Hyster B233 User manual

Hyster B233 (B80ZAC) Forklift

AC MOTOR
CONTROLLER
B60ZAC [B230];
B80ZAC [B233];
B60ZHD [A262];
B80ZHD [A257]
PART NO. 1640805 2200 SRM 1286

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic 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 exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a 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.

AC Motor Controller Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Discharging the Capacitors............................................................................................................................. 1
Description ........................................................................................................................................................... 2
Electrical System............................................................................................................................................. 2
AC Traction Motor....................................................................................................................................... 3
Controller..................................................................................................................................................... 3
Service PC Connection ................................................................................................................................ 3
Parameters ........................................................................................................................................................... 3
General............................................................................................................................................................. 3
Parameter Description......................................................................................................................................... 5
Parameters....................................................................................................................................................... 5
Extended Shift............................................................................................................................................. 5
Walk Speed (Both Directions)..................................................................................................................... 5
Hi Speed (FWD)........................................................................................................................................... 5
Hi Speed (REV)............................................................................................................................................ 5
Minimum Acceleration................................................................................................................................ 5
Maximum Acceleration ............................................................................................................................... 5
Plugging ....................................................................................................................................................... 5
ADS-Neutral ................................................................................................................................................ 5
ADS-Throttle ............................................................................................................................................... 5
Pick Acceleration ......................................................................................................................................... 5
Pick Deceleration......................................................................................................................................... 6
Battery Full Voltage.................................................................................................................................... 6
Lift Interrupt ............................................................................................................................................... 6
Troubleshooting ................................................................................................................................................... 6
General............................................................................................................................................................. 6
Non-Status Code Errors.................................................................................................................................. 7
Powered Black Screen ................................................................................................................................. 7
Tiller Oscillation and Bias (EPAS Option)................................................................................................. 8
Status Codes .................................................................................................................................................... 8
Electrical Checks.............................................................................................................................................. 101
General Electrical System Checks.............................................................................................................. 101
Static Checks on Power and Ground Connections..................................................................................... 101
Static Checks on CAN Connections............................................................................................................ 102
Tiller Harness Shorts and Continuity Checks........................................................................................... 103
Control Card Functional Test.......................................................................................................................... 104
Dash Display .................................................................................................................................................... 107
General......................................................................................................................................................... 107
Startup ......................................................................................................................................................... 107
Status LED .................................................................................................................................................. 107
Performance Mode Indicator....................................................................................................................... 107
Hourmeter.................................................................................................................................................... 108
Battery Charge Indicator ............................................................................................................................ 108
Fault Log ...................................................................................................................................................... 108
Connector Pin-Outs.......................................................................................................................................... 109
System Logic Diagram..................................................................................................................................... 110
©2011 HYSTER COMPANY i

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Table of Contents AC Motor Controller
TABLE OF CONTENTS (Continued)
This section is for the following models:
B60ZAC [B230];
B80ZAC [B233];
B60ZHD [A262];
B80ZHD [A257]
ii

2200 SRM 1286 General
General
This section describes the Iskra® motor controller
and dash display used in B60ZAC, B80ZAC,B60Z
HD,
and B80ZHD lift trucks. Procedures are outlined for
controller programming and troubleshooting.
DISCHARGING THE CAPACITORS
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.
1. Move the truck to a safe, level area. Turn the
key switch to the OFF position and disconnect
the battery.
2. Remove the drive unit compartment cover to ac-
cess the controller.
3. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals. SeeFigure1.
DO NOT short across the motor controller termi-
nals with a screwdriver or jumper wire. Remove
the 200-ohm, 2-watt resistor before reconnecting
the battery.
1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
Figure 1. Discharging the Capacitors
1

Description 2200 SRM 1286
Description
ELECTRICAL SYSTEM
The Iskra® AC motor controller controls the AC trac-
tion motor and the DC pump motor. The controller
can also be used with the optional brushless DC
power steering motor. The controller uses CANbus
communication to interact with the dash display and
the control handle. See Figure 2.
1. GRAB RAIL
2. AUXILIARY CONTROL BOX
3. DASHDISPLAY
4. POWER FUSE
5. PC CONNECTOR (ETACC)
6. KEY SWITCH
7. HORN
8. PUMP MOTOR
9. BRAKE
10. STEER MOTOR (POWER STEER ONLY)
11. TRACTION MOTOR
12. CONTACTOR
13. CONTROLLER
14. CONTROL MODULE
15. PROXIMITY SWITCH
Figure 2. Component Location (Power Steer Shown)
2

