524164719-2200YRM0928-(07-2010)-US-EN 1 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... CURTIS 1297 TRANSISTOR MOTOR CONTROLLER MPE080-E [A890]; MPW080-E [A891]; MPW065-E [A894]; MPE060-E [A896]; MPW060-E [A897]; MTR005-E [A902]; MTR007-E [A903]; MPC060-E [A904]; MPC080-E [A905] 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.
524164719-2200YRM0928-(07-2010)-US-EN 2 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background.
524164719-2200YRM0928-(07-2010)-US-EN 3 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... flow from the battery can cause personal injury or property damage. All checks, adjustments, and repairs in the drive unit compartment are done with the compartment cover removed. Remove the drive unit compartment cover for access to the electrical components. WARNING The capacitor in the transistor controller can hold an electrical charge after the battery has been disconnected.
524164719-2200YRM0928-(07-2010)-US-EN 4 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... NOTE: There are no user-serviceable parts in the Curtis 1297 controller. No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty. INSTALL 1. Make certain the mounting surface for the traction motor controller is clean.
24164719-2200YRM0928-(07-2010)-US-EN 5 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... M2 Deceleration Limit Sec 10.0 10.0 - 0.1 to 10.0 Mode 2 Deceleration Rate M1 Max Speed Limit % 48 48 82 M2 Max Speed Limit % 100 100 - Coast Current Limit Amps 0 0 25 0 to 350 Restraint Amps 9.2 6.0 9.0 Min. Field to 40.
524164719-2200YRM0928-(07-2010)-US-EN 6 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... The programmer handset is a handheld tool that allows the user to program, test, and diagnose the traction motor controller. See Figure 3. It has been designed for ease of use with eight keys to control all functions. A MORE INFO key is included to provide more detail on any display item. The display window contains a four-line LCD display.
524164719-2200YRM0928-(07-2010)-US-EN 7 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected. DO NOT use a screwdriver to discharge the traction motor controller.
524164719-2200YRM0928-(07-2010)-US-EN 8 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... SYS MODE Software info for factory troubleshooting. BATT VOLTAGE Battery voltage across B+ and B− in volts. BDI % Battery state of charge, as % of full charge. HEAT SINK °C Heat sink temperature in °C. THROTTLE % Throttle reading, as % of full throttle. FIELD CURRENT Traction motor field current, in amps. ARM CURRENT Traction motor armature current, in amps.
524164719-2200YRM0928-(07-2010)-US-EN 9 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... 1. Turn the key switch to the OFF position. 2. Disconnect and separate battery connector. 3. Remove drive unit compartment cover. WARNING The capacitor in the traction motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses.
524164719-2200YRM0928-(07-2010)-US-EN 10 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... 12. Press the more info key to return to the PROGRAM menu if the MORE INFO screen had been selected. 13. Repeat Step 9 through Step 12, as required, until all of the functions are set to the desired values.
524164719-2200YRM0928-(07-2010)-US-EN 11 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Figure 7. Menu Selection After selection of a main menu item, submenus for the main selection can be opened using the right arrow. See Figure 8. As submenus are opened, a new series of indicator boxes will appear with a blinking square to indicate the current submenu selection. You can move up and down within the submenus using the up and down arrows.
524164719-2200YRM0928-(07-2010)-US-EN 12 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... re-navigate the entire menu structure. While you are positioned at a menu item you want to bookmark, press one of the bookmark keys and hold it down for 4 seconds until the BOOKMARK SET screen appears. You can return to this preset menu item at any time by pressing the bookmark key you assigned to this item. Bookmarks are permanently retained in the programmer memory.
524164719-2200YRM0928-(07-2010)-US-EN 13 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Figure 10. Menu Selection Figure 11. Menu Selection Monitor Menu The monitor menu will contain a list of all truck functions that can be read and displayed by the programmer. Using the menu navigation key, scroll up or down to select a parameter from the list. See Figure 12. Each menu item is constantly monitored and displayed to show real-time information about the selected function.
