TROUBLESHOOTING

AND ADJUSTMENTS
WITH A COMPUTER
EV-100ZX, EV-T100, SR (SEM), AND
SP MOTOR CONTROLLERS
(DOS VERSION)
E25-40XM, XM 2 [D114]; E45-65XM, XM 2 [F108];
J40-60XM, XM 2 [A216]; N30XMH, N30XMH 2 [C210];
E70-120XL, XL 3 [C098]; J30-40XMT 2 [H160];
J1.6-2.0XMT 2 [G160];

PART NO. 897830 2200 SRM 597

Troubleshooting and Adjustments with a Computer Table of Contents

TABLE OF CONTENTS

Computer System............................................................................................................................................... 1
Connect PC to Control Card.......................................................................................................................... 2
HYTECH™ Software Program ......................................................................................................................... 3
How to Start HYTECH Software Program .................................................................................................. 3
Communications Port Selection.................................................................................................................... 4
Controller and Lift Truck Verification.......................................................................................................... 4
Lift Truck Series Selection ............................................................................................................................ 6
Undefined Controller Card ........................................................................................................................... 6
Controller Card Register Parameter List..................................................................................................... 6
How to Enter New Parameter ...................................................................................................................... 8
How to Save Changed Parameter File ......................................................................................................... 8
How to Load Saved Parameter File.............................................................................................................. 8
How to Return to Factory Default Settings ................................................................................................. 10
How to Save Changes to Controller Card .................................................................................................... 10
How to View Status Codes ............................................................................................................................ 10
Saving Status Code to Disk........................................................................................................................... 12
Closing and Clearing Status Code List ........................................................................................................ 12
Communications Program (Modem) ................................................................................................................. 14
Requirements................................................................................................................................................. 14
README File ................................................................................................................................................ 15
GE Sentry Software® ......................................................................................................................................... 16
Getting Started .............................................................................................................................................. 16
Where to Get Help ......................................................................................................................................... 16
Hardware and Software Requirements........................................................................................................ 16
GE SENTRY SOFTWARE Installation ........................................................................................................ 17
How to Start GE SENTRY Program............................................................................................................. 17
How to Reset MIN and MAX Display........................................................................................................... 18
How to Exit GE SENTRY Program .............................................................................................................. 18

This section is for the following models:

E25-40XM, XM 2 [D114];
E45-65XM, XM 2 [F108];
J40-60XM, XM 2 [A216];
N30XMH, N30XMH 2 [C210];
E70-120XL, XL 3 [C098];
J30-40XMT 2 [H160];
J1.6-2.0XMT 2 [G160];

