CURTIS TRANSISTOR

MOTOR CONTROLLER
W40-60XL, B40-60XL [D135]; N30FR [A217];
R30ES [B174]; R30XMS [C174]; R30XMS2 [D174];
W60-80XT [E135]; B60-80XT [B199]; C60-80XT [B199];
W40XT [A218]; W45XT [A215, B215]; T5XT [E142];
W20/30/40XTA [A453]; W20/25/30/40XTC [A454];
W20/30XTR [A455]

PART NO. 897340 2200 SRM 411

 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!
Curtis Transistor Motor Controller Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Principles of Operation ...................................................................................................................................... 2
General ........................................................................................................................................................... 2
Transistor Motor Controller .......................................................................................................................... 3
Basic Controller Operation ....................................................................................................................... 5
Field Effect Transistor (FET).................................................................................................................... 5
Motor Circuit That Operates With Pulses ............................................................................................... 5
Induction Current From Motor ................................................................................................................ 7
Plugging ..................................................................................................................................................... 8
Control Circuit........................................................................................................................................... 9
Static-Return-To-Off (SRO) Function....................................................................................................... 9
Thermal Protection Function.................................................................................................................... 10
Low Voltage Protection Function.............................................................................................................. 10
Current Limit Protection Function .......................................................................................................... 10
Power Circuit............................................................................................................................................. 10
Sequence of Operation ....................................................................................................................................... 12
Key Switch ..................................................................................................................................................... 12
Brake Switch.................................................................................................................................................. 12
Control Circuit ............................................................................................................................................... 12
FWD/REV Switch Closed .............................................................................................................................. 12
Forward Contactor Energized....................................................................................................................... 12
Gate Pulse to FETs ........................................................................................................................................ 12
FETs ON for Time of Gate Pulse .................................................................................................................. 12
Gate Pulse Removed...................................................................................................................................... 12
Induction Current Flows Through Motor and Flyback Diode..................................................................... 20
Plugging ......................................................................................................................................................... 20
Checks................................................................................................................................................................. 22
Checking Contactor Coil................................................................................................................................ 22
Checking Transistor Controller .................................................................................................................... 22
Checks With Controller Installed ............................................................................................................. 23
Bench Checks ............................................................................................................................................ 25
Accelerator Potentiometer Checks and Adjustments.............................................................................. 26
Adjustments ....................................................................................................................................................... 27
Plugging Adjustment..................................................................................................................................... 28
Acceleration Adjustment ............................................................................................................................... 28
Current Limit Adjustment ............................................................................................................................ 28
Repairs................................................................................................................................................................ 28
Contactors ...................................................................................................................................................... 28
Replace ....................................................................................................................................................... 30
Curtis Contactor Parts, Replace ................................................................................................................... 30
GE Contactor Parts, Replace ........................................................................................................................ 30
Controller, Replace ........................................................................................................................................ 32
Accelerator Potentiometer and Control Switches, Replace and Adjust...................................................... 32
Troubleshooting.................................................................................................................................................. 32
General ........................................................................................................................................................... 32
General Procedures ....................................................................................................................................... 33
Fault Procedures ................................................................................................................................................ 33

©2004 HYSTER COMPANY i

Table of Contents Curtis Transistor Motor Controller

TABLE OF CONTENTS (Continued)

This section is for the following models:

W40-60XL, B40-60XL [D135];

N30FR [A217];
R30ES [B174];
R30XMS [C174];
R30XMS2 [D174];
W60-80XT [E135];
B60-80XT [B199];
C60-80XT [B199];
W40XT [A218];
W45XT [A215, B215];
T5XT [E142];
W20/30/40XTA [A453];
W20/25/30/40XTC [A454];
W20/30XTR [A455]

ii
2200 SRM 411
General
This section describes the operation, checks, repairs,
and troubleshooting of the Curtis PMC 1204 or 1205
series. It also covers the 1207 series and the new
series of the 1243 motor controller. See Figure 1,
Figure 2, and Figure 4. This transistor motor con-
troller is used to control the operation of some 24-
and 36-volt electric lift trucks. The controllers are
made for Hyster Company by a division of Curtis In-
struments, Inc.
The controller for the traction system uses digital
logic. Digital logic uses transistors to operate like
very fast switches. The transistors are controlled
by electrical gate pulses. Electrical noise is also
high voltage pulses caused by momentarily oper-
ating other electrical devices. Digital logic cannot
understand the difference between control pulses
and electrical noise. Filter capacitors are connected
between the B+ and B terminals in the controller
to prevent electrical noise from entering the logic
and causing errors.
NOTE: B60-80XT SHOWN. W45XT, W60-80XT, C60-80XT, AND T5XT MODELS SIMILAR.
Figure 1. Transistor Controller on Truck (Early Production)
General
The logic of the controller also checks the following
functions:
1. Checks the temperature and gives both low and
high temperature thermal protection to the con-
troller.
2. Electrically checks that an operator follows the
correct starting sequence to help prevent unex-
pected operation. This function has been called
Static-Return-To-Off (SRO) in other Hyster mo-
tor controller Service Manual sections.
3. Electrically checks the traction circuit for certain
malfunctions. This function prevents lift truck
operation if a failure is sensed.
4. Checks the current in the motor circuit and auto-
matically decreases the motor voltage to reduce
the current and prevent damage. The plugging
circuit is also controlled for smoother operation.
1
Principles of Operation 2200 SRM 411

Additional information showing how the motor
controller is electrically connected in the lift truck
is shown in the section Diagrams 8000 SRM 457
for the walkie low lift motorized hand trucks,
Diagrams Curtis Transistor 8000 SRM 495
for N30FR units, Diagrams Curtis Transistor
8000 SRM 475 for R30ES units, Diagrams 8000
SRM 653 for the walkie high lift motorized hand
trucks, and Diagrams 8000 SRM 923 for the
R30XM2/XMA2/XMF2/XMS2 units.

NOTE: B60-80XT SHOWN. W40XT, W45XT, W60-80XT, C60-80XT, AND T5XT MODELS SIMILAR.

Figure 2. Transistor Controller on Truck (Late Production)

Principles of Operation
GENERAL
A motor controller for an electric lift truck controls
the speed of the traction motor by making a vari-
ation in the applied voltage. This controller uses
solid-state electronic devices to permit efficient con-
trol of the applied voltage.
The motor controller also generates a high current
flow in the traction motor while keeping a low cur-
rent draw from the battery. A battery is less efficient
at a high current draw. A battery will not give all
of its electrical power at a high current draw. The
traction motor is a series wound motor that gener-
ates torque. This torque is proportional to the cur-
rent moving through the motor. The speed of the mo-
tor is controlled by the voltage and mechanical load
connected to the motor.
The motor will accelerate until the mechanical load
equals the torque required. If the torque increases,
the current and acceleration will increase.
The two functions look like a problem of opposite
needs. How a solid-state electronic controller bal-
ances those needs with efficiency is described in this
section.

2
2200 SRM 411
TRANSISTOR MOTOR CONTROLLER
The motor controller controls the speed of the trac-
tion motor. The direction of rotation of the motor is
controlled by the Forward/Reverse switch and con-
tactors. See Figure 3, Figure 4, and Figure 5. The
controller is sealed in an aluminum case and has no
parts that can be repaired or replaced. The com-
plete unit must be replaced if correct troubleshooting
methods show that the unit is damaged.
External contactors are used to control the direction
of rotation of the traction motor. Contactors are elec-
trical switches that use an electromagnet to operate
1. PMC
2. ELECTRIC BRAKE
3. APS
4. STEERING MOTOR
Figure 3. Transistor Controller on Truck (New Production)
Principles of Operation
the power contacts of the switch. A small electric
signal is used to energize the electromagnet to close
the power contacts and control the large current flow
needed for the motor circuit. The electromagnetic
field in the coil moves the armature against spring
pressure to close the power contacts. When the coil
is de-energized, the spring pressure moves the arma-
ture and opens the contacts. When a spring holds the
contacts of a switch open, the switch is called nor-
mally open (NO). If the switch spring holds the con-
tacts of a switch closed, the switch is called normally
closed (NC).
5. CONTACTOR PANEL
6. HYDRAULIC PUMP MOTOR
7. DRIVE MOTOR
3
Principles of Operation 2200 SRM 411

There are two contactors that control the direction of

rotation of the traction motor. Each direction contac-
tor has two sets of contacts on the same plunger as-
sembly. Each contactor has a set of NO contacts and a
set of NC contacts. When one set of contacts is closed,
the other set of contacts must be open. This arrange-
ment prevents the wrong sequence of closed contacts
that could cause an open circuit. This arrangement
of contactors also permits current flow through the
motor field in either direction. See Figure 5 and Fig-
ure 6. One set of contacts causes the motor armature
to rotate in one direction. The other set of contacts
causes the motor armature to rotate in the opposite
direction. See Figure 7. Other contactors used for
control functions on the lift truck only have one set
of contacts because a forward and reverse operation
1. CONTROLLER is not required. An example is the hydraulic pump
2. LC CONTACTOR motor contactor.
3. POWER FUSE
4. LIFT PUMP CONTACTOR
5. 1A CONTACTOR Contactors are used to energize and de-energize mo-
6. CONTROL FUSES tors, but cannot control the speed. The transistor
7. TIMER motor controller applies battery voltage in short, fast
8. FORWARD/REVERSE CONTACTOR pulses to a DC motor to control the speed. How this
circuit controls the speed of a motor with pulses is
Figure 4. Transistor Controller Panel described in this section.
(W/B40-60XL Units)
The direction and speed control operates the FWD/
REV switch to energize the direction contactor. The
control also supplies the speed input to the motor
controller.

