Hyster n35zdr n45zr (n264) n30zdr n35-40zr-d470

AC MOTOR
CONTROLLERS/
DISPLAY PANEL
DESCRIPTION, CHECKS,
ADJUSTMENTS, AND
TROUBLESHOOTING
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470]
PART NO. 1590940 2200 SRM 1190

AC Motor Controllers/ Display Panel Table of Contents
TABLE OF CONTENTS
Description ........................................................................................................................................................... 1
General ............................................................................................................................................................. 1
AC Motors .................................................................................................................................................... 1
Motor Controllers ........................................................................................................................................ 1
Master Controller ........................................................................................................................................ 2
Dash Display ............................................................................................................................................... 2
Controller Area Network Bus (CANbus).................................................................................................... 2
AC Transistor Motor Controller Replacement ................................................................................................... 3
General ............................................................................................................................................................. 3
General Maintenance Instructions................................................................................................................. 5
Special Precautions ..................................................................................................................................... 5
Fuses ................................................................................................................................................................ 6
Fan.................................................................................................................................................................... 6
Contactors ........................................................................................................................................................ 6
Repair........................................................................................................................................................... 6
Master Controller Checks and Adjustments ...................................................................................................... 8
Function Settings................................................................................................................................................. 8
General ............................................................................................................................................................. 8
Troubleshooting.................................................................................................................................................. 10
General ........................................................................................................................................................... 10
Controller Status Light Emitting Diodes (LEDs) ........................................................................................ 11
Master Controller ...................................................................................................................................... 11
AC Motor Controllers ................................................................................................................................ 11
Operator Status Messages ............................................................................................................................ 14
Status Codes .................................................................................................................................................. 18
Checking the Motor Controller ..................................................................................................................... 90
Display Panel ..................................................................................................................................................... 90
General ........................................................................................................................................................... 90
Premium Display Panel ............................................................................................................................ 90
Standard Display Panel ............................................................................................................................ 91
Standard Display Functions and Features ...................................................................................................... 92
Key-On Initialization..................................................................................................................................... 92
Passwords....................................................................................................................................................... 92
Performance Modes ....................................................................................................................................... 93
Battery Discharge Indicator (BDI) ............................................................................................................... 93
Hourmeters .................................................................................................................................................... 93
Standard Dash Display Service Menu Navigation .......................................................................................... 94
General ........................................................................................................................................................... 94
Moving Through Menu Selections ................................................................................................................ 94
Editing and Adding Information .................................................................................................................. 94
Access to Service Functions .......................................................................................................................... 95
Service Functions .......................................................................................................................................... 95
Premium Display Functions and Features....................................................................................................... 97
Key-On Initialization..................................................................................................................................... 97
Passwords....................................................................................................................................................... 97
Operator Checklist Function......................................................................................................................... 97
Performance Modes ....................................................................................................................................... 97
Battery Discharge Indicator ......................................................................................................................... 98
Hourmeters .................................................................................................................................................... 98
Shelf Height Selector..................................................................................................................................... 98
Premium Dash Display Service Menu Navigation .......................................................................................... 99
©2008 HYSTER COMPANY i

Table of Contents AC Motor Controllers/ Display Panel
TABLE OF CONTENTS (Continued)

General ........................................................................................................................................................... 99
Moving Through Menu Selections ................................................................................................................ 99
Access to Service Functions ........................................................................................................................ 100
Service Functions ........................................................................................................................................ 100
Connector Pin-Outs.......................................................................................................................................... 102
System Logic Diagram..................................................................................................................................... 109
This section is for the following models:
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470]
ii
2200 SRM 1190 Description
Description
GENERAL interrupted indirectly by the key switch. The mo-
tor controllers get motor speed and temperature
The alternating current (AC) system consists of AC information directly from the motors. The motor
motors, motor controller(s), a master controller, and controllers do not get any other input from the truck.
a dash display. The major difference between the The master controller relays speed, acceleration, and
AC system and the direct current (DC) system is the direction commands to the motor controllers. See
master controller performs many of the same func- Figure 1 and Figure 2 for the component locations.
tions that previously were performed in the motor
controllers on the DC system.
AC Motors
The AC motors are three-phase AC induction motors.
They do not include motor brushes or commutators.
An AC induction motor operates on three-phase AC
power provided directly by the motor controller. The
motor’s speed is controlled by the motor controller
and can be changed by changing the frequency of
the AC power provided to the motor. A speed sensor
is built into the rear motor bearing, which provides
RPM and direction feedback to the motor controller.
The motor controller continuously monitors motor di-
rection and speed. Using this feedback, the AC mo-
tor control system can provide much better vehicle
top speed control than is available with DC SEM sys-
tems.
The AC motors also have thermal sensors embedded

in the motor windings that are continuously moni-
tored by the motor controllers.
Motor Controllers
The motor controllers receive power from the truck’s
battery and convert it into three-phase AC power at
the frequencies and currents necessary to drive the
respective pump and/or traction motor. Each AC in-
duction motor provides feedback of speed, rotation 1. TRACTION CONTROLLER
direction, and temperature directly to the motor con- 2. LIFT MOTOR
troller. The two motor controllers used to power the 3. AUXILIARY PUMP AND MOTOR
4. MASTER AND STEERING CONTROLLERS
traction motor and hydraulic pump motor are very 5. TRACTION MOTOR
similar. The primary motor controller difference is 6. MDU STEER MOTOR
in the power output rating. 7. CASTER STEER MOTOR (OPTIONAL)
8. PUMP MOTOR CONTROLLER
The motor controller logic board receives power
from the key switch. Power to the motors can be Figure 1. Component Location (Top View)
1
Description 2200 SRM 1190
Master Controller
The master controller is a general-purpose mi-
cro-controller for CANbus-based electric vehicles.
It contains processing power, memory resources,
analog and digital input/output (I/O) to provide the
required full-featured functionality. The master
controller is designed to manage the traction motor
controller and pump motor controller, interface to
the operator controls, auxiliary functions, and to
control the vehicle dash display.
The master controller also manages the operating

truck parameters, status codes, battery discharge
indicator (BDI) function, hourmeters, password fea-
ture, and all operator inputs. It also controls the
contactor, cooling fans, and strobe light relay.
Dash Display
The AC dash display provides expanded service ca-
pabilities. The dash display has a password-accessi-
ble service mode that allows a technician to change
control settings and view real-time RPMs, current,
temperature, and switch closure information. Previ-
ously, a separate handset or computer was required
for these operations. For a complete description of
1. CASTER STEER MOTOR (OPTIONAL) the display panel, see the Display Panel section of
2. MDU STEER MOTOR
3. STEERING CONTROLLER this manual.
4. MASTER CONTROLLER
5. LIFT PUMP MOTOR Controller Area Network Bus (CANbus)
6. INTEGRATED FUSE BOARD
7. TRACTION CONTROLLER The motor controllers, master controller, and dash
8. HYDRAULIC CONTROLLER display are connected together with a CANbus
9. SELECTOR VALVE
10. TILT/SIDESHIFT SELECTOR communication system. A personal computer (PC)
11. OPTION MODULE with the appropriate Electric Truck AC Controller
12. REMOTE CAN MODULE (ETACC) service software and interface cable can
13. AUXILIARY PUMP AND MOTOR easily communicate with all system nodes by simply
14. CASTER STEER CONTROLLER (OPTIONAL) connecting to the CANbus. A special connector is
15. TRACTION MOTOR
located on the right front truck panel cover, adjacent
Figure 2. Component Location (Side View) to the 12V power supply connector.
2
2200 SRM 1190 AC Transistor Motor Controller Replacement
AC Transistor Motor Controller Replacement

GENERAL controllers that can be repaired. Each of these motor
controllers must be replaced if an internal malfunc-
The AC traction motor controller and AC pump motion occurs.
tor controller assembly is shown in Figure 3 and Fig-
ure 4. There are NO internal parts of these motor
1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

2. AC PUMP MOTOR CONTROLLER 4. STATUS LED
Figure 3. AC Traction and AC Pump Motor Controllers (450A)
3
AC Transistor Motor Controller Replacement 2200 SRM 1190

4
GENERAL MAINTENANCE During installation of the controller, apply a suffi-

INSTRUCTIONS cient layer of silicone (heat transfer) grease, Hyster
P/N 1198757, between the controller and the heat
The motor controllers, like other electronic devices, sink to not allow air gaps between the two.
have temperature limits. These devices can be dam-
aged if they get too hot. Normal maintenance will Controller wire plugs and other exposed transistor
help prevent high-temperature conditions. Always controller parts should be kept free of dirt and paint
make sure motor controllers are installed using heat that might change the effective resistance between
sink compound and that all heat sink surfaces are points.
clean. DO NOT block cooling airflow.
CAUTION
Special Precautions
DO NOT operate the traction system at high
speed or rapidly change direction of operation
WARNING with the wheels raised. Motor controller dam-
To avoid injury and prevent electrical shock, age can occur.
perform the following steps before trou-
bleshooting, adjustments, or repair: DO NOT subject the controller to any high voltage
• Turn the key switch to the OFF position and (hipot or megger) testing.
disconnect the battery connector. Use a lead acid battery with the voltage and ampere
• Discharge the capacitors in the controllers hour rating specified for the lift truck. Follow normal
by pushing and holding the horn button battery maintenance procedures, recharging at 80
down until the horn stops making a sound. percent discharge, with monthly equalizing charges.
CAUTION Parts of these assemblies not covered in this manual

cannot be repaired and must be replaced if they mal-
To help prevent controller damage:
function. The contactors are serviceable.
• ALWAYS disconnect the battery when servic-
ing the controllers.
• ALWAYS discharge the capacitors before per- WARNING
forming any service. Some checks in this section must be done with
• NEVER make a short circuit at any motor the battery connected and power applied to
controller terminal to battery (+), battery ( ), the controller. When making these checks,
or the frame. make sure the drive wheels are raised from
• Remove the motor controllers before per- the floor. See procedures given in the Periodic
forming any authorized welding procedures. Maintenance Manual or the Operating Manual
for your lift truck.
Never add any electrical component to the lift
truck without approval from your dealer for Make sure you disconnect the battery and
your lift truck. Other electrical components separate the connector before you remove any
can prevent operation and/or damage the mo- power cables from the power terminals of the
tor controller. motor controller. The capacitor stores electri-
cal energy and can cause injury, if a person
NEVER USE STEAM TO CLEAN ELECTRONIC discharges a capacitor, to parts of the body.
COMPONENTS. AFTER the battery is disconnected and the
key switch is in the OFF position, make sure
In dusty areas, blow low-pressure air over the con- you also discharge the capacitors.
troller to remove dust. In oily or greasy areas, a
mild solution of detergent or denatured alcohol can Discharge the capacitors in the controllers by
be used to wash off the controller; and then, low-pres- pushing and holding the horn button down un-
sure air should be used to completely dry the con- til the horn stops making a sound.
troller.
NOTE: The bolts and screws connected to the elec-
For the controller to be most effective, it must be tronic components are normally metric sizes.
mounted against the finned aluminum heat sink.
5
AC Transistor Motor Controller Replacement 2200 SRM 1190
Make sure that you use the correct fastener for the screws and remove the contactor assembly. See Fig-
part that has been disassembled or removed. ure 7.
FUSES Contactor Contacts. The contacts in a contactor

are made of special silver alloy. The contacts will look
The fuses are found on the Integrated Fuse Board. black and rough from normal operation. This condi-
See Figure 5. The condition of the fuses can be tion does not cause problems with the operation of
checked with an ohmmeter. the lift truck. Cleaning is not necessary. DO NOT
USE A FILE ON THE CONTACTS. DO NOT LU-
BRICATE THE CONTACTS.
CAUTION
ALWAYS replace all of the contacts in a con-
tactor at the same time. Replace the contacts
when the thickness of any area of a contact is
less than 30 percent of the thickness of a new
contact or if there is any transfer of contact ma-
terial.
Check the coil with an ohmmeter for an open circuit

or a short circuit. Coil resistance should read 32 ±4
ohms at room temperature. Replace the coil if resis-
1. 7.5 AMP FUSE tances are not within the specification.
2. 10.0 AMP FUSE
3. IDENTIFICATION LABEL
Figure 5. Integrated Fuse Board
FAN
The controller cooling fans operate with battery volt-
age. If battery voltage is present at the fan termi-
nal strip and the fans do not run, replace the fan.
If battery voltage is not present at the fan terminal
strip, look for problems in the positive circuit from
the key switch or the negative circuit to the master
controller.
CONTACTORS
1. CONTACTOR 4. MOVABLE
The main (line) contactor is located on the controller 2. POWER CONTACTS
platform beside the pump motor controller. See Fig- TERMINALS 5. SPRING
ure 6. 3. FIXED CONTACTS 6. PLUNGER
Figure 6. Main (Line) Contactor

Repair
Tag, identify, and disconnect the wires and cables
from the contactor assembly. Remove the mounting
6
Legend for Figure 7

1. TOP COVER
2. FIXED CONTACT SETS
3. MOVABLE CONTACTS
4. SCREW
5. RETURN SPRING
6. INSULATOR
7. COIL ASSEMBLY
Figure 7. Replacement Parts of Line Contactor
7
Function Settings 2200 SRM 1190
Master Controller Checks and Adjustments

NOTE: All checks and adjustments to the master con- • Check the system status codes history.
troller can be done using ETACC software with a per- • Check the state of charge of the battery.
sonal computer (PC). A diagnostics connector is lo- • Check the hourmeter readings on the traction cir-
cated on the right front cover panel next to the 12V cuit and hydraulic pump controllers.
power supply. Many checks can also be done at the • Monitor or adjust the register values for each func-
display panel without being connected to a PC. tion as shown in Table 1.
The following checks and adjustments may be made

using a PC or the dash display:
Function Settings
GENERAL Table 1. Factory Parameter Defaults
(Continued)
The master controller has several functions (pa-
rameters) that can be changed to configure differ- Parameter Factory Default
ent lift truck models and voltages. The function set-
tings are stored and used by the master controller to Extended Shift Off
determine lift truck performance or other operation LL W/O Override Off*
variables.
LL W/ Override Off*
NOTE: Table 1 and Table 2 show the default settings
for each control function. The factory settings are the Audible Alarm Off*
recommended settings for new units. These settings Visible Alarm Off*
will give satisfactory performance for most applica-
Auto Tilt Option Off*
tions.
Laser Option Off*
All functions can be adjusted within the permitted
range to change the lift truck operation for a spe- Carry Level Option Beep*
cific application. Adjustment of a register to a num- Slow Extended Off*
ber that is different than the factory setting is al-
lowed, but follow the instructions carefully. Adjust- Simultaneous Full
ments other than the factory settings will cause the Hydraulics
lift truck performance and energy consumption to Password Option Off
change.
Shutdown Time Out 15
Table 1. Factory Parameter Defaults
Truck Inspection Off*
Parameter Factory Default Impact Sensor*
Truck Set-Up Parameters Impact Action Off
Truck Serial Number AXXXX12345Z Impact Sound 1
Truck Voltage 24 or 36 Clear Impact --
Truck Capacity 3000, 3500, 4000, Hard Duration 0
or 4500 Hard Accel 0
Battery Type Flooded or Soft Duration 0
Maintenance-Free
Soft Accel 0
BDI Adjust 0
* - Not active on all models
8
2200 SRM 1190 Function Settings
Table 1. Factory Parameter Defaults Table 1. Factory Parameter Defaults

(Continued) (Continued)
Parameter Factory Default Parameter Factory Default

Maintenance Reminder* Lift Parameters
Maint Reminder Off Lift Max RPM 100%
Maint Interval 200 Lower Max RPM 100%
Auxiliary Function Parameters Steering Parameters
Fast Extend Speed 100% Steer Effort Medium
Slow Extend Speed 60% Steer Mode Auto
Fast Retract Speed 100% Steer Ratio 65
Slow Retract Speed 60% Display Parameters
Tilt Up Speed 100% Language English
Tilt Down Speed 100% Aft Control Parameter
Side Shift Speed 100% Aft Enable Off*
Reach Cushion On * - Not active on all models
Table 2. Traction Parameter Defaults
Factory Default
Model N30ZDR or N35-40ZR N45ZR or N35ZDR
Power 24V Std 36V Std 36V Std 36V HP 36V EE
or HP
Turtle Mode Speed 60 60 60 60 60
Low Speed 80 80 80 80 80
High Speed 90 90 90 90 90
Rabbit Mode Speed 100 100 100 100 100
Turtle Mode 10 15 15 15 10
Acceleration
Low 15 20 20 20 15
Acceleration
High 20 25 30 30 20
Acceleration
Rabbit Mode 20 35 40 50 20
Acceleration
Braking Neutral 0 0 0 0 0
Braking Plugging 50 50 50 50 50
Aft Handle Speed Reverse 25 25 25 25 25
9
Troubleshooting 2200 SRM 1190
Troubleshooting
GENERAL or controller fault could be caused by an internal fail-
ure of the master controller. After all other status
The AC motor and master controllers are sealed code procedures have been followed and no problem
units with no serviceable components. Troubleshoot- is found, the master controller should be replaced as
ing is usually limited to accessing status codes and the last option to correct the problem.
following the diagnostic procedures listed in the
Status Code Charts. Tools and test equipment required are: clip leads,
digital multimeter (20,000 ohms per volt minimum),
Use standard testing procedures to verify inputs and and basic hand tools.
outputs when necessary.
Check resistance on RX1000 scale from frame to
power and controller terminals. Resistance of less
CAUTION than 20,000 ohms can cause misleading symptoms.
Never attempt to probe through the back of Resistance of less than 1000 ohms should be cor-
the connector plugs of the motor controller. rected first.
These plugs are special sealed plugs. Probing
through the back of the plugs will destroy the The onboard diagnostic system employed on this lift
seal and can cause a short circuit. If a circuit truck can assist in the troubleshooting process. Read
must be tested for voltage, check for voltage at and be familiar with the instructions for accessing
an amp-type plug, a switch, or a component. If and using the dash display diagnostic system found
a circuit is suspect, check the circuit for conti- in User Interface, Service Technician (Stan-
nuity by disconnecting the P plug and testing dard Display) 2200 SRM 1193 or User Interface,
continuity from the front (pin end) of the plug. Service Technician (Premium Display) 2200
SRM 1241. Reference to these systems will be noted
Standard probes are too large to be inserted in the Troubleshooting instructions found in this
into the center of the female pins (sockets) of section.
the special sealed plugs and can expand the
pins. Expanded pins will not provide good con- Prior to troubleshooting systems and components on
nections once the plug is reconnected. The con- this lift truck, ensure the battery is the correct volt-
nectors are shaped to allow the insertion of a age and is fully charged. Make sure the battery con-
small flat-blade screwdriver into the connec- nector contacts are clean of corrosion and the battery
tor. After inserting the screwdriver into the polarity within the connector is correct. Inspect to
connector, attach probes with alligator clips to ensure all fuses are correct and have not failed. En-
the shank of the screwdriver to obtain read- sure the key switch is in the ON position when mak-
ings. An additional method would be to use a ing voltage checks or checking the operation of a com-
breakout kit, Hyster P/N 1397311. ponent. Make sure the floor (reset) switch and the
operator presence switch has been properly closed.
See Diagrams 8000 SRM 1199 for additional wiring
details. Many faults noted by lift truck systems are the result
of loose wiring connections and/or broken or shorted
If the lift truck does not operate correctly, a status wiring within the lift truck. Begin the troubleshoot-
code is displayed on the display panel. ing process by carefully inspecting the wiring involv-
ing the device or devices noted by the onboard diag-
Once the status code number is obtained, follow the
nostic system. Faults noted with components located
procedures outlined in the Status Code Charts of this
on the reach attachment may be caused by broken or
manual to determine the problem.
shorted wires in the mast cable. Ensure the integrity
NOTE: Due to the interaction of the master controller of this cable before troubleshooting attachment-re-
with all lift truck functions, almost any status code lated faults.
10
2200 SRM 1190 Troubleshooting
CONTROLLER STATUS LIGHT EMITTING AC Motor Controllers

DIODES (LEDS)
This section covers both the AC traction motor con-
The AC traction motor controller, AC pump motor troller and AC pump motor controller. Remove the
controller, and AC master controller each have a sep- rear cover to view the motor controllers. See Figure 9
arate LED to indicate its operating status. Each LED and Figure 10.
is green in color and may be lit continuously or blink-
• The LED only turns on when the key switch is in
ing. See each description for the location of each
the ON position.
LED.
• The LED will show a steady continuous green color
Master Controller if there is no fault condition detected.
• When a fault condition is detected that is not seri-
• The LED is located next to the wire harness con- ous enough to shut down the truck, the LED blink-
nector. See Figure 8. ing rate is twice a second. A status code should ap-
• The LED blinking rate is usually twice a second, pear on the dash display to reference the problem.
when the battery is connected and the key switch • When a fault condition is detected that has shut
is in the OFF position. down the truck, the LED blinking rate will be at
• The LED blinking rate slows to once every two sec- a very rapid rate (too fast to count). A status code
onds when the battery is connected and the key should appear on the dash display to reference the
switch is moved to the ON position. problem.
• If the above conditions are not present, the master • If the above conditions are not present, the AC mo-
controller may not be properly connected or may be tor controller may not be getting power from the
faulty. key switch or may be faulty.
• Due to the location of the master controller, a small
inspection mirror may be needed to view the LED.
1. LED
Figure 8. Master Controller LED
11

12

13
OPERATOR STATUS MESSAGES These messages are only codes to help identify a pos-
sible malfunction. A short description of the different
NOTE: An operator message does not always mean status messages is shown in Table 3.
there is a malfunction. A temporary operating con-
dition can cause a status code display.
Table 3. List of Operator Warning Messages
Message Description Explanation

Brk Ped Message is displayed at key switch ON Normal Operation.
position.
Power On Message is displayed when truck has timed Normal Operation.
out (approximately 15 minutes without
operation). Screen will go blank and display
message. Key switch must be reset to
resume operation.
Foot Sw Message is displayed after brake pedal is Normal Operation.
depressed. Operator must depress foot
switch to activate lift truck controls.
Ready Message is displayed after start-up Normal Operation.
procedure is complete and lift truck is ready
for operation.
Press If Handle Notification to operator that handle control Operator must press the key to activate
Decal Is Correct parameters have been changed. the lift truck controls.
Forward Message is displayed once the forward Normal Operation.
direction has been selected.
Reverse Message is displayed once the reverse Normal Operation.
direction has been selected with the control
handle.
Lift Message is displayed once the lift function Normal Operation.
has been selected with the control handle.
Lower Message is displayed once the lower function Normal Operation.
Extend Message is displayed once the extend Normal Operation.
function has been selected with the control
handle.
Retract Message is displayed once the retract Normal Operation.
function has been selected with the control
handle.
Tilt Up Message is displayed once the tilt up function Normal Operation.
Tilt Down Message is displayed once the tilt down Normal Operation.
function is selected with the control handle.
SS Right Message is displayed once the sideshift right Normal Operation.
14
Table 3. List of Operator Warning Messages (Continued)

SS Left Message is displayed once the sideshift left Normal Operation.
Load "XXXX" lbs Message is displayed when the load weight Normal Operation.
option is activated and there is a load on the
forks.
Enter Password Message is displayed when passwords option Operator must enter correct password to
is activated. activate the lift truck controls.
Traction Low Traction controller senses a battery voltage Make sure battery voltage matches the
Voltage lower than the reference voltage stored in voltage listed on the lift truck nameplate.
the lift truck voltage parameter.
Lift Low Voltage Lift controller senses a battery voltage lower Make sure battery voltage matches the
than the reference voltage stored in the lift voltage listed on the lift truck nameplate.
truck voltage parameter.
Traction High Traction controller senses a battery voltage Make sure battery voltage matches the
Voltage lower than the reference voltage stored in voltage listed on the lift truck nameplate.
Lift High Voltage Lift controller senses a battery voltage Make sure battery voltage matches the
higher than the reference voltage stored in voltage listed on the lift truck nameplate.
Motor Master controller senses a fault in the Sensor is disconnected or damaged.
Temperature traction motor temperature sensor.
Sensor Fault
Password Error Password has been incorrectly entered or Reenter password.
doesn’t match any password stored in the lift
truck memory.
Password Error Password has been incorrectly entered The lift truck cannot be operated until
exceeding the number of attempts allowed the password system has been reset
by the system. using supervisor password.
Lower Forks Hydraulic tank float switch is indicating a Check hydraulic oil level and fill as
low oil level in the tank. needed. Check for leaks.
Cycle Brake Lift truck will not complete start-up Operator must cycle brake pedal to start
Pedal procedure. truck.
Cycle Foot Lift truck will not complete start-up Operator must cycle brake pedal to start
Switch procedure. truck.
Reset Handle Lift truck will not complete start-up Control handle must be in the neutral
procedure. position at truck startup.
Step on Brake Traction is disabled. Brake must be disengaged for traction
to be active.
Step on Foot Lift truck will not complete start-up Operator must engage floor switch to
Switch procedure. complete start-up procedure.
15

Switches Must Lift truck will not complete start-up Operator is holding switch closed. All
Be Released to procedure. control handle switches must be in the
Start neutral position to complete start-up
procedure.
End of Stroke Function has reached end of stroke and Switch is continuing to be held closed
operator is continuing to operate function after function has reached end of stroke,
switch. or a failure of the switch to turn off.
Reduced Lift The master controller has detected a The lift system will operate at reduced
Speed condition that requires the lift speed to be speed until corrected.
reduced.
Mast Up Speed Mast switch has been activated. Traction If message is displayed when mast is
Reduced speed has been reduced by the master lowered, check for a failed mast switch.
controller.
Carriage Extend The extend switch has been activated. Carriage is not in the fully retracted
Traction speed has been reduced by the position. If message is displayed with the
master controller. carriage fully retracted, check for a failed
extend switch.
Steer Temp High Temperature sensor in the steering motor Truck is being used in a high ambient
has reached 140 C (284 F) degrees. The temperature environment. Reduce use of
master controller has reduced the speed of steering function to allow cooling.
the steering motor.
Traction Motor The temperature of the traction motor is Truck is being operated in a low
Temp Low below 20 C ( 4 F) degrees. temperature environment. Move truck
to a higher temperature area or increase
usage of traction function to increase
motor temperature.
Traction Motor The temperature of the traction motor is Truck is being used in a high ambient
Temp High above 145 C (293 F) degrees. The master temperature environment. Move to a
controller has reduced the speed of the lower temperature area or decrease use
traction motor. of traction system to lower temperature
of the traction motor.
Traction The temperature of the traction motor Truck is being used in a low ambient
Controller Temp controller is below 20 C ( 4 F) degrees. temperature environment. Move to a
Low The master controller has reduced the speed higher temperature area or increase use
of the traction motor. of traction system to raise temperature
of the controller.
Traction The temperature of the traction motor Truck is being used in a high ambient
Controller Temp controller is above 85 C (185 F) degrees. The temperature environment. Move to a
High master controller has reduced the speed of lower temperature area or decrease use
the traction motor. of traction system to lower temperature
of the controller.
16

Lift Motor The temperature of the lift motor is below Truck is being used in a low ambient
Temperature 20 C ( 4 F) degrees. temperature environment. Move to a
Low higher temperature area or increase use
of lift system to raise temperature of the
lift motor.
Lift Motor The temperature of the lift motor is above Truck is being used in a high ambient
Temperature 145 C (293 F) degrees. The master controller temperature environment. Move to a
High has reduced the speed of the lift motor. lower temperature area or decrease use
of lift system to lower temperature of the
lift motor.
Lift Controller The temperature of the lift motor controller Truck is being used in a low ambient
Temperature is below 20 C ( 4 F) degrees. The master temperature environment. Move to a
Low controller has reduced the speed of the lift higher temperature area or increase use
motor. of lift system to raise temperature of the
controller.
Lift Controller The temperature of the lift motor controller Truck is being used in a high ambient
Temperature is above 85 C (185 F) degrees. The master temperature environment. Move to a
High controller has reduced the speed of the lift lower temperature area or decrease use
motor. of lift system to lower temperature of the
controller.
Fan Overcurrent The master controller has detected an Check the controller fan for obstructions.
overcurrent condition in the controller fan The fan motor should be receiving 24
circuit. Traction speed has been reduced by volts. Check for broken wiring in the
the master controller. truck wiring harness and make sure all
connections are tight.
Lift Stalled The lift controller has detected a stalled Mast is at end of stroke. Return control
motor condition in the lift motor. handle to neutral. Operator is trying
to lift overcapacity load. Reduce load
weight. Mast movement is obstructed.
Inspect and repair mast. Lift pump
has failed and prevents the motor from
rotating.
Lift Lockout The battery charge is low. The master Install charged battery.
controller has locked out the lifting function
until a properly charged battery is installed
in the lift truck.
Hyd Disabled Hydraulic functions are disabled and cannot The factory disables hydraulic functions
be actuated. for shipment. Before delivery, technician
should reinstall the hydraulic tank
breather then re-enable hydraulic
functions by holding down the #3 and #4
buttons on the display for 2 seconds.
17
STATUS CODES • Correct input voltages that occur at the wrong time
NOTE: Make sure the parameter values are correct NOTE: A status code indication does not always mean
for your lift truck to ensure the trouble is not just that there is a malfunction. A temporary operating
an incorrect setting. See Function Settings to set the condition can cause a status code display.
correct parameter values. If there is no status code
display and the lift truck does not operate correctly, These code numbers are only codes to help identify
there can be a fault in the master controller. a possible malfunction. A short description of the
different status codes is shown in Table 4.
The status codes are code numbers for malfunctions
or lift truck operations that are not correct and that NOTE: If a "C" appears at the end of a fault code,
the motor controller can sense. The master controller it indicates that the fault is in the caster steering
will indicate this code number on the LCD screen of system.
the display panel.
The Fault Message charts in this section have a more
The master and motor controllers sense the following complete description of the status code, the circuit
types of malfunctions: that has generated the input for the status code, the
• Input voltages that are too high or too low symptom, and the possible causes.
• Input voltages in the wrong sequence or
Table 4. List of Fault Messages
Fault Message Description

Blank Blank Screen No Power to Unit
10/10C STEER FEEDBACK FAULT Steer Feedback Fault
14/14C STR CENTER FAULT Steer Centering Fault
16/16C STEER HIGH VOLT Steer High Voltage
28 LD HOLD CI OPEN Load Hold Coil Open
42 LIFT DRV TMP HIGH Lift Drive Temperature High
49 LOWER FAULT Lower Fault
52 STR ENCODER FAULT Steer Encoder Fault (Tiller)
62 HORN SHORTED Horn Shorted
65 MAIN COIL SHORTED Main Coil Shorted
66 TRACTION SHORTED Traction Shorted
90 TRAC MTR TEMP HI Traction Motor Temperature High
91 LIFT MTR TMP HIGH Lift Motor Temperature High
214 LIFT SHORT CIRC Lift Short Circuit
222 BRAKE COIL SHORT Brake Coil Shorted
223 MAIN COIL OPEN Main Coil Open
230 FAN OVER CURRENT Fan Over Current (Traction)
238 TRACTION CONTROL FLT Traction Control Fault
239/239C STEER CONT FAULT Steer Control Fault
241/241C STEER COMM ERR Steer Communication Error
348 TRAC COMM ERROR Traction Communication Error
18
Table 4. List of Fault Messages (Continued)

242 HANDLE COMM ERR Handle Communication Error
243 PRES SENS FLT Pressure Sensor Fault
247 REMOTE COMM ERR Remote Communication Error
260 LIFT LOW VOLTAGE Lift Low Voltage
271 HANDLE FAULT Handle Fault (Forward/Reverse)
271 HANDLE FAULT Handle Fault (Lift/Lower)
272 AFT HANDLE FAULT Aft Throttle or Sensor Fault
273 HANDLE FAULT Handle Fault (Hall-Error)
275 REMOTE MODULE FAULT Remote Module Fault
279 TILT COIL SHORTED Tilt Coil Shorted
280 SS COIL SHORT Sideshift Coil Shorted
281 SS COIL OPEN Sideshift Coil Open
283 TILT COIL OPEN Tilt Coil Open
284 EXTEND COIL SHORT Extend Coil Shorted
285 EXTEND COIL OPEN Extend Coil Open
286 AUX COIL SHORT Aux Direction Coil Shorted
287 AUX COIL OPEN Aux Direction Coil Open
300 TILT SENS FAULT Tilt Sensor Fault
301 EXTEND SENS FAULT Extend Sensor Fault
310 LIFT CONTROL FAULT Lift Control Fault
311 LIFT COMM ERROR Lift Communication Error
312 LIFT SPD SENSOR Lift Speed Sensor Error
313 LIFT OVER CURRENT Lift Overcurrent
314 NO CHARGE DC BUS No Charge DC Bus
316 LIFT HIGH VOLTAGE Lift High Voltage
320/320C STR MTR HI CUR Steer Motor High Current
321/321C STEER HIGH TMP Steer High Voltage
322/322C STR CONT HI CUR Steer Continuously High Current
323/323C STEER POS ERR Steer Position Error
330 FAN OVER CURRENT Fan Over Current (Lift)
331 LD HOLD COIL SHORT Load Hold Coil Shorted
341 TRAC DRVE TMP HI Traction Drive Temperature High
342 TRACTION OVERCUR Traction Overcurrent
19
Table 4. List of Fault Messages (Continued)

343 NO CHARGE DC BUS No Charge DC Bus
344 TRACTION LOW VOLT Traction Low Voltage
345 TRACTION HIGH VOLT Traction High Voltage
347 TRAC SPD SENS ER Traction Speed Sensor Error
348 TRAC COMM ERROR Traction Communication Error
350 AUX COMM ERROR Auxiliary Motor Communication Error
- SOFT IMPACT Soft Impact
- HARD IMPACT Hard Impact
- IMPACT SENSOR FAULT Impact Sensor Fault
20
Status Display Message Circuit

Code
Blank Blank Blank
Description
Dead Truck
Symptom
No power to the lift truck; blank screen on display.
Probable Causes and Test Procedures
– Verify battery is plugged into the battery connec-
tor.
– Verify condition of FU 10.
– Verify Battery disconnect switch is closed.
– Verify key switch is in the ON position.
– Verify battery voltage at pin #10 at the inte-
grated fuse board.
• Check for battery voltage at run terminal of the
key switch.
• Check continuity of wire #5 from key switch to
integrated fuse board.
– Verify battery voltage at all fuses on integrated
fuse board.
• Check condition of all fuses.
• Replace integrated fuse board.
– Verify battery voltage at pin #1 at the integrated
fuse board.
– Verify 24 volts at pin #4 at the integrated fuse
board connector.
• Replace integrated fuse board.
– Check dash display for fault codes or messages.
• Enter the Diagnostics - Error Log menu for
stored error codes. Clear any errors.
– Verify operation of the main contactor.
• Contactor should close.
– Check for a steady illuminated LED on all con-
trollers. Blinking LED indicates a fault in the
controllers.
• Enter the Diagnostics - Error Log menu.
Check for stored error codes. Clear any errors.
• Replace controller.
– Turn the key switch to the OFF position and
check the resistance between pin #A and pin #B
at the service PC connection.
• Resistance should read between 50 and 70
ohms.
• Check wiring for damage.
21

Code
10/10C 10 STEER FEEDBACK FAULT Steering
CALL SERVICE
Description
The steer controller or caster controller has
sensed either an open or short in the steer motor
or caster motor feedback circuit.
Symptom
Truck is disabled; does not center on startup.
– Check wiring for any loose or shorted connec-
tions in the MDU or caster steering circuit.
– Ensure the connectors in these circuits are tight.
– Check the MDU proximity switch and steering
proximity switch (if equipped) for proper adjust-
ment (1.50 mm (0.06 in.) of the drive gear or tar-
get plate.
– Check proximity switch face for damage.
– Steer the truck to determine which steering mo-
tor is causing the fault.
• Trucks without a steered caster: If the MDU
steering motor fails to operate, the MDU steer-
ing motor is causing the fault.
• Trucks with a steered caster: If the MDU steer-
ing motor operates and the caster steering mo-
tor fails to operate, the caster steering motor is
causing the fault.
– Check for continuity in the wiring between the
steering controller and the steering. Repair as
necessary.
– Check for 5 volts at terminal #3 on the steering
controller and on the red wire at the steering mo-
tor.
• If there is no voltage at terminal #3 of the steer-
ing controller, the steering controller may be
bad.
• If there is voltage at terminal #3 and no voltage
at the red wire, ensure there is contact within
the connector between the steering controller
and the steer motor.
– If no wiring faults are found, the problem is in
the steering motor. Replace the steering motor.
22

Code
14/14C 14 STR CENTER FAULT Steering
CALL SERVICE
Description
The steering controller or caster controller has
sensed a fault in the steer centering operation.
The truck has not centered the steering on system
startup. Drive wheel moves to mechanical stop.
Symptom
Truck is disabled.
– Enter the Diagnostic - Static Diagnostic - Str
Ctr Prox Switch1 and verify the operation of the
MDU steering proximity switch as the steering
system is operated from lock to lock. The dash
display should change from 0 to 1 and back to 0
as the steering system passes through the center
position.
• Check that the MDU proximity switch and
steering proximity switch (if equipped) is ad-
justed within 1.50 mm (0.06 in.) of the drive
gear or target plate.
• Check that the indicator light on the end of the
proximity switch illuminates when the tire is
in the straight-ahead position. Refer to Steer-
ing System 1600 SRM 1187 for instructions
on adjusting the steering proximity sensors.
• Check proximity switch face for damage.
– If the truck is equipped with a steered caster as-
sembly, enter the Diagnostics - Static Diagnostic
- Str Ctr Prox Switch2 and verify the operation of
the caster steering proximity switch as the steer-
ing system is operated lock to lock. The dash dis-
play should change from 0 to 1 and back to 0 as
the system passes thought the center position.
• Check that the proximity sensor is adjusted
within 1.50 mm (0.06 in.) of the drive gear or
target plate.
• Check that the indicator light on the end of the
proximity switch illuminates when the tire is
in the straight-ahead position. Refer to Steer-
ing System 1600 SRM 1187 for instructions
on adjusting the steering proximity sensors.
– Check continuity of all wiring to the proximity
switches from the steering controller to the MDU
or caster assembly.
23

Code
14/14C 14 STR CENTER FAULT Steering
(cont) CALL SERVICE
Description
The steering controller or caster controller has
sensed a fault in the steer centering operation.
The truck has not centered the steering on system
startup. Drive wheel moves to mechanical stop.
Symptom
Truck is disabled. (cont)
– Check for 24 volts at terminal #19 on the steering
controller.
– Check for 24 volts at pin #4 or wire #285 on the
integrated fuse board connector.
• Check FU 11 for continuity and replace as nec-
essary.
• Check for battery voltage at FU 11.
– Replace the proximity switch.
24

Code
16/16C 16 STEER HIGH VOLT Steering
CALL SERVICE
Description
The steer controller or caster controller has sensed
a high voltage condition of its power connection.
Symptom
Truck is disabled.
– Check that the MDU proximity switch and steer-
ing proximity switch (if equipped) is adjusted
within 1.50 mm (0.06 in.) of the drive gear or
target plate.
– Check that the indicator light on the end of the
proximity switch illuminates when the tire is in
the straight-ahead position. Refer to Steering
System 1600 SRM 1187 for instructions on ad-
justing the steering proximity sensors.
– Check proximity switch face for damage.
– Enter the Setup - Truck Settings - Voltage menu
and ensure the battery voltage matches the volt-
age setting shown on the dash display.
• Install the correct voltage battery.
– Check to ensure the battery polarity is correct at
the battery connector.
– Check voltage at B+ terminal of the steering con-
troller. Voltage should not exceed 42 volts.
– Replace steering controller.
25

Code
28 28 LD HOLD CI OPEN Lift
CALL SERVICE
Description
The controller has sensed an open condition in
the load hold coil.
Symptom
Lifting is disabled.
– Enter the Diagnostics - Hydraulic System - Load
Hold Coil and check the operation of the load
hold coil.
• The dash display should change from 0 to 1 as
the hoist system is operated and then returned
to neutral.
– Check for loose wiring connections at the load
hold coil.
– Check for battery voltage at terminal #1 of the
load hold coil.
• Check for battery voltage at pin #1 on the in-
tegrated fuse board.
• Check wiring continuity between pin #1 on the
integrated fuse board connector and terminal
#1 on the load hold coil.
– Check wiring continuity between terminal #2 of
the load hold coil and pin #39 at the master con-
troller.
– Disconnect the wires from the terminals of the
load hold coil and check the coil for continuity.
Coil should show continuity and should measure
approximately 30 ohms resistance.
• Replace the coil
– Connect an external ground to terminal #2 of the
load hold coil.
• If coil operates, the problem is internal in the
master controller. Replace the master con-
troller.
26

Code
42 42 LIFT DRV TMP HIGH Lift
CALL SERVICE
Description
The lift controller temperature sensor has sensed
a controller temperature in excess of 85 C (185 F).
Normal system operation will resume when the
lift controller has cooled.
Symptom
The lift motor is operating at a reduced speed.
– Enter the Diagnostics - Hydraulic System -
Pump Control Temp to verify the pump motor
controller has exceeded 85 C (185 F).
– Check the operation of the cooling fan.
• The fan should be operating if the controller
temperature is above 50 C (122 F).
• Check for airflow through the cooling fins at
the base of the motor controllers and that the
cooling fins are not clogged.
• Check that the fan is not blocked and is free to
rotate.
• Check for 24 volts on the red wire at the fan.
• Check for 24 volts at terminal #4 on the inte-
grated fuse board.
• Check the condition of FU 11 on the integrated
fuse board. If FU 11 is good and there is no
voltage at terminal #4, replace the integrated
fuse board.
• If there is 24 volts at the red wire, connect a
jumper from the black wire from the fan to a
system ground.
• If the fan operates, and the controller temper-
ature is above 50 C (122 F), the problem is in
pump motor controller.
• If the fan does not operate, replace the fan.
– Reduce lift system use to allow the controller to
cool and remain below 85 C (185 F).
27

Code
49 49 LOWER FAULT Lower
CALL SERVICE
Description
Lowering speed has exceeded the requested
lowering speed from the control handle. The
master controller activates the load check valve
to stop the lowering operation.
Symptom
Lowering is disabled. Traction is disabled.
– If forks are elevated, open the manual lowering
valve and carefully lower the forks to the floor
level.
– Enter the Diagnostics - Error Log menu and
check for additional fault information.
– Check the operation of the load check valve.
• Enter the Diagnostics - Hydraulic System -
Load Hold Coil menu. Move the control handle
to the lower position. The value on the display
should change from 0 to 1 with the handle in
the lower position.
• The valve should operate as the control handle
is moved to the lowering position.
• Check for battery voltage at wire #208 at the
load hold coil connector. Ensure the connector
is tight. Check the harness wiring for continu-
ity.
• Check the load hold coil. Disconnect the con-
nector. Check coil continuity.
• Provide an external ground to the white wire
from the coil. If the load hold valve operates,
the problem is in the master controller, the con-
trol handle, or the wiring from the control han-
dle to the master controller.
– Pump motor has failed.
• Check the pump motor for phase-to-phase and
phase-to-ground shorts or open circuits. For
phase-to-phase resistance values, refer to the
section AC Motor Repair 620 SRM 1186, Hy-
draulic Motor Windings.
• Replace pump motor.
28

Code
49 (cont) 49 LOWER FAULT Lower
CALL SERVICE
Description
Lowering speed has exceeded the requested
lowering speed from the control handle. The
master controller activates the load check valve
to stop the lowering operation.
Symptom
Lowering is disabled. Traction is disabled. (cont)
– Check the pump motor encoder.
• Open the manual lowering valve and carefully
lower the forks to the floor.
• Check for 12 volts at pin #1, wire #280, at the
pump motor encoder. Check for 12 volts at pin
#3 at the pump controller.
• Check pump motor encoder. Voltage between
pin #2 and ground and pin #3 and ground
should read 5.65 VDC when the lift pump is
activated.
• Check continuity of wire #103 from pin #4 at
the pump motor encoder to pin #4 at the pump
controller.
Pump Motor Speed menu and observe the
RPM value as the hoist system is operated.
The value should read approximately 3000
RPMs (standard) or 3200 RPMs (high perfor-
mance) at full speed. Pump speeds should
read within ±10% of normal values.
• Hold the control handle to operate the hoist
function at a steady speed. RPM reading
should remain steady and not fluctuate. Re-
place the pump motor encoder bearing.
29

Code
52 52 STR ENCODER FAULT Steering
CALL SERVICE
Description
The steer controller or caster controller has
sensed a fault in the tiller encoder.
Symptom
If moving, the speed command is set to zero,
the electric brake is enabled, and the truck is
disabled. If the fault is sensed at truck startup,
vehicle systems will not be engaged.
– Verify 5 volts on pin #3 of the steering controller.
If voltage is not present, check the steer con-
troller for B+ voltage at the B+ terminal. Check
the LED for solid light.
– If voltage is good on pin #3, check voltage at pin
#1 to the steer encoder unit, pin #B to th epres-
sure transducer, and pin #1 (wire 250A) to the
steer motor.
– If any circuit is open, check the wiring harness
for continuity. Inspect for loose or damaged pin
connectors and for broken or damaged wires.
– If voltage is less than 5 volts at any point, check
for a grounded circuit by disconnecting the fol-
lowing components one at a time:
• Steer Motor Connection
• Pressure Transducer Connection
• Steer Encoder Connection
Any voltage drop should be determined and the
affected part replaced as necessary.
– Check the continuity of all wiring from the
steering encoder connections to the steering
controller, steering pressure transducer and the
steer motor.
– Check voltage on wire #573, wire #574, wire
#575, and wire #576.
• Voltage on each wire should switch back and
forth between 5 volts and 0 volts as the steer-
ing encoder is slowly rotated.
• If voltage on all wires stays at 5 volts and 0
volts as the steering encoder is rotated, replace
the steering encoder.
30

Code
62 62 HORN SHORTED Horn
CALL SERVICE
Description
The master controller has detected a shorted
condition in the horn circuit.
Symptom
Horn does not operate.
– The horn should be receiving 24 volts when the
horn button is depressed. Check for broken
wiring in the truck wiring harness and make
sure all connections are tight.
• Replace the horn.
– Enter the Diagnostics - Static Diagnostics - Horn
Switch menu to check the operation of the horn
switch.
• The value on the display should switch from 0
to 1 as the horn switch is operated. If the value
does not change, check the horn switch.
• Replace handle.
– Check for 24 volts at terminal #1 at the horn.
grated fuse board (wire #285).
• Check condition of FU 11 on the integrated
fuse board. Replace as necessary.
– Connect an external ground to terminal #2 on the
horn.
• If the horn now operates, the problem is in
the master controller. Replace the master con-
troller.
31

Code
65 65 MAIN COIL SHORTED Traction
CALL SERVICE
Description
The master controller has sensed the main
contactor coil is shorted at system startup.
Symptom
Truck is disabled.
– Remove the wires from the terminals on the
main contactor.
– Check the contactor coil for a shorted condition.
The coil should measure approximately 32 ±4
ohms resistance.
• Replace the contactor coil.
– Check harness wiring from the contactor nega-
tive terminal to terminal #40 at the master con-
troller for any shorted wires.
– Ensure there is 24 volts at the positive terminal
of the main contactor when the truck is on.
– Connect an external wire from the main contac-
tor negative terminal to terminal #40 at the mas-
ter controller.
• If contactor works properly and fault clears,
the problem is in the wiring.
• If the contactor fails to operate, the problem is
in the master controller. Replace the master
controller.
32

Code
66 66 TRACTION SHORTED Traction
CALL SERVICE
Description
The controller has sensed a shorted condition in
the traction motor.
Symptom
Traction is disabled.
– Restart lift truck to see if the fault reoccurs.
Overcurrent condition may occur during periods
of high use.
– Check battery condition and state of charge.
– Check wiring from traction controller to traction
motor for any loose connections, burned wiring,
or shorted wiring.
• Replace or repair any damaged or shorted
wiring.
• Tighten any loose connections.
– Check the motor controller for shorts. See
Checking the Motor Controller.
• Replace motor controller if any shorts are
found in the controller FET’s and internal
diodes.
– Checking for a shorted motor is possible but re-
quires a low ohm reading meter (milliohms) and
a low cost resistance bridge. The reading for each
phase should be around 0.0032 ohms.
• Replace the traction motor.
33

Code
90 90 TRAC MTR TEMP HI Traction
CALL SERVICE
Description
The traction motor temperature sensor has
sensed a high temperature condition in the
traction motor. The traction motor temperature
has exceeded 145 C (293 F).
Symptom
Traction performance is reduced. If motor
temperature continues to rise above 165 C
(329 F), traction will be disabled.
– Truck is being operated in high ambient tem-
peratures or the truck is being used in a very
high-duty cycle application.
• Reduce the duty cycle to return to normal trac-
tion system operation.
• Enter the Diagnostics - Traction System - Trac-
tion Motor Temp menu to verify the high tem-
perature condition via the dash display.
– If equipped, ensure the compartment fan is op-
erating.
• Clear the fan of any debris.
– Check the drive train to ensure there is no bind-
ing or excessive tightness in the drive unit.
– Check the temperature sensor.
• Allow the motor to cool and measure resistance
between pin #1 and pin #2 at the tempera-
ture sensor connector. Resistance should be
approximately 650 ohms at 27 C (80 F).
34

Code
91 91 LIFT MTR TMP HIGH Lift
CALL SERVICE
Description
The temperature sensor in the lift motor has
sensed a temperature exceeding 145 C (293 F)
degrees. Normal system operation will resume
when motor has cooled.
Symptom
The lift motor is operating at a reduced speed.
– Truck is being operated in high ambient tem-
peratures or the truck is being used in a very
high-duty cycle application.
• Reduce the duty cycle to return to normal trac-
tion system operation.
Pump Motor Temp menu to verify the high
temperature condition via the dash display.
– If equipped, ensure the compartment fan is op-
erating.
• Clear the fan of any debris.
– Check the mast to ensure there is no binding or
excessive tightness in the mast.
– Check the temperature sensor.
• Allow the motor to cool and measure resistance
between pin #1 and pin #2 at the tempera-
ture sensor connector. Resistance should be
approximately 650 ohms at 27 C (80 F).
35

Code
214 214 LIFT SHORT CIRC Lift
CALL SERVICE
Description
The lift motor controller has sensed a short circuit
condition in the lift motor.
Symptom
Lift is disabled.
– Restart the lift truck to see if the fault reoccurs.
– Check wiring from pump controller to the lift mo-
tor for any loose connections, burned wiring, or
shorted wiring.
wiring.
– Check the lift motor for phase-to-phase or phase-
to-ground shorts.
• Replace lift motor if shorted or resistance is
not within ±10% of the acceptable resistance
value. Refer to section AC Motor Repair 620
SRM 1186 for phase-to-phase resistance values
and replacement instructions.
– If no fault is found with the lift motor or wiring
and problem reoccurs, the problem may be an
internal fault within the pump controller.
• Replace the pump controller.
36

Code
222 222 BRAKE COIL SHORT Brake
CALL SERVICE
Description
The master controller has sensed a shorted coil
condition in the brake circuit.
Symptom
Truck is disabled. If fault is detected while
moving, the speed command is set to zero and the
truck will come to a stop. If fault is detected at
startup, truck is disabled.
– Check the brake coil.
• Remove the wires from the brake coil termi-
nals and check the resistance across the termi-
nals. The coil should measure approximately
12 ohms resistance across the terminals.
• If the resistance is not correct, replace the coil.
– Verify the wiring.
• Check all wiring between the integrated fuse
board and the brake coil (wire #206) and be-
tween the brake coil and terminal #24 at the
master controller (wire #96).
• Verify that all connections are tight and con-
nectors are secure. Repair any broken or
shorted wires.
• Verify there are no shorted wires within con-
nector at the brake coil.
– Verify battery voltage at the positive (wire #206)
terminal of the brake coil.
• Verify battery voltage at terminal #1 at the in-
• Verify the condition of fuse #13 at the inte-
grated fuse board.
– Disconnect wire #96 at the brake coil. Connect
an external ground to the negative terminal of
the main contactor coil.
• If the brake operates as the key switch is op-
erated, the problem may be an internal fault
within the master controller. Replace the mas-
ter controller.
37

Code
223 223 MAIN COIL OPEN Traction
CALL SERVICE
Description
The master controller has sensed the main
contactor coil is open at system startup.
Symptom
Truck is disabled, may give other codes, such as
No Charge DC bus.
– Check the main contactor coil.
• Remove the wires from the main contactor coil
terminals and check for continuity across the
terminals. The coil should measure approxi-
mately 32 ±4 ohms resistance across the ter-
minals.
• If no continuity or the resistance is not correct,
replace the coil.
– Check all wiring for continuity between the inte-
grated fuse board (pin #1) and the main contactor
(wire #206) and between the main contactor and
terminal #40 at the master controller (wire #24).
• Repair any broken or shorted wires.
• Check that all connections are tight and con-
nectors are secure.
– Verify battery voltage at the positive (wire #206)
terminal of the main contactor coil.
• Verify the condition of FU 13 at the integrated
fuse board.
– Verify the CANbus wiring - main contactor will
not close if a CANbus fault is present.
• Turn the key switch to the OFF position
• Check the resistance between pin #A and pin
#B at the service PC connection.
• Resistance should read between 50 and 70
ohms. If resistance of 120 ohms is present,
check CANbus wiring for damage.
– Disconnect wire #24 at the main contactor coil.
Connect an external ground to the negative ter-
minal of the main contactor coil.
• If the main contactor closes as the key switch
is operated, the problem may be an internal
fault within the master controller. Replace the
master controller.
38

Code
230 230 FAN OVER CURRENT Traction
CALL SERVICE
Description
The master controller has sensed an overcurrent
condition in the motor controller (traction) fan
circuit.
Symptom
Truck is disabled.
– Check fan:
• Verify fan is not prevented from rotating.
• Clean any debris from fan.
– Check fan motor for a shorted condition.
• Measure resistance between pin #1 and pin #2
at the fan connector. Resistance should mea-
sure approximately 1.2 ohms.
• Replace fan.
– Check for 24 volts at pin #1 of the fan connector.
• Check for 24 volts at pin #1 of the fan connec-
tor.
39

Code
238 238 TRACTION CONTROL FLT Traction
CALL SERVICE
Description
The master controller has sensed a fault in the
traction controller.
Symptom
restart the lift truck.
– Check all CANbus wiring between the traction
motor controller and the master controller.
• Ensure all connectors are tight and pins are in
good condition.
• Check all CANbus wiring between terminals
for continuity.
– Wire #113 between pin #8 at the master con-
troller connector and pin #7 at the traction
controller connector.
– Wire #900 between pin #23 at the master
controller connector and pin #14 at the trac-
tion controller connector.
controller connector and pin #22 at the steer-
ing controller connector.
– Replace any defective wiring.
– Verify condition of the traction motor controller.
• Verify steady green LED at the traction motor
controller - controller is OK.
• No illuminated LED at the traction motor con-
troller.
– Verify battery voltage at the B+ terminal of
the traction motor controller.
– Verify battery is connected to the truck.
– Verify battery is charged and is correct volt-
age for the lift truck.
• Flashing LED at the traction motor controller
- Internal Fault. Replace the traction motor
controller.
40

Code
239/239C 239 STEER CONT FAULT Steering
CALL SERVICE
Description
The master controller or caster controller has
sensed a fault in the controller. The controller
has an internal fault. This error is usually
accompanied by a more detailed fault code.
Symptom
Truck is disabled. If the truck is moving, the
speed command is set to zero, the electric brake is
engaged, and the truck systems are disabled.
– If the lift truck is equipped with caster steering,
determine which steering controller is producing
the fault.
• Operate the steering system.
• If only the drive unit turns, the caster con-
troller is producing the fault.
• If neither the drive unit nor the caster turns,
the drive unit controller is at fault.
– Enter the Diagnostics - Error Log menu of the
dash display and note any other steering system
fault error codes.
• Refer to the procedures for any other error code
listed in the menu.
41

Code
(cont) CALL SERVICE
Description
Symptom
speed command is set to zero, the electric brake
is engaged, and the truck systems are disabled.
(cont)
– Check all CANbus wiring between the steering
good condition.
for continuity.
troller connector and pin #8 at the steering
Note: If the lift truck is equipped with the
steered caster option, there will be no con-
nection to pin #14 at the steering controller
for the MDU steering motor.
– Wire #901 between pin #23 at the steering
42

Code
(cont) CALL SERVICE
Description
Symptom
speed command is set to zero, the electric brake
is engaged, and the truck systems are disabled.
(cont)
– Verify condition of the steering motor controller.
• Verify steady green LED at the steering motor
• No illuminated LED at the steering motor con-
troller.
the steering motor controller.
• Flashing LED at the steering motor controller -
internal fault. Replace the steering motor con-
troller.
43

Code
241/241C 241 STEER COMM ERR Steering
CALL SERVICE
Description
The master controller cannot establish or has lost
CANbus communication with the steering motor
controller or caster controller.
Symptom
Truck is disabled.
– If the lift truck is equipped with caster steering,
determine which steering controller is producing
the fault.
• Operate the steering system.
• If only the drive unit turns, the caster con-
troller is producing the fault.
• If neither the drive unit nor the caster turns,
the drive unit controller is at fault.
– Enter the Diagnostics - Error Log menu of the
dash display and note any other steering system
fault error codes.
• Refer to the procedures for any other error code
listed in the menu.
– Check all CANbus wiring between the steering
good condition.
for continuity.
troller connector and pin #8 at the steering
44

Code
241/241C 241 STEER COMM ERR Steering
(cont) CALL SERVICE
Description
CANbus communication with the steering motor
controller or caster controller.
Symptom
Truck is disabled. (cont)
– Check all CANbus wiring between the steer-
ing motor controller and the master controller.
(cont)
for continuity. (cont)
– Wire #901 between pin #23 at the steering
ing controller connector. Note: If the lift
truck is equipped with the steered caster op-
tion, there will be no connection to pin #14 at
the steering controller for the MDU steering
motor.
– Verify condition of the steering motor controller.
• Verify steady green LED at the steering motor
• No illuminated LED at the steering motor con-
troller.
the steering motor controller.
• Flashing LED at the steering motor controller
- Internal Fault. Replace the steering motor
controller.
45

Code
242 242 HANDLE COMM ERR Controls
CALL SERVICE
Description
CANbus communication with the control handle.
Handle must establish communication with the
master controller within four seconds at startup.
Symptom
Truck is disabled. Main contactor will not pull in.
– Check for 24 volts at pin #1 of the handle connec-
tor, wire #1285.
• Check for 24 volts at pin #5 at the IFB connec-
tor.
• Check FU 11 on the IFB.
– Check continuity of wire #1285 from pin #5 of the
IFB connector to pin #1 of the handle connector.
• Check FU 11 on the IFB.
– Verify all CANbus wiring between the steering
good condition.
for continuity. Replace any defective wiring.
– Wire #113 between ground and pin #4 at the
multifunction handle connector.
controller connector and pin #2 at the mul-
tifunction handle connector.
– Control handle is defective.
• Replace the control handle.
46

Code
243 243 PRES SENS FAULT STEER
CALL SERVICE
Description
The Master Controller has sensed an out of range
fault with the pressure transducer.
Symptom
The truck does not limit or always limits, for
weighted speed reduction.
– Ensure the sensor has power (5V +/-15% on wire
#250A Red).
• If power not present at sensor, trace #250 wire
back to steer controller pin 3.
– If connection is good, including pins, unplug
sensor and measure again.
– If connection is good, including pins, unplug
sensor and measure again.
– If 5V still not present, and connection is good
check ground wire #105-Grn, should have
continuity to B .
– If good continuity, but 5V & Gnd reference
still show no power then replace steer con-
troller.
• If power is present, move on to the next check:
– Check the pressure sensor: With the forks sitting
on the ground the output should be ~2.5V on wire
#62.
• If output shows > 4.5 or < 0.25V, replace sensor.
• If output within 2.2 to 2.7V, then check conti-
nuity in harness to pin 7 of steer controller.
• If continuity OK, check pressure variability:
– Lift forks in air, no load, and check value
– Repeat with a 2000lb load and check value
– Value should have increased > 2.7V
– If no change found replace sensor.
– If sensor changes output, then replace steer
controller
47

Code
247 247 REMOTE COMM ERR REMOTE
CALL SERVICE
Description
The Master Controller has lost communication

with the Remote Module.
Symptom
The auxiliary hydraulic functions do not operate.
– Ensure the remote module has power (24V
+/-15% on wire #285C).
• If power not present at aft handle, trace wire
#285C back to the over-the-mast cable.
– If connection is good, but still no power,
check over the mast cable connection to
main harness.
– If connection is bad, replace reach harness.
– If mast connection is good, but no power,
check wire #285 from IFB.
– If main harness connection is good, check
FU13 on IFB.
– If fuse is good, replace IFB.
• If power is present, move onto the next check:
– Measure CAN bus impedance with truck off and
battery disconnected.
• CAN should be 60 Ohms between wire #900
and #901 at diagnostic connector.
• If CAN impedance is 110 Ohms or greater,
there is a broken CAN line to the remote:
– Check wire #900 and #901 on the over the
mast wire.
– if either have no continuity.
– Replace reach harness if continuity bad or
shorted to B+ or GND.
– If a good connection exists, check wires #900 and
#901 on reach harness through mechanism.
• If connections have been good, check harness
& connector pins for continuity. Repair as nec-
essary
• If no faults in harness found, replace remote
module.
– NOTE: Usually a bad harness or lack of power to
module is the cause.
48

Code
260 260 LIFT LOW VOLTAGE Lift
CALL SERVICE
Description
The lift motor controller has sensed a low voltage
condition in the lift motor circuit.
Symptom
Lift is disabled.
– Verify correct lift truck voltage.
• Enter the Setup - Truck Settings - Voltage and
verify correct voltage.
• Ensure this matches the voltage on the lift
truck nameplate.
– Verify correct voltage battery is installed in the
lift truck.
– Check the battery indicator on the dash display
to verify the battery is sufficiently charged.
– If the battery voltage and the state of charge are
correct, turn the lift truck off for 10 seconds.
• Turn the key switch to the ON position to
– If the status code reoccurs, the problem is inter-
nal to the pump controller.
• Check the status LED on the controller. See
Controller Status Light Emitting Diodes
(LEDs).
• Replace the pump motor controller.
49

Code
271 271 HANDLE FAULT Controls
CALL SERVICE (Forward/Reverse)
Description
control handle operation. The forward/reverse
signal is out of range.
Symptom
If the truck is moving, the speed command is set
to zero, the electric brake is engaged, and the
truck systems are disabled.
– Enter the Diagnostics – Static Diagnostics -
Reach/Retract Switch menu through the dash
display.
• Switch output should show a range between
+100% to 100% as the switch is moved from
the center to the ends of the switch travel.
– Using ETACC, verify that the control select
parameter is correct for the type of control
present on the truck.
– Check wiring for loose connections or broken
wires between the control handle and the mas-
ter controller.
– Verify all CANbus wiring and connections are se-
cure.
good condition.
• Check all CANbus wiring between the steering
controller and the master controller for conti-
nuity.
– Pin #2 & pin #3 at the handle connector and
pin #22 and pin #23 at the master controller
connector.
– Replace the control handle.
50

Code
271 271 HANDLE FAULT Controls
CALL SERVICE (Lift/Lower)
Description
The controller has sensed the handle output
voltage is out of range when requesting a lift or
lower operation.
Symptom
Lifting and lowering are disabled. Traction
operates at turtle speed.
– Enter the Diagnostics - Static Diagnostics - Hy-
draulic Throttle menu through the dash display.
• Throttle output should show a range between
+100% to 100% as the control handle is
moved from full lift to full lower.
• Using ETACC, verify that the handle parame-
ters are correct.
wires between the control handle and the mas-
ter controller.
– Ensure all connectors are tight and pins are in
good condition.
• Check all CANbus wiring between the control
handle and the master controller for continu-
ity. Replace any defective wiring.
troller connector and pin #4 at the multifunc-
tion handle connector.
• Verify all CANbus wiring and connections are
secure.
– Replace the control handle.
51

Code
272 272 AFT HANDLE FAULT TRACTION
CALL SERVICE
Description
The Master Controller has sensed a fault in the

Aft Handle Throttle or Sensor.
Symptom
The aft handle does not work, and the truck will
operate in limp mode.
– Ensure the aft handle assembly has power (24V
+/-15% on wire #285).
• If power not present at aft handle, trace #285
wire back to IFB pin 4.
– If connection is good, check FU13 fuse on
IFB.
• If power present, move onto the next check:
– Using Static Dash Diagnostics, check the aft
throttle:
• When moving the aft throttle, output should
vary from 100 to -100%.
– If throttle does not vary, replace aft handle.
– Using Static Dash Diagnostics, check the aft sen-
sor:
• The status of “aft sensor” will change to “1”
when hand is inserted, and “0” when removed.
– If no transition occurs, replace Aft Handle.
– With no faults are found with above, re-key the
truck, and ensure no object is in the aft handle
area.
• NOTE: The truck WILL produce this fault code
if any object is within aft handle sensor area
upon key on.
52

Code
273 273 HANDLE FAULT CONTROLS
CALL SERVICE
Description
The handle has detected an internal fault.

Symptom
The primary handle does not function or operate
the truck to some degree. Some functions may
still exist.
– Internal diagnostics has already pointed to the
problem. No troubleshooting is possible.
– Replace handle.
53

Code
275 275 REMOTE MODULE FAULT Attachment
CALL SERVICE
Description
The master controller has detected a fault in the
remote module.
Note: This fault code will be logged each time
the remote module or the over-the-mast cable
is disconnected with the truck electrical system
energized.
Symptom
Auxiliary functions disabled.
– Turn the key switch to the OFF position.
#B at the service PC connector. Resistance
should read between 50 and 70 ohms.
• If resistance of 120 ohms is seen, check mast
cable for damage. Check continuity of CANbus
wires #900 and #901 within the mast cable.
– Replace the mast cable.
wires between the remote module and the mas-
ter controller.
– Verify all CANbus wiring and connections are se-
cure.
good condition.
• Check all CANbus wiring between the steering
controller and the master controller for conti-
nuity.
troller connector and pin #6 at the remote
module connector.
controller connector and pin #2 at the remote
module connector.
controller connector and pin #1 at the remote
module connector.
– Restart the lift truck and check for 24 volts on
wire #285 at the remote module.
– Replace the remote module.
54

Code
279 279 TILT COIL SHORTED Tilt
CALL SERVICE
Description
The master controller has detected an overcurrent
condition in the tilt coil circuit.
Symptom
Auxiliary hydraulic functions will not operate.
– Disconnect the wires from the tilt coil terminals
and measure the resistance across the terminals.
• The resistance should be approximately 40
ohms. If less than 30 ohms, replace the coil.
– Check the harness between the tilt coil and the
remote module for shorted wiring. Repair as nec-
essary.
– Unplug the connector at the remote module.
• Check for 24 volts on pin #4 in the connector
grated fuse board.
• Check condition of FU 11.
• Check wiring for continuity of wire #285 be-
tween integrated fuse board and the tilt coil.
– Plug the connector into the remote module.
• Check for 24 volts on pin #4.
– If 0 volts, replace the remote module.
– If 36 volts, check for shorted 24-volt regula-
tor at the IFB.
55

Code
280 280 SS COIL SHORT Attachment
CALL SERVICE
Description
situation in the sideshift coil circuit.
Symptom
– Disconnect the wires from the side shift coil ter-
minals and measure the resistance across the
terminals.
– Check the harness between the sideshift coil and
the remote module for shorted wiring. Repair as
necessary.
• Check for 24 volts on pin #7 in the connector.
grated fuse board.
• Check for 24 volts on pin #7. If 0 volts, replace
the remote module.
56

Code
281 281 SS COIL OPEN Attachment
CALL SERVICE
Description
The master controller has sensed an undercurrent
condition in the sideshift coil circuit.
Symptom
– Disconnect the wires from the side shift coil and
measure the resistance across the terminals.
ohms. If reading indicates no continuity
through the coil, replace the coil.
– Check the harness between the side shift coil and
the remote module for broken wires or loose con-
nections. Repair wiring as necessary.
• Check for 24 volts on pin #7 in the connector
grated fuse board.
tween integrated fuse board and the remote
module.
the remote module.
57

Code
283 283 TILT COIL OPEN Tilt
CALL SERVICE
Description
The master controller has detected an
undercurrent condition in the tilt coil circuit.
Symptom
Tilt functions will not operate.
– Disconnect the wires from the tilt coil and mea-
sure the resistance across the terminals.
– Check the harness between the tilt coil and the
remote module for broken wires or loose connec-
tions. Repair wiring as necessary.
grated fuse board.
– Check condition of FU 11.
– Check for battery voltage at FU 11.
– Replace integrated fuse board.
module.
the remote module.
58

Code
284 284 EXTEND COIL SHORT Attachment
CALL SERVICE
Description
The master controller has detected an overcurrent
condition in the extend/retract coil circuit.
Symptom
– Disconnect the wires from the extend/retract coil
terminals and measure the resistance across the
terminals.
– Check the harness between the extend/retract
coil and the remote module for shorted wiring.
Repair wiring as necessary.
grated fuse board.
tween integrated fuse board and the extend/re-
tract coil.
the remote module.
59

Code
285 285 EXTEND COIL OPEN Attachment
CALL SERVICE
Description
undercurrent condition in the extend/retract coil
circuit.
Symptom
– Disconnect the wires from the extend/retract coil
and measure the resistance across the terminals.
ohms.
• If reading indicates no continuity through the
coil, replace the coil.
– Check the harness between the extend/retract
coil and the remote module for broken wires or
loose connections. Repair wiring as necessary.
grated fuse board.
module.
the remote module.
60

Code
286 286 AUX COIL SHORT Attachment
CALL SERVICE
Description
The master controller has detected an over-current
condition in the aux straight or reverse direction
coil circuit.
Symptom
– Disconnect the wires from the auxiliary straight
and the auxiliary reverse coils terminals and
measure the resistance across the terminals.
– Check the harness between the auxiliary
straight and the auxiliary reverse coils and
the remote module for shorted wiring. Repair
wiring as necessary.
• Check for 24 volts on pin #3 and pin #9 in the
connector.
grated fuse board.
• Check for 24 volts on pin #3 and pin #9. If 0
volts on either pin, replace the remote module.
61

Code
287 287 AUX COIL OPEN Attachment
CALL SERVICE
Description
undercurrent condition in the aux forward or
reverse direction coil circuit.
Symptom
– Disconnect the wires from the auxiliary straight
and the auxiliary reverse coils and measure the
resistance across the terminals.
– Check the harness between the auxiliary
straight and the auxiliary reverse coils and
the remote module for broken wires or loose
connections. Repair wiring as necessary.
• Check for 24 volts on pin #3 and pin #9 in the
connector.
grated fuse board.
module.
• Check for 24 volts on pin #3 and pin #9. If 0
volts, replace the remote module.
62

Code
300 300 TILT SENS FAULT Attachment
CALL SERVICE
Description
The remote module is reporting a tilt sensor
voltage less than 0.5 volts or greater that 4.5 volts.
Symptom
The autotilt feature does not operate. Forks will
not stop at the preset position.
– Enter the Diagnostics - Hydraulic System - Tilt
Sensor menu in the dash display.
• Cycle the tilt function from full up to full down
several times.
– Observe the tilt sensor voltage output value
on the dash display. The value should not
exceed 4.5 volts. Replace tilt sensor.
– The value should not be less than 0.5 volts.
Replace tilt sensor.
– The value should change smoothly through-
out the range. Replace tilt sensor.
– Check for 5 volts on pin #1 (the orange wire) at
the tilt sensor.
• Check continuity of the wiring from the option
module to the tilt sensor. Repair wiring.
• Check for 5 volts on the orange wire at the op-
tion module.
• Check for 24 volts at pin #1 (wire #285) at the
option module. Check for loose connections or
broken wires in the truck wiring between the
tilt sensor and the integrated fuse board.
• Check condition of all wiring in the mast cable.
• Check for 24 volts at terminal #4 of the inte-
grated fuse board.
•
• Check condition of FU 11. Replace fuse as nec-
essary.
• Replace the option module.
– Check voltage at pin #12 at the remote CAN
module.
• Cycle the tilt function from full up to full down
several times.
• Observe the tilt sensor voltage output value on
the dash display.
– The value should not exceed 4.5 volts.
– The value should not be less than 0.5 volts.
– The value should change smoothly throughout
the range.
63

Code
300 (cont) 300 TILT SENS FAULT Attachment
CALL SERVICE
Description
The remote module is reporting a tilt sensor
Symptom
The autotilt feature does not operate. Forks will
not stop at the preset position. (cont)
– Check continuity of all wiring between the re-
mote CAN module and the option module.
– Replace the option module.
64

Code
301 301 EXTEND SENS FAULT Attachment
CALL SERVICE
Description
The remote module is reporting an extend sensor
Symptom
Reach attachment extend speed is reduced below
normal operating speed.
– Cycle the reach function from full extend to full
retract several times. Observe the extend sensor
voltage output value on the dash display.
• The value should not exceed 4.5 volts. Replace
the sensor
• The value should not be less than 0.5 volts.
Replace the sensor
• The value should change smoothly throughout
the range as the reach mechanism moves. Re-
place the sensor.
– Check for 24 volts between pin #1 (black wire)
and pin #2 (red wire) at the reach position sensor.
• Check wire #285 for continuity between the ex-
tend sensor and terminal #4 at the integrated
fuse board.
• Check for 24 volts at terminal #4 at the inte-
grated fuse board.
– Check condition of FU 11 fuse. Replace fuse.
– Check for battery voltage at FU 11. Replace
• Check for ground to battery negative on pin #1
at the reach position sensor.
– Check voltage at pin #11 at the remote CAN mod-
ule. Cycle the reach mechanism from full extend
to full retract and observe the voltage reading.
Voltage should cycle between 0.5 volts and 4.5
volts.
• Check wiring for continuity between the sensor
and the Remote CAN Module.
• Check all truck wiring for loose connections or
broken wires.
#B at the service PC connector.
Resistance should read between 50 and 70
ohms.
If resistance is approximately 120 ohms,
check mast cable for damage. Check CAN-
bus wire #900 and wire #901.
Replace the remote CAN module.
65

Code
310 310 LIFT CONTROL FAULT Lift
CALL SERVICE
Description
lift controller.
Symptom
Lift is disabled.
– Ensure all wiring connections at the lift con-
troller are secure and connector is tight.
– Check the lift controller LED.
• LED is illuminated and not flashing. Con-
troller is OK.
• LED is flashing. There is an error with the
controller.
• LED is not illuminated.
Check for battery voltage at the B+ terminal
of the lift controller.
Check that main contactor is closed.
Check for continuity across the contactor tips
when closed. Replace contactor tips.
– Enter the Diagnostics – Error Log menu at the
dash display.
• Correct any errors noted in the Error Log.
• If problem returns, replace the lift controller.
66

Code
311 311 LIFT COMM ERROR Lift
CALL SERVICE
Description
CANbus communication with the lift controller.
Symptom
Lift is disabled.
– Check the lift controller LED.
troller is OK.
controller.
Check for continuity across the contactor tips
– Check the CANbus wiring between the lift con-
troller and the master controller.
• Check continuity of wire #900 and wire #901.
• Ensure the harness connectors at the pump
controller and the master controller are tight
and secure.
• Problem returns. Replace the lift controller.

Code
312 312 LIFT SPD SENSOR Lift
CALL SERVICE
67

Code
Description
The controller system has sensed a fault in the
lift motor speed sensor.
Symptom
Lifting is disabled.
– Enter the Diagnostics - Hydraulic System -
Pump Motor Speed menu at the dash display.
• Operate the lift motor and observe the RPM
value. If no RPM value is displayed or reading
is erratic:
Check all wiring connections are tight and se-
cure.
Check continuity of wire #103, wire #280, wire
#579, and wire #580 from the pump motor en-
coder to the pump motor controller.
– Check continuity of wire #103, wire #280, wire
#579, and wire #580 from the pump motor en-
coder to the pump motor controller.
– Check for 12 volts on wire #280 at the speed sen-
sor connector.
• Check for 12 volts between pin #3 and pin #4
at the pump motor controller.
• Check for battery voltage at B+ terminal of the
controller.
– Check for voltage between pin #2 and pin #4 at
the connector from the pump motor encoder.
• Voltage should be between 0.0 volts and 10.8
volts. Replace speed sensor bearing.
the connector from the pump motor encoder.

volts. Replace the pump motor encoder.
68

Code
313 313 LIFT OVER CURRENT Lift
CALL SERVICE
Description
The lift motor controller has sensed an overcurrent
condition in the lift motor.
Symptom
Lift is disabled.
restart the lift truck to verify the error.
– Ensure wiring between the lift pump controller
and the lift pump motor is tight and secure.
• Check wiring for a short to ground condition.
– Check the lift pump motor for phase-to-phase
shorts or phase-to-ground shorts.
• Repair or replace the lift pump motor.
69

Code
314 314 NO CHARGE DC BUS Lift
CALL SERVICE
Description
The integrated fuse board has detected a fault in
the lift controller precharge circuit.
Symptom
Lift is disabled. Main contactor will not pull in.
– Check power on circuit:
• Verify the main contactor is closing at the key
switch ON position.
• Verify the battery is charged, properly con-
nected to the lift truck and cables and connec-
tors are in good working order.
• Check the key switch and E-Stop for proper
connections and operation.
• Ensure the accessory light connections are not
mistakenly connected to the key switch (these
connectors are normally tied to the wiring har-
ness when not used).
• Recycle the key switch and check to see if the
fault clears.
– Check the main contactor and power circuits.
• Check main contactor coil: Remove the wires
from the main contactor coil terminals and
check for continuity across the terminals. The
coil should measure approximately 32 ±4 ohms
– If no continuity or the resistance is not cor-
rect, replace the coil.
• Check all wiring for continuity between the in-
tegrated fuse board (pin #1) and the main con-
tactor (wire #206) and between the main con-
tactor (wire #24) and terminal #40 at the mas-
ter controller.
nectors are secure.
• Verify battery voltage at the positive (wire
#206) terminal of the main contactor coil.
fuse board.
70

Code
314 (cont) 314 NO CHARGE DC BUS Lift
CALL SERVICE
Description
Symptom
(cont)
– Verify the CANbus wiring – Main contactor will
not close if a CANbus fault is present. Turn the
key switch to the OFF position and disconnect
the battery.
#B at the service PC connection. Resistance
• If resistance of 120 ohms is seen, check CAN-
bus wiring for shorts, loose connections, or
damaged wiring.
• Use ETACC software to verify all devices are
present and communicating on the CANbus.
Use the menu bar "reports’ then "devices re-
port" to view the communication of the compo-
nents.
– Check the Precharge Status LED on the inte-
grated fuse board to verify the fault.
• LED is off. Check the condition of FU 10. Re-
place the fuse.
– Check for battery voltage at pin #7 at the inte-
grated fuse board connector with the key switch
in the ON position.
• Verify battery is connected.
• Verify battery disconnect switch is closed.
• Verify the key switch is in the ONposition.
• Check continuity of the wiring between the key
switch and the integrated fuse board.
in the ON position.
• If the problem persists, replace the integrated
fuse board.
71

Code
314 (cont) 314 NO CHARGE DC BUS Lift
CALL SERVICE
Description
Symptom
(cont)
– Check the Master Controller:
• Disconnect wire #24 at the main contactor coil.
Connect an external ground to the negative
– If the main contactor closes as the key switch
fault within the master controller.
– Replace the master controller.
72

Code
316 316 LIFT HIGH VOLTAGE Lift
CALL SERVICE
Description
The lift motor controller has sensed a high voltage
condition in the lift motor circuit.
Symptom
Lift is disabled.
– Enter the Setup - Truck Settings - Voltage menu

at the dash display.
• Verify battery installed in lift truck is the same
voltage as listed on the dash display and the
lift truck nameplate. Install correct battery.
– Verify the battery state of charge. Install cor-
rectly charged battery.
– Turn the key switch to the OFF position. Wait 10
seconds. Turn the key switch to the ON position
and restart the lift truck.
73

Code
320/320C 320 STEER MTR HI CURR Steering
CALL SERVICE
Description
The controller has sensed a high current condition
in the steer motor drive or caster motor circuit.
Symptom
Truck is disabled.
– Enter the Diagnostics – Steer System – Steer
Motor Temp menu at the dash display.
• Verify the reading on the dash exceeds 125 C
(257 F) while the fault is being displayed.
• Trucks without a steered caster:
If the MDU steering motor fails to oper-
ate, the MDU steering motor is causing the
fault.
• Trucks with a steered caster:
If the MDU steering motor operates and the
caster steering motor fails to operate, the
caster steering motor is causing the fault.
If both steering motors fail to operate, the
MDU steering motor is causing the fault.
– Elevate the rear of the lift truck to allow the
drive and/or caster wheels to be slightly off the
floor.
• Verify there is no binding in the steering sys-
tem. Wheels should rotate freely during opera-
tion of the steering system. Repair the steering
system.
– Verify operation of the steer motor temperature
sensor.
• Check for voltage at pin #16 of the motor con-
troller identified in the above step while the
fault is being displayed. Replace faulty steer-
ing controller.
• Allow motor to cool.
– Measure resistance between pin #1 and pin
#2 at the temperature sensor connector. Re-
sistance should be approximately 650 ohms
at 27 C (80 F).
– Allow the steering motor to cool and check for no
voltage at pin #16 of the motor controller.
• Replace the steer motor.
74

Code
321/321C 321 STEER HIGH TMP Steering
CALL SERVICE
Description
The controller has sensed a high temperature in
the steer motor drive or caster motor circuit.
Symptom
Truck is disabled.
Motor Temp menu at the dash display.
• Verify the reading on the dash exceeds 125 C
(257 F) while the fault is being displayed.
fault.
floor.
tion of the steering system. Repair the steering
system.
– Verify operation of the steer motor temperature
sensor.
• Check for voltage at pin #16 of the motor con-
troller identified in the above step while the
fault is being displayed. Replace faulty steer-
ing controller.
• Allow motor to cool.
– Measure resistance between pin #1 and pin
#2 at the temperature sensor connector. Re-
sistance should be approximately 650 ohms
at 27 C (80 F).
– Allow the steering motor to cool and check for no
voltage at pin #16 of the motor controller.
• Replace the steer motor.
75

Code
322/322C 322 STR CONT HI CUR Steering
CALL SERVICE
Description
The master controller has sensed a continuous
overcurrent condition in the steering or caster
actuator.
Symptom
Truck is disabled.
Motor Current menu at the dash display.
• Verify the reading on the dash exceeds 25 amps
for a 24-volt truck or 35 amps for a 36-volt
truck while operating the steering system on
a smooth level floor.
fault.
floor.
tion of the steering system Repair steering sys-
tem.
– Check the motor wiring for a shorted condition.
• Remove the power leads from the motor at the
steering controller. Check the motor for phase-
to-phase or phase-to-ground shorts. Replace
the steering motor.
• Replace the steering controller.
76

Code
323/323C 323 STEER POS ERR Steering
CALL SERVICE
Description
The deviation between the calculated steering
position and the measured steering position is too
large.
Symptom
Truck is disabled.
– If the MDU steering motor fails to operate,
the MDU steering motor is causing the fault.
– If the MDU steering motor operates and the
– Inspect all wiring from the steering proximity
switch (either SW-1 or SW-2) of the faulty motor
to the steering controller.
• Check for loose connections or damaged
wiring. Repair as necessary.
drive and/or caster wheels to be slightly off
the floor. Rotate the drive wheel or the caster
wheels.
• Verify the steering proximity switch indicator
light illuminates as the wheel is rotated.
• Check for 24 volts at pin #1 at the steering
proximity switch connector.
• Check for 24 volts at pin #4 at the integrated
fuse board.
• Check for battery voltage at FU 11.
– Verify the steering proximity switch spacing is
not greater than 1.5 mm (0.06 in.).
• Adjust proximity switch.
– Inspect the sensor for any damage to the sensor.
• Replace proximity switch.
77

Code
330 330 FAN OVER CURRENT Lift
CALL SERVICE
Description
condition in the motor controller (lift) fan circuit.
Symptom
Truck is disabled.
– Check fan:
• Verify fan is not prevented from rotating.
• Clean any debris from fan.
– Check fan motor for a shorted condition.
• Measure resistance between pin #1 and pin #2
at the fan connector. Resistance should mea-
sure approximately 1.2 ohms.
• Replace fan.
– Check for 24 volts at pin #1 of the fan connector.
• Check for 24 volts at pin #1 of the fan connec-
tor.
78

Code
331 331 LD HOLD COIL SHORT Lift
CALL SERVICE
Description
The controller has sensed a shorted condition in
the load hold coil. The controller will slow the
pump motor to a stop.
Symptom
Lifting and lowering is disabled.
– Check the load hold coil.
• Disconnect the wires from the coil terminals
• Check coil resistance. Coil should measure 40
±10 ohms resistance.
• Replace the coil.
– Check coil wiring for a shorted condition. Repair
as necessary.
– Disconnect wire #811 at the coil and check for 0
volts on wire #811 from the master controller.
• Replace master controller.
– Enter the Diagnostics – Hydraulic System –
Load Hold Coil menu at the dash display to
check for proper operation of the load hold coil.
Operate the lift system.
• Dash display value = 0 as the lift system is
activated.
• Dash display value =1 with lifting stopped.
79

Code
341 341 TRAC DRVE TMP HI Traction
CALL SERVICE
Description
The temperature controller temperature sensor
has sensed a controller temperature in excess
of 85 C (185 F). Normal system operation will
resume when the traction controller has cooled.
Symptom
Traction performance is reduced. If motor
temperature continues to rise above 165 C
(329 F), traction will be disabled.
– Enter the Diagnostics – Traction System – Trac-
tion Control Temp to verify the traction motor
controller has exceeded 85 C (185 F).
– Check the operation of the cooling fan.
• The fan should be operating if the controller
temperature is above 50 C (122 F).
• Check for airflow through the cooling fins at
the base of the motor controllers. Check the
cooling fins are not obstructed. Check the fan
is not blocked and is free to rotate.
• Check for 24 volts on the red wire at the fan.
Check for 24 volts at terminal #4 on the
Check the condition of FU 11 on the inte-
grated fuse board.
If FU 11 is good and there is no voltage
at terminal #4, replace the integrated fuse
board.
If there is 24 volts at the red wire, con-
nect a jumper from the black wire from
the fan to a system ground. If the fan op-
erates, and the controller temperature is
above 50 C (122 F), the problem is in trac-
tion motor controller.
If the fan does not operate, replace the fan.
– Reduce traction system use to allow the con-
troller to cool and remain below 85 C (185 F).
80

Code
342 342 TRACTION OVERCUR Traction
CALL SERVICE
Description
The controller has sensed an overcurrent
condition in the traction circuit.
Symptom
– Restart lift truck to see if the fault reoccurs.
– Check wiring from traction controller to traction
motor for any loose connections, burned wiring,
or shorted wiring.
wiring.
– Check the traction motor for phase-to-phase or
phase-to-ground shorts.
• Replace traction motor.
– If no fault is found with the traction motor or
wiring and problem reoccurs, the problem may
be an internal fault within the traction con-
troller.
• Replace the traction controller.
81

Code
343 343 NO CHARGE DC BUS Traction
CALL SERVICE
Description
the traction controller precharge circuit.
Symptom
– Check power on circuit:
• Verify the main contactor is closing at the key
switch ON position.
• Verify the battery is charged, properly con-
nected to the lift truck and cables and connec-
tors are in good working order.
• Check the key switch and E-Stop for proper
connections and operation.
• Ensure the accessory light connections are not
mistakenly connected to the key switch (these
connectors are normally tied to the wiring har-
ness when not used).
• Recycle the key switch and check to see if the
fault clears.
– Check the main contactor and power circuits.
• Check main contactor coil: Remove the wires
from the main contactor coil terminals and
check for continuity across the terminals. The
coil should measure approximately 32 ±4 ohms
– If no continuity or the resistance is not cor-
rect, replace the coil.
• Check all wiring for continuity between the in-
tegrated fuse board (pin #1) and the main con-
tactor (wire #206) and between the main con-
tactor (wire #24) and terminal #40 at the mas-
ter controller.
nectors are secure.
• Verify battery voltage at the positive (wire
#206) terminal of the main contactor coil.
fuse board.
82

Code
343 (cont) 343 NO CHARGE DC BUS Traction
CALL SERVICE
Description
Symptom
Traction is disabled. (cont)
– Verify the CANbus wiring – Main contactor will
not close if a CANbus fault is present. Turn the
key switch to the OFF position and disconnect
the battery.
#B at the service PC connection. Resistance
• If resistance of 120 ohms is seen, check CAN-
bus wiring for shorts, loose connections, or
damaged wiring.
• Use ETACC software to verify all devices are
present and communicating on the CANbus.
Use the menu bar "reports’ then "devices re-
port" to view the communication of the compo-
nents.
– Check the Precharge Status LED on the inte-
grated fuse board to verify the fault.
• LED is off. Check the condition of FU 10. Re-
place the fuse.
in the ON position.
• Verify battery is connected.
• Verify battery disconnect switch is closed.
• Verify the key switch is in the ONposition.
in the ON position.
• If the problem persists, replace the integrated
fuse board.
83

Code
343 (cont) 343 NO CHARGE DC BUS Traction
CALL SERVICE
Description
Symptom
Traction is disabled. (cont)
– Check the Master Controller:
• Disconnect wire #24 at the main contactor coil.
Connect an external ground to the negative
– If the main contactor closes as the key switch
fault within the master controller.
– Replace the master controller.
84

Code
344 344 TRACTION LOW VOLT Traction
CALL SERVICE
Description
The controller has sensed a low voltage condition
in the traction circuit.
Symptom
– Enter the Setup – Truck Settings – Voltage and
verify correct voltage.
• Ensure this matches the voltage on the lift
truck nameplate.
– Verify correct voltage battery is installed in the
lift truck.
– Verify the battery is sufficiently charged.
– If the battery voltage and the state of charge are
correct, turn the lift truck off for 10 seconds.
• Turn the key switch to the ON position to
– If the status code reoccurs, the problem is inter-
nal to the traction controller.
• Replace the traction motor controller.
85

Code
345 345 TRACTION HIGH VOLT Traction
CALL SERVICE
Description
The controller has sensed a high voltage condition
in the traction circuit.
Symptom
– Enter the Setup – Truck Settings – Voltage menu
at the dash display.
• Verify battery installed in lift truck is the same
voltage as listed on the dash display and the
lift truck nameplate.
– Verify the battery state of charge.
– Turn the key switch to the OFF position. Wait 10
seconds. Turn the key switch to the ON position
and restart the lift truck.
• If problem returns, replace the traction con-
troller.
86

Code
347 347 TRAC SPD SENS ER Traction
CALL SERVICE
Description
traction motor speed sensor.
Symptom
– Enter the Diagnostics – Traction System – Trac-
tion Motor Speed menu at the dash display.
– Operate the traction system and observe the
RPM value. If no RPM value is displayed or
reading is erratic:
• Check all wiring connections are tight and se-
cure.
• Check continuity of wire #104, wire #281, wire
#577, and wire #578 from the traction motor
encoder to the traction motor controller.
– Check continuity of wire #104, wire #281, wire
#577, and wire #578 from the traction motor en-
coder to the traction motor controller.
– Check for 12 volts on wire #281 at the traction
motor encoder connector.
• Check for 12 volts between pin #3 and pin #4
at the traction motor controller.
• Check for battery voltage at B+ terminal of the
controller.
the connector from the traction motor encoder.
volts.
• Replace traction motor encoder.
the connector from the traction motor encoder.
volts.
• Replace traction motor encoder.
87

Code
348 348 TRAC COMM ERROR Traction
CALL SERVICE
Description
The master controller has lost communication

with the traction motor controller.
Symptom
– Check the traction controller LED.
troller is OK.
controller.
Check for continuity across the contactor
tips when closed. Replace contactor tips.
– Check the CANbus wiring between the traction
controller and the master controller.
• Check all connectors are secure.
• If the problem returns, replace the traction
controller.
88

Code
350 350 AUX COM ERROR AUX
CALL SERVICE
Description
The master controller cannot establish or has
lost CANbus communication with the aux pump
controller.
Symptom
Aux functions are disabled.
– Check for battery voltage at the B+ terminal of
the lift controller.
– Check that main contactor is closed.
– Check for continuity across the contactor tips
– Check the CANbus wiring between the lift con-
troller and the master controller.
• Ensure the harness connectors at the pump
controller and the master controller are tight
and secure.
• Problem returns. Replace the lift controller.
89
Display Panel 2200 SRM 1190
CHECKING THE MOTOR CONTROLLER a. Each phase should measure equal readings.
Check the traction motor controller for shorts to the 4. Using a multi-meter set to diode check, measure
internal FET’s; from B to each phase’s terminal on the con-
troller (U,V,W).
1. Disconnecting the motor U,V,W leads from the
controller. a. Each phase should measure open (OL).
2. Using a multi-meter set to diode check, measure 5. Reverse the leads and check each phase again.
from B+ to each phase’s terminal on the con-
troller (U,V,W). a. Each phase should measure equal readings.
a. Each phase should measure open (OL). 6. Replace the motor controller if any shorts are
found in the controller FET’s and internal diodes.
3. Reverse the leads and check each phase again.
Display Panel
GENERAL Premium Display Panel
There are two dash display options, Standard and • Allows preassigned user passwords to control
Premium. See Figure 11 and Figure 12. See the fol- driver access to the vehicle.
lowing sections for more detailed information on the • Provides four driving modes that are accessed
operation of the dash display for this lift truck: through the keypad.
Operating Manual • Allows preassigned service passwords to control ac-
User Interface, Supervisor Password Func- cess to the service functions available through the
tions (Premium Display) 2200 SRM 1240 display.
User Interface, Supervisor Password Func- • Provides a comprehensive set of service functions,
tions (Standard Display) 2200 SRM 1192 which are accessed through the mode keys and liq-
User Interface, Service Technician (Premium uid crystal display (LCD).
Display) 2200 SRM 1241 • Allows use of an operator checklist, so the operator
User Interface, Service Technician (Standard verifies truck function prior to vehicle startup.
Display) 2200 SRM 1193
90
2200 SRM 1190 Display Panel
Figure 11. Premium Display Panel
Standard Display Panel • Provides the same comprehensive set of service

functions using the mode keys and LCD as the
• Allows preassigned service passwords to control ac- Premium Display.
cess to the service functions available through the • Provides four driving modes that are accessed
display. through the keypad.
Figure 12. Standard Display Panel
91
Standard Display Functions and Features 2200 SRM 1190
Standard Display Functions and Features

KEY-ON INITIALIZATION If the password is not entered within 5 to 8 seconds,
a reminder screen is shown on the LCD display. See
Upon turning the key to the ON position, the display Table 6.
sequentially lights the indicators, from left to right,
located along the top of the display. See Figure 13. Table 6. Password Reminder Screen
Password Invalid
Disabled in ## X
Enter Password
Until a password is entered that matches a password

stored in the vehicle master controller, the lift and
traction systems are inoperative. Passwords may
1. INDICATOR LIGHTS be entered in the master controller using either the
dash display or by using the ETACC PC service soft-
Figure 13. Dash Display ware.
PASSWORDS A few seconds after the correct password has been en-
tered, the BDI and performance mode are displayed
Following the initialization sequence given above, and the vehicle can be operated. See Figure 14.
the LCD displays the prompt for the operator to
enter a password if this function has been enabled.
See Table 5. If the password function is disabled, the
display will bypass the password prompt. To enable
the password function, see User Interface, Super-
visor Password Functions (Standard Display)
2200 SRM 1192 or User Interface, Supervisor
Password Functions (Premium Display) 2200
SRM 1240.
Table 5. Password Prompt Screen
Enter Password 1. BATTERY DISCHARGE INDICATOR (BDI)

2. PERFORMANCE MODE SELECTION
XXXXX
Figure 14. Battery Discharge Indication in
Standard Dash Display LCD Window
92
2200 SRM 1190 Standard Display Functions and Features
PERFORMANCE MODES When lift interrupt is initiated, it will remain in ef-

fect until the battery is disconnected and a recharged
The following four operator selectable performance battery is reconnected to the vehicle. When a bat-
modes are available. These modes are preconfigured tery is replaced or recharged, the new state of charge
from the factory as described below. Rabbit mode must be at least 25 percent greater than the previ-
provides the highest performance. The other three ous state of charge. This prevents the BDI from be-
modes are a percentage of the rabbit performance. A ing activated by a battery that has recovered slightly
service technician, using either the dash display or during an idle period.
the PC service tool, can revise the control settings
and configure the top speed and acceleration of the A BDI adjustment feature is provided through the
lift truck. The relationship between the modes re- control setup function, which is accessible using ei-
mains constant and cannot be altered. ther the dash display or the PC service software. The
adjustment scale is 0-100, with a value of 30 for the
The operator can change performance modes by factory setting. The setting of 30 is the starting point
pressing the performance key on the dash display to for flooded cell-type batteries of all voltages and amp-
cycle through the four modes. An arrow on the dash hour capacities. The adjustment can then be used to
display indicates the selected performance mode. fine-tune the BDI lift interrupt feature. For example,
Any change to the performance mode does not take if it is desired to have the lift interrupt to occur at a
effect until the operator releases the control handle. higher battery specific gravity, then the value would
If the password function is enabled, the operator be increased. The value is decreased if a lower spe-
will be limited by the performance level set in the cific gravity is desired for the lift interrupt point.
password function.
If a maintenance-free battery is installed, the BDI
BATTERY DISCHARGE INDICATOR (BDI) adjustment should be increased to a value of about
50 as a starting point. Fine-tuning can be done from
The AC control system includes a Battery Discharge that value.
Indicator (BDI) that provides indication of the bat-
tery state of charge. See Figure 14. The BDI feature HOURMETERS
is displayed to the operator on the dash display with
a 20-segment bar. There are four hourmeter functions:
• Truck - accumulates time when the operator pres-
The BDI provides full functionality when used with ence switch is activated.
a full range of batteries including: • Traction - accumulates time when the traction mo-
• Flooded cell, standard amp-hour batteries tor is activated.
• Flooded cell, high amp-hour capacity batteries • Lift - accumulates time when the lift motor is acti-
• Valve regulated (absorbed glass mat) maintenance- vated.
free batteries (VRLA) • Auxiliary - accumulates time when the auxiliary
motor is activated.
The lift interrupt feature is controlled by the vehicle
master controller and prevents the lift function when The hourmeter data is stored in the master controller
the battery is 80 percent discharged. Although lift during every six minutes of operation. If there is a
interrupt prevents lifting, low speed functions, such loss of power, data is not lost.
as tilt and sideshift, remain operational to allow the
operator to more easily remove the forks from the
load and return to the battery charging area.
93
Standard Dash Display Service Menu Navigation 2200 SRM 1190
Standard Dash Display Service Menu Navigation

GENERAL 2. To move into a submenu of a main menu item,
press the → (right arrow) key on the dash display
To enter the service mode, turn the key to the ON po- numeric key pad. To move into a sub submenu,
sition and press the (enter) key twice. Enter Pass- as with the Diagnostics menu, press the → (right
word prompt will appear on the display. See Table 7. arrow) key again.
All lift trucks will have 55555 as the default service
password at the time of delivery. This password can 3. To move up or down within the submenu or the
be changed by a service technician. Go to Editing and sub submenu, press the ↑ (up arrow) or ↓ (down
Adding Information. arrow) keys.
Table 7. Password Prompt Screen 4. To move out of the sub submenu and return to
the submenu, press the ← (left arrow) key.
5. To move out of the submenu and return to the

Enter Password Main Menu, press the ← (left arrow) key.
XXXXX 6. To exit the service mode, press the ← (left arrow)

key.
EDITING AND ADDING INFORMATION

The ↑ (up arrow) and the ↓ (down arrow) keys allow NOTE: The setup and password menus can be used to
you to move up and down within a menu. The ← (left edit or add information to the truck software. When
arrow) key and the → (right arrow) key allow you to an item in these menus is selected, the current value
move from menu to menu. The (enter) key allows will be displayed. The characters available to be se-
you to enter or save a parameter. The 5 (five) key lected from the display are 0 through 9, A through Z,
is only used if it is part of the password required to blank, and dash. Each line in the display can have
enter the service mode. See Figure 15. no more than 20 characters including blanks.
1. If a change is to be made, press the → (right ar-

row) key and the cursor will blink on one of the
characters. The ← (left arrow) key and → (right
arrow) key are used to move from character to
character in the item being changed.
2. When a character that is to be changed is blink-

Figure 15. Dash Display Keys ing, use the ↑ (up arrow) and ↓ (down arrow)
keys to scroll up or down until the desired char-
MOVING THROUGH MENU SELECTIONS acter is found. Use the ← (left arrow) or → (right
arrow) keys to move to the next character to be
1. When the service technician’s password has been changed. This is repeated until all changes in the
correctly entered, the first menu item, which is item have been made.
the Setup menu, is displayed on the dash dis-
play LCD screen. To view the next menu item, 3. When all changes have been made, press the
press the ↓ (down arrow) key on the dash dis- (enter) key to store the value. Press the ↑ (up ar-
play numeric key pad. Repeat this until the de- row) key or the ↓ (down arrow) key to access the
sired menu item has been reached. To return to a next item to be changed. Repeat this procedure
previous menu item, press the ↑ (up arrow) key. for each item that is to be changed.
When the last menu item is reached and the ↓ 4. When all changes have been made, press the ←
(down arrow) key is pressed again, the first menu (left arrow) key to exit the menu.
item will return to the display.
94
2200 SRM 1190 Standard Dash Display Service Menu Navigation
ACCESS TO SERVICE FUNCTIONS Operator Sensing Switch

Steer OK?
All service functions are accessible from either Stan- Steer Centering Proximity Switch 1
dard or Premium displays. The following functions Steer Centering Proximity Switch 2
are the same with either display version, except as Free Lift Proximity Switch
noted in the following sections. Tilt Sensor
Hydraulic Level Switch
Once the vehicle is turned ON with the key switch
Tilt Up Switch
and the initialization process has been completed, a
Tilt Down Switch
service technician can gain access to the service func-
Extend Switch
tions by pressing the (enter) key twice.
Retract Switch
The display will prompt the service technician for a Sideshift Right Switch
five-digit password. See Table 8. The default setting Sideshift Left Switch
for the password is 55555. When a correct password Horn Switch
is entered, the Main Menu is displayed as follows: Traction Throttle
• Diagnostics Menu Hydraulic Throttle
• View Hourmeters Reach Throttle
• Setup Menu Aft Throttle
• View Software Versions Aft Sensor
• Passwords Menu Aft Horn
• Impact Sensor Menu Traction System
Traction Motor Speed
Table 8. Password Prompt Screen Traction Motor Current
Traction Motor Temperature
Traction Controller Temperature
Traction Throttle
Enter Password Aft Throttle
XXXXX Brake Coil
Hydraulic System
Pump Motor Speed
Pump Motor Current
The technician can scroll through the menu using the Pump Motor Temperature
← (left arrow) and the → (right arrow) keys to move Pump Controller Temperature
up and down within a menu and the ↑ (up arrow) or Pump Throttle
↓ (down arrow) keys to move from menu to menu. Load Hold Coil
Use the (enter) key to enter a menu selection. Each Pressure Transducer
menu selection has a list of submenu functions. The Auxiliary Motor Speed
submenus are viewed and items selected by scrolling Auxiliary Motor Current
through the menu in the same manner as described Auxiliary Motor Temperature
above. Auxiliary Forward Coil
Reverse Coil
To exit a selected function and return to the previ- Reach Coil
ous function, press the ↑ (up arrow) key. Continue to Tilt Coil
press the ↑ (up arrow) key until you are returned to Sideshift Coil
the Main Menu. Reach Direction
Reach Sensor
SERVICE FUNCTIONS Tilt Sensor
Lift PV
The following submenu functions are accessible from
Lower PV
the Main Menu described above.
Steer System
Steering Motor Speed
1. Diagnostic Menu Steer Motor Temperature
Static Diagnostics Steer Controller Temperature
Brake Pedal Switch Steer OK?
95
Standard Dash Display Service Menu Navigation 2200 SRM 1190
Steer Motor Angle Audible Alarm

General Truck Visible Alarm
Height Sensor Autotilt Option
Cal Fork Tare (Free Lift) Laser Option
Cal Fork Tare (Above Free Lift) Carry Level Option
Cal Cush Inpoint Slow Extended
Cal Cush Outpoint Simultaneous Hydraulics
Cal Mast Slow Down Password Option
Error Log Shutdown Timeout
Error # Traction Settings
Last Time Rabbit Speed
First Time Rabbit Acceleration
Count High Speed
2. View Hourmeters High Acceleration
Truck Hourmeter Mid Speed
Traction Hourmeter Mid Acceleration
Pump Hourmeter Turtle Speed
Auxiliary Hourmeter Turtle Acceleration
3. Setup Menu Neutral Braking
Lift Settings Plug Braking
Lift Maximum Speed Aft Speed Reverse
Lower Maximum Speed 4. View Software Versions
Auxiliary Settings Master Controller Software Version
Fast Extend Speed Display Software Version
Slow Extend Speed Traction Controller Software Version
Fast Retract Speed Hydraulic Controller Software Version
Slow Retract Speed Control Handle Software Version
Tilt Up Speed Remote CAN Module Software Version
Tilt Down Speed Steer Controller Software Version
Sideshift Speed Caster Controller Software Version
Reach Cushioning Aux Pump Software Version
Steer Settings 5. Impact Sensor Menu
Steer Mode Impact Action
Steer Effort Impact Sound
Steer Ratio Clear Impact
Truck Settings Hard Duration
Serial Number Hard Accel
Voltage Soft Duration
Capacity Soft Accel
Carriage Type 6. Password Menu
BDI Adjust Add Password
Extended Shift Delete Password
Lift Limit Without Override Edit Password
Lift Limit With Override
96
2200 SRM 1190 Premium Display Functions and Features
Premium Display Functions and Features

