remov-
priority level is provided to show the relative order ing the MIB and disconnecting the J1 and J2
codes that would be displayed in the event of more plugs. Refer to MIB, Remove. Test continuity
than one simultaneous status, warning, or fault con- from the front (pin end) of the plugs.
dition.
See Figure 16 for plug pin identification.
CAUTION
Never attempt to probe through the back of the
J1 or J2 MIB plugs. These plugs are specially
A. J1 FRONT VIEW B. J2 FRONT VIEW
Figure 16. MIB Plug - Pin Identification
MIB Code Dash Display Message Priority Level Code Type Signal Source
Code displayed Priority assigned Origin of message
on MIB. X in the software Status, Warning, sent to dash
Message displayed on dash display
represents any (relative to other or Fault display (MIB
number codes) or Traction)
CONDITION CORRESPONDING SCHEMATIC OR DIAGRAM
TRUCK RESPONSE
LOGIC
POSSIBLE CAUSES AND TEST PROCEDURES
30
2200 SRM 978 Blank or Undefined Code Conditions
Blank or Undefined Code Conditions

Blank Display Blank Display - - -
Condition
No display on MIB or dash display.
Truck Response
Travel and hydraulic functions are disabled.
Possible Causes and Test Procedures

• B+ and/or B− missing at the MIB and dash display.
Check to ensure battery disconnect switch is
closed by measuring for battery voltage on both
sides of the switch. (POS connection and bus bar
connection to power fuses)
Check fuses 4 and 5 for open condition. If open,
replace them. J2-2 and J2-10 (wire #15) at the Logic
MIB should measure near battery voltage. J2-1 Displayed if any of the following conditions are not
and J2-9 (wire #13) should be B−. X4-1 (wire #24) satisfied: J2-2 and J2-10 (wire #15) at the MIB
and (wire #15) at the dash display should measure should measure near battery voltage, and J2-1
near battery voltage, and X4-8 and X4-10 should and J2-9 (wire #13) should be B−. X4-2 (wire #15)
be B−. at the dash display should measure near battery
• Defective MIB and/or dash display. voltage, and X4-8 and X4-10 should be B−.
Replace MIB and/or dash display.
XXXX Blank Display - - -

Condition
Dash display blank.
Truck Response
LIFT function is disabled; traction and auxiliary
functions are normal.

• B+ and/or B− missing at the dash display.
X4-2 and X4-1 at the dash display should measure
near battery voltage, and X4-8 and X4-10 should
be B−.
• Defective dash display. Logic
Verify B+ and B− as detailed above. If these mea- Displayed if any of the following conditions are not
surements are correct replace the dash display. satisfied: X4-2 (wire #15) at the dash display should
measure near battery voltage. X4-8 (wire #13-1)
and X4-10 (wire #13-5) should be B−.
31
Blank or Undefined Code Conditions 2200 SRM 978
LOST MIB SIGNAL NO
Blank Display - 1 -
LIFT OR DRIVE
Condition
MIB display is blank.
Truck Response

• B+ or B− missing at the MIB.
J2-2 and J2-10 (wire #15) should measure near
battery voltage. J2-1 and J2-9 should be B−.
• Defective MIB.
Verify B+ and B− as detailed above. If these mea-
surements are correct, replace the MIB.
NOTE: This fault occurs when there is a loss of com- Logic

munication between the MIB and display. This may Displayed if any of the following conditions are not
be due to a loose wire or from total failure of the elec- satisfied: J2-2 and J2-10 (wire #15) should measure
tronics board. If the board fails, the MIB will disable near battery voltage. J2-1 and J2-9 should be B−.
traction and hydraulics. If a wire is loose, only the dis-
play will be disabled.
XXXX LOST MIB SIGNAL NO

1 - -
LIFT OR DRIVE
Condition
Communication between MIB and dash display
is not functioning properly.
Truck Response
LIFT function is disabled. Travel and AUXILIARY
HYDRAULIC functions may or may not be disabled.

• Open in wire 81, 82, or 83.
Disconnect plug J2 at the MIB and plug X-6 at the Logic
dash display. Displayed when any of the following conditions
Check continuity from J2-18 (wire #81) to X6-8 are not satisfied: Continuity should exist from
(wire #81). J2-18 (wire #81) to X6-8 (wire #81), from J2-3
Check continuity from J2-3 (wire #82) to X6-9 (wire #82) to X6-9 (wire #82), and from J2-11
(wire #82). (wire #83) to X6-10 (wire #83).
Check continuity from J2-11 (wire #83) to X6-10
(wire #83).
Locate and repair any open circuits.
32
2200 SRM 978 Blank or Undefined Code Conditions
DRIVE CTRL LIMIT SPEED TRACTION
XXXX REDUCED
26 WARNING
CONTROLLER
NOTE
Warning and Fault messages originating from the
traction controller are NOT shown as codes on the
MIB, but will be displayed on the dash display.
Condition
Traction controller too hot or too cold.
Battery voltage too high or too low.
Truck Response
Yellow WARNING indicator illuminates.
Traction controller output reduced.
Logic
Symptom Displayed when the internal temperature of the
Reduced or no travel speeds. traction motor controller is beyond the operating
range of −25 to +85 C (−13 to 185 F) or if the
Possible Causes and Test Procedures battery voltage is too high or too low. Battery
• See TRACTION MOTOR CONTROLLER, TEST/DI- voltage (across the capacitor) and the internal
AGNOSTICS, thermal cutback fault. heatsink temperature can be displayed by accessing
the test menu on the handset.
DRIVE CTRL ERROR TRACTION
XXXX CHECK ERROR CODE
20 WARNING
CONTROLLER
NOTE
Condition
Traction controller error.
Truck Response
Yellow WARNING indicator illuminates. Traction
is disabled until error condition is corrected.
Possible Causes and Test Procedures Logic

• Traction controller error. Determine and correct Displayed when the traction motor controller
cause. determines that the throttle input is out of
See TRACTION MOTOR CONTROLLER, range, or a High Pedal Disable or Static Return
TEST/DIAGNOSTICS, THROTTLE FAULTS, to Off error is present.
SRO, HPD.
33
Blank or Undefined Code Conditions 2200 SRM 978
XXXX TRACTION
DRIVE FAULT CODE 19 FAULT
CONTROLLER
NOTE
Condition
Traction controller fault.
Truck Response
Red FAULT indicator illuminates.
Traction is disabled until fault condition is corrected.
Possible Causes and Test Procedures Logic

• Traction controller fault. Determine and correct Displayed when the traction motor controller
cause. determines that an internal fault has occurred.
See TRACTION MOTOR CONTROLLER, TEST/ NOTE: Throttle input faults and traction motor con-
DIAGNOSTICS, DRIVE CONTROL FAULT. troller high-temperature warnings are displayed by
separate dash display messages.
See MIB CODE
MIB SETUP MODE 21 WARNING MIB
Below
MIB Code
The two digits on the left will display the current
function number and the two digits on the right
will display the current function value.
Condition
MIB was placed in SET UP MODE by simultaneously
pressing the A and C buttons located on top of the
MIB. Refer to MIB CALIBRATION PROCEDURE.
Truck Response

Logic
• MIB is in the SET UP MODE.
Displayed when MIB is in SET UP MODE.
Turn the key switch to the OFF position. Restart
the truck using the normal procedure
or
exit the MIB SET UP MODE.
Refer to MIB CALIBRATION procedure.
34
2200 SRM 978 Status Codes
Status Codes
02XX POWER ON 30 STATUS MIB

Condition
Operator is not on the truck, key is on.
Truck Response
Main contactor, MIB, and dash display are energized.
Traction and hydraulic functions are not available
until the operator steps onto the truck.
Logic
Displayed when MIB terminals J2-2, J2-10, and
dash display terminals X4-1, X4-2 are near battery
voltage. MIB terminals J2-1, J2-9, and dash
display terminals X4-8, X4-10 are B−.
03XX READY 29 STATUS MIB

Condition
Key is on and traction contactor is energized.
Operator enters the truck and presses both the
operator sensing pedal and the brake pedal.
Truck Response
PS (power steering) pump starts. Traction and
hydraulic functions are enabled.
CAUTION
If this status code occurs without both pedals be-
ing pressed, either the brake switch, the opera-
tor sensing switch, or both are shorted. Check
both switches for proper operation.
Logic
Displayed when MIB terminals J1-19 and J1-18
are near battery voltage.
35
Status Codes 2200 SRM 978
04XX FORWARD MODE 28 STATUS MIB