1. BATTERY
2. TRACTION MOTOR ARMATURE
3. TRACTION MOTOR FIELD
4. REVERSE CONTACTOR CONTACTS
5. FORWARD CONTACTOR CONTACTS
6. FETS SWITCH
Figure 6. Current Flow Through Field in
Figure 5. Basic Traction Motor Circuit FORWARD Direction

4
2200 SRM 411
Figure 7. Current Flow Through Field in
REVERSE Direction
Basic Controller Operation
This transistor motor controller has a power section
and a logic section with solid-state electronic circuits
that control the operation of a DC motor. The speed
of DC motors is controlled by the average applied
voltage. The higher the average applied voltage, the
faster the motor will rotate. If a switch is put in the
traction motor circuit (see Figure 4) and the switch is
changed to OFF and ON quickly (see Figure 9) the
traction motor will rotate. The speed of rotation in-
creases as the time the switch is ON increases. The
speed of rotation will decrease if the ON time de-
creases. OFF time will increase at the same time.
The speed of the motor can be controlled using this
principle.
This controller uses an electronic device called a
Field Effect Transistor (FET) to generate the rapid
ON and OFF pulse times. It has no moving parts.
The FETs are turned on and off by the logic circuits
in the controller to act as the switch. Several power
FETs are connected in parallel to carry the necessary
motor current.
Field Effect Transistor (FET)
A FET is a solid-state device that operates like a very
fast switch. A FET is a transistor that has an ele-
ment called a gate. FETs are electronic devices that
permit electricity to flow as long as there is a gate
Principles of Operation
voltage. See Figure 8. Electricity flows easily from
the input to the output. A FET will only permit cur-
rent flow when there is a positive voltage at the in-
put, a negative voltage at the output AND a positive
voltage applied to the gate. A FET will permit elec-
tricity to flow from the input to the source as long as
there is the signal voltage at the gate. The FETs ON
time is the same as the gate pulse ON time as shown
in Figure 9. Current flows as shown in Figure 8. The
FET stops conducting when the signal voltage is re-
moved from the gate.
When FETs are used as a switch:
a. The FETs are ON when the electric current flows
through them (gate voltage applied).
b. The FETs are OFF when the electric current can-
not flow through them (no gate voltage).
Motor Circuit That Operates With Pulses
A schematic that shows the controller and FETs in a
traction circuit is shown in Figure 8. When a signal
is applied to the gate of the FETs, the FETs are ON
and current flows from the battery through the mo-
tor. When the gate signal is removed, the FETs are
changed to OFF.
The battery voltage is applied to the motor in pulses.
The pulses of energy through the FETs to the motor
are very fast (15,000 on/off cycles per second). The
motor cannot follow each pulse, but the motor runs
smoothly based on the average voltage generated by
the ON and OFF times. The average motor voltage
applied to the traction motor is shown in Figure 9.
The length of the ON TIME of the pulses changes
the average motor voltage. As the ON TIME of each
pulse increases (OFF TIME decreases), the average
motor voltage increases. This change in the ratio of
ON TIME to OFF TIME of the pulses is called pulse
width modulation.
The control circuit has an oscillator and a pulse
width modulator. The oscillator generates a saw
tooth waveform at a constant frequency of 15,000
cycles per second (15 kHz). The pulse width modula-
tor uses this saw tooth waveform to generate a pulse
output that can be smoothly changed from a full ON
to a full OFF condition. This pulse output is used
by the gate driver circuit for the high pulse currents
needed to turn the FETs ON and OFF. The pulse
width modulator controls the ON and OFF times of
the FETs through the gate driver. The ratio of ON
TIME to OFF TIME sets the average motor voltage
and the motor speed.
5
Principles of Operation 2200 SRM 411

Legend for Figure 8

1. BATTERY
2. TRACTION MOTOR
3. GATE DRIVE
4. FET INPUT (+)
5. FET OUTPUT ( )
6. FET GATE (+)
7. POSITIVE SUPPLY THROUGH MOTOR
8. POSITIVE GATE VOLTAGE
9. NO GATE VOLTAGE
10. NO GATE SIGNAL

Figure 9. Average Motor Voltage

Figure 8. Transistor Control

6
2200 SRM 411 Principles of Operation

The accelerator potentiometer, at the speed control of
the lift truck, regulates a voltage that changes as the
operator sets the speed of operation. This voltage is
an input to the controller and the pulse width modu-
lator. As the voltage changes with the selected speed,
a direct change in the ratio of FET ON TIME to FET
OFF TIME also occurs. The voltage for maximum
speed changes the ratio to pulses with the maximum
ON TIME, to produce a maximum average motor
voltage. See Figure 9. The pulse rate (15 kHz) stays
the same for all speeds.
Induction Current From Motor
When a DC motor is controlled by a pulsed circuit,
the magnetic field in the armature and field wind-
ings is continuously expanding and decreasing. The
fields expand when voltage is applied (ON TIME)
and decreases when the voltage is removed (OFF
TIME). The voltage causes an increasing current
flow through the windings to make the expanding
magnetic field. When the voltage is removed, the
decreasing magnetic field causes current to flow
in the same direction through the windings. See
Table 1. This expansion and decrease of the mag-
netic field is lost energy for doing work unless the
controller is designed to use this energy. A Flyback
Diode (sometimes called a Freewheel Diode) is in the
controller circuit for this purpose.
The Flyback Diode permits the current, from the
decreasing magnetic field, to flow through the field
and armature again to do work. The torque of a se-
ries DC motor is directly proportional to the amount
ofcurrent flowing through it. At slower speeds, the
OFF times are longer. When the FETs are OFF, the
decreasing magnetic field generates a voltage and
current in the motor.

Table 1. Inductance

Beginning conditions as the switch is closed:

1. Large current flow from battery through induc-
tor.
2. Increasing magnetic field generates reverse volt-
age within inductor.
3. Reverse voltage decreases current through induc-
tor. Current energy changed to energy in mag-
netic field.

Constant conditions after switch is closed for a short

time period:
1. Voltage and current flow is the same in all parts
of the circuit.
2. Magnetic field is constant.

Ending conditions as the switch is opened:

1. Decreasing magnetic field generates voltage
within inductor.
2. Decreasing magnetic field generates current flow
in original direction.

