Hyster P2.0 Operating instructions

Hyster A290 (P2.0) Forklift

AC MOTOR
CONTROLLER
P2.0 [A290]
PART NO. 4035864 2200 SRM 1507

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2014 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Safety Precautions .............................................................................................................................................. 1
Description ...............................................................................................................................................................2
AC Motor Controller ........................................................................................................................................... 2
Principles of Operation ....................................................................................................................................... 2
Install ...................................................................................................................................................................3
Programming Controller .....................................................................................................................................3
1311 Programmer Handset .....................................................................................................................................6
Description/Features ...........................................................................................................................................6
Menu Navigation Key .....................................................................................................................................7
Data Increase/Decrease Key .......................................................................................................................... 8
Bookmark Keys ...............................................................................................................................................8
Operation .............................................................................................................................................................8
Connecting Handset to Traction Motor Controller .......................................................................................8
Disconnecting the Handset From the Traction Motor Controller ................................................................8
Main Menu Selections ........................................................................................................................................ 9
Program Menu ................................................................................................................................................ 9
Monitor Menu ................................................................................................................................................. 9
Faults Menu ..................................................................................................................................................10
Functions menu ............................................................................................................................................ 11
Information Menu .........................................................................................................................................11
Programmer Setup Menu .............................................................................................................................11
Programming the Traction Motor Controller - 1311 Handset ............................................................................ 12
Display (BDI)/Hourmeter ......................................................................................................................................13
Fault Codes ............................................................................................................................................................13
This section is for the following models:
P2.0 [A290]
Table of Contents
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"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

General
This section describes the AC Motor Controller.
Procedures are outlined for controller programming
and troubleshooting.
SAFETY PRECAUTIONS
WARNING
Disconnect the battery and separate the
connectors before opening the compartment
cover or inspecting or repairing the electrical
system. If a tool causes a short circuit, the high
current flow from the battery can cause personal
injury or property damage.
All checks, adjustments, and repairs in the drive
unit compartment are done with the compartment
cover removed. Remove the drive unit compartment
cover for access to the electrical components.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery has been
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspection or repairing any component in the
drive unit compartment. Wear safety glasses.
Make certain the battery has been disconnected.
DO NOT use a screwdriver to discharge the
traction motor controller.
CAUTION
To avoid controller damage, always disconnect
the battery before disconnecting any cables from
the controller. Discharge the capacitor, and never
put power to the controller with any power wire
disconnected. Never short any controller terminal
or motor terminal to the battery. Make sure to use
proper procedure when servicing the controller.
The following steps must be followed to discharge
the capacitors before any checks or repairs are
performed on the controller or any part of the
electrical system.
1. Block the wheels so that the truck will not roll
or block the truck so that the wheels are off the
floor. See
•Periodic Maintenance 8000SRM1510
for lift truck model A290
2. Turn the key switch to the OFF position and
disconnect the battery.
3. Discharge the capacitors in the controller by
connecting a 100-ohm, 25-watt resistor across
the controller's B+ and B- terminals using two
insulated jumper wires. See Figure 1.
NOTE: DO NOT use any other method of
discharging the capacitors. Remove the 100-ohm,
25-watt resistor before reconnecting the battery.
2200 SRM 1507 General
1

Figure 1. Discharging the Capacitors
Legend for Figure 1
1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 100-OHM, 25-WATT RESISTOR
5. NEGATIVE CONNECTION
Description
AC MOTOR CONTROLLER
The controller is a solid-state, AC motor controller.
It can control the traction motor, brake, and hy-
draulic system. The controller receives inputs from
the control handle by serial communication, and di-
rect inputs from other switches depending on
model. These may include the following:
• Key switch
• Control handle arm position switch
The controller directly controls the traction motor,
lift pump motor, main contactor, and the brake.
The motor controller controls the speed of the trac-
tion motor and the hydraulic lift pump motor oper-
ation. The controller software provides self diagnos-
tics which are accessed by means of a Curtis hand-
set.
PRINCIPLES OF OPERATION
The Traction Motor Controller uses a sophisticated
microprocessor to control the logic and operation of
the controller, eliminating the need for forward and
reverse contactors. The controller has many pro-
grammable features, including maximum speed, ac-
celeration rate, neutral braking, and braking cur-
rent limit. The controller includes a full range of
features as well as diagnostic and setup capability
for reliable operation.
NOTE: There are no user-serviceable parts in the
Curtis controller. No attempt should be made to
open, repair, or otherwise modify the controller. Do-
ing so may damage the controller and will void the
warranty.
Description 2200 SRM 1507
2

INSTALL
1. Make certain the mounting surface for the trac-
tion motor controller is clean. There should be
no dirt between the contactor panel mounting
plate and the traction motor controller.
2. Connect wires and cables to controller termi-
nals. See Figure 2.
3. Refer to Programming Controller for setup of
the controller.
The motor controller controls the speed of the trac-
tion motor and the hydraulic pump motor opera-
tion. The complete unit must be replaced if correct
troubleshooting methods show that the unit is dam-
aged.
PROGRAMMING CONTROLLER
The controller can be programmed using a 1311
handset. The areas that can be programmed are lis-
ted in Table 1 along with the adjustable ranges.
1. TRACTION MOTOR CONNECTION "U"
2. TRACTION MOTOR CONNECTION "V"
3. TRACTION MOTOR CONNECTION "W"
4. CONNECTOR
5. LED INDICATOR
6. B− CONNECTION
7. B+ CONNECTION
Figure 2. Controller
2200 SRM 1507 Description
3

Table 1. Program Menu
Parameter Listing
Parameter Units Range Default
Setting Description
Main Menu
Interlock Timeout Sec 0 - 120 Max time for tiller in opening position with
no input to controller
Buzzer Option 0 - 2 0 - None, 1 - Reverse Only, 2 - Forward &
Reverse
Buzzer Deadband Rpm 0 - 1000 Min motor rpm to activate buzzer
Throttle Setup Menu
Forward Max Rpm 3500 - 6000 Rotation of butterfly to max speed in for-
ward direction
Forward Map % 0 - 100 Adjust relationship to butterfly rotation for
forward truck speed
Forward Dead Band 0 - 500 Minimum rotation of butterfly to enable for-
ward travel
Reverse Dead Band 0 - 500 Minimum rotation of butterfly to enable re-
verse travel
Reverse Map % 0 - 100 Adjust relationship of butterfly rotation to
reverse truck speed
Reverse Max Rpm Rotation of butterfly to max speed in reverse
direction
Hydraulic Functions Menu
Lockout Enable On/Off ON-Lift Lockout Enabled OFF-Lift Lockout
Disabled
Lift Run Time Sec 0 - 10 Max time continuous lifting is enabled
Lift Delay Time Sec 0 - 5 Max time hydraulic valve is open after pump
stops
Lowering Delay time Sec 0 - 5 Max time hydraulic valve is open after low-
ering valve is deactivated
Traction Settings Menu
Snail Speed Rpm 0 - 1000 Maximum motor speed in Snail Mode
Max Speed Rpm 0 - 4330 Maximum motor speed
Max Acceleration Sec 0.1 - 5 Time required to accelerate to max speed at
full butterfly rotation
Description 2200 SRM 1507
4