Hyster G117 (H1050HD-16CH, H1150HD-16CH) Internal Combustion Engine Trucks Service Repair Manual

Hyster G117 (H1050HD-16CH, H1150HD-16CH) Internal Combustion Engine Trucks Service Repair Manual

HYDRAULIC CONTROL SYSTEM H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917]; H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD, H1150HD) [G117]

PART NO. 4046726

1900 SRM 1561

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 instructions 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 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.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Description ...............................................................................................................................................................1 Control Valve .......................................................................................................................................................2 Analog Inputs ......................................................................................................................................................2 Joysticks/Levers ..............................................................................................................................................2 Sensors ............................................................................................................................................................ 3 Temperature Sensor ...................................................................................................................................3 Pressure Transducer .................................................................................................................................. 3 Accumulator Pressure Transducer ............................................................................................................3 Digital Inputs ...................................................................................................................................................... 3 Hydraulic Control Switches ........................................................................................................................... 3 Interrupts ............................................................................................................................................................ 3 Lift Interrupt (Twist Module) ........................................................................................................................ 4 Lower Interrupt (Twist Module) .................................................................................................................... 4 Function Override ...........................................................................................................................................4 Operator Presence System (OPS) .................................................................................................................. 4 Digital Switched Inputs ......................................................................................................................................4 ECO eLo HiP Switch ...................................................................................................................................... 4 Not Locked Signal ...........................................................................................................................................4 (Lift Position, Tilt Position, Slew RH Position, Slew LH Position) Sensor ................................................. 4 Calibration Switch ..........................................................................................................................................4 Ignition Switch Signal ....................................................................................................................................4 Brake Filter Pressure Switch .........................................................................................................................4 Pressure Signal ...............................................................................................................................................4 CAN Bus Communication ...................................................................................................................................4 Output Signals .................................................................................................................................................... 5 Analog Outputs ...............................................................................................................................................5 Digital Outputs ............................................................................................................................................... 5 Lowering Interrupt .....................................................................................................................................5 Accumulator Charge Enable ......................................................................................................................6 Hydraulic Relay Take Over ....................................................................................................................... 6 Programmed Features ........................................................................................................................................ 6 High Temperature Protection (Optional) ...................................................................................................... 6 Adjustable Loaded Vehicle Speed Reduction (Optional B917 only) .............................................................6 Traction Speed Limiter - Container Position (Optional G117 only) ............................................................ 7 Temperature Protection (Standard) .............................................................................................................. 7 Cold Temperature Protection (Standard) ......................................................................................................7 Traction Speed Limiter-Loaded (Standard) .................................................................................................. 7 Automatic Throttle Up (Standard) ................................................................................................................ 8 HiP/ECO eLo Operating Mode (Standard) ....................................................................................................8 Drive Over Lift (Standard) .............................................................................................................................8 FAN Drive System (Standard) .......................................................................................................................8 Hibernate Idle (Standard Tier 4 Only) ..........................................................................................................8 Settings ................................................................................................................................................................9 Adjustable Parameters ...................................................................................................................................9 Truck Configuration Screen .......................................................................................................................9 Installed Features Screen .......................................................................................................................... 9 General Functions of the Interface .........................................................................................................................9 Main Functional Requirements ......................................................................................................................... 9 What is Needed for the Hydraulic User Interface Program ............................................................................. 9