©2002 HYSTER COMPANY i

2200 SRM 597 Computer System

Computer System
A personal computer (PC) can be used to set traction Table 1. Cable Connections - Computer
or pump motor functions, indicate status codes (pos- to Control
sible faults), and make adjustments to the operating
limits set in the control cards. The PC must have the Model EV-100ZX and EV-T100 Controls
following minimum configuration to program motor
Computer Controller Connector
controllers:
Connector (9-Pin) (14-Pin) Plug-Y
a. IBM® (or clone) Personal Computer (80286 or
better) with 640 KB (512KB available) of RAM, Pin 2 (Receive) Pin 14
a disk drive for a 3.5 inch diskette. A second disk
Pin 3 (Transmit) Pin 13
drive or a hard disk is strongly recommended for
data storage. Pin 5 (Signal ground) Pin 4
b. The GE SENTRY SOFTWARE® program will re-
Pin 4 to pin 6 (Jumper)
quire an IBM 486DX/33 MHZ or faster compati-
ble computer to operate Real Time diagnostics. Pin 7 to pin 8 (Jumper)
c. One open serial Communications Port, either
Model SR & SP Controls
COM 1 or COM 2 on the PC.
d. Shielded cable assembly, nine-pin DB-9 serial Computer Controller Connector
cable, male to female. This cable assembly Connector (9-Pin) (12-Pin) Plug-Y
is a standard computer extension cable with
Pin 2 (Receive) Pin 12
straight-through wiring. Other cable lengths
can be used that are within the serial cable lim- Pin 3 (Transmit) Pin 11
its of personal computers. The recommendation Pin 5 (Signal ground) Pin 4
is less than 10 m (30 ft). This cable assembly
is normally available from vendors of computer Pin 4 to pin 6 (Jumper)
equipment. Pin 7 to pin 8 (Jumper)
e. Adapter cable for ZX controls. This cable has a
female D-9 connector on one end and a Y-plug
adapter on the other end. The cable can be con- Table 2. Adapter Pins (DB25F to DB9)
structed from individual parts. Cable connector
pin assignments are shown in Table 1. 25-Pin Connector 9-Pin Connector
f. Adapter cable for SR controls. This cable has a Pin 2 Pin 3
female DB-25 connector on one end and a 12-pin
(Y-plug available for ZX controllers) adapter on Pin 3 Pin 2
the other end. The cable can be constructed from Pin 4 Pin 7
individual parts. Cable connector pin assign-
Pin 5 Pin 8
ments are shown in Table 1.
g. Some computers can require an adapter DB-25F Pin 6 Pin 6
(female) to DB-9 (male). Connector-to-connector
Pin 7 Pin 5
pin assignments are shown in Table 2.
h. HYTECH™ software diskette (Hyster Part No. Pin 8 Pin 1
1492529). This diskette has two main programs:
Pin 20 Pin 4
• A program to set traction or pump motor func-
tions, indicate status codes (possible malfunc- Pin 22 Pin 9
tions), and make adjustments to the operating
limits set in the control cards. NOTE: The programs on the diskette can be copied
• A communications program that permits a re- to a hard disk drive on the PC. Some files in the sub-
mote computer to connect to a local computer directories have the same file name as files in other
through a telephone and modem connection. subdirectories but are not the same. Make sure all
This communications program permits a ser- files for a program are installed correctly in their sub-
vice engineer at a remote location to run the directory or the programs will not work.
local programs and make checks and adjust-
ments to the lift truck.

1
Computer System 2200 SRM 597

NOTE: Future releases of this software diskette will

have programs for other kinds of controllers. Make
sure the correct program is used for your motor con-
troller.

CONNECT PC TO CONTROL CARD

WARNING
Prevent movement of the lift truck and pos-
sible injury when making checks and adjust-
ments. Before the PC is connected or discon-
nected to the control card or SEM Display
Panel of the lift truck, do the following steps:
1. Raise the drive wheels as described in the
Operating Manual or the section Periodic
Maintenance of the Service Manual for this
lift truck.
2. Turn the key to the OFF position, discon-
nect the battery, and discharge the capaci-
tor(s) as described in the motor controller
section of the Service Manual for your lift
truck.
The capacitors can be discharged on lift
trucks with the SEM Display Panel using 1. PERSONAL COMPUTER (PC)
the horn. Disconnect the battery connec- 2. COMPUTER SERIAL PORT
tor, move the key to the OFF position, and 3. ADAPTER (PART OF KIT HYSTER P/N 1361412)
operate horn until it stops making a sound. 4. CABLE ASSEMBLY (PART OF KIT HYSTER P/N
1361412)
Do NOT make a short circuit at any of these 5. SMALL (9-PIN) CONNECTOR
motor controller terminals. 6. BACK OF DISPLAY PANEL
7. LARGE (18-PIN) CONNECTOR FOR MOTOR
Connect PC to small (9-pin) connector on back CONTROLLERS
of SEM Display Panel (under instrument panel).
Connect PC as shown in Figure 1. All other units Figure 1. Connecting PC to Display Panel
without the SEM Display Panel require connecting
the computer at the motor controller. Connect bat- NOTE: If the control card or motor controller is on
tery. the bench, make sure the control card or motor con-
troller is connected to a 24 vdc, 0.5 A power source.
NOTE: The ITW Switches program allows a tech- SeeTable 3 to make the connections to the SR and SP
nician to use the HYTECH or GE SENTRY SOFT- motor controllers.
WARE program through the SEM Display Panel.
These programs allow the technician to create dif- Table 3. Plug-Z Connection
ferent lift truck operating parameters for different
users. The ITW Switches program is available on a Plug-Z 24 vdc Power Source
3.5 inch software diskette. Refer to or How to Start Pin 2 Negative terminal
HYTECH Software Program of this manual.
Pin 7 Positive terminal
Use this procedure to connect the computer to the SR or SP Motor 24 vdc Power Source
control card or the SR or SP motor controller in units Controller
without the SEM Display Panel. Turn key switch to
OFF. Connect PC adapter cable at connector Plug Pin 1 (23-Pin) Positive terminal
Y on control card (EV-100ZX, EV-T100) or to 12-pin NEG Power Terminal Negative terminal
connector of SR or SP motor controllers. See Table 3.

