Servicio E45z Hyster - 230906 - 091517

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 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 motor controller logic board receives power from
the key switch. Power to the motors can be inter-
The alternating current (AC) system consists of AC rupted indirectly by the key switch. The motor con-
motors, motor controller(s), a master controller, and trollers get motor speed and temperature informa-
a dash display. The major difference between the tion directly from the motors. The motor controllers
AC system and the direct current (DC) system is the do not get any other input from the truck. The mas-
master controller performs many of the same func- ter controller relays speed, acceleration, and direc-
tions that previously were performed in the motor tion commands to the motor controllers.
controllers on the DC system.
Master Controller
AC Motors
The master controller is a general-purpose mi-
The AC motors are three-phase AC induction motors. cro-controller for CANbus-based electric vehicles.
They do not include motor brushes or commutators. It contains processing power, memory resources,
An AC induction motor operates on three-phase AC analog and digital input/output (I/O) to provide the
power provided directly by the motor controller. The required full-featured functionality. The master
motor’s speed is controlled by the motor controller controller is designed to manage the traction motor
and can be changed by changing the frequency of controller and pump motor controller, interface to
the AC power provided to the motor. A speed sensor the operator controls, auxiliary functions, and to
is built into the rear motor bearing, which provides control the vehicle dash display.
RPM and direction feedback to the motor controller.
The motor controller continuously monitors motor di- The master controller also manages the operating
rection and speed. Using this feedback, the AC mo- truck parameters, status codes, battery discharge
tor control system can provide much better vehicle indicator (BDI) function, hourmeters, password fea-
top speed control than is available with DC SEM sys- ture, and all operator inputs. It also controls the
tems. contactor, cooling fans, and strobe light relay.
The AC motors also have thermal sensors embedded Dash Display

in the motor windings that are continuously moni-
tored by the motor controllers. The new AC dash display is similar in appearance
to the SEM dash display and includes the same fea-
Motor Controllers tures. In addition, the AC dash display provides ex-
panded service capabilities. The dash display has a
The motor controllers receive power from the truck’s password-accessible service mode that allows a tech-
battery and convert it into three-phase AC power at nician to change control settings and view real-time
the frequencies and currents necessary to drive the RPMs, current, temperature, and switch closure in-
respective pump and/or traction motor. Each AC information. Previously, a separate handset or com-
duction motor provides feedback of speed, rotation puter was required for these operations. For a com-
direction, and temperature directly to the motor con- plete description of the display panel, see the Display
troller. The two motor controllers used to power the Panel section of this manual.
traction motor and hydraulic pump motor are very
similar. The primary motor controller difference is
in the power output rating.
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 The following checks and adjustments may be made
controller can be done with a personal computer (PC) using a PC or the dash display:
that has the ETACC service software installed. See • Check the system status codes history.
Troubleshooting and Adjustments Using the • Check the state of charge of the battery.
AC Controls Program (ETACC) 2200 SRM 1058 • Check the hourmeter readings on the traction cir-
for software installation procedures. A diagnostics cuit and hydraulic pump controllers.
connector in the wiring harness below the display • Monitor or adjust the register values for each func-
panel can connect the PC to the CANbus system to tion as shown in Table 1, Table 2, and Table 3.
communicate to the master controller (see Figure 1).
Many checks can also be done at the display panel
without being connected to a PC.
2
2200 SRM 1056 Function Settings
Function Settings
GENERAL Table 1. Factory Parameters for J2.00-3.20XM
(J40-65Z) (A416/B416)
The master controller has several functions (pa-
rameters) that can be changed to configure differ- Factory Factory
ent lift truck models and voltages. The function set- Function Setting Setting
tings are stored and used by the master controller to 72V 80V
determine lift truck performance or other operation
variables. 1-BATTERY
72 80
VOLTAGE
NOTE: Table 1, Table 2, Table 3, and Table 4 show the
2-EXTENDED SHIFT ENABLED ENABLED
default settings for each control function. The factory
settings are the recommended settings for new units. 3-ACCELERATION 1 40 40
These settings will give satisfactory performance for
4-ACCELERATION 2 7 7
most applications.
5-TOP SPEED LIMIT 94 100
All functions can be adjusted within the permitted
range to change the lift truck operation for a spe- 6-REGEN BRAKING 75 75
cific application. Adjustment of a register to a num- 7-AUTO
ber that is different than the factory setting is al- 70 70
DECELERATION
lowed, but follow the instructions carefully. Adjust-
ments other than the factory settings will cause the 8-BDI ADJUSTMENT 30 30
lift truck performance and energy consumption to 9-LIFT INTERRUPT ENABLED ENABLED
change.
10-PS TIME DELAY 20 20
FUNCTION NUMBERS 11-SERVICE
0 0
REMINDER
WARNING 12-CUSTOM 0 0
NEVER adjust any of the function registers
without using the procedures and settings 13-PUMP SPEED 1 25 25
given in this section. 14-PUMP SPEED 2 50 50
NOTE: Functions 13, 14, and 15 do not apply to lift 15-PUMP SPEED 3 95 95
trucks that are equipped with the electro-hydraulics 16-PUMP
option. 25 25
ACCELERATION
The function numbers are code numbers for the dif-
ferent parameters that can be set for the master con-
troller. The PC or the dash display must be used to
adjust the parameters for the master controller.
Table 2. Factory Setting for V30ZMD (D210/E210) and E2.00-3.20XM (E45-65Z) (G108)
Factory Factory Factory Factory

Function
Setting 36V Setting 48V Setting 72V Setting 80V
1-BATTERY VOLTAGE 36 48 72 80
2-EXTENDED SHIFT ENABLED ENABLED ENABLED ENABLED
3-ACCELERATION 1 40 49 46 50
4-ACCELERATION 2 5 8 6 9
5-TOP SPEED LIMIT 85 92 91 98
6-REGEN BRAKING 60 60 60 70
3
Function Settings 2200 SRM 1056
Table 2. Factory Setting for V30ZMD (D210/E210) and E2.00-3.20XM (E45-65Z) (G108) (Continued)
Factory Factory Factory Factory

Function
Setting 36V Setting 48V Setting 72V Setting 80V
7-AUTO DECELERATION 65 70 70 70
8-BDI ADJUSTMENT 30 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20 20
11-SERVICE REMINDER 0 0 0 0
12-CUSTOM 0 0 0 0
13-PUMP SPEED 1 25 25 25 25
14-PUMP SPEED 2 50 50 50 50
15-PUMP SPEED 3 95 95 95 95
16-PUMP ACCELERATION 25 25 25 25
Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
Factory Setting Factory Setting Factory Setting

Function
36V 48V 48V (Europe)
1-BATTERY VOLTAGE 36 48 48
2-EXTENDED SHIFT ENABLED ENABLED ENABLED
3-ACCELERATION 1 48 66 62
5-TOP SPEED LIMIT 80 100 100
6-REGEN BRAKING 60 60 75
7-AUTO DECELERATION 65 70 70
8-BDI ADJUSTMENT 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20
11-SERVICE REMINDER 0 0 0
12-CUSTOM 0 0 0
13-PUMP SPEED 1 25 25 25
14-PUMP SPEED 2 50 50 50
15-PUMP SPEED 3 95 95 95
16-PUMP ACCELERATION 25 25 25
4
2200 SRM 1056 Function Descriptions
Table 4. Factory Parameters for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)
Factory Setting Factory Setting Factory Setting

Function
36V 48V 80V
1-BATTERY VOLTAGE 36V 48V 80V
2-EXTENDED SHIFT ENABLED ENABLED ENABLED
5-TOP SPEED LIMIT 85 100 100
6-REGEN BRAKING 65 65 65
7-AUTO DECELERATION 80 80 80
8-BDI ADJUSTMENT 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20
11-SERVICE REMINDER 0 0 0
12-CUSTOM 0 0 0
13-PUMP SPEED 1 25 25 25
14-PUMP SPEED 2 50 50 50
15-PUMP SPEED 3 95 95 95
16-PUMP ACCELERATION 25 25 25
Function Descriptions
GENERAL Function Number 2 EXTENDED SHIFT
(Enable or Disable)
WARNING
If any of the register values are changed, the Function 2 enables or disables a preset motor per-
operators must be told that the lift truck will formance program in the traction motor controller.
operate differently.
When enabled, this function provides a balance be-
The following section contains descriptions for the tween truck performance and battery shift life that
different functions. The register setting for each will meet the requirements of most applications.
function is specific for each motor controller. Truck acceleration and top speed will vary with the
amount of load on the forks.
Function Number 1 BATTERY VOLTAGE
When disabled, truck acceleration and top speed are
(36, 48, 72, or 80) determined by values set in Functions 3, 4, and 5.
Function 1 is used to inform the master controller If the motor and controller can deliver the power,
what voltage battery is installed in the truck. The then the truck performance will not vary with the
battery choices are: 36, 48, 72, or 80. amount of load on the forks or the battery state of
charge
Grade climbing speed will also improve because the

motor controller will deliver maximum current. Any
5
Function Descriptions 2200 SRM 1056
increase in performance will decrease the battery Any increase in performance will decrease the bat-
shift life. tery shift life.
Function Number 3 ACCELERATION 1 Function Number 6 REGEN BRAKING

