Hyster H160 (J30xmt2, J35xmt2, J40xmt2) Electric Forklift Parts Manual

SX/SR TRANSISTOR MOTOR CONTROLLERS AND HANDSET ALL ELECTRIC LIFT TRUCKS THAT HAVE A SX OR SR TRANSISTOR MOTOR CONTROLLER PART NO. 1454588 2200 SRM 697

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!

SX/SR Transistor Motor Controllers and Handset Table of Contents TABLE OF CONTENTS Introduction to SEM .......................................................................................................................................... 1 Advantages of Transistorized SEM .............................................................................................................. 1 Features of SEM ............................................................................................................................................ 2 Solid-State Reversing ................................................................................................................................ 2 Performance and Efficiency ...................................................................................................................... 2 Field Weakening ........................................................................................................................................ 2 Regenerative Braking ............................................................................................................................... 2 SX Transistor Motor Controllers ....................................................................................................................... 3 Introduction ................................................................................................................................................... 3 Proportional Operation for Dual-Motor Trucks ........................................................................................... 3 General....................................................................................................................................................... 3 Operation ................................................................................................................................................... 5 Controller Features ....................................................................................................................................... 7 General....................................................................................................................................................... 7 Creep Speed ............................................................................................................................................... 7 Controlled Acceleration ............................................................................................................................. 7 Current Limit ............................................................................................................................................ 7 Braking........................................................................................................................................................... 7 Regenerative Braking to Zero Speed........................................................................................................ 7 Pedal Position Braking ............................................................................................................................. 8 Auto Braking ............................................................................................................................................. 8 Conventional Plug Braking ...................................................................................................................... 8 Auxiliary Speed Control ................................................................................................................................ 8 Field Weakening ........................................................................................................................................ 8 Speed Limits .............................................................................................................................................. 8 Ramp Operation............................................................................................................................................. 8 Ramp Start ................................................................................................................................................ 8 Antirollback ............................................................................................................................................... 9 Steer Pump Contactor Time Delay ............................................................................................................... 9 On-Board Coil Drivers and Internal Coil Suppression................................................................................ 9 System Protective Override .......................................................................................................................... 9 SRO (Static Return to Off) ........................................................................................................................ 9 Accelerator Volts Hold Off......................................................................................................................... 9 Pulse Monitor Trip (PMT) ......................................................................................................................... 9 Thermal Protector (TP) ............................................................................................................................. 9 Low Voltage................................................................................................................................................ 9 SR Lift Pump Controllers .................................................................................................................................. 10 Sensor Interface/Contactor Driver Module ...................................................................................................... 14 Diagnostic Status Codes and Troubleshooting ................................................................................................. 14 General Maintenance Instructions ............................................................................................................... 14 Special Precautions ................................................................................................................................... 14 Diagnostics ..................................................................................................................................................... 15 Systems Diagnostics.................................................................................................................................. 15 Status Codes .................................................................................................................................................. 15 Standard Status Codes ............................................................................................................................. 15 Stored Status Codes .................................................................................................................................. 16 Other Features............................................................................................................................................... 16 Hourmeter Readings ................................................................................................................................. 16 Maintenance Alert and Speed Limit ........................................................................................................ 16 Battery Discharge Indication (BDI) ......................................................................................................... 16 Internal Resistance Compensation .......................................................................................................... 16 ©2003 HYSTER COMPANY i

Table of Contents SX/SR Transistor Motor Controllers and Handset TABLE OF CONTENTS (Continued) Handset Programmable ............................................................................................................................ 16 RS 232 Communication Ports ................................................................................................................... 16 Circuit Board Coil Driver Modules........................................................................................................... 17 Maintenance Management Capability ..................................................................................................... 17 Interactive Instrument Panel Modes ....................................................................................................... 17 General Troubleshooting Instructions .......................................................................................................... 19 Status Code Troubleshooting Tables ................................................................................................................. 21 SX/SR Handset Instructions ............................................................................................................................. 59 General Features ........................................................................................................................................... 59 Connecting the Handset ................................................................................................................................ 61 Startup Sequence........................................................................................................................................... 61 Setup Mode .................................................................................................................................................... 62 Stored Status Code Mode .............................................................................................................................. 63 Clearing the Stored Status Codes................................................................................................................. 63 Restarting Lift Truck..................................................................................................................................... 63 SX Traction Controller Function Descriptions ................................................................................................. 64 Premium Instrument Panel Interactive Modes ........................................................................................... 71 SR Pump Controller Function Descriptions ..................................................................................................... 74 Premium Instrument Panel Interactive Modes ........................................................................................... 77 This section is for the following models: All Electric Lift Trucks That Have a SX or SR Transistor Motor Controller ii

2200 SRM 697 Introduction to SEM Introduction to SEM ADVANTAGES OF TRANSISTORIZED SEM Historically, most electric lift trucks have relied on series motor designs because of their ability to pro- duce very high levels of torque at low speeds. See Fig- ure 1. As the demand for high-efficiency systems increases, shunt motors are now often being considered over series motors. In most applications, by indepen- dently controlling the field and armature currents in the separately excited motor, the best attributes of both the series- and the shunt-wound motors can be combined. Figure 1. Series Motor In a shunt motor, the field is connected directly across the voltage source and is therefore indepen- dent of variations in load and armature current. If field strength is held constant, the torque developed will vary directly with the armature current. If the mechanical load on the motor increases, the motor slows down, reducing the back EMF (which depends on the speed, as well as the constant field strength). The reduced back EMF allows the armature current to increase, providing the greater torque needed to drive the increased mechanical load. If the mechanical load is decreased, the process reverses. The motor speed and the back EMF increase, while the armature current and the torque developed de- crease. Thus, whenever the load changes, the speed changes also, until the motor is again in electrical balance. In a shunt motor, the variation of speed from no load to normal full load on level ground is less than 10 per- cent. For this reason, shunt motors are considered to be constant speed motors. See Figure 2. Figure 2. Shunt Motor In the separately excited motor, the motor is operated as a fixed field shunt motor in the normal running range. When additional torque is required (climbing a ramp, etc.) the field current is increased to provide the higher level of torque. In most cases, the performance can be very similar to that of a comparable size series motor. See Figure 3. Figure 3. Separately Excited Motor 1

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Hyster H160 (J30xmt2, J35xmt2, J40xmt2) Electric Forklift Parts Manual

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