KEY-ON INITIALIZATION and traction systems are inoperative. Passwords
may be entered in the master controller using either
Upon entering the key to the ON position, the display the dash display or by using the PC software.
will illuminate and display the POWER ON screen.
See Figure 16. A few seconds after the correct password has been en-
tered, the BDI and performance mode are displayed
and the vehicle can be operated.
OPERATOR CHECKLIST FUNCTION

If this function is enabled in the premium display, the
operator is prompted to answer a checklist of ques-
tions. The operator indicates a 1 for pass or a 4 for
fail. If the operator indicates the vehicle passes the
inspection, the display will show the previous infor-
mation and the operator can drive the lift truck. If
the operator indicates that the vehicle fails the in-
spection, Service Required will appear on the display
Figure 16. Power On Screen screen, and the vehicle will only operate in turtle
mode until the required action is taken.
PASSWORDS
The checklist feature can be enabled with or with-
Following the initialization sequence given above, out the password function enabled, depending upon
the LCD displays the prompt for the operator to the user’s preference. The checklist feature, as with
enter a password if this function has been enabled. the password feature, may be setup using either the
See Table 9. If the password function is disabled, the dash display or using the PC service tool. For the
display will bypass the password prompt. To enable PC instruction, go to the section Troubleshooting
the password function, see the password menu. and Adjustments Using the AC Controls Pro-
Table 9. Password Prompt Screen gram (ETACC) 2200 SRM 1058. The checklist must
be enabled or disabled by a service technician.
PERFORMANCE MODES
Enter Password XXXXX Four different performance modes of operation can
be selected. Each mode can change acceleration and
top speed. The factory settings increase operating
speeds from slowest, turtle, to the fastest, rabbit.
If the password is not entered within 5 to 8 seconds, Upon startup, either the rabbit symbol or one of the
a screen is shown on the LCD display. See Table 10. bars beneath the rabbit symbol will be illuminated.
If the top performance level is selected, the rabbit
Table 10. Password Screen
symbol is illuminated. To change the performance
mode, the operator must activate the lift truck with
the key switch and be positioned on the floor switch,
Password Invalid and the brake pedal must be depressed. To change
Disabled in ## X performance modes, press the performance mode
key until the correct performance indicator is illu-
minated. Any change to the performance mode does
Enter Password not take effect until the operator releases the control
handle. If the password function is enabled, the
operator will be limited by the performance level set
in the password function.
Until a password is entered that agrees with a pass-
word stored in the vehicle master controller, the lift
97
Premium Display Functions and Features 2200 SRM 1190
BATTERY DISCHARGE INDICATOR If the lift truck is not equipped with the shelf height
selector option, contact your local Hyster® dealer for
The Battery Discharge Indicator (BDI) uses a bar installation information.
graph and a color chart as a fuel gauge for the bat-
tery state of charge. As the battery discharges, the Input the shelf PICK height (no load condition) into
bar gets shorter to show less fuel. The green band the lift truck operating system using the dash dis-
near the bar graph shows the normal operating range play. The system then calculates the PLACE height
for the battery. The yellow band shows the range in (loaded condition) using the offset dimension loaded
which the battery can still be operated without dam- with the PC Service Tool. The PLACE height must
age. This band indicates that the battery is nearing be slightly above the PICK height to allow for deflec-
the point of discharge where it can be damaged with tion of the mast and forks when the truck is in the
continued hard use. The red band indicates the dis- loaded condition.
charge condition where battery damage can occur. At
this point, the battery should be charged very soon The dash display allows direct input of the shelf
to prevent battery damage. When the battery is dis- height or the forks can be elevated to the correct
charged approximately 75%, segments 1 and 2 al- height and the system can be instructed to remem-
ternately flash on and off, and the battery symbol ber that elevation. Up to 10 heights may be stored in
flashes. Continued operation will cause lift interrupt the dash display. Each height is assigned a number
(if enabled) to occur to help prevent battery damage. from 1 to 0. These numbers are used by the shelf
Lift interrupt prevents the operator from lifting loads height selector to access the preprogrammed shelf
and saves enough battery power for operator to move heights.
the lift truck to a battery charger. At lift interrupt,
After setting a shelf height in the dash display, se-
there are no segments (bars) displayed, and the bat-
lect the desired shelf height number using the num-
tery symbol is flashing.
ber keys on the dash display and activate the lift or
lower control to move the forks to the desired eleva-
HOURMETERS
tion. The shelf height selector system will automati-
There are five hourmeter functions: cally slow the forks as the forks approach the selected
• Truck – accumulates time when the operator pres- height and will stop the forks at the desired height
ence switch is activated. regardless of control handle position.
• Traction – accumulates time when the traction mo-
To input a shelf height directly into the dash display,
tor is activated.
enter the Main Menu. If the shelf height selector
• Lift – accumulates time when the lift motor is ac-
option is enabled, scroll to Setup Shelf Height. See
tivated.
Figure 17.
• Auxiliary – accumulates time when the auxiliary
motor is activated.
• Steer – accumulates time when the steer motor is
activated.
The hourmeter data is stored in the master controller

during every six minutes of operation. If there is a
loss of power, data is not lost.
SHELF HEIGHT SELECTOR

If your lift truck is equipped with the shelf height se-
lector option, the free-lift height and a required load
offset must be set using the PC Service Tool (ETACC)
before entering any shelf height settings into the lift Figure 17. Main Menu
truck. Free-lift should be preset at the factory and
Press the right arrow key to enter the Setup Shelf
offset will be set at the default value of 3.00 inches.
Height menu. See Figure 18.
NOTE: All heights must be input in tenths of an inch
and must be in whole number format.
98
2200 SRM 1190 Premium Dash Display Service Menu Navigation
the number keys. Press the (enter) key to save the

value or press the left arrow key to cancel the entry
and return to the Main Menu. You can edit any shelf
height by repeating the above procedure.
To allow the system to “learn” a shelf height, enter

the Main Menu and move to the Learn Shelf Height
menu. Press the right arrow key to enter the Learn
Shelf Height menu. See Figure 20.
Figure 18. Setup Shelf Height

Scroll down the screen to highlight the pick height
number you want to associate with the shelf height
you are entering. Press the (pencil) key, and the
cursor will move to allow the height to be input. See
Figure 19.
Figure 20. Learn Shelf Height
Scroll down to highlight the learn height number you

want to associate with the shelf height you are learn-
ing. Move the forks to the correct PICK (no load con-
dition) elevation and press the (enter) key to save
the shelf height in the dash display.
NOTE: Entering a shelf height in either the Setup

Shelf Height or the Learn Shelf Height menu will
Figure 19. Selecting Pick Height
save and display the value in the other menu. Edit-
Input the correct height in tenths of an inch (the de- ing a value in either menu will also make the change
sired height in inches and add a zero at the end) using and display the new value within the other menu.
Premium Dash Display Service Menu Navigation

GENERAL MOVING THROUGH MENU SELECTIONS
To enter the service mode, turn the key to the ON po- Upon successful entry of your supervisor password,
sition and press the (enter) key twice. Enter Pass- the Main Menu screen will appear on the LCD
word prompt will appear on the display. See Table 11. screen, and the four menu navigation keys on the
All lift trucks will have 55555 as the default service right side of the display will be activated. Action
password at the time of delivery. This password can symbols will appear on the LCD screen just to the
be changed by a service technician. left of the menu navigation keys. See Figure 21.
These symbols indicate the action that will be taken
Table 11. Password Prompt Screen when that key is pressed. The ↑ (up arrow) key and
the ↓ (down arrow) key are used to move up and
down within a selected menu. The → (right arrow)
key is used to select a menu item. The ← (left arrow)
Enter Password XXXXX key is used to return to the previous menu. The
(door indicator) key is used to exit the Main Menu
and return to the truck operation screen.
99
Premium Dash Display Service Menu Navigation 2200 SRM 1190
When a menu item is available for editing, the Table 12. Password Prompt Screen
(pencil) key will appear in place of the → (right ar-
row) key, and is used to edit a menu selection. The
(enter) key is used to save a value or menu choice
when in the edit mode. When in edit mode, use the ↑ Enter Password XXXXX
(up arrow) and ↓ (down arrow) keys to scroll through
the options available for that menu selection. Use
the (enter) key to save the chosen value. Press the The technician can scroll through the menu using the
←(left arrow) key repeatedly to return to the Main → (right arrow) key and the ← (left arrow) key to
Menu. Push the (door indicator) key to return to move from menu to menu, and the ↑ (up arrow) key
normal truck operation. and the ↓ (down arrow) key to scroll within a menu.
Use the (enter) key to enter a menu selection. Each
menu selection has a list of submenu functions. The
submenus are viewed and items selected by scrolling
through the menu in the same manner as described
above.
To exit a selected function and return to the previous

function, press the ←(left arrow) key. Continue to
press the ←(left arrow) key until you are returned to
the Main Menu.
SERVICE FUNCTIONS
Figure 21. Menu Navigation Action Symbols The following submenu functions are accessible from
the Main Menu described above.
ACCESS TO SERVICE FUNCTIONS
1. Diagnostic Menu
All service functions are accessible from either Stan- Static Diagnostics
dard or Premium displays. The following functions Brake Pedal Switch
are the same with either display version, except as Operator Sensing Switch
noted in the following sections. Steer OK?
Steer Centering Proximity Switch 1
Once the vehicle is turned ON with the key switch
Steer Centering Proximity Switch 2
and the initialization process has been completed, a
Free Lift Proximity switch
service technician can gain access to the service func-
Tilt Sensor
tions by pressing the (enter) key twice.
Hydraulic Level Switch
The display will prompt the service technician for a Tilt Up Switch
five-digit password. See Table 12. The default set- Tilt Down Switch
ting for the password is 55555. When a correct pass- Extend Switch
word is entered, the Main Menu is displayed as fol- Retract Switch
lows: Sideshift Right Switch
• Diagnostics Sideshift Left Switch
• View Hourmeters Horn Switch
• Setup Traction Throttle
• View Software Versions Hydraulic Throttle
• Passwords Aft Throttle
• Setup Shelf Height Aft Sensor
• Learn Shelf Height Aft Horn
• Impact Sensor Traction System
• Maintenance Reminder Traction Motor Speed
Traction Motor Current
Traction Motor Temperature
Traction Controller Temperature
100
2200 SRM 1190 Premium Dash Display Service Menu Navigation
Traction Throttle Fast Extend Speed

Travel Direction Slow Extend Speed
Brake Coil Fast Retract Speed
Aft Throttle Slow Retract Speed
Hydraulic System Tilt Up Speed
Pump Motor Speed Tilt Down Speed
Pump Motor Current Sideshift Speed
Pump Motor Temperature Reach Cushioning
Pump Controller Temperature Steer Settings
Pump Throttle Steer Mode
Pressure Transducer Steer Effort
Auxiliary Motor Speed Steer Ratio
Auxiliary Motor Current Display Settings
Auxiliary Motor Temperature Display Language
Auxiliary Forward Coil Year
Reverse Coil Month
Reach Coil Day
Tilt Coil Hour
Sideshift Coil Minute
Reach Direction Second
Reach Sensor Truck Settings
Tilt Sensor Serial Number
Lift PV Voltage
Lower PV Capacity
Steer System Carriage Type
Steering Motor Speed BDI Adjust
Steer Motor Temperature Extended Shift
Steer Controller Temperature Shelf Height Selection
Steer OK? Load Weight Option
Steer Motor Angle Lift Limit Without Override
General Truck Lift Limit With Override
Height Sensor Audible Alarm
Cal Fork Tare (Free Lift) Visible Alarm
Cal Fork Tare (Above Free Lift) Fork Height Display
Cal Cush Inpoint Autotilt Option
Cal Cush Outpoint Laser Option
Cal Mast Slow Down Carry Level Option
Error Log Slow Extended
Error # Simultaneous Hydraulics
Last Time Password Option
Count Shutdown Timeout
First Time Truck Inspection
Last Date Traction Settings
Time Rabbit Speed
2. View Hourmeters Rabbit Acceleration
Truck Hours High Speed
Traction Hours High Acceleration
Pump Hours Mid Speed
Auxiliary Hours Mid Acceleration
3. Setup Menu Turtle Speed
Lift Settings Turtle Acceleration
Lift Maximum Speed Neutral Braking
Lower Maximum Speed Plug Braking
Auxiliary Settings Aft Speed Reverse
101
Connector Pin-Outs 2200 SRM 1190
4. View Software Versions Pick Height 9

Master Controller Software Version Pick Height 10
Display Software Version 7. Learn Shelf Height
Traction Controller Software Version Learn Height 1
Hydraulic Controller Software Version Learn Height 2
Control Handle Software Version Learn Height 3
Remote CAN Module Software Version Learn Height 4
Steer Controller Software Version Learn Height 5
Caster Controller Software Version Learn Height 6
Aux Pump Software Version Learn Height 7
5. Password Menu Learn Height 8
View Password Log Learn Height 9
Add Password Learn Height 10
Delete Password 8. Impact Sensor
Edit Password Impact Action
6. Setup Shelf Height Impact Sound
Pick Height 1 Clear Impact
Pick Height 2 Hard Duration
Pick Height 3 Hard Accel
Pick Height 4 Soft Duration
Pick Height 5 Soft Accel
Pick Height 6 9. Maintenance Reminder
Pick Height 7 Maintenance Reminder
Pick Height 8 Maintenance Interval
Connector Pin-Outs
Traction Controller (Connector CPS 11)
Pin Wire Number Function
1 W206-G-RED IFB Battery Pos Input
2 W765-A-WHT Compartment Fan Input
3 W281-A-WHT 12V B+ Traction Motor Encoder Output
4 W104-A-GRN Traction Motor Encoder Ground
5 W577-A-WHT Traction Motor Encoder Phase A
6 W578-A-WHT Traction Motor Encoder Phase B
7 W-CT-01 / BAR CANbus Bare
8 W-CTP-01 / BAR CANbus Bare
9 BLANK -
10 BLANK -
11 BLANK -
12 W-JUMPER -
13 W-JUMPER -
14 W-CT-01 / BLK CANbus Low
15 W-CTP-01 / BLK CANbus Low
102
2200 SRM 1190 Connector Pin-Outs
Traction Controller (Connector CPS 11)

16 W386-A-WHT Traction Motor Temp Sensor Output
17 W102-A-WHT Traction Motor Temp Sensor Input
18 BLANK -
19 BLANK -
20 BLANK -
21 BLANK -
22 W-CT-01 / WHT CANbus Hi
23 W-CTP-01 / WHT CANbus Hi
24 BLANK -
Hydraulic Controller (Connector CPS 12)

1 W206-F-RED IFB Battery Pos Input
2 W701-A-WHT Compartment Fan Input
3 W280-A-WHT 12V B+ Hydraulic Motor Encoder Output
4 W103-A-GRN Hydraulic Motor Encoder Ground
5 W580-A-WHT Hydraulic Motor Encoder Phase A
6 W579-A-WHT Hydraulic Motor Encoder Phase B
7 W-CP-01 / BAR CANbus Bare
8 W-CTP-01 / BAR CANbus Bare
9 BLANK -
10 BLANK -
11 BLANK -
12 BLANK -
13 BLANK -
14 W-CP-01 / BLK CANbus Low
15 W-CTP-01 / BLK CANbus Low
16 W100-A-WHT Hydraulic Motor Temp Sensor Output
17 W101-A-WHT Hydraulic Motor Temp Sensor Input
18 BLANK -
19 BLANK -
20 BLANK -
21 BLANK -
22 W-CP-01 / WHT CANbus Hi
103
Hydraulic Controller (Connector CPS 12)

23 W-CTP-01 / WHT CANbus Hi
24 BLANK -
Master Controller (Connector CPS 31)

1 W910-A-WHT IFB Input
2 W7-A-WHT Operator Sensor Input
3 W10-D-RED Key Switch Input B+
4 BLANK -
5 W503-A-WHT Spare Digital Input
6 815-A Retract Prox Sensor (Optional)
7 W106 Aft Handle Return
8 W-CT-02-BAR CANbus Spare
9 W30-A-WHT Height Encoder Input
10 X801-ZA Lower Coil
11 BLANK -
12 X804-ZC Aux. Straight Coil
13 W830-A-WHT Strobe Light Relay Coil Input
14 W206-J-RED IFB Battery Pos Input
15 W724-A-WHT Motion Alarm Input
16 W98-A-WHT Foot Switch Input
17 W25-A WHT Aft Handle Horn Switch Input
18 W571-A-WHT Freelift Prox Sensor Input
19 W504-A-WHT Lift Limit Sensor Input
20 BLANK -
21 BLANK -
22 W-CT-02-WHT CANbus Hi
23 W-CT-02-BLK CANbus Lo
24 W96-A-WHT Electric Brake Coil Input
25 W27-A-WHT Steering Unit Input
26 BLANK -
27 BLANK -
28 W13-V-GRN Battery Neg
29 W45-A-WHT Horn Input
104
Master Controller (Connector CPS 31)

30 BLANK -
31 W30-A BRN Aft Handle Sensor Input
32 W90-2A-WHT Hyd. Fluid Level Sensor #2 Input
33 W90-1A-WHT Hyd. Fluid Level Sensor #1 Input
34 BLANK -
35 BLANK -
36 W62-A-WHT Pressure Transducer Input
37 W29-A GRN Aft Handle Throttle Input
38 W572-A-WHT Height Encoder Input
39 W811-S Lift Coil Input
40 W24-A-WHT Main Contactor Coil Input
41 X805-ZB Aux. Rev. Coil
42 X803-A Ext / Ret Coil
Remote CAN Module (Connector CPS 66)

1 CBL-10 / WHT CAN Hi
2 CBL-10 / BRN CAN Lo
3 CBL-11 / BLK1 Aux Rev Coil Input
4 W-151-A-WHT Tilt Sel Coil Input
5 W285-TL-WHT Battery Pos
6 W-13-MM-GRN Battery Neg
7 W152-A-WHT Sideshift Sel Coil Input
8 CBL-11 / BLK4 Extend/Retract Sel Coil Input
9 CBL-11 / BLK3 Aux Straight Coil Input
10 CBL-11 / BLK2 Carry Height Prox Sensor Input
11 CBL-10 / YEL Retract Limit Sensor Input
12 W302-A-WHT Tilt Sensor (Optional) Input
Integrated Fuse Board (Connector CPS 1)

1 W-206-A-RED B+ Fused Output
2 BLANK -
3 W33-A-WHT 12V Pos Output
105
Integrated Fuse Board (Connector CPS 1)

4 W285-A-WHT 24V Pos Output
5 W1285-A-WHT 24V power to Control Handle
6 W2-A-RED Main Contactor B+ Input
7 W10-A-RED Key Switch B+ Input
8 W35-A-RED B+ Output to Power Disconnect Switch
9 BLANK -
10 W-5-A-RED Key Switch B+ Input
11 BLANK -
12 W-205-A-RED Spare B+ Output
Dash Display (Connector CPS 22)

1 W285-S-WHT 24V Battery Pos
4 BLANK -
Steering Unit (Connector CPS 45)

1 W250-B-RED 5V Input From Steering Controller
2 W573-A-WHT CH1 Output to Steering Controller
3 W574-A-WHT CH2 Output to Steering Controller
4 W13-E-GRN Battery Negative
5 W576-A-WHT CB1 Output to Steering Controller
6 W575-A-WHT CB2 Output to Steering Controller
7 W27-A-WHT Master Controller Input
8 W206-N-RED B+ Power to Lord® Coil
106
Steering Controller (Connector CPS 59)

1 W206-P-RED Battery Pos Input
2 BLANK -
3 W-RED 5V Pos Output
4 W-C-APS1 / BAR Steering Motor Encoder Ground
5 W-C-APS1 / NAT Steering Motor Encoder Input
6 W-C-APS1 / GRN Steering Motor Encoder Input
7 BLANK -
9 BLANK -
10 W573-A-WHT Steering Unit CH1 Input
11 W574-A-WHT Steering Unit CH2 Input
12 BLANK -
13 BLANK -
14 W-CT-06A-WHT CANbus Hi (Blank if Power Caster Equipped)
15 W-CT-06-BLK CANbus Low
16 W-C-APS1 / BLK Steering Motor Temp Input
17 W576-A-WHT Steering Unit CB1 Input
18 BLANK -
19 W515-A-WHT Steering Centering Sensor Input
20 W575-A WHT Steering Unit CB2 Input

21 BLANK -
22 BLANK -
23 W-CT-06-WHT CANbus Hi
24 BLANK -
Caster Controller (Connector CPS 82)

1 W260-EC-RED Battery Pos Input
2 BLANK -
3 W-C-APS2 / RED 5V Pos Output
4 W-C-APS2 / BAR Steering Motor Encoder Ground
5 W-C-APS2 / NAT Steering Motor Encoder Input
6 W-C-APS2 / GRN Steering Motor Encoder Input
107
Caster Controller (Connector CPS 82)

7 BLANK -
9 BLANK -
10 BLANK -
11 BLANK -
12 BLANK -
13 BLANK -
14 W-CT-08B-WHT CANbus Hi
15 W-CT-08 / WHT CANbus Low
16 W-C-APS2 / BLK Steering Motor Temp Input
17 BLANK -
18 BLANK -
19 W1515-A-WHT Caster Centering Sensor Input
20 BLANK -
21 BLANK -
22 BLANK -
23 W-CT-08B-WHT CANbus Hi
24 BLANK -
108
2200 SRM 1190 System Logic Diagram
System Logic Diagram

The System Logic Diagram may be able to assist
in troubleshooting.
Aux. Straight Coil -- -- Aux. Reverse Coil
Sideshift Select Coil -- -- Reach Position Sensor
Remote CAN Module
Tilt Select Coil -- -- Option Module -- Tilt Sensor
Extend/Retract Select Coil -- -- Carry Height Sensor
Traction Motor ------- ------- Shelf Selector
CAN Bus
Speed Encoder -------

------- Mode Selection
Temperature Sensor ------- CAN Bus Dash Display

Traction
Motor ------- Truck Parameter
Controller Input
-------
Compartment Fan C
N
------- Forward/Reverse
Input
B ------- Truck Speed Input
Pump Motor ------- U
S ------- Lift/Lower Input
Compartment Fan -------

Multifunction
CAN Bus
Control
------- Reach/Retract Input
Speed Encoder ------- Pump Handle

Motor
Controller ------- Tilt Up/Tilt Down
Input
Temperature Sensor ------- CAN Bus
------- Sideshift Left/

Sideshift Right Input
------- Horn
109
System Logic Diagram 2200 SRM 1190
Horn -------
------- MDU Steering Motor
Operator Sensing -------

Switch
CAN Bus
------- MDU Steering Motor
Encoder
Free-lift Prox. Sensor -------

C
------- MDU Centering Prox.
MDU Switch
Steering
Pressure Transducer ------- A
Controller
N
------- Steering Unit
Encoder
Aft Control -------

------- Pressure Transducer
Lift Limit Prox. -------

Sensor
Foot Switch ------- U
Main Contactor
------- ------- Caster Steering
Motor
Master
Controller
Load Hold Selector ------- CAN Bus
Optional - Caster ------- Caster Steering
Coil Steering Controller Motor Encoder
Electric Brake Coil

------- CAN Bus
------- Caster Centering
Prox. Switch
Motion Alarm ------- A
N CAN Bus
Auxiliary Motor
Strobe Light Relay -------
Coil
Optional - Height ------- U CAN Bus

Encoder PC Connection
Hydraulic Fluid -------

Level Switch #1
CAN Bus Impact Sensor
Hydraulic Fluid ------- C

Level Switch #2
Key Switch ------- N
110
AC MOTOR REPAIR
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]
PART NO. 1590934 620 SRM 1186

AC Motor Repair Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Traction Motor Repair ....................................................................................................................................... 2
Disassemble ................................................................................................................................................... 2
Inspect ............................................................................................................................................................ 2
Assemble ........................................................................................................................................................ 3
Drive End Bearing, Replace.......................................................................................................................... 4
Hydraulic Motor Repair..................................................................................................................................... 5
Disassemble ................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 6
Assemble ........................................................................................................................................................ 7
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];

620 SRM 1186 General
General
This section describes disassembly, assembly, inspec-
tion, and checks for malfunctions of AC motors.
AC traction motors and AC hydraulic pump motors

are similar in function. See Figure 1, Figure 2, and
Figure 3. Disassembly and repair of these motors is
similar.
Figure 2. AC Hydraulic Motor (N35ZDR,

N45ZR, N30ZDR, N35-40ZR)
Figure 1. AC Traction Motor
Figure 3. AC Hydraulic Motor (N30ZDRS,

N35-40ZRS)
1
Traction Motor Repair 620 SRM 1186
Traction Motor Repair

DISASSEMBLE CAUTION
Never reuse a bearing that has been removed
WARNING from a rotor shaft.
The bearings and seals on the traction motor
are serviceable parts. The AC traction motor 12. Using a bearing puller, remove bearing from
weighs 109 kg (240 lb). To prevent injury, use drive end of rotor shaft.
a lifting device of adequate capacity for lifting
the assembly. INSPECT
NOTE: When replacing the encoder bearing, also re- Inspect the rotor and the inside of the motor case for
place the bearing on the drive end of the motor. marks or grooves indicating contact between the ro-
tor and the motor case. Replace if damaged. Bear-
1. Remove traction motor from the lift truck. See ings should fit snug where they seat on the shaft. If
Master Drive Unit 630 SRM 1022 for removal there is excessive wear, replace the bearing and/or
information. shaft. Check the bearings for smooth operation. If a
bearing does not roll smoothly, it must be replaced.
2. Screw lifting eye into the threaded hole in the Check that resistance between the windings and the
end of the rotor shaft and connect a chain to the case is above 50,000 ohms. Resistance of the wind-
lifting eye. ings (line to line) should be within specification. See
Table 1.
3. Remove temperature sensor wire and encoder
wire from holding bracket. See Figure 4.
4. Remove screws from the non drive rear end bell.
5. Place alignment marks on the end bell and motor

case. Marks will be used to correctly align the
end bell on the motor case during assembly.
6. Lift end bell and rotor assembly from AC motor

case. Place horizontally on a flat surface.
7. Remove chain and lifting eye.
8. Remove screws from air guide.
9. Remove end bell from rotor assembly. See Fig-

ure 5.
10. Remove air guide, being careful not to damage

encoder bearing wire.
CAUTION
from a rotor shaft.
NOTE: Before removing the encoder bearing, note its

orientation and install the new encoder bearing in
1. END BELL
the same orientation. 2. SCREW
3. ENCODER WIRE
11. Using a bearing puller, remove encoder bearing. 4. TEMPERATURE SENSOR WIRE
See Figure 6. 5. HOLDING BRACKET
Figure 4. AC Motor Assembly
2
620 SRM 1186 Traction Motor Repair
ASSEMBLE
CAUTION
To avoid damage to the encoder bearing elec-
tronics, use a bearing driver and arbor press.
Press only on the inner race of the bearing.
1. Install the bearing on the drive end of the rotor

shaft using a bearing driver and arbor press.
NOTE: The encoder bearing must be oriented as

noted during removal.
2. Using a bearing driver and arbor press, install

the encoder bearing as noted during removal.
Press only on the inner race of the bearing dur-
ing installation.
3. Place encoder wire through air guide and move

1. SCREW 3. END BELL SLOT air guide back over encoder bearing. See Fig-
2. AIR GUIDE 4. ENCODER WIRE ure 7.
Figure 5. Rotor Disassembly 4. Place end bell on rotor assembly.
1. ENCODER 2. BEARING PULLER

BEARING 3. ENCODER WIRE
Figure 6. Bearing Removal
Table 1. Traction Motor Windings
Winding to Line Resistance

Voltage (Ohm)
1. ENCODER WIRE
Min Max 2. AIR GUIDE
3. ENCODER BEARING
24 3.22 3.83
36 3.22 3.83 Figure 7. Alignment of Air Guide and End Bell
3
Traction Motor Repair 620 SRM 1186
1. Follow Step 1 through Step 10 of Disassemble

CAUTION procedure.
To prevent damage to the encoder bearing, en-
sure encoder wire is inserted in end bell slot
when air guide is attached to the end bell. CAUTION
5. Insert encoder wire in the end bell slot and attach from a motor.
air guide to end bell.
2. Using a bearing puller, remove drive end bearing
6. Install eyebolt into end bell and rotor assembly from shaft. See Figure 8.
and connect a chain to the lifting eye.
3. Using a bearing driver and arbor press, install
7. Lift the end bell and rotor assembly to a vertical drive end bearing. Press only on the inner race
position. of the bearing during installation.
4. Follow Step 3 through Step 12 of the Assemble

CAUTION procedure.
To prevent damage to the encoder wire, line up
end bell and rotor assembly slot with visible
mark to guide encoder wire into end bell and
rotor assembly case.
8. Using the alignment marks made during disas-

sembly, line up the end bell and rotor assembly
with the motor case.
9. Lower the end bell and rotor assembly back into

the case and place the encoder bearing and tem-
perature sensor wires into position.
10. Attach end bell and rotor assembly to AC motor

case.
11. Install temperature sensor wire and encoder

wire onto holding bracket.
12. Remove chain and lifting eye.
13. Install motor into the lift truck. See Master 1. END BELL SLOT
Drive Unit 630 SRM 1022 for your lift truck 2. AIR GUIDE
model for installation information. 3. DRIVE END BEARING
4. ENCODER WIRE
DRIVE END BEARING, REPLACE Figure 8. Alignment of End Shaft Bearing
NOTE: Drive end bearing is to be replaced if worn or
damaged.
4
620 SRM 1186 Hydraulic Motor Repair
Hydraulic Motor Repair

DISASSEMBLE 5. Loosen and remove the power cable terminal
nuts. Remove the power leads from the terminal
1. Remove the pump and motor assembly from the block and remove the screws (2) retaining the
lift truck. See Hydraulic System 1900 SRM terminal block to the motor case. See Figure 9
1189 or Hydraulic System 1900 SRM 1307 for and Figure 10. Remove the terminal block.
instructions on removing the pump and motor
assembly. 6. Unscrew the four tie bar screws (6) holding the
end heads to the motor case. See Figure 9 and
2. Place the pump and motor assembly on a clean Figure 10. Remove the terminal end head from
work bench or other suitable surface. the motor case.
3. Remove the two capscrews (3) retaining the 7. Remove the drive end head from the motor case.
pump to the motor. See Figure 9 and Figure 10. Remove the pump seal from the drive end head.
Remove the pump. See Figure 11.
4. Place the motor in a vise with the terminal block
on top and carefully clamp the vise on the motor
case.
1. POWER CABLE TERMINAL NUT

2. SCREW
3. CAPSCREW
4. TERMINAL END HEAD 1. POWER CABLE TERMINAL NUT
5. DRIVE END HEAD 2. DRIVE END HEAD
6. TIE BAR SCREW 3. CAPSCREW
7. MOTOR CASE 4. TERMINAL END HEAD
8. LIFT PUMP 5. LIFT PUMP
6. MOTOR CASE
Figure 9. Hydraulic Pump and Motor (N35ZDR, 7. TIE BAR SCREW
Figure 10. Hydraulic Pump and Motor
(N30ZDRS, N35-40ZRS)
5
Hydraulic Motor Repair 620 SRM 1186
1. ROTOR 5. DRIVE END HEAD

2. RETAINING RING 6. MOTOR CASE
3. DRIVE END BEARING 7. ENCODER BEARING
4. PUMP SEAL 8. TERMINAL END HEAD
Figure 11. Hydraulic Motor

INSPECT
CAUTION
Use an arbor press and a soft punch when re- Inspect the rotor and the inside of the motor case for
moving bearings to avoid damage to the bear- marks or grooves indicating contact between the ro-
ings and/or end head. Never reuse a bearing tor and the motor case. Replace, if damaged. Bear-
that has been removed from a rotor. ings should fit snug where they ride on the shaft. If
there is excessive wear, replace the bearing and/or
8. Remove retaining ring and bearing from drive shaft. Check the bearings for smooth operation. If a
end head. clean bearing does not roll smoothly, it must be re-
placed. Check that resistance between the windings
9. Remove the rotor from the motor case. and the case is above 50,000 ohms. Resistance of the
windings (line to line) should be within specification.
10. Fit a bearing puller to the encoder bearing on
See Table 2.
the end of the motor shaft. Carefully remove the
bearing from the motor shaft.
6
620 SRM 1186 Hydraulic Motor Repair
Table 2. Hydraulic Motor Windings
Winding to Line Resistance (Ohm)

Pump Displacement Voltage
Min Max
20cc 24 2.27 2.70
25cc 36 2.55 3.03
25cc 36 2.27 2.70
28cc 36 1.19 1.37

20cc 36 (EE) 2.27 2.70
ASSEMBLE routing the motor power leads through the end

head.
CAUTION 6. Install the four tie bar screws (6) through the
To avoid damage to the encoder bearing elec- holes in the end heads. See Figure 9 and Fig-
tronics, use a bearing driver and arbor press ure 10.
to install the encoder bearing onto the rotor
shaft. Press only on the inner race of the bear- 7. Install the pump seal into the drive end head.
ing during installation.
8. Install the terminal block using screws (2) as re-
1. Install the encoder bearing onto the rotor shaft. moved. See Figure 9 and Figure 10.
See Figure 11.
9. Install the power leads to the terminal block. In-
2. Insert the rotor into the motor case. stall power cable terminal nuts and torque to
15 N•m (11 lbf in).
CAUTION 10. Apply Loctite® 271 to the two capscrews (3) and
Use an arbor press and a proper size driver install the pump to the drive end head. Tighten
when installing bearings to avoid damage to capscrews to 47 N•m (35 lbf in). See Figure 9 and
bearings and/or end head. Figure 10.
3. Press bearing into the drive end head. Install 11. Install the pump and motor assembly into the
retaining ring. Press only on the inner race of lift truck. See Hydraulic System 1900 SRM
the bearing. 1189 or Hydraulic System 1900 SRM 1307 for
installation instructions.
4. Install the drive end head onto the motor case.
5. Install the terminal end head over the encoder

bearing and onto the motor case. Use care when
7
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Truck moves slow or in a Encoder broken. Replace encoder bearing.

jerky motion.
Encoder wire broken. Check and repair encoder wire or re-

place encoder bearing.
Temperature sensor failure. Temperature sensor wire damaged. Measure resistance with ohmmeter.
Resistance should be 530 ohms at
25 C (77 F). Inspect and repair tem-
perature sensor wire. The tempera-
ture sensor wire can be repaired, but
the temperature sensor must be re-
placed if faulty.
Temperature sensor malfunction. Measure resistance with ohmmeter.

If wiring is ok, resistance should be
530 ohms at 25 C (77 F). Replace the
temperature sensor.
Stator shorting. Loss of insulation in wire. Disconnect the battery and check re-
sistance between winding and case.
Resistance should be at 50,000 ohms
or above.
Stator open circuit. Broken coil windings. Raise drive wheel off the floor and
verify voltage at motor terminals.
Disconnect the battery and check
resistance of windings.
8
BRAKE SYSTEM
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590938 1800 SRM 1188

Brake System Table of Contents
TABLE OF CONTENTS
Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Electric Brake..................................................................................................................................................... 2
Air Gap ........................................................................................................................................................... 3
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 4
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];

1800 SRM 1188 Introduction
Introduction
GENERAL immediately. If repair is necessary, attach a
DO NOT OPERATE tag on the steering wheel.
This section contains the description and replace- Remove the key from the key switch.
ment procedures for the spring applied, electri-
cally-released parking brake. Some parts associated Disconnect the battery before opening the elec-
with the brake system are not covered in this section trical compartment covers or inspecting or re-
because they are more closely associated with other pairing the electrical system. If a tool causes
systems. See the section Electrical System 2200 a short circuit, the high current flow from the
SRM 1191 for information on parking brake wiring battery can cause personal injury or property
and the brake foot switch. damage.
Throughout this section, forward will refer to travel Some checks and adjustments are done with
in the direction of the forks and left and right deter- the battery connected. DO NOT connect the
mined by an operator standing in the operator com- battery until the procedure tells you to do so.
partment facing the forks. See Figure 1. Never have any metal on your fingers, arms,
or neck. Metal items can accidentally make an
electrical connection and cause injury.
Before performing any tests or adjustments,

block the lift truck to prevent unexpected
movement.
The capacitor in the transistor controller(s)

can hold an electrical charge after the battery
is disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor(s)
before inspecting or repairing any component
in the electrical compartments. Wear safety
glasses. Make certain that the battery has
been disconnected.
DO NOT short across the motor controller ter-

A. LEFT SIDE
B. RIGHT SIDE minals with a screwdriver or jumper wire.
C. FORWARD TRAVEL
Figure 1. Truck Orientation CAUTION

To avoid controller damage, always disconnect
DISCHARGING THE CAPACITORS the battery, discharge the capacitor(s), and
never put power to the controller while any
When working with the electrical systems of the power wires are disconnected. Never short
truck, it is necessary to discharge the capacitors of any controller terminal or motor terminal to
the controllers associated with each circuit affected. the battery. Make sure to use proper proce-
dure when servicing the controller.
WARNING
1. Move the lift truck to a safe, level area and com-
DO NOT make repairs or adjustments unless pletely lower the mast. Turn the key switch to
you have both authorization and training. Re- the OFF position and attach a DO NOT OPER-
pairs and adjustments that are not correct can ATE tag to the control handle. Block the drive
create dangerous operating conditions. DO wheel to prevent unexpected movement.
NOT operate a lift truck that needs repairs.
Report the need for repairs to your supervisor
1
Electric Brake 1800 SRM 1188
2. Disconnect the battery power cable connector

from the truck connector located on the right side
of the frame. Pull the battery cable connector
handle to separate the battery connector from
the truck connector.
3. Remove the operator compartment cover.
4. Discharge the capacitor in the controllers by

connecting a 200-ohm, 2-watt resistor across the
controller B+ and B terminals of the motor
controller. Remove the resistor after discharging
the capacitors. See Figure 2.
1. POSITIVE CONNECTION (B+)

2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 2. Discharging the Capacitors
Electric Brake
The electric brake is located in the drive unit com-
partment mounted to the top of the traction motor.
It consists of a spring-applied, electrically-released
brake mounted directly to the drive motor. See
Figure 3. The electric brake is controlled by the
master controller. After receiving input signals from
the floor switches and a traction input from the
multifunction control handle, the master controller
will complete the circuit to the brake coil, releasing
the brake. The master controller breaks the power
supply to the brake coil, engaging the electric brake
when the truck is stopped. Pressing the emergency
disconnect will apply the electric brake immediately
in any mode of operation. The electric brake may
be manually released for towing by inserting two
standard 1/4-20 × 1-1/4 in. capscrews into the two
threaded holes in the top of the brake assembly. See 1. FRAME
Figure 4. 2. MAST TRUNNIONS
3. BATTERY COMPARTMENT
4. FLOOR MAT
5. TRACTION MOTOR
6. BRAKE ASSEMBLY
Figure 3. Brake Location
2
1800 SRM 1188 Electric Brake
5. If the air gap is too tight for a minimum feeler

gauge to enter any of the six locations, the air
gap has been altered by internal damage or tam-
pering. Replace the entire brake assembly. See
Remove.
NOTE: During brake operation, the brake should en-

gage and release with a solid, single-click noise. A
double-clicking noise indicates that one side of the
brake is releasing before the other.
6. Listen to verify the brake releases and applies

in one smooth operation. A double-clicking noise
indicates that one side of the brake is releasing
before the other due to internal damage or tam-
pering. Replace the entire brake assembly. See
Remove.
1. SERVICE CAPSCREWS
2. SERVICE PORTS
3. BRAKE ASSEMBLY
4. ASSEMBLY HOLES
Figure 4. Manual Release
AIR GAP
CAUTION
The brake is not adjustable. Check the air gap
to determine if replacement is necessary.
NOTE: The air gap is very thin and may not be

checked visually. Dimensions are not to scale and
are for location references only.
1. Check the three outer socket head screws for ap-

propriate torque to secure the brake to the motor.
2. Check for correct air gap by measuring the

distance between the bottom of the stator and
the top of the pressure plate with the brake
applied (disconnected) using feeler gauges. Air
gap should measure 0.20 to 0.40 mm (0.008 to
0.015 in.). See Figure 5.
1. STATOR
3. The air gap should be checked for minimum and 2. AIR GAP
maximum clearance at the six locations shown in 3. PRESSURE PLATE
Figure 6. 4. FEELER GAUGE
4. If the air gap allows the maximum feeler gauge to Figure 5. Air Gap
enter any of the six locations, replace the entire
brake assembly. See Remove.
3
Electric Brake 1800 SRM 1188
1. ELECTRIC BRAKE AND HUB

2. CAPSCREW
3. LOCKWASHER
Figure 6. Check Locations (Typical Brake) 4. WASHER
5. RETAINING RING
REMOVE 6. WOODRUFF KEY
The following procedures detail the removal and in- Figure 7. Electric Brake
stallation procedures for the electric brake. 7. Remove the retaining ring securing the hub to
The brake assembly is nonadjustable and contains no the motor shaft.
service parts. If the brake fails to function, it must be 8. Remove the hub from the motor shaft. Recover
replaced as a complete assembly. Check the electric the Woodruff key.
brake before each shift for proper operation. Refer to
Periodic Maintenance 8000 SRM 1197. INSTALL
1. Move the lift truck to a safe, level area and com- 1. Install the Woodruff key to the motor shaft. Align
pletely lower the mast. Turn the key switch to the groove in the hub with the Woodruff key and
the OFF position and attach a DO NOT OPER- Install the hub onto the motor shaft.
ATE tag to the control handle. Block the drive
wheel to prevent unexpected movement. See Fig- 2. Install the retaining ring onto the motor shaft to
ure 7. secure the hub.
2. Disconnect the battery power cable connector 3. Position the brake assembly onto the hub. Align
from the truck connector located on the right side the brake mounting slots with the mounting
of the frame. Pull the battery cable connector holes in the motor housing (as removed) and
handle to separate the battery connector from secure using four capscrews, lockwashers, and
the truck connector. washers. See Figure 7.
3. Open the drive unit compartment door. 4. Install brake wiring harness to the main wiring
harness as removed.
4. Disconnect the electric brake wiring harness
from the main wiring harness near the electric 5. Connect the battery. Turn key switch to the ON
brake assembly. position and listen for the electric brake to re-
lease. Check for proper operation.
5. Remove the four capscrews, lockwashers, and
washers securing the brake assembly to the 6. Secure the drive unit compartment door closed.
drive motor. Remove the DO NOT OPERATE tag from the
control handle and remove the blocks from drive
6. Lift the brake assembly up off the hub and the wheel.
motor housing.
4
Troubleshooting
Electric brake will not re- Key switch is in the OFF position. Turn key switch to the ON position.
lease.
Battery is not connected or is dis- Connect or clean battery connections.

charged. Charge if necessary.
Wiring or controller malfunction(s). Refer to wiring diagrams.
Excessive wear. Replace the brake assembly.
Brake coil is defective. Check brake coil resistance. Resis-

tance should read 11.9 ohms ±1.0
ohm. Replace brake assembly if nec-
essary.
Foot switches not engaged or not Check battery voltage at brake coil
working properly. connector.
Multifunction handle not in FWD or Set multifunction handle to FWD or

REV position. REV position.
Electric brake will not apply. Internal mechanical damage to Replace the brake assembly.
brake.
Electric brake does not hold Oil or grease on the friction surfaces. Replace the brake assembly.
truck loaded to specification.
Friction surfaces are worn out. Replace the brake assembly.
Springs are too weak. Replace the brake assembly.
Load exceeds truck capacity. Handle only approved load weight.
Brake components worn or damaged. Replace the brake assembly.
Brake coil defective. Replace the brake assembly.
5
Brake drags or gets hot. Battery is discharged or connections Clean battery connections. Charge if
are loose or dirty. necessary.
Excessive wear. Replace brake assembly.
Brake coil defective. Check coil resistance. Resistance

should read 11.9 ohms ±1.0 ohm.
Oil or grease in brake. Replace brake assembly.
Incorrect brake air gap. Check air gap is within 0.007 to 0.015
inch. Replace brake assembly if gap
is not within specification.
6
CAPACITIES AND
SPECIFICATIONS
N30ZDRS, N35-40ZRS [A265];
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470]
PART NO. 1590961 8000 SRM 1198

Capacities and Specifications Table of Contents
TABLE OF CONTENTS
Lubrication Specifications ................................................................................................................................. 1

Oil Capacities ..................................................................................................................................................... 1
Hydraulic System............................................................................................................................................... 2
Lift Specifications .............................................................................................................................................. 3
Tire Sizes ............................................................................................................................................................ 8
Torque Specifications ......................................................................................................................................... 8
Master Drive Unit ......................................................................................................................................... 8
Reach Carriage .............................................................................................................................................. 8
Mast................................................................................................................................................................ 8
Hydraulic System (N30-35ZDR and N35-40-45ZR)..................................................................................... 9
Hydraulic System (N30ZDRS and N35-40ZRS)........................................................................................... 9
Steering System............................................................................................................................................. 9
Load Wheels................................................................................................................................................... 9
Fuses................................................................................................................................................................... 9
Coil Resistance Values ....................................................................................................................................... 10
Battery Specifications........................................................................................................................................ 11
N30ZDRS, N35-40ZRS [A265];

N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470]

8000 SRM 1198 Oil Capacities
Lubrication Specifications
Lubrication Application
Type Standard Cold Storage/Freezer Arctic
ISO VG 46 Antiwear
Hydraulic Oil Exxon Univis® HVI 26 Exxon Univis® HVI 26
(HCE-140)
Multipurpose (Lithium Multipurpose (Lithium Mobilgrease® 28 Synthetic
Grease
Complex) Grease Complex) Grease Extra-Protection Grease
80W-90 (GL-5) 80W-90 (GL-5) 75W-90 (GL-5) Synthetic
Gear Oil
Conventional Gear Oil Conventional Gear Oil Gear Oil
Antiseize Lubricant Antiseize Lubricant Antiseize Lubricant
Antiseize
(MIL-A-706) (MIL-A-706) (MIL-A-706)
Oil Capacities
Hydraulic System
Battery Compartment
Truck Models Tank (Full Capacity) Usable Oil
Size
368.0 mm 27.0 liter 19.6 liter
(14.5 in.) (28.5 qt) (20.7 qt)
N30ZDR, N35ZDR, N35ZR, (16.5 in.) (28.5 qt) (20.7 qt)
N40ZR, N45ZR 470.0 mm 27.0 liter 19.6 liter
(18.5 in.) (28.5 qt) (20.7 qt)
(21.5 in.) (32.4 qt) (25.1 qt)
N30ZDRS, N35ZRS, (14.5 in.) (28.5 qt) (20.7 qt)
N40ZRS 419.0 mm 27.0 liter 19.6 liter
(16.5 in.) (28.5 qt) (20.7 qt)
Master Drive Unit

Truck Models Drive Type Oil Capacity
N30ZDR, N35ZR, N40ZR,
GK20 MDU 2.5 liter (2.6 qt)
N30ZDRS, N35ZRS, N40ZRS
N35ZDR, N45ZR GK25 MDU 3.7 liter (3.9 qt)
1
Hydraulic System 8000 SRM 1198
Hydraulic System
N30ZDR, N35ZDR, N35ZR, N40ZR, and N45ZR
Pump Speed Max Pump
Hydraulic System Motor
Displacement (RPM) Pressure
20.68 MPa
36V 25.00cc 105 to 3300
(3000 psi)
36V 20.68 MPa
Main Lift Pump and Motor 28.00cc 105 to 3300
Hi Performance (3000 psi)
20.68 MPa
36V - EE 20.00cc 105 to 3300
(3000 psi)
17.92 MPa
Auxiliary Pump and Motor 24V/36V 2.08cc 600 to 3500
(2600 psi)
N30ZDRS, N35ZRS, and N40ZRS
Pump Speed Max Pump
Hydraulic System Motor
Displacement (RPM) Pressure
20.68 MPa
24V 19.20cc 105 to 3300
(3000 psi)
Main Lift Pump and Motor
20.68 MPa
36V 19.20cc 105 to 3300
(3000 psi)
Relief Valves
Model Valve Function Relief Pressure 1
N30ZDR, N35ZDR, N35ZR, Main Lift Relief Valve Pressure 20.99 MPa (3045 psi)
N40ZR, N45ZR Auxiliary Relief Valve Pressure 17.92 MPa (2600 psi)
N30ZDRS, N35ZRS, N40ZRS Main Lift Relief Valve Pressure 17.24 MPa (2500 psi)
1
All measurements made when hydraulic oil temperature is 38 to 66 C (100 to 150 F).
2
8000 SRM 1198 Lift Specifications
Lift Specifications
Lift Amp Draw Pressure (psi) Lower
Speed 1 Speed 2
Model Voltage Load Free Main Free Main
(Ft/ (Ft/
Min) Lift Lift Lift Lift Min)
4.48 MPa 5.86 MPa
0 100 245 365 98
(650 psi) (850 psi)
907 kg
- - - - -
N35ZR (2000 lb)
1134 kg
Lift Capacity 36 - - - - -
(2500 lb)
1588 kg
(3500 lb) 1361 kg
- - - - -
(3000 lb)
1588 kg 10.48 MPa 13.20 MPa
60 320 380 103
(3500 lb) (1520 psi) (1915 psi)
4.48 MPa 5.86 MPa
0 100 245 365 98
(650 psi) (850 psi)
907 kg
N40ZR - - - - - -
(2000 lb)
Standard
1361 kg
36 70 - - - - -
Lift Capacity (3000 lb)
1814 kg
1588 kg
(4000 lb) - - - - - -
(3500 lb)
1814 kg 11.41 MPa 14.48 MPa
60 320 380 103
(4000 lb) (1655 psi) (2100 psi)
5.52 MPa 8.62 MPa
0 115 375 480 100
(800 psi) (1250 psi)
N40ZR
907 kg
High - - - - - -
(2000 lb)
Performance
Option 1134 kg
36 80 - - - - -
(3000 lb)
Lift Capacity
1588 kg
1814 kg - - - - - -
(3500 lb)
(4000 lb)
1814 kg 11.38 MPa 16.20 MPa
65 480 530 105
(4000 lb) (1650 psi) (2350 psi)
1
Lift Speed Tolerance +3% and 10%
2
Lower Speed Tolerance +5% and 10%
3
Lift Specifications 8000 SRM 1198

Speed 1 Speed 2
(Ft/ (Ft/
4.48 MPa 5.86 MPa
0 100 245 365 98
(650 psi) (850 psi)
N30ZDR
Standard 907 kg
- - - - - -
(2000 lb)
36
Lift Capacity 1134 kg
1361 kg - - - - - -
(2500 lb)
(3000 lb)
1361 kg 10.48 MPa 13.20 MPa
70 320 380 103
(3000 lb) (1520 psi) (1915 psi)
5.52 MPa 8.62 MPa
N30ZDR 0 115 375 480 100
(800 psi) (1250 psi)
High
Performance 907 kg
- - - - - -
Option (2000 lb)
36
1134 kg
Lift Capacity - - - - - -
(2500 lb)
1361 kg
(3000 lb) 1361 kg 11.03 MPa 15.86 MPa
80 480 530 105
(3000 lb) (1600 psi) (2300 psi)
5.52 MPa 8.62 MPa
0 115 300 440 105
(800 psi) (1250 psi)
907 kg
- - - - - -
(2000 lb)
N45ZR
Standard 1361 kg
80 - - - - -
(3000 lb)
36
Lift Capacity 1588 kg
2041 kg 75 - - - - -
(3500 lb)
(4500 lb)
1814 kg
70 - - - - -
(4000 lb)
2041 kg 11.38 MPa 16.55 MPa
65 500 540 105
(4500 lb) (1650 psi) (2400 psi)
1
2
4

Speed 1 Speed 2
(Ft/ (Ft/
5.45 MPa 8.89 MPa
0 130 375 482 105
(790 psi) (1290 psi)
907 kg
N45ZR - - - - - -
(2000 lb)
High
Performance 1361 kg
90 - - - - -
Option (3000 lb)
36
1588 kg
Lift Capacity - - - - - -
(3500 lb)
2041 kg
(4500 lb) 1814 kg 13.67 MPa 18.44 MPa
80 560 690 -
(4000 lb) (1982 psi) (2675 psi)
2041 kg 14.48 MPa 19.65 MPa
75 - - 105
(4500 lb) (2100 psi) (2850 psi)
4.94 MPa 8.53 MPa
0 115 307 440 100
(717 psi) (1237 psi)
907 kg
N35ZDR - - - - - -
(2000 lb)
Standard
1134 kg
36 - - - - - -
Lift Capacity (2500 lb)
1588 kg
1361 kg
(3500 lb) 75 - - - - -
(3000 lb)
1588 kg 11.27 MPa 16.06 MPa
70 500 540 105
(3500 lb) (1635 psi) (2330 psi)
5.17 MPa 8.62 MPa
0 130 - - 105
(750 psi) (1250 psi)
N35ZDR
907 kg
High - - - - - -
(2000 lb)
Performance
Option 1134 kg
36 - - - - - -
(2500 lb)
Lift Capacity
1361 kg
1588 kg - - - - - -
(3000 lb)
(3500 lb)
1588 kg 11.38 MPa 16.20 MPa
70 - - 105
(3500 lb) (1650 psi) (2350 psi)
1
2
5
Lift Specifications 8000 SRM 1198

Speed 1 Speed 2
(Ft/ (Ft/
2.76 MPa 4.14 MPa
0 66 323 329 85
N35ZRS (400 psi) (600 psi)
1361 kg 8.96 MPa 11.03 MPa
Lift Capacity 24 45 352 367 -
(3000 lb) (1300 psi) (1600 psi)
1588 kg
(3500 lb) 1588 kg 9.65 MPa 12.41 MPa
37 353 374 100
(3500 lb) (1400 psi) (1800 psi)
2.76 MPa 4.14 MPa
0 66 323 329 85
(400 psi) (600 psi)
N40ZRS 1361 kg 8.96 MPa 11.03 MPa
45 352 367 -
(3000 lb) (1300 psi) (1600 psi)
Lift Capacity 24
1814 kg 1588 kg 9.65 MPa 12.41 MPa
37 353 374 100
(4000 lb) (3500 lb) (1400 psi) (1800 psi)
1814 kg 10.34 MPa 13.10 MPa
35 366 382 103
(4000 lb) (1500 psi) (1900 psi)
2.76 MPa 4.14 MPa
0 66 323 329 85
(400 psi) (600 psi)
N30ZDRS 907 kg
- - - - - -
(2000 lb)
Lift Capacity 24
1361 kg 1134 kg
- - - - - -
(3000 lb) (2500 lb)
1134 kg 8.96 MPa 11.03 MPa
45 352 367 100
(3000 lb) (1300 psi) (1600 psi)
2.76 MPa 4.14 MPa
0 77 216 224 85
(400 psi) (600 psi)
N35ZRS 907 kg 6.89 MPa 9.65 MPa
62 305 325 -
(2000 lb) (1000 psi) (1400 psi)
Lift Capacity 36
1588 kg 1361 kg 8.96 MPa 11.03 MPa
57 318 330 -
(3500 lb) (3000 lb) (1300 psi) (1600 psi)
1588 kg 9.65 MPa 12.41 MPa
56 327 344 100
(3500 lb) (1400 psi) (1800 psi)
1
2
6

Speed 1 Speed 2
(Ft/ (Ft/
2.76 MPa 4.14 MPa
0 77 216 224 85
(400 psi) (600 psi)
907 kg 6.89 MPa 9.65 MPa
62 305 325 -
N40ZRS (2000 lb) (1000 psi) (1400 psi)
1361 kg 8.96 MPa 11.03 MPa
Lift Capacity 36 57 318 330 -
(3000 lb) (1300 psi) (1600 psi)
1814 kg
(4000 lb) 1588 kg 9.65 MPa 12.41 MPa
56 327 344 -
(3500 lb) (1400 psi) (1800 psi)
1814 kg 10.34 MPa 13.10 MPa
50 341 352 103
(4000 lb) (1500 psi) (1900 psi)
2.76 MPa 4.14 MPa
0 77 216 244 85
(400 psi) (600 psi)
N30ZDRS 907 kg
- - - - - -
(2000 lb)
Lift Capacity 36
1361 kg 1134 kg
- - - - - -
(3000 lb) (2500 lb)
1361 kg 8.96 MPa 11.03 MPa
57 318 330 100
(3000 lb) (1300 psi) (1600 psi)
1
2
7
Torque Specifications 8000 SRM 1198
Tire Sizes
Model Drive (in.) Caster (mm) Load Wheels (in.)
N30ZDR, N35ZR, 12.5 × 5.5 × 8.0 Rubber 5 × 3
N40ZR, N30ZDRS, 200 × 50
N35ZRS, N40ZRS 12.5 × 5.5 × 8.0 Poly 5 × 4
13.5 × 5.5 × 8.0 Rubber 5 × 3

N45ZR, N35ZDR 13.5 × 5.5 × 8.0 Poly 200 × 50 5 × 4
13.5 × 5.5 × 8.0 Siped Poly 6 × 4
Torque Specifications
MASTER DRIVE UNIT Scissor Arm Stud Castle Nuts (Dou-
ble Reach Only)
Wheel Nuts 115 N•m (85 lbf ft)
136 N•m (100 lbf ft) Slightly loosen castle nut as necessary to
Use cross pattern to snug, half torque, then full align cotter pin holes.
torque. Apply antiseize to threads.
Reach Cylinder Rod End Capscrews
Drive Unit to Frame Capscrews 35 to 40 N•m (26 to 30 lbf ft)
95 N•m (70 lbf ft)
Use cross pattern to snug, half torque, Tilt Cylinder Rod Nut
then full torque. 34 N•m (25 lbf ft)
then back off 2 turns.
Traction Motor to Drive Unit
23 N•m (17 lbf ft) Load Backrest
Use cross pattern to snug, half torque, 102 N•m (75 lbf ft)
then full torque.
MAST
REACH CARRIAGE
Overhead Guard to Mast
Center Bearing Retainer Capscrews 149 N•m (110 lbf ft)
Apply Loctite® 242 to capscrews and install
into bearing cap along with belleville washers. Cylinder Bleed Screws
Tighten to snug, then tighten each capscrew 7 ±1 N•m (62 ±9 lbf in)
incrementally in a clockwise rotation to maintain
Lower Mast Mounting Capscrews
even pressure the bearing. Capscrews are tight
203 N•m (150 lbf ft)
when belleville washers are flat.
Mast Trunnion Capscrews
210 N•m (155 lbf ft)
8
8000 SRM 1198 Fuses
HYDRAULIC SYSTEM (N30-35ZDR AND Tank Plug (Top)

N35-40-45ZR) 20 N•m (15 lbf ft)
Hydraulic Filter Cover Tank Plug (Bottom)

6 N•m (53 lbf in) 67 N•m (50 lbf ft)
Hydraulic Filter Housing to Tank Tank Plug (Top)

8 N•m (72 lbf in) 8 N•m (72 lbf in)
Breather Assembly to Tank Pump Fittings

1.5 N•m (18.0 lbf in) 80 N•m (59 lbf ft)
Tighten to touch, then 1/8th turn alternately
Pump Pressure Flange until full torque.
40 N•m (30 lbf ft)
Tighten to touch, then 1/8th turn alternately Lift Pump to Motor Mounting Capscrews
until full torque. 61 N•m (45 lbf ft)
Tighten to touch, then 1/8th turn alternately
Lift Pump to Motor Mounting Capscrews until full torque.
47 N•m (35 lbf ft)
Tighten to touch, then 1/8th turn alternately STEERING SYSTEM
until full torque.
Steer Motor Mounting Capscrews
HYDRAULIC SYSTEM (N30ZDRS AND 23 N•m (17 lbf ft)
N35-40ZRS)
LOAD WHEELS
Hydraulic Filter Cover
Load Wheel Axle Bolt
6 N•m (53 lbf in)
68 N•m (50 lbf ft)
Hydraulic Filter Housing to Tank Apply antiseize to axles on nongreaseable
8 N•m (72 lbf in) load wheel assemblies.
Breather Assembly to Tank

1.5 N•m (18.0 lbf in)
Fuses
Fuse Circuit Rating
FU 10 Key Switch Input 10 Amp
FU 11 24-Volt Supply 10 Amp
FU 12 12-Volt Supply 10 Amp
FU 13 Input to Controllers 10 Amp
FU 14 Spare 10 Amp
FU JP2 Voltage Regulator 7.5 Amp
9
Coil Resistance Values 8000 SRM 1198
Coil Resistance Values

Coil Location Resistance Test Points
Main Contactor Control Compartment 32.0 ±4.0 ohms Coil Leads
Load Hold Hydraulic Pump 40.0 ±5.0 ohms Coil Leads
Tilt Selector Attachment 40.0 ±5.0 ohms Coil Leads
Sideshift Attachment 40.0 ±5.0 ohms Coil Leads
Auxiliary Straight Attachment 40.0 ±5.0 ohms Coil Leads
Auxiliary Reverse Attachment 40.0 ±5.0 ohms Coil Leads
Extend/Retract Attachment 40.0 ±5.0 ohms Coil Leads
Brake Traction Motor 11.9 ±1.0 ohms Coil Leads
Under Front Panel (LH)
Electrical Cooling Fan(s) 2.2 ±0.5 milliohms Connector Pins
Drive Unit Door (Optional)
Traction Motor Windings

Winding to Line Resistance (milliohm)
Voltage
Min Max
24 3.22 3.83
36 3.22 3.83
Hydraulic Motor Windings

Winding to Line Resistance (milliohm)
Pump Displacement Voltage
Min Max
19.2cc 24 to 36 2.27 2.70
25.0cc 36 2.55 3.03
25.0cc 36 2.27 2.70
28.0cc 36 1.19 1.37

20.0cc 36 (EE) 2.27 2.70
10
8000 SRM 1198 Battery Specifications
Battery Specifications
Battery Compartment Maximum Battery
Model Minimum Clearance 1 Dimensions 1
Length Width Length Width
986.0 mm 318.0 mm 986.0 mm 311.0 mm
(38.8 in.) (12.5 in.) (38.8 in.) (12.3 in.)
N30ZDRS, N35ZRS, 986.0 mm 371.0 mm 986.0 mm 365 mm
24V
N40ZRS (38.8 in.) (14.6 in.) (38.8 in.) (14.4 in.)
986.0 mm 422.0 mm 986.0 mm 416.0 mm
(38.8 in.) (16.6 in.) (38.8 in.) (16.4 in.)
986.0 mm 371.0 mm 986.0 mm 365.0 mm
N30ZDR, N35ZR, N40ZR, (38.8 in.) (14.6 in.) (38.8 in.) (14.4 in.)
N30ZDRS, N35ZRS, 36V
N40ZRS 986.0 mm 422.0 mm 986.0 mm 416.0 mm
(38.8 in.) (16.6 in.) (38.8 in.) (16.4 in.)
986.0 mm 422.0 mm 986.0 mm 416.0 mm
(38.8 in.) (16.6 in.) (38.8 in.) (16.4 in.)
986.0 mm 478.0 mm 986.0 mm 473.0 mm
N45ZR, N35ZDR 36V
(38.8 in.) (18.8 in.) (38.8 in.) (18.6 in.)
986.0 mm 536.0 mm 986.0 mm 530.0 mm
(38.8 in.) (21.1 in.) (38.8 in.) (20.9 in.)
Battery Maximum Height (All Models) 787.0 mm (31.0 in.)
1
Battery measurements refer to length as the dimension between battery retainer plates on either side of
the lift truck. Width refers to the most narrow dimension of the battery.
Battery Weight
Model
Min Max
635 kg (1400 lb) 862 kg (1900 lb)
N30ZDRS, N35ZRS, N40ZRS 24V 703 kg (1550 lb) 953 kg (2100 lb)
771 kg (1700 lb) 1032 kg (2275 lb)
N30ZDR, N35ZR, N40ZR, N30ZDRS, 703 kg (1550 lb) 953 kg (2100 lb)
36V
N35ZRS, N40ZRS 771 kg (1700 lb) 1089 kg (2400 lb)
771 kg (1700 lb) 1089 kg (2400 lb)
N45ZR, N35ZDR 36V 998 kg (2200 lb) 1293 kg (2850 lb)
1134 kg (2500 lb) 1361 kg (3000 lb)
11
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
12
DIAGRAMS
N35-40ZRS, N30ZDRS [A265];
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470]
PART NO. 1590963 8000 SRM 1199

Diagrams Table of Contents
TABLE OF CONTENTS
Diagrams, Schematics, or Arrangements ......................................................................................................... 1

Figure 1. Schematic / Wiring Diagram .................................................................................................... 1
Figure 2. Hydraulic Schematic (N35-40-45ZR) ....................................................................................... 30
Figure 3. Hydraulic Schematic (N30-35ZDR).......................................................................................... 31
Figure 4. Hydraulic Schematic (N35-40ZRS and N30ZDRS) ................................................................. 32
N35-40ZRS, N30ZDRS [A265];

N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470]

8000 SRM 1199 Diagrams, Schematics, or Arrangements
Figure 1. Schematic / Wiring Diagram (Sheet 1 of 29)
1
Diagrams, Schematics, or Arrangements 8000 SRM 1199
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Figure 2. Hydraulic Schematic (N35-40-45ZR)
30
Figure 3. Hydraulic Schematic (N30-35ZDR)
31
Figure 4. Hydraulic Schematic (N35-40ZRS and N30ZDRS)
32
ELECTRICAL SYSTEM
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590941 2200 SRM 1191

Electrical System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
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
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
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

Table of Contents Electrical System

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

Install ............................................................................................................................................................. 55
Wiring Harness .................................................................................................................................................. 56
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
iii
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 )
the controllers associated with each circuit affected. 4. 200-OHM, 2-WATT RESISTOR
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-
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
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
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.
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.
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
power to the traction motor. Constant communica-
tion between the controller and the motor is neces-
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.
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
3. WASHER 20. CAPSCREW
5. STEERING HANDLE 22. LOCKWASHER
6. STEERING UNIT 23. 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
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

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
FRAME
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590933 100 SRM 1185

Frame Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Repairs - General ............................................................................................................................................... 1
Welding........................................................................................................................................................... 2
Covers, Panels, and Plates ................................................................................................................................ 2
Front Frame Panel (Left and Right)............................................................................................................. 2
Operator Compartment Cover ...................................................................................................................... 3
Drive Unit Compartment Door ..................................................................................................................... 3
Door Pad......................................................................................................................................................... 3
Operator Back Pad ........................................................................................................................................ 3
Side-Stance Models ................................................................................................................................... 3
Forward-Stance Models ............................................................................................................................ 3
Operator Front Pad ....................................................................................................................................... 4
Caster Wheel Cover ....................................................................................................................................... 4
Load Wheels ....................................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 4
Overhead Guard Replacement .......................................................................................................................... 5
Remove ........................................................................................................................................................... 7
Install ............................................................................................................................................................. 7
Front Lights ................................................................................................................................................... 9
Bulb Replacement ..................................................................................................................................... 9
Assembly Replacement ............................................................................................................................. 10
Rear Work and Caution Light .................................................................................................................. 11
Caution Light ............................................................................................................................................ 11
Painting Instructions......................................................................................................................................... 12
Safety Labels Replacement ............................................................................................................................... 13
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];

100 SRM 1185 Repairs - General
General
from the perspective of an operator in the operator
WARNING compartment facing the forks. See Figure 1.
DO NOT make repairs or adjustments unless
you have been properly trained and specifi-
cally authorized to do so. Repairs and adjust-
ments that are incorrect can create dangerous
operating conditions.
DO NOT operate a lift truck that needs repairs.

immediately. If repair is necessary, disconnect
the battery and attach a DO NOT OPERATE tag
to the control handle.
This section contains descriptions of the frame com-

ponents, repair procedures, and assembly informa-
tion. These components include the frame weldment,
door, floor plate, and covers. The overhead guard and
base arms are also covered in this section. A. LEFT C. FORWARD
B. RIGHT
Throughout this section, forward will refer to travel
in the direction of the forks, and left and right will be Figure 1. Travel Orientation
Description
The frame is available in two sizes: small chassis • Steering System Parts
and large chassis. The small chassis is used for the • Electrical System Parts
N30ZDR, N35-40ZR, N30ZDRS, and N35-40ZRS • Hydraulic System Parts
unit and uses a smaller drive unit. The small chas- • Door, Floor Plate, Access Panels, and Covers
sis frame is available with a 368.3 mm (14.5 in.) or
419.1 mm (16.5 in.) battery compartment width. The overhead guard fastens to the mast. A rear op-
The large chassis is used for the N35ZDR and N45ZR erator guard leg provides protection for the operator
unit and uses a larger drive unit. The large chas- and unobstructed operation of the lift truck. The op-
sis frame is available with a 419.1 mm (16.5 in.), erator guard leg fastens between the overhead guard
469.9 mm (18.5 in.), or 546.1 mm (21.5 in.) battery and the frame. Repair procedures for major compo-
compartment width. nents that fasten to the frame are in separate sec-
tions. See each section for the system that has the
The frame has mounts for the following parts: part to be repaired.
• Mast Assembly
Repairs - General
Repair is seldom required on the frame unless the To replace the load wheels in the base arms, see the
truck has been structurally damaged. Most truck re- section Periodic Maintenance 8000 SRM 1197 or
pairs involve removing the system parts that attach Load Wheels in this section.
to the frame. Refer to the appropriate section for the The caster wheel assembly is part of the steering
system that needs repair. To separate the mast from assembly. See the section Steering System 1600
the frame, refer to the sections Mast, Repair 4000 SRM 1187 to replace the caster wheel assembly or
SRM 1195 and Reach Carriages 4500 SRM 1196. the caster wheels.
To replace the drive wheels or tires, see the section
Periodic Maintenance 8000 SRM 1197.
1
Covers, Panels, and Plates 100 SRM 1185
WELDING the area to be welded. Use local ventilation,

and/or supplied, air-respiratory protection.
WARNING
Remove the battery and disconnect the battery CAUTION
connector before welding. Welding can cause a Certain welding repairs require factory ap-
fire and/or an explosion. Make sure there is no proval. Structural members such as base
oil or grease near the weld area and that the arms, axle weldments, and mast components
area is well-ventilated. require written Hyster engineering approval
before repairing or replacing. Contact your
Forklift truck frames and components may
local dealer for factory assistance.
have polyurethane paint. Welding, burning, or
other heat sufficient to cause thermal decom-
position of the paint may release isocyanates. CAUTION
These chemicals are allergic sensitizers to the Connect the welding ground clamp as close to
skin and respiratory tract irritants. Overexpo- the weld area as possible to prevent welding
sure may occur without odor warning. When current from straying.
performing work, utilize good industrial hy-
giene practices, including removal of all paint Only properly trained, authorized technicians should
(prime and finish coats) to the metal around perform welding repairs.
Covers, Panels, and Plates

FRONT FRAME PANEL (LEFT AND RIGHT)
Remove the screws from the upper and lower ends of
the front frame panel. Pull the lower end of the panel
away from the frame of the lift truck and gently work
up the side of the panel to pull it from the retainer
clips securing the panel to the frame. Pull the top end
tabs out of the operator compartment cover. Repeat
for opposite side as necessary. See Figure 2.
NOTE: On right-side, front frame panels, ensure the

diagnostic connector cap is positioned correctly to al-
low the cover to seat properly.
To install the panel, position the upper end of the

panel partially into the retaining clip on the frame.
Insert the tabs on the upper end of the panel into
the slots in the operator compartment cover. Work
the sides of the panel into the retaining clips until all
areas of the panel are aligned with the frame. Align
the holes in the panel with the mounting brackets
on the frame and loosely install the screws into the
upper end and lower end of the panel. Make certain
the panel is seated correctly against the frame and
tighten the screws to secure in place. See Figure 2.
Figure 2. Front Frame Panel (Left Side)
2
100 SRM 1185 Covers, Panels, and Plates
Legend for Figure 2 To install, position the cover over the electrical com-
partment. Align the lip of the cover to the retaining
1. OPERATOR COMPARTMENT COVER clips. Press the lip of the cover into the retaining
2. FRAME
3. LOWER BRACKET clips starting at the overhead guard post and con-
4. LOWER SCREW tinue around until completely seated. Align the holes
5. FRONT COVER PANEL (LEFT) in cover with the mounting brackets and install re-
6. TABS taining screws as removed. Install the front frame
7. UPPER BRACKET panels to complete assembly. Refer to Front Frame
8. UPPER SCREW
Panel (Left and Right).
OPERATOR COMPARTMENT COVER
DRIVE UNIT COMPARTMENT DOOR
Remove the front frame panels from the lift truck.
Completely loosen the two socket head capscrews se-
See Front Frame Panel (Left and Right). Remove
curing the drive unit compartment door closed. The
the two screws securing the operator cover to the
screws are spring-loaded and are retained to the door
frame brackets. One is located on the lower right
by clips. Pull the door open on its hinges. To close,
side of the operator compartment above the opera-
push the door closed and start both socket head cap-
tor presence switch. The other is located beside the
screws loosely into the mounting holes. When both
overhead guard post mount, at the bottom of the cup
screws are started, verify that the door seats prop-
holder. Pull the operator compartment cover up from
erly against the frame and tighten the screws.
the front right corner. Continue pulling the cover up
along the edge of the frame in both directions until
the cover is free from the retaining clips. See Fig-
DOOR PAD
ure 3. Open compartment door and remove the seven cap-
screws holding the pad to the door. Lift the pad over
the steering mechanism and remove.
To instal the pad, lower it over the steering mecha-

nism and position it onto the door. Install the seven
socket head capscrews as removed.
OPERATOR BACK PAD

Side-Stance Models
Remove the five socket head capscrews retaining pad
to the adjuster mechanism and remove the pad.
To install, position the back pad onto the adjuster

mechanism and loosely install the five socket head
capscrews as removed. Verify that the back pad seats
properly to the adjuster mechanism and tighten to
secure as removed.
Forward-Stance Models
NOTE: On models with Aft Travel controls, guide
the aft travel control handle wiring harness into/out
of the frame when installing/removing the operator
back pad.
1. OPERATOR COMPARTMENT COVER Remove the operator compartment cover to access
2. RETAINING SCREW
3. FRAME the screw securing the front of the operator back pad
4. FRONT COVER PANEL (LEFT) to the frame. Remove the two screws securing the
operator back pad to the frame and remove the pad
Figure 3. Operator Compartment Cover from the frame.
3
Load Wheels 100 SRM 1185
To install, position the back pad against the frame the frame. Align the pad bracket holes and install the
as removed. Install the two screws securing pad to screws to secure the pad in place. Install the operator
frame as removed, and reinstall the operator com- compartment cover in place.
partment cover.
CASTER WHEEL COVER
OPERATOR FRONT PAD
Remove the two socket head capscrews on top of the
Remove the operator compartment cover from the lift caster wheel cover and lift cover from the clips secur-
truck. See Operator Compartment Cover. Remove ing it to the frame.
the screws securing the pad brackets to the frame.
Pull the top of the pad away from the frame and then To replace, fit the bottom of the cover into the clips
lift the pad from the lower retaining clips. inside the opening and slide the cover into place. In-
stall two socket head capscrews to secure the top of
To install, position the lower pad brackets into the the cover in place.
retaining clips. Position the upper end of the pad to
Load Wheels
REMOVE 3. Remove the axle sleeves and bearings from the
load wheels. Check for wear or roughness as
Slightly raise the base arms and support on blocks as the bearings are rotated. Replace both bearings
described in the Periodic Maintenance 8000 SRM if wear or roughness is noted. Inspect the load
1197. Make sure the base arms and load wheels do wheels for damage or wear. Replace as necessary.
not support any weight.
1. Remove the nut, washers, and axle bolt. See Fig- CAUTION
ure 4. Use a hammer and a soft punch when removing
bearings to avoid damage to bearings and/or
2. Remove the load wheels from the hanger brack-
load wheel.
ets.
4. Remove the hanger bracket from the base arms
and inspect thoroughly. Inspect the base arms
thoroughly for damage.
INSTALL
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. Wear protection
when handling solvents and always follow the
recommendations of the manufacturer.
CAUTION
1. Clean all parts with solvent and inspect thor-
oughly. Replace damaged parts as necessary.
2. Apply lithium grease to the pivot contact on the

1. AXLE BOLT 4. AXLE SLEEVE hanger brackets. Position the hanger brackets
2. WASHER 5. BEARING into the base arms and install the load wheels
3. HANGER 6. LOAD WHEEL and axle sleeves into the hanger brackets. See
BRACKETS 7. NUT
Figure 5.
Figure 4. Load Wheels
4
100 SRM 1185 Overhead Guard Replacement
3. Install the bearings into the load wheels.
a. Sealed Bearings - Install the bearings into

the load wheel assemblies. Position the axle
sleeve into the assembly. Apply antiseize lu-
bricant to the axle bolt.
b. Side-Shielded Bearings - Install one bear-

ing into the load wheel with the shielded side
facing out. Fill the cavity inside of the load
wheel with grease. Install the other bearing
into the load wheel with the shielded side fac-
ing out. Position the axle sleeve into the as-
1. PIVOT CONTACT sembly.
2. HANGER BRACKET
3. LOAD WHEELS 4. Apply grease to the pivot contact on the hanger
4. BASE ARM brackets. Position the hanger brackets into the
base arms and install the load wheels and axle
Figure 5. Hanger Bracket Pivots sleeves into the hanger brackets.
5. Install a washer onto the axle bolt. Install the

CAUTION axle bolt through the hanger brackets, bearings,
The bearings are replaced by pressing on the and axle sleeve with the threads to the inside of
outer race of the bearing only. Pressing or tap- the base arms.
ping on the inner race will damage the bearing.
Use a suitable driver when installing bearings 6. Install washers and nuts to the axle bolts. Torque
to avoid damage to bearings and/or load wheel. to 68 N•m (50 lbf ft).
Replace bearings in sets to maintain proper NOTE: If axle shafts are equipped with lube fittings,
wheel loading and operation. grease to fill load wheel cavity. Refer to Periodic
Maintenance 8000 SRM 1197 for regularly sched-
NOTE: Load wheel assemblies that have axle bolts uled maintenance procedures.
equipped with lube fittings use side-shielded bear-
ings and must be greased. Assemblies with axle bolts
not equipped with lube fittings use sealed bearings
and cannot be greased.
Overhead Guard Replacement

The overhead guard assembly is heavy. Be sure
WARNING that all lifting devices (hoists, cables, chains,
DO NOT weld mounts for lights or accessories slings, etc.) are suitable and of adequate capac-
to the overhead guard. The strength of the ity to lift the overhead guard.
overhead guard can be reduced by welding or
heating. The overhead guard assembly consists of the over-
head guard and a support post. See Figure 6 and
Install lights and accessories or their mounts Figure 7. The overhead guard is attached to the mast
with clamps. The strength of the overhead with six capscrews (2) and lockwashers (3). The top
guard can be reduced if holes are drilled in the of the support post is bolted to the overhead guard.
wrong location or are too large. Contact your The bottom of the post fits into a retainer in the drive
lift truck dealer before welding or drilling unit compartment.
holes in any part of the overhead guard.
5
Overhead Guard Replacement 100 SRM 1185
Figure 6. Overhead Guard (N35ZDR, N45ZR, N30ZDR, N35-40ZR)
6
Legend for Figure 6

1. OVERHEAD GUARD 6. CAPSCREW
2. CAPSCREW 7. PLUG
3. LOCKWASHER 8. SUPPORT POST
4. PLUG (W/O HEAD LAMPS) 9. BUSHING
5. CAPSCREW
The size of the overhead guard varies depending INSTALL

upon the battery compartment size.
Refer to WARNING (above) before performing ser-
REMOVE vice to any overhead guard components.
Refer to WARNING (above) before performing ser- 1. Attach a suitable lifting device to the overhead
vice to any overhead guard components. guard.
1. Attach a suitable lifting device to the overhead 2. Align the overhead guard with the top of the mast
guard. and install the six capscrews (2) and lockwash-
ers (3). See Figure 6. Torque the capscrews to
2. Remove the two capscrews (6) retaining the sup- 149 N•m (110 lbf ft).
port post to the overhead guard. See Figure 6.
Pull the support post out of the retainer in the 3. Slide the support post into the retainer in the
lift truck frame. Remove the support post. lift truck frame. Install the two capscrews (6)
retaining the support post to the overhead guard.
3. Remove the six capscrews (2) and lockwashers (3)
retaining the overhead guard to the mast. Lower
the overhead guard to the floor.
7
Figure 7. Overhead Guard (N30ZDRS, N35-40ZRS)
8
Legend for Figure 7

1. OVERHEAD GUARD 5. CAPSCREW
2. CAPSCREW 6. CAPSCREW
3. LOCKWASHER 7. SUPPORT POST
4. PLUG (W/O HEAD LAMPS) 8. BUSHING
FRONT LIGHTS
Two front (head) lights are mounted by their brackets
to the front of the overhead guard.
Bulb Replacement
1. Remove the four screws securing the lens re-
tainer and lens to the assembly. Hold the lens
in place until all screws have been removed
then remove the lens and retainer. Replace as
required. See Figure 8.
2. Remove the bulb from the fixture and replace

with new.
CAUTION
Overtightening the screws can break the lens.
3. Position the lens and the retainer to the fixture

and install the four screws.
1. BRACKET
2. RETAINING CAPSCREW AND NUT
3. SCREW
4. LENS RETAINER
5. LENS
Figure 8. Lens Removal
9
Assembly Replacement 3. Remove the bracket from the overhead guard and
replace, if necessary.
1. Disconnect the wiring harness from the light as-
sembly connector. 4. Install bracket to overhead guard, if removed.
2. Remove the nut and washers from the capscrew 5. Position the light assembly to the bracket and in-
securing the headlight assembly to the bracket. stall capscrew and attaching hardware. Tighten
Slide the capscrew from the bracket and remove slightly to allow for adjustment.
the headlight. See Figure 9.
1. ADJUSTMENT SLOT 5. HEADLIGHT

2. ADJUSTMENT BOLT 6. CONNECTOR
3. OVERHEAD GUARD 7. WIRE CLAMP
4. WIRING HARNESS 8. ATTACHING HARDWARE
Figure 9. Head Light Mounting
10
Rear Work and Caution Light 8. Position the cage onto the studs of the light as-
sembly. Install nuts and washers onto studs.
The rear work and caution lights are options that
mount to the overhead guard near the rear of the 9. Remove blocks from the wheel and return to ser-
truck. Several configurations of these assemblies are vice.
available and connect to the options harness. To re-
pair the light assemblies, perform the following pro-
cedures. Some repairs may not require total disas-
sembly. Perform only the steps necessary to safely
complete the required service. See Figure 10.
The work light is very similar to the front light, ex-

cept for its mounting platform and location. To re-
pair or replace the work light, refer to the instruc-
tions for repairing or replacing the front lights. See
Front Lights.
Caution Light

3. Remove the nuts securing the cage to the light

assembly. Remove the cage.
1. CAGE
4. Remove the screws and washers securing the 2. GLOBE
lens globe to the light assembly. Remove the lens 3. STUDS AND NUTS
globe. 4. UPPER MOUNTING FLANGE
5. LOWER MOUNTING FLANGE
5. Remove the bulb from the fixture and replace if 6. SCREW
7. MOUNTING BRACKET
necessary. 8. WORK LIGHT WITH ADJUSTABLE BRACKET
9. WORK LIGHT WIRING HARNESS
6. Connect the battery and turn the key switch to 10. STROBE WIRING HARNESS
the ON position. Test for proper operation.
Figure 10. Rear and Caution Light
7. Position the lens globe to the light assembly. In-
stall screws to secure.
11
Painting Instructions 100 SRM 1185
Painting Instructions
2. Use sandpaper to remove the top surface of
WARNING paint and rust from the metal. All metal sur-
Some frames and components are painted with faces where the paint has been removed to the
polyurethane paint. Welding, burning, or other bare metal must be primed. Apply primer BE-
heat sufficient to cause thermal decomposition FORE applying the paint.
of the paint may release isocyanates. These
chemicals are allergic sensitizers to the skin 3. Protect all surfaces that will not be painted. DO
and respiratory tract irritants. Overexposure NOT paint:
may occur without odor warning. When heat All Plastic Covers
must be applied, use good industrial hygiene Steering Handle
practices, including removal of all paint (prime Dash Display
and finish coats) to the metal around the area Control Handles
to be heated. Use local ventilation, and/or sup- Labels and Information Plates
plied, air-respiratory protection. Operator Pads
Tires and Load Wheels
Cleaning solvents may be flammable and/or Chains and Hoses
toxic and may cause skin irritation. Always Battery Connectors
wear proper eye and skin protection. All Switches
Cylinder Rods
Always use solvents and paints in an area with Pumps and Motors
adequate ventilation. DO NOT use solvents or Wiring Harnesses or Connectors
paints near heat, fire, or electrical equipment
that can make sparks. Follow the paint manu-
facturer’s instructions and precautions. CAUTION
Protect electrical components, wiring, and
CAUTION electrical contacts from overspray.
DO NOT put tape on cylinder rods to protect 4. Paint the surfaces using Hyster approved paints.
from paint. Use a thick layer of multipurpose Follow the proper paint scheme for your lift truck
grease to protect cylinder rods. Cylinders can model (refer to the Parts Manual for specific in-
be damaged if operated with tape on the cylin- formation on paint for your lift truck).
der rod.
5. Install new safety labels. See Safety Labels Re-
1. Clean the surface to be painted. Use a solvent placement.
on surfaces to be painted to remove grease and
oil before sanding. DO NOT use solvent to clean
new paint. Make sure all oil and grease is re-
moved.
12
100 SRM 1185 Safety Labels Replacement
Safety Labels Replacement

all air is removed from under the label or plate
WARNING and the corners and edges are tight. DO NOT
Safety labels are installed on the lift truck to attempt to move the label or plate once it has
give information about operation and possible been stuck down.
hazards. It is important that all safety labels
are installed on the lift truck and can be read.
DO NOT add to or modify the lift truck. Any

change to the lift truck, the tires, or its equip-
ment can change the lifting capacity. The lift
truck must be rated as equipped and the name-
plate must show the new capacity rating. Con-
tact your lift truck dealer for a replacement
nameplate.

and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
If an adhesive plate or label must be replaced, use

the following procedure to install a new label or plate.
See Figure 11 and Figure 12.
1. Clean area with an oil-free cleaner to remove all

oil, grease, and foreign matter. Wipe until com-
pletely dry.
1. MULTIFUNCTION CONTROL LABEL
2. Carefully remove only the paper backing from 2. NAMEPLATE
adhesive. DO NOT touch adhesive surface with 3. NAMEPLATE COVER
hands or remove front mask from label or plate 4. RIVET
face. 5. HYDRAULIC FUNCTION DECAL
3. Exposed adhesive face must be free from all for- Figure 11. Operator Compartment Label
eign matter before positioning label or plate on Placement
surface.
4. Press label or plate down firmly making sure that

all corners are stuck down tight. Make sure that
13
Safety Labels Replacement 100 SRM 1185
Figure 12. Label Placement
14
100 SRM 1185 Safety Labels Replacement

A. LEFT SIDE C. FRONT
B. RIGHT SIDE D. REAR
1. HYSTER LOGO LABEL 12. INFO CASE COVER
2. FORK WARNING LABEL 13. OPERATOR WARNING LABEL
3. PINCH WARNING LABEL 14. HYSTER LOGO DECAL
4. HYSTER NUMERALS DECAL 15. CRUSH WARNING LABEL
5. AC LABEL 16. FREEZER LABEL
6. HYSTER MATRIX LABEL 17. PATENT PLATE
7. BATTERY NOTICE LABEL 18. UL LABEL
8. RIVET 19. RIVET
9. INFO CASE BASE 20. EE LABEL
10. MOUNTING STRIP 21. NON-POWERED LOWERING LABEL (LOCATED
11. OVERHEAD GUARD WARNING DECAL INSIDE DOOR)
15
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
16
HYDRAULIC SYSTEM
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470]
PART NO. 1590939 1900 SRM 1189

Hydraulic System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 3
Control Handle................................................................................................................................................... 3
Side-Stance Control Handle.......................................................................................................................... 3
Forward-Stance ............................................................................................................................................. 4
Maintenance....................................................................................................................................................... 5
Oil Level and Leaks....................................................................................................................................... 5
Operation ....................................................................................................................................................... 5
Oil Change ..................................................................................................................................................... 5
Drain .......................................................................................................................................................... 5
Cylinder Identification .............................................................................................................................. 7
Fill .............................................................................................................................................................. 8
Main Lift Cylinders............................................................................................................................... 8
Free-Lift Cylinders................................................................................................................................ 9
Breather Cap.................................................................................................................................................. 10
Inspect........................................................................................................................................................ 10
Oil Filter......................................................................................................................................................... 10
Change ....................................................................................................................................................... 10
Oil Strainer .................................................................................................................................................... 11
Check.......................................................................................................................................................... 11
General ........................................................................................................................................................... 11
Cleaning ..................................................................................................................................................... 11
Noise Levels............................................................................................................................................... 11
Hoses .............................................................................................................................................................. 12
Fittings ........................................................................................................................................................... 14
Lift Pump and Motor ......................................................................................................................................... 14
Complete Unit................................................................................................................................................ 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 15
Lift Pump ....................................................................................................................................................... 17
Components ............................................................................................................................................... 17
Pressure Flange Fitting........................................................................................................................ 17
Supply and Return Fittings.................................................................................................................. 18
Manual Lowering Valve ........................................................................................................................ 18
Pressure Test Ports ............................................................................................................................... 19
Pressure Transducer ............................................................................................................................. 19
Relief Valve............................................................................................................................................ 21
Lowering Control Valve ........................................................................................................................ 21
Remove Pump ............................................................................................................................................ 22
Install Pump .............................................................................................................................................. 22
Auxiliary Hydraulics.......................................................................................................................................... 23
Auxiliary Pump and Motor ........................................................................................................................... 23
Remove....................................................................................................................................................... 23
Disassemble ............................................................................................................................................... 24
Assemble .................................................................................................................................................... 24
Install ......................................................................................................................................................... 25
Front Selector Valve ...................................................................................................................................... 25
Rear Selector Valve........................................................................................................................................ 26
Hydraulic Tank .................................................................................................................................................. 28

Table of Contents Hydraulic System

Remove ........................................................................................................................................................... 28
Disassemble ................................................................................................................................................... 29
Breather Assembly .................................................................................................................................... 29
Filter Assembly ......................................................................................................................................... 31
Low Oil Indicator Switch .......................................................................................................................... 32
Tank Fittings ............................................................................................................................................. 32
Clean and Inspect .......................................................................................................................................... 32
Assemble ........................................................................................................................................................ 33
Breather Assembly .................................................................................................................................... 33
Filter Assembly ......................................................................................................................................... 33
Low Oil Indicator Switch .......................................................................................................................... 33
Tank Fittings ............................................................................................................................................. 33
Install ............................................................................................................................................................. 33
Specifications...................................................................................................................................................... 34
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470]
ii
General
wire aftermarket components to this truck
CAUTION without factory approval.
larity sensitive and may be damaged if wired The hydraulic system consists of two separately
incorrectly. Make sure each electrical wire powered hydraulic circuits for main lift and auxil-
connection is tagged and properly identified iary functions. Main lift functions refer to raising
before removal or installation. If the proper and lowering the mast sections and carriage. The
location for connection is unclear, consult the auxiliary functions can include: extend and retract,
wiring diagram for the truck. Make sure test- tilt up and tilt down, and sideshift left and right.
ing meters have adequate voltage and current Both pumps draw their oil supply from a common
capacities to handle the output of the electri- hydraulic tank. See Figure 1.
cal components they are used to check. Never
Figure 1. Hydraulic System
1
Legend for Figure 1

1. LIFT MOTOR 7. FILTER ASSEMBLY
2. LIFT PUMP 8. TANK
3. AUXILIARY MOTOR 9. BREATHER ASSEMBLY
4. AUXILIARY PUMP 10. AUXILIARY RETURN HOSE
5. LIFT SUPPLY HOSE 11. AUXILIARY SUPPLY HOSE
6. LIFT RETURN HOSE 12. LIFT PRESSURE HOSE
The lift pump is a gear-type pump driven by an AC 1. Move the lift truck to a safe, level area and com-
induction motor which activates only when the lift pletely lower the mast. Turn the key switch to
controls are operated. When the mast is lowered, an the OFF position and attach a DO NOT OPER-
electro-hydraulic lowering control valve opens to al- ATE tag to the control handle. Block the drive
low the hydraulic oil to exit back through the pump wheel to prevent unexpected movement.
into the hydraulic tank. The hydraulic oil passing
through the pump on its way back to the tank turns 2. Disconnect the battery power cable connector
the lift pump and motor in reverse. The lift motor from the truck connector located on the right side
enters regen mode during lowering which generates of the frame. Pull the battery cable connector
a small charge to the battery. This action recovers handle to separate the battery connector from
some of the energy used to raise the mast and maxi- the truck connector.
mizes battery economy.
Selector valves are used to control the reach carriage
assembly hydraulic functions. These valves con-
sist of valve blocks with electro-hydraulic solenoid
valves. The rear selector valve is located in the rear
frame of the reach carriage assembly and controls
after discharging the capacitors. See Figure 2.
the reach and retract modes of the reach cylinders.
The front selector valve is mounted in the front
frame of the reach carriage assembly and controls
tilt and sideshift functions. An optional auxiliary
function selector valve is available for use with other
approved auxiliary hydraulic devices.
This section addresses the lift pump and motor

assembly, auxiliary pump and motor assembly, hy-
draulic hoses, the hydraulic tank, and control handle
functions. Components that are sometimes associ-
ated with the hydraulic system, but more closely
related to other systems, are covered in other sec-
tions. For additional information see the sections:
Electrical System 2200 SRM 1191
AC Motor Repair 620 SRM 1186
Mast, Repair 4000 SRM 1195
Reach Carriages 4500 SRM 1196
DISCHARGING THE CAPACITORS

1. POSITIVE CONNECTION (B+)
WARNING 2. NEGATIVE CONNECTIONS (B )
Capacitors inside the controllers can hold an 4. 200 OHM, 2-WATT RESISTOR
electrical charge after the battery has been
disconnected. Discharge the capacitors before Figure 2. Discharging the Capacitors
servicing the electrical system to prevent in-
jury or electronic damage.
2
1900 SRM 1189 Control Handle
Description
The hydraulic system uses an AC induction motor Table 1. Main Lift Pump and Motor
and gear-type pump to supply hydraulic pressure for Configurations (Continued)
the main lift functions. Lift pump and motor assem-
blies are available in a variety of combinations. See Motor Pump Availability
Table 1.
36V 4500 lb 25cc All Models
Table 1. Main Lift Pump and Motor Standard
Configurations
36V 4500 lb 28cc N35ZDR and
High Performance N45ZR
Motor Pump Availability
36V 25cc N30ZDR and
N35-40ZR
36V EE Option 20cc All Models
Control Handle
SIDE-STANCE CONTROL HANDLE A thumb-operated tilt/sideshift disk, located on the
face of the control handle, controls tilt and sideshift.
The control handle provides operator control for See Figure 4. To tilt forward, press the top of the
travel, lift, lower, tilt, sideshift, horn, and reach disk. To tilt back, press the bottom of the disk. To
functions. See Figure 3. activate the sideshift function, press the right side of
the disk to move the carriage to the right. Press the
Travel is activated by moving the control handle in
left side of the disk to move the carriage to the left. A
the direction of travel. Moving the control handle
button which activates the horn is located to the left
in the direction of the forks provides forward travel.
of the tilt/sideshift disk.
For travel in reverse, the control handle is moved
toward the rear of the truck. The travel speed for
both forward and reverse directions is proportional
to the distance the handle is moved; the further the
distance, the faster the lift truck travels.
NOTE: Diagonal movement of handle will control

both travel and a hydraulic function simultaneously.
The control handle also controls the lift/lower func-

tions. When the control handle is pulled toward
the operator, the carriage lifts. When the handle is
pushed away from the operator, the carriage lowers.
The speed of the mast is proportional to the distance
the control handle is moved.
NOTE: During lift truck operation, the auxiliary

functions can only be operated one at a time. 1. TILT/SIDESHIFT DISK
2. HORN BUTTON
The extend and retract functions are controlled by 3. EXTEND/RETRACT BUTTONS ARE ON THE
UNDERSIDE OF THE HANDLE
two buttons located on the underside of the control
handle shaft. Figure 3. Control Handle
3
Control Handle 1900 SRM 1189
1. TILT BACK 3. SIDESHIFT RIGHT

2. SIDESHIFT LEFT 4. TILT FORWARD
Figure 4. Tilt/Sideshift Disk
FORWARD-STANCE
The forward-stance trucks utilize a different control
configuration than the multifunction control handle
on side-stance models. The operator directs forward
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
lift/lower function is controlled by a paddle switch on
the face of the control handle. Sideshift and tilt func-
tions are controlled by button switches located to the
right of the paddle switch facing the operator. A but-
ton switch located below the lift/lower paddle acti-
vates the horn. Another paddle switch which con-
trols the reach/extend functions is located on the op-
posite side of the grip and is operated with the index
finger. See Figure 5.
Legend for Figure 5

1. TILT DOWN
2. SS LEFT
3. SS RIGHT
4. TILT UP
5. HORN BUTTON
6. CONTROL HANDLE GRIP
7. REAR GRIP
8. HORN BUTTON Figure 5. Control Handle (Forward-Stance)
9. BOOT
10. CONTROL HANDLE HARNESS The control handle is designed to allow operation of
11. REAR GRIP HARNESS the directional functions of the control handle while
12. EXTEND/RETRACT PADDLE facing the rear of the truck by using the rear grip. A
(BACKSIDE OF HANDLE) thumb-operated button located at the end of the rear
13. LIFT/LOWER PADDLE
grip operates the horn when facing the rear of the
truck.
4
1900 SRM 1189 Maintenance
Maintenance
OIL LEVEL AND LEAKS level drops below the minimum level during opera-
tion.
WARNING
Always wear the proper protective equipment
OPERATION
including eye protection and petroleum-resis- Turn the key switch to the ON position. Raise and
tant gloves when handling hydraulic oil. Thor- lower the mast repeatedly. The mast should move
oughly wash oil from exposed areas of skin as smoothly and should not bounce or jerk when stop-
soon as possible. ping or starting. Check each function of the control
handle for proper operation. See Control Handle for
Completely lower all mast components and re-
explanations of hydraulic functions.
lieve pressure by opening the manual lowering
valve before disassembling any part of the lift
OIL CHANGE
pump or disconnecting any hydraulic hoses.
The hydraulic oil is hot at normal operating Drain

temperatures. Be careful when draining the
oil. WARNING
Never put your hands on pressurized hydraulic including eye protection and petroleum-resis-
components. Highly-pressurized hydraulic oil tant gloves when handling hydraulic oil. Thor-
escaping through pin-hole leaks can be in- oughly wash oil from exposed areas of skin as
jected into the skin. Visually inspect to find soon as possible.
hydraulic leaks.
CAUTION lieve pressure by opening the manual lowering
Protect the hydraulic system from dirt and
contaminants by cleaning hydraulic compo-
nent areas before servicing the hydraulic The hydraulic oil is hot at normal operating
system. temperatures. Be careful when draining the
oil.
Never operate the pump without the proper
amount of oil in the hydraulic system. The Never put your hands on pressurized hydraulic
operation of the hydraulic pump with low oil components. Highly-pressurized hydraulic oil
levels will damage the pump. escaping through pin-hole leaks can be in-
jected into the skin. Visually inspect to find
Check for leaks by looking for oil under the lift truck
hydraulic leaks.
and where the lift truck has been parked. Make sure
the key switch is in the OFF position, remove the op-
erator compartment covers, and open the drive unit CAUTION
compartment door to visually inspect the hydraulic Disposal of lubricants and fluids must meet lo-
system and hoses. Small oil leaks may appear as cal environmental regulations.
wet, oily leaks or unusually dirty areas where dirt
and dust sticks to oil that has slowly leaked out. The hydraulic oil should be changed every 2000
hours or yearly. When the hydraulic system com-
Check the hydraulic oil level. Make sure the key ponents such as the pump or cylinders have been
switch is in the OFF position, and remove the opera- damaged or the oil has otherwise been contaminated,
tor compartment covers to access the hydraulic tank. the hydraulic system should be drained, flushed,
Add hydraulic oil only as needed. If too much hy- and refilled with new hydraulic oil.
draulic oil is added, hydraulic oil will be forced out
through the breather cap during operation. An in- 1. Park the lift truck on a level surface and lower
dicator light notifies the operator if the hydraulic oil the mast. Turn the key switch to the OFF po-
sition, and attach a DO NOT OPERATE tag to
5
Maintenance 1900 SRM 1189
the control handle. Block the wheels to prevent

unexpected movement.

3. Remove the operator compartment cover and the

drive unit compartment door to access the hy-
draulic tank.
4. Remove the breather cap from the top of the tank.