2
2200 SRM 597
HYTECH™ Software Program
The information in this section is subject to
change without notice and does not represent a
commitment on the part of GE. This software
is furnished under a license agreement and/or
nondisclosure agreement. The software can be
used or copied only in accordance with terms of
the agreement.
Copyright by General Electric Company, 1994,
1995. All rights reserved.
GE SENTRY SOFTWARE is a registered
trademark of GE Company.
Microsoft, MS and MS-DOS are registered
trademarks of Microsoft Corporation.
IBM and PS/2 are registered trademarks of
International Business Machines Corporation.
HYTECH is a registered trademark of Hyster
Company.
HOW TO START HYTECH SOFTWARE
PROGRAM
If the HYTECH software has been installed on a hard
disk in the PC (normally drive C), enter the program
from that directory. Check to see if a directory HYS-
TERSC has been created on the hard drive. If not it
will have to be created and the program copied into
it from the computers disk drive. Then you can start
Figure 2. Hyster Desktop Display
HYTECH™ Software Program
the program from the hard drive. At the prompt en-
ter:
C:\>CD HYSTERSC [RETURN]
At the prompt C:\>HYSTERSC enter:
HYSTER [RETURN]
The screen displays a list of languages as follows:
English
Francais
Deutsch
Italiano
Espanol
Select the language by entering that number.
After selecting the language, the screen momentar-
ily displays the copyright data for the program. The
screen then displays the HYSTER desktop shown in
Figure 2.
The menu bar is accessed by pressing F10. Then, use
the arrow keys to select an item. Items can also be se-
lected by pressing the Alt key and the highlighted let-
ter of the item. For example, Alt-L selects the Logon
menu. If a mouse is connected to the computer, the
menu items can be selected with the mouse. Make
sure that the mouse driver is installed.
3
HYTECH™ Software Program
COMMUNICATIONS PORT SELECTION
Select the Logon menu to start the program and the
Card I/O dialogue box is displayed with the COM
PORT list shown in Figure 3.
Figure 3. Port Selection
CONTROLLER AND LIFT TRUCK
VERIFICATION
The system tries to identify the type of card under
test and then displays the screens for that type of
card. If the card type is determined, the system
displays the screen for that card as shown in Fig-
ure 4. If the card type is not determined, the system
displays the Undefined Control Card screen
shown in Figure 6.
The computer then checks the serial number of the
lift truck, the customer assigned number of the lift
truck (if used), and the hourmeter data in the control
card.
NOTE: Use only the Tab key to move to the different
data fields on this screen. The use of the cursor keys
can cause the program to quit or enter wrong data.
The Truck Serial Number: field accepts num-
bers and letters as shown in Figure 4. The first and
fifth positions must be an alpha, the other positions
must be numbers.
4
2200 SRM 597
CAUTION
Selecting a port already in use can cause un-
predictable results or lockup the computer.
Use the Tab key to move to the correct serial port for
your PC. Use the Return (or Enter) key to select the
port. If your PC has a mouse, the left button can be
used to select the port.
The Truck I.D.: field shows the customer as-
signed number of the lift truck. This field only
accepts numbers.
The Card Hourmeter: field shows the number of
hours the engine has been run. This field only ac-
cepts numbers.
The hourmeter time will be the same time as that
indicated on the instrument panel display.
NOTE: The hourmeter data is the time the control
card has been in service since this data field was re-
set. If a new control card is being installed or if the
control card is now used in a different lift truck, en-
ter the hourmeter time for the lift truck.
The Card Information dialogue box contains sev-
eral data fields.
The Control: field indicates the type of control
card and the revision level.
The Truck I.D.: field is the customer assigned
truck identification number.
2200 SRM 597 HYTECH™ Software Program

The Model: field shows the truck serial number
data listed or entered in the Card Information
screen, Figure 4.
The first four numbers in the field after Card/Se-
cure HM: is the operating hourmeter time set in
Figure 4. The next four numbers are the "secure"
hourmeter data for the total time the control card
has been in service and this data field cannot be
changed.

