Hyster E174 User manual

Hyster E174 (R30XMS3) Forklift

ELECTRICAL SYSTEM
[E174 (R30XMS3)]
R30XMS3 [E174]
PART NO. 4031797 2200 SRM 1467

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.

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©2014 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Discharging the Capacitors ................................................................................................................................ 2
Major Electrical System Features ..........................................................................................................................3
Integrated System ...............................................................................................................................................3
CANbus Advantages ...........................................................................................................................................3
CANbus Communications .................................................................................................................................. 3
Electric Steering ............................................................................................................................................. 3
Centering Proximity Sensor ...................................................................................................................... 3
Traction ........................................................................................................................................................... 4
CAN I/O ...........................................................................................................................................................4
Input Devices ..............................................................................................................................................4
Output Devices ........................................................................................................................................... 4
Encoder Integrity ................................................................................................................................................ 4
Test Encoders ......................................................................................................................................................5
Proximity Switches ............................................................................................................................................. 5
Key Switch ...........................................................................................................................................................5
Multifunction Displays ....................................................................................................................................... 5
BDI .......................................................................................................................................................................5
Speed ....................................................................................................................................................................5
Steer Angle .......................................................................................................................................................... 6
Truck Hours ........................................................................................................................................................ 6
Operational Mode ................................................................................................................................................6
Setup ........................................................................................................................................................................ 6
Setup Instructions ...............................................................................................................................................6
ACE0 Traction Control Unit .......................................................................................................................... 6
Normal Operation ............................................................................................................................................... 6
Display .............................................................................................................................................................6
Password Access ......................................................................................................................................... 6
Startup Checklist ....................................................................................................................................... 7
Truck Operation Mode ............................................................................................................................... 7
Diagnostics .......................................................................................................................................................... 8
Power-On Self-Test .........................................................................................................................................8
Interlocks ........................................................................................................................................................ 8
Setup Menu Diagnostics .................................................................................................................................8
Calibration ...............................................................................................................................................................9
Traction Throttle .................................................................................................................................................9
AC Traction Motor Controller ...............................................................................................................................10
Controller Removal ........................................................................................................................................... 10
Install .................................................................................................................................................................10
Low-Voltage Protection Function .....................................................................................................................10
Contactor and Electrical Panel Checks ................................................................................................................11
Fuses ..................................................................................................................................................................11
Contactors ..........................................................................................................................................................12
General ..........................................................................................................................................................12
Test ................................................................................................................................................................12
Tips ................................................................................................................................................................13
Disassemble and Assemble .......................................................................................................................... 13
Traction Throttle Sensor Removal and Installation ........................................................................................... 14
Instrument Panel Removal and Installation .......................................................................................................16
Key Switch Removal and Installation ..................................................................................................................16
Table of Contents
i

TABLE OF CONTENTS (Continued)
Remove .............................................................................................................................................................. 16
Install .................................................................................................................................................................16
Foot Switch Removal and Installation .................................................................................................................17
Slack Chain Switch Removal and Installation ....................................................................................................18
Limit Switch Removal and Installation ...............................................................................................................19
DC to DC Converter .............................................................................................................................................. 20
This section is for the following models:
(R30XMS3) [E174]
Table of Contents
ii

General
This section applies to the R30XMS3. This section
has the checks, adjustments, and repair procedures
for parts of the electrical system. Throughout this
section, forward will refer to an operator standing
in the truck facing the steer tire with the forks
trailing. Left and right will be determined by the
point of view of an operator situated in the operator
compartment and facing the steer tire. See
Figure 1.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
WARNING
DO NOT operate a lift truck that needs
adjustments or repairs. Report the need for
adjustments or repairs immediately. If adjustment
or repair is necessary, attach a DO NOT OPERATE
tag to the control handle. Remove the key from
the key switch. Some of the checks and
adjustments are done with the battery connected.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally make an
electrical connection and cause injury.
WARNING
To avoid injury and prevent electrical shock,
perform the following steps before doing any
troubleshooting, adjustments, connecting, or
disconnecting a handset or PC:
1. Block the lift truck so that the drive wheels
are off the floor. See the Operator's Manual.
2. Turn the key switch to the OFF position and
disconnect the battery.
3. Discharge the capacitors in the controllers.
See Discharging the Capacitors. DO NOT
short across the motor controller terminals
with a screwdriver or jumper wire. Remove
the 200-ohm, 2-watt resistor before
reconnecting the battery.
CAUTION
To avoid controller damage:
1. ALWAYS disconnect the battery when
servicing the controllers.
2. ALWAYS discharge the capacitors using
the proper procedure before performing
any service. See Discharging the
Capacitors.
3. NEVER put power to the controller with any
power wire disconnected or loose.
4. NEVER short any controller terminal or
motor terminal to battery (+), battery (−), or
the frame.
2200 SRM 1467 General
1