See Breather Assembly.
5. Position a suitable container oil with a minimum

capacity of 19 liter (5 gal) next to the lift truck to
drain the oil.
CAUTION
DO NOT cut the hose when removing the wire
tie.
6. Locate the drain hose at the bottom of the hy-

draulic tank. See Figure 6. Carefully clip the
wire tie securing the hose. Loosen and remove
the hose clamp securing the plug in the end of the
hose. Remove the plug from the hose and drain
the hydraulic oil into the container.
7. Some lift trucks use displacement-type, main lift

cylinders, which retain some amounts of oil even
when at rest. Refer to Cylinder Identification.
These cylinders may be further drained to re-
duce levels of contaminants left in the hydraulic
system. If your truck is equipped with displace-
ment-type, main lift cylinders:
a. Loosen both main lift cylinder bleed screws 1. PLUG 4. TANK

1/2 turn. 2. HOSE 5. WIRE TIE
3. ELBOW (WITH 6. CLAMP
b. Open the lowering control valve. CLAMP)
c. Allow time for the oil to gravity feed into the Figure 6. Drain Hose
tank.
8. Drain the remaining oil from the tank. Place the
d. Turn the lowering control valve to the OFF plug into the hose and secure with hose clamp
position. as removed. Coil the drain hose and secure with
wire tie as removed.
e. Retighten the bleed screws at the top of the
main lift cylinder shells. 9. Inspect the tank. Check for damage to the tank
or hoses. Clean the tank, if necessary. See Hy-
draulic Tank.
6
10. Reinstall the breather cap as removed. See cylinder rod to determine your lift truck configura-
Breather Assembly. tion. See Figure 8 and Table 2.
Cylinder Identification
Two main lift cylinders and one free-lift cylinder are
present on all models of this series lift truck. How-
ever, cylinders may be either displacement-type or
piston-type. Certain cylinder types require different
hydraulic oil drain and fill procedures.
The main lift cylinders may be identified by the pres-

ence of a bleed screw near the top of the cylinder shell
on displacement-type cylinders. Piston-type, main
lift cylinders are not equipped with bleed screws. See
Figure 7.
1. TOP OF INTERMEDIATE MAST

2. CYLINDER ROD
3. BLEED SCREW 1. CROSSHEAD ASSEMBLY
(INDICATES DISPLACEMENT-TYPE CYLINDER) 2. CYLINDER ROD DIAMETER
4. CYLINDER SHELL 3. BLEED OR FILL SCREW
4. RETAINER BRACKET
Figure 7. Main-Lift Cylinder Identification 5. CYLINDER SHELL
6. GLAND
Free-lift cylinders can be identified by the cylinder
rod diameter. Measure the diameter of the free-lift Figure 8. Free-Lift Cylinder Rod
7
Table 2. Cylinder Identification 2. Install the breather cap.
Type Free-Lift Cylinders 3. Determine the types of main lift cylinders and
free-lift cylinders used. Refer to Cylinder Iden-
Displacement 73.00 mm (2.87 in.) tification.
Piston 44.40 mm (1.75 in.)
Main Lift Cylinders
Fill 1. Piston-type, main lift cylinders do not require

bleeding. If your lift truck is equipped with pis-
NOTE: Refer to Specifications in this section, for the ton-type, main lift cylinders, skip to Free-Lift
proper hydraulic oil selection. Cylinders.
1. Fill the hydraulic tank to the proper level with
new hydraulic oil. The hydraulic oil should be WARNING
filled to 25 mm (1 in.) below the bottom of the Keep clear of the mast when bleeding the cylin-
hydraulic filter housing on the tank. DO NOT ders. Mast parts may shift or lower unexpect-
overfill the hydraulic tank. See Figure 9. edly.
Never put your hands on pressurized hydraulic

components. Highly-pressurized hydraulic oil
escaping through pin-hole leaks can be in-
hydraulic leaks.
2. Displacement-type, main lift cylinders must be

bled:
a. Engage the battery connectors and turn the

b. Activate the lift function using the operator

controls. Continue until the free-lift cylinder
rod extends approximately 150 mm (6 in.) to
apply pressure to the hydraulic system.
c. Turn the key switch to the OFF position and

remove the key.
WARNING
Use a personnel lift or a ladder to access the
bleed screws. DO NOT climb on the mast or lift
truck.
CAUTION
DO NOT completely remove the bleed screw.
Loosen it slowly and gradually.
NOTE: Use a cloth to wipe up foam and oil as it is

expelled to minimize cleanup.
1. HYDRAULIC FILTER HOUSING
2. HYDRAULIC RETURN FITTING d. Slightly open the bleed screw of either main
3. HYDRAULIC OIL FILL LEVEL lift cylinder by turning it counterclockwise
4. HYDRAULIC TANK until air and/or oil foam is expelled. Allow
air/foam to bleed from cylinder until clear hy-
Figure 9. Hydraulic Oil Level draulic oil is present. Close the bleed screw
8
and tighten to 6 to 8 N•m (53 to 71 lbf in). If injected into the skin. Visually inspect to find
the free-lift cylinder completely lowers before hydraulic leaks.
all the air is expelled, close the bleed screw
and return to Step a. Wipe up the expelled 2. Displacement-type, free-lift cylinders must be
oil and repeat procedure for the other main bled:
lift cylinder.
Free-Lift Cylinders key switch to the ON position.
1. Piston-type, free-lift cylinders are not bled but b. Activate the lift function using the operator
do have an oil chamber that must be filled for controls. Continue until the free-lift cylinder
cylinder cushion functions to work properly: rod extends approximately 150 mm (6 in.) to
a. Completely lower the mast and carriage.
Turn the key switch to the OFF position and c. Turn the key switch to the OFF position and
disconnect the battery. disconnect the battery.
b. Slightly open the fill screw on the side of

the free-lift cylinder shell near the gland by
CAUTION
turning it counterclockwise to make sure the DO NOT completely remove the bleed screw.
cylinder is not pressurized. Slowly remove
the fill screw and seal.
expelled to minimize cleanup.
NOTE: Use a clean oil can to measure and inject hy-
d. Slightly open the bleed screw on the side
draulic oil into the cylinder fill hole.
of the free-lift cylinder shell near the gland
c. Measure approximately 150 cc (5 oz) of clean by turning it counterclockwise until air
hydraulic oil and fill the oil chamber through and/or oil foam is expelled. Allow air/foam to
the fill hole. Fill until all the oil is used or bleed from the cylinder until clear hydraulic
until oil flows out of the fill hole. oil is present. Close the bleed screw and
tighten to 6 to 8 N•m (53 to 71 lbf in). If the
d. Install the fill screw and seal and tighten to free-lift cylinder completely lowers before all
6 to 8 N•m (53 to 71 lbf in). Wipe up any air/foam is expelled, close the bleed screw
spilled oil. and repeat Step a. Wipe up the expelled
oil. Some displacement-type, free-lift cylin-
e. Connect the battery and turn the key switch ders also have an additional bleed screw
to the ON position. Completely raise and located in the end of the cylinder rod. In-
lower the mast several times to check for spect the cylinder rod where it emerges from
proper operation. The free-lift cylinder the crosshead. If the rod is equipped with
should slow smoothly near the end of its the additional bleed screw, repeat the bleed
stroke. Check the hydraulic oil level in the procedure using the additional bleed screw.
tank and fill as necessary. Replace all covers
as removed, remove blocks from the wheels, e. Connect the battery and turn the key switch
and return the lift truck to service. to the ON position. Completely raise and
lower the mast several times to check for
WARNING proper operation. Repeat the bleed proce-
dure until no air is present when bleeding
Keep clear of the mast when bleeding the cylin-
the free-lift cylinder. Check the hydraulic oil
ders. Mast parts may shift or lower unexpect-
level in the tank and fill as necessary. Re-
edly.
place all covers as removed, remove blocks
Never put your hands on pressurized hydraulic from the wheels, and return the lift truck to
components. Highly-pressurized hydraulic service.
oil escaping through pin-hole leaks can be
9
BREATHER CAP 3. Loosen the four capscrews securing cover to the

hydraulic oil filter housing.
Inspect
4. Press the cover down by hand to depress the el-
The hydraulic breather cap allows air to enter the hy- ement retainer spring, and remove the four cap-
draulic tank when the hydraulic oil is pumped out to screws.
the cylinders. When the hydraulic oil returns to the
tank, air is expelled through the hydraulic breather 5. Remove the cover and spring from housing.
cap. A filter in the cap protects the hydraulic system Check the O-ring seal on the cover for cracks
from particles of dirt and other contaminants. If the or deterioration. Replace, if damaged. See Fig-
filter becomes excessively dirty, air flow can be re- ure 10.
stricted, causing pressures and vacuums to build in-
6. Remove element from housing and replace with
side the tank. If air flow becomes restricted through
a new element.
the hydraulic breather cap, replace the breather cap.
Keep the hydraulic breather area clean and do not 7. Position the cover and spring to the housing.
overfill the hydraulic tank. Press the cover down by hand to depress the
element retainer spring, and install the four cap-
OIL FILTER screws. Torque capscrews to 6 N•m (53 lbf in).
Change 8. Engage the battery connectors and remove the
Replace the filter element after the first 500 hours of dle. Remove the drive wheel blocks and test for
service and every 2000 hours or yearly thereafter. proper operation.
WARNING
including eye protection and petroleum-resis-
tant gloves when handling hydraulic oil. Thor-
oughly wash oil from exposed areas of skin as
soon as possible.

The hydraulic oil is hot at normal operating

oil.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
1. HYDRAULIC TANK
1. Move the lift truck to a safe, level area and com- 2. COVER
pletely lower the mast. Turn the key switch to 3. FILTER
the OFF position and disconnect the battery. At- 4. PUMP RETURN HOSE
tach a DO NOT OPERATE tag to the control 5. HYDRAULIC FILTER HOUSING
handle. Block the drive wheel to prevent unex- 6. SPRING
pected movement.
Figure 10. Cover Removal
2. Remove the operator compartment cover(s) to ac-
cess the hydraulic tank.
10
1900 SRM 1189 Hydraulic System
OIL STRAINER inside the fill hole. The screen must be kept clean
in order to strain the new oil added to the system.
Check If dirt, trash, rust, or sludge is present, remove and
clean the strainer. If the strainer cannot be cleaned
Clean around the breather assembly to prevent or is broken, it should be replaced. See Hydraulic
contamination to the hydraulic system. Remove the Tank for oil strainer and breather assembly replace-
breather cap from the top of the hydraulic tank. ment.
Visually inspect the hydraulic oil strainer located
Hydraulic System
GENERAL Cleaning
Take precautionary measures to ensure that the hy-
WARNING draulic system remains clean.
including eye protection and petroleum-resis- 1. Clean the reservoir and pump area before servic-
tant gloves when handling hydraulic oil. Thor- ing to prevent contaminants from entering the
oughly wash oil from exposed areas of skin as hydraulic system.
soon as possible.
2. Clean (flush) the entire system when a failure is
Completely lower all mast components and re- encountered to make sure all paint, metal chips,
lieve pressure by opening the manual lowering and debris are removed.
pump or disconnecting any hydraulic hoses. 3. Filter each change of oil to prevent the introduc-
tion of contaminants into the system.
temperatures. Be careful when draining the 4. Provide continuous protection from airborne con-
oil. tamination by keeping the breather cap clean
and serviceable.
Never check for leaks by putting hands on
hydraulic lines or components under pressure. Noise Levels
Hydraulic oil under pressure can be injected
into the skin. Hydraulic system noise may be caused by both im-
properly selected oil and loose or damaged system
components.
CAUTION • Cavitation - Can be caused by high fluid viscosity,
Protect the hydraulic system from dirt and cold fluid temperatures, or a restriction in the in-
contaminants when servicing the hydraulic let screen or inlet tubing. At startup, low temper-
system. atures can cause pump noises due to cavitation.
• Aerated hydraulic oil - Results in system noise that
Never operate the pump without the proper
is similar to cavitation. Aerated oil is caused by
amount of oil in the hydraulic system. The
the ingestion of air through the joints of the in-
operation of the hydraulic pump with low oil
let lines and high-velocity discharge lines. Aera-
levels will damage the pump.
tion can also be caused by oil discharging above the
The hydraulic oil in the system performs the dual fluid level in the hydraulic reservoir. Aerated hy-
function of power transmission and lubrication. Us- draulic oil occurs when air does not have sufficient
ing the proper oil is essential to system operation. time to escape from the fluid while in the reservoir
The hydraulic oil level should be checked first when before recycling through the system.
troubleshooting hydraulic system problems. Low oil
levels may cause it to appear that a problem exists
with the battery or hydraulic components.
11
HOSES steel mesh molded into the rubber to support the high
pressures created by the pump. These hoses have hy-
The hydraulic hoses carry hydraulic fluid from the draulic fittings crimped onto each end. The lift pump
tank to the hydraulic pumps, to the hydraulic func- has separate supply, return, and pressure hoses. The
tions, and back to the tank. Hoses may be pressur- auxiliary pump has a supply and a pressure hose.
ized or non-pressurized. Non-pressurized hoses slide See Figure 11 and Figure 12.
onto barbed fittings and are secured in place with
hose clamps. Pressurized hoses are reinforced with
Figure 11. Hoses (Top)
12

1. AUXILIARY RETURN HOSE 8. FILTER ASSEMBLY
2. AUXILIARY PRESSURE HOSE 9. LIFT RETURN HOSE
3. AUXILIARY RETURN ELBOW 10. LIFT PUMP
4. AUXILIARY PRESSURE ELBOW 11. HYDRAULIC TANK
5. LIFT PUMP PRESSURE HOSE 12. LIFT MOTOR
6. MAST CONNECTION FITTING 13. CLAMP
7. BREATHER CAP 14. LOW OIL INDICATOR SWITCH
oil.
NOTE: The hydraulic oil must be completely drained

from the system before any hydraulic hoses may be
removed. Refer to Drain for the proper procedures
for your lift truck. Oil will remain in the hoses even
when the hydraulic system has been drained.
Visually inspect the hoses for leaks. Small oil leaks

may appear as wet, oily leaks or unusually dirty ar-
eas where dirt and dust sticks to oil that has slowly
leaked out. Check around fittings and hose con-
nections for seeping oil. Replace hoses immediately
when damage or significant wear is found. Loosen
fittings slowly and cover with a cloth to make sure
pressure has been relieved in the system. Empty the
hoses into a drain pan and cap or plug all open ports
and hoses at once to prevent contaminants from
entering the system. All hydraulic hoses and tubes
must be thoroughly cleaned before installation.
1. CLAMP
2. AUXILIARY PUMP AND MOTOR ASSEMBLY WARNING
3. AUXILIARY PRESSURE HOSE
4. AUXILIARY SUPPLY HOSE Failure to return the manual lowering valve to
5. MAIN LIFT SUPPLY HOSE the full clockwise position will cause the forks
6. TANK to lower unexpectedly.
Figure 12. Hoses (Auxiliary) NOTE: The hydraulic system (including the mast)
must be purged of air when refilling the hydraulic
system with oil.
WARNING
Always wear the proper protective equipment When making repairs, use the least number of fit-
including eye protection and petroleum resis- tings and connections to minimize flow resistance
tant gloves when handling hydraulic oil. Thor- and the possibility of leakage. Route new hoses prop-
oughly wash oil from exposed areas of skin as erly to avoid contact that may cause premature wear.
soon as possible. Close the manual lowering valve and refill the hy-
draulic system with oil when repairs are complete.
Completely lower all mast components and re- Refer to Fill for the proper procedures for your lift
lieve pressure by opening the manual lowering truck.
13
Lift Pump and Motor 1900 SRM 1189
FITTINGS Check the threads and mating surfaces of each fitting

when removed. Fittings with O-rings should be in-
Various types of fittings are used to connect hoses spected carefully and the O-ring replaced if it is brit-
and hydraulic system components. Some of these in- tle, cracked, or otherwise damaged. Make sure mat-
clude flared fittings, O-ring fittings, and flat-faced ing surfaces are clean and smooth and do not over-
O-ring fittings. Certain fittings have properties that tighten fittings. Inspect fittings for leaks often fol-
make them better suited for particular applications. lowing repairs.
Lift Pump and Motor

COMPLETE UNIT 2. Disconnect the battery power cable connector
WARNING of the frame. Pull the battery cable connector
tant gloves when handling hydraulic oil. Thor- 3. Remove the operator compartment cover(s) to ac-
oughly wash oil from exposed areas of skin as cess the lift pump and motor assembly. Remove
soon as possible. the capscrews securing the drive unit compart-
ment door, and pull the door open.
lieve pressure by opening the manual lowering 4. Tag and disconnect the electrical connections
valve before disassembling any part of the lift from the lift motor terminals.
5. Open the manual lowering valve to relieve any
The hydraulic oil is hot at normal operating pressure present in the hydraulic system. See
temperatures. Be careful when draining the Manual Lowering Valve.
oil.
NOTE: Models with displacement-type cylinders can
Never put your hands on pressurized hydraulic retain significant quantities of oil in the cylinders
components. Highly pressurized hydraulic oil and hoses even when the hydraulic tank is empty.
escaping through pin-hole leaks can be in- Properly drain the hydraulic system of your model to
jected into the skin. Visually inspect to find avoid large spills. Refer to Drain.
hydraulic leaks.
6. Drain the oil from the hydraulic system well be-
low the height of the hoses being removed. See
CAUTION
Oil Change. Store the oil in clean, approved con-
Disposal of lubricants and fluids must meet lo- tainers if it is to be reused.
7. Disconnect the hoses from the lift pump. Se-
The following procedures outline the steps for remov- cure the hose ends above the fluid level in the
ing the entire lift pump and motor assembly as a com- tank. Cap and plug the ports and hoses to pre-
plete unit. If it is not necessary to remove the lift mo- vent contamination to the system. Remove the
tor, follow the procedures for removing the lift pump hose clamp securing the lift pump pressure hose
only. See Lift Pump, Remove Pump. Perform only to the terminal end mounting plate by remov-
the procedures necessary to safely complete the re- ing the four capscrews and washers securing the
quired service. clamp halves.
Remove 8. Attach a sling and an overhead lifting device to
the lift pump and motor assembly.
1. Park the lift truck on a level surface and lower
the mast. Turn the key switch to the OFF po- 9. Remove the capscrews from the mounting bush-
sition, and attach a DO NOT OPERATE tag to ing of each motor mount.
14
1900 SRM 1189 Lift Pump and Motor
Install
CAUTION
Carefully route the assembly from the truck to 1. Install the motor mount brackets to the lift motor
avoid damaging the threads of the forward mo- as removed. See Figure 14 or Figure 15.
tor mount studs.
10. Lift the lift pump and motor assembly from the
lift truck and position on a clean workbench. Re-
move the sling and lifting device.
11. Remove the capscrews securing mounting brack-

ets to the lift motor.
12. Inspect the motor mount bushings. Replace as

necessary. See Figure 13.
1. AUXILIARY RETURN HOSE

2. HYDRAULIC TANK
3. HOSE CLAMP
4. ATTACHING HARDWARE
5. MOUNTING BRACKET (TERMINAL END)
6. MOUNTING BUSHING
7. LIFT PUMP PRESSURE HOSE
8. LIFT MOTOR
9. MOUNTING CAPSCREW A. STANDARD 24 OR 36 VOLT
10. MOUNTING BUSHING B. 4500 LB OR EE OPTION
11. LIFT PUMP
12. MOUNTING BRACKET (PUMP END) 1. CAPSCREW
2. MOUNTING BRACKET
Figure 13. Lift Pump and Motor 3. MOTOR END HEAD
Figure 14. Mounting Brackets (Pump End)
15
2. Attach a sling and an overhead lifting device to

the lift pump and motor assembly.
3. Position the lift pump and motor assembly into

the lift truck as removed.
4. Install the capscrew into the mounting bushing

of each motor mount.
5. Install the return and supply hoses as removed.
6. Install the pressure hose end with new O-ring

into the pressure port. Install the retaining
flanges onto the pump and hose, and install the
four capscrews and washers. Tighten each screw
until the retaining flanges are pressed lightly to
the pump. Alternately tighten each screw 1/8 th
turn until each capscrew is torqued to 40 N•m
(30 lbf ft).
7. Connect the wiring to the motor terminals as re-

moved.
NOTE: Models with displacement-type cylinders

have significantly different filling procedures than
models with piston-type cylinders. Fill the hydraulic
system using the appropriate procedures for your
model to ensure proper operation. Refer to Fill.
8. Fill the hydraulic system to the proper level.
9. Engage the battery connectors, turn the key

switch to the ON position, and fully cycle the hy-
draulic system several times to check for proper
operation.
10. Install the operator compartment cover(s) as re-

moved. Remove the DO NOT OPERATE tag
from the control handle and remove the blocks
from the wheels.
A. STANDARD 24- OR 36-VOLT

B. 4500 LB OR EE OPTION
1. CAPSCREW
2. MOUNTING BRACKET
3. MOTOR END HEAD
Figure 15. Mounting Brackets (Terminal End)
16
LIFT PUMP lowering valve IMMEDIATELY after verifying

pressure has been removed.
WARNING
Components
including eye protection and petroleum-resis- Some components may be serviced without removing
tant gloves when handling hydraulic oil. Thor- the lift pump. Perform only the procedures necessary
oughly wash oil from exposed areas of skin as to safely complete the required service.
soon as possible.
Pressure Flange Fitting
lieve pressure by opening the manual lowering NOTE: Certain lift truck models retain significant
valve before disassembling any part of the lift quantities of oil in the cylinders and hoses even when
pump or disconnecting any hydraulic hoses. the hydraulic tank is empty. Drain the hydraulic sys-
tem using the appropriate procedures for your model
The hydraulic oil is hot at normal operating before servicing to avoid large spills. Refer to Oil
temperatures. Be careful when draining the Change.
oil.
1. Drain the oil from the hydraulic system. Refer
CAUTION to Drain. Make sure any oil remaining in the
tank is well below the height of the components
being removed. Store the oil in clean, approved
containers if the oil is to be reused.
When repairing damaged lift pump compo-
nents, it is recommended to change the oil CAUTION
filter. Clean the pressure flange area and protect the
surrounding area from oil spills. Have shop
The following procedures outline the steps for servic-
rags and containers ready to catch oil from the
ing, removing, and installing the lift pump. If it is not
pump pressure hose.
necessary to remove the lift pump, follow the proce-
dures for servicing the components only. See Compo- 2. Loosen the four capscrews securing each half of
nents. the retaining flanges to the pump 1/8 th turn al-
If the gears or housing of the pump are damaged, ternately to avoid breaking the retaining flanges.
the pump assembly must be replaced. See Remove Remove the capscrews, washers, and retaining
Pump. Perform only the procedures necessary to flanges.
safely complete the required service.
3. Remove the hose end from the pressure port.
1. Park the lift truck on a level surface and lower Drain the hose into a suitable container and cap
the mast. Turn the key switch to the OFF po- the end.
the control handle. Block the wheels to prevent 4. Check the O-ring. Replace if brittle, torn, or
unexpected movement. cracked. Inspect the hose end for damage and
wear. If the hose end is damaged, the pressure
2. Disconnect the battery power cable connector hose must be replaced.
of the frame. Pull the battery cable connector 5. Inspect the pump for cracks and damage. Check
handle to separate the battery connector from that the port receiving the hose end is smooth
the truck connector. and clean. If the hose and the port do not mate to-
gether properly, the connection will leak. A pump
3. Remove the operator compartment cover(s) to ac- with cracks cannot be repaired and must be re-
cess the lift pump and motor assembly. placed.
4. Open the manual lowering valve to relieve any 6. Install the hose end into the pressure port. In-
pressure present in the hydraulic system. See stall the retaining flanges onto the pump and
Manual Lowering Valve. Close the manual
17
hose, and install the four capscrews and wash- NOTE: Models with displacement-type cylinders
ers. Tighten each capscrew until the retaining have significantly different filling procedures than
flanges are pressed lightly to the pump. models with piston-type cylinders. Fill the hydraulic
7. Alternately tighten each capscrew 1/8 th turn un- model to ensure proper operation. Refer to Fill.
til all are torqued to 40 N•m (30 lbf ft).
7. Fill the hydraulic system to the proper level. See
NOTE: Models with displacement-type cylinders Oil Change.
models with piston-type cylinders. Fill the hydraulic Manual Lowering Valve
model to ensure proper operation. See Oil Change. The manual lowering valve can be opened by turn-
ing the manual lowering valve knob counterclock-
8. Fill the hydraulic system to the proper level. Re- wise to relieve pressure from the hydraulic system.
fer to Fill. This can be used to manually lower the mast in case
of malfunction. If the mast leaks down during op-
Supply and Return Fittings eration, lower the mast and check that the knob is
completely closed (turn clockwise). Always close the
NOTE: Certain lift truck models retain significant
manual lowering valve after use. See Figure 16.
quantities of oil in the cylinders and hoses even when
the hydraulic tank is empty. Drain the hydraulic sys-
before servicing to avoid large spills. Refer to Oil
Change.

to Drain. Make sure any oil remaining in the
tank is well below the height of the components
being removed. Store the oil in clean, approved
2. Disconnected the supply and/or return hose from

the lift pump. Secure the hose ends above the
fluid level in the tank. Cap and plug the ports
and hoses to prevent contamination to the sys-
tem.
NOTE: Inspect fittings for damage to the threads and

sealing surfaces. Replace damaged fittings as neces-
sary.
3. Remove the fittings as necessary.
4. Inspect the pump for cracks and damaged

threads.
1. LOWERING CONTROL VALVE
5. Install new fittings as removed. 2. UPPER MOUNTING HOLE
3. M2 TEST PORT
NOTE: Hose clamps are properly positioned centered 4. MANUAL LOWERING VALVE
between the end of the hose and the barb end of the 5. M1 TEST PORT
6. RETURN FITTING
fitting inside the hose. 7. RELIEF VALVE
8. SUPPLY FITTING
6. Place hose clamps loosely over the lift pump 9. LOWER MOUNTING HOLE
supply and return hoses, and install hoses onto 10. OVERRUN CHECK VALVE
the lift pump fittings. Position hose clamps and 11. PRESSURE FLANGE
tighten to 13 N•m (108 lbf in).
Figure 16. Pump (Valve Manifold)
18
Pressure Test Ports position when complete. Voltage must be

present to test the transducer.
Two ports on the lift pump are available for test-
ing hydraulic pressures. These ports are normally
plugged except when the second test port (M2) is fit-
ted with the pressure transducer for the load sens-
ing option (see Pressure Transducer). Both test ports
can be accessed by removing the plug and installing
a male, 7/16 20 UNF-2A thread O-ring fitting into
the port. Connect a pressure gauge [24.1 to 27.6 MPa
(3500 to 4000 psi) range] to the fitting to monitor hy-
draulic pressures.
The first test port (M1) taps directly into the main
lift pressure circuit before the lowering control valve.
This allows a technician to install a pressure gauge
into the port to check the pressures generated when
the lift pump is activated without pressure from the
weight of the load. The relief valve setting can also
be checked by completely raising the mast and then
continuing to activate the UP function of the control
handle for 1-second intervals. 1. M1 TEST PORT 4. RETURN PORT
2. M2 TEST PORT 5. SUPPLY INTAKE
The second test port (M2) taps directly into the main 3. PRESSURE PORT
lift pressure circuit beyond the lowering control Figure 17. Lift Pump and Motor Schematic
valve. When the pump is at rest, the pressure in
this circuit is produced by the weight of the mast c. Attach jumper wires from the transducer
components and load. When the pump is activated, terminal to the wiring harness connector to
pressures should remain below the maximum relief complete the ground and the supply circuits.
valve pressure until the mast is fully extended. See Figure 18.
Pressures reaching the maximum relief valve pres-
sure before the mast is completely extended may
indicate obstructions in the hoses or cylinders or a
load greater than lift truck capacity. This allows the
technician to verify that pressure is present beyond
the lowering control valve and rule out obstructions
in the pump valves when troubleshooting. Refer to
Figure 17.
Pressure Transducer
1. Test the transducer:
a. Load a 3/4 capacity load onto the forks and

lower the forks to the floor. Open the manual
lowering valve to relieve all pressure from
the hydraulic system. Close the manual low-
ering valve immediately after relieving the
pressure.
b. Unplug the transducer connector from the

wiring harness. Check between the supply 1. SUPPLY TERMINAL
and the ground pins of the wiring harness 2. OUTPUT TERMINAL
3. GROUND TERMINAL
using a voltmeter with the key switch in
the ON position. There should be 5 volts Figure 18. Transducer Terminals
present. Turn the key switch to the OFF
19
d. Connect a voltmeter between the transducer NOTE: Certain lift truck models retain significant
terminal and the wiring harness to complete quantities of oil in the cylinders and hoses even when
the output circuit. Turn the key switch to the the hydraulic tank is empty. Drain the hydraulic sys-
ON position and check the voltage. Voltage tem using the appropriate procedures for your model
should measure 0.5 volts. before servicing to avoid large spills. Refer to Oil
Change.
e. Raise the load approximately 305 mm
(12 in.). Voltage should increase from 0.5 a. Drain the oil from the hydraulic system. Re-
volts to between 1.5 and 3.5 volts. fer to Drain. Make sure any oil remaining
in the tank is well below the height of the
f. Remove the load from the forks and com- components being removed. Store the oil in
pletely raise the mast. With the mast fully clean, approved containers if the oil is to be
raised, press the lift button for one second reused.
intervals to cause the hydraulic system to
reach maximum relief valve pressure. The b. Remove the pressure transducer by unscrew-
voltage should measure 4.5 volts at maxi- ing it from the lift pump. See Figure 19.
mum relief valve pressure.
2. Remove and replace the pressure transducer:
Figure 19. Transducer Removal
20

1. UPPER MOUNTING CAPSCREW 5. M1 TEST PORT
2. M2 TEST PORT 6. LOWER MOUNTING CAPSCREW
3. PRESSURE TRANSDUCER 7. LOWERING CONTROL VALVE
4. MANUAL LOWERING VALVE
c. Install the pressure transducer by screwing e. Fill the hydraulic system to the proper level.
it in the lift pump as removed.
f. Test for proper operation.
have significantly different filling procedures than OR
3. Adjust:
model to ensure proper operation. See Oil Change. a. Loosen the jam nut on the relief valve.
d. Fill the hydraulic system to the proper level. b. Adjust the valve as required.
Refer to Fill.
c. Tighten the jam nut.
Relief Valve
d. Test for proper operation.
1. Check the relief valve:
e. Repeat until the relief pressure is within the
a. The pressure at which the relief valve should acceptable range.
open is 20.68 ±0.70 MPa (3000 ±100 psi).
This can be checked using the pressure test Lowering Control Valve
ports (see Pressure Test Ports). If the relief
pressure is not within the acceptable range, NOTE: Certain lift truck models retain significant
repair or replace the relief valve. quantities of oil in the cylinders and hoses even when
2. Replace: tem using the appropriate procedures for your model
before servicing to avoid large spills. Refer to Oil
NOTE: Certain lift truck models retain significant Change.
the hydraulic tank is empty. Drain the hydraulic sys- 1. Drain the oil from the hydraulic system. Refer
tem using the appropriate procedures for your model to Drain. Make sure any oil remaining in the
before servicing to avoid large spills. Refer to Oil tank is well below the height of the components
Change. being removed. Store the oil in clean, approved
a. Drain the oil from the hydraulic system. Re-
fer to Drain. Make sure any oil remaining 2. Disconnect the lowering control valve wiring
in the tank is well below the height of the from the main wiring harness.
components being removed. Store the oil in
clean, approved containers if the oil is to be 3. Remove the lowering control valve from the
reused. pump.
b. Remove the relief valve from the pump. 4. Install new lowering control valve as removed.
c. Install new relief valve as removed. 5. Connect the lowering control valve wiring to the
main wiring harness as removed.
d. Tighten the jam nut.
NOTE: Models with displacement-type cylinders have significantly different filling procedures than
have significantly different filling procedures than models with piston-type cylinders. Fill the hydraulic
models with piston-type cylinders. Fill the hydraulic system using the appropriate procedures for your
system using the appropriate procedures for your model to ensure proper operation. Refer to Fill.
model to ensure proper operation. Refer to Fill.
6. Fill the hydraulic system to the proper level.
21
Remove Pump 2. Assemble lift pump end head and housing and
position pump assembly to motor as removed.
The following procedures outline the steps for remov-
ing the lift pump only. This step may be performed 3. Apply Loctite 271™ to threads of pump retaining
with the lift pump and motor assembly installed or capscrews, and install through the pump into the
removed from the lift truck. If it is necessary to re- motor as removed. Turn capscrews by hand to en-
move the lift motor, remove the entire assembly first. sure they start into the mounting holes properly.
Refer to Complete Unit, Remove.
4. Tighten each screw until the pump is lightly se-
NOTE: Certain lift truck models retain significant cured to the end head of the motor. Alternately
quantities of oil in the cylinders and hoses even when tighten each screw 1/8 th turn until each capscrew
the hydraulic tank is empty. Drain the hydraulic sys- is torqued to 47 N•m (35 lbf ft).
before servicing to avoid large spills. Refer to Oil NOTE: Hose clamps are properly positioned centered
Change. between the end of the hose and the barb end of the
fitting inside the hose.
to Drain. Make sure any oil remaining in the 5. Place hose clamps loosely over the lift pump
tank is well below the height of the components supply and return hoses, and install hoses onto
being removed. Store the oil in clean, approved the lift pump fittings. Position hose clamps and
containers if the oil is to be reused. tighten to 13 N•m (108 lbf in).
2. Remove the pressure hose end by loosening the 6. Install the pressure hose end with new O-ring
four capscrews securing each half of the retaining into the pressure port. Install the retaining
flanges to the pump. Turn each capscrew 1/8 th flanges onto the pump and hose, and install
turn alternately to avoid breaking the retaining the four capscrews and washers. Tighten each
flanges. Remove the capscrews, washers, and re- screw until the retaining flanges are flush with
taining flanges. Remove the hose end from the the pump. Alternately tighten each screw 1/8 th
pressure port. Drain the hose into a suitable con- turn until each capscrew is tightened to 40 N•m
tainer and cap the end. (30 lbf ft).
3. Disconnect the supply and return hoses from the NOTE: Models with displacement-type cylinders
lift pump. Secure the hose ends above the fluid have significantly different filling procedures than
level in the tank. Cap and plug the ports and models with piston-type cylinders. Fill the hydraulic
hoses to prevent contamination to the system. system using the appropriate procedures for your
model to ensure proper operation. Refer to Oil
4. Loosen each of the two retaining capscrews 1/4 th Change.
turn alternately to gradually loosen the pump as-
sembly. Remove the lift pump with the capscrews 7. Fill the hydraulic system to the proper level. Re-
in place to steady the assembly. fer to Fill.
8. Engage the battery connectors and turn the key

Install Pump
to the ON position. Operate the hydraulic sys-
The following procedures outline the steps for in- tem several times to remove air from the system.
stalling the lift pump to the lift motor. This step Check for leaks and to ensure proper operation.
may be performed with the lift motor installed or
9. Install the operator compartment covers. Re-
removed from the lift truck.
move the blocks from the wheels and the DO
1. Apply antiseize lubricant to the splines of the lift NOT OPERATE tag from the control handle.
motor shaft.
22
1900 SRM 1189 Auxiliary Hydraulics
Auxiliary Hydraulics
Lift trucks are equipped with either a 24v or 36v aux- the control handle. Block the wheels to prevent
iliary pump and motor assembly which supplies hy- unexpected movement.
draulic pressure to the auxiliary hydraulics.
AUXILIARY PUMP AND MOTOR from the truck connector located on the right side
Remove handle to separate the battery connector from
WARNING 3. Remove the battery from the lift truck.
including eye protection and petroleum-resis- 4. Remove the operator compartment cover(s) to ac-
tant gloves when handling hydraulic oil. Thor- cess the lift pump and motor assembly. Open the
oughly wash oil from exposed areas of skin as drive unit compartment by removing the two cap-
soon as possible. screws securing the door closed and pull the door
open.
lieve pressure by opening the manual lowering NOTE: Certain lift truck models retain significant
valve before disassembling any part of the lift quantities of oil in the cylinders and hoses even when
pump or disconnecting any hydraulic hoses. the hydraulic tank is empty. Drain the hydraulic sys-
tem using the appropriate procedures for your model.
temperatures. Be careful when draining the 5. Drain the oil from the hydraulic system. See Oil
oil. Change.
NOTE: Remove the electric brake assembly from the

CAUTION top of the traction motor for easier access to the auxil-
The auxiliary motor power cable connections iary pump. Refer to Brake System 1800 SRM 1188.
must be installed on the proper terminals. Fail-
ure to install the power cables on the correct 6. Disconnect the auxiliary bearing sensor connec-
terminals will damage other electrical compo- tor from the main wiring harness.
nents.
NOTE: Tag and identify each cable removed for cor-
NOTE: Disposal of lubricants and fluids must meet rect reinstallation.
local environmental regulations.
7. Remove the auxiliary motor cable connections
The auxiliary pump and motor must be removed as a from the motor.
unit. The unit cannot be removed until the hydraulic
oil has been drained from the tank, and the battery 8. Loosen the three nuts securing the auxiliary
removed from the lift truck. pump and motor assembly bracket to the battery
compartment wall to allow greater access to the
1. Park the lift truck on a level surface and lower hydraulic fittings. See Figure 20.
the mast. Turn the key switch to the OFF po-
sition and attach a DO NOT OPERATE tag to
23
Auxiliary Hydraulics 1900 SRM 1189
Disassemble
1. Remove the two capscrews securing the auxiliary
pump to the motor. Remove the pump from the
motor. See Figure 21.
1. LIFT PUMP AND MOTOR ASSEMBLY

2. AUXILIARY UNIT MOUNTING BRACKET 1. COUPLING
3. MOUNTING HARDWARE 2. PRESSURE FITTING (90 )
4. BATTERY COMPARTMENT 3. PUMP HOUSING
5. ACCESS HOLE 4. SUPPLY FITTING (BARBED)
6. AUXILIARY PUMP AND MOTOR 5. MOUNTING CAPSCREWS
Figure 20. Auxiliary Pump and Motor Figure 21. Auxiliary Pump
9. Position a drip pan underneath the lift truck be- 2. Remove the auxiliary supply fitting.
low the auxiliary pump and motor assembly.
3. Remove the auxiliary pressure fitting.
NOTE: Access the hydraulic pump fittings through
the access hole in the battery compartment. Assemble
10. Disconnect the hydraulic hoses from the auxil- NOTE: Lubricate the pump splines with antiseize lu-
iary pump. Cap and plug the hoses and ports to bricant before assembling to the motor.
prevent contamination and leakage.
1. Position the auxiliary pump to the motor. Install
11. Remove the three nuts securing the auxiliary the two capscrews securing the auxiliary pump
pump and motor assembly to the frame. Slide to the motor. Tighten to 26 N•m (19 lbf ft).
the assembly off the studs, and guide the assem-
bly out of the lift truck. Place on a clean work 2. Install the auxiliary supply fitting. Tighten to
bench. 88 N•m (65 lbf ft).
12. If the any of the studs are damaged, drive them 3. Install the auxiliary pressure fitting. Tighten to
backward into the battery compartment using a 61 N•m (45 lbf ft).
hammer and a long punch. Collect the damaged
studs and discard.
24
Install 9. Test for proper operation and inspect for leaks:
a. Engage the battery connectors BEFORE in-

CAUTION stalling the battery, and turn the key switch
The auxiliary motor power cable connections to the ON position.
must be installed on the proper terminals. Fail-
ure to install the power cables on the correct b. Cycle the auxiliary functions several times to
terminals will damage other electrical compo- check for proper operation. Inspect for leaks.
nents.
c. Turn the key switch to the OFF position
1. Install new auxiliary pump and motor retaining again, and disconnect the battery connec-
studs as required into the battery compartment tors.
wall.
10. Install the electric brake assembly to the top of
2. Guide the auxiliary pump and motor assembly the traction motor, if removed. Refer to Brake
into the lift truck, and position the unit onto the System 1800 SRM 1188. Test the electric brake
three studs in the battery compartment wall. for proper operation.
3. Loosely install the nuts and washers onto the 11. Install the battery to the lift truck, and engage
studs. the battery connectors.
NOTE: Access the hydraulic pump fittings through 12. Install the operator compartment cover as re-
the access hole in the battery compartment. moved. Secure the drive unit compartment door
closed.
4. Remove the caps and plugs from the hoses and
ports. Install the hydraulic hoses to the pump 13. Remove the DO NOT OPERATE tag from the
fittings as removed. control handle. Remove the blocks from the
wheels.
NOTE: Refer to tags attached to cables during re-
moval for proper locations. FRONT SELECTOR VALVE
5. Reinstall the motor power cable connections to The front selector valve is located in the front frame
the proper terminals as removed. of the reach carriage assembly. It is secured to a
cover plate with three capscrews. A relay is mounted
6. Connect the auxiliary sensor bearing connector
below the front selector valve on the cover plate. The
to the main wiring harness as removed.
cover plate is mounted to the front of the front frame,
7. Tighten the auxiliary unit mounting hardware. just above the tilting frame. See Figure 22.
NOTE: Models with displacement-type cylinders The front selector valve is an electro-hydraulic valve
have significantly different filling procedures than block that directs hydraulic flow to the tilt and
models with piston-type cylinders. Fill the hydraulic sideshift cylinders (where applicable). The relay
system using the appropriate procedures for your controls the front selector valve by receiving signals
model to ensure proper operation. Refer to Oil through a wiring harness, which runs to the front
Change. frame inside the hose guard along side the hydraulic
hoses and activating the electro-hydraulic valves in
8. Fill the hydraulic system to the correct level with the selector valve. See Figure 23.
the proper oil. See Fill.
25
Auxiliary Hydraulics 1900 SRM 1189
1. TILT (DOWN)
2. TILT (UP)
3. SIDESHIFT (EXTEND RIGHT)
4. SIDESHIFT (EXTEND LEFT)
Figure 23. Front Selector Valve (From Rear)

1. FRONT SELECTOR VALVE
2. RELAY
3. BRACKET REAR SELECTOR VALVE
4. COVER
The rear selector valve is mounted inside the top of
Figure 22. Front Frame the rear frame with three capscrews. A cover mounts
to the front side of the valve and shields it from expo-
sure. The rear selector valve is an electro-hydraulic
valve block that directs hydraulic flow to the reach
cylinders and supplies the front frame (front selector
valve) hydraulics. See Figure 24.
26
1. REACH CYLINDER (LH) 6. LINE

2. REACH CYLINDER (RH) 7. HOSE GUARD
3. SUPPLY LINE 8. FRONT SELECTOR VALVE
4. RETURN LINE 9. REAR SELECTOR VALVE
5. LINE
Figure 24. Reach Carriage Hydraulics
27
Hydraulic Tank 1900 SRM 1189
Hydraulic Tank
REMOVE Properly drain the hydraulic system of your model to
avoid large spills. Refer to Oil Change.
WARNING 5. Drain the oil from the hydraulic system. See
Always wear the proper protective equipment Drain.
tant gloves when handling hydraulic oil. Thor- 6. Remove the battery from the lift truck for access
oughly wash oil from exposed areas of skin as to rear tank line hose fittings.
soon as possible.
NOTE: Secure hoses as high as possible, and cap or
Completely lower all mast components and re- plug hoses and fittings to minimize leakage.
valve before disassembling any part of the lift 7. Tag and disconnect the lower hose fitting clamps
pump or disconnecting any hydraulic hoses. from the bottom of the tank. These fittings and
hoses can be reached through the access slots in
The hydraulic oil is hot at normal operating the battery compartment. See Figure 25.
oil.
CAUTION
Certain components such as the oil filter assembly

and breather assembly may be disassembled from
the hydraulic tank without removing the tank. See
Disassemble. Perform only the steps necessary to
safely perform the required service.
1. Park the lift truck on a level surface and com-

ATE tag to the control handle. Block the wheels
to prevent unexpected movement.

3. Remove the battery from the lift truck for access 1. LIFT PUMP RETURN FITTING
to rear tank line hose fittings. 2. FILTER ASSEMBLY
3. LOW OIL SWITCH WIRING
4. Remove the operator compartment cover(s) to ac- 4. BREATHER ASSEMBLY
5. AUX RETURN FITTING
cess the hydraulic tank. Open the drive unit com- 6. FOAM PAD
partment by removing the two capscrews secur- 7. AUX SUPPLY FITTING
ing the door closed. 8. LIFT PUMP SUPPLY FITTING
9. DRAIN HOSE ASSEMBLY
NOTE: Models with displacement-type cylinders can
retain significant quantities of oil in the cylinders Figure 25. Tank (Profile)
and hoses even when the hydraulic tank is empty.
28
1900 SRM 1189 Hydraulic Tank
8. Disconnect the lift pump return hose from the oil necessary to completely disassemble the hydraulic
filter assembly. tank. Perform only the steps necessary to complete
the required service.
9. Disconnect the auxiliary pump return hose from
the top of the tank. If removing components with the hydraulic tank in-
stalled:
10. Disconnect the low oil indicator switch wiring
from the main wiring harness. 1. Position the lift truck on a level surface and lower
the mast. Turn the key switch to the OFF posi-
11. Remove the tank ground wire from the hydraulic tion and attach a DO NOT OPERATE tag to the
filter housing and breather housing by removing control handle. Block the wheels to prevent un-
the capscrews and washers. expected movement.
12. Lift the tank from the truck and position on its 2. Disconnect the battery power cable connector
side on a clean work area. from the truck connector located on the right side
DISASSEMBLE handle to separate the battery connector from
CAUTION
Clean around the various assemblies before re- Breather Assembly
moving to ensure dirt and debris do not fall
1. Remove the breather cap.
into the tank. If the tank becomes contami-
nated, it must be drained and cleaned to pre- 2. Remove the three screws securing the breather
vent damage to the hydraulic system. assembly to the tank.
NOTE: The various assemblies and the auxiliary 3. Remove the breather assembly screen and gas-
pump return fitting may be removed without drain- kets from the tank. See Figure 26.
ing or removing the hydraulic tank. It may not be
29
1. BREATHER CAP 6. LOWER GASKET

2. SCREW 7. HYDRAULIC TANK
3. CAP MOUNT 8. AUXILIARY RETURN
4. UPPER GASKET 9. HYDRAULIC FLUID LEVEL SWITCH
5. SCREEN ASSEMBLY
Figure 26. Breather Assembly
30
Filter Assembly
1. Remove the hose clamp and disconnect the lift
pump return hose, if attached. Cap and plug all
hoses and ports to prevent spills and contamina-
tion.
2. The lift pump return fitting may be removed at

this time, if necessary.
3. Remove the two capscrews securing the filter as-

sembly to the tank. See Figure 27.
4. Lift the assembly from the tank and position it

in a clean drip pan.
5. Recover and discard the oil seal.
A. TOP VIEW
B. SIDE VIEW
1. FILTER ASSEMBLY MOUNTING LOBES
2. FILTER CAP RETAINING CAPSCREWS
3. LIFT PUMP RETURN
4. FILTER CAP
5. FILTER ASSEMBLY MOUNTING FLANGE
6. OIL DIFFUSER
Figure 27. Filter Assembly
31
Low Oil Indicator Switch

1. Disconnect the low oil indicator switch wiring
from the main wiring harness.
2. Turn the plastic nut on top of the low oil indica-

tor switch counterclockwise to relax the rubber
stopper securing it to the tank.
3. Pull the low oil indicator switch out of the tank.

See Figure 28.
Tank Fittings
The tank must be drained and removed to remove the
two lower tank fittings. See Oil Change. However,
the auxiliary pump return, on top of the tank, may be
removed while the tank is full. The following instruc-
tions refer to removing fittings (one at a time) from a
tank which has been drained and removed from the
lift truck. Perform only the steps necessary to safely
complete the repair.
1. Loosen the jam nut of the fitting to be removed.
2. Turn the fitting counterclockwise until com-

pletely removed from the tank.
3. Inspect the threads of the tank to ensure they are

not damaged before replacing the fitting.
4. Repeat as necessary to remove the remaining fit-

tings.
CLEAN AND INSPECT

Clean the outside of the tank with mild soap solu-
tion sprayed on a cleaning cloth. Inspect the inside
for contamination and flush with clean oil if neces-
sary. Do not use cleaning solutions on the inside of
the tank.
Inspect the inside and outside of the tank for cracks,

leaks, holes, distortion, and abrasion. Inspect the
tank threaded fitting mounts for cracks and dam-
aged threads. Inspect the molded-in filter housing
area and breather area for bond separation, leaks, 1. CONNECTOR 4. PLUG
2. WIRING HARNESS 5. FLOAT
and damaged threads. Replace the tank as neces- 3. NUT 6. STEM
sary.
Figure 28. Low Oil Indicator Switch
32
ASSEMBLE Tank Fittings

Breather Assembly 1. Install the upper and lower hydraulic tank fit-
tings:
CAUTION a. Completely loosen the jam nut of each fitting

Be careful that dirt and debris do not fall into until it reaches the top of its threads.
the tank when removing the various assem-
blies. If the tank becomes contaminated, it b. Start each fitting into the tank by turning
must be drained and cleaned to prevent dam- clockwise by hand.
age to the hydraulic system. c. Turn each fitting all the way in (until the end
The breather assembly and the auxiliary pump re- of the threads reach the tank).
turn fitting may be removed without draining or re- d. Turn counterclockwise (if necessary) until fit-
moving the tank. tings are aligned as shown in Figure 26 and
1. Position the new breather assembly into the Figure 29.
tank.
CAUTION
DO NOT overtighten screws.
2. Install the three screws securing the breather to

the tank.
3. Install the breather cap.
Filter Assembly
1. Install the new seal to the assembly flange and
position the new filter assembly into the tank.
1. DRAIN HOSE ASSEMBLY
2. Install the two retaining capscrews. Tighten to 2. AUXILIARY PUMP SUPPLY
3. GROUND WIRE (ABOVE)
8 N•m (72 lbf in). 4. LIFT PUMP SUPPLY
5. LIFT PUMP RETURN (ABOVE)
3. Install lift pump return fitting, if removed. 6. HYDRAULIC TANK (BOTTOM)
4. Place hose clamp loosely over the end of the lift Figure 29. Tank (Bottom)
pump return hose, and install hose onto the filter
assembly return fitting. Position hose clamp and e. Hold each fitting in position while turning
tighten to 13 N•m (108 lbf in). the jam nut clockwise until it touches the
tank. Then, tighten an additional 1/8 th turn.
Low Oil Indicator Switch
INSTALL
1. Position the new low oil indicator switch into the
hole in the top of the tank. Push the rubber stop- 1. Position tank into lift truck and align on frame
per into the hole until the shoulder of the stopper and support bracket.
rests on the top of the tank.
NOTE: Hose clamps are properly installed centered
2. Turn the plastic nut on top of the switch clock- between the end of the hose and the barb end of the
wise while holding the top of the switch station- fitting inside the hose.
ary with a wrench. This will expand the rubber
stopper below the tank. Tighten until the switch 2. Place hose clamps loosely over ends of lower
is securely seated in the tank. hoses, and install hoses to bottom of tank as
removed. Position hose clamps and tighten to
3. Connect the switch wiring connector to the main 13 N•m (108 lbf in).
wiring harness.
33
Specifications 1900 SRM 1189
3. Place hose clamp loosely over end of auxiliary NOTE: Refer to Specifications for the proper hy-
pump return hose and install hose to top of tank draulic oil selection.
as removed. Position hose clamps and tighten to
13 N•m (108 lbf in). 6. Fill the hydraulic tank to the proper level with
new hydraulic oil. DO NOT overfill the hy-
4. Place hose clamps loosely over end of lift pump draulic tank.
return hose, and install hose to filter return fit-
ting. Position hose clamp and tighten to 13 N•m 7. Install the breather cap.
(108 lbf in).
8. Connect the battery and operate the lift pump for
5. Connect the switch wiring to the main wiring 1 to 2 minutes to purge air from the hydraulic
harness. system then recheck the hydraulic oil level.
Install the drain plug to the bottom of tank, if re- 9. Install the operator compartment covers as re-
moved. Turn clockwise until the head of the drain moved. Remove the blocks from the wheels.
plug touches the bottom of the tank, then tighten an
additional 1/8 th turn.
Specifications
Hydraulic Oil
Battery Specification
Compartment Tank Capacity Usable Oil
Size Standard Freezer
368 mm (14.5 in.) ISO VG 46 Exxon™ Univis 27.0 liter (7.13 qt) 19.6 liter (5.17 gal)
Anti-wear HVI 26
Anti-wear HVI 26
Anti-wear HVI 26
546 mm (21.5 in.) ISO VG 46 Exxon™ Univis 30.7 liter (8.12 gal) 23.8 liter (6.30 gal)
Anti-wear HVI 26
Relief Pressures
Component Specification
Main Relief Valve 20.68 ±0.70 MPa (3000 ±100 psi)
Auxiliary Relief Valve 17.23 ±0.35 MPa (2500 ±50 psi)
34
Troubleshooting
Low hydraulic pressure. Manual lowering valve is open or Close manual lowering valve or re-
damaged. place pump.
Relief valve damaged or out of ad- Check relief pressure. Adjust or re-
justment. place relief valve.
Pump is worn or damaged. Repair or install new pump.
Hydraulic system relief Restriction in the system. Remove restriction or install new
valve opens frequently. line.
Load beyond capacity. Handle only loads rated within the

working capacity of your model lift
truck. See the nameplate.
Relief valve needs adjustment or re- Adjust or replace relief valve.

lief valve is defective.
The pump noise is not nor- Oil in the hydraulic tank is low. Fill tank to correct level. Check for
mal. leaks.
Restriction in the inlet hose. Remove restriction or install new

line.
Inlet fitting or inlet hose clamp is Tighten fitting. Install new hoses.
loose. Remove air from system.
The bearings or gears are damaged. Repair or install new pump.
The housing is damaged. Repair or replace pump housing.
Loose capscrews holding the pump Tighten capscrews to specified

housing together. torque.
Loose capscrews in the pump mount- Tighten capscrews to specified

ing. torque.
Pump motor is damaged or worn. Check, repair, or install new parts as

required.
35
The pump has low output. The pump is worn. Check, repair, or install new parts as
required.
Seals or gaskets are damaged and Install new seals or gaskets.

cause leaks.
The fitting at the pump leaks. Tighten fittings. Install new parts as
necessary.
The pump has leaks. Fittings are loose or defective. Tighten fittings. Install new parts as
necessary.
Loose capscrews holding the pump Tighten capscrews to specified

housing together. torque.
Seals are defective. Install new seals or gaskets.
Pump housing is damaged. Repair or install new pump.
Slow auxiliary functions Oil in the hydraulic tank is low. Fill tank to correct level. Check for
leaks.
Auxiliary speeds require adjustment Adjust auxiliary speeds in the dash

using the dash display menus. display parameter setup procedures.
Auxiliary relief pressure is low. Check auxiliary relief pressure. Re-

place as necessary.
Auxiliary relief valve is damaged. Check auxiliary relief pressure and

auxiliary pump relief valve for con-
tamination or damage. Replace as
necessary.
Lift pump and motor oper- Oil in the hydraulic tank is low. Fill tank to correct level. Check for
ates but the mast will not leaks.
raise.
Relief valve is defective. Replace relief valve.
36
INDUSTRIAL BATTERY
ALL ELECTRIC LIFT TRUCKS
PART NO. 899648 2240 SRM 1

Industrial Battery Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Lead-Acid Batteries ........................................................................................................................................... 1
Specific Gravity .................................................................................................................................................. 2
Chemical Reaction in a Cell .............................................................................................................................. 2
Electrical Terms ................................................................................................................................................. 3
Battery Selection................................................................................................................................................ 4
Battery Voltage .................................................................................................................................................. 5
Battery as a Counterweight .............................................................................................................................. 5
Battery Ratings.................................................................................................................................................. 6
Kilowatt-Hours .............................................................................................................................................. 6
Battery Maintenance ......................................................................................................................................... 6
Safety Procedures .......................................................................................................................................... 6
Maintenance Records .................................................................................................................................... 7
New Battery ................................................................................................................................................... 7
Cleaning Battery ........................................................................................................................................... 7
Adding Water to Battery ............................................................................................................................... 9
Hydrometer .................................................................................................................................................... 10
Battery Temperature ..................................................................................................................................... 10
Charging Battery ........................................................................................................................................... 11
Types of Battery Charges.......................................................................................................................... 12
Methods of Charging ................................................................................................................................. 13
Troubleshooting Charger .......................................................................................................................... 14
Knowing When Battery Is Fully Charged ............................................................................................... 14
Where to Charge Batteries............................................................................................................................ 14
Equipment Needed .................................................................................................................................... 14
Battery Connectors........................................................................................................................................ 15
Battery Care .................................................................................................................................................. 15
All Electric Lift Trucks

2240 SRM 1 Lead-Acid Batteries
General
This section describes how to select and do the main- batteries have a nameplate attached to the face of the
tenance for large batteries used in electric lift trucks. battery cover. This nameplate communicates specific
This information is for service personnel that must information about the battery including the name of
do the maintenance on large lead-acid batteries. Bat- the battery manufacturer, battery type, serial num-
tery repair requires special training and equipment. ber, nominal voltage, capacity in amperes at the five-
Do not try to repair a battery unless you have the cor- hour rate, and service mass (with ballast if used to
rect tools, equipment, and experience. Most battery compensate for lack of battery mass).
repairs are done by a special repair service. Some
Lead-Acid Batteries
A lead-acid battery converts chemical energy into
electrical energy. See Figure 1. Chemical changes
within the battery give the electrical energy. When
the chemical reaction has occurred so the battery
will not give its rated voltage and current, the bat-
tery is discharged. A reverse chemical action must
occur so the battery can be used again. The batteries
described in this section can be charged again by an
electric voltage and current from an outside source
so there is a reverse chemical action. The lead-acid
chemicals store the electric energy until the electric
energy is needed to operate an electric device.
Figure 1. Lead-Acid Industrial Battery 1. VENT AND FILL 5. POSITIVE PLATE

CAP 6. EXPANSION MATS
A lead-acid battery is made from several lead-acid 2. POST 7. RETAINER
batteries called cells. Each cell has positive and 3. POST SEAL 8. SEPARATOR
negative plates with dielectric spacers between each 4. PLATE 9. NEGATIVE PLATE
plate. All of the plates are within a solution of PROTECTOR 10. BATTERY JAR
(SHIELD)
electrolyte. See Figure 2.
Figure 2. Battery Cell
1
Chemical Reaction in a Cell 2240 SRM 1
Specific Gravity
The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric
acid has a specific gravity of 1.835. Water has a specific gravity of 1.000. Electrolyte is 27 percent acid and 73
percent water and has a specific gravity of 1.275.
Chemical Reaction in a Cell

During the discharge of the cell, lead peroxide and
WARNING sponge lead mix with sulfuric acid to make lead sul-
NEVER pour water into concentrated acid. fate (PbSO 4) on both plates. See Figure 4. This ac-
Combining these liquids creates the rapid pro- tion decreases the voltage in the cell. When the sul-
duction of heat which can cause the water to furic acid is removed from the electrolyte, the specific
boil and the acid to erupt and splash out of the gravity of the electrolyte decreases. See Figure 5.
container. ALWAYS pour concentrated acid The potential difference of a discharged cell is ap-
into water when making a dilute solution of proximately 1.75 volts.
acid.
When a direct current is applied to a discharged cell,
In a fully-charged cell, the electrolyte has a specific the lead sulfate is changed into lead and sulfuric acid.
gravity of 1.270 to 1.130. NEVER discharge a battery The lead goes to the positive plate and stays as lead
below a specific gravity of 1.130. The battery can and to the negative plate and stays as lead peroxide.
have permanent damage if discharged below 1.130. See Figure 6. The concentration of sulfuric acid in
the electrolyte increases. The specific gravity of the
The cell generates a voltage (potential difference)
electrolyte increases as the concentration of sulfuric
when two different types of metal are in the elec-
acid increases. In a fully charged cell, the positive
trolyte. The two metals in a lead-acid cell are lead
plate again contains the lead peroxide and the nega-
peroxide (PbO 3) for positive plates, and sponge lead
tive plate contains the sponge lead.
(Pb) for negative plates. See Figure 3. A poten-
tial difference of approximately 2 volts per cell is
generated. The potential difference does not vary
according to the size of the cell.
Figure 4. Discharging Cell
Figure 3. Fully Charged Cell
2
2240 SRM 1 Electrical Terms
Figure 5. Discharged Cell Figure 6. Charging Cell
Electrical Terms
Voltage: Is an electromotive force (EMF) (also called maintenance-free battery, the amount of free-stand-
"potential difference") caused by the difference in ing electrolyte above the plates is much higher, en-
electric charge between two points. See Figure 7. suring enough electrolytes to keep the plates covered
during extended periods of use. Therefore, there is
Ampere: Is a measurement of electric current. no need to add water to a maintenance-free battery
during the course of its life.
Watt: Is a measure of electric power. The number
of watts is equal to the number of volts multiplied Flooded Cell: This is a lead acid battery that has
by the number of amperes. A kilowatt-hour is 1000 free flowing electrolyte fluid in each cell of the bat-
watts of electric power used in 1 hour. tery. The electrolyte is a mixture of sulfuric acid and
water.
Ohms: Is the measurement of electrical resistance.
Direct Current (DC): When the voltage between
Polarity: In a battery, the electric current is shown
the two terminals is always the same polarity, the
to flow from the positive terminal to the negative ter-
current flow and voltage are called Direct Current.
minal.
Alternating Current (AC): When the polarity of
Maintenance-Free Battery: The electrolyte level
voltage between two terminals is changing between
in the battery does not need to be checked during
positive and negative at a quick and constant rate,
the life of the battery. Maintenance-free batteries
the voltage is called Alternating Current.
use a calcium alloy of lead instead of an antimony
alloy, which reduces the amount of electrolysis. In a
3
Battery Selection 2240 SRM 1
Figure 7. Electrical Terms
Battery Selection
NOTE: The capacity of the battery can be found on
the lift truck’s Nameplate. See the Frame section or
Operating Manual for your lift truck for the loca-
tion of the Nameplate.
The battery needed to operate a period of 8 hours de-

pends on many conditions. Operations that require
the lift truck to go up ramps or require the use of ad-
ditional attachments increase the use of power from
the battery. Some work conditions require that more
than one battery must be used during a work period.
The number of 8-hour work periods per day is nor-
mally equal to the number of batteries needed. For
example, for three work periods, you need three bat-
teries. The capacity of the battery you need is found
as follows:
• The size of the lift truck and the attachments.
• The type of work. Heavy-duty operation or normal
operation for one 8-hour work period.
Lift trucks are available in various voltage ranges.

See Figure 8. The small "walkie" lift trucks are nor-
mally 12 or 24 volts. The larger sit-down rider lift
trucks are normally 24, 36, 48, 72, or 80 volts. The
number of cells in a lead-acid battery gives the bat-
tery voltage. See Figure 9. A fully charged cell has Figure 8. Cell Voltage
a potential difference of approximately 2 volts. See
Figure 8. This potential difference does not change
with size of the cell.
4
2240 SRM 1 Battery as a Counterweight
Figure 9. Multicell Battery for Electric Lift Truck
Battery Voltage
NOTE: The voltage of the battery can be found on the To reach the necessary battery voltage, the cells are
lift truck’s Nameplate. See the Frame section or Op- connected in series. For example:
erating Manual for your lift truck for the location 24 volts = 12-cell battery
of the Nameplate. 36 volts = 18-cell battery
48 volts = 24-cell battery
The battery voltage you need is found as follows: 72 volts = 36-cell battery
• Will your lift truck operate on more than one volt- 80 volts = 40-cell battery
age?
• If you have more than one lift truck in operation,
do the battery voltages need to be the same?
Battery as a Counterweight
On electric lift trucks that use the battery as part See the Frame or Periodic Maintenance service
of the counterweight, the battery is part of the ca- manual or Operating Manual for your lift truck
pacity of the lift truck to lift loads. The minimum model for the correct measurements for installing
weight of the battery is shown on the nameplate. If battery spacers.
the battery is not the minimum weight, the capacity
of the lift truck is reduced. If the battery used in the
lift truck is less than the size of the battery compart-
ment, blocks and spacers must be installed to hold
the battery in position.
5
Battery Maintenance 2240 SRM 1
Battery Ratings
The ratings of batteries are measured in ampere- KILOWATT-HOURS
hours and kilowatt-hours at a constant rate of dis-
charge. A rating of 6 hours is the standard. Ampere- A kilowatt is 1000 watts. A watt is a measure of
hours is the measurement of battery capacity. To electric power. The capacity in kilowatt-hours is the
calculate ampere-hours, multiply amperes by hours. total power generated by the battery. Watt-hours
See Table 1. For example, 5 amperes times 5 hours are measured by multiplying the voltage by ampere-
is 25 ampere-hours. You cannot change the potential hours. To measure the kilowatt-hours, divide the
difference of a cell. You can increase the ampere-hour watt-hours by 1000.
rating by increasing the number of plates in a cell,
volts × amperes × hours
or by installation of larger plates. The constant rate = kilowatt-hours or kWh
of discharging can be compared to a measurement of 1000
the battery capacity and ampere-hours. For exam-
ple, a battery with a rating of 600 ampere-hours dur- To calculate the kilowatt-hours for a battery that has
ing a work period of 6 hours will generate 100 am- a rating of 600 ampere-hours and a 48-volt system,
peres per hour for 6 hours. The same battery cannot use this formula:
generate 300 amperes for 2 hours. The heat gener-
ated within the battery will damage the battery. 48 volts × 600 amperes × hours
= 28.8 kWh
Table 1. Battery Capacity Terms 1000
Amperes × Hours = Ampere-Hours The watt-hours can be converted to kilowatt-hours

to indicate the battery needed for the operation. Al-
600 Ampere Hours = 100 Amperes for 6 Hours ways select the correct type of battery. Remember,
Volts × Amperes × Hours/1000 = Kilowatt-Hours a battery that has a rating of 300 ampere-hours will
(KWH) not do the same job as a battery that has a rating of
600 ampere-hours. Do not permit the specific gravity
to go below the limits shown in the manual.
Battery Maintenance
Battery maintenance must include the following match or a lighter. Do not smoke and do not cre-
items: ate sparks.
• A good battery charger
• A clean battery 3. Lift batteries correctly with a crane or equipment
• Keep the electrolyte at the correct level (see Fig- designed for the job. Always use a spreader bar
ure 13) designed and adjusted for the battery. Move bat-
• Keep a record of the battery teries with a lift truck or a conveyor or rollers de-
• An Equalization Charge once a month signed for that purpose. If the battery does not
have a cover, a rubber mat or insulating material
SAFETY PROCEDURES must be put over the top of the battery to prevent
a short circuit with other equipment. Make sure
1. Wear a rubber apron, gloves, boots, and goggles the lifting equipment has enough capacity for the
or a face shield when doing maintenance on bat- job. Do not use chain or wire rope slings.
teries.
4. Never put metal materials or tools on a battery.
2. Batteries generate hydrogen gas when they are
being charged. Keep open fire away from bat- 5. Disconnect battery from lift truck before doing
teries. Do not check the electrolyte level with a maintenance or repairs.
6
2240 SRM 1 Battery Maintenance
6. When maintenance on the battery or the battery vent caps must be in position when the battery
charger is required, disconnect both the AC and is in service. If the vent caps are not installed,
DC power. If the battery connectors must be re- the electrolyte will leak, causing corrosion on
placed, make sure the positive and negative ter- the battery case and in the battery compart-
minals and cables are kept separate and insu- ment.
lated from each other. Even a momentary short
circuit can cause an explosion and damage the Inspect a new battery for damage. Make sure the
battery. electrolyte in each of the cells is at the correct level.
Charge the battery for 6 hours or until the specific
7. Keep water readily available to flush spilled elec- gravity is correct. Make sure the battery is correctly
trolyte. Electrolyte in the eyes must be flushed installed in the lift truck. Use a spreader bar with
with water immediately, and then quickly get slings designed for the battery to lift and move the
medical attention. Special showers and eye battery. See Figure 10.
wash systems are required in areas where bat-
tery maintenance is done. Always complete the Battery Inspection Report and
the Daily Battery Report. See Figure 11 and Fig-
8. If electrolyte is spilled on a work surface or the ure 12.
floor, flush area with water, use a solution of soda
(sodium bicarbonate) to make the acid neutral. CLEANING BATTERY
9. Only trained persons are permitted to do main-
WARNING
tenance on batteries and battery chargers. Make
sure the regulations by government safety agen- Compressed air can move particles so that they
cies, government insurers, private insurers, and cause injury to the user or to other personnel.
private organizations are followed when doing Make sure that the path of the compressed air
maintenance on batteries. is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
MAINTENANCE RECORDS eyes.
NOTE: Follow the same sequence when you record Keep the battery compartment clean and dry. Use a
the cell number. Always begin the record with a pos- clean cloth to wash the battery with water. Dry with
itive cell. Follow a sequence so the last cell is always compressed air.
the cell for the negative cable.
CAUTION
Record the beginning ampere reading of the charger
each time the battery is charged. Any difference in Do not clean the battery with steam or hot wa-
the daily ampere reading can indicate a problem with ter. Do not use a high-pressure hose.
the battery or the charger. Remove any electrolyte from the battery compart-
ment to prevent corrosion. If there is electrolyte on
NEW BATTERY the top of the battery, apply a solution of bicarbonate
of soda. Mix a solution containing 0.5 kg of soda for
CAUTION every 4 liters of water. Apply the solution, then flush
Always use a spreader bar and slings that lift the solution from the battery with clean water. Wash
vertically on the lifting eyes of the battery. DO the battery and battery compartment as needed, but
NOT use a chain or sling without a spreader within a 6-month period as the maximum time.
bar or you will damage the battery case.
NOTE: If the top of the battery is wet from electrolyte,
Use the correct blocks or spacers to hold the check that the electrolyte level is not too high or the
battery in position in the lift truck. Make sure battery charger is not operating correctly.
the battery compartment is clean and dry. All
7

1. INSULATED SPREADER BAR
2. INSULATED STRAPS
Figure 10. Change the Battery
Figure 11. Battery Inspection Report
8
Figure 12. Daily Battery Report
ADDING WATER TO BATTERY vent plugs. The electrolyte can flow out of the cell
through the fill hole. The correct electrolyte level is
NOTE: Some batteries have sealed cells. These bat- shown in Figure 13.
teries do not need water added to the electrolyte.
Some water is lost from the electrolyte of each cell

during the charge and discharge cycle when the bat-
tery is in service. Check the electrolyte level daily.
Some service persons check some of the cells each day
so all cells are checked each week. If the level of the
electrolyte goes below the level of the top of the sep-
arators for the plates, the cell can be damaged.
KEEPING THE ELECTROLYTE LEVEL WITHIN

THE CORRECT LIMITS IS THE MOST IMPOR-
TANT ITEM OF BATTERY MAINTENANCE.
See the instructions from the manufacturer of your

battery for the operating level of the electrolyte. Al- 1. FILL TUBE
ways use distilled water. If you add distilled water, 2. BOTTOM OF FILL TUBE
wait 5 minutes before measuring the specific grav- 3. CELL COVER
4. MAXIMUM LEVEL OF ELECTROLYTE
ity with a hydrometer. DO NOT add water to a cell 5. MINIMUM LEVEL OF ELECTROLYTE
before or during the charging cycle; water must be 6. PLATE PROTECTOR
added after the charging cycle. If water is added be- 7. TOP OF SEPARATORS
fore the charging cycle, the electrolyte level may rise,
which will cause electrolyte to be forced out of the Figure 13. Electrolyte Level
9
HYDROMETER electrolyte level is low, the percent of sulfuric acid in

the electrolyte increases. When the electrolyte level
NOTE: Some batteries have sealed cells. The specific decreases by 3 mm (1/8 in.), the specific gravity mea-
gravity of the electrolyte cannot be checked on these surement can increase by 3 to 5 points.
batteries.
When you use the hydrometer, make sure there is
Use a hydrometer to measure the specific gravity of enough liquid in the barrel to let the float move freely.
the battery. Make sure there is enough electrolyte in The float must not touch the side, top, or bottom of
the battery cells. See Adding Water to Battery in this the barrel. See Figure 14 for the correct method of
section. A high level or low level of the electrolyte can reading the hydrometer.
change the specific gravity measurement. When the
1. HIGH FLOAT MEANS HIGH SPECIFIC GRAVITY. 3. CORRECT METHOD OF READING

2. LOW FLOAT MEANS LOW SPECIFIC GRAVITY. HYDROMETER: EYE LEVEL EVEN WITH
SURFACE OF ELECTROLYTE.
Figure 14. Reading Hydrometer
BATTERY TEMPERATURE is increased and make sure the charge or discharge

rate is not too high. A recommendation for a battery
The temperature of the electrolyte will change the in service is 8 hours of use (discharge), followed by 8
reading of the specific gravity. When the tempera- hours of charging, followed by 8 hours of cooling.
ture increases approximately 6 C (10 F), the specific
gravity will decrease by 0.003 point. See Figure 15 To charge the battery, a direct current must pass
for making specific gravity corrections. If the hy- through the cells in the opposite direction to the dis-
drometer you are using does not have a temperature charging current. The ampere-hours must be equal
correction, you will have to use a thermometer. Spe- to the discharging ampere-hours plus the energy lost
cial battery thermometers are available that will in- as heat. This additional amount of charge will vary
dicate the correction factor directly and add or sub- according to the battery and the temperature, but the
tract the correct number of points. See Figure 16. average additional charge is 12 percent. When the
battery is nearly charged, the final charging must be
NEVER charge a battery at a rate that will raise the at a low rate. A charging rate that is too high will
electrolyte temperature above 49 C (120 F). NEVER cause heating in the battery and a high loss of wa-
let a battery stay discharged for long periods. A tem- ter from the electrolyte. The charging of the battery
perature above this amount will damage the battery. must be done correctly, or the service life of the bat-
The cells in the center of the battery are normally at tery will be decreased.
the highest temperature. If the battery temperature
is too hot, make sure the ventilation of the battery
10
has sealed cells. The sealed batteries require a dif-

ferent charger. The electrolyte level or specific grav-
ity cannot be checked, and water cannot be added to
the electrolyte of these sealed batteries.
WARNING
The acid in the electrolyte can cause injury.
If electrolyte is spilled, use water to flush the
area. Make the acid neutral with a solution of
sodium bicarbonate.
Batteries generate explosive fumes when they

are being charged. Keep fire, sparks, and burn-
ing material away from the battery charger
area. Prevent sparks from the battery connec-
tors.
Charge batteries only in the special area for

Specific Electrolyte Correction Correct
charging batteries. When charging the bat-
Gravity Temp. Points Value
teries, keep the vent caps clean. The battery
Reading
charger area must have ventilation so that
1.210 31 C (88 F) +0.003 1.213 explosive fumes are removed. Open the hood
over the battery or remove the cover if the
1.210 27 C (81 F) +0.001 1.211
battery has a cover.
1.210 25 C (77 F) 0.000 1.210
Disconnect the battery when doing cleaning
1.210 18 C (64 F) 0.004 1.206 and maintenance.
+0.001 or 0.001 for each 2 degrees C from the
If the lift truck has been operated with a low
25-degree base value.
battery, check the contactors for welded con-
tacts before a charged battery is connected.
Figure 15. Specific Gravity Check The circuit will not reset and lift truck oper-
ation cannot be controlled if the contacts are
welded. To check the contacts, see the Contac-
tor inspection procedure for your lift truck.
CAUTION
Use only battery chargers approved by the bat-
tery manufacturer or dealer.
CAUTION
NEVER connect the battery charger plug to
the plug of the lift truck. You can damage the
traction control circuit. Make sure the charger
voltage is the correct voltage for the battery.
Correct use of the hydrometer (see Figure 14) and

proper operation of the battery charger is impor-
Figure 16. Battery Thermometer tant. Also see Figure 15. Follow the instructions of
the charger manufacturer. NEVER let the battery
CHARGING BATTERY discharge below the minimum value given by the
battery manufacturer. A fully charged battery will
NOTE: There can be one of two types of batteries. have a specific gravity of 1.265 to 1.310 at 25 C
One type has removable cell caps. The other type
11
(77 F). See Figure 15. NEVER charge a battery at a

rate that will raise the electrolyte temperature above
49 C (120 F). Never let a battery stay discharged for
long periods.
Types of Battery Charges

1. NORMAL CHARGE. This charge is usually
given to a battery that is discharged from nor-
mal operation. This is often an 8-hour charge.
Many customers charge the battery at regular
intervals that depend on use. This procedure will
keep the battery correctly charged if the battery
is not discharged below the limit. Always use a
hydrometer to check the battery if the battery is
charged at regular intervals. Frequent charging
of a battery that has a 2/3 or more charge can
decrease the life of the battery.
2. EQUALIZING CHARGE. This charge is at a low

rate and balances the charge in all the cells. The
equalizing charge is usually given approximately
once a month. It is a charge at a slow rate for 3
to 6 hours in addition to the regular charging cy-
cle. Do not give an equalizing charge more than
once a week. The most accurate specific gravity
measurements for a charged battery will be after
an equalizing charge. If the specific gravity dif-
ference is more than 0.020 between cells of the
battery after an equalizing charge, there can be
a damaged cell. Consult your battery dealer.
NOTE: Many customers have battery chargers that

can follow a program to automatically charge a
battery according to recommendations of the battery
manufacturer. Use the recommendations of the Figure 17. Specific Gravity Versus Percent
battery manufacturer for charging the battery. Discharge
The discharge limits and the limits for the specific

gravity before the battery must be charged again are
shown in Figure 17. NEVER discharge a battery be-
low the limits shown in Figure 18. Discharging a bat-
tery beyond the design limits will decrease the ser-
vice life of the battery.
NOTE: Sometimes the capacity of a battery is not

enough to complete a work period. Check for the fol-
lowing conditions:
• The battery is too small for the job.
• The battery is not fully charged.
• The battery charger is not operating correctly. Figure 18. Specific Gravity Compared to
• The battery is near the end of its service life. Charging Time
12
Methods of Charging a lower rate. Two resistors control the charging

rate. One resistor controls the charging rate at
There are three methods of charging a battery. the beginning of the cycle and a second resistor
reduces the charging rate when the voltage in the
1. GRADUAL CHARGE. This method uses a
cells reaches 2.37 volts. A relay automatically
solid-state automatic battery charger. The
controls the second resistor. The two-rate charg-
charging rate begins at 20 to 25 amps/100
ing cycle is shown in Figure 21.
amp-hours and decreases to less than 5 amps/100
amp-hours when the battery is 80 percent
charged. The charging current decreases when
the voltage across the cell increases during the
charging cycle shown in Figure 19. The increase
in the voltage from the charger is approximately
the same as the increase in the specific gravity
in the cells.
Figure 20. Modified Constant Voltage Charger
Figure 19. Specific Gravity Compared to

Charging Time
2. MODIFIED CONSTANT VOLTAGE. This

method uses a generator to generate a con-
stant voltage that is controlled by a resistor.
When the charging current decreases, the volt-
age across the resistor increases. The increasing
voltage across the resistor causes an increasing
voltage at the battery terminals. The charging
is similar to the gradual charge. The resistor Figure 21. Two-Rate Charging Cycle
must be correctly set, or the charging rate will
be wrong. The typical graphs for a modified NOTE: Many users have battery chargers that can
constant voltage charger are shown in Figure 20. follow a program to automatically charge a battery
according to recommendations of the battery man-
3. TWO-RATE CHARGE. This method also uses a ufacturer. Use the recommendations of the battery
high charging rate at the beginning followed by manufacturer for charging the battery.
13
Troubleshooting Charger either fully charged or in the final stage of charg-

ing.
Battery chargers normally operate automatically
without constant attention. It is necessary to make 3. The specific gravity reading is constant and
a periodic check that the charger is operating cor- within the limits of a charged battery. If the tem-
rectly. Check for the following conditions: perature increases after the battery is charged,
the specific gravity will decrease a small amount.
1. Battery temperature is too high. The temper-
ature in a battery will not normally rise more 4. Constant meter indications on the charger will
than 14 C (25 F) during an 8-hour charging pe- indicate the end of the charging cycle.
riod. Higher temperatures indicate the charging
rate needs adjustment. WHERE TO CHARGE BATTERIES
2. Continuous operation of the charger. Check the To increase the service life and reduce maintenance,
automatic controls on the charger. Check the a special area is needed for charging the batteries.
charging rate. A low charging rate can be the The following information is necessary for the design
problem. of this area:
• Location of power supply
3. Continuous operation of a charger at a high rate. • Ventilation; hydrogen gas comes from the batteries
Normally, the charging rate begins at a high rate during charging
and decreases as the battery becomes charged. • Drains for cleaning the batteries
If the rate does not decrease, the controls need • Type and size of the batteries
repair or adjustment. • Type of lift trucks
• Distances the lift trucks must travel for service
Knowing When Battery Is Fully Charged • Safety regulations and instructions
WARNING Equipment Needed

Always connect the positive cable to the pos- • A lifting device to remove the battery from the lift
itive terminal and connect the negative cable truck
to the negative terminal. Any other connection • Racks to hold the batteries during charging and
will cause injury and damage. storage (these racks must be made of wood or must
not be metal; metal racks that are covered with an
Always charge the battery at the end of the
insulating material can be used)
work period (shift). Never let the specific
• A battery charger that will charge your batteries
gravity decrease to a level less than the limits
• Tools for maintenance
shown in the manual.
• An area with a drain for cleaning batteries and bat-
Always de-energize the charger before you con- tery compartments
nect or disconnect the charger from the bat- • Distilled water
tery. • Air and water supplies for cleaning
• Maintenance records (see Figure 11 and Figure 12)
NEVER connect the battery charger plug to • A workbench
the plug of the lift truck. You can damage the • Spare parts and repair equipment
traction control circuit. Make sure the charger • Protective clothing and safety equipment for han-
voltage is the correct voltage for the battery. dling batteries
• Water source for washing eyes and preventing acid
1. During charging, the voltage increases slowly. burns
When the battery is fully charged, the voltage • Install a NO SMOKING sign in the service area
level is constant. • Keep the charger in a clean, dry area with good
ventilation
2. Remove a vent cap and look in the opening. If
you see bubbles in the electrolyte, the battery is
14
BATTERY CONNECTORS Legend for Figure 22
A special heavy-duty connector is used to connect the 1. SB CONNECTOR FOR BATTERY CABLES
battery to the electrical system of the lift truck. See 2. SB CONNECTOR FOR POWER CABLES TO
LIFT TRUCK
Figure 22 and Figure 23. When a connector has a 3. BRACKET
handle and is within the operator’s reach, the connec- 4. CONNECT AND DISCONNECT HANDLES
tor is also a safety device that can be used to quickly
disconnect the battery in an emergency. Most con- BATTERY CARE
nectors have a handle to connect the two halves of the
connector. The connector can be quickly disconnected 1. Keep batteries clean. Remove any spilled elec-
by pulling the handle upward. This action separates trolyte.
the two halves of the connector. The connector and
its attached handle must be kept in good repair so 2. DO NOT overcharge the battery. This action will
that it will function correctly. The battery connec- damage the battery.
tor must be disconnected when maintenance is done 3. DO NOT discharge the battery to less than the
on the lift truck that does not require electric power. recommendation. A deep discharge will shorten
The SBE, SBX, and FEM or DIN 12- volt battery con- the battery life.
nectors are shown in Figure 23.
4. Charge batteries in an area with good ventilation
to remove explosive gases and acid fumes.
5. Keep the electrolyte at the correct level. Check

the electrolyte level before and after charging the
battery. Use distilled water. Do not add acid.
6. Prevent batteries from freezing.
7. Keep batteries charged. A discharged battery in

storage will shorten the battery life.
8. Use a battery charger that is correct for the bat-

tery. A battery charger that is set for an am-
pere-hour rate that is too high will cause a high
internal heat and damage the battery. A low am-
pere-hour rate setting on a battery charger can
require a longer charging time but will not dam-
age the battery.
9. When batteries are moved, make sure a short

circuit does not occur. See the Safety Procedures
in Battery Maintenance of this section.
Figure 22. SB Battery Connector
15
NOTE: INDICATOR INSERT (2). GREEN - FOR BATTERY WITH CELL CAPS. GRAY - FOR BATTERY WITH
SEALED CELLS.
NOTE: CONNECTOR BODY COLOR [ANDERSON SBE CONNECTOR ONLY (1)]. GRAY - 36-VOLT BATTERY.
BLUE - 48-VOLT BATTERY. GREEN - 72-VOLT BATTERY. BLACK - 80-VOLT BATTERY.
A. ANDERSON SBE OR SBX CONNECTOR B. FEM OR DIN CONNECTOR
1. HALF OF CONNECTOR SET 9. +12 VOLT WIRE TO TRUCK (TRUCK HALF) OR
2. RED HOUSING FOR +12 VOLT "BATTERY TAP" TO BATTERY (BATTERY HALF)
3. LOCK SPRING (TIP OF CONTACT MUST LOCK 10. INDICATOR INSERT FOR BATTERY VOLTAGE
OVER TOP OF LOCK SPRING) AND BATTERY TYPE [ROTATE FOR CORRECT
4. BLACK CONNECTOR HOUSING (ASSEMBLED VOLTAGE IN WINDOW (12); COLOR SHOWS
ON RED HOUSING WITH SLOTS FOR LOCK BATTERY TYPE]
PINS ALIGNED AS SHOWN - NO WIRE OR 11. LOCK FOR ALL CABLE TERMINALS AND
CONTACT IN HOUSING) INDICATOR
5. SLOT FOR LOCK PIN 12. WINDOW SHOWING BATTERY VOLTAGE
6. CONTACT FOR CONNECTOR OF +12 VOLT 13. IN-LINE FUSE ASSEMBLY AND CONTACT
BATTERY TAP FOR +12 VOLT CONNECTOR (TRUCK HALF
7. KEY [RED (2) AND BLACK (4) CONNECTORS OF BATTERY CONNECTOR ONLY) (SBE/SBX
ALIGN ON KEY] CONTACT SHOWN)
8. LOCK PINS FOR +12 VOLT CONNECTOR (MUST
INSTALL FROM FRONT OF CONNECTOR
THROUGH RED AND BLACK CONNECTORS)
Figure 23. Detail of Battery Connectors With +12 Volt Tap
16
LIFT CYLINDERS
N30XMXDR3, N45XMXR3 [B264]; N30FR; N40-45FR;
N50FA; R30ES; N30XMH, N30XMH 2 [C210];
N25XMDR3, N30/40XMR3 [C470]; N50XMA3 [C471];
N30XMDR3, N45XMR3 [G138]; W30-40ZA [B453];
W20-30ZR [B455]; W25-30-40ZC [B454];
V30ZMD [D210/E210]; N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470]; N30ZDRS,
N35-40ZRS [A265]; W25-30ZA 2 [B495]
PART NO. 897446 4000 SRM 481

Lift Cylinders Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Lowering Control Valve ................................................................................................................................. 2
Main Cylinder Repair ........................................................................................................................................ 4
Disassemble ................................................................................................................................................... 4
Assemble ........................................................................................................................................................ 5
Free-Lift Cylinder Repair .................................................................................................................................. 6
Disassemble ................................................................................................................................................... 6
Assemble ........................................................................................................................................................ 6
N30XMXDR3, N45XMXR3 [B264];

N30FR; N40-45FR; N50FA; R30ES; N30XMH, N30XMH 2 [C210];
N25XMDR3, N30/40XMR3 [C470];
N50XMA3 [C471];
N30XMDR3, N45XMR3 [G138];
W30-40ZA [B453];
W20-30ZR [B455];
W25-30-40ZC [B454];
V30ZMD [D210/E210];
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265];
W25-30ZA 2 [B495]

General
This section has the description and repair in- W20-30ZR, N30-35ZDR, N35-40-45ZR, N30ZDRS,
structions for the lift cylinders used on the and N35-40ZRS masts. See the section Reach Car-
N30FR, N40/45FR, N50FA, R30ES, N30XMH, riages 4500 SRM 971 or Reach Carriages 4500
N30XMH 2, N25XMDR3, N30/40XMR3, N50XMA3, SRM 1196 for hydraulic cylinder repair instructions
N30XMDR3, N45XMR3, N30XMXDR3, N45XMXR3, for the reach carriages.
V30ZMD, W25-30ZA 2, W30-40ZA, W25-30-40ZC,
Description
The two-stage masts generally have two main lift oil raises the piston, the air within the upper part
cylinders. However, models W25/30ZA 2, W30/40ZA, of the cylinder is compressed into a chamber of the
and W25/30/40ZC lift trucks with 2 Stage LFL have piston rod. Any oil that is above the piston will be
only one main lift cylinder centered in the mast. The forced, under pressure, through a check valve back
three-stage FFL models have two main lift cylinders, under the piston.
as well as a shorter free-lift cylinder. See Figure 1.
Displacement cylinders operate by hydraulic oil
All of these lift cylinders are single-acting cylinders. entering the cylinder and displacing the rod. Seals
The hydraulic force is applied only in one direction. are located in the retainer, and the entire cylinder is
When hydraulic oil enters one end of the lift cylinder, filled with oil. This type of cylinder will have a bleed
the hydraulic force extends the piston rod. When the screw located near the top of the cylinder to remove
force is removed, the weight of the mast components air from the cylinder. The rod of displacement cylin-
and carriage causes the piston rod to retract. ders is almost the size of the inside of the shell. See
Figure 1.
These cylinders are also single-stage lift cylinders.
A single-stage lift cylinder has only one rod. See The design and repairs for these displacement cylin-
Figure 1. There are two types of single-stage cylinders are similar to the other lift cylinders in this sec-
ders used on these lift trucks. One type is the piston tion. A displacement cylinder does not have a piston
cylinder. The other type is a displacement cylinder. or piston seal. The rod diameter is almost the same
Trucks may be equipped with either piston or disas the inside diameter of the cylinder shell. There are
placement type cylinders or a combination of both. wear rings on the rod that are the bearings between
the rod and the walls of the cylinder. The wiper seal
Piston cylinders operate by hydraulic oil entering at the top of the cylinder is also the high-pressure
under the piston of the cylinder rod. Seals are used seal for these cylinders. See Figure 3.
in the piston to keep the oil from moving from under
the piston to the top of the piston. As the hydraulic
1
oil in the rod end of the lift cylinder. The hydraulic oil
transfers through the check valve to the piston end of
the free-lift cylinder. This action prevents hydraulic
damage to the single lip seal and the wiper ring. See
Figure 3.
Lift cylinders and other hydraulic parts can have

some internal leaks. Internal leakage will increase
as the temperature of the hydraulic oil increases.
The internal leak rate of the hydraulic system is
checked periodically. See the sections Periodic
Maintenance 8000 SRM 1197, Periodic Main-
tenance 8000 SRM 970, Periodic Maintenance
8000 SRM 1379, or Periodic Maintenance 8000
SRM 1027, Maintenance Schedule for your lift
truck and Mast, Repair 4000 SRM 482 for test
procedures and leakage rate specifications.
LOWERING CONTROL VALVE

A lowering control valve (also called a velocity fuse)
is installed in the inlet port of each lift cylinder. See
Figure 2. It permits easy entry of hydraulic oil into
the cylinder, but gives a restriction when the rod is
retracted. This restriction limits the speed that a
load on the forks can be lowered.
There are two types of lowering control valves: low-

pressure designs and high-pressure designs. Both
types have the same function and similar operation.
The most common type of valve has a design that
has good operation using large flows and lower pres-
sures. Some lift trucks have a lift system design us-
ing higher pressures and a lower flow. These systems
need a different type of lowering control valve.
The most common type of lowering control valve (low

1. MAIN CYLINDER
2. FREE-LIFT CYLINDER pressure) uses these parts: (1) a special fitting for
3. LOWERING CONTROL VALVE the valve body, (2) a spring, and (3) a special washer.
There is a variation in the shapes of the special
Figure 1. Lift Cylinders washer. Different lift cylinders use different shapes
of special washers. The volume of the hydraulic oil
Spacers are used in some cylinders to limit the stroke flowing through the inlet port controls the shape
of the piston rod. Worn spacers must be replaced of the special washer. A typical shape of a special
with the same-size spacer. washer is shown in Figure 2. When the piston rod
During operation, some hydraulic oil will leak past is lowered, the oil flow pushes against the special
the piston area to the rod end of the lift cylinder. washer and spring. When the oil flow reaches the
Small leaks are permitted if the internal leak rate limit, the special washer is moved against the spe-
of the hydraulic system is not greater than the spec- cial fitting. The oil then flows only through the hole
ification. An internal check valve is installed in the in the center of the special washer. This restriction
piston of the main-lift cylinders. When the piston rod permits the piston rod to lower only at a maximum
extends, the pressure increases more quickly on any controlled speed.
2
The other type of lowering control valve (high pres- During lowering, oil from the lift cylinder moves the
sure) uses these basic parts: (1) valve body, (2) orifice sleeve. The orifice sleeve moves away from the
spring, (3) washer, (4) cylinder, (5) orifice sleeve, larger inner diameter area of the bore in the valve
(6) plunger, and (7) main sleeve. The orifice sleeve body. This movement makes a restriction to the oil
position is controlled completely by oil flow. The flow. As the pressure increases, the plunger begins
plunger position is controlled by oil pressure and to move against the spring. The movement begins
spring tension. During lifting, oil entering the lift to close the openings of the large holes in the main
cylinder goes through the center of the main sleeve sleeve. Additional pressure will push the plunger
to the large holes. The oil flow through the plunger against the main sleeve to close the large holes com-
and bore moves the orifice sleeve to the end of the pletely. All the oil must then go through the small
plunger. The flange of the orifice sleeve is then holes to the center of the main sleeve. This restric-
aligned with the large part of the bore in the body. tion permits the piston rod to lower only at a maxi-
This alignment lets the oil flow past the orifice sleeve mum controlled speed.
to the cylinder.
1. SPECIAL FITTING OR VALVE BODY 5. ORIFICE SLEEVE

2. SPRING 6. PLUNGER
3. WASHER 7. MAIN SLEEVE
4. CYLINDER
Figure 2. Lowering Control Valves
3
Main Cylinder Repair 4000 SRM 481
Main Cylinder Repair

DISASSEMBLE
NOTE: To disassemble and repair a cylinder, the
cylinder must be removed from the mast assembly.
See the section Mast, Repair 4000 SRM 482 to
remove the cylinders from the mast assembly.
WARNING
Use slings and a crane to handle and disassem-
ble the lift cylinders of most lift trucks. Make
sure that the crane and slings can lift the load.
CAUTION
Carefully disassemble and assemble the lift
cylinders in a clean area so that the rods and
sliding surfaces are not damaged.
NOTE: Make a note of the position of the replaceable

parts so that they can be installed in the correct po-
sitions during assembly.
Disassemble the cylinder as follows: See Figure 3.
1. Clean the outside of the cylinder before begin-

ning disassembly to prevent system damage from
dirt.
2. Loosen the retainer using a spanner wrench. Re-

move the retainer from the shell.
3. Remove the cap from the inlet and carefully slide

the piston rod assembly from the shell. Use drain
pans for the hydraulic oil.
4. Remove the retainer from the piston rod. Re-

move and discard the wiper ring, O-rings, seals,
and wear rings.
5. Remove the internal check valve and, if neces-

sary, the floating piston.
6. Remove the lowering control valve.