7
Principles of Operation
This current is often called the flyback current. The
Flyback Diode permits the current to flow through
the field and armature again to do work. At slower
speeds, the motor current is part battery current
and part flyback current. There is less battery
current used for the specific torque requirement.
High current draw from the battery is to be avoided,
if possible, because it is less efficient. At higher
speeds, the OFF time is less, so that less induction
1. BATTERY
2. MOTOR ARMATURE
3. MOTOR FIELD
Figure 10. Induction Motor Current
Plugging
The plugging circuit is an added feature of the con-
troller that provides smooth electrical braking when
the operator wants to change the truck’s direction
of travel. See Figure 11. The plugging feature also
saves wear and tear on the drive tires and the drive
unit gears.
Plugging occurs when the truck is traveling in one di-
rection but the operator has switched the directional
control to the opposite direction. In this instance, the
motor armature is rotating in one direction while the
magnetic forces of the fields are trying to force the ar-
mature the other way. This reaction generates cur-
rent that is allowed to flow through a loop formed by
8
2200 SRM 411
current (flyback current) is generated. Most of the
motor current must come from the battery at higher
speeds. However, the torque and current require-
ments are also usually less.
The typical induction current during equal ON and
OFF times of the FETs is shown in the graph in Fig-
ure 10.
4. CONTROLLER
5. FETS (NOT ON)
6. FLYBACK DIODE
the plugging diode in the controller. This generated
current helps to slow the truck’s speed magnetically
in the same manner that compression in a gas engine
will help to control the speed of an automobile when
it is coasting. When a lift truck is in the plugging
mode, the pulse rate of the controller must be main-
tained at a slow rate. To accomplish this the logic
section of the controller signals that the truck is in a
plugging mode and controls the oscillating rate. The
oscillating rate pulses slowly no matter what posi-
tion the directional control is in on a controller with
fixed plugging. Some controllers are furnished with
throttle position plugging and the oscillating rate can
vary.
2200 SRM 411
1. BATTERY
2. MOTOR ARMATURE
3. MOTOR FIELD
4. CONTROLLER
5. PLUG DIODE
Figure 11. Plugging Current Circuit
The plugging function of the controller is designed to
allow the truck to travel 1 to 2 times the length of the
lift truck after the truck is plugged before it reverses
direction.
During plugging, the oscillating rate is decreased
from 15 kHz to 1 kHz. The controller regulates the
pulse widths of the pulses to the motor field for the
correct amount of plugging. The accelerator circuit
is also set to a low speed so that normal acceleration
in the opposite direction will occur. The plugging dis-
tance is adjustable. The plugging adjustment on the
controller changes the amount of motor field current
allowed. The plugging adjustment can be changed
as needed for an application. See Adjustments.
Plugging an electric lift truck is not a harmful prac-
tice, however, avoid plugging the drive motor when
the drive wheel is jacked off the ground.
Principles of Operation
Control Circuit
The control circuit has operator inputs from the key
and brake switches as well as the accelerator poten-
tiometer. The circuit also has internal inputs from
the power circuit for thermal protection, plugging
sensing, low voltage protection and motor current
(current limit). The control circuit uses the inputs to
regulate the ON TIME pulses to the FETs for speed
control, current limit and plugging strength.
Static-Return-To-Off (SRO) Function
The control circuit includes a function to prevent the
operation of the lift truck if the starting sequence is
not correct. The function uses the inputs to the con-
trol circuit to make sure the operator is ready to oper-
ate the controls. The starting sequence is as follows:
1. Turn the key switch to the ON position. The
key switch supplies battery voltage to the brake
switch.
2. The operator must close the brake switch. Bat-
tery voltage is now supplied to the control circuit.
3. Rotate the Direction/Speed control in the desired
direction of travel to select travel direction and
speed.
If Step 3 is done before both Step 1 and Step 2 are
complete, the lift truck will not move in either di-
rection. The control circuit must get battery voltage
through both the key and brake switches before it
gets a speed signal from the accelerator potentiome-
ter. If the starting sequence is not correct, the control
circuit will not send a gate pulse to the FETs for trac-
tion motor current.
The SRO function also prevents the lift truck from go-
ing to full speed operation because of a malfunction
in the accelerator circuit. On the B/W40-60XL units,
an open circuit in the accelerator circuit is normally
sensed as a full speed signal by the control card. If
this malfunction exists, the SRO function will pre-
vent the start of traction pulses. If the malfunction
occurs during normal operation, the control circuit
senses an accelerator potentiometer input of more
than 7000 ohms (open circuit) and stops the traction
pulses. The circuit will return to normal operation
after the malfunction is repaired.
9
Principles of Operation
Thermal Protection Function
There is a sensor to sense the heat within the con-
troller housing. If the controller gets too hot or
too cold for correct operation, the control circuit
will reduce the ON TIME of the pulses to decrease
the current to protect the controller. The lift truck
will still operate at a slower speed to permit it to
be moved to a location out of the work area. The
controller can then return to a normal operating
temperature. The controller is designed to operate
with an internal temperature between 85 C (185 F)
and 25 C ( 13 F). Controller performance will be
reduced when the controller is in Thermal Protec-
tion.
Low Voltage Protection Function
This function protects the controller and the battery.
The controller will not operate correctly if there is
not a minimum voltage from the battery. The bat-
tery current drain increases as the battery voltage
decreases. Too large a battery drain will damage the
battery. If the battery voltage is low, the control cir-
cuit will decrease the ON TIME of the pulses to de-
crease the current drain. The battery can still oper-
ate the lift truck to move it for battery charging or
replacement. The controller requires a minimum of
10
2200 SRM 411
9 volts on the 12-volt controllers and a minimum of
16 volts on the 24-volt controllers for the system to
function properly.
Current Limit Protection Function
The control circuit limits the traction motor current
to a maximum value to protect the controller, motor
and battery. The control circuit will decrease the ON
TIME of the motor pulses to keep the motor current
less than the maximum value. The maximum value
is set by the manufacturer.
Power Circuit
The power circuit is controlled by the control circuit.
See Figure 12. The complete power circuit is inside
the controller and has the following parts:
• Field Effect Transistors
• Flyback Diode
• Plug Diode
• Filter Capacitors
The parts in the power circuit cannot be replaced by
users. Cables connect the battery and traction motor
to the power circuit at the controller power terminals
B+, A2, M , and B . All of the traction motor cur-
rent flows through the power circuit of the controller.
2200 SRM 411 Principles of Operation

Figure 12. N30FR Transistor Controller Circuit Schematic

11
Sequence of Operation
Sequence of Operation
The sequence of operation describes a complete cycle
of the transistor traction circuit. A sequence of the
beginning conditions and the FET cycle is shown in
Figure 13.
NOTE: Gray lines on the circuit lines show positive
voltage with respect to battery negative. Slash lines
show negative voltage with respect to battery posi-
tive.
The line codes do not always indicate full battery
voltage. The gray tone is used only for the circuits
being described. Some parts of the energized circuit
are not shown with gray tones or slashes. The thick
(bold) lines show the traction power circuit. The thin
lines show the control circuits.
NOTE: The following circuit schematics from the
W40-60XL and B40-60XL lift trucks are used to de-
scribe the sequence of operation. Basic operation of
the transistor controller for other lift truck models is
similar. See the Diagrams sections for the complete
schematics.
NOTE: The N30FR, W40-60XL, and B40-60XL lift
trucks have an additional LC contactor that is ener-
gized when the key switch closes. The basic circuit
operation is the same as described.
KEY SWITCH
Key Switch closed by moving key to the ON position.
On N30FR units, the LC contactor is energized. Bat-
tery power to brake switch, lift, lower, horn and to
optional heater and battery meter. See Figure 14.
BRAKE SWITCH
Brake switch must be closed by lowering steering
handle (W/B40-60XL, W/B60-80XT, W20-40XTA,
W20-40XTC, and W20-30XTR only); operator re-
leasing brake handles (C60-80XT and T5XT); or
operator stepping on brake switch (R30ES only) so
that the FWD/REV switch, Traction Reverse switch
(W/B40-60XL and W/B60-80XT only), Accelerator
Potentiometer, and Control Circuit will have battery
voltage when key switch is closed. See Figure 15.
12
2200 SRM 411
CONTROL CIRCUIT
Battery positive to the Control Circuit, Hourmeter,
Traction Reverse switch (W/B40-60XL and W/B60-
80XT only), and Direction switch through the key
and brake switches. Hourmeter begins to operate.
Circuit checks that there is no speed signal from the
accelerator potentiometer. If there is a speed signal
as battery power is applied, the control circuit will
prevent the gate signal from going to the FETs. See
Figure 15.
FWD/REV SWITCH CLOSED
Forward contacts of FWD/REV switch close. Accel-
erator potentiometer speed signal to control circuit.
Battery positive voltage available to Forward contac-
tor. See Figure 16.
FORWARD CONTACTOR ENERGIZED
Normally open contacts of Forward contactor close.
Normally closed contacts open. Battery positive volt-
age is applied to FETs through traction motor. FETs
are still OFF, so there is no current flow and the trac-
tion motor does not operate. See Figure 17.
GATE PULSE TO FETS
Gate Driver of control circuit sends gate ON pulse to
FETs gate. ON TIME (pulse width) set by accelera-
tor potentiometer signal. See Figure 18.
FETS ON FOR TIME OF GATE PULSE
FETs conduct to provide power pulse to the traction
motor. Traction motor starts to operate. Pulse ON
TIME is the same as gate ON TIME. See Figure 18.
GATE PULSE REMOVED
FETs stop conducting when gate pulse is removed.
Power pulse is removed from traction motor. Pulse
OFF TIME is set by the time remaining for one cycle
at 15 kHz. See Figure 19.
2200 SRM 411 Sequence of Operation

Figure 13. Sequence of Operation

13
Sequence of Operation 2200 SRM 411

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.

Figure 14. Sequence of Operation - Key Switch Closed

14
2200 SRM 411 Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.

Figure 15. Sequence of Operation - Power to Control Circuit

15
Sequence of Operation 2200 SRM 411

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.

Figure 16. Sequence of Operation - Direction/Speed Control Set for Slow Forward Speed

16
2200 SRM 411 Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.

Figure 17. Sequence of Operation - Forward Contactor Energized

17
Sequence of Operation 2200 SRM 411

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.

Figure 18. Sequence of Operation - Gate Pulse to FETs, FETs ON

18
2200 SRM 411 Sequence of Operation

NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.