CAUTION
Correct meter polarity is necessary for some
checks. Meter correct positive is indicated as (+).
Meter correct negative is indicated as (−).
Use a digital meter with a minimum rating of
20,000 ohms per volt to make accurate
measurements.
DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag on the
steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to
discharge before opening any compartment
covers or inspecting or repairing the electrical
system. DO NOT place tools on top of the battery.
If a tool causes a short circuit, the high current
flow from the battery can cause personal injury or
property damage.
Some checks and adjustments are performed with
the battery connected. DO NOT connect the
battery until the procedure instructs you to do so.
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidentally make
an electrical connection and cause injury.
Before performing any tests or adjustments, block
the lift truck to prevent unexpected movement.
The capacitor in the transistor controller(s) can
hold an electrical charge after the battery is
disconnected. To prevent an electrical shock and
personal injury, discharge the capacitor(s) before
inspecting or repairing any component in the
drive unit compartment. Make certain that the
battery has been disconnected.
DO NOT short across the motor controller
terminals with a screwdriver or jumper wire.
1. To avoid injury and prevent electrical shock,
perform the following steps (Step 2 through
Step 6 below) to discharge the capacitors before
troubleshooting, making adjustments or
repairs, or connecting or disconnecting a PC
service tool:
2. Turn the key or keyless switch to the OFF
position and DISCONNECT THE BATTERY.
3. Block the lift truck so the drive wheels are off
the floor to prevent lift truck from moving.
4. Remove the electrical compartment cover to
access the lift controller.
5. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across
the lift controller’s negative (B−) and positive
(B+) terminals. Wait at least 20 seconds to be
sure that the capacitors are fully discharged.
See Figure 2.
6. Remove the resistor from the controller(s) and
reinstall the covers before returning the lift
truck to service.
1. B+ TERMINAL
2. B− TERMINAL
3. JUMPER LEADS
4. 200-OHM, 2-WATT RESISTOR
Figure 2. Traction Controller
Major Electrical System Features 2200 SRM 1467
2

Major Electrical System Features
• Keep It Simple philosophy - a simple hard-
ware design with fewer parts - better relia-
bility
• Programmable setup of the truck with opera-
tor controls and dash display
• Noncontact encoders that give position of lift,
steering input, and steer drive tire angle
• Variable Hall effect sensor for throttle
• On-board diagnostics with text display
• AC traction motor and controller
• Regenerative braking for minimal wear of
park brake
• Control Area Network (CAN) bus digital
data link
• Alphanumeric multifunction display
• Continuous height sensing (encoder)
• Height, steer angle, and travel speed rela-
tionships
• Battery discharge indication adjustable for
regular or maintenance-free batteries
INTEGRATED SYSTEM
This orderpicker uses a CANbus, two-wire, twisted
pair, serial communications network bus to connect
several electronic subsystems together to form one
integrated system.
CANBUS ADVANTAGES
• Increased reliability
• Substantial reduction in connections and
wiring complexity
• Extensive function monitoring capability
• Serial bus simplicity (two wires)
• Easy information exchange between subsys-
tems
CANBUS COMMUNICATIONS
Electronic controllers connected by the CANbus
data link are as follows:
• CAN I/O
• ACE0
• EPS
• ECO Smart Dash Display
• Forward Antenna
• Reverse Antenna
The two-wire, twisted pair, CANbus carries the fol-
lowing data:
• Traction throttle
• Traction direction
• Horn
• Lift/Lower
• Steering position and steering rate
• Status information and diagnostic informa-
tion.
Electric Steering
The electric steering is accomplished using an AC
Induction Motor connected to a 50:1 gear reduction
unit. This AC motor and gear reduction unit is sup-
plied complete and is called the Steer Unit Assem-
bly. The AC Induction Motor is powered by a 3-
Phase AC Induction Motor Controller. The AC In-
duction Controller accepts steering commands via
the CANbus from the CAN I/O unit located under
the dash.
Centering Proximity Sensor
CAUTION
It is very important that the proximity sensor be
connected to the harness and that the sensor air
gap is set correctly prior to key-on. If the proxim-
ity sensor is not in place and not able to sense the
target plate, then the steer system will hit the me-
chanical stops at key-on. If the steer system hits
the mechanical stops, then the steer motor and
gear reduction assembly must be replaced.
Every time the key switch is turned on the steering
system centers the drive wheel. The steering sys-
tem uses the feedback from a proximity sensor
mounted next to the drive unit assembly. The prox-
imity sensor senses a target plate that establishes
the drive wheel center position.
2200 SRM 1467 Major Electrical System Features
3