A. NONCUSHIONED B. CUSHIONED
7. Clean all the parts. Check the sliding surfaces
for damage. Repair or replace any damaged 1. ROD 10. SNAP RING
parts. 2. RETAINER 11. FLOATING PISTON
3. WIPER RING 12. SPACER
4. SEAL 13. BACKUP RING
8. Discard all seals, O-rings, wipers, and wear 5. O-RING 14. WEAR RING
rings. 6. SHELL 15. LOWERING
7. CHECK VALVE CONTROL VALVE
8. WASHER (ALL CYLINDERS)
9. SHIM
Figure 3. Main-Lift Piston Cylinder
4
4000 SRM 481 Main Cylinder Repair
NOTE: Inspect the piston rod surface for scratches. • Use new O-rings, seals, and bearings from the kit.
Check the area of the rod where the wiper ring con- Apply appropriate lubricant during assembly.
tacts the rod. If scratches are found, use a piece • Make sure the seal assemblies are installed with
of crocus cloth to polish the rod. DO NOT polish the "open" end toward the base of the lift cylinder.
lengthwise; use a rotary motion. After the scratch • The spacer controls the maximum stroke of the pis-
or scratches have been removed, use another piece of ton rod assembly. If a new spacer is necessary,
fine crocus cloth with oil on it to polish the rod. Use make sure the same-size spacer is installed.
a rotary motion to polish the rod until the finish is
free of scratches and has a fine finish. Clean the rod 1. Install the internal check valve. See Figure 3.
thoroughly to remove any metal shavings, before as- Install the floating piston on applicable units.
sembly. Make sure the arrow on the internal check valve
is toward the base of the piston.
ASSEMBLE
2. Install the seal and bearing (and spacer if
NOTE: equipped) on the piston rod. Use shim material
• Use a seal kit to replace the seals. Use the instal- and a clamp as a guide to move the seal past the
lation sleeves included in the kit. See Figure 4. threads of the shell.
• Lubricate all internal parts of the lift cylinder with
hydraulic oil during assembly.
1. EXTERNAL INSTALLATION SLEEVE 5. PISTON ROD

2. SEAL 6. CYLINDER SHELL
3. WEAR RING 7. INTERNAL INSTALLATION SLEEVE
4. BACKUP RING
Figure 4. Seal Installation Sleeves
5
Free-Lift Cylinder Repair 4000 SRM 481
6. Engage the threads and tighten the retainer in

CAUTION the shell to 340 to 410 N•m (251 to 302 lbf ft).
A difficult and important step in assembling Use the correct spanner wrench. DO NOT hit
cylinders is the correct installation of the seals the retainer with a hammer and driver.
without damage. Most cylinder maintenance is
caused by seal leakage. Special tools are avail-
CAUTION
able in the seal kit for correct installation of
the seals. Wrong installation of the special washer and
spring can make the load lower too fast.
3. Carefully push the piston and piston rod into the
shell. Release the clamp on the seal when the 7. Install the lowering control valve. Make sure the
seal travels past the threads of the shell. special washer and the spring are installed cor-
rectly. A wrong installation can cause the load to
4. Install the seals, O-rings, and wiper ring in the lower too fast.
retainer. If the wiper ring has a spring backup
ring, the spring must be toward the base of the 8. See the section Mast, Repair 4000 SRM 482 for
lift cylinder. cylinder installation in the mast assembly.
5. Carefully install the retainer on the piston rod.
Free-Lift Cylinder Repair

DISASSEMBLE 5. Clean all the parts. Check the sliding surfaces
for damage. Repair or replace any damaged
NOTE: To disassemble and repair a cylinder, the parts.
cylinder must be removed from the mast assembly.
See the section Mast, Repair 4000 SRM 482 to ASSEMBLE
remove the cylinder from the mast assembly.
NOTE: Inspect the piston rod surface for scratches.
Check the area of the rod where the wiper ring con-
WARNING
tacts the rod. If scratches are found, use a piece
Use slings and a crane to handle and disassem- of crocus cloth to polish the rod. DO NOT polish
ble the lift cylinders of most lift trucks. Make lengthwise; use a rotary motion. After the scratch
sure that the crane and slings can lift the load or scratches have been removed, use another piece
correctly. of fine crocus cloth with oil on it to polish the rod.
Use a rotary motion to polish the rod until the finish
CAUTION is free of scratches and has a fine finish. Clean rod
Carefully disassemble and assemble the lift thoroughly to remove any metal shavings, before as-
cylinders in a clean area so that the piston sembly.
rods and sliding surfaces are not damaged.
NOTE:
1. Loosen the retainer with a spanner. Remove the • Use a seal kit to replace the seals. Use the instal-
retainer from the shell. See Figure 5. lation sleeves included in the kit. See Figure 4.
• Lubricate all internal parts of the lift cylinder with
2. Remove the protective cap from the inlet and hydraulic oil during assembly.
slide the rod and piston assembly from the shell. • Use new O-rings, seals, and bearings. Apply appro-
Drain the hydraulic oil into a container. priate lubricant (hydraulic oil) during assembly.
• Make sure the seal assemblies are installed with
3. Remove the retainer from the piston rod. Re- the "open" end toward the base of the lift cylinder.
move and discard all O-rings, seals, and bear-
ings.
4. Remove the internal check valve plugs and balls

from the base of the rod.
6
4000 SRM 481 Free-Lift Cylinder Repair
CAUTION
A difficult and important step in assembling
lift cylinders is the correct installation of the
seals. Most lift cylinder maintenance is caused
by seal leaks. Special installation sleeves come
in the seal kits.
1. Install the internal check valve, if installed. See

Figure 5. Make sure the arrow on the internal
check valve is toward the base of the piston.
2. Install the wear ring, single lip seal, and backup

ring onto the piston assembly. If a spacer is used,
install it. Use shim material and a clamp as a
guide to move the seal over the threads of the
shell.
3. Carefully push the piston and rod assembly into

the shell. Release the clamp on the seal when the
seal travels past the threads of the shell.
4. Install the seal, O-ring, wear ring, and wiper ring

in the retainer. If the wiper ring has a spring for a
backup ring, the spring must be toward the base
of the lift cylinder.
5. Carefully install the retainer on the piston rod.
6. Engage the threads and tighten the retainer

in the shell to the proper torque. Refer to Ca-
pacities and Specifications 8000 SRM 1198,
Capacities and Specifications 8000 SRM
1028, Capacities and Specifications 8000
SRM 1380, or Capacities and Specifications
8000 SRM 972 for your truck model. Use the cor-
rect spanner wrench. DO NOT hit the retainer
with a hammer and driver.
CAUTION
1. ROD 8. SHELL Wrong installation of the special washer and
2. RETAINER 9. CHAIN ANCHOR spring can make the load lower too fast.
3. WIPER RING 10. LOWERING
4. SEAL CONTROL VALVE 7. Install the lowering control valve. Make sure the
5. O-RING (ALL CYLINDERS) special washer and the spring are installed cor-
6. BACKUP RING 11. STEEL BALL rectly. A wrong installation can cause the load to
7. BLEED SCREW 12. PLUG lower too fast.
AND SEAL 13. WEAR PLUG
8. See the section Mast, Repair 4000 SRM 482 for
Figure 5. Free-Lift Displacement Cylinders
cylinder installation in the mast assembly.
7
Troubleshooting
No movement of lift cylin- No oil or not enough oil supply to lift Check oil level and add oil as needed.
ders. cylinder.
Hydraulic leaks, damaged hydraulic Repair hydraulic leaks. Replace

pump, or damaged hydraulic pump pump or pump drive. Replace check
drive. valve. Reset relief valve to correct
setting.
Relief valve setting wrong or check Adjust relief valve setting. Replace
valve damaged. check valve.
Slow action of the lift cylin- Not enough oil supply to the lift Check oil level and add oil as needed.
ders. cylinder.
Bad cylinder seal. Check for internal Replace cylinder seals.

leaks. Install a gate valve in the hy-
draulic line. Raise the mast. Close
the gate valve. See if the mast or car-
riage slowly lowers because of an in-
ternal leak.
Low relief valve setting. Adjust relief valve to correct setting.
Rough movement of the mast Air in the hydraulic system. Remove air from hydraulic system.
assembly.
Bent piston rod, or cylinder shell is Replace cylinders.

damaged.
Mast assembly is damaged or not in Repair damage or realign mast as-

alignment. sembly.
8
MAST
DESCRIPTION
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590945 4000 SRM 1194

Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 3
Mast Weldments ................................................................................................................................................ 4
Reach Carriage Assembly.................................................................................................................................. 4
Three-Stage Mast............................................................................................................................................... 6
Description ..................................................................................................................................................... 6
Operation ....................................................................................................................................................... 7
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];

General
This section contains the description and operation The mast assemblies include the following parts:
for three-stage mast assemblies. • Outer Mast Weldment
• Intermediate Mast Weldment
Masts can be identified by unit codes and serial num- • Inner Mast Weldment
bers which are stamped on the outside of the right- • Main Lift Cylinders
side, outer weldment of the mast. • Free-Lift Cylinder
• Load Rollers
The repair procedures for the mast assemblies and
• Lift Chains and Sheaves
their components are outlined in the sections Mast,
• Sheave Support
Repair 4000 SRM 1195, Lift Cylinders 4000 SRM
• Hydraulic Tubing, Hoses, and Sheaves
481, and Reach Carriages 4500 SRM 1196.
• Wiring Harness for the Reach Carriage
A mast is used to raise a load vertically. Hydraulic
cylinders are installed vertically on the masts. The
cylinders raise and lower the vertical frames or weld-
ments and the reach carriage assembly. Mast assem-
blies used on these model lift trucks are three-stage
masts. See Figure 1.
1
Figure 1. Mast
2
4000 SRM 1194 Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast

WARNING WARNING
All chains, ropes, and lifting equipment MUST Perform the following steps from the side of the
be fully examined by qualified personnel at mast using a ladder. Never stand under the car-
least once a year or more at frequent intervals riage until safety chains are installed.
according to the local conditions of use.
1. Remove forks from carriage if possible.
WARNING 2. Raise mast to align the crossmembers of the in-

Mast parts are heavy and may shift. Distances termediate mast weldment with a crossmember
between parts are small. Serious injury can re- on outer weldment.
sult if part of the body is hit by parts of the mast
or the carriage. 3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum
• Never put any part of the body into or under size, around crossmembers of inner and outer
the mast or carriage unless all parts are com- weldment. Secure it in place. See Figure 2.
pletely lowered or a safety chain is installed. 4. Lower mast until safety chain stops mast. Lower
Also make sure the power is off and the key the mast until all components of the mast that
is removed. Attach a DO NOT OPERATE tag can move are completely lowered. Make sure
to the control handle. there is no movement of mast.
• DO NOT make repairs or adjustments unless
you have been properly trained and autho- 5. Turn key switch to the OFF position, disconnect
rized to do so. Repairs and adjustments must the battery, and attach a DO NOT OPERATE
be performed by trained service technicians. tag to the control handle.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• Move the truck to a safe location with room to
raise the mast if necessary. Block the wheels
of the truck to prevent movement.
The forks may be difficult to see when the mast is

raised. Be careful not to hit your head when working
around raised forks. Also, be careful not to trip over
forks on or near the floor. If possible, remove forks
from carriage before safety chaining the mast.
WHEN WORKING NEAR THE MAST, ALWAYS:

• Lower the mast and carriage completely. Make
sure there is no movement in the mast. Make sure
all parts of the mast that can move are fully low-
ered.
1. OUTER MAST WELDMENT

OR 2. INNER MAST LOWER CROSSMEMBER
3. SAFETY CHAIN
• If the mast must be in a raised position for re- 4. CARRIAGE CROSSMEMEBER
pairs, install a safety chain around the top or mid-
Figure 2. Safety Chain the Mast
dle crossmember of the outer weldment and the
crossmember of the inner weldment to secure the
mast.
3
Reach Carriage Assembly 4000 SRM 1194
6. Wrap a second safety chain, 9.5 mm (3/8 in.) min- NOTE: The mast operator guard MUST be removed
imum size, around crossmembers of intermedi- to install safety chain. Remove safety chain and in-
ate and outer weldments. Secure it in place as stall guard AFTER repairs are complete.
an additional precaution.
Mast Weldments
The main vertical frames of a mast assembly are are installed between the moving parts. Wear strips
called weldments. These weldments are assembled are used on these models. The side rollers and
so they telescope. The inner mast weldment moves load rollers, with the wear plugs, travel along the
inside the intermediate mast weldment. The car- channels within the weldments. The thrust rollers
riage moves inside the inner mast weldment. The and wear strips travel on the outside edges of the
outer mast weldment is attached to the lift truck weldments.
frame. The outer mast weldment is a support for the
overhead guard. The three-stage masts have two main cylinders that
raise the intermediate weldment, with lift chains
When the telescopic weldments and the carriage raising the inner mast weldment, free-lift cylinder,
lift a load, forces are put on the mast assembly. and carriage. The free-lift cylinder raises lift chains
To decrease friction caused by these forces, load that lift the carriage.
rollers, wear plugs, side rollers, and thrust rollers
Reach Carriage Assembly

Reach carriages are used to extend the forks of the of each scissor arm assembly allow the linkage to ex-
carriage beyond the ends of the base arms. There tend and retract smoothly. The forks and load back-
are two types of reach carriages. There is a sin- rest are mounted to the fork carriage which attaches
gle-reach carriage with one set of scissor arms. The to the top of the front frame assembly by pins. The
other carriage has two sets of scissor arms for dou- forks hang on the fork carriage and are held in posi-
ble reach. See Figure 3. The rear and front frame tion with lock pins. See Figure 4. A tilt cylinder tilts
assemblies are connected by a scissor linkage. The the forks by pushing the bottom of the front frame
top of the scissor arm weldment is fastened to the out. Each carriage is also available with the optional
top of the rear frame by pins located within the rear sideshift function.
frame assembly. The top of each scissor arm at the
front frame is fastened by pins located at the top of NOTE: The reach assembly can be removed from the
the front frame assembly. On double reach units, mast assembly with the load backrest and forks at-
the ends of each set of scissor arms and scissor arm tached. The three-stage mast assemblies can also be
weldments are fastened together by studs with bush- removed with the reach assembly installed. Perform
ings. The bushings protect the studs from wear as only those procedures necessary for repair. See the
the arms pivot. Large bearings at the center pivot section Reach Carriages 4500 SRM 1196.
4
4000 SRM 1194 Reach Carriage Assembly
A. SINGLE-REACH CARRIAGE B. DOUBLE-REACH CARRIAGE

1. FORK CARRIAGE 6. FRONT FRAME ASSEMBLY
2. TILT CYLINDER 7. FRONT SELECTOR VALVE
3. REAR FRAME ASSEMBLY 8. VALVE COVER PLATE
4. REAR SELECTOR VALVE 9. HOSE AND WIRING GUIDE
5. SCISSOR ARMS 10. REACH CYLINDER
Figure 3. Reach Carriage Assembly (Major Components)

Legend for Figure 4
1. FORK 4. SPRING
2. KNOB 5. PIN
3. LOCK PIN
Figure 4. Forks and Lock Pin Assembly
5
Three-Stage Mast 4000 SRM 1194
Three-Stage Mast
DESCRIPTION
The three-stage mast assembly consists of three pri-
mary mast weldments. There is an outer, an inter-
mediate, and an inner mast weldment. The weld-
ments are telescopic and have load rollers and wear
strips or wear plug arrangements. The three-stage
masts have three hydraulic cylinders: the free-lift
cylinder and two main cylinders. See Figure 5. They
are all single-stage lift cylinders. The free-lift cylin-
der fastens to the inner mast weldment and controls
the movement of the carriage. The free-lift chains
transfer force from the free-lift cylinder to the car-
riage. The two main cylinders fasten to the inter-
mediate mast weldment and control the movement
of the intermediate mast. The two outer lift chains
transfer the force from the main cylinders to the in-
ner mast weldment.
Movement of the carriage that does not cause an in-

crease in the height of the mast assembly is free-lift.
The three-stage mast has free-lift. The free-lift cylin-
der raises the carriage to the top of the mast as-
sembly before the intermediate and inner mast weld-
ments move.
The free-lift cylinder is positioned vertically between

the channels of the inner mast weldment. A free-lift
sheave support is positioned on the rod of the free-lift
cylinder and the lower end is locked in position on
the bottom crossmember of the frame. The free-lift
sheave support also has sheaves for the hoist chain,
hydraulic hose, and electrical cable.
The free-lift chain fastens to a chain anchor on the

inner mast crossmember or to a bracket welded to
the rear of the free-lift cylinder (depending on mast
model). The chain then goes through the sheave sup-
port and fastens to the rear frame of the reach assem-
bly. When the free-lift cylinder rod extends, the reach
assembly rises at two times the speed of the rod.
1. MAIN LIFT CYLINDERS

2. FREE-LIFT CYLINDER
3. TO TRUCK CONTROL VALVE
4. FLOW REGULATOR HOUSING
5. FREE-LIFT HOSE SHEAVE
6. HYDRAULIC TUBE (MAIN LIFT)
7. HYDRAULIC HOSE (MAIN LIFT)
Figure 5. Mast Hydraulic Connections
6
4000 SRM 1194 Three-Stage Mast
The two main cylinders control the movement of the at two times the speed of the free-lift cylinder rod
intermediate mast weldment. The cylinders are in- speed. When the free-lift cylinder reaches the end of
stalled vertically behind the channels of the outer its stroke, the main cylinders begin to extend. The
mast weldments. The cylinders fasten to the outer main cylinders raise the intermediate mast weld-
mast weldment at the back of each channel. The ment. Since the hoist chains go over the sheaves
base of each cylinder is located by a pin installed of the intermediate mast weldment, the inner mast
in the lower crossmember bracket of the outer mast weldment also raises. The inner mast weldment
weldment. Removable supports for the main cylin- rises at two times the speed of the intermediate
der are bolted to the chain anchor weldments or the mast weldment.
crossmember of the outer mast weldments (depend-
ing on mast model. The rods of each main cylinder The three main cylinders are connected hydraulically
are fastened to the top crossmember of the interme- in parallel. When the LIFT function begins, the pres-
diate mast weldment with snap rings. sure of the oil is increased in all the main cylinders.
The free-lift cylinder raises the weight of the car-
The lift chains fasten to the anchors near the top riage and the load on the forks. The main cylinders
rear of the outer mast weldment. The chains go must raise the carriage, the load on the forks, plus
over the sheaves at the top of the intermediate mast the weight of the intermediate and inner mast weld-
weldment. The other end of the chains fasten to ments. It takes less force to extend the rod of the
the chain anchors at the bottom of the inner mast free-lift cylinder, so this rod and the carriage will
weldment. When the main cylinders raise the in- move first.
termediate mast weldment, the chains raise the
inner mast weldment, the free-lift cylinder, and the When the LOWER function begins, the oil from the
carriage. main cylinders returns to the hydraulic tank. The
main cylinders lower first since they have a greater
OPERATION load. When the main cylinder rods have fully re-
tracted, the free-lift rod retracts. Each cylinder has
The three-stage mast operates in two phases. See a lowering control valve installed in its base. These
Figure 6. First, the free-lift cylinder extends and lowering control valves control the lowering speed of
lifts the carriage to the top of the mast assembly a load if a hydraulic line breaks.
7
Three-Stage Mast 4000 SRM 1194
A. LOWERED POSITION B. RAISED POSITION

1. OUTER WELDMENT 6. FREE-LIFT CYLINDER
2. MAIN LIFT CYLINDERS (2) 7. INNER WELDMENT
3. MAIN LIFT CHAINS (2) 8. FREE-LIFT CHAIN (2)
4. INTERMEDIATE WELDMENT 9. CARRIAGE
5. CHAIN SHEAVE (2)
Figure 6. Three-Stage Mast Assembly Operation
8
MAST
REPAIR
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590956 4000 SRM 1195

Mast Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Load Backrest .................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 2
Forks ................................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 3
Checks ............................................................................................................................................................ 4
Sheaves............................................................................................................................................................... 4
Hydraulic Oil ................................................................................................................................................. 9
Drain .......................................................................................................................................................... 9
Cylinder Identification .............................................................................................................................. 10
Fill .............................................................................................................................................................. 12
Remove ........................................................................................................................................................... 14
Install ............................................................................................................................................................. 15
Load Rollers........................................................................................................................................................ 16
Mast................................................................................................................................................................ 16
Reach Assembly ............................................................................................................................................. 18
Load Rollers ............................................................................................................................................... 18
Side Rollers ................................................................................................................................................ 18
Mast .................................................................................................................................................................... 19
Remove ........................................................................................................................................................... 19
Disassemble ................................................................................................................................................... 20
Assemble ........................................................................................................................................................ 23
Install ............................................................................................................................................................. 24
Lift Cylinders ..................................................................................................................................................... 25
Main Lift Cylinders ....................................................................................................................................... 25
Remove....................................................................................................................................................... 25
Install ......................................................................................................................................................... 25
Free-Lift Cylinder.......................................................................................................................................... 28
Remove....................................................................................................................................................... 28
Install ......................................................................................................................................................... 30
Lift Chains.......................................................................................................................................................... 31
Mast Adjustments.............................................................................................................................................. 32
General ........................................................................................................................................................... 32
Mast Back Angle Adjustment ....................................................................................................................... 32
Load Rollers Adjustment............................................................................................................................... 33
Reach Carriage Assembly ......................................................................................................................... 33
Adjust Wear Plugs - Mast ............................................................................................................................. 34
Adjust Main-Lift Chains ............................................................................................................................... 35
Adjust Free-Lift Chain .................................................................................................................................. 35
Adjust Wear Strips ........................................................................................................................................ 37
Mast Racking ................................................................................................................................................. 38
Proximity Switches........................................................................................................................................ 40

Table of Contents Mast

Replace ....................................................................................................................................................... 40
Free-Lift Proximity Switch................................................................................................................... 40
Load Lowering Proximity Switch (Optional)....................................................................................... 41
Adjust ......................................................................................................................................................... 41
Mast Operation Check ....................................................................................................................................... 41
Lift System Leak Check .................................................................................................................................... 42
Lift Cylinder Leak Check .............................................................................................................................. 42
Tilt Cylinder Leak Check .............................................................................................................................. 42
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
ii
General
This section contains instructions for the removal, rollers take the forward and back stress loads during
installation, repair, and adjustment procedures on operation of the mast, and roll on sealed bearing
the three-stage, full free-lift (FFL) reach truck masts. assemblies.
Masts are available in a 5.5-in. configuration, 6.9-in.
configuration, as well as a 5.5 heavy-duty configura- WARNING
tion, which uses a 6.9-in. outer mast weldment with
The mast and carriage assemblies and their
5.5-in. inner and intermediate weldments. The de-
components are heavy. To help prevent dam-
scription and operation of these masts are outlined
age or an injury, a lifting device of suitable
in the section Mast, Description 4000 SRM 1194. A
capacity must be used during all service pro-
troubleshooting chart is listed at the end of this sec-
cedures.
tion. Repair procedures for the reach carriages are
presented in Reach Carriages 4500 SRM 1196. The mast assemblies must have the mast weldments
parallel with equal clearance on each side between
These mast assemblies and carriages have wear
all weldments. Correct operation also depends on
plugs and shims to allow for wear and adjustment.
periodic cleaning, lubrication, and adjustment. See
The wear plugs are housed in the stub shafts of
Mast Operation Check, Hydraulic System Leaks
the load rollers and slide against the center of the
Check, Lift Chains, Mast Adjustments, and Car-
weldment channels. A setscrew and jam nut secure
riage Adjustments at the end of this section.
each wear plug in the correct position. The load

The forks may be difficult to see when the mast is
WARNING raised. Be careful not to hit your head when working
All chains, ropes, and lifting equipment MUST around raised forks. Also, be careful not to trip over
be fully examined by qualified personnel at forks on or near the floor. If possible, remove forks
least once a year or more at frequent intervals from carriage before safety chaining the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely. Make
WARNING
sure there is no movement in the mast. Make sure
Mast parts are heavy and may shift. Distances all parts of the mast that can move are fully low-
between parts are small. Serious injury can re- ered.
sult if part of the body is hit by parts of the mast
or the carriage.
• Never put any part of the body into or under OR
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed. • If the mast must be in a raised position for re-
Also make sure the power is off and the key pairs, install a safety chain around the top or mid-
is removed. Attach a DO NOT OPERATE tag dle crossmember of the outer weldment and the
to the control handle. crossmember of the inner weldment to secure the
• DO NOT make repairs or adjustments unless mast.
you have been properly trained and autho-
rized to do so. Repairs and adjustments must WARNING
be performed by trained service technicians.
Perform the following steps from the side of the
• DO NOT climb on the mast or lift truck at any
mast using a ladder. Never stand under the car-
time. Use a ladder or personnel lift to work
riage until safety chains are installed.
on the mast.
• Move the truck to a safe location with room to 1. Remove forks from carriage if possible.
raise the mast if necessary. Block the wheels
1
Load Backrest 4000 SRM 1195
2. Raise mast to align the crossmembers of the in-

termediate mast weldment with a crossmember
on outer weldment.
3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum

size, around crossmembers of inner and outer
weldment. Secure it in place. See Figure 1.
4. Lower mast until safety chain stops mast. Lower

the mast until all components of the mast that
can move are completely lowered. Make sure
there is no movement of mast.
5. Turn key switch to the OFF position, disconnect

the battery, and attach a DO NOT OPERATE
tag to the control handle.
6. Wrap a second safety chain, 9.5 mm (3/8 in.) min-

imum size, around crossmembers of intermedi-
ate and outer weldments. Secure it in place as 1. OUTER MAST WELDMENT
2. INNER MAST LOWER CROSSMEMBER
an additional precaution. 3. SAFETY CHAIN
4. CARRIAGE CROSSMEMBER
NOTE: The mast operator guard MUST be removed
to install safety chain. Remove safety chain and in- Figure 1. Safety Chain the Mast
stall guard AFTER repairs are complete.
Load Backrest
REMOVE INSTALL
1. Position the load backrest onto the tilting frame
WARNING using a lifting device. Align the holes on the load
The load backrest is heavy and can cause an backrest with the proper mounting holes on the
injury. DO NOT try to remove it without using tilting frame.
a lifting device.
2. Loosely install the four capscrews securing the
1. Attach a lifting device to steady the load back- load backrest to the carriage.
rest.
3. Tighten all four capscrews to 102 N•m (75 lbf ft).
2. Remove the four capscrews that fasten the load
backrest to the carriage.
3. Lift the load backrest from the tilting frame us-

ing the lifting device.
2
4000 SRM 1195 Forks
Forks
The forks are held on the carriage by hooks. The
forks are kept in position by pins that fit through the
top fork hooks and into slots in the top bar carriage.
If pin does not remain engaged in carriage slot, re-
place with new pin. Always check that the pins for
the forks keep the forks in position on the carriage.
Replace damaged fork pin parts. The forks can be
removed from the carriage by aligning the forks with
the fork removal notch. The fork removal notch is in
the bottom bar of the carriage.
REMOVE
WARNING 1. CARRIAGE BARS 3. BLOCKS

DO NOT try to remove a fork without a lifting 2. HOOK FORK
device. Each hook fork for these lift trucks can
Figure 2. Hook Fork Removal
weigh 45 to 115 kg (99 to 254 lb).
A fork can be removed from the carriage for replace-

ment or other maintenance. Slide the fork to the fork
removal notch in the bottom bar of the carriage. See
Figure 2 and Figure 3. Lower the fork onto blocks so
the bottom hook of the fork moves through the fork
removal notch. See Figure 2. Lower the carriage fur-
ther so the top hook of the fork is disengaged from
the top carriage bar. Move the carriage away from
the fork or use a lifting device to move the fork away
from the carriage.
INSTALL
Move the fork and carriage so the top hook on the
fork can engage the upper carriage bar. Raise the 1. FORK 4. SPRING
carriage to move the lower hook through the fork re- 2. KNOB 5. PIN
moval notch. Slide the fork on the carriage so both 3. LOCK PIN
upper and lower hooks engage the carriage bars. En-
Figure 3. Forks and Lock Pin Assembly
gage the lock pin with a notch in the upper carriage
bar.
3
Sheaves 4000 SRM 1195
CHECKS be replaced. Check that the bottom of each fork is

not excessively worn. Check for smooth and proper
WARNING operation of the fork lock pins. Repair or replace any
damaged or broken fork lock pins or components and
Never repair damaged forks by heating or
lubricate, as necessary. See Figure 4.
welding. Forks are made of tempered steel
using special procedures. Always replace dam-
aged forks as a pair.
Inspect the forks for cracks and wear. Check the

alignment of the fork tips. The difference in height
of the fork tips must be less than three percent of the
length of the forks. See Table 1.
Table 1. Fork Tip Alignment
Fork Tip Alignment Specifications

Standard Fork Maximum Fork Tip
Lengths Difference 1
mm (in.) mm (in.)
914 (36) 27 (1.08)
1067 (42) 32 (1.26)
1219 (48) 37 (1.44) A. HEEL OF FORK (MUST BE 90% OF DIMENSION
B)
1372 (54) 41 (1.62) B. ORIGINAL FORK THICKNESS (DIMENSION B)
1524 (60) 46 (1.80) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
1829 (72) 55 (2.16) FORK LENGTH)
2. CRACKS
1Difference of alignment between fork tips must
3. MAXIMUM ANGLE 93
be no more than 3% of the total fork length. 4. FORK REMOVAL NOTCH
5. CARRIAGE
Some applications may require closer alignment. If Figure 4. Fork Check

the forks do not meet specification, they both must
Sheaves
The following procedures relate to removing, repair- b. Attach an overhead lifting device of suitable
ing, and replacing sheaves on a mast installed to a lift capacity to the top of the reach carriage.
truck. If the mast has been removed, skip to the ap- Raise the reach carriage 305 mm (12 in.) to
propriate steps. Complete only the steps necessary loosen the free-lift chains and hoses.
to safely complete the repairs.
2. Install safety chains to the mast to prevent unex-
1. Remove the weight of the mast from the hoses pected movements. See Safety Procedures When
and chains from the sheave assemblies: Working Near Mast.
a. Attach an overhead lifting device of suitable 3. Remove the retaining ring(s) securing the sheave
capacity to the top of the inner mast. Raise assembly(s) to be removed, and slide the sheaves
the inner mast 305 mm (12 in.) to loosen the and bearings from the stub shaft. See Figure 5,
main lift chains and hoses. Figure 6, and Figure 7.
4
4000 SRM 1195 Sheaves
1. CAPSCREW 15. BEARING

2. SHOULDER WASHER 16. RETAINING RING
3. RETAINING RING 17. SHEAVE
4. BEARING 18. STUB SHAFT
5. SHEAVE 19. RETAINING RING
6. STUB SHAFT 20. WASHER
7. GUIDE BOLT 21. HOSE SHEAVE
8. TUBE CLAMP 22. RETAINING RING
9. HOSE CLAMP 23. RETAINING RING
10. FLAT WASHER 24. CHAIN SHEAVE
11. LOCKWASHER 25. BEARING
12. CAPSCREW 26. STUB SHAFT
13. CAPSCREW 27. FOAM CUSHIONS
14. RETAINING RING 28. INTERMEDIATE MAST
Figure 5. Sheaves (5.5 Mast)
5
Sheaves 4000 SRM 1195
1. BEARING 7. RETAINING RING

2. RETAINING RING 8. CHAIN SHEAVE
3. CHAIN SHEAVE 9. CAPSCREW
4. RETAINING RING 10. RETAINING RING
5. HOSE SHEAVES 11. WIRE SHEAVE
6. WASHER 12. BEARING
Figure 6. Sheaves (6.9 Mast)
4. Clean and inspect the sheave assembly compo- 6. Position the lift chains and hoses onto the
nents. Replace the damaged components. Check sheaves as removed and secure with retaining
the bearings and stub shafts for damage or ex- rings.
cessive wear. Repair or replace as necessary.
7. Remove the safety chains and lower the mast
5. Reassemble the sheave assembly(s) onto the stub weldments and carriage to tighten the lift chains
shafts as removed. and hoses.
8. Check the mast for proper operation. Verify

proper tracking of the hoses and chains.
6
Legend for Figure 7

1. SCREW
2. GUARD BRACKET
3. STUB SHAFT
4. HOSE SHEAVES
5. RETAINING RING
6. MAST CHANNEL
Figure 7. Lower Sheave (6.9 Mast)
Hydraulic System
WARNING CAUTION
Always wear the proper protective equipment Protect the hydraulic system from dirt and
including eye protection and petroleum-resis- contaminants when servicing the hydraulic
tant gloves when handling hydraulic oil. Thor- system.
soon as possible. Never operate the pump without the proper
amount of oil in the hydraulic system. The
Completely lower all mast components and re- operation of the hydraulic pump with low oil
lieve pressure by opening the manual lowering levels will damage the pump.
pump or disconnecting any hydraulic hoses. The hydraulic oil in the system performs the dual
function of power transmission and lubrication. Us-
The hydraulic oil is hot at normal operating ing the proper oil is essential to system operation.
temperatures. Be careful when draining the The hydraulic oil level should be checked first when
oil. troubleshooting mast hydraulic problems. Low oil
levels may cause it to appear that a problem exists
Never put your hands on pressurized hydraulic with the mast or other hydraulic components.
escaping through pin-hole leaks can be in- NOTE: The hydraulic oil must be completely drained
jected into the skin. Visually inspect to find from the system before any hydraulic hoses may be
hydraulic leaks.
7
removed. Refer to Hydraulic Oil for the proper proce- make them better suited for particular applications.
dures for your lift truck. Oil will remain in the hoses Check the threads and mating surfaces of each fit-
even when the hydraulic system has been drained. ting when removed. Fittings with O-rings should be
inspected carefully and the O-ring replaced if it is
Visually inspect the hoses for leaks. Small oil leaks brittle, cracked, or otherwise damaged. Make sure
may appear as wet, oily leaks or unusually dirty ar- mating surfaces are clean and smooth and DO NOT
eas where dirt and dust sticks to oil that has slowly over tighten fittings. Inspect fittings for leaks often
leaked out. Check around fittings and hose con- following repairs.
nections for seeping oil. Replace hoses immediately
when damage or significant wear is found. Loosen
fittings slowly and cover with a cloth to make sure
pressure has been relieved in the system. Empty the
hoses into a drain pan and cap or plug all open ports
and hoses at once to prevent contaminants from
entering the system. All hydraulic hoses and tubes
must be thoroughly cleaned before installation.
WARNING
Failure to return the manual lowering valve
knob to the full clockwise position will cause
the forks to lower unexpectedly.
The hydraulic system may remain pressurized even

after the mast is completely lowered and all hy-
draulic components are at rest. Pressure can be
relieved from the system by opening the manual
lowering valve located on the main lift pump. Turn
the manual lowing valve knob counterclockwise to
open the valve. Make certain the valve is closed be-
fore returning to service. See Figure 8 and Figure 9.
NOTE: The hydraulic system (including the mast)

must be purged of air when refilling the hydraulic 1. LOWERING VALVE
system with oil. 2. UPPER MOUNTING HOLE
3. M2 PORT
When making repairs, use the least number of fit- 4. MANUAL LOWERING VALVE KNOB
tings and connections to minimize flow resistance 5. M1 PORT
and the possibility of leakage. Route new hoses prop- 6. RETURN FITTING
7. RELIEF VALVE
erly to avoid contact that may cause premature wear. 8. SUPPLY FITTING
Close the manual lowering valve and refill the hy- 9. LOWER MOUNTING HOLE
draulic system with oil when repairs are complete. 10. OVERRUN CHECK VALVE
11. PRESSURE FLANGE
Various types of fittings are used to connect hoses
and hydraulic system components. Some of these in- Figure 8. Lift Pump Components (N35ZDR,
clude flared fittings, O-ring fittings, and flat-faced N45ZR, N30ZDR, N35-40ZR)
O-ring fittings. Certain fittings have properties that
8

hydraulic leaks.
CAUTION
The hydraulic oil should be changed every 2000

hours or yearly. When the hydraulic system com-
ponents such as the pump or cylinders have been
damaged or the oil has otherwise been contaminated,
the hydraulic system should be drained, flushed,
and refilled with new hydraulic oil.
1. Park the lift truck on a level surface and lower

the mast. Turn the key switch to the OFF po-

1. HYDRAULIC GEAR PUMP from the truck connector located on the right side
2. SUPPLY FITTING of the frame. Pull the battery cable connector
3. PRESSURE FITTING handle to separate the battery connector from
4. MOUNTING CAPSCREW the truck connector.
5. LOCKWASHER
6. PUMP SPLINES 3. Remove the operator compartment cover and the
Figure 9. Lift Pump Components (N30ZDRS, drive unit compartment door to access the hy-
N35-40ZRS) draulic tank.

HYDRAULIC OIL
5. Position a suitable container oil with a minimum
Drain capacity of 19 liter (5 gal) next to the lift truck to
drain the oil.
WARNING
Always wear the proper protective equipment CAUTION
including eye protection and petroleum-resis- DO NOT cut the hose when removing the wire
tant gloves when handling hydraulic oil. Thor- tie.
soon as possible. 6. Locate the drain hose at the bottom of the hy-
draulic tank. See Figure 10. Carefully clip the
Completely lower all mast components and re- wire tie securing the hose. Loosen and remove
lieve pressure by opening the manual lowering the hose clamp securing the plug in the end of the
valve before disassembling any part of the lift hose. Remove the plug from the hose and drain
pump or disconnecting any hydraulic hoses. the hydraulic oil into the container.
oil.
9
7. Some lift trucks use displacement-type, main lift

These cylinders may be further drained to re-
duce levels of contaminants left in the hydraulic
system. If your truck is equipped with displace-
ment-type, main lift cylinders:
a. Loosen both main lift cylinder bleed screws

1/2 turn.
b. Open the lowering control valve.
c. Allow time for the oil to gravity feed into the

tank.
d. Turn the lowering control valve to the OFF

position.

main lift cylinder shells.

plug into the hose and secure with hose clamp
as removed. Coil the drain hose and secure with
9. Inspect the tank. Check for damage to the tank

or hoses. Clean the tank, if necessary.
10. Reinstall the breather cap as removed.
ever, cylinders may be either displacement-type or
piston-type. Certain cylinder types require different
hydraulic oil drain and fill procedures.
The main lift cylinders may be identified by the pres-

1. PLUG 4. TANK
2. HOSE 5. WIRE TIE ence of a bleed screw near the top of the cylinder shell
3. ELBOW (WITH 6. CLAMP on displacement-type cylinders. Piston-type, main
CLAMP) lift cylinders are not equipped with bleed screws. See
Figure 11.
Figure 10. Drain Hose
10

2. CYLINDER ROD
3. BLEED SCREW
(INDICATES DISPLACEMENT-TYPE
CYLINDER)
4. CYLINDER SHELL
Figure 11. Main Lift Cylinder Identification

rod diameter. Measure the diameter of the free-lift
cylinder rod to determine your lift truck configura-
tion. See Figure 12 and Table 2.
Table 2. Cylinder Identification
Type Free-Lift Cylinders

1. CROSSHEAD ASSEMBLY
Displacement 73.00 mm (2.87 in.) 2. CYLINDER ROD DIAMETER
3. BLEED OR FILL SCREW
Piston 44.40 mm (1.75 in.) 4. RETAINER BRACKET
5. CYLINDER SHELL
6. GLAND
Figure 12. Free-Lift Cylinder Rod
11
Fill Main Lift Cylinders
NOTE: Refer to Capacities and Specifications 1. Piston-type, main lift cylinders do not require
8000 SRM 1198 for the proper hydraulic oil selection. bleeding. If your lift truck is equipped with pis-
ton-type, main lift cylinders, skip to Free-Lift
1. Fill the hydraulic tank to the proper level with Cylinders.
new hydraulic oil. The hydraulic oil should be
filled to 25 mm (1 in.) below the bottom of the
hydraulic filter housing on the tank. DO NOT WARNING
overfill the hydraulic tank. See Figure 13. Keep clear of the mast when bleeding the cylin-
edly.

hydraulic leaks.
2. Displacement-type, main lift cylinders must be

bled:



remove the key.
WARNING
truck.
CAUTION
1. HYDRAULIC FILTER HOUSING NOTE: Use a cloth to wipe up foam and oil as it is
2. HYDRAULIC RETURN FITTING expelled to minimize spills.
3. HYDRAULIC OIL FILL LEVEL
4. HYDRAULIC TANK d. Slightly open the bleed screw of either main
lift cylinder by turning it counterclockwise
Figure 13. Hydraulic Oil Level until air and/or oil foam is expelled. Allow
air/foam to bleed from cylinder until clear hy-
2. Install the breather cap. draulic oil is present. Close the bleed screw
3. Determine the types of main lift cylinders and and tighten to 6 to 8 N•m (53 to 71 lbf in). If
free-lift cylinders used. Refer to Cylinder Iden- the free-lift cylinder completely lowers before
tification. all the air is expelled, close the bleed screw
and return to Step a. Wipe up the expelled
12
oil and repeat procedure for the other main 2. Displacement-type, free-lift cylinders must be
lift cylinder. bled:
Free-Lift Cylinders a. Engage the battery connectors and turn the

1. Piston-type, free-lift cylinders are not bled but
do have an oil chamber that must be filled for b. Activate the lift function using the operator
cylinder cushion functions to work properly: controls. Continue until the free-lift cylinder
a. Completely lower the mast and carriage. apply pressure to the hydraulic system.
Turn the key switch to the OFF position and
disconnect the battery. c. Turn the key switch to the OFF position and
disconnect the battery.
turning it counterclockwise to make sure the CAUTION
cylinder is not pressurized. Slowly remove DO NOT completely remove the bleed screw.
NOTE: Use a clean oil can to measure and inject hy- expelled to minimize cleanup.
c. Measure approximately 150 cc (5 oz) of clean of the free-lift cylinder shell near the gland
hydraulic oil and fill the oil chamber through by turning it counterclockwise until air
the fill hole. Fill until all the oil is used or and/or oil foam is expelled. Allow air/foam to
until oil flows out of the fill hole. bleed from the cylinder until clear hydraulic
oil is present. Close the bleed screw and
d. Install the fill screw and seal and tighten to tighten to 6 to 8 N•m (53 to 71 lbf in). If the
6 to 8 N•m (53 to 71 lbf in). Wipe up any free-lift cylinder completely lowers before all
spilled oil. air/foam is expelled, close the bleed screw
and repeat Step a. Wipe up the expelled
e. Connect the battery and turn the key switch
oil. Some displacement-type, free-lift cylin-
to the ON position. Completely raise and
ders also have an additional bleed screw
located in the end of the cylinder rod. In-
proper operation. The free-lift cylinder
spect the cylinder rod where it emerges from
should slow smoothly near the end of its
the crosshead. If the rod is equipped with
stroke. Check the hydraulic oil level in the
the additional bleed screw, repeat the bleed
procedure using the additional bleed screw.
as removed, remove blocks from the wheels,
and return the lift truck to service. e. Connect the battery and turn the key switch
WARNING lower the mast several times to check for
Keep clear of the mast when bleeding the cylin- proper operation. Repeat the bleed proce-
ders. Mast parts may shift or lower unexpect- dure until no air is present when bleeding
edly. the free-lift cylinder. Check the hydraulic oil
Never put your hands on pressurized hydraulic place all covers as removed, remove blocks
components. Highly-pressurized hydraulic oil from the wheels, and return the lift truck to
escaping through pin-hole leaks can be in- service.
hydraulic leaks.
13

REMOVE WARNING
1. Remove the forks. See Forks. Reach carriage assemblies are heavy. Be sure
that all lifting devices are suitable and of ade-
2. Remove the load backrest. See Load Backrest. quate capacity to lift the components.
3. Remove the hardware securing the operator 4. Attach an overhead lifting device to the top of the
guard from the rear of the mast, and remove the reach carriage assembly:
operator guard.
a. Install heavy-duty, industrial C-clamps to
the top of each side of the rear frame. See
Figure 14.
Figure 14. C-Clamp Installation
14
b. Install a chain loop or sling through each INSTALL

clamp separately, and attach each loop to the
overhead lifting device. 1. Position the reach carriage assembly in an up-
right position with the back of the reach carriage
5. Raise the reach carriage assembly high enough aligned with the front of the mast assembly.
to access the hydraulic and wiring harness con-
nections on the rear frame.
WARNING
6. Safety chain the reach carriage assembly in Mast assemblies are heavy. Be sure that all lift-
place. See Safety Procedures When Working ing devices are suitable and of adequate capac-
Near Mast. ity to lift the components.
7. Disconnect the lift chains from the reach carriage NOTE: Use an overhead lifting device of suitable ca-
assembly: pacity to raise the inner mast when installing the
reach carriage assembly. Use a second lifting device
a. Remove the cotter pin and chain anchor pin or lift truck to position the reach carriage assembly
securing the chain to the anchors. under the inner mast channels.
b. Secure chains to the mast using stiff wire to 2. Raise the inner mast until clearly higher than
keep them from falling from the sheaves. the reach carriage assembly. Position the reach
carriage assembly so the load rollers of the rear
c. If the mast must be disassembled or the frame are centered under the channels of the in-
chains need to be cleaned/lubricated, remove ner mast.
the lift chains and clean and inspect.
NOTE: Check that all lift chains, hoses, and wiring
8. Tag and disconnect the attachment hoses from are seated properly on the sheaves as the inner mast
the two fittings at the bottom of the rear frame is lowered.
of the reach carriage assembly. Cap or plug all
open hydraulic hoses. 3. Lower the inner mast channels onto the load
rollers of the rear frame. If the inner mast does
9. Disconnect the reach wiring connector. Remove not lower smoothly and completely, raise the
the reach wiring harness from the top of the rear inner mast, reposition the reach carriage assem-
frame. bly, and lower the inner mast again.
10. Remove the safety chains and completely lower
the reach carriage assembly to the floor. WARNING
Reach carriage assemblies are heavy. Be sure
WARNING that all lifting devices are suitable and of ade-
Mast assemblies are heavy. Be sure that all lift- quate capacity to lift the components.
ing devices are suitable and of adequate capac- 4. Attach an overhead lifting device to the top of the
ity to lift the components. reach carriage assembly:
NOTE: Use a lifting device or a second lift truck to a. Install heavy-duty, industrial C-clamps to
move the reach carriage assembly. each side of the rear frame. See Figure 14.
11. Attach an overhead lifting device to the top b. Install a chain loop or sling through each
of the inner mast. Raise the inner mast until clamp separately, and attach each loop to the
clearly higher than the reach carriage assembly. overhead lifting device.
Move the reach carriage assembly away and
completely lower the mast. 5. Raise the reach carriage assembly high enough
to access the hydraulic connections and wiring
12. Disconnect the lifting device from the inner mast. harness connection on the rear frame.
15
Load Rollers 4000 SRM 1195
6. Safety chain the reach carriage assembly. See 10. Remove the safety chains and completely lower
Safety Procedures When Working Near Mast. the reach carriage assembly.
11. Remove the C-clamps and lifting device from the

CAUTION reach carriage assembly.
If reusing chains, make sure chains have been
properly inspected, cleaned, and lubricated. 12. Raise and lower the mast several times to remove
See Lift Chains. air from the system. Cycle the tilt and side shift
(if so equipped) functions several times to remove
7. Reconnect the lift chains to anchors on reach car- air from the system. Check for proper operation.
riage assembly as removed. Install anchor pins
and cotter pins. 13. Check the hydraulic oil level and add as required.
8. Connect the wiring connector to the top of the 14. Check reach carriage assembly height and align-
rear frame. ment and adjust the lift chains as required. See
Carriage Adjustments.
9. Remove caps/plugs from the attachment hoses
and fittings. Reconnect the hoses as removed. 15. Install the load backrest. See Load Backrest.
NOTE: Check that all lift chains, hoses, and wiring 16. Install the forks. See Forks.
are seated properly on the sheaves as the reach car-
17. Install the operator guard as removed.
riage assembly is lowered.
Load Rollers
MAST
NOTE: It is necessary to remove the mast assembly
from the truck to remove or replace load rollers, wear
plugs, weldments, or lift cylinders.
1. Remove the reach carriage assembly from the

mast. Refer to Reach Carriage Assembly.
2. Remove the mast from the lift truck and posi-

tion it face down and level with the floor across
wooden beams. See Mast, Remove in this section.
3. Disconnect the lift chains, hoses, and wiring as

necessary to slide the mast weldments up or
down to access each of the load rollers. Secure
the weldments in place using chains to prevent
4. Remove the jam nuts and setscrews from the load

rollers. See Figure 15.
1. LOAD ROLLER 5. JAM NUT
5. Remove the wear plugs by inserting a screw- 2. WEAR PLUG 6. STUB SHAFT
driver through the setscrew hole and pushing 3. RETAINING RING 7. MAST CHANNEL
the wear plug out of the stub shaft. Inspect the 4. SETSCREW
wear plug for wear and replace as necessary. Figure 15. Load Roller and Wear Plug
16
4000 SRM 1195 Load Rollers
10. Install the wear plugs as removed. Adjust as nec-

WARNING essary. See Mast Adjustments.
Be careful when removing or installing snap
rings. Snap rings can eject during removal or 11. Reconnect the lift chains, hoses, and wiring as
installation with enough force to cause an in- removed.
jury. Always use the correct snap ring pliers,
and wear eye and face protection during re- 12. Install the mast to the lift truck. Refer to Mast,
moval or installation. Install.
6. Remove the snap rings from the stub shaft. 13. Install the reach carriage assembly as removed.
See Reach Carriage Assembly.
7. Use a pry bar to remove the load roller from the
stub shaft. Refer to Figure 16 and Figure 17.
1. LOAD ROLLER WITH SNAP RING REMOVED

2. PRY BAR
3. REAR FRAME
4. SIDE ROLLER
Figure 16. Removing Load Roller (6.9 Mast 1. WEAR PLUG 4. STUB SHAFT
Shown) 2. RETAINING RING 5. SETSCREW
3. LOAD ROLLER 6. JAM NUT
8. Use a cloth to clean each load roller. Inspect the
load rollers for cracks, flat spots, or bearings that Figure 17. Load Roller and Wear Plug
do not turn freely. Replace any roller that shows
wear or is damaged.
9. Install the load rollers onto the stub shafts and

install the retaining rings as removed.
17
Load Rollers 4000 SRM 1195
REACH ASSEMBLY 5. Use a cloth to clean each load roller. Inspect the
load rollers for cracks, flat spots, or bearings that
Load Rollers do not turn freely. Replace any roller that shows
wear or is damaged.
1. Check the reach assembly for loose play where
shims may need to be added. 6. Install an equal number of shims to both sides
of the rear frame stub shafts. Install additional
2. Remove the reach assembly from the mast as- shims as necessary. See Mast Adjustments.
sembly to access the rear frame load rollers. See
Reach Carriage Assembly. 7. Install the load rollers onto the stub shafts and
WARNING 8. Install the reach carriage assembly if repairs are
Be careful when removing or installing snap complete. Check for proper operation.
rings. Snap rings can eject during removal or
installation with enough force to cause an in- Side Rollers
jury. Always use the correct snap ring pliers,
and wear eye and face protection during re- NOTE: Check the side roller adjustment before re-
moval or installation. moving the reach assembly from the mast.
3. Remove the snap rings from the stub shaft. Use 1. Remove the reach assembly from the mast to re-
a pry bar to remove the load roller from the stub place the side rollers.
shaft. See Figure 16.
2. Remove the capscrews that fasten the side roller
4. Recover the shims from behind the load roller. bracket. See Figure 16.
Tag the shim pack and identify the location for
proper reassembly. See Figure 18. NOTE: Observe the position of the shims.
NOTE: Correct placement of shims is critical for the

operation of the reach mechanism. The reach mech-
anism will not operate if the shims are installed in-
correctly.
3. Inspect and replace all damaged or worn parts.
4. Install an equal number of shims to both sides

under the side rollers. Install additional shims
as necessary. See Mast Adjustments.
5. Install the load rollers onto the stub shafts and

6. Install and check the reach assembly when re-

pairs are complete.
1. RETAINING RING 3. SHIM PACK
2. LOAD ROLLER 4. STUB SHAFT
Figure 18. Load Roller and Shims
18
4000 SRM 1195 Mast
Mast
REMOVE CAUTION
DO NOT move the control button for the reach,
WARNING retract, tilt, or sideshift functions.
DO NOT remove the mast assembly unless it is
completely assembled or has safety chains in- 6. Raise the inner and intermediate weldments
stalled. Mast parts can move and cause an in- high enough to access to the bottom of the outer
jury if not secured together during removal. weldment.
Mast parts are heavy and can shift. Distances 7. Install safety chains to keep the mast compo-
between parts are small. Serious injury can re- nents from moving. See Safety Procedures When
sult if part of the body is hit by parts of the mast Working Near Mast.
or reach assembly.
8. Remove the four capscrews, shims, and nutplates
Mast assemblies are heavy. Be sure that all lift- attaching the bottom of the mast to the truck
ing devices are suitable and of adequate capac- frame.
ity to lift the mast and its components.
9. Remove the safety chains. Lower the inner and
1. Remove the mast operator guard: intermediate weldments fully. Make sure all hy-
draulic pressure is removed from the system.
a. Remove capscrews and nuts that secure the
guard.
WARNING
b. Lift the guard from the mast. Always wear the proper protective equipment
2. Remove the forks from the reach assembly. See tant gloves when handling hydraulic oil. Thor-
Forks. oughly wash oil from exposed areas of skin as
soon as possible.
NOTE: If the mast assembly will not be disassembled,
it may not be necessary to remove the reach assembly NOTE: Certain lift truck models retain significant
before removing the mast. quantities of oil in the cylinders and hoses even when
3. If the reach assembly will not be removed from
the mast, secure the reach assembly using safety
before servicing to avoid large spills. Refer to Hy-
chains:
draulic Oil.
a. Operate the REACH/RETRACT control but-
ton to retract the reach assembly fully and
to Hydraulic Oil. Store the oil in clean, approved
center the sideshift if equipped.
NOTE: Make sure a safety chain does not touch com-
ponents other than the mast weldments. CAUTION
Make sure the chains will not damage the
b. Install the safety chains around the front
sheaves or other parts of the mast assembly.
frame and rear frame so the reach carriage
assembly cannot extend. 11. Use chains to connect a crane or other lifting de-
vice to the top of the outer mast assembly. Use
NOTE: It is necessary to remove the reach assembly
safety chains to fasten all the mast weldments
before removing the mast if the mast will be disas-
together so they cannot move. If the reach as-
sembled.
sembly is not being removed from the mast, in-
4. Remove the reach carriage assembly. See Reach stall a chain or sling to keep the reach assembly
Carriage Assembly in this section. from extending during removal.
5. Remove the capscrews that fasten the top of the 12. Remove the front panel covers to access the trun-
rear leg to the overhead guard. nion caps. Mark the trunnion caps so they can
19
Mast 4000 SRM 1195
be reassembled in the same position and on the Mast assemblies are heavy. Be sure that all lift-
same trunnion from which they are removed. Re- ing devices are suitable and of adequate capac-
move the four capscrews that fasten the trunnion ity to lift the mast and its components.
caps. Remove the trunnion caps.
1. Position the mast horizontally on a level floor
13. Remove the battery to expose the access hole in with the overhead guard on the bottom as a
the battery compartment. support. Install a support under the other end.
Make sure the mast is level.
NOTE: Tag and identify the bulkhead hoses before
removal for correct connection during installation. 2. Tag and remove the free-lift chains and wiring
and inspect for damage and wear. If the chains
14. Disconnect the mast hoses from their fittings at are to be reused, clean and lubricate as indicated
the front of the truck frame. Cap and plug all fit- in Lift Chains.
tings and ports to prevent hydraulic system con-
tamination and leakage. NOTE: The free-lift cylinder may be also removed
while the mast is installed in the lift truck. Refer
15. Tag and disconnect the plugs and wires of the to Lift Cylinders in this section.
wiring harness cable so the cable is completely
disconnected from the truck. The plugs are lo- 3. Remove the free-lift cylinder.
cated next to the left side trunnion.
a. Attach a lifting device and a sling to the cylin-
16. Tighten the crane to support the weight of the der. Tighten to support the weight of the
mast assembly. Move the crane to a position so cylinder when removed.
that the mast assembly will be lifted vertically.
Raise the mast assembly high enough to clear the NOTE: Mast models consists of three categories: 5.5
trunnions. Move the mast assembly away from Standard Masts, 5.5 Heavy Duty Masts, and 6.9
the truck. Masts. Refer to General in this section for more
information.
NOTE: If the mast will be disassembled, position the
mast on a level floor with the overhead guard on the b. 5.5 Std Mast Only - Remove the four nuts
bottom as a support. Install a support under the and washers securing the lower cylinder retaining
other end. Make sure the mast is level. Keep the bracket to the outer mast and remove the bracket.
safety chains installed securing the mast weldments Next, remove the corresponding four capscrews also
together. If the mast will NOT be disassembled, put securing the hydraulic mounting bracket to the back
the mast on a level floor with the overhead guard on of the inner mast, or thread the nuts and washers
top, or secure it vertically to an approved mast stand. back on the capscrews finger tight if the hydraulic
mounting bracket is not to be removed.
DISASSEMBLE
The following procedures refer to disassembling a c. Tag and identify the hydraulic hoses. Re-
mast removed from the lift truck with the reach as- move the hoses from the cylinder and cap/
sembly previously removed. Total disassembly of the plug the hoses and ports to prevent contami-
mast weldments is not always necessary. Perform nation to the hydraulic system.
only the steps necessary to safely complete the re-
d. Remove the two screws securing the upper
pairs.
cylinder retaining bracket to the inner mast.
Remove the brackets and guide the cylinder
WARNING out of the mast using the lifting device.
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury can re- 4. Remove the main lift cylinders. See Lift Cylin-
sult if part of the body is hit by parts of the mast ders in this section.
or reach assembly.
20
4000 SRM 1195 Mast
5. Remove the inner mast weldment: 8. Remove and disassemble the hose and chain
sheave assemblies from the weldments if neces-
a. Slide the inner mast halfway out of the top of sary. See Sheaves.
the intermediate mast.
b. Connect the crane to the center of each side CAUTION

of the inner mast using chains or slings. Improper welding procedures can damage the
See Figure 19. Tighten crane to support the structure of the mast or cause incorrect func-
weight of the inner mast. tion of the mast. Mast weldment components
require factory approval before repairing or
c. Carefully slide the inner mast from the in-
replacing. Contact your local Hyster lift truck
termediate mast and place it on a pallet for
dealer for assistance.
transport/storage. Disconnect the crane.
9. Clean and inspect the weldments. Repair as nec-
d. Disassemble the load rollers from the weld-
essary.
ment as necessary.
CLEAN AND INSPECT
CAUTION
DO NOT use steam to clean lift chains, sheaves,
or load rollers. The bearings in the sheaves and
load rollers are sealed and lubricated.
1. Inspect the chain sheaves and load rollers for

wear or damage.
WARNING
Never replace only the worn section of a chain.
Replace the complete chain. Never replace
only one chain of a chain pair. Replace both
chains.
Figure 19. Mast Disassembly
NOTE: The chains must be inspected in the area of
6. Remove the intermediate mast weldment: chain that passes over the chain sheave during the
first portion of a lift. Those links will show maximum
a. Slide the intermediate mast halfway out of wear.
the top of the outer mast.
NOTE: The lift chains must be installed in the mast
b. Connect the crane to the center of each side of and the mast must be installed on the lift truck to
the intermediate mast using chains or slings. be checked for correct length. Check lift chains for
See Figure 19. Tighten crane to support the proper length before removing the mast.
weight of the intermediate mast.
2. Inspect the lift chains for wear or damage. A lift
c. Carefully slide the intermediate mast from chain becomes longer when it is worn. If a chain
the outer mast and place it on a pallet for is 3% longer than a new lift chain, the lift chain
transport/storage. Disconnect the crane. must be replaced. If a chain scale is available,
check the lift chain as shown in Figure 20. If a
d. Disassemble the load rollers from the weld- chain scale is not available, measure 20 links of
ment as necessary. the lift chain. Compare the measurement with
the lengths given in Figure 20.
7. Disassemble the load rollers from the outer mast
as necessary. Tag and identify all shims to prop-
erly reinstall the weldment.
21
Mast 4000 SRM 1195
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
3. Clean the lift chains by soaking in solvent for

30 minutes and remove all dirt and grease.
Hang lift chains up and remove solvent using
compressed air. Lubricate the chains by soaking
them in SAE 30 engine oil for 30 minutes. Hang
chains over a drip pan for one hour to remove
excess oil.
4. Inspect the chain anchors and pins. Replace any

parts that are worn or damaged.
WARNING
Be careful when cleaning with steam. Steam NOTE: THE INSTRUCTIONS FOR MEASURING
can cause serious burns. Wear protective cloth- CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
ing, gloves, and eye protection. Never expose SCALE
your skin to steam.
1. CHAIN WEAR SCALE
and can cause severe skin irritation. When Pitch Wear Limit
Total length
using cleaning solvents, always follow the The
of 20 links
solvent manufacturer’s recommended safety maximum
(pitch) of new
precautions. length of 20
chain
links
5. Clean the mast weldments with steam or solvent.
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
CAUTION 15.9 mm 317.5 mm 327.0 mm
Improper welding procedures can damage (0.63 in.) (12.5 in.) (12.9 in.)
the structure of the mast or cause incorrect 19.1 mm 381.0 mm 392.4 mm
function of the mast. Mast components require (0.75 in.) (15.0 in.) (15.5 in.)
written engineering approval before repairing 25.4 mm 508.0 mm 523.3 mm
or replacing. Contact your local Hyster lift (1.00 in.) (20.0 in.) (20.6 in.)
truck dealer for factory assistance.
Figure 20. Lift Chains Check
6. Inspect sliding surfaces for wear or damage. In-
spect load roller contact surfaces for wear or dam-
age. Inspect all welds for cracks.
22
4000 SRM 1195 Mast
ASSEMBLE d. Slide the inner mast completely into the in-

termediate mast.
WARNING
Mast parts are heavy and can shift. Distances WARNING
between parts are small. Serious injury can re- Always wear the proper protective equipment
sult if part of the body is hit by parts of the mast including eye protection and petroleum resis-
or reach assembly. tant gloves when handling hydraulic oil. Thor-
Mast assemblies are heavy. Be sure that all lift- soon as possible.
ing devices are suitable and of adequate capac-
ity to lift the mast and its components. 5. Install the main lift cylinders into the intermedi-
ate masts. See Lift Cylinders in this section.
1. Assemble and install the hose and chain sheave
assemblies if removed. See Sheaves.
WARNING
2. Install the load rollers to the weldments. See Always wear the proper protective equipment
Load Rollers. including eye protection and petroleum resis-
3. Assemble the intermediate weldment into the oughly wash oil from exposed areas of skin as
outer weldment as removed: soon as possible.
a. Connect the crane to the center of each side of 6. Install the free-lift cylinder:
the intermediate mast using chains or slings.
See Figure 19. a. Attach a lifting device and a sling to the cylin-
der. Guide the cylinder into the mast using
b. Raise the intermediate mast level with the the lifting device.
outer mast. Insert the bottom of the inter-
mediate mast into the top of the outer mast b. 5.5 HD and 6.9 Mast Only - Properly posi-
as removed. tion the free-lift cylinder to align the pin lo-
cated on the bottom of the cylinder shell with
c. Carefully slide the intermediate mast the hole in the inner mast.
halfway into the outer mast and discon-
nect the crane. c. Install to the upper cylinder retaining
bracket. Install the two screws securing
d. Slide the intermediate mast completely into the brackets to the inner mast.
the outer mast.
d. Install the reach hoses and wiring through
4. Assemble the inner weldment into the interme- the cylinder crosshead as removed. Install
diate weldment as removed: the hydraulic lines to the free-lift cylinder as
a. Connect the crane to the center of each side removed.
of the inner mast using chains or slings. See e. 5.5 Std Mast Only - Position the lower cylin-
Figure 19. der retaining bracket over the bottom of the
b. Raise the inner mast level with the interme- free-lift cylinder and onto the four capscrews
diate mast. Insert the bottom of the inner (as removed). Install the four nuts and wash-
mast into the top of the intermediate mast ers securing the bracket to the outer mast.
as removed. 7. Install the main lift chains. See Lift Chains.
c. Carefully slide the inner mast halfway into 8. Secure the free lift chains until they can be at-
the intermediate mast and disconnect the tached when the reach assembly is installed. See
crane. Mast, Install.
23
Mast 4000 SRM 1195
INSTALL are not connected can short circuit and cause

damage.
WARNING 6. Attach a lifting device and raise the inner and
DO NOT install the mast assembly unless it is intermediate weldments high enough to allow ac-
completely assembled or has safety chains in- cess to the bottom of the outer weldment.
stalled. Mast parts can move and cause an in-
jury if not secured together during assembly. 7. Install safety chains to keep the intermediate
and inner weldments from moving.
Mast parts are heavy and can shift. Distances
between parts are small. Serious injury can re- 8. Use a pry bar to align and install the four mount
sult if part of the body is hit by parts of the mast capscrews and the nut plates that fasten the bot-
or reach assembly. tom of the mast to the truck frame. Move the
bottom of the weldment in or out and add shims
Be sure that all lifting devices are suitable and until the mast back tilt is properly adjusted. See
of adequate capacity to lift the mast and its Mast Adjustments in this section.
components.
9. Tighten the four mount capscrews to 203 N•m
NOTE: Use safety chains to keep the mast assembly (150 lbf ft).
from moving as described in Safety Procedures When
Working Near Mast. 10. Install the hose clamps and hose bracket. Oper-
ate the LIFT/LOWER control to raise the inner
1. Use the crane or lifting device to lift the mast as- weldment high enough to carefully remove the
sembly into an upright position and move it close safety chains. Remove the safety chains.
enough to the truck to make the necessary con-
nections. Make sure the truck and mast assem- 11. Tighten the four trunnion cap capscrews to
bly cannot move. 210 N•m (155 lbf ft). Use the crane to remove
the safety chains and lower the inner and inter-
NOTE: Remove the caps and plugs from the hoses and mediate weldments. Disconnect the crane and
ports and clean the threads of the hoses as necessary chains.
before installation.
12. Install the mast operator guard and capscrews
2. Install and tighten the mast and attachment that fasten the rear leg to the overhead guard.
hoses on their correct bulkhead fittings as re-
moved.
WARNING
3. Move the mast assembly into position where the Always wear the proper protective equipment
outer weldment stub shafts are aligned directly including eye protection and petroleum resis-
over the trunnion blocks on the lift truck frame. tant gloves when handling hydraulic oil. Thor-
Lower the mast until the stub shafts are seated oughly wash oil from exposed areas of skin as
in the trunnion blocks. soon as possible.
NOTE: Make sure all hoses and the electrical cable NOTE: Models with displacement-type cylinders
are not between a mast crossmember and the truck. have significantly different filling procedures than
4. Align the trunnion caps according to the marks system using the appropriate procedures for your
made during removal. Install the capscrews but model to ensure proper operation. Refer to Hydraulic
leave them loose. System in this section.
5. Connect all the wires of the electrical cable ac- 13. Fill the hydraulic system to the proper level and
cording to the labels made during removal. bleed the air from the mast and hydraulic sys-
tem. Refer to Hydraulic System in this section.
CAUTION
14. Make all adjustments and test the operation of
Install tape on all electrical wires for the reach
the mast assembly before returning the truck to
assembly that are not connected. Wires that
service. See Mast Adjustments.
24
4000 SRM 1195 Lift Cylinders
Lift Cylinders
MAIN LIFT CYLINDERS hoses and ports to prevent leakage and contami-
nation to the hydraulic system.
WARNING NOTE: Use only a brass driver and a hammer to tap
Always wear the proper protective equipment the cylinder rods from the intermediate mast. Use of
including eye protection and petroleum-resis- harder material can disfigure the cylinder rod.
oughly wash oil from exposed areas of skin as 6. Remove the retaining rings, shims, and rubber
soon as possible. bushings (5.5 HD and 6.9 mast only) from the top
of the cylinder rods. Carefully pull the interme-
Completely lower all mast components and re- diate weldment outward while lightly tapping on
lieve pressure by opening the needle valve be- the top of the cylinder rods to remove them from
fore disassembling any part of the mast or dis- their mounts in the intermediate mast. Recover
connecting any hydraulic hoses. and tag the bevelled shim packs from the shoul-
der of each cylinder rod for proper installation.
See Figure 21.
oil. 7. Remove the two screws securing each lower
cylinder retaining bracket to the outer mast. Re-
The main lift cylinders can be removed only when the
move the brackets. See Figure 22 or Figure 23.
mast has been removed from the lift truck. It is rec-
ommended to service both cylinders at the same time 8. Carefully guide the cylinders from the mast.
if cylinder repair is necessary. Refer to Mast, Disas- Reposition the lifting devices as necessary to
semble for instructions on disassembling the mast. support the cylinder until completely removed
from the mast.
Remove
9. Remove the cylinder alignment pin from the bot-
1. Remove the reach assembly from the truck. tom of the lift cylinder.
NOTE: Certain lift truck models retain significant
Install
the hydraulic tank is empty. Drain the hydraulic sys- 1. Attach lifting device to the cylinder using a sling
tem using the appropriate procedures for your model and guide the cylinder into the mast.
before servicing to avoid large spills. Refer to Hy-
draulic System. 2. Install the cylinder alignment pin into the bot-
tom of the cylinder shell and guide it into the hole
2. Drain the oil from the hydraulic system. Refer to in the base mount.
Hydraulic Oil in this section. Make sure any oil
remaining in the tank is well below the height 3. Position the lower retaining brackets onto the
of the components being removed. Store the oil cylinders. Secure each to the outer mast using
in clean, approved containers if the oil is to be two capscrews as removed.
reused.
4. Install bevelled shims to the top of the lift cylin-
3. Remove the mast from the lift truck. See Mast, ders as removed. Carefully slide the intermedi-
Remove. ate mast into the outer mast while guiding the
cylinder rods into their seats in the top of the in-
4. Attach a lifting device to the cylinder using a termediate mast. Tap the top of the intermediate
sling. Tighten to support the weight of the cylin- mast using a rubber mallet until the rod are com-
der when removed. pletely seated.
NOTE: Tag and identify hoses before removal. 5. Install rubber bushing (5.5 HD and 6.9 mast
only), shims and retaining ring onto the top of
5. Remove the hose clamp(s) securing the cylinder
the cylinder rods as removed.
connecting hose. Disconnect the cylinder con-
necting hose from the lift cylinders. Cap/plug the
25
Lift Cylinders 4000 SRM 1195
6. Install cylinder connecting hose as removed.
7. Remove the lifting devices and slings from the

cylinders.
8. Install the mast to the lift truck. See Mast In-

stall.
9. Install the reach assembly to the lift truck.

model to ensure proper operation. Refer to Hydraulic
System in this section.
10. Fill the hydraulic system to the proper level and

bleed the air from the cylinders and the hydraulic
system. See Hydraulic System in this section.
1. OUTER MAST
2. RETAINING RING
3. SHIM(S)
4. INTERMEDIATE MAST
5. BEVELLED SHIM(S)
6. LIFT CYLINDER ASSEMBLY
Figure 21. Lift Cylinder Removal (5.5 Std)
26
1. LIFT CYLINDER 9. CAPSCREWS

2. FREE-LIFT HOSE 10. HYDRAULIC MOUNTING BRACKET
3. CYLINDER RETAINING BRACKET 11. CAPSCREWS
4. TEE FITTING 12. VELOCITY FUSE
5. CAPSCREWS 13. CAPSCREWS
6. TUBE CLAMP 14. HOSE CLAMP
7. CAPSCREWS 15. CYLINDER CONNECTING HOSE
8. DUAL TUBING CLAMP
Figure 22. Lift Cylinder Removal (5.5 Mast)
27
A. LIFT SYSTEM HOSES B. AUX SYSTEM HOSES

1. LIFT CONNECTING HOSE 7. VELOCITY FUSE
2. FREE-LIFT SHEAVE 8. LIFT CYLINDER
3. SCREW 9. FREE-LIFT SUPPLY HOSE
4. RETAINER 10. WIRING TAKE-UP SLING
5. FITTING 11. TAKE-UP SPRING
6. AUX CONNECTIONS 12. CYLINDER ALIGNMENT PIN
Figure 23. Lift Cylinder Removal (6.9 Mast)
FREE-LIFT CYLINDER The following procedures refer to removing the free-

lift cylinder with the mast installed to the lift truck.
Remove The free-lift cylinder may be removed while the mast
is installed to the lift truck or when the mast is be-
WARNING ing disassembled. For instructions for removing the
Always wear the proper protective equipment free-lift cylinder during disassembly, see Mast, Dis-
including eye protection and petroleum-resis- assemble - Remove.
tant gloves when handling hydraulic oil. Thor- NOTE: Certain lift truck models retain significant
oughly wash oil from exposed areas of skin as quantities of oil in the cylinders and hoses even when
soon as possible. the hydraulic tank is empty. Drain the hydraulic sys-
Completely lower all mast components and re- tem using the appropriate procedures for your model
lieve pressure by opening the needle valve be- before servicing to avoid large spills. Refer to Hy-
fore disassembling any part of the mast or dis- draulic System.
connecting any hydraulic hoses.

oil.
28
1. Drain the oil from the hydraulic system. Refer 8. 5.5 HD and 6.9 Mast - Remove the cylinder
to Hydraulic Oil. Make sure any oil remaining alignment pin from the bottom of the cylinder
in the tank is well below the height of the com- shell.
ponents being removed. Store the oil in clean,
approved containers if the oil is to be reused.
NOTE: The free-lift cylinder can be removed with-

out disconnecting the free lift chains or wiring har-
ness. This is done by removing the snap ring retain-
ing the crosshead assembly to the cylinder rod after
the reach assembly has been raised. However, it is
advised to inspect, clean, and lubricate the free-lift
chains anytime the free-lift cylinder is removed.
2. Tag and remove the free-lift chains and wiring

and inspect for damage and wear. If the chains
are to be reused clean and lubricate as indicated
in Lift Chains. Remove the wiring harness from
the crosshead.
3. Attach an overhead lifting device to the top of

the reach assembly. Install heavy-duty, indus-
trial C-clamps and a sling or chain loop to each
side of the inner frame. Raise the reach assem-
bly to the top of the inner frame. Install a safety
chain to secure the reach assembly in place.
4. Attach a lifting device and a sling to the cylin-

der. Tighten to support the weight of the cylinder
when removed.
5. 5.5 Std - Remove the four nuts and washers se-

curing the lower cylinder retaining bracket to the
outer mast and remove the bracket if necessary.
Next, thread the nuts and washers back on the
capscrews finger tight. See Figure 24 or Fig-
ure 25.
6. Remove the hose clamps securing the hydraulic

lines to the free-lift cylinder. Tag and identify
the hydraulic hoses. Remove the hoses from the 1. CROSSHEAD ASSEMBLY
cylinder and cap/plug the hoses and ports to pre- 2. FREE-LIFT CYLINDER
vent contamination to the hydraulic system. 3. UPPER RETAINING BRACKET
4. CAPSCREWS AND LOCKWASHERS
7. Remove the two screws securing the upper cylin- 5. LOCKWASHER
der retaining bracket to the inner mast. Remove 6. NUT
the brackets and guide the cylinder out of the 7. LOWER RETAINING BRACKET
mast using the lifting device. Figure 24. Free-Lift Cylinder (5.5 Std)
29
securing the bracket to the inner mast. Remove

the lifting device and sling from the free-lift
cylinder.
NOTE: Remove all caps/plugs from the hydraulic

lines and ports as necessary.
5. Install the hydraulic hoses to the cylinder as re-

moved. Install the hose clamps securing the hy-
draulic lines to the free-lift cylinder as removed.
6. 5.5 Std - Remove the nuts and washers from the

four capscrews at the bottom of the free-lift cylin-
der (finger tight). Position the lower cylinder re-
taining bracket into place. Install the four nuts
and washers securing the bracket to the outer
mast. See Figure 24.
7. Remove the safety chains from the reach assem-

bly and lower the reach assembly low enough to
1. UPPER RETAINING BRACKET install the free-lift chains.
2. FREE-LIFT CYLINDER
3. INNER MAST 8. Install the free-lift chains to the chain anchors
4. ALIGNMENT PIN or install the crosshead to the cylinder rod if re-
moved.
Figure 25. Free-Lift Cylinder (5.5 HD and 6.9
Mast) NOTE: Models with displacement-type cylinders
Install models with piston-type cylinders. Fill the hydraulic
For the following procedures, refer to Figure 24 or model to ensure proper operation. Refer to Hydraulic
Figure 25. System.
1. Attach an overhead lifting device to the lift cylin- 9. Fill the hydraulic system to the proper level and
der using a sling. bleed the air from the cylinders and the hydraulic
system. See Hydraulic System in this section.
2. 5.5 HD and 6.9 Mast - Install alignment pin
to bottom of cylinder shell and align with lower 10. Check that the mast is properly adjusted before
mounting holes in inner mast. returning to service. See Mast Adjustments in
this section.
3. Position the free-lift cylinder into the mast using
the lifting device.
4. Position the upper cylinder retaining bracket

onto the free-lift cylinder. Install the two screws
30
4000 SRM 1195 Lift Chains
Lift Chains
CLEAN AND INSPECT d. Hang chains over a drip pan for one hour to
remove excess oil.
WARNING 3. Inspect the chain anchors and pins. Replace any
Never replace only the worn section of a chain. parts that are worn or damaged.
chains.
CAUTION
or load rollers. The bearings in the sheaves and
NOTE: Lift chains must be checked for correct length

while installed in the mast when the mast is installed
on the lift truck.

chain that passes over the chain sheave during the
wear.
1. Inspect the lift chains for wear or damage. A lift

chain becomes longer when it is worn. If a chain
is 3% longer than a new lift chain, the lift chain
must be replaced. If a chain scale is available, NOTE: THE INSTRUCTIONS FOR MEASURING
check the lift chain as shown in Figure 26. If a CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
chain scale is not available, measure 20 links of SCALE.
the lift chain. Compare the measurement with
the lengths given in Figure 26. 1. CHAIN WEAR SCALE
Pitch Wear Limit

WARNING Total length
The
Cleaning solvents may be flammable and toxic of 20 links
maximum
and can cause severe skin irritation. When (pitch) of new
length of 20
using cleaning solvents, always follow the chain
links
solvent manufacturer’s recommended safety
precautions. 12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
2. Clean and lubricate the lift chains: 15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
a. Soaking the lift chains in solvent for 30 min- 19.1 mm 381.0 mm 392.4 mm
utes and remove all dirt and grease. (0.75 in.) (15.0 in.) (15.5 in.)
25.4 mm 508.0 mm 523.3 mm
b. Hang lift chains up and remove solvent using (1.00 in.) (20.0 in.) (20.6 in.)
compressed air.
c. Lubricate the chains by soaking them in SAE Figure 26. Lift Chains Check
30 engine oil for 30 minutes.
31
Mast Adjustments 4000 SRM 1195
Mast Adjustments
GENERAL b. If the angle is greater than 90.5 :
Read and follow the Safety Procedures When Work- (1) Safety chain the mast so the lower mast
ing Near Mast as well as all WARNINGS and CAU- mounting capscrews can be accessed.
TIONS.
(2) Loosen all of the lower mast mounting
The mast weldments must be aligned so that they are hardware and remove shims evenly.
parallel to each other during operation. Keeping the
weldments parallel will have the result of smoother (3) Tighten all of the lower mast mounting
operation and wear. hardware evenly.
The only adjustment for the load rollers is the ad- (4) Torque to 203 N•m (150 lbf ft). Verify
justment of the wear plugs. These adjustments are torques after tightening.
made for minimum side clearance and to keep the
3. Check the angle between the outer mast and the
weldments parallel with equal clearance on each side
top of the lift truck frame again. When the angle
between all weldments.
is between 90.0 and 90.5 , the mast back angle
Chains are adjusted for the following reasons: adjustment is correct.
• So each lift chain of a pair has an equal load to
prevent too much load and wear on one chain of
a pair.
dle. Remove the safety chains and the drive
• So mast weldments move in the correct sequence.
wheel blocks.
• So chains move over chain sheaves correctly.
Adjustments must be made to both the free-lift

(three-stage only) and main-lift chain sets. Each lift
chain is adjusted at the chain anchor.
MAST BACK ANGLE ADJUSTMENT

The following procedures refer to adjusting a mast
already installed to the lift truck.

2. Measure the angle between the outer mast and

the top of the lift truck frame. See Figure 27.
a. If the angle is less than 90.0 :
(1) Safety chain the mast so the lower mast

mounting capscrews can be accessed.
1. MAST MOUNTING CAPSCREW AND WASHER
(2) Loosen all of the lower mast mounting 2. LIFT TRUCK FRAME
hardware and add shims evenly. 3. MAST BACK ANGLE (90.0 TO 90.5 )
(3) Tighten all of the lower mast mounting Figure 27. Mast Back Angle
hardware evenly.
(4) Torque to 203 N•m (150 lbf ft). Verify

torques after tightening.
32
4000 SRM 1195 Mast Adjustments
LOAD ROLLERS ADJUSTMENT 2. Measure and record the distance between the
outside of the side rollers and load rollers of the
Reach Carriage Assembly rear frame of the reach assembly. See Figure 29.
1. Measure the width between the outside edges of 3. If the difference between dimension A and the
the inner mast in several places. Make a note largest measurement between the inner mast
of the location and the value of the maximum channels is more than 4 mm (0.16 in.), install
measurement. See Figure 28. shims to the side rollers and/or load rollers
evenly. If the difference is less than 4 mm
(0.16 in.), remove shims from the side rollers
and/or load rollers evenly.
Figure 29. Side and Load Roller Widths
Figure 28. Measuring Channel Width
33
ADJUST WEAR PLUGS - MAST Adjust the wear plugs as follows:
Wear plugs are located in the stub shaft of the load 1. Loosen the jam nut on the wear plug. See Fig-
rollers of the mast. See Figure 30. ure 31. Raise and lower the mast weldments sev-
eral times to find the point of minimum clearance
of the weldment.
2. Adjust the wear plugs to attain zero clearance be-

tween the wear plug and the weldment channel
at the tightest point. Adjust wear plugs on oppo-
site sides to keep the weldment in the center.
3. Adjust the clearance to approximately 0.02 in. by

turning the adjustment handle 1/8 turn counter-
clockwise. Keep the clearance between the weld-
ments equal on both sides. Keep the weldments
parallel to each other.
4. Tighten each jam nut without moving the

setscrew.
5. Raise and lower the weldments without a load.

Check that there is minimum clearance, as de-
scribed in Step 3, with free movement. If the
weldments do not move smoothly during lower-
ing, follow the WARNING and adjust the wear
plugs equally for more clearance.
1. TOP OF INTERMEDIATE MAST 1. LOAD ROLLER 5. JAM NUT

2. BOTTOM OF INNER MAST 2. WEAR PLUG 6. STUB SHAFT
3. TOP OF OUTER MAST 3. RETAINING RING 7. MAST CHANNEL
4. BOTTOM OF INTERMEDIATE MAST 4. SETSCREW
Figure 30. Wear Plugs Location Figure 31. Load Roller and Wear Plug Assembly
34
same, and tighten the lock nuts. Recheck

WARNING that the top of the weldments are still within
NEVER loosen the wear plugs if a mast weld- specification. See Step 1.
ment does not move freely during checks after
an adjustment. The weldments or carriage can b. If the tension on both chains are equal, pro-
suddenly move and cause an injury. Raise the ceed to the next step.
weldment, move the key to the OFF position,
and install safety chains as described in Safety 3. Adjust the free-lift chains. See Adjust Free-Lift
Procedures When Working Near Mast. Loosen Chain.
the wear plugs to allow movement. 4. Check the mast operation as described in Mast
6. If necessary, operate the system so that the lift Operation Check.
chains are the supports and carefully remove the 5. Install the mast operator guard (if removed).
safety chains. Raise and lower the weldments
with a load. Check that there is minimum clear- ADJUST FREE-LIFT CHAIN
ance, as described in Step 3, with free movement.
If the weldments do not move smoothly during NOTE: Make sure the forks of the reach carriage are
lowering, follow the WARNING and adjust the parallel to the floor (no forward or backward tilt).
wear plugs equally for more clearance. The main lift chains must be adjusted BEFORE ad-
justing the free-lift chains.
7. Repeat Step 1 through Step 6 for each weldment.
1. Fully lower the carriage. With the forks level
ADJUST MAIN-LIFT CHAINS (parallel to the floor), measure the distance from
the floor to the top of forks. The correct distance
The main lift chains must be adjusted BEFORE ad- is 63.5 mm (2.5 in.).
justing the free-lift chains.
2. If the distance is correct, the free-lift chains are
Adjust chain anchors at main lift cylinders so top of adjusted for the correct height. Perform Step 5
inner mast weldment is even with top of outer mast next. If the distance is NOT correct, perform all
weldment. of the steps.
NOTE: Remove the mast operator guard if adjust- 3. Raise the mast until the free-lift cylinder chain
ment is necessary. anchors at the rear of the free-lift cylinder can be
1. Completely lower the mast. Check to verify that accessed from the operator compartment. Install
the top of the outer weldment is even (±1.5 mm safety chains as described in Safety Procedures
(0.06 in.)) with the top of the inner mast. When Working Near Mast. Remove the mast op-
erator guard for easier access to the chain an-
a. If the top of the weldments are not even, chors. Loosen both lock nuts at the chain anchors
adjust the nuts on the chain anchors until to make any adjustments.
the weldments are even, and tighten the lock
nuts. 4. Adjust the nuts of the chain anchors equal
amounts for the correct distance (Step 1).
b. If the top of the weldments are even (within
specification), proceed to the next step. 5. Check chain tension by pushing on both chains
at the same time. If the tension is not the same,
2. Check chain tension by pushing on both main-lift adjust the nuts on the chain anchors until the
chains at the same time. tension is the same and the distance (Step 1) is
also correct. When the tension is equal on both
a. If the tension is not the same, adjust the nuts chains, the chain sheave assembly will be level.
on the chain anchors until the tension is the Tighten the lock nuts.
35
CAUTION
When the chain adjustments are complete,
make sure the cotter pin at the bottom of the
chain anchor can be installed under the ad-
justment nut. If there is no room to install
the cotter pin, the chains are too short. Make
sure the lock nuts on the chain anchors are
tight against the mount plate. If there are
not enough threads on the chain anchor for
correct adjustment, new chains are too long or
old chains are too worn. See Lift Chains.
6. Check the mast operation as described in Mast

Operation Check.
7. Recheck the distance from the floor to the top of

the forks.
8. Raise the reach carriage to the top of the inner

mast. Check to ensure the reach carriage stops
before hitting the stops at the top of the inner
weldment. If the reach mechanism reaches the
stops prior to full elevation, recheck fork height
with the mast fully lowered.
9. Extend the mast fully to check the maximum

fork height (MFH). The MFH specifications are
stamped into the side of the outer mast. With the
forks level (parallel to the floor), verify MFH by
measuring from the floor to the top of the forks
with the mast fully extended. See Figure 32.
10. Install the mast operator guard if removed.
1. REACH CARRIAGE STOP

2. MAXIMUM FORK HEIGHT (MFH)
3. FLOOR LEVEL
Figure 32. Maximum Fork Height (MFH)
36
ADJUST WEAR STRIPS

NOTE: The wear plugs and lift chains must be ad-
justed before the wear strips are checked for wear,
replaced, and adjusted.
The wear strips and shims are fastened to the lower

guide blocks of weldments that move. See Figure 33
and Figure 34.
The wear strips and shims are adjusted:

• For minimum clearance to prevent too much side
movement of the weldments.
• To keep the weldments parallel.
Check and adjust the wear strips as follows:
1. Raise the carriage for access to the wear strips.

Install safety chains as described in Safety Pro-
cedures When Working Near Mast.
2. Remove the capscrews, washers, wear strips, and

shims. Replace all worn or damaged parts. One
wear strip and one shim on each side is usually
the correct adjustment. There must be the same
number of shims under the wear strip on both
sides of the weldment. Equal shims will keep the
weldment parallel with equal clearance.
3. Use a pry bar to move the weldment to install

shims for minimum clearance. Install the shims
and new wear strips as shown in Figure 34. Re-
move the safety chains.
4. Make sure the mast operates correctly as de-

scribed in Mast Operation Check.
1. INNER AND INTERMEDIATE WELDMENTS

2. CAPSCREW AND WASHER
3. SHIM PACK
Figure 33. Wear Strip Locations
37
4. Add bevelled shim(s) (5) to the main cylinder rod

on the same side as the direction of rack until
the rack is eliminated. Remove the same amount
of shims (3) from the top to install the retaining
ring. See Figure 37.
1. CAPSCREW 4. SHIM
2. WASHER 5. WELDMENT
3. WEAR STRIP CHANNEL
Figure 34. Typical Wear Strip Assembly
MAST RACKING
1. Extend the mast fully. If the mast racks (leans)
to either side, the main lift cylinders must be ad-
justed. Make note of direction of racking and
lower the mast. See Figure 35.
2. Raise the mast approximately 150 mm (6 in.).

Safety chain the mast in place. See Safety Pro-
cedures When Working Near Mast.
3. Retract the cylinder rods from the intermediate

mast:
NOTE: Use only a brass driver and a hammer to tap

the cylinder rods from the intermediate mast. Use of
harder material can disfigure the cylinder rod.
a. Remove the retaining rings, shims and rub- 1. MAIN LIFT CYLINDER (LH)
ber bushings (5.5 HD and 6.9 only) from the 2. FREE-LIFT CYLINDER
top of the cylinder rods. Carefully pull the in- 3. MAIN LIFT CYLINDER (RH)
termediate weldment outward while lightly
tapping on the top of the cylinder rods to re- Figure 35. Mast Racking
move them from their mounts in the inter-
mediate mast. Recover the bevelled shims
from the shoulder of the cylinder rod. See
Figure 36.
38
1. OUTER MAST
3. RETAINING RING, SHIMS, AND BUSHINGS
4. BEVELLED SHIMS
5. MAIN LIFT CYLINDER
Figure 36. Main Lift Cylinder Shims
1. OUTER MAST
2. RETAINING RING
3. SHIM(S)
5. BEVELLED SHIM(S)
6. LIFT CYLINDER ASSEMBLY
Figure 37. Lift Cylinder Shims (5.5 Std)
39
PROXIMITY SWITCHES face of the switch to the bracket. Remove the nut
and lockwasher from the face side of the switch
The lift truck uses a proximity switch to monitor and remove the switch from the bracket. See Fig-
when the mast has passed from the free-lift stage ure 38.
(free-lift cylinder stroke) to the main lift stage (mast
telescoping). It is located on a mounting bracket at
the bottom of the left hand main lift cylinder which
holds the switch in position. The switch detects
the lower crossmember of the intermediate mast
when the mast weldments are lowered. When the
mast weldments raise, the proximity switch loses
its target signaling the main controller to increase
the lift pump and motor speed to compensate for the
increased load of the mast weldments. The switch
reacquires its target as the mast weldments lower
and signals the controller to slow the hydraulic flow
for the free-lift stage.
On certain models there is a second proximity switch
mounted to the bottom of the rear frame of the reach
carriage assembly. This switch detects the reach
carriage assembly height when lowered approxi-
mately 610 mm (24 in.) above the floor. At this
point, the master controller either slows the descent
of the reach carriage assembly or stops the carriage
completely, depending on the setting selected in the
dash display. The controller slows the carriage by
signaling the lift pump and motor to slow, cushioning
the final descent. It stops the carriage by signaling
the lift pump and motor to stop, holding the load at a
preset carry height. The lower button on the control
handle must be released an repressed to completely
lower the reach carriage assembly.
The proximity switches must be adjusted within

10 mm (0.39 in.) to detect their targets. Always
check wiring connections and air gap adjustments
before replacing components.
Replace
Free-Lift Proximity Switch
1. Position the mast and reach carriage assembly

for access to the proximity switch. Safety chain
1. AIR GAP 4. LOCKWASHERS
the mast in place. See Safety Procedures When 2. SWITCH FACE 5. NUT
Working Near Mast. 3. NUT 6. WIRING
2. Disconnect the battery and attach a DO NOT Figure 38. Proximity Switch
OPERATE tag to the control handle.
5. If necessary to replace the bracket, remove the
3. Disconnect the proximity switch connector. capscrews and hardware securing the mounting
bracket to the mast. Install new bracket using
4. Make note of the position of the switch within
capscrews and hardware as removed.
the bracket by measuring the distance from the
40
4000 SRM 1195 Mast Operation Check
6. Remove one nut and lockwasher from the face wiring side of the switch until distance from face
side of the new switch. Adjust the nut on the of switch is same as old switch.
wiring side of the switch until distance from face
of switch is same as old switch. 6. Position the new switch into the bracket. Install
7. Position the new switch into the bracket. Install switch. Secure in place.
switch. Secure in place. 7. Connect the switch wiring to the mast wiring.
Secure with wire ties as removed.
8. Connect the switch wiring to the mast wiring.
8. Reconnect the battery. Test for proper operation.
9. Reconnect the battery. Remove the tag from the control handle and re-
turn to service.
10. Remove the safety chains from the mast.
Adjust
11. Test for proper operation. Remove the tag from
the control handle and return to service. The proximity switch must be adjusted within 10 mm
(0.39 in.) to detect its target.
Load Lowering Proximity Switch (Optional)
1. Position the mast and reach carriage for access
1. Position the reach carriage assembly for access
to the proximity switch. If raised, safety chain
to the proximity switch.
the mast in place. See Safety Procedures When
2. Disconnect the battery and attach a DO NOT Working Near Mast.
OPERATE tag to the control handle.
2. Slightly loosen jam nuts.
3. Disconnect the proximity switch connector. Clip
3. Adjust the nuts to move the switch to a position
wire ties securing wiring in place.
within 10 mm (0.39 in.) from its target.
4. Make note of the position of the switch within the
4. Tighten the jam nuts.
bracket by measuring the distance from the face
of the switch to the bracket. Remove the nut and 5. Remove the safety chains and test for proper op-
lockwasher from the face side of the switch and eration. If moving the switch in the direction of
remove the switch from the bracket. the target does not restore correct function, the
switch may be faulty. See Proximity Switches,
5. Remove one nut and lockwasher from the face
Replace.
side of the new switch. Adjust the nut on the
Mast Operation Check

Read and follow the Safety Procedures When Work- NOTE: Some parts of the mast move at different
ing Near Mast as well as all WARNINGS and CAU- speeds during raising and lowering.
TIONS.
3. The weldments and the carriage must lower com-
pletely.
WARNING
DO NOT try to locate hydraulic leaks by 4. Check that the controls for the carriage operate
putting hands on pressurized hydraulic com- the functions of the carriage. See the symbols by
ponents. Hydraulic oil can be injected into the each of the controls and refer to the Operating
body by pressure. Manual for your lift truck. Make sure all of the
hydraulic lines are connected correctly and do not
1. Check for leaks in the hydraulic system. Check leak.
the condition of the hydraulic hoses and tubes.
2. Slowly raise and lower the mast several times

without a load. The mast components must raise
and lower smoothly in the correct sequence.
41
Lift System Leak Check 4000 SRM 1195
Lift System Leak Check

LIFT CYLINDER LEAK CHECK Close gate valve. If carriage or mast weldments
lower slowly, seals in lift cylinders have leaks.
WARNING 4. If carriage does not move, open gate valve and
During the test procedures for the hydraulic check movement again. If carriage lowers when
system, use chains to fasten the load to the car- gate valve is open, check for leaks in hydraulic
riage to prevent it from falling. Keep all people lines and fittings. If no leaks are found, main
away from the lift truck during the tests. control valve can be worn or damaged. Remove
load from forks.
TILT CYLINDER LEAK CHECK
jected into the skin. Visually inspect to find 1. Put capacity load on forks. Use safety chain to
hydraulic leaks. secure load to the reach carriage assembly. With
the forks level (parallel to the floor) raise load
1. Operate hydraulic system. Put capacity load on
approximately 2.5 m (8 ft).
forks. Use safety chain to hold load to carriage.
Raise and lower load several times. Lower load 2. Measure distance from fork tip to floor. After 1
and tilt mast forward and backward several minute re-measure distance; difference must not
times. Check for leaks. exceed:
2. Raise carriage and load 1 m (3 ft). If carriage Fork Length Allowable
slowly lowers when control valve is in NEU- Measurement
TRAL position, there are leaks in hydraulic Difference
system. The maximum speed the carriage is
allowed to lower is 50 mm (2 in.) per 10 minutes 914 mm (36 in.) 7.86 mm (0.31 in.)
when hydraulic oil is 30 C (90 F). If oil tem- 1067 mm (42 in.) 9.18 mm (0.36 in.)
perature is 70 C (160 F), the maximum speed
the carriage can lower is 150 mm (6 in.) per 10 1219 mm (48 in.) 10.48 mm (0.41 in.)
minutes. 1372 mm (54 in.) 11.80 mm (0.46 in.)
3. Check lift cylinders for internal leaks. Remove 1524 mm (60 in.) 13.11 mm (0.52 in.)
load from forks. Install gate valve in supply line
1829 mm (72 in.) 15.73 mm (0.62 in.)
between main control valve and mast. Put capac-
ity load on forks again. Raise carriage 1 m (3 ft).
42
MASTER DRIVE UNIT
N25XMDR3, N30-40XMR3 [C470];
N50XMA3 [C471];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265];
N35ZDR, N45ZR [C264]
PART NO. 1523820 630 SRM 1022

Master Drive Unit Table of Contents
TABLE OF CONTENTS
HFK400 Master Drive Unit............................................................................................................................... 1

General ........................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
Drive Unit Maintenance and Repair ............................................................................................................ 2
Remove....................................................................................................................................................... 2
Install ......................................................................................................................................................... 3
Disassemble ............................................................................................................................................... 4
Assemble .................................................................................................................................................... 7
Troubleshooting ............................................................................................................................................. 15
GK Master Drive Unit ....................................................................................................................................... 17
General ........................................................................................................................................................... 17
Description ..................................................................................................................................................... 17
Maintenance and Repair ............................................................................................................................... 18
Install ............................................................................................................................................................. 19
Assemble ........................................................................................................................................................ 19
Mounting Electric Motor........................................................................................................................... 20
Pivoted Connection - Geared Steering ..................................................................................................... 20
Disassemble ................................................................................................................................................... 20
Troubleshooting ............................................................................................................................................. 21
N25XMDR3, N30-40XMR3 [C470];

N50XMA3 [C471];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265];
N35ZDR, N45ZR [C264]

630 SRM 1022 HFK400 Master Drive Unit
HFK400 Master Drive Unit

GENERAL
CAUTION
Some of the hardware used on the MDU and
traction motor is metric. Use the correct tool
to avoid damage.
This section contains a description, repair, and ad-

justment procedures for the parts of the HFK400
master drive unit (MDU) used on the narrow aisle
and grocery reach lift trucks. The traction motor,
steering, and brake repair information are in sepa-
rate manuals.
DESCRIPTION
The main component parts of the MDU are the case,
the motor pinion and large gear set, the pinion and
spiral bevel gear set, the bearings, and the axle and
wheel. See Figure 1. The traction motor fastens to an
adapter ring fastened to the MDU. This adapter ring
is part of the large ball bearing and allows the MDU
to turn on the axis of the traction motor for steering.
The traction motor does not turn with the MDU.
Six capscrews fasten the large ball bearing and MDU

to the articulating axle. There is a small pinion gear
on the traction motor armature shaft. This gear
turns a large gear on the pinion shaft in the MDU.
The pinion shaft turns a spiral bevel gear on the axle
to turn the drive wheel. The brake is fastened to the
other end of the traction motor shaft and provides
friction for braking to stop rotation of the shaft. The
braking action works through the gears to stop the
unit.
Figure 1. Master Drive Unit With Motor and

Wheel
1
HFK400 Master Drive Unit 630 SRM 1022
DRIVE UNIT MAINTENANCE AND REPAIR drain plug. Tighten the drain plug to 22 N•m
(16 lbf ft).
Remove
6. Remove the six capscrews and lockwashers that
fasten the traction motor to the adapter ring on
WARNING
the MDU. Carefully lift the motor and set the mo-
The lift truck and components are heavy. tor out of the way. DO NOT damage the pinion
Be sure that all lifting devices (hoists, ca- gear on the motor shaft. Use a rope to fasten the
bles, chains, slings, etc.) are suitable and motor to prevent the motor from falling. See Fig-
of adequate capacity to lift the lift truck or ure 2.
component. The lift truck can weigh up to
approximately 3541 kg (7800 lb) empty.
1. Move the steering control so the drive wheel is in

a position for straight travel.
WARNING
nector before opening the drive unit compart-
ment door and before inspecting or repairing
the electrical system. If a tool causes a short
circuit, the high-current flow from the battery
can cause injury or parts damage.
2. Disconnect and remove the battery. Use the

battery removal procedure described in either
the Operating Manual or the section Periodic
Maintenance 8000 SRM 970.
3. Remove the electrical compartment cover for ac-

cess to the traction motor controller. Remove the
capscrews retaining the cover to the frame.
WARNING
is disconnected. To prevent electrical shock 1. TRACTION MOTOR 8. LOCKWASHER
or injury, discharge the capacitor before in- 2. CAPSCREW 9. NUT
specting or repairing any component. Wear 3. LOCKWASHER 10. WHEEL NUT
4. CAPSCREW 11. WHEEL
safety glasses. Make certain the battery has 5. LOCKWASHER 12. DRIVE UNIT
been disconnected. Discharge the capacitors 6. O-RING 13. ARTICULATING
in the controller by connecting a load (such as 7. PINION GEAR AXLE
a contactor coil or horn) across the controller’s
B+ and B terminals (center two terminals). Figure 2. Separating Traction Motor
DO NOT use a screwdriver to discharge the
7. Loosen the lock nut at the chain anchor for the
traction motor controller.
steering chain. Remove the capscrew at the
4. Discharge the traction motor controller by con- chain anchor. Put a mark on the MDU for the
necting a load across terminals B+ and B . location of the pin that fastens the chain anchor
to the sprocket. Remove the pin. Carefully
5. Open the drive unit compartment door. Fasten remove the chain anchor and chain from the
the door so that it is fully open. Put a pan under sprocket. Refer to the section Steering System
the MDU drain plug and remove the drain plug. 1600 SRM 974.
After the oil has completely drained, install the
2
4. Install the six capscrews and lockwashers that

WARNING fasten the adapter ring and MDU to the frame
There are close clearances between the MDU, or axle plate. Use a cross pattern to tighten the
drive chassis, and base arm that can cause se- capscrews to 25 N•m (18 lbf ft). Make sure the
rious injury. NEVER put hands, arms, head, or large ball bearing and adapter ring are in the cor-
legs between these parts unless the parts have rect position around the complete circumference.
blocks to prevent movement. If the MDU falls, Use the cross pattern to tighten the capscrews to
it can cause an injury. Support the MDU verti- 68 N•m (50 lbf ft).
cally to prevent it from falling.
5. If the pinion gear on the motor shaft was re-
8. Place a sling under the lift truck frame on the moved, install the key, gear, lockwasher, and nut.
mast side of the MDU. Make sure the lifting de- Tighten the nut to 54 N•m (40 lbf ft). If an impact
vice and sling have the ability to lift approxi- wrench is used, make sure it does not tighten the
mately 3541 kg (7800 lb). nut to more than the correct torque.
9. Remove the six capscrews and lockwashers that 6. Install a new O-ring on the motor using O-ring
fasten the adapter ring and MDU to the articu- lubricant. Carefully install and align the motor
lating axle. on the adapter ring and MDU. DO NOT damage
the pinion gear on the motor shaft or the large
10. Hold the MDU and raise the truck frame so that gear of the MDU. Install the six capscrews and
the MDU is free. The steer axle will pivot on the lockwashers. Tighten the capscrews to 20 N•m
articulation shaft. Lower the MDU to the floor (15 lbf ft).
and move it from under the lift truck. Lower the
lift truck frame on blocks. 7. Make sure the MDU is in the position for straight
travel with the tire to the left of the case (facing
Install MDU). Carefully install the steering chain. Use
the pin to install the chain anchor on the adapter
WARNING ring. Use the capscrew to fasten the two chain
The lift truck and components are heavy. anchors together. Adjust the steering chain,
Be sure that all lifting devices (hoists, ca- steering potentiometer, and limit switches using
bles, chains, slings, etc.) are suitable and the procedures in the section Steering System
of adequate capacity to lift the lift truck or 1600 SRM 974.
component. The lift truck can weigh up to
approximately 3541 kg (7800 lb) empty. CAUTION
The steering system MUST be adjusted before
1. Use a crane and chain or sling with a capacity
operating the lift truck.
rating of 3541 kg (7800 lb) to lift the frame. Lift
the frame for clearance to slide the MDU un- 8. Lubricate the large ball bearing using the proper
der the frame or steer axle. Temporarily install grease. Fill the MDU to the level/fill plug using
blocks under the frame to prevent lowering. Lay the proper oil. The proper lubricants are listed in
the MDU on the floor. Slide the MDU under the the Operating Manual or the section Periodic
drive chassis. Maintenance 8000 SRM 970. Add oil slowly.
The oil passes through the bearings to the lower
2. Move the MDU into approximate alignment un-
part of the MDU.
der the frame or axle plate.
9. Install the battery and close the drive unit com-
3. Hold the MDU in the vertical position through
partment doors. Install the electrical compart-
the hole in the plate. DO NOT put any part
ment cover. Connect the battery connector.
of your body between the MDU and the frame
or axle plate. Carefully raise the frame and re-
move the blocks. Carefully lower the frame and
align the capscrew holes in the large ball bear-
ing, adapter ring, and frame or axle plate.
3
Disassemble 3. The upper housing is retained to the lower hous-

ing with two dowel pins. Use a plastic hammer
1. Remove the wheel nuts and the drive/steer against the lower portion of the upper housing to
wheel. separate the upper housing from the lower hous-
ing. Carefully slide the upper housing for clear-
2. Remove the nine capscrews that fasten the lower
ance between the upper housing and helical gear.
housing to the upper housing. Remove the four
Remove the upper housing.
capscrews inside the upper housing. See Fig-
ure 3. There are also two capscrews inside the
case that are secured with washers and nuts on CAUTION
the opposite side of the upper housing. Make The helical gear and pinion shaft assembly can
certain to remove the capscrews, lockwashers, only be removed after the bevel gear and axle
and nuts before attempting to separate the up- shaft have been removed from the drive unit
per housing from the lower housing. lower housing.
4. Remove the capscrews retaining the drive unit

cover. Remove the drive unit cover.
5. Install two wheel nuts on to the wheel bolts. Po-

sition a piece of wood or bar between the nuts
to retain the drive axle while removing the spe-
cial capscrew retaining the bevel gear to the axle
shaft. Remove the special capscrew (24 mm) and
the special washer.
WARNING
Toxic vapors may be generated by heating the
axle shaft to remove the Loctite® adhesive.
Wear a protective mask during this operation.
Use gloves to remove the bevel gear if it has
been heated.
NOTE: The bevel gear is secured to the axle shaft us-

ing Loctite® 270. It may be necessary to use a weld-
ing torch to heat the bevel gear to 100 to 120 C (212
to 248 F) to free the bevel gear from the axle shaft.
6. Use a strap wrench or place a wood wedge under

the helical gear to keep the gear from rotating.
Remove the nut retaining the helical spur gear.
Use a gear puller to remove the helical gear from
the pinion shaft. Carefully remove the pinion
1. TOP CASE shaft and bearing cone from the lower housing.
2. CAPSCREWS INSIDE TOP CASE Use a plastic hammer, if necessary. Remove the
3. BOTTOM CASE spacer bushing from the pinion shaft.
4. CAPSCREWS (3 EACH SIDE)
5. CAPSCREW (CENTER)
6. CAPSCREW IN PIN
7. SPACER
Figure 3. Separating Cases
4
7. Use a copper mandrel and a plastic hammer to 11. Remove the wheel bolts from the axle shaft, us-
drive the axle shaft out of the lower housing. Re- ing a hydraulic press, if necessary. See Figure 5.
move the bevel pinion out of the lower housing.
12. If necessary, remove the bearing cups. See Fig-
ure 6. Use a puller or copper mandrel and a plas-
CAUTION tic hammer. DO NOT damage or lose the shims
Keep all shim sets together and labeled for cor- between the cups and the bore in the case. Keep
rect location and installation during assembly. each set of shims together and separate from the
other sets of shims. Put a label on each set so that
NOTE: If the bevel pinion and gear set will NOT be the sets can be installed in the correct position
replaced, the same shim sets can be used during as- during assembly. Measure the distance between
sembly. Adjustment will not be necessary. the edge of the case and the inner seal ring at the
axle bore. The replacement seal ring MUST be
8. If necessary, remove the bearing cones from the
installed in the same position as the old seal. Re-
axle shaft, the bevel gear, and the bevel pinion
move the seal ring.
shaft. To remove the bearing cone from the axle
shaft, it is necessary to cut the bearing cage, then
open the cage and remove the rollers. Use a
puller to remove the cage from the axle shaft.
9. Remove the bearing shield from the lower hous-

ing using a plastic hammer. See Figure 4.
10. If necessary, remove the motor nut, lockwasher,

bevel pinion, and key from the motor shaft. Re-
move the O-ring from the motor.
Figure 4. Removing Bearing Shield
5
Figure 5. Master Drive Unit Parts
6
Legend for Figure 5

1. SCREW 19. SHIM
2. CENTERING RING 20. PLUG/OIL DRAIN
3. SOCKET HEAD SCREW 21. SEAL RING
5. NUT 23. COVER
6. SOCKET HEAD SCREW 24. WHEEL SHAFT
7. SOCKET HEAD SCREW 25. WHEEL STUD
8. SOCKET HEAD SCREW 26. SEALING RING
9. DOWEL PIN 27. BEARING
10. UPPER HOUSING 28. SHIM
11. BREATHER VALVE 29. OIL RING
12. PLUG/OIL FILL 30. SEALING RING
13. SEAL RING 31. CAPSCREW
14. LUBE FITTING 32. DISK
15. PINION GEAR 33. RING AND PINION
16. LOCK NUT 34. BEARING
17. GEAR 35. SHIM
18. BEARING 36. LOWER HOUSING
Assemble
WARNING
cleaning solvents, always follow the recom-
mendations of the manufacturer. Wear eye
protection.
CAUTION
Some of the hardware used on the master drive
unit (MDU) and traction motor is metric. Use
the correct tool to avoid damage.
NOTE: The pinion gear and the large gear MUST be

replaced as a set. The spiral bevel pinion and gear
set MUST be replaced as a set.
NOTE: The large ball bearing is part of the top case.

