Hyster E45XM-27:
Hyster E45XM-27 won't lift, tilt, shift, other functions work OK Help PLEASE!

Was working fine ,steering still works as it should , after removing the back cover I found by pushing in bottom contactor.I could hear hydraulic pump run , and can lift while this is done. There is a potted ?(covered in silicone) part above the contactor that has many wires on a plug ? maybe from micro switches ? and then 3 no plug wires , I found using my car remote starter switch , jumping from the black to the yellow the hydro pump will run and I can use the lift.( if you keep the pump running with out using any hydro it times out and shuts off , let off remote starter switch , and it resets to working by button again) I am thinking it's the "potted " part that's bad. The micro switches ohmed out okay , plus the chances off all of them going bad at once is slim. PLEASE HELP , fuses have ohmed out okay. The black wire is picking up power from the hot side of the contactor , and the yellow is connected to the coil that pulls in the contactor , the 3rd wire is red is connected to other side of coil.
  • Posted 27 Aug 2021 10:44
  • Discussion started by Daniel_Cross
  • Virginia, United States
Showing items 1 - 8 of 8 results.
THANKS!
  • Posted 10 Sep 2021 22:15
  • Reply by Daniel_Cross
  • Virginia, United States
Your part number for that pump contactor driver module is:
2038829 DRIVER MODULE, 24-48 VOLT
  • Posted 10 Sep 2021 14:42
  • Reply by swoop223
  • North Carolina, United States
You've been swooped!
swoop223@gmail.com
Could I get a partnumber for that please ?
Thanks
  • Posted 10 Sep 2021 12:42
  • Reply by Daniel_Cross
  • Virginia, United States
yep that module is what controls the contactor
in the parts info they call it a 'driver module' for the hydraulic contactor.
i think i mentioned that in my reply back to your email and gave you the part number as well?
anyway replace that and it should come back to life if there are not any other wiring or switch issues.
  • Posted 10 Sep 2021 12:22
  • Reply by swoop223
  • North Carolina, United States
You've been swooped!
swoop223@gmail.com
Thanks for all the help. Here is a link with a pic of the contactor ,and the controller module ?My best guess is that controller module is bad. Anyone have any more idea's on testing ?

https://photos.app.goo.gl/G2eqvnB145XpUifb7
  • Posted 10 Sep 2021 11:46
  • Reply by Daniel_Cross
  • Virginia, United States
Daniel,
first off, using golf cart batteries is not a good idea, maybe for moving the truck from one place to another in certain circumstances but they should not be used in normal conditions at all. Testing maybe if they are fully charged.
now with that said, what is the serial number of the truck?
most cases when the hydraulic system won't function is a bad connection or control valve switch adjustment.
knowing the serial number will tell me alot as to what system is on this unit. they changed them so much during that period in the XM series it's hard to guess.
I'm going to presume it has a standard hydraulic contactor controlled system on it and NOT an SCR Premium controlled system. If it was SCR there wouldn't be a contactor to activate the pump motor, it would have a 2nd ev100 controller mounted on the RH side of the traction controller. This simplifies things quite a bit if this is the standard control.
The switch design on the levers and control valve is a rather bad one and can get out of wack pretty easy when it wears and does not have much tolerance in adjustments. Getting those switches to activate on the ramps on the guide block assy can be nerve racking. You can go to the switches and use a small screw driver and manually activate the switch to see if the motor will turn on. If the ramps on the guides that activate the switches are worn they will have to be replaced, you'll never get it adjusted correctly otherwise and it will not work right. Adjusting them will be near impossible.
As for the control for the pump they show several configurations of different ones. If you can take a picture of it and send it to my email address shown in my signature here.
  • Posted 6 Sep 2021 01:52
  • Modified 6 Sep 2021 02:25 by poster
  • Reply by swoop223
  • North Carolina, United States
You've been swooped!
swoop223@gmail.com
Thanks so much for the help. I don't see a card under the control levers ? I googled EV100 , other than 1 contactor , the one I jump , it's not the same as my forklift. I wish I could post a pic. Maybe email me and I'll send you a pic of what set up my lift has. [email address removed]
I suspect one part , a pic would go along way

The lift was working fine, we stopped for lunch , after lunch nothing? It had worked fine before , even with the batteries at a lower voltage. I do power it with 6 huge 6 volt golf cart batteries.

Thanks Again !
Daniel
  • Posted 3 Sep 2021 06:17
  • Reply by Daniel_Cross
  • Virginia, United States
Daniel,

I assume you have an EV 100 system? When you turn on the key switch, do you show any codes on the dash? You said you checked all fuses using ohms. I have found using a volt meter is best as sometimes a bad fuse can still show continuity. These systems have multiple cards also. Since the steering is working I assume the battery is good. Since you have lost hydraulics, I would verify voltage. If you have a 36 volt operating system, battery at full charge should read 38 to 38.5 volts. If it is reading 36 volts, battery needs to be charged. These lifts used a card mounted under the hydraulic handles. Verify all wiring is good. Connections, fuses, contactors and control cards were the biggest issues with these trucks.
  • Posted 3 Sep 2021 04:43
  • Reply by Fishmech
  • Virginia, United States
The hard to do we do right away. The impossible just takes a little longer.

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