Figure 19. Sequence of Operation - FETs OFF

19
Sequence of Operation
INDUCTION CURRENT FLOWS THROUGH
MOTOR AND FLYBACK DIODE
Induction current, generated by motor, flows through
the flyback (freewheel) diode and returns through
the motor. This current is used instead of battery
current to keep the motor operating. See Figure 20.
NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.
Figure 20. Sequence of Operation - Induction Current
20
2200 SRM 411
PLUGGING
Plugging is a method of stopping an electric lift truck
by changing the direction of current flow in the motor
field. Figure 21. To actuate the plugging circuit, the
operator must change the Direction/Speed control for
travel in the opposite direction of present travel.
2200 SRM 411
NOTE: W/B40-60XL SHOWN. OTHERS SIMILAR.
Figure 21. Sequence of Operation - Plugging
The controller prevents motor current flow during
the time the FWD/REV contactors change to the
reverse direction. The controller senses when the
FWD/REV switch goes through neutral and momen-
tarily interrupts the battery positive input from the
key and brake switches. This action momentarily
turns the FETs OFF when the high current flow
can cause an arc and burn the contactor contacts.
The controller senses plugging action by the voltage
across the plug diode. The frequency of the oscillator
is reduced from 15 kHz to 1 kHz to limit torque.
Current limit is also reduced to prevent the plugging
current from becoming too great. This current limit
Sequence of Operation
can be changed by the external plugging adjust-
ment. The controller regulates the pulse widths of
the pulses to the motor field for the correct amount
of plugging. The controller accelerator circuit is also
set to a low speed so that normal acceleration in
the opposite direction will occur after the lift truck
comes to a stop.
The motion of the lift truck drives the traction mo-
tor armature to make the motor operate as a gen-
erator. This additional generator current (armature
current) adds to the current flow through the field
to reverse the motor at an even faster rate. Unless
21
Checks
the control circuit provides a way to slow this change
of direction, the lift truck will stop very quickly. The
plug diode in the control circuit prevents the lift truck
from stopping too quickly. While the motor is acting
as a generator, the plug diode prevents this generator
Checks
WARNING
Do not make repairs or adjustments unless you
have both authorization and training. Repairs
and adjustments that are not correct can cre-
ate a dangerous operating condition. Do not
operate a lift truck that needs repairs. Report
the need for repairs to your supervisor imme-
diately. If repair is necessary, put a DO NOT
OPERATE tag on the control handle. Remove
the key from the key switch.
There are several checks that can be made that check
for correct operation of the system. There are only
two external adjustments on early units and three
adjustments on later units. There are no internal
adjustments for the transistor controller.
NOTE: The checks require a volt-ohmmeter with a
meter movement. Most digital meters will not oper-
ate correctly for some of the checks. Specific checks
require additional equipment.
CHECKING CONTACTOR COIL
WARNING
Disconnect the battery and separate the con-
nector before opening the hood or inspecting
or repairing the electrical system. If a tool
causes a short circuit, the high current flow
from the battery can cause an injury or parts
damage.
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
injury, discharge the capacitor before inspect-
ing or repairing components under the hood.
Wear safety glasses. To discharge the capaci-
tor, first disconnect the battery. Then connect
an insulated jumper wire between the B+ and
22
2200 SRM 411
current from adding to the field current. The control
circuit lets all of the plugging current flow from the
armature through the plug diode, then flow with the
battery current through the armature again. This
reduces the effect of the induction current.
B terminals (see Figure 23) of the transistor
controller.
Some checks require the battery connected.
Do not connect the battery until the proce-
dure tells you to connect the battery. Make
sure the drive wheel is raised to prevent truck
movement and possible injury. Raise the drive
wheel as described in the Operating Manual
or the Periodic Maintenance section of the
Service Manual.
Check the Forward or Reverse contactor coil with an
ohmmeter. A suppressor diode with a resistor in se-
ries is part of the coil. The diode will cause the ohm-
meter to indicate a difference in resistance in one di-
rection. Reverse the probes of the ohmmeter to the
opposite terminals and measure the resistance. Use
the highest resistance indication. Replace the coil if
the resistance readings are a short circuit in both di-
rections or if there is an open circuit in both direc-
tions. Make sure the coil wires are connected again
to the correct terminals.
CHECKING TRANSISTOR CONTROLLER
These checks are in two sections: checks with the
controller installed in the lift truck and checks of the
controller out of the lift truck (bench checks).
The controller is protected against operation with a
low battery. Controller output is slowly decreased as
battery voltage decreases. The battery can be low if
an operator notices slower operation or less power.
This operation is not a defect of the transistor con-
troller. Make sure all checks are done with a fully
charged battery.
NOTE: The following checks must be done in the or-
der they are listed because some steps depend on con-
ditions set in previous steps.
2200 SRM 411 Checks

Checks With Controller Installed Resis-

Resis-
Pot tance
1. Raise the drive/steer wheel as described in the Rotation tance
P/N Full
Operating Manual or the Periodic Mainte- Neutral
Speed
nance section of the Service Manual.
uni- 4.5K to
2. Make sure the battery is fully charged. 2304385 50 to 0
directional 5.5K
3. Make a physical check to be sure that battery 368034 bi-directional Infinity 0
negative is connected to the B terminal of the
controller. Connect the negative meter lead to 4.5K to
the B terminal. 826064 bi-directional 0 to 200
5K
4. Check for battery positive voltage at the B+ ter- 2302033 bi-directional 3.5K 0
minal of the controller (see Figure 23) and the ca-
All values ±10%
ble P2 terminal of the Reverse contactor. If there
is no battery positive voltage, check the cables
between battery positive and the two terminals.
If the cables are not damaged, the controller can
be damaged.

5. Tag all wires and cables before they are removed.

Make sure the key switch is in the OFF position
and remove the wires from terminals 1 and 2 of
the controller. See Figure 22 and Figure 23 for
the correct unit. If a resistor is used between
terminals 1 and 2, do not disconnect the resistor.
Check for an open circuit (at least 1 megohm)
between the wires with the Direction/Speed con-
trol in the NEUTRAL position. If there is no
open circuit, check to see that the accelerator
potentiometer is in the centered position. Check
for maximum resistance by moving the control
to the full speed position(s). See the following
chart. Check for at least one megohm resistance Figure 22. New Controller
between each wire and the lift truck frame. If
any of the resistance readings are wrong, check
the wiring to the accelerator potentiometer and
check the adjustment of the FWD/REV switch.
Connect wires to terminal 1 and terminal 2. See
the sections Diagrams 8000 SRM 457, Dia-
grams 8000 SRM 475, Diagrams 8000 SRM
495, or Diagrams 8000 SRM 653 for the walkie
high lift motorized hand trucks.

23
Checks 2200 SRM 411

NOTE: SOME CONNECTORS HAVE DIFFERENT FUNCTIONS DEPENDING ON MODEL OF LIFT TRUCK AND
MODEL OF CONTROLLER USED.
1. M POWER TERMINAL 8. STATIC-RETURN-TO-OFF, 1A OR NOT USED ON
2. TERMINAL 2 W40XT, W45XT, W/B/C60-80XT, AND T5XT
3. TERMINAL 1 9. BRAKE OR TRACTION REVERSE (W/B40-60XL,
4. B POWER TERMINAL W40XT, W45XT, AND W/B60-80XT ONLY)
5. B+ POWER TERMINAL 10. FORWARD INPUT
6. KEY SWITCH INPUT 11. REVERSE INPUT
7. F/R CONTACTOR OUTPUT 12. A2 POWER TERMINAL

Figure 23. Controller Wire (Control) and Cable (Power) Terminals

6. Connect the voltmeter positive lead to the con-
troller B+ terminal. Connect the voltmeter nega-
tive lead to the controller M terminal. Move the
key to the ON position, lower the control handle
(W/B40-60XL, W/B60-80, W40XT, W45XT, W20-
40XTA, W20-40XTC, W20-30XTR), or step on the
brake switch (R30ES, N30FR). Release the brake
levers (C60-80XT and T5XT units). Check for
zero or near zero volts. Move the Direction/Speed
control for full speed travel. Check for full bat-
tery voltage.
7. If there is not full battery voltage, the controller
is defective. If there is battery voltage and the
motor does not operate, disconnect the battery
connector and discharge the internal capacitor.
The correct procedure to discharge the capacitor
is described in the WARNING at the beginning
of this section.
8. Disconnect the cable from the controller A2 ter-
minal. Use the ohmmeter to check for a diode be-
tween the A2 and B+ terminals. There must be
a high resistance in one direction and a low re-
sistance with the meter leads reversed. If there
is a low or high resistance in both directions, the
diode is damaged. If the readings are correct and
the motor does not operate, there is a short cir-
cuit in the motor circuit. Check for a short cir-
cuit at the motor cables or direction contactors. If
there are no short circuits, the motor has a short
circuit. Replace any defective item(s).
9. Connect all wires or cables that had been discon-
nected.

