Hyster P2.0 Service & Repair Manual
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Hyster P2.0 Service & Repair Manual

Hyster P2.0 Service & Repair Manual

Ac motor controller
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Hyster A290 (P2.0) Forklift

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Summary of Contents for Hyster P2.0

  • Page 1 Hyster A290 (P2.0) Forklift...
  • Page 2 AC MOTOR CONTROLLER P2.0 [A290] PART NO. 4035864 2200 SRM 1507...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed 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.

  • Page 4: Table Of Contents

    Faults Menu ..............................10 Functions menu ............................11 Information Menu ............................11 Programmer Setup Menu ..........................11 Programming the Traction Motor Controller - 1311 Handset ................12 Display (BDI)/Hourmeter ............................13 Fault Codes ................................13 This section is for the following models: P2.0 [A290] ©2014 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 6 "THE QUALITY KEEPERS" HYSTER APPROVED PARTS...

  • Page 7: General

    2200 SRM 1507 General General This section describes the AC Motor Controller. CAUTION Procedures are outlined for controller programming and troubleshooting. To avoid controller damage, always disconnect the battery before disconnecting any cables from SAFETY PRECAUTIONS the controller. Discharge the capacitor, and never put power to the controller with any power wire disconnected.

  • Page 8: Description

    Description 2200 SRM 1507 Legend for Figure 1 1. CONTROLLER 2. POSITIVE CONNECTION 3. INSULATED JUMPER WIRES 4. 100-OHM, 25-WATT RESISTOR 5. NEGATIVE CONNECTION Figure 1. Discharging the Capacitors Description AC MOTOR CONTROLLER PRINCIPLES OF OPERATION The controller is a solid-state, AC motor controller. The Traction Motor Controller uses a sophisticated It can control the traction motor, brake, and hy- microprocessor to control the logic and operation of...

  • Page 9: Install

    2200 SRM 1507 Description INSTALL 1. Make certain the mounting surface for the trac- tion motor controller is clean. There should be no dirt between the contactor panel mounting plate and the traction motor controller. 2. Connect wires and cables to controller termi- nals.
  • Page 10 Description 2200 SRM 1507 Table 1. Program Menu Parameter Listing Default Parameter Units Range Description Setting Main Menu Max time for tiller in opening position with Interlock Timeout 0 - 120 no input to controller 0 - None, 1 - Reverse Only, 2 - Forward & Buzzer Option 0 - 2 Reverse...
  • Page 11 2200 SRM 1507 Description Table 1. Program Menu (Continued) Parameter Listing Default Parameter Units Range Description Setting Braking time required when butterfly is Max Deceleration 0.1 - 5 fully reversed from full speed Braking time required when butterfly is re- Neutral Braking 0.1 - 5 leased to neutral from full speed...

  • Page 12: 1311 Programmer Handset

    1311 Programmer Handset 2200 SRM 1507 Table 1. Program Menu (Continued) Parameter Listing Default Parameter Units Range Description Setting Preset Pump Hourme- When replacing controller, resets pump On/Off ters hourmeters Motor Temperature Control Temperature limit when current to motor is Temperature Hot °C reduced...

  • Page 13: Menu Navigation Key

    2200 SRM 1507 1311 Programmer Handset Menu Navigation Key The menu navigation key is a 4-position switch that allows you to move up and down a menu list using the up or down arrows, or you can open and close submenus using the right and left arrows.

  • Page 14: Data Increase/Decrease Key

    1311 Programmer Handset 2200 SRM 1507 Data Increase/Decrease Key WARNING The data increase/decrease key allows the adjust- The capacitor in the traction motor controller can ment of various parameter settings. Press the (+) hold an electrical charge after the battery is dis- side of the data increase/decrease key to increase a connected.

  • Page 15: Main Menu Selections

    2200 SRM 1507 1311 Programmer Handset 5. Install drive unit compartment cover. 6. Reconnect the battery. MAIN MENU SELECTIONS Program Menu The program menu will contain submenus of ad- justable parameters downloaded to the program- mer from the motor controller. The motor controller can be setup for specific operating conditions by changing the parameters that can be accessed through the program menu selections.