Figure 4. Verification of Controller and Lift Truck

The Card Information dialogue box is displayed
on all the remaining screens in the program.
If Enter is used at the OK field, the program accepts
any changes and goes to the next screen.
If Enter is used at the Cancel field, the program re-
jects any changes and displays the Truck Menu Se-
lection Screen shown in Figure 5. The Truck Menu
Selection screen displays a Card Information di-
alogue box and a list of available truck types.

Figure 5. Select Lift Truck Series

5
HYTECH™ Software Program
LIFT TRUCK SERIES SELECTION
Use the up and down cursor keys to select one of the
lift truck series shown on the menu. The program
automatically determines if the control card is a trac-
tion card or a hydraulic pump card at login. If the
model series for your lift truck is not listed, you can
select Model Undefined in the menu shown in Fig-
ure 5. The next menu will appear as shown in menu
Figure 6.
NOTE: The sequence of example screens are for
N30XMH and N30XMH 2 lift trucks. There will be
variations in the screens for the other lift trucks that
use this motor controller.
Figure 6. Undefined Controller Type
CONTROLLER CARD REGISTER
PARAMETER LIST
After the truck model has been selected, the Card
Register List screen is displayed. This screen shows
the first nine functions that set the operating param-
eters of the lift truck. Use either the Arrow keys or
the PgUp and PgDn keys to scroll through the list to
show the other functions. See Figure 7.
The columns show the following information:
Function indicates the data register shown in the
Parameter Tables.
6
2200 SRM 597
UNDEFINED CONTROLLER CARD
CAUTION
This Model Undefined option will permit a user
to set Cards (parameter numbers) and Values
that can cause damage to the motor controller
and the lift truck. Do not use this software op-
tion without the instructions from a service en-
gineer from Hyster Company.
If Model Undefined was selected, or the program
does not recognize the card I.D. type (card identifica-
tion), the Undefined model screen appears as shown
in Figure 6. You must enter the correct data in all of
the data fields to make sure the lift truck will oper-
ate.
Function Name
This column indicates the name of the parameter
that can be checked or adjusted.
Card
This column indicates the current parameter set in
the register. The software prevents parameters less
than the minimum (Min) or greater than the maxi-
mum (Max) to be entered into the registers.
Value
This column indicates the actual value that the Card
number represents.
2200 SRM 597 HYTECH™ Software Program

Figure 7. Lift Truck Operating Parameters

Min The functions indicated at the bottom of the Card

Register List screen do the following operations:
This column indicates the minimum parameter num-
ber that the can be set in the register. F1 Help

Fac(Factory) This function displays the Help dialogue box for the
screen in use. Press Esc to close the Help screen.
This column indicates the parameter number that
was set in the controller at the factory when the lift Alt F3 Close
truck was manufactured.
This closes the register list. After the current param-
NOTE: If the parameters shown in the Default eters of the control card are shown on the PC screen
columns of the Parameter Tables are different than the screen displays SAVE Yes No.
indicated by the software, always use the parame-
ters shown by the software. Contact your dealer for Alt F4
Hyster lift trucks if your version of the software is
This function changes the values in the register list
not correct.
to the factory default settings.
Max
Alt-S Save
This column indicates the maximum parameter
This function allows the present control card settings
number that the can be set in the register.
to be saved to a file that can be loaded at a later time.
NOTE: An attempt to enter a parameter outside of Pressing Alt-S displays the Save Settings dialogue
the permitted range causes an Error dialogue box to box. See Figure 9.
be displayed with the message Value Out of Range
Select OK to close Error notice.

