Hyster P2.0 Istruzioni operative

Hyster A290 (P2.0) Forklift

AC MOTOR

CONTROLLER

P2.0 [A290]

PART NO. 4035864 2200 SRM 1507

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.

TABLE OF CONTENTS

General .....................................................................................................................................................................1

Safety Precautions .............................................................................................................................................. 1

Description ...............................................................................................................................................................2

AC Motor Controller ........................................................................................................................................... 2

Principles of Operation ....................................................................................................................................... 2

Install ...................................................................................................................................................................3

Programming Controller .....................................................................................................................................3

1311 Programmer Handset .....................................................................................................................................6

Description/Features ...........................................................................................................................................6

Menu Navigation Key .....................................................................................................................................7

Data Increase/Decrease Key .......................................................................................................................... 8

Bookmark Keys ...............................................................................................................................................8

Operation .............................................................................................................................................................8

Connecting Handset to Traction Motor Controller .......................................................................................8

Disconnecting the Handset From the Traction Motor Controller ................................................................8

Main Menu Selections ........................................................................................................................................ 9

Program Menu ................................................................................................................................................ 9

Monitor Menu ................................................................................................................................................. 9

Faults Menu ..................................................................................................................................................10

Functions menu ............................................................................................................................................ 11

Information Menu .........................................................................................................................................11

Programmer Setup Menu .............................................................................................................................11

Programming the Traction Motor Controller - 1311 Handset ............................................................................ 12

Display (BDI)/Hourmeter ......................................................................................................................................13

Fault Codes ............................................................................................................................................................13

This section is for the following models:

P2.0 [A290]

Table of Contents

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"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

General

This section describes the AC Motor Controller.

Procedures are outlined for controller programming

and troubleshooting.

SAFETY PRECAUTIONS

WARNING

Disconnect the battery and separate the

connectors before opening the compartment

cover or inspecting or repairing the electrical

system. If a tool causes a short circuit, the high

current flow from the battery can cause personal

injury or property damage.

All checks, adjustments, and repairs in the drive

unit compartment are done with the compartment

cover removed. Remove the drive unit compartment

cover for access to the electrical components.

WARNING

The capacitor in the transistor controller can hold

an electrical charge after the battery has been

disconnected. To prevent electrical shock and

personal injury, discharge the capacitor before

inspection or repairing any component in the

drive unit compartment. Wear safety glasses.

Make certain the battery has been disconnected.

DO NOT use a screwdriver to discharge the

traction motor controller.

CAUTION

To avoid controller damage, always disconnect

the battery before disconnecting any cables from

the controller. Discharge the capacitor, and never

put power to the controller with any power wire

disconnected. Never short any controller terminal

or motor terminal to the battery. Make sure to use

proper procedure when servicing the controller.

The following steps must be followed to discharge

the capacitors before any checks or repairs are

performed on the controller or any part of the

electrical system.

1. Block the wheels so that the truck will not roll

or block the truck so that the wheels are off the

floor. See

•Periodic Maintenance 8000SRM1510

for lift truck model A290

2. Turn the key switch to the OFF position and

disconnect the battery.

3. Discharge the capacitors in the controller by

connecting a 100-ohm, 25-watt resistor across

the controller's B+ and B- terminals using two

insulated jumper wires. See Figure 1.

NOTE: DO NOT use any other method of

discharging the capacitors. Remove the 100-ohm,

25-watt resistor before reconnecting the battery.

2200 SRM 1507 General

Figure 1. Discharging the Capacitors

Legend for Figure 1

1. CONTROLLER

2. POSITIVE CONNECTION

3. INSULATED JUMPER WIRES

4. 100-OHM, 25-WATT RESISTOR

5. NEGATIVE CONNECTION

Description

AC MOTOR CONTROLLER

The controller is a solid-state, AC motor controller.

It can control the traction motor, brake, and hy-

draulic system. The controller receives inputs from

the control handle by serial communication, and di-

rect inputs from other switches depending on

model. These may include the following:

• Key switch

• Control handle arm position switch

The controller directly controls the traction motor,

lift pump motor, main contactor, and the brake.

The motor controller controls the speed of the trac-

tion motor and the hydraulic lift pump motor oper-

ation. The controller software provides self diagnos-

tics which are accessed by means of a Curtis hand-

set.

PRINCIPLES OF OPERATION

The Traction Motor Controller uses a sophisticated

microprocessor to control the logic and operation of

the controller, eliminating the need for forward and

reverse contactors. The controller has many pro-

grammable features, including maximum speed, ac-

celeration rate, neutral braking, and braking cur-

rent limit. The controller includes a full range of

features as well as diagnostic and setup capability

for reliable operation.

NOTE: There are no user-serviceable parts in the

Curtis controller. No attempt should be made to

open, repair, or otherwise modify the controller. Do-

ing so may damage the controller and will void the

warranty.

Description 2200 SRM 1507

INSTALL

1. Make certain the mounting surface for the trac-

tion motor controller is clean. There should be

no dirt between the contactor panel mounting

plate and the traction motor controller.

2. Connect wires and cables to controller termi-

nals. See Figure 2.

3. Refer to Programming Controller for setup of

the controller.

The motor controller controls the speed of the trac-

tion motor and the hydraulic pump motor opera-

tion. The complete unit must be replaced if correct

troubleshooting methods show that the unit is dam-

aged.

PROGRAMMING CONTROLLER

The controller can be programmed using a 1311

handset. The areas that can be programmed are lis-

ted in Table 1 along with the adjustable ranges.

1. TRACTION MOTOR CONNECTION "U"

2. TRACTION MOTOR CONNECTION "V"

3. TRACTION MOTOR CONNECTION "W"

4. CONNECTOR

5. LED INDICATOR

6. B− CONNECTION

7. B+ CONNECTION

Figure 2. Controller

2200 SRM 1507 Description

Table 1. Program Menu

Parameter Listing

Parameter Units Range Default

Setting Description

Main Menu

Interlock Timeout Sec 0 - 120 Max time for tiller in opening position with

no input to controller

Buzzer Option 0 - 2 0 - None, 1 - Reverse Only, 2 - Forward &

Reverse

Buzzer Deadband Rpm 0 - 1000 Min motor rpm to activate buzzer

Throttle Setup Menu

Forward Max Rpm 3500 - 6000 Rotation of butterfly to max speed in for-

ward direction

Forward Map % 0 - 100 Adjust relationship to butterfly rotation for

forward truck speed

Forward Dead Band 0 - 500 Minimum rotation of butterfly to enable for-

ward travel

Reverse Dead Band 0 - 500 Minimum rotation of butterfly to enable re-

verse travel

Reverse Map % 0 - 100 Adjust relationship of butterfly rotation to

reverse truck speed

Reverse Max Rpm Rotation of butterfly to max speed in reverse

direction

Hydraulic Functions Menu

Lockout Enable On/Off ON-Lift Lockout Enabled OFF-Lift Lockout

Disabled

Lift Run Time Sec 0 - 10 Max time continuous lifting is enabled

Lift Delay Time Sec 0 - 5 Max time hydraulic valve is open after pump

stops

Lowering Delay time Sec 0 - 5 Max time hydraulic valve is open after low-

ering valve is deactivated

Traction Settings Menu

Snail Speed Rpm 0 - 1000 Maximum motor speed in Snail Mode

Max Speed Rpm 0 - 4330 Maximum motor speed

Max Acceleration Sec 0.1 - 5 Time required to accelerate to max speed at

full butterfly rotation

Description 2200 SRM 1507

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