AUTOSHIFT TRANSMISSION TRANSMISSI ON CONTROLLER CONTROLLER H8.00-12.00XM H8.00-12.00XM (H170-280HD) [F007]; H13.00-16.00XM H13.00-16.00XM (H300-360HD) [E019]; H10.00-12.00XM-12EC H10.00-12.00XM-12EC (H360EC-HD) [E019]
PART NO. 1493993
1300 SRM 932
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, fastened, and that the load being lifted is balanced. balanced. Make sure the crane, cables, 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 Disconnect the battery ground cable on internal combustion combustion lift trucks. • Always use correct blocks blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating the Operating Manual or Manual or the Periodic the Periodic Maintenance section. nance 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 parts when making repairs. repairs. Replacement 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. • Alway Alwayss fast fasten en a DO NOT OPERA OPERATE TE tag tag to the the cont contro rols ls of of the the unit unit when when makin making g repai repairs rs,, or if the unit needs repairs. • Be sure to follow the WARNING and WARNING and CAUTION notes CAUTION notes in the instructions. • Gasolin Gasoline, e, Liq Liquid uid Petrol Petroleum eum Gas (LPG), (LPG), Compre Compresse ssed d Natural Natural Gas (CNG), (CNG), and Diesel Diesel fuel fuel are flammable. flammable. Be sure to follow the necessary necessary safety precautions precautions when handling these fuels and when working on these fuel systems. • Batteries Batteries generate generate flammable gas when they are being charged. 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!
Autoshift Transmission Controller
Table of Contents
TABLE OF CONTENTS General ............................................................................................................................................................... 1 Autoshift Control Module .................................................................................................................................. 1 Transmission Shift Control Valve ..................................................................................................................... 1 Autoshift Functions ........................................................................................................................................... 2 System Interaction With Operator Display ................................................................................................. 2 Error Code Descriptions ................................................................................................................................ 2 System Audible Alarm .................................................................................................................................. 2 Park Brake Interlock ..................................................................................................................................... 4 System Reset/Override .................................................................................................................................. 4 System Degraded Operating Mode ............................................................................................................... 4 System Failure Mode..................................................................................................................................... 4 Transmission Oil High-Temperature Fault.................................................................................................. 4 Loss of Transmission Oil Pressure Fault ..................................................................................................... 4 Controller Bypass .......................................................................................................................................... 5 Automatic/Manual Shift Mode...................................................................................................................... 5 Automatic Transmission Shifting ................................................................................................................. 5 Manual Transmission Shifting ..................................................................................................................... 6 Direction Change ........................................................................................................................................... 6 Direction Change Inhibit .............................................................................................................................. 6 Downshift Inhibit .......................................................................................................................................... 7 Driveshaft Engagement Inhibit .................................................................................................................... 7 Lift Height Transmission Interrupt (Optional) ............................................................................................ 7 Engine Dethrottle (Optional) ........................................................................................................................ 8 Autoshift Hardware ........................................................................................................................................... 8 Autoshift Lever .............................................................................................................................................. 8 Speed Sensors ................................................................................................................................................ 9 Transmission System Monitor Diagnostics ...................................................................................................... 10 Controller Parameter Adjustment Software User Interface ........................................................................... 10 User Interface Description ............................................................................................................................ 10 Components Required to Communicate With Controller ............................................................................ 10 Userlink Installation Instructions ................................................................................................................ 10 Start Procedures ............................................................................................................................................ 10 Controller Product Codes .............................................................................................................................. 10 Main Menu Description ................................................................................................................................. 11 Language Selection........................................................................................................................................ 11 Help Menu...................................................................................................................................................... 11 PC Serial Communication Port ..................................................................................................................... 12 Monitor Screen............................................................................................................................................... 12 Event Log ....................................................................................................................................................... 12 Parameter Adjustment .................................................................................................................................. 13 Current Parameters .................................................................................................................................. 13 Load Parameters ....................................................................................................................................... 14 Restore Factory Parameters ..................................................................................................................... 14 Load Controller Software from File ......................................................................................................... 14 Exit Menu....................................................................................................................................................... 14 Controller Connector Pin-Out Tables ............................................................................................................... 16
©2004 HYSTER COMPANY
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Table of Contents
Autoshift Transmission Controller
TABLE OF CONTENTS (Continued) This section is for the following models: H8.00-12.00XM (H170-280HD) [F007]; H13.00-16.00XM (H300-360HD) [E019]; H10.00-12.00XM-12EC (H360EC-HD) [E019]
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1300 SRM 932
Transmission Shift Control Valve
General The autoshift transmission controller is installed on units using the T-50 powershift transmission. See the sections Three-Speed Powershift Transmission, Description and Operation (Hyster Model T-50) 1300 SRM 930 and Three-Speed Powershift Transmission, Repairs (Hyster Model T-50) 1300 SRM 931 and for transmission information. This section contains the description, replacement, checks, and adjustments for the autoshift controller. The autoshift system provides a weatherproof, automatic shift control system with manual override capabilities for the T-50 transmission that automatically shifts 1-2-3 gears in forward or reverse based on preset, fully programmable parameters. The system includes a NACCO-designed controller with logic that utilizes a Motorola 68HC16 microcontroller, column-mounted shifter or MONOTROL pedal capabilities, engine rpm sensor, transmission output rpm sensor, throttle pedal switch assembly, error code/warning lights, audible alarm, a system communication port, and software providing parameter adjustments and error log access.
The control lever or MONOTROL pedal sends an electrical direction signal directly to either the forward or reverse solenoid. The forward solenoid operates the forward spool of the transmission control valve, and the reverse solenoid operates the reverse spool. The speed range signal goes to the control module. Inputs from sensors also give the control module signals for correct operation. The following information goes to the control module: engine rpm, transmission output rpm, transmission oil temperature, transmission oil pressure, gear selector position, park brake on or off, ignition switch on or off. The control module uses the inputs and its programming for correct operation of the solenoid valves. The solenoid valves move the range spools of the transmission control valve. For the complete electrical wiring of this system, see the section Diagrams in the Service Manual of your lift truck.