Condition
Multifunction control handle positioned for
FORWARD travel.
Truck Response
Truck travels in the forward direction.
Logic
Displayed when MIB terminal J2-17 is 12 volts
and MIB terminal J2-7 increases from 2.5 volts at
neutral to 4.5 volts at full throttle. J1-19 is 0 volts
at neutral and 5 volts out of neutral.
05XX REVERSE MODE 28 STATUS MIB

Condition
Multifunction control handle positioned for
REVERSE travel.
Truck Response
Truck travels in the reverse direction.
Logic
Displayed when MIB terminal J2-17 is 12 volts
and MIB terminal J2-7 decreases from 4.5 volts at
full throttle to 2.5 volts at neutral. J1-19 is 0 volts
at neutral and 5 volts out of neutral.
36
Figure 17. Multifunction Control Handle Plug - Pin and Wire Identification
Refer to Figure 17 for the following MIB Codes.
06XX LIFT 27 STATUS MIB

Condition Logic
Multifunction control handle positioned for LIFTING. Displayed when MIB terminal J2-17 is 12 volts and
MIB terminal J2-14 increases from the neutral value.
Truck Response
Yellow LIFT/LOWER indicator illuminates.
Lift pump starts and forks lift.
37
Status Codes 2200 SRM 978
07XX LOWER 27 STATUS MIB

Condition Logic
Multifunction control handle positioned Displayed when MIB terminal J2-17 is 12 volts and
for LOWERING. MIB terminal J2-14 decreases from the neutral value.
Truck Response
Yellow LIFT/LOWER indicator illuminates.
Forks lower.
09XX EXTEND 27 STATUS MIB

Condition Logic
EXTEND button is pressed. Displayed when MIB terminal J1-10 is near
battery voltage.
Truck Response
Forks extend.
10XX RETRACT 27 STATUS MIB

Condition Logic
RETRACT button is pressed. Displayed when MIB terminal J1-21 is near
battery voltage.
Truck Response
Forks retract.
12XX TILT UP 27 STATUS MIB

Condition Logic
Displayed when MIB terminal J1-17 is near
battery voltage.
Truck Response
38
13XX TILT DOWN 27 STATUS MIB

Condition Logic
TILT DOWN button is pressed. Displayed when MIB terminal J1-9 is near
battery voltage.
Truck Response
Forks tilt down.
15XX SIDESHIFT RIGHT 27 STATUS MIB

Condition Logic
SIDESHIFT RIGHT button is pressed. Displayed when MIB terminals J1-20 is
near battery voltage.
Truck Response
Forks sideshift to the right.
16XX SIDESHIFT LEFT 27 STATUS MIB

Condition Logic
SIDESHIFT LEFT button is pressed. Displayed when MIB terminal J1-1 is near
battery voltage.
Truck Response
Forks sideshift to the left.
39
Warning Codes 2200 SRM 978
Warning Codes
NOTE: When WARNING codes and FAULT codes oc- FAULT code (e.g., XX34 becomes 3458, when 34 is
cur simultaneously, the left two digits display the the WARNING code and 58 is the concurrent FAULT
WARNING code and the right two digits display the code).
34 MAST UP SPEED REDUCED 27 WARNING MIB

Condition
Mast elevated while traveling FORWARD
or REVERSE.
Truck Response
Maximum travel speed is reduced.

• Mast elevated.
IF THE MAST IS NOT ELEVATED:
• Height limit switch damaged or out of adjustment.
Adjust height limit switch. Verify proper opera-
tion of switch.
• Height limit switch shorted.
Unplug connector #11 from the switch. Check
resistance between switch terminals 7 and 8. Logic
Replace any switch that does not read continuity Displayed when voltage at MIB terminal J1-4 is
with mast primary elevated and no continuity near battery voltage and voltage at MIB terminal
with mast primary lowered. J1-13 or J1-14 is near battery voltage.
• Shorted height limit switch circuit.
Disconnect the battery. Disconnect the J1 plug
from MIB. Check resistance between wires #56
and #74. There should not be continuity. If conti-
nuity (low ohms) is measured, wires #56 and #74
are shorted together somewhere in the harness.
Locate and repair the short.
40
2200 SRM 978 Warning Codes
RESET TO NEUTRAL
35 BEFORE OPERATING
25 WARNING MIB
Condition Refer to Figure 17

Traction or hydraulic control (multifunction control
Logic
handle) is not in NEUTRAL position or the auxiliary
Displayed when voltage at wire 49 (J1-19) is greater
functions are selected when the operator steps on the
than 0 volts and the handle is in NEUTRAL.
brake pedal and the operator sensing switch.
Displayed when voltage at wire 40 (J1-10), 42 (J1-17),
44 (J1-21), 46 (J1-20), 47 (J1-1), and 48 (J1-9) is
Truck Response
greater than 0 volts and the handle is in NEUTRAL.
Horn sounds.

• Multifunction control handle not in NEUTRAL.
• Auxiliary function selected before stepping on brake
pedal and operator sensing switch.
IF MULTIFUNCTION CONTROL HANDLE
IS IN NEUTRAL:
• Check for 12 volts at wire 115 (J2-17).
• Check wires 22 (J2-7) and 32 (J2-14) for 2.5 volts
and wire 49 (J1-19) for 0 volts. If incorrect, replace
multifunction control handle.
• Check wires 40 (J1-10), 42 (J1-17), 44 (J1-21), 46
(J1-20), 47 (J1-1), and 48 (J1-9) for 0 volts. If 12
volts, then switches are stuck or defective (replace
multifunction control handle).
• Check wire 13-8 (brown) from B- to multifunction
control handle for continuity.
41
Warning Codes 2200 SRM 978
STEP ON PLATFORM
36 BEFORE OPERATING
24 WARNING MIB
Condition Refer to Figure 17

Operator sensing switch not closed. Operator tries to
Logic
travel or perform hydraulic functions and the operator
Displayed when greater than 12 volts is present
is on the brake pedal. (This only applies when the
at J1-19, J2-7, J2-14, or at pins J1-9, J1-17,
operator initially steps onto the lift truck. After the
J1-20, J1-1, J1-10, J1-21, and J2-17, and near
operator sensing pedal and the brake pedal have both
0 volts present at J1-18.
been actuated, the operator sensing pedal can be
released, as long as the brake pedal is not released.)
Truck Response
Horn sounds.

• Operator sensing switch is not closed or the multi-
function control handle is not in the neutral position.
Stand in the operator compartment and step on the
operator sensing pad. Reset multifunction control
handle to neutral position.
• Open in operator sensing switch circuit.
Disconnect the battery and MIB J1 plugs. Check
continuity between MIB plug terminal J1-18 and
wire #11 at switch connector X-13.
• Operator sensing switch defective.
Replace operator sensing switch.
• Auxiliary functions selector button stuck in the
closed position.
Troubleshoot as a code 35.
42
2200 SRM 978 Warning Codes
37 BRAKE PEDAL UP 23 WARNING MIB

Condition Refer to the Wiring Schematics
Brake switch not closed and operator moves
Logic
the multifunction control handle to travel or
Displayed when greater than 14 volts is present
perform a hydraulic function.
at J1-2, with battery voltage present at J1-1
and near 0 volts present at J1-9.
Truck Response
Displayed when the voltage at J2-16 or J2-21 is
above or below approximately 2.5 volts (neutral
voltage), with battery voltage present at J1-1
and near 0 volts present at J1-9.
• Brake switch not closed.
Stand on the platform and press the brake pedal
to close the brake switch. Reset the multifunction
control handle to neutral.
• Brake switch out of adjustment or defective.
Adjust or replace the brake switch.
• Open in the brake switch circuit.
Disconnect the battery and MIB J plugs. Check
continuity between MIB plug terminal J1-9 and
wire #56 at the brake switch. Check continuity be-
tween wire #15 at fuse FU6 and the brake switch.
Repair any open circuits in the brake switch cir-
cuit.
43
Fault Codes 2200 SRM 978
MUST BE ON TRUCK
38 BEFORE OPERATING
22 WARNING MIB

Brake switch and operator sensing switch
Logic
are not closed and operator tries to travel or
Displayed when greater than 14 volts is present at
perform hydraulic function.
J1-2, with near 0 volts present at J1-1 and J1-9.
Displayed when the voltage at J2-16 or J2-21 is above
Truck Response
or below approximately 2.5 volts (neutral voltage),
with near 0 volts present at J1-1 and J1-9.