(Range 0-100) (Range 0-100)
Function 3 determines the truck acceleration rate Function 6 determines the maximum deceleration
when traction motor speed is below 1,500 rpm. The rate when the accelerator pedal is fully depressed
truck will accelerate at this rate regardless of the during regen braking.
load on the forks, provided that the motor and con-
trol can deliver the required power. NOTE: The deceleration rate is less when the pedal
is not fully depressed.
To increase the acceleration rate above the factory
setting, Function 2 will need to be set to disabled. Function Number 7 AUTO DECELERATION
To reduce the acceleration rate below the factory (Range 0-100)
setting, Function 2 may be enabled or disabled.
Function 7 determines the maximum deceleration
Any increase in performance will decrease the bat- rate when the accelerator pedal is released. The
tery shift life. strength of auto deceleration is a percentage of the
regen braking strength determined by Function 6.
Function Number 4 ACCELERATION 2
A Function 7 setting of zero will turn off auto decel-
(Range 0-100) eration completely, and a setting of 100 will give auto
deceleration the same strength as regen braking.
Function 4 determines the truck acceleration rate
when traction motor speed is above 1,500 rpm. The Function Number 8 BDI ADJUSTMENT
truck will accelerate at this rate regardless of the
load on the forks, provided that the motor and con- (Range 0-100)
trol can deliver the required power.
Function 8 allows for adjustment to improve the ac-
To increase the acceleration rates above the factory curacy of the Battery Discharge Indicator in the
setting, Function 2 will need to be disabled. dash display. Increasing the setting will cause the
gage to show empty at a higher specific gravity or
To reduce the acceleration rate below the factory battery voltage.
setting, Function 2 may be enabled or disabled.
A setting of 30 is the recommended starting point for
Any increase in performance will decrease the bat- flooded cell batteries, and a setting of 50 for main-
tery shift life. tenance-free batteries. Further adjustments may be
used to fine-tune the BDI accuracy.
Function Number 5 TOP SPEED LIMIT
Function Number 9 LIFT INTERRUPT
(Range 1-100)
(Enable or Disable)
Function 5 determines the top speed limit of the
truck. Function 9 enables or disables the lift interrupt
feature. The lift interrupt feature stops hoist opera-
To increase the top speed above the factory setting,
tion when the BDI reads empty to protect the bat-
Function 2 will need to be disabled.
tery from excessive discharge and possible damage.
To reduce the top speed below the factory setting,
NOTE: Trucks are shipped from the factory with this
Function 2 may be enabled or disabled.
feature enabled.
For speed limits slower than the normal truck speed,
the top speed is the same regardless of the load on
the forks. Acceleration rates are also unaffected by
lowering the top speed.
6
2200 SRM 1056 Function Descriptions
Function Number 10 POWER STEERING Function Number 13 PUMP SPEED 1

TIME DELAY
NOTE: This function does not apply for lift trucks
(Range 0-100) that are equipped with the e-hydraulics option.
Function 10 sets the time delay for the power steer- (Range 0-100)
ing contactor to open after the seat switch opens. The
Function 13 determines the hydraulic pump motor
setting range is 1.5 to 65 seconds. Opening the key
low speed. Low speed is used for tilt and some
switch will open the power steering contactor with no
auxiliary operations (sideshift).
delay.
Any increase in performance will decrease the bat-
Function Number 11 SERVICE REMINDER tery shift life.
(Set Next Hourmeter)
Function Number 14 PUMP SPEED 2
Function 11 can be used by the service technician
NOTE: This function does not apply for lift trucks
to show a Status Code 99 when the truck is due for
that are equipped with the e-hydraulics option.
service.
(Range 0-100)
To use this feature, set this function to the hourme-
ter reading that the service is to occur. When that Function 14 determines the hydraulic pump motor
hourmeter is reached, the dash display will display medium speed. Medium speed is used for slow
Status Code 99 for 10 seconds each time the key is hoist and some auxiliary operations.
turned ON. After 20 hours of operation, the truck will
slow to half speed and the code will display continu- Any increase in performance will decrease the bat-
ously until the service is performed. After servicing tery shift life.
the truck, Function 11 should be set to the next ser-
vice hourmeter reading to regain full performance. Function Number 15 PUMP SPEED 3
NOTE: A setting of zero will disable this feature. NOTE: This function does not apply for lift trucks
that are equipped with the e-hydraulics option.
Function Number 12 CUSTOM
(Range 0-100)
(Range 0-100)
Function 15 determines the hydraulic pump motor
Function 12 is not used except for special func- high speed. High speed is used for maximum
tions required for special applications. Normally, hoist speed.
this function is set to zero.
Any increase in performance will decrease the bat-
A setting value of 1 will change auto deceleration to tery shift life.
work even with a partial release of the accelerator
pedal. Normally, auto deceleration only works when Function Number 16 PUMP
the accelerator pedal is fully released. ACCELERATION
A setting value of 2 will cause the maximum lift (Range 0-100)
speed and pump motor acceleration rate to change
with the performance mode selected. Normally, only Function 16 determines the hydraulic pump motor
traction speeds and acceleration rates change with acceleration rate. Higher numbers bring up motor
the performance mode selected. speed quicker.
A setting value of 3 will combine the changes de- Any increase in performance will decrease the bat-
scribed for setting values of 1 and 2. tery shift life.
A setting value of 4 directs the master controller to

output forward and reverse signals that are compat-
ible with wire guided trucks.
7
Troubleshooting 2200 SRM 1056
Troubleshooting
GENERAL NOTE: Due to the interaction of the master controller
with all lift truck functions, almost any status code
The AC motor and master controllers are sealed or controller fault could be caused by an internal fail-
units with no serviceable components. Troubleshoot- ure of the master controller. After all other status
ing is usually limited to accessing status codes and code procedures have been followed and no problem
following the diagnostic procedures listed in the is found, the master controller should be replaced as
Status Code Charts. the last option to correct the problem.
Use standard testing procedures to verify inputs and Tools and test equipment required are: clip leads,
outputs when necessary. digital multimeter (20,000 ohms per volt minimum),
and basic hand tools.
CAUTION Check resistance on RX1000 scale from frame to
Never attempt to probe through the back of power and controller terminals. Resistance of less
the connector plugs of the motor controller. than 20,000 ohms can cause misleading symptoms.
These plugs are special sealed plugs. Probing Resistance of less than 1000 ohms should be cor-
through the back of the plugs will destroy the rected first.
seal and can cause a short circuit. If a circuit
must be tested for voltage, check for voltage at Before proceeding, visually check for loose wiring,
an amp-type plug, a switch, or a component. If misaligned linkage to the accelerator switch, signs
a circuit is suspect, check the circuit for conti- of overheating of components, etc.
nuity by disconnecting the P plug and testing
continuity from the front (pin end) of the plug. Prior to troubleshooting systems and components on
this lift truck, ensure the battery is the correct volt-
Standard probes are too large to be inserted age and is fully charged. Make sure the battery con-
into the center of the female pins (sockets) of nector contacts are clean of corrosion and the battery
the special sealed plugs and can expand the polarity within the connector is correct. Inspect to
pins. Expanded pins will not provide good con- ensure all fuses are correct and have not failed. En-
nections once the plug is reconnected. The con- sure the key switch is in the ON position when mak-
nectors are shaped to allow the insertion of a ing voltage checks or checking the operation of a com-
small flat-blade screwdriver into the connec- ponent. Make sure the floor (reset) switch and the
tor. After inserting the screwdriver into the operator presence switch has been properly closed.
connector, attach probes with alligator clips to
the shank of the screwdriver to obtain read- Many faults noted by lift truck systems are the result
ings. An additional method would be to use a of loose wiring connections and/or broken or shorted
breakout kit, Hyster P/N 1397311. wiring within the lift truck. Begin the troubleshoot-
ing process by carefully inspecting the wiring involv-
See Electrical Diagrams, AC Motor Control ing the device or devices noted by the onboard diag-
System 8000 SRM 1059for J2.00-3.20XM (J40-65Z) nostic system. Faults noted with components located
(A416); V30ZMD (D210/E210); E1.50-2.00XM on the reach attachment may be caused by broken or
(E25-35Z, E40ZS) (E114/F114); and E2.00-3.20XM shorted wires in the mast cable. Ensure the integrity
(E45-65Z) (G108) or Diagrams, AC Motor Con- of this cable before troubleshooting attachment-re-
trol System 8000 SRM 1203 for E3.50-5.50XL lated faults.
(E70-120Z, E100ZS) (D098/E098) or Electrical Di-
agrams, AC Motor Control System 8000 SRM CONTROLLER STATUS LIGHT EMITTING
1225 for J2.00-3.20XM (J40-65Z) (B416) for addi- DIODES (LEDS)
tional wiring details.
The AC traction motor controller, AC pump motor
If the lift truck does not operate correctly, a status controller (optional), and AC master controller each
code is displayed on the display panel. have a separate LED to indicate its operating status.
Each LED is green in color and may be lit continu-
Once the status code number is obtained, follow the
ously or blinking. See each description for the loca-
procedures outlined in the Status Code Charts of this
tion of each LED.
manual to determine the problem.
8
2200 SRM 1056 Troubleshooting
Master Controller AC Motor Controllers

• The master controller location varies with NOTE: In Figure 3 through Figure 7 the terms Gen IV
the truck model. On J2.00-3.20XM (J40-60Z) and Gen V refer to Generation IV and Generation V
(A416/B416), it is located behind the battery and respectively. Controller and contactor panels labeled
can be reached by removing the plastic cover at the Gen IV are used in early model lift trucks and con-
rear of the hood. On the E1.50-2.00XM (E25-35Z, troller and contactor panels labeled Gen V are used
E40ZS) (E114/F114), it is located under the frame in later model lift trucks.
side plate on the right-hand side, and on the
left-hand side for the V30ZMD and E2.00-3.20XM This section covers both the AC traction motor con-
(E45-65Z) (D210/E210, G108) line of trucks. A troller and AC pump motor controller. Remove the
mirror can be used to view the LED through an ac- rear cover to view the motor controllers. See Fig-
cess hole. On E3.50-5.50XL, E4.50XLS (E70-120Z, ure 3, Figure 4, Figure 5, Figure 6, and Figure 7.
E100ZS) (D098/E098) lift trucks, the master con-
• The LED is located next to the label on the plastic
troller is located under the rear floor plate.
cover of the controller. See Figure 3 or Figure 4
• The LED is located next to the wire harness con-
Figure 5 or Figure 6.
nector. See Figure 2.
• The LED only turns on when the key switch is in
• The LED blinking rate is usually twice a second,
the ON position.
when the battery is connected and the key switch
• The LED will show a steady continuous green color
is in the OFF position.
if there is no fault condition detected.
• The LED blinking rate slows to once every two sec-
• When a fault condition is detected that is not seri-
onds when the battery is connected and the key
ous enough to shut down the truck, the LED blink-
switch is moved to the ON position.
ing rate is twice a second. A status code should ap-
• If the above conditions are not present, the master
pear on the dash display to reference the problem.
controller may not be properly connected or may be
• When a fault condition is detected that has shut
faulty.
down the truck, the LED blinking rate will be at
• Due to the location of the master controller, a small
a very rapid rate (too fast to count). A status code
inspection mirror may be needed to view the LED.
should appear on the dash display to reference the
problem.
• If the above conditions are not present, the AC mo-
tor controller may not be getting power from the
key switch or may be faulty.
1. LED
Figure 2. Master Controller LED
9
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE 8. LINE CONTACTOR
SOLENOID 9. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (15A) LIGHTS 10. POSITIVE TEMPERATURE COEFFICIENT
4. FUSE 4 (5A) KEY SWITCH RESISTOR (PTC)
5. POWER STEERING CONTACTOR 11. LED INDICATOR
6. FUSE 5 (40 A) POWER STEERING
Figure 3. AC Traction and AC Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for J2.00-3.20XM
(J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models Only and for J2.00-3.20XM
(J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and V30ZMD (D210/E210) Lift Truck
Models
10
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. LINE CONTACTOR