24
2200 SRM 411 Checks

Bench Checks • A contactor (similar to the pump motor contactor)

To test the controller on the bench, you will need the
following equipment (see Figure 24):
• A power supply with a voltage equal to the lift truck
voltage. The power supply can be any of the fol-
lowing: the lift truck battery, automotive batteries
connected in series or an AC power supply with a
regulated D.C. output of 12 to 48 volts. Only low
power tests will be done, so a 10-amp fuse is wired
in series with the power supply to protect the oper-
ator and controller from accidental short circuits.
Do NOT use a battery charger as a power supply
since the no load voltage can be higher than the
voltage of the controller.
• A speed control, a 5K ohm potentiometer wired as
a 2-terminal rheostat will work fine.
with a 5-watt, 250-ohm resistor across the contacts.
A toggle switch and key switch connected as shown
are also needed.
• A test load of incandescent lamps with a voltage
equal to the lift truck voltage. 12-volt lamps wired
in series work fine.
• A multimeter or digital voltmeter.
1. Shake the transistor controller to see if any parts
are loose inside. If there are loose parts, replace
the controller.
2. Connect the controller as shown in Figure 24.
Connect the voltmeter to the B+ and B termi-
nals of the controller.

1. POWER SUPPLY 6. RESISTOR

2. 10-AMP FUSE 7. TRANSISTOR CONTROLLER
3. TOGGLE SWITCH 8. TEST LOAD
4. KEY SWITCH 9. SPEED CONTROL
5. CONTACTOR

Figure 24. Bench Checks

25
Checks
3. Make sure the key switch is OFF. Turn the power
supply and toggle switch ON. Look at the volt-
meter. The voltmeter indication must slowly in-
crease to the truck voltage. If the voltage does
not increase to the truck voltage, replace the con-
troller.
4. The lamps must not illuminate now. If they illu-
minate, replace the controller.
5. Move the key switch to the ON position.
6. Move the speed control and look at the lamp
brightness. The lamps must slowly increase in
brightness as the speed increases.
7. Test the controller’s SRO functions:
a. Turn the key switch to the OFF position.
b. Move the speed control to the full speed posi-
tion.
c. Turn the key switch to the ON position and
check that the lamps do NOT illuminate un-
til the speed control is moved to OFF and re-
turned to ON.
8. Check the controllers fault function by removing
a wire from terminal 2 or 3 on the controller. The
lamps must NOT illuminate.
9. Disconnect all wires and cables from the con-
troller and use the ohmmeter or diode checker
to check the plug diode. Connect the meter be-
tween the A2 and B+ terminals. Reverse the me-
ter leads and check the reading. There must be
a high resistance in one direction and a low re-
sistance with the meter leads reversed. If there
is a low or high resistance in both directions, the
diode is damaged. Replace the controller.
10. Check the flyback (freewheel) diode. Connect
the meter between the M and B+ terminals.
Reverse the meter leads and check the reading.
There must be a high resistance in one direc-
tion and a low resistance with the meter leads
reversed. If there is a low or high resistance in
both directions, the diode is damaged. Replace
the controller.
Accelerator Potentiometer Checks and
Adjustments
The following procedures are for checking and ad-
justing the accelerator potentiometer and control
26
2200 SRM 411
switches for the W/B40-60XL units ONLY. different
series of lift trucks have their own checks and ad-
justments. See the sections for the following models:
N30FR, N40-50FR, N50FA - Electrical Adjust-
ments 2200 SRM 381 and Diagrams 8000 SRM
495.
R30ES - Electrical System 2200 SRM 420 and
Diagrams 8000 SRM 475.
W40XT, W45XT, W/B/C60-80XT, T5XT - Electri-
cal System 2200 SRM 279 and Diagrams 8000
SRM 457.
W20-40XTA, W20-40XTC, W20-30XTR - Electri-
cal System 2200 SRM 279 and Diagrams 8000
SRM 653.
NOTE: The direction switch must be correctly ad-
justed before the accelerator potentiometer can be
checked. The accelerator potentiometer must be ad-
justed after each installation.
1. Make sure the battery is disconnected and the ca-
pacitor in the controller is discharged. The cor-
rect procedure to discharge the capacitor is de-
scribed in the WARNING at the beginning of this
section.
2. Adjust the accelerator potentiometer when it is
installed with the pulley belt in place and both
wires disconnected.
3. Connect an ohmmeter between wires 15 and 16
on the accelerator potentiometer.
4. Rotate the direction and speed control. The ohm-
meter will indicate changes of resistance. Loosen
the two setscrews in the pulley block. Adjust the
potentiometer in the pulley block so that when
the control is in the neutral position, the ohmme-
ter shows maximum resistance. The maximum
resistance of the potentiometer will be approxi-
mately 4750 ±0%.
5. Tighten the two setscrews on the pulley block. Do
not let the pulley or shaft move as the setscrews
are tightened.
6. Rotate the direction and speed control to the for-
ward and reverse directions. Check that the re-
sistance of the potentiometer is less than 200
ohms at the maximum speed positions.
7. Connect the wires 14, 15, and 16 from the accel-
erator potentiometer to the correct wires on the
lift truck and the traction reverse switch. Install
the cover plate and connect the battery.
2200 SRM 411 Adjustments

Adjustments
Limit. See Figure 25. The older controllers have two
WARNING adjustments, Braking and Controlled Acceleration.
Disconnect the battery and separate the con- The plugging adjustment adjusts how far the lift
nector before opening the hood or inspecting truck travels before reversing direction. The Direc-
or repairing the electrical system. If a tool tion/Speed control can be moved to the maximum
causes a short circuit, the high current flow speed position from stop or a slow travel speed. The
from the battery can cause a personal injury controlled acceleration adjustment allows adjust-
or property damage. ment of the maximum rate of acceleration. The
Current Limit adjustment controls the motor cur-
The capacitor in the transistor controller can rent to a preset maximum.
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing components under the
hood. Wear safety glasses. To discharge the ca-
pacitor, first disconnect the battery. Then con-
nect an insulated jumper wire between the B+
and B terminals ( Figure 23) of the transistor
controller.

Some checks require the battery connected.

Do not connect the battery until the proce-
dure tells you to connect the battery. Make
sure the drive wheel is raised to prevent truck
movement and possible injury. Raise the drive
wheel as described in the Operating Manual
or the Periodic Maintenance section of the
Service Manual.

WARNING
Do not make repairs or adjustments unless you
have both authorization and training. Repairs
and adjustments that are not correct can cre-
ate a dangerous operating condition. Do not
operate a lift truck that needs repairs. Report
the need for repairs to your supervisor imme-
diately. If repair is necessary, put a DO NOT
A. MIDPOINT ADJUSTMENT 12 O’CLOCK
OPERATE tag on the control handle. Remove POSITION
the key from the key switch. B. MINIMUM ADJUSTMENT
C. MAXIMUM ADJUSTMENT
NOTE: The new 1243 controller as no adjustment it D. ENLARGED VIEW OF ADJUSTING SCREWS (2,
is preset and has electronic boxes connected by the 3, AND 4)
Can bus data link system.
1. TRANSISTOR CONTROLLER
2. BRAKING (PLUGGING) ADJUSTMENT SCREW
NOTE: The SEM motor controller operates on the (CW = HARDER BRAKING)
principle of controlling the motor field circuit and the 3. CURRENT LIMIT ADJUSTMENT SCREW
motor armature circuit independently. The SEM con- (CW = HIGHER CURRENT) (NOT USED ON
troller includes a full range of built-in safety features W/B40-60XL CONTROLLERS)
and diagnostic and setup capability for safe reliable 4. CONTROLLED ACCELERATION ADJUSTMENT
SCREW (CW = FASTER ACCELERATION)
operation.
Figure 25. Controller Adjustment Locations
The older controller has three adjustments: Braking
(plugging), Controlled Acceleration, and Current

