Hyster J007 (H190HD2, H210HD2, H230HD2, H230HDS2, H250HD2, H280HD2) Forklift Service Repair Manual

Hyster J007 (H190HD2, H210HD2, H230HD2, H230HDS2, H250HD2, H280HD2) Forklift Service Repair Manual

HYDRAULIC CONTROL SYSTEM H8.0-12.0XM-6 (H190-280HD2) [J007]; H13.0-14.0XM-6 (H300-330HD2) [H019]; H16.0XM-6 (H360HD2) [H019]; H10.0-12.0XM-12EC (H360HD2-EC) [H019]; H13-16XM-6, H10-12XM-12EC (H300-360HD2, H360HD2-EC) [J019]; H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS) [K007]; H16XM-9, H18XM-7.5, H16XM-12, H18XM-9 (H360-36HD, H360-48HD) [A238]

PART NO. 4034399

2200 SRM 1481

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 .......................................................................................................................................................3 Analog Inputs ......................................................................................................................................................3 Levers and Joysticks ...................................................................................................................................... 3 Sensors ............................................................................................................................................................ 3 Temperature Sensor ...................................................................................................................................4 Pressure Sensor ..........................................................................................................................................4 Digital Inputs ...................................................................................................................................................... 4 Switches .......................................................................................................................................................... 4 Interrupts ........................................................................................................................................................4 CAN Bus Communication ...................................................................................................................................5 Output Signals .................................................................................................................................................... 5 Analog Outputs ...............................................................................................................................................5 Digital Outputs ............................................................................................................................................... 5 Programmed Features ........................................................................................................................................ 5 Anti-Stall (Standard) ......................................................................................................................................6 Temperature Protection (Standard) .............................................................................................................. 6 Low Temperature Protection (Standard) ...................................................................................................... 6 High Temperature Protection (Optional) ...................................................................................................... 6 Dynamic Control (Optional) ........................................................................................................................... 6 Loaded Speed Reduction (Optional) .............................................................................................................. 6 Settings ................................................................................................................................................................7 Adjustable Parameters ...................................................................................................................................7 Truck Configuration Screen .......................................................................................................................7 Mode Definition Responsiveness (Smooth, Medium, and Rapid) ............................................................ 7 Set Default Flow Settings Screen ..............................................................................................................7 Features Screen ..........................................................................................................................................7 Loaded Speed Reduction Screen ................................................................................................................7 Flow Settings Screen ..................................................................................................................................7 General Functions of the Interface .........................................................................................................................8 Main Functional Requirements ......................................................................................................................... 8 What is Needed for the Hydraulic User Interface Program ............................................................................. 8 Installation of the Program ............................................................................................................................8 Start Screen .................................................................................................................................................. 11 Reminder Screen ...........................................................................................................................................12 Basic Screen Layout of the Hydraulic User Interface Program .................................................................12 Truck Configuration Screen .........................................................................................................................15 Mode Definition Screen ................................................................................................................................ 17 Default Flow Settings Screen .......................................................................................................................18 Load Moment Interrupt Screen ................................................................................................................... 19 Features Screen ............................................................................................................................................ 20 Dynamic Control Screen ...............................................................................................................................21 Loaded Speed Reduction Screen .................................................................................................................. 22 Temperature Protection Screen ................................................................................................................... 23 Anti-Stall Screen ...........................................................................................................................................24 Calibration Screen ........................................................................................................................................ 25 Calibrating the Connected Levers/Joystick Without the Interface Software ....................................... 26 Calibrating the Connected Levers/Joystick With the Interface Software ............................................ 26 Profile Configuration Screen ........................................................................................................................26

©2014 HYSTER COMPANY

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Table of Contents

TABLE OF CONTENTS (Continued) Flow Settings Screen .................................................................................................................................... 27 Valve Settings Screen ...................................................................................................................................28 Diagnostic Screen ......................................................................................................................................... 29 Active Errors Screen .....................................................................................................................................30 Error History Screen .................................................................................................................................... 31 All Parameters Screen ..................................................................................................................................32 Installing the Hydraulic Controller Software and Read-Only Parameter File .........................................33 Calibration .............................................................................................................................................................36 Calibrating the Lever With the Hydraulic User Interface Program ..............................................................36 Calibrating the Joystick With the Hydraulic User Interface Program ......................................................... 36 Calibrating the Lever Without the Hydraulic User Interface Program ........................................................ 36 Calibrating the Joystick Without the Hydraulic User Interface Program .................................................... 36 Fault Codes ............................................................................................................................................................37 Controller Pinning .................................................................................................................................................46 This section is for the following models: H8.0-12.0XM-6 (H190-280HD2) [J007]; H13.0-14.0XM-6 (H300-330HD2) [H019]; H16.0XM-6 (H360HD2) [H019]; H10.0-12.0XM-12EC (H360HD2-EC) [H019]; H13-16XM-6, H10-12XM-12EC (H300-360HD2, H360HD2-EC) [J019]; H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS) [K007]; H16XM-9, H18XM-7.5, H16XM-12, H18XM-9 (H360-36HD, H360-48HD) [A238]

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2200 SRM 1481

General

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

Hydraulic System 1900SRM1478 Diagrams 8000SRM1500 Electrical System 2200SRM1499

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 controller. See Figure 1.

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

•

Input signals

•

Programmed functions

•

Settings

1

Description

2200 SRM 1481

1. INPUT FOR HYDRAULIC CONTROLLER 2. HYDRAULIC CONTROLLER 3. LIFT/LOWER OUTPUT OF THE HYDRAULIC CONTROLLER 4. TILT FORWARD/BACKWARD OUTPUT OF THE HYDRAULIC CONTROLLER

5. AUXILIARY OUTPUT OF THE HYDRAULIC CONTROLLER 6. APC 200 7. INSTRUMENT PANEL 8. ENGINE CONTROL MODULE (ECM)

Figure 1. System Overview 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.

The controller continually monitors the system for fault conditions, displays the appropriate fault codes, and takes action when necessary.

2

The controller requires a 24 volt power supply for operation. Power is provided through the ignition switch, the relay hydraulic controller, and a 30 amp fuse. There is a Red and Green LED next to the main connector of the controller. The Green LED is ON when the controller is powered. If a fault condition is detected, the Red LED is also illuminated.

2200 SRM 1481

CONTROL VALVE Hydraulic oil flow through the 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.

Depending on the hydraulic function, different types of solenoid are used: PVEO, PVEH, or PVEA. For hydraulic functions that just require hydraulic supply to be ON or OFF, the electrical signal is ON or OFF as well. The solenoid used is PVEO. Operating voltage is 24 volts.

Description Cycling the ignition key resets the LED to Green.

The LED will immediately turn Red if the fault condition continues.

ANALOG INPUTS Levers and Joysticks Levers and joysticks are used to proportionally control the movement of the following functions: •

Lifting and lowering

•

Tilting forward and backward

•

Aux0 (often sideshift)

•

Aux1 (often fork positioning)

For hydraulic functions that require more precise control, the actual spool position is regulated according to a PWM (Pulse Width Modulation) signal of 6–12–18 volts at the solenoid.

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

The solenoids used are PVEH or PVEA.

The controller monitors the signals provided by the levers and if the signals are out of range, the controller activates a fault code and enters a fail safe mode.

PVEH affords more precise control of the spool position and is used for the lift and lower functions.

PVEA affords less precise control of the spool position and is used for the tilt and auxiliary functions.

The actuation module has an integrated circuit (IC) that compares the controller signal/desired spool position with the actual spool position, and attempts to adjust the spool position accordingly.

A fault code will be displayed in the form of an LED light if the actual spool position cannot be matched with the desired spool position. In addition, each electrical actuation module has an LED:

Levers must be calibrated before being put into service. This provides a reference to the controller for the two extreme and neutral lever positions.

The controller converts the lever position input signal into a PWM-output signal and sends it to the control valve.

For backward lever movements, the lever output signals are linked with flow direction A. For forward lever movements, the lever output signals are linked with flow direction B. The specific lever position and connector orientation assures lever directions cannot inadvertently result in incorrect oil flow directions.

•

OFF indicates no power signal.

•

Green indicates normal operation of the control valve section.

•

Red indicates a sticking spool or an internal error in the actuation module.

Sensors

•

Flashing Red indicates an input signal fault.

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

3

Description

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: •

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

•

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

Activates Low Temperature Protection: •

The controller reduces maximum engine speed through a CAN bus message.

Activates High Temperature Protection (optional): •

The controller reduces vehicle speed through a CAN bus message.

See Programmed Features.

Pressure Sensor A pressure sensor in the main valve provides a signal to the hydraulic controller as an input for the optional features: Dynamic Control, Loaded Speed Reduction, and Load Moment Interrupt.

See Programmed Features.

DIGITAL INPUTS Switches Two auxiliary functions can be activated by manual switches (digital inputs): Aux2 and Aux3.

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 and/or tilt functions under specific circumstances. These circumstances are set by switches to interrupt an existing signal, or by the operator who activates a switch which sends a signal to the controller.

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2200 SRM 1481 Some of the following interrupt functions can be configured in the Hydraulic User Interface program from the Truck Configuration Screen: Operator Presence System (OPS) The OPS has an electrical switch in the seat which sends a signal to disable the hydraulic lift, lower, and tilt functions 1 second after the OPS switch has been activated. In order to reset the OPS and re-enable the hydraulic functions, the operator has to sit on the seat again.

Lift Interrupt (ECH) The Lift Interrupt function disables the lift and backward tilt functions during locking and unlocking of the twist locks (ECH-version).

Lift Interrupt Disabled This function disables the Lift/Height Interrupt function and can be set on the Truck Configuration screen.

NOTE: This function is NOT related to the Lift Interrupt Disable button on the Twist Module for CH trucks. On CH trucks this button provides a forced seated signal that allows repositioning of the attachment on the container.

Lowering Interrupt (ECH) This function disables the lowering function when there is a risk that lift chains may become slack.

The lowering interrupt can be disabled by pushing the override button on the container handler control box.

Height Interrupt (Optional) A proximity switch disables the lift function when a certain mast height position has been reached. The input signal connects to the same controller pin as for the Lift Interrupt function, but the setting of this input in the controller is made through the Truck Configuration screen under Height Interrupt.

2200 SRM 1481 Load Moment Interrupt (Optional) This function disables the lift and backward tilt functions via a pressure switch in the main control valve. This function also limits the maximum load that can be lifted.

CAN BUS COMMUNICATION CAN Bus communication can be considered both as an input and output signal.

The hydraulic controller communicates via the SAE J1939 CAN Bus circuit with the following controllers: •

Instrument cluster - for displaying messages on the fault code display. See Fault Codes.

•

Engine Control Module - for the Anti-Stall and Temperature Protection features. See Programmed Features.

•

Transmission Controller (APC200 or TCU) - for the Loaded Speed Reduction feature. See Programmed Features.

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, the output signals can be different than standard programming. See Settings and Programmed Features.

Description Analog outputs are used for the lift, tilt, and auxiliary functions.

Digital Outputs Digital signals are ON/OFF signals providing 24 volts when activated, and 0 volts when deactivated.

In general, digital signals are used for auxiliary functions.

For alternating PT systems there is a maximum of four digital outputs available: Digital Out Aux0, Digital Out Aux1, Digital Out Aux2, and Digital Out Aux3.

For fixed PT systems, each of the above Digital Out signals receives an additional letter designation (A or B) to indicate the different flow directions for these functions. The letters A and B correspond to flow direction as intended by the lever movement.

The connector housing on the auxiliary valve prevents incorrect connection of the signal wires.

One digital output (pin 39) is used as a power supply for all PVEA and PVEH solenoids.

Another digital output (pin 40) is used to enable the lowering functionality when there is no oil supply coming from the hydraulic pumps.

PROGRAMMED FEATURES The controller has been programmed for a number of standard features and can also be programmed for optional features. The following standard and optional features are described below:

Analog Outputs

•

Anti-Stall (Standard)

Analog signals for proportional hydraulic functions are PWM outputs and operate in a nominal range of 6-12-18 volts. The neutral position of the valve corresponds with 12 volts. 6 volts and 18 volts each determine maximum demanded flow and flow direction.

•

Temperature Protection (Standard)

•

Low Temperature Protection (Standard)

•

High Temperature Protection (Option)

•

Dynamic Control (Option)

•

Loaded Speed Reduction (Option)

For front-end equipment using fixed PT hydraulic lines, the analog output signal is between 12 and 6 volts, which determines the valve flow in one direction only. The direction of the hydraulic function is determined by a separate valve that receives a separate digital signal.

5

Description

2200 SRM 1481

Anti-Stall (Standard)

High Temperature Protection (Optional)

The Anti-Stall feature prevents the engine from stalling by reducing the hydraulic output for the lift, tilt, and auxiliary functions. When engine speed is between 850 and 600 rpm, the spool activation signal is proportionally reduced every 2 seconds. When engine speed is recovering, the reduced spool activation will increase every 4 seconds until the spools are fully activated according to the position of the lever.

The High Temperature Protection feature limits vehicle speed to 10 km/h (6 mph) when hydraulic oil temperature is above 90°C (194°F) to reduce the heat generated during braking. When High Temperature Protection is activated, the fault code hhot is displayed.

In the event engine speed is below 600 rpm, the output signal for lift, tilt, and auxiliary functions is set to zero to completely remove the hydraulic load immediately.

Temperature Protection (Standard) The Temperature Protection feature warns the operator of extreme hydraulic oil temperatures by displaying the fault code h-cold or h-hot. When h-hot is displayed, a warning light turns ON simultaneously.

Dynamic Control (Optional) The Dynamic Control feature consists of two different components: •

Dynamic Load Compensation uses information from the pressure sensor to adjust the lowering output signal.

•

Dynamic Ramp Times scales actual ramp times between a maximum increase/decrease time when the truck is fully loaded, and a minimum increase/decrease time when the truck is empty. Depending on the actual load, ramp times will vary between rapid, normal, and smooth.

Low Temperature Protection (Standard)

Loaded Speed Reduction (Optional)

Depending on the hydraulic oil temperature, engine speed is reduced proportionally in order to protect the hydraulic pumps against cavitation. See Table 1 for the relationship between temperature and maximum engine speed. When the Low Temperature Protection is activated, the fault code h-cold is displayed.

The Loaded Speed Reduction feature limits vehicle speed when the weight of the load exceeds a certain value. The required input signal is provided by the pressure sensor. The Hydraulic User Interface Program allows adjustment of both weight and limited vehicle speed.

Table 1. Temperature and Maximum Engine Speed

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Temperature

Maximum Rpm

−5°C (23°F)

Unrestricted

−10°C (14°F)

1600

−13°C (9°F)

1200

−20°C (−4°F)

1000

NOTE: Loaded Speed Reduction is different from container handler speed limitations that can be triggered either by exceeding a certain lift height for a container, or by insufficient locking of a container for model 584.

2200 SRM 1481

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

Instructions for making perform these adjustments are in the description for the Hydraulic User Interface Program. See also Table 2 for an overview of the relevant program screens.

Adjustable Parameters Truck Configuration Screen •

Aux Type/Front-end selection

•

Truck setup selection

•

Truck responsiveness selection

•

Interrupt selection

Mode Definition Responsiveness (Smooth, Medium, and Rapid)

Description Depending on the preselection of the pumps, the dealer can choose the settings for the mast and the accompanying carriage.

•

Pump Selection (factory set)

•

Mast Selection

•

Carriage Selection

Features Screen •

Dynamic Control enable/disable

•

Loaded Speed Reduction enable/disable

•

Temperature Protection enable/disable

•

Anti-Stall enable/disable

Loaded Speed Reduction Screen •

Weight/Pressure for speed limit

•

Speed Limit

Flow Settings Screen •

Lift Limit Max

•

Lowering Limit Max

•

Auxiliary 2 increase ramp-time

•

Tilt Forward Limit Max

•

Auxiliary 2 decrease ramp-time

•

Tilt Backward Limit Max

•

Auxiliary 3 increase ramp-time

•

Aux0 Limit Max A

•

Auxiliary 3 decrease ramp-time

•

Aux0 Limit Max B

•

Twist Lock (pressure) increase ramp-time

•

Aux1 Limit Max A

•

Twist Lock (pressure) decrease ramp-time

•

Aux1 Limit Max B

•

Aux2 Limit Max A

•

Aux2 Limit Max B

•

Aux3 Limit Max A

•

Aux3 Limit Max B

•

Twist Lock/Pressure Limit Max

Set Default Flow Settings Screen This screen consists of three parameters: pumps, mast, and carriage.

7

General Functions of the Interface

2200 SRM 1481

General Functions of the Interface MAIN FUNCTIONAL REQUIREMENTS •

Set the truck configuration (levers and type of front-end valves).

•

Adjust flows and valve timing.

•

Reset all changed parameters back to factory settings.

•

Provide ability to load settings from other trucks.

•

Disable features/parameters for diagnostic reasons or personal preference.

•

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

WHAT IS NEEDED FOR THE HYDRAULIC USER INTERFACE PROGRAM 1. A PC with the Hydraulic User Interface Program installed and a free USB port.

2. An IFAK interface (Hyster part number 1532578) and a IFAK Interface Cable (Hyster part number 1534009) to connect the PC with the controller on the truck.

3. A truck equipped with a hydraulic controller.

Double-click the Hydraulic User Interface Program icon. See Figure 2. The icon is placed on the PC desktop after installation.

Figure 2. Service Icon

After starting the program, a warning message displays. See Figure 3. This warning message is generated because the hydraulic user interface program is designed to support multiple controllers and the program has now detected that only one is connected. To advance to the Start screen, simply click on the Cancel button.

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 in the side console.

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

8

Figure 3. Warning Message

The Hydraulic User Interface Program screens listed below are accessible at dealer level and related parameters are adjustable.

2200 SRM 1481

General Functions of the Interface Table 2. Hydraulic User Interface Program Overview

Hydraulic User Interface Program Screen

Dealer

Affected Parameters

Hyster

Yes

Not applicable

Hyster

Yes

Not applicable

Name

Main Screen

Start Screen Reminder Screen

Truck Configuration Screen

Mode Screen (Smooth, Medium, Rapid)

Default Flow Settings Screen

Features Screen

Access Level

Subscreen

Yes

Limited

•

Aux Type/Front-end selection

•

Truck setup selection

•

Truck responsiveness selection

•

Interrupt selection

•

Imperial/Metric selection

•

Auxiliary2 increase time

•

Auxiliary2 decrease time

•

Auxiliary3 increase time

•

Auxiliary3 decrease time

•

Twist Lock increase time

•

Twist Lock decrease time Mast•selection

Limited

Carriage • selection •

Dynamic Control enable/ disable

•

Loaded Speed Reduction enable/disable

•

Temperature Protection enable/disable

•

Anti-Stall enable/disable

Yes

Loaded Speed Reduction Screen

Limited

Temperature Protection Screen

Yes

Weight/pressure • for speed limit Speed • limit Not applicable

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General Functions of the Interface

2200 SRM 1481

Table 2. Hydraulic User Interface Program Overview (Continued) Hydraulic User Interface Program Screen Name Calibration Screen

Flow Settings Screen

Main Screen

Subscreen

Access Level Dealer

Affected Parameters

Yes

Not applicable

Yes

•

Lift Limit Max

•

Lowering Limit Max

•

Tilt Forward Limit Max

•

Tilt Backward Limit Max

•

Aux0 Limit Max A

•

Aux0 Limit Max B

•

Aux1 Limit Max A

•

Aux1 Limit Max B

•

Aux2 Limit Max A

•

Aux2 Limit Max B

•

Aux3 Limit Max A

•

Aux3 Limit Max B

•

Twist Lock/Pressure Limit Max

Diagnostic Screen

Yes

Not applicable

Active Errors Screen

Yes

Not applicable

Error History Screen

Yes

Not applicable

All Parameters File Screen

Yes

Not applicable

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2200 SRM 1481

General Functions of the Interface

Start Screen

Figure 4. Start Screen The Start Screen displays automatically upon start up of the Hydraulic User Interface Program and 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.

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

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

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General Functions of the Interface

2200 SRM 1481

Reminder Screen

Figure 5. Reminder Screen The Reminder screen is an additional reminder to the user to always click on the Download Parameters button or press the F4 key to save a changed parameter 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 Truck Configuration screen.

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Basic Screen Layout of the Hydraulic User Interface Program The screens for Truck Configuration through Active Errors contain the same list of icons. These icons appear along the left-hand margin of each screen and serve as shortcuts to other screens. See Figure 6.

2200 SRM 1481

1.

2.

3.

4.

General Functions of the Interface

TRUCK CONFIGURATION SCREEN ICON FEATURES SCREEN ICON CALIBRATION SCREEN ICON FLOW SETTINGS SCREEN ICON

5.

6.

7.

8.

VALVE SETTINGS SCREEN ICON DIAGNOSTIC SCREEN ICON ACTIVE ERROR SCREEN ICON ACTIVE ERROR INDICATOR

Figure 6. Screen Layout

13

General Functions of the Interface Following is a brief description of each screen: 1. Truck Configuration Screen Contains all basic truck configuration settings and provides access to the default flow settings page.

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

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

4. Flow Settings Screen Adjusts flow demands of lift/tilt and all auxiliary functions.

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2200 SRM 1481 5. Valve Settings Screen Displays the settings for the electric/hydraulic valves. (Service Technician level only).

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

7. Active Errors Screen Provides an overview of actual active errors.

8. Active Error Indicator Takes the user to the Active Errors Screen when a number displays in the box to the left of the icon.

2200 SRM 1481

General Functions of the Interface

Truck Configuration Screen

Figure 7. Truck Configuration Screen

15

General Functions of the Interface NOTE: Check your Parts Manual to make sure this software applies to the Lift Truck you are servicing.

The Truck Configuration screen contains several drop-down list boxes for configuring the hydraulic controller to the truck to which it is connected. See Figure 7.

2200 SRM 1481 drop-down list box representing the active mode.

When clicked on, this link will take the user to the appropriate mode definition subscreen. See Figure 10.

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

The first drop-down list box on the left lists the types of front-end valve. The carriage type and accompanying valves associated with the truck will determine which choice to select. See Figure 8.

Figure 10. Hydraulic Responsiveness Drop-Down List Box NOTE: The Lift/Height Interrupt drop-down list box is an optional feature that can be enabled/disabled if the truck has the necessary hardware. The hardware may be obtained via SPED.

Figure 8. Front-End Valve Drop-Down List Box The next drop-down list box lists the possible hydraulic input devices. See Figure 9.

The Interrupt function limits the movement of the mast depending on the appropriate input. For the lift and height interrupt, an input pin on the controller is defined and when this input is active the movement of the mast is interrupted. See Figure 11. For Load Moment Interrupt, the pressure signal from the pressure transducer placed in the lift section is used. This interrupt is active at a certain pressure signal and inactive below a certain pressure signal. Both Lift/Height Interrupt and Load Moment Interrupt values are adjustable at the service/technician or engineering level of the Hydraulic User Interface program.

Figure 9. Hydraulic Input Devices Drop-Down List Box The next drop-down list box is for selecting the degree of responsiveness in the hydraulic system. In addition, a hyper link displays to the right of the

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Figure 11. Lift/Height Interrupt Drop-Down List Box

2200 SRM 1481

General Functions of the Interface

Mode Definition Screen

Figure 12. Mode Definition Screen NOTE: The arrow icon that displays in the upper left of the screen acts as a back button, indicating the active screen is a subscreen.

NOTE: The settings displayed on the Mode Definition screen for lift, lower, tilt, aux0, and aux1 can only be changed at the engineering level and are accessible via the Truck Configuration screen by clicking on the Truck Configuration icon. The settings for aux2, aux3, and twist lock pressure are adjustable at the dealer level.

See Figure 12.

Acceleration and deceleration ramp times can be defined for each function, within reasonable limits, for each analog function. See Table 3. Figure 12 illustrates the different ramping time behavior for jumping input.

Up to three lever profiles can be defined for analog functions. The icon to the right of the lever profile drop-down list displays the active configuration and when clicked on takes the user to the Lever Profile Configuration screen.

Table 3. Parameters Input Device

Adjustable Times

Lift/Lower

Min. 200 ms; Max. 2000 ms

Tilt

Min. 200 ms; Max. 2000 ms

Aux0

Min. 200 ms; Max. 2000 ms

Aux1

Min. 200 ms; Max. 2000 ms

Aux2

Min. 200 ms; Max. 2000 ms

Aux3

Min. 200 ms; Max. 2000 ms

Pressure Input

Min. 200 ms; Max. 2000 ms

17

General Functions of the Interface

2200 SRM 1481

Default Flow Settings Screen

Figure 13. Default Flow Settings Screen NOTE: The arrow icon that displays in the upper left of the screen acts as a back button, indicating the active screen is a subscreen.

and press the F4 key to save the pump setting to the controller. Changing pump settings can only be done at the service/engineering level.

The Default Flow Settings screen contains three drop-down list boxes and a set button for easy setting of the valve and flow settings. See Figure 13.

The screen is accessible via the Truck Configuration screen by clicking on the Set Default Flow Values button. See Figure 7.

Next, mast and carriage settings can be selected from their corresponding drop-down list boxes, and saved to the controller by pressing the F4 key.

Using the serial number of the truck, the hydraulic controller automatically selects the pump settings.

Check this selection against actual installed parts

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To load the default flow and valve settings for the pump, mast, and carriage, click on the Set Default Flow Settings button that appears below the drop-down list boxes.

2200 SRM 1481

General Functions of the Interface

Load Moment Interrupt Screen

Figure 14. Load Moment Interrupt Screen NOTE: The arrow icon that displays in the upper left of the screen acts as a back button, indicating the active screen is a subscreen.

NOTE: The settings displayed on the Load Moment Interrupt screen can only be changed at the engineering level, and are accessible via the Truck Configuration screen by clicking on the Truck Configuration icon.

The Cut Out Pressure value is set from where the Load Moment Interrupt is inactive. The actual pressure and a symbol that shows whether the Load Moment Interrupt is active or inactive displays making it easier to adjust the settings. See Figure 14.

Settings for Cut In Pressure and Cut Out Pressure are adjustable. The Cut In Pressure value is set from where the Load Moment Interrupt is active.

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