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CONTROLLER
B60Z AC [B230];
B80Z AC [B233]
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 Mainte-
nance section.
Keep the unit clean and the working area clean and orderly.
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.
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 condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
AC Motor Controller Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Description ......................................................................................................................................................... 2
Electrical System ........................................................................................................................................... 2
AC Traction Motor..................................................................................................................................... 3
Controller................................................................................................................................................... 3
Service PC Connection .............................................................................................................................. 3
Parameters ......................................................................................................................................................... 3
General ........................................................................................................................................................... 3
Parameter Description....................................................................................................................................... 4
Parameters..................................................................................................................................................... 4
Extended Shift........................................................................................................................................... 4
Walk Speed (Both Directions) ................................................................................................................... 4
Hi Speed (FWD)......................................................................................................................................... 5
Hi Speed (REV).......................................................................................................................................... 5
Minimum Acceleration.............................................................................................................................. 5
Maximum Acceleration ............................................................................................................................. 5
Plugging ..................................................................................................................................................... 5
ADS-Throttle ............................................................................................................................................. 5
ADS-Neutral .............................................................................................................................................. 5
Pick Acceleration ....................................................................................................................................... 5
Pick Deceleration....................................................................................................................................... 5
Battery Full Voltage .................................................................................................................................. 5
Battery Empty Voltage.............................................................................................................................. 5
Min Steering Assist (High Speed FWD)................................................................................................... 5
Min Steering Assist (High Speed REV) ................................................................................................... 5
Maximum Steering Assist ........................................................................................................................ 6
Troubleshooting.................................................................................................................................................. 6
General ........................................................................................................................................................... 6
Status Codes .................................................................................................................................................. 6
Dash Display ...................................................................................................................................................... 52
General ........................................................................................................................................................... 52
Startup ........................................................................................................................................................... 52
Status LED .................................................................................................................................................... 52
Performance Mode Indicator......................................................................................................................... 52
Hourmeter...................................................................................................................................................... 53
Battery Charge Indicator .............................................................................................................................. 53
Fault Log ........................................................................................................................................................ 53
Connector Pin-Outs............................................................................................................................................ 54
System Logic Diagram....................................................................................................................................... 55
B60Z AC [B230];
B80Z AC [B233]
HYSTER
APPROVED
PARTS
2200 SRM 1286 General
General
This section describes the Iskra motor controller
and dash display used in B60Z AC and B80Z AC lift
trucks. Procedures are outlined for controller pro-
gramming and troubleshooting.
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has
been disconnected. DO NOT use a screwdriver
to discharge the traction motor controller.
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments,
and connecting or disconnecting a handset or
PC.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
sure to use proper procedures when servicing
the controller.
1
Description 2200 SRM 1286
Description
ELECTRICAL SYSTEM power steering motor. The controller uses CANbus
communication to interact with the dash display and
The Iskra AC motor controller controls the AC trac- the control handle. See Figure 2.
tion motor and the DC pump motor. The controller
can also be used with the optional brushless DC
2
2200 SRM 1286 Parameters
Parameters
GENERAL Parameters can be adjusted through the dash dis-
play. The factory default values listed in Table 1 are
A parameter is a measurement or a setting that de- the recommended settings for new units. These set-
fines a lift truck function. A specific function param- tings will give satisfactory performance for most ap-
eter works with other function parameters to control plications.
the operation of the lift truck.
WARNING
WARNING If any of the parameter values are changed, the
The parameter for each function has a value operators must be told the lift truck will oper-
range so the motor controller can be used on ate differently.
different models of lift trucks. This variation
is needed for lift trucks of different sized and NEVER adjust any of the following parameters
operation voltages. Adjustment of a function without using the procedures and settings
to the wrong number value for your lift truck given in this section.
model can cause the truck to operate differ-
ently than normal. This different operation of Function Parameter Descriptions in this section
the truck can cause an injury. contains descriptions for the different parameters.
These parameters can also be accessed using the
NOTE: Table 1 shows the factory default setting for ETACC PC software.
each parameter that is adjustable by the user.
3
Parameter Description 2200 SRM 1286
Parameter Description
PARAMETERS Extended Shift
This parameter when on, will reduce traction perfor-
WARNING mance by 15% to provide extended battery shift life.
