Hyster L007 Operating instructions

Hyster L007 (H190HD2, H210HD2, H230HD2,
H230HDS2, H250HD2, H280HD2) Forklift
Service Repair Manual

HYDRAULIC CONTROL
SYSTEM (L007)
(USER INTERFACE MANUAL)
H8-12XM-6, H10XMS-6
(H190-280HD2, H230HDS2) [L007]
PART NO. 4133477 1900 SRM 1935

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.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Safety Precautions and Tips ...................................................................................................................................1
List of Terms and Abbreviations ............................................................................................................................2
Installing the Hydraulic User Interface Program .................................................................................................2
Starting the Hydraulic User Interface Program ...................................................................................................2
Truck Selection Window .................................................................................................................................3
Start Screen/Language Selection ........................................................................................................................... 4
Warning Screen .......................................................................................................................................................6
Basic Screen Explanation .......................................................................................................................................7
Truck Configuration ................................................................................................................................................8
Pump Selection ...............................................................................................................................................9
Control Selection .............................................................................................................................................9
Front-End Selection ........................................................................................................................................9
Responsiveness Settings .............................................................................................................................. 10
Interrupt Selection ....................................................................................................................................... 10
Units selection .............................................................................................................................................. 10
All Parameter Screen ...................................................................................................................................10
Installed Features .................................................................................................................................................12
Software Enabled Options ............................................................................................................................13
Dynamic Control .......................................................................................................................................13
High Temperature Protection ..................................................................................................................13
Loaded Speed Reduction ..........................................................................................................................14
Standard Installed Features ........................................................................................................................15
Anti-stall ...................................................................................................................................................15
Cold Temperature Protection .................................................................................................................. 15
Drive/Hydraulic Priority ..........................................................................................................................16
Automatic Throttle Up .............................................................................................................................16
HIP/ECO Operating Mode .......................................................................................................................18
Hibernate Idle ...........................................................................................................................................18
Dynamic Pump Control ............................................................................................................................19
Calibration Screen .................................................................................................................................................20
Flow Settings .........................................................................................................................................................22
Valve Settings ........................................................................................................................................................23
About Valve Actuation ......................................................................................................................................24
Diagnostics .............................................................................................................................................................25
Hydraulic Diagnostics .......................................................................................................................................25
Interrupt Indicators ..........................................................................................................................................25
Main Valve Solenoid Power Supply .............................................................................................................26
Operator Presence ........................................................................................................................................26
Lift Interrupt ................................................................................................................................................ 26
Lower Interrupt ............................................................................................................................................26
Controller Information ......................................................................................................................................27
Active Errors ..........................................................................................................................................................28
Error History .........................................................................................................................................................29
Fault Code Table ...................................................................................................................................................30
HCU Pinning .........................................................................................................................................................38
File Uploads/Downloads ........................................................................................................................................41
Connecting to the Hydraulic Control Unit ......................................................................................................41
Setup a Connection .......................................................................................................................................41
Check the Current Software Version .......................................................................................................... 49
Table of Contents
i

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TABLE OF CONTENTS (Continued)
Download a P1T (Parameter-file) ................................................................................................................52
Download a ROP File ................................................................................................................................... 53
Tips and Tricks ..................................................................................................................................................54
Controller Identification ...............................................................................................................................54
This section is for the following models:
H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS2) [L007]
Table of Contents
ii

General
This SRM describes the hydraulic control system,
and its interaction with the Hydraulic User
Interface Program.
See the following resources for additional
information:
Hydraulic System1900SRM1934
Diagrams 8000SRM1938
Safety Precautions and Tips
Before connecting the Hydraulic User Interface, ap-
ply the park brake, lower the mast completely and
shut down the engine. Turn the ignition key to the
ON position.
Always make sure your system is properly connec-
ted (green icon, bottom of screen) and logging (blue
icon, bottom of screen) before servicing the truck.
See File Uploads/Downloads.
If making a connection is not working, check if the
green LED on the HCU is on. This indicates the
power is on.
Never disconnect the system while making changes
to settings or downloading a file to the HCU.
The red LED on the HCU will switch on when there
is a fault active.
After an application download always go to the Di-
agnostic screen and click the ‘Controller Defaults’
button when available.
After an application download always make sure
the truck configuration is correct.
After an application download always recalibrate
your levers/joystick.
If your trucks design deviates from the standard
truck design, contact your Service representative
for additional information.
1900 SRM 1935 General
1

