HYSTER N30XMR, N40XMR, N45XMR, N25XMDR, N30XMDR, N50XMA Electric Forklift Service Repair Manual & Parts Manual (E138)

1 244-4505 SEM TRACTION MOTOR CONTROLLER AND HANDSET PART NO. 1465581 2200 SRM 758

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When liftingparts or assemblies, make sure that all slings, chains, and cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables, and chains have the capacity to support the weight of the load. • Do not 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 rollingor falling. See "How to Put the Lift Truck on Blocks" in the OPERATING MANUAL or the PERIODIC MAINTENANCE section. • Keep the unit and working area clean and in order. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTERAPPROVED parts when makingrepairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure that all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. • Make sure you follow the WARNING and CAUTIONnotes inthe instructions. • Gasoline, Liquid Petroleum Gas (LPG), and Diesel fuels are flammable. Make sure that you follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area has ventilation.

CONTENTS SEM TRACTION MOTOR CONTROLLER 1 Description/Features 1 Removal 1 Testing 2 Installation 2 PROGRAMMER HANDSET 3 Description/Features 3 SCROLL DISPLAY Keys 3 CHANGE VALUE Keys 3 MORE INFO Key 3 OPERATION 4 Connecting the Handset to the Traction Motor Controller 4 Disconnecting the Handset from the Traction Motor Controller 4 Programmer Self Test 4 OPERATING MODES 5 Program Menu 5 Test Menu 5 Diagnostics Menu 6 Diagnostic History 6 Special Program Menu 7 PROGRAMMING THE TRACTION MOTOR CONTROLLER 7 TROUBLESHOOTING 9 Status LED Diagnostics 9 Programmer Diagnostics 10 Diagnostics Menu 11 Test Menu 19 This section is for the following models: All electric lift trucks with the 1244-4505 SEM Traction Motor Controller. ©HYSTER COMPANY 1999

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

SEM TRACTION MOTOR CONTROLLER Description/Features The Curtis Model 1244-4505 SEM Traction Motor Controller uses a sophisticated microprocessor to con¬ trol the logic and operation of the controller, eliminating the need for forward and reverse contactors. The SEM motor controller operates on the principle of controlling the motor field circuit and the motor armature circuit in¬ dependently. The controller has many programmable features, including acceleration rate, maximum speed, braking current limit, and throttle braking current limit. The operator can also select from three different perfor¬ mance modes to customize the operation of the truck to the application, as required. The SEM controller in¬ cludes a full range of features as well as diagnostic and setup capability for reliable operation. FIGURE 1- TRACTION MOTOR CONTROLLER The Curtis Model 1307 Programmer Handset (Hyster P/N 2309750) is used to program and troubleshoot the traction motor controller. 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 selec¬ tion feature allows the operator to choose from three dif¬ ferent motor controller performance levels by pushing a button on the dash display. The rate of acceleration, maximum top speed, and throttle braking rate can be specifically assigned for each mode using the program¬ mer handset. Simplified diagnostic information is communicated to the dash display to alert the operator to adverse condi¬ tions, such as controller overtemperature, operator se¬ quence error, or motor controller malfunction. Removal 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 control handle. Put blocks under the drive wheels to keep the lift truck from moving. See the section PERIODIC MAINTE¬ NANCE, 8000 SRM 578. Refer to HOW TO PUT THE LIFT TRUCK ON BLOCKS. A WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspect¬ ing/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. 2. Disconnect and separate the battery connector. Re¬ move the battery. See the section PERIODIC MAIN¬ TENANCE, 8000 SRM 578. Refer to HOW TO CHANGE THE BATTERY. 3. Remove the electrical compartment cover. See the section FRAME, 100 SRM 604 for the removal proce¬ dures. Refer to COVERS, PANELS AND PLATES. A WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is discon¬ nected. To prevent electrical shock and injury, dis¬ charge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. Discharge the ca¬ pacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller's B+ andB— terminals. DONOT use a screwdriver to discharge the traction motor controller. 4. Discharge the controller by connecting a load across terminals B + and B — . 5. Unplug the connector from the traction motor con¬ troller. Tag and disconnect the wires to the power termi¬ nals. 6. Remove the washers and nuts retaining the control¬ ler to the frame. Carefully remove the traction motor controller from the lift truck. 1

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HYSTER N30XMR, N40XMR, N45XMR, N25XMDR, N30XMDR, N50XMA Electric Forklift Service Repair Manual & Parts Manual (E138)

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