Autoshift Control Module The autoshift control module is located in the electrical console of the operator compartment. An electrical connector connects the module to the rest of the system with pins for power, inputs, and outputs. The system is protected by 1-amp and 10-amp fuses. These fuses should be removed before removing or reconnecting the controller harness. Resetting the controller is accomplished by cycling the ignition switch (OFF/ON) or removing the 1-amp fuse. An electrical connector, located in the fuse panel, allows connection of a personal computer (PC) to set the operating
parameters. The operator can also manually override the system. The controller computer processes all the inputs from the truck sensors. It then produces output signals to operate the direction solenoid valves for the selected direction. It also produces output signals to operate the solenoid valves for control of the gear range of the transmission. Output signals also depend on the operating parameters as previously set.
Transmission Shift Control Valve The transmission shift control valve is located on the transmission and has two directional control and two range control electric solenoid valves. The transmission electric solenoid valve functionality is as follows: • Forward - Forward solenoid energized • Neutral - No solenoids energized
• Reverse - Reverse solenoid energized • First Gear - First gear range solenoid energized • Second Gear - Second gear range solenoid energized • Third gear - No range solenoids energized, the range spool de-energized position
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Autoshift Functions
1300 SRM 932
Autoshift Functions The functions of the autoshift system are listed below and described in the following sections. • System Interaction With Operator Display • Error Code Descriptions • System Audible Alarm • Park Brake Interlock • System Reset/Override • System Degraded Operating Mode • System Failure Mode • Transmission Oil High-Temperature Fault • Loss of Transmission Oil Pressure Fault • Controller Bypass • Automatic/Manual Shift Mode • Automatic Shifting • Manual Shifting • Direction Change • Direction Change Inhibit • Downshift Inhibit • Drive Shaft Engagement Inhibit • Lift Height Transmission Interrupt (Optional) • Engine Dethrottle (Optional)
SYSTEM INTERACTION WITH OPERATOR DISPLAY The operator display incorporates a dual role LCD that displays an hourmeter under normal operating conditions and at startup or an alphanumeric error code that identifies transmission system error/exceeded parameter conditions. The display also incorporates a transmission low oil pressure and high oil temperature light, transmission oil pressure and oil temperature gauges, and a transmission warning light. A steering column-mounted warning light will illuminate when a system error condition exists, requiring the operator to review the operator display. Exceeded parameter conditions do not illuminate the steering column warning light. The transmission system warning light in the operator display will illuminate solid when an error condition exists or flash at a rate of two times per second when an exceeded parameter condition exists. Error/exceeded parameter conditions take precedence over the hourmeter and will display an error code to identify the error condition. When the error condition is resolved and the transmission system
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restores full functionality, the hourmeter returns as the normal display.
ERROR CODE DESCRIPTIONS The transmission system error codes take precedence over the hourmeter and will display the error codes listed in Table 1 as required. If multiple errors occur simultaneously, the error codes will continually scroll every 3 seconds until the error condition is resolved. When multiple errors exist, truck functionality responds to the worst case error condition. Transmission system exceeded parameters occur when the operator makes a transmission system request that is outside the normal operating parameters. The transmission system helps prevent accidental drivetrain damage from overspeed conditions. Transmission system exceeded parameters (error codes 1 through 6) are self-correcting error conditions and will return the truck to normal functionality when parameter requirements are satisfied. Transmission system errors occur when equipment failure creates a condition that could lead to possible safety issues and/or equipment damage (error codes 30 through 41) and requires component repair or replacement and a system reset to resume normal truck functionality. The normal hourmeter display will return when error conditions are corrected and truck functionality is restored.
SYSTEM AUDIBLE ALARM An audible alarm for the automatic shift control system is installed in the operator console. The audible alarm will activate when the system detects a loss of transmission oil pressure, or lift height interrupt when applicable. The alarm will reset and turn off when the exceeded parameter returns to normal operation. The alarm can be activated or deactivated with the Lift Height Transmission Interrupt (Optional) function by using a PC with the controller parameter ad justment software as described in the user-interface instructions.
1300 SRM 932
Autoshift Functions
Table 1. Error Code Descriptions ERR01
Exceeded the maximum truck speed allowing reversals.
ERR02
Exceeded the maximum truck speed allowing downshifts.
ERR03
Exceeded the maximum engine rpm allowing driveshaft engagement from neutral.
ERR04
Open.
ERR05
Exceeded the maximum lift height before activating the transmission interrupt circuit, no audible alarm.
ERR06
Exceeded the maximum lift height before activating the transmission interrupt circuit with audible alarm.
ERR07
Controller communication failure.
ERR08
Transmission speed sensor-downshift inhibit.
ERR09
Open.
ERR10
Open.
ERR11
Open.
ERR12
Open.
ERR30
Low transmission oil pressure.
ERR31
High transmission oil temperature.
ERR32
Transmission speed sensor failure.
ERR33
Engine speed sensor failure.
ERR34
Throttle positon switch failure.
ERR35
Forward solenoid failure.
ERR36
Reverse solenoid Failure.
ERR37
First gear solenoid failure.
ERR38
Second gear solenoid failure.
ERR39
Forward/reverse selected at the same time.
ERR40
Multiple range shifter positions selected at the same time.
ERR41
Transmission controller failure.
ERR42
Open.
ERR43
Open.
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Autoshift Functions
PARK BRAKE INTERLOCK Applying the park brake de-energizes the transmission directional solenoids. The park brake must be applied to adjust controller parameters. Starting the truck can be accomplished by applying the park brake, selecting neutral on the column-mounted shifter, or applying the inching pedal.
SYSTEM RESET/OVERRIDE The autoshift system can be reset by applying the park brake, turning the ignition switch OFF then back ON, or by removing and reinserting the 1-amp controller fuse located inside the fuse panel.
