Hyster D098 (E70Z E80Z E100Z E120Z E100ZS) Forklift Service Repair Manual

Hyster D098 (E70Z E80Z E100Z E120Z E100ZS) Forklift

TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM (ETACC) J2.00-3.20XM (J40-65Z) [A416/B416]; V30ZMD [D210/E210]; E3.50-5.50XL (E70-120Z, E100ZS) [D098/E098]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; E2.00-3.20XM (E45-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]; N30ZDRS, N35-40ZRS [A265]; N35ZDR, N45ZR [C264]; N30ZDR, N35-40ZR [D470]; B60Z AC [B230]; B80Z AC [B233]; T5Z AC [B476]; T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]; B60Z HD [A262]; B80Z HD [A257]

PART NO. 1534737

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SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • 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 exceed 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 flammable. 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 background. The CAUTION symbol and word are on yellow background.

Troubleshooting and Adjustments Using the AC Controls Program (ETACC)

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Computer Requirements ...............................................................................................................................

Software, Install ............................................................................................................................................

Language Selection........................................................................................................................................

Demo Mode.....................................................................................................................................................

Connect PC to Lift Truck ..............................................................................................................................

Starting AC Controls Program .....................................................................................................................

Lift Truck Control Setup ...................................................................................................................................

Change Lift Truck Serial Number or Hourmeter ........................................................................................

Setting Factory Default Values or Changing Lift Truck Parameters .........................................................

Create New Custom Lift Truck Configuration ............................................................................................

Lift Truck Configuration Properties.............................................................................................................

Import New Lift Truck Configuration From Disk .......................................................................................

Delete Custom Lift Truck Configuration or Password File.........................................................................

Dash Display ......................................................................................................................................................

Custom Display Languages...........................................................................................................................

Download Display Language ........................................................................................................................

Clear Operator Log ........................................................................................................................................

Password Functions ...........................................................................................................................................

Enable/Disable Password and Lift Truck Inspection Functions .................................................................

Truck Inspection Checklist .......................................................................................................................

Password ....................................................................................................................................................

Password Properties ......................................................................................................................................

Create New Password File ............................................................................................................................

Download Passwords .....................................................................................................................................

Upload Passwords..........................................................................................................................................

Reports Menu .....................................................................................................................................................

Devices Report ...............................................................................................................................................

Custom Report ...............................................................................................................................................

Password Report ............................................................................................................................................

Operator Report .............................................................................................................................................

Current Settings Report................................................................................................................................

Status Code Report........................................................................................................................................

Status Codes Log ...........................................................................................................................................

Troubleshooting .................................................................................................................................................

Diagnostics .....................................................................................................................................................

Help Menu ..........................................................................................................................................................

General ...........................................................................................................................................................

Contents .........................................................................................................................................................

Technical Support ..........................................................................................................................................

About Electric Truck AC Controls Program.................................................................................................

©2011 HYSTER COMPANY

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Table of Contents

Troubleshooting and Adjustments Using the AC Controls Program (ETACC)

TABLE OF CONTENTS (Continued) This section is for the following models: J2.00-3.20XM (J40-65Z) [A416/B416]; V30ZMD [D210/E210]; E3.50-5.50XL (E70-120Z, E100ZS) [D098/E098]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; E2.00-3.20XM (E45-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160]; N30ZDRS, N35-40ZRS [A265]; N35ZDR, N45ZR [C264]; N30ZDR, N35-40ZR [D470]; B60Z AC [B230]; B80Z AC [B233]; T5Z AC [B476]; T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]; B60Z HD [A262]; B80Z HD [A257]

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General

General The information contained in this manual gives the user a brief overview of the Electric Truck AC Controls Program. This manual also explains the common drop-down menu features for the user that are listed under the File menu, the Reports menu, the Tools menu, and the Help menu.

To run the setup program, follow these steps:

A personal computer (PC) can be used to set the traction motor and pump motor controller functions, read status codes, and perform numerous diagnostic and troubleshooting functions.

2. Click Start.

COMPUTER REQUIREMENTS The PC must have the following minimum configuration: 1. Microsoft Windows 2000™ or later operating system must be installed.

2. There must be an open Universal Serial Bus (USB) port available on the computer to connect to the lift truck.

3. There must be a compact disk read-only-memory (CD-ROM) drive installed on the computer.

4. Microsoft Internet Explorer™ Version 5.01 or later must be installed on the computer.

1. Place the CD in the CD-ROM drive. Installation will start automatically if the computer is set for automatic startup. If the computer is not set for automatic startup, go to Step 2.

