Hyster Forklift V30ZMDD210,E210 E2 00 3 20XME45 65ZG108 service manual – PDF DOWNLOAD

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Hyster Forklift V30ZMDD210,E210 E2 00 3 20XME45 65ZG108 service manual

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Hyster Forklift V30ZMDD210,E210 E2 00 3 20XME45 65ZG108 service manual

Language : English
Pages : 1008
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HYSTER FORKLIFT V30ZMDD210,E210 E2 00 3 20XME45 65ZG108 SERVICE MANUAL – PDF DOWNLOAD:

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Hyster Forklift V30ZMDD210,E210 E2 00 3 20XME45 65ZG108 service manual

• GENERAL The alternating current (AC) system consists of AC motors, motor controller(s), a master controller, and a dash display. The major difference between the AC system and the direct current (DC) system is the master controller performs many of the same functions that previously were performed in the motor controllers on the DC system. AC Motors The ACmotors are three-phase AC induction motors. They do not include motor brushes or commutators. An AC induction motor operates on three-phase AC power provided directly by the motor controller. The motor’s speed is controlled by the motor controller and can be changed by changing the frequency of the AC power provided to the motor.
• A speed sensor is built into the rear motor bearing, which provides RPM and direction feedback to the motor controller. Themotor controller continuously monitors motor direction and speed. Using this feedback, the AC motor control system can provide much better vehicle top speed control than is available with DC SEM systems. The ACmotors also have thermal sensors embedded in the motor windings that are continuously monitored by the motor controllers. Motor Controllers The motor controllers receive power from the truck’s battery and convert it into three-phase AC power at the frequencies and currents necessary to drive the respective pump and/or traction motor.
• Each AC induction motor provides feedback of speed, rotation direction, and temperature directly to the motor controller. The two motor controllers used to power the traction motor and hydraulic pump motor are very similar. The primary motor controller difference is in the power output rating. The motor controller logic board receives power from the key switch. Power to the motors can be interrupted indirectly by the key switch. The motor controllers get motor speed and temperature information directly from the motors. The motor controllers do not get any other input from the truck. The master controller relays speed, acceleration, and direction commands to the motor controllers.
• Master Controller The master controller is a general-purpose micro- controller for CANbus-based electric vehicles. It contains processing power, memory resources, analog and digital input/output (I/O) to provide the required full-featured functionality. The master controller is designed to manage the traction motor controller and pump motor controller, interface to the operator controls, auxiliary functions, and to control the vehicle dash display. The master controller also manages the operating truck parameters, status codes, battery discharge indicator (BDI) function, hourmeters, password feature, and all operator inputs. It also controls the contactor, cooling fans, and strobe light relay.
• Dash Display The new AC dash display is similar in appearance to the SEM dash display and includes the same features. In addition, the AC dash display provides expanded service capabilities. The dash display has a password-accessible service mode that allows a technician to change control settings and view real-time RPMs, current, temperature, and switch closure information. Previously, a separate handset or computer was required for these operations. For a complete description of the display panel, see the Display Panel section of this manual.

Table of Contents:

Hyster Forklift V30ZMDD210,E210 E2 00 3 20XME45 65ZG108 service manual

Description ……………………………………………………………………………………………………………………………………… 1
General……………………………………………………………………………………………………………………………………….. 1
AC Motors ……………………………………………………………………………………………………………………………….. 1
Motor Controllers …………………………………………………………………………………………………………………….. 1
Master Controller …………………………………………………………………………………………………………………….. 1
Dash Display …………………………………………………………………………………………………………………………… 1
Controller Area Network Bus (CANbus)…………………………………………………………………………………….. 2
Master Controller Checks and Adjustments ………………………………………………………………………………………. 2
Function Settings…………………………………………………………………………………………………………………………….. 3
General……………………………………………………………………………………………………………………………………….. 3
Function Numbers……………………………………………………………………………………………………………………….. 3
Function Descriptions………………………………………………………………………………………………………………………. 5
General……………………………………………………………………………………………………………………………………….. 5
Function Number 1 BATTERY VOLTAGE…………………………………………………………………………………. 5
Function Number 2 EXTENDED SHIFT …………………………………………………………………………………… 5
Function Number 3 ACCELERATION 1 ……………………………………………………………………………………. 6
Function Number 4 ACCELERATION 2 ……………………………………………………………………………………. 6
Function Number 5 TOP SPEED LIMIT……………………………………………………………………………………. 6
Function Number 6 REGEN BRAKING…………………………………………………………………………………….. 6
Function Number 7 AUTO DECELERATION ……………………………………………………………………………. 6
Function Number 8 BDI ADJUSTMENT…………………………………………………………………………………… 6
Function Number 9 LIFT INTERRUPT …………………………………………………………………………………….. 6
Function Number 10 POWER STEERING TIME DELAY …………………………………………………………… 7
Function Number 11 SERVICE REMINDER……………………………………………………………………………… 7
Function Number 12 CUSTOM…………………………………………………………………………………………………. 7
Function Number 13 PUMP SPEED 1 ………………………………………………………………………………………. 7
Function Number 14 PUMP SPEED 2 ………………………………………………………………………………………. 7
Function Number 15 PUMP SPEED 3 ………………………………………………………………………………………. 7
Function Number 16 PUMP ACCELERATION………………………………………………………………………….. 7
Troubleshooting……………………………………………………………………………………………………………………………….. 8
General……………………………………………………………………………………………………………………………………….. 8
Controller Status Light Emitting Diodes (LEDs) ……………………………………………………………………………. 8
Master Controller …………………………………………………………………………………………………………………….. 9
AC Motor Controllers ……………………………………………………………………………………………………………….. 9
Status Codes ……………………………………………………………………………………………………………………………….. 15
AC Motor Controllers Status Code Charts …………………………………………………………………………………………. 17
AC Transistor Motor Controller Replacement ……………………………………………………………………………………. 37
General……………………………………………………………………………………………………………………………………….. 37
General Maintenance Instructions………………………………………………………………………………………………… 43
Special Precautions ………………………………………………………………………………………………………………….. 43
Fuses ………………………………………………………………………………………………………………………………………….. 44
Fan Test………………………………………………………………………………………………………………………………………. 44
Contactors …………………………………………………………………………………………………………………………………… 44
Repair……………………………………………………………………………………………………………………………………… 44
Thermal Sensors………………………………………………………………………………………………………………………….. 48
Motor Controller, Replace …………………………………………………………………………………………………………….. 48
Display Panel ………………………………………………………………………………………………………………………………….. 49
General……………………………………………………………………………………………………………………………………….. 49
Premium Display Panel ……………………………………………………………………………………………………………. 49
Standard Display Panel ……………………………………………………………………………………………………………. 49
Display Functions and Features ……………………………………………………………………………………………………….. 50
©2008 HYSTER COMPANY i
Table of Contents AC Motor Controllers/Display Panel
TABLE OF CONTENTS (Continued)
Key-On Initialization……………………………………………………………………………………………………………………. 50
Standard Display…………………………………………………………………………………………………………………………. 51
Premium Display…………………………………………………………………………………………………………………………. 51
Lift Truck Inspection Function ……………………………………………………………………………………………………… 52
Access to Service Functions ………………………………………………………………………………………………………….. 52
Service Functions ………………………………………………………………………………………………………………………… 52
Service Functions ………………………………………………………………………………………………………………………… 53
Performance Modes ……………………………………………………………………………………………………………………… 55
Battery Discharge Indicator (BDI) ………………………………………………………………………………………………… 55
Hourmeter…………………………………………………………………………………………………………………………………… 56
Dash Display Service Menu Navigation…………………………………………………………………………………………….. 64
General……………………………………………………………………………………………………………………………………….. 64
Moving Through Menu Selections …………………………………………………………………………………………………. 64
Editing and Adding Information …………………………………………………………………………………………………… 64

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]