Electrical System: N35ZDR, N45ZR (C264) N30ZDR, N35-40ZR (D470) N30ZDRS, N35-40ZRS (A265)

ELECTRICAL SYSTEM
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]
PART NO. 1590941 2200 SRM 1191

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, 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 the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance 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 when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Electrical System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 2
Static Strap .................................................................................................................................................... 2
Inspect........................................................................................................................................................ 2
Replace ....................................................................................................................................................... 2
Battery Connection ............................................................................................................................................ 3
Inspect ............................................................................................................................................................ 3
Replacing Cables............................................................................................................................................ 3
Key Switch.......................................................................................................................................................... 4
Replace ........................................................................................................................................................... 4
Contactors .......................................................................................................................................................... 6
Function ......................................................................................................................................................... 6
Testing ............................................................................................................................................................ 6
Remove ........................................................................................................................................................... 8
Install ............................................................................................................................................................. 8
EE Contactors ................................................................................................................................................ 8
Motor Controllers............................................................................................................................................... 10
Functions........................................................................................................................................................ 10
Master Controller ...................................................................................................................................... 10
Steering Motor Controller......................................................................................................................... 10
Traction Motor Controller ......................................................................................................................... 10
Lift Motor Controller................................................................................................................................. 10
Steer Caster Controller (Optional) ........................................................................................................... 10
Replace ........................................................................................................................................................... 10
Traction and Lift Motor Controllers ......................................................................................................... 11
Master Controller ...................................................................................................................................... 11
Steering Controller.................................................................................................................................... 12
Steer Caster Controller (Option) .............................................................................................................. 12
Integrated Fuse Board (IFB) ............................................................................................................................. 12
Fuses .......................................................................................................................................................... 13
Replace ........................................................................................................................................................... 13
Power Disconnect Switch................................................................................................................................... 14
Replace ........................................................................................................................................................... 14
Side-Stance Controls.......................................................................................................................................... 16
Multifunction Control Handle ...................................................................................................................... 16
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 17
Assemble ........................................................................................................................................................ 19
Install ............................................................................................................................................................. 19
Forward-Stance Controls................................................................................................................................... 20
Control Handle Functions ............................................................................................................................. 20
Repair......................................................................................................................................................... 20
Aft Travel Control Handle Option ................................................................................................................ 22
Repair......................................................................................................................................................... 23
Steering Handle ................................................................................................................................................. 24
Steering Unit Repair ..................................................................................................................................... 24
Foot Switches ..................................................................................................................................................... 28
Brake Switch.................................................................................................................................................. 28
Operator Sensing ........................................................................................................................................... 28
Repair ............................................................................................................................................................. 28
Dash Display Assembly ..................................................................................................................................... 30
©2008 HYSTER COMPANY i

Table of Contents Electrical System
TABLE OF CONTENTS (Continued)

Description ..................................................................................................................................................... 30
Remove ........................................................................................................................................................... 30
Test ................................................................................................................................................................. 31
Install ............................................................................................................................................................. 31
Horn .................................................................................................................................................................... 32
Audible Alarm................................................................................................................................................ 32
Light Assemblies................................................................................................................................................ 33
Front Lights ................................................................................................................................................... 33
Bulb Replacement ..................................................................................................................................... 33
Assembly Replacement ............................................................................................................................. 33
Rear Work and Caution Light....................................................................................................................... 34
Rear Work Light ........................................................................................................................................ 34
Caution Light ............................................................................................................................................ 34
Light Switches ............................................................................................................................................... 35
Cooling Fans....................................................................................................................................................... 37
Electrical Compartment Fans....................................................................................................................... 37
Replace ....................................................................................................................................................... 38
Operator Fan.................................................................................................................................................. 38
Repair......................................................................................................................................................... 38
Impact Sensor .................................................................................................................................................... 41
Remove ........................................................................................................................................................... 41
Install ............................................................................................................................................................. 41
Height Proximity Switch ................................................................................................................................... 42
Test ................................................................................................................................................................. 42
Remove ........................................................................................................................................................... 42
Install ............................................................................................................................................................. 43
Adjust ............................................................................................................................................................. 43
Load Transport Proximity Switch..................................................................................................................... 44
Replace ....................................................................................................................................................... 44
Adjust ......................................................................................................................................................... 45
Fork Height Sensor Option ............................................................................................................................... 45
Remove ........................................................................................................................................................... 45
Encoder Assembly ..................................................................................................................................... 45
Timing Belt ................................................................................................................................................ 46
Install ............................................................................................................................................................. 47
Encoder Assembly ..................................................................................................................................... 47
Timing Belt ................................................................................................................................................ 48
Reach Position Sensor ....................................................................................................................................... 48
Remove ........................................................................................................................................................... 48
Install ............................................................................................................................................................. 50
Retract Sensor.................................................................................................................................................... 51
Remove ........................................................................................................................................................... 51
Install ............................................................................................................................................................. 51
Tilt Leveling ....................................................................................................................................................... 53
Remove ........................................................................................................................................................... 53
Install ............................................................................................................................................................. 53
Laser Option....................................................................................................................................................... 54
Remove ........................................................................................................................................................... 54
Install ............................................................................................................................................................. 54
Camera Option ................................................................................................................................................... 55
Remove ........................................................................................................................................................... 55
ii
Electrical System Table of Contents
TABLE OF CONTENTS (Continued)

Install ............................................................................................................................................................. 55
Wiring Harness .................................................................................................................................................. 56
This section is for the following models:
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
2200 SRM 1191 General
General
WARNING
This electrical system utilizes capacitors that
maintain a charge on the electrical system
even after the battery is disconnected. Dam-
age to the truck components and injury from
electrical shock may occur if the capacitors
are not properly discharged prior to servicing
the electrical systems. Refer to Discharging
the Capacitors in this section.
CAUTION
Electrical components on this truck are po-
larity sensitive and may be damaged if wired
incorrectly. Make sure each electrical wire
connection is tagged and properly identified
before removal or installation. If the proper
location for connection is unclear, consult the
wiring diagram for the truck. Make sure test-
ing meters have adequate voltage and current
capacities to handle the output of the electri-
cal components they are used to check. Never
wire aftermarket components to this truck
without factory approval.
The electrical system is an alternating current (AC)

system. DC current from the battery is converted
into AC current by a series of transistor motor
controllers to power each AC induction motor. See 1. TRACTION CONTROLLER
Figure 1. Other components of this system include 2. LIFT MOTOR
battery connectors and cables, cooling fans, main 3. AUX HYDRAULIC MOTOR (BELOW) (N35ZDR,
N45ZR, N30ZDR, N35-40ZR ONLY)
contactor, master controller, display unit, integrated 4. MASTER AND STEERING CONTROLLERS
fuse board (IFB), horn, lights, multifunction control 5. TRACTION MOTOR
handle, emergency battery disconnect switch, key or 6. STEERING MOTOR
lever switch, and wiring harnesses. 7. CASTER MOTOR (OPTIONAL)
8. HYDRAULIC CONTROLLER
9. CASTER CONTROLLER (OPTIONAL)
10. INTEGRATED FUSE BOARD (IFB)
Figure 1. Electrical System
1
General 2200 SRM 1191
DISCHARGING THE CAPACITORS Legend for Figure 2
When working with the electrical systems of the 1. POSITIVE CONNECTION (B+)
truck, it is necessary to discharge the capacitors of 2. NEGATIVE CONNECTIONS (B )
3. INSULATED JUMPER WIRES
the controllers associated with each circuit affected. 4. 200-OHM, 2-WATT RESISTOR
5. PUMP MOTOR CONTROLLER
WARNING 6. TRACTION MOTOR CONTROLLER
Capacitors inside the controllers can hold
an electrical charge after the battery is dis-
STATIC STRAP
connected. Discharge the capacitors before The static strap is a rubber strap molded with non-
servicing the electrical system to prevent in- sparking metal inside. It is mounted to the frame
jury or electronic damage. of the lift truck near the lower mast mounting plate.
See Figure 3. Static electricity builds during oper-
1. Move the lift truck to a safe, level area and com-
ation of the lift truck. The tires of the lift truck iso-
pletely lower the mast. Turn the key switch to
late the metal components of the truck from the floor.
the OFF position and attach a DO NOT OPER-
The strap allows limited conductivity between the
ATE tag to the control handle. Block the drive
lift truck frame and the floor to disperse the static
wheel to prevent unexpected movement.
charge. If the static strap is removed or damaged,
2. Disconnect the battery power cable connector the static charge may build. This can cause dam-
from the truck connector located on the right side age to electronic components of the lift truck and
of the frame. Pull the battery cable connector may discharge with a spark when the forks or other
handle to separate the battery connector from parts of the lift truck frame contact items that per-
the truck connector. mit grounding to the floor. Sparks caused by static
electricity can cause an explosion when it occurs near
3. Remove the operator compartment cover. flammable materials or around batteries which vent
flammable gasses during normal operation. Check
4. Discharge the capacitor in the controllers by that the static strap is present and is in good work-
connecting a 200-ohm, 2-watt resistor across the ing condition before operating the lift truck. Replace
controller B+ and B terminals of the motor the strap if necessary.
controller for 10 seconds. Remove the resistor
after discharging the capacitors. See Figure 2. Inspect
Check that the static strap is present and is in good
working condition before operating the lift truck.
Inspect the static strap for wear, cracks, tears, or
missing length. Inspect the strap for cleanliness
and clean if necessary with a mild, soapy detergent
if dirty or oily. Replace the strap as necessary. See
Replace.
Replace
1. Raise the carriage approximately 915 mm
(36 in.). Safety chain the reach carriage assem-
bly in place. Refer to Periodic Maintenance
8000 SRM 1197 for instructions on safety chain-
ing the mast. Turn the key switch to the OFF
position and disconnect the battery. Attach a
DO NOT OPERATE tag to the control handle.
Figure 2. Discharging the Capacitors
2
2200 SRM 1191 Battery Connection
NOTE: Access the static strap from the front of the

lift truck.
2. Remove the hardware securing the old static

strap to the frame. See Figure 3.
3. Install the new static strap using the hardware

as removed.
4. Reconnect the battery, remove the tag from the

control handle, and turn the key switch to the
ON position. Remove the safety chains from the
mast. Refer to Periodic Maintenance 8000
SRM 1197.
1. MAST MOUNTING HOLES
2. HARDWARE
3. STATIC STRAP
Figure 3. Static Strap
Battery Connection
The batter cables supply power from the battery short circuit. High current flow during a short
terminals through the battery cable connectors and circuit can result in injury or parts damage.
then to the connections of the motor controllers and
main contactor in the truck. 1. Move the lift truck to a safe, level area and com-
INSPECT the OFF position and attach a DO NOT OPER-
Inspect the battery cables for cuts or damage to the wheel to prevent unexpected movement.
insulation. Inspect for abrasions of the insulation or
burned insulation or connector ends. Inspect the bat- 2. Pull the connector (battery side) from the fixed
tery connectors for worn or damaged cable ends or connector (truck side) to separate the battery ca-
cracked housings. Overheated cables or heat affected ble connectors. See Figure 4.
terminal lug ends are signs of cable damage, loose
3. If the power cables or connector (battery side) are
connections, or improper battery charging or main-
damaged, replace the cables:
tenance. Replace any damaged cables and repair or
replace damaged battery connectors. a. Remove the battery from the lift truck.
REPLACING CABLES b. Disconnect the cables from the battery termi-
nals.
WARNING
c. Install new cables.
Making repairs with the battery connected can
cause a short circuit. Disconnect the battery by d. Reinstall the battery to the lift truck.
separating the connectors before inspecting or
repairing the electrical system. e. Connect the battery connectors.
Be careful using tools near the battery termi-

nals. Contact between terminals can cause a
3
Key Switch 2200 SRM 1191
b. Discharge the capacitors in the motor con-

trollers. Refer to Discharging the Capacitors.
NOTE: Make note of position of cables for proper re-

installation.
c. Remove the nuts securing the cables to the

terminals of the main contactor and bus bar.
Remove the cables from the terminals.
d. Remove the two clamps securing cables to the

frame inside the electrical compartment.
e. Remove the hardware securing the connector

(truck side) to the frame.
f. Remove the power cables from the lift truck.
g. Route new cables into the electrical compart-

ment.
h. Secure the connector to the frame using two

capscrews and attaching hardware.
i. Position the power cables onto the terminals

as removed. Secure the cables to the termi-
nals of the main contactor and bus bar using
the attaching hardware.
j. Install the two clamps securing power cables