CAUTION Due to possible equipment damage, resetting the system and driving the truck with a fault condition present should be limited to emergency situations only. Possible conditions requiring reset: • Autoshift system not functioning correctly • Failure to establish communications with controller • System override for the loss of transmission oil pressure fault mode • System override for the high transmission oil temperature fault mode
SYSTEM DEGRADED OPERATING MODE
1300 SRM 932
In the event of an automatic shift control system failure, the controller can be bypassed to provide the truck with limited manual shift capabilities. (Note: the autoshift system safety features are not active when the controller is bypassed. See Controller Bypass and System Interaction With Operator Display.)
TRANSMISSION OIL HIGH-TEMPERATURE FAULT ERROR CODE 31
CAUTION Due to possible equipment damage, resetting the system and driving the truck with a fault condition present should be limited to emergency situations only. The operator display supplies transmission oil temperature information to the autoshift controller. If the transmission oil temperature exceeds 132 C (270 F), the truck goes into a degraded mode, the steering column-mounted warning light, the transmission system warning light, and the transmission high-temperature warning light located in the operator display illuminates solid, the transmission oil temperature gauge registers hot, the hourmeter changes to error code ERR30. The transmission will downshift to first gear as parameters permit. No upshifting will occur, and the truck will remain in a degraded operating mode until the oil temperature drops below 126 C (259 F).
If an error condition occurs or parameter value is exceeded with the truck in either automatic or manual shift modes (controller bypass excluded), the operator display will illuminate a transmission system warning light, display the appropriate error code, activate the audible alarm as required, and will either automatically shift the transmission into neutral or not allow upshifting or reversals to occur until error condition is repaired or the parameter value is satisfied. See System Interaction With Operator Display and Error Code Descriptions.
If the truck is equipped with dethrottle (optional), high transmission oil temperature will activate dethrottle until the truck slows enough to allow downshift to first gear.
SYSTEM FAILURE MODE
ERROR CODE 30
The transmission will default to neutral if there is a controller failure, loss of power to the controller, loss of power to the directional solenoids, loss of transmission oil pressure, or a speed sensor problem.
The operator display supplies transmission oil pressure information to the autoshift controller. If the transmission oil pressure drops below 1000 kPa (145 psi) for more than 3 seconds (factory preset
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The transmission overheat fault mode is active in both automatic and manual mode, but excluded when using the controller bypass.
LOSS OF TRANSMISSION OIL PRESSURE FAULT
1300 SRM 932
Autoshift Functions
value), the steering column-mounted warning light, the transmission system warning light, and the transmission oil pressure warning light located in the operator display illuminate solid, the transmission oil pressure gauge registers low oil pressure, the hourmeter changes to error code ERR31, and the audible alarm is activated. The transmission will shift into neutral 30 seconds after low oil pressure is detected and remain in neutral until the oil pressure returns, or the system is reset. The transmission low oil pressure timers can be ad justed by using a PC with the controller parameter adjustment software as described in the user-interface instructions. Timer parameter limits are 15.0 to 30.0 seconds.
CAUTION Due to possible equipment damage, resetting the system and driving the truck with a fault condition present should be limited to emergency situations only. In the event of a loss of transmission oil pressure fault condition, the autoshift system provides an override feature allowing truck movement in first gear only for a period of approximately 30 seconds. The fault condition override can be accomplished by resetting the autoshift system (turning the ignition switch OFF and restarting the truck).
CONTROLLER BYPASS In the event of a controller failure, the automatic shift control system provides controller bypass capabilities, which permits the truck to be shifted manually, gears 1-2-3 through the column-mounted gear shifter and forward/reverse directional control through the column-mounted shifter or MONOTROL pedal.
To bypass the controller, disconnect the harness from the controller located inside the operator console and install a controller bypass module. Bypassing the controller hard wires the system from the column-mounted shifter to the shift control valve via the bypass box and provides only limited system protection features. Operating in a bypass mode does not allow third gear reversals (the truck will shift into neutral) or no third gear starts when coming out of neutral (the truck will remain in neutral until the operator selects either first or second gear). Directional control in the bypass mode is achieved by moving the shifter lever or MONOTROL pedal. Gear selection in the bypass mode is achieved by rotating the shifter barrel, with position one providing first gear, position two provides second gear, and positions three or four providing third gear. See Autoshift Lever.
AUTOMATIC/MANUAL SHIFT MODE The truck can be operated in either automatic or manual shift mode, depending on the selected shifter position. See Autoshift Lever. For manual shift mode functionality when bypassing the controller, see Controller Bypass.
AUTOMATIC TRANSMISSION SHIFTING Automatic transmission upshifting occurs when the available tractive effort in the current gear is less than the tractive effort in the next higher gear, and a minimum vehicle speed is obtained. See Table 2. Automatic transmission downshifting occurs when the available tractive effort in the current gear is less than the tractive effort in the next lower gear. See Table 3.
Table 2. Automatic Transmission Upshift
Standard Upshift
Minimum Driveshaft RPM
Shift Point Torque Converter Speed Ratio
Shift Stabilize Duration
1st - 2nd
350
0.92
1.0 sec
2nd - 3rd
750
0.88
1.0 sec
Upshifting occurs at the speed ratio shift point after obtaining the minimum driveshaft rpm. A shift stabilization timer is activated after the upshift to allow engine/transmission rpm stabilization before allowing the next gear up/downshift. (No upshifts allowed if the speed ratio is > 1.)
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Autoshift Functions
1300 SRM 932
Table 3. Automatic Transmission Downshift
Standard Downshift
Maximum Driveshaft RPM
Shift Point Torque Converter Speed Ratio
Shift Stabilize Duration
2nd - 1st
225
0.5
0.5
3rd - 2nd
650
0.7
0.25
Downshifting requires a driveshaft rpm at or below the max driveshaft rpm before allowing the speed ratio shift point. After the downshift, a shift stabilize duration to allow engine/transmission rpm stabilization is required before the next gear up/downshift can occur. Automatic transmission shift mode can be achieved by rotating the shifter barrel to position three (labeled 2-3) for automatic shifting between second and third gears only (truck starts in second gear) or position four (labeled D) for full automatic shifting gears 1-2-3 (truck starts in first gear). See Autoshift Lever. The controller continuously monitors engine speed, output speed, gear shifter position, forward-reverse selection, throttle pedal position, and possible fault conditions to allow upshifting or downshifting to occur. Optional automatic transmission shifting between first and second gears only can be achieved by using a PC with the controller parameter adjustment software as described in the user-interface instructions, and activating the optional first and second gear only shift pattern. Replace the 3-2 shifter label with a 1-2 label. To select automatic shifting between first and second gears only, after changing the above parameters, rotate the shifter barrel to position three (labeled 1-2). The direction change inhibit, downshift inhibit, driveshaft engagement inhibit, transmission oil pressure and overheat fault modes are active in automatic mode, but excluded when bypassing the controller.