Traction
Traction is provided by an AC motor and a control-
ler. The controller is connected to the CANbus com-
munications link over which it receives commands
and reports faults and status information. It also
has auxiliary transistor outputs that control the
traction main contactor, lift pump contactor, lower
solenoid valve, brake coil, and horn.
CAN I/O
The CAN I/O connects the following devices to the
CANbus network.
Input Devices
• Throttle Hall Sensor - three wires, battery
negative, positive 5 volts, and the variable
output having an approximate range of 1.0
volt (full reverse command) to 4.0 volts (full
forward command), with 2.5 volts at neutral.
• Lift and Lower switches - connect to two digi-
tal inputs on the CAN I/O. Used on small
chassis trucks, not on large chassis trucks.
• Lift and Lower Hall effect sensor - used on
large chassis trucks, not on small chassis
trucks.
• Horn switch - connects to one digital input
on the CAN I/O.
• Foot switch - connects to one digital input on
the CAN I/O.
NOTE: The foot switch, side gate switches, and the
slack chain switches are sourced from wire 202.
Wire 202 is connected to pin 9 of the CAN I/O. Pin
9 is at battery positive voltage.
• Side gate switches - both in series, connect to
one digital input on the CAN I/O.
• Slack chain switches - both in series, connect
to one digital input on the CAN I/O.
• Steering analog input for Return-to-Center -
a dual Hall Effect device is utilized connec-
ted to a 5 volt supply. There are two comple-
mentary outputs with a voltage range of 0.5
to 4.5 volts. The voltages are converted to a
digital signal. This information is then sent
over the CANbus to provide the steer motor
speed and direction. See Figure 3.
Figure 3. Rotary Hall Effect Sensor Signal
• Steering input for Multiturn Steering - a
stepper motor is used as a generator to pro-
vide the steer motor direction and speed con-
trol. The stepper motor supplies two quadra-
ture sine waves that are converted to digital
signals. This information is then sent over
the CANbus to provide the steer motor speed
and direction.
• Height encoder - a digital output device with
two bits each with 128 pulses per revolution
(256 total). It is powered by the 5-volt source
from the CAN I/O.
Output Devices
• Piezo beeper - driven by one digital output,
pull-down transistor.
ENCODER INTEGRITY
Steering and height encoders are tested continu-
ously for current draw. If the total current draw
from the two encoders and the Hall effect sensor is
too high or too low, a fault will be generated and
truck operation will be inhibited. Additional soft-
ware continuously checks the output bit sequence
activity of the steering input encoder to ensure that
both bits are operating.
Major Electrical System Features 2200 SRM 1467
4