Figure 4. Battery Connector and Cables to the frame inside the electrical compart-
ment as removed.
4. If the power cables or connector (truck side) are
damaged, replace the cables: k. Install the plastic covers to the operator com-
partment as removed.
a. Remove the cover(s) from the operator com-
partment to access the main contactor.
Key Switch
The key switch is used to power ON and OFF the lift
WARNING truck operating systems including the dash display
The key switch does not remove electrical and integrated fuse board.
power from the main contactor and controllers
of the lift truck. Before servicing the truck, REPLACE
disconnect the battery and discharge the ca-
pacitors. See Discharging the Capacitors.
CAUTION
Check the electrical connections to the key
WARNING switch before replacing. Loose connections
Making repairs with the battery connected can of key switch wiring can cause malfunctions
cause a short circuit. Disconnect the battery similar to those caused by a faulty switch.
by separating the connectors before opening
the electrical compartment covers or inspect- NOTE: Some models have lever switches in the place
ing/repairing the electrical system. High cur- of key switches. The lever switch operates identical
rent flow during a short circuit can cause in- to the key switch other than there is no key to be
jury or parts damage. removed.
4
2200 SRM 1191 Key Switch
In the following instructions, both key switches and 2. Disconnect the battery power cable connector
lever switches will be referred to as key switches. See from the truck connector located on the right side
Figure 5 and Figure 6. of the frame. Pull the battery cable connector
handle to separate the battery connector from
1. Move the lift truck to a safe, level area, and com- the truck connector.
the OFF position and remove the key. Attach a 3. Discharge the capacitors. See Discharging the
DO NOT OPERATE tag to the control handle Capacitors.
and block the drive wheels to prevent unexpected
movement. 4. Access the key switch wiring:
a. Remove the plastic cover from the operator

compartment on fore/aft stance models.
OR
b. Remove the plastic cover from the bottom of

the arm rest console on sidestance models.
NOTE: Make note of the position of the key switch

before removal.
5. Remove the nut retaining the key switch to the

mounting bracket and remove the key switch
with the wiring attached.
6. Tag and disconnect the electrical wiring from the

key switch. See Figure 7.
Figure 5. Key Switch
Figure 6. Lever-Type Switch Figure 7. Electrical Connections
5
Contactors 2200 SRM 1191
7. Install the electrical wiring to the new key switch 11. Engage the battery cable connectors. Install the
as removed. key and turn the key switch to the ON position.
Test for proper operation.
8. Position the switch into the mounting hole as re-
moved. 12. Remove the blocks from the drive wheels and the
DO NOT OPERATE tag from the control han-
9. Install the jam nut onto the key switch as re- dle.
moved.
10. Install the plastic cover(s) to the operator com-

Contactors
FUNCTION present. DO NOT wear any rings, watches,
or any other jewelry while working around
Contactors are switches, controlled by electromag- the contactor panel assembly. When manually
nets (coils), that close and open a high current power closing a contactor with the power connected,
circuit. The electromagnetic field in the coil moves use a properly insulated tool.
the armature against spring pressure to close the
contact. When the coil is de-energized, the spring 1. Check the condition of the battery. If it is not
pressure moves the armature and opens the contacts. fully charged, charge or replace the battery with
When a spring holds the contacts of a switch open, a fully charged battery before continuing.
the switch is called normally open (NO). If a spring
holds the contacts of a switch closed, the switch is 2. Remove the electrical compartment cover located
called normally closed (NC). See Figure 8. in the operator compartment.
3. Visually check to see if the contactor closes when

CAUTION the circuit is energized. If the contactor closes,
Cleaning is not necessary. DO NOT use a file on skip to Step 9. If the contactor does not close,
the contacts. DO NOT lubricate the contacts. proceed to Step 4.
The contactor contacts are made of special silver al- 4. Connect a voltmeter across the coil terminals.
loy. The contacts will normally look black and rough Verify that the correct voltage is being applied to
from normal operation. This condition does not in- the coil with the circuit energized.
terfere with the operation of the lift truck. There is
5. Check the contactor for loose, broken, or corroded
no procedure to clean or lubricate the contacts. Re-
connections at the contactor.
place the contacts when the silver alloy is worn away
to the base support metal, when the contacts stick 6. Check the mechanical function of the contactor.
in the closed position, or will not make contact when Use an insulated tool, such as an electrician’s
the contactor is closed. screwdriver, to manually close the contactor
tips. Check for looseness or binding of the mov-
The main contactor is a SPNO (single-pole, normally
ing parts of the contactor. The parts should move
open) contactor. SPNO contactors have one set of
freely, but the parts must not be so loose that the
contacts that remain normally open until power is
movement is sloppy.
applied to the contactor.
7. Visually check the tips for pitting, burning, or
TESTING wear.
WARNING
Parts of this procedure requires working
on the lift truck with full electrical current
6
2200 SRM 1191 Contactors
1. TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

2. LIFT MOTOR CONTROLLER 4. STATUS LED
Figure 8. Controller and Contactor Mounting
8. Remove wires from contactor coil and check the connected and all switches closed, connect a volt
resistance of the coil across the coil leads. Coil ohmmeter across the high current terminals of
resistance should measure 32 ±4 ohms. Readings the contactor.
not within the listed limits indicate the following:
High Resistance - Corrosion or an open coil Check the voltage drop across the contactor tips. Set
Low Resistance - Shorted or a burnt coil the voltage scale of the meter to the lowest range,
higher than battery voltage (50 volts for a 36-volt
9. If the contactor closes but the truck does not battery, etc.). On SPNO contactors, read the voltage
work properly, check the electrical function of across the contactor with the tips open. Battery volt-
the high current section of the contactor (the age should drop to zero or near zero as the tips close.
tips and buss bars). With the lift truck battery
7
Contactors 2200 SRM 1191
A voltage drop of 2 volts or more across the closed tips 5. Tag and disconnect the wires and bus bars to the
indicates a poor contact or high resistance. Check for contactor.
burned or worn tips, incorrect size, or mismatched
tips. 6. Remove the hardware retaining the contactor to
the contactor panel assembly.
REMOVE
INSTALL
pletely lower the mast. Turn the key switch to 1. Align the contactor to the contactor panel assem-
the OFF position and attach a DO NOT OPER- bly. Install hardware to secure the contactor as
ATE tag to the control handle. Block the drive removed.
WARNING
Making repairs with the battery connected can 3. Engage the battery cable connectors. Install the
cause a short circuit. Disconnect the battery key and turn the key switch to the ON position.
by separating the connectors before opening Test for proper operation.
the electrical compartment covers or inspect- 4. Remove the blocks from the wheels, and remove
ing/repairing the electrical system. High cur- the DO NOT OPERATE tag from the control
rent flow during a short circuit can cause in- handle.
jury or parts damage.
2. Disconnect the battery power cable connector EE CONTACTORS

from the truck connector located on the right side When EE contactors are used, additional steps are
of the frame. Pull the battery cable connector required to service the contactors, as the contactors
handle to separate the battery connector from are covered by an enclosure shroud. See Figure 9.
the truck connector.
1. Remove the capscrews retaining the enclosure
WARNING shroud to the contactor. Remove the shroud.
The capacitor in the traction motor controller
2. Remove the insulator.
can hold an electrical charge after the battery
is disconnected. To prevent electrical shock 3. Service the contactor.
and injury, make certain the battery has been
disconnected and discharge the capacitor be- 4. Install the insulator.
fore inspecting or repairing any component.
Always wear safety glasses. 5. Position the enclosure shroud over the contactor
and fasten the shroud to the coil and frame as-
3. Discharge the capacitors. sembly.
4. Remove the electrical compartment covers from

inside the operator compartment to access the
contactor.
8
2200 SRM 1191 Contactors
Legend for Figure 9

1. ENCLOSURE 7. RETURN SPRING
SHROUD 8. MOVING CONTACT
2. CAPSCREW 9. BASE
3. INSULATOR 10. PLUNGER
4. FIXED CONTACT 11. COIL AND FRAME
5. CAPSCREW
6. COVER
Figure 9. Typical EE Contactor
9
Motor Controllers 2200 SRM 1191
Motor Controllers
The motor controllers convert DC power from the and braking are directed and monitored closely by
truck battery to three-phase AC power at the fre- the controller. It is secured beside the lift motor con-
quencies and currents necessary to drive the respec- troller within a mounting bracket beneath the front
tive motor. Each AC induction motor provides feed- operator compartment cover. The bracket is mounted
back of speed, rotation direction, and temperature to the inside wall of the front frame, adjacent to the
directly to the motor controller. The two motor con- electrical compartment cooling fan and allows room
trollers used to power the traction motor and hy- for air circulation behind the controller casings. Bus
draulic pump motor are very similar. The primary bars connect the traction controller and the lift mo-
difference is in the power output rating. The motor controller to the main contactor.
tor controller logic board receives power from the key
switch. Power to the motors can be interrupted indi- Lift Motor Controller
rectly by turning the key switch to the OFF position.
The motor controllers monitor motor speed and tem- The lift motor is driven and monitored by the lift mo-
perature information directly from the motors. The tor controller. Bus bars connect the lift motor con-
motor controllers do not receive any other input from troller and the traction controller to the main contac-
the truck. The master controller relays speed, accel- tor. It oversees lift pump motor operation and cur-
eration, and direction commands to the motor con- rents recovered by the lift pump motor during low-
trollers. The controllers can communicate problems ering. Different controller options are available de-
to the operator through the dash display. pending on truck model. The lift motor controller is
secured to a heat sink within the mounting bracket
NOTE: See Figure 1 for location of the controllers. beside the traction motor controller and is cooled by
the front cooling fan.
FUNCTIONS
Steer Caster Controller (Optional)
Master Controller
Units with the steered caster option use a steer
The master controller is a general purpose micro-con- caster controller to monitor, direct, and power the
troller for CANbus based electric vehicles. It con- motor which rotates the caster. The steer caster
tains processing power, memory resources, analog controller is located beneath the floor plate of the
and digital input/output (I/O) to provide the required operator compartment.
full featured functionality. The master controller is
designed to manage the traction motor controller and REPLACE
pump motor controller, interface to the operator con-
trols, and control the display unit. The master con- WARNING
troller is located inside the drive unit compartment. Making repairs with the battery connected can
It is mounted on the wall of the frame just above the cause a short circuit. Disconnect the battery
steering controller. by separating the connectors before opening
the electrical compartment covers or inspect-
Steering Motor Controller ing/repairing the electrical system. High cur-
The steering motor controller monitors, powers, and rent flow during a short circuit can cause in-
directs the motor controlling the angle of the drive jury or parts damage.
unit. The steering motor controller is located inside
the drive unit compartment. It is mounted on the
wall of the frame just below the master controller.
Traction Motor Controller wheel to prevent unexpected movement.
The traction motor controller monitors and supplies
2. Disconnect the battery power cable connector
power to the traction motor. Constant communica-
from the truck connector located on the right side
tion between the controller and the motor is neces-
of the frame. Pull the battery cable connector
sary to ensure seamless operation between the oper-
ator controls and the motor. Direction, acceleration,
10
2200 SRM 1191 Motor Controllers
3. Remove the operator compartment covers. 5. Remove the controller mounting plate with the
steering and master controllers from the drive
4. Discharge the capacitors. Refer to Discharging unit compartment. Remove and replace the
the Capacitors. faulty controller(s) as necessary.
Traction and Lift Motor Controllers 6. Install the controller mounting plate back into
the drive unit compartment and secure to frame
CAUTION wall using screws as removed.
Each controller is mounted on an aluminum 7. Install power cables to controller terminals as re-
heat sink plate. DO NOT remove the controller moved.
module from the heat sink.
8. Connect the battery connectors, turn the key
CAUTION switch to the ON position. Set up controller
using ETACC:
On some models, the traction motor controller
and lift motor controller appear visually iden- a. Connect the PC (with latest ETACC config-
tical. However, these components are NOT IN- uration files) to the lift truck via the IFAK
TERCHANGEABLE. Refer to the Parts Manual dongle.
for ordering information when replacing trac-
tion motor or lift motor controllers. b. Choose the correct truck configuration and
connect.
NOTE: When replacing either the traction or lift
motor controller, both must be removed with the c. Open the Restore Factory Defaults/New
mounting bracket. However, only the controller be- Master Controller view.
ing replaced should be removed from the mounting
bracket. d. Enter the serial number of the truck in the
first line under the Set Value column.
1. Make note of power cables and buss bars place-
ment and remove from both controllers and the e. Choose the handle type of the truck (side
main contactor. stance or forward stance) in the Set Value col-
umn.
2. Remove hardware securing wire clamps and
hoses to the mounting bracket. f. Click "Download."
3. Remove screws securing mounting bracket to g. Verify that all parameters downloaded cor-
the frame. Lift the mounting bracket, both con- rectly.
trollers, and the main contactor from the lift
h. Perform calibrations.
truck. Refer to Figure 8.
i. Enter any custom settings at this time.
Master Controller
j. All options must be reconfigured by entering
1. Open the drive unit compartment door and re- the appropriate option codes.
move the operator compartment covers as neces-
sary. 9. Connect the battery connectors, turn the key
switch to the ON position, and test for proper
2. Drain the oil from the tank and remove the main operation.
lift supply hose from the lift pump for access
to the controller mounting plate. Refer to Hy- 10. Close the drive unit compartment door and se-
draulic System 1900 SRM 1189. cure closed with two capscrews as removed.
3. Tag and disconnect the power cables and remove 11. Install the electrical compartment covers as re-
from the controllers. moved. Remove the DO NOT OPERATE tag
and remove blocks from the wheels.
4. Remove the screws securing the controller
mounting plate to the wall of the frame.
11
Integrated Fuse Board (IFB) 2200 SRM 1191
Steering Controller e. Click "Download."
1. Open the drive unit compartment door and re- 9. Connect the battery connectors, turn the key
move the operator compartment covers as neces- switch to the ON position, and test for proper
sary. operation.
2. Drain the oil from the tank and remove the main 10. Close the drive unit compartment door and se-
lift supply hose from the lift pump for access cure closed with two capscrews as removed.
to the controller mounting plate. Refer to Hy-
draulic System 1900 SRM 1189. 11. Install the electrical compartment covers as re-
moved. Remove the DO NOT OPERATE tag
3. Tag and disconnect the power cables and remove and remove blocks from the wheels.
from the controllers.
Steer Caster Controller (Option)
4. Remove the screws securing the controller
mounting plate to the wall of the frame. 1. Remove the floor mat from the operator compart-
ment.
5. Remove the controller mounting plate with the
steering and master controllers from the drive 2. Remove the four capscrews securing the floor
unit compartment. Remove and replace the plate to the frame. Remove the floor plate
faulty controller(s) as necessary.
3. Tag and disconnect the wiring from the controller
6. Install the controller mounting plate back into terminals.
the drive unit compartment and secure to frame
wall using screws as removed. 4. Remove the four screws securing the steer caster
controller. Remove the controller.
7. Install power cables to controller terminals as re-
moved. 5. Position the new controller and secure in place
using four screws as removed.
switch to the ON position. Set up controller 6. Install wiring to the controller terminals as re-
using ETACC: moved.
a. Connect the PC (with latest ETACC config- 7. Install the floor plate and floor mat as removed.
uration files) to the lift truck via the IFAK
dongle.
switch to the ON position, and test for proper
b. Choose the correct truck configuration and operation.
connect.
9. Install the electrical compartment covers as re-
c. Open the Restore Factory Defaults/New moved. Remove the DO NOT OPERATE tag
Master Controller view. and remove blocks from the wheels.
d. Enter any custom settings at this time.
Integrated Fuse Board (IFB)