The top case and the ball bearing are replaced as a
unit.
1. Clean all components thoroughly. Use Loctite®

Fast Cleaner No. 706 to remove all traces of ad-
1. UPPER PINION BEARING CUP hesive from the lower housing in the area where
2. LOWER PINION BEARING CUP the thread-protecting shield had been located.
3. INNER AXLE SHAFT BEARING CUP
4. OUTER AXLE SHAFT BEARING CUP Spray the cleaner from a distance of approxi-
5. UPPER PINION BEARING SHIMS mately 30 cm (12 in.) while holding the can up-
6. LOWER PINION BEARING SHIMS right. Allow the cleaner to work; then thoroughly
7. INNER AXLE SHAFT SHIMS remove the dissolved dirt from the lower housing
8. OUTER AXLE SHAFT SHIMS using a clean cloth. Spray the surface with the
9. INNER SEAL RING
10. BEARING SHIELD cleaner again and allow to air-dry.
Figure 6. Bearing and Shim Location 2. Check all parts for damage or cracks. Replace
any damaged parts.
7
indicator. The procedure below specifies the use of

CAUTION a special measuring tool (Hyster P/N 2036120) and
The axle and gear assemblies are installed and a special clamping tool (Hyster P/N 2036121). The
removed several times during this procedure. measuring tool can be fabricated, if desired, as fol-
Be careful not to damage the seals. lows: Make a bushing to fit the bore of the lower pin-
ion shaft bearing. The bushing must have an out-
NOTE: The helical pinion and gear and the bevel side diameter of 51.5 mm (2.03 in.) and a length of
pinion shaft and bevel gear are matched sets and 67.5 mm (2.66 in.). The special clamping tool can be
MUST be replaced as sets. When replacing the gear used to facilitate easy assembly.
sets, always replace the tapered roller bearings. The
bearing cup and bearing cone MUST be from the 3. Insert the special measuring tool in the pinion
same manufacturer. Lubricate the bearings with shaft lower bearing bore. Determine the correct
clean transmission oil prior to assembly. thickness for the lower bearing shim set (dimen-
sion X) as follows (see Figure 7):
NOTE: Assembly of the drive unit requires the use
of a standard micrometer, torque wrench, and dial
NOTE: THERE ARE TWO NUMBERS STAMPED ON THE BEVEL PINION SHAFT. THERE ARE ALSO TWO
NUMBERS STAMPED ON THE BEVEL GEAR. ONE NUMBER ON EACH PART IS THE SET NUMBER. THESE
NUMBERS MUST BE THE SAME. CHECK THAT THE BEVEL PINION SHAFT AND THE BEVEL GEAR ARE
A MATCHED SET BY COMPARING THE SET NUMBERS. THE SECOND NUMBER ON THE BEVEL PINION
SHAFT IS THE ASSEMBLY DIMENSION OF THE SHAFT (DIMENSION B, BELOW). THE SECOND NUMBER
ON THE BEVEL GEAR IS THE GEAR CLEARANCE NUMBER.
1. BEVEL PINION SHAFT 6. LOWER BEARING SHIM SET
2. SPACER 7. UPPER BEARING SHIM SET
3. SPECIAL MEASURING TOOL 8. UPPER BEARING
4. LOWER CASE 9. DIMENSION B (MM) STAMPED ON END OF
5. LOWER BEARING BEVEL PINION SHAFT
Figure 7. Bevel Pinion Shaft Installation
8
a. Measure dimension F (the difference be-

tween the axle bearing bore and the end of
the bushing).
b. Subtract the value F from the length (L) of

the bushing.
c. Add the value of d/2. The result is dimension

E.
E = L F + d/2
L = bushing length
F = the difference between the bearing bore
for the axle and the end of the bushing
d/2 = 45.00 mm (1.7716 in.)
d. Measure dimension T (the width of the lower

bearing).
e. Subtract assembly dimension B (stamped

on the bevel pinion shaft) from dimension 1. BEARING CUP
E (found in Step c, above). Then subtract 2. WHEEL SHAFT INNER BEARING BORE SHIM
dimension T. The result is dimension X (the SET
3. WHEEL SHAFT OUTER BEARING BORE SHIM
correct thickness of the lower bearing shim SET
set).
X=E B T Figure 8. Wheel Shaft Shim Sets
E = the value found in Step c
B = the number stamped on the pinion shaft 6. Install the shim set removed during disassembly
T = the total thickness of the bearing from the outer bearing bore of the wheel shaft
into the outer bearing bore. This shim set will be
4. Assemble the proper combination of shims to used for the preliminary adjustment of the wheel
equal the correct thickness for the lower bear- shaft. Press the outer bearing cup into the outer
ing shim set, as determined above [±0.05 mm bearing bore. See Figure 8.
(0.002 in.)]. Install the lower bearing shim set
into the lower bearing bore. Press the lower NOTE: DO NOT install the wheel shaft seal until
bearing cup into the bore. after the adjustment procedure has been completed.
7. Press the taper roller bearing cone up to the stop

CAUTION on the pinion shaft.
DO NOT use damaged or distorted shims in the
following steps. 8. Lubricate the bearing cup with transmission
oil. Install the pinion shaft into the housing
5. Install the shim set removed during disassembly and preload it against the bearing cup with the
from the inner bearing bore of the wheel shaft special clamping tool or a piece of wood.
into the inner bearing bore. This shim set will be
used for the preliminary adjustment of the wheel 9. Measure distance A between the top of the shoul-
shaft. Drive the inner bearing cup into the inner der of the pinion shaft and the bottom of the bore
bearing bore. See Figure 8. for the upper bearing. See Figure 9.
9
Figure 9. Shim Measurement Figure 10. Pinion Shaft Bearing Clearance

Check
10. Add 0.02 mm (0.00079 in.) to the value of dimen-
sion A and install a shim set equal to that sum 16. Remove the pinion shaft and bearing. Remove
into the bearing bore. the upper bearing cup. Additional shims must
Shim set (mm) = A + 0.02 mm be added to the upper bearing bore to preload
the bearing. To determine the correct amount
11. Press the upper bearing cup into the bearing of additional shims, add 0.07 mm (0.0028 in.) to
bore. Press the upper bearing cone onto the the clearance value measured in Step 15. Install
pinion shaft up to the stop. shims equal to that sum into the bearing bore
with the shims installed earlier.
12. Place the helical gear onto the pinion shaft and
Additional shim set (mm) = value measured on
install the nut. Hold the helical gear with a strap
dial indicator + 0.07 mm
wrench and tighten the nut to a torque value of
150 N•m (111 lbf ft). DO NOT stake the nut. The If no clearance was measured, add a total of
bearing clearance must be checked and adjusted 0.02 mm (0.00079 in.) to the shims installed
before staking the nut. earlier.
13. Remove the special clamping tool or piece of wood 17. Install the pinion shaft. Press the upper bearing
holding the pinion shaft in place. cup into the bearing bore. Press the upper bear-
ing cone onto the pinion shaft up to the stop.
14. Press the pinion shaft downward by hand while
turning the shaft several times to align the taper 18. Cover the splines of the helical gear with a thin
rollers within the bearing. coat of Loctite® 270. Wipe off any excess with a
rag.
15. Place the dial indicator on the housing as shown
in Figure 10. Adjust the dial to indicate zero. 19. Place the helical gear onto the pinion shaft and
Mark the point of measurement on the helical install the nut. Hold the helical gear with a strap
spur gear with a colored pencil. Lift the pinion wrench and tighten the nut to a torque value of
shaft upward by carefully prying up beneath the 150 N•m (111 lbf ft). Stake the nut to the pinion
helical spur gear with two levers. Read any de- shaft.
flection on the dial indicator. This value is the
bearing clearance. Repeat the procedure to be 20. Press the wheel bolts into the wheel shaft until
sure to obtain the correct value. the bolt contacts the stop. Be sure the flattened
side of the bolt faces the wheel shaft center.
10
21. Push the sealing ring onto the wheel shaft. 28. Check the tooth contact pattern by coating three
Press the outer wheel bearing cone onto the to four tooth flanks of the bevel gear with ink.
wheel shaft until the bearing contacts the stop. Mesh the coated teeth with the pinion gear sev-
Wait to grease the bearing until after the preload eral times and then inspect the wear pattern of
adjustments are performed. the ink on the coated teeth. Slight deviations
from the ideal tooth contact pattern are admis-
NOTE: After the proper backlash has been obtained, sible. Significant tooth contact pattern misalign-
grease the seal ring and fill the outer bearing cone ment is an indication that a mistake was made
using Shell Alvania R3 grease prior to assembly. at an earlier step in the procedure and will ne-
cessitate repeating the assembly procedure. See
22. Press the inner wheel bearing cone onto the bevel
Table 1.
gear until the bearing cone contacts the stop.
23. Insert the bevel gear into the MDU housing.
NOTE: DO NOT install the inner seal ring until the

bearing preload has been adjusted.
24. Insert the wheel shaft into the housing and en-
gage the splines of the shaft into the bevel gear.
Secure the bevel gear on the wheel shaft using
the M16 capscrew and special washer.
25. Prevent the axle from turning. Tighten the M16

capscrew to 245 N•m (181 lbf ft).
26. Use a dial indicator to check the backlash

between the bevel gear and the pinion. The
backlash is the clearance between the teeth of 1. SPIRAL BEVEL GEAR
the bevel gear and the teeth of the pinion gear. 2. DIAL INDICATOR
See Figure 11. Position the dial indicator on the 3. WOOD WEDGE
housing so that the dial indicator foot is as close Figure 11. Checking Backlash
as possible to being perpendicular to the tooth
flank of the bevel gear. Install a wood wedge 29. Check the wheel bearing clearance. Press down
under the large gear at the top of the MDU to on the wheel shaft by hand and rotate it several
keep the gear and pinion from moving. times. Arrange the dial indicator on the housing
as shown in Figure 12. Adjust the dial to indi-
27. Adjust the dial indicator to zero. Turn the cate zero. Lift the wheel shaft upward by care-
wheel shaft in both directions to measure any fully prying up beneath the bevel gear with two
deflection. The admissible range for backlash is levers. Read any deflection on the dial indicator.
between 0.03 to 0.11 mm (0.0012 to 0.0043 in.). This value is the bearing clearance. Repeat the
Backlash is adjusted by adding or removing procedure to be sure to obtain the correct value.
shims beneath the inner wheel bearing cup. The
ideal backlash is 0.07 mm (0.028 in.).
11
Table 1. Tooth Contact Pattern
Correct Contact Pattern Step 1. Apply a colored dye or grease to

approximately 12 of the teeth of the spiral
bevel gear.
Step 2. Apply a small friction load to the
edge of the gear so that the gear does not
turn easily. Rotate the gear one revolution
by turning the large gear on the spiral bevel
pinion.
Step 3. Check the tooth contact pattern on
the spiral bevel gear. Make sure that the
pattern is checked on the side of the tooth
where the pinion teeth apply the force.
Wrong Tooth Contact Pattern
Tip Contact The spiral bevel pinion is too far from
the center of the spiral bevel gear. Some
movement in the direction of the arrows can
be necessary. Adjust the thickness of the
shim as described in the assembly procedure.
Base Contact The spiral bevel pinion is too close to

the center of the spiral bevel gear. Some
movement in the direction of the arrows
can be necessary. Adjust the thickness of
the shim sets as described in the assembly
procedure.
Inner Contact The spiral bevel pinion is too far from the
center of the spiral bevel pinion. Some
movement of the spiral gear away from the
spiral bevel pinion can be necessary. Adjust
the shim sets at the spiral bevel gear as
described in the assembly procedure.
Outer Contact The spiral bevel pinion is too far from the
center of the spiral bevel pinion. Some
movement of the spiral gear toward the
spiral bevel pinion can be necessary. Adjust
the shim sets at the spiral bevel gear as
described in the assembly procedure.
12
a shim from beneath the inner bearing cup, you

must add it to the shims beneath outer bearing
cup). The ideal backlash is 0.07 mm (0.003 in.).
34. After the proper backlash and preload have been

obtained, remove the bevel gear and wheel shaft
in order to mount the thread-protective shield
and the radial shaft seal.
35. Thoroughly clean the seat of the thread-protec-

tive shield on the housing with Loctite® Fast
Cleaner 706 or equivalent.
36. Coat the seat of the thread-protective shield with

Figure 12. Wheel Shaft Bearing Clearance
Loctite® 270. Press the thread-protective shield
Check
on the lower housing as far as possible. See Fig-
30. Remove the wheel shaft and outer bearing. Re- ure 13.
move the outer bearing cup. Add or remove
shims as required to obtain a bearing clear-
ance of 0.02 mm (0.00079 in.). Install the outer
bearing cup, bearing, and wheel shaft. Repeat
Step 29. After the bearing clearance is confirmed
to be 0.02 mm (0.00079 in.), remove the wheel
shaft, outer bearing, and outer bearing cup
again. Add 0.10 mm (0.004 in.) additional shims
to the outer bearing bore to preload the bearing.
31. Install the outer bearing cup, outer bearing, and

wheel shaft. Verify that the wheel shaft can be
turned by hand. If not, reduce the preload set
in the previous step in 0.01 mm (0.00039 in.) in-
crements until the wheel shaft can be turned by
hand.
32. After the bearing preload has been properly set,

check the backlash again. Use a dial indicator to
check the backlash between the bevel gear and 1. RADIAL SHAFT SEAL
the pinion. The backlash is the clearance be- 2. THREAD-PROTECTIVE SHIELD
tween the teeth of the bevel gear and the teeth of
the pinion gear. See Figure 11. Position the dial Figure 13. Inner Seal Installation
indicator on the housing so that the dial indicator
foot is as close as possible to being perpendicular 37. Remove the outer bearing cup and shims. Thinly
to the tooth flank of the bevel gear. Install a wood coat the radial shaft seal with Loctite® 574. In-
wedge under the large gear at the top of the MDU stall the inner seal into the lower housing. The
to keep the gear and pinion from moving. inner seal should be 3.0 mm (0.118 in.) below
the bottom edge of the outer bearing bore, when
33. Adjust the dial indicator to zero. Turn the wheel properly installed. See Figure 13. Install the
shaft in both directions to measure any deflec- shims and outer bearing cup.
tion. The admissible range for backlash is be-
tween 0.03 to 0.11 mm (0.0012 to 0.0043 in.). If 38. Coat the entire surface of the inner splines of the
the backlash needs to be adjusted at this point, bevel gear with Loctite® 270. Insert the bevel
the total thickness of the outer plus the inner gear in the housing. See Figure 13.
shims must remain constant (i.e., if you remove
13
c. The maximum trunnion bearing clearance is

exceeded. Check the clearance as described
below.
45. Clamp the upper part of the MDU to an assembly

table. Install three eyebolts into the outer race
of the trunnion bearing and rotate the bearing
several times. See Figure 15.
1. M16 CAPSCREW 5. WHEEL SHAFT

2. SPECIAL WASHER 6. GREASE
3. BEVEL GEAR 7. LOCTITE® 270
4. HOUSING
Figure 14. Wheel Shaft Assembly
39. Fill the inner seal ring and the cone on the wheel
shaft with Shell Alvania R3 grease. See Fig-
ure 14.
40. Insert the wheel shaft into the housing and en-
gage the splines of the shaft into the bevel gear. Figure 15. Wheel Shaft Assembly
Remove excess with a clean cloth. 46. Install a cable in each eye bolt. Position three
41. Secure the bevel gear on the wheel shaft using dial indicators on the trunnion bearing and set
the M16 capscrew and special washer. Prevent the indicators to zero. Mark the position of one
the axle from turning. Tighten the M16 capscrew dial indicator on the trunnion bearing with a
to 245 N•m (181 lbf ft). marking pen.
42. Coat the flat housing surface with Loctite® 574 47. Raise the upper housing using a lifting device
before mounting the housing cover. Apply one and a spring balance to obtain approximately
drop of Loctite® 243 to the threads of each of 50 kg (110 lb) of force. Rotate the trunnion
the housing cover mounting bolts and install the bearing several times and position at the mark
bolts. again. The maximum bearing clearance is
0.03 mm (0.0012 in.). If the bearing clearance
NOTE: If the tapped holes in the bottom of the lower is more than the recommended clearance, the
housing extend through the housing, completely seal trunnion bearing and upper housing must be
the capscrews with Loctite® adhesive to prevent oil replaced.
from leaking from around the threads.
NOTE: The large ball bearing is part of the upper
43. Tighten the housing cover capscrews to 9.5 N•m housing. The upper housing and the ball bearing are
(7 lbf ft). replaced as a unit.
44. Inspect the upper part of the MDU. The upper 48. Install the drive venting filter as far as possible
part of the MDU must be replaced if: into the upper part of the MDU. Install grease
fitting. See Figure 16.
a. The caulked cover plate on the trunnion bear-
ing has separated. Check visually.
b. The trunnion bearing is difficult to turn or

binds. Check manually.
14
23 N•m (17 lbf ft). Tighten the 10 mm capscrews

to 46 N•m (34 lbf ft). Install the socket head
capscrews, the washers, and the nuts. Tighten
the nuts to 23 N•m (17 lbf ft).
50. Install the wheel and the lug nuts. Tighten the
nuts in a cross pattern to one-half the torque
value specified in Section 2. Tighten the lug nuts
again using the cross pattern to obtain the proper
torque.
51. Lubricate trunnion bearing using the recom-

mended grease listed in Section 2. Add the
grease through both fittings. Slowly rotate the
1. DRIVE VENTING FILTER
2. GREASE FITTING MDU while filling the fittings with grease. A
dry bearing will take approximately 55 grams
Figure 16. Drive Venting Filter and Grease (0.12 lb) of grease to fill the bearing completely.
Fitting Installation
52. Fill the MDU to the level/fill plug using the rec-
49. Use Loctite® 574 to install the upper housing ommended oil listed in Section 2. Add the oil
on the lower housing. Make sure the upper slowly. The oil must go through the bearings to
housing is aligned correctly and use a punch the lower part of the MDU. Fill until the oil just
to install the two dowels if removed. Install starts to run out. Install the plug and tighten to
the capscrews. Tighten the 8 mm capscrews to 22 N•m (16 lbf ft).
TROUBLESHOOTING
Lift truck will not move. Traction motor not operating. Repair or replace traction motor.
Damaged gears or bearings. Replace gears or bearings.
MDU makes noise. Insufficient lubricant or incorrect lu- Lubricate as needed.

bricant.
Dry, damaged, or incorrect bearings. Lubricate as needed.
Bearing preload or backlash not Adjust backlash.

properly adjusted.
Worn or damaged gears. Replace gears.
Oil leaks at the housing Housing cover is not sealed or prop- Seal properly.
cover. erly seated.
Capscrews not sealed off or not tight- Tighten to appropriate torque.

ened to specified torque.
15
Oil leaks at the wheel shaft. Shaft seal incorrectly mounted or Replace shaft seal.
damaged.
Surface of axle shaft damaged. Replace axle shaft.
Oil leaks at the filler plug or Dirt between sealing ring and hous- Clean sealing ring and housing.
drain plug. ing.
Plugs not tightened to specified Tighten plugs to appropriate torque.

torque.
Oil leakage between lower Sealing surface not sealed off. Seal properly.
and upper housings.
Capscrews not tightened to specified Tighten to appropriate torque.

torque.
Oil leaks in motor compart- Too much oil in MDU. Drain excess oil.
ment.
Breather defective. Clean or replace breather.
Traction motor seal defective. Replace motor seal.
Trunnion bearing difficult to Centering ring separated, allowing Torque capscrews holding centering
turn, binds, or exceeds max- dirt to penetrate into bearing. ring to MDU.
imum clearance.
Cage segments are damaged. Replace cage segments.
Deformation of the balls or ball Replace balls and ball races.

races.
Bearing not properly lubricated. Lubricate as needed.
16
630 SRM 1022 GK Master Drive Unit
GK Master Drive Unit

GENERAL Some of the hardware used on the MDU and
traction motor is metric. Use the correct tool
This section contains a description, repair, and ad- to avoid damage.
justment procedures for the parts of the GK master
drive unit (MDU) used on the narrow aisle lift trucks. The GK MDU is vertically installed in the truck and
The traction motor, steering, and brake repair infor- allows an effective utilization of space. The com-
mation are in separate manuals. pact, one-piece housing is made of high-duty nodular
iron; thus having a high rigidity and optimum guid-
DESCRIPTION ing precision. This allows a fully integrated bearing
of the helical spur gear stage with a very high run-
CAUTION ning smoothness; i.e., no drive pinion on the motor
shaft of the electric motor. See Figure 17.
Certain specifications and procedures differ
depending upon the type of master drive unit. The MDU consists of two ratio steps. Gear ratio 1 is
Verify the type of MDU by inspecting the hous- designed as helical spur gear stage and permanently
ing. integrated in the housing. Gear ratio 2 is designed as
Gleason bevel gearing of the hypoid type with offset
bevel pinion shaft.
1. MDU HOUSING 6. WHEEL SHAFT

2. VENT HOLE 7. INPUT PINION
3. GEAR RIM 8. HOUSING COVER
4. STEERING PINION 9. OIL FILLER PLUG
5. STEERING BEARING 10. OIL DRAIN PLUG
Figure 17. GK Master Drive Unit
17
GK Master Drive Unit 630 SRM 1022
MAINTENANCE AND REPAIR
WARNING
The lift truck and components are heavy. All
lifting devices (hoists, cables, chains, slings,
etc.) must be suitable and of adequate capac-
ity to lift the lift truck or component. The lift
truck can weigh up to approximately 3541 kg
(7800 lb) empty.
1. Move the steering control so the drive wheel is in

a position for straight travel.
WARNING
nector before opening the drive unit compart-
ment door and before inspecting or repairing
the electrical system. If a tool causes a short
circuit, the high-current flow from the battery
can cause injury or parts damage.
2. Disconnect and remove the battery. Use the

battery removal procedure described in either 1. TRACTION MOTOR 6. WHEEL NUT
the Operating Manual or the section Peri- 2. CAPSCREW 7. WHEEL
odic Maintenance 8000 SRM 970 or Periodic 3. LOCKWASHER 8. DRIVE UNIT
4. CAPSCREW 9. ARTICULATING
Maintenance 8000 SRM 1197.
5. LOCKWASHER AXLE
3. Remove the electrical compartment cover for ac-
Figure 18. Drive Unit Assembly
cess to the traction motor controller. Remove the
capscrews retaining the cover to the frame. See
Figure 18.
WARNING
is disconnected. To prevent electrical shock or
injury, discharge the capacitor before inspect-
ing or repairing any component. Wear safety
glasses. Make certain the battery has been dis-
connected.
4. Discharge the capacitor in the controller by

connecting a 200-ohm, 2-watt resistor across
the controller’s a load across the B+ and B
terminals of the motor controller for 10 seconds.
Remove the resistor after discharging the capac-
itor See Figure 19.
5. Open the drive unit compartment door and fas- 1. POSITIVE CONNECTION (B+)
ten the door so that it is fully open. Put a pan 3. INSULATED JUMPER WIRES
under the MDU drain plug and remove the plug. 4. 200-OHM, 2-WATT RESISTOR
After the oil has completely drained, reinstall the
drain plug. Tighten to 22 N•m (16 lbf ft). Figure 19. Discharging the Capacitors
18
1. Use a crane and chain or sling with appropri-

WARNING ate capacity to lift the frame. Lift the frame for
The motor is heavy. Use appropriate lifting enough clearance to slide the MDU under the
equipment to avoid personal injury. frame or steer axle. Temporarily install blocks
under the frame to prevent lowering. Lay the
6. Remove the capscrews and lockwashers that fas- MDU under the drive chassis.
ten the traction motor to the adapter ring on the
MDU. Carefully lift and sit the motor out of the 2. Move the MDU into approximate alignment un-
way. Use rope to fasten the motor to prevent it der the frame or axle plate.
from falling.
3. Align both the MDU with the screw holes and
the steer gear with the axle pilot hole. Carefully
WARNING raise the frame and remove the blocks. Lower the
There are close clearances between the MDU, frame and align the capscrew holes in the large
drive chassis, and base arm that can cause se- ball bearing, adapter ring, and the frame or axle
rious injury. NEVER put hands, arms, head, plate.
or legs between these parts unless there are
blocks in place to prevent movement. If the 4. Install the capscrews and lockwashers that fas-
MDU falls, it can cause an injury. Support the ten the adapter ring and MDU to the frame or
MDU vertically to prevent it from falling. axle plate. Use cross pattern to tighten the cap-
screws to the appropriate torque. Make sure the
7. Place a sling under the lift truck frame on the large ball bearing and adapter ring are in the cor-
mast side of the MDU. Make sure the lifting de- rect position around the complete circumference.
vice and sling have the ability to lift approxi-
mately 3541 kg (7800 lb). ASSEMBLE
8. Remove capscrews and lockwashers that fasten
the adapter ring and MDU to the articulating CAUTION
axle or truck frame. The MDU is only allowed to be lifted with
soft ropes or belts, never with steel cables or
WARNING chains. Care must be taken during transport
The MDU is heavy. It can weigh approximately to avoid shocks. This is especially important
52 kg (114.6 lb). Use appropriate lifting equip- pertaining to wheel bolts, the electric motor,
ment to avoid personal injury. and accessories.
9. Hold the MDU and raise the truck frame so that The corrosion protection can only be removed
the MDU is free. Move the MDU from under the from the connecting points using a suitable
lift truck. Lower the lift truck frame on blocks. cleaner. Never use benzene, solvents, or other
combustible substances for cleaning. Use
INSTALL only nontoxic, noncombustible, and commer-
cially permissible cleaning agents. Wear safety
gloves and goggles!
WARNING
The lift truck and components are heavy. DO NOT drain cleaners into the soil. DO NOT al-
Be sure that all lifting devices (hoists, ca- low cleaners to contact rubber parts, electrical con-
bles, chains, slings, etc.) are suitable and of nections of accessories, or the motor ventilation.
adequate capacity to lift the lift truck or com-
ponent to avoid personal injury.
19
GK Master Drive Unit 630 SRM 1022
Mounting Electric Motor DISASSEMBLE

1. Apply a thin coat of lubrication grease onto the To disassemble, reverse the assembly process ex-
splined shaft-hub connection. plained in previous section.
2. Assemble the electric motor into the centering

seat of the steering bearing and cautiously join
it with the splined hub connection of the drive
pinion.
3. Turn the hole pattern of the steering bearing so

that it is aligned with the electric motor.
4. Install the six capscrews and lockwashers that

fasten the electric motor and tighten to appropri-
ate torque.
Pivoted Connection - Geared Steering

1. Make sure that the gear rim is clean and pay
attention that no foreign substances or cleaning
agents get through the threaded boreholes of the
connecting structure into the transmission inte-
rior. See Figure 20.
2. Align the gear rim and bolt holes with the

threaded boreholes of the connecting structure.
Install the steering bearing on the correct side
and turn it so the bolt holes are aligned with the
hole pattern of the gear rim and the housing.
3. Install capscrews to 34 N•m (25 lbf ft) to fasten

the steering bearing and the gear rim onto the
connecting structure.
1. BOREHOLES 3. STEERING
NOTE: Use Loctite® adhesive as needed. During dis- 2. GEAR RIM BEARING
assembly and later reuse of the screws, the adhesive 4. CAPSCREWS
remaining on the thread must be removed and new
screws must be used. Figure 20. Geared Steering
The fixing bolts should be checked at fixed inter-

vals or operating hours, especially in case of high
breakdown torque load or suspended axial load.
20
TROUBLESHOOTING
Lift truck will not move. Traction motor not operating. Repair or replace traction motor.
Damaged gears or bearings. Replace drive unit.
Master drive unit makes Insufficient lubricant or incorrect lu- Lubricate as needed.
noise. bricant.
Dry, damaged, or incorrect bearings. Lubricate as needed.
Worn or damaged gears. Replace drive unit.
Oil leaks at the wheel shaft. Shaft seal incorrectly mounted or Replace drive unit.
damaged.
Surface of axle shaft damaged. Replace drive unit.
Oil leaks at the filler plug or Dirt between sealing ring and hous- Clean sealing ring and housing.
drain plug. ing.
Plugs not tightened to specified Tighten to appropriate torque.

torque.
Oil leaks in motor compart- Too much oil in MDU. Drain excess oil.
ment.
Breather defective. Clean or replace breather.
Trunnion bearing difficult to Centering ring separated, allowing Torque capscrews holding centering
turn, binds, or exceeds max- dirt to penetrate into bearing. ring to MDU.
imum clearance.
Cage segments are damaged. Replace trunnion bearing.
Deformation of the balls or ball Replace trunnion bearing.

races.
Bearing not properly lubricated. Replace trunnion bearing.
21
NOTES
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22
METRIC AND INCH
(SAE) FASTENERS
ALL MODELS
PART NO. 910442 8000 SRM 231

Metric and Inch (SAE) Fasteners Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Threaded Fasteners....................................................................................................................................... 1
Nomenclature, Threads................................................................................................................................. 1
Strength Identification .................................................................................................................................. 2
Cotter (Split) Pins.......................................................................................................................................... 2
Fastener Torque Tables ................................................................................................................................. 7
Conversion Table ........................................................................................................................................... 9
All Models

General
THREADED FASTENERS shown first in the series [M12 = 12 mm, M20 = 20
mm (1/2 = 1/2 in., 3/4 = 3/4 in.)].
Threaded fasteners, like bolts, nuts, capscrews, and
studs, are made to specifications that describe the The number of threads per inch is normally not
mechanical strength and hardness of the fastener. shown for inch nomenclature and only the UNC
A fastener used in a design application is selected (Unified National Coarse) or UNF (Unified National
according to its specifications. Hyster® Company Fine) is shown. This number of threads per inch is
buys parts from many countries. Parts that are not shown because a UNC or UNF fastener has a
purchased must be to Hyster® Company standards. standard number of threads per inch for a specific
There are several standards used by these countries diameter. Metric fasteners show the number of
in the manufacture of threaded fasteners. Many of threads per millimeter.
these fasteners are similar, but cannot be used as a
direct replacement. To make sure that you have the The length of the shank is often indicated as part of
correct fastener, order fasteners and parts through the description of a fastener. This length is shown
the Hyster® Parts Depot. in inches for inch fasteners and in millimeters for
metric fasteners.
Service persons must use replacement fasteners
that have the same specifications. Fasteners made A capscrew will have the following description:
to each specification have identification marks for
Metric Inch
that specification. This specification is commonly
called "Grade" for SAE standards and "property M12 × 1.75 × 50 1/2 × 13 UNC × 1-1/2
class" for metric standards. This section describes
ABC ABCD
the identification of some common fasteners.
A = Thread Size A = Shank Diameter
The metric system used by Hyster® Company is
described as SI (Le Systeme d’Unites or the In- B = Pitch B = Number of Threads
ternational System of units, also called SI in all Per Unit of Length
languages). The SI System of measurement is de- C = Length C = type of Thread
scribed in ISO Standard 1000, 1973. A conversion
table of common measurements is shown in Table 7. D = Shank Length
NOMENCLATURE, THREADS
The thread design is specified by a series of numbers
and letters for inch and metric fasteners. See Fig-
ure 1. The diameter of the shank of the fastener is
Figure 1. Thread Design
1
STRENGTH IDENTIFICATION
CAUTION
When fasteners must be replaced, the new fas-
teners must be of the same strength or greater
than the original fasteners. The new fasteners
must also be the correct size.
NOTE: Identification marks are according to bolt

strength. The higher the number or the increase
in the number of marks indicates increased bolt Figure 2. Minimum Angle Between Cotter Pin
strength. Legs
The most common property classes for metric fasten- Unless otherwise specified, the legs of chain anchor
ers are 8.8 and 10.9. The property class is marked cotter (split) pins are to be bent against the pin. See
with a number on the head of the capscrew or on Figure 3.
a nut. Property classes less than 8.8 are often not
marked. Grades for inch bolts go from 2 to 8. Grade
2 fasteners normally do not have any marks. The
following tables show the marks that identify the
grades and property classes for different fasteners.
COTTER (SPLIT) PINS

Cotter (split) pins are used in many applications on
your forklift. They are typically used to retain parts
such as pins and nuts. Cotter (split) pins are typi-
cally not used as load-bearing members. Service per-
sonnel must use new cotter (split) pins. Do not reuse
a cotter (split) pin. Replacement cotter (split) pin
must be of the correct size. See Table 8.
The legs of a cotter (split) pin are bent for the follow-
ing reasons: 1. COTTER PIN
• To retain the cotter (split) pin in the part
Figure 3. Cotter (Split) Pins Used On Mast
• To provide clearance between the cotter pin legs
Chain Anchors
and other parts or members. One or both cotter
(split) pin legs must be bent to provide a minimum
90 angle between the legs. See Figure 2.
2
Table 1. Bolts and Screws
3
Table 2. Studs and Nuts
4
Table 3. Torque Nuts
5
Table 4. Torque Nuts With Nylon Insert
6
FASTENER TORQUE TABLES

Table 5. Torque Values for Metric Fasteners*
Property Class Grade Grade

Size and Pitch 5.8 1 8.8 2 10.9 3
N•m lbf ft N•m lbf ft N•m lbf ft
M3 × 0.5 0.62 0.5 0.99 0.7 1.34 1.0
M3.5 × 0.6 0.97 0.7 1.55 1.1 2.11 1.6
M4 × 0.7 1.44 1.1 2.30 2.1 3.13 2.3
M5 × 0.8 2.91 2.1 4.65 3.6 6.33 4.7
M6 × 1 4.94 3.6 7.90 6 10.8 8
M8 × 1.25 12.0 9 19.2 14 26.1 19
M8 × 1 12.8 9 20.5 15 27.9 21
M10 × 1.5 23.8 18 38.0 28 52 38
M10 × 1.25 25.1 19 40.1 30 55 41
M12 × 1.75 41.4 31 66 49 90 66
M12 × 1.25 45.3 33 72 53 98 72
M14 × 2 66 49 105 77 145 105
M14 × 1.5 72 53 115 85 155 115
M16 × 2 105 77 165 122 225 165
M16 × 1.5 110 81 175 130 240 175
M20 × 2.5 200 150 320 235 435 320
M20 × 1.5 225 165 355 260 485 360
M24 × 3 345 255 555 410 755 560
M24 × 2 375 275 605 445 820 605
M27 × 3 505 370 810 600 1,100 810
M27 × 2 550 405 875 645 1,190 880
M30 × 3.5 690 510 1,100 810 1,500 1,100
M30 × 3 715 530 1,140 840 1,550 1,140
M30 × 2 765 565 1,220 900 1,660 1,230
M33 × 3.5 940 695 1,500 1,100 2,040 1,510
M33 × 2 1,030 760 1,640 1,210 2,240 1,660
M36 × 4 1,200 885 1,930 1,430 2,620 1,940
M36 × 3 1,280 945 2,040 1,510 2,780 2,050
M39 × 4 1,560 1,150 2,490 1,840 3,390 2,500
M39 × 3 1,640 1,210 2,630 1,940 3,570 2,640
M42 × 4.5 1,930 1,430 3,080 2,280 4,200 3,100
M42 × 3 2,070 1,530 3,320 2,450 4,510 3,330
M45 × 4.5 2,410 1,780 3,850 2,840 5,240 3,870
M45 × 3 2,580 1,910 4,120 3,040 5,610 4,140
M48 × 5 2,900 2,140 4,630 3,420 6,300 4,650
M48 × 3 3,160 2,330 5,040 3,720 6,860 5,060
* Unless otherwise specified
1
Approximately equal to Grade 2
2
3
7
Table 6. Torque Values for Inch Fasteners*
Grade Grade Grade

Size and Pitch 21 52 83
lbf ft N•m lbf ft N•m lbf ft N•m
1/4 20 UNC 4 6 6 9 9 12
1/4 28 UNF 5 6 7 10 10 14
5/16 18 UNC 8 11 13 18 18 25
5/16 24 UNF 9 13 14 20 20 28
3/8 16 UNC 15 20 23 31 33 44
3/8 24 UNF 17 23 26 36 37 50
7/16 14 UNC 24 33 37 50 52 71
7/16 20 UNF 27 36 41 56 58 79
1/2 13 UNC 37 50 57 77 80 110
1/2 20 UNF 41 56 64 86 90 120
9/16 12 UNC 53 72 82 110 115 155
9/16 18 UNF 59 80 91 125 130 175
5/8 11 UNC 73 99 115 155 160 215
5/8 18 UNF 83 110 130 175 180 245
3/4 10 UNC 130 175 200 270 280 380
3/4 16 UNF 145 195 225 300 315 425
7/8 9 UNC 125 170 320 435 455 615
7/8 14 UNF 140 185 355 480 500 680
1 8 UNC 185 255 485 655 680 925
1 14 UNF 210 285 540 735 765 1,040
1-1/8 7 UNC 265 360 595 805 965 1,310
1-1/8 12 UNF 300 405 670 905 1,080 1,470
1-1/4 7 UNC 375 510 840 1,140 1,360 1,850
1-1/4 12 UNF 415 565 930 1,260 1,500 2,050
1-3/8 6 UNC 490 665 1,100 1,490 1,780 2,420
1-3/8 12 UNF 560 760 1,250 1,700 2,040 2,760
1-1/2 6 UNC 650 885 1,460 1,980 2,370 3,210
1-1/2 12 UNF 735 995 1,650 2,230 2,670 3,620
* Unless otherwise specified
1
Approximately equal to metric Property Class 5.8
2
3
8
CONVERSION TABLE
Table 7. Conversion Table for Metric and English Units
Multiply By To Get Multiply By To Get

Area
2 2 2 2 2
inches (in. ) × 6.452 = centimeters (cm ) centimeters (cm 2) × 0.155 = inches 2
(in. 2)
2
feet (ft 2) × 0.093 = meters 2
(m 2) meters 2
(m 2) × 10.764 = feet 2
(ft 2)
Linear
inches (in.) × 25.4 = millimeters (mm) millimeter (mm) × 0.039 = inches (in.)
feet (ft) × 0.305 = meters (m) meter (m) × 3.281 = feet (ft)
yards (yd) × 0.914 = meters (m) meter (m) × 1.094 = yards (yd)
miles (mi) × 1.609 = kilometers (km) kilometer (km) × 0.621 = miles (mi)
Mass
ounces (oz) × 28.35 = grams (g) grams (g) × 0.035 = ounces (oz)
pounds (lb) × 0.454 = kilograms (kg) kilograms (kg) × 2.205 = pounds (lb)
tons (2,000 lb) × 907.18 = kilograms (kg) kilograms (kg) × 0.001 = tons (2,000 lb)
tons (2,000 lb) × 0.907 = metric ton (t) metric ton (t) × 1.102 = tons (2,000 lb)
Power
horsepower (hp) × 0.746 = kilowatts (kW) kilowatts (kW) × 1.34 = horsepower (hp)
Pressure
2 2
pounds/in. (psi) × 6.895 = kilopascal (kPa) kilopascals (kPa) × 0.145 = pounds/in. (psi)
2 2
pounds/in. (psi) × 0.007 = megapascal (MPa) megapascals (MPa) × 145.04 = pounds/in. (psi)
Temperature
( Fahrenheit 32) × 0.56 = Celsius (C) ( Celsius × 1.8) +32 = Fahrenheit
Torque
pound inches (lbf in.) × 0.113 = Newton meter (N•m) Newton meter (N•m) × 8.851 = pound inches (lb f in.)
pound feet (lbf ft) × 1.356 = Newton meter (N•m) Newton meter (N•m) × 0.738 = pound feet (lb f ft)
Velocity
miles/hour (mph) × 1.609 = kilometer/hour (km/h) kilometer/hr (km/h) × 0.621 = miles/hour (mph)
Volume
3 3 3 3 3
inches (in. ) × 16.387 = centimeters (cm ) centimeters (cm 3) × 0.061 = inches 3
(in. 3)
3
inches (in. 3) × 0.016 = liters (l) liters (l) × 61.024 = inches 3
(in. 3)
quarts, U.S. (qt) × 0.946 = liters (l) liters (l) × 1.057 = quarts, U.S. (qt)
quarts, U.S. (qt) × 0.83 = quarts, Imp. (qt) quarts, Imp. (qt) × 1.205 = quarts, U.S. (qt)
gallons, U.S. (gal) × 3.785 = liters (l) liters (l) × 0.264 = gallons, U.S. (gal)
gallons, U.S. (gal) × 0.83 = gallons, Imp. (gal) gallons, Imp. (gal) × 1.205 = gallons, U.S. (gal)
ounces (oz) × 29.57 = milliliters (ml) milliliters (ml) × 0.034 = ounces (oz)
9
Table 8. Cotter Pin Dimensional Data
Nominal Shank Diameter Head Dia. Length of Recommended

Size A A B Extended Prong Hole Size
C
max min min max min min max
1.00 mm 0.90 mm 0.70 mm 1.50 mm 1.52 mm 0.25 mm 0.91 mm 1.37 mm
(0.031 in.) (0.035 in.) (0.028 in.) (0.060 in.) (0.060 in.) (0.01 in.) (0.036 in.) (0.054 in.)
10
Nominal Length Range Nominal Size - Part Numbers

Length L
1.00 mm 1.60 mm 2.00 mm 2.50 mm 3.20 mm
max min (0.031 in.) (0.047 in.) (0.062 in.) (0.094 in.) (0.125 in.)
6.35 mm 7.10 mm 5.50 mm 0221870 0221875
(0.250 in.) (0.280 in.) (0.217 in.)
9.525 mm 10.5 mm 8.80 mm 0221871 0221876
(0.375 in.) (0.413 in.) (0.345 in.)
12.7 mm 13.5 mm 11.5 mm 0221872 0221877 0015200 0015211 0015221
(0.500 in.) (0.530 in.) (0.453 in.)
19.05 mm 20.5 mm 18.3 mm 0221873 0221878 0015201 0015212 0015222
(0.750 in.) (0.807 in.) (0.720 in.)
25.4 mm 26.9 mm 23.9 mm 0221874 0221879 0015202 0015213 0015223
(1.000 in.) (1.060 in.) (0.940 in.)
31.75 mm 33.3 mm 29.2 mm 0015203 0015216 0015224
(1.250 in.) (1.310 in.) (1.150 in.)
38.1 mm 40.9 mm 36.6 mm 0015204 0015217 0015225
(1.500 in.) (1.610 in.) (1.440 in.)
44.45 mm 46.0 mm 42.9 mm 0015205 0015218 0015226
(1.750 in.) (1.810 in.) (1.690 in.)
50.8 mm 52.3 mm 49.3 mm 0015206 0015219 0015227
(2.000 in.) (2.060 in.) (1.940 in.)
57.15 mm 58.7 mm 55.1 mm 0015220 0056997
(2.250 in.) (2.310 in.) (2.170 in.)
63.5 mm 65.0 mm 62.0 mm 0221894 0015229
(2.500 in.) (2.560 in.) (2.440 in.)
69.85 mm 72.1 mm 68.3 mm 0015230
(2.750 in.) (2.840 in.) (2.690 in.)
76.2 mm 81.3 mm 74.7 mm 0015279
(3.000 in.) (3.200 in.) (2.940 in.)
88.9 mm 91.4 mm 87.4 mm
(3.500 in.) (3.600 in.) (3.440 in.)
101.6 mm 113.3 mm 98.8 mm
(4.000 in.) (4.460 in.) (3.890 in.)
11
Table 9. Cotter Pin Dimensional Data (Continued)

Length L
1.00 mm 1.60 mm 2.00 mm 2.50 mm 3.20 mm
127.0 mm 128.5 mm 123.7 mm
(5.000 in.) (5.060 in.) (4.870 in.)
152.4 mm 153.9 mm 5.460 mm
(6.000 in.) (3.060 in.) (138.7 in.)

Length L
4.00 mm 5.00 mm 6.30 mm 8.00 mm 9.52 mm
6.35 mm 7.10 mm 5.50 mm
(0.250 in.) (0.280 in.) (0.217 in.)
9.525 mm 10.5 mm 8.80 mm
(0.375 in.) (0.413 in.) (0.345 in.)
12.7 mm 13.5 mm 11.5 mm
(0.500 in.) (0.530 in.) (0.453 in.)
19.05 mm 20.5 mm 18.3 mm 0015232 0015241
(0.750 in.) (0.807 in.) (0.720 in.)
25.4 mm 26.9 mm 23.9 mm 0015233 0015242 0015251 0015261
(1.000 in.) (1.060 in.) (0.940 in.)
12

Length L
4.00 mm 5.00 mm 6.30 mm 8.00 mm 9.52 mm
31.75 mm 33.3 mm 29.2 mm 0015234 0015243 0015252 0015262 0221884
(1.250 in.) (1.310 in.) (1.150 in.)
38.1 mm 40.9 mm 36.6 mm 0015235 0015244 0015253 0015263 0221885
(1.500 in.) (1.610 in.) (1.440 in.)
44.45 mm 46.0 mm 42.9 mm 0015236 0015245 0015254 0015264 0221886
(1.750 in.) (1.810 in.) (1.690 in.)
50.8 mm 52.3 mm 49.3 mm 0015237 0015246 0015255 0015265 0015271
(2.000 in.) (2.060 in.) (1.940 in.)
57.15 mm 58.7 mm 55.1 mm 0015238 0015247 0015256 0221880 0221887
(2.250 in.) (2.310 in.) (2.170 in.)
63.5 mm 65.0 mm 62.0 mm 0015240 0015248 0015257 0221881 0015273
(2.500 in.) (2.560 in.) (2.440 in.)
69.85 mm 72.1 mm 68.3 mm 0015280 0015249 0015258 0221882 0015286
(2.750 in.) (2.840 in.) (2.690 in.)
76.2 mm 81.3 mm 74.7 mm 0015283 0015250 0015259 0015267 0015272
(3.000 in.) (3.200 in.) (2.940 in.)
88.9 mm 91.4 mm 87.4 mm 0015239 0015284 0015266 0015274
(3.500 in.) (3.600 in.) (3.440 in.)
101.6 mm 113.3 mm 98.8 mm 0015301 0015260 0128754 0015275
(4.000 in.) (4.460 in.) (3.890 in.)
127.0 mm 128.5 mm 123.7 mm 0221883 0015277
(5.000 in.) (5.060 in.) (4.870 in.)
152.4 mm 153.9 mm 5.460 mm 0221888
(6.000 in.) (3.060 in.) (138.7 in.)
13
Nominal Length Length Range Nominal Size - Part Numbers

L
13.0 mm 16.00 mm
max min (0.500 in.) (0.625 in.)
19.05 mm 20.5 mm 18.3 mm
(0.750 in.) (0.807 in.) (0.720 in.)
25.4 mm 26.9 mm 23.9 mm
(1.00 in.) (1.060 in.) (0.940 in.)
31.75 mm 33.3 mm 29.2 mm
(1.250 in.) (1.310 in.) (1.150 in.)
38.1 mm 40.9 mm 36.6 mm
(1.500 in.) (1.610 in.) (1.440 in.)
44.45 mm 46.0 mm 42.9 mm 0221889
(1.750 in.) (1.810 in.) (1.690 in.)
50.8 mm 52.3 mm 49.3 mm 0221890
(2.000 in.) (2.060 in.) (1.940 in.)
57.15 mm 58.7 mm 55.1 mm 0221891
(2.250 in.) (2.310 in.) (2.170 in.)
63.5 mm 65.0 mm 62.0 mm 0221892
(2.500 in.) (2.560 in.) (2.440 in.)
69.85 mm 72.1 mm 68.3 mm 0221893 0221895
(2.750 in.) (2.840 in.) (2.690 in.)
76.2 mm 81.3 mm 74.7 mm 0015291 0221896
(3.000 in.) (3.200 in.) (2.940 in.)
88.9 mm 91.4 mm 87.4 mm 0015292 0221897
(3.500 in.) (3.600 in.) (3.440 in.)
101.6 mm 113.3 mm 98.8 mm 0015293 0221898
(4.000 in.) (4.460 in.) (3.890 in.)
14
Nominal Length Length Range Nominal Size - Part Numbers

L
13.0 mm 16.00 mm
max min (0.500 in.) (0.625 in.)
127.0 mm 128.5 mm 123.7 mm 0015295 0221899
(5.000 in.) (5.060 in.) (4.870 in.)
152.4 mm 153.9 mm 138.7 mm 0015297 0221900
(6.000 in.) (3.060 in.) (5.460 in.)
15
NOTES
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____________________________________________________________
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16
PERIODIC
MAINTENANCE
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590959 8000 SRM 1197

Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Removing Covers ........................................................................................................................................... 1
Front Frame Panel (Left and Right) ........................................................................................................ 1
Operator Compartment Cover.................................................................................................................. 2
Drive Unit Compartment Door................................................................................................................. 3
Caster Wheel Cover................................................................................................................................... 3
How to Move Disabled Truck ........................................................................................................................ 4
How to Tow Lift Truck............................................................................................................................... 4
How to Put Lift Truck on Blocks................................................................................................................... 5
How to Raise Load Wheels ....................................................................................................................... 5
How to Raise the Drive Tire End.............................................................................................................. 5
How to Raise the Entire Lift Truck .......................................................................................................... 6
Manual Lowering Valve ................................................................................................................................ 7
N30-35ZDR and N35-40-45ZR ................................................................................................................. 7
N30ZDRS and N35-40ZRS ....................................................................................................................... 7
Transporting....................................................................................................................................................... 8
Loading........................................................................................................................................................... 8
Unloading....................................................................................................................................................... 8
Preparation for Use............................................................................................................................................ 9
Preparation After Shipment ......................................................................................................................... 9
Preparation After Storage............................................................................................................................. 9
Maintenance Schedule....................................................................................................................................... 10
Maintenance Procedures Every 8 Hours or Daily............................................................................................ 14
Checks With Key Switch Turned OFF.......................................................................................................... 14
Battery ....................................................................................................................................................... 14
Tires and Wheels ....................................................................................................................................... 15
Frame and Load Wheels ........................................................................................................................... 15
Safety Labels ............................................................................................................................................. 16
Overhead Guard ........................................................................................................................................ 16
Forks Check ............................................................................................................................................... 16
Lift Chain Check ....................................................................................................................................... 17
Mast Check ................................................................................................................................................ 18
Reach, Tilt, and Sideshift.......................................................................................................................... 18
Checks With Key Switch Turned ON ........................................................................................................... 18
Operation ................................................................................................................................................... 18
Hydraulic System ...................................................................................................................................... 19
Dash Display ............................................................................................................................................. 19
Lift System Operation............................................................................................................................... 20
Multifunction Control Handle .................................................................................................................. 21
Brake.......................................................................................................................................................... 21
Steering System ........................................................................................................................................ 22
Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. 22
Master Drive Unit ......................................................................................................................................... 22
Hydraulic System .......................................................................................................................................... 22
Hydraulic Filter Element Change ................................................................................................................ 24
Caster Adjustment......................................................................................................................................... 24
Elastomer Spring Type Adjustment ......................................................................................................... 24
Belleville Spring Type Adjustment .......................................................................................................... 26
Spring Pack Replacement ......................................................................................................................... 27

Table of Contents Periodic Maintenance

Remove Spring Assembly ..................................................................................................................... 27
Replace Spring Pack ............................................................................................................................. 28
Install Spring Assembly ....................................................................................................................... 28
Drive Tire Check............................................................................................................................................ 28
Lift System Operation ................................................................................................................................... 29
Forks .......................................................................................................................................................... 29
Mast ........................................................................................................................................................... 29
Lift Chains ................................................................................................................................................. 29
Other Lubrication .......................................................................................................................................... 29
Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... 30
Brakes ............................................................................................................................................................ 30
Check.......................................................................................................................................................... 30
Electric System .............................................................................................................................................. 30
Main Contactor.......................................................................................................................................... 30
Inspect ................................................................................................................................................... 30
Drain .......................................................................................................................................................... 31
Cylinder Identification.......................................................................................................................... 32
Fill .............................................................................................................................................................. 34
Hydraulic Filter Change ........................................................................................................................... 36
Check Hydraulic Strainer ......................................................................................................................... 36
Lift and Tilt System Leaks Check..................................................................................................................... 37
Lift System..................................................................................................................................................... 37
Tilt System ..................................................................................................................................................... 37
Battery Maintenance ......................................................................................................................................... 38
How to Charge Battery.................................................................................................................................. 38
How to Change Battery ................................................................................................................................. 39
Tires and Wheels................................................................................................................................................ 42
Drive Tire ....................................................................................................................................................... 42
How to Change Drive Tire............................................................................................................................. 42
Tandem Load Wheels .................................................................................................................................... 43
Caster Wheels ................................................................................................................................................ 43
Remove....................................................................................................................................................... 43
Install ......................................................................................................................................................... 44
Preparation for Storage ..................................................................................................................................... 45
Short-Term Storage (1 to 6 months) ............................................................................................................. 45
Long-Term Storage (6 months or longer) ..................................................................................................... 45
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
ii
General
shift per day, in a relatively clean environment, on
WARNING an improved surface. Operating a lift truck for more
DO NOT make repairs or adjustments un- than eight hours per day is considered Heavy opera-
less you have been properly trained and tion and requires the 3-month checks to be performed
specifically authorized to do so. Repairs and at 350 hours. Lift trucks operating in freezer envi-
adjustments that are not correct can create ronments or dirty conditions are considered Severe
dangerous operating conditions. operation and require the 3-month checks to be per-
formed at 200 hours.
Report the need for repairs to your supervisor Your lift truck dealer has the facilities and trained
immediately. If repair is necessary, disconnect personnel to perform required maintenances. A com-
the battery and attach a DO NOT OPERATE tag plete program of inspection, lubrication, and mainte-
to the control handle. nance will help your lift truck perform efficiently and
operate over a longer period of time.
CAUTION
Some users have service personnel and facilities to
Electrical components on this truck are po- perform the tasks listed in the Maintenance Sched-
larity sensitive and may be damaged if wired ule. Service Manuals are available from your lift
incorrectly. Make sure each electrical wire truck dealer to help users who do their own mainte-
connection is tagged and properly identified nance.
location for connection is unclear, consult the DO NOT make repairs or adjustments unless you
wiring diagram for the truck. Make sure test- have been properly trained and specifically autho-
ing meters have adequate voltage and current rized to do so.
capacities to handle the output of the electri-
cal components they are used to check. Never Put the lift truck on a level surface. Lower the car-
wire aftermarket components to this truck riage and forks, apply the parking brake, and turn
without factory approval. the key switch to the OFF position. Open the access
panels and inspect for leaks and conditions that are
Certain welding repairs require factory ap- not normal. Clean any oil spills. Make sure that lint,
proval. Structural members such as base dust, paper, and other materials are removed from
arms, axle weldments, and mast components the compartments.
require written Hyster® engineering approval
before repairing or replacing. Contact your REMOVING COVERS
local dealer for assistance.
Front Frame Panel (Left and Right)
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection. Remove the screws from the upper and lower ends of
the front frame panel. Pull the lower end of the panel
The Maintenance Schedule is divided into three time away from the frame of the lift truck and gently work
intervals which call for particular maintenance pro- up the side of the panel to pull it from the retainer
cedures to be performed. The intervals are 1 Day clips securing the panel to the frame. Pull the top end
or 8 hours, 3 Months or 500 Hours, and 1 Year or tabs out of the operator compartment cover. Repeat
2000 Hours for normal operations (whichever comes for opposite side as necessary. See Figure 1.
first). Normal operation is considered one 8-hour
1
Operator Compartment Cover

Remove the front frame panels from the lift truck.
Refer to Front Frame Panel (Left and Right). Re-
move the two screws securing the operator cover to
the frame brackets. One is located on the lower right
side of the operator compartment above the opera-
tor presence switch. The other is located beside the
overhead guard post mount, at the bottom of the cup
holder. Pull the operator compartment cover up from
the front right corner. Continue pulling the cover up
along the edge of the frame in both directions until
the cover is free from the retaining clips. See Fig-
ure 2.
1. OPERATOR COMPARTMENT COVER

2. FRAME
3. LOWER BRACKET
4. LOWER SCREW
5. FRONT FRAME PANEL (LEFT)
6. TABS
7. UPPER BRACKET
8. UPPER SCREW
Figure 1. Front Frame Panel (Left Side)
NOTE: On right side front frame panels, ensure the

diagnostic connector cap is positioned to allow the
cover to seat properly.
To install the panel, position the upper end of the

panel partially into the retaining clip on the frame. 1. OPERATOR COMPARTMENT COVER
Insert the tabs on the upper end of the panel into 2. OVERHEAD GUARD POST MOUNT
the slots in the operator compartment cover. Work 3. FRAME
4. FRONT FRAME PANEL (LEFT)
the sides of the panel into the retaining clips until all
areas of the panel are aligned with the frame. Align Figure 2. Operator Compartment Cover
the holes in the panel with the mounting brackets
on the frame and loosely install the screws into the
upper end and lower end of the panel. Make certain
the panel is seated correctly against the frame and
tighten the screws to secure in place. See Figure 1.
2
To install, position the cover over the electrical com- the OFF position and attach a DO NOT OPER-
partment. See Figure 2. Align the lip of the cover to ATE tag to the control handle. Block the drive
the retaining clips. Press the lip of the cover into the wheel to prevent unexpected movement.
retaining clips starting at the overhead guard post
and continue around until completely seated. Align 2. Disconnect the battery power cable connector
the holes in cover with the mounting brackets and in- from the truck connector located on the right side
stall retaining screws as removed. Install the front of the frame. Pull the battery cable connector
frame panels to complete assembly. Refer to Front handle to separate the battery connector from
Frame Panel (Left and Right) in this section. the truck connector.

Drive Unit Compartment Door
Completely loosen the two socket head capscrews se-
curing the drive unit compartment door closed. The
screws are spring loaded and retained to the door
by clips. Pull the door open on its hinges. To close,
after discharging the capacitors. See Figure 3.
push the door closed and start both socket head cap-
screws loosely into the mounting holes. When both
screws are started, verify that the door seats prop-
erly against the frame and tighten the screws.
Caster Wheel Cover

Remove the socket head capscrews on top of the
caster wheel cover and lift cover from the clips se-
curing it to the frame.
To replace, fit the bottom of the cover into the clips

inside the opening and slide the cover into place. In-
stall two socket head capscrews to secure the top of
the cover in place.
DISCHARGING THE CAPACITORS
WARNING
an electrical charge after the battery is dis- 1. POSITIVE CONNECTION (B+)
connected. Discharge the capacitors before 2. NEGATIVE CONNECTIONS (B )
servicing the electrical system to prevent in- 3. INSULATED JUMPER WIRES
jury or electronic damage. 4. 200-OHM, 2-WATT RESISTOR
6. TRACTION MOTOR CONTROLLER
pletely lower the mast. Turn the key switch to Figure 3. Discharging the Capacitors
3
HOW TO MOVE DISABLED TRUCK b. Tighten the capscrews alternately until the
brake is released.
How to Tow Lift Truck
2. Raise the carriage and forks approximately
30 cm (12 in.) from the surface. Use safety
WARNING
chains to secure in place if the mast is not func-
Use extra care when moving a lift truck during tional.
the following conditions:
• Brakes do not operate correctly. 3. Attach a towing strap of adequate capacity to
• Steering does not operate correctly. the LOWER truck frame beneath the operator’s
• Tires are damaged. compartment.
• Traction conditions are bad.
• The lift truck must be moved on a steep 4. If a counterbalanced lift truck is used to tow the
grade. disabled lift truck, that lift truck must have an
equal or larger capacity than the disabled lift
Poor traction can cause the disabled lift truck truck. If an increased load will increase the load
or towing vehicle to slide. Steep grades will on the drive tire(s), install an approximate half-
require additional brake force to stop the lift capacity load on the forks of the lift truck that
truck. is being used to tow the disabled lift truck. This
half-capacity load will increase the traction of the
Never carry a disabled lift truck unless the lift lift truck. Keep the load as low as possible.
truck MUST be moved and cannot be towed.
The mast MUST be removed before the lift
truck can be lifted. The lift truck used to carry
the disabled lift truck MUST have a rated ca-
pacity equal to or greater than the weight of
the disabled lift truck. The capacity must be
for a load center equal to half the width of the
disabled lift truck. See the nameplate of the
disabled lift truck for the approximate total
weight. The forks must extend the full width
of the disabled lift truck. Center the weight
of the disabled lift truck on the forks and be
careful not to damage the under side of the lift
truck.
If towing a lift truck equipped with a steered

caster, the caster may resist tracking with the
drive wheel.
If there is no electrical power to the lift truck,

the electric parking brake will not automati-
cally release and the steering will not operate.
1. CAPSCREWS (1/4-20 × 1)
NOTE: The parking brake can be manually released 2. MANUAL RELEASE HOLE
by installing two service capscrews into the brake as- 3. BRAKE ASSEMBLY
sembly. Ensure the two capscrews are removed prior 4. ASSEMBLY HOLES
to returning to the lift truck to service.
Figure 4. Manual Release
1. Manually release the parking brake if problems
prevent it from releasing normally.
a. Insert two 1/4-20 × 1 (UNC) capscrews into

the two holes on the outer edge of the top of
the parking brake assembly. See Figure 4.
4
How to Raise Load Wheels

WARNING
If towing a lift truck equipped with a steered Refer to the precautions at the beginning of the How
caster, the caster may resist tracking with the to Put Lift Truck on Blocks instructions in this sec-
drive wheel. tion before attempting to raise the lift truck.
The towed lift truck must have an operator. 1. Put blocks on both sides (front and back) of the
drive/steer tire and the caster wheels to prevent
5. Tow the lift truck slowly. movement of the lift truck. See Figure 5.
6. Remove the capscrews from the brake, lower the 2. Use an overhead crane and web sling under the
mast, and disconnect the towing strap when com- base arms at the mast to raise the load wheels.
plete. Another lift truck can also be used to raise the
base arms. Make sure that the crane and sling
HOW TO PUT LIFT TRUCK ON BLOCKS or other lifting device has a capacity of at least
2/3 of the total weight of the lift truck as shown
WARNING on the nameplate.
The lift truck must be put on blocks or an ap-
3. Raise the base arms only enough to suspend the
proved stand for some types of maintenance
wheels. Install blocks under the base arms at
and repair. The removal of the following as-
the rear of the wheels near the truck frame to
semblies will cause large changes in the center
support the lift truck.
of gravity: mast and load axle, battery, and the
counterweight. When the lift truck is put on
How to Raise the Drive Tire End
blocks, put additional blocks under the rear of
the frame before removing the mast so the lift Refer to the precautions at the beginning of the How
truck cannot fall backward or to the side. to Put Lift Truck on Blocks instructions in this sec-
tion before attempting to raise the lift truck.
DO NOT raise any point of the truck more than
50 mm (2 in.) without raising the opposite side 1. Put blocks on each side (front and back) of the
to level the truck. If raising the frame above load wheels to prevent movement of the lift truck.
150 mm (6 in.) remove the mast first and raise See Figure 5.
both ends of the frame in 50 mm (2 in.) incre-
ments. 2. Use a low-clearance, hydraulic jack under the
rear of the frame to raise the drive/steer tire and
DO NOT raise the lift truck by attaching an caster wheels. Another lift truck can also be used
overhead crane to the overhead guard or ar- to raise the lift truck. Make sure that the jack or
eas of the mast that will be damaged. Some other lifting device has a capacity of at least 2/3
of these components and other lift points are of the total weight of the lift truck as shown on
not designed to support the weight of the lift the nameplate.
truck. The truck can be damaged or it can fall
on someone causing serious injury. Attach a 3. Raise the lift truck only enough to suspend the
chain or sling to a support structure of the lift drive/steer tire and the caster wheels. Install
truck frame. blocks under the rear of the frame to support the
lift truck.
Put the lift truck on blocks only if the surface is solid,
even, and level. Make sure that any blocks used to
support the lift truck are solid, one-piece units. Put
blocks in front and back of the tires to prevent move-
ment of the lift truck.
5
1. DRIVE AND CASTER WHEELS 2. LOAD WHEELS
Figure 5. How to Put Lift Truck on Blocks
How to Raise the Entire Lift Truck WARNING

Refer to the precautions at the beginning of the How The battery is heavy. Use appropriate lifting
to Put Lift Truck on Blocks instructions in this sec- equipment to avoid personal injury.
tion before attempting to raise the lift truck.
3. Remove the battery from the lift truck.
WARNING WARNING
The mast MUST BE REMOVED to raise the
The truck must be kept level while raising.
frame above 150 mm (6 in.).
4. Raise the lift truck and position solid, one-piece
1. Remove the mast from the lift truck. Refer to
hardwood blocks or an approved lift truck frame
Mast, Repair 4000 SRM 1195.
stand under the frame. The truck must be kept
2. Turn the key switch to the OFF position and dis- level while raising. Frequently reposition jack
connect the battery from the lift truck at the bat- stands or blocks under the frame while raising as
tery connector. a safety precaution in case of equipment failure.
DO NOT raise any point of the frame 50 mm
(2 in.) more than any other point of the frame.
6
MANUAL LOWERING VALVE lower the mast in case of malfunction or to relieve

pressure from the system before servicing the hy-
N30-35ZDR and N35-40-45ZR draulics. If the mast leaks down during operation,
lower the mast and check that the knob is completely
WARNING closed (turn clockwise). Always close the manual
Allow no on under or near the lift mechanism lowering valve after use. See Figure 6.
or load during the manual lowering procedure.
N30ZDRS and N35-40ZRS
Always verify that there are no obstructions
beneath the lift mechanism or load before at- WARNING
tempting to lower the mast manually. Allow no on under or near the lift mechanism
or load during the manual lowering procedure.
Always verify that there are no obstructions

beneath the lift mechanism or load before at-
tempting to lower the mast manually.
Manual lowering is accomplished by pushing in the

manual lowering valve knob and turning it counter-
clockwise 180 until the knob pops back out. See Fig-
ure 7. This will open the valve and the mast will be-
gin lowering at a controlled rate. Push the load hold-
ing check valve knob in and turn it clockwise 180
until it pops back out to close. See Figure 7.
1. LOWERING CONTROL VALVE

2. UPPER MOUNTING HOLE
3. M2 TEST PORT
4. MANUAL LOWERING VALVE KNOB
5. M1 TEST PORT
6. RETURN FITTING
7. RELIEF VALVE
8. SUPPLY FITTING
9. LOWER MOUNTING HOLE
10. OVERRUN CHECK VALVE
11. PRESSURE FLANGE
Figure 6. Pump (Valve Manifold)
The manual lowering valve is located on the main A. MANUAL LOWERING VALVE KNOB
lift pump manifold beside the hydraulic tank. The B. MAIN CONTROL VALVE BODY
manual lowering valve can be opened by turning the
valve knob counterclockwise to relieve pressure from Figure 7. Main Control Valve
the hydraulic system. This can be used to manually
7
Transporting 8000 SRM 1197
Transporting
3. Turn the key switch to the OFF position to stop
WARNING the engine.
Maintain a safe distance from the edge of
docks, ramps, platforms, and other similar 4. Check that all switches and accessories are
working surfaces. Watch the "tailswing." Re- turned off.
member, when traveling in the forward direc-
tion, and the steering wheel is turned to move 5. Put blocks in front and back of the lift truck tires
the lift truck away from the edge of the dock, to prevent any movement of the lift truck. Make
the rear will swing toward the edge. This can sure the blocks are attached to the transport sur-
cause the lift truck to fall off the dock. face.
If the lift truck falls off the dock, DO NOT jump WARNING
off! Hold firmly to the steering wheel, brace The straps or chains used to attach the lift
your feet, and lean forward and away from the truck to the transporter must be directly at-
point of impact. tached to the lift truck frame or to a component
Before the lift truck is transported, check the se- (drive axle, tow pin) that is solidly attached to
lected route to make sure there is adequate clearance the frame. DO NOT attach the straps or chains
for the lift truck as loaded on the transport vehicle to the mast or any attachment.
(bridges, overpasses, power lines, and natural bar-
riers). In some cases, removal of the mast can be CAUTION
required. Make sure that any straps or chains used to at-
tach the lift truck to the transporter do not con-
If a trailer is the method of transportation, use blocks
tact any tubes, hoses, hydraulic cylinders, or
in front and back of the trailer tires to prevent move-
other parts of the lift truck that are easily dam-
ment of the trailer when the lift truck is loaded and
aged.
unloaded. If a loading ramp is used, make sure that
the ramp is the proper design and capacity. 6. If the lift truck is transported in severe weather
or any other condition that can damage the lift
Use approved lifting eyes to lift the truck. If the lift
truck, cover the lift truck. Make sure the tarp
truck is not equipped with approved lifting eyes, DO
or protective material is designed for the appli-
NOT lift the truck by attaching a lifting device to any
cation and is securely attached.
other part of the lift truck for the purposes of loading
or unloading.
UNLOADING
LOADING If components attached to the lift truck must be re-
moved for transport, refer to the section(s) for those
If components attached to the lift truck must be re-
components for proper handling procedures.
moved for transport, refer to the section(s) for those
components for proper handling procedures. 1. If used, remove any covering.
The operator must never leave a lift truck in a condi- 2. Make sure the park brake is applied.
tion so it can cause damage or injury. When parking
the lift truck, do the following operations: 3. Disconnect the straps or chains.
1. After the lift truck has been loaded, apply the 4. Remove the wheel blocks.
parking brake.
5. Check that all switches and accessories are
2. If the mast is mounted on the lift truck, fully turned off.
lower the forks or carriage. If the lift truck is fur-
nished with a tilt mechanism, tilt the forks for- 6. Unload the lift truck.
ward until the tips of the forks touch the ground.
8
Preparation for Use

3. Follow the steps in the section Maintenance Pro-
CAUTION cedures Every 8 Hours or Daily.
Transporting trucks in the horizontal position
may cause some looseness in the mast chains, PREPARATION AFTER STORAGE
hoses, and other components. Always check for
loose or shifted components before raising the 1. Remove all tape, covers, and preservation mate-
mast. Raise the mast very slowly after standing rials.
the truck up, to ensure all hoses and chains are
2. Check the lift truck for damaged or missing com-
properly seated in their respective sheaves and
ponents. Repair damage and/or replace missing
anchor points. Raise the mast up and down a
components.
few times to ensure the hoses and chains are
working and adjusted properly. If the truck is NOTE: If the lift truck has been stored longer than
equipped with displacement main or free-lift 1 year, all lubricants and fluids must be drained and
cylinders, the cylinders should be bled. See Lift replaced. Refer to Maintenance Schedule.
Cylinders 4000 SRM 481.
3. Clean battery cables. Check the battery volt-
After being transported or stored, the lift truck must age. If the voltage is less than nominal, charge
be prepared for proper operation. All problems must the battery. Connect the cables to battery and
be corrected before use of the lift truck. See the tighten.
proper section for component repair procedures.
4. Follow the steps in the section Maintenance Pro-
PREPARATION AFTER SHIPMENT cedures Every 8 Hours or Daily.
1. Complete the unloading procedures.
2. Inspect the lift truck for damage and missing

components.

The following procedures must be used when inspect- • DO NOT climb on the mast or lift truck at any
ing or working near the mast. Additional precautions time. Use a ladder or personnel lift to work
and procedures can be required when repairing or re- on the mast.
moving the mast. • DO NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
WARNING
moval of parts and can require removal
Mast parts are heavy and can move. Distances of the mast or carriage. Follow the repair
between parts are small. Serious injury or procedures in the correct Service Manual
death can result if part of the body is hit by section for the mast.
parts of the mast or the carriage.
• Never put any part of the body into or under WHEN WORKING NEAR THE MAST, ALWAYS:
pletely lowered or a safety chain is installed. 1. Lower the mast and carriage completely. Press
Also make sure that the power is off and the the lower button on the control handle. If the
key is removed. Put a DO NOT OPERATE tag lowering controls do not operate correctly, slowly
in the operator’s compartment. Disconnect open the lowering control valve to relieve pres-
the battery on electric lift trucks and put a sure from the hydraulic system. and make sure
tag or lock on the battery connector. there is no movement in the mast. Make sure
• Be careful of the forks. When the mast is that all parts of the mast that move are fully low-
raised, the forks can be at a height to cause ered.
an injury.
OR
9
Maintenance Schedule 8000 SRM 1197
2. If parts of the mast must be in raised position, Disconnect the battery and put a tag or lock on
install a safety chain to restrain the moving parts the battery connector.
of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
a. Raise the mast to align the bottom cross-

member of the weldment that moves in the
outer weldment with a crossmember on the
outer weldment (1). See Figure 8.
b. Use a 3/8-in. minimum safety chain with

a hook (4) to fasten the crossmembers to-
gether so that the movable member cannot
lower. Put the hook on the back side of the
mast. Make sure the hook is completely en-
gaged with a link in the chain. Make sure
the safety chain does not touch lift chains or
chain sheaves, tubes, hoses, fittings, or other
parts on the mast.
c. Lower the mast until there is tension in the

safety chain, and the free-lift cylinder (5) is
completely retracted. Install a DO NOT RE-
MOVE tag on the safety chain(s).
d. Install another safety chain (3/8 in. min- 1. OUTER MAST

2. INNER MAST
imum) around the safety chain already 3. INTERMEDIATE MAST
installed as a secondary safety precaution. 4. HOOK
Hook the chain as tight as possible by hand. 5. FREE-LIFT CYLINDER
6. CROSSMEMBER
3. After lowering or restraining the mast, shut off 7. CROSSMEMBER
the power and remove the key. Put a DO NOT
OPERATE tag in the operator’s compartment. Figure 8. Safety Chains
Maintenance Schedule
NOTE: Certain components on the truck require an 2000 Hours for normal operations (whichever comes
initial inspection earlier than the prescribed main- first). Normal operation is considered one 8-hour
tenance schedule to preserve the original manufac- shift per day, in a relatively clean environment, on
turer’s warranties. Perform the 3 month 500 hour an improved surface. Operating a lift truck for more
inspection at 150 to 250 hours after the initial instal- than eight hours per day is considered Heavy opera-
lation of the truck and then follow the scheduled in- tion and requires the 3-month checks to be performed
spections as listed in the maintenance schedule (see at 350 hours. Lift trucks operating in freezer envi-
the notes after Table 1). ronments or dirty conditions are considered Severe
operation and require the 3-month checks to be per-
The Maintenance Schedule is divided into three time formed at 200 hours. For an approximate location of
intervals which call for particular maintenance pro- the items listed in Table 1, see Figure 9.
cedures to be performed. The intervals are 1 Day
or 8 Hours, 3 Months or 500 Hours, and 1 Year or
10
8000 SRM 1197 Maintenance Schedule
Figure 9. Maintenance Points
Table 1. Maintenance Schedule
Item Item 1 day/ 3 mo/ 1 yr/ Procedure or Specification

No. 8 hr 500 hr 2000 hr Quantity
1 Battery X, C 1 Check for Full Charge or Change Out
Charge
Fluid Level X Check Distilled Water
Restraint Panels X Check Condition Repair as Necessary
Power Disconnect X Check Operation Repair as Necessary
2 Brake X Check Operation Repair as Necessary
X Hold on Grade Test Capacity Load on
10% Slope
3 Control Handle X Check Operation Repair as Necessary
4 Electrical Circuits X Check Operation Repair as Necessary
Contactors X Check Condition Repair as Necessary
5 Forks X Check for Damage
Guides and Locks X L As Required Multipurpose Grease 2
Sideshift Wear Bearings X Check Wear Replace as Necessary
6 Dash Display, Horn, Lights, Fuses X Check Operation Repair as Necessary
X=Check C=Change L=Lubricate
11
Maintenance Schedule 8000 SRM 1197
Table 1. Maintenance Schedule (Continued)

7 Hydraulic System X Visually Inspect Repair as Necessary
for Leaks
X Check for Proper Repair as Necessary
Operation
X Check Level See Table 3
C Change Oil ISO VG 46 Antiwear
(Standard
Hydraulic Oil
Operation)
C Change Oil (Freezer Exxon Univis® HVI 26
Applications)
Breather Cap X Inspect Replace as Necessary
Hydraulic Oil Filter C5 C Replace See Parts Manual
Hydraulic Oil Strainer X Inspect Replace as Necessary
X Inspect for Visible Adjust, Repair, or
Damage and Replace as Necessary
Hydraulic Hoses, Fittings, and Defects
Clamps X Inspect for Kinked, Replace as Necessary
Flattened, Stiff, or
Charred Hoses
8 Lift Chains X Inspect for Visible Check Operation
Damage
X Check Stretch Replace as Necessary
L Lubricate as SAE 20 or 30 Engine Oil
Required
9 Mast X Inspect for Visible Check Operation
Damage
Bleed Cylinders (Displacement Type X Remove all air from See Cylinder
Only) cylinders using Identification.
bleeder screws
Header Hoses, Fittings, and Clamps X Inspect for Visible Adjust, Repair, or
Damage and Replace as Necessary
Defects
X Inspect for Kinked, Replace as Necessary
Flattened, Stiff, or
Charred Hoses
Sliding Surfaces L2 As Required Multipurpose Grease 2
12
8000 SRM 1197 Maintenance Schedule

10 Reach Carriage Assembly X Inspect for Visible Check Operation
Damage
Single Reach Scissor Arms L 4 Lube Fittings Multipurpose Grease 2
Double Reach Scissor Arms L 8 Lube Fittings Multipurpose Grease 2
Reach Cylinder Pivot Pins L 4 Lube Fittings Multipurpose Grease 2
Tilting Frame L 2 Lube Fittings Multipurpose Grease 2
Side Shift Carriage L 4 Lube Fittings Multipurpose Grease 2
11 Frame X Visually Inspect Repair as Necessary
Overhead Guard X Visually Inspect Replace as Necessary
Door Hinges L Lightly Oil SAE 20 or 30 Engine Oil
12 Safety Labels and Operating Manual X Replace if See Parts Manual
Necessary
13 Steering Operation X Check Operation
14 Caster and Load Wheels X Check Condition
Caster Wheel Assembly X Check Condition
L Belleville Springs Brush With Antiseize
(If Equipped) Lubricant
L 1 Lube Fitting Multipurpose Grease 2
X Check Adjustment Adjust With Shims
Gap
Load Wheel Bolts L Check Condition/ Antiseize Lubricant
Lube
L Optional Grease Multipurpose Grease 2
Fittings
15 Master Drive Unit X Check Operation
N30ZDR, N35ZR, N40ZR,
N30ZDRS, N35-40ZRS, GK - 20
N45ZR, N35ZDR, GK - 25
MDU Steering Gear L Apply to Gear Multipurpose Grease 2
MDU Gearcase
Standard Operation X, C 3 0.98 liter (0.26 gal) Gear Oil
Hyster® P/N 2046459
Freezer Applications X, C 3 0.98 liter (0.26 gal) Gear Oil
Hyster® P/N 2308302
13
Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1197

16 Drive Wheel and Tire X Check Condition
Tire X Inspect for Damage Smooth Edges/Remove
Embedded Objects
Axle Seal X Inspect for Leaks Remove Wrapped Debris
4
Wheel Lug Torque X Tighten as Required 135 N•m (100 lbf ft)
1
Equalization charge approximately each month, but not more than each week.
2
Use Amsoil® GHD synthetic multipurpose grease (lithium complex) for standard, freezer, and cold storage
configurations.
Use Mobilgrease® 28 synthetic extra-protection grease (clay) for arctic configurations.
3
Change after 150 to 250 hours; no subsequent change for life of unit.
4
Apply antiseize lubricant at installation and check every 2 to 5 hours until nuts stay tight for an entire 8-hour shift.
Check tightness every 3 months or 500 hours thereafter.
5
Replace the filter element after the first 150 to 250 hours of service and every 2000 hours or yearly thereafter.
Maintenance Procedures Every 8 Hours or Daily

Battery
WARNING
If a repair is necessary, put a DO NOT OPER- WARNING
ATE tag in the operator’s area. Remove the key DO NOT put tools on the battery.
from the key switch.
The acid in the electrolyte can cause injury. If
Inspect the lift truck every 8 hours or daily before the electrolyte is spilled, use water to flush the
use. Put the lift truck on a level surface. Lower the area. Make the acid neutral with a solution
carriage and forks, and turn the key switch to the of sodium bicarbonate (soda). Acid in the eyes
OFF position. If repair is required, put a tag in the must be flushed with water continuously for 15
operator’s area that indicates the lift truck cannot minutes then seek medical attention.
be operated. DO NOT operate a lift truck until the
Batteries generate explosive fumes. Keep the
problems are corrected.
vents in the caps clean. Keep sparks or open
CHECKS WITH KEY SWITCH TURNED OFF flames away from the battery area. DO NOT
make a spark from the battery connections.
Make the following checks: Disconnect the battery when doing mainte-
• Electrolyte and specific gravity of the battery nance.
• Make sure the battery is clean and the correct size
and weight for the lift truck The battery must fit the battery compartment
• Check that the battery restraint plates are in place so the battery restraint panels will operate cor-
• Leaks in the hydraulic system rectly. Use spacers to prevent the battery from
• Condition of the wheels and tires moving more than 13.0 mm (0.5 in.) in any di-
• Condition of the forks, carriage, mast, and over- rection.
head guard
14
8000 SRM 1197 Maintenance Procedures Every 8 Hours or Daily
Inspect the tires for embedded rocks, glass, wire,

CAUTION pieces of metal, holes, cuts, and other damage. See
Disposal of batteries must meet local environ- Figure 8. Remove any object that will cause damage.
mental regulations. Check for loose or missing nuts and broken studs.
Remove any wire strapping or other material that is
Make sure the battery weight is within the maximum wrapped around the axle to prevent damage to the
and minimum weight shown on the nameplate. axle seal. See Figure 10.
Keep the battery case, top cover, and the area for the
battery clean and painted. Leakage and corrosion
from the battery can cause a malfunction in the elec-
tric controls of the lift truck. Use a water and sodium
bicarbonate solution (soda) to clean the battery and
the battery area. Keep the top of the battery clean,
dry, and free of corrosion.
Make sure the battery is charged and has the correct

voltage and ampere hour rating for the lift truck. See
the nameplate.
Inspect the battery case, connector, and cables for

damage, cracks, or breaks. Contact your local bat-
tery dealer to discuss repair options for the battery
case. Check the level of the electrolyte daily on a
minimum of one cell. The correct level is halfway be-
tween the top of the plates and the bottom of the fill 1. CHECK FOR DAMAGE. REMOVE NAILS, GLASS,
hole. Add only distilled water. METAL, AND OTHER OBJECTS.
2. MAKE EDGES SMOOTH
Make certain the battery restraint panels are prop-
erly installed. Figure 10. Check Tires
If the wheel and tire has recently been installed,

WARNING check to ensure the lug nuts are properly tightened
Make sure the key switch is in the OFF position to 135 N•m (100 lbf ft). When installing, snug all
and the brake is set before connecting the bat- the nuts, then tighten to half the torque value, then
tery. tighten to the full torque value. Tighten the nuts in
a cross pattern to properly seat the wheel to the hub.
If the lift truck was operated with a discharged
battery, check the contactor for welded tips be- Frame and Load Wheels
fore a charged battery is connected.
Inspect the frame for structural damage and loose/
The battery should have an equalization charge each missing hardware. Make certain all covers are in
month, but not more than each week. place and secured before operating the lift truck. In-
spect the load wheels. Loose or crooked load wheels
Tires and Wheels may indicate bearing failure. If failure is suspected,
raise the lift truck front end slightly (refer to How to
WARNING Put Lift Truck on Blocks) and check that load wheels
When the wheels have been installed, check are secure on their axles and rotate smoothly. Repair
all wheel nuts after 2 to 5 hours of operation. or replace as necessary.
When the nuts stay tight after an 8-hour check,
the interval for checking the torque can be ex-
tended to 500 hours. Refer to the Maintenance
Schedule, Table 1 in this section.
15
Safety Labels Table 2. Fork Tip Alignment
Fork Tip Alignment Specifications

WARNING
Safety labels are installed on the lift truck to Standard Fork Maximum Fork Tip
give information about possible hazards. It is Lengths Difference 1
important that all safety labels are installed on mm (inch) mm (inch)
the lift truck and can be read.
914 (36) 27.00 (1.08)
Check that all safety labels are installed in the cor-
rect locations on the lift truck. See the Parts Man- 1067 (42) 32.00 (1.26)
ual or the section Frame 100 SRM 1185 for the cor- 1219 (48) 37.00 (1.44)
rect locations of the safety labels.
1372 (54) 41.00 (1.62)
Overhead Guard 1524 (60) 46.00 (1.80)
1829 (72) 55.00 (2.16)
WARNING
DO NOT operate the lift truck without the over- 1Difference of alignment between fork tips must
head guard correctly fastened to the lift truck. be no more than 3% of the total fork length.
DO NOT make changes to the overhead guard
by welding. Changes that are made by welding
or by drilling holes can reduce the strength of
the overhead guard.
DO NOT weld mounts for lights or accessories

to the leg of the overhead guard. The strength
of the overhead guard components can be com-
promised by welding or heating.
Make sure the capscrew that holds the vertical

support post that supports the overhead guard
is in the correct position and is tight. The over-
head guard and support post reinforce one an-
other to provide protection to the operator.
Make certain the overhead guard is in place and se-

curely attached to the mast. Make certain that the
operator’s guard is installed between the mast and
the operator’s compartment. A. HEEL OF FORK (MIN. 90% OF DIMENSION B)
B. ORIGINAL FORK THICKNESS
Forks Check
1. TIP ALIGNMENT (WITHIN 3% OF FORK
LENGTH)
WARNING 2. CRACKS
Never repair damaged forks by heating or 3. MAXIMUM ANGLE 93
4. FORK REMOVAL NOTCH
welding. Forks are made of tempered steel 5. CARRIAGE
using special procedures and can be weakened
by heating or welding. Always replace dam- Figure 11. Fork Check
aged forks as a pair.
Some applications may require closer alignment. If
Inspect the forks for cracks and wear. Check the the forks do not meet specification, both forks must
alignment of the fork tips. The difference in height be replaced. Check that the bottom of each fork is
of the fork tips must be less than 3% of the length of not excessively worn. Check for smooth and proper
the forks. See Table 2. operation of the fork lock pins. Repair or replace any
damaged or broken fork lock pins or components and
lubricate as necessary. See Figure 11.
16
Lift Chain Check

wear.
1. Apply a 1/2 capacity load to the forks and raise

approximately 25 mm (1 in.) off the floor. Inspect
the lift chains for wear or damage. A lift chain
becomes longer when it is worn. If a chain is 3%
longer than a new lift chain, the lift chain must
be replaced. If a chain scale is available, check
the lift chain as shown in Figure 12. If a chain
scale is not available, measure 20 links of the
lift chain. Compare the measurement with the
lengths given in Figure 12. Lower and remove
the load when complete.
2. Inspect the chain anchors and pins. Replace any

parts that are worn or damaged.
Pitch Wear Limit
3. Completely lower the mast. Check to verify that Total length
The
the top of the outer weldment is even (±1.50 mm of 20 links
maximum
(0.06 in.)) with the top of the inner mast. (pitch) of new
length of 20
chain
links
4. Check chain tension by pushing on both main-lift
chains at the same time. 12.7 mm 254.0 mm 261.6 mm
(0.5 in.) (10.0 in.) (10.3 in.)
5. Fully lower the carriage. With the forks level 15.90 mm 317.5 mm 327.0 mm
(parallel to the floor), measure the distance from (0.63 in.) (12.5 in.) (12.9 in.)
the floor to the top of forks. The correct distance 19.10 mm 381.0 mm 392.4 mm
is 63.5 mm (2.5 in.). (0.75 in.) (15.0 in.) (15.5 in.)
25.4 mm 508.0 mm 523.3 mm
6. Check chain tension by pushing on both chains (1.0 in.) (20.0 in.) (20.6 in.)
at the same time. When the tension is equal on
both chains, the chain sheave assembly will be
NOTE: THE INSTRUCTIONS FOR MEASURING
level. If the tension is not the same, adjust the
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
lift chains so the tension is the same and the fork
SCALE (HYSTER® PART NO. 599737).
height is also correct.
1. CHAIN WEAR SCALE
17
Mast Check drive wheel and caster assembly when the key
switch is turned to the ON position.
WARNING The lift truck is equipped with a Static Return to OFF
Always wear the proper protective equipment (SRO) circuit that prevents travel of the lift truck if
including eye protection and petroleum-resis- the starting sequence is not correct. The function of
tant gloves when handling hydraulic oil. Thor- the SRO circuit is to make sure the operator is in
oughly wash oil from exposed areas of skin as the correct position to operate the controls before the
soon as possible. lift truck will operate. The starting sequence is as
follows:
hydraulic lines or components under pressure. 1. Stand in the operator compartment and turn the
Hydraulic oil under pressure can be injected key switch to the ON position. Stand on the
into the skin. brake switch with the left foot and then depress
the operator presence switch with the right foot.
1. Inspect sliding surfaces for wear or damage. In-
spect load roller contact surfaces for wear or dam- 2. Move the control handle for forward travel.
age. Inspect all welds for cracks.
If the control handle is moved before the operator
2. Inspect the sheaves, chain anchors, and pins. Re- stands on the brake switch and depresses the oper-
place any parts that are worn or damaged. ator presence switch, and the lift truck moves, the
SRO function is not operating correctly. The lift truck
3. Inspect the mast header hoses and fittings for hy-
must not be operated if the SRO circuit does not func-
draulic leaks. Check the hose cover for cracks or
tion correctly.
exposed reinforcement. Check for broken or de-
fective clamping devices and sheaves. Repair or
replace any damaged components as necessary.
Operation
To travel in the forward or reverse direction:
Reach, Tilt, and Sideshift
1. Make sure a charged battery of the correct volt-
WARNING age is installed and connected.
Make sure the key switch is in the OFF position 2. Stand in the operator compartment and turn the
and the key is removed from the switch before key switch to the ON position. Stand on the
doing this check. brake switch and then depress the operator pres-
ence switch.
1. Check for cracks at the welds on the reach frames
and scissor arms. 3. Move the control handle for forward or reverse
travel.
2. Check the frame channel for excessive wear in
the areas of roller contact. Check the rollers for
wear or damage. CAUTION
The key switch should be used as the primary
3. Check the load backrest extension for cracks and means of shutting down the truck. Use the bat-
damage. Make sure the nuts and bolts for the tery power disconnect to shut down the truck
load backrest extension are tight. only in an emergency.
CHECKS WITH KEY SWITCH TURNED ON Key Switch - The key switch is a three-position
switch. The first position is OFF (marked O). The
WARNING second position is ON (marked I). The third position
Make sure the area around the lift truck is is spring-loaded and automatically returns the key
clear before moving the lift truck. Always look to the ON position after the key is released. The
in the direction that you intend to move the third position is not utilized for any functions on this
lift truck. Be careful when making the checks. lift truck. The key switch is located to the right side
of the battery power disconnect knob.
The lift truck will self-center the steering tire
upon startup. Make sure feet are clear of the
18
Hydraulic System 2000 hours or yearly thereafter. See Hydraulic Filter

Change section for the initial filter change instruc-
tions.
WARNING
Always wear the proper protective equipment Dash Display
tant gloves when handling hydraulic oil. Thor- The dash display interfaces with the master con-
oughly wash oil from exposed areas of skin as troller, control handle, and the traction controller. It
soon as possible. is located adjacent to the steering handle on fore/aft
stance models and attached to the control handle
Completely lower all mast components and re- armrest of sidestance models. The dash display is
lieve pressure by opening the manual lowering the primary message communication to the operator
valve before disassembling any part of the lift and displays the truck status and active functions,
pump or disconnecting any hydraulic hoses. as well as warning and advisory messages. The
display is also the communication display during
controller programming and diagnostic operations.
The dash display is energized when the key switch is
oil.
in the ON position and the battery disconnect switch
Never check for leaks by putting hands on is closed. An internal backup battery provides mem-
hydraulic lines or components under pressure. ory retention of the battery indicator and hourmeter
Hydraulic oil under pressure can be injected readings when the battery is disconnected from the
into the skin. truck.
The drive mode switch is used to select the level of

CAUTION traction motor controller performance most suited
Protect the hydraulic system from dirt and to the application. Indicators on the dash display
contaminants when servicing the hydraulic change to correspond to the performance selected.
system. The three indicators are as follows: The turtle indi-
cates slowest acceleration, reduced top speed, and
Never operate the pump without the proper maximized energy efficiency. The rabbit indicates
amount of oil in the hydraulic system. The maximum acceleration and maximum top speed.
operation of the hydraulic pump with low oil The middle setting is a compromise between the
levels will damage the pump. turtle and rabbit settings and indicates reduced
acceleration, but with maximum top speed still
Visually inspect the floor under and around the lift
available. When the key switch is turned to the OFF
truck for oil leaks. Check for proper operation of hy-
position, the selected drive mode is retained.
draulic controls. If hydraulic controls do not function
properly or if leaks are suspected, turn the key to the The message center is a 16-character, alphanumeric,
OFF position and open the drive unit compartment liquid crystal display (LCD), with green backlight-
door. Visually check the oil level and inspect the hy- ing. The hourmeter, truck performance status mes-
draulic system for leaks and damaged or loose com- sages, warning messages, fault messages, and the
ponents. Refer to Hydraulic System, in Maintenance master controller programming default values are
Procedures Every 500 Hours or 3 Months of this sec- shown on the Message Center. See Figure 13.
tion.
The hydraulic filter element should be replaced af-

ter the first 150 to 250 hours of service and every
19
Lift System Operation
WARNING
Lower the lift mechanism completely. Never
allow anyone under a raised carriage. DO NOT
put any part of your body in or through the
mechanism unless all parts of the mast are
completely lowered and the key switch is in
the OFF position.
Before making any repairs, use chains on the

mast weldments and carriage so they cannot
move. Make sure the moving parts are at-
tached to a part that does not move.

soon as possible.

hydraulic lines or components under pressure.
A. PREMIUM B. STANDARD Hydraulic oil under pressure can be injected
into the skin.
Figure 13. Displays
1. Check for leaks in the hydraulic system. Inspect
The hourmeter button is used to display truck hours
the hydraulic hoses and tubes. Make sure all of
information. The switch is marked with an hourglass
the hydraulic lines are connected correctly and
symbol. Press and hold to display truck hours.
do not leak. Check for broken or defective clamp-
The warning indicator is a yellow circle with a trian- ing devices. Repair or replace any damaged or
gle inside. This indicator alerts the operator when defective components as necessary.
a fault code has been stored in the system memory.
2. Check that the controls for the hydraulic func-
The wrench indicator symbol is a red circle with a
tions make the functions operate correctly. See
wrench silhouette inside. The wrench indicator sym-
the symbols by each of the controls.
bol alerts the operator when status code numbers are
shown or when maintenance is due. 3. Slowly raise and lower the mast several times
without a load. The mast components must raise
The function selection lights are for the display of
and lower smoothly in the correct sequence.
Lift, Reach, Tilt, and Sideshift operations.
4. Extend the mast fully. If the mast racks (leans)
The battery indicator is displayed as a 10 bar graph
to either side, the main lift cylinders must be ad-
on the LCD. It is displayed next to a green, yellow,
justed. Make note of direction of racking and
and red strip on the dash display adjacent to the LCD
lower the mast. See Figure 14.
which indicates the level of battery charge. As power
is used, the bars will turn off in sequence, starting 5. Lower the mast. The inner mast, intermediate
at the top. The second bar from the bottom, flashes mast, and the carriage must lower completely.
to indicate when the battery is nearly discharged.
The bar on the bottom of the display will alternately
flash with the low-battery indicator symbol to indi-
cate that the battery is discharged and the lift func-
tion is disabled.
20
8. If the lift system does not operate correctly, the

mast or carriage may require adjustment. See
the section Mast, Repair 4000 SRM 1195.
Multifunction Control Handle

Check that the controls for the lift/lower, extend/re-
tract, tilt, and sideshift operate as described in the
Operating Manual.
NOTE: Each lift truck does not have all of these func-
tions. Do the checks for the functions that are on the
lift truck.
If the reach mechanism is retracted, it will be neces-

sary to extend the mechanism to make the following
checks.
1. If the unit has the optional functions, check for

leaks in the hydraulic system. Check the condi-
tion of the hydraulic hoses and tubes.
2. Slowly extend and retract the forks several times

without a load. The components must extend and
retract smoothly.
3. The reach mechanism must slow near the end of

the reach cycle for a smooth stopping action.
4. The forks must fully retract and stay in the fully

retracted position.
5. Repeat Step 2 through Step 4 with a capacity

load on the forks.
6. The controls must operate smoothly.
Brake
NOTE: The normal method of stopping the lift truck
1. MAIN LIFT CYLINDER (LH)
2. FREE-LIFT CYLINDER is through the use of "Plugging" using the control
3. MAIN LIFT CYLINDER (RH) handle.
Figure 14. Mast Racking A spring-applied, electrically-released brake is

mounted to the top of the traction motor to hold the
NOTE: Some parts of the mast move at different lift truck stationary when the traction motor is not
speeds during raising and lowering. being operated. The brake is nonserviceable and
nonadjustable. Check the brake for proper opera-
6. Raise the carriage 1 m (3 ft), with a capacity load. tion. If the brake will not release or fails to apply or
The carriage must raise smoothly within the in- will not hold the lift truck, the brake assembly must
ner mast. Lower the mast. All moving compo- be replaced.
nents must lower smoothly. When the controller senses the truck has come to
7. With the load lowered, tilt the forks backward a complete stop, the brake is applied and acts as a
and forward. The forks must tilt smoothly. parking brake. When the operator removes his foot
from the brake switch, the traction motor will begin
neutral braking or "regen" mode (regenerate power
21
Maintenance Procedures Every 500 Hours or 3 Months 8000 SRM 1197
to the battery using the motion of the truck) slow- Steering System
ing the truck. The control handle can be pushed in
the opposite direction of travel to "plug," slowing the When turning the key switch to the ON position,
truck as a means of braking. However the brake will the controller will automatically center the drive
not apply until the truck has come to a stop or unless tire (and steered caster if equipped). Check that the
the unit looses power due to a traction fault. steering system operates smoothly with the turning
of the handle and gives good steering control.
Maintenance Procedures Every 500 Hours or 3 Months

NOTE: Certain components on the truck require an HYDRAULIC SYSTEM
initial inspection earlier than the prescribed main-
tenance schedule to preserve the original manufac- WARNING
turer’s warranties. Perform the 3 month 500 hour
inspection at 150 to 250 hours after initial installa-
tion of the truck and then follow the scheduled in-
spections as listed in the Maintenance Schedule. See
the notes section after the Maintenance Schedule ta-
soon as possible.
ble.
Completely lower forks to relieve hydraulic
NOTE: Do these procedures in addition to the 8-hour
pressure disassembling any part of the lift
checks.
MASTER DRIVE UNIT The hydraulic oil is hot at normal operating
NOTE: The oil used in the master drive unit should be
oil.
drained and replaced after 150 to 250 hours of initial
operation in accordance with the maintenance sched- Never check for leaks by putting hands on
ule. See Maintenance Schedule. After the initial oil hydraulic lines or components under pressure.
change, the master drive unit requires only the ad- Hydraulic oil under pressure can be injected
dition of the recommended oil to maintain the oil at into the skin.
the proper level.
Drain the oil when it is warm by removing the drain CAUTION

and fill plugs. Use a drain pan under the drain to Protect the hydraulic system from dirt and
keep oil off the floor. Install the drain plug and fill the contaminants when servicing the hydraulic
unit by adding oil slowly. Allow enough time for the system.
oil to flow through the bearings to fill the reservoir.
The correct level is at the bottom of the fill plug hole. Never operate the pump without the proper
Use the lubricant shown in the Maintenance Sched- amount of oil in the hydraulic system. The
ule, Table 1. See the repair procedures described in operation of the hydraulic pump with low oil
the section Master Drive Unit 630 SRM 1022. levels will damage the pump.
Lubricate the master drive unit steer gear in accor-

dance with Maintenance Schedule, Table 1.
22
8000 SRM 1197 Maintenance Procedures Every 500 Hours or 3 Months
The hydraulic oil level can be checked by opening the reach mechanism is retracted, and the key switch is
drive unit compartment door and visually checking in the OFF position. See Figure 16 or Figure 17. Add
that the oil is up to the proper level on the tank as hydraulic oil only as needed. If the tank is overfilled,
indicated for the battery box size of the truck. See hydraulic oil may leak from the breather during op-
Figure 15. Make all checks when the oil is at oper- eration. Refer to Table 3 for the capacities of the hy-
ating temperature, the carriage is fully lowered, the draulic tanks used on these models of lift trucks.
Table 3. Hydraulic Tank Capacities
368.0 mm 419.0 mm 470.0 mm 546.0 mm

Battery Compartment
(14.5 in.) (16.5 in.) (18.5 in.) (21.5 in.)
26.99 liter 26.99 liter 26.99 liter 30.74 liter
Tank Capacity
(7.13 gal) (7.13 gal) (7.13 gal) (8.12 gal)
19.57 liter 19.57 liter 19.57 liter 23.85 liter
Usable Oil
(5.17 gal) (5.17 gal) (5.17 gal) (6.30 gal)

1. FILTER HOUSING
2. RETURN FITTING
3. FILL LEVEL (EVEN WITH FLANGE)
(21.5 INCH BATTERY COMPARTMENT ONLY)
4. FILL LEVEL (40.0 mm (1.6 in.) BELOW FLANGE)
(ALL OTHER BATTERY COMPARTMENTS)
5. HYDRAULIC TANK
WARNING
into the skin.
Inspect all hydraulic hoses and fittings for leaks.

Check for broken or defective clamping devices.
Repair or replace any damaged components as nec-
essary.
Check the condition of the breather cap. See Fig-

ure 16 for breather cap location. Clean the breather
cap in solvent. If the breather cap cannot be cleaned
so air will flow through it easily, or it is damaged, re-
place the breather cap.
Inspect all hydraulic hoses for kinks. Verify that

there are no crushed, flattened, or twisted hoses.
Check for hard, stiff, or charred hoses. Adjust or
Figure 15. Tank Fill Level replace any hoses as necessary.
23

1. RETURN HOSE
2. BREATHER CAP
3. AUXILIARY HOSES
4. LIFT HOSE
5. TANK
6. DRAIN HOSE
7. SUPPLY FITTING
8. SUPPLY HOSE
9. MAIN CONTROL VALVE
10. PUMP PRESSURE HOSE
11. LIFT PUMP AND MOTOR
HYDRAULIC FILTER ELEMENT CHANGE

Change the hydraulic filter element in the first 150
to 250 hours of service and every 2000 hrs or yearly
thereafter. See Hydraulic Filter Change.
CASTER ADJUSTMENT
Casters must be adjusted periodically. Adjustment
procedures differ depending on the caster spring
1. BREATHER CAP
2. TANK type. Two spring types are used on caster assem-
3. FILTER HOUSING blies: Belleville Springs and Elastomer Springs. If
4. AUXILIARY PUMP AND MOTOR the caster can no longer be adjusted within speci-
5. LIFT PUMP AND MOTOR fication, check the drive tire wear and replace as
necessary. If the spring pack (Belleville or Elas-
Figure 16. Hydraulic System (N30-35ZDR and tomer) shows any visible damage, the spring pack
N35-40-45ZR ) should be replaced. Belleville Spring packs (includ-
ing washers) should be replaced with Elastomer
Spring packs and corresponding washers when
replacement becomes necessary. See Spring Pack
Replacement.
Elastomer Spring Type Adjustment

NOTE: The battery must be installed in the lift truck
with no load on the forks.
1. Ensure the lift truck is on a flat and level floor.
2. Loosen upper and lower stop jam nuts, then turn

capscrews clockwise to clear lower support hous-
ing.
3. Measure the caster spring preload (dimension 3).

See Figure 18.
4. Spring preload measurements (dimension 3)

should be within specifications for your lift
truck. Refer to Table 4.
Figure 17. Hydraulic System (N30ZDRS and

N35-40ZRS )
24

1. MOUNTING CAPSCREWS
2. SHIMS
3. CASTER SPRING PRELOAD
4. UPPER ADJUSTMENT CAPSCREW
5. UPPER ADJUSTMENT GAP
6. LOWER ADJUSTMENT CAPSCREW
7. LOWER ADJUSTMENT GAP
5. If spring preload measurements are not within

specification, raise the rear of the lift truck
approximately 50 mm (2 in.), loosen the three
mounting capscrews, and add or subtract shims
as necessary.
• Greater than Specification = Add Shims
• Less than Specification = Remove Shims
Figure 18. Caster Adjustment (Elastomer Type)
Table 4. Caster Specifications
Truck Battery Spring O.D. Mast Max Fork Dimension Dimension Dimension
Series Compartment Height "3" "5" "7"
mm (in.) mm (in.) mm (in.) mm mm mm
368.3 and (14.5 and 53 (2.09) 6375 (251) 70 to 74 9.5 2 to 4

A265 419.1 16.5)
and
D470 368.3 and (14.5 and 53 (2.09) 6350 (250) 70 to 74 6.5 2 to 4
419.1 16.5)
419.1 (16.5) 53 (2.09) 6375 (251) 70 to 74 9.5 2 to 4
419.1 (16.5) 53 (2.09) 6350 (250) 70 to 74 6.5 2 to 4
469.9 and (18.5) 60 (2.36) 8153 (321) 75 to 79 9.5 2 to 4
C264 546.1 and
(21.5)
469.9 and (18.5) 60 (2.36) 8128 (320) 75 to 79 6.5 2 to 4
546.1 and
(21.5)
6. Retighten the mounting capscrews and lower 7. Set the upper adjustment capscrew (see Fig-
the rear of the lift truck. Remeasure the spring ure 18) to the proper gap (dimension 5). Refer to
preload. If the spring measurement is not within Table 4.
specification, return to Step 5. If the spring mea-
surement is within specification, continue to 8. Set the lower adjustment capscrew (see Fig-
Step 7. ure 18) to the proper gap (dimension 7). Refer to
Table 4.
25
Belleville Spring Type Adjustment

For the following instructions, refer to Figure 19.
NOTE: Battery must be installed in truck with no

load on forks.
2. If the upper or lower adjustment capscrews are

touching the lower housing, loosen jam nuts then
turn bolts clockwise to clear lower support hous-
ing.
NOTE: A Go/No Go gauge (Hyster P/N 2069423 avail-

able from your lift truck dealer) may be used to check
this gap. See Figure 20.
3. Measure the gap (3) between the upper and lower

support housings. This gap should be between
39.9 mm (1.57 in.) and 42.9 mm (1.69 in.). A. FRONT B. BACK
Figure 20. Go/No Go Gauge
4. If gap is not within specification, raise the rear

of the lift truck approximately 50 mm (2 in.) to
access the caster wheels.
5. Loosen the three mounting capscrews (1) and add

or subtract shims between the caster wheel as-
sembly and the top frame mount to adjust the gap
(3).
6. Tighten the mounting capscrews (1) and lower

the lift truck to the floor. Re-check the gap (3)
and repeat Step 3 through Step 6 as necessary
until correct gap is achieved. If the proper gap
value cannot be obtained by adjustment, check
the drive tire wear and replace as necessary. If
any part of the spring pack is damaged the entire
spring pack must be replaced. See Spring Pack
Replacement.

1. MOUNTING CAPSCREWS this gap.
2. SHIMS
3. GAP BETWEEN UPPER AND LOWER 7. Set the upper adjustment capscrew (4) to the up-
HOUSINGS per adjustment gap measurement (5) shown in
5. UPPER ADJUSTMENT GAP Table 5.
7. LOWER ADJUSTMENT GAP 8. Set the lower adjustment capscrew (6) to obtain
the lower adjustment gap measurement (7) of
Figure 19. Caster Adjustment (Belleville Type) 2 mm (0.079 in.) to 4 mm (0.157 in.).
26
Table 5. Upper Adjustment Gap Measurement
Truck Battery Mast Maximum Upper Adjustment

Model Compartment Fork Height Gap Measurement (5)
368.3 mm (14.5 in.) and Less Than 9.5 mm
N30ZDR, N30ZDRS, 419.1 mm (16.5 in.) 6375 mm (251 in.) (0.374 in.)
N35-40ZR, N35-40ZRS 368.3 mm (14.5 in.) and Greater Than 6.5 mm
419.1 mm (16.5 in.) 6350 mm (250 in.) (0.256 in.)
419.1 mm (16.5 in.) Less Than 9.5 mm
6375 mm (251 in.) (0.374 in.)
419.1 mm (16.5 in.) Greater Than 6.5 mm
6350 mm (250 in.) (0.256 in.)
N35ZDR, N45ZR
546.1 mm (21.5 in.) 8153 mm (321 in.) (0.374 in.)
469.9 mm (18.5 in.) and Greater Than 6.5 mm
546.1 mm (21.5 in.) 8128 mm (320 in.) (0.256 in.)
Spring Pack Replacement 6. LOWER ADJUSTMENT CAPSCREW
If the spring pack (Belleville or Elastomer) shows any

visible damage, the spring pack should be replaced.
Belleville Spring packs (including washers) should
be replaced with Elastomer Spring packs and corre-
sponding washers when replacement becomes neces-
sary.
Remove Spring Assembly

load on forks.
2. Disconnect the battery connectors and discharge

the capacitors.
3. Raise the rear of the lift truck approximately

50 mm (2 in.).
4. Loosen jam nut and screw in the lower adjust-

ment capscrew. See Figure 21.
5. On steered units, remove steer motor to access

the caster spring.

1. UPPER SUPPORT HOUSING
2. SPRING ASSEMBLY
3. PIN
4. RETAINING CAPSCREW Figure 21. Caster Spring Removal
5. LOWER SUPPORT HOUSING
27
5. Apply a thin coat of antiseize lubricant to guide

CAUTION rod shaft.
Make sure the spring assembly has free play
before removing the pin. 6. Install new bottom washer onto guide rod.
6. Remove retaining capscrew and slide pin from NOTE: Different size elastomer springs are use on
lower support housing. Remove spring assembly. different models. Make sure to use the proper spring
for your model lift truck. Refer to the Parts Manual.
Replace Spring Pack
7. Install new Elastomer Spring onto guide rod.
1. Remove capscrew and washer from top of spring
assembly. See Figure 22. 8. Install new top washer onto guide rod.
2. Remove spring retainer and spherical bearing 9. Install spherical bearing and spring retainer
from guide rod. onto guide rod.
3. Remove upper washer, belleville spring pack, 10. Install washer and capscrew onto spring assem-
and lower washer(s) from guide rod. bly.
4. Check bushing and replace as necessary. Install Spring Assembly
1. Position spring pack to align with holes in lower

housing.
2. Apply a thin coat of antiseize lubricant to pin and

install.
3. Install retaining capscrew.
4. On steered units, install steer motor as removed.
5. Lower the rear of the lift truck to the floor and

adjust the caster. See Elastomer Spring Type Ad-
justment.
DRIVE TIRE CHECK
WARNING
When the wheels have been installed, check
all wheel nuts after 2 to 5 hours of operation.
When the nuts stay tight after an 8-hour check,
the interval for checking the torque can be
extended to 500 hours.
A. BELLEVILLE SPRING Check to ensure the lug nuts are properly tightened
B. ELASTOMER SPRING to 135 N•m (100 lbf ft). Inspect the tires for embed-
1. CAPSCREW ded rocks, glass, wire, pieces of metal, holes, cuts,
2. WASHER and other damage. Remove any object that will cause
3. SPRING RETAINER damage. Check for loose or missing nuts and broken
4. SPHERICAL BEARING lugs. Remove any wire strapping or other material
5. GUIDE ROD that is wrapped around the axle to prevent damage
6. BUSHING
7. LOWER WASHER to the axle seal. Make sure the drive wheel nuts are
8. SPRING PACK tight.
9. UPPER WASHER When installing the tire and wheel, snug the nuts,
then tighten to half the torque value, then tighten
Figure 22. Spring Assemblies to the full torque value. Tighten the nuts in a cross
pattern to properly seat the wheel to the hub.
28
LIFT SYSTEM OPERATION Cleaning solvents can be flammable and toxic

WARNING cleaning solvents, always follow the recom-
mendations of the manufacturer.
When working on or near the mast or carriage,
see Safety Procedures When Working Near
Mast. CAUTION
DO NOT use steam to clean the lift chains,
Lower the lift mechanism completely. Never al- sheaves, or load rollers. The sheaves and
low anyone under a raised carriage. DO NOT roller bearings are sealed and permanently lu-
put any part of your body in or through the bricated. DO NOT use compressed air to clean
lift mechanism unless all parts of the mast are the bearings. The air can force the lubricant
completely lowered and the battery is discon- out of the bearings.
nected.
Lubricate the sliding surfaces and the load roller sur-
Always wear the proper protective equipment faces along the full length of the channels. Mainte-
including eye protection and petroleum-resis- nance Schedule, Table 1.
oughly wash oil from exposed areas of skin as NOTE: The load rollers and sheaves have sealed bear-
soon as possible. ings that do not need additional lubrication.
Never check for leaks by putting hands on Lift Chains

into the skin.
WARNING
Inspect the header hoses for kinks. Verify that there see Safety Procedures When Working Near
are no crushed, flattened, or twisted hoses. Check Mast located before the 8-hour or daily checks.
for hard, stiff, or charred hoses. Adjust or replace
any hoses as necessary. DO NOT work under a raised carriage. Lower
the carriage or use a safety chain to prevent
Check for leaks and test the lift system operation as the carriage from lowering when doing main-
described in the Lift and Tilt System Leaks Check tenance on the mast and lift chains.
section.
Check chains for acceptable stretch first before per-
Forks forming any service. Chains that are stretched be-
yond specification should be replaced. Lubricate the
Wipe the fork carriage and forks clean of grease and lift chains with SAE 20 or 30 engine oil or chain and
dirt and inspect for damage. Inspect the fork locking cable lubricant. The best procedure is to remove the
pins for proper operation. Use penetrating oil to free chains from the lift truck and soak them in oil. How-
the pins if difficult to move. If pin assembly does not ever, the chains may be lubricated by brushing on oil.
operate correctly, remove fork and repair as neces- Chains within specification that are dirty should be
sary. Apply a thin film of grease to the top bar of the removed, cleaned with solvent, inspected, and oiled
carriage assembly to lubricate the forks sliding path. before reinstalling.
See Maintenance Schedule, Table 1. Lightly oil the
fork pin assemblies with a few drops SAE 20 or 30 OTHER LUBRICATION
engine oil.
Lubricate the drive unit compartment door hinges
Mast pins with SAE 20 or 30 engine oil as needed. Wipe
away excess oil. Control handle buttons should be
cleaned thoroughly and may be lubricated sparingly
WARNING
using a silicone spray lubricant. See Electrical Sys-
DO NOT work under a raised carriage. Lower tem 2200 SRM 1191. Several grease fittings are also
the carriage or use a safety chain to prevent present on the lift truck and mast. For a complete list
the carriage from lowering when doing main- of lubrication points, refer to Maintenance Schedule,
tenance on the mast and lift chains. Table 1, in this section.
29
Maintenance Procedures Every 2000 Hours or Yearly 8000 SRM 1197
Maintenance Procedures Every 2000 Hours or Yearly

NOTE: Perform these procedures in addition to the ELECTRIC SYSTEM
8-hour and 500-hour checks.
Inspect all visible electrical wiring and terminals
BRAKES when performing these checks. Repair any areas
where rubbing has frayed wiring.
Check
Main Contactor
A spring applied, electrically released brake is
mounted to the top of the traction motor to hold CAUTION
the lift truck stationary when the traction motor
Cleaning is not necessary. DO NOT use a file on
is not being operated. See Figure 23. The brake is
the contacts. DO NOT lubricate the contacts.
nonserviceable and nonadjustable. Check the brake
for proper operation. If the brake will not release or The contactor contacts are made of special silver al-
fails to hold the lift truck plus a capacity load on a loy. The contacts will normally look black and rough
10% slope [1.0 m rise in 10 m (1.0 ft rise in 10 ft)] from normal operation. This condition does not in-
with the forks facing uphill, the brake assembly terfere with the operation of the lift truck. There is
must be replaced. no procedure to clean or lubricate the contacts. Re-
place the contacts when the silver alloy is worn away
to the base support metal, when the contacts stick
in the closed position, or will not make contact when
the contactor is closed.
Inspect

connect the battery. Discharge the capacitors.
See Discharging the Capacitors in this section.
2. Remove the electrical compartment cover located

in the operator compartment.
3. Check the contactor for loose, broken, or corroded

connections at the contactor.
4. Check the mechanical function of the contactor.