7
HYTECH™ Software Program
HOW TO ENTER NEW PARAMETER
Use either the Arrow keys or the PgUp and PgDn
keys to scroll through the list. Press Enter to select
the parameter to be changed and the Change Register
Value dialogue box is displayed. The Change Reg-
ister Value dialogue box shows the name of the
Figure 8. Changing Operating Parameters
HOW TO SAVE CHANGED PARAMETER
FILE
After the operating parameters are changed, the
data can be saved to the PC disk for loading at
a later time. Pressing ALT-S displays the Save
Settings dialogue box as shown in Figure 9. The
Name field indicates a file extension for the type of
controller selected. It is recommended that you do
not change this extension. The standard convention
for the file name, indicated by an asterisk (*), is to
use the truck number. After the file name is entered,
select OK. The default file name extensions are:
*.nat Traction controller
*.nap Pump controller
DO NOT use the extension .TXT. Press Esc to save
the register data to file and close the Save Set-
tings dialogue box.
8
2200 SRM 597
function selected in the upper right hand corner of
the box. Make sure that this is the function that you
want to change. See Figure 8. Enter the new values
and select OK to make the change.
HOW TO LOAD SAVED PARAMETER FILE
NOTE: If the file was saved with an extension other
than the recommended extension, change the Name
field search criteria to show the extension used or
change to the universal search criteria *.* to find the
file to load. The file MUST have the correct extension
in order to be loaded.
After saving the controller data and closing the
Save Settings dialogue box, the data can be re-
trieved by pressing ALT-L. Pressing ALT-L opens
the Load Saved Settings dialogue box shown in
Figure 10.
Use the Tab key to move to the Files field. Then
use the down arrow to select the file to be loaded.
When the selected file name appears in the Name
field, select Open. The selected controller parame-
ter file is loaded and the screen appears as shown in
Figure 7.
2200 SRM 597 HYTECH™ Software Program

Figure 9. Save Parameters in Control Card to File on PC Disk

Figure 10. Loading Saved Parameter File From PC Disk

9
HYTECH™ Software Program
HOW TO RETURN TO FACTORY DEFAULT
SETTINGS
From the Card Register List screen, press Alt-F4.
Pressing ALT-F4 opens the Confirm dialogue box
Figure 11. Return Control Card Parameters to Factory Default Settings
HOW TO SAVE CHANGES TO
CONTROLLER CARD
From the Card Register List screen, press Alt-F3.
Pressing Alt-F3 opens the Confirm dialogue box
with the message Save changes to card?
shown in Figure 12. Once the changes have been
made to the register values, use the Tab key to move
to the Yes option and press Enter. This saves all
the changes made to the controller card parameters.
Selecting No, discards all changes made to the regis-
ter values. Selecting Cancel, cancels the operation
10
2200 SRM 597
with the message Set Card to Factory De-
faults shown in Figure 11. Use the Tab key to
move to the Yes option and press Enter. This re-
turns all control card parameters to the original
factory settings.
and returns the display to the Card Register List.
Pressing Esc also cancels the operation and closes
the dialogue box.
HOW TO VIEW STATUS CODES
To view the status codes of the selected truck, press
ALT-C to select Card from the login screen. Then
use the down arrow to select Status Codes from
the list displayed. See Figure 13.
2200 SRM 597 HYTECH™ Software Program

Figure 12. Saving Changes to Control Card

Figure 13. Access to Status Code List

11
HYTECH™ Software Program
This opens the Status Codes dialogue box with a
list of stored status codes. See Figure 14.
The columns show the following information:
# column indicates the Status Codes in the order
they were sensed. The most recent Status Code is
number 1.
Code indicates the Status Code (-01 through -181).
Figure 14. Viewing Status Code List
SAVING STATUS CODE TO DISK
After viewing the status codes, the data can be saved
to the PC disk for reference or to make a hard copy.
Pressing Alt-S displays the Status Codes dialogue
box as shown in Figure 15. The Name field indicates
a file extension for the Status Codes list. It is rec-
ommended that you do not change this extension.
The standard convention for the file name, indicated
by an asterisk (*), is to use the truck number. The
default file name extensions is: *.stc. After the
file name is entered, select OK. This saves the status
codes to the disk and closes the Status Codes dia-
logue box.
12
2200 SRM 597
Description shows the title of the Status Code
Chart.
BDI shows the battery charge at the time the Status
Code was sensed (traction control cards only on lift
trucks with a GE BDI.)
Hours shows the number of hours indicated by the
Hourmeter when the status code was sensed.
CLOSING AND CLEARING STATUS CODE
LIST
To close the status codes list, press Alt F3. The
Confirm dialogue box is displayed with the message
Clear Status Codes? and the options Yes, No
and Cancel. See Figure 16.
Use the Tab key to move to the different options.
Selecting Yes clears the Status Code screen and
closes the dialogue boxes. Selecting No closes the
Confirm dialogue box and the Status Code screen
and returns you to the HYSTER Desktop Display, see
Figure 2. Selecting Cancel. closes the Confirm
dialogue box and returns you to the Status Code
list.
2200 SRM 597 HYTECH™ Software Program