The Integrated Fuse Board (IFB) is located on the in- turned to the ON position, the IFB closes the K1 re-
side of the front frame wall, beside the traction and lay on the IFB to provide power to the lift truck logic
lift motor controllers. The IFB can be accessed by circuits.
removing the operator compartment covers. See Fig-
ure 10. The IFB is used to precharge the power am- NOTE: The IFB is voltage specific to the lift truck.
plifiers in the motor controllers when the battery is Though some are similar in appearance, not all IFBs
connected to the lift truck. When the key switch is are interchangeable. Refer to the Parts Manual
when replacing the IFB for proper part selection.
12
2200 SRM 1191 Integrated Fuse Board (IFB)
The IFB also provides power for electrical compo- to the OFF position and disconnect the battery.
nents and optional equipment that may be installed Discharge the capacitors. See Discharging the
on the lift truck. IFBs are specific for 24 volt and Capacitors.
36 volt lift trucks, and may be identified by the part
number located on the IFB connector. See Figure 10. 2. Remove the two screws securing the plastic cover
All IFBs for 36-volt units are equipped with a 24-volt on the IFB for access to the fuses.
regulator to power 24-volt accessories. An optional
3. Test the fuses using an ohmmeter to check fuses:
12-volt regulator is available on both 24- and 36-volt
IFBs depending on truck options. a. Infinite Resistance = Defective Fuse
b. Continuity = Fuse Ok
4. Replace any defective fuse with a proper rated

fuse. See Figure 10.
REPLACE
WARNING
1. 7.5 AMP FUSE (JP2) Making repairs with the battery connected can
2. 10 AMP FUSES (FOUR PLACES) cause a short circuit. Disconnect the battery
3. IDENTIFICATION LABEL ON CONNECTOR
Figure 10. Integrated Fuse Board (IFB) the electrical compartment covers or inspect-
ing/repairing the electrical system. High cur-
NOTE: The integrated fuse board is not repairable. rent flow during a short circuit can cause in-
If damaged, it must be replaced. Check the IFB for jury or parts damage.
signs of damaged or burned components. Fuses are
the only replaceable component on the IFB. 2. Disconnect the battery power cable connector
Fuses of the frame. Pull the battery cable connector
WARNING
Making repairs with the battery connected can 3. Remove the plastic cover from the operator com-
cause a short circuit. Disconnect the battery partment.
the electrical compartment covers or inspect- 4. Discharge the capacitors. See Discharging the
ing/repairing the electrical system. High cur- Capacitors.
rent flow during a short circuit can cause in-
jury or parts damage. 5. Tag and remove IFB wire connections. Remove
the IFB from the mounting posts on the truck
The fuses are found on the IFB. See Figure 10. The frame.
condition of the fuses can often be checked visually.
If unsure of condition, check fuses for continuity with 6. Install the electrical wiring to the IFB as re-
an ohmmeter. moved.
1. Completely lower the mast and park the lift truck

in a safe, level location. Turn the key switch
13
Power Disconnect Switch 2200 SRM 1191

CAUTION partment as removed.
Overtightening the attaching hardware can
damage the IFB. 9. Engage the battery cable connectors. Install the
key and turn the key switch to the ON position.
7. Position the IFB onto the mounting posts and se- Test for proper operation. Remove the blocks
cure as removed. from the drive wheels and the DO NOT OPER-
ATE tag.
Power Disconnect Switch

REPLACE 3. Access the lower half of the battery disconnect
switch:
WARNING a. Remove the plastic cover from the operator
Making repairs with the battery connected can compartment on fore/aft stance models.
cause a short circuit. Disconnect the battery OR
the electrical compartment covers or inspect- b. Remove the plastic cover from the bottom of
ing/repairing the electrical system. High cur- the arm rest console on sidestance models.
rent flow during a short circuit can cause in- See Figure 11.
WARNING
The power disconnect switch does not remove
electrical power from the main contactor and
controllers of the lift truck. Its primary pur-
pose is for allowing removal of truck power
quickly to operating systems during an emer-
gency. Before servicing the lift truck, discon-
nect the battery and discharge the capacitors.
See Discharging the Capacitors.
CAUTION
Check the electrical connections to the battery
disconnect switch before replacing. Loose con-
nections of switch wiring can cause malfunc-
tions similar to those caused by a faulty switch.
1. Move the lift truck to a safe level area and com-

the OFF position and remove the key. Attach a
DO NOT OPERATE tag to the control handle
and block the drive wheels to prevent unexpected
movement.

A. TOP VIEW B. SIDE VIEW
handle to separate the battery connector from Figure 11. Battery Disconnect Switch
14
2200 SRM 1191 Power Disconnect Switch
4. Loosen the adjustment screw pressing the 12. Remove the blocks from the drive wheels and the
mounting collar of the lower switch to the dash. DO NOT OPERATE tag from the control han-
See Figure 12. dle.
5. Pull the release lever in the side of the contact

block to release the switch into two halves. Re-
move the upper half of the switch from the dash
panel.
6. Tag and disconnect the electrical wiring from the

lower switch. Remove the lower switch from the
truck.
7. Install the wiring to the new lower switch as re-

moved. Position the lower switch to the under-
side of the dash.
8. Install the new upper switch half through the

hole in the top of the dash panel. Align the upper
half with the lower half and press until they lock
together.
9. Turn the adjustment screw to press the mounting

collar against the dash panel to secure the switch
in place. A. UPPER SWITCH HALF
B. LOWER SWITCH HALF
10. Replace the dash covers as removed: 1. SWITCH BUTTON
2. DASH PANEL
a. Install the plastic cover to the operator com- 3. MOUNTING COLLAR
partment on fore/aft stance models. 4. RELEASE LEVER
OR 5. CONTACT BLOCK
6. MICRO-SWITCH
b. Install the plastic cover to the bottom of the 7. ADJUSTMENT SCREW
arm rest console on sidestance models.
Figure 12. Switch Mounting
11. Engage the battery cable connectors. Install the
Test for switch proper operation.
15
Side-Stance Controls 2200 SRM 1191
Side-Stance Controls
MULTIFUNCTION CONTROL HANDLE The control handle also controls the lift/lower func-
tions. When the control handle is pulled toward
The multifunction control handle provides operator the operator, the carriage lifts. When the handle is
control for travel, lift, tilt, sideshift, horn, and reach pushed away from the operator, the carriage lowers.
functions. See Figure 13. The speed of the mast is proportional to the distance
the control handle is moved.
Travel is activated by moving the control handle in
the direction of travel. Pushing the control handle NOTE: During lift truck operation, the auxiliary
in the direction of the forks will cause the lift truck functions can only be operated one at a time.
to move in the direction of the forks. Pushing the
control handle in the opposite direction of the forks The reach functions are controlled by two buttons lo-
will cause the lift truck to move with the forks trail- cated on the underside of the control handle shaft.
ing. The travel speed for both forward and reverse
directions is proportional to the distance the handle A thumb-operated tilt/sideshift disk, located on the
is moved; the further the distance, the faster the lift face of the control handle, controls tilt and sideshift.
truck travels. See Figure 14. To tilt forward, press the top of the
disk. To tilt back, press the bottom of the disk. To
activate the sideshift function, press the right side of
the disk to move the carriage to the right. Press the
left side of the disk to move the carriage to the left. A
button which activates the horn is located to the left
of the tilt/sideshift disk.
1. TILT/SIDESHIFT DISK
2. HORN BUTTON
3. EXTEND/RETRACT (UNDERSIDE OF HANDLE)
Figure 13. Control Handle 1. TILT BACK 3. SIDESHIFT RIGHT

2. SIDESHIFT LEFT 4. TILT FORWARD
NOTE: Diagonal movement of handle will control
both travel and a hydraulic function simultaneously. Figure 14. Tilt/Sideshift Disk
16
2200 SRM 1191 Side-Stance Controls
REMOVE DISASSEMBLE
When disassembling the control handle, it is recom-
WARNING mended that the technician have a working knowl-
Disconnect the battery by separating the con- edge of circuit board repairs. See Figure 15.
nector before opening the compartment cover
or inspecting/repairing the electrical system. NOTE: The lower control mechanism is non-re-
If a tool causes a short circuit, the high-cur- pairable and the entire control handle must be
rent flow from the battery can cause an injury replaced if it is defective.
or parts damage.
1. Remove four screws from the handle mounting
1. Move the lift truck to a safe, level area. Turn the plate. See Figure 16.
key switch OFF and remove the key. Put blocks
under the drive wheels to keep the lift truck from 2. Remove the handle mounting plate from the han-
moving. dle assembly.
2. Disconnect the battery by separating the connec- 3. Remove two screws from the lower handle grip.
tors.
4. Remove the upper plastic handle cover from the
handle.
WARNING
The capacitor in the traction motor controller 5. If necessary, replace the reach switches or horn
can hold an electrical charge after the battery switches by removing the red buttons and re-
is disconnected. To prevent electrical shock move the existing wires from the switch circuit
and injury, discharge the capacitor before board.
inspecting or repairing any component. Wear
safety glasses. Make certain the battery has 6. Solder in the new switches.
been disconnected. 7. After replacing the switch, perform a circuit test
3. Discharge the capacitors. Refer to Discharging on the switch checking for continuity.
the Capacitors in this section. 8. Remove the tilt/sideshift cover button.
4. Access the control handle wiring: 9. Remove two screws from the circuit board.
a. Remove the plastic cover from the operator NOTE: Mark the position of the screws during re-
compartment on forward facing models. moval. The longer screws go in the top two holes.
OR
10. Remove four screws on the lower handle base.
the arm rest console on sidestance models. 11. Remove the bracket.
5. Remove the multifunction control handle by dis- 12. Remove the upper and lower handle pieces.
connecting the plug from the connector and re-
moving the four capscrews retaining the handle
to the frame.
17
Side-Stance Controls 2200 SRM 1191
1. SWITCH 5. TOP HOUSING