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE 8. POSITIVE TEMPERATURE COEFFICIENT
SOLENOID RESISTOR (PTC)
3. FUSE 3 (15A) LIGHTS 9. AC TRACTION MOTOR CONTROLLER
4. FUSE 4 (5A) KEY SWITCH 10. FUSE (325A) PUMP
5. POWER STEERING CONTACTOR 11. CONTACTOR FOR DC PUMP MOTOR
6. FUSE 5 (40A) POWER STEERING 12. LED INDICATOR
Figure 4. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (Gen V)
(36v/48v or 72v/80v) for J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later
Models Only and for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114);
and V30ZMD (D210/E210) Lift Truck Models
11
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 6 (15A) LIGHTS 8. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (5A) KEY SWITCH 9. LED INDICATOR
4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT
5. FUSE 4 (40A) POWER STEERING RESISTOR (PTC)
6. LINE CONTACTOR
Figure 5. AC Traction and AC Pump Motor Controllers (72v/80v) (Gen IV) for Early Model
J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks
12
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 5 (15A) LIGHTS RESISTOR (PTC)
3. FUSE 3 (5A) KEY SWITCH 8. AC TRACTION MOTOR CONTROLLER
4. POWER STEERING CONTACTOR 9. FUSE 2 (325A) PUMP
5. FUSE 4 (40A) POWER STEERING 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 6. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (72v/80v)
(Gen IV) for Early Model J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift
Trucks
13
1. FUSE 1 (15A) AUXILIARY 5. POWER STEERING 9. AC PUMP MOTOR

TERMINAL STRIP CONTACTOR CONTROLLER
2. FUSE 2 (15A) (SLOW BLOW) 6. LINE TRACTION CONTACTOR 10. FUSE 5 (40A) POWER
SEAT BRAKE SOLENOID 7. POSITIVE TEMPERATURE STEERING
3. FUSE 3 (15A) LIGHTS COEFFICIENT RESISTOR 11. LED INDICATOR
4. FUSE 4 (5A) KEY SWITCH (PTC) 12. LINE PUMP CONTACTOR
8. AC TRACTION MOTOR
CONTROLLER
Figure 7. AC Traction and Pump Motor Controllers for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) Lift Truck Models
14
STATUS CODES • Input voltages that are too high or too low
• Input voltages in the wrong sequence or
NOTE: Make sure the parameter values are correct • Correct input voltages that occur at the wrong time
for your lift truck to ensure the trouble is not just
an incorrect setting. See Function Settings to set the NOTE: A status code indication does not always mean
correct parameter values. If there is no status code that there is a malfunction. A temporary operating
display and the lift truck does not operate correctly, condition can cause a status code display.
there can be a fault in the master controller.
These code numbers are only codes to help identify
The status codes are code numbers for malfunctions a possible malfunction. A short description of the
or lift truck operations that are not correct and that different status codes is shown in Table 5.
the motor controller can sense. The master controller
will indicate this code number on the LCD screen of The Status Code Charts in this section have a more
the display panel. complete description of the status code, the circuit
that has generated the input for the status code, the
The master and motor controllers sense the following symptom, and the possible causes.
types of malfunctions:
Table 5. List of Status Codes
Status Code Description Status Code Description

BLANK No input voltage to controller or 52 Traction or pump motor speed sensor
display panel. error.
1 No seat switch input. 53 Traction controller does not respond
to master controller.
2 The forward switch is closed before 54 Pump controller does not respond to
the key or seat switch closes. master controller.
3 The reverse switch is closed before 55 Dash display cannot communicate
the key or seat switch closes. with master controller.
4 Park brake applied while the key 56 Mini-lever module or joystick cannot
switch is in the ON position. communicate with master controller.
5 Start switch fails to close. 57 Valve driver module cannot
communicate with master controller.
6 Accelerator depressed, no direction 61 Current to cooling fans is too high
selected. during operation.
7 Acceleration voltage too high when 62 Current to reverse relay is too high
the key switch is first moved to the during operation.
ON position.
8 Acceleration input voltage too low 63 Current to DC pump contactor coil is
when the key switch is first moved too high during operation.
to the ON position.
9 Both the forward and reverse 64 Current to power steering contactor
directional switches are closed at coil is too high during operation.
the same time.
10 Armrest is up. 65 Current to the line contactor coil is
too high during operation.
11 The acceleration start switch 66 Short circuit sensed on power output
closed before the key and/or the to traction motor.
seat switch.
15
Table 5. List of Status Codes (Continued)
Status Code Description Status Code Description

12 Mini-levers or joystick out of 67 Short circuit sensed on power outage
neutral when the key switch is to pump motor.
moved to the ON.
13 Brake pressure is out of range. 68 Current to seat brake controller too
high during operation.
15 Battery voltage is too low or master 69 Current to the pump line contactor
controller is adjusted to the wrong coil is too high during operation.
voltage.
16 Battery voltage is too high or 70 Current to brake light relay is too
master controller is adjusted to the high during operation.
wrong battery voltage.
21 Error in mini-lever module or 76 Capacitor voltage is too high.
joystick input.
22 Coil current to a valve coil is out of 90 Traction motor temperature too high.
range, too low.
23 Coil current to a valve coil is out of 91 Pump motor temperature too high.
range, too high.
41 Traction motor controller 95 Lift pump motor brushes are worn.
overheated.
42 Pump motor controller overheated. 99 Maintenance Alert and Speed Limit.
43 Traction motor temperature sensor
out of range.
44 Pump motor temperature sensor
out of range.
51 Capacitor volts are too low before
line contactor closes.
16
2200 SRM 1056 AC Motor Controllers Status Code Charts
AC Motor Controllers Status Code Charts

Status Code Description Memory Recall Circuit
No seat switch input. No Traction
1
Symptom
Lift truck does not move.
Hydraulic functions are disabled.
Possible Causes and Test Procedures

• Seat switch malfunction.
Check to see that the seat switch operates prop-
erly.
Replace a failed switch.
• Check wiring to the seat switch and from the seat
switch to the master controller

The forward switch is closed before the No Traction
2 key or seat switch closes.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static
Return to Off (SRO) Startup Procedure, move the
directional lever to the neutral position, and then
select a direction.
• A directional switch is failed closed or out of adjust-
ment.
17
AC Motor Controllers Status Code Charts 2200 SRM 1056

The reverse switch is closed before key No Traction
3 or seat switch closes.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static
Return to Off (SRO) Startup Procedure, move the
directional lever to the neutral position, and then
select a direction.
• A directional switch is failed closed or out of adjust-
ment.

Park brake applied while the key switch No Traction
4 is in the ON position.
Symptom

• Park brake is applied.
Truck will not operate with park brake applied.
Release the park break.
• Park brake switch is out of adjustment or is shorted.
18

Start switch fails to close. No Traction
5
Symptom

• Malfunction of start switch circuit.
Check for open circuit or loose connections in
wiring from key switch to start switch and from
P16 to start switch.
• Malfunction of start switch.
Check start switch for correct operation and out-
put.

Accelerator depressed with no direc- No Traction
6 tion selected.
Symptom

• Accelerator pedal is depressed before closing a direc-
tion switch.
Status code will disappear when directional
switch is closed or when accelerator pedal is re-
leased.
• Malfunction of directional switch.
Check forward or reverse switch to make sure
there is continuity when direction is selected.
• Open circuit between directional switch and battery
positive or between directional switch and P4 or P5.
Check all wires and connections shown in trou-
bleshooting diagram.
19

Accelerator input voltage too high when key No Traction
7 is first moved to ON position.
Symptom

• Accelerator unit has a malfunction or is out of adjust-
ment. Maximum accelerator wiper voltage should be
11.00 volts with the pedal fully up.
• Open circuit between accelerator unit and P7.

Accelerator input voltage too low when key No Traction
8 is first moved to the ON position.
Symptom

• Minimum accelerator wiper voltage should be 10.70
volts with the pedal fully up.
• Accelerator unit has malfunction or is out of adjust-
ment.
20

Both the forward and reverse directional No Traction
9 switches are closed at the same time.
Symptom

• Forward or reverse directional switch is failed closed
or out of adjustment (adjusted to be held closed).
Replace or adjust directional switches to make
sure they open when directional switch is re-
turned to neutral.
• Short circuit between battery positive and P4 and/or
P5.
Disconnect wires from P4 and P5 and check wire
for short circuit to positive side of directional
switch.

Armrest is up No E-Hydraulics
10
Symptom

• Put the armrest in the down position and ensure that
it is latched properly.
• Armrest switch malfunction.
Replace a failed switch.
• Check wiring to the armrest switch from the mini-
lever module or joystick.
21

The accelerator start switch closed before No Traction
11 the key and/or the seat switch.
Symptom

• The accelerator pedal was depressed when the key
was turned to the ON position. This violates the
Static Return to Off (SRO) Startup Procedure. To
correct this action, release the accelerator pedal and
resume normal operation.
• The accelerator pedal was depressed when the oper-
ator sat down. This violates the SRO Startup Proce-
dure. To correct this action, release the accelerator
pedal and resume normal operation.
• The accelerator start switch is out of adjustment or
has a short.
22

Mini-levers or joystick out of neutral when No E-Hydraulics
12 the key is moved to the ON position.
Symptom

• One (or more) hydraulic functions are commanded
while the key is turned to the ON position.
Status code will disappear when all hydraulic
commands are returned to neutral.
• Malfunction of joystick, if equipped.
Power-On truck.
Display the diagnostic menu on the dash display
panel.
•Is the joystick input = 128?
•Yes: Go to next step.
•NO: Replace joystick. See Electro-Hy-
draulic Control Valve 2000 SRM 1224.
• Malfunction of mini-lever, if equipped.