• Operator sensing switch and brake switch are not
closed.
Stand in the operator compartment to close oper-
ator sensing switch and brake switch. Reset trac-
tion and/or hydraulic controls to neutral position.
• Operator sensing switch and brake switch out of ad-
justment or defective.
Adjust or replace operator sensing switch and
brake switch.
• Open in operator sensing switch and brake switch
circuit.
Disconnect the battery and MIB J plugs.
Check continuity between MIB plug terminal J1-1
and wire #11 at switch connector X-13. Check con-
tinuity between wire #15 at switch connector X-13
and wire 15 at fuse FU6. Repair any opens in the
operator sensing switch circuit. Check continuity
between MIB plug terminal J1-9 and wire #56 at
the brake switch. Check continuity between wire
#15 at fuse FU6 and the brake switch. Repair any
open circuits in the brake switch circuit.
Fault Codes
XX41 EXTEND COIL OPEN 18 FAULT MIB

Low current with coil on.
Logic
Truck Response
Power on testing is delayed until the brake is cycled.

• Coil is open or wire is disconnected.
44
2200 SRM 978 Fault Codes
XX43 SS COIL OPEN 17 FAULT MIB

Logic
Truck Response

XX44 AUX OUT SHORT 16 FAULT MIB

Auxiliary out coil current too high.
Logic
Truck Response Auxiliary out coil current is greater than 1.5 amperes.
Auxiliary functions disabled until brake is cycled.

• Aux in or aux out coil is shorted; faulty wiring.
XX45 AUX OUT OPEN 16 FAULT MIB

Logic
Truck Response

XX46 AUX COIL SHORT 15 FAULT MIB

Auxiliary metering coil current too high.
Logic
Truck Response Auxiliary metering coil current is greater
Auxiliary functions are disabled until brake is cycled. than 1.5 amperes.

• Auxiliary metering coil is shorted; faulty wiring.
45
XX47 AUX IN/OUT SHORT 15 FAULT MIB

Auxiliary in/out coil current too high.
Logic
Truck Response Auxiliary in or auxiliary out coil current is
Auxiliary functions disabled until brake is cycled. greater than 1.5 amperes.

• Auxiliary in or auxiliary out coil is shorted, faulty
wiring.
XX47 AUX IN COIL OPEN 15 FAULT MIB

Logic
Truck Response

XX48 LIFT - LOWER SHORT 14 FAULT MIB

Lift - lower coil current too high.
Logic
Truck Response Lift - lower coil current is greater than 1.5 amperes.
Lift - lower are disabled until brake is cycled.

• Lift - lower coil is shorted, faulty wiring.
XX48 LIFT CONT SHORT 14 FAULT MIB

Too much voltage across FET when on.
Logic
Truck Response Voltage across FET is greater than 5 volts with FET on.

• Shorted coil or wire.
46
XX49 LFT-LO COIL OPEN 14 FAULT MIB

Logic
Truck Response

XX51 LOWER COIL OPEN 13 FAULT MIB

Logic
Truck Response

XX53 OPEN PUMP CONT 13 FAULT MIB

Not enough voltage across FET when off.
Logic
Truck Response Voltage across FET is less than 5 volts with FET off.

XX54 TILT COIL OPEN 12 FAULT MIB

Logic
Truck Response

47
HYDRAULIC HANDLE
XX57 ERROR
12 FAULT MIB

Hydraulic signal from handle is outside of neutral
band, but the neutral signal is high. Logic
Hydraulic signal from handle is outside of neutral
Truck Response band, but the neutral signal is high.

• Neutral band is much too small; handle fault; faulty
wiring.
HYDRAULIC HANDLE
XX58 ERROR
12 FAULT MIB

Hydraulic signal from handle is too low.
Logic
Truck Response Hydraulic signal from handle is less than 0.2 volt.

• Handle fault; faulty wiring.
HYDRAULIC HANDLE
XX59 ERROR
12 FAULT MIB

Hydraulic signal from handle is too high.
Logic
Truck Response Hydraulic signal from handle is greater than 4.8 volts.

48
XX60 PS CONT SHORTED 12 FAULT MIB

Too much voltage across FET when on.
Logic
Truck Response Voltage across FET is greater than 5 volts with FET on.
Traction and auxiliary functions are disabled
until brake is cycled.

XX61 PS CONT OPEN 12 FAULT MIB

Not enough voltage across FET when off.
Logic
Truck Response Voltage across FET is less than 5 volts with FET off.
Traction and auxiliary functions are disabled
until brake is cycled.

XX62 THR HANDLE ERROR 12 FAULT MIB

Throttle signal from handle is outside of neutral
band, but the neutral signal is high. Logic
Throttle signal from handle is outside of neutral
Truck Response band, but the neutral signal is high.
Traction is disabled until brake is cycled.

• Neutral band is much too small; handle fault; faulty
wiring.
49

Throttle signal from handle is too low.
Logic
Truck Response Throttle signal from handle is less than 0.2 volts.


Throttle signal from handle is too high.
Logic
Truck Response Throttle signal from handle is greater than 4.8 volts.

HANDLE ERROR 12 FAULT MIB
There is both a throttle fault and a hydraulic fault.
Logic
Truck Response
Traction, lift, and lower is disabled until
brake is cycled.

• Handle fault; problem with 115, 13, or 49 wire.
XX67 AUX COIL OPEN 14 FAULT MIB

Logic
Truck Response

50
XX71 ER DOESN’T WORK 14 FAULT MIB

No voltage to lift contactor or power steering contactor.
Logic
Truck Response Voltage on 10 wire is less than 5 volts with ER on.
All functions disabled until condition is corrected.

• Defective relay or disconnected wire.
XXC2 LOWER SHORTED 14 FAULT MIB

Lower holding coil current too high.
Logic
Truck Response Lower holding coil current is greater than 1.5 amperes.

XXC6 EXTEND SHORTED 14 FAULT MIB

Extend coil current too high.
Logic
Truck Response Extend coil current is greater than 1.5 amperes.

XXC7 SS COIL SHORTED 14 FAULT MIB

Sideshift coil current too high.
Logic
Truck Response Sideshift coil current is greater than 1.5 amperes.

51
SEM Traction Motor Controller 2200 SRM 978
XXC8 TILT COIL SHORTED 14 FAULT MIB

Tilt coil current too high.
Logic
Truck Response Tilt coil current is greater than 1.5 amperes.

HORN SHORTED 14 FAULT MIB
Horn current too high.
Logic
Truck Response Horn current is greater than 1.5 amperes.

ER SHORTED 14 FAULT MIB
Enable relay current too high.
Logic
Truck Response Enable relay current is greater than 1.5 amperes.