2. HORN SWITCH 6. CIRCUIT BOARD
3. QUAD BUTTON 7. BOTTOM HOUSING
4. BUTTONS
Figure 15. Control Handle Repair
18
2200 SRM 1191 Side-Stance Controls
5. Install the tilt/sideshift cover button.
6. Ensure the wires and switches are positioned

properly and install the top cover with two
screws.
7. Test the reach, horn, and tilt/sideshift buttons for

proper operation.
8. Slide the handle mounting plate over the handle

wiring and secure with four screws.
INSTALL
1. Install the multifunction control handle by re-
versing the steps above.
1. SCREWS
Figure 16. Control Handle Mounting Plate
NOTE: Record the number and color of the wire posi-

tions.
13. Remove the wires from the switch. See Fig-

ure 17.
ASSEMBLE
1. Install four way switch circuit board by soldering
the wires.
1. WHITE 4. WHITE/BLACK
2. Conduct a circuit test on each switch, checking 2. BLUE STRIPE
for continuity. 3. ORANGE 5. PURPLE
3. Install bottom handle piece with four screws and Figure 17. Wire Identification
locking bracket.
4. Install the circuit board with two screws.
19
Forward-Stance Controls 2200 SRM 1191
Forward-Stance Controls
CONTROL HANDLE FUNCTIONS Block the drive wheel to prevent unexpected
movement.
The forward-stance models utilize a different control
configuration than the multifunction control handle 2. Remove the operator compartment cover to ac-
on side-stance models. The operator directs forward cess the control handle mounting hardware.
and reverse movement by pushing the control han-
dle in the desired direction. There is no side-to-side
movement of the forward-stance control handle. The
CAUTION
lift functions are controlled by a paddle switch on the The handle box is sealed by the manufacturer
face of the control handle. Sideshift and tilt functions with a tamper evident label. The warranty will
are controlled by button switches located to the right be void if the seal is broken.
of the paddle switch facing the operator. A button
3. Disconnect the control handle wiring harness
switch located below the lift/lower paddle activates
from the main wiring harness. Repair wiring as
the horn. Another paddle switch, which controls the
necessary.
reach functions, is located on the opposite side of the
grip and is operated with the index finger. See Fig-
ure 18. Forward-stance models with rear grip are
designed to allow operation of the directional func-
tions of the control handle while facing the rear of the
truck using the rear grip. A thumb-operated button
located at the end of the rear grip operates the horn
when facing the rear of the truck. See Figure 19.
Repair
CAUTION
The handle box is sealed by the manufacturer
with a tamper evident label. The warranty will
be void if the seal is broken.
NOTE: The handle box is non-repairable and the en-

tire control handle must be replaced if it is defective.
NOTE: Heater components on freezer application

control handles are not repairable. The control
handle must be replaced.
Perform the following procedures to repair the for-

ward-stance control handle. For the following in-
structions, refer to Figure 21 or Figure 20.
WARNING 1. TILT DOWN

Capacitors inside the controllers can hold 2. SIDESHIFT RIGHT
an electrical charge after the battery is dis- 3. SIDESHIFT LEFT
connected. Discharge the capacitors before 4. TILT UP
servicing the electrical system to prevent in- 5. HORN BUTTON
6. LIFT/LOWER
jury or electronic damage. 7. PALM REST
1. Move the lift truck to a safe, level area and Figure 18. Forward-Stance Control Handle
completely lower the mast. Turn the key switch (With Palm Rest)
to the OFF position and disconnect the battery.
20
2200 SRM 1191 Forward-Stance Controls
4. Remove the four capscrews securing the control

handle to the dash assembly. Remove the control
handle from the dash.
5. On models with rear grip handles, remove the

screws securing the rear grip and trunnion to the
control handle. Separate the rear grip and trun-
nion and disconnect the horn button wiring. Re-
move the horn button if necessary. See Figure 20.
or
6. On models with palm rest, remove the roll pin se-

curing the palm rest and trunnion to the control
handle. Separate the palm rest and trunnion.
See Figure 21.
1. UPPER GRIP
1. TILT DOWN 9. CONNECTOR 2. SCREWS AND WASHERS
2. SIDESHIFT LEFT 10. RUBBER BOOT 3. REAR GRIP
3. SIDESHIFT RIGHT 11. CONNECTOR 4. HORN BUTTON
4. TILT UP 12. EXTEND/RETRACT 5. RUBBER BOOT
5. HORN BUTTON PADDLE 6. HANDLE BOX
6. CONTROL (UNDERSIDE OF 7. WIRING HARNESS
HANDLE GRIP HANDLE) 8. TRUNNION
7. REAR GRIP 13. LIFT/LOWER 9. SCREWS
8. HORN BUTTON PADDLE 10. LOWER GRIP
Figure 19. Forward Stance Control Handle Figure 20. Forward Stance (With Rear Grip)
(With Rear Grip)
21
Forward-Stance Controls 2200 SRM 1191
9. Disconnect the wiring harness terminals from

the switches being removed. Tag and identify
the wiring harness connections that are removed.
Inspect the wiring and connectors. Repair wiring
as necessary.
10. Remove and replace faulty switches as necessary.
11. Connect the wiring and connectors to the

switches as removed. Route the wiring so it
does not interfere with assembly of the grips.
12. Position the grip halves together and secure us-

ing screws as removed.
13. On models with rear grip, install the horn but-

ton into the rear grip if removed. Connect the
horn button wiring. Position the rear grip and
trunnion around the control handle and secure
in place using screws and washers as removed.
or
14. On models with palm rest, position the palm rest

and trunnion around the control handle and se-
cure in place using roll pin as removed.
15. Install the handle assembly to the dash using

four capscrews and washers as removed.
16. Connect the handle wiring harness to the main

wiring harness.
17. Install operator compartment cover.
1. UPPER GRIP 18. Connect the battery, turn the key switch to the
2. PALM REST ON position, and test for proper operation.
3. RUBBER BOOT
4. HANDLE BOX AFT TRAVEL CONTROL HANDLE OPTION
5. WIRING HARNESS
6. TRUNNION The Aft Travel Control Handle is an option available
7. SCREWS
8. LOWER GRIP on the forward-stance lift trucks which features an
optional control handle mounted to the operator back
Figure 21. Forward Stance (With Palm Rest) pad. This feature allows the operator to turn and face
the rear of the operator compartment, while driving
7. Remove the screws securing the upper grip to the the lift truck in reverse. The Aft Travel Control Han-
lower grip. Gently separate the grips. dle consists of a handle body, a directional control
thumb switch, a horn button, and an optical sensor
8. Inspect the rubber boot for cracks or tears. Re-
to detect hand position. See Figure 22.
place as necessary.
22
2200 SRM 1191 Forward-Stance Controls
1. UPPER COVER 5. HORN BUTTON

2. LOWER COVER 6. SCREWS
3. CAPSCREWS 7. CAPSCREW
4. WASHERS
Figure 22. Aft Control Handle
Repair Block the drive wheel to prevent unexpected

movement.
NOTE: The horn switch is the only internal compo-
nent of the Aft Travel Control Handle which can be 2. Remove the operator compartment cover to ac-
replaced. cess the operator backpad mounting screw.
Perform the following procedures to repair the Aft 3. Disconnect the Aft Travel Control Handle wiring.
Travel Control Handle. Repair wiring as necessary.
4. Remove the two screws securing the operator

WARNING backpad to the frame. Remove the backpad.
an electrical charge after the battery is dis- 5. Remove the three capscrews and washers secur-
connected. Discharge the capacitors before ing the Aft Travel Control Handle to the operator
servicing the electrical system to prevent in- backpad. Remove the Aft Travel Control Handle.
jury or electronic damage.
6. Remove the three screws securing the upper and
1. Move the lift truck to a safe, level area and lower housings together. Lift the upper housing
completely lower the mast. Turn the key switch from the lower housing.
to the OFF position and disconnect the battery.
23
Steering Handle 2200 SRM 1191
7. Carefully clip the wiring harness where soldered 10. Position the Aft Travel Control Handle to the op-
to the horn switch. Remove the nut securing the erator backpad as removed. Secure in place with
horn switch to the lower housing and remove the three capscrews and washers as removed.
switch.
11. Route the aft handle wiring harness through the
8. Install a new horn switch and secure to the lower frame and connect to the main wiring harness.
housing with nut as removed. Solder the wiring
harness to the horn leads as removed. 12. Position the operator backpad to the frame and
secure using two capscrews as removed.
9. Assemble the upper housing to the lower housing
of the Aft Travel Control Handle. Secure in place 13. Reinstall the operator compartment cover.
with three screws as removed.
14. Connect the battery, turn the key switch to the
ON position, and test for proper operation.
Steering Handle
The steering handle assembly is the input device for 3. Disconnect the steering handle connector from
the lift truck steering system. As the operator turns the main wiring harness. Remove all clamps se-
the steering handle, a steering sensor inside the as- curing the handle wiring.
sembly rotates. The steering sensor detects the di-
rection and speed of the handle rotation and commu- 4. Loosen the four capscrews securing the steering
nicates this data to the steering motor controller. support pad to the mounting plate. Lift the steer
support pad and steering unit from the lift truck.
STEERING UNIT REPAIR
5. Remove the cover from the steering handle and
The following procedures refer to the replacement of remove the nut and washer from the steering
the steering unit sensor inside the steering handle. unit shaft. Lift the steering handle from the steer
See Figure 23 or Figure 24. support pad and recover the key from the steer-
ing unit shaft.
pletely lower the mast. Turn the key switch to 6. Turn the assembly upside down on a clean work
the OFF position and disconnect the battery. At- surface. Remove the four screws and washers
tach a DO NOT OPERATE tag to the control securing the steering unit to the steering support
handle and block the drive wheel to prevent un- pad. Remove the steer unit.
expected movement.
2. Remove the two capscrews securing the drive

unit compartment door and pull the door open.
Legend for Figure 23

1. COVER 12. CAPSCREW
2. NUT 13. LOCKWASHER
3. WASHER 14. WASHER
4. WOODRUFF KEY 15. CAPSCREW
5. STEERING HANDLE 16. MOUNTING BRACKET
6. STEER SUPPORT PAD 17. SPACER
7. STEERING UNIT 18. MOUNTING PLATE
8. WASHER 19. PLUG
9. SCREW 20. KNOB
10. WASHER 21. RETAINING RING
11. LOCKWASHER 22. CAP
24
2200 SRM 1191 Steering Handle
Figure 23. Steering Handle (Fixed)
25
Steering Handle 2200 SRM 1191
Figure 24. Steering Handle (Adjustable)
26
2200 SRM 1191 Steering Handle