©2014 HYSTER COMPANY

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Table of Contents

TABLE OF CONTENTS (Continued) Installation of the Program ............................................................................................................................9 Start Screen .................................................................................................................................................. 12 Warning Screen ............................................................................................................................................ 13 Basic Screen Layout of the Hydraulic User Interface Program .................................................................14 Truck Configuration Screen .........................................................................................................................16 Installed Features Screen ............................................................................................................................ 18 Temperature Protection Screen ................................................................................................................... 20 High Temperature Protection (Optional) ................................................................................................20 Traction Speed Limiter - Container Position (Optional G117 only) .......................................................... 21 Adjustable Loaded Speed Reduction (Optional B917 only) ........................................................................22 Temperature Protection Screen ................................................................................................................... 23 Temperature Protection (Standard) ........................................................................................................ 23 Cold Temperature Protection (Standard) ............................................................................................... 23 Traction Speed Limiter - Loaded ................................................................................................................. 24 Automatic Throttle Up - Lift Screen ............................................................................................................25 HiP/ECO eLo Operating Mode Screen ........................................................................................................ 26 Drive Over Lift (Standard) ...........................................................................................................................27 Hibernate Idle Screen ...................................................................................................................................28 Fan Drive Settings Screen ........................................................................................................................... 29 Calibration Screen ........................................................................................................................................ 30 Calibrating the Connected Joystick/Lever Without the Interface Software .........................................30 Calibrating the Connected Joystick/Lever With the Interface Software .............................................. 31 Flow Settings Screen .................................................................................................................................... 31 Profile Lift Screen .........................................................................................................................................32 Valve Settings Screen ...................................................................................................................................33 Diagnostic Screen ......................................................................................................................................... 34 Active Errors Screen .....................................................................................................................................35 Error History Screen .................................................................................................................................... 36 All Parameters Screen ..................................................................................................................................37 Installing the Hydraulic Controller Software and Read-Only Parameter File .........................................39 File Download Screen ...............................................................................................................................39 Calibration .............................................................................................................................................................40 Calibrating the Lever With the Hydraulic User Interface Program ..............................................................40 Calibrating the Joystick With the Hydraulic User Interface Program ......................................................... 40 Calibrating the Lever Without the Hydraulic User Interface Program ........................................................ 41 Calibrating the Joystick Without the Hydraulic User Interface Program .................................................... 41 Fault Codes ............................................................................................................................................................42 Controller Pinning .................................................................................................................................................50 This section is for the following models: H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917]; H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD, H1150HD) [G117]

ii

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1900 SRM 1561

General

General This SRM describes the electronic hydraulic control system, and its interaction with the Hydraulic User Interface Program.

Hydraulic System 1900SRM1562 Diagrams 8000SRM1563

See the following resources for additional information:

Description The hydraulic system is operated through an electrically-operated control valve that receives its signals from the hydraulic frame controller. The hydraulic frame controller contains the actual software logic and therefore controls most of the outputs. It is located near the main control valve.

The hydraulic cab controller is placed in the side console of the cabin and controls most of the input signals. The two units communicate with each other through CAN Bus, see Figure 1. The frame controller determines what the accompanying output must be.

Figure 1. CAN Bus Connections

1

Description

1900 SRM 1561

The hydraulic controller has been programmed to supply these output signals to the electrically-operated control valve depending on the following variables: •

Input signals

•

Programmed functions

•

Settings

See Figure 2.

CONTROL VALVE The flow of hydraulic oil through the electricallyoperated control valve is determined by the position of the spools. The position of each spool depends on the electrical controller signal received at the actuation module for that spool.

For hydraulic functions that just require hydraulic supply to be ON or OFF, the electrical signal is ON or OFF as well. Operating voltage is ±24 volts (System Voltage).

For hydraulic functions that require flow control, the desired spool position is obtained by a voltagecontrolled PWM (Pulse Width Modulation) signal.

Depending on the hydraulic function, the average voltage varies in relation to the PWM duty cycle between ±8% and ±50% of the truck supply voltage at the solenoid.

ANALOG INPUTS A. CAB AND FRAME CONTROLLER INPUTS B. SOFTWARE LOGIC CONTROLS C. CAB AND FRAME CONTROLLER OUTPUTS Figure 2. Control Flow

Output signals can be Pulse Width Modulation (PWM) signals for proportional hydraulic functions, digital signals for ON/OFF functions, or CAN Bus messages for other linked controllers.

Both hydraulic controllers continually monitor the system for fault conditions, display appropriate fault codes, and take action when necessary.

Each controller requires a 24 volt power supply for operation. Power is provided through the ignition switch, the hydraulic controller relay, and a 30 amp fuse. There is a Red and Green LED next to the main connector of each controller. The Green LED is ON when the controller is powered. The Red LED is ON when a hydraulic control system fault condition is detected, and blinks when the fault is related to a CAN Bus message.

2

Joysticks/Levers Joysticks/Levers are used to proportionally control the following functions: •

Lift and Lower

•

Tilt Forward and Tilt Backward

•

Aux0 (Power Pile Slope)

•

Aux1 (Rotate)

Depending on the position of the joystick/lever, the 5-volt sensor supply signal from the controller is converted to a signal between 0.5 volts and 4.5 volts. The neutral position of the joystick/lever translates to a signal of 2.5 volts.