524164719-2200YRM0928-(07-2010)-US-EN 14 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Figure 13. Menu Selection Faults Menu The FAULTS menu will provide the present status of the motor controller and access to past fault history. The fault history is uploaded to the programmer when the programmer is connected to the motor controller. Use the menu navigation key to access system faults, fault history, or to clear the fault history. See Figure 14.
524164719-2200YRM0928-(07-2010)-US-EN 15 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Figure 16. Menu Selection Functions menu The FUNCTIONS menu is used to copy controller to the original settings. Use the access the SETTINGS menu. See Figure from an existing controller and download Figure 18. data between motor controllers or reset the data in a menu navigation key to select the FUNCTIONS menu to 17.
524164719-2200YRM0928-(07-2010)-US-EN 16 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Figure 19. Menu Selection Programmer Setup Menu The PROGRAMMER SETUP menu contains several items that can be viewed, setup, or customized to the user’s preference. See Figure 20. Figure 20. Menu Selection Programming the Traction Motor Controller - 1311 Handset WARNING NEVER adjust function settings outside the range recommended for the specific truck model. See Table 1 or Table 3.
524164719-2200YRM0928-(07-2010)-US-EN 17 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... See Table 1 or Table 3. 11. Using the data increase/decrease key, change the function setting to the new setting. Pressing the (+) side of the key will increase the parameter value. Pressing the (−) side of the key will decrease the parameter setting. WARNING Program changes affect lift truck performance and operation.
524164719-2200YRM0928-(07-2010)-US-EN 18 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Figure 21. BDI/Hourmeter LED Fault Codes The Curtis 1297 controller has a Status LED built into it and can be seen through a window in the label on top of the controller. This Status LED displays fault codes. During normal operation, with no faults present, the Status LED flashes steadily on and off like a heartbeat.
524164719-2200YRM0928-(07-2010)-US-EN 19 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Fault codes 20, 32, or 34 may also intermittently appear after the battery has been changed. If the BDI indicator will not reset, this may indicate that the battery is not properly charged. Always install fully charged, properly functioning batteries to the lift truck. NOTE: Minimum reset voltage for the BDI is 25.2 volts (open cell), specific gravity should be approximately 1.
524164719-2200YRM0928-(07-2010)-US-EN 20 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Disconnect motor leads from controller. Logic Resistance between Traction motor current sensor error. motor terminals on The controller uses the traction motor current sensor to detect incorrect current in the controller and B− traction motor circuit. should be 1 mega ohm or more.
524164719-2200YRM0928-(07-2010)-US-EN 21 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Code Display 1,4 Code 14 MPE060E, MPE080E, MPW060E, MPW065E, MPW080E, MPC060-E, MPC080-E Condition Low current sensed in lowering solenoid coil circuit when lower function is selected. Valve Fault Circuit Description Truck Response No Lowering Function Possible Causes and Test Procedures 1. Check wiring to the lowering solenoid coil. Ensure all wiring and connectors are tight. 2.
524164719-2200YRM0928-(07-2010)-US-EN 22 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... MPW080E, MPE060E, MPE080E Condition Voltage from the throttle handle is too high. Circuit Description Truck Response No Traction Possible Causes and Test Procedures 1. Throttle sensor not centered. 2. Throttle sensor input shorted to B+. 3. Failed throttle sensor. 4. Improper parameters on software, use handset to verify parameters.
524164719-2200YRM0928-(07-2010)-US-EN 23 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Logic Controller checks for the throttle signal to be less than 4.8 V. LED Dash Code Display 2,1 Code 21 Model Programmer Display MPW060E, MPW065E, MPW080E, MPE060E, MPE080E Throttle Wiper Low Condition Voltage from the throttle handle is too low. Circuit Description Truck Response No Traction Possible Causes and Test Procedures 1. Throttle sensor not centered. 2.
524164719-2200YRM0928-(07-2010)-US-EN 24 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Logic Controller checks for the throttle signal to be above 0.1 V. LED Dash Code Display 2,1 Code 21 Model Programmer Display MTR005-E, MTR007-E, MPC060-E, MPC080-E Throttle Wiper Low Condition Voltage from the throttle sensor is too low. Circuit Description Truck Response No Traction Possible Causes and Test Procedures Throttle sensor not centered.