SEM Traction Motor Controller

DESCRIPTION/FEATURES current limit, and neutral braking current limit.
The operator can also select from three different
The Curtis Model 1244-4405 SEM traction motor performance modes to customize the operation of
controller uses a sophisticated microprocessor to the truck to the application, as required. The SEM
control the logic and operation of the controller, elim- controller includes a full range of built-in safety
inating the need for forward and reverse contactors. features, and diagnostic and setup capability for
See Figure 18. The SEM motor controller operates safe, reliable operation.
on the principle of controlling the motor field circuit
and the motor armature circuit independently. The
controller has many programmable features, in-
cluding acceleration rate, maximum speed, braking
52
2200 SRM 978 SEM Traction Motor Controller
WARNING
been disconnected. Discharge the capaci-
tors in the controller by connecting a load
(such as a contactor coil or a horn) across
the controller’s B+ and B− terminals (center
2 terminals). DO NOT use a screwdriver to
discharge the traction motor controller.
Figure 18. Traction Motor Controller
The Curtis Model 1307 Programmer Handset is used across terminals B+ and B−. See Figure 19.
to program and troubleshoot the traction motor con-
troller. Refer to Programmer Handset.
The traction motor controller communicates with the

dash display for selection of performance modes and
for diagnostic information. The performance-mode
selection feature allows the operator to choose from
three different motor controller performance levels
by pushing a button on the dash display. The rate of
acceleration, maximum top speed, and braking rate
can be specifically assigned for each mode using the
programmer handset.
Simplified diagnostic information is communicated

to the dash display to alert the operator to adverse
conditions such as controller over temperature, oper-
ator sequence error, or motor controller malfunction.
REMOVE
1. Move the lift truck to a safe, level area. Turn the
key switch to the OFF position and remove the
key. Put a DO NOT OPERATE tag on the mul-
tifunction control handle. Put blocks under the
drive wheels to keep the lift truck from moving. 1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
See HOW TO PUT A LIFT TRUCK ON BLOCKS. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
WARNING
nector before opening the compartment cover 5. Unplug the connector from the traction motor
or inspecting/repairing the electrical system. controller. Tag and disconnect the wires to the
If a tool causes a short circuit, the high-cur- terminals.
or parts damage. 6. Remove the four capscrews, lockwashers, and
L brackets retaining the controller within the
2. Disconnect and separate the battery connector. mounting brackets. Carefully remove the trac-
tion motor controller from the lift truck.
3. Remove the socket head capscrews retaining the
operator’s compartment cover. Remove the cover.
53
SEM Traction Motor Controller 2200 SRM 978
TEST motor controller. Align the traction motor con-

troller in the lift truck between the upper and
See Programmer Handset for complete testing and lower mounting brackets. Verify that the cap-
troubleshooting procedures for the Traction Motor tive nuts are in place on the mounting brackets.
Controller. Install the L brackets, capscrews, and lockwash-
ers to retain the controller between the mounting
The traction motor controller cannot be repaired.
brackets.
The traction motor controller is sealed and contains
no serviceable parts. If testing has determined the 2. Connect the wires to the terminals. See Dia-
traction motor controller to be faulty, it must be grams 8000 SRM 980 or 8000 SRM 982. Plug the
replaced. X-3 connector into the J1 receptacle of the trac-
tion motor controller. See Figure 20.
INSTALL
3. See Programming the Traction Motor Controller
1. Make certain that the mounting surface for the to set up the controller.
traction motor controller is clean. There should
be no dirt between the frame and the traction
Figure 20. Traction Motor Controller Pin Arrangement
54
2200 SRM 978 Programmer Handset
Legend for Figure 20
X-3 Pin 1: Key Switch Input X-3 Pin 13: Not Used
X-3 Pin 2: Brake Switch X-3 Pin 14: Not Used
X-3 Pin 3: Drive Mode Select #2 Input X-3 Pin 15: 0-5 Volt Throttle Signal Input
X-3 Pin 4: Drive Mode Select #1 Input X-3 Pin 16: Not Used
X-3 Pin 5: Fault 2 Output X-3 Pin 17: Traction Coil Driver
X-3 Pin 6: Fault 1 Output X-3 Pin 18: Not Used
X-3 Pin 7: Not Used X-3 Pin 19: Not Used
X-3 Pin 9: Key Switch Input (Coil Return) X-3 Pin 21: Not Used
X-3 Pin 10: Forward Switch Input X-3 Pin 22: Not Used
X-3 Pin 11: Reverse Switch Input X-3 Pin 23: Not Used
1. CONNECT TO J1 2. PROGRAMMER HANDSET CONNECTION
Programmer Handset
DESCRIPTION/FEATURES the selected item will be highlighted with a flashing
arrow).
The Programmer Handset is a hand-held tool that al-
lows the user to PROGRAM, TEST, and DIAGNOSE SCROLL DISPLAY KEYS
the Traction Motor Controller. See Figure 21. It has
been designed for ease of use with eight keys to con- To scroll up and down within a menu, use the two
trol all functions. A MORE INFO key is included to SCROLL DISPLAY arrow keys. The SCROLL DIS-
provide more detail on any display item. PLAY arrow keys can be pressed repeatedly or held
down. When a key is held down, the scrolling speed
The programmer is powered by the controller. When increases the longer the key is held.
the programmer is plugged into the controller, it will
acquire all the controller function values and display To the left of the PROGRAM, TEST, and DIAGNOS-
the model number, date of manufacture, and revision TICS menu, a small scroll bar is displayed. The scroll
code. After the initial display, the programmer will bar gives a rough indication of the position of the
prompt the user with further instructions. four displayed items within the entire menu. That is,
when the scroll bar is at the top of the window, the top
The display window contains a four-line LCD dis- of the menu is displayed. When scrolling through the
play. This display is visible in most lighting condi- menu, the bar will move downward. When the bar is
tions. When the programmer is in the PROGRAM, at the bottom, the end of the menu has been reached.
TEST, or DIAGNOSTICS mode, four lines of a menu
are displayed. The item at the top of the display win-
dow is the selected item (in the PROGRAM menu,
55
Programmer Handset 2200 SRM 978
in any of the operating modes, the MORE INFO key

may be pressed to display additional information
about the selected item. Press the MORE INFO
key again to return to the original list. In the
PROGRAM menu, a bar graph is displayed along
with the minimum and maximum values available
for the selected item. If the minimum or maximum
value has been programmed, a message replaces the
bar graph and any dependencies are listed.
OPERATION
Connecting Handset to Traction Motor
Controller
NOTE: Each time the programmer handset is
connected to the controller, it acquires all of the
controller function value settings and stores them
in its temporary memory. This allows the user to
revert back to the original settings at any time. The
SPECIAL PROGRAM menu selection RESET ALL
SETTINGS is used to revert to the original settings.
1. FOUR-LINE LCD DISPLAY WINDOW Any inadvertent change made to any of the function
2. SELECTS PROGRAM MENU
3. SCROLLS DISPLAY UP AND DOWN values can be "undone" in this manner, as long as
4. SELECTS MORE INFO, SPECIAL PROGRAM, the programmer has not been unplugged or the key
AND DIAGNOSTICS MENUS switch turned OFF (power disconnected).
5. SELECTS TEST MENU
6. SELECTS DIAGNOSTICS MENU 1. Turn the key switch to the OFF position.
7. CHANGES VALUE OF SELECTED ITEM
2. Disconnect and separate the battery connector.
Figure 21. Curtis Model 1307 Programmer
Handset 3. Remove the two screws retaining the metal cover
located on the right side of the operator compart-
CHANGE VALUE KEYS ment. Remove the cover.
The CHANGE VALUE arrow keys increase or de-

crease the value of the selected menu item. There WARNING
is an LED on each arrow key to indicate when the The capacitor in the traction motor controller
key is active and a change is permissible. When the can hold an electrical charge after the battery
LED is off, the limit setting (maximum or minimum) is disconnected. To prevent electrical shock
of the function has been reached. and injury, discharge the capacitor before
The CHANGE VALUE keys may be pressed repeat- safety glasses. Make certain the battery has
edly or held in the same manner as the SCROLL DIS- been disconnected. Discharge the capacitors in
PLAY keys. The longer the key is held, the faster the controller by connecting a load (such as a
the value changes. This allows rapid changing of any contactor coil or a horn) across the controller’s
function value. B+ and B− terminals (center 2 terminals). DO
NOT use a screwdriver to discharge the trac-
MORE INFO KEY tion motor controller.
The MORE INFO key is used to display additional 4. Discharge the capacitors in the traction motor
information about the selected item and to access the controller by connecting a load (such as a contac-
SPECIAL PROGRAM MENU and the DIAGNOS- tor coil or a horn) across the controller’s B+ and
TICS HISTORY MENU. When the programmer is B− terminals.
56
NOTE: The Programmer Handset should only be con- 4. Disconnect the Programmer Handset from the
nected and disconnected with the key switch in the four-pin Molex connector on the traction motor
OFF position. controller.
5. Connect the Programmer Handset to the four-pin NOTE: The Programmer Handset should only be con-
Molex connector on the traction motor controller. nected and disconnected with the key switch in the
See Figure 20. OFF position.
6. Reconnect the battery. 5. Install the cover in the operator’s compartment.