MANUAL TRANSMISSION SHIFTING Manual transmission shifting can be achieved by rotating the column-mounted shifter barrel to position one (labeled 1) for first gear or position two (labeled 2) for second gear. The truck will remain in the gear selected until the operator moves the shifter selecting a different gear. See Autoshift Lever. The factory default controller settings activate the direction change, downshift, driveshaft engagement inhibits, and the transmission oil pressure and transmission overheat fault modes in manual mode.
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The controller can be adjusted to turn off the direction change, downshift, and driveshaft engagement inhibits in manual mode by using a PC with the controller parameter adjustment software, as described in the user-interface instructions.
DIRECTION CHANGE Direction change (reversals) is achieved by moving either the column-mounted shifter lever or MONOTROL pedal, depending on truck configuration. The shifter is labeled F-N-R. If the truck is equipped with MONOTROL pedal, the column-mounted shifter does not have forward-reverse capabilities. See Autoshift Lever and Direction Change Inhibit.
DIRECTION CHANGE INHIBIT ERROR CODE 01 (Reversal Truck Speed Exceeded) ERROR CODE 03 (Excessive Engine RPM) The direction change inhibit prevents driveline shock and minimizes transmission clutch overheating from excessive engine and/or truck speed when changing directions. The controller will allow a direction change only after sequencing through the gears as required and slowing the vehicle to a factory controller preset speed of less than 4.0 km/h (2.5 mph) and an engine speed of 1400 rpm or less. If the gear selector is reversed on a truck with the dethrottle option, with the truck moving faster than 4.0 km/h (2.5 mph) and/or the engine speed is greater than 1400 rpm, the engine speed will automatically reduce to an idle, and the transmission will remain in gear to take advantage of the engine braking capabilities to help reduce the truck speed, the operator display will flash a transmission system warning light, the hourmeter will change to error code ERR01 and/or ERR03, indicating the reversal speed
1300 SRM 932
is exceeded and the truck is in a degraded operating mode. The transmission system will not allow a reversal to occur until both the transmission and engine speed parameters are obtained. Normal throttle control returns after reversal speed parameters are met. The direction change inhibit for manual mode can be turned off, or the allowable truck speed, or maximum engine speed for reversals can be adjusted by using a PC with the controller parameter adjustment software as described in the user-interface instructions. The maximum truck speed limit allowing reversals is 4.8 km/h (3.0 mph) or 50 rpm minimum to 400 rpm maximum. See Manual Transmission Shifting . The engine speed requirement allowing reversals can be turned off in either automatic and manual modes by using the user-interface software as described in the above paragraph. The maximum engine speed allowing reversals is 1600 rpm. The controller direction change inhibit is active in both automatic and manual modes, but excluded when bypassing the controller.
Autoshift Functions
DRIVESHAFT ENGAGEMENT INHIBIT The driveshaft inhibit function prevents driveline shock from excessive engine speed when doing re versals or engaging either forward or reverse from neutral. The controller will not allow driveshaft engagement unless the engine speed is 1400 rpm or below (factory preset parameter). If parameters are exceeded, the operator display will illuminate a transmission system warning light, the hourmeter changes to error code ERR03, indicating that driveshaft parameters are exceeded and the truck is in a degraded operating mode. The truck will remain in neutral until the engine rpm has fallen to within acceptable limits. The driveshaft engagement inhibit for manual mode can be turned off or the driveshaft engagement speed can be adjusted by using a PC with the controller parameter adjustment software as described in the user-interface instructions. Driveshaft engagement preset parameter limits are 600 to 1600 rpm. The driveshaft engagement inhibit is active in both automatic and manual modes, but excluded when bypassing the controller.
DOWNSHIFT INHIBIT ERROR CODE 02 The downshift inhibit function prevents engine, torque converter, and transmission overspeeding by not allowing downshifts to occur unless the truck speed is within the preset parameter limits. If the operator tries to downshift the transmission when the truck speed exceeds the preset downshift parameters, the operator display will illuminate a transmission system warning light, the hourmeter changes to error code ERR02, indicating that downshift parameters are exceeded and the truck is in a degraded operating mode. The truck will remain in the current operating gear and will not allow the downshift to occur until the truck slows enough to satisfy downshift parameters. See System Interaction With Operator Display. The downshift inhibit for manual mode can be turned off or the allowable truck speed for downshifts can be adjusted by using a PC with the controller parameter adjustment software as described in the user-interface instructions. The downshift inhibit is active in both automatic and manual modes, but excluded when using the controller bypass.