If any of the parameter values are changed, the The parameter may be set to the OFF or ON condi-
operators must be told the lift truck will oper- tion.
ate differently.
4
2200 SRM 1286 Parameter Description
Hi Speed (FWD) the rate of deceleration; the truck will coast until it
comes to a stop. Increasing the value will increase
This parameter sets the maximum forward speed of the rate of deceleration. Decreasing the value will
the lift truck when the truck is in Ride mode. In- decrease the rate of deceleration.
creasing the setting increases the speed. Decreasing
the setting will decrease the speed. Pick Acceleration
Hi Speed (REV) This parameter controls the rate of acceleration
when the coast control switch is activated. Increas-
This parameter sets the maximum reverse speed of ing the value will increase the rate of acceleration.
the lift truck when the truck is in Ride mode. In- Decreasing the value will decrease the rate of accel-
creasing the setting increases the speed. Decreasing eration.
the setting will decrease the speed.
Pick Deceleration
Minimum Acceleration
This parameter controls the rate of deceleration
This parameter sets the minimum acceleration rate when the coast control switch is released. Increas-
of the lift truck when the truck is in traveling at the ing the value will increase the rate of deceleration.
lowest throttle. Increasing the setting increases the Decreasing the value will decrease the rate of decel-
minimum rate of acceleration. Decreasing the set- eration. Setting the value at 1 will result in no effect
ting will decrease the minimum rate of acceleration. on the rate of deceleration; the truck will coast until
it comes to a stop.
Maximum Acceleration
Battery Full Voltage
This parameter sets the maximum acceleration rate
of the lift truck when the truck is traveling at max- This is the battery voltage in millivolts at which the
imum throttle. Increasing the setting increases the battery is considered fully charged. Increasing the
maximum rate of acceleration. Decreasing the set- setting increases the voltage. Decreasing the setting
ting will decrease the maximum rate of acceleration. reduces the voltage.
5
Troubleshooting 2200 SRM 1286
Maximum Steering Assist rest or very low speed. Increasing the parameter set-
ting will increase the amount of assist. Decreasing
This parameter sets the maximum steer assist pro- the setting will decrease the amount of assist.
vided by the steering motor when the lift truck is at
Troubleshooting
GENERAL Tools and test equipment required are:
Clip Leads
The controllers are sealed units with no serviceable Digital Multimeter (20,000 ohms per volt)
components. Troubleshooting is usually limited to Basic Hand Tools
accessing status codes and following the diagnostic
procedures listed in the status code charts. Check resistance on the proper scale from frame to
power and controller terminals. Resistance of less
Use standard testing procedures to verify inputs and than 20,000 ohms can cause misleading symptoms.
outputs when necessary. Resistance of less than 1000 ohms indicates a short
and should be corrected immediately.
CAUTION The on-board diagnostic system employed on this lift
Never attempt to probe through the back of truck can assist in the troubleshooting process. Read
the connector plugs of the motor controller. and be familiar with the instructions for accessing
The plugs are special sealed plugs. Probing and using the dash display diagnostic system.
through the back of the plugs will destroy the
seal and can cause a short circuit. If a circuit Prior to troubleshooting systems and components on
must be tested for voltage, check for voltage this lift truck, ensure the battery is the correct volt-
at an amp-type plug, a switch, or a component. age and is fully charged. Make sure the battery con-
If a circuit is suspect, check the circuit for nector contacts are clean of corrosions and the bat-
continuity from the front (pin end) of the plug. tery polarity within the connector is correct. Inspect
to ensure all fuses are correct and have not failed.
Standard probes are too large to be inserted Ensure the key switch is in the ON position when
into the center of the female pins (sockets) of making voltage checks or checking the operator of a
the special sealed plugs and can expand the component.
pins. Expanded pins will not provide good con-
nections once the plug is reconnected. The con- Many faults noted by lift truck systems are the result
nectors are shaped to allow the insertion of a of loose wiring connections and/or broken or shorted
flat blade screwdriver into the connector. After wiring within the lift truck. Begin the troubleshoot-
inserting the screwdriver into the connector, ing process by carefully inspecting the wiring involv-
attach probes with alligator clips to the shank ing the device or devices noted by the on-board diag-
of the screwdriver to obtain readings. An addi- nostics system.
tional method would be to use a breakout kit.