Install the two screws.
NOTE: The brake pedal must be released (up posi-
tion). 6. Reconnect the battery.
7. Turn the key switch to the ON position. Ensure Programmer Self Test
the battery disconnect switch is closed.
You can test the programmer by displaying two spe-
Disconnecting Handset from Traction cial test screens. See Figure 22. Press and hold the
Motor Controller MORE INFO key while the programmer is powering
up. During the SELF TEST, you can toggle between
1. Turn the key switch to the OFF position. the two test screens by pressing the SCROLL DIS-
PLAY keys. The first screen turns on every LCD ele-
2. Disconnect and separate the battery connector. ment, and the second screen displays all the charac-
ters used in the various menus. As part of the SELF
3. Discharge the capacitors in the traction motor
TEST, you can also test the keys by pressing each one
controller by connecting a load (such as a contac-
and observing whether its corner LED lights up. To
tor coil or a horn) across the controller’s B+ and
exit the SELF TEST, unplug the programmer or turn
B− terminals (center 2 terminals).
off the controller.
Figure 22. Programmer Handset Self Test
OPERATING MODES with the corresponding settings. The setting of the

selected item (the item at the top of the display
Program Menu with the flashing arrow) can be changed using the
CHANGE VALUE keys. The CHANGE VALUE
Press the PROGRAM key to enter the PROGRAM keys have LEDs to indicate whether the key can be
mode. See Table 15. The LED in the corner of the used to increase or decrease the value any further.
PROGRAM key illuminates to indicate that the When the LED is no longer lit, the limit for the key
programmer has been placed in the PROGRAM direction has been reached.
mode. All of the adjustable functions and features
are shown in the display window, four at a time,
57
Press the MORE INFO key to display more detailed Test Menu
information for the setting selected, including a bar
graph indicating the position of the current setting Press the TEST key to enter the TEST mode. See
relative to the range for the setting, the unit of mea- Table 16. The LED in the corner of the TEST key il-
sure, and the specific minimum and maximum val- luminates to indicate that the programmer has been
ues for the setting. If the range is limited by the val- placed in the TEST mode. The TEST menu displays
ues assigned for a different function, the name of the real time information about the status of the inputs,
limiting function is displayed in place of the mini- outputs, and controller temperature. In the TEST
mum and maximum values. mode, the item of interest does not need to be the top
item in the window; it only needs to be one of the
Table 15. Program Menu four items displayed in the window. The TEST mode
is useful for checking out the operation of the con-
Program Menu troller during initial installation. The MORE INFO
Description
Display key, when used in the TEST mode, displays addi-
tional information about the top item in the window.
M3 Brake C/L Mode 3 braking current, in
amps Table 16. Test Menu
amps Test Menu
Description
Display
amps THROTTLE % Throttle reading, as % of full
throttle.
M3 Neut Brk % Mode 3 neutral braking, as
% of brake C/L ARM CURRENT Motor armature current, in
amps.
M2 Neut Brk % Mode 2 neutral braking, as
% of brake C/L FIELD CURRENT Motor field current, in amps.
M1 Neut Brk % Mode 1 neutral braking, as BATT VOLTAGE Battery voltage across the
% of brake C/L capacitors.
M3 Accel Rate Mode 3 acceleration rate, in HEATSINK C Heatsink temperature in C.

seconds FORWARD Forward switch on or off.
M2 Accel Rate Mode 2 acceleration rate, in INPUT
seconds REVERSE INPUT Reverse switch on or off.
M1 Accel Rate Mode 1 acceleration rate, in INTERLOCK Brake switch on or off.
seconds INPUT
Taper Rate Regen braking decrease MAIN CONT Traction contactor open or
rate, when transitioning to closed.
plug, in 1/32 seconds
FAULT 1 Fault 1 driver status: on
M3 Max Speed Mode 3 maximum speed, as OUTPUT (low)/off (high).
% of top speed
FAULT 2 Fault 2 driver status: on
M2 Max Speed Mode 2 maximum speed, as OUTPUT (low)/off (high).
% of top speed
MODSEL 1 Mode select inputs 1 and 2
M1 Max Speed Mode 1 maximum speed, as together define the operating
% of top speed mode from the dash display
MODSEL 2 to the controller. Refer to
Table 17.
58
Table 17. Dash Display Drive Mode Inputs Table 18. Diagnostic and Diagnostic
History Display (Continued)
Drive Mode
Test Menu
Turtle Middle Rabbit Diagnostics
Definition
Menu Display
MODE SELECT
OFF ON OFF
INPUT 1 MAIN CONT Traction contactor did not
DNC close
MODE SELECT
ON OFF OFF
INPUT 2 MAIN CONT Traction contactor welded
WELDED
Diagnostics Menu MISSING Missing Contactor
CONTACTOR
Press the DIAGNOSTIC key to enter the DIAGNOS-
TIC mode. The LED in the corner of the DIAGNOS- NO KNOWN No known faults have
TIC key illuminates to indicate that the programmer FAULTS occurred
has been placed in the DIAGNOSTIC mode. The OVERVOLTAGE Battery voltage too high
DIAGNOSTICS menu displays all currently active
faults detected by the controller. It is capable of dis- SRO Static Return to Off activated
playing 19 different faults, four at a time. THERMAL Cutback, due to over/under
CUTBACK temperature
NOTE: The DIAGNOSTIC and DIAGNOSTIC
HISTORY display shown in Table 18 is not a menu THROTTLE Throttle out of range
as such, but simply a list of the possible messages FAULT 1
displayed when the programmer is operating in the
THROTTLE Throttle low fault
DIAGNOSTICS or DIAGNOSTIC HISTORY modes.
FAULT 2
The messages are listed in alphabetical order for
easy reference.
Diagnostic History
Table 18. Diagnostic and Diagnostic
History Display Press the DIAGNOSTICS key and the MORE INFO
key simultaneously to enter the DIAGNOSTIC HIS-
Diagnostics TORY menu. The DIAGNOSTIC HISTORY lists all
Definition of the faults observed and recorded by the controller
Menu Display
since the history was last cleared. Press the SCROLL
ARM SENSOR Armature sensor fault DOWN key to display any recorded faults. Each fault
CONT DRVR OC Contactor driver overcurrent will be listed only once, regardless of the number of
times the fault may have occurred.
FIELD OPEN Field winding open or
disconnected The diagnostic history can be cleared from the
FLD SENSOR Field sensor fault controller using the SPECIAL PROGRAM MENU
function, CLEAR DIAG HISTORY. Press the PRO-
HPD High Pedal Disable activated GRAM key while holding the MORE INFO key.
HW FAILSAFE 1 Power-on self test fault Press the SCROLL DOWN key until CLEAR DIAG
HISTORY appears in the top line of the display.
HW FAILSAFE 2 External watchdog fault Press the MORE INFO key again, and then press
HW FAILSAFE 3 Internal watchdog fault the VALUE UP key to clear the history, or VALUE
DOWN to cancel the operation.
LOW BATTERY Battery voltage too low
VOLTAGE
M− SHORTED M− output shorted
(Controller M− Terminal)
to B−
59
Special Program Menu Table 19. Special Program Menu
Press and hold the MORE INFO key, then press the Special Program
PROGRAM key to enter the SPECIAL PROGRAM Definition
Menu Display
menu. See Table 19. The SPECIAL PROGRAM
menu allows the user to: revert the controller to RESET ALL Revert to previous
previous settings; save controller settings to the SETTINGS settings
programmer memory; load controller settings from CONT SET- Save controller settings
the programmer memory; clear diagnostic history; TINGS→PROG to programmer
adjust the contrast of the programmer display; select
language; and display basic controller and program- PROG SET- Load programmer
mer information. Press the SCROLL DISPLAY key TINGS→CONT settings to controller
until the desired function is on the top line. Press CLEAR DIAG Clear DIAGNOSTIC
the MORE INFO key for information on how to HISTORY HISTORY memory
make the desired adjustment.
CONTRAST Adjust programmer
The SPECIAL PROGRAM menu also allows the user ADJUSTMENT display contrast
to "clone" controllers. After one controller is pro-
LANGUAGE Select displayed
grammed with all of the desired values, the values
SELECTION language
can be saved to the programmer memory. The pro-
grammer can then be used to load the saved values PROGRAMMER INFO Display programmer
to other similar controllers (same model number). information
CONTROLLER INFO Display controller
information
60
2200 SRM 978 Programming the Traction Motor Controller
Programming the Traction Motor Controller