LIFT HEIGHT TRANSMISSION INTERRUPT (OPTIONAL) ERROR CODE 05 (Without Audible Alarm) ERROR CODE 06 (With Audible Alarm) The lift height transmission interrupt function can only be activated to operate in the automatic shift mode of operation. The lift height transmission interrupt function prevents a truck with an elevated load from tipping forward during aggressive braking conditions by limiting upshifts to control the truck speed when the load is elevated to a predetermined mast-mounted switch contact height. A normally closed limit switch or inductive proximity switch will be mounted on the mast to provide the load height signal. Actuating the switch will lose input voltage to the controller. If the lift height transmission interrupt switch is actuated prior to the preset upshift limit, the steering column-mounted warning light and the transmission system warning light in the operator display will illuminate, the hourmeter changes to display error code ERR05 or ERR06 (depending on audible alarm status), indicating that the maximum lift height parameters are exceeded, and the truck is in a degraded operating mode. The transmission will remain in the
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Autoshift Hardware
1300 SRM 932
existing gear, and will not allow upshifting above the preset upshift limit. Lowering the load below the lift height transmission interrupt switch will eliminate the error condition and return the truck to a normal operating status. If the lift height transmission interrupt switch is actuated after the preset upshift limit, the steering column-mounted warning light and the transmission system warning light in the operator display will illuminate, the hourmeter changes to display error code ERR05 or ERR06 (depending on audible alarm status), indicating that the maximum lift height parameters are exceeded, and the truck is in a degraded operating mode. The transmission will shift into neutral until either the load is lowered to eliminate the error condition or the truck slows to the preset lift height transmission interrupt upshift limit. If the transmission defaults to neutral, neutral start parameters must be satisfied before driveshaft re-engagement can occur. Adjustable lift height transmission interrupt parameters are as follows: • The lift height transmission interrupt routine can be turned on or off in the automatic mode of operation only. Factory default turns the lift interrupt routine off. • Neutral default when exceeding the upshift limit before limit switch contact can be turned on or off. Factory default turns the neutral default on. If parameters are adjusted to turn neutral default off, the audible alarm is automatically turned on and cannot be adjusted to turn off. • The audible alarm for the lift height transmission interrupt routine can be turned on or off only when
neutral default is turned on. Factory default turns the audible alarm off. If parameters are adjusted to turn neutral default off, the audible alarm is automatically turned on and cannot be adjusted to turn off. • The upshift range can be selected by entering a value of 1-3. A value of 1 allows first gear only, a value of 2 allows upshifting to second gear only, and a value of 3 allows upshifting to third gear.
ENGINE DETHROTTLE (OPTIONAL) When engine dethrottle components are installed, the transmission system has the ability to override engine speed and automatically reduce engine rpm to an idle. This happens prior to range upshifts and/or if the direction change inhibit, transmission overspeed inhibit, engine overspeed inhibit, or transmission overheat parameters are exceeded in either automatic or manual mode. After parameters are met, normal throttle control returns. The controller can be programmed to activate or deactivate the engine dethrottle in either automatic or manual mode prior to each upshift for a programmed amount of time, and remain dethrottled for a programmed amount of time after the shift occurs. The transmission system factory default parameters turn dethrottle OFF in automatic shift mode and turn dethrottle OFF in manual shift mode. Dethrottle can be turned ON and OFF in either automatic or manual shift mode, as required, by using a PC with the controller parameter adjustment software.
Autoshift Hardware AUTOSHIFT LEVER The shifter is mounted on the steering column and can select forward-neutral-reverse by moving the shifter lever to the desired position. See Figure 1. When the shifter is used in conjunction with a MONOTROL ® pedal, the shift lever is locked and does not have forward-neutral-reverse capabilities. Reversals are achieved through the MONOTROL pedal while range selections are achieved by rotating the shifter barrel. The shifter has four gear shift positions that can be selected by rotating the shifter barrel as follows:
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1 - Shifter position one (labeled 1) will manually shift the transmission into first gear and will remain there until the shifter is moved. 2 - Shifter position two (labeled 2) will manually shift the transmission into second gear and will remain there until the shifter is moved. 2-3 - Shifter position three (labeled 2-3) allows the truck to start in second gear and will automatically shift the transmission between second and third gear as parameters permit. Optional shifter position three (labeled 1-2) allows the truck to start in first gear and will automatically shift the transmission between first and second gear as parameters permit.
1300 SRM 932
Autoshift Hardware
D - Shifter position four (labeled D) will place the truck into full automatic, allowing the truck to start in first gear and shift the full range of gears as parameters permit. When the shifter is used in conjunction with a MONOTROL pedal, the shift lever is locked and does not have forward-neutral-reverse capabilities. Reversals are achieved through the MONOTROL pedal while range selections are achieved by rotating the shifter barrel. The controller program has a timer duration of 0.5 second to verify the selected gear shifter position and 1.0 second to verify the neutral shifter position (controller factory preset values). The selector position timers or optional functionality for selector position three can be adjusted by using a PC with the controller parameter adjustment software as described in the user-interface instructions. The preset parameter limits are 0.13 to 2.0 seconds.
SPEED SENSORS The engine speed sensor is a Hall-effect-type sensor that monitors the engine rpm. The engine speed sensor is mounted in the flywheel housing and counts the number of teeth on the engine flywheel per one engine revolution (controller factory preset value). If the controller loses feedback from the engine speed sensor or determines the sensor is not functional, the steering column mounted warning light and the transmission system warning light located in the operator display illuminate solid, the hourmeter changes to error code ERR33, and the transmission shifts into neutral until the error is corrected or the system is reset. See System Reset/Override. The transmission speed sensor is also a Hall-effecttype sensor that monitors the transmission output rpm (driveshaft rpm). The transmission speed sensor is mounted in the transmission output gear housing and counts the number of teeth on the output gear per one driveshaft revolution. If the controller loses feedback from the transmission speed sensor or determines the sensor is not functional, the steering column-mounted warning light and the transmission system warning light located in the operator display illuminate solid, the hourmeter changes to error code ERR32, and the truck will remain in the current operating gear and will not allow upshifting or downshifting until the error condition is corrected. See System Reset/Override. The speed sensors are four-wire sensors to include power, ground, output signal, and byte line. The byte line provides active sensor diagnostics to help establish the sensor functional status.
1. 2. 3.
HANDLE DUST COVER SWITCH
4.
ELECTRICAL CONNECTOR
The number of target teeth per revolution for both the engine and transmission speed sensors can be ad justed by using a PC with the controller parameter adjustment software as described in the user-interface instructions.
Figure 1. Autoshift Control Lever
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Controller Parameter Adjustment Software User Interface
1300 SRM 932
Transmission System Monitor Diagnostics The transmission system can be monitored for correct controller input/output signals on either a stationary or moving truck for diagnostic purposes. No transmission system parameter adjustments can be made when using the monitor function. Monitoring different input/output signals requires operator interaction by either operating and or
driving the truck and manually or automatically selecting different gears, directions, actuating switches, sensors, or sending units. The autoshift system diagnostics routine can be accessed by using a PC with the controller parameter adjustment software as described in the user-interface instructions.