List of Terms and Abbreviations
Abbreviation Explanation
(E)CH (Empty) Container Handler
AIN Analog Input
Application file The operating software program on the HCU
DIN Digital Input
DOUT Digital Output
ECM Engine Control Module
FLT Fork Lift Truck
HCU Hydraulic Control Unit
HiP/ECO eLo High Performance/Economic energy Low
LED Light-Emitting Diode
OPS Operator Present Switch
P1T-file Parameter (settings) file
PVE Proportional Valve Electric actuator
PWM Pulse Width Modulation
ROP Read Only Parameter
TCU Transmission Control Unit
Installing the Hydraulic User Interface Program
The Hydraulic User Interface Program can be ob-
tained through Hypass Online. Save the download
from Hypass Online to a location on your computer.
The download contains 2 executables that both
need to be installed. Double click the
HUIP_Dealer_setup.exe and follow the steps in the
installation guide. Once completed double click the
HUIP_Package_setup.exe and follow the steps in
the installation guide.
Starting the Hydraulic User Interface Program
This section describes how to setup the Hydraulic
User Interface Program for the truck that needs to
be serviced. Start the program by clicking the Hy-
draulic User Interface Program icon on your desk-
top. See Figure 1, or through the Windows Start
Menu. See Figure 2.
Figure 1. Desktop Icon Hydraulic User Interface
List of Terms and Abbreviations 1900 SRM 1935
2

Figure 2. Windows Start Menu Access
Truck Selection Window
The Hydraulic User Interface Program will start
with showing the window where the truck serial
number needs to be entered. See Figure 3. This way
the Hydraulic User Interface Program will make
sure the file is opened that matches the truck.
For additional information about the Truck Selec-
tion window check the Help section.
After entering the truck serial number or selecting
one from the drop-down box, click the ‘Open’ button
and the Hydraulic User Interface Program will
open the diagnostic file applicable for the truck.
Figure 3. Truck Selection Window
1900 SRM 1935 Starting the Hydraulic User Interface Program
3

Start Screen/Language Selection
The start screen is the first screen shown when
starting the Hydraulic User Interface Program. In
this screen the user can select the desired lan-
guage. See Figure 4.
Once the language is selected, click on the Continue
button (1) to proceed to the next screen.
The start screen also contains the part number (2)
of the diagnostic file.
From anywhere in the Hydraulic User Interface
Program the user can return to the start screen by
moving the pointer over the left margin of the
screen. This will open the Diagnostic Navigator.
See Figure 5.
Any screen can be accessed through the Diagnostic
Navigator. Under Parameter Functions select the
‘Start Screen’ to return to the Start screen.
1. CONTINUE BUTTON 2. PART NUMBER
Figure 4. Start Screen
Start Screen/Language Selection 1900 SRM 1935
4

Figure 5. Diagnostic Navigator
1900 SRM 1935 Start Screen/Language Selection
5

Warning Screen
After clicking ‘Continue’ on the Start screen, the
Warning screen is opened. The warning screen is a
reminder to always confirm any changes made to
parameters. See Figure 6.
After changing a setting in any screen of the Hy-
draulic User Interface Program, the setting must
be downloaded to the HCU. To download an altered
setting, click the download button, or press [F4] on
your keyboard. If you did not make changes, there
is no need to click the button. See Figure 7.
To continue to the next screen, click on the ‘Click
here to Continue’ button (1).
The download button can only be found on screens
that have the possibility to make changes to set-
tings. Only the settings in the active screen will be
downloaded to the HCU. The button can be found
in the bottom-right of the screens. See Figure 7.
In addition an upload button can be found in the
bottom-left of the screens. Clicking this button or
pressing [F2] will refresh the parameters in the ac-
tive screen with the values in the HCU. See Fig-
ure 8.
1. CONTINUE BUTTON
Figure 6. Warning Screen
Figure 7. Download Button Figure 8. Upload Button
Warning Screen 1900 SRM 1935
6

