Hyster Forklift N30ZDRS, N35 40ZRSA265 N35ZDR, N45ZRC264 N30ZDR, N35 40ZRD470 service manual
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Hyster Forklift N30ZDRS, N35 40ZRSA265 N35ZDR, N45ZRC264 N30ZDR, N35 40ZRD470 service manual
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Hyster Forklift N30ZDRS, N35 40ZRSA265 N35ZDR, N45ZRC264 N30ZDR, N35 40ZRD470 service manual
- GENERAL The alternating current (AC) system consists of AC motors, motor controller(s), a master controller, and a dash display. The major difference between the AC system and the direct current (DC) system is the master controller performs many of the same functions that previously were performed in the motor controllers on the DC system. AC Motors The ACmotors are three-phase AC induction motors. They do not include motor brushes or commutators. An AC induction motor operates on three-phase AC power provided directly by the motor controller. The motor’s speed is controlled by the motor controller and can be changed by changing the frequency of the AC power provided to the motor
- . A speed sensor is built into the rear motor bearing, which provides RPM and direction feedback to the motor controller. Themotor controller continuously monitors motor direction and speed. Using this feedback, the AC motor control system can provide much better vehicle top speed control than is available with DC SEM systems. The ACmotors also have thermal sensors embedded in the motor windings that are continuously monitored by the motor controllers.
- Motor Controllers The motor controllers receive power from the truck’s battery and convert it into three-phase AC power at the frequencies and currents necessary to drive the respective pump and/or traction motor. Each AC induction motor provides feedback of speed, rotation direction, and temperature directly to the motor controller. The two motor controllers used to power the traction motor and hydraulic pump motor are very similar. The primary motor controller difference is in the power output rating.
- The motor controller logic board receives power from the key switch. Power to the motors can be interrupted indirectly by the key switch. The motor controllers get motor speed and temperature information directly from the motors. The motor controllers do not get any other input from the truck. Themaster controller relays speed, acceleration, and direction commands to the motor controllers. See Figure 1 and Figure 2 for the component locations. 1. TRACTION CONTROLLER 2. LIFT MOTOR 3. AUXILIARY PUMP AND MOTOR 4. MASTER AND STEERING CONTROLLERS 5. TRACTION MOTOR 6. MDU STEER MOTOR 7. CASTER STEER MOTOR (OPTIONAL) 8. PUMP MOTOR CONTROLLER Figure 1. Component Location (Top View) 1
Table of Contents:
Hyster Forklift N30ZDRS, N35 40ZRSA265 N35ZDR, N45ZRC264 N30ZDR, N35 40ZRD470 service manual
TABLE OF CONTENTS
Description ……………………………………………………………………………………………………………………………………….. 1
General…………………………………………………………………………………………………………………………………………. 1
AC Motors …………………………………………………………………………………………………………………………………. 1
Motor Controllers ………………………………………………………………………………………………………………………. 1
Master Controller ………………………………………………………………………………………………………………………. 2
Dash Display …………………………………………………………………………………………………………………………….. 2
Controller Area Network Bus (CANbus)………………………………………………………………………………………. 2
AC Transistor Motor Controller Replacement ……………………………………………………………………………………… 3
General…………………………………………………………………………………………………………………………………………. 3
General Maintenance Instructions………………………………………………………………………………………………….. 5
Special Precautions ……………………………………………………………………………………………………………………. 5
Fuses ……………………………………………………………………………………………………………………………………………. 6
Fan……………………………………………………………………………………………………………………………………………….. 6
Contactors …………………………………………………………………………………………………………………………………….. 6
Repair……………………………………………………………………………………………………………………………………….. 6
Master Controller Checks and Adjustments ………………………………………………………………………………………… 8
Function Settings………………………………………………………………………………………………………………………………. 8
General…………………………………………………………………………………………………………………………………………. 8
Troubleshooting……………………………………………………………………………………………………………………………….. 10
General……………………………………………………………………………………………………………………………………….. 10
Controller Status Light Emitting Diodes (LEDs) ……………………………………………………………………………. 11
Master Controller …………………………………………………………………………………………………………………….. 11
AC Motor Controllers ……………………………………………………………………………………………………………….. 11
Operator Status Messages ……………………………………………………………………………………………………………. 14
Status Codes ……………………………………………………………………………………………………………………………….. 18
Checking the Motor Controller ……………………………………………………………………………………………………… 90
Display Panel ………………………………………………………………………………………………………………………………….. 90
General……………………………………………………………………………………………………………………………………….. 90
Premium Display Panel ……………………………………………………………………………………………………………. 90
Standard Display Panel ……………………………………………………………………………………………………………. 91
Standard Display Functions and Features ………………………………………………………………………………………… 92
Key-On Initialization……………………………………………………………………………………………………………………. 92
Passwords……………………………………………………………………………………………………………………………………. 92
Performance Modes ……………………………………………………………………………………………………………………… 93
Battery Discharge Indicator (BDI) ………………………………………………………………………………………………… 93
Hourmeters …………………………………………………………………………………………………………………………………. 93
Standard Dash Display Service Menu Navigation ……………………………………………………………………………… 94
General……………………………………………………………………………………………………………………………………….. 94
Moving Through Menu Selections …………………………………………………………………………………………………. 94
Editing and Adding Information …………………………………………………………………………………………………… 94
Access to Service Functions ………………………………………………………………………………………………………….. 95
Service Functions ………………………………………………………………………………………………………………………… 95
Premium Display Functions and Features…………………………………………………………………………………………. 97
Key-On Initialization……………………………………………………………………………………………………………………. 97
Passwords……………………………………………………………………………………………………………………………………. 97
Operator Checklist Function…………………………………………………………………………………………………………. 97
Performance Modes ……………………………………………………………………………………………………………………… 97
Battery Discharge Indicator …………………………………………………………………………………………………………. 98
Hourmeters …………………………………………………………………………………………………………………………………. 98
Shelf Height Selector……………………………………………………………………………………………………………………. 98
Premium Dash Display Service Menu Navigation ……………………………………………………………………………… 99
©2008 HYSTER COMPANY i
Table of Contents AC Motor Controllers/ Display Panel
TABLE OF CONTENTS (Continued)
General……………………………………………………………………………………………………………………………………….. 99
Moving Through Menu Selections …………………………………………………………………………………………………. 99
Access to Service Functions ………………………………………………………………………………………………………… 100
Service Functions ………………………………………………………………………………………………………………………. 100
Connector Pin-Outs………………………………………………………………………………………………………………………… 102
System Logic Diagram……………………………………………………………………………………………………………………. 109
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]