Use an insulated tool, such as an electrician’s
screwdriver, to manually close the contactor
tips. Check for looseness or binding of the mov-
ing parts of the contactor. The parts should move
1. CAPSCREWS (MANUAL RELEASE) freely, but the parts must not be so loose that the
2. SERVICE PORTS (MANUAL RELEASE) movement is sloppy.
3. BRAKE ASSEMBLY
4. ASSEMBLY HOLES 5. Visually check the tips for pitting, burning, or
wear.
Figure 23. Brake
30
8000 SRM 1197 Maintenance Procedures Every 2000 Hours or Yearly
6. Check that the resistance of the contactor coil is

within 32 ±5 ohms. Readings not within specifi- CAUTION
cation indicate the following: Protect the hydraulic system from dirt and
High Resistance - Corrosion or an open coil contaminants when servicing the hydraulic
Low Resistance - Shorted or a burnt coil system.
7. Check the voltage drop across the contactor tips. Disposal of lubricants and fluids must meet lo-
Set the voltage scale of the meter to the low- cal environmental regulations.
est range, higher than battery voltage (50 volts
for a 36-volt battery, etc.). On SPNO contactors, The hydraulic oil should be changed every 2000
read the voltage across the contactor with the hours or yearly. When the hydraulic system com-
tips open. Battery voltage should drop to zero or ponents such as the pump or cylinders have been
near zero as the tips close. damaged or the oil has otherwise been contaminated,
the hydraulic system should be drained, flushed, and
A voltage drop of 2 volts or more across the closed refilled with new hydraulic oil. See Maintenance
tips indicates a poor contact or high resistance. Schedule in this section.
Check for burned or worn tips, incorrect size,
or mismatched tips. Also check for an incorrect 1. Park the lift truck on a level surface and lower
gap setting on contactors with adjustable point the mast. Turn the key switch to the OFF po-
gaps. Repair as necessary. See Electrical Sys- sition, and attach a DO NOT OPERATE tag to
tem 2200 SRM 1191. the control handle. Block the wheels to prevent
HYDRAULIC SYSTEM 2. Disconnect the battery power cable connector
Drain
WARNING the truck connector.
including eye protection and petroleum-resis- 3. Remove the operator compartment cover and the
tant gloves when handling hydraulic oil. Thor- drive unit compartment door to access the hy-
oughly wash oil from exposed areas of skin as draulic tank.
soon as possible.
Completely lower forks to relieve hydraulic
pressure before disassembling any part of 5. Position a suitable oil container with a minimum
the lift pump or disconnecting any hydraulic capacity of 19 liter (5 gal) next to the lift truck to
hoses. drain the oil.
The hydraulic oil is hot at normal operating CAUTION

temperatures. Be careful when draining the DO NOT cut the hose when removing the wire
oil. tie.
Never check for leaks by putting hands on 6. Locate the drain hose at the bottom of the hy-
hydraulic lines or components under pressure. draulic tank. See Figure 24. Carefully clip the
Hydraulic oil under pressure can be injected wire tie securing the hose. Loosen and remove
into the skin. the hose clamp securing the plug in the end of the
hose. Remove the plug from the hose and drain
the hydraulic oil into the container.
31
7. Some lift trucks use displacement-type main lift

These cylinders may be further drained to reduce
levels of contaminants left in the hydraulic sys-
tem.
If your truck is equipped with displacement type

main lift cylinders:
a. Loosen both main lift cylinder bleed screws

1/2 turn.
b. Open the manual lowering valve.
c. Allow time for the oil to gravity feed into the

tank.
d. Close the manual lowering valve.

main lift cylinder shells.

plug into the hose and secure with hose clamp
as removed. Coil the drain hose and secure with
9. Inspect the tank. Check for damage to the tank

or hoses. Clean the tank if necessary.
10. Reinstall the breather assembly as removed.

ever, cylinders may be either displacement type or
piston type. Different cylinder types require differ-
ent hydraulic oil drain and fill procedures.
1. PLUG The main lift cylinders may be identified by the pres-

2. HOSE ence of a bleed screw near the top of the cylinder shell
3. ELBOW (WITH CLAMP) on displacement type cylinders. Piston type main lift
4. TANK
5. WIRE TIE cylinders are not equipped with bleed screws. See
6. CLAMP Figure 25.
Figure 24. Drain Hose
32

2. CYLINDER ROD
3. BLEED SCREW
(INDICATES DISPLACEMENT
TYPE)
4. CYLINDER SHELL
Figure 25. Main Lift Cylinder Identification

rod diameter. Measure the diameter of the free-lift
cylinder rod to determine your lift truck configura-
tion. See Figure 26 and Table 6.
Table 6. Free-Lift Cylinder Rod Widths
Type Diameter
1. CROSSHEAD ASSEMBLY
Displacement 73.00 mm (2.87 in.) 2. CYLINDER ROD DIAMETER
3. BLEED OR FILL SCREW
Piston 44.40 mm (1.75 in.) 4. RETAINER BRACKET
5. CYLINDER SHELL
6. GLAND
Figure 26. Free-Lift Cylinder Identification
33
Fill Main Lift Cylinders
NOTE: Refer to Capacities and Specifications 1. Piston-type main lift cylinders do not require
8000 SRM 1198 for the proper hydraulic oil selection. bleeding. If your lift truck is equipped with
piston-type main lift cylinders, skip to Free-Lift
1. Fill the hydraulic tank to the proper level with Cylinders.
new hydraulic oil. The hydraulic oil should be
filled to the level specified for the battery box
compartment of the truck. DO NOT overfill the WARNING
hydraulic tank. See Figure 27. Keep clear of the mast when bleeding the cylin-
2. Install the breather cap. edly.
3. Determine the types of main lift cylinder and Always wear the proper protective equipment
free-lift cylinders used. See Cylinder Identifica- including eye protection and petroleum-resis-
tion. tant gloves when handling hydraulic oil. Thor-
soon as possible.
2. Displacement-type main lift cylinders must be

bled:



disconnect the battery connectors.
WARNING
truck.
CAUTION

expelled to minimize spills.
1. FILTER HOUSING d. Slightly open the bleed screw of either main
2. RETURN FITTING
3. FILL LEVEL (EVEN WITH FLANGE) lift cylinder by turning it counterclockwise
(21.5 INCH BATTERY COMPARTMENT ONLY) until air and/or foam is expelled. Allow
4. FILL LEVEL (40.0 mm (1.6 in.) BELOW FLANGE) air/foam to bleed until clear hydraulic oil is
(ALL OTHER BATTERY COMPARTMENTS) present. Close the bleed screw and tighten
5. HYDRAULIC TANK to 6 to 8 N•m (53 to 73 lbf in). If the free-lift
cylinder completely lowers before all the air
Figure 27. Hydraulic Oil Level
is expelled, close the bleed screw and return
to Step a. Wipe up the expelled oil and repeat
procedure for the other main lift cylinder.
34
Free-Lift Cylinders a. Engage the battery connectors and turn the

1. Piston type free-lift cylinders are not bled but do
have an oil chamber that must be filled for cylin- b. Activate the lift function using the operator
der cushion functions to work properly: controls. Continue until the free-lift cylinder
a. Completely lower the mast and carriage. apply pressure to the hydraulic system.
Turn the key switch to the OFF position and
disconnect the battery. c. Turn the key switch to the OFF position and
disconnect the battery.
turning it counterclockwise to make sure the CAUTION
cylinder is not pressurized. Slowly remove DO NOT completely remove the bleed screw.
NOTE: Use a clean oil can to measure and inject hy- expelled to minimize spills.
c. Measure approximately 150 cc (5 oz) of clean of the free-lift cylinder shell near the gland
hydraulic oil and fill the oil chamber through by turning it counterclockwise until air
the fill hole. Fill until all the oil is used or and/or oil foam is expelled. Allow air/foam to
until oil flows out of the fill hole. bleed from the cylinder until clear hydraulic
oil is present. Close the bleed screw and
d. Install the fill screw and seal and tighten to tighten to 6 to 8 N•m (53 to 73 lbf in). If the
6 to 8 N•m (53 to 73 lbf in). Wipe up any free-lift cylinder completely lowers before all
spilled oil. air/foam is expelled, close the bleed screw
and repeat Step a. Wipe up the expelled
e. Connect the battery and turn the key switch
oil. Some displacement type free-lift cylin-
ders also have an additional bleed screw
located in the end of the cylinder rod. In-
proper operation. The free-lift cylinder
spect the cylinder rod where it emerges from
should slow smoothly near the end of its
the crosshead. If the rod is equipped with
stroke. Check the hydraulic oil level in the
the additional bleed screw, repeat the bleed
procedure using the additional bleed screw.
as removed, remove blocks from the wheels,
and return the lift truck to service. e. Connect the battery and turn the key switch
WARNING lower the mast several times to check for
Keep clear of the mast when bleeding the cylin- proper operation. Repeat the bleed proce-
ders. Mast parts may shift or lower unexpect- dure until no air is present when bleeding
edly. the free-lift cylinder. Check the hydraulic oil
Never check for leaks by putting hands on place all covers as removed, remove blocks
hydraulic lines or components under pressure. from the wheels, and return the lift truck to
Hydraulic oil under pressure can be injected service.
into the skin.
2. Displacement type free-lift cylinders must be

bled:
35
Hydraulic Filter Change

Replace the filter element after the first 150 to 250
hours of service and every 2000 hours or yearly there-
after.
WARNING
soon as possible.


oil. 1. HYDRAULIC TANK
2. COVER
3. FILTER
CAUTION 4. PUMP RETURN HOSE
Disposal of lubricants and fluids must meet lo- 5. HYDRAULIC FILTER HOUSING
cal environmental regulations. 6. SPRING
1. Move the lift truck to a safe, level area and com- Figure 28. Cover Removal
8. Position the cover and spring to the housing.
Press the cover down by hand to depress the
element retainer spring, and install the four cap-
screws. Torque capscrews to 6 N•m (53 lbf in).
dle. Remove the drive wheel blocks and test for
proper operation.
3. Remove the operator compartment cover(s) to ac- Check Hydraulic Strainer

cess the hydraulic tank. The hydraulic breather cap allows air to enter the hy-
4. Loosen the four capscrews securing cover to the draulic tank when the hydraulic oil is pumped out to
hydraulic oil filter housing. the cylinders. When the hydraulic oil returns to the
tank, air is expelled through the hydraulic breather
5. Press the cover down by hand to depress the el- cap. A filter in the cap protects the hydraulic system
ement retainer spring, and remove the four cap- from particles of dirt and other contaminants. If the
screws. filter becomes excessively dirty, air flow can be re-
stricted, causing pressures and vacuums to build in-
6. Remove the cover and spring from housing. side the tank. If air flow becomes restricted through
Check the O-ring seal on the cover for cracks the hydraulic breather cap, replace the breather cap.
or deterioration. Replace if damaged. See Fig- Keep the hydraulic breather area clean and DO NOT
ure 28. overfill the hydraulic tank.
7. Remove element from housing and replace with
a new element.
36
8000 SRM 1197 Lift and Tilt System Leaks Check
Lift and Tilt System Leaks Check

LIFT SYSTEM 10 minutes when the hydraulic oil is 30 C (86 F).
If the oil temperature is 70 C (158 F), the maxi-
WARNING mum speed that the carriage can lower is 150 mm
(6 in.) per 10 minutes.
see Safety Procedures When Working Near 5. Check the lift cylinder for internal leaks. Remove
Mast. the load from the forks. Install a gate valve in the
supply line between the main control valve and
Never allow anyone under a raised carriage.
the mast. Put a capacity load on the forks again.
DO NOT put any part of your body in or
Raise the carriage 1 m (3 ft). Close the gate valve.
through the lift mechanism unless all parts of
If the carriage or mast weldments lower slowly,
the mast are completely lowered, the key is
the seals in the lift cylinders have leaks. Refer to
removed, and the battery is disconnected.
the section Lift Cylinders 4000 SRM 481.
6. If the carriage does not move, open the gate valve
and check for movement again. If the carriage
lowers when the valve is open, check for leaks
in the hydraulic lines or fittings. If no leaks are
soon as possible.
found, the lowering solenoid might be damaged.
Never check for leaks by putting hands on Remove the load from the forks.
Hydraulic oil under pressure can be injected TILT SYSTEM
into the skin.
1. Put a capacity load on the forks. Slowly tilt the
During the test procedures for the hydraulic mast forward. If the forks continue to slowly
system, fasten the load to the carriage with tilt forward when the control valve is in a neu-
chains to prevent it from falling. Keep all tral position, there are leaks inside the hydraulic
personnel away from the lift truck during the system. The maximum speed that the forks are
tests. allowed to tilt forward when there are internal
leaks in the lift system is 13.0 mm (0.5 in.) per
1. Slowly raise and lower the mast several times 10 minutes (measured at the tilt cylinder). This
without a load. The mast components must raise maximum speed is measured when the hydraulic
and lower smoothly in the correct sequence. The oil is 30 C (86 F). If the oil temperature is 70 C
carriage raises first, then the inner mast and in- (158 F), the maximum speed is 39.0 mm (1.5 in.)
termediate mast (three-stage, full free-lift mast per 10 minutes.
only).
2. If the leak rate is greater than specifications, re-
NOTE: Some parts of the mast move at different move the load from the forks. Install a gate valve
speeds during raising and lowering. between the port at the front of the tilt cylin-
der and the hydraulic line. Put the load on the
2. The inner mast and the carriage must lower com- forks again. Close the gate valve. If the forks tilt
pletely. slowly forward, the cylinder seals are leaking. Be
sure to check both tilt cylinders.
3. Put a capacity load on the forks, and raise and
lower the load several times. Lower the load, 3. If the forks do not move, open the gate valve and
and tilt the mast forward and backward several check for movement again. If the forks move for-
times. Check for leaks. ward when the gate valve is open, check for leaks
in the hydraulic lines or fittings. If no leaks are
4. Raise the carriage and the load 1 m (3 ft). If the
found, the carriage selector valve on the front
carriage lowers slowly with the control valve in a
frame of the reach carriage might be damaged.
neutral position, there are leaks inside the hy-
Remove the load from the forks.
draulic system. The maximum speed that the
carriage is allowed to lower is 50 mm (2 in.) per
37
Battery Maintenance
HOW TO CHARGE BATTERY
WARNING
If the lift truck was operated with a low battery,
check all contactors for welded contacts before
a charged battery is connected.
Make sure the key switch is in the OFF position

and the park brake is set before connecting the
battery.
The acid in the electrolyte can cause injury.

Use water to flush the area and make the acid
neutral with a water and soda solution. Acid
in the eyes must be immediately flushed with
water continuously for 15 minutes, then seek
medical attention.
Specific Electrolyte Correction Correct
Batteries generate explosive fumes when they
Gravity Temp. Points Value
are being charged. Keep fire, sparks, and burn-
Reading
ing material away from the battery charger
area. Avoid sparks from the battery connec- 1.210 31 C (88 F) +0.003 1.213
tions. Charge batteries only in the special area
1.210 27 C (81 F) +0.001 1.211
for charging batteries. When the battery is
being charged, keep the vent caps clear. The 1.210 25 C (77 F) 0.000 1.210
battery charger area must have ventilation so
1.210 18 C (64 F) 0.004 1.206
that explosive fumes are removed.
±0.001 for each 2 C from the 25 base value.
Disconnect the battery when doing cleaning
and maintenance.
Figure 29. Battery Check
CAUTION NORMAL CHARGE: This charge is the charge that

Never connect the battery charger plug to the is normally given to a battery that is discharged from
plug of the lift truck. You can damage the normal service. Many users give this charge at a
electronic controller. Make sure the battery regular interval based on usage. This practice will
charger voltage is the correct voltage for the keep the battery fully charged if the battery is not
battery. discharged below the limit. Always use a hydrome-
ter to check the battery if the interval charge cycle is
NOTE: Use only battery chargers approved by the used. Frequent charging of a battery that has a 2/3
battery manufacturer or dealer. or more charge can decrease battery life.
Correct use of the hydrometer and proper operation EQUALIZING CHARGE: This charge is at a low rate
of the battery charger is important. See Figure 29. and balances the charge in all of the cells. The equal-
Follow the instructions of the charger manufacturer. izing charge is normally given approximately once a
Never let the battery discharge below the minimum month. It is a charge at a slow rate for 3 to 6 hours
value given by the battery manufacturer. A fully- in addition to the regular charging cycle.
charged battery will have a specific gravity of 1.265
to 1.310 at 25 C (77 F). Never charge a battery at a DO NOT give an equalizing charge more than once
rate that will raise the electrolyte temperature above a week. The most accurate specific gravity mea-
49 C (120 F). Never let a battery stay discharged for surements for a charged battery will be after an
long periods. equalizing charge. If the specific gravity difference
is more than 0.020 between cells of the battery after
38
an equalizing charge, there can be a defective cell.

Consult your battery dealer. WARNING
To prevent personal injury and battery move-
Also see the section Industrial Battery 2240 SRM 1 ment that is not expected, the battery must be
for additional information on the charging and main- level when it is moving. Make sure the battery
tenance of a battery. stand is on a level surface and is aligned and
adjusted as described in the following proce-
NOTE: Many users have battery chargers that can dure.
follow a program to automatically charge a battery
according to recommendations of the battery man- 2. Align the battery stand with the battery so the
ufacturer. Use the recommendations of the battery end of the stand is against the roller frame for
manufacturer for charging the battery. the battery. Adjust the capscrew legs of the bat-
tery stand so the tops of the rollers are the same
HOW TO CHANGE BATTERY height as the bottom of the battery. Adjust all
four capscrew legs of the stand so the rollers are
WARNING level. Install the battery puller on the end of the
Make sure the capacity of the crane and stand at the center.
spreader bar is greater than the weight of the
3. Release the ratchet lock and attach the hook to
battery. The weight of the battery is normally
the lifting hole of the battery. DO NOT permit
shown on the battery case. The spreader bar
hook to make contact with cell terminals. Make
must NOT be made of metal or it must have
sure the battery cables are not damaged during
insulated straps.
battery removal. Stand on the base of the battery
Batteries are heavy. Use care to avoid injury. puller, release the ratchet lever, and operate the
crank to pull the battery onto the battery stand.
The replacement battery must fit the battery
area correctly. Use spacers to prevent the bat- 4. Make sure the battery voltage and weight of the
tery from moving in the battery compartment. replacement battery is correct as shown on the
nameplate for the lift truck. When a replacement
Make sure the battery is installed in the proper battery is installed, it must fit the battery com-
direction. Ensure the battery cables are routed partment correctly. See Table 7. Make sure the
in a manner not to protrude from the battery battery is in a position so it will be installed to
box container except where necessary to con- the rear of the compartment and has clearance
nect to the truck SB connector. Any excess for installation. Make sure the battery connec-
length cable should be secured to the inside tor can be connected after installation. DO NOT
dimensions of the battery to prevent pinching damage the battery cables during installation.
or damaging the cables. Replace any damaged
cables prior to installing the battery in the 5. Use a spreader bar and crane to lift the battery
truck. from the battery stand.
Make sure the weight of the replacement bat- 6. Install the battery puller on the lift truck frame
tery is within the maximum and minimum at the center of the battery compartment on the
weights shown on the nameplate. side opposite the battery stand. See Figure 30.
Release the ratchet lock, pass the hook through
Make sure the key switch is in the OFF position the battery compartment, and attach the hook to
and the park brake is set before connecting the the battery lifting hole. DO NOT permit hook
battery. to make contact with cell terminals. Stand on
the base of the battery puller, release the ratchet
lever. Operate the crank to pull the battery off
CAUTION the stand into the battery compartment.
Disposal of batteries must meet local environ-
mental regulations. 7. Install the battery retainer plates. Connect the
battery.
1. Disconnect the battery. See Figure 30. Remove
the battery retainer panels.
39
8. Tighten the lock nuts. 9. Close and lock the traction motor compartment
door.
A. INSTALLATION B. REMOVAL
1. BATTERY RESTRAINT PANEL 4. BATTER PULLER
2. BATTERY STAND 5. RATCHET LOCK LEVER
3. ROLLERS 6. BATTERY
Figure 30. Change Battery
40
Table 7. Battery Size Specifications
Battery Maximum Battery Size* Battery Weight

Model Volts Compartment
(Length × Width) Length Width Min. Max.
986.0 × 368.3 mm 986.0 mm 365.00 mm 681 kg 953 kg

(38.8 × 14.5 in.) (38.8 in.) (14.38 in.) (1500 lb) (2100 lb)
N30ZDR, 24
N35-40ZR, 986.0 × 419.1 mm 986.0 mm 416.00 mm 726 kg 1033 kg
N30ZDRS, (38.8 × 16.5 in.) (38.8 in.) (16.38 in.) (1600 lb) (2275 lb)
N35-40ZRS
986.0 × 368.3 mm 986.0 mm 365.00 mm 704 kg 953 kg
(38.8 × 14.5 in.) (38.8 in.) (14.38 in.) (1550 lb) (2100 lb)
36
986.0 × 419.1 mm 986.0 mm 416.00 mm 840 kg 1090 kg
(38.8 × 16.5 in.) (38.8 in.) (16.38 in.) (1850 lb) (2400 lb)
986.0 × 419.1 mm 986.0 mm 416.00 mm 840 kg 1090 kg
(38.8 × 16.5 in.) (38.8 in.) (16.38 in.) (1850 lb) (2400 lb)
N35ZDR, 986.0 × 469.9 mm 986.0 mm 473.00 mm 999 kg 1294 kg
36
N45ZR (38.8 × 18.5 in.) (38.8 in.) (18.62 in.) (2200 lb) (2850 lb)
986.0 × 546.1 mm 986.0 mm 530.00 mm 1135 kg 1362 kg
(38.8 × 21.5 in.) (38.8 in.) (20.88 in.) (2500 lb) (3000 lb)
Compartment width is measured from the sides of the battery compartment. Battery length refers to
measures from the front to the rear of the battery compartment.
*Maximum height for all batteries is 787.0 mm (31.0 in.).
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use the battery compartment spacers to prevent the battery from moving more than
13.0 mm (0.5 in.) in any direction.
NOTE: Maximum tolerances are within 13.0 mm (0.5 in.) of the size of the battery compartment. The battery
specification chart shows the maximum battery dimensions that will fit into the battery compartment.
41
Tires and Wheels 8000 SRM 1197
Tires and Wheels

DRIVE TIRE tire treads, or wheels of different manufactures
on any one lift truck. Tire sizes listed in Table 8
WARNING are for the drive tires, load wheels, and caster
wheels.
Wheels must be changed and tires repaired by
trained personnel only. Always wear safety Table 8. Tires and Wheels
glasses.
1. Raise the rear of the lift truck as described in Tires and Tire Size
Compound
How to Put Lift Truck on Blocks. Wheels
Drive Tire 12 × 5.5 Rubber
WARNING Drive Tire 12 × 5.5 Polyurethane
The lifting and carrying of solid tires is not rec-
ommended because their weight could be in ex- Caster 8 × 2 Polyurethane
cess of 45 kg (100 lb). Where applicable, use a Load Wheels 5 × 3 Polyurethane
wheel or tire dolly to assist in the removal and
Load Wheels 5 × 4 Polyurethane
installation of the wheel.
4. Position the new tire in the press. See Figure 31.

CAUTION Align the wheel and tire assembly removed from
Check all wheel nuts after 2 to 5 hours of op- the truck on top of the new tire. Make certain the
eration: when new lift trucks begin operation wheels are aligned. Make certain the tires are
and on all lift trucks when the wheels have level. Position a press ring on top of the wheel
been removed and installed. Tighten the nuts hub.
if required. Tighten the nuts in a cross pattern
to 136 N•m (100 lbf ft). When the nuts stay 5. Carefully apply hydraulic pressure until the
tight for 8 hours, the interval for checking the wheel hub is forced from the old tire into the new
torque can be extended to 500 hours. tire. When properly seated, the new drive tire
will be flush to the outer edge or the inner edge
2. Remove the wheel nuts that fasten the drive of the wheel hub. See Figure 32.
wheel to the hub. Slide the wheel out from
under the lift truck. Use the reverse procedure
to install the wheel. Tighten the wheel nuts to
136 N•m (100 lbf ft) after installation.
HOW TO CHANGE DRIVE TIRE

NOTE: To change cushion tires, the wheel must be
pressed out of the rim. The proper tools, equipment,
and press ring must be used. DO NOT attempt to
change tires (rims) or wheels unless you have the
proper tools, equipment, and experience.
1. Remove the drive tire from the lift truck.
2. To remove the tire from the wheel, the correct

tools, equipment, and a press ring must be used 1. PRESS RING 3. NEW TIRE
for each size of wheel. Use a press to push the 2. OLD TIRE 4. WHEEL HUB
wheel from the rim and tire.
Figure 31. Position Tire on Wheel
3. Make sure the wheel hub is the correct size for
the tire. DO NOT mix types of tires, types of
42
8000 SRM 1197 Tires and Wheels
1. AXLE SHAFT 5. BEARING

2. WASHER 6. LOAD WHEEL
3. BRACKET 7. NUT
1. SOLID TIRE 4. PRESS TIRE 4. AXLE SLEEVE
2. WHEEL HUB FLUSH TO THIS
3. OUTER EDGE SIDE OF WHEEL Figure 33. Tandem Load Wheels
Figure 32. 12 × 5.5 Solid Tire Pressed Onto CASTER WHEELS
Drive Wheel
6. Install the tire and wheel on the hub. Tighten

Remove
the lug nuts to the torque value shown in the For the following instructions, see Figure 34.
Maintenance Schedule, Table 1.
7. Raise the lift truck high enough to remove the 50 mm (2 in.) to access the caster wheels. Re-
blocks. Lower the lift truck to the floor. fer to How to Put Lift Truck on Blocks.
TANDEM LOAD WHEELS

CAUTION
Put the base arms on blocks as described in How to Replace bearings in sets to maintain proper
Put Lift Truck on Blocks. For easier installation, re- wheel loading and operation.
move and install one load wheel before removing the
next load wheel. The load wheels are held in the 2. Inspect the bearings by rotating each caster
load arms by the load wheel brackets. Remove the wheel. The wheels should have no side-to-side
axle nut, axle, washers, bearings, and load wheel. free play and should turn smoothly. If the wheels
Remove the axle sleeve from the load wheel. Pack can be moved side to side or do not turn freely,
the new load wheel with grease. Install the new load the bearings should be replaced.
wheel, axle, axle sleeve, bearings, washers, and axle
nut. See Figure 33. On lift trucks used in freezer ap- 3. Use a punch to tap around the edge of the bearing
plications, apply antiseize lubricant to the load wheel cap to work it out of the caster wheel.
axle. 4. Unstake the bearing lockwasher from the bear-
ing lock nut and remove the lock nut and lock-
washer.
43
Tires and Wheels 8000 SRM 1197
5. Remove the caster wheel from the axle shaft. 7. Inspect the caster wheel for damage to the
bonded wheel surface and cracks in the hub
CAUTION or wheel material. Replace any wheel that is
damaged, cracked, or has large cracks or large
Use a hammer and a suitable brass or alu-
chunks of the outside material missing. Replace
minum driver when removing bearings to
wheels in sets if damaged.
avoid damage to the bearings and/or caster
wheel.
Install
The bearings are removed and replaced by
pressing on the outer race of the bearing only. WARNING
Pressing on the inner race will damage the Cleaning solvents can be flammable and toxic
bearing. and can cause skin irritation. Wear protection
6. Remove the bearing by pressing it from the wheel recommendations of the manufacturer.
hub using a suitable brass or aluminum driver.
oughly. Replace damaged parts as necessary.
CAUTION
The bearings are replaced by pressing on the
outer race of the bearing only. Pressing or tap-
ping on the inner race will damage the bearing.
Replace bearings in sets to maintain proper

wheel loading and operation.
2. Press new bearings into wheel assemblies. Use

a suitable brass or aluminum driver when in-
stalling bearings to avoid damage to bearings
and/or wheels. See Figure 34. Bearings must be
replaced in sets.
3. Install the caster wheels to the axle shaft.
CAUTION
4. Install the bearing lockwashers and lock nuts

onto the axle shaft.
5. Torque the bearing lock nuts to 136 N•m

(100 lbf ft).
6. Ensure the caster wheels rotate freely and

smoothly and are securely mounted on the axle
shaft. Stake the bearing lockwashers in place.
1. BEARING CAP
2. BEARING LOCKWASHER 7. Inspect the caps for damage. Repair or replace
3. BEARING LOCK NUT as necessary. Install the caps to the wheels by
4. CASTER WHEEL
5. AXLE SHAFT tapping around the edge of the caps. Make sure
6. BEARING the caps are properly seated in the hubs.
Figure 34. Caster Wheels
44
8000 SRM 1197 Preparation for Storage
Preparation for Storage

The following storage procedures are guidelines for 5. Put blocks at the front and rear of the drive tire
conditions and temperatures above 0 C (32 F). Ad- when parked. DO NOT use the parking brake.
just these procedures to meet local conditions as well
as any expected change in conditions during storage. 6. Clean dust and dirt from interior surfaces and
Determine the amount of preparation necessary for exterior surfaces. Clean frame to remove sand or
storage based on the following: road salt. Allow frame to air dry.
• Length of Storage. Short-term storage is from 1 to
7. If lift truck is parked outside, cover with a tarp
6 months. Long-term storage is over 6 months.
or protective material to keep direct sunlight out
• Storage Locations. A lift truck stored indoors will
of the operator’s compartment and water out of
not require as much external protection as a lift
the controls.
truck stored outdoors.
LONG-TERM STORAGE (6 MONTHS OR
SHORT-TERM STORAGE (1 TO 6 MONTHS)
LONGER)
CAUTION 1. Complete all short-term storage procedures.
Make sure all caps, lids, and dipsticks are in-
2. Wrap or cover all exterior lights and air vents
stalled correctly.
with moisture barrier paper and tape closed.
1. Check lubricants and fluid levels.
3. Remove the batteries from the lift truck. Put the
2. Masts are to be stored fully lowered. Lubricate batteries in storage. Be sure to follow local fire
any exposed part of all cylinder rods with SAE regulations.
30 or SAE 40 engine oil.
4. Spray exterior surfaces and frame with preser-
3. Check that all switches and accessories are off. vative coating.
4. Disconnect battery cables from the batteries. Ap-

ply corrosion preventive to battery terminals.
45
NOTES
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46
REACH CARRIAGES
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590957 4500 SRM 1196

Reach Carriages Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Repair - General................................................................................................................................................. 4
Load Backrest .................................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 4
Forks ................................................................................................................................................................... 5
Replacement................................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Install ......................................................................................................................................................... 5
Remove ........................................................................................................................................................... 6
Inspect ............................................................................................................................................................ 7
Install ............................................................................................................................................................. 7
Reach Carriage Assembly Repair ..................................................................................................................... 9
Load Rollers Repair ........................................................................................................................................... 9
Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS).................................................................. 10
Reach Assembly Front Frame ........................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Disassemble (With Sideshift) ........................................................................................................................ 12
Disassemble (Without Sideshift)................................................................................................................... 14
Assemble (With Sideshift) ............................................................................................................................. 15
Assemble (Without Sideshift)........................................................................................................................ 15
Install ............................................................................................................................................................. 15
Single-Reach Scissor Arms ................................................................................................................................ 16
Remove and Disassemble .............................................................................................................................. 16
Assemble and Install ..................................................................................................................................... 19
Double-Reach Scissor Arms............................................................................................................................... 21
Disassemble ................................................................................................................................................... 21
Assemble ........................................................................................................................................................ 24
Rear Frame Assembly........................................................................................................................................ 26
Remove ........................................................................................................................................................... 26
Disassemble ................................................................................................................................................... 28
Assemble ........................................................................................................................................................ 29
Install ............................................................................................................................................................. 29
Reach Cylinders ................................................................................................................................................. 30
Remove ........................................................................................................................................................... 30
Disassemble ................................................................................................................................................... 32
Assemble ........................................................................................................................................................ 33
Install ............................................................................................................................................................. 33
Tilt Cylinder ....................................................................................................................................................... 34
Remove ........................................................................................................................................................... 34
Clean, Inspect, and Repair............................................................................................................................ 34
Install ............................................................................................................................................................. 34
Sideshift Cylinder .............................................................................................................................................. 36

Table of Contents Reach Carriages

Repair ............................................................................................................................................................. 36
Front Selector Valve........................................................................................................................................... 37
Rear Selector Valve ............................................................................................................................................ 38
Reach Assembly Adjustments ........................................................................................................................... 39
Check Adjustment ......................................................................................................................................... 39
Adjust Side Rollers and Load Rollers ........................................................................................................... 40
Adjust Reach Cylinders ................................................................................................................................. 41
Lift Chains.......................................................................................................................................................... 42
Inspect ............................................................................................................................................................ 42
Clean and Lubricate ...................................................................................................................................... 43
Adjust Main-Lift Chains ............................................................................................................................... 43
Adjust Free-Lift Chains ................................................................................................................................ 43
Specifications...................................................................................................................................................... 45
Troubleshooting ................................................................................................................................................. 48
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
ii
General
This section contains the descriptions and repair pro- N35-40ZDR, see the section Hydraulic System
cedures for single-reach and double-reach carriages. 1900 SRM 1189. For additional information
Additional information can be found in the following on hydraulic systems for models N30ZDRS and
sections: N35-40ZRS, see the section Hydraulic System
For additional information on mast configura- 1900 SRM 1307.
tions, see Mast, Repair 4000 SRM 1195. For the recommended service intervals and regu-
For additional information on hydraulic sys- larly scheduled maintenance procedures, see the
tems for models N35ZDR, N45ZR, N30ZDR, and section Periodic Maintenance 8000 SRM 1197.

WHEN WORKING NEAR THE MAST, ALWAYS:
WARNING • Lower the mast and carriage completely. Make
All chains, ropes, and lifting equipment MUST sure there is no movement in the mast. Make sure
be fully examined by qualified personnel at all parts of the mast, that can move, are fully low-
least once a year or more at frequent intervals ered.
OR
WARNING
• If the mast must be in a raised position for re-
Mast parts are heavy and can shift. Distances pairs, install a safety chain around the top or mid-
between parts are small. Serious injury can re- dle crossmember of the outer weldment and the
sult if part of the body is hit by parts of the mast crossmember of the inner weldment to secure the
or the carriage. mast.
• Never put any part of the body into or under
pletely lowered or a safety chain is installed. WARNING
Also make sure the power is off and the key Perform the following step from the side of the
is removed. Attach a DO NOT OPERATE tag mast using a ladder. Never stand under the car-
to the control handle. riage until safety chains are installed.
• DO NOT make repairs or adjustments unless
1. Remove forks from carriage if possible.
specifically authorized to do so. Repairs and
adjustments must be performed by trained 2. Raise mast to align bottom crossmember(s) of
service technicians. weldment(s) that move within the outer weld-
• DO NOT climb on the mast or lift truck at any ment with a crossmember on outer weldment.
time. Use a ladder or personnel lift to work On the two-stage mast, the moving part is the
on the mast. inner weldment. On the three-stage mast, it is
• Be careful of the forks. When the mast is the intermediate weldment.
raised, the forks can be at a height to cause
an injury. 3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum
• Move the truck to a safe location with room to size, around crossmembers of inner and outer
raise the mast if necessary. Block the wheels weldment. Secure it in place. See Figure 1.
4. Lower mast until safety chain stops mast. Make
The forks may be difficult to see when the mast is sure there is no movement of mast.
raised. Be careful not to hit your head when working
around raised forks. Also, be careful not to trip over 5. Turn key switch to OFF, disconnect battery, and
forks on or near the floor. If possible, remove forks place a DO NOT OPERATE tag on control han-
from carriage before safety chaining mast. dle head.
1
6. Wrap a second safety chain, 9.5 mm (3/8 in.) min-

imum size, around crossmembers of inner and
outer weldment. Secure it in place as an addi-
tional precaution.
NOTE: The mast operator guard MUST be removed

to install safety chain. Remove safety chain and in-
stall guard AFTER repairs are complete.
1. OUTER MAST WELDMENT

2. INNER MAST LOWER CROSSMEMBER
3. SAFETY CHAIN
4. CARRIAGE
Figure 1. Safety Chain the Mast
Description
The reach carriages are used to extend the forks of the front frame assembly. On double reach units, the
the carriage. There are two types of reach carriages. ends of each set of scissor arms and scissor arm weld-
There is a single-reach carriage with one set of scis- ments are fastened together by studs with bushings.
sor arms. The other carriage has two sets of scis- The bushings permit the arms to pivot. Large bear-
sor arms for double reach. See Figure 2. Both car- ings at the center pivot of each scissor arm assembly
riages have a tilt cylinder to tilt the forks. Each car- also permit the linkage to pivot. Refer to Figure 11
riage is available with sideshift function. Refer to and Figure 15.
Figure 9 and Figure 10. The rear and front frame
assemblies are connected by a scissor linkage. The NOTE: The reach assembly can be removed from the
top of the scissor arm weldment is fastened to the mast assembly with the load backrest and forks at-
top of the rear frame by pins located within the rear tached. The three-stage mast assemblies can also be
frame assembly. The top of each scissor arm at the removed with the reach assembly installed. Perform
front frame is fastened by pins located at the top of only those procedures necessary for repair.
2
A. SINGLE-REACH CARRIAGE B. DOUBLE-REACH CARRIAGE

1. FORK CARRIAGE 6. FRONT FRAME ASSEMBLY
2. TILT CYLINDER 7. FRONT SELECTOR VALVE
3. REAR FRAME ASSEMBLY 8. VALVE COVER PLATE
4. REAR SELECTOR VALVE 9. HOSE AND WIRING GUIDE
5. SCISSOR ARMS 10. REACH CYLINDER
Figure 2. Reach Carriage Assembly (Major Components)
3
Load Backrest 4500 SRM 1196
Repair - General
NOTE: Most repairs of the reach carriage can be
WARNING
done without removing the carriage from the mast.
These repair procedures require that the carriage is Hydraulic oil is hot after system operation and
installed in the mast and the scissor arms are fully can cause burns. DO NOT disconnect any hy-
extended. draulic lines of the system until the oil for the
system is cool.
WARNING
The reach carriage can fall or tip easily and CAUTION
cause an injury when not installed in the mast. Make sure the lift truck is in a location that is
If the reach carriage cannot be installed in a level and has access to a crane or other lifting
mast during repair, make sure the rear frame device before doing any repairs on the reach
is fastened to a support that cannot move. The carriage.
rear frame must be in the same position as it is
in the mast. The rear frame must also be fas- NOTE: It is usually not necessary to completely dis-
tened so that it cannot move on the support. assemble the reach carriage. Do only the steps of the
The support must be strong enough to allow procedures necessary to make the required repairs.
full extension of the reach carriage without tip- Read and follow the Safety Procedures When Work-
ping. ing Near Mast in this section, as well as all WARN-
INGS and CAUTIONS.
Load Backrest
REMOVE INSTALL
WARNING WARNING
The load backrest is heavy and can cause an The load backrest is heavy and can cause an
injury. Remove using a lifting device. injury. Install using a lifting device.
1. Use a hoist to secure the load backrest in posi- 1. Raise the load backrest into position using the
tion. lifting device.
2. Remove the four capscrews and lockwashers that 2. Align the holes in load backrest with the mount-
fasten the load backrest to the carriage frame. ing holes in the carriage frame, and install the
four capscrews and lockwashers.
3. Lift the load backrest off the carriage frame.
3. Torque the capscrews to 102 N•m (75 lbf ft).
4
4500 SRM 1196 Forks
Forks
REPLACEMENT 2. Using a lifting device, move the fork or carriage
so the top hook on the fork engages the top cross-
WARNING member of the fork carriage.
Forks are heavy and can cause an injury. DO 3. Raise the carriage or lower the fork to move the
NOT try to remove forks without using a lifting lower hook through the removal notch.
device.
4. Slide the fork on the carriage so both upper and
The forks are connected to the fork carriage by hooks. lower hooks are engaged and the latch pin aligns
Spring-loaded latch pins, installed in the top fork with a notch.
hooks, extend into slots on the top crossmember of
the carriage to hold the forks in position. See Fig- 5. Release the latch pin and check that it properly
ure 3. engages in a top bar notch.
Remove
1. Pull the latch pin and turn it 180 degrees to lock
the pin in a retracted position.
2. Slide the fork to the fork removal notch located

in the center of the bottom crossmember of the
fork carriage.
3. Place a wooden block under the tip of the fork and

tilt the carriage forward. The bottom hook of the
fork will move through the fork removal notch.
4. Using a lifting device and a sling, raise the fork

so the top hook of the fork is disengaged from 1. FORK
the top crossmember. Remove the fork from the 2. BUTTON CAP
carriage. 3. LATCH PIN
4. SPRING
Install 5. PIN
1. Make sure the latch pin is locked in a retracted Figure 3. Forks

position.
5

REMOVE WARNING
NOTE: The following steps outline the procedures for Reach carriage assemblies are heavy. Be sure
removing the reach carriage assembly from a mast, that all lifting devices are suitable and of ade-
which is installed to a lift truck. quate capacity to lift the components.
1. Remove the forks. See Forks. 4. Attach an overhead lifting device to the top of the
reach carriage assembly:
2. Remove the load backrest. See Load Backrest.
3. Remove the hardware securing the operator each side of the rear frame. See Figure 4.
guard from the rear of the mast, and remove the
operator guard. b. Ensure clamps are secure before lifting the
reach carriage assembly.
Figure 4. Install C-Clamps to Rear Frame
6
c. Install a chain loop or sling through each INSPECT

overhead lifting device. 1. Inspect the rollers for excessive wear or damage.
Rollers with visible flat spots or cracks should be
5. Raise the reach carriage assembly high enough replaced.
harness mounting plate on the rear frame. 2. Inspect the load roller bearings and thrust roller
bearing by turning the rollers on their shafts.
6. Safety chain the reach carriage assembly in Rollers with roughness or noticeable restrictions
place. See Safety Procedures When Working to turning must be replaced.
Near Mast.
7. Disconnect the lift chains from the reach carriage WARNING

assembly: Welding repairs to the reach carriage assem-
bly or mast must be factory approved by Hys-
a. Remove the cotter pin and chain anchor pin ter® before the repair is performed. Written
securing the chain to the anchors. instructions outlining specifications and weld-
ing techniques will be provided upon approval
NOTE: Make sure lift chains, wiring, and hoses are to ensure the structural integrity and safety of
secured out of the way so they do not interfere with the repair.
reach assembly removal procedures.
3. Inspect all welds between the reach carriage as-
b. Secure chains to the mast using stiff wire to sembly side plates and the carriage fork bars. If
keep them from falling from the sheaves. any welds are cracked, repair or replace the dam-
c. If the mast must be disassembled or the aged components as necessary.
chains need to be cleaned/lubricated, remove 4. Inspect the roller stub shafts. If they are dam-
the lift chains and inspect and clean. aged or if there are cracks at the base of the
8. Tag and disconnect the attachment hoses from stub shafts, repair or replace the damaged com-
the two fittings at bottom of the rear frame of ponents as necessary.
the reach carriage assembly. Cap or plug all open 5. Inspect the chain anchor mounts for wear or
hydraulic hoses. damage.
9. Remove the plate securing the reach wiring har- 6. Inspect the lift chains for wear or damage. If
ness to the top of the rear frame. Disconnect the removed, clean and lubricate. See Lift Chains.
wiring connector.
NOTE: The side rollers must be adjusted while the
10. Remove the safety chains and completely lower reach carriage assembly is removed from the mast.
the reach carriage assembly to the floor.
7. 6.9 Mast Only (N30ZDRS and N35-40ZRS) -
WARNING Adjust the side rollers. See Adjust Side Rollers
and Load Rollers.
Mast assemblies are heavy. Be sure that all lift-
INSTALL
ity to lift the components.
NOTE: Use a second lift truck or overhead lifting de-
vice to move the reach carriage assembly.
1. Position the reach carriage assembly in an up-
11. Attach an overhead lifting device to the top of the
right position in front of the mast. Align the load
inner mast. Raise the inner mast until clearly
rollers on the rear frame of the reach carriage as-
higher than the reach carriage assembly. Move
sembly with the inner mast.
the reach carriage assembly away from the lift
truck and completely lower the mast.
12. Disconnect the lifting device from the reach car-

riage assembly.
7
6. Safety chain the reach carriage assembly in

WARNING place. See Safety Procedures When Working
Mast assemblies are heavy. Be sure that all lift- Near Mast.
CAUTION
NOTE: Use an overhead lifting device of suitable ca- If reusing chains, make sure chains have been
pacity to raise the inner mast when installing the properly inspected, cleaned, and lubricated.
reach carriage assembly. Use second lift truck to po- See Lift Chains.
sition the reach carriage assembly if the first truck
is not mobile. 7. Reconnect the lift chains to anchors on reach car-
riage assembly as removed. Install anchor pins
2. Raise the inner mast until clearly higher than and cotter pins.
the reach carriage assembly. Position the reach
carriage assembly so the load rollers on the rear 8. Connect the wiring connector and install the
frame are centered within the channels of the in- mounting plate to the top of the rear frame.
ner mast.
9. Remove caps/plugs from the attachment hoses
3. Lower the inner mast channels onto the load and fittings. Reconnect the hoses as removed.
10. Remove the safety chains and completely lower
not lower smoothly and completely, raise the
the reach carriage assembly.
inner mast, reposition the reach carriage assem-
bly, and lower the inner mast again. 11. Remove the C-clamps and lifting device from the
reach carriage assembly.
WARNING
12. Raise and lower the mast several times to remove
Reach carriage assemblies are heavy. Be sure air from the system. Cycle the sideshift function
that all lifting devices are suitable and of ade- and the tilt function several times to remove air
quate capacity to lift the components. from the circuit. Check for proper operation.
4. Attach an overhead lifting device to the top of the 13. Check the hydraulic oil level and add as required.
14. Check reach carriage assembly height and align-
a. Install heavy-duty, industrial C-clamps to ment and adjust the lift chains as required. See
each side of the rear frame. See Figure 4. Reach Assembly Adjustments.
b. Install a chain loop or sling through each 15. Install the load backrest. See Load Backrest.
overhead lifting device. 16. Install the forks. See Forks.
5. Raise the reach carriage assembly high enough 17. Install the operator guard as removed.
harness mounting plate on the rear frame.
8
4500 SRM 1196 Load Rollers Repair
Reach Carriage Assembly Repair

NOTE: Most repairs of the reach carriage assembly
WARNING
can be done without removing the reach carriage as-
sembly from the mast. These repair procedures re- Hydraulic oil is hot after system operation and
quire that the reach carriage assembly is installed in can cause burns. DO NOT disconnect any hy-
the mast and the scissor arms are fully extended. draulic lines of the system until the oil for the
system is cool.
WARNING
The reach carriage assembly can fall or tip eas- CAUTION
ily and cause an injury when not installed in Make sure the lift truck is in a location that is
the mast. If the reach carriage assembly can- level and has access to a crane or other lifting
not be installed in a mast during repair, make device before doing any repairs on the reach
sure the rear frame is fastened to a support carriage assembly.
that cannot move. The rear frame must be in
It is usually not necessary to completely disassemble
the same position as it is in the mast. The rear
the reach carriage assembly. Do only the steps of the
frame must also be fastened so it cannot move
procedures necessary to make the required repairs.
on the support. The support must be strong
enough to allow full extension of the reach car-
riage assembly without tipping.
Load Rollers Repair

1. Remove the rear frame from the mast as required
to remove and install the load rollers. See Reach
Carriage Assembly.
WARNING
rings. Snap rings can eject during removal or
installation with enough force to cause an in-
jury. Always use the proper snap ring pliers
and wear eye and face protection during re-
moval or installation.
2. Remove the snap rings from the load rollers. See

Figure 5.
1. SNAP RING 3. SPACER
2. LOAD ROLLER 4. STUB SHAFT
Figure 5. Load Roller Assembly
9
Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS) 4500 SRM 1196
NOTE: Lightly pry the load roller from the stub shaft
if necessary. See Figure 6.
3. Remove the load roller from the stub shaft. Re-

place as necessary.
NOTE: Tag and identify the shim packs for each

roller.
4. Remove the shims from the stub shaft.
5. Use a cloth to clean each load roller. Inspect the

load rollers for cracks, flat spots, or bearings that
do not turn freely. Replace any roller that shows
wear or is damaged.
1. LOAD ROLLER (WITH SNAP RING REMOVED)

2. PRY BAR
3. REAR FRAME
Figure 6. Removing Load Roller (6.9 Mast)

(N30ZDRS and N35-40ZRS)
Side Rollers Repair (6.9 Mast Only) (N30ZDRS and N35-40ZRS)

1. Remove the reach carriage assembly from the
mast to adjust or replace the side rollers. See
CAUTION
Reach Carriage Assembly. Correct placement of shims is critical for the
operation of the reach carriage assembly. Un-
NOTE: Make note of the position of the shims. Shim less the shims are installed correctly, the reach
requirements should be similar to the previous re- carriage assembly will not operate properly.
quirements.
4. Install the side rollers using shim packs, wash-
2. Remove the capscrews, shim packs, and washers ers, and capscrews.
that secure the side roller bracket.
5. Measure and adjust the side rollers as necessary.
3. Inspect and replace all damaged or worn parts. See Reach Assembly Adjustments.
6. Install the reach carriage assembly to the mast.
10
4500 SRM 1196 Reach Assembly Front Frame
Reach Assembly Front Frame

REMOVE channels of the rear frame to make sure the
load bearings cannot move in the channel. See
NOTE: It is not necessary to remove the reach car- Figure 8.
riage assembly from the mast to service the front
frame. NOTE: Use safety chains on the rear frame and mast
weldments to keep the reach carriage assembly and
The front frame is located at the front of the reach mast weldments from moving. Install the safety
carriage assembly and is attached to the outer end chains as described in Safety Procedures When
of the scissor arms. The assembly consists of a Working Near Mast in this section.
tilting frame, a fixed frame with tilt cylinder, and
front selector valve hydraulics. See Figure 7. When NOTE: Make sure the reach carriage assembly is in
equipped with optional sideshift, a movable fork the fully-extended position. The front frame should
carriage and the sideshift cylinder are included. be removed with the forks removed.
1. Remove the forks and the load backrest. Refer to

Load Backrest and Forks.
2. Extend the reach fully and install blocks and

clamps inside the channels of the rear frame to
make sure the load rollers cannot move in the
channel. See Figure 8.
1. FIXED FRAME
2. SELECTOR VALVE
3. FORK CARRIAGE
4. SIDE SHIFT CYLINDER
5. TILT CYLINDER
Figure 7. Front Frame Assembly
WARNING 1. REAR FRAME ASSEMBLY

2. LOAD BEARING
There are pinch points on the reach carriage 3. WOOD BLOCK
assembly that can cause an injury. Use clamps 4. CLAMP
and blocks to prevent the scissor arms from
moving. Install the clamps and blocks at the Figure 8. Blocking the Rear Frame
11
Reach Assembly Front Frame 4500 SRM 1196
3. Tag and disconnect the hydraulic lines from the 3. Remove tilt cylinder nuts (20).
hose guide at the valve. Cap or plug the hy-
draulic lines and valve ports to prevent dirt from 4. Remove brackets and capscrews (24) from the
entering the system. Make note of the location fork carriage.
of all cable ties for replacement during installa-
5. Remove fork carriage.
tion. Disconnect the sideshift cylinder hydraulics
if equipped. See Sideshift Cylinder, Repair. 6. Remove wear strips (2, 3, and 19).
4. Tag and disconnect the wire connectors from the 7. Remove capscrews (6), washers (5), and retainer
hose guide. plates (4) from each side of tilting frame.
5. Connect an overhead lifting device (crane) to the 8. Use a punch to remove pins (8) from each side of
top of the front frame. tilting frame.
6. Remove the screws that retain the pivot pins in 9. Remove tilting frame from fixed frame.
the front frame to the inner scissor arms. Re-
move the pivot pins. 10. Remove bushings from fixed frame.
7. Use the crane to lift the front frame high enough 11. Disassemble sideshift cylinder only if needed for
to allow the inner scissor arm rollers to come out service. See Sideshift Cylinder.
of the bottom of the front frame channels. Move
the front frame away from the lift truck and place 12. Remove trunnion caps, capscrews (12), and pins
it face down on the floor. (25) from each side of tilt cylinder.
13. Remove tilt cylinder.

DISASSEMBLE (WITH SIDESHIFT)
14. Remove bushings from tilt cylinder.
For the following procedures, refer to Figure 9.
15. Disassemble tilt cylinder only if repair is neces-
1. Orient front frame assembly with roller guides
sary. See Tilt Cylinder.
down and secure the unit.
2. Remove the selector valve. Refer to Front Selec-

tor Valve.
12
1. LUBE FITTING 11. TRUNNION CAP 21. FORK CARRIAGE

2. WEAR STRIP 12. CAPSCREW 22. CAPSCREW
3. WEAR STRIP 13. ROD 23. BRACKET
4. RETAINER PLATE 14. WIPER 24. CAPSCREW
5. LOCKWASHER 15. SEAL 25. PIN
6. CAPSCREW 16. SLEEVE 26. BUSHING
7. TILT CYLINDER 17. SEAL 27. LUBE FITTING
8. PIVOT PIN 18. TILTING FRAME 28. PIVOT PIN
9. BUSHING 19. WEAR STRIP 29. RETAINER CAPSCREW
10. FIXED FRAME 20. NUT
Figure 9. Front Frame With Sideshifter
13
Reach Assembly Front Frame 4500 SRM 1196
DISASSEMBLE (WITHOUT SIDESHIFT) 5. Use a punch to remove pivot pins (8) from each
side of tilting frame.
6. Remove tilting frame from fixed frame.
1. Orient front frame assembly with roller guides
down and secure the unit. 7. Remove bushings from fixed frame.
2. Remove the selector valve. Refer to Front Selec- 8. Remove tilt cylinder trunnion caps, capscrews
tor Valve. (5), and pin (4).
3. Remove nuts from tilt cylinder. See Figure 10. 9. Remove tilt cylinder. Remove bushings from tilt
cylinder.
4. Remove capscrews (3), washers (2), and retainer
plate (1) from each side of tilting frame. 10. Disassemble tilt cylinder if repair is necessary.
See Tilt Cylinder.
1. RETENTION PLATE 8. PIVOT PIN

2. LOCKWASHER 9. BUSHING
3. CAPSCREW 10. BUSHING
4. PIN 11. TILT CYLINDER
5. CAPSCREW 12. TILTING FRAME
6. TRUNNION CAP 13. CAPSCREW
7. FIXED FRAME 14. NUT
Figure 10. Front Frame Without Sideshifter
14
CLEAN AND INSPECT 11. Install tilt cylinder nuts (20) as removed.
12. Install the selector valve. Refer to Front Selector

WARNING Valve.
and can cause skin irritation. Always wear 13. Install load backrest. See Load Backrest section.
the proper protective equipment including
eye protection and petroleum resistant gloves 14. Install forks. Refer to Forks.
when handling. Always follow the recommen-
dations of the manufacturer. ASSEMBLE (WITHOUT SIDESHIFT)
For the following procedures, see Figure 10.
CAUTION
DO NOT use steam to clean the load bearings. 1. Install bushings to fixed frame if removed.
DO NOT use compressed air or immerse in sol-
2. Assemble tilt cylinder if necessary. See Tilt
vent to clean the bearings. The bearings are
Cylinder.
sealed and permanently lubricated. Wipe bear-
ings off with a clean cloth and turn to check for 3. Install tilt cylinder bushings and install tilt
proper operation. Replace if movement is re- cylinder to fixed frame.
stricted or if bearing does not turn smoothly.
4. Install tilt cylinder trunnion cap and hardware
Clean all of the parts of the front frame with solvent. (4 and 5).
Dry the parts with compressed air. Inspect the parts
of the front frame for damage and wear. Replace all 5. Position tilting frame to fixed frame. Align pivot
bushings. pin holes using a prybar.
ASSEMBLE (WITH SIDESHIFT) 6. Install pivot pins (8) through the tilting frame
into the fixed frame. Secure in place using pin-
For the following procedures, refer to Figure 9. retaining hardware (1, 2, and 3).
1. Assemble tilt cylinder if necessary. See Tilt 7. Install tilt cylinder nuts as removed.
Cylinder.
8. Install the selector valve if removed. Refer to
2. Install tilt cylinder bushings and install tilt Front Selector Valve.
cylinder to fixed frame.
9. Install load backrest. See Load Backrest section.
3. Install trunnion cap and hardware (12 and 25) to
tilt cylinder. 10. Install forks. Refer to Forks.
4. Assemble sideshift cylinder (13 through 17) if INSTALL

disassembled. Refer to Sideshift Cylinder Re-
pair. WARNING
5. Install bushings to fixed frame if removed. The points between the scissor arms and the
front frame is a pinch point and can cause an
6. Position tilting frame to fixed frame. Use a pry- injury. DO NOT put any part of your body be-
bar to align pivot pin holes. tween these assemblies. Use a screwdriver or
other tool to move the bearing blocks or assem-
7. Install pivot pins (8) through tilting frame into blies into the correct positions.
fixed frame. Secure using pin-retaining hard-
ware (4, 5, and 6). 1. Use multipurpose grease to lubricate the bush-
ings on the inner and outer scissor arms. Use
8. Install wear strips (2, 3, and 19) to tilting frame. multipurpose grease to lube the bottom bearings
in the channel at the bottom of the front frame.
9. Install fork carriage to tilting frame.
2. Use a crane to lift the front frame. Align the front
10. Install brackets and hardware (24) to fork car-
frame with the outer scissor arms. Install the
riage.
15
Single-Reach Scissor Arms 4500 SRM 1196
pivot pins that retain the inner scissor arms to 4. After all hydraulic lines are connected, operate
the front frame. the functions to check for leaks and correct oper-
ation. Remove the air from the system and ad-
3. Install the brackets and hardware to retain the just the stroke of the tilt cylinder as described in
pivot pins. Reach Assembly Adjustments.
NOTE: The reach carriage assembly must be in- 5. Install the forks and load backrest as removed.
stalled on the mast before starting. See Forks and Load Backrest.
Single-Reach Scissor Arms

REMOVE AND DISASSEMBLE The following procedures refer to removing the scis-
sor arms from the rear frame. See Figure 11.
NOTE: The reach assembly must be in the fully-ex-
tended position.
Figure 11. Single-Reach Scissor Arms
16
4500 SRM 1196 Single-Reach Scissor Arms

2. BELLEVILLE WASHER 17. BUSHING
3. BEARING CAP 18. PIVOT PIN
4. WASHER 19. SHOULDER BOLT
5. RH OUTER SCISSOR ARM 20. PIN
6. LH OUTER SCISSOR ARM 21. PIN
7. LOAD ROLLER AND SHIM 22. NUT
8. WEAR PLUG 23. 90 HYDRAULIC FITTING
9. LUBE FITTING 24. PIN
10. CAPSCREW 25. RH CYLINDER ASSEMBLY
11. BEARING 26. LH CYLINDER ASSEMBLY
12. SETSCREW 27. POSITION SENSOR (N35ZDR, N45ZR, N30ZDR,
13. JAM NUT N35-40ZR)
14. LOAD ROLLER AND SHIMS 28. BRACKET
15. INNER SCISSOR ARM 29. CAPSCREW
points when removing the pivot pins. Use a
WARNING hammer and brass drift to remove the pins.
There are pinch points on the reach carriage
assembly that can cause an injury. Use clamps 4. Remove the shoulder bolt and nut from the reach
and blocks to prevent the scissor arms from cylinder pins. Use a drift to drive out the cylin-
moving. Install the clamps and blocks at the der rod end pins attaching the reach cylinders
channels of the rear frame to make sure that to the inner scissor arm. Use wire to hold each
the load rollers cannot move in the channel. reach cylinder and their hoses in position when
See Figure 8. the pins are removed. Remove the bushings from
the mounts.
rings. These snap rings are large and can
WARNING
come loose during removal or installation with
enough force to cause an injury. Always use The load rollers and scissor arms can move and
the correct snap ring pliers, and wear eye and cause an injury when the clamps and blocks at
face protection during removal or installation. the load rollers are removed. Make sure the
crane is in a position to prevent movement of
NOTE: Use safety chains on the rear frame and mast the scissor arms as the clamps and blocks are
weldments to keep the rear frame and mast weld- removed.
ments from moving. Install the safety chains as de-
scribed in Safety Procedures When Working Near 5. Carefully remove the clamps and blocks at the
Mast in this section. load rollers on the channels of the rear frame.
Carefully move the scissor arms to align the load
1. Remove the front frame as described in Reach rollers with the removal notch in the rear frame.
Assembly Front Frame. Secure the cable guide Raise the crane to move the load rollers out of the
at the rear frame to avoid damage. rear frame.
2. Remove the hydraulic components from the WARNING

reach carriage assembly as required.
The scissor arms are heavy and can cause an
3. Use a crane to support the inner scissor arm. Se- injury if allowed to fall. Have another person
curely attach chains or slings to the arm so that help you support the scissor arm during re-
it cannot slip. Be careful not to damage the hose moval and installation.
mount sheaves.
NOTE: Install labels identifying scissor arm compo-
nent locations and orientation for correct installa-
WARNING tion.
The points between the scissor arms and the
rear frame are pinch points and can cause an 6. Remove the three capscrews, lockwashers, and
injury. DO NOT put your hands near pinch end plate at the center pivot. Hold the outer scis-
sor arm and carefully slide it and the bearing off
17
the stub shaft. Remove the bearing assembly and spacer securing sensor bracket to the rear
spacer. Repeat for the other side. See Figure 12. frame. The sensor can now be turned, but
the sensor shaft should still be attached to
the pivot pin. See Figure 13.
1. STUB SHAFT
2. SPACER
3. LH OUTER SCISSOR ARM
4. BEARING ASSEMBLY
5. BEARING RETAINER CAP 1. INNER SCISSOR ARM
6. BELLEVILLE WASHER 2. PIVOT PIN
7. CAPSCREW 3. SETSCREW
4. PIN RETAINER
5. SCREW
Figure 12. Outer Arm and Bearing Assembly 6. SENSOR SHAFT (FLAT TOWARD SETSCREW)
7. POSITION SENSOR AND BRACKET
NOTE: Tag and identify each shim pack and the load
roller. When new load rollers are installed, the shim Figure 13. Position Sensor
arrangement will normally be the same or similar.
b. Remove the screw securing the pin retainer
to the scissor arm and slide the pin retainer
WARNING
from behind the sensor.
The points between the scissor arms and the
rear frame are pinch points and can cause an c. A setscrew in the pivot pin (behind the sen-
injury. DO NOT put hands near pinch points sor) secures the sensor shaft to the pivot pin.
when you remove the pins. Use a hammer and Loosen the setscrew and slide the position
brass drift to remove the pivot pins. sensor from the pivot pin.
7. Models N35ZDR, N45ZR, N30ZDR, and 8. Remove the pivot pins from the inner scissor
N35-40ZR have a position sensor mounted to arms using a hammer and a brass drift. Remove
the right side inner scissor arm pivot pin at the inner scissor arms from the rear frame.
the rear frame. Remove the position sensor as Remove the bushings from the inner arms if
follows: replacement is necessary.
a. Disconnect the wiring harness, carefully clip
the wire tie, and remove the capscrew and
18
4500 SRM 1196 Single-Reach Scissor Arms
CLEAN AND INSPECT 2. Install position sensor to right pivot pin as re-
moved:
WARNING a. Check that the pin retainer hole aligns with
Cleaning solvents can be flammable and toxic mounting hole in scissor arm. Adjust to align
and can cause skin irritation. Always wear if necessary. DO NOT install the pin retainer
the proper protective equipment including at this time. See Figure 13.
eye protection and petroleum resistant gloves
when handling. Always follow the recommen- b. Remove the setscrew from the pivot pin
dations of the manufacturer. and clean old thread-lock residue from the
threads. Apply Loctite® 242 to the threads
CAUTION and start screw into the pivot pin.
DO NOT use steam to clean sealed bearings. c. Position the sensor assembly to the pivot pin
DO NOT use compressed air or immerse in sol- so that the sensor shaft enters the pin with
vent to clean sealed bearings. Sealed bearings the flat side of the shaft facing the setscrew.
are self-contained and permanently lubri- Tighten the setscrew.
cated. Wipe bearings off with a clean cloth and
turn to check for proper operation. Replace if d. Install the pin retainer onto the pivot pin and
movement is restricted or if bearing does not secure in place with screw as removed.
turn smoothly.
e. Align the sensor and mounting bracket hole
Clean all of the parts of the scissor arm assembly and install capscrew and spacer.
with solvent. Inspect the parts of the scissor arm
assembly for damage and wear. Replace all bushings f. Install wiring connector and secure harness
and load rollers. to bracket with new wire tie as removed.
ASSEMBLE AND INSTALL WARNING

Always use new bushings and load rollers. Install a
injury if allowed to fall. Have another person
thin coat of multipurpose grease on all new bushings,
help you support the scissor arm during re-
all thrust washers, all shims, all stub shafts, and all
moval and installation. NEVER put any part
pins of the scissor arm assembly. For the following
of your body between the parts of the scissor
procedures, refer to Figure 11.
arm assembly.
WARNING NOTE: Move the outer scissor arm when tightening

Use safety chains on the rear frame and mast the capscrews to make sure the bearings seat prop-
weldments to keep the rear frame and mast erly.
weldments from moving. Install the safety
3. Install the bearing assembly onto the left hand
chains as described in Safety Procedures
stub shaft of the inner scissor arms. Install the
When Working Near Mast in this section.
left hand outer scissor arm over the bearing
The points between the scissor arms and the assembly. Install the bearing cap, and align the
rear frame are pinch points and can cause an holes with the stubshaft holes. Apply Loctite®
injury. DO NOT put your hands near pinch 290 and install three capscrews and belleville
points when removing the pivot pins. Use a washers. Tighten the three capscrews to snug,
hammer and brass drift to remove the pivot then tighten each capscrew incrementally to
pins. maintain even pressure on the bearing until
each of the belleville washers are flattened.
1. Install the bushings to inner scissor arm if re- When the belleville washers are flat, the cap-
moved. Using an overhead lifting device (crane), screws are properly tightened.
raise inner scissor arm to align the mounts with
the mounts of the rear frame. Install both pivot
pins, the LH pin retainer, and screw to secure.
19
5. Use the crane to slowly raise the scissor arms to

CAUTION align the load rollers with the removal notches in
DO NOT let the load rollers or shims fall off the the rear frame. Use the crane to move the scissor
scissor arms. arm assembly so the load rollers move into the
channels.
NOTE: Correct placement of shims is critical for the
operation of the reach mechanism. Unless the shims 6. Slowly raise the scissor arm assembly to align
are installed correctly, the reach mechanism will not the mounts with the rod ends of the reach cylin-
operate. ders. Install the bushings, pins, and shoulder
bolt to fasten the reach cylinders to the inner scis-
4. Install the shim sets and load rollers on each sor arm. See Figure 21.
outer scissor arm as marked during removal and
disassembly. Install snap rings onto stub shafts
to secure. See Figure 14. WARNING
injury if allowed to fall. Have another person
help you support the scissor arm during re-
moval and installation. NEVER put any part
of your body between the parts of the scissor
arm assembly.
CAUTION
DO NOT let the load rollers or shims fall off the
scissor arms.
7. Install the shims and load rollers on the inner

scissor arm weldment as marked during removal
and disassembly. If necessary, use tape to keep
the load rollers on the scissor arms. Install the
hoses on the hose sheaves, and install the hose
1. SNAP RING
2. LOAD ROLLER sheaves and snap rings at the mount of the scis-
3. SHIM(S) sor arm weldment. Refer to Figure 14.
4. STUB SHAFT
8. Install the front frame as removed. Refer to
Figure 14. Load Roller Assembly Reach Assembly Front Frame.
20
4500 SRM 1196 Double-Reach Scissor Arms
Double-Reach Scissor Arms

DISASSEMBLE points when removing the pivot pins. Use a
hammer and brass drift to remove the pins.
The entire scissor assembly may not need to be dis-
assembled to make repairs. Perform only the steps 5. Remove the shoulder bolt and nut from the reach
necessary to safely complete the necessary repairs. cylinder pins. Use a drift to drive out the cylin-
For the following procedures, refer to Figure 15. der rod end pins attaching the reach cylinders
to the inner scissor arm. Use wire to hold each
reach cylinder and their hoses in position when
WARNING
the pins are removed. Remove the bushings from
There are pinch points on the reach car- the mounts. See Figure 21.
riage that can cause an injury. Use clamps
and blocks to prevent the scissor arms from 6. Remove the cotter pin, castle nut, and washer
moving. Install the clamps and blocks at the from the threaded shaft on the bottom pivot
channels of the rear frame to make sure that points of outer scissor arms D and C. See Fig-
the load rollers cannot move in the channel. ure 15.
See Figure 8.
Be careful when removing or installing snap WARNING

rings. These snap rings are large and can The scissor arms are heavy and can cause an
come loose during removal or installation with injury if allowed to fall. Have another person
enough force to cause an injury. Always use help you support the scissor arm during re-
the correct snap ring pliers and wear eye and moval and installation.
face protection during removal or installation.
7. Remove the three capscrews, lockwashers, end
NOTE: Use safety chains on the rear frame and mast cap, and the spacer at the center pivot for outer
weldments to keep the rear frame and mast weld- scissor arm D. Hold outer scissor arm D and slide
ments from moving. Install the safety chains as de- it and the bearing assembly off the stub shaft.
scribed in Safety Procedures When Working Near Remove the bearing at the center pivot. Remove
Mast in this section. scissor arm C following this same procedure.
1. Remove the front frame as described in Reach 8. Slowly lower inner scissor arm A so it hangs from
Assembly Front Frame. Remove the snap rings the ends of outer scissor arms F and E. Discon-
and hose sheaves at the scissor arm weldments. nect the crane and sling from inner scissor arm
Fasten the cable and hoses at the rear frame so A and attach it securely to inner scissor arm B.
they are not damaged.
2. Remove the hydraulic components from the

WARNING
reach carriage assembly as required. The load rollers and scissor arms F and E can
shift and cause an injury when the clamps
3. Use a crane to support scissor arm weldment A. and blocks at the load rollers are removed.
Securely attach chains or slings to the weldment Make sure the crane is in a position to prevent
so that it cannot slip. Be sure not to damage the movement of the scissor arms as the clamps
hose mount sheaves. and blocks are removed.
4. Install the clamps and blocks at the channels of 9. Carefully remove the clamps and blocks at the
the rear frame to make sure the load rollers can- load rollers on the channels of the rear frame.
not move in the channel and the scissor arms can- Slowly move outer scissor arm B using the crane
not retract. See Figure 8. to align the load rollers of outer scissor arms F
and E with the removal notch in the rear frame.
See Figure 15. Use the crane to move the as-
WARNING
semblies until the load rollers are out of the rear
The points between the scissor arms and the frame. Lower the crane so the scissor arm assem-
rear frame are pinch points and can cause an bly retracts as the ends of the scissor arms move
injury. DO NOT put your hands near pinch down the outside of the channel.
21
Double-Reach Scissor Arms 4500 SRM 1196
Figure 15. Double-Reach Scissor Arms
22

A. INNER SCISSOR ARM (FRONT) D. OUTER SCISSOR ARM (RIGHT FRONT)
B. INNER SCISSOR ARM (REAR) E. OUTER SCISSOR ARM (LEFT REAR)
C. OUTER SCISSOR ARM (LEFT FRONT) F. OUTER SCISSOR ARM (RIGHT REAR)
2. BELLEVILLE WASHER 19. POSITION SENSOR (N35ZDR, N45ZR, N30ZDR,
3. BEARING CAP AND N35-40ZR)
4. FRONT FRAME PIN 20. RETAINING BRACKET AND CAPSCREW
5. CAPSCREW 21. ROD END PIN
6. BEARING ASSEMBLY 22. NUT
7. WASHER 23. SHOULDER BOLT
8. COTTER PINS 24. ROD ENDS
9. LUBE FITTING 25. CYLINDER RODS
10. BUSHING 26. LH EXTEND CYLINDER
11. SHIM 27. RH EXTEND CYLINDER
12. LOAD ROLLER ASSEMBLY 28. 90 HYDRAULIC FITTING
13. SNAP RING 29. PIVOT PIN
14. WASHER 30. CYLINDER MOUNTING PIN
15. LOAD ROLLER 31. NUT
16. WEAR PLUG AND SETSCREW 32. SHOULDER BOLT
17. JAM NUT 33. CASTLE NUT
10. Install a safety chain between the rear frame and NOTE: Tag and identify the location of each shim
inner scissor arm B so the scissor arm assemblies pack and load roller. When new load rollers are in-
cannot extend. Reattach the crane and chains or stalled, the shim arrangement will normally be the
slings so they again support the weight of inner same or similar.
scissor arm A.
14. Remove the snap ring securing the load wheel to
11. Remove the cotter pin and castle nut from the the outer scissor arms F and E. Remove the load
threaded shaft on the top pivot points of outer rollers assembly and recover the shim pack from
scissor arms F and E. the stub shaft.
WARNING WARNING
The scissor arms are heavy and can cause an The points between the scissor arms and the
injury if allowed to fall. Have another person rear frame are pinch points and can cause an
help you support the scissor arm during re- injury. DO NOT put your hands near pinch
moval and installation. points when removing the pivot pins. Use a
hammer and brass drift to remove the pivot
NOTE: This action will also release scissor arm weld- pins.
ment A.
15. Models N35ZDR, N45ZR, N30ZDR, and
12. Remove the three capscrews, lockwashers, end N35-40ZR have a position sensor mounted over
cap, and the spacer at the center pivot for outer the right pivot pin at the rear frame. Remove
scissor arm F. Hold outer scissor arm F and slide the position sensor as follows:
it and the bearing assembly off the stub shaft.
Remove the bearing at the center pivot. Remove a. Disconnect the wiring harness, carefully clip
outer scissor arm E following this same proce- the wire tie, and remove the capscrew and
dure. spacer securing sensor bracket to the rear
frame. The sensor can now be turned, but
13. Use the crane to remove and lower the inner scis- the sensor shaft should still be attached to
sor arm A to the floor. Move the crane and chains the pivot pin. See Figure 16.
or slings again to support the weight of inner scis-
sor arm B. Carefully remove the safety chain.
23
Double-Reach Scissor Arms 4500 SRM 1196
sealed and permanently lubricated. The air

can force the lubricant out of the bearings.
Clean all of the parts of the scissor arm assembly

with solvent. Dry the parts with compressed air. In-
spect the parts of the scissor arm assembly for dam-
age and wear. Replace all bushings and load rollers
as necessary.
ASSEMBLE
NOTE: Use safety chains on the rear frame and mast

weldments to keep the rear frame and mast weld-
ments from moving. Install the safety chains as de-
scribed in Safety Procedures When Working Near
Mast in this section.
NOTE: Always use new bushings and load rollers.

Install a thin coat of multipurpose grease on all
1. INNER SCISSOR ARM new bushings, all thrust washers, all shims, all stub
2. PIVOT PIN
3. SETSCREW shafts, and all pins of the scissor arm assembly.
4. PIN RETAINER
5. SCREW
6. SENSOR SHAFT (FLAT TOWARD SETSCREW) WARNING
7. POSITION SENSOR AND BRACKET The points between the scissor arms and the
rear frame are pinch points and can cause an
Figure 16. Position Sensor injury. DO NOT put your hands near pinch
points when removing the pivot pins. Use a
b. Remove the screw securing the pin retainer
hammer and brass drift to remove the pivot
to the scissor arm and slide the pin retainer
pins.
from behind the sensor.
1. Install the bushings to inner scissor arms A and
c. A setscrew in the pivot pin (behind the sen-
B if removed.
sor) secures the sensor shaft to the pivot pin.
Loosen the setscrew and slide the position 2. Install the load rollers on the stub shafts at the
sensor from the pivot pin. end pivot of outer scissor arms F and E. Secure
using retaining ring and install wear plugs,
16. Remove the pivot pins from the scissor arms. Re-
setscrews, and jam nuts.
move inner scissor arm B. Remove the bushings
from the scissor arms if replacement is necessary. 3. Using the lifting device (crane), raise inner scis-
sor arm B to align the mounts with the mounts
CLEAN AND INSPECT of the rear frame. Install both pivot pins, the LH
pin retaining bracket, and screw to secure.
WARNING
4. Install position sensor to right pivot pin as re-
moved:
for eyes and skin. When using cleaning sol- a. Check that the pin retainer hole aligns with
vents, always follow the recommendations of mounting hole in scissor arm. Adjust to align
the manufacturer. if necessary. DO NOT install the pin retainer
at this time. See Figure 16.
CAUTION
b. Remove the setscrew from the pivot pin
DO NOT use steam or compressed air to clean
and clean old thread-lock residue from the
the load rollers. The load roller bearings are
24
threads. Apply Loctite 242 to the threads inner scissor arm A at the same time. On in-
and start screw into the pivot pin. ner scissor arm B, install the bearing cap, and
align the holes with the stubshaft holes. Ap-
c. Position the sensor assembly to the pivot ply Loctite® 290 and install three capscrews and
pin so that the sensor shaft enters the pivot belleville washers. Tighten the three capscrews
pin with the flat side of the shaft facing the to snug, then tighten each capscrew incremen-
setscrew. Tighten the setscrew. tally to maintain even pressure on the bearing
until each of the belleville washers are flattened.
d. Install the pin retainer onto the pivot pin and
When the belleville washers are flat, the cap-
secure in place with screw as removed.
screws are properly tightened. Install washer
e. Align the sensor and mounting bracket hole and castle nut on inner scissor arm A. Torque to
and install capscrew and spacer. 115 N•m (85 lbf ft). Slightly loosen castle nut
(if necessary) to align the cotter pin hole. Install
f. Install wiring connector and secure harness cotter pin through the hole in the direction of the
to bracket with new wire tie as removed. forks and bend prongs to set.
8. Install the bearing assemblies onto each stub

WARNING shaft of the inner scissor arm A. Use the lifting
The scissor arms are heavy and can cause an devices to position the weldments where outer
injury if allowed to fall. Have another person scissor arm D can be installed to inner scissor
help you support the scissor arm during re- arm A and inner scissor arm B at the same
moval and installation. NEVER put any part time. Install the bearing cap, and align the holes
of your body between the parts of the scissor with the stubshaft holes. Apply Loctite® 290
arm assembly. and install three capscrews and belleville wash-
ers. Tighten the three capscrews to snug, then
NOTE: Move the outer scissor arm when tightening
tighten each capscrew incrementally to main-
the capscrews to make sure the bearings seat prop-
tain even pressure on the bearing until each of
erly.
the belleville washers are flattened. When the
5. Install the bearing assemblies onto each stub belleville washers are flat, the capscrews are
shaft of the inner scissor arm B. Install the outer properly tightened. On inner scissor arm A,
scissor arm E over the bearing assembly. Install install the washer, castle nut, and cotter pin.
the bearing cap, and align the holes with the
9. Use the lifting devices to position the weldments
stubshaft holes. Apply Loctite® 290 and install
where outer scissor arm C can be installed to
three capscrews and belleville washers. Tighten
inner scissor arm A and inner scissor arm B
the three capscrews to snug, then tighten each
at the same time. Install the bearing cap, and
capscrew incrementally to maintain even pres-
align the holes with the stubshaft holes. Apply
sure on the bearing until each of the belleville
Loctite® 290 and install three capscrews and
washers are flattened. When the belleville
belleville washers. Tighten the three capscrews
washers are flat, the capscrews are properly
to snug, then tighten each capscrew incremen-
tightened.
tally to maintain even pressure on the bearing
6. Attach another lifting device to inner scissor arm until each of the belleville washers are flattened.
A. Move inner scissor arm A into a position of When the belleville washers are flat, the cap-
alignment to install outer scissor arm E to in- screws are properly tightened. On inner scissor
ner scissor arm A. Install washer and castle nut. arm A, install washer and castle nut. Torque to
Torque to 115 N•m (85 lbf ft). Slightly loosen cas- 115 N•m (85 lbf ft). Slightly loosen castle nut
tle nut (if necessary) to align the cotter pin hole. (if necessary) to align the cotter pin hole. Install
Install cotter pin through the hole in the direc- cotter pin through the hole in the direction of the
tion of the forks and bend prongs to set. forks and bend prongs to set.
7. Install outer scissor arm F over the bearing as-

sembly on inner scissor arm B and position into
25
Rear Frame Assembly 4500 SRM 1196
assembly to guide the load rollers into the rear

WARNING frame.
The load rollers and outer scissor arms F and E
can move and cause an injury when the clamps 11. Install the clamps and blocks at the channels of
and blocks at the load rollers are removed. the rear frame to make sure that the load rollers
Make sure the crane is in a position to prevent cannot move with in the channel. See Figure 8.
movement of the scissor arms as the clamps
and blocks are removed. 12. Slowly raise scissor arm assembly to align the
mounts with the rod ends of the reach cylinders.
10. Slowly position the scissor arm assembly to align Install the bushings, pins, and shoulder bolts to
the load rollers of outer scissor arms F and E fasten the reach cylinders to the inner scissor
with the removal notches in the rear frame. See arm B.
Figure 15. Use the crane to move the scissor arm
Rear Frame Assembly

REMOVE
NOTE: The following steps outline the procedures for
removing the reach carriage assembly from a mast,
which is installed to a lift truck.
1. Remove the forks. See Forks.
2. Remove the load backrest. See Load Backrest.
3. Remove the hardware securing the operator

guard from the rear of the mast, and remove the
operator guard.
WARNING
Reach carriage assemblies are heavy. Be sure
quate capacity to lift the components.


each side of the rear frame. See Figure 18.
b. Ensure clamps are secure before lifting the 1. GREASE FITTING

2. BUSHING
reach carriage assembly. 3. WASHER
4. CAPSCREW
c. Install a chain loop or sling through each 5. SHIM
clamp separately, and attach each loop to the 6. SIDE ROLLER ASSEMBLY
overhead lifting device. 7. SHIM
8. LOAD ROLLER
5. Raise the reach carriage assembly high enough 9. RETAINING RING
to access the hydraulic connections and wiring 10. SHIM
harness mounting plate on the rear frame.
Figure 17. Rear Frame (6.9 Mast Shown)
(N30ZDRS and N35-40ZRS)
26
4500 SRM 1196 Rear Frame Assembly
Figure 18. Install C-Clamps to Rear Frame
6. Safety chain the reach carriage assembly in 8. Tag and disconnect the attachment hoses from
place. See Safety Procedures When Working the two fittings at bottom of the rear frame of
Near Mast. the reach carriage assembly. Cap or plug all open
hydraulic hoses.
7. Disconnect the lift chains from the reach carriage
assembly: 9. Disconnect the wiring connector at the top of the
rear frame. Remove the reach wiring harness.
a. Remove the cotter pin and chain anchor pin
securing the chain to the anchors. See Lift NOTE: Make sure lift chains, wiring, and hoses are
Chains. secured out of the way so they do not interfere with
reach assembly removal procedures.
b. Secure chains to the mast using stiff wire to
keep them from falling from the sheaves. 10. Remove the safety chains and completely lower
the reach carriage assembly to the floor.
c. If the mast must be disassembled or the
chains need to be cleaned/lubricated, remove
the lift chains and inspect and clean.
27
Rear Frame Assembly 4500 SRM 1196
5. If necessary, remove the hydraulic lines and

WARNING hoses at the base of the rear frame.


inner mast. Raise the inner mast until clearly
higher than the reach carriage assembly. Move
the reach carriage assembly away from the lift
truck and completely lower the mast.
12. Disconnect the lifting device from the reach car-

riage assembly.
DISASSEMBLE
1. SNAP RING
NOTE: It is usually not necessary to remove all the 2. LOAD ROLLER
3. SPACER
parts of the rear frame assembly. Remove only the 4. STUB SHAFT
necessary parts to do the repair.
Figure 19. Load Roller Assembly
1. If necessary, remove the reach cylinders. See
Reach Cylinders.
WARNING
rings. These snap rings are large and can
come loose during removal or installation with
enough force to cause an injury. Always use
the correct snap ring pliers, and wear eye and
2. Remove the snap rings from the stub shaft for the
load roller. See Figure 19.
3. Use a pry bar to remove the load roller from the

stub shaft for the load roller. See Figure 20.
4. 6.9 Mast Only (N30ZDRS and N35-40ZRS) -

Remove the capscrews that fasten the side roller
brackets. Remove the side rollers and shim sets.
Install labels for correct installation of the shim 1. LOAD ROLLER WITH SNAP RING REMOVED
sets in the same positions. When the new side 2. PRY BAR
rollers are installed, the shim arrangement will 3. REAR FRAME
normally be the same or similar. Figure 20. Removing Load Roller (6.9 Mast
NOTE: Correct placement of shims is critical for the Shown) (N30ZDRS and N35-40ZRS)
operation of the reach mechanism. Unless the shims
are installed correctly, the reach mechanism will not
operate.
28
4500 SRM 1196 Rear Frame Assembly
CLEAN AND INSPECT Measure and adjust the load rollers as necessary.
See Reach Assembly Adjustments.
WARNING 2. Install the scissor arms if removed. See Sin-
Cleaning solvents can be flammable and toxic gle-Reach Scissor Arms or Double-Reach Scissor
and can cause skin irritation. Always wear Arms.
the proper protective equipment including
eye protection and petroleum resistant gloves 3. 6.9 Mast Only (N30ZDRS and N35-40ZRS) -
when handling. Always follow the recommen- Install the side rollers as removed. Measure and
dations of the manufacturer. adjust the side rollers as necessary. See Reach
Assembly Adjustments.
CAUTION 4. If the rod ends of the reach cylinders were re-
DO NOT use steam to clean sealed bearings. moved, the reach cylinders must be adjusted
DO NOT use compressed air or immerse in sol- after the reach assembly is completely assem-
vent to clean sealed bearings. Sealed bearings bled and installed in the mast. See Adjust Reach
self-contained and permanently lubricated. Cylinders, Reach Assembly Adjustments.
Wipe bearings off with a clean cloth and turn
to check for proper operation. Replace if INSTALL
movement is restricted or if bearing does not
turn smoothly. NOTE: Use a second lift truck or overhead lifting de-
Clean all of the parts of the rear frame with solvent.
Dry the parts with compressed air. Inspect the parts 1. Position the reach carriage assembly in an up-
of the rear frame for damage and wear. Inspect all right position in front of the mast. Align the load
rollers for cracks, flat spots, or bearings that do not rollers on the rear frame of the reach carriage as-
turn freely. Replace any roller that shows wear or is sembly with the inner mast.
damaged.
WARNING
ASSEMBLE
WARNING ity to lift the components.
rings. These snap rings are large and can NOTE: Use an overhead lifting device of suitable ca-
come loose during removal or installation with pacity to raise the inner mast when installing the
enough force to cause an injury. Always use reach carriage assembly. Use second lift truck to po-
the correct snap ring pliers, and wear eye and sition the reach carriage assembly.
2. Raise the inner mast until clearly higher than
the reach carriage assembly. Position the reach
WARNING carriage assembly so the load rollers on the rear
The rear frame assembly is heavy and can frame are centered under the channels of the in-
cause an injury if it tips or falls. Make sure the ner mast.
rear frame assembly is stable before installing
any parts. 3. Lower the inner mast channels onto the load
NOTE: If the scissor arms are not installed, install not lower smoothly and completely, raise the
the rear frame in the mast before installing the scis- inner mast, reposition the reach carriage assem-
sor arm assembly. See Install. bly, and lower the inner mast again.
1. Install the load roller on to the rear frame.
Install shims in the same location as removed.
29
Reach Cylinders 4500 SRM 1196
7. Reconnect the lift chains to anchors on reach car-

WARNING riage assembly as removed. Install anchor pins
Reach carriage assemblies are heavy. Be sure and cotter pins.
quate capacity to lift the components. 8. Connect the wiring connector and install the
mounting plate to the top of the rear frame.
reach carriage assembly: 9. Remove caps/plugs from the attachment hoses
and fittings. Reconnect the hoses as removed.
each side of the rear frame. See Figure 18. 10. Remove the safety chains and completely lower
the reach carriage assembly.
b. Install a chain loop or sling through each
clamp separately, and attach each loop to the 11. Remove the C-clamps and lifting device from the
overhead lifting device. reach carriage assembly.
5. Raise the reach carriage assembly high enough 12. Raise and lower the mast several times to remove
to access the hydraulic connections and wiring air from the system. Cycle the sideshift function
harness mounting plate on the rear frame. several times to remove air from the sideshift cir-
cuit, if so equipped. Check for proper operation.
6. Safety chain the reach carriage assembly in
place. See Safety Procedures When Working 13. Check the hydraulic oil level and add as required.
Near Mast.
14. Check reach carriage assembly height and align-
ment and adjust the lift chains as required. See
CAUTION Reach Assembly Adjustments.
If reusing chains, make sure chains have been
properly inspected, cleaned, and lubricated. 15. Install the load backrest. See Load Backrest.
See Lift Chains.
16. Install the forks. See Forks.
17. Install the operator guard as removed.
Reach Cylinders
REMOVE cylinders from the operator compartment of the
lift truck.
2. Remove the operator guard from the rear of the
mast.
CAUTION
DO NOT operate any functions if the front 3. Install labels on the hydraulic lines for correct
frame has been removed. Hydraulic oil can connection during installation. Disconnect the
come out of the hoses. hydraulic lines at the reach cylinders. Install
caps on the hydraulic lines and cylinder ports to
NOTE: Fully extend the reach mechanism. If the prevent dirt from entering the system. Check the
scissor arms and front frame are installed, use hydraulic fittings for damage. Replace as neces-
clamps and blocks to prevent the scissor arms from sary.
retracting. Install the clamps and blocks on the
channels of the rear frame and the front frame. In- 4. Remove nuts and capscrews from each cylinder
stall the blocks under the load rollers. See Figure 22. rod end. Remove pins from rod ends and mast by
tapping out with a drift.
Tighten the clamps so the blocks cannot move.
1. Operate the LIFT/LOWER control handle to

raise the reach assembly for access to the reach
30
4500 SRM 1196 Reach Cylinders
1. INNER SCISSOR ARM 9. REACH CYLINDER

2. GREASE FITTING 10. HYDRAULIC FITTING
3. ROD END 11. RETRACT HOSE
4. NUT 12. HYDRAULIC FITTING
5. CAPSCREW 13. EXTEND HOSE
6. BUSHING 14. NUT
7. PIN 15. PIN
8. CAPSCREW 16. CAPSCREW
Figure 21. Reach Cylinder Mounting
31
Reach Cylinders 4500 SRM 1196
the other reach cylinder using the same proce-

dure.
7. Remove the bushings from each mount of the

rear frame and each scissor arm.
DISASSEMBLE
NOTE: In most instances, it is more cost effective to

simply replace the reach cylinders with a whole new
unit than to repair them.
NOTE: Take care not to scratch the cylinder rod dur-

ing the repair process.
1. Loosen the capscrew at the rod end. Hold the rod

to keep it from turning and remove the rod end
from the cylinder rod.
2. Carefully remove the retainer and rod assembly

from the cylinder shell.
3. Carefully remove the parts of the rod assembly.
CLEAN AND INSPECT

1. REAR FRAME
2. LOAD ROLLER
3. BLOCK WARNING
4. CLAMP Cleaning solvents can be flammable and toxic
Figure 22. Block and Clamp Installation for eyes and skin. When using cleaning sol-
NOTE: If disassembly of a reach cylinder is neces- vents, always follow the recommendations of
sary, loosen the retainer in the cylinder shell while the manufacturer.
the cylinder is installed in the reach assembly. It
is possible that reach adjustments will not be nec- CAUTION
essary. If disassembly is NOT necessary and the rod DO NOT operate any functions if the front
ends will NOT be replaced, mark the reach cylinders frame has been removed. Hydraulic oil can
for installation in the same position. come out of the hoses.
5. Mark each rod end of the reach cylinders for cor- Clean all of the parts of the reach cylinder with sol-
rect installation. The RH and LH reach cylinders vent. Dry the parts with compressed air. Inspect the
are not interchangeable. parts of the reach cylinder for damage and wear. Re-
place all parts that are worn or damaged. Replace all
6. Have a helper hold the reach cylinder to keep it parts included in the cylinder repair kit.
from falling. Use a drift to remove the pins that
fasten each end of cylinder to the frame. Remove
32
4500 SRM 1196 Reach Cylinders
1. LOCK NUT 7. O-RING

2. PISTON RINGS 8. BACKUP RING
3. PISTON PACKING 9. ROD SEAL
4. PISTON 10. WIPER RING
5. CYLINDER TUBE 11. PACKING GLAND
6. PISTON ROD
Figure 23. Reach Cylinder Parts
ASSEMBLE INSTALL
1. Install the parts of the rod assembly as shown NOTE: It may be necessary to loosen the hydraulic
in Figure 23. Make sure to replace all seals and fittings to allow movement of the rods. The rods need
other parts included in the cylinder repair kit. to move for correct alignment at the mounts for the
Use Loctite® No. 242 on the rod and nut for the scissor arms.
piston. Install the piston seal and piston rings.
If removed, tighten the piston nut to 95 N•m 1. If removed, install the correct rod end on the rod
(70 lbf ft). as marked during removal. Install new bushings
in all four mounts for the reach cylinders. Lubri-
cate the bushings with multipurpose grease.
CAUTION
DO NOT cut or damage seals during installa- 2. Align the anchor end of the cylinders on the cylin-
tion. Be especially careful when moving seals der mount of the rear frame of the reach assem-
across threads or edges of parts. Install tape bly. See Figure 21. Install the mount pins and
over the rod threads to protect the seals. shoulder bolt and nut to fasten the cylinders to
the rear frame. Use a hammer with a soft metal
2. Install the rod seal, backup ring, O-ring, and (brass or copper) or a plastic face to install the
wiper on the retainer. Put a thin coat of hydraulic pins.
fluid on the inside of the shell and all parts of the
piston and rod. Use O-ring lubricant and install 3. Connect the hydraulic lines to the reach cylin-
the rod assembly in the shell. Carefully install ders as marked during removal. Always use new
the retainer on the rod and in the shell. Use a O-rings on the O-ring fittings.
spanner wrench to tighten the retainer to 129 to
142 N•m (95 to 105 lbf ft). 4. Hold each reach cylinder to align the rod end to
the scissor arm mounts. Use a hammer with a
33
Tilt Cylinder 4500 SRM 1196
soft metal (brass or copper) or a plastic face to in- 6. Make sure the hydraulic fittings are tightened,
stall the mount pins to fasten the rod end of each and remove the clamps and blocks under the load
reach cylinder. Align the holes for the shoulder bearings.
bolt and nut. Install the shoulder bolt and nut.
NOTE: If the rod ends were not removed and the CAUTION
cylinders are installed in the same positions, reach DO NOT operate any functions if the front
adjustment is normally not necessary. frame has been removed. Hydraulic oil can
come out of the hoses.
5. If the rod ends were NOT removed, install the
shoulder bolt and nut at each mount pin. If the 7. Operate the REACH control lever to operate the
rod ends were removed, reach adjustment IS nec- function to check for leaks and correct operation.
essary. Make sure the adjustment is complete be-
fore installing the shoulder bolt and nut. 8. Remove the air from the system and adjust the
stroke of each reach cylinder as described in
Reach Assembly Adjustments.
Tilt Cylinder
REMOVE Cylinder components can be disassembled to repair
the seals if damaged. Consult the Parts Manual to
The tilt cylinder is removable as an assembly. The select the proper cylinder repair kit for your truck.
cylinder block is mounted to the front frame. If the Replace all parts included in the cylinder repair kit.
cylinder block is damaged, it can be removed and Seals and O-rings may become brittle and lose elas-
replaced. See Reach Assembly Front Frame, Dis- ticity over time even when the old parts show no ap-
assemble (With Sideshift) or Disassemble (Without parent damage. See Figure 24. Clean all of the parts
Sideshift) in this section. of the tilt cylinder with solvent. Dry the parts with
compressed air. Inspect the parts of the tilt cylinder
NOTE: If the front frame is installed on the scissor
for damage and wear. Replace all parts that are worn
arms, fully extend the reach mechanism. Use clamps
or damaged. Replace all parts included in the cylin-
and blocks to prevent the scissor arms from retract-
der repair kit. Use hydraulic oil to lubricate the new
ing. Install the clamps and blocks on the channels
seals and O-rings when installing. Be careful not to
of the rear frame and the front frame. Install the
damage new seals and O-rings when installing.
clamps and blocks under the load bearings. See Fig-
ure 8. Tighten the clamps so the blocks cannot move.
INSTALL
CLEAN, INSPECT, AND REPAIR Install tilt cylinder into front frame as removed. Re-
fer to Reach Assembly Front Frame, or Assemble
WARNING (With Sideshift) in this section.
for eyes and skin. When using cleaning sol-
vents, always follow the recommendations of
the manufacturer.
34
4500 SRM 1196 Tilt Cylinder
1. NUT 8. WIPER RING

2. TILTING FRAME 9. SEAL
3. WASHER 10. ROD
4. WASHER 11. BLOCK
5. SEAL 12. BUSHING
6. PISTON 13. FRONT FRAME
7. SEAL
Figure 24. Tilt Cylinder
35
Sideshift Cylinder 4500 SRM 1196
Sideshift Cylinder
REPAIR
The sideshift cylinder is not removable as an assem-
bly. The cylinder shell is an integral part of the tilt-
ing frame. If the cylinder shell repair is necessary,
prior approval from Hyster® Company is required. If
repair is not an option, the tilting frame must be re-
placed. Refer to Front Frame With Sideshifter.
The sideshift cylinder components can be disassem-

bled to repair the seals if damaged. Check the wear
strips on the tilting frame when the fork carriage is
removed. Replace as necessary. Consult the Parts
Manual to select the proper cylinder repair kit for
your truck. Replace all parts included in the cylin-
der repair kit. Seals and O-rings may become brittle
and lose elasticity over time even when the old parts
show no apparent damage. See Figure 25. 1. WEAR STRIP
2. WEAR STRIP
3. ROD
4. WIPER RING
5. SEAL
6. SLEEVE
7. SEAL
8. TILTING FRAME
9. LUBE FITTING
Figure 25. Sideshift Repair
36
4500 SRM 1196 Front Selector Valve
Front Selector Valve

The front selector valve is located in the front frame The front selector valve is an electro-hydraulic valve
of the reach carriage. It is secured to a cover plate block that directs hydraulic flow to the tilt and
with three capscrews. The remote CAN module is sideshift cylinders (where applicable). The remote
mounted below the front selector valve on the cover CAN module controls the front selector valve by re-
plate. The cover plate is mounted to the front of the ceiving CAN communication signals from the truck
front frame, just above the tilting frame. See Fig- control system and operating the electro-hydraulic
ure 26. solenoid valves in the front selector valve. The
remote CAN module receives these signals through
a wiring harness, which runs to the front frame
inside the hose guard along side the hydraulic hoses
and activating the electro-hydraulic valves in the
selector valve. See Figure 27.
1. FRONT SELECTOR VALVE 1. TILT (DOWN)

2. REMOTE CAN MODULE (N35ZDR, N45ZR, 2. TILT (UP)
N30ZDR, AND N35-40ZR ONLY) 3. SIDESHIFT (EXTEND RIGHT)
3. BRACKET 4. SIDESHIFT (EXTEND LEFT)
4. COVER
Figure 27. Front Selector Valve
Figure 26. Front Frame
37
Rear Selector Valve 4500 SRM 1196
Rear Selector Valve

The rear selector valve is mounted inside the top of valve block that directs hydraulic flow to the reach
the rear frame with three capscrews. A cover mounts cylinders and supplies the front frame (front selector
to the front side of the valve and shields it from expo- valve) hydraulics. See Figure 28.
sure. The rear selector valve is an electro-hydraulic
1. REACH CYLINDER (LH) 6. LINE

2. REACH CYLINDER (RH) 7. HOSE GUARD
3. SUPPLY LINE 8. FRONT SELECTOR VALVE
4. RETURN LINE 9. REAR SELECTOR VALVE
5. LINE
Figure 28. Reach Carriage Hydraulics
38
4500 SRM 1196 Reach Assembly Adjustments
Reach Assembly Adjustments

CHECK ADJUSTMENT assembly. If the lift chains are loose, operate
the lift button to raise the free-lift cylinder just
Check the adjustment of the reach assembly to en- enough that the lift chains are supporting the
sure proper operation of the reach assembly, mast, weight of the reach assembly. See Figure 29.
and carriage. If the reach assembly has been re-
moved, always check the condition and adjustment 2. Check between the inside of the inner mast
of the load rollers and side rollers on the rear frame channels and the load roller at the top of the
before reinstalling the reach assembly. See Adjust rear frame. Clearance should be approximately
Side Rollers and Load Rollers. 0.5 mm (0.02 in.) with the reach assembly par-
allel to the channels.
1. Fully lower the reach assembly. Make sure the
lift chains are supporting the weight of the reach
A. TWO-STAGE B. THREE-STAGE
1. INNER WELDMENT 7. SNAP RING
2. CHAIN SHEAVE 8. OUTER WELDMENT
3. LIFT CHAIN 9. ADJUSTMENT NUT
4. COTTER PIN 10. REACH ASSEMBLY
5. ANCHOR PIN 11. TYPICAL FIXED ANCHOR
6. CHAIN ANCHOR 12. INTERMEDIATE WELDMENT
Figure 29. Main Lift Chain Adjustment
39
Reach Assembly Adjustments 4500 SRM 1196
3. Raise and lower the reach assembly with a load.