Basic Screen Explanation
This section explains the basic navigation of the
Hydraulic User Interface Program.
The user can use the various buttons to navigate to
the desired functionality. The functions of the but-
tons are explained and appear in almost every page
of the Hydraulic User Interface Program. See Fig-
ure 9.
For screens not accessible through the tabs on the
left of the screen, use the Diagnostic Navigator. See
Start Screen/Language Selection.
1. TRUCK CONFIGURATION. SEE TRUCK CONFIGURATION
2. INSTALLED FEATURES. SEE INSTALLED FEATURES
3. CALIBRATION. SEE CALIBRATION SCREEN
4. FLOW SETTINGS. SEE FLOW SETTINGS
5. VALVE SETTINGS. SEE VALVE SETTINGS
6. DIAGNOSTICS. SEE DIAGNOSTICS
7. ACTIVE ERRORS. SEE ACTIVE ERRORS
8. LINK TO ACTIVE ERRORS SCREEN. ONLY VISIBLE WHEN AN ERROR IS ACTIVE. SEE ACTIVE ER-
RORS
9. NUMBER OF ACTIVE ERRORS
10. UPLOAD SETTINGS: UPDATES THE ACTIVE SCREEN WITH THE APPLICABLE SETTINGS IN THE HCU.
SEE WARNING SCREEN
11. DOWNLOAD SETTINGS: DOWNLOADS SETTINGS ON THE ACTIVE SCREEN INTO THE HCU. SEE
WARNING SCREEN
12. TRUCK SERIAL NUMBER (EG L007E01501M). SEE INSTALLED FEATURES
Figure 9. Basic Screen Layout
1900 SRM 1935 Warning Screen
7

Truck Configuration
The Truck Configuration screen is used to setup
the truck’s controls and front-end. Figure 10 shows
the screen when the configuration of the HCU has
not yet been completed. This may occur when a new
HCU is installed. As long as the warning (1) is dis-
played, the truck’s hydraulic system will not be op-
erational.
1. WARNING, TRUCK CONFIGURATION NOT
COMPLETED
2. PUMP SELECTION
3. CONTROLS SELECTION
4. FRONT-END SELECTION
5. RESPONSIVENESS SELECTION
6. LINK TO RESPONSIVENESS SETTINGS
7. INTERRUPT SELECTION
8. UNITS SELECTION
9. LINK TO ALL PARAMETER SCREEN
Figure 10. Truck Configuration Screen (Not Configured)
Basic Screen Explanation 1900 SRM 1935
8

Pump Selection
In the pump selection box the installed pump con-
figuration needs to be selected. The pump selection
determines the valve settings. See Figure 11.
Figure 11. Pump Selection Box
Control Selection
In the control selection box (see Figure 12) the in-
stalled lever and/or switches or joystick type needs
to be selected. After selecting the control option,
click on the download button. After downloading
the control option to the HCU, the Hydraulic User
Interface Program will present the corresponding
front-end options in the front-end selection box (see
Figure 13) and the resulting lever-calibration op-
tions (see Calibration Screen).
If the installed controls do not match with any of
the options in the Hydraulic User Interface Pro-
gram, contact your Service representative.
Figure 12. Controls Selection Box
Front-End Selection
In the front-end selection the user can select the in-
stalled front-end. This selection determines which
auxiliary functions are enabled and corrects the
flow settings to match the front-end. See Figure 13.
If the installed front-end does not match with any
of the options in the Hydraulic User Interface Pro-
gram, contact your Service representative.
Figure 13. Front-End Selection
1900 SRM 1935 Truck Configuration
9

Responsiveness Settings
The responsiveness settings can be used to alter
the control reaction of the hydraulic system. By de-
fault the responsiveness is set to ‘Medium’. See Fig-
ure 14.
By clicking the link to responsiveness settings (see
Figure 10, item 5), the user navigates to the sub-
screen Mode definition screen linked to the chosen
responsiveness.
Figure 14. Responsiveness Selection
Interrupt Selection
In the Interrupt selection the user can enable the
Lift interrupt function. For ECH models the lift in-
terrupt is enabled by default and cannot be
switched off. For ECH models, a Lift interrupt is
activated when the twist-locks are neither locked
nor unlocked. See Figure 15.
Contact your Service representative to establish if
any additional hardware is required.
Figure 15. Interrupt Selection Box
Units selection
In the unit selection the user can switch between
Metric or Imperial units. See Figure 16.
Figure 16. Unit Selection Box
All Parameter Screen
By clicking the link to the ‘All Parameter’ screen,
the All Parameter screen is displayed. See Fig-
ure 17. Here the user can upload and download
files from and to the HCU. See File Uploads/Down-
loads.
Figure 17. Link to all Parameter Screen
Truck Configuration 1900 SRM 1935
10