1. COVER 18. WASHER
2. NUT 19. LOCKWASHER
3. WASHER 20. CAPSCREW
4. WOODRUFF KEY 21. CAPSCREW
5. STEERING HANDLE 22. LOCKWASHER
6. STEERING UNIT 23. WASHER
7. WASHER 24. WASHER
8. SCREW 25. LOCKWASHER
9. OUTER RACE (TOP) 26. CAPSCREW
10. MOUNTING PLATE (INNER RACE) 27. RETAINING CLIP
11. OUTER RACE (BOTTOM) 28. SPACER
12. TILLER LATCH PLATE 29. TILLER LATCH PIN
13. MOUNTING BRACKET 30. STEER SUPPORT PAD
14. NUT 31. PIN CAP
15. SPACER 32. KNOB AND KNOB CAP
16. WASHER 33. RETAINING RING
17. CAPSCREW
7. Position the new steering unit to bottom of the and spacers as removed. Install the clamps se-
steer support pad and secure in place using the curing the steering unit wiring harness in place.
screws and washers as removed.
11. Connect the steering unit connector to the main
8. Install the key into the steering unit shaft and wiring harness. Secure wiring with connectors
position the steering handle onto the steer sup- as removed. Close the drive unit compartment
port pad. Carefully align the steering unit shaft door and secure using capscrews as removed.
and key with the groove in the steering handle.
12. Engage the battery connectors and turn the key
9. Install the washer and nut securing the steer- switch to the ON position. Test for proper opera-
ing handle to the steering unit shaft. Install the tion.
cover to the steering handle.
13. Remove the DO NOT OPERATE tag from the
10. Position the steer support pad to the mounting control handle, blocks from the wheels, and re-
plate. Secure in place using capscrews, washers, turn the unit to service.
27
Foot Switches 2200 SRM 1191
Foot Switches
The foot switches are safety devices located in the the normal position of the operator is slightly differ-
floor of the operator compartment. The operator ent. The brake switch is accessible when standing
must depress operator sensing switch on initial normally in the operator compartment and must be
startup for lift functions to operate. The brake continuously depressed to operate the lift truck. Re-
switch must then be depressed to allow the truck leasing the switch activates neutral braking which
to travel. These features prevent the unexpected slows the truck gradually using the traction motor.
movement of the lift truck when the operator is As the neutral braking brings the lift truck to a stop,
not properly positioned at the controls and stops the main controller applies the parking brake to hold
the truck if an operator leaves brake switch. See the truck stationary.
Figure 25.
OPERATOR SENSING
The operator sensing switch is a safety device lo-
cated in the floor of the operator compartment. The
operator depresses (and releases) the switch using
the right foot after the key switch has been turned
ON and the brake switch is being depressed. Press-
ing the operator sensing switch activates the con-
trol handle functions including directional travel and
hydraulic functions. When reentering the operator
compartment, the operator sensing switch must be
pressed again to reset the lift truck functions.
REPAIR
For the following procedures, see Figure 26.
WARNING
an electrical charge after the battery is dis-
connected. Discharge the capacitors before
servicing the electrical system to prevent in-
1. OPERATOR SENSING SWITCH jury or electronic damage.
2. FLOOR MAT
3. BRAKE SWITCH 1. Move the lift truck to a safe, level area and com-
4. TRACTION MOTOR pletely lower the mast. Turn the key switch to
Figure 25. Foot Switch Locations ATE tag to the control handle. Block the drive
BRAKE SWITCH
The brake switch is a foot switch located in the floor from the truck connector located on the right side
near the entrance of the operator compartment. The of the frame. Pull the battery cable connector
operator depresses and holds the switch using the handle to separate the battery connector from
left foot when standing in the operator compartment. the truck connector.
Placement of the switch varies slightly in fore/aft
stance models and the sidestance models because
28
2200 SRM 1191 Foot Switches
3. Discharge the capacitors. See Discharging the 13. Install all covers as removed and return to ser-
Capacitors. vice.
4. Lift the floor mat from the floor of the operator

compartment.
5. Remove the four capscrews securing the floor

plate to the mounting feet.
6. Lift the floor plate on its side and disconnect the

foot switch connectors from the wiring harness.
Remove the floor plate from the lift truck.
NOTE: Replace only the components necessary to

complete the repairs.
7. Remove the operator sensing switch retaining

screws from the bottom of the floor plate and re-
move the operator sensing switch. Install the
new operator sensing switch and secure in place
with screws as removed.
8. Remove the reset switch retaining screws from

the bottom of the floor plate and remove the reset
switch. Install the new reset switch and secure
in place with screws as removed.
9. Position the floor plate into the operator com- 1. FLOOR MAT
2. OPERATOR SENSING SWITCH
partment on its side and connect the switch con- 3. MOUNTING PLATE
nectors as removed. 4. MOUNTING PLATE SCREWS
5. SWITCH MOUNTING HARDWARE
10. Lay the floor plate flat and check that the cap- 6. MOUNTING FEET
screw holes are aligned with the threads in the 7. MOUNTING FEET HARDWARE
mounting feet. Adjust the mounting feet if nec- 8. SWITCH MOUNTING HARDWARE
essary. Install the capscrews as removed. 9. BRAKE SWITCH
11. Install the floor mat into the operator compart- Figure 26. Foot Switch Assemblies
ment cover as removed.
12. Connect the battery cables and test for proper

operation.
29
Dash Display Assembly 2200 SRM 1191
Dash Display Assembly

DESCRIPTION The Warning/Fault Indicator blinks to alert the op-
erator to check the Message Center. When a warn-
The dash display interfaces with the master con- ing message is displayed, the Warning/Fault Indica-
troller, control handle, and the traction controller. It tor blinks yellow. When a fault message is displayed,
is located adjacent to the steering handle on fore/aft the Warning/Fault Indicator blinks red.
stance models and attached to the control handle
armrest of sidestance models. The dash display is The battery indicator has a 10 bar green, yellow, and
the primary message communication to the operator red light emitting diode (LED) to indicate the battery
and displays the truck status and active functions, charge. As power is used, the LEDs will turn off in
as well as warning and advisory messages. The sequence, starting with green, the yellow, then red.
display is also the communication display during The red LED, second from the bottom, flashes to in-
controller programming and diagnostic operations. dicate when the battery is nearly discharged. The
The dash display is energized when the key switch is red LED on the bottom of the display will alternately
ON and the battery disconnect switch is closed. An flash with the low-battery indicator LED (a crossed
internal backup battery provides memory retention battery symbol) to indicate that the battery is dis-
of the battery indicator and hourmeter readings charged and the lift function is disabled.
when the battery is disconnected from the truck.
REMOVE
The message center is a 16-character, alphanumeric,
liquid crystal display (LCD), with green backlight- The dash display assembly cannot be repaired and
ing. The hourmeter, truck performance status mes- must be replaced if inoperable or damaged. Check
sages, warning messages, fault messages, and the connections to the unit by unplugging connectors,
master controller programming default values are cleaning plug terminals, reconnecting, and testing
shown on the Message Center. See Figure 27. the unit before replacing the display.

WARNING
Disconnect the battery and separate the con-
nector before opening the compartment cover
or inspecting/repairing the electrical system.
If a tool causes a short circuit, the high cur-
rent flow from the battery can cause an injury
or parts damage.

3. Remove the plastic cover(s) from the operator

compartment or armrest to access the display
mounting.
A. PREMIUM B. STANDARD
Figure 27. Displays
30
2200 SRM 1191 Dash Display Assembly
INSTALL
1. Connect the wiring harness connector to the dash
display assembly.
2. Position the dash display assembly in the arm-

rest mount or dash panel.
3. Install the retainers and the thumbscrews to se-

cure the dash display assembly.
4. Install the operator compartment covers.
5. Engage the battery cable connectors. Turn the

key switch to the ON position and test for proper
operation.
6. Install the battery cable compartment cover and

remove the blocks from the drive wheels. Re-
move the DO NOT OPERATE tag and return
to service.
A. PREMIUM
B. STANDARD
1. THUMB SCREWS
2. VENTS
3. CONNECTOR PLUG
Figure 28. Display (Back View)
4. Remove the 2 thumbscrews and the retainers se-

curing the display to the display panel or cover
as applicable. See Figure 28.
5. Disconnect the electrical plug from the back of

the display.
TEST
The pins of the connector/display may be tested to
determine the nature of the malfunction. See Fig-
ure 29.
1. BATTERY (POS) 5. CAN (LOW)
2. BATTERY (NEG) 6. CAN (HIGH)
3. CAN (GROUND) 7. CAN (LOW)
4. N/C 8. CAN (HIGH)
Figure 29. Pins
31
Horn 2200 SRM 1191
Horn
The horn is located on the outside of the left front horn when the horn switch on the control handle is
frame. It is situated under the plastic cover beside depressed. When proper voltage is reaching the as-
the mast. The horn is activated by depressing the sembly yet no sound is produced, the assembly must
horn switch located in the operator compartment. be replaced. Disconnect the unit connector from the
See Figure 30. main wiring harness. Remove the hardware attach-
ing the horn to the frame. Position the new unit as re-
moved and secure using the hardware. Connect the
connector as removed and test for proper operation.
Replace the compartment covers and return to ser-
vice.
AUDIBLE ALARM
WARNING
DO NOT operate a truck if the audible alarm
does not function properly.
An audible alarm is used to indicate backwards

travel. When backing up, the operator may be pre-
occupied with the position of the mast or carriage
or have a restricted range of visibility. The audible
alarm sounds when the lift truck is moved back-
wards to alert nearby traffic to pay close attention
when near the lift truck. The alarm is located in the
left front frame compartment near the horn. See
Figure 30. If the audible alarm is not functioning
properly, raise the drive wheel of the lift truck (refer
to Periodic Maintenance 8000 SRM 1197), remove
the left front frame cover, and test the voltage to
the audible alarm when the control handle is moved
to the reverse position. When proper voltage is
reaching the assembly yet no sound is produced,
the assembly must be replaced. Disconnect the unit
connector from the main wiring harness. Remove
the hardware attaching the alarm to the frame. Po-
1. AUDIBLE ALARM sition the new unit as removed and secure using the
2. HORN hardware. Connect the connector as removed and
Figure 30. Horn and Audible Alarm test for proper operation. Replace the compartment
covers, remove the truck from blocks, and return to
If the horn is not functioning properly, remove the service.
left front frame cover, and test the voltage to the
32
2200 SRM 1191 Light Assemblies
Light Assemblies
FRONT LIGHTS Legend for Figure 31
Two front (head) lights are mounted by their brackets 1. BRACKET

to the front of the overhead guard. 2. RETAINING CAPSCREW AND NUT
3. SCREW
4. LENS RETAINER
Bulb Replacement 5. LENS
1. Remove the four screws securing the lens re- 2. Remove the bulb from the fixture and replace
tainer and lens to the assembly. Hold the lens with new.
in place until all screws have been removed
then remove the lens and retainer. Replace as
required. See Figure 31.
CAUTION
Overtightening the screws can break the lens.
3. Position the lens and the retainer to the fixture

and install the four screws.
Assembly Replacement
1. Disconnect the wiring harness from the light as-
sembly connector.
2. Remove the nut and washers from the capscrew

securing the headlight assembly to the bracket.
Slide the capscrew from the bracket and remove
the headlight. See Figure 32.
3. Remove the bracket from the overhead guard and

replace if necessary.
4. Install bracket to overhead guard if removed.
5. Position the light assembly to the bracket and in-

stall capscrew and attaching hardware. Tighten
slightly to allow for adjustment.
Figure 31. Lens Removal
33
Light Assemblies 2200 SRM 1191
1. ADJUSTMENT SLOT 5. HEADLIGHT

2. ADJUSTMENT BOLT 6. CONNECTOR
3. OVERHEAD GUARD 7. WIRE CLAMP
4. WIRING HARNESS 8. ATTACHING HARDWARE
Figure 32. Head Light Mounting
REAR WORK AND CAUTION LIGHT Caution Light

The rear work and caution lights are options that 1. Move the lift truck to a safe, level area and com-
mount to the overhead guard near the rear of the pletely lower the mast. Turn the key switch to
truck. Several configurations of these assemblies are the OFF position and attach a DO NOT OPER-
available and connect to the options harness. To re- ATE tag to the control handle. Block the drive
pair the light assemblies, perform the following pro- wheel to prevent unexpected movement.
cedures. Some repairs may not require total disas-
sembly. Perform only the steps necessary to safely 2. Disconnect the battery power cable connector
complete the required service. See Figure 33. from the truck connector located on the right side
Rear Work Light handle to separate the battery connector from
The work light is very similar to the front light, ex-
cept for its mounting platform and location. To re- 3. Remove the nuts securing the cage to the light
pair or replace the work light, refer to the instruc- assembly. Remove the cage.
tions for repairing or replacing the front lights. See
Front Lights.
34
2200 SRM 1191 Light Assemblies
4. Remove the screws and washers securing the Legend for Figure 33
lens globe to the light assembly. Remove the lens
globe. 1. CAGE
2. GLOBE
3. STUDS AND NUTS
5. Remove the bulb from the fixture and replace if 4. UPPER MOUNTING FLANGE
necessary. 5. LOWER MOUNTING FLANGE
6. SCREW
6. Connect the battery and turn the key switch to 7. MOUNTING BRACKET
the ON position. Test for proper operation. 8. WORK LIGHT WITH ADJUSTABLE BRACKET
9. WORK LIGHT WIRING HARNESS
7. Position the lens globe to the light assembly. In- 10. STROBE WIRING HARNESS
stall screws to secure.
LIGHT SWITCHES
8. Position the cage onto the studs of the light as-
sembly. Install nuts and washers onto studs. The lights are controlled with push button switches
located on dash of fore/aft stance models and on the
9. Remove blocks from the wheel and return to ser- arm rest of sidestance models. See Figure 34.
vice.
WARNING
cause a short circuit. Disconnect the battery
the electrical compartment covers or inspect-
ing/repairing the electrical system. High cur-
rent flow during a short circuit can cause in-

the OFF position and disconnect the battery. At-
tach a DO NOT OPERATE tag to the control
handle. Block the drive wheel to prevent unex-
pected movement.
2. Discharge the capacitors. See Discharging the