TEST ENCODERS
NOTE: This procedure applies to the height en-
coder and the AC motor speed encoders. The height
encoder operates from a 5 volt supply and the AC
motor speed encoders operate from a 12 volt supply.
Conventional means can be used to diagnose the
encoders as follows. Using a voltmeter, determine if
5 or 12 volts and battery negative are going to each
encoder by back-probing the connector. If good,
then connect to one output channel and battery
negative, and rotate the encoder very slowly to see
if the input goes on/off/on (0 then 5 volts from the
height encoder) when the encoder is rotated slowly.
Check the other bit also. If they are both output-
ting, the encoder is OK. See Setup.
PROXIMITY SWITCHES
These are noncontact devices which sense the pres-
ence of steel. They have three wires going to them:
battery negative, supply voltage, and an output sig-
nal. See Table 1. They also have a built-in indicator
light that lights the collar where the wires enter
the proximity switch. These devices can be checked
by looking at the indicator light and by testing the
output with a voltmeter to see that it changes with
and without the steel in front of it.
KEY SWITCH
Battery positive is connected to the key switch,
through the Over-the-Mast cable, when the battery
disconnect switch is closed and 10 amp fuse,
FUSE1, is in place. The output side of the key
switch, wire 10, powers the logic for the traction
controller, the steer controller, and the AC hoist
controller option when preset. The key switch also
directly powers the main contactor coil, the mast
prox sensor, and the strobe light. The CAN I/O unit
and display are powered from the key switch
through a 2.7 amp PTC, labeld PTC1. The PTC,
Positive Temperature Coefficient Thermister, is
built into the harness.
MULTIFUNCTION DISPLAYS
The Ecosmart™ display is connected to the system
via the CANbus. It has a graphic LCD display with
back lighting. During operation the graphics show
battery charge, throttle percent, travel speed, steer
angle, truck hours, and the selected performance
mode. When in setup mode or if a fault condition
occurs, the LCD will change from the normal
graphics to an alphanumeric message stating spe-
cific codes and parameter values. Five LED status
indicators are provided with symbols (left to right):
battery, wrench, thermometer, operator presence,
and one extra LED for optional use. There are five
buttons used for entering passwords, changing per-
formance modes, and navigating the service menu.
BDI
The battery state of charge is determined in the
traction controller circuitry and software. The bat-
tery voltage is sensed at the traction controller.
There are 10 steps shown on the left of the display.
Flooded cell and maintenance-free battery types
can be accommodated by changing the setup pa-
rameters. In the Setup Menu, choose Battery Type;
Flooded Cell or Maintenance Free. Check with your
battery manufacturer for recommended settings.
SPEED
The traction throttle command is shown by 8 step
bars at the top of the display. The actual speed is
shown below in km/h or mph, selectable by a pa-
rameter in the setup menu.
Table 1. Proximity Switches
Device Supply Voltage
(Sensing Metal)
Output Voltage
(Sensing Metal)
Indicator Light
(Sensing Metal)
PNP or NPN
Mast Proximity
Switch
B+ (Wire 10) B+ ON PNP Sourcing
MDU Proximity
Switch
+12 Volts +12 Volts ON NPN Sourcing
2200 SRM 1467 Major Electrical System Features
5

STEER ANGLE
The actual steer wheel angle is shown as a graphic
bar, this will display straight (0°) to full left and
right (±90°).
TRUCK HOURS
The Truck Hours are displayed in the lower right
corner by default.
OPERATIONAL MODE
The current operating mode being used is indicated
by numbers 1 to 4 in the upper right corner. These
correspond to modes 1 through 4. Mode 1 being
"Turtle" mode and Mode 4 being "Rabbit" or Hi-per-
formance mode.
Setup
NOTE: For additional information on the menu
system, refer to the section User Interface Serv-
ice-Level Functions =>S/N A169N02999L =>S/N
A185N02999L =>S/N H118N02999L =>S/N
E174N02999L 2200SRM1470 or User Interface
Supervisor Functions =>S/N A169N02999L
=>S/N A185N02999L =>S/N H118N02999L
=>S/N E174N02999L 2200SRM1469.
The setup menu can be entered at any time by
pressing the "Enter" (#5 button) twice. To exit the
setup menu, press the left (#4 button) several times
or turn the key switch to the OFF position, and
then back to the ON position.
SETUP INSTRUCTIONS
1. Move the lift truck to a safe, level area.
2. Block the drive wheels to prevent movement of
the lift truck. See Periodic Maintenance
8000SRM1472 - How To Put A Lift Truck On
Blocks.
3. Remove the front cover to gain access to con-
trollers.
ACE0 Traction Control Unit
NOTE: For all the display examples shown below,
x's represent numerical values which will vary with
parameter adjustments.
If the Traction Controller is replaced, perform the
following procedure immediately after installation.
1. Connect all electrical connections prior to ini-
tial startup of the Traction Controller. During
initial startup, the Traction Controller senses
system devices to determine option configura-
tion and initial calibrations.
Check that the multifunction handle is in the
neutral position and the brake pedal is up dur-
ing initial startup.
2. When a controller is replaced then the truck
CDF file is to be downloaded with the Field
Service Tool
3. Check and ensure all parameters are set to the
default values. After reviewing and adjusting
all setup parameters, refer to Steering Sys-
tem 1600SRM1462 for the Steer Calibration
procedure.
NORMAL OPERATION
Display
Password Access
Following truck startup, if the Operator Password
feature is enabled, the operator will be prompted to
enter their operator password. The display will
show five empty placeholders. The operator then
must enter the five-digit operator-level password.
The number of possible password combinations
range from 11111 to 55555. Pressing a display but-
ton will result in the corresponding digit being
shown on the LCD display from left to right. After
the 5th password digit is entered, the display will
proceed with approval of the password. If the code
is correct, the display will revert to normal opera-
tion, and the vehicle is enabled. If the code is incor-
rect, the truck will remain disabled until the cor-
rect operator password is entered (multiple at-
tempts are allowed).
Setup 2200 SRM 1467
6

