Hyster G117 Operating instructions

Hyster G117 (H1050HD-16CH, H1150HD-16CH)
Internal Combustion Engine Trucks Service Repair
Manual

HYDRAULIC CONTROL
SYSTEM
H36XMS-12, H40XM-12, H44XM-12, H48XM-12
(H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH, H48-16CH,
H50-16CH, H52XM-16CH (H1050HD, H1150HD)
[G117]
PART NO. 4046726 1900 SRM 1561

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
Description ...............................................................................................................................................................1
Control Valve .......................................................................................................................................................2
Analog Inputs ......................................................................................................................................................2
Joysticks/Levers ..............................................................................................................................................2
Sensors ............................................................................................................................................................ 3
Temperature Sensor ...................................................................................................................................3
Pressure Transducer .................................................................................................................................. 3
Accumulator Pressure Transducer ............................................................................................................3
Digital Inputs ...................................................................................................................................................... 3
Hydraulic Control Switches ........................................................................................................................... 3
Interrupts ............................................................................................................................................................ 3
Lift Interrupt (Twist Module) ........................................................................................................................ 4
Lower Interrupt (Twist Module) ....................................................................................................................4
Function Override ...........................................................................................................................................4
Operator Presence System (OPS) .................................................................................................................. 4
Digital Switched Inputs ......................................................................................................................................4
ECO eLo HiP Switch ...................................................................................................................................... 4
Not Locked Signal ...........................................................................................................................................4
(Lift Position, Tilt Position, Slew RH Position, Slew LH Position) Sensor ................................................. 4
Calibration Switch ..........................................................................................................................................4
Ignition Switch Signal ....................................................................................................................................4
Brake Filter Pressure Switch .........................................................................................................................4
Pressure Signal ...............................................................................................................................................4
CAN Bus Communication ...................................................................................................................................4
Output Signals .................................................................................................................................................... 5
Analog Outputs ...............................................................................................................................................5
Digital Outputs ...............................................................................................................................................5
Lowering Interrupt .....................................................................................................................................5
Accumulator Charge Enable ......................................................................................................................6
Hydraulic Relay Take Over ....................................................................................................................... 6
Programmed Features ........................................................................................................................................ 6
High Temperature Protection (Optional) ...................................................................................................... 6
Adjustable Loaded Vehicle Speed Reduction (Optional B917 only) .............................................................6
Traction Speed Limiter - Container Position (Optional G117 only) ............................................................ 7
Temperature Protection (Standard) .............................................................................................................. 7
Cold Temperature Protection (Standard) ......................................................................................................7
Traction Speed Limiter-Loaded (Standard) .................................................................................................. 7
Automatic Throttle Up (Standard) ................................................................................................................ 8
HiP/ECO eLo Operating Mode (Standard) ....................................................................................................8
Drive Over Lift (Standard) .............................................................................................................................8
FAN Drive System (Standard) .......................................................................................................................8
Hibernate Idle (Standard Tier 4 Only) ..........................................................................................................8
Settings ................................................................................................................................................................9
Adjustable Parameters ...................................................................................................................................9
Truck Configuration Screen .......................................................................................................................9
Installed Features Screen ..........................................................................................................................9
General Functions of the Interface .........................................................................................................................9
Main Functional Requirements ......................................................................................................................... 9
What is Needed for the Hydraulic User Interface Program .............................................................................9
Table of Contents
i

TABLE OF CONTENTS (Continued)
Installation of the Program ............................................................................................................................9
Start Screen .................................................................................................................................................. 12
Warning Screen ............................................................................................................................................ 13
Basic Screen Layout of the Hydraulic User Interface Program .................................................................14
Truck Configuration Screen .........................................................................................................................16
Installed Features Screen ............................................................................................................................ 18
Temperature Protection Screen ................................................................................................................... 20
High Temperature Protection (Optional) ................................................................................................20
Traction Speed Limiter - Container Position (Optional G117 only) .......................................................... 21
Adjustable Loaded Speed Reduction (Optional B917 only) ........................................................................22
Temperature Protection Screen ................................................................................................................... 23
Temperature Protection (Standard) ........................................................................................................23
Cold Temperature Protection (Standard) ............................................................................................... 23
Traction Speed Limiter - Loaded ................................................................................................................. 24
Automatic Throttle Up - Lift Screen ............................................................................................................25
HiP/ECO eLo Operating Mode Screen ........................................................................................................ 26
Drive Over Lift (Standard) ...........................................................................................................................27
Hibernate Idle Screen ...................................................................................................................................28
Fan Drive Settings Screen ........................................................................................................................... 29
Calibration Screen ........................................................................................................................................30
Calibrating the Connected Joystick/Lever Without the Interface Software .........................................30
Calibrating the Connected Joystick/Lever With the Interface Software .............................................. 31
Flow Settings Screen .................................................................................................................................... 31
Profile Lift Screen .........................................................................................................................................32
Valve Settings Screen ...................................................................................................................................33
Diagnostic Screen ......................................................................................................................................... 34
Active Errors Screen .....................................................................................................................................35
Error History Screen .................................................................................................................................... 36
All Parameters Screen ..................................................................................................................................37
Installing the Hydraulic Controller Software and Read-Only Parameter File .........................................39
File Download Screen ...............................................................................................................................39
Calibration .............................................................................................................................................................40
Calibrating the Lever With the Hydraulic User Interface Program ..............................................................40
Calibrating the Joystick With the Hydraulic User Interface Program ......................................................... 40
Calibrating the Lever Without the Hydraulic User Interface Program ........................................................ 41
Calibrating the Joystick Without the Hydraulic User Interface Program .................................................... 41
Fault Codes ............................................................................................................................................................42
Controller Pinning .................................................................................................................................................50
This section is for the following models:
H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD,
H1150HD) [G117]
Table of Contents
ii