3. Select Run and in the Open line enter D:\disk1\setup.exe.

4. Click OK. The setup program will guide you through the rest of the steps to install the Electric Truck AC Controls Program Hyster on the computer.

It is recommended that the program is installed to the default directories.

LANGUAGE SELECTION 1. When the program is first installed the language setup screen will appear. Click on the down arrow to see the languages to be selected. Select the desired language from the list. See Figure 1.

The Electric Truck AC Controls Program Hyster text will appear in the selected language.

5. The display screen resolution should be set to 800×600 pixels.

SOFTWARE, INSTALL NOTE: See instructions included with CD, Hyster part number 1539240 (Initial Installation), and/or readme.txt file on the CD for additional instructions and possible password requirements.

NOTE: You must have Administrator rights to install this software on a PC. After installation, folders "EVS" and "Program Files/ETACC HYSTER/" and their sub-folders must have their security permissions set to allow full control.

NOTE: When installing the software on a PC with Microsoft Windows 2000 or a later Operating System, make sure that the computer is setup with Administrator rights on the computer.

NOTE: In the following examples, the D: drive represents the CD-ROM drive. The CD-ROM drive could be a different letter on the computer.

Figure 1. Language Selection

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General 2. After initial installation, if the selected language is to be changed, click File and select Settings from the drop down menu. A Settings pop-up box will appear on the screen. See Figure 2. Click the language tab and click on the down arrow. A drop down list of languages will appear. Select one of the following languages from the list: • English • German • French • Italian • Spanish

DEMO MODE 1. Select Settings from the File menu. A Settings pop-up box appears with a Communication, Language, General, and Window tab.

See Figure 3.

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2200 SRM 1058 NOTE: In the Settings dialog box, on the Communication tab, if the Normal button is selected, the system is in the default status for operation and must be connected to an actual lift truck. See Figure 3.

If the Demo button is selected, the program is in the demonstration mode, and the program can be operated without being connected to an actual lift truck.

See Figure 3.

2. Select the Communication tab and click the Demo selection.

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General

Figure 2. Language Options

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Figure 3. Settings Menu (Sheet 1 of 2)

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Figure 3. Settings Menu (Sheet 2 of 2)

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General

CONNECT PC TO LIFT TRUCK To connect the Interface Cable Kit Hyster part number 1534010 to the lift truck wire harness, follow these steps: 1. Connect the USB connector of the Interface Cable to the USB port on the PC. See Figure 4.

1.

2.

3.

4.

2200 SRM 1058 compartment below the main contactor. See Figure 5. On models N30ZDRS, N35-40ZRS (A265), N35ZDR, N45ZR (C264), N30ZDR, N35-40ZR (D470), remove the cap covering the connector on the front frame panel. See Figure 6. On models J2.00-3.20XM (J40-65Z) (A416/B416), V30ZMD (D210/E210), E1.50-2.00XM (E25-40Z) (E114/F114), E2.00-3.20XM (E45-65Z) (G108), and E3.50-5.50XL (E70-120Z) (D098/E098), connect to the wiring harness three-pin connector which is located behind the dashboard cowl liner cutout under the dash display. See Figure 4. The connection between the PC and lift truck is now complete.

INTERFACE CABLE LAPTOP COMPUTER INTERFACE CABLE EXTENSION LIFT TRUCK WIRING HARNESS

Figure 4. Interface Cable Kit Connected to USB Connector 2. If provided, connect the nine-pin connector of the Interface Cable extension to the Interface Cable.

See Figure 4.

3. Disconnect the battery connector or depress the battery disconnect switch if the lift truck is so equipped. See Figure 7.

4. Connect the three-pin connector of the Interface Cable to the lift truck ETACC connector. On models B60Z AC (B230), B80Z AC (B233), C60Z AC (B478), C80Z AC (B479), T5Z AC (B476), T7Z AC (B477), B60Z HD (A262), and B80Z HD (A257), the ETACC connector is located inside the drive unit

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1. MAIN CONTACTOR 2. ETACC CONNECTION 3. INTERFACE CABLE Figure 5. ETACC Connection - B60Z AC, B80Z AC, C60Z AC, C80Z AC, T5Z AC, T7Z AC, B60Z HD, and B80Z HD (B230, B233, B478, B479, B476, B477, A262, and A257)

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General

1. BATTERY DISCONNECT SWITCH 2. KEY SWITCH Figure 7. Power Switches - J2.00-3.20XM (J40-65Z) [A416/B416] Models Only 1.

2.

3.

4.