Check that there is minimum clearance with
free movement. If the reach assembly does not
move smoothly during lowering, remove the
reach assembly and adjust the side rollers and
load rollers.
ADJUST SIDE ROLLERS AND LOAD

ROLLERS
NOTE: Side rollers are used only on 6.9 inch mast
carriages.
1. Measure the width between the outside edges of

the inner weldment in several places. Make a
note of the location and the value of the maxi-
mum measurement. See Figure 30.
2. Measure and record the distance between the

outside of the side rollers and load rollers of the
reach assembly. See Figure 31.
3. If the difference between dimension A and the

largest measurement between the inner mast
weldments is more than 4 mm (0.16 in.), in-
stall shims to the side rollers and/or load rollers
evenly. If the difference is less than 4 mm
(0.16 in.), remove shims from the side rollers
and/or load rollers evenly.
Figure 30. Measuring Channel Width
40
4500 SRM 1196 Reach Assembly Adjustments
1. Cycle the reach system several times to remove

air from the system. Operate the reach mecha-
nism to fully extend and retract the forks for sev-
eral cycles to check for proper operation.
2. Fully extend the forks, move the key to the OFF

position, and disconnect the battery. Measure
the distance between the contact surface of the
rear frame and the stops on the front frame.
Measure the distance on both sides. The correct
distance for a single-reach unit is 610 +3 6 mm
(24 +0.12 0.24 in.). The correct distance for a
double-reach unit is 1067 +3 6 mm (42 +0.12
0.24 in.).
3. If the distance is not within specifications on both

sides, loosen the capscrews at the rod ends of the
reach cylinders. Use a wrench on the wrench
flats to rotate the cylinder rods for adjustment.
Temporarily tighten the capscrews.
4. Operate the reach mechanism through several

cycles and fully extend the forks. Move the key
Figure 31. Side and Load Roller Widths
Measure the distance on each side again. Both
measurements must be within specifications
ADJUST REACH CYLINDERS
AND the measurements must be within 3 mm
NOTE: The reach cylinders must be adjusted if either (0.12 in.) of each other. If the measurements
reach cylinder has been replaced or the rod ends have are not within specifications, repeat Step 3 and
been removed. Adjustment is also necessary if major Step 4 until all measurements are correct. Tem-
parts of the reach mechanism have been replaced. porarily tighten the capscrews without moving
the rods after all measurements are correct.
The reach cylinders must be adjusted so the assem-
bly can fully extend to its maximum stroke. It must 5. Fully retract the forks and check each stop on the
also be adjusted to lightly touch the stops on the rear front frame. The rear frame must be touching the
frame with the cylinders fully retracted. Both cylin- stop pads.
ders must be adjusted equally to avoid a condition
6. Extend the reach mechanism, move the key to
known as racking. When racking occurs, one side of
the OFF position, and disconnect the battery.
the reach assembly is being pushed or pulled ahead
Add or remove shims under each stop pad as nec-
of the other. This can cause excessive stress on com-
essary. DO NOT use more than 3/8-in. shims.
ponents of the reach assembly resulting in erratic
Repeat Step 5 and Step 6 until the front frame
movement and premature wear.
touches on both sides.
WARNING 7. Fully extend the forks, move the key to the OFF
The points between the scissor arms and the position, and disconnect the battery. Loosen the
rear frame/front frame are pinch points and capscrews at the rod ends of the reach cylinders.
can cause an injury. DO NOT put any part of Use a wrench to rotate the cylinder rods 1/4 turn
your body between these assemblies if they clockwise into the cylinder. This adjustment al-
can move. Always move the key to the OFF lows the stop pads to absorb the shock instead of
position and disconnect the battery. the reach cylinders as the mechanism retracts.
Tighten the rod end capscrews to 35 to 40 N•m
(26 to 30 lbf ft).
41
Lift Chains 4500 SRM 1196
Lift Chains
INSPECT
WARNING
Never replace only the worn section of a chain.
chains.
CAUTION
Lift chains, which were not checked before
removal, must be checked for correct length
again once installed in the mast and the mast
installed on the lift truck.

wear.
Inspect the lift chains for wear or damage. A lift Pitch

chain becomes longer when it is worn. If a chain is Total Length
Wear Limit
3% longer than a new lift chain, the lift chain must be of 20 Links
Maximum of
replaced. If a chain scale is available, check the lift (Pitch) of
20 Links
chain as shown in Figure 32. If a chain scale is not New Chain
available, measure 20 links of the lift chain. Com-
25.4 mm 508 mm 523 mm
pare the measurement with the lengths given in Fig-
(1.00 in.) (20.0 in.) (20.6 in.)
ure 32.
31.8 mm 635 mm 654 mm
(1.25 in.) (25.0 in.) (25.7 in.)
38.1 mm 762 mm 785 mm
(1.50 in.) (30.0 in.) (30.9 in.)
44.5 mm 889 mm 915 mm
(1.75 in.) (35.0 in.) (36.0 in.)
50.8 mm 1016 mm 1047 mm
(2.00 in.) (40.0 in.) (41.2 in.)
NOTE: The instructions for measuring chain wear
are shown on the Chain Wear Scale.
1. CHAIN WEAR SCALE
42
4500 SRM 1196 Lift Chains
CLEAN AND LUBRICATE a. If the tension is not the same, adjust the nuts
on the chain anchors until the tension is the
WARNING same, and tighten the lock nuts. Recheck
that the top of the weldments are still within
specification. See Step 1.
and can cause severe skin irritation. When
using cleaning solvents, always follow the b. If the tension on both chains are equal, pro-
solvent manufacturer’s recommended safety ceed to the next step.
precautions.
3. Adjust the free-lift chains. See Adjust Free-Lift
Always wear protective clothing and eye pro- Chains.
tection when working with compressed air.
4. Check the mast operation.
CAUTION 5. Install the mast operator guard (if removed).
or load rollers. The bearings in the sheaves and ADJUST FREE-LIFT CHAINS
NOTE: Make sure the forks of the reach carriage are
Clean the lift chains by soaking in solvent for 30 min- parallel to the floor (no forward or backward tilt). See
utes and remove all dirt and grease. Hang lift chains Figure 32. The main lift chains must be adjusted
over a drip pan and let drip. Remove residual solvent BEFORE adjusting the free-lift chains.
using compressed air. Lubricate the chains by soak-
ing them in SAE 30 engine oil for 30 minutes. Hang 1. Fully lower the carriage. With the forks level
chains over a drip pan for one hour to remove excess (parallel to the floor), measure the distance from
oil. the floor to the top of forks. The correct distance
is 63.5 mm (2.5 in.).
ADJUST MAIN-LIFT CHAINS
2. If the distance is correct, the free-lift chains are
The main lift chains must be adjusted BEFORE ad- adjusted for the correct height. Perform Step 5
justing the free-lift chains. next. If the distance is NOT correct, perform all
of the steps.
Adjust chain anchors at main lift cylinders so top of
inner mast weldment is even with top of outer mast 3. Raise the mast until the free-lift cylinder chain
weldment. anchors at the rear of the free-lift cylinder can be
accessed from the operator compartment. Install
NOTE: Remove the mast operator guard if adjust- safety chains as described in Safety Procedures
ment is necessary. When Working Near Mast. Remove the mast op-
erator guard for easier access to the chain an-
1. Completely lower the mast. Check to verify that chors. Loosen both lock nuts at the chain anchors
the top of the outer weldment is even (±1.5 mm to make any adjustments.
(0.06 in.)) with the top of the inner mast.
4. Adjust the nuts of the chain anchors equal
a. If the top of the weldments are not even, amounts for the correct distance (Step 1).
adjust the nuts on the chain anchors until
the weldments are even, and tighten the lock 5. Check chain tension by pushing on both chains
nuts. at the same time. If the tension is not the same,
adjust the nuts on the chain anchors until the
b. If the top of the weldments are even (within tension is the same and the distance (Step 1) is
specification), proceed to the next step. also correct. When the tension is equal on both
2. Check chain tension by pushing on both main-lift chains, the chain sheave assembly will be level.
chains at the same time. Tighten the lock nuts.
43
Lift Chains 4500 SRM 1196
CAUTION
When the chain adjustments are complete,
make sure the cotter pin at the bottom of the
chain anchor can be installed under the ad-
justment nut. If there is no room to install
the cotter pin, the chains are too short. Make
sure the lock nuts on the chain anchors are
tight against the mount plate. If there are
not enough threads on the chain anchor for
correct adjustment, new chains are too long or
old chains are too worn.
6. Check the mast operation.
7. Recheck the distance from the floor to the top of

the forks.
8. Raise the reach carriage to the top of the inner

mast. Check to ensure the reach carriage stops
before hitting the stops at the top of the inner
weldment. If the reach mechanism reaches the
stops prior to full elevation, recheck fork height
with the mast fully lowered. See Step 1.
9. Extend the mast fully to check the maximum

fork height (MFH). The MFH specifications are
stamped into the side of the outer mast. With the
forks level (parallel to the floor), verify MFH by
measuring from the floor to the top of the forks
with the mast fully extended. See Figure 33.
10. Install the mast operator guard if removed.
1. REACH CARRIAGE STOP

2. MAXIMUM FORK HEIGHT (MFH)
3. FLOOR LEVEL
Figure 33. Maximum Fork Height (MFH)
44
4500 SRM 1196 Specifications
Specifications
Table 1. General Specifications
Action Specification
Load Backrest Capscrews, Torque 203 N•m (150 lbf ft)
Scissor Arms, Torques
Center Pivot Capscrews 41 N•m (30 lbf ft)
End Pivot Capscrews (Double Reach Only) 39 N•m (29 lbf ft)
Reach Cylinder, Torques
M8 Bolt 34 N•m (25 lbf ft)
Reach Mechanism
Reach Cylinder Stroke +6.4/ 9.6 mm (+0.25/ 0.38 in.)
Reach Assembly Travel
Single Reach 610 mm (24 in.)
Double Reach 1067 mm (42 in.)
45
Specifications 4500 SRM 1196
Table 2. Operating Times
Voltage Action Time

24V Fast Reach Time, Minimum Load [ 0 kg (0 lb)] 2.7 to 3.5 sec. 3.7 to 4.5 sec.
Fast Reach Time, Maximum Load [ 2041 kg (4500 lb)] 3.2 to 4.0 sec. 4 to 5 sec.
Slow Reach Time, Minimum Load [ 0 kg (0 lb)] 6 to 8 sec. 6 to 8 sec.
Tilt Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Tilt Time, Maximum Load [ 2041 kg (4500 lb)] 2 to 3 sec. 2 to 3 sec.
Sideshift per 3" Travel Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Sideshift per 3" Travel Time, Maximum Load [ 2041 kg 2 to 3 sec. 2 to 3 sec.
(4500 lb)]
(4500 lb)]
36V Fast Reach Time, Minimum Load [ 0 kg (0 lb)] 2.7 to 3.5 sec. 3.7 to 4.5 sec.
Fast Reach Time, Maximum Load [ 1361 kg (3000 lb)] 3.2 to 4.0 sec. 4 to 5 sec.
Slow Reach Time, Minimum Load [ 0 kg (0 lb)] 6 to 8 sec. 6 to 8 sec.
Tilt Time, Minimum Load [ 0 kg (0 lb)] 1.5 to 2.5 sec. 1.5 to 2.5 sec.
Tilt Time, Maximum Load [ 2041 kg (4500 lb)] 2 to 3 sec. 2 to 3 sec.
(4500 lb)]
(4500 lb)]
Fork Tilt Angle (Truck Level ±1 )
Down 3 ±1
Up 4 ±1
Fork Height, Fully Lowered (no tilt) 64 mm (2.50 in.)
Operating Pressures and Amperes (Measured at pump, ±10% acceptable)
46
4500 SRM 1196 Specifications
Table 2. Operating Times (Continued)
Voltage Action Time

Relief 24 V 16,547.4 kPa 175 Amps
(2400 psi)
36 V 16,547.4 kPa 112 Amps
(2400 psi)
Reach No Load 24 V 7584 kPa 90 Amps
(1100 psi)
Capacity Load 24 V 7584 kPa 90 Amps
(1100 psi)
No Load 36 V 7584 kPa 60 Amps
(1100 psi)
(1100 psi)
Retract No Load 24 V 11,721 kPa 127.5 Amps
(1700 psi)
Capacity Load 24 V 11,721 kPa 142.5 Amps
(1700 psi)
No Load 36 V 11,721 kPa 85 Amps
(1700 psi)
Capacity Load 36 V 11,032 kPa 95 Amps
(1600 psi)
Tilt Forward No Load 24 V 9191 kPa 97.5 Amps
(1333 psi)
(825 psi)
(1333 psi)
(825 psi)
Tilt Backward No Load 24 V 3916 kPa 73.5 Amps
(568 psi)
Capacity Load 24 V 14,527 kPa 175.5 Amps
(2107 psi)
(568 psi)
Capacity Load 36 V 14,527 kPa 117 Amps
(2107 psi)
47
Troubleshooting
The forks will not extend, Wiring disconnected or damaged. Check dash display for error mes-
tilt, or sideshift. sages.
Check that all connectors are tight
and the mast cable is not damaged.
Auxiliary motor not operating. Use dash display diagnostics to check

auxiliary motor RPM.
Replace defective motor.
Control handle not operating prop- Use dash display diagnostics to check
erly. operation of handle switches. Repair
and replace as required.
Selector valve is damaged or not op- Check for correct signals from Re-
erating. mote CAN Module to the selector
valve.
Clean, repair, or replace selector
valve or valve components.
Auxiliary relief valve not operating Check for an open valve at the auxil-
properly. iary pump.
Clean, repair, or replace valve as nec-
essary.
The forks reach/retract Binding in the carriage mechanism. Ensure the mechanism moves freely.
slowly. Check for failed bearings in the
mechanism.
Reduced hydraulic flow to the reach/ Use dash display diagnostics to check
retract cylinders. auxiliary motor RPM.
Ensure parameter settings are cor-
rect.
Check the auxiliary pump for flow.
Replace pump if motor operates and
there is low flow from the pump.
Hydraulic fluid level is low. Check Fill as necessary.

levels.
48
Sideshift operation is slow. Reduced hydraulic flow to the Use dash display diagnostics to check
sideshift cylinder. auxiliary motor RPM.
rect.
Sideshift cylinder is worn or dam- Repair or replace sideshift cylinder.

aged.
Tilt operation is slow. Reduced hydraulic flow to the tilt Use dash display diagnostics to check
cylinder. auxiliary motor RPM.
rect.
Tilt cylinder is worn or damaged. Repair or replace tilt cylinder.
49
NOTES
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50
STEERING SYSTEM
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590937 1600 SRM 1187

Steering System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Raising the Lift Truck ................................................................................................................................... 3
How to Raise the Drive Tire End.............................................................................................................. 3
How to Raise the Entire Lift Truck .......................................................................................................... 4
Description ......................................................................................................................................................... 4
Steering Handle Assembly ................................................................................................................................ 7
Fixed Handle.................................................................................................................................................. 7
Description................................................................................................................................................. 7
Remove....................................................................................................................................................... 7
Disassemble ............................................................................................................................................... 7
Assemble .................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Adjustable Handle ......................................................................................................................................... 11
Description................................................................................................................................................. 11
Remove....................................................................................................................................................... 11
Disassemble ............................................................................................................................................... 11
Assemble .................................................................................................................................................... 15
Install ......................................................................................................................................................... 15
Steering Controller ............................................................................................................................................ 16
Description ..................................................................................................................................................... 16
Remove ........................................................................................................................................................... 16
Disassemble ................................................................................................................................................... 17
Assemble ........................................................................................................................................................ 17
Install ............................................................................................................................................................. 17
Steering Proximity Switch ................................................................................................................................ 17
Replace ........................................................................................................................................................... 17
Steering Motor ................................................................................................................................................... 18
Description ..................................................................................................................................................... 18
Remove ........................................................................................................................................................... 18
Disassemble ................................................................................................................................................... 19
Assemble ........................................................................................................................................................ 19
Install ............................................................................................................................................................. 19
Caster Assembly - General ................................................................................................................................ 20
Caster Adjustment......................................................................................................................................... 20
Elastomer Spring Type Adjustment ......................................................................................................... 20
Belleville Spring Type Adjustment .......................................................................................................... 22
Spring Pack Replacement ......................................................................................................................... 23
Remove Spring Assembly ..................................................................................................................... 23
Replace Spring Pack ............................................................................................................................. 24
Install Spring Assembly ....................................................................................................................... 24
Caster Wheels .................................................................................................................................................... 25
Remove ........................................................................................................................................................... 25
Install ............................................................................................................................................................. 26
Caster Wheel Assembly (Nonsteered)............................................................................................................... 26
Description ..................................................................................................................................................... 26
Remove ........................................................................................................................................................... 26
Disassemble ................................................................................................................................................... 28
Upper and Lower Support Housings........................................................................................................ 28
Spring Assembly From Lower Support Assembly ................................................................................... 28
Caster Spindle From Lower Support ....................................................................................................... 28

Table of Contents Steering System

Caster Wheels............................................................................................................................................ 29
Lower Support Housing ............................................................................................................................ 30
Upper Support Housing ............................................................................................................................ 31
Assemble ........................................................................................................................................................ 31
Caster Wheels............................................................................................................................................ 33
Caster Spindle to Lower Support ............................................................................................................. 33
Spring Assembly to Lower Support.......................................................................................................... 33
Install ............................................................................................................................................................. 34
Caster Assembly (Steered) ................................................................................................................................ 35
Description ..................................................................................................................................................... 35
Remove ........................................................................................................................................................... 35
Disassemble ................................................................................................................................................... 37
Upper and Lower Support ........................................................................................................................ 37
Spring Assembly From Lower Support Housing ..................................................................................... 37
Caster Spindle From Lower Support ....................................................................................................... 38
Caster Wheels............................................................................................................................................ 38
Caster Steering Motor............................................................................................................................... 41
Assemble ........................................................................................................................................................ 42
Caster Steering Motor............................................................................................................................... 42
Caster Wheels............................................................................................................................................ 44
Caster Spindle to Lower Support ............................................................................................................. 44
Spring Assembly to Lower Support.......................................................................................................... 45
Install ............................................................................................................................................................. 45
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
ii
General
part of the steering system. The steering system is
WARNING primarily electronic. The steering handle assembly
The AC Reach Truck has a cooling fan installed turns a steering sensor, which supplies a signal to
under the front left cover to regulate the mo- the steering controller. The steering controller sends
tor controller temperatures. Some trucks have current to the steering motor, which drives the mas-
a motor door fan installed as an added option ter drive unit (MDU) through a gear set to steer the
for higher temperatures or extreme duty cycle lift truck.
operations. The cooling fans of the motor con-
trollers and motor compartment (if installed)
WARNING
run continuously when power is on. Remove
power from the truck by turning the key switch These lift truck models may be furnished with
OFF and unplugging the battery before servic- automotive or reverse steering. Before work-
ing the truck or removing covers. ing on any of these lift trucks, be sure of the
If power-on diagnostic checks are necessary re- type of steering that has been installed on the
quiring servicing the truck with the covers re- lift truck.
moved or the motor door open, the fans should Throughout this section, forward will refer to travel
be unplugged first or suitable guards installed in the direction of the forks. Left and right will be
over the fans to prevent possible injury from determined by an operator standing in the operator
the rotating blades of the fans. If diagnostic compartment facing the forks. See Figure 1.
checks require the lift motor or drive motor to
be used, the motor controller fan is required to
prevent the motor controllers from overheat-
ing and the front left cover for the fan must re-
main in place during operation of the truck.
CAUTION
incorrectly. Make sure each electrical wire
connection is tagged and properly identified
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- A. LEFT SIDE
cal components they are used to check. Never B. RIGHT SIDE
wire aftermarket components to this truck C. FORWARD TRAVEL
without factory approval.
Figure 1. Truck Orientation
This section describes the disassembly and assembly
of the steering system. There is a description for each
1
DISCHARGING THE CAPACITORS never put power to the controller while any
power wires are disconnected. Never short
WARNING any controller terminal or motor terminal to
the battery. Make sure to use proper proce-
DO NOT make repairs or adjustments unless
dure when servicing the controller.
you have both authorization and training. Re-
pairs and adjustments that are not correct can 1. Turn key switch to OFF position and disconnect
create dangerous operating conditions. DO the battery. Block load wheels to prevent lift
NOT operate a lift truck that needs repairs. truck from moving.
immediately. If repair is necessary, attach a 2. Remove two screws securing the electrical com-
DO NOT OPERATE tag on the steering wheel. partment and pull the compartment door open on
Remove the key from the key switch. its hinges.
Disconnect the battery before opening the elec- NOTE: Some lift trucks are equipped with a premium
trical compartment covers or inspecting or re- controller, which controls the hydraulic motor as well
pairing the electrical system. If a tool causes as the traction motors.
a short circuit, the high current flow from the
battery can cause personal injury or property 3. Discharge the capacitor in the controller by con-
damage. necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals for 10 seconds
Some checks and adjustments are done with using insulated jumper wires. See Figure 2.
the battery connected. DO NOT connect the
battery until the procedure tells you to do so.
Never have any metal on your fingers, arms,
or neck. Metal items can accidentally make an
electrical connection and cause injury.
Before performing any tests or adjustments,

block the lift truck to prevent unexpected
movement.
The capacitor in the transistor controller(s)

is disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor(s)
before inspecting or repairing any component
in the electrical compartments. Wear safety
glasses. Make certain that the battery has
been disconnected.
DO NOT short across the motor controller ter-

minals with a screwdriver or jumper wire. 1. POSITIVE CONNECTION (B+)
CAUTION 4. 200-OHM, 2-WATT RESISTOR
To avoid controller damage, always disconnect
the battery, discharge the capacitor(s), and Figure 2. Discharging the Capacitors
2
RAISING THE LIFT TRUCK of these components and other lift points are
not designed to support the weight of the lift
WARNING truck. The truck can be damaged or it can fall
on someone causing serious injury. Attach a
The lift truck must be put on blocks or an ap-
chain or sling to a support structure of the lift
proved stand for some types of maintenance
truck frame.
and repair. The removal of the following as-
semblies will cause large changes in the center Put the lift truck on blocks only if the surface is solid,
of gravity: mast and load axle, battery, and the even, and level. Make sure that any blocks used to
counterweight. When the lift truck is put on support the lift truck are solid, one-piece units. Put
blocks, put additional blocks under the rear of blocks in front and back of the tires to prevent move-
the frame before removing the mast so the lift ment of the lift truck.
truck cannot fall backward or to the side.
DO NOT raise any point of the truck more than

How to Raise the Drive Tire End
50 mm (2 in.) without raising the opposite side Refer to the precautions at the beginning of the Rais-
to level the truck. If raising the frame above ing the Lift Truck instructions in this section before
150 mm (6 in.), remove the mast first and raise attempting to raise the lift truck.
both ends of the frame in 50 mm (2 in.) incre-
ments. 1. Put blocks on each side (front and back) of the
load wheels to prevent movement of the lift truck.
DO NOT raise the lift truck by attaching an See Figure 3.
overhead crane to the overhead guard or ar-
eas of the mast that will be damaged. Some
1. DRIVE AND CASTER WHEELS 2. LOAD WHEELS
Figure 3. How to Put Lift Truck on Blocks
3
2. Use a special low-clearance hydraulic jack under 1. Remove the mast from the lift truck. Refer to
the rear of the frame to raise the drive/steer tire Mast, Repair 4000 SRM 1195.
and caster wheels. Another lift truck can also be
used to raise the lift truck. Make sure that the 2. Turn the key to the OFF position and disconnect
jack or other lifting device has a capacity of at the battery from the lift truck at the battery con-
least 2/3 of the total weight of the lift truck as nector.
shown on the nameplate.
WARNING
3. Raise the lift truck only enough to suspend the
The battery is heavy. Use appropriate lifting
drive/steer tire and the caster wheels. Install
equipment to avoid personal injury.
blocks under the rear of the frame to support the
lift truck. 3. Remove the battery from the lift truck.
How to Raise the Entire Lift Truck

WARNING
Refer to the precautions at the beginning of the Rais- The truck must be kept level while raising.
ing the Lift Truck instructions in this section before
attempting to raise the lift truck. 4. Raise the lift truck and position solid one-piece
blocks or an approved lift truck frame stand
under the frame. The truck must be kept level
WARNING while raising. Frequently reposition jack stands
The mast MUST BE REMOVED to raise the or blocks under the frame while raising as a
frame above 150 mm (6 in.). safety precaution in case of equipment failure.
DO NOT raise any point of the frame 50 mm
(2 in.) more than any other point of the frame.
Description
The steering system is primarily electronic. See Fig- • Adjustable
ure 4. The steering handle assembly is attached to The fixed steering handle assembly has the steering
a sensor unit that senses the direction and speed handle rotation center fixed and cannot be moved.
of rotation of the steering handle. The sensor unit The adjustable steering handle assembly has a fea-
sends a signal to the steering controller, which, in ture where the steering handle center of rotation may
turn, controls electrical power to the steering motor be moved to provide more efficient and comfortable
mounted to the MDU mounting plate. The steering operation. Both steering handle options are avail-
motor turns a gear on the end of the motor shaft that able with either stance configuration. With the fore/
meshes with a large gear attached to the MDU. As aft stance configuration, the steering handle assem-
the steering motor rotates, the MDU also rotates. bly is mounted in the horizontal position. In the
The speed of rotation is directly proportional to how sidestance configuration, the steering handle assem-
fast the steering wheel is being rotated. The speed bly is mounted at a slight angle toward the operator.
of rotation is also regulated by the speed of the lift
truck. As the speed of the lift truck increases, the Two versions of the caster assembly are also avail-
steering controller will slow the speed of the steering able on these lift trucks. The standard configuration
motor as the steering handle is turned. is a nonsteered caster assembly. An optional steered
caster with a separate caster steering controller is
The lift truck listed on the front cover of this section also available.
come in several optional configurations. All configu-
rations are covered by this section. These lift trucks During startup, the steering system will perform a
are available with two steering operating positions: self-test and center the drive wheel. The proximity
• Sidestance sensor located on the MDU plate signals the steering
• Fore/Aft Stance controller when the drive wheel is in the centered
position. The lift truck will "wiggle" during startup
The steering handle assembly used on these lift as the drive tire self-centers. The optional steered
trucks also comes in two optional configurations: caster assembly also includes a centering proximity
• Fixed switch and will self-center at truck startup.
4
1. STEERING HANDLE ASSEMBLY 4. STEERING MOTOR

2. SENSOR UNIT 5. PROXIMITY SENSOR
3. STEERING CONTROLLER 6. CASTER CONTROLLER (OPTIONAL)
Figure 4. Typical Steering System
5
The steering caster wheel assembly comprises the drive. The caster wheel centered position is moni-
other part of the steering system. The steering tored by an electronic proximity sensor mounted in
caster wheel assembly comes in two different config- the steer caster axle beside the steer caster motor.
urations. See Figure 5 and Figure 6. The caster steering motor is controlled by a separate
caster steering controller located beneath the opera-
The standard configuration is a spring-loaded, non- tor compartment. As the steering handle is rotated,
steered caster wheel assembly. See Figure 5. The the steering signal is sent to both the MDU steering
caster wheel assembly has two polyurethane wheels controller and the caster steering controller to allow
that are free to rotate about a pivot shaft as the truck the caster wheels to turn in the same direction as the
is driven. The caster is spring loaded to allow the MDU. The movement of the MDU and caster wheels
caster wheel assembly to move up and down with is coordinated to allow for optimum steering geom-
variations in the floor surface and allow the truck to etry to be obtained during steering maneuvers. As
maintain four-wheel contact at all times. with configuration one, the caster wheel assembly is
spring loaded to allow the caster assembly to move
up and down with variations in the floor surface and
allow the truck to maintain four-wheel contact at all
times.
Figure 5. Nonsteered Caster Wheel Assembly
The optional configuration is a steered caster assem-

bly. See Figure 6. With this configuration, a mo-
tor is mounted to the caster wheel assembly and ro-
tates the polyurethane caster wheels through a gear
Figure 6. Steered Caster Wheel Assembly
6
1600 SRM 1187 Steering Handle Assembly
Steering Handle Assembly

FIXED HANDLE clamps securing the steering unit wiring to the
frame.
Description
The steering handle assembly links the lift truck op-
erator to the lift truck steering system. See Fig-
ure 7 and Figure 8. As the operator rotates the steer-
ing handle, the handle rotates a steering sensor in
the steering handle assembly. The steering sensor
senses the direction and speed of the steering han-
dle’s rotation and sends signals to the steering con-
troller to steer the lift truck.
Figure 8. Steering Handle Assembly (Fore/Aft

Stance)
4. If removing the mounting plate from the lift

truck, loosen the capscrews (1) holding the steer-
ing handle assembly to the compartment door.
Remove the steering handle assembly from the
lift truck. Place the assembly on a clean work
surface.
Disassemble
For the following instruction, refer to Figure 10.
1. Remove the four capscrews (12), lockwashers

Figure 7. Steering Handle Assembly (11), and washers (10) securing the steer support
(Sidestance) pad to the mounting plate.
Remove 2. Remove clamps retaining the steering unit har-

ness (not shown).
1. Turn the key to the OFF position and disconnect
the battery connector. 3. Pry the cover up from the steering handle and
loosen and remove the nut (2) and washer (3)
2. Loosen the compartment door mounting cap- from the steering unit shaft.
screws (2) and open the compartment door. See
Figure 9. 4. Remove the steering handle from the steer sup-
port pad and recover the Woodruff key from the
3. Disconnect the wiring from the steering handle steering unit shaft.
assembly at the harness connector. Remove the
7
Steering Handle Assembly 1600 SRM 1187
Figure 9. Door Attaching Parts (Sidestance Shown)

steering handle pin and remove the knob. Re-
WARNING move the plug from the steer support pad if nec-
Be careful when removing or installing retain- essary.
ing rings. Retaining rings can eject during
removal or installation with enough force to NOTE: The steering unit contains no serviceable
cause injury. Always use the correct retaining parts. If the steering unit fails, it must be replaced
ring pliers and wear eye and face protection as a complete unit.
during removal or installation.
6. Loosen and remove the four capscrews (9) and
5. Remove the cap from the top of the steering han- washers (8) holding the steering unit to the steer
dle knob. Remove the retaining ring from the support pad.
8
Figure 10. Steering Handle (Fixed)
9

1. COVER 12. CAPSCREW
2. NUT 13. WASHER
3. WASHER 14. LOCKWASHER
5. STEERING HANDLE 16. MOUNTING BRACKET
6. STEER SUPPORT PAD 17. SPACER
7. STEERING UNIT 18. MOUNTING PLATE
8. WASHER 19. PLUG
9. CAPSCREW 20. KNOB
11. LOCKWASHER 22. CAP
7. Remove the four capscrews (15), lockwashers removal or installation with enough force to
(14), and washers (13) securing the mounting cause injury. Always use the correct retaining
plate to the mounting bracket. Recover the spac- ring pliers and wear eye and face protection
ers from between. during removal or installation.
Assemble 6. Slide the knob onto the steering handle pin and
install the retaining ring. Install the cap into the
For the following instruction, refer to Figure 10. knob.
1. Position the spacers between the mounting 7. Install the plug to the steer support pad if re-
bracket and the mounting plate as removed. moved.
Align the holes in the mounting plate and the
spacers with the holes in the mounting bracket. 8. Install clamps to retain the steering unit harness
Install the four capscrews (15), lockwashers (14), to the steering handle assembly as removed (not
and washers (13) to secure. shown).
2. Assemble the steering unit to the steer support Install

pad with the four capscrews (9) and washers (8).
1. Install the steering handle assembly to the
3. Position the steer support pad to the mounting compartment door with the capscrews (2) as
plate. Secure in place using the four capscrews removed. See Figure 9.
(12), lockwashers (11), and washers (10).
2. Connect the harness from the steering handle as-
4. Install the Woodruff key into the steering unit sembly to the connector on the main truck har-
shaft. Align the slot in the steering handle with ness. Secure using clamps as removed.
the key and install the steering handle onto the
steer support pad. 3. Close the compartment door and tighten the cap-
screws (1). See Figure 9.
5. Install the washer (3) and nut (2) to secure the
steering handle. Install the cover onto the steer- 4. Reconnect the battery and turn the key switch to
ing handle assembly. the ON position. Test for proper operation.
WARNING
Be careful when removing or installing retain-
10
ADJUSTABLE HANDLE 3. Disconnect the wiring from the steering handle

assembly at the harness connector.
Description
4. If necessary, loosen the capscrews (1) holding the
The steering handle assembly links the lift truck op- steering handle assembly to the drive unit com-
erator to the lift truck steering system. See Fig- partment door. Remove the steering handle as-
ure 11. As the operator rotates the steering handle, sembly from the lift truck. Place the assembly on
the handle rotates a steering sensor in the steering a clean work surface.
handle assembly. The steering sensor senses the di-
rection and speed of the steering handle’s rotation Disassemble
and sends signals to the steering controller to steer
the lift truck. For the following instructions, refer to Figure 13.
1. Remove the four capscrews, washers, and spac-

ers holding the steer support pad to the mount-
ing plate (inner race). Remove the steer support
pad.
2. Remove the clamps retaining the steering unit

harness to the steering handle assembly (not
shown).
3. Pry the cover up from the steering handle and re-

move the nut and washer from the steering unit
shaft.
4. Remove the steering handle from the steer sup-

port pad and recover the Woodruff key from the
steering unit shaft.
WARNING
Figure 11. Steering Handle Assembly
removal or installation with enough force to
The steering handle assembly is adjustable. The lift cause injury. Always use the correct retaining
truck operator can move the steering handle’s center ring pliers and wear eye and face protection
of rotation away from or toward the operating posi- during removal or installation.
tion. To adjust the steering handle assembly, lift the
5. Remove the cap from the top of the handle knob.
locking pin and rotate the complete steering handle
Remove the retaining ring and remove the han-
assembly clockwise or counterclockwise to one of the
dle knob from the steering pin.
eight adjustment positions.
NOTE: The steering unit contains no serviceable
Remove parts. If the steering unit fails, it must be replaced
as a complete unit.
6. Loosen and remove the four capscrews (8) and
washers (7) securing the steering unit to the steer
support pad. Separate the steering unit from the
2. Loosen the compartment door mounting cap- steer support pad.
screws (2) and open the compartment door.
11
Figure 12. Compartment Door Attaching Parts
12
Figure 13. Steering Handle (Adjustable)
13

1. COVER 18. WASHER
5. STEERING HANDLE 22. LOCKWASHER
6. STEERING UNIT 23. WASHER
8. CAPSCREW 25. LOCKWASHER
9. OUTER RACE (TOP) 26. CAPSCREW
10. MOUNTING PLATE (INNER RACE) 27. RETAINING RING
11. OUTER RACE (BOTTOM) 28. BUSHING
12. TILLER LATCH PLATE 29. LOCKING PIN ASSEMBLY
13. MOUNTING BRACKET 30. STEER SUPPORT PAD
14. NUT 31. PULL KNOB
15. SPACER 32. HANDLE KNOB AND CAP
16. LOCKWASHER 33. RETAINING RING
17. CAPSCREW
outer race (top), mounting plate (inner race),
WARNING and outer race (bottom) to the tiller latch plate.
Be careful when removing or installing retain- Unstack the races from the tiller latch plate to
ing rings. Retaining rings can eject during complete disassembly.
cause injury. Always use the correct retaining
ring pliers and wear eye and face protection
7. Remove the locking pin assembly from the steer

support pad:
a. Unscrew the pull knob from the shaft.
b. Remove the upper retaining ring and pull the

locking plunger assembly from the steer sup-
port pad.
c. Remove the lower retaining ring and slide

the bushing from the bottom of the steer sup-
port pad.
d. Remove the clip from the lower locking rod

and remove the bushings and the spring
as necessary for repair. Reassemble as re-
moved. See Figure 14. 1. CLIP
2. LOCKING ROD
8. Remove the three capscrews (20), lockwashers 3. BUSHING
(19), and washers (18) securing the race assem- 4. SPRING
5. BUSHING
bly to the mounting bracket.
Figure 14. Locking Pin Assembly
9. Remove the four capscrews (26), lockwashers
(25), washers (24) and nuts (14) securing the
14
Assemble a. Install the bushing and lower retaining ring

into the steer support pad.
For the following instruction, refer to Figure 13.
b. Install the locking plunger assembly and the
1. Install the outer race (bottom) onto the tiller top retaining ring into the top of the steer
latch plate. Stack the mounting plate (inner support pad.
race) and then the outer race (top) as removed.
c. Screw the pull knob onto the locking plunger
2. Align the holes in the outer race (top), inner assembly
race, outer race (bottom), and tiller latch plate
as removed. Secure together using the four cap- 8. Align on the bottom of the steer support pad with
screws (26), lockwashers (25), washers (24) and the holes in the top of the mounting plate (inner
nuts (14). race). Install four capscrews, washers, and spac-
ers as removed to secure the steer support pad to
3. Position the race assembly (tiller latch plate side) the mounting plate.
onto the top of mounting bracket. Align mount-
ing holes and secure using three capscrews (20), 9. Secure the steering unit harness to the steering
lockwashers (19), and washers (18). handle assembly using clamps as removed (not
shown).
4. Assemble the steering unit to the steer support
pad with the four capscrews (8) and washers (7). Install
5. Insert the Woodruff key into the steering unit For the following instructions, refer to Figure 12.
shaft. Align the slot in the steering handle with
the Woodruff key and install the steering handle 1. If removed, install the steering handle assembly
onto the steering unit shaft. Install the washer to the drive unit compartment door with the cap-
(3) and nut (2) to secure. Install the cover onto screws (2) as removed.
the steering handle.
2. Connect the harness from the steering handle as-
sembly to the connector on the main truck har-
WARNING ness. Secure harness to the frame with clamps
Be careful when removing or installing retain- as removed.
removal or installation with enough force to 3. Close the compartment door and tighten the two
cause injury. Always use the correct retaining capscrews (1).
during removal or installation. 4. Reconnect the battery to the lift truck. Turn the
key switch to the ON position and test for proper
6. Slide the handle knob onto the steering handle operation.
pin and install the retaining ring. Install the cap
onto the handle knob.
7. Install the locking pin assembly into the steer

support pad:
15
Steering Controller 1600 SRM 1187
Steering Controller
DESCRIPTION 6. Disconnect the remaining wiring from the steer-
ing controller. Tag the wiring to assist when re-
The steering controller receives signals from the installing the steering controller.
steering sensor in the steering handle assembly, the
steering motor encoder, and the steering centering 7. The controller assembly sits into two clips at the
proximity switch. The steering controller translates bottom of the compartment and is retained to the
those signals into commands to the steering motor. lift truck frame by two capscrews and washers
The steering controller determines the correct di- at the top of the mounting plate. See Figure 15.
rection and speed to drive the steering motor from Remove the capscrews and washers from the top
the input received from the steering sensor. The of the mounting plate.
steering motor encoder sends signals back to the
steering controller to verify the correct direction 8. Carefully maneuver the controller assembly
and speed. The steering centering proximity switch between the lift pump inlet hose and the truck
signal is used by the steering controller to center frame and remove from the lift truck.
the steering system to the straight-ahead position
at system startup.
The steering controller is located on the left side of

the compartment adjacent to the drive motor. The
controller is mounted to a plate that also mounts the
master controller. The master controller is at the top
of the mounting plate and the steering controller is
at the bottom.
REMOVE
2. Discharge the capacitor in the controller. See

Discharging the Capacitors in this section.
3. Loosen the compartment door mounting cap-

screws and open the compartment door.
NOTE: Access to the controller mounting plate is lim-

ited. In some repair operations, draining oil from the
hydraulic tank and removing the inlet hose from the
lift pump hose fitting may assist in accessing the con-
troller mounting plate. DO NOT disconnect the
inlet hose without removing oil from the hy-
draulic tank, as the oil level in the tank may be 1. CAPSCREWS AND WASHERS
2. MOUNTING CLIPS
above the level of the inlet hose. This allows the 3. MASTER CONTROLLER
inlet hose to be moved and allows additional access 4. STEERING CONTROLLER
to components in the compartment.
Figure 15. Controller Assembly Mounting
4. Disconnect the wiring harness connector from
the bottom of the master controller.
5. Disconnect the wiring harness connector from

the steering controller.
16
1600 SRM 1187 Steering Proximity Switch
DISASSEMBLE 2. Place the bottom of the controller assembly

mounting plate in the two clips on the side of the
1. Remove the four nuts retaining the steering lift truck frame. See Figure 15.
controller to the mounting plate and remove the
steering controller. 3. Install the two capscrews and washer to retain
the top of the controller assembly mounting plate
NOTE: There are no serviceable parts within the to the lift truck frame.
steering controller. A failed steering controller must
be replaced as a complete unit. 4. Reconnect the wiring to the steering controller.
See Diagrams 8000 SRM 1199.
ASSEMBLE
5. Connect the truck wiring harness connector to
1. Install the steering controller over the four the steering controller.
mounting studs on the controller assembly
mounting plate. 6. Connect the truck wiring harness connector to
the master controller.
2. Install the mounting nuts.
7. Close the compartment door and tighten the door
INSTALL mounting capscrews.
1. Carefully maneuver the controller assembly be- 8. Reconnect the battery connector.
tween the truck frame and the lift pump inlet
hose.
Steering Proximity Switch

The steering proximity switch is located inside the
drive unit compartment mounted in the frame beside
the master drive unit (MDU). See Figure 16.
REPLACE

screws and open the compartment door.
3. Disconnect the switch wiring from the main

wiring harness.
NOTE: Make note of the depth of the old switch for

proper installation of the new switch.
4. Slightly loosen the jam nut securing the switch

to the frame. See Figure 17.
1. TRACTION MOTOR
5. Remove the switch by turning the switch shaft 2. STEERING MOTOR
counterclockwise and unscrewing it from the 3. PROXIMITY SWITCH
frame. 4. STEERING GEAR
5. FRAME
6. DRIVE TIRE
7. BATTERY COMPARTMENT
Figure 16. Switch Location
17
Steering Motor 1600 SRM 1187

6. Install the jam nut to the switch shaft in the

same position. Apply antiseize lubricant lightly
to the threads of the new switch shaft and install
to the frame by turning clockwise as removed.
Adjust the proximity switch to obtain a gap of 1
±0.5 mm (0.039 ±0.020 in.) between the end of
the proximity switch and the target plate. See
Figure 17. Lock the proximity switch in place
with the jam nut on the switch.
NOTE: Because the proximity switch gap is not easily

measurable, the distance is determined by the num-
ber of turns of the proximity switch off the target
plate face. Adjustments of 1 to 1 1/4 turns off the
target plate face is approximately 1.016 to 1.270 mm
(0.040 to 0.050 in.) gap distance.
1. JAM NUT
2. FRAME 7. Connect the switch wiring to the main wiring
3. STEER GEAR harness.
4. GAP MEASURE
5. PROXIMITY SWITCH 8. Close the compartment door and tighten the door
6. TARGET PLATE mounting capscrews.
7. CAPSCREW
8. WASHER 9. Reconnect the battery. Turn the key switch to the
ON position and test for proper operation.
Figure 17. Switch Mounting
Steering Motor
DESCRIPTION CAUTION
The 3-phase AC permanent magnet steering motor Electrical components on this truck are po-
is located in the drive unit compartment to the right larity sensitive and may be damaged if wired
of the traction motor. The steering motor receives incorrectly. Make sure each electrical wire
signals from the steering controller that control di- connection is tagged and properly identified
rection and speed of the steering motor. The steering before removal or installation. If the proper
motor encoder is built into the steering motor and location for connection is unclear, consult the
sends signals back to the steering controller to verify wiring diagram for the truck.
the steering motor is operating in the correct direc-
3. Disconnect the two wiring connectors connecting
tion and speed.
the steering motor to the lift truck wiring har-
REMOVE ness.
1. Turn the key to the OFF position and disconnect 4. Loosen and remove the four capscrews and wash-
the battery connector. ers retaining the steering motor to the lift truck
frame. See Figure 18.
screws and open the compartment door. 5. Carefully lift the steering motor vertically and
remove from the lift truck.
18
1600 SRM 1187 Steering Motor
1. CAPSCREW 2. WASHER
Figure 18. Steering Motor Mounting
DISASSEMBLE 1. CAPSCREW
2. WASHER
1. Remove the capscrew and washers from the bot- 3. WASHER
4. DRIVE GEAR
tom of the motor shaft. See Figure 19.
Figure 19. Gear Mounting
NOTE: The capscrew has been installed with thread-
lock.
INSTALL
2. Slide the drive gear from the motor shaft.
1. Insert the drive gear into the lift truck so that it
NOTE: There are no serviceable parts within the meshes with the MDU gear. Ensure the steering
steering motor. A failed steering motor must be motor is fully seated in the lift truck frame.
replaced as a compete unit.
2. Install the four washers and capscrews to retain
the steering motor to the lift truck frame. See
ASSEMBLE
Figure 18. Torque the capscrews to 23 N•m
1. Insert the key supplied with the motor into the (17 lbf ft).
motor shaft.
CAUTION
2. Slide the drive gear onto the motor shaft fully
engaging the key. Electrical components on this truck are po-
3. Remove old threadlock residue from the gear incorrectly. Make sure each electrical wire
mounting capscrew. Apply Loctite® 242 to the connection is tagged and properly identified
capscrew and install the washers and the cap- before removal or installation. If the proper
screw onto the bottom of the motor shaft. See location for connection is unclear, consult the
Figure 19. wiring diagram for the truck.
3. Reconnect the wiring connectors from the steer-

ing motor to the lift truck wiring harness.
19
Caster Assembly - General 1600 SRM 1187
4. Close the compartment door and tighten the door 5. Reconnect the battery. Turn the key switch to the
mounting capscrews. ON position and test for proper operation.
Caster Assembly - General

2. Loosen upper and lower stop jam nuts, then turn
CAUTION capscrews clockwise to clear lower support hous-
Any repairs to the caster assembly components ing.
require the caster shimming and adjustment
procedure to be performed. See Caster Adjust- 3. Measure the caster spring preload (dimension 3).
ment. See Figure 20.
The caster assembly does not require removal of the

entire assembly to service some of its components.
The caster wheel lower assembly with wheels and
bearings, the caster steer motor (on steered units),
and the caster spring assembly may be removed from
the truck for service or repair without removing the
entire assembly. If the entire caster assembly must
be removed, it requires raising the truck up high
enough for the entire assembly to be lowered from
the truck. Refer to Raising the Lift Truck in this sec-
tion.
CASTER ADJUSTMENT
Casters must be adjusted periodically. Adjustment
procedures differ depending on the caster spring
type. Two spring types are used on caster assem-
blies: Belleville Springs and Elastomer Springs. If
the caster can no longer be adjusted within speci-
fication, check the drive tire wear and replace as
necessary. If the spring pack (Belleville or Elas-
tomer) shows any visible damage, the spring pack
should be replaced. Belleville Spring packs (includ-
1. MOUNTING CAPSCREWS
ing washers) should be replaced with Elastomer 2. SHIMS
Spring packs and corresponding washers when 3. CASTER SPRING PRELOAD
replacement becomes necessary. See Spring Pack 4. UPPER ADJUSTMENT CAPSCREW
Replacement. 5. UPPER ADJUSTMENT GAP
7. LOWER ADJUSTMENT GAP
Elastomer Spring Type Adjustment
Figure 20. Caster Adjustment (Elastomer Type)
NOTE: The battery must be installed in the lift truck
with no load on the forks.
20
1600 SRM 1187 Caster Assembly - General
4. Spring preload measurements (dimension 3) preload. If the spring measurement is not within
should be within specifications for your lift specification, return to Step 5. If the spring mea-
truck. Refer to Table 1. surement is within specification, continue to
Step 7.
5. If spring preload measurements are not within
specification, raise the rear of the lift truck 7. Set the upper adjustment capscrew (see Fig-
approximately 50 mm (2 in.), loosen the three ure 20) to the proper gap (dimension 5). Refer to
mounting capscrews, and add or subtract shims Table 1.
as necessary.
• Greater than Specification = Add Shims 8. Set the lower adjustment capscrew (see Fig-
• Less than Specification = Remove Shims ure 20) to the proper gap (dimension 7). Refer to
Table 1.
6. Retighten the mounting capscrews and lower
the rear of the lift truck. Remeasure the spring
Table 1. Caster Specifications
Truck Battery Spring O.D. Mast Max Dimension Dimension Dimension

Series Compartment Fork Height "3" "5" "7"
mm (in.) mm (in.) mm (in.) mm mm mm
368.3 (14.5 53 (2.09) 6375 (251) 70 to 74 9.5 2 to 4
and and
A265 419.1 16.5)
and
D470 368.3 (14.5 53 (2.09) 6350 (250) 70 to 74 6.5 2 to 4
and and
419.1 16.5)
419.1 (16.5) 53 (2.09) 6375 (251) 70 to 74 9.5 2 to 4
419.1 (16.5) 53 (2.09) 6350 (250) 70 to 74 6.5 2 to 4
469.9 (18.5) 60 (2.36) 8153 (321) 75 to 79 9.5 2 to 4
C264 and and
546.1 (21.5)
469.9 (18.5) 60 (2.36) 8128 (320) 75 to 79 6.5 2 to 4
and and
546.1 (21.5)
21
Belleville Spring Type Adjustment


load on forks.
2. If the upper or lower adjustment capscrews are

touching the lower housing, loosen jam nuts then
turn bolts clockwise to clear lower support hous-
ing.

this gap. See Figure 22.
3. Measure the gap (3) between the upper and lower

support housings. This gap should be between
39.9 mm (1.57 in.) and 42.9 mm (1.69 in.). A. FRONT B. BACK
Figure 22. Go/No Go Gauge
4. If gap is not within specification, raise the rear

of the lift truck approximately 50 mm (2 in.) to
access the caster wheels.
5. Loosen the three mounting capscrews (1) and add

or subtract shims between the caster wheel as-
sembly and the top frame mount to adjust the gap
(3).
6. Tighten the mounting capscrews (1) and lower

the lift truck to the floor. Re-check the gap (3)
and repeat Step 3 through Step 6 as necessary
until correct gap is achieved. If the proper gap
value cannot be obtained by adjustment, check
the drive tire wear and replace as necessary. If
any part of the spring pack is damaged the entire
spring pack must be replaced. See Spring Pack
Replacement.

1. MOUNTING CAPSCREWS this gap.
2. SHIMS
3. GAP BETWEEN UPPER AND LOWER 7. Set the upper adjustment capscrew (4) to the up-
HOUSINGS per adjustment gap measurement (5) shown in
5. UPPER ADJUSTMENT GAP Table 2.
7. LOWER ADJUSTMENT GAP 8. Set the lower adjustment capscrew (6) to obtain
the lower adjustment gap measurement (7) of
Figure 21. Caster Adjustment (Belleville Type) 2 mm (0.079 in.) to 4 mm (0.157 in.).
22
1600 SRM 1187 Caster Assembly - General
Table 2. Upper Adjustment Gap Measurement
Truck Battery Mast Maximum Upper Adjustment

Model Compartment Fork Height Gap Measurement (5)
N30ZDR, N30ZDRS, 419.1 mm (16.5 in.) 6375 mm (251 in.) (0.374 in.)
N35-40ZR, N35-40ZRS 368.3 mm (14.5 in.) and Greater Than 6.5 mm
419.1 mm (16.5 in.) 6350 mm (250 in.) (0.256 in.)
419.1 mm (16.5 in.) Less Than 9.5 mm
6375 mm (251 in.) (0.374 in.)
419.1 mm (16.5 in.) Greater Than 6.5 mm
6350 mm (250 in.) (0.256 in.)
N35ZDR, N45ZR
546.1 mm (21.5 in.) 8153 mm (321 in.) (0.374 in.)
469.9 mm (18.5 in.) and Greater Than 6.5 mm
546.1 mm (21.5 in.) 8128 mm (320 in.) (0.256 in.)
Spring Pack Replacement

Belleville Spring packs should be replaced with
Elastomer Spring packs and corresponding washers
when replacement becomes necessary.
Remove Spring Assembly

load on forks.
2. Disconnect the battery connectors and discharge

the capacitors.

50 mm (2 in.).
4. Loosen jam nut and screw in the lower adjust-

ment capscrew. See Figure 23.
5. On steered units, remove steer motor to access

the caster spring.

2. SPRING ASSEMBLY
3. PIN
4. RETAINING CAPSCREW
5. LOWER SUPPORT HOUSING Figure 23. Caster Spring Removal
23
3. Install retaining capscrew.

CAUTION
Make sure the spring assembly has free play 4. On steered units, install steer motor as removed.
before removing the pin.
5. Lower the rear of the lift truck to the floor and
6. Remove retaining capscrew and slide pin from adjust the caster. See Elastomer Spring Type Ad-
lower support housing. Remove spring assembly. justment.
Replace Spring Pack
1. Remove capscrew and washer from top of spring

assembly. See Figure 24.
2. Remove spring retainer and spherical bearing

from guide rod.
3. Remove upper washer, belleville spring pack,

and lower washer(s) from guide rod.
4. Check bushing and replace as necessary.
5. Apply a thin coat of antiseize lubricant to guide

rod shaft.
6. Install new bottom washer onto guide rod.
NOTE: Different size elastomer springs are use on

different models. Make sure to use the proper spring
for your model lift truck. Refer to the Parts Manual.
7. Install new Elastomer Spring onto guide rod.
8. Install new top washer onto guide rod. A. BELLEVILLE SPRING

B. ELASTOMER SPRING
9. Install spherical bearing and spring retainer
onto guide rod. 1. CAPSCREW
2. WASHER
3. SPRING RETAINER
10. Install washer and capscrew onto spring assem- 4. SPHERICAL BEARING
bly. 5. GUIDE ROD
6. BUSHING
Install Spring Assembly 7. LOWER WASHER
8. SPRING PACK
1. Position spring pack to align with holes in lower 9. UPPER WASHER
housing.
Figure 24. Spring Assemblies
2. Apply a thin coat of antiseize lubricant to pin and
install.
24
1600 SRM 1187 Caster Wheels
Caster Wheels
REMOVE 7. Inspect the caster wheel for damage to the
For the following instructions, see Figure 25. or wheel material. Replace any wheel that is
WARNING chunks of the outside material missing. Replace
Cleaning solvents can be flammable and toxic wheels in sets if damaged.

50 mm (2 in.) to access the caster wheels. Re-
fer to Raising the Lift Truck in this section.
CAUTION
2. Inspect the bearings by rotating each caster

wheel. The wheels should have no side-to-side
free play and should turn smoothly. If the wheels
can be moved side to side or do not turn freely,
the bearings should be replaced.
3. Use a punch to tap around the edge of the bearing

cap to work it out of the caster wheel.
4. Unstake the bearing lockwasher from the bear-

washer.
5. Remove the caster wheel from the axle shaft.
CAUTION
wheel. 1. BEARING CAP
2. BEARING LOCKWASHER
The bearings are removed and replaced by 3. BEARING LOCK NUT
pressing on the outer race of the bearing only. 4. CASTER WHEEL
Pressing on the inner race will damage the 5. AXLE SHAFT
bearing. 6. BEARING
6. Remove the bearing by pressing it from the wheel Figure 25. Caster Wheels
25
Caster Wheel Assembly (Nonsteered) 1600 SRM 1187
INSTALL 2. Press new bearings into wheel assemblies. Use

WARNING stalling bearings to avoid damage to bearings
and/or wheels. See Figure 25. Bearings must be
replaced in sets.
when handling solvents and always follow the 3. Install the caster wheels to the axle shaft.
1. Clean all parts with solvent and inspect thor- onto the axle shaft (using special tool Hyster spe-
oughly. Replace damaged parts as necessary. cial tool P/N 1683617).
5. Torque the bearing lock nuts to 136 N•m

CAUTION
(100 lbf ft).
The bearings are replaced by pressing on the
outer race of the bearing only. Pressing or tap- 6. Ensure the caster wheels rotate freely and
ping on the inner race will damage the bearing. smoothly and are securely mounted on the axle
CAUTION 7. Inspect the caps for damage. Repair or replace
Replace bearings in sets to maintain proper as necessary. Install the caps to the wheels by
wheel loading and operation. tapping around the edge of the caps. Make sure
the caps are properly seated in the hubs.
Caster Wheel Assembly (Nonsteered)

DESCRIPTION 2. Turn the key to the OFF position and disconnect
the battery from the lift truck at the battery con-
The caster wheel assembly is located on the right- nector.
hand side of the lift truck. It is bolted to the lift truck
frame and is shim adjustable to accommodate wear of
the caster wheels. The standard caster wheel assem-
WARNING
bly has two polyurethane wheels, which are free to The battery is heavy. Use appropriate lifting
rotate about a pivot shaft as the truck is driven. See equipment to avoid personal injury.
Figure 26. The two caster wheels are mounted on a
pivoting axle that allows the two wheels to maintain
equal contact with the floor at all times. The caster
wheel assembly is spring loaded to allow the caster WARNING
wheels to move up and down with variations in the When lifting the rear of the lift truck frame,
floor surface and allow the truck to maintain four- block the front of the load wheels so the lift
point contact at all times. The caster wheel assem- truck cannot roll forward while lifting.
bly moves up and down within the lift truck frame on
guide bearings mounted to the caster wheel assembly 4. The truck must be raised level and high enough
frame. The caster wheel assembly can be replaced as to remove the caster wheel assembly from be-
a unit or the wheels can be replaced. neath the truck frame (typically 305 mm (12 in.)
or higher). The truck should be raised and placed
NOTE: Always replace the caster wheels as a set for on blocks in a manner to support the truck prop-
better caster operation and wheel wear. erly and in a level position. Make sure the lifting
or jacking equipment is suitable and of adequate
REMOVE capacity to lift the truck frame. See Periodic
Maintenance 8000 SRM 1197 - How to Put Lift
1. Remove the mast from the lift truck. Refer to Truck on Blocks.
26
1600 SRM 1187 Caster Wheel Assembly (Nonsteered)
1. CAPSCREW
2. WASHER
3. WASHER
4. CAPSCREW
5. SHIMS
Figure 27. Caster Wheel Assembly Mounting
8. From inside the operator compartment, remove

the two capscrews (4) and four washers (2, 3)
from the top of the caster wheel assembly. Retain
the shims for reuse when installing the caster
Figure 26. Nonsteered Caster Assembly
wheel assembly. See Figure 27.
5. Remove the caster compartment cover from the
right-hand side of the operator compartment. WARNING
The caster wheel assembly is heavy. Be sure
6. Remove the mounting capscrew (1) from the in-
that all lifting devices (hoists, cables, chains,
side of the frame. See Figure 27.
slings, etc.) are suitable and of adequate capac-
7. Support the caster wheel assembly with a crane ity to lift the caster wheel assembly.
or other suitable lifting device.
9. Slowly lower the caster wheel assembly. Remove
the assembly from the lift truck and place the
assembly on a clean work surface.
27
DISASSEMBLE (7) holding the spring assembly to the lower sup-

port housing. See Figure 28.
Upper and Lower Support Housings
2. Remove the spring assembly.
1. Remove the retaining pins from the links on
both sides of the caster wheel assembly. See 3. Repair the spring assembly as necessary. See
Figure 28. Replace Spring Pack in this section.
Caster Spindle From Lower Support

1. Use a punch to fold down the retaining tabs on
the locking washer.
2. Remove the bearing lock nut (using special tool

Hyster P/N 1683617), locking washer, and spacer
securing the caster spindle to the lower support
housing. See Figure 29.
3. Slide the spindle out of the bearing in the lower

support housing.
1. RETAINING PIN
2. LINK
3. LINKAGE PIN
6. CAPSCREW
7. PIN
8. SPRING ASSEMBLY
Figure 28. Caster Wheel Assembly
2. Remove the four links from the linkage pins and

remove the four linkage pins from the two pieces
of the caster wheel assembly.
3. Remove the upper support housing from the

lower support housing.
Spring Assembly From Lower Support

Assembly
1. Remove the retaining capscrew (6) from the side Figure 29. Caster Wheels From Lower Support
of the lower support housing and remove the pin
28
Legend for Figure 29 or wheel material. Replace any wheel that is

1. SPACER chunks of the outside material missing. Replace
2. BEARING LOCK NUT
3. LOCKING WASHER wheels in sets, if damaged.
Caster Wheels
CAUTION

wheel. The wheels should have no side-to-side
free play and should turn smoothly. If the wheels


washer.
CAUTION
wheel.

pressing on the outer race of the bearing only.
Pressing on the inner race will damage the 1. BEARING CAP
bearing. 3. BEARING LOCK NUT
4. CASTER WHEEL
5. Remove the bearing by driving it from the wheel 5. AXLE SHAFT
hub using a suitable brass or aluminum driver. 6. BEARING
6. Inspect the caster wheel for damage to the Figure 30. Caster Wheels
29
avoid damage to the bearings and/or lower

support housing.

Pressing or tapping on the inner race will
damage the bearing.
2. Remove the retaining ring from the lower sup-

3. Check all bushings for wear. Bushings should

have an inside diameter of 22.30 to 22.33 mm
(0.878 to 0.879 in.).
4. Press the bushings out of the lower support hous-

ing using a suitable brass or aluminum driver if
replacement is needed.
5. Remove any worn guide bearings from the sides

of the lower support housing. See Figure 32.
The guide bearing should be replaced if less than
10 mm (0.39 in.) in length.
1. BUSHINGS
2. BEARING
3. RETAINING RING
Figure 31. Lower Support Housing
Lower Support Housing
WARNING
1. Inspect the lower support housing bearing by ro-

tating it. If the bearing is worn or rough, it
should be replaced. 1. GUIDE BEARING
Figure 32. Guide Bearings

CAUTION
30
Upper Support Housing 3. Replace the adjustment capscrews and jam nuts
if damaged. Install the adjustment capscrews
For the following instructions, refer to Figure 33. and jam nuts.
4. Install the bushings into the upper support hous-

CAUTION ing. Press the bushings into the upper support
Use a hammer and a suitable brass or alu- housing using a suitable driver and install the
minum driver when removing bearings to bushings to be recessed 1.0 mm (0.04 in.) from
avoid damage to the bearings and/or upper the outside surface of the upper support housing.
support housing. See Figure 34.
1. Clean all parts with solvent. Thoroughly inspect
and repair as necessary.
2. Press the spherical bearing from the upper sup-

port housing.
3. Remove the two adjustment capscrews and jam

nuts.
4. Check all bushings for wear. Bushings should

(0.878 to 0.879 in.).
5. Press the bushings out of the upper support hous-

ing if replacement is needed.
ASSEMBLE
Upper Support Housing
WARNING
1. SPHERICAL BEARING
CAUTION 2. ADJUSTMENT CAPSCREW
Use a brass or aluminum driver when in- 3. JAM NUT
stalling bearings to avoid damage to bearings 4. BUSHING
and/or upper support housing.
Figure 33. Upper Support Housing
1. Clean all parts with solvent.
2. Press the spherical bearing into the upper sup-

port housing and ensure that the bearing is fully
seated.
31
CAUTION
Use a suitable brass or aluminum driver when
installing bearings to avoid damage to bear-
ings and/or lower support housing.
1. Clean all parts with solvent.
2. Pack the bearing with multipurpose grease and

install the bearing into the lower support hous-
ing. See Figure 31.
3. Install the retaining ring in the lower support

housing.
4. Install bushings if removed during disassembly.
5. Install the guide bearings onto the sides of the

lower support housing. The guide bearings must
be shimmed to be 2.0 mm (0.079 in.) less than the
frame opening for the caster wheel assembly. See
Figure 35. Measure the frame opening and shim
the guide bearings evenly to obtain the correct
dimension. Tighten all hardware.

2. 1.0 mm (0.04 in.)
3. BUSHING
Figure 34. Bushing Installation
WARNING

during removal or installation. Figure 35. Guide Bearing Shimming
32
Legend for Figure 35 Caster Spindle to Lower Support

1. FRAME OPENING 1. Insert the caster spindle through the bearings in
2. GUIDE BEARING the lower support housing.
Caster Wheels 2. Install the spacer, locking washer, and bearing
lock nut on the shaft. See Figure 29.
WARNING
3. Torque the bearing lock nut to 136 N•m
(100 lbf ft) (using special tool Hyster P/N
1683617) and stake the locking washer to the
bearing lock nut.
Spring Assembly to Lower Support
CAUTION
The bearings are replaced by pressing on the For the following instructions, refer to Figure 28.
outer race of the bearing only. Pressing or tap- NOTE: Repair the spring assembly as necessary. See
ping on the inner race will damage the bear- Replace Spring Pack in this section.
ing. Use a suitable brass or aluminum driver
when installing bearings to avoid damage to 1. Install the spring assembly into the lower sup-
bearings and/or caster wheel. port housing.
Replace bearings in sets to maintain proper 2. Install the pin through the lower support housing
wheel loading and operation. and spring assembly.
1. Clean all parts with solvent and inspect thor- 3. Install the capscrew and washer through the pin
oughly. Repair as necessary. retainer and into the lower support housing.
2. Press new bearings into wheel assemblies. Use Upper and Lower Support Housings
stalling bearings to avoid damage to bearings 1. Install the spherical bearing in the upper support
and/or wheels. See Figure 30. Bearings must be housing. See Figure 33.
replaced in sets.
2. Install the links, linkage pins, and new retain-
3. Install the caster wheels to the axle shaft. ing pins into the lower support housing. See Fig-
ure 28.
(using special tool Hyster P/N 1683617) onto the 3. Install the upper support housing onto the top of
axle shaft. the spring assembly. Ensure the spherical bear-
ing is fully seated.
(100 lbf ft). 4. Install the linkage pins through the links and the
upper support housing. Install the new retaining
6. Ensure the caster wheels rotate freely and pins in the links. If necessary, turn the adjust-
smoothly and are securely mounted on the axle ment screws into the upper support housing to
shaft. Stake the bearing lockwashers in place. gain additional clearance for installing the link-
age.
7. Inspect the cap for damage. Repair or replace
as necessary. Install the caps to the wheels by
tapping around the edge of the caps. Make sure
33
INSTALL 8. Adjust the caster assembly. See Caster Adjust-

ment, in this section.
WARNING
The caster wheel assembly is heavy. Be sure
that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capac-
ity to lift the caster wheel assembly.
1. Insert the caster wheel assembly into the lift

truck frame using a suitable lifting device.
2. While supporting the caster wheel assembly,

install the two capscrews and four washers
through the top frame mount and the top of the
caster wheel assembly. Snug the capscrews, but
DO NOT tighten. Install the shims between the
top frame mount and the caster wheel assembly.
See Figure 36.
3. Install the mounting capscrew from inside the

battery compartment into the upper support
housing. See Figure 27. Snug the capscrew to
hold the caster wheel assembly in place.
4. Loosen the jam nuts and turn the adjustment

capscrews into the upper support housing to al-
low the caster wheel assembly to move freely. See
Figure 36.
5. Remove the lift truck from blocks.
WARNING 1. CAPSCREW
The battery is heavy. Use appropriate lifting 2. WASHER
equipment to avoid personal injury. 3. TOP FRAME MOUNT
4. SHIMS
6. Install the battery. 6. JAM NUT
7. ADJUSTMENT CAPSCREW
7. Install the mast to the lift truck. Refer to Mast,
Repair 4000 SRM 1195. Figure 36. Caster Wheel Assembly Installation
34
1600 SRM 1187 Caster Assembly (Steered)
Caster Assembly (Steered)

DESCRIPTION WARNING
The caster wheel assembly is located on the The battery is heavy. Use appropriate lifting
right-hand side of the lift truck. It is bolted to equipment to avoid personal injury.
the lift truck frame and is shim adjustable to ac-
commodate wear of the caster wheels. The steered
caster wheel assembly has two polyurethane wheels
which are steered by the caster steering motor. See
Figure 37. The two caster wheels are mounted on a
pivoting axle that allows the two wheels to maintain
equal contact with the floor at all times. The caster
wheel assembly is spring loaded to allow the caster
wheels to move up and down with variations in
the floor surface and allow the truck to maintain
four-point contact at all times. The caster wheel
assembly moves up and down within the lift truck
frame on guide bearings mounted to the caster wheel
assembly frame. The caster wheel assembly can be
replaced as a unit or the wheels can be replaced.
The caster steering motor is controlled by the caster

steering controller located beneath the operator com-
partment floorboard. The caster steering controller
receives signals from the steering handle sensor and
sends signals to the caster steering motor controlling
the direction and speed of the caster steering motor.
The steering motor rotates the steering caster wheels
through a gear drive. Motion of the caster wheels is
coordinated with the movement of the MDU to en-
sure proper steering geometry.
NOTE: Always replace the caster wheels as a set for

better caster operation and wheel wear.
REMOVE
1. Remove the mast from the lift truck. Refer to

the battery from the lift truck at the battery con-
nector.
Figure 37. Steered Caster Wheel Assembly
35
Caster Assembly (Steered) 1600 SRM 1187
WARNING WARNING
When lifting the rear of the lift truck frame, The caster wheel assembly is heavy. Be sure
block the front of the load wheels so the lift that all lifting devices (hoists, cables, chains,
truck cannot roll forward while lifting. slings, etc.) are suitable and of adequate capac-
ity to lift the caster wheel assembly.
4. The truck must be raised level and high enough
to remove the caster brake assembly from be- 11. Slowly lower the caster wheel assembly. Remove
neath the truck frame (typically 305 mm (12 in.) the assembly from the lift truck and place the
or higher). The truck should be raised and placed assembly on a clean work surface.
on blocks in a manner to support the truck prop-
erly and in a level position. Make sure the lifting
or jacking equipment is suitable and of adequate
capacity to lift the truck frame. See Periodic
Maintenance 8000 SRM 1197 - How to Put Lift
Truck on Blocks.
5. Remove the caster compartment cover from the

right-hand side of the operator compartment.

6. Disconnect the caster proximity switch wiring

from the main wiring harness. See Figure 38.
7. Remove the floor pad from the operator compart-

ment. Remove the four capscrews retaining the
floor plate to the lift truck frame. Lift the floor
plate and remove the caster wheel steering mo-
tor wiring connector from the controller.
8. Remove the mounting capscrew (1) from the in-

side of the frame.
9. Support the caster wheel assembly with a crane

or other suitable lifting device.
10. From inside the operator compartment, remove 1. CAPSCREW

2. WASHER
the two capscrews (4) and four washers (2, 3) 3. WASHER
from the top of the caster wheel assembly. Retain 4. CAPSCREW
the shims for reuse when installing the caster 5. PROXIMITY SWITCH CONNECTOR
wheel assembly. See Figure 38. 6. SHIMS
Figure 38. Caster Wheel Assembly Mounting
36
DISASSEMBLE
Upper and Lower Support
1. Remove the capscrews and washers (9) retaining
the steering motor to the caster wheel assembly.
Remove the steering motor. See Figure 39.
NOTE: There are no serviceable parts within the

steering motor. A failed steering motor must be
replaced as a complete unit.
2. Remove the retaining pins from the links on both

sides of the caster wheel assembly.
3. Remove the four links from the linkage pins and

remove the four linkage pins from the two pieces
of the caster wheel assembly.
4. Remove the upper support housing from the

lower support housing and set the upper support
housing to the side.
Spring Assembly From Lower Support

Housing
Refer to Figure 39 for the following instructions.
1. Remove the capscrew (6) from the side of the

lower support housing and remove the pin (7)
holding the spring assembly to the lower support
2. Remove the spring assembly. 1. RETAINING PIN

2. LINK
3. Repair the spring assembly as necessary. See 3. LINKAGE PIN
Replace Spring Pack in this section. 4. UPPER SUPPORT HOUSING
6. CAPSCREW
7. PIN
8. SPRING ASSEMBLY
9. CAPSCREWS AND WASHERS
10. STEERING MOTOR
Figure 39. Caster Wheel Assembly
37
Caster Spindle From Lower Support Caster Wheels

1. Use a punch to fold down the retaining tabs on For the following instructions, refer to Figure 41.
the locking washer.
2. Remove the bearing lock nut (using special tool CAUTION

Hyster P/N 1683617), locking washer, and spacer Replace bearings in sets to maintain proper
securing the caster spindle to the lower support wheel loading and operation.
3. Slide the spindle out of the bearing in the lower wheel. The wheels should have no side-to-side
support housing. free play and should turn smoothly. If the wheels


washer.
CAUTION
wheel.

Pressing on the inner race will damage the
bearing.
5. Remove the bearing by driving it from the wheel

6. Inspect the caster wheel for damage to the

or wheel material. Replace any wheel that is
chunks of the outside material missing. Replace
wheels in sets if damaged.
1. SPACER
2. BEARING LOCK NUT
3. LOCKING WASHER
Figure 40. Caster Wheels From Lower Support
38
WARNING
CAUTION
avoid damage to the bearings and/or lower
support housing.

pressing or tapping on the outer race of the
bearing only. Pressing or tapping on the inner
race will damage the bearing.

2. Inspect the lower support housing bearing by ro-

tating it. If the bearing is worn or rough, it
should be replaced.

port housing. Press or tap out the old bearing.
1. BEARING CAP 4. Remove the capscrew retaining the steering stop
3. BEARING LOCK NUT pin and remove the pin.
4. CASTER WHEEL
5. AXLE SHAFT 5. Lift the caster gear slightly and slide the gear out
6. BEARING the side of the lower support housing.
Figure 41. Caster Wheels 6. Check all bushings for wear. Bushings should
(0.878 to 0.879 in.).
39
1. GUIDE BEARING
Figure 43. Guide Bearings
1. RETAINING RING Upper Support Housing

2. BEARING
3. CAPSCREW For the following instructions, refer to Figure 44.
4. STEERING STOP PIN
5. CASTER GEAR
6. BUSHINGS CAUTION
Figure 42. Lower Support Housing minum driver when removing bearings to
avoid damage to the bearings and/or upper
7. Press the bushings out of the lower support hous-
support housing.
ing using a suitable brass or aluminum driver if
replacement is needed. 1. Press the spherical bearing from the upper sup-
port housing.
8. Remove any worn guide bearings from the sides
of the lower support housing. See Figure 43. 2. Remove the two adjustment capscrews and jam
The guide bearing should be replaced if less than nuts.
9.9 mm (0.39 in.) in length.
40
3. Check all bushings for wear. Bushings should 3. Retain the key to the motor shaft.
(0.878 to 0.879 in.).
4. Press the bushings out of the upper support hous-

ing if replacement is needed.
1. SPHERICAL BEARING
3. JAM NUT
4. BUSHING
Figure 44. Upper Support Housing
Caster Steering Motor

1. Remove the capscrew and washers from the end 1. GEAR 3. WASHER
of the caster steering motor shaft. See Figure 45. 2. WASHER 4. CAPSCREW
2. Remove the drive gear from the end of the shaft. Figure 45. Caster Steering Motor
41
ASSEMBLE housing using a suitable driver and install the

bushings to be recessed 1 mm (0.04 in.) from the
Caster Steering Motor outside surface of the upper support housing. See
Figure 46.
1. Insert the key supplied with the motor into the
motor shaft.
2. Slide the drive gear onto the motor shaft fully

engaging the key.
3. Remove the old threadlock residue from the gear

mounting capscrew. Apply Loctite® 242 to the
capscrew and install the washers and capscrew
onto the bottom of the motor shaft. See Fig-
ure 45.
Upper Support Housing

WARNING
CAUTION
ings and/or upper support housing.
1. Clean all parts with solvent. Thoroughly inspect

and repair as necessary.
2. Press the spherical bearing into the upper sup-

port housing and ensure that the bearing is fully
seated.
3. Replace the adjustment capscrews and jam nuts,

if damaged. Install the adjustment capscrews 1. UPPER SUPPORT HOUSING
and jam nuts. 2. 1.0 mm (0.04 in.)
3. BUSHING
4. Install the bushings into the upper support hous-
ing. Press the bushings into the upper support Figure 46. Bushing Installation
42
Lower Support Housing be shimmed to be 2 mm (0.079 in.) less than the

frame opening for the caster wheel assembly. See
Figure 47. Measure the frame opening and shim
CAUTION the guide bearings evenly to obtain the correct
The bearing set in the lower support housing dimension. Tighten all hardware.
is sealed and lubricated for the life of the bear-
ing. DO NOT attempt to lubricate or clean the
bearing set.

ings and/or lower support housing.
1. Press the bearing set into the lower support

housing until fully seated. See Figure 42.
WARNING
2. Install the retaining ring in the lower support

housing.
3. Slide the gear into the lower support housing

with the steering stop pin groove facing up.
4. Install the steering stop pin. Ensure the pin is

inserted into the groove in the top of the gear.
5. Install the capscrew and washer to retain the

steering stop pin.
6. Install bushings if removed during disassembly. 1. FRAME OPENING

2. GUIDE BEARING
7. Install the guide bearings onto the sides of the
lower support housing. The guide bearings must Figure 47. Guide Bearing Shimming
43
Caster Wheels 3. Install the bearing washer and bearing lock nut
(using special tool Hyster P/N 1683617) on the
WARNING shaft.
Cleaning solvents can be flammable and toxic 4. Torque the bearing lock nut to 136 N•m
and can cause skin irritation. Wear protection (100 lbf ft) and stake the bearing washer to
when handling solvents and always follow the the bearing lock nut.
CAUTION proper installation of the new switch.
The bearings are replaced by pressing on the NOTE: Because the proximity switch gap distance
outer race of the bearing only. Pressing or tap- is not easily measurable, the distance can be deter-
ping on the inner race will damage the bear- mined by the number of turn of the proximity switch
ing. Use a suitable brass or aluminum driver off the top of the target gear surface. Adjustment of
when installing bearings to avoid damage to 1 to 1-1/4 turns off the target gear surface face is ap-
bearings and/or caster wheel. proximately 1.016 to 1.270 mm (0.040 to 0.050 in.)
gap distance).
wheel loading and operation. 5. Install the jam nut to the switch shaft in the
same position. Apply antiseize lubricant lightly
to the threads of the new switch shaft and install
oughly. Repair as necessary.
to the caster by turning clockwise as removed.
2. Press new bearings into wheel assemblies. Use Adjust the proximity switch to obtain a gap of 1.0
a suitable brass or aluminum driver when in- ±0.5 mm (0.039 ±0.020 in.) between the end of
stalling bearings to avoid damage to bearings the proximity switch and the target (gear). See
and/or wheels. See Figure 41. Bearings must be Figure 48. Lock the proximity switch in place
replaced in sets. with the jam nut on the switch.
3. Install the caster wheels to the axle shaft.

(using special tool Hyster P/N 1683617) onto the
axle shaft.

(100 lbf ft).
6. Ensure the caster wheels rotate freely and

smoothly and are securely mounted on the axle
7. Inspect the cap for damage. Repair or replace

as necessary. Install the caps to the wheels by
tapping around the edge of the caps. Make sure
Caster Spindle to Lower Support

1. Install the square key in the caster wheel shaft.
1. PROXIMITY SWITCH
2. Insert the caster wheel shaft through the bear- 2. ADJUSTMENT GAP
ing set and gear in the lower support housing.
Ensure the key fully engages the gear. See Fig- Figure 48. Proximity Switch Adjustment
ure 40.
44
Spring Assembly to Lower Support 2. While supporting the caster wheel assembly,
install the two capscrews and four washers
NOTE: Repair the spring assembly as necessary. See through the top frame mount and the top of the
Replace Spring Pack in this section. caster wheel assembly. Snug the capscrews, but
DO NOT tighten. Install the shims between the
top frame mount and the caster wheel assembly.
1. Install the spring assembly into the lower sup- See Figure 49.
port housing.
2. Install the pin through the lower support housing

and spring assembly.
3. Install the retaining capscrew and washer

through the pin retainer and into the lower
support housing.
Upper and Lower Support Housings

1. Install the spherical bearing in the upper support
2. Install the links, linkage pins, and new retain-

ing pins into the lower support housing. See Fig-
ure 39.
3. Install the upper support housing onto the top of

the spring assembly. Ensure the spherical bear-
ing is fully seated.
4. Install the linkage pins through the links and the

upper support housing. Install the new retaining
pins in the links. If necessary, turn the adjust-
ment screws into the upper support housing to
gain additional clearance for installing the link-
age.
1. CAPSCREW
5. Install the caster wheel steering motor into the 2. WASHER
caster wheel assembly. Ensure the drive gear on 3. TOP FRAME MOUNT
the steering motor meshes with the caster wheel 4. SHIMS
gear. 5. UPPER SUPPORT HOUSING
6. JAM NUT
6. Install the four mounting capscrews and wash-
ers. Torque the capscrews to 23 N•m (17 lbf ft). Figure 49. Caster Wheel Assembly Installation
INSTALL 3. Install the mounting capscrew from inside the

battery compartment into the upper support
WARNING housing. See Figure 38. Snug the capscrew to
The caster wheel assembly is heavy. Be sure hold the caster wheel assembly in place.
that all lifting devices (hoists, cables, chains, 4. Loosen the jam nuts and turn the adjustment
slings, etc.) are suitable and of adequate capac- capscrews into the upper support housing to al-
ity to lift the caster wheel assembly. low the caster wheel assembly to move freely. See
1. Insert the caster wheel assembly into the lift Figure 49.
truck frame using a suitable lifting device. 5. Connect the caster proximity switch wiring to the
main wiring harness.
45
6. Connect the caster steering motor wiring to the

caster steering controller located beneath the op- WARNING
erator compartment floor. Ensure the wiring is The battery is heavy. Use appropriate lifting
properly routed and installed in all wiring clips. equipment to avoid personal injury.
Lower the floor plate. Install the four capscrews
retaining the floor plate to the lift truck frame. 8. Install the battery.
Install the floor pad to cover the operator com- 9. Install the mast to the lift truck. Refer to Mast,
partment floor. Repair 4000 SRM 1195.
7. Remove the lift truck from blocks. 10. Adjust the caster assembly. See Caster Adjust-
ment, in this section.
Troubleshooting
Most troubleshooting procedures can be accom- Use the dash display menus and the troubleshooting
plished using the on-board diagnostic menus avail- fault codes to help identify and correct the problem.
able through the dash display. The service menus
will allow you to check the status and operation of If the steering system still does not operate correctly
most steering system electrical components. after verifying the correct performance of the elec-
trical components, check the system for mechanical
When a fault occurs, a fault code is displayed on the binding.
dash display. A description of these fault codes and
troubleshooting instructions can be found in section Ensure the gear drives are meshing properly and are
AC Motor Controllers/Display Panel, Descrip- not prevented from rotating due to debris.
tion, Checks, Adjustments, and Troubleshoot-
Ensure the MDU bearing is operating smoothly and
ing 2200 SRM 1190 or AC Motor Controllers/Dis-
does not need service or repair.
play Panel, Description, Checks, Adjustments,
and Troubleshooting 2200 SRM 1308. Instruc- Ensure the caster wheel assembly can rotate freely.
tions for navigating the dash display menu system
can be found in section User Interface, Service
Technician (Standard Display) 2200 SRM 1193.
46
TROUBLESHOOTING
AND ADJUSTMENTS
USING THE AC
CONTROLS PROGRAM
(ETACC)
J2.00-3.20XM (J40-65Z) [A416/B416]; V30ZMD [D210/E210];
E3.50-5.50XL (E70-120Z, E100ZS) [D098/E098];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108]; J1.60-2.00XMT (J30-40ZT) [J160];
N30ZDRS, N35-40ZRS [A265]; N35ZDR, N45ZR [C264]; N30ZDR,
N35-40ZR [D470]; B60Z AC [B230]; B80Z AC [B233]; T5Z AC [B476];
T7Z AC [B477]; C60Z AC [B478]; C80Z AC [B479]
PART NO. 1534737 2200 SRM 1058

Troubleshooting and Adjustments Using the AC Controls Program (ETACC) Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Computer Requirements ............................................................................................................................... 1
Software, Install ............................................................................................................................................ 1
Language Selection........................................................................................................................................ 1
Demo Mode..................................................................................................................................................... 2
Connect PC to Lift Truck............................................................................................................................... 6
Starting AC Controls Program ..................................................................................................................... 8
Lift Truck Control Setup ................................................................................................................................... 12
Change Lift Truck Serial Number or Hourmeter ........................................................................................ 12
Setting Factory Default Values or Changing Lift Truck Parameters ......................................................... 14
Create New Custom Lift Truck Configuration............................................................................................. 20
Lift Truck Configuration Properties ............................................................................................................. 23
Import New Lift Truck Configuration From Disk ....................................................................................... 26
Delete Custom Lift Truck Configuration or Password File......................................................................... 28
Dash Display ...................................................................................................................................................... 31
Custom Display Languages .......................................................................................................................... 31
Download Display Language ........................................................................................................................ 33
Clear Operator Log ........................................................................................................................................ 33
Password Functions ........................................................................................................................................... 36
Enable/Disable Password and Lift Truck Inspection Functions ................................................................. 36
Truck Inspection Checklist ....................................................................................................................... 36
Password .................................................................................................................................................... 36
Password Properties ...................................................................................................................................... 36
Create New Password File ............................................................................................................................ 41
Download Passwords ..................................................................................................................................... 43
Upload Passwords.......................................................................................................................................... 43
Reports Menu ..................................................................................................................................................... 47
Devices Report ............................................................................................................................................... 47
Custom Report ............................................................................................................................................... 47
Password Report ............................................................................................................................................ 47
Operator Report ............................................................................................................................................. 54
Current Settings Report................................................................................................................................ 57
Status Code Report........................................................................................................................................ 60
Status Codes Log ........................................................................................................................................... 63
Diagnostics ..................................................................................................................................................... 65
Help Menu .......................................................................................................................................................... 68
General ........................................................................................................................................................... 68
Contents ......................................................................................................................................................... 68
Technical Support .......................................................................................................................................... 68
About Electric Truck AC Controls Program................................................................................................. 68

Table of Contents Troubleshooting and Adjustments Using the AC Controls Program (ETACC)

J2.00-3.20XM (J40-65Z) [A416/B416];

V30ZMD [D210/E210];
E3.50-5.50XL (E70-120Z, E100ZS) [D098/E098];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
J1.60-2.00XMT (J30-40ZT) [J160];
N30ZDRS, N35-40ZRS [A265];
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
B60Z AC [B230];
B80Z AC [B233];
T5Z AC [B476];
T7Z AC [B477];
C60Z AC [B478];
C80Z AC [B479]
ii
General
The information contained in this manual gives the To run the setup program, follow these steps:
user a brief overview of the Electric Truck AC Con-
trols Program. This manual also explains the com- 1. Place the CD in the CD-ROM drive. Installation
mon drop-down menu features for the user that are will start automatically if the computer is set for
listed under the File menu, the Reports menu, the automatic startup. If the computer is not set for
Tools menu, and the Help menu. automatic startup, go to Step 2.
A personal computer (PC) can be used to set the trac- 2. Click Start.
tion motor and pump motor controller functions, read
3. Select Run and in the Open line enter
status codes, and perform numerous diagnostic and
D:\disk1\setup.exe.
troubleshooting functions.
4. Click OK. The setup program will guide you
COMPUTER REQUIREMENTS through the rest of the steps to install the Elec-
tric Truck AC Controls Program Hyster on the
The PC must have the following minimum configu-
computer.
ration:
It is recommended that the program is installed to
1. Microsoft Windows 2000™ or later operating
the default directories.
system must be installed.
2. There must be an open Universal Serial Bus LANGUAGE SELECTION

(USB) port available on the computer to connect
1. When the program is first installed the language
to the lift truck.
setup screen will appear. Click on the down ar-
3. There must be a compact disk read-only-memory row to see the languages to be selected. Select
(CD-ROM) drive installed on the computer. the desired language from the list. See Figure 1.
The Electric Truck AC Controls Program Hyster
4. Microsoft Internet Explorer™ Version 5.01 text will appear in the selected language.
or later must be installed on the computer.
5. The display screen resolution should be set to

800×600 pixels.
SOFTWARE, INSTALL
NOTE: See instructions included with CD, Hyster
part number 1539240 (Initial Installation), and/or
readme.txt file on the CD for additional instruc-
tions and possible password requirements.
NOTE: You must have Administrator rights to in-

stall this software on a PC. After installation, folders
"EVS" and "Program Files/ETACC HYSTER/" and
their sub-folders must have their security permis-
sions set to allow full control.
NOTE: When installing the software on a PC with

Microsoft Windows 2000 or a later Operating Sys-
tem, make sure that the computer is setup with Ad-
ministrator rights on the computer.
NOTE: In the following examples, the D: drive repre- Figure 1. Language Selection
sents the CD-ROM drive. The CD-ROM drive could
be a different letter on the computer.
1
2. After initial installation, if the selected language DEMO MODE

is to be changed, click File and select Settings
from the drop down menu. A Settings pop-up box 1. Select Settings from the File menu. A Set-
will appear on the screen. See Figure 2. Click the tings pop-up box appears with a Communica-
language tab and click on the down arrow. A drop tion, Language, General, and Window tab.
down list of languages will appear. Select one of See Figure 3.
the following languages from the list:
NOTE: In the Settings dialog box, on the Commu-
• English
nication tab, if the Normal button is selected, the
• German
system is in the default status for operation and must
• French
be connected to an actual lift truck. See Figure 3.
• Italian
• Spanish If the Demo button is selected, the program is in the
demonstration mode, and the program can be oper-
ated without being connected to an actual lift truck.
See Figure 3.
2. Select the Communication tab and click the

Demo selection.
2
Figure 2. Language Options
3
Figure 3. Settings Menu (Sheet 1 of 2)
4
Figure 3. Settings Menu (Sheet 2 of 2)
5
CONNECT PC TO LIFT TRUCK the main contactor. See Figure 5. On mod-

els N30ZDRS, N35-40ZRS (A265), N35ZDR,
To connect the Interface Cable Kit Hyster part num- N45ZR (C264), N30ZDR, N35-40ZR (D470),
ber 1534010 to the lift truck wire harness, follow remove the cap covering the connector on
these steps: the front frame panel. See Figure 6. On
models J2.00-3.20XM (J40-65Z) (A416/B416),
1. Connect the USB connector of the Interface Ca-
V30ZMD (D210/E210), E1.50-2.00XM (E25-40Z)
ble to the USB port on the PC. See Figure 4.
(E114/F114), E2.00-3.20XM (E45-65Z) (G108),
and E3.50-5.50XL (E70-120Z) (D098/E098), con-
nect to the wiring harness three-pin connector
which is located behind the dashboard cowl liner
cutout under the dash display. See Figure 4. The
connection between the PC and lift truck is now
complete.
1. INTERFACE CABLE
2. LAPTOP COMPUTER
3. INTERFACE CABLE EXTENSION
4. LIFT TRUCK WIRING HARNESS
Figure 4. Interface Cable Kit Connected to USB

Connector
2. If provided, connect the nine-pin connector of the

Interface Cable extension to the Interface Cable.
See Figure 4.
3. Disconnect the battery connector or depress the

battery disconnect switch if the lift truck is so 1. MAIN CONTACTOR
equipped. See Figure 7. 2. ETACC CONNECTION
3. INTERFACE CABLE
4. Connect the three-pin connector of the Inter-
face Cable to the lift truck ETACC connector. Figure 5. ETACC Connection - B60Z AC, B80Z AC,
On models B60Z AC (B230), B80Z AC (B233), C60Z AC, C80Z AC, T5Z AC, and T7Z AC [B230, B233,
C60Z AC (B478), C80Z AC (B479), T5Z AC (B476), B478, B479, B476, and B477]
and T7Z AC (B477), the ETACC connector is lo-
cated inside the drive unit compartment below
6
5. Connect the battery connector, or lift the red

battery disconnect button, if the lift truck is so
equipped. See Figure 7.
6. Turn the key switch to the ON position. See Fig-

ure 7.
1. ETACC CONNECTOR (CAP INSTALLED)

2. 12V POWER CONNECTION
3. FRONT FRAME COVER (RH) 1. BATTERY DISCONNECT SWITCH
4. MAST 2. KEY SWITCH
Figure 6. N30ZDRS, N35-40ZRS, N30-35ZDR, Figure 7. Power Switches - J2.00-3.20XM

and N35-40-45ZR [A265, C264, and D470] (J40-65Z) [A416/B416] Models Only
ETACC Connector
7
STARTING AC CONTROLS PROGRAM 2. Double-click the Electric Truck AC Controls Pro-

gram Hyster icon located on the desktop. See
1. Connect the PC to the lift truck. See Connect PC Figure 8.
to Lift Truck.
Figure 8. Desktop
8
3. Click the appropriate Factory or Custom file

folder for correct configuration of the lift truck.
See Figure 9.
Figure 9. Connected to Lift Truck
9
4. Select Connect on the File menu, or click the icon changes to an arrow → which indicates connec-
Connect icon on the toolbar menu in the upper tion and communication between the computer and
left corner. See Figure 9 and Figure 10. lift truck. See toolbar icon Figure 9.
NOTE: On the computer, under the Views menu, the

red X that appears in the Computer Connection
Figure 10. File Menu, Connect PC to Lift Truck
10
NOTE: If the connection fails between the computer computer and the lift truck. Also, check that the
and lift truck, an error screen will appear. See Fig- battery connect/disconnect switch is engaged, if so
ure 11. equipped, and that the key switch is in the ON
position.
NOTE: If this connection error appears on the com-
puter screen, check all connections between the
Figure 11. Communication Error PC to Lift Truck
11
Lift Truck Control Setup 2200 SRM 1058
Lift Truck Control Setup

This section includes the following processes: model. See Figure 12. A dialog box pops up with
• Change Lift Truck Serial Number and the following information on the lift truck. See
Hourmeter Figure 13.
• Setting Factory Default Values or Changing
Lift Truck Parameters Parameter: Represents the lift truck function name
• Create New Custom Lift Truck Configuration that can be setup on the lift truck and is changeable.
• Lift Truck Configuration Properties The items that are listed in this column are: lift truck
• Import New Lift Truck Configuration from serial number, traction hours, and pump hours.
Disk
NOTE: The New Value column should be blank, un-
• Delete Custom Lift Truck Configuration or
less the user has entered new values in this column
Password File
before downloading this information to the lift truck
display panel.
CHANGE LIFT TRUCK SERIAL NUMBER
OR HOURMETER NOTE: If the Master Controller is replaced, the lift
truck serial number SHOULD be entered in the
1. From the Views menu, click Individual Setup New Value column.
or Truck Infomation depending on truck
Figure 12. View Menu Individual Setup
12
2200 SRM 1058 Lift Truck Control Setup
Figure 13. Individual Setup Menu
New Value: Displays the new value input by the 3. Click Download button to download New Val-
user. ues to the lift truck.
Truck Value: Displays values for that specific lift NOTE: If the traction motor or pump motor is re-
truck that have been stored in the lift truck master placed, the traction or pump hours can be changed to
controller. zero. If the Master controller is replaced, the Truck
Value will be shown as zero for the hourmeters.
2. Input desired values in the New Value column. They can be updated, if desired, from this screen.
13
SETTING FACTORY DEFAULT VALUES OR Value. The Truck Value can be changed in this
CHANGING LIFT TRUCK PARAMETERS column.
NOTE: Make sure there is a connection between the Truck Value: Represents the actual value that
lift truck and the computer before making adjust- has been stored in the lift truck control.
ments through the Views menu. See the Connect
NOTE: If there is a difference in value between
PC to Lift Truck section for more information.
the Factory/Set Value column and Truck Value
1. Select a Custom Configuration file or Factory column, the row where the difference occurs will be
Configuration file from the drop-down list. highlighted in yellow. This indicates that the current
lift truck value is NOT at the default setting.
2. From the Views menu, click System Setup,
Factory Setup, Set Performance, or Prefer- NOTE: All values in the Factory/Set column will be
ence Adjustment, depending on truck model. downloaded to the lift truck when the Download
See Figure 14 for lift trucks with the following Button is clicked.
Unit Codes: A416, B416, D098, D210, E098,
3. To change a value in the Truck Value column,
E114, E210, F114, and G108.
click on the item to be changed in the Factory/
See Figure 15 for the following Unit Code: J160.
Set column.
See Figure 16 for the Unit Codes: A265, C264,
and D470. NOTE: The new value must be entered in the Fac-
See Figure 17 for the Unit Codes: B230, B233, tory/Set Value column and downloaded to the lift
B478, B479, B476, and B477. truck to change the Truck Value column.
A System Setup-Connected dialog box pops up
with the following information on the lift truck. 4. Enter the new value in the Factory/Set Value
See Figure 18 and Figure 19. column.
Parameter: Represents functions that can be 5. Click the Download button to download the new
setup on the lift truck and are changeable. values to the lift truck. See Figure 19.
Factory/Custom Value: Represents the value 6. Click the Apply button to save Custom Values to
for either the Factory Configuration or Custom the Custom Configuration file. See Figure 18.
14
Figure 14. Views Menu System Setup, J2.00-3.20XM (J40-65Z) (A416/B416), V30ZMD (D210/E210),
E1.50-2.00XM (E25-40Z) (E114/F114), E2.00-3.20XM (E45-65Z) (G108), and E3.50-5.50XL (E70-120Z)
(D098/E098)
15
Figure 15. Views Menu System Setup, J1.60-2.00XMT (J30-40ZT) (J160)
16
Figure 16. View Menu Factory Setup N30ZDRS, N35-40ZRS (A265), N35ZDR, N45ZR (C264),
N30ZDR, N35-40ZR (D470)
17
Figure 17. View Menu Factory Setup - B60Z AC (B230), B80Z AC (B233), C60Z AC (B478), C80Z AC (B479),
T5Z AC (B476), and T7Z AC (B477)
18
Figure 18. Custom Configuration Setup
19
Figure 19. System Setup Change Screen
CREATE NEW CUSTOM LIFT TRUCK 4. In the New Configuration dialog box, in the
CONFIGURATION Configuration Name line, type the Configura-
tion Name of the truck. For example, the Mid-
NOTE: Before changing cables between lift trucks, night Shift Truck is displayed in the Configura-
make sure the previous lift truck information is tion Name line. See Figure 21.
saved on the computer, or the information will be
lost and need to be reentered. NOTE: The performance settings of the Factory
Configuration file will be copied into the Custom
1. Click the Connect/Disconnect icon to discon- Configuration file as a starting point for customiz-
nect the computer from the lift truck. ing.
2. Disconnect the Interface Cable from the three- 5. In the Copy Factory Configuration line,
pin connector located behind the dashboard cowl click on a file in the drop-down menu that
liner cutout under the dash display. will customize the truck. For example,
E1.50XM-2.00XMS is displayed in the Copy
3. Click New Truck Configuration in the File Factory Configuration line.
menu, or click the New Truck Configuration
File icon on the toolbar. See Figure 20. 6. Click OK.
20
Figure 20. New Truck Configuration
21
Figure 21. Completed New Truck Configuration
22
NOTE: The new file name appears in the Cus- 2. Select Properties from the File menu or right-
tom Configuration file folder. For example, the click the mouse and select Properties from the
4-Wheel Special is displayed in the Custom Con- pop-up box. See Figure 22.
figuration file folder. See Figure 21.
The Properties dialog box pops up and contains
7. Select the new Custom Configuration file in the the following information on the lift truck. See
Custom Configuration folder. Figure 23.
8. Connect the Interface Cable to the three-pin con- File Name: Identifies the name of the Truck Con-
nector, located behind the dashboard cowl liner figuration File. For example, E1.50XM-2.00XMS is
cutout under the dash display, to the lift truck to the truck configuration file.
be customized.
Location: Identifies the directory path to the Truck
9. Enter the customized information for the lift Configuration File.
truck. See Setting Factory Default Values or
Changing Lift Truck Parameters. Truck Type: Identifies the truck configuration’s ref-
erence to a lift truck model.
10. Click the Connect/Disconnect icon to connect
the computer to the lift truck. Article Number: Indicates the control types and
software numbers used on the lift truck.
LIFT TRUCK CONFIGURATION
Passwords File: Refers to the current password file
PROPERTIES associated with the lift truck configuration.
There are various lift truck properties that can be 3. To change the Password File, select a different
viewed on the computer. These properties are: Lift password from the drop-down list and click OK.
Truck Configuration Properties and Password For example, 4-Wheel Special is selected. See
Properties. This section will deal only with Lift Figure 24.
Truck Configuration Properties. To view Pass-
word Properties, go to Password Properties.
1. Select a lift truck in Custom Configurations

folder or Factory Configurations folder. See
Figure 22.
23
Figure 22. Truck Configuration Selections
24
Figure 23. Lift Truck Properties
25
Figure 24. Passwords File
IMPORT NEW LIFT TRUCK 3. Select the disk drive where the CD is located
CONFIGURATION FROM DISK from the Look in line in the Import Configu-
ration Files dialog box. See Figure 25.
NOTE: The import feature is used to update the Elec-
tric Truck AC Control Program Hyster with new in- 4. Select the file to be imported. Click Open. The
formation through an update CD. new file is imported and updates the Electric
Truck AC Control Program Hyster.
1. Place the update CD in the CD-ROM drive.
2. Select Import from the File menu. An Import

Configuration Files dialog box pops up. See
Figure 25.
26
Figure 25. Import Configuration Files
27
DELETE CUSTOM LIFT TRUCK 3. A Confirm Configuration Delete dialog box

CONFIGURATION OR PASSWORD FILE will appear to confirm the deletion of the selected
configuration or passwords. See Figure 27.
NOTE: Delete can be used to remove either a Custom
Configurations file or a Passwords file. 4. Click the Yes button in the Confirm Configu-
ration Delete dialog box to delete the Custom
1. Click on the Custom Configurations file or Configurations file or Passwords file. Click
Passwords file to be deleted. the No button to cancel this selection in the Con-
firm Configuration Delete dialog box.
2. Select Delete from the File menu, or right-click
the mouse on the selected drop-down Custom
Configuration file or Passwords file and select
Delete. See Figure 26.
28
Figure 26. Delete Configuration
29
Figure 27. Delete Configuration Confirmation
30
2200 SRM 1058 Dash Display
Dash Display
This section contains the following processes: Cus- NOTE: The Custom Display Languages table is a
tom Display Language which allows technicians to two-column table. The left column is the Select
create a language that is not loaded in the system. Standard Language line that is the current lan-
Download Display Language which allows cus- guage on the computer. The right column is where
tomized changes to be downloaded to the lift truck. the customized language will appear.
Clear Operator Log allows the operator log to be
cleared from the display after the log has been either 2. Click the Select Standard Language line; a
saved or printed. drop-down list will appear containing English,
French, German, Italian, or Spanish. See Fig-
CUSTOM DISPLAY LANGUAGES ure 29.
1. Click Custom Display Languages on the 3. Select one of the drop-down list languages.
Tools menu. See Figure 28.
Figure 28. Tools Menu Custom Display Languages
31
Dash Display 2200 SRM 1058
Figure 29. Custom Display Languages
32
NOTE: The right column is the Select Custom Lan- Language line will automatically be moved to the
guage line. This gives the operator the ability to cre- Custom Language line.
ate a custom language or pick a different language
that is not included in the Standard Language list. NOTE: If more Custom Language changes need to
For example, a technician may use different termi- be made later to the same lift truck, the user can
nology than the terminology shown in the Standard return to the Custom Display Language section
Language line. The Custom Language line allows and enter those changes to the same lift truck.
new terms to be cross-referenced to the same term in
the Standard Language line. DOWNLOAD DISPLAY LANGUAGE
NOTE: The Custom Language line allows only a The Download Display Language allows changes
20-character description for the new term. that were made in the Custom Display Language to
be downloaded to the current connected truck. See
4. Click Select Custom Language line. A Figure 30.
drop-down list will appear containing previ-
ously installed custom languages or customer 1. Select Download Display Language from the
created languages. Tools menu.
To create a Custom Language or make a change from 2. Select the desired language from Select Lan-
the Standard Language line to the Custom Lan- guage drop-down box. See Figure 30.
guage line, follow these steps:
3. Click the download button.
5. Click the New Custom Language button. See
NOTE: The Language Download may take a few mo-
Figure 29.
ments to download the information to the lift truck.
6. Enter the appropriate name or term in the New
Language dialog box. CLEAR OPERATOR LOG
7. Click the Add button. The new language ap- NOTE: The Operator Log can store 1,700 en-
pears in the Select Custom Language line. tries/changes before the first entry is overwritten
and PERMANENTLY removed. Make sure you
8. Place the cursor in the Custom Language line want to overwrite the Operator Log before contin-
across from a term in the Standard Language uing with this process. To avoid overwriting the
line. Operator Log, it can be saved to another file or
printed. See Reports Menu.
9. In the Custom Language line, enter the new
language or new terminology. Repeat Step 8 and 1. Select Clear Operator Log from the Tools
Step 9 until all desired Custom Language lines menu. See Figure 31.
are changed.
2. The Clear Operator Log dialog box will pop up,
10. Click Save. click the Yes button to clear the Operator Log or
click the No button to cancel this operation.
NOTE: If there are rows where No Custom Language
changes were made, the text from the Standard
33
Dash Display 2200 SRM 1058
Figure 30. Download Display Language
34
Figure 31. Tools Menu, Clear Operator’s Log
35
Password Functions 2200 SRM 1058
Password Functions
This section contains the following processes: and add or remove user names. The user can also
• Enable/Disable Password and Lift Truck In- display, edit, and save mode levels and operator/ser-
spection functions vice settings.
• Password Properties
• Create New Password File 1. Select the Password File. See Figure 33.
• Download and Upload Passwords
2. The Password File Properties pop-up box ap-
pears. It contains the following information. See
ENABLE/DISABLE PASSWORD AND LIFT
Figure 34.
TRUCK INSPECTION FUNCTIONS
NOTE: To edit the table, use the left arrow (←) and
Click Display Setup from the Views menu. See Fig- right arrow (→) keys to move between columns, use
ure 32. the up (↑) and down (↓) arrows to move between the
The Display Setup Connected dialog box will pop rows or use a mouse to select the desired column or
up and allow the user to enable or disable the lift row and left click the mouse. The table can be sorted
truck inspection checklist and password functions. by columns by clicking on any of the column headers.
Password: Identifies the numeric password as-

Truck Inspection Checklist signed to a specific user.
If this option is enabled, the Truck Inspection List User Name: Identifies the Operator or Service
must be completed each time before operating the lift Personnel assigned to the password.
truck. The items in the Truck Inspection List are
answered by pressing the 1 key for YES or the 4 key Mode: Identifies the maximum performance set-
for NO. ting for the user.
NOTE: If an item in the Truck Inspection List is Type: Identifies the user as an Operator or Ser-
answered with a NO response and the action is not vice Personnel.
corrected or repaired, the lift truck traction speed
will be reduced by one-half speed until the problem 3. To select Mode, click on the drop-down list, select
is corrected or repaired. 1 through 4. See Figure 35.
Password 4. To select Type, click on the drop-down list, select