27
Repairs
All adjustments are made with the key switch off
and the battery disconnected. Discharge the ca-
pacitor. Remove the nylon seal washer and the
3 mm (0.12 in.) socket head screws to access the
adjustment screws. Make the adjustments using
a small insulated screwdriver. Replace the socket
head screws and nylon seal washers after all adjust-
ments are made. Tighten the setscrews to 0.9 N•m
(8 lbf in).
PLUGGING ADJUSTMENT
Turning the braking (plugging) adjustment clock-
wise will increase the plugging effect and stop the lift
truck in a shorter distance. Turning the adjustment
counterclockwise will decrease the plugging effect.
The traction motor brushes have a faster wear rate
when the control is set for the shortest stopping
distance (maximum plugging). More heat is also
generated in the traction motor at this maximum
setting. This adjustment should be set in the one
o’clock position.
Repairs
CONTACTORS
WARNING
Disconnect the battery and separate the con-
nector before opening the hood or inspecting
or repairing the electrical system. If a tool
causes a short circuit, the high current flow
from the battery can cause a personal injury
or property damage.
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing components under the
hood. Wear safety glasses. To discharge the ca-
pacitor, first disconnect the battery. Then con-
nect an insulated jumper wire between the B+
and B terminals (Figure 23) of the transistor
controller.
Some checks require the battery connected.
Do not connect the battery until the proce-
dure tells you to connect the battery. Make
sure the drive wheel is raised to prevent truck
movement and possible injury. Raise the drive
wheel as described in the Operating Manual
28
2200 SRM 411
ACCELERATION ADJUSTMENT
Turning the controlled acceleration adjustment
clockwise will increase the acceleration rate. Turn-
ing the adjustment counterclockwise will give a
slower rate of acceleration. The traction motor
brushes have a faster wear rate when the control
is set for an increased acceleration rate. More heat
is also generated at this maximum setting. This
setting should be set in the twelve o’clock position.
CURRENT LIMIT ADJUSTMENT
Turning the current limit adjustment clockwise will
increase the current limit. This setting is factory
set at the maximum 400 amps. The truck will also
run at a higher than normal speed especially when it
has no load. Lowering this adjustment can cause the
truck to have limited starting torque and can cause
the truck not to run at top speed when fully loaded.
This setting should be set at the maximum adjust-
ment position.
or the Periodic Maintenance section of the
Service Manual.
The FORWARD and REVERSE contactor assembly
controls the direction of current flow through the
traction motor. See Figure 26. The contactor is a
heavy-duty switch that opens and closes the power
circuit. The traction circuit has a FORWARD and
REVERSE contactor assembly. Each contactor as-
sembly has the following parts: two sets of normally
open (NO) contacts, two sets of normally closed (NC)
contacts and a coil. The coil is an electromagnet
that moves the NO contacts to the closed position
against spring pressure. The coil is in the control
circuit. The contactor tips are in the traction circuit.
A suppressor is part of each coil.
When a contactor coil is energized, the normally open
(NO) contacts close and the normally closed (NC) con-
tacts open. Current flows through the traction motor
field in one direction when the FORWARD contactor
is energized and in the other direction when the RE-
VERSE contactor is energized. This action gives di-
rection control to the traction motor. The contacts
normally have a long service life because the current
flow through the contacts is stopped before the con-
tacts open. The FETs are OFF before the contactor
coil is de-energized.
2200 SRM 411 Repairs

NOTE: THE POWER CONNECTIONS FOR THE FIXED CONTACTS CAN BE DIFFERENT THAN SHOWN.
1. SCREW 7. COVER BASE
2. BUSS BAR 8. COIL AND FRAME
3. COVER 9. MOUNT BRACKET
4. SPRING 10. ARMATURE CAP
5. FIXED CONTACTS
6. PLUNGER ASSEMBLIES AND MOVABLE
CONTACTS

Figure 26. Forward and Reverse Curtis Contactor Assembly

29
Repairs
Replace
Make sure the battery is disconnected and the capac-
itor in the controller is discharged. The correct pro-
cedure to discharge the capacitor is described in the
WARNING at the beginning of this section. If the
lift truck has an EE rating, remove the cover of the
contactor box for access to the contactor terminals.
Make an identification of the wires and cables and
disconnect them from the contactor assembly. Re-
move the mounting screws and replace the contactor
assembly. Install the wires and cables as removed.
Install the cover of the contactor box on EE units.
CURTIS CONTACTOR PARTS, REPLACE
NOTE: If both the contacts and coil of a contactor
will be replaced, replace the complete contactor as
described in Contactors, Replace. Do only the parts
of the procedure necessary to replace the damaged
parts you are replacing.
NOTE: All of the contacts for each contactor must be
replaced at the same time if any contact needs replac-
ing.
The contactor contacts are made of special silver
alloy. The contacts will look black and rough from
normal operation. This condition does not cause
problems with the operation of the lift truck. Clean-
ing is not necessary. DO NOT USE A FILE ON THE
CONTACTS. DO NOT LUBRICATE THE CON-
TACTS. Replace the contacts when the silver alloy
is worn away to the base support metal.
1. Remove the contactor as described in Contactors,
Replace. See Figure 26.
2. Make an identification of the buss bars for correct
installation. Remove the buss bars and nuts that
fasten to the fixed contacts.
3. Remove the two screws that fasten the covers for
each contactor. Remove the cover of each contac-
tor. Do NOT lose the plunger springs.
4. Replace the four fixed contacts in the contactor
covers.
5. Remove the two plunger assemblies and movable
contacts and replace the three fixed contact bars.
Replace the contacts of the plungers.
6. If a coil will be replaced, remove the cover base.
Remove the screws that fasten the coil frame to
the mount bracket. Remove the coil and frame.
30
2200 SRM 411
Remove the bushing part of the plunger and the
armature cap from the coil. Install these parts
on the replacement coil.
7. Install the coil and frame on the mount bracket.
8. Install the cover base, fixed contact bars, and
plungers on the coil frame. Make sure both
springs are on both plungers.
9. Install the covers and electrical bars on the cov-
ers as removed during disassembly.
10. Install the contactor assemblies on the lift truck
as described in Contactors, Replace.
GE CONTACTOR PARTS, REPLACE
NOTE: If both the contacts and coil of a contactor
will be replaced, replace the complete contactor as
described in Contactors, Replace. Do only the parts
of the procedure necessary to replace the damaged
parts you are replacing.
NOTE: All of the contacts for each contactor must be
replaced at the same time if any contact needs replac-
ing.
The contactor contacts are made of special silver
alloy. The contacts will look black and rough from
normal operation. This condition does not cause
problems with the operation of the lift truck. Clean-
ing is not necessary. DO NOT USE A FILE ON THE
CONTACTS. DO NOT LUBRICATE THE CON-
TACTS. Replace the contacts when the silver alloy
is worn away to the base support metal.
1. Remove the contactor as described in Contactors,
Replace.
2. Make an identification of any buss bars for cor-
rect installation. Remove the buss bars, spacers,
and nuts that fasten to the fixed contacts.
3. Remove the four screws that fasten the contactor
parts together.
4. Carefully remove the upper clamp and the two
fixed contact bars.
5. Remove the two lower clamp pieces and the other
two fixed contact bars.
6. Remove the contact carrier. Then remove the
movable contact assembly and armature assem-
bly as a unit. Remove the spring.
2200 SRM 411 Repairs

7. If necessary, carefully disassemble the assem- and make sure to make a note of the shims and
blies as shown in Figure 27. Do not lose any parts their positions for correct assembly.

1. BASE 8. LOWER CLAMP

2. COIL 9. MOVABLE CONTACT CARRIER
3. FRAME 10. SHIM
4. SPRING (SMALL END UP) 11. MOVABLE CONTACT ASSEMBLY
5. ARMATURE ASSEMBLY 12. UPPER CLAMP
6. CONTACT CARRIER 13. SCREW (4 EA)
7. FIXED CONTACTS