Figure 15. Saving Status Codes to Disk

Figure 16. Closing and Clearing Status Codes

13
Communications Program (Modem) 2200 SRM 597

Communications Program (Modem)

The HYTECH software diskette has a communica- REQUIREMENTS
tions program (MODEM.EXE) that permits a remote
computer to connect to a local control card through a NOTE: This modem program was developed for
telephone and modem connection. This communica- an Intel 14.4EX modem. Other modem initiation
tions program permits a service engineer at a remote scripts have been developed and are installed on
location to run the HYTECH software programs and the HYTECH disk. Contact a field service engineer
make checks and adjustments to the lift truck. Cable for Hyster Company if a different modem initiation
connector pin assignments are shown in Table 4. program is needed. All modems are not compatible
with each other. Some testing can be necessary to
NOTE: The user must have enough experience to con- find the correct modem parameters that enable two
nect a modem to a PC and be able to enter the correct modems to communicate with each other.
commands in the registers of the modem.
NOTE: A standard analog telephone connection is re-
Table 4. Cable Connections - Modem quired. The modem program will not operate cor-
to Controller rectly if it is connected to a digital telephone sys-
tem and the modem can be damaged. Also, the tele-
Model EV-100 and EV-T100 Controller phone connection can be unreliable if the connection
is through some older types of PBX systems.
Model Connector Controller Connector
(9-Pin) (14-Pin) The requirements for the connection to the control
Pin 2 (Receive) Pin 13 card are:
• A telephone connection between the modem and a
Pin 3 (Transmit) Pin 14 dial-in telephone line. This connection is normally
Pin 5 (Signal Ground) Pin 4 through a telephone extension wire with RJ-11 con-
nections on both ends of the wire. This connec-
Pin 4 to pin 6 (Jumper) tion is often not reliable if the telephone line goes
Pin 7 to pin 8 (Jumper) through a telephone switchboard.
• A 9600 bps modem that uses a Hayes® command
Model SR Controller set that is compatible with the remote modem. Not
Modem Connector Controller Connector all modems are compatible with each other because
(9-Pin) (12-Pin) some modems use error correction functions that
are special to that model of modem. A recommen-
Pin 2 (Receive) Pin 11 dation is to disable error correction functions if
Pin 3 (Transmit) Pin 12 communications problems occur.
• The MODEM Transmit and Receive lines are re-
Pin 7 (Signal Ground) Pin 4 versed when compared to the PC-to-card (motor
Pin 4 to pin 6 (Jumper) controller) cable.
Pin 7 to pin 8 (Jumper) This message appears on the screen when the com-
mand MODEM is entered. See Figure 17.

14
2200 SRM 597 Communications Program (Modem)