Stroke each lever to full stroke and allow lever
to snap back to center.
Power-On truck.
Display the diagnostics menu on the dash dis-
play panel.
•Is each mini-lever input = 128?
•YES: Go to next step
•NO: Replace the lever. See Electro-Hy-
Operate each lever to full stroke forward and

slowly release (1-2 seconds from full stroke).
Read input when fully released.
•Is each mini-lever input = 128?
•YES: Go to next step.
•NO: Replace lever. See Electro-Hydraulic
Control Valve 2000 SRM 1224.
Operate each lever to full stroke back and slowly

release (1-2 seconds from full stroke). Read input
when fully released.
• Is each mini-lever input = 128?
• YES: Problem resolved.
• NO: Replace lever. See Electro-Hydraulic
23

Brake Pressure is out of range No Traction
13
Symptom
Top speed reduced to half

• Failed sensor
Check wiring for damage. Replace sensor.

Battery voltage is too low or truck is adjusted No Traction
15 to the wrong battery voltage.
Symptom

• Discharged battery.
Check battery for correct open circuit voltage.
Correct voltages are listed on right. Charge bat-
tery if required.
• Battery is damaged.
Check each battery cell for correct voltage (greater
than 1.85 volts each cell). Replace or repair bat-
tery.
• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller for the correct battery volts.
• Check the battery volts on the main power cables at
the motor controllers.
24

Battery voltage is too high or master controller No Traction
16 is adjusted to the wrong battery voltage.
Symptom

• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller for the correct battery volts.
• Battery overcharged or incorrect battery used.
Check battery for correct open circuit voltage.
Correct voltages are listed on right. If voltage is
too high, check battery charger for correct output
voltage.

Error in the mini-lever module or joystick input. No E-hydraulics
21
Symptom

• Malfunction of joystick, if equipped.
Power-On truck.
Display the diagnostics menu on the dash.
•Is the joystick input = 128?
•NO: Replace joystick. See Electro-Hy-
• Malfunction of mini-lever, if equipped.
Power-On truck.
Display the diagnostics menu on the dash display
panel.
•Is the mini-lever input = 128?
•NO: Replace lever. See Electro-Hydraulic
• Check "No. of functions Setting" in the "E-Hyd Setup
Menu"
25

A valve coil current is out of range, too low. No E-Hydraulics
22
Symptom

• Wiring from the valve driver module to the valve coil
is open.
• Valve coil malfunction.
Check the resistance of the valve coil. The approx-
imate coil resistance at room temperature should
be 8 ohms.

A valve coil current is out of range, too high. No E-Hydraulics
23
Symptom

• Wiring from the valve driver module to the valve coil
is shorted.
• Valve coil malfunction.
Check the resistance of the valve coil. The approx-
imate coil resistance at room temperature should
be 8 ohms.
26

Traction motor controller overheated. Yes Traction
41
Symptom
Truck acceleration is reduced or truck may
stop completely.

• Excessive pushing or stalling of traction motor.
• Check operation of cooling fans.
See Fan Test.
• Check for proper application of thermal grease be-
tween motor controller and heat sink.

Pump motor controller overheated. Yes Traction
42
Symptom
Truck acceleration and travel speed is reduced
and pump motor may stop completely.

• Excessive operation or stalling of the pump motor.
• Check operation of the cooling fans.
See Fan Test.
• Check for proper application of thermal grease be-
tween motor controller and heat sink.
27

Traction motor temperature sensor out of range. No Traction
43
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but traction
motor overtemperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.

Pump motor temperature sensor out of range. No Pump
44
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but pump
motor overtemperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.

Capacitor volts are too low before line No Traction
51 contactor closes.
Symptom
Lift truck does not move and line contac-
tor does not close.

• A Positive Temperature Coefficient (PTC) is discon-
nected or malfunctioning, preventing the capacitors
to charge when the battery is plugged in.
• An accessory or component other than the motor con-
trollers is connected to load side of line contactor.
This will cause the PTC to get hot and not charge
the capacitors.
• Repeated charging/discharging the capacitors dur-
ing troubleshooting may cause a Status Code 51. If
the PTC is hot, allow it to cool.
• Status code will occur if the line contactor does not
close properly and truck operation is attempted.
• Status code will occur if battery voltage drops below
50% nominal voltage.
28

Traction or pump motor speed sensor error. No Traction
52
Symptom
Traction or pump motor operates very slowly and jerky.

• Disconnected or broken sensor wires between motor and motor controller.
• Malfunction of motor encoder bearing.

Traction controller does not respond to No Traction
53 master controller.
Symptom

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working.
Check for loose or broken wires.
• Open connection between motor controller pin 13 (ground) and pin 12 and/or pin 20. See the Electrical
Diagrams manual for your lift truck model. Pins 12 and 20 are truck I.D. pins.

Pump controller does not respond to No Pump
Symptom
Hydraulic pump motor does not operate.

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working
• This status code may appear on trucks with contactor controlled DC pump motors. The master controller
senses the presence of a contactor by a voltage on pin 40. If there is no voltage on pin 40, the master con-
troller assumes an AC pump motor controller is present, but not able to communicate.
Check for voltage at the pump contactor coil.
Check wiring from pump contactor coil to master controller, pin 40.
29

Dash display cannot communicate with Yes Traction
Symptom
Varies due to problem.

• If truck operates and code is displayed on dash, the CANbus communication is not working.
• If truck does not operate and code is displayed on dash, fault may be in master controller.

Mini-lever module or joystick cannot No E-Hydraulics
56 communicate with the master controller.
Symptom

• Check input to the mini-lever module (or joystick).
Voltage should be in the range 9-16V.
• Check LED status of the valve driver module.
Green LED should be on.
• CANbus communication between mini-lever module and master controller is not working

Valve driver module cannot communicate No E-Hydraulics
57 with master controller.
Symptom

• Check LED status of the valve driver module.
Green LED should be on.
• CANbus communication between mini-lever module and master controller is not working
30

Current to cooling fans is too high No Traction
61 during operation.
Symptom
Lift truck does not move. If fault occurred during
truck operation, status code will not display until the
key switch is cycled to OFF and then to ON again.

• A fan or wiring to fan may have a short.
• Trucks using a fan power supply may have a short in
the power supply.
• If the status code is displayed while fans or power
supply are disconnected, fault is probably in the mas-
ter controller.

Current to reverse relay is too high No Traction
Symptom

• Reverse relay coil or wiring may have a short.
Check the coil resistance with the wires discon-
nected. The approximate resistance is 576 ohms.
• If status code is displayed while relay coil wires are
disconnected, the fault is probably in master con-
troller.
31

Current to DC pump contactor coil is too No Traction
63 high during operation.
Symptom

• DC pump contactor coil or wiring to coil may have a
short.
Check the coil resistance with wires disconnected.
Approximate coil resistance, at room tempera-
ture, should be:
36/48 volt trucks 31 ohms
• If status code is displayed while contactor coil wires
are disconnected, the fault is probably in master con-
troller.

Current to power steering contactor coil No Traction
64 is too high during operation.
Symptom

• Power steering contactor coil or wiring to coil may
have a short.
ture, should be:
troller.
32

Current to the line contactor coil is too No Traction
Symptom

• Line contactor coil or wire to coil has a short.
ture, should be:
troller.

Short circuit sensed on power output No Traction
66 to traction motor.
Symptom

• Short circuit in motor or heavy power wires going to
motor.
• If status code is displayed with motor power wires
disconnected, the short circuit is internal.
Replace motor controller.
33

Short circuit sensed on power output No Traction
67 to pump motor.
Symptom
Hydraulic pump motor does not operate.

• Short circuit in motor or heavy power wires going to
motor
• If status code is displayed with motor power wires
disconnected, short circuit is internal.
Replace motor controller.
Status Code Description Memory Recall

No
Current to seat brake controller too
Symptom
Lift truck does not move, and seat brake
does not release.
If fault occurs during truck operation, status code
does not display until the key switch is turned to the
OFF position and then turned to the ON position.

• Seat brake controller or wire to controller has a short
• If status code is displayed with the wires discon-
nected, the fault is probably in the master controller
34

Current to the pump line contactor coil is No Traction
69 too high during operation.
Symptom

• Pump line contactor coil or wire to coil has a short.
ture, should be:
troller.

Current to brake light relay is too high No Traction
Symptom

• Brake light relay coil or wiring may have a short.
Check the coil resistance with the wires discon-
nected. The approximate resistance is 160 ohms.
• If status code is displayed while relay coil wires are
disconnected, the fault is probably in master con-
troller.

Capacitor voltage too high. No Traction
76
Symptom
Lift truck does not work.

• Regen setting too high.
Combination of a fully charged battery and a high regen setting may cause status code.
35

Traction motor temperature too high. Yes Traction
90
Symptom
Truck acceleration is reduced, or truck may stop completely.

• Excessive pushing or stalling of traction motor.
• Operation may continue at slower duty cycle.
Allow traction motor to cool to regain full performance.
• Comparing the motor temperature through the display panel with a known motor temperature, such as
room temperature, can check the motor temperature sensor.
• A shorted or open temperature sensor will generate a status code 43.

Pump motor temperature is too high. Yes Pump
91
Symptom
Truck acceleration and travel speed reduced. Pump motor may stop completely.

• Excessive operation or stalling of pump motor.
• Operation may continue at slower duty cycle.
Allow pump motor to cool off to regain full performance.
• Comparing the motor temperature through the display panel with a known motor temperature, such as
room temperature, can check the motor temperature sensor.
• A shorted or open temperature sensor will generate a status code 43.

DC lift pump motor brushes are worn. Yes Pump
95
Symptom
Status code warning only.

• Pump motor brushes are worn too short.
• Motor brush wear sensor wires to motor controller
may have a short to battery positive.
36
2200 SRM 1056 AC Transistor Motor Controller Replacement

Maintenance Alert and Speed Limit. No Traction
99
Symptom
Status code is displayed and, after 20 hours, truck speed is reduced to 50% of normal top speed.