2200 SRM 1286 Parameters
AC Traction Motor
The AC traction motor is a three-phase AC induction
motor. The motor does not include motor brushes or
a commutator. An AC induction motor operates on
three-phase AC power provided directly by the con-
troller. The motor speed is controlled by the motor
controller and can be changed by the frequency of the
AC power supplied to the motor. A speed sensor has
been built into one of the motor bearings which pro-
vides feedback to the motor controller allowing soft-
ware to continually monitor motor direction and rev-
olutions per minute (RPM). Using this feedback sys-
tem, the AC motor control can provide much better
vehicle top speed control than the older DC SEM sys-
tems.
Controller
The motor controller converts DC power from the
truck battery to three-phase AC power at the fre-
quencies and currents necessary to drive the traction
motor. A bearing in the traction motor provides feed-
back of speed, rotation direction, and temperature di-
rectly to the motor controller.
The motor controller receives power through the
main contactor which is controlled by the key
switch. The controller receives inputs from the con-
trol handle and the hand rail switches to control lift
truck functions.
NOTE: There are no serviceable parts in the motor
controller. No attempt should be made to open re-
pair, or otherwise modify the controller. Doing so
may damage the controller and/or lift truck. Remov-
ing the cover from the controller will void the war-
ranty.
Service PC Connection
The lift truck is equipped with a connection point to
connect a laptop computer with ETACC software in-
stalled. This connection can be used to adjust certain
lift truck parameters and to assist with troubleshoot-
ing the lift truck.
Parameters
GENERAL
A parameter is a measurement or a setting that de-
fines a lift truck function. A specific function param-
eter works with other function parameters to control
the operation of the lift truck.
WARNING
The parameter for each function has a value
range so the motor controller can be used on
different models of lift trucks. This variation
is needed for lift trucks of different sized and
operation voltages. Adjustment of a function
to the wrong number value for your lift truck
model can cause the truck to operate differ-
ently than normal. This different operation of
the truck can cause an injury.
NOTE: Table 1 shows the factory default setting for
each parameter that is adjustable by the user.
Parameters can be adjusted through the dash dis-
play. The factory default values listed in Table 1 are
the recommended settings for new units. These set-
tings will give satisfactory performance for most ap-
plications.
WARNING
If any of the parameter values are changed, the
operators must be told the lift truck will oper-
ate differently.
NEVER adjust any of the following parameters
without using the procedures and settings
given in this section.
Function Parameter Descriptions in this section
contains descriptions for the different parameters.
These parameters can also be accessed using the
ETACC PC software.
3

Parameters 2200 SRM 1286
Table 1. Parameter Default Values
Default RangeParameter
B60ZAC and
B60ZHD B80ZAC and B80ZHD Min Max
Extended Shift OFF OFF ON OFF
Walk Speed (Both
Directions)
3.8 3.8 0.5 4.0
Hi Speed Fwd 9.0 9.0 0.5 9.0
Hi Speed Rev 6.0 6.0 0.5 9.0
Minimum Acceleration 55110
Maximum Acceleration 77110
Plugging 77110
ADS-Neutral11110
ADS-Throttle 11110
Pick Acceleration 66110
Pick Deceleration 11110
Battery Full Voltage125.300 25.300 24.500 26.500
Lift Interrupt123.520223.520218.000324.000
PS Fwd Trav 33110
PS Rev Trav 33110
PS Max Assist 55110
NOTE: Certain lift truck models are not capable of operating at the Max range allowed by the Dash Display.
If a parameter value higher than the truck’s ability is entered, the value will revert to the maximum allowed
for that lift truck.
1Values shown in ETACC format. When viewed through the dash display, values will be rounded and
formatted as three digit numbers without decimals. Example: A value of 23.520 in ETACC will appear as
235 in the dash display.
2Maintenance-free battery option uses value 24.000.
3This parameter value should not be set below 20 for normal operations. Contact NMHG Service
Engineering Contact Management for approval before operating trucks below this value.
4