the programmer has not been unplugged or the key
WARNING switch turned OFF (power disconnected).
NEVER adjust function settings outside the
range recommended for the specific truck 6. Reconnect the battery.
model.
NOTE: The brake pedal must be released (up posi-
tion) during Step 7.
WARNING
Program changes affect lift truck perfor- 7. Turn the key switch to the ON position. Ensure
mance and operation. If function settings are battery disconnect switch is closed.
changed, make sure all operators of the lift
truck know that the truck has been changed 8. Press the PROGRAM button on the PROGRAM-
and may operate differently. MER HANDSET. The green LED in the corner of
the PROGRAM button lights to indicate that the
1. Turn the key switch to the OFF position. HANDSET has been placed in the PROGRAM
mode.
2. Disconnect and separate the battery connector.
9. Press the SCROLL DISPLAY buttons, as re-
3. Remove the two screws retaining the metal cover quired, until the desired function is shown on
located on the right side of the operator compart- the top line of the display. See Table 20.
ment. Remove the cover.
10. Press the MORE INFO button to display addi-
WARNING tional information, if desired, on the selected
function. The green LED in the corner of the
MORE INFO button lights to indicate that the
MORE INFO option has been selected.
and injury, discharge the capacitor before NOTE: Some function values are limited by values
inspecting or repairing any component. Wear set for other functions. For example, the value for M2
safety glasses. Make certain the battery has ACCELERATION RATE (Mid Mode) must be equal
been disconnected. DO NOT use a screwdriver to or less than the value for M1 ACCELERATION
to discharge the traction motor controller. RATE (Turtle Mode) and equal to or greater than the
value for M3 ACCELERATION RATE (Rabbit Mode).
4. Discharge the capacitors in the traction motor
Press the MORE INFO key to display the limiting
controller by connecting a load (such as a contac-
function, shown on the bottom line in place of the
tor coil or a horn) across the controller’s B+ and
minimum and maximum values normally displayed.
B− terminals.
5. Connect the PROGRAMMER HANDSET to the WARNING

traction motor controller. The cord of the hand- NEVER adjust function settings outside the
set plugs into the four-pin Molex, Mini-Fit Jr. re- range recommended for the specific truck
ceptacle on the front of the controller. model.
NOTE: Each time the programmer handset is 11. Press the CHANGE VALUE buttons to change
connected to the controller, it acquires all of the the function value higher or lower, as required.
controller function value settings and stores them A green LED on each CHANGE VALUE button
in its temporary memory. This allows the user to lights to indicate that the function value can be
revert back to the original settings at any time. The changed in the corresponding direction. If the
SPECIAL PROGRAM menu selection RESET ALL green LED on one of the CHANGE VALUE but-
SETTINGS is used to revert to the original settings. tons is not illuminated, the value has reached the
Any inadvertent change made to any of the function limit for the corresponding direction.
values can be "undone" in this manner, as long as
61
Programming the Traction Motor Controller 2200 SRM 978
Table 20. Program Menu Range and Default Values
Min./Max.
Units of
Menu Display Function Description Factory Value Values
Measure
Allowed
M3 BRAKE C/L 24-volt trucks
320 100 to 450
M2 BRAKE C/L Brake Current only
M1 BRAKE C/L Amps
Limit 36-volt trucks
280 100 to 450
only
NOTE: Changes made to the BRAKE C/L settings may necessitate changes to the TAPER RATE setting below
to ensure smooth operation when plugging to a stop or transitioning from one direction to the other.
M3 NEUT BRK
%
M2 NEUT BRK
Neutral Braking Level 16 0 to 50 % of Regen C/L
%
M1 NEUT BRK
%
24-volt trucks
0.5 0.1 to 5.0
M3 ACCEL M3 Acceleration only
Seconds
RATE Ramp Rate 36-volt trucks
0.7 0.1 to 5.0
only
24-volt trucks
1.6 0.1 to 5.0
Seconds
1.6 0.1 to 5.0
only
24-volt trucks
3.2 0.1 to 5.0
Seconds
2.5 0.1 to 5.0
only
24-volt trucks
25 1 to 64
End Regen only
TAPER RATE 1/32 second
Taper Rate 36-volt trucks
27 1 to 64
only
NOTE: Changes made to the TAPER RATE setting may necessitate changes to the BRAKE C/L settings above
to ensure smooth operation when plugging to a stop or transitioning from one direction to the other.
24-volt trucks Standard 100 0 to 100

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

only EE 85 0 to 85
M2 MAX
36-volt trucks
only EE 75 0 to 75
62
2200 SRM 978 Programming the Traction Motor Controller
Table 20. Program Menu Range and Default Values (Continued)
Min./Max.
Units of
Menu Display Function Description Factory Value Values
Measure
Allowed

only EE 65 0 to 65
M1 MAX
36-volt trucks
only EE 65 0 to 65
WARNING WARNING
Program changes affect lift truck perfor- The capacitor in the traction motor controller
mance and operation. If function settings are can hold an electrical charge after the battery
changed, make sure all operators of the lift is disconnected. To prevent electrical shock
truck know that the truck has been changed and injury, discharge the capacitor before
and may operate differently. inspecting or repairing any component. Wear
12. Press the MORE INFO button to return to the been disconnected. DO NOT use a screwdriver
PROGRAM menu, if the MORE INFO screen had to discharge the traction motor controller.
been selected.
16. Discharge the capacitors in the controller by con-
13. Repeat Step 9 through Step 12, as required, until necting a load (such as a contactor coil or a horn)
all of the functions are set to the desired values. across the controller’s B+ and B− terminals.
NOTE: Any inadvertent change made to any of the 17. Disconnect the programmer handset cord from
function values can be "undone" using the SPECIAL the traction motor controller.
PROGRAM menu selection RESET ALL SETTINGS,
as long as the programmer has not been unplugged 18. Install the cover in the operator’s compartment.
or the key switch turned OFF (power disconnected). Install the two screws to retain the cover. Recon-
nect the battery.
14. Turn the key switch to the OFF position.
19. Install the cover in the operator’s compartment.
15. Disconnect and separate the battery connector. Install the two screws to retain the cover. Recon-
nect the battery.
63
Troubleshooting 2200 SRM 978
Troubleshooting
The traction motor controller provides diagnostic in- faults - such as a fault in SRO sequencing - are
formation to the programmer handset, the dash dis- cleared by cycling the key switch.
play, and the Status LED on the controller. The fol-
lowing four-step process is recommended for diagnos- Table 21. Status LED Fault Codes
ing and troubleshooting an inoperative vehicle:
LED Code Explanation
1. Visually inspect the truck for obvious problems.
OFF (no No power or defective controller
2. Diagnose the problem using the DIAGNOSTIC flashes)
menu in the programmer handset. ON Controller or microprocessor
(continuously) fault
3. Test the circuitry (inputs/outputs) using the
TEST menu in the programmer handset. 0,1 Controller operational, no faults
4. Correct the problem. 1,2 Hardware failsafe fault