  • Page 16: Faults Menu

    1311 Programmer Handset 2200 SRM 1507 Figure 10. Menu Selection Figure 11. Menu Selection Faults Menu The FAULTS menu will provide the present status of the motor controller and access to past fault his- tory. The fault history is uploaded to the program- mer when the programmer is connected to the mo- tor controller.

  • Page 17: Functions Menu

    2200 SRM 1507 Programming the Traction Motor Controller - 1311 Handset Functions menu Information Menu The FUNCTIONS menu is used to copy data be- The INFORMATION menu will display informa- tween motor controllers or reset the data in a con- tion about the controller.

  • Page 18: Programming The Traction Motor Controller - 1311 Handset

    Programming the Traction Motor Controller - 1311 Handset 2200 SRM 1507 Programming the Traction Motor Controller - 1311 Handset 8. Select the PROGRAM menu on the program- WARNING mer handset. NEVER adjust function settings outside the range 9. Use the up or down arrows on the menu navi- recommended for the specific truck model.

  • Page 19: Display (Bdi)/Hourmeter

    2200 SRM 1507 Display (BDI)/Hourmeter 16. Discharge the capacitors in the traction motor WARNING controller by connecting a 100-ohm, 25-watt re- sistor across the controller's B+ and B− termi- The capacitor in the traction motor controller can nals using two insulated jumper wires. hold an electrical charge after the battery is dis- connected.
  • Page 20 Fault Codes 2200 SRM 1507 Status Code Display Message Fault Fault 12 Controller Overcurrent Description Causes Main contactor open Short circuit in traction motor All truck functions disabled Motor parameters are incorrect Brake activated Controller fault Troubleshooting 1. Turn off and restart the truck. 2.
  • Page 21 2200 SRM 1507 Fault Codes Status Code Display Message Fault Fault 15 Controller Severe Under Temp Description Causes Main contactor open Controller is being operated below −40°C All truck functions disabled Brake activated Troubleshooting 1. Check the value of the parameter Main Menu Monitor / Controller / Temperature. 2.
  • Page 22 Fault Codes 2200 SRM 1507 Status Code Display Message Fault Fault 17 Severe Undervoltage Description Causes Traction reduced Incorrect battery parameters Battery resistance too high Battery disconnected during truck operation Loss of capacitor chare to below critical limit Fuse to key switch open Main contactor not closing Troubleshooting 1.
  • Page 23 2200 SRM 1507 Fault Codes Status Code Display Message Fault Fault 21 Controller Undertemp Cutback Description Causes Reduced performance Controller is being operated below −30°C Troubleshooting 1. Check the value of the parameter Main Menu Monitor / Battery /Controller / Temperature. 2.
  • Page 24 Fault Codes 2200 SRM 1507 Status Code Display Message Fault Fault 24 Overvoltage Cutback Description Causes Braking reduced Battery voltage too high during regen braking Incorrect battery parameters Battery resistance too high to supply regen current Voltage at capacitors above maximum limit Troubleshooting 1.
  • Page 25 2200 SRM 1507 Fault Codes Status Code Display Message Fault Fault 28 Motor Temp Hot Cutback Description Causes Reduced traction Motor temperature has exceeded parameter limit Motor temperature parameters incorrect Troubleshooting 1. Check values of parameters Main Menu Monitor / Motor / Temperature and Inputs / Analog 2. 2.
  • Page 26 Fault Codes 2200 SRM 1507 Status Code Display Message Fault Fault 32 EM Brake Driver Open/Short Description Causes Truck stops Brake coil driver open or shorted Brake activated Troubleshooting 1. Check the wiring between the controller and the brake. Check for clean and tight connections. 2.
  • Page 27 2200 SRM 1507 Fault Codes Status Code Display Message Fault Fault 35 PD Open/Short Description Causes Auxiliary function inoperable Auxiliary function driver open or shorted Connector not making good contact Wiring damaged Troubleshooting 1. Check wiring and insure connectors are clean and making good contact. 2.
  • Page 28 Fault Codes 2200 SRM 1507 Status Code Display Message Fault Fault 38 Main Contactor Welded Description Causes Main contactor open Main contactor tips are welded All truck function disabled Phases U and V of traction motor are open Brake activated Troubleshooting 1.

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A290

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