Startup Checklist
If the Startup Checklist feature has been enabled,
the operator will be prompted to complete the
Startup Checklist. The Startup Checklist will con-
sist of items that the operator must complete each
time the key switch is turned ON.
1. The display presents a series of questions to the
operator.
2. The operator must respond to each question by
either pressing the Up Arrow button (#1) for
"Yes" or the Down Arrow button (#3) for "NO."
There must be an answer to each request before
the next request is shown on the display. All re-
quests must be performed before the truck can
begin operation.
3. When this feature is enabled, the following
items will show on the display each time the
key is turned ON. Display button 1 (Up Arrow)
is used to answer "OK." Display button 3 (Down
Arrow) is used to answer "NOT OK."
• Chck Display
• Chck Multif Handl
• Chck Hyd Oil Lvl
• Chck Lights
• Chck Horn
• Chck Back Alarm
• Chck Brakes
• Chck for Leaks
• Chck Steering
• Chck Battery
• Chck Devals
• Chck Forks
• Chck Plaft/Chain
• Chck Restraint
• Chck Lift Chains
• Chck OVHD Guard
• Chck Static Straps
• Chck Tire and Wheel
• Chck Load Wheels
NOTE: If "NOT OK" is selected for any of the check
list items, "Service Required, No lift Permit-
ted" will be displayed. The operator must re-key to
re-enter the check list.
Following successful completion of the startup
checklist, the display will revert to the normal
screen and the truck will become operational.
Truck Operation Mode
The dash display button 1 through 4 are used for
mode selection during key switch ON. When the
display is in normal operation, the respective Mode
number will be displayed at the top right of the
screen.
• The modes are numbered 1, 2, 3, and 4. Mode
1 corresponds to slowest performance mode
and 4 corresponds to most aggressive per-
formance mode.
• Modes are selected using the corresponding
numbered display buttons (1 through 4).
• To change the operating mode, the lift truck
MUST BE stopped with the control handle
in the neutral position.
• The last mode selected will be retained and
will be displayed on the dash even after the
key has been recycled.
If the Operator Password feature is enabled, each
password has a maximum mode programmed with
it. This will be the highest mode level allowed for
that particular operator. The operator may select
lesser modes.
2200 SRM 1467 Setup
7

DIAGNOSTICS
Several levels of diagnostics are utilized. Internal
tests are performed at every truck startup. Run-
time diagnostic information is available through
the display. This would include controller tempera-
tures, motor speeds, and motor AC line current.
The units for the motor AC line current is amps
RMS. There are also non-run-time diagnostics. In-
put interlock switches can be cycled and checked,
such as the slack chain switches and the foot
switch. If the operator is on the foot switch at the
Key-ON, then the operator must lift their foot to
the open condition, then close the foot switch to be-
gin operation. If the operator is off the foot switch
at Key-ON then depressing the foot switch allows
for truck operation. Also available are the output
voltages of the analog input sensors such as the hy-
draulic throttle for the large chassis, straddle, and
furniture trucks. See User Interface Service-
Level Functions =>S/N A169N02999L =>S/N
A185N02999L =>S/N H118N02999L =>S/N
E174N02999L 2200SRM1470 for more details.
During truck operations, fault conditions detected
by any of the controllers are logged in the fault log.
For fault codes and display messages, see AC Mo-
tor Controller 2200SRM1466.
Power-On Self-Test
The power-on self-test is completed upon every
truck startup. During the power-on self-test, the
traction controller will check for the presence of the
brake coil, the main contactor coil, and the valve
coils. All AC controllers will check for the presence
of their associated AC motor windings. The CAN
I/O unit will check for the presence of the traction
throttle, hydraulic throttle, and the steer input sen-
sors. At power-on controllers must begin transmit-
ting the correct messages on the CANbus before
truck operation is allowed. If any of these items are
missing, then specific fault codes will be noted on
the display.
Interlocks
After startup, the following controls and switches
must be in the noted positions to allow truck opera-
tion:
1. Traction throttle, hoist throttle, and the RTC
must be all in there neutral positions. This is
commonly referred to as Static Return of Off
(SRO).
2. The side gate switches and slack chain
switches must be closed. When an interlock
switch is not set, the display the "Wrench
Icon" will blink and the alarm message will
be noted on the display.
3. The foot switch must be cycled to allow trac-
tion and hoist function. The display "Man
Icon" is illuminated when the brake switch is
open. The message "Foot SW Open" is noted
on the display when traction is selected and
the foot switch is open.
4. When installed, the optional service key
switch must be closed.
Setup Menu Diagnostics
Enter the Service menu by turning the key to the
ON position and pressing the display button #5
(Enter) twice. The display screen will indicate "En-
ter Password." Use the five display buttons to enter
the five digit service-level password. (The middle
button (Enter) is used to enter the number 5.) If the
wrong password is entered, the screen will indicate
"Incorrect Password" and then return to the pri-
mary graphic mode. Once the service-level pass-
word is correctly entered, the first menu item ap-
pears. To view the next menu item, press the dis-
play button #3 (Down Arrow). Repeat this until the
desired menu item has been reached. The Setup
and Diagnostic menus are now available. Refer to
User Interface Service-Level Functions =>S/N
A169N02999L =>S/N A185N02999L =>S/N
H118N02999L =>S/N E174N02999L
2200SRM1470 for more information on the Setup
Menu.
Setup 2200 SRM 1467
8