1,3 M-, current sensor, or motor
STATUS LED DIAGNOSTICS fault
A Status LED is built into the traction motor 2,1 Throttle fault
controller. See Table 21. It is visible through a
2,2 Static return to off (SRO) fault
window in the label on the top of the controller. The
Status LED displays fault codes when there is a 2,3 High pedal disable (HPD) fault
problem with the controller or with the inputs to the
3,1 Contactor driver overcurrent
controller. During normal operation, with no faults
present, the Status LED flashes steadily on and off. 3,2 Welded contactor
If the controller detects a fault, a two-digit fault 3,4 Missing contactor, or traction
identification code is flashed continuously until the contactor did not close
fault is corrected. For example: code 3,2 - welded
traction contactor - appears as three flashes, pause, 4,1 Low battery voltage
two flashes, long pause, three flashes, pause, two 4,2 Overvoltage
flashes, long pause...and so on, continuously until
the problem is corrected. 4,3 Thermal cutback;
over/undertemp
NOTE: Only one LED fault code is indicated at a
time, and faults are not queued up. Operational
64
2200 SRM 978 Troubleshooting
PROGRAMMER DIAGNOSTICS DOWN key to display any recorded faults. Each fault
will be listed only once, regardless of the number of
The programmer presents complete diagnostic infor- times the fault may have occurred.
mation in plain language. Faults are displayed in the
DIAGNOSTIC menu. The status of the controller in- Press the TEST key to enter the TEST mode. The
puts and outputs is displayed in the TEST menu. The LED in the corner of the TEST key illuminates to in-
DIAGNOSTIC HISTORY menu provides a list of the dicate that the programmer has been placed in the
faults that have occurred since the diagnostic history TEST mode. The TEST menu displays real-time in-
file was last cleared. Checking (and clearing) the di- formation about the status of the inputs, outputs,
agnostic history file is recommended each time the and controller temperature. In the TEST mode, the
truck is serviced. item of interest does not need to be the top item in the
window; it only needs to be one of the four items dis-
Press the DIAGNOSTIC key to enter the DIAGNOS- played in the window. The MORE INFO key, when
TIC mode. The LED in the corner of the DIAGNOS- used in the TEST mode, displays additional informa-
TIC key illuminates to indicate that the programmer tion about the top item in the window.
has been placed in the DIAGNOSTIC mode. The
DIAGNOSTICS menu displays all currently active The charts on the following pages should be used in
faults detected by the controller. It is capable of dis- conjunction with the wiring Diagrams 8000 SRM
playing 16 different faults, four at a time. 980 or 8000 SRM 982. The DIAGNOSTIC (and DI-
AGNOSTIC HISTORY) menu items are shown, fol-
Press the DIAGNOSTICS key and the MORE INFO lowed by the TEST menu items.
key simultaneously to enter the DIAGNOSTIC HIS-
TORY menu. The DIAGNOSTIC HISTORY lists all DIAGNOSTICS MENU
of the faults observed and recorded by the controller
since the history was last cleared. Press the SCROLL
LED Code Dash Display Message Programmer Handset Display Message

COMMUNICATION ERROR WITH CON-
TROLLER. PRESS SCROLL DOWN TO
0, 1 Any Message ATTEMPT TO RESTART
PROGRAMMER FAULT
Condition
Handset is plugged into the traction motor
controller. Key switch is in the ON position.
Truck Response
Traction may or may not function normally.

• Brake pedal is pressed when programmer handset
is connected.
Turn key switch to the OFF position. Release
the brake pedal. Turn the key switch to the ON
position.
• Interface cable between traction motor controller
and programmer handset is defective.
Replace the interface cable. Logic
Initial communication between the traction motor
controller and the programmer handset is not valid.
65

NO KNOWN FAULTS
0, 1 Any Message
NO KNOWN FAULTS HAVE OCCURRED
Condition
Diagnostic menu is selected.
Truck Response
Traction functions normally.

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

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

• Caused by a defective handset.
Replace the handset.
Logic
Displayed when the internal check logic of the
traction motor controller does not get the correct
communication from the programmer handset.
66

THERMAL CUTBACK
DRIVE CTRL LIMIT SPEED
4, 3 THERMAL CUTBACK DUE TO OVER/
REDUCED
UNDER TEMP
Condition
Truck Response
Traction speed is reduced.

• Temperature of the traction motor controller is
greater than 85 C (185 F) or less than −25 C
(−13 F).
Determine the cause of the out-of-range temper- Logic
ature and correct (low battery, overloading, etc.). Displayed when the internal temperature of the
Can be caused by excessive load on vehicle, op- traction motor controller is beyond the operating
eration in extreme environments, or improper range of −25 to +85 C. The internal temperature can
mounting of controller. When controller cools off be read by accessing the test menu on the handset.
or warms up, normal operation will resume.
If controller is improperly mounted, remount ac-
cording to specifications. See SEM Traction Mo-
tor Controller, Install.
DRIVE CONTROL ERROR SRO

2, 2
CHECK ERROR CODE STATIC RETURN TO OFF ACTIVATED
Condition
Truck Response

• Forward or reverse direction is selected before the
brake is released (operator is on the truck, initial
startup only).
Check brake switch for proper operation; an
open brake switch can cause this fault.
NOTE: The brake can be released while traveling. If Logic

the operator presses the brake pedal within 3 sec- Displayed when battery volts is simultaneously
onds, SRO will not be activated. If the operator waits supplied to terminals 2 and 10 or terminals 2 and 11.
more than 3 seconds, SRO will be activated and the
handle will have to be returned to neutral to resume
normal operation of the truck.
67
DRIVE CONTROL ERROR HPD

2, 3
CHECK ERROR CODE HIGH PEDAL DISABLE ACTIVATED
Logic
Displayed when voltage at pin 14 or pin 15 is above
approximately 1.25 volts with 0 volts at pin 2.
[5.00 volts (full-speed throttle voltage) ×
Truck Response
25% =1.25 volts]
Traction is disabled until fault condition is
corrected. (The HPD function has a 3-second
delay during normal operation.)

• Throttle greater than 25% before the brake pedal
is pressed.
Check multifunction control handle to ensure it
is in the neutral position.
• MIB failed.
Check the MIB for proper operation.

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

• M− output shorted or internal short in the traction
motor.
Verify voltage between battery− and M− to be Logic
10% less than battery volts, with the multifunc- M− bus bar should measure approximately 10%
tion control handle in neutral. less than battery volts. Pin 2-7 should measure
• Traction motor shorted. near zero volts, with multifunction control handle
Check traction motor for shorted condition. in neutral. Pin 2-7 should measure near battery
voltage, with corresponding direction selected.
68
DRIVE CTRL LIMIT SPEED OVERVOLTAGE

4, 2
REDUCED OVERVOLTAGE
Condition
Truck Response

• Truck voltage greater than 45 volts.
Check to ensure proper battery is in the truck.
• Plugging the charger into the truck instead of the
battery can also cause this fault.
Check to ensure the proper battery charging pro-
cedure is followed.
Logic
Traction controller is designed to operate with
24- and 36-volt batteries only.

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

• Traction contactor coil shorted.
Check traction contactor coil for a shorted con-
dition. Contactor coil should measure approxi-
Logic
mately 17 ±1 ohms.
Displayed when higher-than-normal current is
• Shorted wire between the traction motor controller
sensed in the traction contactor coil.
and the contactor coil.
69

HW FAILSAFE
HARDWARE FAILSAFE ACTIVATED
Condition
Truck Response

• Defective traction motor controller.
Replace traction motor controller.
Logic
Displayed when the internal check logic of the
traction motor controller determines an internal
failure of the traction motor controller.
DRIVE CTRL LIMIT SPEED LOW BATTERY VOLTAGE

4, 1
REDUCED LOW BATTERY VOLTAGE
Condition
Truck Response

• Battery voltage less than 16 volts.
Check battery voltage to ensure proper voltage
for truck.
Check for loose or corroded connections between
the battery and the traction motor controller.
Logic
B+ bus bar on traction motor controller should
measure near truck battery voltage. Connections
should be tight and corrosion free.
70
Any or No LED PROC/WIRING FAULT

DRIVE CTRL FAULT
Code PROCEDURE OR WIRING FAULT
Condition
Truck Response

• Traction motor controller is not wired properly or
is missing required inputs.
Check controller connections. See WIRING
Logic
SCHEMATICS AND DIAGRAMS.
Displayed when internal logic of the traction motor
controller detects improper inputs.

MISSING CONTACTOR
MISSING CONTACTOR
Condition
Truck Response

• Traction contactor missing or contactor coil open.
Check traction contactor coil for open condition.
Contactor coil should measure approximately 17
Logic
±1 ohms. If contactor coil is open, replace it.
Displayed when lower than normal current is
• Open wire between the traction motor controller
sensed in the traction contactor coil.
and the contactor coil.
Check for continuity between pin 17 at the trac-
tion motor controller and wire #14 at the contac-
tor coil.
Check for continuity between pin 9 at the trac-
tion motor controller and wire #15 at the contac-
tor coil.
These checks should read near zero ohms; if they
do not, locate the open and repair it.
71

THROTTLE FAULT 1
THROTTLE INPUT FAULT (OUT OF RANGE)
Logic
Pin 15 at the traction motor controller is above
(approximately) 5.0 volts (full-speed reference
voltage) or below (approximately) 0.2 volt
Truck Response
(neutral reference voltage).