STATUS CODES
If the controller detects an issue, a status code is dis-
played on the display panel. Make sure the parameter values are correct for your
lift truck to ensure the trouble is not just an incorrect
Once the status code number is obtained, follow the setting. See function settings to set the correct pa-
procedures outlined in the status code charts of this rameter values. If there is no status code display and
manual to determine the problem. the lift truck does not operate correctly, there may be
a fault in the master controller.
NOTE: Due to the interaction of the controller with
all lift truck functions, almost any status code or con- The status codes are numbers for malfunction or lift
troller fault could be caused by an internal failure of truck operation that are not correct and that the mo-
the controller. After all other status code procedures tor controller can sense. The master controller will
have been followed and no problem is found, the con- indicate this code number on the LCD screen of the
troller should be replaced as the last option to correct display panel.
the problem.
6
2200 SRM 1286 Troubleshooting
NOTE: There are identifiers to determine which de- NOTE: A status code indication does not always mean
vice generated the code: that there is a malfunction. A temporary operation
Xy = XXXX (Co 23538) condition can cause a status code display.
Co = Controller
Ep = PAS Unit These code numbers are only indicators that may
Ti = Steer Handle Card help diagnose a possible malfunction. A short de-
scription of the different status codes is shown in Ta-
The controller senses the following types of malfunc- ble 2.
tion:
Input voltages that are too high or too low The Fault Message charts in this section have a more
Input voltages in the wrong sequence or complete description of the status code, the circuit
Correct input voltages that occur at the wrong time that has generated the input for the status code, the
symptom, and the possible cause.
Code Description
9024 Controller failure of the traction motor power circuit
9088 Pump motor shorted
9089 Pump motor open
9090 Pump at relief
9091 Controller failure of the pump motor power circuit.
12816 Controller internal voltage over 36 volts
12819 Incorrect voltage battery connected
12832 Controller internal voltage less than 16 volts
12835 Incorrect voltage battery connected
16912 Controller power section is over temperature
7
Troubleshooting 2200 SRM 1286
Code Description
21553 Hi Speed switch is closed at startup
21555 Lift or lower switch is closed at startup
21568 Main contactor circuit is open
21569 Main contactor circuit is shorted to B+
21570 Main contactor circuit is open
21571 Main contactor circuit is shorted to B
21588 Internal failure of the power steering unit
29445 Traction motor encoder failure
29448 Steer handle switch closed at startup
29456 Error in steer handle card speed/direction sensor
29458 Steer handle sensor is out of limits
29472 Failed or maladjusted sensor
33056 Controller cannot establish communication with steer handle card
33057 Controller cannot establish communication the power steering controller
36864 Power Steering security line set to LOW
65281 Power steering torque sensor has failed
65282 Mechanical failure within the power steering system
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2200 SRM 1286 Troubleshooting
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Troubleshooting 2200 SRM 1286
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Troubleshooting 2200 SRM 1286
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Troubleshooting 2200 SRM 1286
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Troubleshooting 2200 SRM 1286
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Troubleshooting 2200 SRM 1286
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2200 SRM 1286 Troubleshooting
25
Troubleshooting 2200 SRM 1286
DESCRIPTION SYMPTOM
Controller has lost communication with Traction and hydraulic systems will not operate.
the steer handle card.
Probable Causes and Test Procedures
1. Ensure all wiring connections between the steer handle card and the controller are tight and secure.
2. Measure resistance between pin #A and pin #B at the Service PC Connection.
a. Resistance should be approximately 40 ohms.
i. If resistance is greater than 90 ohms, check wiring for broken or shorted condition.
3. Check for continuity between pin #1 at the steer handle card connector and pin #28 at the controller
connector.
a. Repair any broken wiring.
4. Check for continuity between pin #2 at the steer handle card connector and pin #27 at the controller
connector.
a. Repair any broken wiring.
5. Check for continuity between pin #4 at the steer handle card connector and pin #29 at the controller
connector.
a. Repair any broken wiring.