Capacitors.
3. Access the light switch wiring:
a. Remove the operator compartment cover on

forward stance models.
OR

the arm rest console on sidestance models.
Figure 33. Rear and Caution Light
35
Light Assemblies 2200 SRM 1191
4. Remove the jam nut from the top of the switch

and pull the switch down through the mounting
hole.
5. Tag and disconnect the wiring from the bottom of

the switch.
6. Connect the electrical wiring to the new switch

as removed.
7. Position the new switch into the bottom of the

mounting hole as removed. Install jam nut to the
top of switch to secure.
8. Engage the battery cable connectors. Install the

Test for proper operation.
9. Install the operator compartment cover as re-

moved on forward stance models.
OR
10. Install the plastic cover to the bottom of the arm-

rest assembly as removed on sidestance models.
11. Engage the battery connectors and remove the

DO NOT OPERATE tag from the control han-
dle. Remove the drive wheel blocks and test for
proper operation.
A. SIDESTANCE
B. FORE/AFT STANCE
1. WORK LIGHT SWITCH
2. HEAD LIGHT SWITCH
Figure 34. Light Switches
36
2200 SRM 1191 Cooling Fans
Cooling Fans
ELECTRICAL COMPARTMENT FANS
As some electrical components operate, they gener-
ate heat. Cooling fans are used to disperse this heat
in order to prevent damage to sensitive electronic de-
vices. See Figure 35.
Figure 35. Cooling Fan
A cooling fan is mounted to the frame under front left

frame cover. See Figure 36. This fan disperses heat
generated by the traction and lift motor controllers.
See Motor Controllers in this section. An optional
second cooling fan is located inside the drive unit
compartment door to disperse heat from the drive
unit compartment. See Figure 37.
1. COOLING FAN
2. FAN CONNECTION TO MAIN HARNESS
3. TRUCK FRAME
4. AUDIBLE ALARM
5. HORN
6. OUTER MAST
7. MAST TRUNNION
Figure 36. Front Cooling Fan Location
37
Cooling Fans 2200 SRM 1191


3. Remove the front left compartment cover to ac-

cess the cooling fan.
4. Disconnect the fan wiring connector from the

main wiring harness.
5. Remove the four nuts retaining the fan to studs

in the frame. Remove the fan from the lift truck.
6. Position the new cooling fan into the electrical

compartment.
7. Install the four screws securing the fan to the

studs in the frame.
8. Connect the fan wiring connector to the main

wiring harness.
9. Replace the operator compartment cover as re-

moved. Engage the battery connectors and re-
move the DO NOT OPERATE tag from the con-
1. DRIVE UNIT COMPARTMENT DOOR trol handle. Remove the drive wheel blocks and
2. FAN CONNECTION TO MAIN HARNESS test for proper operation.
3. COOLING FAN
4. TRUCK FRAME
OPERATOR FAN
Figure 37. Rear Cooling Fan (Optional)
An operator fan is available as an option for operator
comfort. This fan is mounted directly to the overhead
Replace guard and attaches readily to connectors provided on
the optional wiring harness. A switch is built into
the fan assembly to turn the unit on and off and to
WARNING control fan speed.
cause a short circuit. Disconnect the battery Repair
the electrical compartment covers or inspect- Refer to the following procedures if repair to the
ing/repairing the electrical system. High cur- operator fan assembly is necessary. Perform only
rent flow during a short circuit can cause in- the steps necessary to safely complete the repairs
jury or parts damage. required.
38
2200 SRM 1191 Cooling Fans
b. Remove the connector from the end of the fan

WARNING wiring by cutting the wires near the connec-
Making repairs with the battery connected can tor or by disassembling the connector. Refer
cause a short circuit. Disconnect the battery to Wire Harness Repair 2200 SRM 1128.
the electrical compartment covers or inspect- c. Pull wires out of the grommet in the upper
ing/repairing the electrical system. High cur- casing. If the grommet is damaged or brittle,
rent flow during a short circuit can cause in- replace the grommet.
d. Install new wiring through the grommet.
1. Move the lift truck to a safe, level area and com- Connector pin ends should be located on the
pletely lower the mast. Turn the key switch to outside of the upper casing.
ATE tag to the control handle. Block the drive e. Install the wiring connectors to the fan
wheel to prevent unexpected movement. switch terminal as removed.
2. Disconnect the battery power cable connector f. Assemble the connector to the pin ends of the
from the truck connector located on the right side wiring. Refer to Wire Harness Repair 2200
of the frame. Pull the battery cable connector SRM 1128.
handle to separate the battery connector from 8. Position the upper casing of the fan assembly to
the truck connector. the lower casing. Install the four screws securing
3. Disconnect the fan wiring connector from the op- casings together. See Figure 39.
tions harness. Remove the capscrew and bracket 9. Position the fan assembly onto the overhead
securing the fan wiring to the overhead guard. guard as removed. Install the two capscrews
See Figure 38. and retaining hardware securing fan in place.
4. Remove the two capscrews and retaining hard-
ware securing the fan assembly to the overhead
guard.
5. Remove the screws securing the upper casing of

the fan assembly to the lower casing. Separate
the casings. See Figure 39.
6. Replace the fan switch:
a. Disconnect the wiring connectors from the

fan switch.
b. Remove the locking nut from the switch and

remove the switch from the lower casing.
c. Position the new switch into the lower casing.

Install the locking nut to the switch.
d. Install the terminal connectors to the new 1. OVERHEAD GUARD

switch as removed. 2. UPPER FAN HOUSING
3. ATTACHING HARDWARE
7. Replace the fan wiring: 4. WIRING HARNESS
a. Disconnect the wiring connectors from the Figure 38. Operator Fan Assembly
fan switch.
39
Cooling Fans 2200 SRM 1191
10. Connect the fan wiring connector to the options 11. Replace the operator compartment covers as re-
harness. Connect the battery. Turn the key moved. Engage the battery connectors and re-
switch to the ON position and test for proper move the DO NOT OPERATE tag from the con-
operation. trol handle. Remove the drive wheel blocks and
test for proper operation.
Figure 39. Operator Fan Assembly
40
2200 SRM 1191 Impact Sensor

1. WASHER 10. TERMINAL CONNECTORS
2. NUT 11. LOWER CASING
3. NUT 12. FAN CASING
4. WASHER 13. WIRING HARNESS
5. SCREW 14. CONNECTOR
6. SWITCH 15. GROMMET
7. SCREEN 16. UPPER CASING
8. HANDLE 17. GRILL
9. SCREW
Impact Sensor
The impact sensor is located beneath the operator 2. Connect the sensor wiring harness to the main
compartment cover and is mounted to the frame of wiring harness as removed.
the lift truck with two screws and washers. If the lift
truck hits (or is hit) with enough force to activate the 3. Connect the battery and turn the key switch to
sensor (as set), the impact sensor alerts the master the ON position.
controller that an impact has occurred. A warning
4. Turn the key switch to the OFF position and
will then be displayed on the dash display. The lift
install the operator compartment cover as re-
truck can also be programmed to respond to impacts
moved.
by limiting truck functions until the sensor is reset
by a supervisor or service technician. An operator
cannot reset the impact sensor.
REMOVE
1. Park the lift truck in a safe, level area and com-
pletely lower the mast.
2. Turn the key switch to the OFF position and dis-

connect the battery.
3. Remove the operator compartment cover and dis-

charge the capacitors. See Discharging the Ca-
pacitors.
4. Locate the impact sensor mounted to the frame

of the lift truck. See Figure 40.
5. Disconnect the sensor wiring from the main

wiring harness.
6. Remove the two screws securing the sensor the

frame. Remove sensor from the lift truck.
INSTALL
1. IMPACT SENSOR
1. Position the impact sensor to the frame and align 2. MAIN HARNESS BRANCH
the mounting holes. Install the two screws and
washers to secure. Figure 40. Impact Sensor Location
41
Height Proximity Switch 2200 SRM 1191
Height Proximity Switch

TEST
WARNING
DO NOT raise the frame of the truck with the 1. Raise the mast past free-lift, the proximity
forks raised. The stability of the truck is re- switch light should go out.
duced. Raising the frame of the truck with the
forks raised could cause it to tip over. Tipping 2. Place a wrench or flat steel plate 6.35 to
of the truck can cause personal injury or prop- 12.70 mm (0.25 to 0.50 in.) from the prox-
erty damage. imity switch and confirm the light will come on.
Disconnect the battery and separate the con- 3. Remove the operator electrical compartment
nector before opening the compartment cover cover and measure voltage on wire 15 (brown
or inspecting/repairing the electrical system. wire) for battery voltage at the proximity switch
If a tool causes a short circuit, the high-cur- connector 11.
rent flow from the battery can cause an injury
4. Check for voltage between wire 13-9 (blue wire)
or parts damage.
and wire 74 (black wire). It should be 0 volts
The height proximity switch alerts the master con- until the wrench or plate is placed in front of the
troller when the mast is raised above free-lift. The switch. Then it should read battery voltage.
controller reduces traction speeds until the mast is
5. If the light stays on with the mast raised past
lowered into the free-lift range. The height proxim-
the target, the switch is shorted closed. If the
ity switch also signals the controller to activate the
light does not come on with the mast lowered, the
laser fork guide on models equipped with the laser
switch is shorted open. See Figure 42.
option. The height proximity switch contains an light
emitting diode (LED) that indicates its operational
mode. It is mounted on the outer mast rail near the
bottom of the rail and targets the intermediate mast
channel. See Figure 41. When mast is within the
free-lift range (main-lift cylinders are not extended),
the switch acquires its target and switches ON illu-
minating the LED. If the mast is raised above free-lift
range, the switch loses its target and switches OFF
de-energizing the LED.
Figure 42. Proximity Switch Schematic
REMOVE
1. Move the lift truck to a safe, level area. Raise the
mast high enough to obtain access to the height
limit switch. Safety chain the mast in place. See
the section Periodic Maintenance 8000 SRM
1197. Refer to Safety Procedures When Working
Near the Mast.
2. Turn the key switch to the OFF position and re-

move the key. Put a DO NOT OPERATE tag on
the control handle. Put blocks under the drive
1. MAST RAIL wheels to keep the lift truck from moving. See
the section Periodic Maintenance 8000 SRM
Figure 41. Height Proximity Switch
42
2200 SRM 1191 Height Proximity Switch
1197. Refer to How To Put the Lift Truck On

Blocks.
3. Disconnect the battery by separating the connec-

tors.
4. Disconnect the proximity switch connector from

the main wire harness.
5. Remove the two nuts and serrated washers re-

taining the switch to the bracket at the bottom of
the mast.
6. Remove the switch from the bracket.
INSTALL
1. Position the new switch on the bracket. Install
the serrated washers and nuts.
2. Connect the proximity switch connector to the

main wire harness and verify switch gap adjust-
ment.
3. Remove the safety chains from the mast. Con-

nect the battery, install the key, and check the
mast for proper operation.
4. Connect the battery, install the key, and turn the

key switch to the ON position.
5. Check the mast for proper operation.
6. Remove the blocks from under the drive wheels.