• Throttle input voltage (pin 15, wire #29) out of
range.
Check wire #29 for short to B− or B+.
Check for continuity between J2-13 (wire #29) at
the MIB and pin 15 (wire #29) at the traction mo-
tor controller. You should read near zero ohms.
If this wire is open, find the open and repair it.
• MIB failed.
Check the MIB for proper operation. The MIB
provides the throttle position signal to the trac-
tion motor controller via wire #29 (J2-13). With
multifunction control handle in neutral, pin 15
(wire #29) should measure approximately 0.2
volt. As the handle is moved in a FORWARD
or REVERSE direction, the voltage should
increase to near 5 volts.
72

THROTTLE FAULT 2
THROTTLE LOW INPUT FAULT
Logic
Pin 15 at the traction motor controller is above or
below (approximately) 0.2 volt (reference voltage).
Truck Response

• Throttle reference voltage (pin 15, wire #29) open
or shorted.
Check wire #29 (pin 15 at the traction motor con-
troller) for a short to B− or B+.
Check continuity between pin 15 (wire #29) at
the traction motor controller and J2-13 (wire
#29) at the MIB. You should read near zero
ohms. If the wire is open, find the open and
repair it. Wire #29 (pin 15 at the traction motor
controller) should measure approximately 0.2
volt.
• MIB failed.
Check the MIB for proper operation. The MIB
provides the throttle reference signal to the trac-
tion motor controller via wire #29 (J2-13). With
the key switch ON, pin 15 should measure ap-
proximately 0.2 volt. As the handle is moved in
a FORWARD or REVERSE direction, the volt-
age should remain at approximately 0.2 volt.
TEST MENU
Menu Test Menu
Operating Range
Item (Neutral position shown)
Scroll display until 0% to 100%
For Additional
THROTTLE % 0 with multifunction control handle in neutral.
Information:
is shown on the 100 with multifunction control handle positioned for
Press MORE INFO
top line full-speed travel (forward or reverse).
1
Throttle % should gradually increase as the
THROTTLE % 0 THROTTLE
multifunction control handle is moved from the
INPUT,
neutral position to the full-speed position (FORWARD
%
0 and REVERSE).
Throttle signal is generated by the MIB and dependant on the throttle pot position.
Displays throttle reading in percent of full as seen by the traction motor controller.
73
Menu
Test Menu Operating Range
Item
Scroll display until
For Additional
ARM CURRENT
Information:
is shown on the
Press MORE INFO
2 top line
ARM CURRENT ARM
CURRENT,
AMPS 0
Indicates traction motor armature current.
Menu
Item
For Additional
FIELD CURRENT
Information:
is shown on the
3 Press MORE INFO
top line
FIELD CURRENT FIELD
CURRENT 0
Indicates traction motor field current.
Menu Test Menu

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

Operating Range
Item 22 C (71.5 F) shown
Scroll display until Between −25 C (−13 F) and 85 C (185 F)
For Additional
HEATSINK C
Information:
is shown on the
Press MORE INFO
5 top line
HEATSINK C 22 HEATSINK
TEMPERA-
TURE C 22
Indicates traction motor controller heatsink temperature.
74
Test Menu
Menu
(Multifunction control handle Operating Range
Item
positioned for forward travel.)
Scroll display until Forward switch OPEN . . . OFF
For Additional
FORWARD INPUT Forward switch CLOSED . . . ON
Information:
is shown on the
6 Press MORE INFO
top line
FORWARD ON FORWARD
INPUT INPUT IS ON
Shows status of forward switch input at traction motor controller. Output of MIB.
Test Menu
Menu
(Multifunction control handle Operating Range
Item
positioned for reverse travel.)
Scroll display until Reverse switch OPEN . . . OFF
For Additional
REVERSE INPUT Reverse switch CLOSED . . . ON
Information:
is shown on the
7 Press MORE INFO
top line
REVERSE ON REVERSE
INPUT INPUT IS ON
Shows status of reverse switch input at traction motor controller. Output of MIB.
Menu
Item
Scroll display until Interlock (brake switch) input . . . ON
For Additional
INTRLCK INPUT
Information:
is shown on the
8 Press MORE INFO
top line
INTRLCK ON INTERLOCK
INPUT INPUT ON
Shows status of interlock (brake) switch.
Menu
Item
For Additional
MAIN CONT is
Information:
shown on the
Press MORE INFO
9 top line
MAIN CONT OPEN MAIN
CONTACTOR
DRIVER IS ON
Shows status of main (traction) contactor.
75
Menu
Item
Scroll display until Fault 1 output low . . . ON
For Additional
FAULT 1 OUTPUT Fault 1 output high . . . OFF
Information:
is shown on the
10 Press MORE INFO
top line
FAULT 1 ON FAULT 1
OUTPUT OUTPUT ON
Shows status of fault 1 output.
Menu
Item
Scroll display until Fault 2 output low . . . ON
For Additional
FAULT 2 OUTPUT Fault 2 output high . . . OFF
Information:
is shown on the
11 Press MORE INFO
top line
FAULT 2 ON FAULT 2
OUTPUT OUTPUT ON
Shows status of fault 1 output.
Menu Test Menu

Operating Range
Item (Rabbit mode shown)
Scroll display For Additional Turtle Mode . . . ON
until MODSEL 1 Information: Mid Mode . . . OFF
is shown on the Press MORE Rabbit Mode . . . OFF
12 top line INFO
MODSEL 1 MODSEL 1
IS OFF
Controlled by the drive mode switch on the dash display.
Menu Test Menu

Operating Range
Item (Rabbit mode shown)
Scroll display Turtle Mode . . . OFF
For Additional
until MODSEL 2 Mid Mode . . . ON
Information:
13 is shown on the Rabbit Mode . . . OFF
Press MORE INFO
top line
MODSEL 2 MODSEL 2 IS OFF
Controlled by the drive mode switch on the dash display.
76
TECHNICAL PUBLICATIONS
2200 SRM 978 7/02 (7/01)(5/01) Printed in U.S.A.

Hyster 1503628 07 02 srm0978

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N30-40XMR3 [C470]; N25XMDR3 [C470];

PART NO. 1503628 2200 SRM 978

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• Disconnect the battery ground cable on internal combustion lift trucks.

• 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.

©2002 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

Figure 1. Logic Diagram

Component Repair and Testing - General

2. Check for voltage between each terminal of the

Contactor Panel Assembly

3. Lift off the battery compartment cover for access

steps listed above must be done to service any item

2. (B264) Replace the contactor panel on the three

3. Install the power wires and fuses. See the man-

4. Reconnect the control wires.

5. Connect the battery.

NOTE: The contactor panel assembly does not nor-

1. Check the condition of the battery. If it is not

2. Lift off the battery compartment cover for access

3. Visually check to see if the contactor closes when

4. Connect a voltmeter across the coil terminals.

5. Check the contactor for loose, broken, or corroded

1. Remove the capscrews retaining the enclosure

2. Remove the insulator.

3. Service the contactor.

4. Install the insulator.

5. Position the enclosure shroud over the contactor

1. ENCLOSURE 7. RETURN SPRING

Figure 4. Typical EE Contactor

WARNING Fuse Circuit Rating

1. INSULATOR - TERMINAL 8. SCREW 15. NUT

Figure 5. Enclosed Fuse Box EE Application

NOTE: On non-EE-rated trucks, there is an auxil-

Table 3. Hydraulic Control Valve/Relay Coil Resistance Values

HMR (hourmeter Robert Bosch Corp. 305 ±15 ohms

Height Proximity Switch

INSTALL 10. Check the truck for proper operation. Maximum

2. Connect wire #15 to terminal 8 and wire #74 to

2. Disconnect the battery and separate the connec-

Battery Disconnect Switch

Proportional Electro-Hydraulic Control Valves

See the section Hydraulic System 1900 SRM 973

WARNING Figure 7. Hydraulic Control Valve

A provision is provided on the lowering valve to allow

Trucks built before 15 July, 2002

If a reading other than those listed are obtained, re-

Figure 9. Manual Lowering Setscrew

NOTE: Sideshift is an option not found on all trucks.

Multifunction Control Handle

been disconnected. Discharge the capacitors

4. Remove the multifunction control handle by dis-

5. The multifunction control handle has no re-

1. Move the lift truck to a safe level area. Turn the

2. Disconnect the battery and separate the connec-

3. Remove the battery compartment cover.

WARNING 1. NEGATIVE CONNECTION