524164719-2200YRM0928-(07-2010)-US-EN 25 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Logic Controller checks for the throttle signal to be above 0.1 V. LED Dash Code Display 2,2 Code 22 Model Programmer Display MPE060E, MPE080E, MPW060E, MPW065E, MPW080E Pump Sensor Condition Pump motor current sensor error. Circuit Description Truck Response No Lifting Possible Causes and Test Procedures 1. Incorrect pump motor wiring. Check wiring to traction motor.
524164719-2200YRM0928-(07-2010)-US-EN 26 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Truck Response No Traction Possible Causes and Test Procedures 1. Return throttle to neutral. 2. Ensure linkage is allowing throttle to return to neutral. 3. Check throttle Hall Effect sensor is centered. Sensor output = 2.5 V when centered. 4. Check connector at J2 is tight and pins are in good condition. 5. Failed throttle sensor. 6. Ensure continuity through proximity switch. 7.
524164719-2200YRM0928-(07-2010)-US-EN 27 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... parameters on software, use handset to verify parameters. 4. For testing procedures refer to Control Card Functional Test in this section. Logic If the high speed switch is activated at startup, the controller will fault. LED Dash Code Display 2,4 Code 24 Model Programmer Display MPE060E, MPE080E, MPW060E, MPW065E, MPW080E Pump M− Condition External short of pump motor M− to B−.
524164719-2200YRM0928-(07-2010)-US-EN 28 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... MPW080E, MPE060E, MTR005E, and MPC060E = Approx. 14.0 ohms MPW065E = Approx. 4.0 ohms If open or shorted, replace coil. 4. Check voltage at pin #J1-12 and pin #J1-20. Voltage should be less than battery voltage. 5. If brake still cannot be energized, replace controller. Logic Controller will output battery volts at pin #J1-20 when brake switch is closed.
524164719-2200YRM0928-(07-2010)-US-EN 29 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... No Traction Possible Causes and Test Procedures 1. Ensure the cable between the controller and the control handle interface module is securely connected. 2. Verify the cable from the control handle is secure to the control handle interface module connector. 3. Verify all pin connections are tight and making contact. 4. Check for correct connector wiring. 5.
524164719-2200YRM0928-(07-2010)-US-EN 30 of 33 Condition Traction motor field windings are shorted. http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Circuit Description Truck Response No Traction Possible Causes and Test Procedures 1. Check field windings at traction motor for shorted condition. 2. Check for continuity between the FU 1 or FU 2 terminal and the motor frame. Refer to the section Electrical System 2200 YRM 1052 or Electrical System 2200 YRM 929, Fuses.
524164719-2200YRM0928-(07-2010)-US-EN 31 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... All other models = Approx. 54 ohms 4. Check coil open or shorted. Replace coil. Logic The controller checks to ensure the main contactor circuit is completed on startup. If the controller senses this circuit has not been completed, the controller will fault. LED Dash Model Code Display Programmer Display 4,2 Code 42 All Condition Controller is sensing voltage above present value.
524164719-2200YRM0928-(07-2010)-US-EN 32 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... Test Procedures 1. Operating in a high-temperature environment. 2. Exceeding normal truck duty cycle. Reduce load size. Increase cycle time. 3. Verify correct operation of heat sink sensor. Use handheld programmer to check that heat sink reading is approximately room temperature after truck has cooled to room temperature.
524164719-2200YRM0928-(07-2010)-US-EN 33 of 33 http://www.yaleaxcessonline.com/lib/service/US/EN/html/2200YRM0928... d. If the above tests pass, the tiller head and the control card are good. 5. If handset does not operate, follow LED OFF instructions listed in LED Fault Codes. 6. If handset tests did not pass, open tiller head and verify connection at control card. a. Power off the forklift and measure continuity between pin 2, on JP2, on the control card and Bat the controller.