Calibration
TRACTION THROTTLE
1. Enter the Setup menu.
2. Scroll to TRACT SETTINGS and press 2 to en-
ter.
3. Press button 1 or 3 to scroll to TRACTION
CALIBR.
4. The Traction Throttle must now be in the neu-
tral position.
5. Press button 2 to enter and wait for 2 seconds.
6. Display reads:
TRACTION CALIB
0.00V
NOTE: “0.00V” should be 2.50V ± 0.50V when the
traction throttle is in neutral position. 2.50V ±
0.50V is the recommended throttle neutral position
voltage after the throttle is mechanically in posi-
tion.
7. Move the Traction Throttle fully forward to the
mechanical stop and hold for 2 seconds.
8. Move the Traction Throttle fully reverse to the
mechanical stop and hold for 2 seconds. Release
the traction throttle back to neutral.
9. Press button 5 to save Neutral, Max and Min
value. Display should read the following for 2
seconds.
NOTE: Press button 4 to cancel calibration during
Step 6 to Step 8.
10. Press button 4 several times to exit set up.
TRACTION CALIB
COMPLETE
2200 SRM 1467 Calibration
9

AC Traction Motor Controller
The ACE0 traction controller delivers smooth, si-
lent control of motor speed and torque. Three-phase
winding control stage provides solid-state motor
control and full regenerative braking without addi-
tional relays or contactors. See Figure 4. There are
no serviceable parts in the ACE0 controller. No at-
tempt should be made to open, repair, or modify the
controller.
1. BATTERY POSITIVE
2. BATTERY NEGATIVE
3. JUMPER WIRES
4. 200-OHM 2 WATT RESISTOR
Figure 4. ACE0 Controller
The controller checks the following functions:
• Checks the temperature and gives both low-
and high-temperature thermal protection to
the controller.
• Electronically checks the traction circuit for
malfunctions and prevents traction motor op-
eration if a failure occurs.
• Regulates the current in the motor circuit
and automatically reduces the current and
prevent damage.
• Checks for incorrect battery usage.
• Checks for and protects from stall conditions.
CONTROLLER REMOVAL
1. Move lift truck to a safe, level area. Turn the
key switch to the OFF position and remove the
key. Attach a DO NOT OPERATE tag to the
multifunction control handle. Put blocks under
drive wheels to keep lift truck from moving. See
Periodic Maintenance 8000SRM1472 - How
To Put A Lift Truck On Blocks.
WARNING
Disconnect the battery and separate the connec-
tor before opening the compartment cover or in-
specting/repairing the electrical system. If a tool
causes a short circuit, the high-current flow from
the battery can cause a personal injury or prop-
erty damage.
2. Disconnect and separate battery connector. Re-
move the cover and discharge the capacitors.
Refer to Discharging the Capacitors in this sec-
tion.
3. Unplug connector from traction motor control-
ler. Tag and disconnect wires to terminals.
4. Remove four capscrews and lockwashers and
carefully remove controller from the truck
frame.
INSTALL
1. Make certain the mounting surface for control-
ler is clean. There should be no dirt between
the frame and the controller. Apply heat-con-
ductive grease to bottom of controller. Align
controller in lift truck with holes and install
lockwashers and capscrews. Tighten the Trac-
tion Controller mounting capscrews to 7 to
8 N•m (62 to 71 lbf in).
LOW-VOLTAGE PROTECTION FUNCTION
This function protects the controller and the bat-
tery. The controller will not operate correctly if
there is less than 18 volts from the battery. The
battery current drain increases as the battery volt-
age decreases. The battery may still operate the lift
truck to move it for battery charging or replace-
ment.
AC Traction Motor Controller 2200 SRM 1467
10