Once the control- and front-end selections have
been made, the warning will disappear. See Fig-
ure 18.
Figure 18. Truck Configuration Completed (FLT)
1900 SRM 1935 Truck Configuration
11

Installed Features
In the Installed Features screen the user can ena-
ble/disable certain features. Some features are
standard and are enabled by default, depending on
engine type. See Figure 19.
Some features are optional and have to be enabled
by downloading an ROP (Read Only Parameter)-file
into the HCU.
For enabling ROP functions contact your Service
representative.
Figure 19 shows how the Installed Features screen
will look for a truck with a Tier4 engine.
Figure 19. Installed Features Screen (Tier4)
Installed Features 1900 SRM 1935
12

Software Enabled Options
There are a few Installed features available which
are not standard. They have to be purchased and
enabled. Figure 20 shows how the Installed Fea-
tures screen looks with the ROP- options enabled.
The ROP-enabled options will only be visible if they
are enabled. For enabling ROP functions contact
your Service representative.
Dynamic Control
The Dynamic Control feature is used to make the
trucks controllability independent of the load. The
HCU uses a pressure transducer in the lift section
to measure the load. Depending on this signal the
HCU makes sure the lowering speed is not influ-
enced by the load. For the lift and lower function,
the responsiveness settings are load-depending to
maintain controllability regardless of the load.
High Temperature Protection
The High Temperature Protection works in two
stages. First it acts as a warning system to indicate
the hydraulic oil temperature is getting too high.
When the hydraulic oil temperature gets too high,
an orange warning light is displayed on the instru-
ment cluster and a exceed code (hHot, see Fault
Code Table) is displayed. The warnings will disable
when the hydraulic oil temperature is reduced.
In the second stage, the High Temperature Protec-
tion will reduce truck performance to avoid over-
temperature. When the hydraulic oil temperature
gets too high, a red warning light is displayed on
the instrument cluster in addition to the orange
warning light and the exceed code. Also the trucks
vehicle speed will be reduced. The vehicle speed
limitation will be disabled when the hydraulic oil
temperature is reduced.
1. ROP ENABLED OPTIONS
Figure 20. Installed ROP-Options
1900 SRM 1935 Installed Features
13

Loaded Speed Reduction
The Loaded Speed Reduction reduces the vehicle
speed once the pressure in the lift section is above
an adjustable threshold. By clicking the function
icon (see Figure 21) the Loaded Speed Reduction
settings screen is opened. See Figure 22.
Figure 21. Link to Loaded Speed Reduction
Settings
The Loaded Speed Reduction has the possibility to
set a speed limiter when more than a preset load is
picked up. To set up a speed limiter like this, pro-
ceed as described below:
•Pick up the maximum load which should not
set a speed limiter.*
•Click the ‘Set’ button (3). The lift pressure is
now stored as a threshold.
*The Loaded speed Reduction keeps a margin over
the threshold. This way the vehicle speed will only
be activated when more than the preset load is
picked up.
1. ACTUAL MEASURED VALUE (% OF PRESSURE RANGE 0-250 BAR)
2. PRESSURE THRESHOLD STORED IN MEMORY (% OF PRESSURE RANGE 0-250 BAR)
3. ‘SET’ BUTTON. CLICKING THIS BUTTON STORES THE ‘ACTUAL VALUE’ (1) INTO ‘SAVED VALUE’ (2)
4. VEHICLE SPEED LIMIT SETTING. THIS SETTING CAN BE CHANGED TO ALTER THE LIMITED VEHICLE
SPEED
5. VEHICLE SPEED LIMIT SETTING STORED IN MEMORY
6. LOADED SPEED REDUCTION ACTIVE INDICATOR
7. ACTUAL VEHICLE SPEED
8. ‘BACK’ BUTTON. RETURNS TO INSTALLED FEATURES
Figure 22. Loaded Speed Reduction Settings
Installed Features 1900 SRM 1935
14