Figure 27. Forward and Reverse GE Contactor Assembly

31
Troubleshooting
8. If necessary, remove the frame and coil.
9. Install the coil on the base. Install the frame over
the coil and install the spring with the large coil
toward the frame.
10. Assemble the armature assembly and movable
contact assembly. Install the assemblies.
11. Install the contact carrier, the lower fixed contact
bars, and the lower clamps.
12. Install the upper fixed contact bars. Make sure
all contacts on the bars are facing the movable
contacts.
13. Install the upper clamp and screws.
14. Install the contactor assemblies on the lift truck
as described in Contactors, Replace.
CONTROLLER, REPLACE
Make an identification and disconnect the wires and
cables from the controller. Remove the mounting
screws and remove the controller. Apply a thin coat-
ing of silicone grease (Hyster Part Number 1198757)
on the bottom of the replacement controller. In-
stall the replacement controller on the lift truck.
Connect the wires and cables to the same termi-
nals as identified during the removal procedure.
If a controller failure has occurred on a R30XM2
(D174) model truck produced prior to serial num-
ber D174N02817A, install diode board assembly
2065361 when installing the new controller. This
Troubleshooting
GENERAL
This section describes the most common faults that
can occur in trucks with the CURTIS Transistor
Controller. Follow the General Procedures to make
32
2200 SRM 411
diode board helps protect the controller from spikes
in current caused by operator misuse.
CAUTION
Make sure the battery side of the diode board
is correctly oriented on the contactor.
To install the diode board, remove the nuts retain-
ing the small wires to the main connector. The board
is polarity sensitive. Install the diode board onto
the main contactor terminal studs. Install the small
wires and tighten nuts, as removed.
ACCELERATOR POTENTIOMETER AND
CONTROL SWITCHES, REPLACE AND
ADJUST
The following SRM sections have the procedures for
replacing and adjusting the accelerator potentiome-
ter and control switches of the different series of lift
trucks:
N30FR, N40-50FR, N50FA - Electrical Adjust-
ments 2200 SRM 381 and Diagrams 8000 SRM
495.
R30ES - Electrical System 2200 SRM 420 and
Diagrams 8000 SRM 475.
W40XT, W45XT, W/B40-60XL, W/B/C60-80, and
T5XT - Electrical System 2200 SRM 279 and Di-
agrams 8000 SRM 457.
W20-40XTA, W20-40XTC, W20-30XTR - Electri-
cal System 2200 SRM 279 and Diagrams 8000
SRM 653.
sure that maintenance problems give the correct
troubleshooting results. Follow the General Proce-
dures and then use the fault procedure that best
describes the problem.
2200 SRM 411
GENERAL PROCEDURES
WARNING
Disconnect the battery and separate the con-
nector before opening the hood or inspecting
or repairing the electrical system. If a tool
causes a short circuit, the high current flow
from the battery can cause a personal injury
or property damage.
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing components under the
hood. Wear safety glasses. To discharge the ca-
pacitor, first disconnect the battery. Then con-
nect an insulated jumper wire between the B+
and B terminals (Figure 23) of the transistor
controller.
Some checks require the battery connected.
Do not connect the battery until the proce-
dure tells you to connect the battery. Make
sure the drive wheel is raised to prevent truck
movement and possible injury. Raise the drive
wheel as described in the Operating Manual
or the Periodic Maintenance section of the
Service Manual.
1. Check the specific gravity of the battery. If the
specific gravity is less than 1.260, the battery is
not fully charged or is damaged. A fully charged
battery has a specific gravity of 1.270-1.290. A
discharged battery has a specific gravity of ap-
proximately 1.130.
Fault Procedures
The following is some common faults of the lift trucks
and the procedures for finding the cause. The follow-
ing SRM sections have the procedures for replacing
and adjusting the accelerator potentiometer and con-
trol switches of the different series of lift trucks:
N30FR, N40-50FR, N50FA - Electrical Adjust-
ments 2200 SRM 381 and Diagrams 8000 SRM
495.
R30ES - Electrical System 2200 SRM 420 and
Diagrams 8000 SRM 475.
Fault Procedures
2. The Hyster electric lift truck has a two-wire sys-
tem. The frame must not be a common electrical
path. Check for 50,000 ohms or more between
each terminal of the battery connector for the
lift truck and a clean connection on the frame.
Remove any circuit paths between the controller
and the frame of the lift truck. Carbon dust in
a motor or other parts can cause a circuit path.
Check for additional equipment that is causing a
circuit path to the frame.
3. Check for voltage between each terminal of the
connector that fastens to the battery and a clean
connection on the frame. Normally there is some
small voltage between the battery and the frame,
even if the resistance is very high. The small
voltage is normally less than 30% of the battery
voltage. A higher voltage can indicate a dirty bat-
tery or a battery with damage. Clean the battery
and battery compartment as necessary.
4. Visually check for parts or wires that are loose or
damaged.
NOTE: The correct meter polarity is necessary for
the checks. The voltage checks are made between
the point indicated in the troubleshooting chart and
battery negative. Connect the meter negative to bat-
tery negative.
NOTE: Make an identification of any wires before
you disconnect them. The wires must be connected
correctly after checks or repairs.
W/B40-60XL, W40XT, W45XT, W/B/C60-80, and
T5XT - Electrical System 2200 SRM 279, Dia-
grams 8000 SRM 457, and Diagrams 8000 SRM
923. There can be a variation in some of the wire
numbers for the different lift truck models.
W20-40XTA, W20-40XTC, W20-30XTR - Electri-
cal System 2200 SRM 279 and Diagrams 8000
SRM 653.
33
Fault Procedures 2200 SRM 411

FAULT NUMBER 1. ONE DIRECTIONAL CONTACTOR WILL NOT CLOSE.

Possible Causes: • Damaged (open) wire(s) in control circuit.
• Direction switch is damaged.
• Traction rev. sw. is damaged (W/B40-60XL, W40XT, W45XT, and W/B60-80XT only).
• Contactor coil is damaged.
• Transistor Controller is damage at FWD or REV term.

34
2200 SRM 411 Fault Procedures

FAULT NUMBER 2. DIRECTIONAL CONTACTORS WILL NOT CLOSE FOR OPERATION IN

EITHER DIRECTION.
Possible Causes: • Battery not connected. • Key switch, brake switch, or LC contactor is dam-
• Control fuse is damaged. aged.
• Pump motor fuse is damaged. • Traction reverse sw. (W/B40-60XL, W40XT, W45XT,
• Battery voltage is low. and W/B60-80XT only) is damaged.
• Wires in circuit are open. • F/R switch is damaged.
• Transistor controller is damaged.

35
Fault Procedures 2200 SRM 411

FAULT NUMBER 3. LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. THE DIRECTIONAL
CONTACTORS CLOSE NORMALLY. NO POWER WHEN DIRECTION/SPEED
CONTROL IS MOVED.
Possible Causes: • Traction fuse is damaged. • Accelerator potentiometer is
• Open circuit between motor and damaged or needs adjustment.
contactors. • Traction motor is damaged.
• Power contacts of direction • Damaged (open) traction motor cables.
contactor are damaged. • Transistor controller is damaged.

36
2200 SRM 411 Fault Procedures

FAULT NUMBER 4. DIRECTIONAL CONTACTORS CLOSE, LIFT TRUCK ACCELERATES TO

FULL SPEED IMMEDIATELY.
Possible Causes: • Accelerator potentiometer is damaged or needs adjustment.
• Transistor controller is damaged.

37
Fault Procedures 2200 SRM 411

FAULT NUMBER 5. NO SPEED CHANGE WHEN FAST SPEED BUTTON IS DEPRESSED.

SLOWER SPEED OPERATION IS NORMAL. (B40-60XL, B60-80XT, C60-80XT,
T5XT ONLY).
Possible Causes: • Fast speed switch has a short circuit.
• Fast speed switch or wiring is open.
• 3.6K ohm resistor is open.
• Wiring at resistor or switch is open.

38
2200 SRM 411 Fault Procedures

Table 2. Fault Codes and Display Messages for R30XMS2 Only

Items to Check if Code

Code ND Display Description
is Displayed
SlackChn Slack Chain circuit open *Chains slack (carriage hung up
on lowering)?
*Slack chain switches functioning
*Wiring between 1310 and slack
chain switches
SideGate Side Gates up *Side Gate switches functioning
*Wiring between 1310 and side
gate switches
HornOpen Horn disconnected (Open circuit) *Horn (bench test for function)
*Wiring to horn
BrakOpen Brake disconnected (Open circuit) *Brake coil (bench test)
*Wiring to brake
LowrOpen Lowering Valve disconnected *Lowering valve (bench test)
(Open circuit) *Wiring to lowering valve
TractErr Misc. traction error *Wiring to 1243
Foot Sw Foot Switch off while requesting *Foot switch
traction or hoist *Wiring to foot switch
Low Batt Low Battery warning, lift cutout
LiftLimt Lift Limit reached
LowrLimt Lowering limit reached
2041 5 Traction-Battery Undervoltage
2042 5 Traction-Battery Overvoltage
2043 5 TractHot Traction: Thermal Cutback *Worn load wheels, pushing loads,
operation with low battery
2301 6 Str Crnt High current *Mechanical binding of MDU

CAUTION
The electrical system on this truck utilizes many control-level circuits (low voltage and current),
which may be disturbed by contamination, wear or damage at the electrical connections. When
investigating problems or fault codes, it may be beneficial to first check and clean/repair all con-
nections in the affected circuit. The use of dielectric grease is recommended for all AMP and
Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION
The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to
abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a
defective truck component or controller. Fault codes may be generated in response to extreme
operating conditions such as potholes or very low battery levels.