Figure 17. Begin Screen for Modem Program

The function keys do the following operations:
F1 - This command is used to dial a remote modem
that is connected to a motor controller.
F2 - This command causes the modems to disconnect
(hang-up) from each other.
F3 - This command is used to set a modem (to be used
as the remote modem) to receive when it is connected
to a motor controller. The modem must be first con-
nected to a PC and this function is used to prepare
the modem for use. After the modem is prepared for
use, it is disconnected from the PC and connected to
the controller.
NOTE: It is not necessary that the HYTECH soft-
ware program must be used to prepare the remote
modem. Many other communications programs will
permit the user to program a modem (set the com-
munications registers) before use. Most modems are
sold with a communications program that permits
the user to program the modem and the initializa-
tion string. See the user’s manual for a specific mo-
dem. The initialization string for the Intel 14.4EX
modem used in the EV-100ZX Software Program is
AT & F V0&D0&C0&S0\N0\Q0 B8 S0 = I&W for re-
mote and AT & F B8VI&D0\Q0 for local connection.
F5 - This command is a toggle that enables and dis-
ables the speaker on the local modem.
F6 - The COM port must be selected before setting
defaults or the modem program will not work.
F7 - This command permits the user to select differ-
ent modems for the local modem.
F8 - This command permits the user to select differ-
ent modems for the remote modem.
F9 - This command starts the EV-100 program.
F10 - This command starts the GE SENTRY pro-
gram.
F11 - This command returns to a DOS prompt.
F12 - This command exits the Modem Dialling pro-
gram.
README FILE
There is a README file on each diskette that has
important information about the HYTECH software
program. Read this file for the latest information.

F4 - This command is used to set the local modem

to call the remote modem. This modem must be con-
nected to the PC that is running the communications
program.