Remove the DO NOT OPERATE tag from the
control handle.
7. Verify that the switch is activated with the inner

mast lowered and not activated with the inner
mast elevated.
8. Check the truck for proper operation. Maximum 1. GAP ADJUSTMENT

travel speed must be limited with the mast ele- 2. SWITCH SENSOR
vated above free lift. 3. JAM NUT
4. LOCKWASHERS
5. JAM NUT
ADJUST 6. WIRING
Adjust the proximity switch gap to 6.350 (+3.175/ Figure 43. Proximity Switch Gap Adjustment
0.000) mm (0.250 (+0.125/ 0.000) in.). See Fig-
ure 43.
43
Load Transport Proximity Switch 2200 SRM 1191
Load Transport Proximity Switch

The lift truck uses a proximity switch mounted to the 8. Connect the switch wiring to the mast wiring.
bottom of the rear frame of the reach carriage as- Secure the wiring with wire ties.
sembly to detect when the reach carriage assembly is
lowered to approximately 610 mm (24 in.) above the 9. Reconnect the battery. Test for proper operation.
floor. At this point, the master controller either slows Remove the tag from the control handle and re-
the descent of the reach carriage assembly or stops turn the lift truck to service.
the carriage completely, depending on the setting se-
lected in the dash display. The controller signals the
lift pump and motor to slow the carriage, cushioning
the final descent. It stops the carriage by signaling
the lift pump and motor to halt, holding the load at a
preset carry height. The lower button on the control
handle must be released and pressed again to com-
pletely lower the reach carriage assembly.
The proximity switch must be adjusted within 10 mm

(0.39 in.) to detect its target. See Figure 44. Al-
ways check wiring connections and air gap adjust-
ments before replacing components.
Replace
1. Move the lift truck to a safe, level area, and posi-
tion the reach carriage assembly for access to the
proximity switch.
2. Turn the key switch to the OFF position and at-

tach a DO NOT OPERATE tag to the control
handle.
3. Block the drive wheel to prevent unexpected

movement. Disconnect the battery.
4. Disconnect the proximity switch connector. Clip

wire ties securing wiring in place.
5. Make note of the position of the switch within the

bracket by measuring the distance from the face
of the switch to the bracket. Remove the nut and
lockwasher from the face side of the switch and
remove the switch from the bracket.
6. Remove one nut and lockwasher from the face

side of the new switch. Adjust the nut on the
wiring side of the switch until the distance from
the face of the new switch is the same as the old
switch. 1. AIR GAP 4. LOCKWASHERS
2. SWITCH FACE 5. NUT
7. Position the new switch into the bracket. Install 3. NUT 6. WIRING
the nut and lockwasher to the face side of the
switch. Secure the switch in place. Figure 44. Load Transport Proximity Switch
44
2200 SRM 1191 Fork Height Sensor Option
Adjust 3. Block the drive wheel to prevent unexpected

movement. Disconnect the battery.
The load transport proximity switch must be ad-
justed within 10 mm (0.39 in.) to detect its target. 4. Slightly loosen jam nuts.
See Figure 44.
5. Adjust the nuts to move the switch to a position
1. Move the lift truck to a safe, level area. Posi- within 10 mm (0.39 in.) from its target.
tion the mast and reach carriage for access to the
proximity switch. If raised, safety chain the mast 6. Tighten the jam nuts.
in place. See Mast, Repair 4000 SRM 1195 -
7. Remove the safety chains and test for proper op-
Safety Procedures When Working Near Mast.
eration. If moving the switch in the direction of
2. Turn the key switch to the OFF position and at- the target does not restore proper function, the
tach a DO NOT OPERATE tag to the control switch may be faulty. See Replace.
handle.
Fork Height Sensor Option

This option allows an operator to set the lift func- d. Remove encoder from plate.
tion so the forks will automatically stop at a selected
height (above free-lift height). 3. Remove the encoder pulley and pin assembly:
a. Remove the setscrew securing pulley to pin.

REMOVE
Slide pulley from pin.
Encoder Assembly b. Slide pin from bearings.
For the following procedures refer to Figure 45. c. Remove snap ring securing bearings in place.
1. Position the lift truck in a safe, level area and d. Remove bearings using a proper sized driver.
completely lower the mast. Turn the key switch
to the OFF position and disconnect the battery 4. Remove the idler pulley and bearing assembly:
connector.
a. Remove the snap ring from the idler pulley
2. Remove the encoder: shaft and remove the idler pulley from the
bearings. Recover the spacer.
a. Loosen the setscrew securing encoder shaft
to pin. b. Remove snap ring securing bearings in place.
b. Disconnect encoder wiring. c. Remove bearings using a proper sized driver.
c. Remove capscrew, lockwasher, and spacer se-
curing encoder plate. Remove encoder and
plate from the lift truck.
45
Fork Height Sensor Option 2200 SRM 1191
1. PLATE 8. SPACER
2. ENCODER PULLEY 9. SPACER
3. IDLER PULLEY 10. LOCKWASHER
4. ENCODER 11. CAPSCREW
5. PIN 12. SNAP RING
6. ENCODER PLATE 13. SETSCREW
7. BEARINGS 14. SNAP RING
Figure 45. Fork Height Sensor Assembly
Timing Belt intermediate mast. Pull the belt from the clamp.
See Figure 46.
1. Position the lift truck in a safe, level area and
completely lower the mast. Turn the key switch 3. Loosen the four capscrews securing the mounting
to the OFF position and disconnect the battery clamp to the mounting plate near the bottom of
connector. the intermediate mast. Pull the belt from the
clamp.
2. Loosen the four capscrews securing the mounting
clamp to the mounting plate on the top of the
46
2200 SRM 1191 Fork Height Sensor Option
1. PLATE 3. MOUNTING CLAMP 5. WIRE TIE

2. MOUNTING PLATE 4. TIMING BELT 6. CABLE
Figure 46. Fork Height Timing Belt
INSTALL c. Slide pin into bearings.
Encoder Assembly d. Position pulley onto pin and install the

setscrew to secure.
1. Install the idler pulley and bearing assembly:
3. Install the encoder and plate:
a. Install the bearings into the mounting plate.
a. Install the encoder to the plate.
b. Install snap ring securing bearings in place.
b. Position the encoder shaft into the pin.
c. Install the spacer onto idler pulley shaft and
insert the idler pulley shaft into the bearings. c. Tighten the setscrew in pin to secure encoder
shaft.
d. Install the snap ring to the end of the shaft
to secure in place. d. Align the plate mounting hole and secure in
place using capscrew, lockwasher, and spacer
2. Install the encoder pulley and pin assembly: as removed.
a. Install bearings into the mounting plate. e. Connect the encoder wiring.
b. Install snap ring securing bearings in place.
47
Reach Position Sensor 2200 SRM 1191
Timing Belt 4. Route the timing belt through the belt pulleys to
the bottom of the mast. Make sure the belt is
1. Position the lift truck in a safe, level area and unobstructed.
completely lower the mast. Turn the key switch
to the OFF position and disconnect the battery 5. Position the mounting clamp to the mounting
connector. plate at the bottom of the intermediate mast.
Loosely install the four mounting capscrews.
2. Position the mounting clamp to the mount-
ing plate on the top of the intermediate mast. 6. Insert the belt down between the mounting plate
Loosely install the four mounting capscrews. and the mounting clamp. Make sure the belt ex-
tends completely through the clamp. Pull down
3. Insert the belt up between the mounting plate and hold the belt as tight as possible by hand,
and the mounting clamp. Make sure the belt then tighten the capscrews on the lower clamp to
is installed completely through the clamp and secure in place. Trim any excess belt protruding
tighten the capscrews to secure in place. from the bottom of the mounting clamp.
Reach Position Sensor

Models (N35ZDR, N45ZR, N30ZDR, and N35-40ZR) 5. Carefully clip the wire tie securing the reach sen-
are equipped with a reach position sensor, which sor wiring harness to the sensor bracket, and dis-
monitors the position of the scissor arms. When connect the reach sensor wiring harness from the
nearing the end of the extend/retract stroke, the sensor. See Figure 48.
sensor alerts the controller to slow the reach cylin-
der speed. The reach position sensor can be serviced 6. Remove the capscrew anchoring the reach sensor
with the reach carriage installed or removed from and bracket to the rear frame. See Figure 49.
the lift truck. The following procedures include
steps for servicing the sensor while the carriage is
installed. Simply omit these steps if carriage has
been removed.
REMOVE
1. Move the lift truck to a safe, level location and
raise the carriage to the top of the mast.

3. Safety chain the carriage and mast in place. Po-

sition a ladder or personnel lift to access the rear
frame of the carriage while the carriage is raised
to the top of the mast.
CAUTION
DO NOT disconnect any hydraulic hoses or fit-
tings.
4. Remove the capscrews securing the valve block 1. CARRIAGE REAR FRAME
to the rear frame to improve access to the reach 2. VALVE BLOCK
position sensor. See Figure 47. 3. REACH POSITION SENSOR
4. REACH CYLINDER (RH)
Figure 47. Sensor Location
48
2200 SRM 1191 Reach Position Sensor
7. Turn the sensor and bracket slightly to access the Legend for Figure 49
pin retainer screw.
1. PIN RETAINER
2. SCREW
3. BRACKET
4. WIRING CONNECTOR
5. CAPSCREW
6. SPACER
7. REACH POSITION SENSOR
8. Remove the pin retainer screw and slide the pin

retainer off of the pin.
9. Loosen the setscrew in the pin (behind the sen-

sor) to release the reach sensor shaft. Remove
the reach sensor and bracket from the lift truck.
See Figure 50.
10. Remove the capscrews and nuts securing the sen-

sor bracket to the sensor if necessary. See Fig-
ure 51.

2. WIRING HARNESS CONNECTOR
3. WIRE TIE
Figure 48. Sensor Wiring
1. PIN
2. SCISSOR ARM
3. SETSCREW
4. PIN RETAINER
5. SCREW
6. BRACKET
Figure 50. Pin, Retainer, and Setscrew

Figure 49. Sensor and Bracket Mounting
49
Reach Position Sensor 2200 SRM 1191
5. Install the pin retainer onto the pin and secure

in place with screw as removed.
6. Align the mounting bracket with hole in rear

frame and install capscrew and spacer.
7. Install wiring connector and secure harness to

bracket with new wire tie as removed.
8. Position valve block to top of rear frame and se-

cure with two capscrews as removed.
9. Remove the safety chains from the mast and car-

riage.
10. Connect the battery and startup the lift truck.

Lower the mast and test the carriage reach and
retract functions for proper operation.
1. CAPSCREW
2. PIN
3. SCISSOR ARM
4. PIN RETAINER
5. SCREW
6. BRACKET
8. NUT
Figure 51. Bracket and Sensor
INSTALL
1. If necessary, assemble the sensor bracket to the
reach position sensor and secure with two cap-
screws and nuts as removed.
2. Check that the pin retainer hole aligns with

mounting hole in scissor arm. Adjust to align if
necessary. DO NOT install the pin retainer at 1. SCISSOR ARM
this time. 2. PIN
3. SETSCREW
3. Remove the setscrew from the pin and clean old 4. PIN RETAINER
5. SCREW
thread-lock residue from the threads. Apply Loc- 6. SENSOR SHAFT (FLAT TOWARD SETSCREW)
tite® 242 to the threads and start setscrew into 7. REACH POSITION SENSOR AND BRACKET
the pin.
Figure 52. Aligning the Sensor Shaft
4. Position the sensor assembly to the pin so that
the sensor shaft enters the pin with the flat side
of the shaft facing the setscrew. Tighten the
setscrew. See Figure 52.
50
2200 SRM 1191 Retract Sensor
Retract Sensor
The retract sensor monitors the reach carriage as- again with it extended to ensure the retract sen-
sembly position and alerts the master controller to sor is functioning properly. The lift truck trac-
limit the lift truck travel speeds when the carriage is tion controls should function only at turtle speed
extended. when the reach carriage is extended.
REMOVE
1. Park the lift truck in a safe, level location and
completely lower the mast.

connect the battery connector.
3. Disconnect the retract sensor wiring harness

from the carriage harness.
4. Remove the sensor from the mounting bracket.

See Figure 53.
5. Clip the wire tie securing wiring.
6. Remove the mounting bracket from the rear

frame.
INSTALL
1. Install the new retract sensor to the mounting
bracket.
2. Install the mounting bracket to the rear frame.
3. Connect the sensor wiring harness to the car-

riage harness.
4. Install new wire ties as removed.
5. Adjust the sensor so air gap from target is within

6.35 to 12.70 mm (0.25 to 0.50 in.) of sensor face.
See Figure 54.
1. RETRACT SENSOR
2. GAP SETTING 3.450 mm (0.136 in.)
6. Connect the battery and turn the key switch to 3. MOUNTING BRACKET
the ON position. 4. SCREW
7. In a safe area, test the lift truck travel speeds Figure 53. Retract Sensor
with the reach carriage assembly retracted and
51
Retract Sensor 2200 SRM 1191

1. AIR GAP
2. SENSOR FACE
3. NUT
4. LOCKWASHERS
5. NUT
6. WIRING
Figure 54. Retract Sensor
52
2200 SRM 1191 Tilt Leveling
Tilt Leveling
REMOVE
1. Park the lift truck in a safe, level area and com-
pletely lower the mast.

3. Disconnect the switch wiring from the option

module.
4. Remove the capscrews securing the switch to the

reach carriage. See Figure 55.
INSTALL
1. Align the switch to the reach carriage as re-
moved.
2. Install capscrews to secure in place as removed.
3. Connect the switch wiring to the option module.
4. Connect the battery and turn the key switch to

the ON position.
5. Test the tilt leveling function using the operator

controls.