• Maintenance reminder indicating it is time to service truck. It was set by a technician through the dash
display or with a PC.
• The technician must perform desired maintenance and reset reminder to next hourmeter reading that main-
tenance should occur.
AC Transistor Motor Controller Replacement

GENERAL in Figure 8, Figure 9, and Figure 10. The assembly
of the AC Traction Motor controller with contactor
NOTE: In Figure 8 through Figure 12, the terms Gen for DC Lift Pump Motor is shown in Figure 11 and
IV and Gen V refer to Generation IV and Genera- Figure 12. There are NO internal parts of these
tion V respectively. Controller and contactor panels motor controllers that can be repaired. Each of these
labeled Gen IV are used in early model lift trucks motor controllers must be replaced if an internal
and controller and contactor panels labeled Gen V malfunction occurs.
are used in later model lift trucks.
The assembly of the AC traction motor controller

with optional AC pump motor controller is shown
37
AC Transistor Motor Controller Replacement 2200 SRM 1056
1. FUSE 1 (15A) 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) (SLOW) 8. LINE CONTACTOR
3. FUSE 3 (15A) 9. AC PUMP MOTOR CONTROLLER
4. FUSE 4 (5A) 10. POSITIVE TEMPERATURE COEFFICIENT
5. POWER STEERING CONTACTOR RESISTOR (PTC)
6. FUSE 4 (POWER STEERING) (40A) 11. LED INDICATOR
Figure 8. AC Traction and AC Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for J2.00-3.20XM
(J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models Only and for J2.00-3.20XM
(J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and V30ZMD (D210/E210) Lift Truck
Models
38

2. FUSE 5 (15A) 8. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (5A) 9. LED INDICATOR
4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT
5. FUSE 4 (POWER STEERING) (40A) RESISTOR (PTC)
6. LINE CONTACTOR
Figure 9. AC Traction and AC Pump Motor Controllers (72v/80v) (Gen IV) for Early Model
J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks
39
1. FUSE 1 (15A) 6. LINE TRACTION CONTACTOR 9. AC PUMP MOTOR

2. FUSE 2 (15A) (SLOW) 7. POSITIVE TEMPERATURE CONTROLLER
3. FUSE 3 (15A) COEFFICIENT RESISTOR 10. POWER STEERING FUSE
4. FUSE 4 (5A) (PTC) (40A)
5. POWER STEERING 8. AC TRACTION MOTOR 11. LED INDICATOR
CONTACTOR CONTROLLER 12. LINE PUMP CONTACTOR
Figure 10. AC Traction and AC Pump Motor Controllers for E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098/E098) Lift Truck Models
40

2. FUSE 2 (15A) (SLOW) RESISTOR (PTC)
4. FUSE 4 (5A) 10. FUSE (PUMP) (325A)
5. POWER STEERING CONTACTOR 11. CONTACTOR FOR DC PUMP MOTOR
6. FUSE 4 (POWER STEERING) (40A) 12. LED INDICATOR
7. LINE CONTACTOR
Figure 11. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (Gen V)
(36v/48v or 72v/80v) for J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later
Models Only and for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114);
and V30ZMD (D210/E210) Lift Truck Models
41

2. FUSE 5 (15A) RESISTOR (PTC)
4. POWER STEERING CONTACTOR 9. FUSE 2 (PUMP) (325A)
5. FUSE 4 (POWER STEERING) (40A) 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 12. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (72v/80v)
(Gen IV) for Early Model J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108)
42
GENERAL MAINTENANCE During installation of the controller, apply a suffi-

INSTRUCTIONS cient layer of silicone (heat transfer) grease, Hyster
P/N 1198757, between the controller and the heat
The motor controllers, like other electronic devices, sink to not allow air gaps between the two.
have temperature limits. These devices can be dam-
aged if they get too hot. Normal maintenance will Controller wire plugs and other exposed transistor
help prevent high-temperature conditions. Always controller parts should be kept free of dirt and paint
make sure motor controllers are installed using heat that might change the effective resistance between
sink compound and that all heat sink surfaces are points.
clean. DO NOT block cooling airflow.
CAUTION
Special Precautions
DO NOT operate the traction system at high
speed or rapidly change direction of operation
WARNING with the wheels raised. Motor controller dam-
To avoid injury and prevent electrical shock, age can occur.
perform the following steps before trou-
bleshooting, adjustments, or repair: DO NOT subject the controller to any high voltage
• Turn the key switch to the OFF position and (hipot or megger) testing.
disconnect the battery connector. Use a lead acid battery with the voltage and ampere
• Discharge the capacitors in the controllers hour rating specified for the lift truck. Follow normal
by pushing and holding the horn button battery maintenance procedures, recharging at 80
down until the horn stops making a sound. percent discharge, with monthly equalizing charges.
CAUTION Parts of these assemblies not covered in this manual

cannot be repaired and must be replaced if they mal-
To help prevent controller damage:
function. The contactors are serviceable.
• ALWAYS disconnect the battery when servic-
ing the controllers.
• ALWAYS discharge the capacitors before per- WARNING
forming any service. Some checks in this section must be done with
• NEVER make a short circuit at any motor the battery connected and power applied to
controller terminal to battery (+), battery ( ), the controller. When making these checks,
or the frame. make sure the drive wheels are raised from
• Remove the motor controllers before per- the floor. See procedures given in the Periodic
forming any authorized welding procedures. Maintenance Manual or the Operating Manual
for your lift truck.
Never add any electrical component to the lift
truck without approval from your dealer for Make sure you disconnect the battery and
your lift truck. Other electrical components separate the connector before you remove any
can prevent operation and/or damage the mo- power cables from the power terminals of the
tor controller. motor controller. The capacitor stores electri-
cal energy and can cause injury, if a person
NEVER USE STEAM TO CLEAN ELECTRONIC discharges a capacitor, to parts of the body.
COMPONENTS. AFTER the battery is disconnected and the
key switch is in the OFF position, make sure
In dusty areas, blow low-pressure air over the con- you also discharge the capacitors.
troller to remove dust. In oily or greasy areas, a
mild solution of detergent or denatured alcohol can Discharge the capacitors in the controllers by
be used to wash off the controller; and then, low-pres- pushing and holding the horn button down un-
sure air should be used to completely dry the con- til the horn stops making a sound.
troller.
NOTE: The bolts and screws connected to the elec-
For the controller to be most effective, it must be tronic components are normally metric sizes.
mounted against the finned aluminum heat sink.
43
Make sure that you use the correct fastener for the CONTACTORS
part that has been disassembled or removed.
There can be three contactors on these lift trucks.
FUSES All lift trucks have a power steering contactor and
a line contactor. See Figure 13 and Figure 14. Lift
The fuses are found on the contactor panels. See Fig- truck models E3.50-5.50XL, E4.50XLS (E70-120Z,
ure 8, Figure 9, Figure 10, Figure 11, and Figure 12. E100ZS) (D098/E098) have a separate line contactor
The condition of the fuses can normally be checked for the pump motor controller. Lift trucks that do not
by looking at them. Some fuses do not change in ap- have a pump motor controller also have a contactor
pearance and must be checked with an ohmmeter. to energize the lift pump motor. See Figure 13.
FAN TEST
To determine if the fans are operating correctly, go
to the Access to Service Functions section of this
SRM. Using the procedures in that section, go to
Diagnostics Menu and select No Run Diagnostics.
From there, go to Fan On, which is the last menu
item. As soon as Fan On is selected, the fans should
start running.
On 36/48 volt trucks, the fans operate at battery volt-

age. If battery voltage is present at the fan terminal
strip and the fan(s) doesn’t run, replace the fan(s).
If battery voltage is not present at the fan terminal
strip, look for problems in the positive circuit from
the key switch or the negative circuit to pin 15 on 1. CONTACTOR 4. MOVABLE
the master controller. 2. POWER CONTACTS
TERMINALS 5. SPRING
On 72/80 volt trucks, the fans operate with a fan 3. FIXED CONTACTS 6. PLUNGER
power supply. If the power supply voltage (48 volts) is
Figure 13. Pump Motor Contactor
present and the fan(s) doesn’t run, then replace the
fan(s). If there is battery voltage to the fan power
Repair
supply and there is no output voltage, then replace
the fan power supply. If battery voltage is not present Tag, identify, and disconnect the wires and cables
at the power supply, look for problems in the positive from the contactor assembly. Remove the mounting
circuit from the key switch or the negative circuit to screws and remove the contactor assembly. See Fig-
pin 15 on the master controller. ure 14.
44
3. MOVABLE CONTACTS
4. SCREW
5. RETURN SPRING
6. INSULATOR
7. COIL ASSEMBLY
Figure 14. Replacement Parts of Power

Steering Contactor
Contactor Contacts. The contacts in a contactor

are made of special silver alloy. The contacts will look
black and rough from normal operation. This condi-
tion does not cause problems with the operation of
the lift truck. Cleaning is not necessary. DO NOT
USE A FILE ON THE CONTACTS. DO NOT LU-
BRICATE THE CONTACTS.
CAUTION
ALWAYS replace all of the contacts in a con-
tactor at the same time. Replace the contacts
when the thickness of any area of a contact is
less than 30 percent of the thickness of a new
contact or if there is any transfer of contact ma-
terial.
Coil. Check the coil with an ohmmeter for an open

circuit or a short circuit. Coil resistance is very low.
Approximate coil resistance, at room temperature,
can be determined by looking at Status Codes 63,
64, 65, and 69. Replace the coil if it is damaged.
Make sure the coil wires are connected again to the
correct terminals.
NOTE: Some wire numbers found in Table 6, Table 7,

and Table 8 may or may not be followed by a letter,
depending on the lift truck model.
1. TOP COVER
2. FIXED CONTACT SETS
45
Table 6. 42-Pin Connections/Descriptions for Master Controller
Pin No. Wire Number Function

1
2 7 SEAT SWITCH
3 10 KEY SWITCH
4 8 REVERSE SWITCH
5 6 FORWARD SWITCH
6 32 +12 V
7 13 ANALOG GROUND
8 72 CANbus GROUND
9 51 PUMP HIGH SPEED
10 84D BRAKE LIGHT RELAY COIL
11* 24A PUMP LINE CONTACTOR
12 6 FORWARD SIGNAL
13 24 LINE CONTACTOR
14 3 BATTERY POSITIVE
15 65 FAN
16 15 ACC START SWITCH
17 107 PUMP MOTOR BRUSH WEAR
18 108 PUMP MOTOR BRUSH WEAR
19 44 PARK BRAKE
20
21
22 74 CANbus HIGH
23 73 CANbus LOW
24
25
26
27
28 13 BATTERY NEGATIVE
29 46 SEAT BRAKE
30
31 45 BRAKE FLUID LEVEL
32 100 DC PUMP MOTOR TEMPERATURE
33 53 PUMP LOW SPEED
34
46
Table 6. 42-Pin Connections/Descriptions for Master Controller (Continued)
Pin No. Wire Number Function