Contactor and Electrical Panel Checks
WARNING
DO NOT operate a lift truck that needs adjustment
or repairs. Report the need for adjustment or re-
pairs immediately. If adjustment or repair is nec-
essary, put a DO NOT OPERATE tag on the instru-
ment panel. Remove the key from the key switch.
WARNING
Some of the checks are done with the battery con-
nected. Never have any metal on your fingers,
arms, or neck. These metal items can accidentally
make an electrical connection and cause a per-
sonal injury.
CAUTION
Correct multimeter polarity is necessary for some
checks. Meter positive is indicated as (+). Meter
negative is indicated as (−).
Use a multimeter with a minimum rating of 20,000
ohms per volt to make measurements. Most digital
voltmeters are acceptable.
NOTE: To perform the following component tests
or to replace any of the components, the drive unit
compartment doors must be opened and the drive
unit compartment cover must be removed.
FUSES
All the fuses are located in the electrical compart-
ment. See Figure 5. Remove cover over electrical
compartment for access. The condition of some
fuses can be checked by looking at them. Other
fuses do not change in looks and must be checked
with an ohmmeter to determine continuity. Discon-
nect battery and remove a fuse before checking the
fuse.
All fuses are on the contactor panel. Ratings of the
fuses are as follows:
Fuses Circuit Rating
FU 1 Platform Key Switch 10A
FU 2 Fans, Lights, Heater 10A
FU 3 Valve Coils, Horn, Back-
Up Alarm, Hydraulic
Pump Contactor Coil
10A
FU 4 Spare 10A
FU 5 Hydraulic Pump 300A
1. FU 1
2. FU 2
3. FU 3
4. FU 4
5. FU 5
Figure 5. Fuse Locations
2200 SRM 1467 Contactor and Electrical Panel Checks
11

CONTACTORS
General
With the key switch turned OFF, the main contac-
tor coil is not connected to either battery positive or
battery negative. When the key switch is turned
ON, battery positive is connected to the main con-
tactor coil. After passing the power-on self-test the
traction controller will turn on a transistor that
will connect the low side of the main contactor to
ground. The main contactor is activated providing
power to all controllers and valve coils.
On trucks with DC hoist, the main contactor tips
must be closed prior to applying battery voltage to
the hydraulic pump contactor tips. The CAN I/O
unit processes a lift command and transmits a
CANbus message to the traction controller. The
traction controller will turn on a low side driver
transistor that energizes the pump contactor coil
and in turn closes the pump contactor tips. Battery
positive is then applied to the pump motor to ini-
tiate lift.
Test
WARNING
Parts of this procedure require working on the
truck with full electric current present. To prevent
personal injury or property damage, DO NOT wear
a watch, rings, or jewelry while working around
the contactor panel. Whenever manually closing a
contactor with the power connected, use a prop-
erly insulated tool.
1. Check condition of battery. If it is not fully
charged, recharge or replace battery with a
fully charged battery before continuing.
2. Raise drive wheel of truck so it is clear of the
floor. Block chassis in this position and remove
lifting device.
3. Visually check to see if contactor closes when
circuit is energized. If contactor closes, proceed
to Step 5. If contactor does not close, proceed to
Step 4.
4. Check for battery voltage at contactor coil.
No voltage: Open circuit in control circuit
wiring to contactor.
Low voltage: High resistance in control
circuit wiring to contactor.
Full battery voltage: No problem with
control circuit. Problem is probably in
contactor. Proceed with test.
5. Check at the contactor for loose, broken, or cor-
roded connections.
6. Visually check the condition of the tips for pit-
ting, burning, or wear.
7. Check ohm value of contactor coil. Disconnect
leads from one side of the coil and connect an
ohmmeter across coil. Reverse ohmmeter leads
and check in the opposite polarity (since spike
suppressors on some coils make them polarity
sensitive). Compare ohm reading against ohm
value for the type contactor. Use the highest
rating. See Table 2.
Table 2. Coil Resistance
Device Location
24v Coil
Resist-
ance @
21°C
(70°F)
Notes
Truck main
contactor
Contactor
panel
44 ohms ±8
ohms
Test coil
both ways.
Use highest
reading.
Lift pump
contactor
Contactor
panel
17 ohms ±4
ohms
Test coil
both ways.
Use highest
reading.
Lower sole-
noid valve
On pump
assembly
40 ohms
±10 ohms
Test coil
both ways.
Use highest
reading.
Load hold
relay
Under
chassis
cover near
the top of
the drive
motor
320 ohms
±65 ohms
Terminals
85 and 86
are the coil.
Brake coil On top of
drive motor
12 ohms ±4
ohms
Contactor and Electrical Panel Checks 2200 SRM 1467
12