Controller Parameter Adjustment Software User Interface USER INTERFACE DESCRIPTION The user-interface software for transmission system is called UserLink™. UserLink™ provides the ability to view and adjust transmission system operating parameters, access to the event log, and a monitor screen that provides real time monitoring of transmission system. The user-interface software also provides the ability to save or download parameters from/to the controller and/or a file disk.
COMPONENTS REQUIRED TO COMMUNICATE WITH CONTROLLER Minimum system requirements: • IBM compatible computer with minimum Pentium 100 MHz processor • Windows 98, Windows NT, or Windows 2000 • 3.5-inch disk drive or CD reader • An open PC serial communication port: Communication port 1, 2, 3, or 4 • Communication cable (P/N 2045415) • User-interface software available from Hyster (Part Number without password protection 1508289, with password protection 1508290)
USERLINK INSTALLATION INSTRUCTIONS 1.
Close all applications before installing UserLink™.
2.
Insert the disk or CD into the appropriate drive.
3.
Install process will start automatically.
If the install process does not start automatically: 4.
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Click OK when prompted and follow the remaining prompts.
5.
A UserLink™ shortcut icon automatically installs on Windows Desktop.
If the install process does not start automatically: 6.
Choose Start, then Run.
7.
Type A:setup.exe, D:setup.exe, or E:setup.exe, depending on your computer disk or CD drive letter.
8.
Click OK when prompted and follow the remaining prompts.
9.
The program installs to C:\program files\UserLink and is called UserLink™.
START PROCEDURES 1.
Double-click on the UserLink™ shortcut icon.
OR 2.
Choose Start, Programs, NACCO, UserLink™.
CONTROLLER PRODUCT CODES Autoshift controllers have preassigned product code numbers to establish the factory default parameter values for different power/drivetrain configurations. The controller product code is available on the main menu. The following product codes and descriptions identify the power/drivetrain configurations with specific factory settings: • Product Code 1. Perkins engine with a T-50 transmission that includes an electric solenoid range shift valve. The transmission shift valve type is not a selectable option for this product code. Dethrottle is turned off. The factory default for the
1300 SRM 932
Controller Parameter Adjustment Software User Interface
number of flywheel teeth is 126. (Product code description listed on the Main Screen: Perkins Engine - Electric Shift Transmission.) • Product Code 2. Cummins engine with a T-50 transmission that includes an electric solenoid range shift valve. The transmission shift valve type is not a selectable option for this product code. Dethrottle is turned off. The factory default for the number of flywheel teeth is 159. (Product code description listed on the Main Screen: Cummins Engine - Electric Shift Transmission.) • Product Code 3. Perkins engine with a T-50 transmission that includes an pneumatic solenoid range shift valve. The transmission shift valve type is a selectable option for this product code. Factory default parameters have the pneumatic shift valve option turned on and the electric shift valve option turned off. Dethrottle is turned on. The factory default for the number of flywheel teeth is 126. (Product code description listed on the Main Screen: Perkins Engine - Non-Electric Shift Transmission, Electric Shift Capable.) • Product Code 4. Cummins engine with a T-50 transmission that includes a hydraulic solenoid range shift valve. The transmission shift valve type is a selectable option for this product code. Factory default parameters has the electric shift valve option turned on and the hydraulic shift valve option turned off. Dethrottle is turned on. The factory default for the number of flywheel teeth is 159. (Product code description listed on the Main Screen: Cummins Engine - Electric Shift Transmission, Non-Electric Capable.)
MAIN MENU DESCRIPTION The main menu screen has a toolbar with seven selectable buttons, the controller version number, controller product number, controller serial number, controller manufacture date, and communication connection status. See Figure 2. The main menu screen has a toolbar with the following selectable buttons: • Language • Help • Com Port • Monitor • Event Log • Parameters • Exit
Figure 2. Main Menu
LANGUAGE SELECTION English is the user interface default language. the user-interface software opens to the language-selection screen that allows the selection of one of the following languages: English, German, Spanish, Italian, French, or Portuguese. UserLink™ provides an option to change languages at any time by selecting the Language button from the main menu screen toolbar. After opening the language selection screen, the user can select the required language by highlighting and clicking the OK button. Changing the language will automatically convert all display text without closing UserLink™ or restarting the computer. After selecting a language, UserLink™ automatically reverts to the main menu screen.
HELP MENU Access the Help menu by selecting the Help button from main screen toolbar. The Help menu provides detailed instructions about the features, use, and functionality of UserLink™. The Help button has a separate pull-down button that provides UserLink™ system information. To navigate through the help menu, use the scroll bar or select one of the highlighted direct links. Close the window to exit the Help guide.
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Controller Parameter Adjustment Software User Interface
1300 SRM 932
PC SERIAL COMMUNICATION PORT Changing the computer serial communication port selection is accomplished by selecting the Com Port button from the main menu screen toolbar. The user has the option of selecting serial communications ports 1 through 4. The factory default setting for the communication port selection is port 1. If communications cannot be established or if the computer serial communication port connection does not match the communication port selection in UserLink™, an error message screen will pop up and alert the user that communications were not established.
MONITOR SCREEN NOTE: Before using the monitor feature of UserLink™, secure the truck stationary by elevating the drive tires and blocking the unit to prevent truck movement or falling. Transmission system parameters cannot be adjusted when using the monitor function. Access the Transmission System Monitor screen by selecting the Monitor button from the main menu screen toolbar. The Monitor screen allows real-time monitoring/troubleshooting of transmission system. See Figure 3. The screen provides a speed ratio readout, an engine and driveshaft tachometer, a low transmission oil pressure and a high transmission oil temperature alert with red LEDs, and a display window that lists error codes. The actual gear shifter position is represented by yellow LEDs. Energized transmission solenoids are represented by green LEDs. The on/off state for ignition switch, park brake, transmission lift interrupt switch (optional), throttle switch (optional), and engine dethrottle (optional) is represented as ON by a green LED. Monitoring different input/output signals can require operator interaction by either operating and/or driving the truck, manually or automatically selecting different gears or directions, or actuating switches, sensors, or sending units. The Monitor screen is normally "live" but can be temporarily frozen for examination by pressing the Freeze button. When the display is frozen, the contents of the display can be printed to your computer’s printer. Pressing the Thaw button resumes live display.