35
36 29 ACCELERATOR PEDAL POSITION
37 359 BRAKE FLUID PRESSURE
38 52 PUMP MEDIUM SPEED
39
40 54 DC PUMP CONTACTOR
41 8 REVERSE SIGNAL
42 60 POWER STEERING CONTACTOR
*E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) LIFT TRUCK MODELS ONLY
Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Motor Controllers
Wire Number
Pin No. Traction Pump Function
1 10 10 KEY SWITCH
2
3 33 33 SENSOR VOLTAGE SUPPLY
4 13 13 BATTERY NEGATIVE
5 104 110 SENSOR BEARING SIGNAL
7 102 100 MOTOR TEMPERATURE
8
9 CONTROLLER ID PIN
10 74 74 CANbus HIGH
11 73 73 CANbus LOW
12 74 CANbus TERMINATION RESISTANCE
13 72 72 CANbus GROUND
47
Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen V) Volt Motor Controllers
Wire Number
Pin No. Traction Pump Function
1 10 10 KEY SWITCH
2
3 33 33 SENSOR VOLTAGE SUPPLY
4 13 13 BATTERY NEGATIVE
7 72 72 CANbus GROUND
12 CONTROLLER ID PIN
13 13 CONTROLLER ID PIN GROUND
14 73 73 CANbus LOW
15 73 CANbus LOW
16 102 100 MOTOR TEMPERATURE
17 13 13 MOTOR TEMPERATURE GROUND
20 CONTROLLER ID PIN
22 74 74 CANbus HIGH
23 74 CANbus HIGH
THERMAL SENSORS CAUTION

The thermal sensors for AC motors are embedded in DO NOT remove the small screws that fasten
the motor windings and are continuously monitored the cover of the motor controller.
by the motor controllers. They are part of the motor
Make sure there is no dirt between the plate of
and cannot be replaced or repaired.
the motor controller and the mount surface of
MOTOR CONTROLLER, REPLACE the lift truck heat sink.
Make sure the battery is disconnected and the capac- 3. Put an even coat of the silicone compound (Hys-
itor is discharged. Discharge the capacitor by holding ter P/N 1198757) or equivalent on the plate of
down the horn button until the horn stops making a the motor controller. Make sure there are no air
sound. Put a DO NOT CONNECT tag on the bat- spaces between the plate and mount surface of
tery connector. Replace the motor controller as de- the lift truck heat sink. The plate of the motor
scribed in the following procedure. controller must make full contact with the heat
sink. Install the mount screws that fasten the
1. Make an identification for correct connection of motor controller to the heat sink.
the power cables on the power terminals of the
motor controller. Disconnect the power cables 4. Install the power cables at the power terminals
and the connector plug for the control wires. of the motor controller as identified during re-
moval. Install the connector plug for the control
2. Remove the eight (traction) or six (pump) mount- wires on the connector of the motor controller.
ing screws that fasten the plate of the motor con-
troller to the lift truck heat sink. Carefully re- 5. Remove the DO NOT CONNECT tag from bat-
move the motor controller. tery connector and reconnect the battery.
48
2200 SRM 1056 Display Panel
Display Panel
GENERAL • Allows access to the User Check List function.
There are two dash display options, Standard and Standard Display Panel
Premium.Both displays look identical. See Fig-
ure 15. • Allows preassigned service passwords to control ac-
cess to the service functions available through the
Premium Display Panel display.
• Provides the same comprehensive set of service
• Allows preassigned user passwords to control functions using the mode keys and LCD as the
driver access to the vehicle. Premium Display.
• Provides four driving modes that are accessed
through the keypad. Standard and Premium display panels are inter-
• Allows preassigned service passwords to control ac- changeable on the vehicle. Therefore, the display
cess to the service functions available through the system can be easily upgraded or downgraded by
display. changing the display panel.
• Provides a comprehensive set of service functions,
which are accessed through the mode keys and liq-
uid crystal display (LCD).
Figure 15. Standard and Premium Display Panel
49
Display Functions and Features 2200 SRM 1056
Display Functions and Features

KEY-ON INITIALIZATION The indicator lights turn off sequentially, except for
the seat belt light, which will remain lighted for ap-
Upon turning the key to the ON position, the display proximately 10 seconds.
sequentially lights the indicators, from left to right,
located along the top of the display. See Figure 16.
NOTE: The seat belt light will stay on whether the

seat belt is fastened or not fastened.
1. HOURMETER INDICATOR 8. LCD SCREEN

2. WRENCH INDICATOR 9. STAR PUSH BUTTON
3. BATTERY INDICATOR 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR (BDI) 11. PUSH BUTTON #2
5. BRAKE FLUID LEVEL 12. PUSH BUTTON #3
6. PARKING BRAKE 13. PUSH BUTTON #4
7. FASTEN SEAT BELT 14. PUSH BUTTON #5
Figure 16. Dash Display
50
2200 SRM 1056 Display Functions and Features
STANDARD DISPLAY SRM 1058, Enable/Disable Password and Lift Truck

Inspection Functions.
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the
BDI as a bar. See Figure 17. As the battery is dis-
charged, the bar becomes shorter.
Figure 19. Password Prompt Screen
If the password is not entered within 5 to 8 seconds,

a reminder screen is shown on the LCD display. See
Figure 20.
Figure 17. Battery Discharge Indicator
When the key is turned to the OFF position, the

Hourglass indicator becomes illuminated, and the
following hourmeter information is flashed on the
LCD screen: Traction Hours for 3-4 seconds, followed
by Pump Hours for 3-4 seconds, after which the dis-
play turns off and appears black. See Figure 18.
Figure 20. Password Reminder Screen
Until a password is entered that matches a pass-

word stored in the vehicle master controller, the lift
and traction systems are inoperative. Passwords
may be entered in the master controller using either
the dash display (see Dash Display Service Menu
Navigation) or by using the ETACC PC service
software. See the section Troubleshooting and
Adjustments Using the AC Controls Program
(ETACC) 2200 SRM 1058.
A few seconds after the correct password has been en-

tered, the BDI and performance mode are displayed
and the vehicle can be operated. See Figure 21.
Figure 18. Traction/Pump Hours
PREMIUM DISPLAY
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the
prompt for the operator to enter a password if this
function has been enabled. See Figure 19. If the
password function is disabled, the display will by-
pass the password prompt. To enable the password
function, see Troubleshooting and Adjustments
Using the AC Controls Program (ETACC) 2200 Figure 21. Display Screen (Premium Display)
51
LIFT TRUCK INSPECTION FUNCTION NOTE: It is suggested that the factory set password,
55555, be changed prior to the lift truck being placed
If this function is turned on, the operator is prompted into service.
to answer a checklist of questions. The operator in-
dicates a 1 for pass or a 4 for fail. If the operator The display will prompt the service technician for a
indicates the vehicle passes the inspection, the dis- five-digit password. See Figure 23. The default set-
play will show the previous information and the op- ting for the password is 55555. When a correct pass-
erator can drive the vehicle. If the operator indicates word is entered, the Service Features menu is dis-
that the vehicle fails the inspection, Service Required played as follows:
will appear on the display screen, and the vehicle will • Setup Menu
only operate in Mode 1 until the required action is • Password Menu (Operator passwords are only
taken. See Figure 22. available with Premium Display)
• Diagnostic Menu
• View Hourmeter
Figure 22. Inspection Failure Screen
The inspection feature can be enabled with or with- Figure 23. Password Request
out the password function enabled, depending upon
the user’s preference. The inspection checklist fea- The technician can scroll through the menu using the
ture, as with the password feature, may be set up up [1] or down [2] arrows and select the desired func-
using either the dash display or using a PC. For the tion by pressing the [4] button. Each menu selection
PC instructions, go to the section Troubleshooting has a list of submenu functions. The submenus are
and Adjustments Using the AC Controls Pro- viewed and items selected by scrolling through the
gram (ETACC) 2200 SRM 1058. The checklist must menu in the same manner as described above.
be enabled or disabled by a service technician.
To exit a selected function and return to the previous
The following is the list of checks: function, press the [3] button. Pressing the [3] but-
• Check for leaks. ton multiple times will return the technician to the
• Check service brake. operator’s driving mode.
• Check park brake.
• Check horn, lights, and reverse alarm. SERVICE FUNCTIONS
• Check gauges and warning lights.
The following submenu functions are accessible
• Check tire condition and pressure.
from the Main Menu of Service Functions, described
• Check hydraulic oil level.
above. This includes the following three vehicle
ACCESS TO SERVICE FUNCTIONS setup values and 16 control function settings. The
16 control function settings are discussed further in
All service functions are accessible from either Stan- Function Descriptions.
dard or Premium displays. The following functions • Setup Menu
are the same with either display version, except as Serial Number
noted in the following sections. Set Traction Hours
Set Pump Hours
Once the vehicle is turned ON with the key switch Control Function Settings
and the initialization process has been completed, a 1. Battery voltage
service technician can gain access to the service func- 2. Extended Shift
tions by pressing the star button ( ) twice. 3. Acceleration 1
4. Acceleration 2
5. Top speed limit
52
6. Regen braking SERVICE FUNCTIONS