The controller monitors the signals provided by the joystick/lever and if the signals are out of range, the controller activates a fault code and enters a fail safe mode. Joysticks/levers must be calibrated before being put into service.

Calibration of the joystick/lever provides a reference to the controller for the two extreme and neutral joystick/lever positions. The controller converts the joystick/lever position input signal into a PWMoutput signal and sends it to the control valve.

1900 SRM 1561 For backward joystick/lever movements, the joystick/lever output signals are indicated with flow direction A. For forward joystick/lever movements, the joystick/lever output signals are indicated with flow direction B. The specific joystick/ lever position and connector orientation prevent joystick/lever directions from inadvertently resulting in incorrect oil flow directions.

Sensors Additional analog input is provided by a temperature sensor and two pressure transducers.

Temperature Sensor A temperature sensor at the bottom of the hydraulic tank has a resistance between 700 and 2000 Ω, depending on the hydraulic oil temperature.

The controller reacts to the temperature signal as follows:

Description When the sensor detects an error, receives an input below 300 mv or above 5200 mv, a fault code is displayed and the features are turned OFF.

Accumulator Pressure Transducer A pressure transducer measuring the accumulator pressure in the main valve (port S ACC) provides an input to the hydraulic controller for enabling/ disabling the electronically-controlled charge function: •

Charging is enabled when the accumulator pressure is below ±16.5 MPa (±2393 psi) for 0.5 seconds.

•

Charging is disabled at an accumulator pressure of ±20.5 MPa (±2973 psi).

DIGITAL INPUTS Hydraulic Control Switches Five auxiliary functions can be activated by manual switches (digital inputs): Aux_2, Aux_3, Aux_4, Aux_5, and Aux_6.

•

When oil temperature is below −5°C (23°F), the controller displays the fault code hcold.

•

When Cold Temperature Protection is activated, the controller reduces maximum engine speed by sending a CAN Bus message to the engine.

•

Aux_2 (Twist Locks) - Lock/Unlock

•

Aux_3 (Hydraulic Stop) - Lock/Unlock

•

Aux_4 (Side Shift) - Right/Left

•

When oil temperature exceeds 90°C (194°F), the controller displays the fault code hhot.

•

Aux_5 (Extend/Retract) - Extend/Retract

•

Aux_6 (Reach) - Forward/Backward

•

When High Temperature Protection (optional) is activated, the controller displays the fault code hhot when oil temperature exceeds 88°C (190°F). When oil temperature exceeds 90°C (194°F), the controller reduces vehicle speed by sending a CAN Bus message to the transmission.

See Programmed Features.

Pressure Transducer A pressure transducer measuring the pressure in the lift cylinders provides an input to the hydraulic controller for the load being lifted. The signal is used for the following standard/optional features: •

Traction Speed Limiter - Loaded

•

Traction Speed Limiter - Container Position

Depending on the position of the switch, the controller sends a 24 volt signal to the relevant solenoid valve.

INTERRUPTS Interrupts disable the lifting/lowering functions under specific circumstances. The interrupts are generated in the Twist Module depending on the following signals: •

Not Locked Signal

•

Locked Signal

•

All Seated Signals

There are separate interrupt signals for lowering and lifting.

3

Description

Lift Interrupt (Twist Module) The lift interrupt function disables the lift function during locking and unlocking of the twist locks.

Both signals “Not Locked” and “Locked” are used to generate this interrupt. When the lift interrupt is active the tilt backward function is also disabled.

Lower Interrupt (Twist Module) The lowering interrupt function disables the lowering function when all “Seated” signals are active.

All “Seated” signals are used to generate this interrupt. When the lowering interrupt is active the tilt forward function is also disabled.

1900 SRM 1561

(Lift Position, Tilt Position, Slew RH Position, Slew LH Position) Sensor The lift position sensor together with the tilt, slew right hand, and slew left hand position sensors act as one input for the “Traction Speed Limiter – Container Position (Optional G117 Only)”. The sensors are located on the mast/gantry and depending on the position of the mast/gantry, the speed limiter switches between max vehicle speed, vehicle speed limit 1 or vehicle speed limit 2. See Programmed Features.

Calibration Switch

The “Lift Interrupt” and “Lower Interrupt” signals can be overruled by the input: Function Override.

The "Function Override" button, if it is included on the truck, is located on the twist module.