Tips
When replacing tips, make sure the new tips have
the same ampere carrying capacity and are direct
replacements for the original tips.
A high-voltage drop (2 volts or more) across the tips
indicates poor contact or high resistance. Check for
burned or worn tips, incorrect size or mismatched
tips, and proper gap settings when open.
Disassemble and Assemble
WARNING
Disconnect the battery and separate the connec-
tor before opening the drive unit and compart-
ment and inspecting or repairing the electrical
system. If a tool causes a short circuit, the high-
current flow from the battery can cause a per-
sonal injury or property damage.
NOTE: If both the contacts and coil of a contactor
will be replaced, replace the complete contactor as
described in Replacing the Contactor. Do only the
parts of the procedure necessary to replace the de-
fective parts being replaced.
NOTE: All of the contacts for each contactor must
be replaced at the same time if any contact requires
replacement.
The contactor contacts are made of special silver al-
loy. The contacts may look black and rough from
normal operation. This condition does not cause
problems with the operation of the lift truck. Clean-
ing is not necessary. DO NOT USE A FILE ON
THE CONTACTS. DO NOT LUBRICATE THE
CONTACTS. Replace contacts when the silver alloy
is worn away to the base support metal. Replace
contactor parts as follows:
1. Make an identification of the buss bars for cor-
rect installation. Remove nuts that fasten fixed
contacts.
2. Remove two screws that fasten covers for each
contactor. See Figure 6. Remove cover of each
contactor. DO NOT lose plunger springs.
1. FIXED CONTACT
2. MOVING CONTACT
3. TOP COVER
4. SCREW - TOP
COVER
5. RETURN SPRING
6. COIL AND FRAME
7. END CAP
Figure 6. Contactor
2200 SRM 1467 Contactor and Electrical Panel Checks
13

3. Replace two fixed contacts in contactor covers.
4. Remove plunger assembly and movable contact
and replace fixed contact bar. Replace contact
of plungers.
5. If a coil will be replaced, remove cover base. Re-
move screws that fasten coil frame to mount
bracket. Remove coil and frame. Remove bush-
ing part of plunger and armature cap from coil.
Install these parts on the replacement coil.
6. Install coil and frame on mount bracket.
7. Install cover base, fixed contact bar, and
plunger on coil frame. Make sure spring is on
plunger.
8. Install covers and electrical bars on covers as
removed during disassembly.
9. Install contactor assemblies on the lift truck.
Traction Throttle Sensor Removal and Installation
WARNING
The operator platform can move abruptly and can
cause personal injury when any lift or lower but-
tons are accidently pushed. Fully lower the opera-
tor platform and remove the key from the key
switch, disconnect the battery, and install a DO
NOT OPERATE tag on the instrument panel.
WARNING
The traction throttle sensor is a Hall effect device.
The sensor provides a voltage output ratio (typi-
cally 5 volts) as a function of mechanical angle to
the shaft as it rotates. The sensor operates on low
supply voltage and is limited to short mechanical
angles, requiring less than 180-degree rotation.
WARNING
Disconnect the battery connector to prevent oper-
ation of the hydraulic system or electrical shock
and possible injury.
1. Disconnect battery.
2. Remove four capscrews that fasten console
panel cover.
3. Disconnect electrical plug.
4. Remove nut that holds sensor on bracket. See
Figure 7.
5. Loosen the two setscrews (21) that secure the
Hall effect sensor stem to the inside of the con-
trol handle shaft.
6. Install new sensor into opening of bracket sup-
port. Align sensor on bracket and tighten nut.
7. Connect electrical plug. Once the plug is con-
nected enter the SETUP menu. Scroll to NO
RUN DIAGNOSTICS and enter the sub-menu.
Now scroll to the TRAC JOYSTICK parameter.
Approximately align the cross hatch on the end
of the Hall Effect sensor stem with the tabs on
the body of the Hall Effect sensor to achieve
2.50 volts. Tighten the setscrews and recheck
the voltage at 2.50 volts in neutral.
8. Install instrument panel cover on cowl.
9. Reconnect the battery.
10. Calibrate the new sensor. See Traction Throttle
in the Calibration section of this manual.
Traction Throttle Sensor Removal and Installation 2200 SRM 1467
14