7. Auto deceleration
8. BDI adjustment NOTE: The following service functions apply only
9. Lift interrupt to J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM
10. PS time delay (E25-35Z, E40ZS) (F114); V30ZMD (E210); and
11. Service reminder E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
12. Custom (E098). In addition these functions also apply to
13. Pump speed 1 E2.00-3.20XM (E45-65Z) (G108) lift trucks produced
14. Pump speed 2 after January 1, 2006.
15. Pump speed 3
The following submenu functions are accessible
16. Pump acceleration
from the Main Menu of Service Functions, described
• Password Menu
above. This includes the following three vehicle
Enter Password
setup values and 16 control function settings. The
Truck Inspection
16 control function settings are discussed further in
Add Password
Function Descriptions.
Delete Password
• Setup Menu
Edit Password
Serial Number
NOTE: All indications in the diagnostic menu are Set Traction Hours
shown as On, Off, or a value (i.e., Throttle Pot Volt). Set Pump Hours
On is indicated by a 1. Off is indicated by a 0. Control Function Settings
1. Battery voltage
• Diagnostic Menu 2. Extended Shift
No Run Diagnostics 3. Acceleration 1
Direction switch 4. Acceleration 2
Accelerator start 5. Top speed limit
Throttle pot volt 6. Regen braking
Seat switch 7. Auto deceleration
Park brake 8. BDI adjustment
Pump switch #1 9. Lift interrupt
Pump switch #2 10. PS time delay
Pump switch #3 11. Service reminder
Steering brush #1 12. Custom
Steering brush #2 13. PUMP SPEED 1 (NOT USED WITH
DC pump brush #1 E-HYD)
DC pump brush #2 14. PUMP SPEED 2 (NOT USED WITH
DC pump motor temp E-HYD)
Fan on 15. PUMP SPEED 3 (NOT USED WITH
Run Diagnostics E-HYD)
Traction motor speed 16. Pump acceleration
Traction motor amps • E-HYD SETUP
Traction motor temp LIFT SPEED
AC pump motor speed Setting 0 to 100: This function determines the
AC pump motor amps top speed of the pump motor when lift is used
AC pump motor temp by the operator. Factory default is 100
• View Hourmeter TILT SPEED
Traction Hourmeter Setting 0 to 25: This function determines the
Pump Hourmeter top speed of the pump motor when tilt is used
Secure Hourmeter by the operator. Factory default is 25.
53
AUX 1 SPEED 2. Press the or keys to select the function

Setting 0 to 30 (standard flow) or 0 to 50 (high for which calibration is desired. Press the
flow option), see Figure 25, Figure 26, Fig- key to start calibration of that function.
ure 27, and Figure 28. This function deter- 3. The master controller will run the pump at a
mines the top speed of the pump motor when slow speed and will command cracking cur-
1 is used by the operator. Factory default is rent to that function. Use the or keys
25. to increase or decrease the cracking current
AUX 2 SPEED until there is creep in the function. A num-
Setting 0 to 30 (standard flow) or 0 to 50 (high ber from 0 to 15 will be displayed on the
flow option), see Figure 25, Figure 26, Fig- Dash Display which corresponds to a crack-
ure 27, and Figure 28. This function deter- ing current off set value. objective is to find
mines the top speed of the pump motor when the value of cracking current that produces
auxiliary 2 is used by the operator. Factory the slowest creep speed. Press the key to
default is 25. save.
AUX 3 SPEED 4. Once the calibration is saved, the pump will
Setting 0 to 30 (standard flow) or 0 to 50 (high stop and the Dash Display will return to the
flow option), see Figure 25, Figure 26, Fig- calibration menu. Repeat the above proce-
ure 27, and Figure 28. This function deter- dure to calibrate the next function.
mines the top speed of the pump motor when 5. No calibration is required for the lowering
auxiliary 3 is used by the operator. Factory function.
default is 25. • PASSWORD MENU
NO OF FUNCTIONS ENTER PASSWORD
Setting 3 or 4: For hydraulic valves with a TRUCK INSPECTION
single auxiliary function, the number of auxil- ADD PASSWORD
iary functions is set to 3. For hydraulic valves DELETE PASSWORD
with double auxiliary functions, the number EDIT PASSWORD
of auxiliary functions is set to 4. • NO RUN DIAGNOSTICS
CLAMP INSTALLED? DIRECTION SWITCH
Setting Yes or No: If a clamp attachment is in- ACCELERATOR LOCK
stalled, then the setting is yes. If the number THROTTLE POT VOLT
of functions is 3, then the clamp is assumed to SEAT SWITCH
be aux 1 position. If the number of functions PARK BRAKE
is 4, then the clamp is assumed to be aux 2. PUMP SWITCH #1
HI FLOW AUX INSTLD? PUMP SWITCH #2
Setting Yes or No: If the E-hydraulic valve PUMP SWITCH #3
has the optional High Flow Auxiliary block in- DC PUMP BRUSH #1
stalled, then set this to Yes. If it is a standard DC PUMP BRUSH #2
flow auxiliary block, then the setting is No. DC PUMP MOTOR
See Figure 25, Figure 26 and Figure 28. FAN ON
• E-HYD CALIBRATION • RUN DIAGNOSTICS
CALIBRATE LIFT TRACTION MOTOR SPEED
CALIBRATE TILT FW TRACTION MOTOR AMPS
CALIBRATE TILE BK TRACTION MOTOR TEMP
CALIBRATE AUX1 DIR A TRACTION CNTRL TEMP
CALIBRATE AUX1 DIR B AC PUMP MOTOR SPEED
CALIBRATE AUX2 DIR A AC PUMP MOTOR AMPS
CALIBRATE AUX2 DIR B AC PUMP MOTOR TEMP
Calibration procedure is as follows: AC PUMP CNTRL TEMP
1. The operator must be on the seat, and the
armrest down and latched in order to cali-
brate the valve.
54
• E-HYD DIAGNOSTICS take effect until the operator releases the accelerator
LIFT/LOWER INPUT pedal. If the password is enabled, the operator will be
The four inputs are displayed on a scale from limited by the performance level set in the password
0 to 255. The value ranges from 0 when the function.
lever is moved to the full back position to 255
when the lever is moved to the full forward Mode 4 is the highest level of performance available
position. The value 128 must be displayed to the operator, regardless of the performance setup
when the lever is in the neutral position. in the control. For instance, if the control is con-
TILT INPUT figured to limit top speed less than maximum, then
AUX1 INPUT Mode 4 top speed is equal to the top speed set in the
AUX2 INPUT control. Three lower performance modes are avail-
CLAMP INTERLOCK able to the operator by using the buttons on the dis-
When the clamp interlock switch on the mini- play. These lower performance settings are percent-
lever module is pressed, 1 will be displayed on ages of the highest performance available in Mode 4
the Dash Display. as described below:
DUAL FUNCTION SW • Mode 4 - This is the highest performance mode.
If the truck is equipped with a third auxiliary Other modes are a lower percentage of Mode 4.
function then the dual function switch will • Mode 3 - Top speed is the same as Mode 4. Accel-
indicate whether it is pressed (1) or released eration is 80 percent of Mode 4.
(0). • Mode 2 - Top speed is 80 percent of Mode 4. Accel-
LIFT COIL CURRENT eration is 70 percent of Mode 4.
The coil currents, as measured by the Valve • Mode 1 - Top speed is 60 percent of Mode 4. Accel-
Driver, is displayed in mA/10. The maximum eration is 60 percent of Mode 4.
value 255 corresponds with 2550 mA (or 2.55
amps). BATTERY DISCHARGE INDICATOR (BDI)
TILT COIL CURRENT
The AC control system includes a Battery Discharge
AUX1 COIL CURRENT
Indicator (BDI) that provides indication of the bat-
AUX2 COIL CURRENT
tery state of charge. See Figure 24. The BDI feature
• VIEW HOURMETER
is displayed to the operator on the dash display with
TRACTION HOURMETER
a 20-segment bar. For information on how the BDI
PUMP HOURMETER
system works, see the Operating Manual for your
SECURE HOURMETER
lift truck.
PERFORMANCE MODES The BDI provides full functionality when used with
a full range of batteries including:
NOTE: Performance modes are not available on the
• Flooded cell, standard amp-hour batteries
Standard Dash display, and the factory configuration
• Flooded cell, high amp-hour capacity batteries
is equivalent to Mode 4.
• Valve regulated (absorbed glass mat) maintenance-
When equipped with the Premium Dash display, free batteries (VRLA)
the following four operator-selectable performance
modes are available. These modes are preconfigured
from the factory as described below. Mode 4 pro-
vides the highest performance and Modes 1-3 are
percentages of Mode 4. A service technician, using
the dash display or connecting with the PC software,
can revise the control settings and configure the top
speed and acceleration of the vehicle. The relation-
ship between Modes 1 through 4 remains constant
and cannot be altered.
With the premium display, the operator can change

modes by pressing the numbered keys on the dash
display. Any number can be selected at any time to Figure 24. Battery Discharge Indication in
change the performance mode. The change does not Dash Display LCD Window
55
The lift interrupt feature is controlled by the vehicle if it is desired to have the lift interrupt to occur at a
master controller and prevents the lift function when higher battery specific gravity, then the value would
the battery is 80 percent discharged. Although lift be increased. The value is decreased if a lower spe-
interrupt prevents lifting, low speed functions, such cific gravity is desired for the lift interrupt point.
as tilt and sideshift, remain operational to allow the
operator to more easily remove the forks from the If a maintenance-free battery is installed, the BDI
load and return to the battery charging area. adjustment should be increased to a value of about
50 as a starting point. Fine-tuning can be done from
When lift interrupt is initiated, it will remain in ef- that value.
fect until the battery is disconnected and a recharged
battery is reconnected to the vehicle. When a bat- HOURMETER
tery is replaced or recharged, the new state of charge
must be at least 25 percent greater than the previ- There are three different hourmeter functions.
ous state of charge. This prevents the BDI from be- 1. Pump hours - accumulates time only when the
ing activated by a battery that has recovered slightly pump motor is operating.
during an idle period. 2. Traction hours - accumulates time when the seat
switch is closed and the key switch is in the ON
A BDI adjustment feature is provided through the position.
control setup function, which is accessible using ei- 3. Secure hours - based on traction hours. The se-
ther the dash display or the PC service software. The cure hours cannot be reset.
adjustment scale is 0-100, with a value of 30 for the
factory setting. The setting of 30 is the starting point The hourmeter data is stored in the master controller
for flooded cell-type batteries of all voltages and amp- during every 6 minutes of operation. If there is a loss
hour capacities. The adjustment can then be used to of power, data is not lost.
fine-tune the BDI lift interrupt feature. For example,
Legend for Figure 25