When the calibration switch is activated, the charger enable output is deactivated. The calibration switch also disables the hibernate idle function and the automatic throttle-up features to make sure the truck operates in normal idle mode so the operator can calibrate the transmission at a fixed engine speed.

Operator Presence System (OPS)

Ignition Switch Signal

The OPS has an electrical switch in the seat that sends a signal to disable the hydraulic lift/lower, tilt forward/backward, and auxiliary functions 1 second after the OPS switch has been activated.

The ignition switch signal is used to activate the “Hydraulic Control Relay” to maintain battery power for 10 seconds after the ignition switch is turned off. This is to provide the fan drive valve with power so the system can be powered down in a steady way.

Function Override

In order to reset the OPS and re-enable the hydraulic functions, the operator has to sit on the seat again.

DIGITAL SWITCHED INPUTS ECO eLo HiP Switch The ECO eLo HiP Switch switches between HiP (High Performance) and ECO eLo (Fuel Efficiency) operating modes. The switch is located on the truck's side console.

Not Locked Signal The Not Locked signal is used for the traction speed limiter – container position, to switch between max vehicle speed, vehicle speed limit 1, or vehicle speed limit 2. See Programmed Features.

Brake Filter Pressure Switch The brake filter pressure switch signal indicates that the brake pressure filter has too high a restriction and needs to be replaced. The hydraulic oil temperature needs to be at least 40°C (104°F) before a fault code is generated.

Pressure Signal The spreader sends a pressure signal to the hydraulic controller to give output on the auxiliary valve so the spreader can lock/unlock the twist locks.

CAN BUS COMMUNICATION CAN Bus communication can consist of both input and output signals.

The hydraulic controller communicates via the CAN Bus circuit with the following controllers:

4

1900 SRM 1561 •

Instrument cluster - for displaying messages on the fault code display or turning ON/OFF warning lights. See Fault Codes.

•

Engine Control Module - for the AntiStall, Automatic Throttle-Up, Hibernate Idle, and Temperature Protection features.

See Programmed Features.

•

•

Transmission Controller - for Vehicle Speed, Traction Speed Limiter - Loaded, Traction Speed Limiter - Container Position, and Adjustable Loaded Vehicle Speed Reduction. See Programmed Features.

Hydraulic Controllers - for communication between both controllers.

OUTPUT SIGNALS Output signals can be digital (ON/OFF), analog (with a certain value and within a specified range), or CAN bus messages. Depending on settings and programmed features, output signals can be different than standard programming. See Settings and Programmed Features.

Analog Outputs Analog signals for proportional hydraulic functions are voltage-controlled PWM (Pulse Width Modulation) outputs and operate within a nominal range of ±8% to ±50% of the truck's supply voltage.

There is a separate proportional control valve for the following functions: •

Lower - Lift A

•

Lift - Lift B1, Lift B2

•

Tilt Forward - Tilt A

•

Tilt Backward - Tilt B

•

Aux - Aux A, Aux B

•

Fan Drive - Fan Drive System

The letters A and B correspond to the flow direction as intended by the lever/switch movement.

For lifting, lowering, and both tilt functions, there are separate control valves to control movement and direction.

Description The auxiliary functions use a separate digital ON/OFF valve, in addition to the two proportional control valves that determine flow direction, to enable/disable the hydraulic function.

The hydraulic fan drive system also uses a proportional control valve to control the cooling fan speed/ cooling performance, which is dependent on four temperature inputs: •

Engine Coolant Temperature

•

Engine Charged Air Temperature

•

Transmission Temperature

•

Hydraulic Oil Temperature

The output for the fan drive system is a voltagecontrolled PWM (Pulse Width Modulation) signal.

Depending on the inputs, the current will vary between 250mA and 600mA. The fan speed/cooling performance is higher when the current drops and vice versa. See Programmed Features.

Digital Outputs Digital signals are ON/OFF signals providing ±24 volts (System Voltage) when active (activated) and 0 volts when inactive (deactivated). In general, digital signals are used for auxiliary functions.

The following outputs are available for auxiliary functions: •

Digital Out Aux_0 - Power Pile Slope (G117)/ Side Shift (B917)

•

Digital Out Aux_1 - Rotation

•

Digital Out Aux_2 - Twist locks

•

Digital Out Aux_3 - Hydraulic Stop Lock

•

Digital Out Aux_3 - Hydraulic Stop Unlock

•

Digital Out Aux_4 - Side Shift (G117 only)

•

Digital Out Aux_5 - Extend/Retract

•

Digital Out Aux_6 - Reach

Lowering Interrupt Digital output Pin 33 (Lowering Interrupt – Blue Light Twist Module) of the cab controller is used to provide input to the Twist module. The Lowering interrupt is activated when the input signal “Lowering interrupt” of the frame controller is active and the “function override” input is NOT active.

