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