39
Fault Procedures 2200 SRM 411

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued)

Items to Check if Code

Code ND Display Description
is Displayed
2390 1 ChkEncdr Encoder supply current drop *Wiring to steer and height
encoders
*Steer and height encoders
*Check current draw using
diagnostics "Enc Crnt"
2391 1 Enc Off? Encoder supply current too low on *Steer and height encoders must
initialization be plugged in during initial set up
of a new 1310
2392 1 Enc Crnt Encoder supply current too high *Use Diagnostic Display to display
encoder current draw; then unplug
individual encoders to determine
which encoder or wiring is drawing
high current
3101 6 Str Volt High Voltage *Check voltage to steer controller
4201 6 Str Temp High Temp *Check for mechanical resistance
in steering mechanism
501A 6 MDU Prox Steer: Feedback sensor error *Check MDU proximity sensor
and wiring
5021 6 StrMotor Steer motor error *Check wiring to steer motor
5022 6 StrSensr Steer: Hall Sensor Error *Check MDU proximity sensor
and wiring
*Check wiring for steering Hall
sensor
5090 1 Lift Sw Lift switch shorted *Lift switch and wiring
5091 1 Lower Sw Lower switch shorted *Lower switch and wiring
5092 1 Steer Sw Steer Handle Proximity switch off *Steer Handle proximity switch
and wiring
5590 1 Memory read warning-block *Repeatedly discharging battery
1-unable to start read process beyond normal limits

CAUTION
The electrical system on this truck utilizes many control-level circuits (low voltage and current),
which may be disturbed by contamination, wear or damage at the electrical connections. When
investigating problems or fault codes, it may be beneficial to first check and clean/repair all con-
nections in the affected circuit. The use of dielectric grease is recommended for all AMP and
Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION
The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to
abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a
defective truck component or controller. Fault codes may be generated in response to extreme
operating conditions such as potholes or very low battery levels.

40
2200 SRM 411 Fault Procedures

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued)

Items to Check if Code

Code ND Display Description
is Displayed
5591 1 Memory read warning-block *Repeatedly discharging battery
1-unable to start read process beyond normal limits
5592 1 MemEr_A3 Memory read warning-block *Repeatedly discharging battery
3-unable to start read process beyond normal limits
6011 5 TracSnsr Traction-Current sensor fault *Replace 1243 if problem persists
6013 5 M Fault Traction M fault *Replace 1243 if problem persists
6110 6 Str Comm Communication time-out *CAN bus wiring to steer
controller
6390 1 MemErr2a Memory read error from block *Rerun truck initialization; if
2, unable to start read process, problem persists, replace 1310
parameter loss
6391 1 MemErr2b Memory read error from block 2, *Rerun truck initialization; if
unable to complete read process, problem persists, replace 1310
parameter loss
6392 1 MemErr4a Memory read error from block *Rerun truck initialization; if
4, unable to start read process, problem persists, replace 1310
parameter loss
6393 1 MemErr4b Memory read error from block 4, *Rerun truck initialization; if
unable to complete read process, problem persists, replace 1310
parameter loss
6394 1 MemErr5a Memory read error from block *Rerun truck initialization; if
5, unable to start read process, problem persists, replace 1310
parameter loss
6395 1 MemErr5b Memory read error from block 5, *Rerun truck initialization; if
unable to complete read process, problem persists, replace 1310
parameter loss

CAUTION
The electrical system on this truck utilizes many control-level circuits (low voltage and current),
which may be disturbed by contamination, wear or damage at the electrical connections. When
investigating problems or fault codes, it may be beneficial to first check and clean/repair all con-
nections in the affected circuit. The use of dielectric grease is recommended for all AMP and
Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION
The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to
abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a
defective truck component or controller. Fault codes may be generated in response to extreme
operating conditions such as potholes or very low battery levels.

41
Fault Procedures 2200 SRM 411

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued)

Items to Check if Code

Code ND Display Description
is Displayed
7305 1 HtEnc Ch Height Encoder error channel *Check wiring to encoder
count mismatch *Check both encoder output
channels using voltmeter, should
pulse with encoder rotation
7306 1 StEnc Ch Steer Encoder error channel count *Check wiring to encoder
mismatch *Check both encoder output
channels using voltmeter, should
pulse with encoder rotation
7307 1 SteerEnc Steer Handle Proximity Sensor *Check Steer Handle proximity
shorted or steering encoder error function using Switch1 in
diagnostics
*Check steer encoder using
"StrInput" in diagnostics
*Check wiring to Steer Handle
proximity and steering encoder
7320 1 HtEncOff Height encoder not responding *Check mast proximity switch
(Position sensor fault) *Check height encoder, using "Lift
Hgt" in diagnostics
7390 1 Throttle Throttle potentiometer out of *Check wiring to throttle
range hall-effect potentiometer
*Check throttle output using
"ThrotOut" in diagnostics
7391 1 Hyd Pot Hydraulic potentiometer out of *Check wiring to potentiometer
range
7392 1 Mast Sw Height proximity not responding *Mast proximity switch and
(encoder functions with lift/lower) wiring
*No handset connected
7393 1 HtEncErr Running Height Encoder reset *Mast proximity switch and
error wiring
*No handset connected
*Height encoder and wiring

CAUTION
The electrical system on this truck utilizes many control-level circuits (low voltage and current),
which may be disturbed by contamination, wear or damage at the electrical connections. When
investigating problems or fault codes, it may be beneficial to first check and clean/repair all con-
nections in the affected circuit. The use of dielectric grease is recommended for all AMP and
Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION
The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to
abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a
defective truck component or controller. Fault codes may be generated in response to extreme
operating conditions such as potholes or very low battery levels.

42
2200 SRM 411 Fault Procedures

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued)

Items to Check if Code

Code ND Display Description
is Displayed
7394 1 HtEncErr Startup error on Height proximity *Mast proximity switch and
switch state (Mast lifted while wiring
truck off) *No handset connected
*No manual hoisting
*Height encoder and wiring
739A 1 HtEncErr Height Encoder error (hoist *Mast proximity switch and
function called for, but encoder wiring
not incrementing) *No handset connected
*Height encoder and wiring
739B 1 HtEncErr Height Encoder error (startup *Mast proximity switch and
check) wiring
*No handset connected
*Height encoder and wiring
739C 1 HtEncErr Height Encoder error: Encoder *Mast proximity switch and
indicated height <22" or >26" wiring
when 24" proximity switch passed *No handset connected
*Height encoder and wiring
739D 1 Throt Lo Throttle voltage too low *Throttle mechanism out of
adjustment (check neutral
position, calibrate throttle)
*Throttle Hall sensor and wiring
739E 1 Throt Hi Throttle voltage too high *Throttle mechanism out of
adjustment (check neutral
position, calibrate throttle)
*Throttle Hall sensor and wiring
8012 5 TrctComm Traction-CAN Communication *CAN wiring to traction controller
fault
8031 5 Cnt Crnt Contactor over current *Wiring shorted to traction
contactor
*Contactor coil or suppressor
shorted

CAUTION
The electrical system on this truck utilizes many control-level circuits (low voltage and current),
which may be disturbed by contamination, wear or damage at the electrical connections. When
investigating problems or fault codes, it may be beneficial to first check and clean/repair all con-
nections in the affected circuit. The use of dielectric grease is recommended for all AMP and
Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION
The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to
abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a
defective truck component or controller. Fault codes may be generated in response to extreme
operating conditions such as potholes or very low battery levels.

43
Fault Procedures 2200 SRM 411

Table 2. Fault Codes and Display Messages for R30XMS2 Only (Continued)

Items to Check if Code

Code ND Display Description
is Displayed
8032 5 Cnt Coil Contactor coil open *Wiring open to traction contactor
*Traction contactor coil failed open
8033 5 Fld Open Field Open *Wiring from 1243 to motor field
*Motor field winding failure
8034 5 TracCont Traction-Contactor Missing *Traction main fuse blown
*Traction contactor tips bad
*Traction contactor coil wiring
8101 6 Str Comm CAN open time-out *CAN Wiring to steering controller
8190 1 SteerErr General steering error *CAN Wiring to steering controller
*Wiring and fuse to steering
controller
*MDU proximity wiring
*Wiring between steer controller
and motor
8191 1 Comm Err Communication error *CAN Wiring
CAN time-out w/multiple nodes
8192 1 TrctComm Communication error *Fuse to traction controller
CAN time-out w/traction *CAN wiring to traction controller
8193 1 Str Comm Communication error *CAN Wiring to steering controller
CAN time-out w/steering *Fuse to steering controller
8194 1 SteerErr Steer error after startup *CAN bus wiring to steer
controller
8197 1 TrctComm No communication from traction *Fuse to traction controller
on startup *CAN bus wiring to traction
controller
8198 1 Comm Off CAN system off on startup *CAN bus wiring to 1310, steer,
traction controllers

CAUTION
The electrical system on this truck utilizes many control-level circuits (low voltage and current),
which may be disturbed by contamination, wear or damage at the electrical connections. When
investigating problems or fault codes, it may be beneficial to first check and clean/repair all con-
nections in the affected circuit. The use of dielectric grease is recommended for all AMP and
Molex electrical connectors when operating in adverse environments (freezers or dirty areas).

CAUTION
The fault detection software and circuits of the traction controller (Curtis 1243) are sensitive to
abrupt changes in currents and voltages. Controller fault codes may not necessarily indicate a
defective truck component or controller. Fault codes may be generated in response to extreme
operating conditions such as potholes or very low battery levels.

44
 TECHNICAL PUBLICATIONS

2200 SRM 411 6/04 (9/00)(7/99)(5/97)(12/96)(12/93)(7/92)(4/90) Printed in U.S.A.