AC MOTOR CONTROLLERS/DISPLAY
PANEL
DESCRIPTION, CHECKS, ADJUSTMENTS, AND
TROUBLESHOOTING
J2.00-3.20XM (J40-65Z) [A416/B416];
V30ZMD [D210/E210];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) [D098/E098]
PART NO. 1534735 2200 SRM 1056
AC Motor Controllers/Display Panel Table of Contents
TABLE OF CONTENTS
Description ......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
AC Motors .................................................................................................................................................. 1
Motor Controllers ...................................................................................................................................... 1
Master Controller ...................................................................................................................................... 1
Dash Display ............................................................................................................................................. 1
Controller Area Network Bus (CANbus).................................................................................................. 2
Master Controller Checks and Adjustments .................................................................................................... 2
Function Settings ............................................................................................................................................... 3
General ........................................................................................................................................................... 3
Function Numbers ......................................................................................................................................... 3
Function Descriptions ........................................................................................................................................ 5
General ........................................................................................................................................................... 5
Function Number 1 BATTERY VOLTAGE .............................................................................................. 5
Function Number 2 EXTENDED SHIFT ................................................................................................ 5
Function Number 3 ACCELERATION 1 ................................................................................................. 6
Function Number 4 ACCELERATION 2 ................................................................................................. 6
Function Number 5 TOP SPEED LIMIT ................................................................................................. 6
Function Number 6 REGEN BRAKING .................................................................................................. 6
Function Number 7 AUTO DECELERATION ........................................................................................ 6
Function Number 8 BDI ADJUSTMENT ................................................................................................ 6
Function Number 9 LIFT INTERRUPT .................................................................................................. 6
Function Number 10 POWER STEERING TIME DELAY ..................................................................... 7
Function Number 11 SERVICE REMINDER .......................................................................................... 7
Function Number 12 CUSTOM................................................................................................................ 7
Function Number 13 PUMP SPEED 1 .................................................................................................... 7
Function Number 14 PUMP SPEED 2 .................................................................................................... 7
Function Number 15 PUMP SPEED 3 .................................................................................................... 7
Function Number 16 PUMP ACCELERATION ...................................................................................... 7
Troubleshooting.................................................................................................................................................. 8
General ........................................................................................................................................................... 8
Controller Status Light Emitting Diodes (LEDs) ........................................................................................ 8
Master Controller ...................................................................................................................................... 9
AC Motor Controllers ................................................................................................................................ 9
Status Codes .................................................................................................................................................. 15
AC Motor Controllers Status Code Charts ....................................................................................................... 17
AC Transistor Motor Controller Replacement ................................................................................................. 37
General ........................................................................................................................................................... 37
General Maintenance Instructions ............................................................................................................... 43
Special Precautions ................................................................................................................................... 43
Fuses .............................................................................................................................................................. 44
Fan Test .......................................................................................................................................................... 44
Contactors ...................................................................................................................................................... 44
Repair ......................................................................................................................................................... 44
Thermal Sensors ............................................................................................................................................ 48
Motor Controller, Replace ............................................................................................................................. 48
Display Panel ..................................................................................................................................................... 49
General ........................................................................................................................................................... 49
Premium Display Panel ............................................................................................................................ 49
Standard Display Panel ............................................................................................................................ 49
Display Functions and Features ....................................................................................................................... 50
©2008 HYSTER COMPANY i
Table of Contents AC Motor Controllers/Display Panel
TABLE OF CONTENTS (Continued)
Key-On Initialization..................................................................................................................................... 50
Standard Display ........................................................................................................................................... 51
Premium Display ........................................................................................................................................... 51
Lift Truck Inspection Function ..................................................................................................................... 52
Access to Service Functions .......................................................................................................................... 52
Service Functions .......................................................................................................................................... 52
Service Functions .......................................................................................................................................... 53
Performance Modes ....................................................................................................................................... 55
Battery Discharge Indicator (BDI) ............................................................................................................... 55
Hourmeter ...................................................................................................................................................... 56
Dash Display Service Menu Navigation ........................................................................................................... 64
General ........................................................................................................................................................... 64
Moving Through Menu Selections ................................................................................................................ 64
Editing and Adding Information .................................................................................................................. 64
This section is for the following models:
J2.00-3.20XM (J40-65Z) [A416/B416];
V30ZMD [D210/E210];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]
ii
2200 SRM 1056 Description
Description
GENERAL
The alternating current (AC) system consists of AC
motors, motor controller(s), a master controller, and
a dash display. The major difference between the
AC system and the direct current (DC) system is the
master controller performs many of the same func-
tions that previously were performed in the motor
controllers on the DC system.
AC Motors
The AC motors are three-phase AC induction motors.
They do not include motor brushes or commutators.
An AC induction motor operates on three-phase AC
power provided directly by the motor controller. The
motor’s speed is controlled by the motor controller
and can be changed by changing the frequency of
the AC power provided to the motor. A speed sensor
is built into the rear motor bearing, which provides
RPM and direction feedback to the motor controller.