12
Figure 3. Transmission Monitor
EVENT LOG NOTE: The park brake must be applied to access the Event Log. Access the Event Log by selecting the Event Log button from the main screen toolbar. The Event Log will record, store, and hourmeter time stamp the transmission system error codes. See Figure 4 and Table 4. The Event Log is updated with new error codes each time the truck ignition switch is turned OFF. A continuous error condition will only be recorded once every 30 minutes or each time the truck or controller power supply is cycled off and on. The Event Log will record both the error code and actual error description. The Event Log is capable of holding 154 separate messages before new messages start recording over the oldest recorded errors. The Event Log has scroll capabilities. NOTE: Exceeded parameters are not error conditions and are not recorded in the event log. Transmission system errors occur when equipment failure creates a condition that could lead to possible safety issues and/or equipment damage and requires component repair/replacement and a system to resume normal truck functionality. The Event Log can be saved to disk files by selecting Save to File button in Event Log screen and selecting appropriate directory.
1300 SRM 932
Controller Parameter Adjustment Software User Interface
Current Parameters Verify or adjust current transmission system operating parameters. Accessing the transmission system parameters opens a screen containing multiple pages of parameter settings. See Figure 5 and Figure 6. Each parameter is labeled to identify the function. The parameter value shown in the left text box is for reference only and shows the value of the parameter currently being used by the controller. The working parameter value shown on the right side is adjustable. Adjust ON and OFF parameters by checking and unchecking the box next to the parameter description or by clicking the right-hand ON/OFF text box.
Figure 4. Event Log
If the current value and the working value of a given parameter differ, this difference is indicated by a small marker to the left of the parameter’s group.
Table 4. Event Log Descriptions and Values Code
Error Description
30
Low transmission oil pressure
31
High transmission oil pressure
32
Transmission speed sensor failure
33
Engine speed sensor failure
39
Forward/reverse selected at same time
40
Multiple range shifter positions selected at same time
41
Transmission controller failure Figure 5. Transmission Parameters
PARAMETER ADJUSTMENT CAUTION Improperly setting parameters can adversely affect the operation of truck. NOTE: The park brake must be applied to adjust transmission system parameters or before changes can be saved to the controller. UserLink™ provides the ability to view and adjust the transmission system operating parameters. Parameter changes can be saved in the controller and/or saved to disk files for retrieval at a later date. Click the Parameters button on the main menu screen toolbar to access the following four choices.
Figure 6. Current Parameters
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Controller Parameter Adjustment Software User Interface
Scroll pages by clicking the Back or Next buttons. When you arefinished making changes, click the Finish button and select the Send Data to Controller or Save to File button. Adjust parameters with numeric values by clicking on the right-hand text box or by pressing the Tab and Shift-Tab keys on your keyboard to move from parameter to parameter. The working value highlights when selected and shows the min/max value range where applicable. Enter the next value and hit the Tab key or use the mouse to select the next parameter for adjustment. If you enter an invalid value, a message is displayed and you’re prompted to re-enter the value. The preset parameter descriptions and values for the autoshift system are listed in Table 5.
1300 SRM 932
Load Parameters Load previously saved parameters from a disk file.
Restore Factory Parameters Restore the original factory parameter default settings.
Load Controller Software from File Upload controller operating software from a disk file into the transmission system controller.
EXIT MENU NOTE: You must save changes before exiting or you will lose your changes. To exit UserLink™, select Exit button from the main menu screen toolbar.
Table 5. Parameter Descriptions and Values Item
14
Description
Value
1
Engine minimum run rpm
400 rpm
2
Driveshaft engagement from neutral maximum engine rpm
1400 rpm
3
Reversal truck speed - maximum driveshaft rpm allowing reversals
362 rpm
4
Reversal engine speed - maximum engine rpm allowing reversals
1400 rpm
5
Reversal engine speed - maximum engine rpm allowing reversals in automatic shift mode
6
Range position timer for the column-mounted shifter
0.5 sec
7
Range position timer for the column-mounted shifter
1.0 rpm
8
Transmission low oil pressure override timer
9
Number of engine flywheel teeth - Perkins
126
Number of engine flywheel teeth - Cummins
159
10
Number of transmission output gear teeth
53
11
Manual shift - truck speed allowing reversals
ON
12
Manual shift - engine speed allowing reversals
ON
13
Manual shift - transmission inhibit for downshift
ON
14
Manual shift - max engine rpm allowing driveshaft engagement from neutral
ON
15
Transmission electric solenoid range shift valve - Product code 1
nonselect
Transmission electric solenoid range shift valve - Product code 2
nonselect
Transmission electric solenoid range shift valve - Product code 3
OFF
Transmission electric solenoid range shift valve - Product code 4
ON
ON
30 sec
1300 SRM 932
Controller Parameter Adjustment Software User Interface
Table 5. Parameter Descriptions and Values (Continued) Item