15
GE Sentry Software®
GE Sentry Software®
*The information in this section is subject to change
without notice and does not represent a commitment
on the part of GE. This software is furnished
under a license agreement and/or nondisclosure
agreement. The software can be used or copied only
in accordance with terms of the agreement.
Copyright by General Electric Company, 1994,
1995. All rights reserved
GE SENTRY SOFTWARE is a registered trademark
of GE Company.
Microsoft, MS and MS-DOS are registered
trademarks of Microsoft Corporation.
IBM and PS/2 are registered trademarks of
International Business Machines Corporation.
HYTECH is a registered trademark of Hyster
Company.
NOTE: There is a program on the HYTECH™ soft-
ware diskette that permits a service engineer to con-
nect a portable PC to the motor controller. The ser-
vice engineer can then check the operation of the
motor controller(s) in real time. This program is a
diagnostic program that is normally only used for
troubleshooting special problems that are not easily
found with the status codes.
GETTING STARTED
The GE SENTRY program is a stand-alone exe-
cutable software designed to run on the IBM® PC
or most PC compatible computers. This software is
designed to be used with all electronic controllers
that use the ZX and SR protocol.
The GE SENTRY permits the user to do various
maintenance, diagnostic, and troubleshooting tasks
without the aid of additional test equipment. The GE
SENTRY program creates a link directly with the
microprocessor in the lift truck and gives the user
real time access to 16 different control parameters.
The GE SENTRY can do the following functions:
• Display the controller software identification
• Display the controller software revision level
• Reset maximum and minimum values for hold
functions
The GE SENTRY can monitor the following system
parameters:
• Status on all of the control input switches
• Actual value of the accelerator input voltage
16
2200 SRM 597
• The motor current
• Controlled acceleration, percent on-time
• Battery voltage
• Capacitor voltage
• Motor T2 voltage
• Regenerative braking current
• Thermal protection status
• Percent of battery charge
• Speed Limits switches conditions (if used)
• Hourmeter switch input position (if used)
The communications software and a modem permit
the GE SENTRY SOFTWARE to monitor the perfor-
mance of a electric lift truck anywhere in the world
that telephone service is available.
WHERE TO GET HELP
The GE SENTRY program has menus and prompts to
help the user. If help is needed, additional support is
available from your Field Service Engineer for Hys-
ter lift trucks.
HARDWARE AND SOFTWARE
REQUIREMENTS
The GE SENTRY SOFTWARE can be installed on
any hard drive that has a minimum of 80 kbytes of
available storage space. The software can also be
run from a diskette, but the performance will be de-
creased. The software is designed to give its best per-
formance on an IBM 486DX 33 MHz or better ma-
chine. The machine is expected to have the following
components:
• Minimum of one Megabyte of RAM and a hard
drive
• VGA monochrome or color monitor adapter card
• Asynchronous communications adapter configured
as COM1 or COM2
• Minimum of one diskette drive
• DB-9 pin serial communications plug adapted to a
GE Y plug. See Table 4.
• MS-DOS® 5.0 or later version of operating software
The GE SENTRY SOFTWARE is made available to
Hyster Company on a master disk. Hyster Company
has authorization to distribute the software to users
of Hyster lift trucks as required.
• HYTECH™ software diskette with the GE SEN-
TRY SOFTWARE on it.
2200 SRM 597
GE SENTRY SOFTWARE INSTALLATION
The GE SENTRY program will be installed on a hard
disk as one of the tasks of MS-DOS batch file instal-
lation program that is part of the HYTECH software.
CAUTION
Do not try to run GE SENTRY through MS-WIN-
DOWS.
If you are running WINDOWS, close all applications
before attempting to load GE SENTRY. The first
time GE SENTRY is run, it will ask several ques-
tions about the application and the computer:
• Which COM port? Enter either a 1 or 2.
• What password do you want to use? The password
can be any combination of alphanumeric charac-
ters up to 128 characters long.
• GE SENTRY tests the CPU speed of the computer.
It records the CPU speed in percent based on a
486DX 33 MHz machine.
NOTE: Some laptop computers, which have a battery
saver feature, will run as much as 50% slower when
not connected to the AC power supply. If you use a
laptop computer, try the setup in both configurations,
first connected to the AC power supply and then us-
ing battery only.
When the configuration is complete, the information
will be stored in an information file and the main
menu will be displayed. The configuration can be
changed any time from the main menu by the selec-
tion of Option 2.
HOW TO START GE SENTRY PROGRAM
Make sure to follow the WARNING of Connect PC to
Control Card at the front of this manual.
1. Make sure the RS232 cable is connected correctly
to the COM port of the computer. The cable must
also be connected to the motor controller as pre-
viously described.
2. Make sure the battery is connected on the lift
truck and the key is in the OFF position.
3. Start GE SENTRY by selecting 1 from the main
menu.
GE Sentry Software®
4. GE SENTRY will try to establish communica-
tion with the control card through the serial
communication port. If the connection is suc-
cessful, a display of the control identification
and the firmware revision is shown. (Example:
HT-1A meaning control type HT with revision
1A firmware.)
If the communications link is not successful,
an error message is displayed on the computer
screen for 3 seconds and the main menu is
displayed again. If an error message occurs,
check that the serial cable is connected to the
correct COM port, the battery in the lift truck
is connected, and the key is turned to the OFF
position.
5. When GE SENTRY finds the control identifica-
tion and the firmware revision, it automatically
searches for a data base that includes that par-
ticular control card. If the control card is not
found, the selection screen asks for a selection of
the controller that you are using.
6. When GE SENTRY has finished Step 5, the
Control Status Monitor screen is displayed (Fig-
ure 18) and the computer emits a tone. After the
tone, you have 20 seconds to turn the key switch
to ON.
DO NOT turn the key switch to ON before you
hear the tone or the program will fail and return
an error code.
If the key switch is not turned to ON before 20
seconds, the program will terminate the Control
Status Monitor program. The header at the top
of the screen will change from Active to In-
active. Press any key to exit the GE SENTRY
program or return to the main menu.
7. In the upper left-hand corner of the Control
Status Monitor screen is the control status box
(STATUS). The status box shows the status codes
in the same format as the standard instrument
panel display. (-01, -02, etc.)
17
GE Sentry Software®
Figure 18. Control Status Monitor Screen
8. The main Control Status Monitor screen shows
six columns and sixteen rows of data. The six
columns have the following data:
a. Function description.
b. Digital value received from the register on
the control card.
c. Current real time converted analog reading.
d. Minimum hold reading, lowest reading since
last reset.
e. Maximum hold reading, highest reading re-
ceived since last reset.
f. Unit, actual unit measurement reading
shown in volts, amps, etc.
18
2200 SRM 597
HOW TO RESET MIN AND MAX DISPLAY
When the Control Status Monitor screen is shown,
press the R key on the keyboard and the display of the
MAXIMUM and MINIMUM columns are reset. New
maximum and minimum levels are then recorded.
When the Control Status Monitor screen is shown,
the lift truck can be operated normally. The mon-
itor will continuously show the real time status of
the control card and also record the MAXIMUM and
MINIMUM of the selected functions.
HOW TO EXIT GE SENTRY PROGRAM
When the Control Status Monitor screen is shown
and the key switch is in the ON position, press the
ESCAPE key. If the key switch is turned to OFF, the
GE SENTRY program is automatically terminated.