5

Description

Accumulator Charge Enable Digital output Pin 39 (Accumulator Charge Enable) of the cab controller controls the charging of the accumulator. Charging of the accumulator is enabled/ disabled under the following circumstances: Charging Disabled:

The following features are standard and can be turned ON/OFF and adjusted at the dealer/ customer level: Standard Features •

Traction Speed Limiter - Loaded

- During engine cranking and 5 seconds after the engine is running to preserve the starter motor.

The following features are standard and can be turned ON/OFF, but only by requesting a new P1T file at the service department:

- Calibration switch activated

Standard Features

- Charge Pressure Transducer Error condition active - Charging/Accumulator pressure is equal to or greater than ±20.5 MPa (±2973 psi).

Charging Enabled: - Charging/Accumulator pressure is equal to or less than ±16.5 MPa (±2393 psi) for 0.5 seconds.

Hydraulic Relay Take Over Digital output Pin 44 (Relay Take Over) of the cab controller is used to activate the relay “Hydraulic Control Relay” to maintain battery power for 10 seconds after the ignition switch is turned off. This is to provide power to the proportional valve of the fan drive system so the fan speed can be powered down in a steady way.

The proportional valve of the fan drive system must be energized to reduce fan speed, and the fan's full speed is reached when the valve is not energized at all. This is done to achieve a fail safe operation of the cooling fan.

PROGRAMMED FEATURES The controller has been programmed for a number of standard features and can be programmed for optional features as well.

The following features are optional and can be turned ON/OFF if they are included on the truck: Optional Features

6

1900 SRM 1561

•

High Temperature Protection

•

Traction Speed Limiter - Container Position

•

Adjustable Loaded Vehicle Speed Reduction

•

Cold Temperature Protection

•

Automatic Throttle-Up

•

HiP/ECO eLo Operating Mode

•

Drive Over Lift

The following features are standard and CANNOT be turned off: Standard Features •

Fan Drive

•

Hibernate Idle

High Temperature Protection (Optional) When High Temperature Protection is activated, the fault code hhot is displayed when the hydraulic temperature is greater than 88°C (190°F), and a warning light is illuminated on the operator's display. The high temperature protection feature limits vehicle speed to 10 km/h (6 mph) when the hydraulic oil temperature is greater than 90°C (194°F) for 120 seconds to reduce heat generated during braking.

Adjustable Loaded Vehicle Speed Reduction (Optional B917 only) When the load to be lifted exceeds the preset value for load saved in the hydraulic controller, the adjustable Loaded Vehicle Speed Reduction feature limits vehicle speed to a preset value saved in the hydraulic controller.

The value for vehicle speed is adjustable from a range of 5 to 20 km/h (3 to 12 mph) with a default setting of 20 km/h (12 mph).

1900 SRM 1561

Description

The preset load value is adjustable by lifting a load that is equal to the switching point of where the speed limiter becomes activated and then pressing the set button on the “Adjustable Loaded Vehicle Speed Reduction Screen”. The load is represented as a percentage of 24.0 MPa (3480 psi).

The required input signal is provided by the pressure transducer located in the lift section of the main valve.

When no container is picked up, the vehicle speed limiter feature is inactive. If a container is picked up and the container position is in a safe driving position, vehicle speed is limited to approximately 15 km/h (9 mph) (Vehicle Speed Limit 1).

If a container is picked up and the container position is in an unsafe driving position, vehicle speed is limited to approximately 8 km/h (5 mph) (Vehicle Speed Limit 2). See Table 1.

Traction Speed Limiter - Container Position (Optional G117 only) The container position vehicle speed reduction feature reduces the maximum allowed vehicle speed, depending on the position of the container.

Table 1. Vehicle Speed Limiter Feature Tilt Position Sensor

Slew RH Position Sensor

Slew LH Position Sensor

Speed Limitation

Load

Lift Position Sensor

None

None

Not Applicable

Not Applicable

Not Applicable

Not Applicable

Vehicle Speed Limit #1

Yes

Active

Active

Active

Active

Vehicle Speed Limit #2

Yes

Temperature Protection (Standard) The Temperature Protection feature warns the operator of extreme hydraulic oil temperatures by displaying the fault code hcold when hydraulic oil temperature is less than −5°C (23°F), or hhot when hydraulic oil temperature is greater than 90°C (194°F). When the fault code hhot is displayed, a warning light turns ON at the same time.

Cold Temperature Protection (Standard) Depending on the hydraulic oil temperature, engine speed is reduced proportionally in order to protect the hydraulic pumps against cavitation. See Table 2 for the relationship between temperature and maximum engine speed. When Cold Temperature Protection is activated, the fault code hcold is displayed.

One of these four inputs is inactive Table 2. Temperature and Maximum Engine Speed Temperature

Maximum RPM

−5°C (23°F)

Unrestricted

−10°C (14°F)

1600

−13°C (9°F)

1200

−20°C (4°F)

1000

Traction Speed Limiter-Loaded (Standard) The “Traction Speed Limiter-Loaded” feature limits vehicle speed when a load is detected. A pressure transducer located in the lift section of the main valve provides an input to the hydraulic controller for the load to be lifted. When the load is equal to or greater than 3000 kg (6614 lb), the speed limiter is activated. The parameter for setting the speed limiter is adjustable by the dealer from a range of 5 to 20 km/h (3 to 12 mph), with a default value of 20 km/h (12 mph).

7

Description

1900 SRM 1561

Automatic Throttle Up (Standard)

•

This feature automatically increases engine speed when the lift function or one of the tilt functions is applied. The relationship between lever movement and engine speed increase is defined in a graph displayed on the screen. Maximum engine speed increase is 80% for lift and tilt functions. The Automatic Throttle Up feature is only active when the transmission is NOT in gear or when it is in inching mode.

The transmission is engaged (Driving/Not Inching)

•

Engine speed is less than 1350 rpm

HiP/ECO eLo Operating Mode (Standard) The ECO elo feature allows the operator to choose between high performance (HiP) or fuel efficiency (ECO elo) modes. Selection between the HiP and ECO modes is made by means of a key switch located on the side console.

The High Performance mode (HiP) provides the normal engine settings and performance behavior.

The ECO eLo mode smoothens throttle reaction time, therefore increasing fuel efficiency. Engine speed is only reduced when the transmission is engaged or when a hydraulic function is applied. Maximum engine speed is reduced to 2000 rpm.

Drive Over Lift (Standard) The Drive Over Lift feature prioritizes driving performance over lift performance when driving and lifting occur at the same time.

The amount of lifting performance is reduced by disabling the second lift section. The second lift section is disabled under the following circumstances:

FAN Drive System (Standard) The FAN drive system is a standard feature that proportionally controls the cooling performance of the cooling fan. Depending on four temperature inputs, the hydraulic controller determines the output for the FAN drive system. See Table 3.

The Minimum and Maximum input temperatures determine the normal operating range, with the Minimum input corresponding to 10% cooling performance and the Maximum input corresponding to 90% cooling performance.

When one of the temperature inputs exceed the Limit temperature input, the output for the fan drive is set to 100% cooling performance.

Hibernate Idle (Standard Tier 4 Only) The Hibernate Idle feature ramps down engine speed if the truck has been left to idle without operator interaction for 30 seconds (no hydraulic operations or accelerator pedal have been applied), to improve fuel economy during extended idle periods.

Engine speed is ramped up when one of the hydraulic functions is applied or when the accelerator pedal is applied. When the calibration switch is activated the hibernate idle function is disabled, allowing the truck to be calibrated.

Table 3. Temperature Inputs

8

Temperature Input

Minimum Temperature

Maximum Temperature

Limit Temperature

Transmission Oil

95°C (203°F)

110°C (230°F)

120°C (248°F)

Engine Coolant

90°C (194°F)

99°C (210°F)

107°C (225°F)

Engine Charged Air

55°C (131°F)

66°C (151°F)

93°C (199°F)

Hydraulic Oil

75°C (167°F)

85°C (185°F)

90°C (194°F)

1900 SRM 1561

Description

SETTINGS Several parameters of the hydraulic controller are adjustable and can be set using the Hydraulic User Interface Program. Following is an overview of program parameters that are adjustable at dealer level.

Instructions for making adjustments to program parameters are listed in the description for the Hydraulic User Interface Program. See also Table 4 for an overview of relevant program screens.