The motor controller continuously monitors motor di-
rection and speed. Using this feedback, the AC mo-
tor control system can provide much better vehicle
top speed control than is available with DC SEM sys-
tems.
The AC motors also have thermal sensors embedded
in the motor windings that are continuously moni-
tored by the motor controllers.
Motor Controllers
The motor controllers receive power from the truck’s
battery and convert it into three-phase AC power at
the frequencies and currents necessary to drive the
respective pump and/or traction motor. Each AC in-
duction motor provides feedback of speed, rotation
direction, and temperature directly to the motor con-
troller. The two motor controllers used to power the
traction motor and hydraulic pump motor are very
similar. The primary motor controller difference is
in the power output rating.
The motor controller logic board receives power from
the key switch. Power to the motors can be inter-
rupted indirectly by the key switch. The motor con-
trollers get motor speed and temperature informa-
tion directly from the motors. The motor controllers
do not get any other input from the truck. The mas-
ter controller relays speed, acceleration, and direc-
tion commands to the motor controllers.
Master Controller
The master controller is a general-purpose mi-
cro-controller for CANbus-based electric vehicles.
It contains processing power, memory resources,
analog and digital input/output (I/O) to provide the
required full-featured functionality. The master
controller is designed to manage the traction motor
controller and pump motor controller, interface to
the operator controls, auxiliary functions, and to
control the vehicle dash display.
The master controller also manages the operating
truck parameters, status codes, battery discharge
indicator (BDI) function, hourmeters, password fea-
ture, and all operator inputs. It also controls the
contactor, cooling fans, and strobe light relay.
Dash Display
The new AC dash display is similar in appearance
to the SEM dash display and includes the same fea-
tures. In addition, the AC dash display provides ex-
panded service capabilities. The dash display has a
password-accessible service mode that allows a tech-
nician to change control settings and view real-time
RPMs, current, temperature, and switch closure in-
formation. Previously, a separate handset or com-
puter was required for these operations. For a com-
plete description of the display panel, see the Display
Panel section of this manual.
1
Master Controller Checks and Adjustments 2200 SRM 1056
Controller Area Network Bus (CANbus)
The motor controllers, master controller, and dash
display are connected together with a CANbus
communication system. A personal computer (PC)
with the appropriate Electric Truck AC Controller
(ETACC) service software and interface cable can
easily communicate with all system nodes by simply
connecting to the CANbus. A diagnostics connector,
located under the dash and next to the display, is
configured specifically for this purpose. See Figure 1
and section Troubleshooting and Adjustments
Using the AC Controls Program (ETACC) 2200
SRM 1058 for procedures to connect a PC to lift
truck.
1. DIAGNOSTIC CONNECTOR
2. DASH DISPLAY
3. DASH WIRE HARNESS
Figure 1. Diagnostic Connector
Master Controller Checks and Adjustments
NOTE: All checks and adjustments to the master
controller can be done with a personal computer (PC)
that has the ETACC service software installed. See
Troubleshooting and Adjustments Using the
AC Controls Program (ETACC) 2200 SRM 1058
for software installation procedures. A diagnostics
connector in the wiring harness below the display
panel can connect the PC to the CANbus system to
communicate to the master controller (see Figure 1).
Many checks can also be done at the display panel
without being connected to a PC.
The following checks and adjustments may be made
using a PC or the dash display:
• Check the system status codes history.
• Check the state of charge of the battery.
• Check the hourmeter readings on the traction cir-
cuit and hydraulic pump controllers.
• Monitor or adjust the register values for each func-
tion as shown in Table 1, Table 2, and Table 3.
2
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Hyster E114 (E1.50XM, E1.75XM, E2.00XM, E2.00XMS Europe) Service Shop Manual Forklift Workshop Repair Book
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Description
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This service manual covers a wide range of topics including the frame, cooling system, LPG fuel system, transmission, differential, steering and brake systems, hydraulic system, electrical components, instrument panel indicators, and more. It also includes diagrams, periodic maintenance guidelines, and specifications.
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- Hand pallet truck
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- Rider low lift truck
- Towing tractor
- Walkie stacker
- Rider stacker
- Reach truck (small forklift, designed for small aisles, usually electrically powered, so-named because the forks can extend to reach the load)
- Electric counterbalanced truck
- IC counterbalanced truck
- Sideloader
- Telescopic handler
- Walkie Order Picking truck
- Rider Order Picking truck (commonly called an "Order Picker"; like a small forklift, except the operator rides up to the load and transfers it article by article)
- Articulated Very Narrow Aisle Counterbalanced trucks (commonly called "Flexi or Bendi Truck")
- Guided Very Narrow Aisle truck - 'Man Down' (a type of reach truck designed for aisles less than five feet wide) and 'Man Riser' Combination pickcle Picker/ Stacker truck
- Truck Mounted Forklift / Sod Loader
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