1. AUXILIARY 2 VALVE (SP5) 15. STEERING RELIEF VALVE
2. AUXILIARY 1 VALVE (SP4) 16. HYDRAULIC TANK
3. TILT CYLINDERS 17. HYDRAULIC FILTER
4. LIFT CYLINDER 18. HYDRAULIC PUMP
5. SECONDARY LOWERING CONTROL INTEGRAL 19. PRIMARY RELIEF VALVE (RV1)
WITH LIFT CYLINDERS 20. SECONDARY RELIEF VALVE (RV2)
6. PRIMARY LOWERING CONTROL (MOUNTED 21. TILT SOLENOID VALVE (SP3)
ON MAST) 22. LIFT SOLENOID VALVE (SP1)
7. STEERING CYLINDER 23. PRIORITY COMPENSATOR VALVE (EC1)
8. STEERING WHEEL 24. LOWERING COMPENSATOR VALVE (EC2)
9. STEERING CHECK PORT 25. TILT COUNTERBALANCE VALVE (CB1)
10. STEERING CONTROL UNIT 26. CHECK VALVE LIFT CIRCUIT (CV1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP 29. GAUGE PORT
56
Figure 25. Electro-Hydraulic Control Valve Schematic (Standard Flow) for Lift Truck Models
J2.00-3.20XM (J40-65Z) (B416), E1.50-2.00XM (E25-35Z, E40ZS) (F114), E2.00-3.20XM (E45-65Z)
(G108)
57
Figure 26. Electro-Hydraulic Control Valve Schematic (High Flow) for Lift Truck Models
J2.00-3.20XM (J40-65Z) (B416), E1.50-2.00XM (E25-35Z, E40ZS) (F114), E2.00-3.20XM (E45-65Z)
(G108)
58

1. PILOT-OPERATED SPOOL VALVE (PE1) 16. HYDRAULIC TANK
2. PILOT-OPERATED SPOOL VALVE (PE2) 17. HYDRAULIC FILTER
3. TILT CYLINDERS 18. HYDRAULIC PUMP
4. LIFT CYLINDER 19. PRIMARY RELIEF VALVE (RV1)
5. SECONDARY LOWERING CONTROL INTEGRAL 20. SECONDARY RELIEF VALVE (RV2)
WITH LIFT CYLINDERS 21. TILT SOLENOID VALVE (SP3)
6. PRIMARY LOWERING CONTROL (MOUNTED 22. LIFT SOLENOID VALVE (SP1)
ON MAST) 23. PRIORITY COMPENSATOR VALVE (EC1)
7. STEERING CYLINDER 24. LOWERING COMPENSATOR VALVE (EC2)
8. STEERING WHEEL 25. PILOT-OPERATED SOLENOID VALVE (EHPR1
9. STEERING CHECK PORT THROUGH 4)
10. STEERING CONTROL UNIT 26. TILT COUNTERBALANCE VALVE (CB1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP 29. CHECK VALVE LIFT CIRCUIT (CV1)
15. STEERING RELIEF VALVE 30. GAUGE PORT
59
Figure 27. Electro-Hydraulic Control Valve Schematic for Lift Truck Models E3.50-5.50XL
(E70-120Z) (E098)
60

1. PILOT OPERATED SPOOL VALVE (PE1) 16. HYDRAULIC TANK
2. PILOT OPERATED SPOOL VALVE (PE2) 17. HYDRAULIC FILTER
3. TILT CYLINDERS 18. HYDRAULIC PUMP
4. LIFT CYLINDERS 19. PRIMARY RELIEF VALVE (RV1)
5. SECONDARY LOWERING CONTROL INTEGRAL 20. SECONDARY RELIEF VALVE (RV2)
WITH LIFT CYLINDERS 21. PROPORTIONAL SOLENOID VALVE (LIFT) (SP1)
6. PRIMARY LOWERING CONTROL MOUNTED 22. PROPORTIONAL SOLENOID VALVE
ON THE MAST (LOWERING) (SP2)
7. STEERING CYLINDER 23. PRIORITY COMPENSATOR VALVE (EC1)
8. STEERING WHEEL 24. LOWERING COMPENSATOR VALVE (EC2)
9. STEERING CHECKPORT 25. PILOT OPERATED SOLENOID VALVE (EHPR 1
10. STEERING CONTROL UNIT THROUGH 6)
11. HAND PUMP 26. TILT COUNTER BALANCED VALVE (CB1)
12. STEERING VALVE 27. FLOW REGULATOR VALVE (FR1)
13. MAINCONTROL VALVE 28. MANUAL LOWERING VALVE (NV1)
14. STEERING PUMP 29. LIFT CIRCUIT CHECK VALVE (CU1)
15. STEERING RELIEF VALVE 30. GAUGE PORT
61
Figure 28. Hydraulic Schematic With Electro-Hydraulics for Lift Trucks Model V30ZMD (E210)
62

1. SINGLE ACTING PIVOT CYLINDER 19. LOWERING COMPENSATOR VALVE (EC2)
2. ADJUSTABLE FLOW RESTRICTOR 20. LOWERING SOLENOID VALVE WITH MANUAL
3. LOCK/CROSS OVER RELIEF VALVE OVERRIDE (SP2)
4. TRAVERSE HYDRAULIC MOTOR 21. PRIORITY COMPENSATOR VALVE (EC1)
5. SIDESHIFT CYLINDER 22. LIFT SOLENOID VALVE (SP1)
6. LIFT CYLINDERS 23. STEERING VALVE
7. SECONDARY LOWERING CONTROL 24. PRIMARY RELIEF VALVE (RV1)
8. PRIMARY LOWERING CONTROL 25. SECONDARY RELIEF VALVE (RV2)
9. STEERING CYLINDER 26. FLOW REGULATOR VALVE (FR1)
10. HAND PUMP 27. TILT CYLINDER VALVE (SP3)
11. STEERING WHEEL 28. TILT COUNTERBALANCE VALVE (CB1)
12. LINE PRESSURE TAP 29. CHECK VALVE LIFT CIRCUIT (CV1)
13. CHECK PORT 30. GAUGE PORT
14. STEERING PUMP 31. PILOT OPERATED SOLENOID VALVE (EHPR 1
15. HYDRAULIC TANK THROUGH 4)
16. HYDRAULIC FILTER 32. PILOT OPERATED SPOOL VALVE (PE1)
17. HYDRAULIC PUMP 33. PILOT OPERATED SPOOL VALVE (PE2)
18. MAIN CONTROL VALVE
63
Dash Display Service Menu Navigation 2200 SRM 1056
Dash Display Service Menu Navigation

GENERAL 2. To move into a submenu of a main menu item,
press the → (right arrow) key on the dash display
To enter the service mode, turn the key to the ON po- numeric key pad. To move into a sub submenu,
sition and press the (enter) key twice. Enter Pass- as with the Diagnostics menu, press the → (right
word prompt will appear on the display. See Fig- arrow) key again.
ure 29. All lift trucks will have 55555 as the default
service password at the time of delivery. This pass- 3. To move up or down within the submenu or the
word can be changed by a service technician. Go to sub submenu, press the ↑ (up arrow) or ↓ (down
Editing and Adding Information. arrow) keys.
4. To move out of the sub submenu and return to

the submenu, press the ← (left arrow) key.
5. To move out of the submenu and return to the

Main Menu, press the ← (left arrow) key.
6. To exit the service mode, press the ← (left arrow)

key.
Figure 29. Password Prompt EDITING AND ADDING INFORMATION

The ↑ (up arrow) and the ↓ (down arrow) keys allow NOTE: The setup and password menus can be used to
you to move up and down within a menu. The ← (left edit or add information to the truck software. When
arrow) key and the → (right arrow) key allow you to an item in these menus is selected, the current value
move from menu to menu. The (enter) key allows will be displayed. The characters available to be se-
you to enter or save a parameter. The 5 (five) key lected from the display are 0 through 9, A through Z,
is only used if it is part of the password required to blank, and dash. Each line in the display can have
enter the service mode. See Figure 30. no more than 20 characters including blanks.
1. If a change is to be made, press the → (right ar-

row) key and the cursor will blink on one of the
characters. The ← (left arrow) key and → (right
arrow) key are used to move from character to
character in the item being changed.
2. When a character that is to be changed is blink-

Figure 30. Dash Display Keys ing, use the ↑ (up arrow) and ↓ (down arrow)
keys to scroll up or down until the desired char-
MOVING THROUGH MENU SELECTIONS acter is found. Use the ← (left arrow) or → (right
arrow) keys to move to the next character to be
1. When the service technician’s password has been
changed. This is repeated until all changes in the
correctly entered, the first menu item, which is
item have been made.
the Setup menu, is displayed on the dash dis-
play LCD screen. To view the next menu item, 3. When all changes have been made, press the
press the ↓ (down arrow) key on the dash dis- (enter) key to store the value. Press the ↑ (up ar-
play numeric key pad. Repeat this until the de- row) key or the ↓ (down arrow) key to access the
sired menu item has been reached. To return to a next item to be changed. Repeat this procedure
previous menu item, press the ↑ (up arrow) key. for each item that is to be changed.
When the last menu item is reached and the ↓
(down arrow) key is pressed again, the first menu 4. When all changes have been made, press the ←
item will return to the display. (left arrow) key to exit the menu.
64

Servicio E45z Hyster - 230906 - 091517

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Servicio E45z Hyster - 230906 - 091517

Uploaded by

Copyright:

Available Formats

AC MOTOR CONTROLLERS/DISPLAY

PART NO. 1534735 2200 SRM 1056

©2008 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

J2.00-3.20XM (J40-65Z) [A416/B416];

The AC motors also have thermal sensors embedded Dash Display

Controller Area Network Bus (CANbus)

Figure 1. Diagnostic Connector

Master Controller Checks and Adjustments

Factory Factory Factory Factory

Factory Factory Factory Factory

Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)

Factory Setting Factory Setting Factory Setting

Table 4. Factory Parameters for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

Factory Setting Factory Setting Factory Setting

Grade climbing speed will also improve because the

Function Number 3 ACCELERATION 1 Function Number 6 REGEN BRAKING

Function Number 10 POWER STEERING Function Number 13 PUMP SPEED 1

A setting value of 4 directs the master controller to

Master Controller AC Motor Controllers

Figure 2. Master Controller LED

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. LINE CONTACTOR

1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

1. FUSE 1 (15A) AUXILIARY 5. POWER STEERING 9. AC PUMP MOTOR

Table 5. List of Status Codes

Status Code Description Status Code Description

Table 5. List of Status Codes (Continued)

Status Code Description Status Code Description

AC Motor Controllers Status Code Charts

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

• Malfunction of mini-lever, if equipped.

Operate each lever to full stroke forward and

Operate each lever to full stroke back and slowly

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit