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Introduces the AC motor controller for Hyster forklifts.
Essential safety guidelines for performing maintenance and repairs.
Step-by-step guide to safely discharge controller capacitors.
Illustrates the placement of key electrical components on the forklift.
Explains the AC traction motor and controller functions.
Describes using a PC for parameter adjustment and troubleshooting.
Introduces the concept and general settings of forklift parameters.
Details parameters affecting walk speed, acceleration, deceleration, and plugging.
Outlines the basic steps for diagnosing forklift issues.
Procedures for troubleshooting errors without status codes.
Steps to diagnose and fix a powered black screen issue.
Addresses mechanical causes for tiller chattering or bias.
Explains status codes and introduces fault code references.
Lists common error codes and their descriptions for diagnostics.
Diagnosing issues related to battery voltage detection.
Troubleshooting thermal cutback due to high component temperatures.
Diagnosing over-temperature conditions in the traction motor or power bridge.
Introduces the AC motor controller for Hyster forklifts.
Essential safety guidelines for performing maintenance and repairs.
Step-by-step guide to safely discharge controller capacitors.
Illustrates the placement of key electrical components on the forklift.
Explains the AC traction motor and controller functions.
Describes using a PC for parameter adjustment and troubleshooting.
Introduces the concept and general settings of forklift parameters.
Details parameters affecting walk speed, acceleration, deceleration, and plugging.
Outlines the basic steps for diagnosing forklift issues.
Procedures for troubleshooting errors without status codes.
Steps to diagnose and fix a powered black screen issue.
Addresses mechanical causes for tiller chattering or bias.
Explains status codes and introduces fault code references.
Lists common error codes and their descriptions for diagnostics.
Diagnosing issues related to battery voltage detection.
Troubleshooting thermal cutback due to high component temperatures.
Diagnosing over-temperature conditions in the traction motor or power bridge.
This document is a Service Repair Manual for the Hyster B233 (B80ZAC) Forklift, specifically focusing on its AC Motor Controller. It also covers other models including B60ZAC [B230], B60ZHD [A262], and B80ZHD [A257].
The Hyster forklift utilizes an Iskra® AC motor controller to manage the AC traction motor and the DC pump motor. For models equipped with it, the controller also supports an optional brushless DC power steering motor. Communication within the system, including interaction with the dash display and control handle, is facilitated by CANbus.
The AC traction motor is a three-phase AC induction motor, notable for not using motor brushes or a commutator. Its speed is precisely controlled by the motor controller, which adjusts the frequency of the AC power supplied. A speed sensor integrated into one of the motor bearings provides continuous feedback to the controller regarding motor direction and revolutions per minute (RPM). This feedback system enables superior vehicle top speed control compared to older DC SEM systems.
The motor controller's primary role is to convert DC power from the truck battery into the three-phase AC power required by the traction motor, at the necessary frequencies and currents. It receives power via the main contactor, which is controlled by the key switch. Inputs from the control handle and hand rail switches allow the controller to manage various lift truck functions.
The manual details various adjustable parameters that define lift truck functions. These parameters have specific value ranges to accommodate different lift truck models, sizes, and operating voltages. Adjustments can be made via the dash display or using ETACC PC software.
Key parameters include:
The manual emphasizes that parameter values are shown in ETACC format (e.g., 23.520) but will appear as three-digit numbers without decimals on the dash display (e.g., 235).
The forklift's operation is governed by the motor controller, which integrates various inputs to manage movement and functions. The system includes an on-board diagnostic system accessible via the dash display, which helps identify issues by displaying status codes.
The manual highlights the importance of understanding how parameter changes affect truck operation, advising that operators must be informed if any values are altered. It also provides guidance on connecting a laptop with ETACC software for parameter adjustment and troubleshooting.
The manual provides comprehensive safety precautions for maintenance and repair, including:
A critical maintenance procedure detailed is DISCHARGING THE CAPACITORS in the controller. This is essential to prevent electrical shock, as capacitors can retain a charge even after the battery is disconnected. The procedure involves:
The motor controllers are sealed units with no serviceable components. Troubleshooting is primarily limited to accessing status codes and following diagnostic procedures. The manual provides a detailed list of STATUS CODES (e.g., Check Battery, High Temp, Overheat, Stalled, various communication errors) with descriptions, symptoms, and probable causes with test procedures. These codes help diagnose malfunctions related to input voltages, incorrect sequences, or timing issues.
For "Powered Black Screen" errors (where the dash display powers on but shows a black screen, and hydraulic/traction functions are inoperable), the manual outlines a troubleshooting process involving:
The manual also addresses Tiller Oscillation and Bias (EPAS Option), noting that these issues are typically physical/mechanical rather than electrical. Troubleshooting involves inspecting and adjusting:
The manual explicitly states that if all other status code procedures have been followed and no problem is found, replacing the controller should be the last option, as internal failure of the controller can cause almost any status code or fault. It also warns against probing through the back of connector plugs, as this can destroy the seal and cause short circuits. Instead, it recommends checking voltage at amp-type plugs, switches, or components, or using a breakout kit for testing.
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