26
2200 SRM 1286 Troubleshooting
27
Troubleshooting 2200 SRM 1286
DESCRIPTION SYMPTOM
Controller has detected an open circuit Hydraulic system will not operate.
in the lower valve.
Probable Causes and Test Procedures
1. Disconnect the pump coil connector at the lift pump.
2. Measure the resistance across pins from the pump coil.
a. Resistance should be approximately 1 ohm.
i. Replace the coil.
3. Check for open circuit condition in wire #150 and wire #86 from the connector to pin #22 and pin #23 at
the controller.
a. Repair broken wiring or loose connections.
28
2200 SRM 1286 Troubleshooting
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Troubleshooting 2200 SRM 1286
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48
2200 SRM 1286 Troubleshooting
49
Troubleshooting 2200 SRM 1286
50
2200 SRM 1286 Troubleshooting
51
Dash Display 2200 SRM 1286
Dash Display
GENERAL If there is a fault noted by the lift truck controller
and the controller has prevented traction and hy-
The dash display is a multifunction device. It con- draulic functions, the LED will be solid red.
tains a truck status LED and an LCD which dis- When the battery charge reaches 75% of full
plays the performance mode indicator and the bat- charge, the horn will sound and the LED will
tery charge indicator. The menu system can be ac- alternately blink from red to green.
cessed through the dash display by starting the truck If the controller has noted a condition that require
in service mode and entering the proper password. the lift truck to operate at a reduced performance
See Figure 3. level, the LED will blink red.
STARTUP
When the key is turned to the ON position and the
handle is in the full upright position, all segments
of the display will be illuminated and the horn will
beep twice. The LED will flash red, green, and then
go blank momentarily. Then the display will show
the truck mode setting and the hourmeter reading.
STATUS LED
The status LED is located in the top center of the dis-
play. When the key switch is in the ON position, the
LED is on. The LED can indicate in either red or
green depending on the information being communi-
cated. Figure 4. Performance Mode Screen
When the lift truck key is in the OFF position, the
LED will be OFF.
When the lift truck is operating normally, the LED
will be solid green when the key is in the ON posi-
tion.
52
2200 SRM 1286 Dash Display
HOURMETER
The hourmeter accumulates hours when the key is
in the ON position and main contactor is closed. The
hourmeter is capable of showing five digits and dis-
plays complete hours. See Figure 5. At truck startup,
the display will show the truck hours for 10 seconds
after the key has been turned to the ON position. The
hourmeter reading will be turned off if the control
handle is moved to the operating position any time
within the 10 second display period.
FAULT LOG
The Fault Log menu will list the truck system initiat-
ing the fault, the error code associated with the fault,
the hourmeter reading when the fault occurred, the
number of times the fault has been logged, and the
system temperature when the fault occurred. See
Figure 7. The Fault Log auto scrolls. The system
will retain the last ten faults noted.
Figure 5. Hourmeter
53
Connector Pin-Outs 2200 SRM 1286
Connector Pin-Outs
Controller Connector (CPS 05)
Pin Wire Number Function
1 W10 - AC RED Battery Positive
2 W342 - A High Speed
3 W26 - A Aux. Lift Switch
4 W27 - A Aux. Lower Switch
5 W28 - A Steer Handle Card
6 W98 - AC Steer Handle Switch
7 W99 - C RED Coast Switch (Optional)
8
9
10 W574 - PS Power Steer Encoder (Optional)
11 W25 - A Aux. Horn Switch
12
13
14 W730 - A RED Cruise Solenoid (Optional)
15
16
17
18 W79 - M RED Main Contactor Coil
19
20 W45 - H Horn
21
22 W150 - A Pump Coil (+)
23 W86 - A Pump Coil ( )
24
25 W386 - A Traction Motor Temp Sensor
26 W354 - TS RED Steer Handle Sensor (Optional)
27 W901/H - WHT CAN Hi
28 W900/L - BLK CAN Lo
29 W102/BARE - GRN Traction Motor Temp Sensor
30 W250 - E Traction Motor Encoder
31 W577 - E Traction Motor Encoder
32 W578 - E Traction Motor Encoder
33
34
35
54
2200 SRM 1286 System Logic Diagram
CANbus
CANbus
PAS |
Service
CANbus
PC Connection
55
NOTES
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