Adjustable Parameters Truck Configuration Screen •

Truck setup selection

Installed Features Screen

•

High Temperature Protection

•

Traction Speed Limiter - Container Position

•

Adjustable Loaded Vehicle Speed Reduction

Standard Features: •

Traction Speed Limiter - Loaded

Flow Settings: •

Flow Value's Power Pile Slope (G117)/Side Shift (B917)

•

Flow Value's Rotate

•

Flow Value's Twist Locks

•

Flow Value's Power Dampening

•

Flow Value's Side Shift

•

Flow Value's Extend Retract

•

Flow Value's Reach

Optional Features:

General Functions of the Interface MAIN FUNCTIONAL REQUIREMENTS •

Set the truck configuration (container handler/fork lift truck).

•

Reset all changed parameters back to factory settings.

•

Disable features/parameters for diagnostic reasons or personal preference.

•

Select different languages (English, French, German, Italian, or Spanish).

WHAT IS NEEDED FOR THE HYDRAULIC USER INTERFACE PROGRAM

Installation of the Program The Hydraulic User Interface program is available via Hypass Online.

After downloading the program, double-click the installation icon. The program automatically installs the Hydraulic User Interface Program and all required drivers for the IFAK interface cable.

After installation is complete, the IFAK interface cable can be connected to the truck at the three-pin Deutsche DT connector located in the side console with the label "HYD".

1. A PC with the Hydraulic User Interface Program installed and a free USB port.

Connect the other end of the cable to a free USB port on the PC.

2. An IFAK interface (Hyster part 1532578) and an IFAK interface cable (Hyster part 1534009) to connect the PC to the controller(s) on the truck.

Double-click the Hydraulic User Interface Program icon. The icon is placed on the PC desktop after installation. See Figure 3.

3. A truck equipped with a hydraulic controller.

9

General Functions of the Interface

1900 SRM 1561 The following Hydraulic User Interface Program screens are accessible at dealer level. All related parameters are adjustable.

Figure 3. Service Icon Table 4. Hydraulic User Interface Program Overview Hydraulic User Interface Program Screen Name

Dealer

Affected Parameters

Start Screen

Not Applicable

Not applicable

Warning Screen

Not Applicable

Not applicable

Truck Configuration Screen

Yes

Installed Features Screen

10

Main Screen

Sub- Screen

Access Level

Yes

Truck setup • selection •

High Temperature Protection

•

Traction Speed Limiter Container Position

•

Adjustable Loaded Vehicle Speed Reduction

•

Cold Temperature Protection

•

Traction Speed Limiter Loaded

•

Automatic Throttle-Up

•

HiP/ECO eLo Operating Mode

•

Drive Over Lift

1900 SRM 1561

General Functions of the Interface Table 4. Hydraulic User Interface Program Overview (Continued)

Hydraulic User Interface Program Screen

Access Level Dealer

Affected Parameters

Temperature Protection Screen

Yes

Not applicable

Calibration Screen

Yes

Not applicable

Diagnostic Screen

Yes

Not applicable

Active Errors Screen

Yes

Not applicable

Error History Screen

Yes

Not applicable

All Parameters Screen

Yes

Not applicable

Name

Main Screen

Sub- Screen

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General Functions of the Interface

1900 SRM 1561

Start Screen The Start Screen displays automatically upon startup of the Hydraulic User Interface Program. It provides basic information about the system such as the truck’s serial number (SN), the name of the application, the version (Ver) number of the interface program, and the corresponding part number (PN). See Figure 4.

When the truck serial number programmed in the ROP file does not match the truck’s initial truck serial number, the optional features are disabled and exclamation marks will display in place of the truck serial number in the box at the top of the screen.

Users can select the desired language before clicking on the Continue button to advance to the next screen.

The truck’s serial number is programmed into the hydraulic controller from the Read-Only Parameter (ROP) File. The serial number entered in the hydraulic controller can be changed by downloading another ROP file.

Figure 4. Start Screen

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1900 SRM 1561

General Functions of the Interface

Warning Screen The Warning screen is an additional reminder to users to always click the Download Parameters button or to press the F4 key to save changed parameters to the hydraulic controller. See Figure 5.

To update information for a particular screen, click on the Upload Parameters button or press the F2 key.

Clicking on the Click here to Continue button advances the program to the next screen.