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General
This SRM describes the electronic hydraulic control
system, and its interaction with the Hydraulic User
Interface Program.
See the following resources for additional
information:
Hydraulic System 1900SRM1562
Diagrams 8000SRM1563
Description
The hydraulic system is operated through an elec-
trically-operated control valve that receives its sig-
nals from the hydraulic frame controller. The hy-
draulic frame controller contains the actual soft-
ware logic and therefore controls most of the out-
puts. It is located near the main control valve.
The hydraulic cab controller is placed in the side
console of the cabin and controls most of the input
signals. The two units communicate with each
other through CAN Bus, see Figure 1. The frame
controller determines what the accompanying out-
put must be.
Figure 1. CAN Bus Connections
1900 SRM 1561 General
1

The hydraulic controller has been programmed to
supply these output signals to the electrically-oper-
ated control valve depending on the following varia-
bles:
• Input signals
• Programmed functions
• Settings
See Figure 2.
A. CAB AND FRAME CONTROLLER INPUTS
B. SOFTWARE LOGIC CONTROLS
C. CAB AND FRAME CONTROLLER OUTPUTS
Figure 2. Control Flow
Output signals can be Pulse Width Modulation
(PWM) signals for proportional hydraulic functions,
digital signals for ON/OFF functions, or CAN Bus
messages for other linked controllers.
Both hydraulic controllers continually monitor the
system for fault conditions, display appropriate
fault codes, and take action when necessary.
Each controller requires a 24 volt power supply for
operation. Power is provided through the ignition
switch, the hydraulic controller relay, and a 30
amp fuse. There is a Red and Green LED next to
the main connector of each controller. The Green
LED is ON when the controller is powered. The
Red LED is ON when a hydraulic control system
fault condition is detected, and blinks when the
fault is related to a CAN Bus message.
CONTROL VALVE
The flow of hydraulic oil through the electrically-
operated control valve is determined by the position
of the spools. The position of each spool depends on
the electrical controller signal received at the ac-
tuation module for that spool.
For hydraulic functions that just require hydraulic
supply to be ON or OFF, the electrical signal is ON
or OFF as well. Operating voltage is ±24 volts (Sys-
tem Voltage).
For hydraulic functions that require flow control,
the desired spool position is obtained by a voltage-
controlled PWM (Pulse Width Modulation) signal.
Depending on the hydraulic function, the average
voltage varies in relation to the PWM duty cycle be-
tween ±8% and ±50% of the truck supply voltage at
the solenoid.
ANALOG INPUTS
Joysticks/Levers
Joysticks/Levers are used to proportionally control
the following functions:
• Lift and Lower
• Tilt Forward and Tilt Backward
• Aux0 (Power Pile Slope)
• Aux1 (Rotate)
Depending on the position of the joystick/lever, the
5-volt sensor supply signal from the controller is
converted to a signal between 0.5 volts and 4.5
volts. The neutral position of the joystick/lever
translates to a signal of 2.5 volts.
The controller monitors the signals provided by the
joystick/lever and if the signals are out of range,
the controller activates a fault code and enters a
fail safe mode. Joysticks/levers must be calibrated
before being put into service.
Calibration of the joystick/lever provides a refer-
ence to the controller for the two extreme and neu-
tral joystick/lever positions. The controller converts
the joystick/lever position input signal into a PWM-
output signal and sends it to the control valve.
Description 1900 SRM 1561
2