ETACC CONNECTOR (CAP INSTALLED) 12V POWER CONNECTION FRONT FRAME COVER (RH) MAST

Figure 6. N30ZDRS, N35-40ZRS, N30-35ZDR, and N35-40-45ZR [A265, C264, and D470] ETACC Connector 5. Connect the battery connector, or lift the red battery disconnect button, if the lift truck is so equipped. See Figure 7.

STARTING AC CONTROLS PROGRAM 1. Connect the PC to the lift truck. See Connect PC to Lift Truck.

2. Double-click the Electric Truck AC Controls Program Hyster icon located on the desktop. See Figure 8.

3. Click the appropriate Factory or Custom file folder for correct configuration of the lift truck.

See Figure 9.

6. Turn the key switch to the ON position. See Figure 7.

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Figure 8. Desktop

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Figure 9. Connected to Lift Truck 4. Select Connect on the File menu, or click the Connect icon on the toolbar menu in the upper left corner. See Figure 9 and Figure 10.

icon changes to an arrow → which indicates connection and communication between the computer and lift truck. See toolbar icon Figure 9.

NOTE: On the computer, under the Views menu, the red X that appears in the Computer Connection

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General

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Figure 10. File Menu, Connect PC to Lift Truck NOTE: If the connection fails between the computer and lift truck, an error screen will appear. See Figure 11.

NOTE: If this connection error appears on the computer screen, check all connections between the

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computer and the lift truck. Also, check that the battery connect/disconnect switch is engaged, if so equipped, and that the key switch is in the ON position.

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Figure 11. Communication Error PC to Lift Truck

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Lift Truck Control Setup

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Lift Truck Control Setup This section includes the following processes: • Change Lift Truck Serial Number and Hourmeter • Setting Factory Default Values or Changing Lift Truck Parameters • Create New Custom Lift Truck Configuration • Lift Truck Configuration Properties • Import New Lift Truck Configuration from Disk • Delete Custom Lift Truck Configuration or Password File

CHANGE LIFT TRUCK SERIAL NUMBER OR HOURMETER 1. From the Views menu, click Individual Setup or Truck Infomation depending on truck model. See Figure 12. A dialog box pops up with the following information on the lift truck. See Figure 13.

Figure 12. View Menu Individual Setup

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Lift Truck Control Setup

Figure 13. Individual Setup Menu Parameter: Represents the lift truck function name that can be setup on the lift truck and is changeable.

The items that are listed in this column are: lift truck serial number, traction hours, and pump hours.

NOTE: The New Value column should be blank, unless the user has entered new values in this column before downloading this information to the lift truck display panel.

NOTE: If the Master Controller is replaced, the lift truck serial number SHOULD be entered in the New Value column.

Truck Value: Displays values for that specific lift truck that have been stored in the lift truck master controller.

2. Input desired values in the New Value column.

3. Click Download button to download New Values to the lift truck.

NOTE: If the traction motor or pump motor is replaced, the traction or pump hours can be changed to zero. If the Master controller is replaced, the Truck Value will be shown as zero for the hourmeters. They can be updated, if desired, from this screen.

New Value: Displays the new value input by the user.

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Lift Truck Control Setup

SETTING FACTORY DEFAULT VALUES OR CHANGING LIFT TRUCK PARAMETERS

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NOTE: Make sure there is a connection between the lift truck and the computer before making adjustments through the Views menu. See the Connect PC to Lift Truck section for more information.

See Figure 16 for the Unit Codes: A265, C264, and D470.

See Figure 17 for the Unit Codes: B230, B233, B478, B479, B476, B477, A262, and A257.

A System Setup-Connected dialog box pops up with the following information on the lift truck.

See Figure 18 and Figure 19.

1. Select a Custom Configuration file or Factory Configuration file from the drop-down list.

Parameter: Represents functions that can be setup on the lift truck and are changeable.

2. From the Views menu, click System Setup, Factory Setup, Set Performance, or Preference Adjustment, depending on truck model.

See Figure 14 for lift trucks with the following Unit Codes: A416, B416, D098, D210, E098, E114, E210, F114, and G108.

See Figure 15 for the following Unit Code: J160.

Factory/Custom Value: Represents the value for either the Factory Configuration or Custom Value. The Truck Value can be changed in this column.

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Truck Value: Represents the actual value that has been stored in the lift truck control.

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Lift Truck Control Setup

Figure 14. Views Menu System Setup, J2.00-3.20XM (J40-65Z) (A416/B416), V30ZMD (D210/E210), E1.50-2.00XM (E25-40Z) (E114/F114), E2.00-3.20XM (E45-65Z) (G108), and E3.50-5.50XL (E70-120Z) (D098/E098) 15