Description
Value
16
Gear shift selector position 3
2-3 or 1-2
17
Automatic standard upshift 1st to 2nd gear parameter adjustments - speed ratio
18
Automatic standard upshift 1st to 2nd gear parameter adjustments - min drive shaft rpm
350 rpm
19
Automatic standard upshift 1st to 2nd gear parameter adjustments - 2nd gear shift stabilization timer
1.0 sec
20
Automatic standard upshift 2nd to 3rd gear parameter adjustments - speed ratio
21
Automatic standard upshift 2nd to 3rd gear parameter adjustments - min drive shaft rpm
750 rpm
22
Automatic standard upshift 2nd to 3rd gear parameter adjustments - 2nd gear shift stabilization timer
1.0 sec
23
Automatic standard downshift 2nd to 1st gear parameter adjustments - speed ratio
0.50
24
Automatic standard downshift 2nd to 1st gear parameter adjustments - max drive shaft rpm
225 rpm
25
Automatic standard downshift 2nd to 1st gear parameter adjustments - 2nd gear shift stabilization timer
0.5 sec
26
Automatic standard downshift 3rd to 2nd gear parameter adjustments - speed ratio
0.70
27
Automatic standard downshift 3rd to 2nd gear parameter adjustments - max driveshaft rpm
650 rpm
28
Automatic standard downshift 3rd to 2nd gear parameter adjustments - 2nd gear shift stabilization timer
0.25 sec
29
Dethrottle for automatic shift mode - Product code 1 (optional)
OFF
Dethrottle for automatic shift mode - Product code 2 (optional)
OFF
Dethrottle for automatic shift mode - Product code 3 (optional)
ON
Dethrottle for automatic shift mode - Product code 4 (optional)
OFF
0.92
0.88
30
Dethrottle duration prior to second gear clutch pack lockup automatic shift mode (optional)
0.25 sec
31
Dethrottle duration after second gear clutch pack lockup automatic shift mode (optional)
0.19 sec
32
Dethrottle duration prior to third gear clutch pack lockup automatic shift mode (optional)
0.19 sec
33
Dethrottle duration after third gear clutch pack lockup for automatic shift mode (optional)
0.12 sec
34
Dethrottle for manual shift mode - Product code 1, 2, 3, 4 (optional)
35
Dethrottle duration prior to second gear clutch pack lockup for manual shift mode (optional)
OFF 0.25 sec
15
Controller Connector Pin-Out Tables
1300 SRM 932
Table 5. Parameter Descriptions and Values (Continued) Item
Description
Value
36
Dethrottle duration after second gear clutch pack lockup for manual shift mode (optional)
0.19 sec
37
Lift height transmission interrupt (optional)
OFF
38
Neutral default for lift height transmission interrupt (optional)
ON
39
Audible alarm for lift height transmission interrupt (optional)
OFF
40
Maximum upshift gear range (optional)
2
Controller Connector Pin-Out Tables The following tables are a list of the controller pinouts for the autoshift system. These controller pinouts are for reference only. A list of current pin-outs can be obtained by contacting NACCO service department. The controller has two connectors that are
keyed and color coded to match the mating harness connectors. The black connector pin-out is shown in Table 6. The blue connector pin-out is shown in Table 7.
Table 6. J2 Controller Connector (Black) Pin
Signal Direction/Level
1
Transmission Speed Sensor Diagnostics
out/diag
2
Engine Speed Sensor Diagnostics
out/diag
3
Dethrottle Solenoid 4
out/ground
4
Open
out/ground
5
Open
out/ground
6
Open
out/ground
7
Second Gear Solenoid (2A Max)
out/0-24v
8
Open (2A Max)
out/0-24v
9
Open (2A Max)
out/0-24v
10
Forward Solenoid (2A Max)
out/0-24v
11
First Gear Solenoid (2A Max)
out/0-24v
12
Reverse Solenoid (2A Max)
out/0-24v
13
Truck Ground
in/ground
14
Open
out/ground PWM 2
15
Open
out/ground PWM 1
16
Open
out/ground PWM 0
17
Battery 24 Volts (10A Fuse)
in/0-24v Fused
18
Battery 24 Volts (10A Fuse)
in/0-24v Fused
19
16
Description
RS232 Ground - Port 1, Port 2, Canbus
out/ground
1300 SRM 932
Controller Connector Pin-Out Tables
Table 6. J2 Controller Connector (Black) (Continued) Pin
Description
Signal Direction/Level
20
Open
in - out/Canbus "L"
21
Open
in - out/Canbus "H"
22
RS232 RXD2 Truck Display (white wire)
in/RS232
23
RS232 TXD2 Truck Display (black wire)
out/RS232
24
RS232 RXD1 Communication Port (white wire)
in/RS232
25
RS232 TXD1 Communication Port (black wire)
out/RS232
26
Throttle Switch
in/0-24v
27
Open
in/0-24v
28
Open
in/0-24v
29
Open
in/0-24v
30
Lift Height Transmission Interrupt Switch
in/0-24v
31
Truck Ground
32
Battery 24 Volts (1A Fuse)
in/truck gnd in/0-24v Fused
T able 7. J1 Controller Connector (Blue) Pin
Description
Signal Direction/Level
Wire Number
1
Engine Speed Sensor Signal
in/pulsed ground
418
2
Transmission Speed Sensor Signal
in/pulsed ground
417
3
Open
in/0-5v
-
4
Open
in/0-5v
-
5
Open
in/0-24v
-
6
Open
in/0-24v w/pullup
-
7
Open
in/0-24v w/pullup
-
8
Open
in/0-24v w/pullup
-
9
Open
in/0-5v
-
10
Open
in/0-5v
-
11
Open
in/0-24v
-
12
Park Brake Switch
in/0-24v
819B
13
Open
in/0-24v
-
14
Ignition Switch
in/0-24v
103C
15
5v Supply for Transmission/Engine Speed Sensors
out/5v
419
16
Ground for Transmission/Engine Speed Sensors
out/ground
433
17
Controller Connector Pin-Out Tables
1300 SRM 932
Table 7. J1 Controller Connector (Blue) (Continued) Pin
18
Description
Signal Direction/Level
Wire Number
17
Open
in/0-24v
-
18
Open
in/0-24v
-
19
Open
in/0-24v
-
20
Open
in/0-24v
-
21
Shifter Position 3 (2-3 Auto or 1-2 Auto)
in/0-24v
811A
22
Shifter Position 4 ("D" Auto)
in/0-24v
812
23
Shifter Position 2 (2nd Gear)
in/0-24v
810
24
Open
in/0-24v
-
25
Shifter Position 2 (1st Gear)
in/0-24v
809A
26
Shifter Position Reverse
in/0-24v
808C
27
Shifter Position Forward
in/0-24v
807C
28
Open
in/0-24v
-
29
Open
in/0-24v
-
30
Open
in/0-24v w/pullup
-
31
Open
in/5v
-
32
Truck Ground
in/truck gnd
644
TECHNICAL PUBLICATIONS 1300 SRM 932
12/04 (3/02)(2/01) Printed in U.S.A.