For backward joystick/lever movements, the joy-
stick/lever output signals are indicated with flow
direction A. For forward joystick/lever move-
ments, the joystick/lever output signals are indica-
ted with flow direction B. The specific joystick/
lever position and connector orientation prevent
joystick/lever directions from inadvertently result-
ing in incorrect oil flow directions.
Sensors
Additional analog input is provided by a tempera-
ture sensor and two pressure transducers.
Temperature Sensor
A temperature sensor at the bottom of the hy-
draulic tank has a resistance between 700 and 2000
Ω, depending on the hydraulic oil temperature.
The controller reacts to the temperature signal as
follows:
• When oil temperature is below −5°C (23°F),
the controller displays the fault code hcold.
• When Cold Temperature Protection is activa-
ted, the controller reduces maximum engine
speed by sending a CAN Bus message to the
engine.
• When oil temperature exceeds 90°C (194°F),
the controller displays the fault code hhot.
•When High Temperature Protection (op-
tional) is activated, the controller displays
the fault code hhot when oil temperature ex-
ceeds 88°C (190°F). When oil temperature
exceeds 90°C (194°F), the controller reduces
vehicle speed by sending a CAN Bus mes-
sage to the transmission.
See Programmed Features.
Pressure Transducer
A pressure transducer measuring the pressure in
the lift cylinders provides an input to the hydraulic
controller for the load being lifted. The signal is
used for the following standard/optional features:
• Traction Speed Limiter - Loaded
• Traction Speed Limiter - Container Position
When the sensor detects an error, receives an input
below 300 mv or above 5200 mv, a fault code is dis-
played and the features are turned OFF.
Accumulator Pressure Transducer
A pressure transducer measuring the accumulator
pressure in the main valve (port S ACC) provides
an input to the hydraulic controller for enabling/
disabling the electronically-controlled charge func-
tion:
• Charging is enabled when the accumulator
pressure is below ±16.5 MPa (±2393 psi) for
0.5 seconds.
• Charging is disabled at an accumulator pres-
sure of ±20.5 MPa (±2973 psi).
DIGITAL INPUTS
Hydraulic Control Switches
Five auxiliary functions can be activated by manual
switches (digital inputs): Aux_2, Aux_3, Aux_4,
Aux_5, and Aux_6.
• Aux_2 (Twist Locks) - Lock/Unlock
• Aux_3 (Hydraulic Stop) - Lock/Unlock
• Aux_4 (Side Shift) - Right/Left
• Aux_5 (Extend/Retract) - Extend/Retract
• Aux_6 (Reach) - Forward/Backward
Depending on the position of the switch, the con-
troller sends a 24 volt signal to the relevant sole-
noid valve.
INTERRUPTS
Interrupts disable the lifting/lowering functions un-
der specific circumstances. The interrupts are gen-
erated in the Twist Module depending on the fol-
lowing signals:
• Not Locked Signal
• Locked Signal
• All Seated Signals
There are separate interrupt signals for lowering
and lifting.
1900 SRM 1561 Description
3

Lift Interrupt (Twist Module)
The lift interrupt function disables the lift function
during locking and unlocking of the twist locks.
Both signals “Not Locked” and “Locked” are used to
generate this interrupt. When the lift interrupt is
active the tilt backward function is also disabled.
Lower Interrupt (Twist Module)
The lowering interrupt function disables the lower-
ing function when all “Seated” signals are active.
All “Seated” signals are used to generate this inter-
rupt. When the lowering interrupt is active the tilt
forward function is also disabled.
Function Override
The “Lift Interrupt” and “Lower Interrupt” signals
can be overruled by the input: Function Override.
The "Function Override" button, if it is included on
the truck, is located on the twist module.
Operator Presence System (OPS)
The OPS has an electrical switch in the seat that
sends a signal to disable the hydraulic lift/lower,
tilt forward/backward, and auxiliary functions 1
second after the OPS switch has been activated.
In order to reset the OPS and re-enable the hy-
draulic functions, the operator has to sit on the seat
again.
DIGITAL SWITCHED INPUTS
ECO eLo HiP Switch
The ECO eLo HiP Switch switches between HiP
(High Performance) and ECO eLo (Fuel Efficiency)
operating modes. The switch is located on the
truck's side console.
Not Locked Signal
The Not Locked signal is used for the traction
speed limiter – container position, to switch be-
tween max vehicle speed, vehicle speed limit 1, or
vehicle speed limit 2. See Programmed Features.
(Lift Position, Tilt Position, Slew RH Position,
Slew LH Position) Sensor
The lift position sensor together with the tilt, slew
right hand, and slew left hand position sensors act
as one input for the “Traction Speed Limiter – Con-
tainer Position (Optional G117 Only)”. The sensors
are located on the mast/gantry and depending on
the position of the mast/gantry, the speed limiter
switches between max vehicle speed, vehicle speed
limit 1 or vehicle speed limit 2. See Programmed
Features.
Calibration Switch
When the calibration switch is activated, the
charger enable output is deactivated. The calibra-
tion switch also disables the hibernate idle function
and the automatic throttle-up features to make
sure the truck operates in normal idle mode so the
operator can calibrate the transmission at a fixed
engine speed.
Ignition Switch Signal
The ignition switch signal is used to activate the
“Hydraulic Control Relay” to maintain battery
power for 10 seconds after the ignition switch is
turned off. This is to provide the fan drive valve
with power so the system can be powered down in a
steady way.
Brake Filter Pressure Switch
The brake filter pressure switch signal indicates
that the brake pressure filter has too high a restric-
tion and needs to be replaced. The hydraulic oil
temperature needs to be at least 40°C (104°F) be-
fore a fault code is generated.
Pressure Signal
The spreader sends a pressure signal to the hy-
draulic controller to give output on the auxiliary
valve so the spreader can lock/unlock the twist
locks.
CAN BUS COMMUNICATION
CAN Bus communication can consist of both input
and output signals.
The hydraulic controller communicates via the
CAN Bus circuit with the following controllers:
Description 1900 SRM 1561
4