Figure 5. Warning Screen

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General Functions of the Interface

Basic Screen Layout of the Hydraulic User Interface Program

1900 SRM 1561 Displays the settings for the electric/hydraulic valves.

A list of screen icons appear along the left margin of each screen and when clicked on serve as shortcuts to other screens within the program. See Figure 6.

6. Diagnostic Screen

Following is a brief description of each of these screens:

7. Active Errors Screen

1. Truck Configuration Screen Contains all basic truck configuration settings and provides access to the All Parameters screen.

2. Installed Features Screen Enables/disables available software-enabled options or standard features.

3. Calibration Screen Calibrates the joystick/levers following replacement or failure, or after replacing a hydraulic controller. See also Calibration.

4. Flow Settings Screen Adjusts flow demands for lifting/tilting and all auxiliary functions.

5. Valve Settings Screen

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Displays the most common hydraulic controller signals and allows users to quickly identify problems or issues.

Provides an overview of actual active errors and provides access to the error history screen.

8. Active Errors Indicator Takes users to the Active Errors Screen. The box to the left of the icon displays the number of active errors.

9. Truck Serial Number Displays the truck serial number that is programmed in the hydraulic controller.

10. Upload Parameters Button Refreshes the parameters displayed on the active screen.

11. Download Parameters Button Saves the parameters displayed on the active screen.

1900 SRM 1561

1.

2.

3.

4.

5.

6.

General Functions of the Interface

TRUCK CONFIGURATION SCREEN ICON INSTALLED FEATURES SCREEN ICON CALIBRATION SCREEN ICON FLOW SETTINGS SCREEN ICON VALVE SETTINGS SCREEN ICON DIAGNOSTIC SCREEN ICON

7.

8.

9.

10.

11.

ACTIVE ERROR SCREEN ICON TRUCK SERIAL NUMBER ACTIVE ERRORS INDICATOR UPLOAD PARAMETERS BUTTON (REFRESH) DOWNLOAD PARAMETERS BUTTON

Figure 6. Screen Layout

15

General Functions of the Interface

1900 SRM 1561

Truck Configuration Screen

Figure 7. Truck Configuration Screen

16

1900 SRM 1561

General Functions of the Interface

NOTE: Check your Parts Manual to make sure this software applies to the truck you are servicing.

The Truck Configuration screen contains a truck setup selection drop-down list box. See Figure 7.

Users can select the desired unit of measure (imperial or metric) from a drop-down list box on the left.

Figure 8. Truck Types Drop-Down Box (G117)

The All Parameters icon that appears above the unit of measure drop-down box provides a shortcut to the All Parameters screen. From this screen, users can upload or download new parameters or controller software.

The truck setup selection drop-down list box lists the different truck types. There are four types of trucks to choose from: two container handler types (for the G117), and two fork lift types (for the B917). See Figure 8 or Figure 9.

Figure 9. Truck Types Drop-Down Box (B917)

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General Functions of the Interface

1900 SRM 1561

Installed Features Screen

Figure 10. Installed Features Screen

18

1900 SRM 1561 NOTE: Users can only enable features that have been purchased. Features that are not part of the original truck configuration may be purchased via the service department.

The available features for the hydraulic controller software are enabled by a separately downloadable read-only parameter file that is specific to the truck serial number. The version number of the current read-only parameter file is displayed below the truck serial number. See Figure 10.

See the chapter Download Controller Software for more information.

The following optional features are listed at the top of the Installed Features screen. They can be adjusted at dealer level only: •

High Temperature Protection

•

Traction Speed Limiter - Container Position (for G117 only)

•

Adjustable Loaded Vehicle Speed Reduction (for B917 only)

General Functions of the Interface department to change the settings. The standard installed features whose settings require a change from the service department are: •

Cold Temperature Protection

•

Automatic Throttle Up

•

Hip/Eco eLo Operating Mode

•

Drive Over Lift

Dealers must send a P1T-file to the service department in order to have settings changed. The service technician will then change the settings and send the adjusted P1T-file back to the dealer.

The following standard feature is adjustable at dealer/customer level: •

Traction Speed Limiter - Loaded

By clicking on the icon for a standard/optional feature, an accompanying subscreen is displayed. If a feature screen is accessed at the dealer/service department level, the values displayed will be readonly.

The standard features are listed below the optional features. Dealers can see what standard features are active/inactive but they need to ask the service

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