1. CONNECTOR
2. TILT SENSOR
3. CAPSCREWS
4. CARRIAGE
Figure 55. Tilt Leveling Sensor
53
Laser Option 2200 SRM 1191
Laser Option
REMOVE 7. Connect the laser assembly wiring harness to the
option module.
completely lower the mast. 8. Connect the battery and turn the key switch to
the ON position.
connect the battery connector. 9. Use the operator controls to raise the mast above
free-lift height. Check that the laser activates
3. Disconnect the laser assembly wiring from the when the mast exceeds free-lift height and deac-
option module. tivates when in free-lift range. Check that the
laser accurately marks its target.
4. Loosen the jam nuts and capscrews and then
slide the laser assembly to the center of the fork 10. If the laser fails to operate check the wiring
carriage. See Figure 56. connections and the height proximity switch for
proper operation. Refer to Height Proximity
5. Lift the bottom hook of the laser assembly
Switch in this section.
through the removal notch in the bottom of the
fork carriage. Lift the laser assembly from the
top bar of the fork carriage and remove from the
lift truck.
INSTALL
completely lower the mast.

3. Maneuver the laser assembly so the top hook of

the laser assembly hooks over the center of the
top bar of the fork carriage.
4. Lower the bottom hook of the laser assembly

fork carriage.
NOTE: Position the laser assembly so that it does not 1. CAPSCREWS AND JAM NUTS
restrict the operator from adjusting the forks. 2. FORK CARRIAGE TOP BAR
3. CAPSCREWS AND JAM NUTS
5. Slide the laser assembly to center between the 4. LEFT FORK
center of the fork carriage and the innermost 5. CAMERA
used position of the right side fork. 6. FORK NOTCH
7. LASER
8. CARRIAGE BOTTOM BAR
6. Install two capscrews with jam nuts to secure 9. RIGHT FORK
laser assembly in position. Tighten capscrews
and snug jam nuts to secure. Figure 56. Laser and Camera Options
54
2200 SRM 1191 Camera Option
Camera Option
REMOVE NOTE: Position the camera assembly so that it does
not restrict the operator from adjusting the forks.
completely lower the mast. 5. Slide the camera assembly to center between the
center of the fork carriage and the innermost
2. Turn the key switch to the OFF position and dis- used position of the left side fork.
6. Install two capscrews with jam nuts to secure
3. Disconnect the camera assembly wiring from the camera assembly in position. Tighten capscrews
mast wiring harness. and snug jam nuts to secure.
4. Loosen the jam nuts and capscrews and then 7. If installing on mast for the first time, the stan-
slide the camera assembly to the center of the dard mast wiring harness must be replaced with
fork carriage. See Figure 56. a mast wiring harness for camera options. Refer
to the Parts Manual for proper part selection
5. Lift the bottom hook of the camera assembly
and Mast, Repair 4000 SRM 1195 for installa-
tion instructions.
fork carriage. Lift the camera assembly from the
top bar of the fork carriage and remove from the 8. Connect the camera assembly wiring harness to
lift truck. the mast wiring harness.
INSTALL 9. Connect the battery and turn the key switch to

the ON position.
completely lower the mast. 10. Check that the monitor displays the feed from
the camera correctly.
connect the battery connector. 11. Use the operator controls to raise the mast above
free-lift height. Check that the wiring harness
3. Maneuver the camera assembly so the top hook does not bind when the mast is extended. Check
of the camera assembly hooks over the center of that the camera is positioned accurately.
the top bar of the fork carriage.
12. If the camera fails to operate check the wiring
4. Lower the bottom hook of the camera assembly connections.
fork carriage.
55
Wiring Harness 2200 SRM 1191
Wiring Harness
of the truck. See Figure 57 and Figure 58. The op-
CAUTION tions wiring harness attaches to the main wiring har-
Electrical components on this truck are po- ness and is routed up through the support post of the
larity sensitive and may be damaged if wired overhead guard and exits through a grommet in the
incorrectly. Make sure each electrical wire mounting plate. See Figure 59. When removing the
connection is tagged and properly identified options wiring harness from the overhead guard post,
before removal or installation. If the proper attach a cord to the harness with tape and pull the
location for connection is unclear, consult the cord into the post while pulling the options harness
wiring diagram for the truck. Make sure test- out. Remove the harness from the cord and tape each
ing meters have adequate voltage and current end of the cord to the outside of the post for use when
capacities to handle the output of the electri- installing the replacement options harness. Always
cal components they are used to check. Never make note of routing and wire tie locations before re-
wire aftermarket components to this truck moving a wiring harness. When making repairs to
without factory approval. the wiring harness, refer to Wire Harness Repair
2200 SRM 1128 for proper procedures.
The main wiring harness begins at the front of the
frame and is routed through the lift truck to the rear

1. CTR PROX SENSOR (CPS51) 24. IFB (CPS01)
2. PRES TRANSDUCER (CPS34) 25. CONNECTOR TERM NEG (TR49)
3. LD HLD/LFT VAR COIL (CPS52) 26. IFB TERM B+ (TSFK53)
4. STRG UNIT (CPS45) 27. HEATER PCB (TBF54)
5. HGT ENCODER SENSOR (CPS107) 28. PC SRV CONN (CRP37)
6. HYD FL SENSOR (CPS133) 29. 12V ACCESS (TSF38)
7. OPTIONAL EQUIPMENT (CRP54) 30. 12V ACCESS (TSF39)
8. STROBE LIGHT RELAY (CPS49) 31. RETAIL SUB HARN (TSF73)
9. RETAIL SUB HARN (TSF72) 32. AFT HANDLE (CRP35)
10. VMC 20 CONTROLLER (CPS31) 33. DASH HARNESS (CRP65)
11. AUX MOTOR (CPS47) 34. DASH HARNESS (TBF74)
12. AUX MTR TERM B (TR68) 35. MN CNCT (TR47)
13. AC PUMP CONT (CPS12) 36. AC PUMP CONT TERM B (TR60)
14. TRACTION CONT (CPS11) 37. COMP FAN (CRP18)
15. FREE L/L SENSOR (CPS33) 38. APSI CONT (CPS59)
16. CONT FAN (CRP17) 39. FOOT SWITCH (CPS39)
17. HORN (CPS36) 40. OPERATOR SEN SW (CPS32)
18. AUDIBLE ALARM (CPS42) 41. AC STEERING MTR (CPS60)
19. AC PUMP ENCODER (CPS16) 42. AC TRAC MTR TEMP (CPS13)
20. AC PUMP ENCODER (CPS15) 43. APS2 HARNESS (CRP62)
21. MAIN CONNECTOR (TSF12) 44. AC TRAC MTR ENCODER (CPS14)
22. MAIN CONNECTOR (TSF13) 45. ELECTRIC BRAKE (CPS41)
23. IFB B (TSFK51)
56
2200 SRM 1191 Wiring Harness
Figure 57. Main Wiring Harness (N35ZDR, N45ZR, N30ZDR, N35-40ZR)
57
Figure 58. Main Wiring Harness (N30ZDRS, N35-40ZRS)
58
2200 SRM 1191 Wiring Harness

1. CTR PROX SENSOR (CPS51) 27. HEATER PCB (TBF54)
2. PRES TRANSDUCER (CPS34) 28. PC SRV CONN (CRP37)
3. LD HLD/LFT VAR COIL (CPS52) 29. 12V ACCESS (TSF38)
4. STRG UNIT (CPS45) 30. 12V ACCESS (TSF39)
5. HGT ENCODER SENSOR (CPS107) 31. RETAIL SUB HARN (TSF73)
6. HYD FL SENSOR (CPS133) 32. AFT HANDLE (CRP35)
7. OPTIONAL EQUIPMENT (CRP54) 33. DASH HARNESS (CRP65)
8. STROBE LIGHT RELAY (CPS49) 34. DASH HARNESS (TBF74)
9. RETAIL SUB HARN (TSF72) 35. MN CNCT (TR47)
10. VMC 20 CONTROLLER (CPS31) 36. AC PUMP CONT TERM B (TR60)
11. AUX MOTOR (CPS47) 37. COMP FAN (CRP18)
12. AUX MTR TERM B (TR68) 38. APSI CONT (CPS59)
13. AC PUMP CONT (CPS12) 39. FOOT SWITCH (CPS39)
14. TRACTION CONT (CPS11) 40. OPERATOR SEN SW (CPS32)
15. FREE L/L SENSOR (CPS33) 41. AC STEERING MTR (CPS60)
16. CONT FAN (CRP17) 42. AC TRAC MTR TEMP (CPS13)
17. HORN (CPS36) 43. APS2 HARNESS (CRP62)
18. AUDIBLE ALARM (CPS42) 44. AC TRAC MTR ENCODER (CPS14)
19. AC PUMP ENCODER (CPS16) 45. ELECTRIC BRAKE (CPS41)
20. AC PUMP ENCODER (CPS15) 46. MAIN HARNESS (TSM72)
21. MAIN CONNECTOR (TSF12) 47. AUX STEERING (CPS138)
22. MAIN CONNECTOR (TSF13) 48. AUX REVERSE (CPS139)
23. IFB B (TSFK51) 49. LOWER VAR (CPS141)
24. IFB (CPS01) 50. MAIN HARNESS (TSM73)
25. CONNECTOR TERM NEG (TR49) 51. MAST CABLE (CRP25AX)
26. IFB TERM B+ (TSFK53)
59
1. MAIN HARNESS CONNECTOR 7. HEADLIGHTS (WHT)

2. OPERATOR LIGHTS (GRN) 8. HEADLIGHTS (GRN)
3. OPERATOR LIGHTS (WHT) 9. OPERATOR FAN
4. STROBE (WHT) 10. REAR WORK LIGHT
5. STROBE (RED) 11. RF TERMINAL (RED)
6. CABLE GRIP 12. RF TERMINAL (GRN)
Figure 59. Options Wiring Harness
60
TECHNICAL PUBLICATIONS
2200 SRM 1191 11/08 (3/07)(2/07)(11/06)(10/06) Printed in U.S.A.

Electrical System: N35ZDR, N45ZR (C264) N30ZDR, N35-40ZR (D470) N30ZDRS, N35-40ZRS (A265)

Uploaded by

Copyright:

Available Formats

Electrical System: N35ZDR, N45ZR (C264) N30ZDR, N35-40ZR (D470) N30ZDRS, N35-40ZRS (A265)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Electrical System: N35ZDR, N45ZR (C264) N30ZDR, N35-40ZR (D470) N30ZDRS, N35-40ZRS (A265)

Uploaded by

Copyright:

Available Formats

ELECTRICAL SYSTEM

N35ZDR, N45ZR [C264];

PART NO. 1590941 2200 SRM 1191

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2008 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

N35ZDR, N45ZR [C264];

The electrical system is an alternating current (AC)

Figure 1. Electrical System

DISCHARGING THE CAPACITORS Legend for Figure 2

Figure 2. Discharging the Capacitors

NOTE: Access the static strap from the front of the

2. Remove the hardware securing the old static

3. Install the new static strap using the hardware

4. Reconnect the battery, remove the tag from the

Figure 3. Static Strap

Be careful using tools near the battery termi-

b. Discharge the capacitors in the motor con-

NOTE: Make note of position of cables for proper re-

c. Remove the nuts securing the cables to the

d. Remove the two clamps securing cables to the

e. Remove the hardware securing the connector

f. Remove the power cables from the lift truck.

g. Route new cables into the electrical compart-

h. Secure the connector to the frame using two

i. Position the power cables onto the terminals

j. Install the two clamps securing power cables

a. Remove the plastic cover from the operator

b. Remove the plastic cover from the bottom of

NOTE: Make note of the position of the key switch

5. Remove the nut retaining the key switch to the

6. Tag and disconnect the electrical wiring from the

Figure 5. Key Switch

Figure 6. Lever-Type Switch Figure 7. Electrical Connections

10. Install the plastic cover(s) to the operator com-

3. Visually check to see if the contactor closes when

1. TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 8. Controller and Contactor Mounting

2. Disconnect the battery power cable connector EE CONTACTORS

4. Remove the electrical compartment covers from

Legend for Figure 9

Figure 9. Typical EE Contactor

Steering Controller e. Click "Download."

d. Enter any custom settings at this time.

Integrated Fuse Board (IFB)

4. Replace any defective fuse with a proper rated

1. Completely lower the mast and park the lift truck

8. Install the plastic cover(s) to the operator com-

Power Disconnect Switch

1. Move the lift truck to a safe level area and com-

2. Disconnect the battery power cable connector

5. Pull the release lever in the side of the contact

6. Tag and disconnect the electrical wiring from the