Operator or Service Personnel.
NOTE: If the Truck Inspection Checklist is en-
abled, the checklist CANNOT be performed until 5. To add a new password, click the Add Password
a correct password has been entered in the display button. To remove a password, select the pass-
panel. word to be removed and click the Remove Pass-
word button.
If this option is enabled, the user is required to enter
a five-digit password before the lift truck can be op- 6. When finished editing the Password File Prop-
erated. erties dialog box, click Save or OK to save the
Password File.
PASSWORD PROPERTIES
With this feature, the user can display, edit, and save
passwords (service technician or lift truck operator),
36
2200 SRM 1058 Password Functions
Figure 32. Tools Menu, Display Setup and Change Menu
37
Figure 33. Passwords Folder
38
Figure 34. Password File Properties Table
39
Figure 35. Password File Editing
40
CREATE NEW PASSWORD FILE 2. In the New Passwords dialog box, enter the
new password file name in the Passwords File
1. Click New Passwords from the File menu, or Name line and select an existing password file
select an existing Password file from the Pass- from the Copy passwords from drop-down list,
words folder, right-click the mouse, and select if applicable. See Figure 37.
New from the pop-up box. A New Password
File pop-up box will appear on the computer 3. Click OK. The New Passwords file is created
screen. See Figure 36 and Figure 37. and placed in the Passwords folder.
Figure 36. File Menu New Password Selection
41
Figure 37. New Passwords File Box
42
DOWNLOAD PASSWORDS 4. Click the Download button and the Download

Passwords file will be downloaded to the lift
This function will download passwords from a pass- truck. See Figure 39.
word file to the master controller on the lift truck.
If a password file does not exist, it must be created UPLOAD PASSWORDS
before continuing with this section. See Create New
Password File. This function will upload all passwords currently
stored in the selected lift truck’s master controller
NOTE: Before downloading passwords, make sure to a computer file.
the computer is logged onto the correct lift truck.
1. Select Upload Passwords from the Tools
1. Select the lift truck from the Custom Configu- menu. See Figure 40.
rations list. If a custom configuration does not
exist for the truck, see Create New Custom Lift 2. Enter the desired file name in the Save to Pass-
Truck Configuration. Right-click the mouse and word File box.
select Properties from the pop-up box. See Fig-
ure 38. 3. Click OK and the file will be saved and appear in
the Passwords folder.
2. In the Configurations section in the Proper-
ties dialog box in the Password File line, click NOTE: To sort columns, click the column header.
the drop-down arrow and select the file to down-
4. Click Cancel and the file will not be saved or
load. See Figure 38. Click OK.
appear in the Passwords folder.
3. From the Tools menu, select Download Pass-
words.
NOTE: Check the File Name of the displayed file to

make sure it is the correct file to be downloaded.
43
Figure 38. Download Passwords
44
Figure 39. Password File in Properties Screen
45
Figure 40. Tools Menu, Upload Passwords
46
2200 SRM 1058 Reports Menu
Reports Menu
Information in the Reports menu includes: Serial Number: Represents the serial number of
• Devices Report the lift truck that is currently connected to the com-
• Custom Report puter.
• Passwords
• Operators NOTE: The master controller is the location where
• Current Settings all of the maintenance hours are stored on the lift
• Status Codes Report truck. This includes: secure hours, traction hours,
• Status Codes Log and pump hours.
The Clear Status Log allows the Status log to be Secure Hours: Represents the total traction motor
cleared from the display after the log has been either hours that have accumulated on the lift truck. If the
saved or printed. traction motor hours have been reset, there will be a
difference between the traction motor hours and se-
DEVICES REPORT cure hours. Secure hours cannot be reset. Secure
hours are only reset to zero when the master con-
Select Devices Report on the Reports menu. This troller is replaced.
brings up another box that shows all devices that are
connected to the lift truck. See Figure 41. NOTE: J1.60-2.00XMT (J30-40ZT) models will only
reset secure hours to zero if both the controller and
The Devices Report screen is used to check which de- dash display are replaced with new components at
vices are on the truck and if ETACC recognizes them the same time.
as connected to the CANbus. This screen also shows
the software article numbers (software revision). If Traction Hours: Represents the number of operat-
the show details box is checked, additional informa- ing hours that have accumulated on the traction mo-
tion is shown about the address used by the CANbus. tor. The traction motor hours are tracked from the
time the operator is seated in the lift truck and turns
CUSTOM REPORT the key switch to the ON position.
Select Custom Report on the Reports menu. See Pump Hours: Represents the number of operating
Figure 42. hours that have accumulated on the pump motor.
The Custom Report screen allows the selection of any User Name: Represents a list of names of operators
or all of the following reports: and service personnel who have a password entered
• System Setup in the master controller for this lift truck.
• Individual Setup
• Display Setup Password: Represents a list of passwords for the
• Diagnostic personnel listed in the User Name column.
The selected reports are combined into one report Mode: Represents one of four operating modes avail-
that can be exported, saved, or printed for later ref- able that the operator listed in the User Name col-
erence. umn has been assigned.
Type: Represents the title of the person listed in the

PASSWORD REPORT User Name column as either the operator or service
Select Passwords on the Reports menu. See Fig- personnel.
ure 43, Figure 44, and Figure 45. The Passwords Report may be printed or saved to a
A Password Report-Connected dialog box pops text file on the computer. See Figure 47.
up and contains the following information on the lift
truck. See Figure 46.
NOTE: If the computer is NOT connected to the lift

truck, the available stored files will be displayed.
47
Reports Menu 2200 SRM 1058
Figure 41. Devices Report
48
Figure 42. Custom Report
49
Figure 43. Reports Menu, Passwords for Lift Truck Models J1.60-2.00XMT (J160)
50
Figure 44. Reports Menu, Passwords for Lift Truck Models J2.00-3.20XM (J40-65Z) (A416),
E3.50-5.50XL (E70-120Z, E100ZS) (D098/E098), E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114), and
(E2.00-3.20XM (E45-65Z) (G108)
51
Figure 45. Reports Menu, Passwords for Lift Truck Models N30ZDRS, N35-40ZRS (A265); N35ZDR,
N45ZR (C264); and N30ZDR, N35-40ZR (D470)
52
Figure 46. Truck Passwords Report
53
Figure 47. Export Passwords Report
OPERATOR REPORT NOTE: The master controller is the location where

all of the maintenance hours are stored on the lift
NOTE: The Operators information is printed in a log truck. This includes: secure hours, traction hours,
format for the operator to view. and pump hours.
Select Operators on the Reports menu. See Fig- Secure Hours: Represents the total traction motor
ure 48. hours that have accumulated on the lift truck. If the
traction motor hours have been reset, there will be a
An Operator Log Report - Connected dialog box
difference between the traction motor hours and se-
pops up and contains the following information on
cure hours. Secure hours cannot be reset. Secure
the lift truck. See Figure 49.
NOTE: If the computer is NOT connected to the lift troller is replaced.
NOTE: J1.60-2.00XMT (J30-40ZT) models will only
Serial Number: Represents the serial number of reset secure hours to zero if both the controller and
the lift truck that is currently connected to the com- dash display are replaced with new components at
puter. the same time.
54
Traction Hours: Represent the number of operat- Password: Represents the operator’s password.
ing hours that have accumulated on the traction mo-
tor. The traction motor hours are tracked from the Time: Represents the hour of operation of the trac-
time the operator is seated in the lift truck and turns tion motor when the operator began operation of the
the key switch to the ON position. lift truck.
Pump Hours: Represents the number of operating The Operator Log Report may be printed or saved to
hours that have accumulated on the pump motor. a text file on the computer. See Figure 50.
Index: Is a sequential number.
Figure 48. Reports Menu, Operators
55
Figure 49. Operator Log Report
56
Figure 50. Operator Log Export Report
CURRENT SETTINGS REPORT Secure Hours: Represents the total traction motor
hours that have accumulated on the lift truck. If the
Select Current Settings on the Reports menu. See traction motor hours have been reset, there will be a
Figure 51. difference between the traction motor hours and se-
cure hours. Secure hours cannot be reset. Secure
A Current Settings Report - Connected dialog
box pops up and contains the following information
troller is replaced.
on the lift truck. See Figure 52.
dash display are replaced with new components at
Serial Number: Represents the serial number of the same time.
the lift truck that is currently connected to the com-
Traction Hours: Represents the number of operat-
puter.
ing hours that have accumulated on the traction mo-
NOTE: The master controller is the location where tor. The traction motor hours are tracked from the
all of the maintenance hours are stored on the lift time the operator is seated in the lift truck and turns
truck. This includes: secure hours, traction hours, the key switch to the ON position.
and pump hours.
57
Pump Hours: Represents the number of operating Parameter: Is the table name given for the sixteen
hours that have accumulated on the pump motor. functions found in the Setting Factory Default Values
or Changing Lift Truck Parameters.
Device Name: Is the name of the device displayed
on the dash display (for example, master controller, Value: Is the number associated with the parame-
traction motor controller, pump motor controller, or ters.
dash display).
The Current Settings Report may be printed, ex-
Node ID, Article No.: Is the software that has been ported, or saved to a text file in the computer. See
installed in each device. Figure 53.
Figure 51. Tool Menu, Current Settings
58
Figure 52. Current Settings Report
59
Figure 53. Current Settings Log Report
STATUS CODE REPORT truck. This includes: secure hours, traction hours,
and pump hours.
Select Status Codes on the Reports menu. See Fig-
ure 54. Secure Hours: Represents the total traction motor
hours that have accumulated on the lift truck. If the
A Status Codes Report - Connected dialog box traction motor hours have been reset, there will be a
pops up and contains the following information on difference between the traction motor hours and se-
the lift truck. See Figure 55. cure hours. Secure hours cannot be reset. Secure
troller is replaced.
Serial Number: Represents the serial number of
the lift truck that is currently connected to the com-
dash display are replaced with new components at
puter.
the same time.
NOTE: The master controller is the location where
all of the maintenance hours are stored on the lift
60
Traction Hours: Represents the number of operat- Time: Represents the hour of operation of the trac-
ing hours that have accumulated on the traction motion motor at which the status code was registered.
tor. The traction motor hours are tracked from the
time the operator is seated in the lift truck and turns Description: Represents a brief description of the
the key switch to the ON position. status code. For example, Traction Motor Tempera-
ture Too High.
Pump Hours: Represents the number of operating
hours that have accumulated on the pump motor. The Status Codes Report may be printed or saved to
a text file on the computer. See Figure 56.
Code: Indicates that a status code has been regis-
tered.
Figure 54. Reports Menu Status Code
61
Figure 55. Truck Status Code Report
62
Figure 56. Export Status Code Report
STATUS CODES LOG 1. Select Status Log from the Reports menu. See
Figure 57.
NOTE: The Status Log can store 16 entries/changes
before the first entry is overwritten and PERMA- 2. The Status Log dialog box will pop up. Click the
NENTLY removed. To avoid losing Status Log en- Clear Log button to clear the status log, or select
tries, they can be saved to another file or printed. the Close button to cancel this operation.
63
Figure 57. Status Codes Log Report
64
Troubleshooting
This section discusses the use of the diagnostic ta- display Failed for each item in the Parameter col-
bles. umn. See Figure 59.
DIAGNOSTICS NOTE: If the computer and the lift truck are commu-
nicating with each other, the status of each item in
Click Diagnostic on the Views menu. See Fig- the Truck Value column will have an actual value
ure 58. for Throttle Pot Volts, Traction/Pump Motor
Amps, Traction/Pump Motor Temp, and RPM.
NOTE: The computer MUST be connected to the lift All other items will be indicated by either a 0 value
truck and communication between the computer and or a 1 value in each row. A Diagnostic Connected
the lift truck MUST be established for diagnostics to dialog box pops up with the following information on
be functional. If the computer is NOT communicat- the lift truck. See Figure 60.
ing with the lift truck, the Truck Value column will
Figure 58. Tools Menu, Diagnostics
65
Figure 59. Diagnostic Screen With No Lift Truck Communication
NOTE: Temperatures shown in the Truck Value col- display 128 at the NEUTRAL position, and values
umn are in Celsius ONLY. should range proportionally from less than 5 at full
back position to greater than 250 at the full forward
Truck Value: The Truck Value will have an actual position. All other items will be indicated by either
value for Throttle Pot Volts, Traction/Pump a 0 value or a 1 value in each row. The 1 value is the
Motor Amps, Traction/Pump Motor and Con- ON condition. The 0 value is the OFF condition for
troller Temp, and RPM. On lift trucks equipped the lift truck.
with Electro-Hydraulics (E-Hydraulics), Lift/Lower
input, Tilt input, Aux 1 input, and Aux 2 input
66
Figure 60. Diagnostic Screen With Lift Truck Communication
For example, if the Park Brake is set, a 1 value changes made to the lift truck WILL NOT be shown
will appear in the Truck Value column of the Park in the Truck Value column.
Brake row. If the Park Brake is not set, a 0 value
will appear in the Truck Value column of the Park To show the new values that have been applied to the
Brake row. If the operator sets the Park Brake Truck Value column:
while the Truck Value is displayed on screen, the
1. Click Update.
value will change from a 0 value or the OFF con-
dition to the 1 value or ON condition in the Park 2. The new values will appear in the Truck Value
Brake row. See Figure 60. If the Truck Value column.
does not change on screen, there could be a problem
with the park brake switch or the adjustment of the If further troubleshooting is required due to Status
switch. Codes displayed on the Dash Panel, see the AC Mo-
tor Controllers/Display Panel section for your lift
Freeze button: This button locks the Diagnostic truck.
- Connected dialog box in the current state. Any
67
Help Menu 2200 SRM 1058
Help Menu
GENERAL TECHNICAL SUPPORT
This section will provide information about receiving 1. If technical assistance is required, click the
additional assistance, if required, while using this Help button located on the Tool Bar to view the
program. Help drop-down menu, and select Technical
Support.
CONTENTS
2. The Technical Support dialog box contains a
1. Click the Help button located on the Tool Bar to list of telephone numbers to be contacted for fur-
view the Help drop-down menu. See Figure 61. ther assistance. See Figure 63.
2. Click on the Contents selection on the ABOUT ELECTRIC TRUCK AC CONTROLS

drop-down menu. See Figure 61.
PROGRAM
3. When Contents is clicked, the Online Guide
1. Click the Help button located on the Tool Bar
will be displayed. See Figure 62.
to view the Help drop-down menu, and select
4. The Online Guide will show two selections, About Electric Truck AC Controls from the
Contents and Search. See Figure 62. If Con- drop-down menu. See Figure 64.
tents is selected, a drop-down guide is provided
2. The About Electric Truck AC Controls Pro-
and the user may select from any of the choices
gram dialog box contains general information
listed. If Search is selected, the user may en-
and version information about the Hyster soft-
ter a key word and click enter or the user can
ware that is currently running and registered on
click List Topics and make a selection from
this computer.
that list by highlighting the desired topic and
clicking Display. The desired topic will then be
displayed on the screen.
68
2200 SRM 1058 Help Menu
Figure 61. Help Menu, Contents
69
Figure 62. Online Guide
70
2200 SRM 1058 Help Menu
Figure 63. Technical Support
71
Figure 64. About Electric Truck AC Control Program
72
USER INTERFACE
SERVICE TECHNICIAN
(STANDARD DISPLAY)
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590943 2200 SRM 1193

User Interface Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
Dash Display Menu Access ........................................................................................................................... 1
Menu Navigation ............................................................................................................................................... 2
Standard Display ........................................................................................................................................... 2
Main Menu ......................................................................................................................................................... 2
Diagnostics Menu............................................................................................................................................... 2
Static Diagnostics .......................................................................................................................................... 2
Traction System ............................................................................................................................................. 6
Steer System .................................................................................................................................................. 10
General Truck ................................................................................................................................................ 11
Error Log ........................................................................................................................................................ 12
View Hourmeters ............................................................................................................................................... 12
Truck Hours ................................................................................................................................................... 12
Traction Hours ............................................................................................................................................... 13
Pump Hours ................................................................................................................................................... 13
Auxiliary Hours ............................................................................................................................................. 14
Setup Menu ........................................................................................................................................................ 14
Lift Settings ................................................................................................................................................... 15
Lift Maximum Speed (N35ZDR, N45ZR, N30ZDR, N35-40ZR).............................................................. 15
Lower Maximum Speed (N35ZDR, N45ZR, N30ZDR, N35-40ZR) ......................................................... 15
Auxiliary Settings.......................................................................................................................................... 16
Fast Extend Speed .................................................................................................................................... 16
Slow Extend Speed .................................................................................................................................... 16
Fast Retract Speed .................................................................................................................................... 17
Slow Retract Speed ................................................................................................................................... 17
Tilt Up Speed ............................................................................................................................................. 18
Tilt Down Speed ........................................................................................................................................ 18
Sideshift Speed .......................................................................................................................................... 19
Reach Cushioning...................................................................................................................................... 19
Steer Settings................................................................................................................................................. 20
Steer Mode ................................................................................................................................................. 20
Steer Effort ................................................................................................................................................ 20
Steer Ratio ................................................................................................................................................. 21
Truck Settings................................................................................................................................................ 21
Truck Serial Number................................................................................................................................. 21
Truck Voltage............................................................................................................................................. 22
Truck Capacity .......................................................................................................................................... 22
Battery Type .............................................................................................................................................. 23
BDI Adjust Calibration ............................................................................................................................. 23
Extended Shift........................................................................................................................................... 24
Lift Limit Without Override (N35ZDR, N45ZR, N30ZDR, N35-40ZR) .................................................. 24
Lift Limit With Override (N35ZDR, N45ZR, N30ZDR, N35-40ZR)........................................................ 25
Audible Alarm ........................................................................................................................................... 25
Visible Alarm ............................................................................................................................................. 26
Autotilt Option .......................................................................................................................................... 27
Laser Option .............................................................................................................................................. 27
Carry Level Option.................................................................................................................................... 28
Slow Extended ........................................................................................................................................... 28
Simultaneous Hydraulics.......................................................................................................................... 29

Table of Contents User Interface

Password Option ....................................................................................................................................... 29
Shutdown Timeout .................................................................................................................................... 30
Traction Settings ........................................................................................................................................... 30
Rabbit Speed.............................................................................................................................................. 30
Rabbit Acceleration ................................................................................................................................... 31
High Speed................................................................................................................................................. 31
High Acceleration ...................................................................................................................................... 32
Mid Speed .................................................................................................................................................. 32
Mid Acceleration........................................................................................................................................ 33
Turtle Speed............................................................................................................................................... 33
Turtle Acceleration .................................................................................................................................... 34
Neutral Braking ........................................................................................................................................ 34
Plug Braking.............................................................................................................................................. 35
View Software Versions ..................................................................................................................................... 35
Master Controller .......................................................................................................................................... 35
Display ........................................................................................................................................................... 36
Traction Controller ........................................................................................................................................ 36
Hydraulic Controller ..................................................................................................................................... 37
Control Handle .............................................................................................................................................. 37
Remote CAN Module (N35ZDR, N45ZR, N30ZDR, N35-40ZR) .................................................................. 38
Steer Controller ............................................................................................................................................. 38
Caster Controller ........................................................................................................................................... 39
Aux Pump....................................................................................................................................................... 39
Impact Sensor .................................................................................................................................................... 40
Functions........................................................................................................................................................ 40
Functions........................................................................................................................................................ 41
Impact Action ............................................................................................................................................ 41
Impact Sound............................................................................................................................................. 41
Clear Impact .............................................................................................................................................. 41
Hard Duration ........................................................................................................................................... 41
Hard Acceleration...................................................................................................................................... 41
Soft Duration ............................................................................................................................................. 41
Sort Acceleration ....................................................................................................................................... 41
Impact Events............................................................................................................................................ 41
Password Menu .................................................................................................................................................. 42
Add Password ................................................................................................................................................ 43
Delete Password ............................................................................................................................................ 44
Edit Password ................................................................................................................................................ 45
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
ii
General
DESCRIPTION automatically enable all dash display menu options
allowed for service technician password access.
This section contains information on accessing the Use the arrow keys to move throughout each menu
additional service technician functions of the dash screen. Press the (enter) key to make a selection
display. With a proper service technician password, within a menu.
the service technician can assess menu items not vis-
ible to persons with operator password level access. If the password option is not activated, press the
(enter) key twice to access the password screen. En-
NOTE: A service technician is required to input ini- ter your five-digit password using the number keys
tial passwords into the dash display. on the dash display.
DASH DISPLAY MENU ACCESS Table 1. Password Screen
When the key is turned to the ON position, the menu

access keys will be activated. See Figure 1.
Enter Password
If the operator password function is activated, the
XXXXX
password screen will be shown at startup. See
Table 1. Enter your five-digit service technician
password using the number keys (1-5) on the dash
display. Successful entry of your password will
Figure 1. Standard Display Menu Access Keys
1
Diagnostics Menu 2200 SRM 1193
Menu Navigation
STANDARD DISPLAY The ↑ (scroll up) key and the ↓ (scroll down) key allow
you to move up and down within a menu. The →
Upon successful entry of your password, you will be (right arrow) key and the ← (left arrow) key allow
directed to the Main Menu. Using the ↑ (scroll up) you to move from menu to menu. The (enter) key
and ↓ (scroll down) keys, scroll through the menu allows you to enter or save a parameter.
selections until you see the menu selection you want
to access. Press the → (right arrow) key to access
that selection. The Main Menu will include only the
menus that are accessible with a password.
Main Menu
Upon entering the Main Menu from the password en- • Setup
try screen, the following menu functions are visible • View Software Versions
to the service technician: • Impact Sensor
• Diagnostics • Passwords
• View Hourmeters
Diagnostics Menu
Upon entering the Diagnostics menu from the Main percentage. All motor speeds will be shown in RPM.
Menu, the following menu functions are visible to the Motor current will be shown in amps. All tempera-
service technician: tures will be shown in degrees Celsius. See Table 3,
• Static Diagnostics Table 4, Table 5, and Table 6.
• Traction System
• Hydraulic System Use the scroll keys to move to the desired function
• Steer System and press the → (right arrow) key to select the func-
• General Truck tion.
• Error Log
STATIC DIAGNOSTICS
For a complete description of the diagnostic func-
tions accessible through the dash display, see AC The Static Diagnostics menu allows the service tech-
Motor Controllers/Display Panel, Description, nician to check various truck functions while the
Checks, Adjustments, and Troubleshooting truck is stationary with the traction and hydraulic
2200 SRM 1190 or AC Motor Controllers/Display functions not operating. Use these menus to check
Panel, Description, Checks, Adjustments, and the status of system inputs and outputs from truck
Troubleshooting 2200 SRM 1308. switches and controls. Digital inputs and outputs
will be displayed as ON or OFF depending upon the
Use these menus to check the various operating sys- state of the switch. Analog inputs or outputs will be
tems of the lift truck. All PWM (Pulse Width Mod- shown as a voltage. See Table 2.
ulation) outputs from controllers will be shown as a
2
2200 SRM 1193 Diagnostics Menu
Table 2. Static Diagnostics Menu
Static Brake Pedal Switch Press ← Key to return to

Diagnostics Press → Key Press → Key
Diagnostics 0 or 1 / 1 = On main menu
↑
SCROLL
↓
Oper Sensing Switch Press ← Key to return to
0 or 1 / 1 = On main menu
↑
SCROLL
↓
Steer OK Press ← Key to return to
0 or 1 / 1 = Fault main menu
↑
SCROLL
↓
Str Ctr Prox Switch 1 Press ← Key to return to
↑
SCROLL
↓
↑
SCROLL
↓
Free Lift Prox SW Press ← Key to return to
↑
SCROLL
↓
Tilt Sensor Press ← Key to return to
XXXXX Count main menu
↑
SCROLL
↓
Hyd Level Switch Press ← Key to return to
↑
SCROLL
↓
3
Table 2. Static Diagnostics Menu (Continued)
Tilt Up Switch Press ← Key to return to

↑
SCROLL
↓
Tilt Down Switch Press ← Key to return to
↑
SCROLL
↓
Extend Switch Press ← Key to return to
↑
SCROLL
↓
Retract Switch Press ← Key to return to
↑
SCROLL
↓
SS Right Switch Press ← Key to return to
↑
SCROLL
↓
SS Left Switch Press ← Key to return to
↑
SCROLL
↓
Horn Switch Press ← Key to return to
↑
SCROLL
↓
Traction Throttle Press ← Key to return to
XXX % main menu
↑
SCROLL
↓
4
Hydraulic Throttle Press ← Key to return to

XXX % main menu
↑
SCROLL
↓
Reach Throttle Press ← Key to return to
XXX % main menu
↑
SCROLL
↓
Aft Throttle Press ← Key to return to
XXX % main menu
↑
SCROLL
↓
Aft Sensor Press ← Key to return to
↑
SCROLL
↓
Aft Horn Press ← Key to return to
5
TRACTION SYSTEM
The following menu allows the service technician to
check various truck functions while operating the
traction functions.
Table 3. Traction System Diagnostics Menu
Diagnostics Press → Key Static Diagnostics
↑
SCROLL
↓
Traction Motor Speed Press ← Key to return

Traction System Press → Key
XXXX RPM to main menu
↑
SCROLL
↓
Traction Motor Current Press ← Key to return

XXX AMPS to main menu
↑
SCROLL
↓
Traction Motor Temp Press ← Key to return

XXX C to main menu
↑
SCROLL
↓
Traction Control Temp Press ← Key to return

XXX C to main menu
↑
SCROLL
↓
Traction Throttle Press ← Key to return

XXX % to main menu
↑
SCROLL
↓
Brake Coil Press ← Key to return

0 or 1 / 1 = On to main menu
↑
SCROLL
↓
Aft Throttle Press ← Key to return

XXX % to main menu
↑
SCROLL
↓
Aft Sensor Press ← Key to return

6
HYDRAULIC SYSTEM
check various truck functions while operating the hy-
draulic functions.
Table 4. Hydraulic System Diagnostics Menu
↑
SCROLL
↓
Pump Motor Speed Press ← Key to return to

Hydraulic System Press → Key
XXX RPM main menu
↑
SCROLL
↓
Pump Motor Current Press ← Key to return to

XXX AMPS main menu
↑
SCROLL
↓
Pump Motor Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Pump Control Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Pump Throttle Press ← Key to return to

XXX % main menu
↑
SCROLL
↓
Load Hold Coil Press ← Key to return to

1=On 0=Off main menu
↑
SCROLL
↓
Pressure Transducer Press ← Key to return to

XXX main menu
↑
SCROLL
↓
7
Table 4. Hydraulic System Diagnostics Menu (Continued)
Auxiliary Motor SPD Press ← Key to return to

XXXX RPM main menu
↑
SCROLL
↓
Auxiliary Motor CURR Press ← Key to return to

XXX AMPS main menu
↑
SCROLL
↓
Auxiliary Motor Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Forward Coil Press ← Key to return to

↑
SCROLL
↓
Reverse Coil Press ← Key to return to

↑
SCROLL
↓
Reach Coil Press ← Key to return to

↑
SCROLL
↓
Tilt Coil Press ← Key to return to

↑
SCROLL
↓
Sideshift Coil Press ← Key to return to

↑
SCROLL
↓
Aux Direction Press ← Key to return to

0 or 1 / 1 = EXT main menu
↑
SCROLL
↓
8
Reach Sensor Press ← Key to return to

XXX COUNT main menu
↑
SCROLL
↓

XXX COUNT main menu
↑
SCROLL
↓
Lift PV Press ← Key to return to

XXX COUNT main menu
↑
SCROLL
↓
Lower PV Press ← Key to return to

XXX COUNT main menu
9
STEER SYSTEM
steering functions.
Table 5. Steering System Diagnostics Menu
↑
SCROLL
↓
Steer Motor Speed Press ← Key to return to

Steer System Press → Key
XXX RPM main menu
↑
SCROLL
↓
Steer Motor Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Steer Control Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Steer OK? Press ← Key to return to

↑
SCROLL
↓
Steer Motor Angle Press ← Key to return to

XXX DEG main menu
10
GENERAL TRUCK
check various settings and lift truck functions.
Table 6. General Truck Diagnostics Menu
↑
SCROLL
↓
Height Sensor Press ← Key to

General Truck Press → Key
XXX IN return to main menu
↑
SCROLL
↓
Cal Fork Tare DN Press ← Key to

XXX lbs. return to main menu
↑
SCROLL
↓
Cal Fork Tare UP Press ← Key to

XXX lbs. return to main menu
↑
SCROLL
↓
Cal Cush Inpoint

XXXXX Count
Press ← Key to
(N35ZDR, N45ZR, return to main menu
N30ZDR, N35-40ZR
Only)
↑
SCROLL
↓
Cal Cush Outpoint

XXXXX Count
Press ← Key to
(N35ZDR, N45ZR, return to main menu
N30ZDR, N35-40ZR
Only)
↑
SCROLL
↓
Cal Mast Slwdn Press ← Key to

XXXXXXXX Count return to main menu
11
View Hourmeters 2200 SRM 1193
ERROR LOG the truck hourmeter reading at the last time the er-
ror occurred can be accessed using the ↑ (scroll up)
Upon entering the Error Log from the Main Menu, and ↓ (scroll down) keys. The display can store up to
the last error recorded will be displayed. The error 16 errors. See Table 7.
code, the number of times the error has occurred, and
Table 7. Error Log
Diagnostics Press → Static

Menus Key Diagnostics
↑
SCROLL
↓
Press Error #1 Press Last HM Press Count Press First HM
Error Log
→ Key Message → Key XXX → Key XXX → Key XXXXX
View Hourmeters
Upon entering the View Hourmeters menu from the Use the ↑ (scroll up) and the ↓ (scroll down) keys to
Main Menu, the following menu functions are visible move to the desired function. When finished, press
to the service technician: the ← (left arrow) key to return to the Main Menu.
• Truck Hours
• Traction Hours TRUCK HOURS
• Pump Hours
• Auxiliary Hours This function allows the service technician to see
the hours that have accumulated while the operator
presence switch has been activated. See Table 8.
Table 8. Truck Hours
Truck Hours
View Hourmeters Press → Key Press ← Key to return to main menu
XXXXX
12
2200 SRM 1193 View Hourmeters
TRACTION HOURS
This function allows the service technician to see the
hours that have accumulated while the traction mo-
tor has been activated. See Table 9.
Table 9. Traction Hours
Truck Hours Press ← Key to return to main

View Hourmeters Press → Key
XXXXX menu
↑
SCROLL
↓
Tract Hours Press ← Key to return to main
XXXXX menu
PUMP HOURS
hours that have accumulated while the lift motor has
been activated. See Table 10.
Table 10. Pump Hours
Truck Hours
XXXXX
↑
SCROLL
↓
Pump Hours
Press ← Key to return to main menu
XXXXX
13
Setup Menu 2200 SRM 1193
AUXILIARY HOURS
hours that have accumulated while the auxiliary mo-
tor has been activated. See Table 11.
Table 11. Auxiliary Hours
Truck Hours
XXXXX
↑
SCROLL
↓
Aux Hours
Press ← Key to return to main menu
XXXXX
Setup Menu
Upon entering the Setup menu from the Main Menu, Use the scroll keys to move to the desired function
the following menu functions are visible to the ser- and press the → (right arrow) key to select the func-
vice technician: tion.
• Lift Settings
• Auxiliary Settings To edit or change a parameter, scroll to the parameter
• Steer Settings and press the → (right arrow) key to enter edit mode.
• Truck Settings Use the ↑ (scroll up) and ↓ (scroll down) keys to edit
• Traction Settings or change the parameter setting. Press the (enter)
key to save the new value. Press the ← (left arrow)
For a complete description of the performance pa- key to return to the main menu.
rameters accessible through the dash display, see the
AC Motor Controllers/Display Panel, Descrip-
tion, Checks, Adjustments, and Troubleshoot-
ing 2200 SRM 1190 or AC Motor Controllers/Dis-
play Panel, Description, Checks, Adjustments,
and Troubleshooting 2200 SRM 1308.
14
2200 SRM 1193 Setup Menu
LIFT SETTINGS lift motor to operate at the maximum rate. Setting

the parameter below 100% will cause the motor speed
Lift Maximum Speed (N35ZDR, N45ZR, to be reduced. Use the number keys to increase or
N30ZDR, N35-40ZR) decrease the count value shown on the dash display.
See Table 12. Press the → (right arrow) key and use
This setting adjusts the maximum speed of the lift the ↑ (scroll up) and ↓ (scroll down) keys to change
motor during lifting. This parameter can be set be- the value. Press the (enter) key to save the changes.
tween 100 and 50. A setting of 100% will allow the
Table 12. Lift Maximum Speed Menu
Press → Lift Maximum Speed Press Key to save

Set Up Press → Key Lift Setting
Key XXXX Press ← Key to cancel
Lower Maximum Speed (N35ZDR, N45ZR, maximum rate. Setting the parameter below 100%
N30ZDR, N35-40ZR) will cause the motor speed to be reduced. See Ta-
ble 13. Press the → (right arrow) key and use the
This setting adjusts the maximum speed of the lift ↑ (scroll up) and ↓ (scroll down) keys to change the
motor during lowering. This setting adjusts the max- value. Press the (enter) key to save the changes.
imum speed of the lift motor during lowering. This
parameter can be set between 100 and 50. A set-
ting of 100% will allow the lift motor to lower at the
Table 13. Lower Maximum Speed Menu
Press → Lift Maximum Speed Press Key to save

Key XXXX Press ← Key to cancel
↑
SCROLL
↓
Lower Max Speed Press Key to save
XXXX Press ← Key to cancel
15
AUXILIARY SETTINGS maximum speed. Setting the parameter below 100%

will reduce the extend speed of the reach attachment.
Fast Extend Speed The minimum setting is 50%. Press the → (right ar-
row) key and use the ↑ (scroll up) and ↓ (scroll down)
Use this menu to adjust the maximum extend speed keys to change the value. Press the (enter) key to
of the reach attachment when the fast extend control save the changes.
is activated. See Table 14. Setting the parameter to
100% will allow the reach attachment to extend at
Table 14. Fast Extend Speed Menu

↑
SCROLL
↓
Press → Fast Extend Speed Press Key to save
Aux Setting
Key XXX Press ← Key to cancel
Slow Extend Speed increase the extend speed of the reach attachment.
The maximum setting is 100%. The parameter may
Use this menu to adjust the maximum extend speed not be set higher than the Fast Extend Speed pa-
of the reach attachment when the slow extend control rameter. Press the → (right arrow) key and use the
is activated. See Table 15. Setting the parameter to ↑ (scroll up) and ↓ (scroll down) keys to change the
50% will allow the reach attachment to extend at the value. Press the (enter) key to save the changes.
slowest speed. Setting the parameter above 50% will
Table 15. Slow Extend Speed Menu

↑
SCROLL
↓
Aux Setting
↑
SCROLL
↓
Slow Extend Speed Press Key to save
XXX Press ← Key to cancel
16
Fast Retract Speed maximum speed. Setting the parameter below 100%
will reduce the retract speed of the reach attachment.
Use this menu to adjust the maximum retract speed Press the → (right arrow) key and use the ↑ (scroll
of the reach attachment when the fast retract control up) and ↓ (scroll down) keys to change the value.
is activated. See Table 16. Setting the parameter to Press the (enter) key to save the changes.
100% will allow the reach attachment to retract at
Table 16. Fast Retract Speed Menu

↑
SCROLL
↓
Fast Extend Speed Press Key to save
Aux Setting Press → Key
↑
SCROLL
↓
Fast Retract Speed Press Key to save
Slow Retract Speed will increase the retract speed of the reach attach-
ment. The parameter may not be set higher than the-
Use this menu to adjust the maximum retract speed Fast Retract Speed parameter. The maximum set-
of the reach attachment when the slow retract con- ting is 100%. Press the → (right arrow) key and use
trol is activated. See Table 17. Setting the parameter the ↑ (scroll up) and ↓ (scroll down) keys to change
to 30% will allow the reach attachment to retract at the value. Press the (enter) key to save the changes.
the slowest speed. Setting the parameter above 30%
Table 17. Slow Retract Speed Menu

↑
SCROLL
↓
Aux Setting
↑
SCROLL
↓
Slow Retract Speed Press Key to save
17
Tilt Up Speed up function. The minimum setting is 30%. Press the

→ (right arrow) key and use the ↑ (scroll up) and ↓
Use this menu to adjust the speed of the tilt up func- (scroll down) keys to change the value. Press the
tion. See Table 18. Setting the parameter to 100% (enter) key to save the changes.
will result in maximum tilt up speed. Setting the pa-
rameter below 100% will reduce the speed of the tilt
Table 18. Tilt Up Speed Menu

↑
SCROLL
↓
Aux Setting
↑
SCROLL
↓
Tilt Up Speed Press Key to save
Tilt Down Speed of the tilt down function. The minimum setting is
30%. Press the → (right arrow) key and use the ↑
Use this menu to adjust the speed of the tilt down (scroll up) and ↓ (scroll down) keys to change the
function. See Table 19. Setting the parameter to value. Press the (enter) key to save the changes.
100% will result in maximum tilt down speed. Set-
ting the parameter below 100% will reduce the speed
Table 19. Tilt Down Speed Menu

↑
SCROLL
↓
Aux Setting
↑
SCROLL
↓
Down Up Speed Press Key to save
18
Sideshift Speed The minimum setting is 40%. Press the → (right ar-
row) key and use the ↑ (scroll up) and ↓ (scroll down)
Use this menu to adjust the speed of the sideshift. keys to change the value. Press the (enter) key to
See Table 20. Setting the parameter to 70% will re- save the changes.
sult in maximum sideshift speed. Setting the param-
eter below 70% will reduce the speed of the sideshift.
Table 20. Sideshift Speed Menu

↑
SCROLL
↓
Fast Extend Speed Press Key to save
Aux Setting Press → Key
↑
SCROLL
↓
Side Shift Speed Press Key to save
Reach Cushioning down) keys to select the Fast Extend Speed or Cush-
ion Speed menu. Press the → (right arrow) key to
Use this menu to adjust the speed of the reach cush- enter. Use the ↑ (scroll up) and ↓ (scroll down) keys
ioning effect. The minimum setting is 300 RPM. The to change the value. Press the (enter) key to save
maximum setting is 1800 RPM. Press the → (right the changes. See Table 21.
arrow) key to enter the menu from the Auxiliary
Settings menu. Use the ↑ (scroll up) and ↓ (scroll
Table 21. Cushioning Speed Menu

↑
SCROLL
↓
Fast Extend Press Key to save
Press →
Aux Setting Speed Press ← Key to cancel
Key
XXX% RPM
↑
SCROLL
↓
Cushion Speed Press Key to save
19
STEER SETTINGS FORE/AFT AUTO will cause the steering to func-

tion the same as AUTO when driving in the forward
Steer Mode stance. When rearward facing and the aft controls
are activated, the steering changes such that it be-
Use this menu to select the action of the steering sys- comes “automotive,” from that orientation.
tem. See Table 22. Setting the parameter to AUTO
will cause the steering system to turn the lift truck NOTE: The FORE/AFT AUTO parameter can be ac-
in the direction the steer disk is turned when mov- tivated only if the lift truck is equipped with the Aft
ing in the direction of the forks, much the same as Travel Control Handle option.
driving an automobile (automotive style). Setting the
parameter to REVERSE will cause the steering sys- Press the → (right arrow) key and use the ↑ (scroll
tem to turn the lift truck in the opposite direction of up) and ↓ (scroll down) keys to change the value.
the steer disk when moving in the direction of the Press the (enter) key to save the changes.
forks, opposite of AUTO. Setting the parameter to
Table 22. Steer Mode Menu

↑
SCROLL
↓
Steer Mode Press Key to save
Steer Setting Press → Key
Auto Press ← Key to cancel
Steer Effort the amount of effort required to turn the steering

wheel. Press the → (right arrow) key and use the
Use this menu to adjust the amount of effort required ↑ (scroll up) and ↓ (scroll down) keys to change the
to turn the steering wheel. See Table 23. Setting the value. Press the (enter) key to save the changes.
parameter to 100% will result in maximum steer ef-
fort. Setting the parameter below 100% will reduce
Table 23. Steer Effort Menu

↑
SCROLL
↓
↑
SCROLL
↓
Steer Effort Press Key to save
20
Steer Ratio maximum setting is 65%. Setting the parameter at

65% will result in the greatest number of turns lock-
Use this menu to set the turns lock-to-lock of the to-lock. See Table 24.
steering function. The minimum setting is 40%. The
Table 24. Steer Ratio Menu

↑
SCROLL
↓
↑
SCROLL
↓
Steer Ratio Press Key to save
TRUCK SETTINGS at the factory. If the master controller is replaced,

the serial number must be reset using ETACC.
Truck Serial Number
This menu is used to store and display the truck se-
rial number. See Table 25. The serial number is set
Table 25. Truck Serial Number Menu

↑
SCROLL
↓
Serial Number
Truck Setting Press → Key
XXXXXXXXXXX
21
Truck Voltage
This menu is used to store and display the truck volt-
age. See Table 26. The truck voltage is set at the fac-
tory. If the master controller is replaced, the voltage
must be reset using ETACC.
Table 26. Truck Voltage Menu
Lift
Set Up Press → Key
Setting
↑
SCROLL
↓
Serial Number
XXXXXXXXXXX
↑
SCROLL
↓
Voltage Press → Key to save
XX Press ← Key to cancel
Truck Capacity
This menu is used to store and display the truck max-
imum capacity. See Table 27. The truck capacity is
set at the factory. If the master controller is replaced,
the capacity must be reset using ETACC.
Table 27. Truck Capacity Menu
Lift
Setting
↑
SCROLL
↓
Serial Number
XXXXXXXXXXX
↑
SCROLL
↓
Capacity Press Key to save
XXXX Lbs Press ← Key to cancel
22
Battery Type between "Flooded" or "Maintenance Free" battery

types.
This menu is used to store and display the type of
battery installed on the truck. See Table 28. Select
Table 28. Truck Type Menu
Lift
Setting
↑
SCROLL
↓
Press → Serial Number
Truck Setting
Key XXXXXXXXXXX
↑
SCROLL
↓
Battery Type Press Key to save
Flooded Press ← Key to cancel
BDI Adjust Calibration Lowering the value will allow the battery to dis-
charge to a lower voltage before Lift Interrupt will
Use the BDI (Battery Discharge Indicator) Adjust occur. The minimum setting is 0%. The maximum
Calibration to adjust the Lift Interrupt setting. setting is 70%. See Table 29.
Adjusting the value higher will increase the level of
battery voltage at which Lift Interrupt will occur.
Table 29. BDI Adjust Calibration Menu
Lift
Setting
↑
SCROLL
↓
Serial Number
XXXXXXXXXXX
↑
SCROLL
↓
BDI Calibration Press Key to save
23
Extended Shift
Use this setting to enable or disable the Extended
Shift option. Setting the parameter to ON will enable
the option, OFF will disable the option. See Table 30.
Table 30. Extended Shift Menu

↑
SCROLL
↓
Truck Setting Press → Serial Number Press Key to save
Key XXXXXXXXXXX Press ← Key to cancel
↑
SCROLL
↓
Extended Shift Press Key to save
Off Press ← Key to cancel
Lift Limit Without Override (N35ZDR, and lift limit heights. These settings can be made
N45ZR, N30ZDR, N35-40ZR) with ETACC. See Table 31.
Use this setting to enable or disable the Lift Limit NOTE: If Lift Limit Without Override and Lift Limit
Without Override option. Setting the parameter to With Override are both enabled then Lift Limit With-
ON will enable the option, OFF will disable the op- out Override will have priority.
tion. The encoder hardware must be correctly in-
stalled along with the settings made for the free lift
Table 31. Lift Limit Without Override

↑
SCROLL
↓
Serial Number Press Key to save
XXXXXXXXXXX Press ← Key to cancel
↑
SCROLL
↓
LL W/O Override Press Key to save
24
Lift Limit With Override (N35ZDR, N45ZR, will enable the option, OFF will disable the option.
N30ZDR, N35-40ZR) The encoder hardware must be correctly installed
along with the settings made for the free lift and
Use this setting to enable or disable the Lift Limit lift limit heights. These settings can be made with
With Override option. Setting the parameter to ON ETACC. See Table 32.
Table 32. Lift Limit With Override

↑
SCROLL
↓
↑
SCROLL
↓
LL W Override Press Key to save
Audible Alarm direction. Setting the parameter to FWD/REV al-

lows the audible alarm to sound only when the truck
Use this setting to select the mode of operation of the is traveling, regardless of direction. Setting the pa-
motion alarm. See Table 33. Setting the parame- rameter to FWD/REV AND L/L allows the audible
ter to OFF disables the audible alarm. Setting the alarm to sound whenever the truck is traveling, and
parameter to BACK UP allows the audible alarm to whenever the truck is lifting or lowering.
sound only when the truck is traveling in the reverse
Table 33. Audible Alarm Menu

↑
SCROLL
↓
↑
SCROLL
↓
Audible Alarm? Press Key to save
25
Visible Alarm to FWD/REV AND L/L allows the visible alarm to

sound whenever the truck is traveling, and/or when-
Use this setting to select the mode of operation of the ever the truck is lifting or lowering. Setting the pa-
visible alarm. See Table 34. Setting the parameter to rameter to CONTINUOUS enables the visible alarm
OFF disables the visible alarm. Setting the param- to operate continuously after the truck key switch is
eter to BACK UP allows the visible alarm to operate turned to the ON position.
only when the truck is traveling in the reverse direc-
tion. Setting the parameter to FWD/REV allows the
visible alarm to operate only when the truck is trav-
eling, regardless of direction. Setting the parameter
Table 34. Visible Light Alarm Menu

↑
SCROLL
↓
Press → Serial Number Press Key to save
Truck Setting
↑
SCROLL
↓
Visible Light Opt? Press Key to save
26
Autotilt Option
Use this menu to enable or disable the Autotilt op-
tion. See Table 35. Setting the parameter to ON will
enable the option.
Table 35. Autotilt Option Menu

↑
SCROLL
↓
Truck Setting
↑
SCROLL
↓
Auto Tilt Option Press Key to save
Laser Option
Use this setting to enable or disable the Laser option.
Setting the parameter to ON will enable the option,
OFF will disable the option. See Table 36.
Table 36. Laser Option

↑
SCROLL
↓
Truck Setting Serial Number Press Key to save
Press → Key
↑
SCROLL
↓
Laser Option? Press Key to save
No Press ← Key to cancel
27
Carry Level Option carry level when the forks are being lowered. Set-
ting the parameter to BEEP will reduce the lowering
Use this menu to enable and set the Carry Level op- speed to the slow lower speed when the forks reach
tion. See Table 37. Use this setting to enable and the preset carry level and will activate the audible
set the Carry Level option. Setting the parameter to alarm.
OFF will disable the Carry Level option. Setting the
parameter to STOP will stop the forks at the preset
Table 37. Carry Level Option Menu

↑
SCROLL
↓
Truck Setting
↑
SCROLL
↓
Carry Level Press Key to save
Option Press ← Key to cancel
Stop/Beep/Off
Slow Extended This menu will allow the service technician to view
the steer controller software version identifier for the
NOTE: This is a paid option and will be initially main steering controller. See Table 38.
enabled with an option code (models N35ZDRS,
N45ZRS, N30ZDRS, N35-40ZRS must also be
equipped with specific hardware for this option).
Table 38. Restore Defaults Menu

↑
SCROLL
↓
Truck Setting Serial Number Press Key to save
Press → Key
↑
SCROLL
↓
Slow Extended Press Key to save
No Press ← Key to cancel
28
Simultaneous Hydraulics disable any simultaneous operation. Setting the pa-

rameter to FULL will allow simultaneous operation
Use this menu to select the mode of operation for si- of hydraulic functions at full operating speed. Set-
multaneous operation of certain hydraulic functions. ting the parameter to LIMITED will allow simulta-
See Table 39. Setting the parameter to NONE will neous operation at reduced operating speed only.
Table 39. Simultaneous Hydraulics Menu

↑
SCROLL
↓
Truck Setting
↑
SCROLL
↓
Simultaneous Press Key to save
Hyd? Press ← Key to cancel
Full/Limited
Password Option
Use this menu to enable or disable the Password Op-
tion. See Table 40. Set the parameter to ON to enable
the Password Option. Set the parameter to OFF to
disable the Password Option.
Table 40. Password Option Menu

↑
SCROLL
↓
↑
SCROLL
↓
Password Opt? Press Key to save
On / Off Press ← Key to cancel
29
Shutdown Timeout parameter to any value between 1 minute and 35

minutes.
Use this menu to adjust the amount of time the
lift truck can remain inactive before activating au-
tomatic power shutdown. See Table 41. Set the
Table 41. Shutdown Timeout Menu

↑
SCROLL
↓
Truck Serial Press Key to save
Setting Press → Key Number Press ← Key to cancel
XXXXXXXXXXX
↑
SCROLL
↓
Shutdown
Timeout
15
TRACTION SETTINGS the parameter below 100% will cause the lift truck
to operate at a reduced top speed. The parameter
Rabbit Speed setting cannot be reduced below the setting for the
Mid Speed parameter. Press the → (right arrow) key
Use this menu to adjust the maximum speed of the and use the ↑ (scroll up) and ↓ (scroll down) keys to
lift truck when the rabbit mode is selected. See Ta- change the value. Press the (enter) key to save the
ble 42. Setting the parameter to 100% will allow changes.
the lift truck to travel at maximum speed. Setting
Table 42. Rabbit Speed Menu

↑
SCROLL ↑
↓ Change Value
Traction Rabbit Speed Press Key to save
Press → Key
Setting 100 Press ← Key to cancel
Change Value
↓
30
Rabbit Acceleration will cause the acceleration rate to be reduced. The

parameter setting cannot be reduced below the set-
Use this menu to adjust the rate at which the lift ting for the Mid Acceleration parameter. Press the
truck will accelerate when the rabbit mode has been → (right arrow) key and use the ↑ (scroll up) and ↓
selected. See Table 43. Setting the parameter to (scroll down) keys to change the value. Press the
100% will allow the lift truck to accelerate at the (enter) key to save the changes.
maximum rate. Setting the parameter below 100%
Table 43. Rabbit Acceleration Menu

↑
SCROLL
↓
Traction Rabbit Speed Press Key to save
Press → Key
Setting 100 Press ← Key to cancel
↑
SCROLL
↓
Rabbit Accel Press Key to save
100 Press ← Key to cancel
High Speed truck to operate at a reduced top speed. The param-

eter setting cannot be reduced below the setting for
Use this menu to adjust the maximum speed of the the Mid Speed parameter. Press the → (right arrow)
lift truck when the High Saver Speed mode is se- key and use the ↑ (scroll up) and ↓ (scroll down) keys
lected. See Table 44. Setting the parameter to 100% to change the value. Press the (enter) key to save
will allow the lift truck to travel at maximum speed. the changes.
Setting the parameter below 100% will cause the lift
Table 44. High Speed Menu

↑
SCROLL
↓
Rabbit Speed Press Key to save
Traction Setting Press → Key
↑
SCROLL
↓
High Speed Press Key to save
31
High Acceleration below 100% will cause the acceleration rate to be

reduced. The parameter setting cannot be reduced
Use this menu to adjust the rate at which the lift below the setting for the Mid Acceleration param-
truck will accelerate when the High Saver Accel eter. Press the → (right arrow) key and use the ↑
mode has been selected. See Table 45. Setting the (scroll up) and ↓ (scroll down) keys to change the
parameter to 100% will allow the lift truck to accel- value. Press the (enter) key to save the changes.
erate at the maximum rate. Setting the parameter
Table 45. High Acceleration Menu

↑
SCROLL
↓
↑
SCROLL
↓
High Accel Press Key to save
Mid Speed reduced below the setting for the Turtle Speed pa-
rameter. Press the → (right arrow) key and use the
Use this menu to adjust the maximum speed of the ↑ (scroll up) and ↓ (scroll down) keys to change the
lift truck when the mid speed mode is selected. See value. Press the (enter) key to save the changes.
Table 46. The parameter may be set up to 80% of
the maximum speed of the lift truck, but cannot be
Table 46. Mid Speed Menu

↑
SCROLL
↓
↑
SCROLL
↓
Mid Speed Press Key to save
32
Mid Acceleration truck, but cannot be reduced below the setting for the
Turtle Acceleration parameter. Press the → (right ar-
Use this menu to adjust the rate at which the lift row) key and use the ↑ (scroll up) and ↓ (scroll down)
truck will accelerate when the mid mode has been keys to change the value. Press the (enter) key to
selected. See Table 47. The parameter may be set up save the changes.
to 80% of the maximum acceleration rate of the lift
Table 47. Mid Acceleration Menu

↑
SCROLL
↓
Press → Rabbit Speed Press Key to save
Traction Setting
Key 100 Press ← Key to cancel
↑
SCROLL
↓
Mid Acceleration Press Key to save
Turtle Speed 0% to 60% of the maximum speed of the lift truck.

Press the → (right arrow) key and use the ↑ (scroll
Use this menu to adjust the maximum speed of the up) and ↓ (scroll down) keys to change the value.
lift truck when the Turtle Speed mode is selected. Press the (enter) key to save the changes.
See Table 48. The parameter may be adjusted from
Table 48. Turtle Speed Menu

↑
SCROLL
↓
↑
SCROLL
↓
Turtle Speed Press Key to save
33
Turtle Acceleration 40% to 60% of the maximum acceleration of the lift

truck. Press the → (right arrow) key and use the
Use this menu to adjust the maximum acceleration of ↑ (scroll up) and ↓ (scroll down) keys to change the
the lift truck when the Turtle Speed mode is selected. value. Press the (enter) key to save the changes.
See Table 49. The parameter may be adjusted from
Table 49. Turtle Acceleration Menu

↑
SCROLL
↓
↑
SCROLL
↓
Turtle Accel Press Key to save
Neutral Braking setting below 50% will cause the lift truck to brake at
a slower rate. The parameter may be adjusted from
Use this menu to adjust the maximum braking rate 0% to 50% of the maximum acceleration of the lift
when the control handle is returned to the neutral truck. Press the → (right arrow) key and use the
position. See Table 50. Setting the parameter to 50% ↑ (scroll up) and ↓ (scroll down) keys to change the
will cause the truck to brake at the maximum rate set value. Press the (enter) key to save the changes.
by the motor controller. Setting the parameter to a
Table 50. Neutral Braking Menu

↑
SCROLL
↓
↑
SCROLL
↓
Neutral Braking Press Key to save
34
2200 SRM 1193 View Software Versions
Plug Braking 100% will cause the lift truck to brake at a slower
rate. The parameter may be adjusted from 0% to
Use this menu to adjust the maximum braking rate 100% of the maximum acceleration of the lift truck.
when the control handle is fully reversed causing the Press the → (right arrow) key and use the ↑ (scroll
lift truck to enter the plugging mode. See Table 51. up) and ↓ (scroll down) keys to change the value.
Setting the parameter to 100% will cause the truck Press the (enter) key to save the changes.
to brake at the maximum rate set by the motor
controller. Setting the parameter at a setting below
Table 51. Plug Braking Menu

↑
SCROLL
↓
↑
SCROLL
↓
Plug Braking Press Key to save
View Software Versions

Upon entering the View Software Versions Menu • Aux Pump
from the Main Menu, the following menu functions
are visible to the service technician: Use the scroll keys to move to the desired function.
• Master Controller When finished, press the ← (left arrow) key to return
• Display to the Main Menu.
• Traction Controller
• Hydraulic Controller MASTER CONTROLLER
• Control Handle
This menu will allow the service technician to view
• Remote CAN Module
the Master Controller software version identifier.
• Steer Controller
See Table 52.
• Caster Controller (Optional)
Table 52. Master Controller Software Version
View Software Master Controller

Press → Key Press ← key to return to main menu
Versions XXXX
35
View Software Versions 2200 SRM 1193
DISPLAY
the display software version identifier. See Table 53.
Table 53. Display Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Display
Press ← key to return to main menu
XXXX
TRACTION CONTROLLER
the Traction Controller software version identifier.
See Table 54.
Table 54. Traction Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Traction Controller
XXXX
36
HYDRAULIC CONTROLLER
the Hydraulic Controller software version identifier.
See Table 55.
Table 55. Hydraulic Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Hydraulic Controller Press ← key to return to main
XXXX menu
CONTROL HANDLE
the Control Handle software version identifier. See
Table 56.
Table 56. Control Handle Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Control Handle Press ← key to return to main
XXXX menu
37
REMOTE CAN MODULE (N35ZDR, N45ZR,

N30ZDR, N35-40ZR)
the Remote CAN Module software version identifier.
See Table 57.
Table 57. Remote CAN Module Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Remote CAN Module
XXXX
STEER CONTROLLER
main steering controller. See Table 58.
Table 58. Steer Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Steer Controller
XXXX
38
CASTER CONTROLLER
the Steer Controller software version identifier. See
Table 59.
Table 59. Caster Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Caster Controller
XXXX
AUX PUMP
the Aux Pump controller software version identifier.
See Table 60.
Table 60. Aux Pump Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Aux Pump Controller
XXXX
39
Impact Sensor 2200 SRM 1193
Impact Sensor
FUNCTIONS • Impact Action
• Impact Sound
CAUTION • Clear Impact
• Hard Duration
The Impact Sensor function should never be
• Hard Acceleration
turned ON unless the truck is equipped with
• Soft Duration
impact sensor hardware.
• Soft Acceleration
Within the Impact Sensor menu, the service techni- These functions are available only to a supervisor or
cian has access to the following dash display func- a service technician and cannot be accessed using an
tions: operator password. See Table 61.
Table 61. Impact Sensor Data Display
Impact
Sensor Press → Key Impact Action
Off Press → Key Impact Action
Off
Press * key to save
Press ← key to cancel
↑ Scroll ↓
Impact Action Press * key to save

Log Only Press ← key to cancel
↑ Scroll ↓

↑ Scroll ↓
Reduced Speed Press ← key to cancel
↑ Scroll ↓

No Lift Press ← key to cancel
Impact Sound Press * key to save

001 Press ← key to cancel
↑ Scroll ↓
Clear Impact Press * key to save

↑ Scroll ↓
Hard Duration Press * key to save

↑ Scroll ↓
Hard Accel Press * key to save

↑ Scroll ↓
Soft Duration Press * key to save

↑ Scroll ↓
Soft Accel Press * key to save

40
FUNCTIONS sustained over the period of time set with the HARD
DURATION parameter. This parameter may be set
Impact Action from 0 to 255. Increasing the parameter number will
increase the amount of deceleration that must be sus-
Entering this function allows the service technician tained to be recorded as an impact.
to change how the lift truck will react after sensing
an impact. This function may be set for the following Soft Duration
actions:
• OFF - No action will be taken This function increased or decreased the amount of
• Log Only - The impact will be logged in the truck time the impact must be sustained at the level set
Error Log with the SOFT ACCELERATION parameter in order
• Reduced Speed - The lift truck will operate at "Tur- to set a soft impact in the error log and initiate the
tle" speed until reset action set by the IMPACT ACTION parameter. This
• No Lift - Lifting will be disabled until reset and the parameter may be set from 0 to 255. Increasing the
lift truck will operate at "Turtle" speed parameter number will increase the amount of time
the impact must be sustained to be recorded as an
Impact Sound impact. For SOFT impacts, this parameter will be
set higher than the HARD DURATION parameter.
Entering this function allows the service technician
to set the duration of the audible alarm. Select a Sort Acceleration
value between 1 and 9. A setting of 1 will turn the
alarm on for 15 seconds. Each additional number will This function increases or decreased the severity
increase the alarm time by 15 seconds. A setting of 9 of the impact required to set a SOFT impact in the
will cause the alarm to be "continuous." error log and initiate the action set by the IMPACT
ACTION parameter. This severity of impact must
Clear Impact be sustained over the period of time set with the
SOFT DURATION parameter. This parameter may
Entering this function allows the service technician be set from 0 to 255. Increasing the parameter value
to clear the impact sensor after an impact has oc- will increase the amount of deceleration that must
curred and restore normal truck operation. be sustained to be recorded as an impact. For SOFT
impacts, this parameter will be set lower than the
Hard Duration HARD ACCELERATION parameter.
This function increased or decreased the amount of
time the impact must be sustained at the level set
Impact Events
with the Hard Acceleration parameter in order to set Lift trucks equipped with the original impact sensor
a HARD impact in the error log and initiate the ac- leave the factory with the sensor deactivated and set
tion set by the IMPACT ACTION parameter. This with default parameter values. The impact sensor is
parameter may be set from 0 to 255. Increasing the equipped with an accelerometer that measures the
parameter number will increase the amount of time rate and time of truck deceleration continuously and
the impact must be sustained to be recorded as an monitors how strong the deceleration is and how long
impact. For HARD impacts, this parameter will be it lasts. A HARD impact is defined as a high rate of
set lower than the SOFT DURATION parameter. deceleration occurring over a short period of time. A
SOFT impact is defined as a lower rated of deceler-
Hard Acceleration ation occurring over a longer period of time. There-
This function increased or decreases the severity of fore a SOFT impact would have the SOFT ACCEL
the impact required to set a Hard impact in the error parameter set to a low level and the Soft Duration
log and initiate the action set by the IMPACT AC- parameter set at a high level.
TION parameter. This severity of impact must be
41
Password Menu 2200 SRM 1193
Password Menu
NOTE: A technician level password is required to in- It is recommended to change the Factory Level pass-
put initial Supervisor and Operator passwords into word from the default after initial setup is complete,
the dash display. to prevent unauthorized access. Changing the Fac-
tory Level password can only be accomplished using
There are four password levels that will allow vary- ETACC to change the Factory Level password in the
ing degrees of access to add, edit, or delete pass- "New Value" column of the "Factory Set Up Menu."
words. The password option must first be turned
on using the display or ETACC for the passwords to Factory level access without a Factory level password
work. is only available when using the ETACC system. Ad-
• Operator Level passwords only allow an operator ditionally, passwords of any level that have been lost
to activate lift truck functions when the password can be reset, added, edited, or deleted using ETACC.
option is enabled. This level does not allow access
to add, edit or delete any passwords. NOTE: Technician level passwords should not be set
• Supervisor Level passwords can add, edit, and the same as the Factory Default password. Addition-
delete all Operator level passwords as well as edit ally, any time a Factory Level password is used to
the currently active Supervisor password. This access the set up menu to change any factory values,
password level also allows the supervisor to reset the Factory Level password number must be reen-
certain functions such as the optional impact sen- tered or changed or ETACC programming will auto-
sor. matically reset the Factory Level password to the de-
• Technician Level password access is required fault (55555SERVICE) when "Download" is selected.
to add, delete, or edit Supervisor level passwords.
Within the Passwords menu, the service technician
Anyone with Technician level access can add,
has access to the following dash display functions:
delete, or edit Supervisor or Operator level pass-
• Add Password
words.
• Delete Password
• The Factory Level password installed at the fac-
• Edit Password
tory is 55555. Use this default password when
These functions are not available when using an op-
initially setting up the lift truck with ETACC for
erator password.
the customer to input the initial Supervisor, Oper-
ator, and additional Technician passwords in the
display.
42
2200 SRM 1193 Password Menu
ADD PASSWORD the → (right arrow) key to move the cursor to the next
position and repeat the process until the correct iden-
NOTE: A total of 50 passwords may be stored within tifier is displayed.
the dash display.
Use the → (right arrow) key to move to the Mode
Within the Passwords menu, use the ↑ (scroll up) or section of the screen. Use the ↑ (scroll up) and ↓
↓ (scroll down) key to highlight the Add Passwords (scroll down) keys to select a number from 1 to 4 that
menu and press the → (right arrow) key to enter the corresponds to the drive mode allowed for this user.
Add Passwords menu. See the Operating Manual for a description of the
Drive Modes available on this lift truck.
Enter the five-digit numeric password. The pass-
word is made up of five numbers from 1 to 5 (example: Use the → (right arrow) key to move to the type sec-
12345, 25314, 22222, etc.). Use the ↑ (scroll up) and tion of the screen. Use the ↑ (scroll up) and ↓ (scroll
↓ (scroll down) keys to change the individual digits down) keys to select OPERATOR, SUPERVISOR, or
of the password at the cursor position. Use the → TECHNICIAN.
(right arrow) key to move the cursor to the next posi-
tion and continue the process until all five digits are The ← (left arrow) key can be used to move the cursor
selected. See Figure 2. to the left to make any corrections to the data that
has been entered. If the information is correct, press
A user identifier may be entered under the user sec- the (enter) key to save the information and return
tion. Use the → (right arrow) key to move the cursor to the Passwords menu. Press the ← (left arrow) key
tor the first position in the user area of the screen. to cancel the entry and return to the Password Menu.
Digits 0 through 9 and letters A through Z are avail- See Figure 2.
able for use within this section. Use the ↑ (scroll up)
and ↓ (scroll down) keys to cycle through the selec-
tions until the desired character is displayed. Use
Figure 2. Add Password
43
Password Menu 2200 SRM 1193
DELETE PASSWORD keys to select the password to be deleted. See Fig-

ure 3.
Within the Passwords menu, use the ↑ (scroll up) or
↓ (scroll down) key to highlight the Delete Password Press the (enter) key. Press the (enter) key again
menu and press the → (right arrow) key to enter the to confirm deletion of the password. Press the ←
Delete Password menu. (left arrow) key twice to return to the main menu.
The password will be deleted after the key switch has
All passwords currently active on the lift truck will be been turned to the OFF position. See Figure 3.
displayed. Use the ↑ (scroll up) and ↓ (scroll down)
Figure 3. Delete Password
44
2200 SRM 1193 Password Menu
EDIT PASSWORD selections until the desired character is displayed.

Use the → (right arrow) key to move the cursor to the
Within the Passwords Menu, use the ↑ (scroll up) or next position and repeat the process until the correct
↓ (scroll down) key to highlight the Edit Password information is displayed. Use the → (right arrow)
menu and press the → (right arrow) key to enter the key to move the cursor to the next position and re-
Edit Password menu. peat the process until the correct information is dis-
played.
All passwords currently active on the lift truck will
be displayed. Use the ↑ (scroll up) and ↓ (scroll down) The ← (left arrow) key can be used to move the cursor
keys to select the password to be edited. Use the → to the left to make any further correction to the data
(right arrow) and ← (left arrow) keys to move the that has been entered. If the information is correct,
cursor to the information that needs to be changed. press the (enter) key to save the information. Press
the ← (left arrow) key twice to return to the main
Digits 0 through 9 and letters A through Z are avail-
menu. See Figure 4.
able for use in the Edit Password menu. Use the ↑
(scroll up) or ↓ (scroll down) key to cycle through the
Figure 4. Edit Password
45
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
46
USER INTERFACE
SUPERVISOR PASSWORD FUNCTIONS
(PREMIUM DISPLAY)
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1622432 2200 SRM 1240

TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
Menu Navigation ............................................................................................................................................... 2
Main Menu ......................................................................................................................................................... 2
Traction System ............................................................................................................................................. 4
Steer System .................................................................................................................................................. 5
Error Log ........................................................................................................................................................ 6
View Hourmeters ............................................................................................................................................... 7
Truck .............................................................................................................................................................. 7
Traction .......................................................................................................................................................... 7
Pump .............................................................................................................................................................. 7
Auxiliary......................................................................................................................................................... 7
Setup Menu ........................................................................................................................................................ 8
Display Settings............................................................................................................................................. 8
Display Language...................................................................................................................................... 8
Year, Month, Date, Hour, Minute, and Second ........................................................................................ 8
Display ........................................................................................................................................................... 9
Control Handle .............................................................................................................................................. 9
Remote CAN Module (N35ZDR, N45ZR, N30ZDR, N35-40ZR Only) ......................................................... 9
Aux Pump....................................................................................................................................................... 10
Passwords Menu ................................................................................................................................................ 10
View Operator Log......................................................................................................................................... 10
Add Password ................................................................................................................................................ 12
Delete Password ............................................................................................................................................ 13
Edit Password ................................................................................................................................................ 14
Setup Shelf Height............................................................................................................................................. 15
Learn Shelf Height ............................................................................................................................................ 15
Impact Sensor .................................................................................................................................................... 16
Functions........................................................................................................................................................ 17
Impact Action ............................................................................................................................................ 17
Impact Sound............................................................................................................................................. 17
Clear Impact .............................................................................................................................................. 17
Hard Duration ........................................................................................................................................... 17
Soft Duration ............................................................................................................................................. 18
Soft Acceleration........................................................................................................................................ 18
Impact Events............................................................................................................................................ 18
Maintenance Reminder ..................................................................................................................................... 18
Functions........................................................................................................................................................ 19
Maintenance Reminder............................................................................................................................. 19
Maintenance Interval................................................................................................................................ 19


N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
ii
General
DESCRIPTION This section contains information to allow a supervi-
sor access to the password functions of the dash dis-
NOTE: Initial setup of operator/supervisor pass- play. With a proper supervisor password, the super-
words must be done by a qualified dealer technician visor can access menu items not visible to persons
with service level access. Other truck functions may with operator password level access. Menu items
be adjusted through the dash display by a qualified covering optional equipment will only be displayed
dealer technician. These functions may include: for those options installed on the lift truck. See Fig-
truck speed, acceleration rate, hydraulic functions ure 1.
speeds, and motion alarm operation.
Figure 1. Premium Display Menu Access
DASH DISPLAY MENU ACCESS Table 1. Enter Password Screen
When the key is turned to the ON position, the dash

display menu access keys will be activated.
Enter Password XXXXX
If the password option is activated, the password
screen will be shown on the dash display at key ON.
Enter your five digit password using the number
keys on the dash display to display the startup If the password option is not activated, the lift truck
screen. The lift truck will be operational at this will be operational at key ON. To bring up the Main
point. To access the Main Menu, press the (enter) Menu, press the (enter) key twice to access the pass-
key twice and enter your supervisor password. Suc- word screen. Enter your five-digit password using
cessful entry of your password will automatically the number keys on the dash display. Successful en-
bring up the Main Menu options for your password try of your password will automatically bring up the
access level. See Table 1. Main Menu options for your password access level.
Refer to Passwords Menu in this section for more in-
formation.
1
Menu Navigation
Upon successful entry of your supervisor password, changing truck setup items. Use the (enter) key to
the Main Menu screen will appear on the LCD save the chosen value. Press the ← (left arrow) key
screen, and the four menu navigation push keys on repeatedly to return to the Main Menu. Press the
the right side of the display will be activated. Action (door indicator) key to return to normal truck opera-
symbols will appear on the LCD screen just to the tion.
left of the menu navigation keys. See Figure 2.
These symbols indicate the action that will be taken
when that key is pressed. The ↑ (up arrow) and the
↓ (down arrow) keys are used to move up and down
within a selected menu. The → (right arrow) key is
used to select a menu item. The ← (left arrow) key
is used to return to the previous menu. The (door
indicator) key is used to exit the Main Menu and
return to the truck operation screen.
The (pencil) key is used to edit a menu selection.

The (enter) key is used to save a value or menu
choice when in the edit mode. When in edit mode, Figure 2. Premium Dash Display Menu
use the ↑ (up arrow) and ↓ (down arrow) keys to scroll Navigation
through the options available for that menu selec-
tion. Use the _← (backspace) key when editing or
Main Menu
Upon entering the Main Menu from the password en- • Learn Shelf Height (Optional)*
try screen, the following menu functions are active to • Impact Sensor (Optional)*
the supervisor: • Maintenance Reminder
• Diagnostics *Optional items will show in menu only if the option
• View Hourmeters has been activated.
• Setup
• View SW Versions Scroll to highlight the Passwords menu option and
• Passwords press the → (right arrow) key to enter the Passwords
• Setup Shelf Height (Optional)* menu. See Passwords Menu.
Diagnostics Menu
Upon entering the Diagnostics menu from the Main with the traction and hydraulic functions not oper-
Menu (see Figure 3), the following menu functions ating. Use these menus to check the status of sys-
are visible to the service technician: tem inputs and output from truck switches and con-
• Static Diagnostics trols. Digital inputs and outputs will be displayed
• Traction System as 0=OFF and 1=ON depending on the state of the
• Hydraulic System switch. Analog inputs or outputs will be shown as
• Steer System a percentage of full output. See Table 2. Use the
• Error Log ↑ (scroll up) and the ↓ (scroll down) keys to move
through the menu items on the display screen. The
STATIC DIAGNOSTICS menu will wrap around to the beginning when the
last menu item has been displayed.
This menu allows the service technician to check the
various truck functions while the truck is stationary
2
Figure 3. Diagnostics Menu
Function Setting
BRAKE PEDAL SWITCH 0 or 1 0 = OFF 1 = ON
OPER SENSING SWITCH 0 or 1 0 = OFF 1 = ON
STEER OK 0 or 1 0 = OK 1 = FAULT
STR CTR PROX SWITCH1 0 or 1 0 = OFF 1 = ON
FREE LIFT PROX SWITCH 0 or 1 0 = OFF 1 = ON
TILT SENSOR XXX COUNT
HYD LEVEL SWITCH 0 or 1 0 = OFF 1 = ON
TILT UP SWITCH 0 or 1 0 = OFF 1 = ON
TILT DOWN SWITCH 0 or 1 0 = OFF 1 = ON
EXTEND SWITCH 0 or 1 0 = OFF 1 = ON
RETRACT SWITCH 0 or 1 0 = OFF 1 = ON
SS RIGHT SWITCH 0 or 1 0 = OFF 1 = ON
SS LEFT SWITCH 0 or 1 0 = OFF 1 = ON
HORN SWITCH 0 or 1 0 = OFF 1 = ON
TRACTION THROTTLE XXX %
HYDRAULIC THROTTLE XXX %
AFT THROTTLE XXX %
3
Function Setting
AFT SENSOR 0 or 1 0 = OFF 1 = ON
AFT HORN 0 or 1 0 = OFF 1 = ON
TRACTION SYSTEM Use the ↑ (scroll up) and the ↓ (scroll down) keys to
move through the menu items on the display screen.
This menu allows the service technician to check var- The menu will wrap around to the beginning when
ious traction system functions while the truck is be- the last menu item has been displayed.
ing operated. Use this menu to check the status and
operation of traction system components. See Ta-
ble 3.
Table 3. Traction System Menu
Function Status
TRACTION MOTOR SPEED XXXX RPM
TRACTION MOTOR CURR XXX AMPS
TRACTION MOTOR TEMP XXX C
TRACTION CONTROL TEMP XXX C
BRAKE COIL 0 or 1 0 = Set 1 = Released
AFT THROTTLE 0 or 1 0 = OFF 1 = ON
HYDRAULIC SYSTEM Use the ↑ (scroll up) and the ↓ (scroll down) keys to
ious hydraulic system functions while the truck is be- the last menu item has been displayed.
operation of hydraulic system components. See Ta-
ble 4.
Table 4. Hydraulic System Menu
Function Status
PUMP MOTOR SPEED XXXX RPM
PUMP MOTOR CURRENT XXX AMPS
PUMP MOTOR TEMP XXX C
PUMP CONTROL TEMP XXX C
PUMP THROTTLE XXX %
4
Table 4. Hydraulic System Menu (Continued)
Function Status
LOAD HOLD COIL 0 or 1 0 = OFF 1 = ON
PRESSURE TRANSDUCER XXX COUNT
AUXILIARY MOTOR SPD XXXX RPM
AUXILIARY MOTOR CURR XXX AMPS
AUXILIARY MTR TEMP XXX C
FORWARD COIL 0 or 1 0 = OFF 1 = ON
REVERSE COIL 0 or 1 0 = OFF 1 = ON
REACH COIL 0 or 1 0 = OFF 1 = ON
TILT COIL 0 or 1 0 = OFF 1 = ON
SIDESHIFT COIL 0 or 1 0 = OFF 1 = ON
AUX DIRECTION 0 or 1 0 = OFF 1 = ON
REACH SENSOR XXX COUNT
LIFT PV XXX COUNT
LOWER PV XXX COUNT
STEER SYSTEM Use the ↑ (scroll up) and the ↓ (scroll down) keys to
ious steering system functions while the truck is be- the last menu item has been displayed.
operation of steering system components. See Ta-
ble 5.
Table 5. Steer System Menu
Function Status
STEER MOTOR SPEED XXXX RPM
STEER MOTOR TEMP XXX C
STEER CONTROL TEMP XXX C
STEER OK? 0 or 1 0 = FAULT 1 = OK
STEER MOTOR ANGLE ±XXX
5
ERROR LOG Use the ↑ (scroll up) and the ↓ (scroll down) keys to
This menu allows the service technician to view the The menu will wrap around to the beginning when
error log. See Figure 4. Errors will be listed by the er- the last menu item has been displayed. Press the →
ror code followed by the error message, the hourme- (right arrow) key to view the first hourmeter reading
ter reading when the fault occurred, and the number and the last date and time the error occurred.
of times the fault has occurred.
Figure 4. Error Log Menu
6
2200 SRM 1240 View Hourmeters
View Hourmeters
Upon entering the View Hourmeters menu from the TRACTION
Main Menu (see Figure 5), the following menu items
are visible to the service technician: This function allows the service technician to see the
• Truck hours that have accumulated while the traction mo-
• Traction tor has been activated.
• Pump
• Auxiliary PUMP
When finished viewing the menu, press the ← (left
arrow) key to return to the Main Menu.
been activated.
TRUCK
This function allows the service technician to see AUXILIARY
presence switch has been activated. Press and hold
the hourglass key to access truck hours.
tor has been activated.
Figure 5. View Hourmeters Menu
7
Setup Menu
DISPLAY SETTINGS • Second
This menu allows the service technician to adjust Display Language

various display settings on the lift truck upon en-
tering the Display Settings menu (see Figure 6), the Use this setting to select the language used to display
following settings are available to the service techni- information on the dash display.
cian:
• Display Language Year, Month, Date, Hour, Minute, and
• Year Second
• Month
• Date Use these settings to enter the correct time and date
• Hour information into the dash display.
• Minute
Figure 6. Display Settings Menu
8

Upon entering the View Software Versions menu TRACTION CONTROLLER
are visible to the service technician: This menu will allow the service technician to view
• Master Controller the traction controller software version identifier.
• Display
• Traction Controller HYDRAULIC CONTROLLER
• Hydraulic Controller
• Control Handle
the hydraulic controller software version identifier.
• Steer Controller CONTROL HANDLE
• Caster Controller
• Aux Pump This menu will allow the service technician to view
See Figure 7. the control handle software version identifier.
MASTER CONTROLLER REMOTE CAN MODULE (N35ZDR, N45ZR,

This menu will allow the service technician to view N30ZDR, N35-40ZR ONLY)
the master controller software version identifier. This menu will allow the service technician to view
the CAN module software version identifier.
DISPLAY
This menu will allow the service technician to view STEER CONTROLLER
the display software version identifier. This menu will allow the service technician to view
main steering controller.
Figure 7. View SW Versions Menu
9
Passwords Menu 2200 SRM 1240
CASTER CONTROLLER AUX PUMP

This menu will allow the service technician to view This menu will allow the Supervisor to view the Aux
the caster controller software version identifier for Pump Controller software version identifier.
the optional caster steering controller.
Passwords Menu
NOTE: A technician level password is required to in- Factory level access without a Factory level password
put initial Supervisor and Operator passwords into is only available when using the ETACC system. Ad-
the dash display. ditionally, passwords of any level that have been lost
can be reset, added, edited, or deleted using ETACC.
There are four password levels that will allow vary-
ing degrees of access to add, edit, or delete pass- NOTE: Technician level passwords should not be set
words. The password option must first be turned the same as the Factory Default password. Addition-
on using the display or ETACC for the passwords to ally, any time a Factory Level password is used to
work. access the set up menu to change any factory values,
• Operator Level passwords only allow an operator the Factory Level password number must be reen-
to activate lift truck functions when the password tered or changed or ETACC programming will auto-
option is enabled. This level does not allow access matically reset the Factory Level password to the de-
to add, edit or delete any passwords. fault (55555SERVICE) when "Download" is selected.
• Supervisor Level passwords can add, edit, and
delete all Operator level passwords as well as edit Within the Passwords menu, the supervisor has ac-
the currently active Supervisor password. This cess to the following dash display functions:
password level also allows the supervisor to reset • View Operator Log
certain functions such as the optional impact sen- • Add Password
sor. • Delete Password
• Technician Level password access is required • Edit Password
to add, delete, or edit Supervisor level passwords. These functions are not available when using an op-
Anyone with Technician level access can add, erator password. See Figure 8.
words. VIEW OPERATOR LOG
Entering this function allows the supervisor to view
the login information of all users who have entered a
password into the dash display. See Figure 9.
ator, and additional Technician passwords in the This provides the supervisor with the following infor-
display. mation:
• Password
It is recommended to change the Factory Level pass-
• Time
word from the default after initial setup is complete,
to prevent unauthorized access. Changing the Fac-
ETACC to change the Factory Level password in the
"New Value" column of the "Factory Set Up Menu."
10
2200 SRM 1240 Passwords Menu
Figure 8. Passwords Menu
Figure 9. Operator Log Menu
11
ADD PASSWORD and ↓ (down arrow) keys to cycle through the selec-
NOTE: A total of 50 passwords may be stored within the → (right arrow) key to move the cursor to the next
the dash display. position and repeat the process until the correct iden-
tifier is displayed.
Within the Passwords menu, use the ↑ (up arrow) or
↓ (down arrow) key to highlight the Add Passwords Use the → (right arrow) key to move to the Mode
menu and press the → (right arrow) key to enter the section of the screen. Use the ↑ (up arrow) and ↓
Add Passwords menu. (down arrow) keys to select a number from 1 to 4 that
corresponds to the drive mode allowed for this user.
Enter the five digit numeric password. The password
See the Operating Manual for a description of the
is made up of five numbers from 1 to 5 (example:
12345, 25314, 22222, etc.). Use the ↑ (up arrow) and
↓ (down arrow) keys (or numeric keys) to change the Use the → (right arrow) key to move to the Type sec-
individual digits of the password at the cursor position of the screen. Use the ↑ (up arrow) and ↓ (down
tion. Use the → (right arrow) key to move the cursor arrow) keys to select OPERATOR or SUPERVISOR.
to the next position and continue the process until all
five are selected. The ← (left arrow) key can be used to move the cursor
to the left to make any corrections to the data that
A user identifier may be entered under the User sec- has been entered. Press the (enter) key to save the
tion. Use the → (right arrow) key to move the cursor information. See Figure 10. Press the (pencil) key
to the first position in the user area of the screen. to go back and edit the information. Press the ← (left
Digits 0 through 9 and letters A through Z are avail- arrow) key to return to the Passwords menu.
able for use within this section. Use the ↑ (up arrow)
12
DELETE PASSWORD arrow) and ↓ (down arrow) keys to select the pass-
word to be deleted.
↓ (down arrow) keys to highlight the Delete Password Press the X (delete) key to delete the selected pass-
menu and press the → (right arrow) key to enter the word. Press the ← (left arrow) key to return to the
Delete Password menu. main menu. See Figure 11.
All operator passwords and the currently active su-

pervisor password will be displayed. Use the ↑ (up
Figure 11. Delete Password
13
EDIT PASSWORD the ↑ (up arrow) and ↓ (down arrow) keys to cycle
through the selections until the desired character is
Within the Passwords menu use the ↑ (up arrow) or displayed. Use the → (right arrow) key to move the
↓ (down arrow) key to highlight the Edit Password cursor to the next position and repeat the process
menu and press the → (right arrow) key to enter the until the correct information is displayed.
Edit Password menu.
The ← (left arrow) key can be used to move the cur-
All passwords currently active on the lift truck will sor to the left to make any further corrections to the
be displayed. Use the ↑ (up arrow) and ↓ (down ar- data that has been entered. If the information is cor-
row) keys to cycle through the selections to select the rect, press the (enter) key to confirm and save the
password to be edited. Press the (pencil) key to information. Press the ← (left arrow) key to return
edit the selected password. Use the → (right arrow) to the main menu. See Figure 12.
and ← (left arrow) keys to move the cursor to the in-
formation that needs to be changed.
Digits 0 through 9 and letters A through Z are

available for use in the Edit Password menu. Use
Figure 12. Edit Password
14
2200 SRM 1240 Learn Shelf Height
Setup Shelf Height

This function presets the heights at which the shelf
height selector system will automatically stop the
forks when the shelf height selector option is enabled.
The system is capable of accepting up to 10 different
preset fork elevations. Use the ↑ (scroll up) and ↓
(scroll down) keys to highlight the pick height num-
ber to be associated with the preset elevation. Enter
the elevation in inches using the number keys on the
dash display and press the (enter) key to save the
preset height. See Figure 13.
Learn Shelf Height

ber to be associated with the preset elevation. Ele-
vate the forks to the desired elevation and press the
(enter) key to save the fork elevation and associate
it to the pick height number. See Figure 14.
15
Impact Sensor
• Clear Impact
CAUTION • Hard Duration
The Impact Sensor function should never be • Hard Acceleration
turned ON unless the truck is equipped with • Soft Duration
impact sensor hardware. • Soft Acceleration
These functions are available only to a supervisor or
Within the Impact Sensor menu, the service techni- a service technician and cannot be accessed using an
cian has access to the following dash display func- operator password. See Table 6.
tions:
• Impact Action
• Impact Sound
Impact Impact Action Impact Action Press *

Sensor
Press → Key Off
Press → Key Off key to save
Press ← key
to cancel
↑ Scroll ↓
↑ Scroll ↓ Impact Action Press *

Log Only key to save
Press ← key
to cancel
↑ Scroll ↓
Impact Action Press *

Reduced Speed key to save
Press ← key
to cancel
↑ Scroll ↓

No Lift key to save
Press ← key
to cancel
Impact Sound Press * key

001 to save
Press ← key
to cancel
↑ Scroll ↓
16
Table 6. Impact Sensor Data Display (Continued)
Clear Impact Press * key

to save
Press ← key
to cancel
↑ Scroll ↓
Hard Duration Press * key

100 to save
Press ← key
to cancel
↑ Scroll ↓
Hard Accel Press * key

160 to save
Press ← key
to cancel
↑ Scroll ↓
Soft Duration Press * key

70 to save
Press ← key
to cancel
↑ Scroll ↓
Soft Accel Press * key

250 to save
Press ← key
to cancel
FUNCTIONS Clear Impact

Impact Action Entering this function allows the service technician
to clear the impact sensor after an impact has oc-
Entering this function allows the service technician curred and restore normal truck operation.
to change how the lift truck will react after sensing
an impact. This function may be set for the following Hard Duration
actions:
• OFF - No action will be taken This function increased or decreased the amount of
• Log Only - The impact will be logged in the truck time the impact must be sustained at the level set
Error Log with the Hard Acceleration parameter in order to set
• Reduced Speed - The lift truck will operate at "Tur- a HARD impact in the error log and initiate the ac-
tle" speed until reset tion set by the IMPACT ACTION parameter. This
• No Lift - Lifting will be disabled until reset and the parameter may be set from 0 to 255. Increasing the
lift truck will operate at "Turtle" speed. parameter number will increase the amount of time
Impact Sound impact. For HARD impacts, this parameter will be
set lower than the SOFT DURATION parameter.
Entering this function allows the service technician
to set the duration of the audible alarm. Select a Hard Acceleration
alarm ON for 15 seconds. Each additional number This function increased or decreases the severity of
will increase the alarm time by 15 seconds. A setting the impact required to set a Hard impact in the error
of 9 will cause the alarm to be continuous. log and initiate the action set by the IMPACT AC-
sustained over the period of time set with the HARD
17
Maintenance Reminder 2200 SRM 1240
DURATION parameter. This parameter may be set sustained over the period of time set with the SOFT
from 0 to 255. Increasing the parameter number will DURATION parameter. This parameter may be set
increase the amount of deceleration that must be sus- from 0 to 255. Increasing the parameter value will
tained to be recorded as an impact. increase the amount of deceleration that must be sus-
tained to be recorded as an impact.
Soft Duration
Impact Events
This function increased or decreased the amount of
time the impact must be sustained at the level set Lift trucks equipped with the original impact sensor
with the SOFT ACCELERATION parameter in order leave the factory with the sensor deactivated and set
to set a soft impact in the error log and initiate the with default values. The impact sensor is equipped
action set by the IMPACT ACTION parameter. This with an accelerometer that measures the rate and
parameter may be set from 0 to 255. Increasing the time of truck deceleration continuously and moni-
parameter number will increase the amount of time tors how strong the deceleration is and how long it
the impact must be sustained to be recorded as an lasts. A HARD impact is defined as a high rate of
impact. For SOFT impacts, this parameter will be deceleration occurring over a short period of time. A
set higher than the HARD DURATION parameter. SOFT impact is defined as a lower rated of deceler-
ation occurring over a longer period of time. There-
Soft Acceleration fore a SOFT impact would have the SOFT ACCEL
parameter set to a low level and the Soft Duration
This function increases or decreased the severity of parameter set at a high level.
the impact required to set a SOFT impact in the error
log and initiate the action set by the IMPACT AC-
Maintenance Reminder
Within the Maintenance Reminder menu, the service • Maintenance Reminder
technician can enable or disable the next truck ser- • Maintenance Interval
vice reminder and set the number of hours until the These functions are available only to a service tech-
reminder is set on the dash display from the follow- nician and cannot be accessed using an operator or
ing functions: supervisor password. See Figure 15.
Figure 15. Maintenance Reminder Menu
18
2200 SRM 1240 Maintenance Reminder
FUNCTIONS Maintenance Interval

Maintenance Reminder Entering this function allows the service technician
to select the reminder interval at 200, 350, 500, 750,
Entering this function allows the service technician or 1000 hours.
to turn the service reminder ON, OFF, or to reset the
reminder time interval.
19
NOTES
____________________________________________________________
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____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
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____________________________________________________________
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____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
20
USER INTERFACE
SERVICE TECHNICIAN
(PREMIUM DISPLAY)
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1622433 2200 SRM 1241

TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
Menu Navigation ............................................................................................................................................... 2
Main Menu ......................................................................................................................................................... 2
Traction System ............................................................................................................................................. 4
Steer System .................................................................................................................................................. 5
General Truck ................................................................................................................................................ 6
Height Sensor ............................................................................................................................................ 6
Calibrate Fork Tare Down ........................................................................................................................ 6
Calibrate Fork Tare Up............................................................................................................................. 6
Calibrate Cushion Inpoint (N35ZDR, N45ZR, N30ZDR, N35-40ZR) ..................................................... 6
Calibrate Cushion Outpoint (N35ZDR, N45ZR, N30ZDR, N35-40ZR) .................................................. 6
Calibrate Mast Slowdown ......................................................................................................................... 6
Error Log ........................................................................................................................................................ 7
View Hourmeters ............................................................................................................................................... 8
Truck .............................................................................................................................................................. 8
Traction .......................................................................................................................................................... 8
Pump .............................................................................................................................................................. 8
Auxiliary......................................................................................................................................................... 8
Setup Menu ........................................................................................................................................................ 9
Lift Settings ................................................................................................................................................... 10
Lift Maximum Speed (N35ZDR, N45ZR, N30ZDR, N35-40ZR).............................................................. 10
Lower Maximum Speed (N35ZDR, N45ZR, N30ZDR, N35-40ZR) ......................................................... 10
Lift Acceleration ........................................................................................................................................ 10
Auxiliary Settings.......................................................................................................................................... 11
Fast Extend Speed .................................................................................................................................... 11
Slow Extend Speed .................................................................................................................................... 11
Fast Retract Speed .................................................................................................................................... 11
Slow Retract Speed ................................................................................................................................... 12
Tilt Up Speed ............................................................................................................................................. 12
Tilt Down Speed ........................................................................................................................................ 12
Sideshift Speed .......................................................................................................................................... 12
Reach Cushioning...................................................................................................................................... 12
Steer Settings................................................................................................................................................. 13
Steer Mode ................................................................................................................................................. 13
Steer Effort ................................................................................................................................................ 13
Steer Ratio ................................................................................................................................................. 13
Display Settings............................................................................................................................................. 14
Display Language...................................................................................................................................... 14
Year, Month, Date, Hour, Minute, and Second ........................................................................................ 14
Truck Settings................................................................................................................................................ 14
Serial Number ........................................................................................................................................... 15
Voltage........................................................................................................................................................ 15
Capacity Lbs .............................................................................................................................................. 15
Battery Type .............................................................................................................................................. 15
BDI Adjust Calibration ............................................................................................................................. 15
Extended Shift........................................................................................................................................... 15


Shelf Height Selection............................................................................................................................... 16
Load Weight Option (N35ZDR, N45ZR, N30ZDR, N35-40ZR) ............................................................... 16
Lift Limit Without Override (N35ZDR, N45ZR, N30ZDR, N35-40ZR) .................................................. 16
Lift Limit With Override........................................................................................................................... 16
Audible Alarm ........................................................................................................................................... 16
Visible Alarm Option................................................................................................................................. 17
Fork Height Display.................................................................................................................................. 17
Auto Tilt Option......................................................................................................................................... 17
Laser Option .............................................................................................................................................. 17
Carry Level Option.................................................................................................................................... 17
Slow Extended ........................................................................................................................................... 17
Simultaneous Hydraulics.......................................................................................................................... 17
Password Option ....................................................................................................................................... 17
Shutdown Timeout .................................................................................................................................... 17
Truck Inspection........................................................................................................................................ 17
Traction Settings ........................................................................................................................................... 18
Rabbit Speed.............................................................................................................................................. 18
Rabbit Acceleration ................................................................................................................................... 18
High Speed................................................................................................................................................. 18
High Acceleration ...................................................................................................................................... 18
Mid Speed .................................................................................................................................................. 19
Mid Acceleration........................................................................................................................................ 19
Turtle Speed............................................................................................................................................... 19
Turtle Acceleration .................................................................................................................................... 19
Neutral Braking ........................................................................................................................................ 19
Plug Braking.............................................................................................................................................. 19
Display ........................................................................................................................................................... 19
Control Handle .............................................................................................................................................. 19
Aux Pump....................................................................................................................................................... 20
Passwords Menu ................................................................................................................................................ 21
Functions........................................................................................................................................................ 22
View Operator Log..................................................................................................................................... 22
Add Password ............................................................................................................................................ 23
Delete Password ........................................................................................................................................ 24
Edit Password............................................................................................................................................ 24
Setup Shelf Height............................................................................................................................................. 25
Learn Shelf Height ............................................................................................................................................ 26
Impact Sensor .................................................................................................................................................... 26
Functions........................................................................................................................................................ 28
Impact Action ............................................................................................................................................ 28
Impact Sound............................................................................................................................................. 28
Clear Impact .............................................................................................................................................. 28
Hard Duration ........................................................................................................................................... 28
ii

Soft Duration ............................................................................................................................................. 28
Impact Events............................................................................................................................................ 28
Maintenance Reminder ..................................................................................................................................... 29
Functions........................................................................................................................................................ 29
Maintenance Reminder............................................................................................................................. 29
Maintenance Interval................................................................................................................................ 29
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
iii
General
DESCRIPTION technician password, the service technician can
access menu items not visible to persons with opera-
This section contains information on accessing tor-password level access.
the additional service technician functions of the
dash display. See Figure 1. With a proper service
Figure 1. Premium Dash Display
NOTE: A service technician is required to input ini- press the (enter) key twice to access the password
tial passwords into the dash display. screen. Enter your five-digit Technician level pass-
word using the number keys on the dash display.
DASH DISPLAY MENU ACCESS Successful entry of your password will automatically
bring up the Main Menu options for your technician
When the key switch is turned to the ON position, level access. See Table 1.
the dash display menu access keys will be activated.
Table 1. Enter Password Screen
If the password option is activated, the password
screen will be shown on the dash display at key
switch ON. Enter your five-digit Technician level
password using the number keys on the dash display. Enter Password XXXXX
Successful entry of your password will automatically
bring up the Main Menu options. If the password
option is not activated, the lift truck will be opera-
tional at key switch ON. To access the Main Menu,
1
Menu Navigation
When the Main Menu screen appears on the LCD or changing truck setup items. Use the (enter) key
screen, the four menu navigation keys on the right to save the chosen value. Press the ← (left arrow)
side of the display are activated. Action symbols will key repeatedly to return to the Main Menu. Push
appear on the LCD screen just to the left of the menu the (door indicator) key to return to normal truck
navigation keys. See Figure 2. These symbols in- operation.
dicate the action that will be taken when that key
is pressed. The ↑ (scroll up) and the ↓ (scroll down)
keys are used to move up and down within a selected
menu. The → (right arrow) key is used to select a
menu item. The ← (left arrow) key is used to return
to the previous menu. The (door indicator) key is
used to exit the Main Menu and return to the truck
operation screen.
The (pencil) key is used to edit a menu selection.

The (enter) key is used to save a value or menu
choice when in the edit mode. When in edit mode,
use the ↑ (scroll up) and ↓ (scroll down) arrow keys Figure 2. Premium Dash Display Menu
to scroll through the options available for that menu Navigation
selection. Use the _← (backspace) key when editing
Main Menu
Upon entering the Main Menu from the password en- • Setup Shelf Height (Optional)*
try screen, the following menu functions are active: • Learn Shelf Height (Optional)*
• Diagnostics • Impact Sensor (Optional)*
• View Hourmeters • Maintenance Reminder
• Setup *Optional items will show in menu only if the option
• View SW Versions has been activated.
• Passwords
Diagnostics Menu
Upon entering the Diagnostics menu from the Main with the traction and hydraulic functions not oper-
Menu (see Figure 3), the following menu functions ating. Use these menus to check the status of sys-
are visible to the service technician: tem inputs and output from truck switches and con-
• Static Diagnostics trols. Digital inputs and outputs will be displayed
• Traction System as 0=OFF and 1=ON depending on the state of the
• Hydraulic System switch. Analog inputs or outputs will be shown as
• Steer System a percentage of full output. See Table 2. Use the
• General Truck ↑ (scroll up) and the ↓ (scroll down) keys to move
• Error Log through the menu items on the display screen. The
menu will wrap around to the beginning when the
STATIC DIAGNOSTICS last menu item has been displayed.
This menu allows the service technician to check the

various truck functions while the truck is stationary
2
Figure 3. Diagnostics Menu
Function Setting
BRAKE PEDAL SWITCH 0 or 1 0 = OFF 1 = ON
OPER SENSING SWITCH 0 or 1 0 = OFF 1 = ON
STEER OK 0 or 1 0 = OK 1 = FAULT
FREE LIFT PROX SWITCH 0 or 1 0 = OFF 1 = ON
HYD LEVEL SWITCH 0 or 1 0 = OFF 1 = ON
TILT UP SWITCH 0 or 1 0 = OFF 1 = ON
TILT DOWN SWITCH 0 or 1 0 = OFF 1 = ON
EXTEND SWITCH 0 or 1 0 = OFF 1 = ON
RETRACT SWITCH 0 or 1 0 = OFF 1 = ON
SS RIGHT SWITCH 0 or 1 0 = OFF 1 = ON
SS LEFT SWITCH 0 or 1 0 = OFF 1 = ON
HORN SWITCH 0 or 1 0 = OFF 1 = ON
HYDRAULIC THROTTLE XXX %
REACH THROTTLE XXX %
3
Function Setting
AFT THROTTLE XXX %
AFT HORN 0 or 1 0 = OFF 1 = ON
TRACTION SYSTEM Use the ↑ (scroll up) and the ↓ (scroll down) keys to
ious traction system functions while the truck is be- the last menu item has been displayed.
operation of traction system components. See Ta-
ble 3.
Table 3. Traction System Menu
Function Status
TRACTION MOTOR SPEED XXXX RPM
TRACTION MOTOR CURR XXX AMPS
TRACTION MOTOR TEMP XXX C
TRACTION CONTROL TEMP XXX C
BRAKE COIL 0 or 1 0 = Set 1 = Released
AFT THROTTLE XXX %
HYDRAULIC SYSTEM Use the ↑ (scroll up) and the ↓ (scroll down) keys to
ious hydraulic system functions while the truck is be- the last menu item has been displayed.
operation of hydraulic system components. See Ta-
ble 4.
Table 4. Hydraulic System Menu
Function Status
PUMP MOTOR SPEED XXXX RPM
PUMP MOTOR CURRENT XXX AMPS
PUMP MOTOR TEMP XXX C
PUMP CONTROL TEMP XXX C
PUMP THROTTLE XXX %
LOAD HOLD COIL 0 or 1 0 = OFF 1 = ON
4
Table 4. Hydraulic System Menu (Continued)
Function Status
PRESSURE TRANSDUCER XXX COUNT
AUXILIARY MOTOR SPD XXXX RPM
AUXILIARY MOTOR CURR XXX AMPS
AUXILIARY MTR TEMP XXX C
FORWARD COIL 0 or 1 0 = OFF 1 = ON
REVERSE COIL 0 or 1 0 = OFF 1 = ON
REACH COIL 0 or 1 0 = OFF 1 = ON
TILT COIL 0 or 1 0 = OFF 1 = ON
SIDESHIFT COIL 0 or 1 0 = OFF 1 = ON
AUX DIRECTION 0 or 1 0 = OFF 1 = ON
REACH SENSOR XXX COUNT
LIFT PV XXX COUNT
LOWER PV XXX COUNT
STEER SYSTEM Use the ↑ (scroll up) and the ↓ (scroll down) keys to
ious steering system functions while the truck is be- the last menu item has been displayed.
operation of steering system components. See Ta-
ble 5.
Table 5. Steer System Menu
Function Status
STEER MOTOR SPEED XXXX RPM
STEER MOTOR TEMP XXX C
STEER CONTROL TEMP XXX C
STEER OK? 0 or 1 0 = FAULT 1 = OK
STEER MOTOR ANGLE ±XXX
5
GENERAL TRUCK portion of lifting. Scroll to the function using the

↑ (scroll up) and the ↓ (scroll down) keys until the
NOTE: Some functions may not be available on some function is highlighted. With no load on the forks,
lift truck models. lift the forks approximately 300 mm (12 in.) above
the ground level and press the (enter) key to cali-
This menu allows the service technician to check and
brate this function.
calibrate certain truck functions. See Table 6.
Calibrate Fork Tare Up
Height Sensor
This function establishes the unloaded zero point
This function allows the service technician to check
when the reach mechanism is within the main lift
the status of the operation of the height sensor. The
portion of lifting. Scroll to the function using the
reading of the height sensor on the dash display
↑ (scroll up) and the ↓ (scroll down) keys until the
should match the actual fork height.
function is highlighted. With no load on the forks,
lift the forks until the main lift cylinders extend
Calibrate Fork Tare Down
approximately 300 mm (12 in.) above the fully
This function establishes the unloaded zero point retracted position and press the (enter) key to
when the reach mechanism is within the freelift calibrate this function.
Table 6. General Truck Menu
Function Status
HEIGHT SENSOR XXX In.
CAL FORK TARE DN XXX lbs.
CAL FORK TARE UP XXX lbs.
CAL CUSH INPOINT XXXXX COUNT
CAL CUSH OUTPOINT XXXXX COUNT
CAL MAST SLWDN XXXXX COUNT
Calibrate Cushion Inpoint (N35ZDR, as the mechanism is being extended and is nearing
N45ZR, N30ZDR, N35-40ZR) the end of the reach cylinder strike. The outpoint can
be changed by using the number keys to increase or
This function establishes the point at which the decrease the count value shown on the dash display.
reach mechanism will begin to cushion (slow down)
as the mechanism is being retracted and is nearing Calibrate Mast Slowdown
the end of the reach cylinder stroke. The inpoint can
be changed by using the number keys to increase or This function establishes the point at which the mast
decrease the count value shown on the dash display. speed will be reduced as the mast is being extended
and the forks are nearing maximum elevation level.
Calibrate Cushion Outpoint (N35ZDR, The mast slowdown point can be changed by using
N45ZR, N30ZDR, N35-40ZR) the number keys to increase or decrease the count
value shown on the dash display.
This function establishes the point at which the
reach mechanism will begin to cushion (slow down)
6
ERROR LOG Use the ↑ (scroll up) and the ↓ (scroll down) keys to
This menu allows the service technician to view the The menu will wrap around to the beginning when
error log. See Figure 4. Errors will be listed by the er- the last menu item has been displayed. Press the →
ror code followed by the error message, the hourme- (right arrow) key to view the first hourmeter reading
ter reading when the fault occurred, and the number and the last date and time the error occurred.
of times the fault has occurred.
Figure 4. Error Log Menu
7
View Hourmeters 2200 SRM 1241
View Hourmeters
Upon entering the View Hourmeters menu from the TRACTION
Main Menu (see Figure 5), the following menu items
are visible to the service technician: This function allows the service technician to see the
• Truck hours that have accumulated while the traction mo-
• Traction tor has been activated.
• Pump
• Auxiliary PUMP
When finished viewing the menu, press the ← (left
arrow) key to return to the Main Menu.
been activated.
TRUCK
This function allows the service technician to see AUXILIARY
presence switch has been activated. Press and hold
the hourglass key to access truck hours.
tor has been activated.
Figure 5. View Hourmeters Menu
8
Setup Menu
Upon entering the Setup menu from the Main Menu Use the ↑ (scroll up) and the ↓ (scroll down) keys
(see Figure 6), the following menu functions are vis- to move through the menu selections. The selected
ible to the service technician: menu item will be highlighted as you move through
• Lift Settings the menu. Use the → (right arrow) key to select a
• Auxiliary Settings menu item.
• Steer Settings
• Display Settings To revise a setting, highlight the parameter to be
• Truck Settings changed and press the (pencil) key. This will high-
• Traction Settings light the setting to be changed. Change the setting
For a complete description of the performance pa- using the 1 through 0 number keys. Pressing the
rameters accessible through the dash display, see AC (enter) key will save the new setting. Press the ←
Motor Controllers/Display Panel, Description, (left arrow) key to return to the previous menu.
Checks, Adjustments, and Troubleshooting
2200 SRM 1308 or AC Motor Controllers/Display
Panel, Description, Checks, Adjustments, and
Troubleshooting 2200 SRM 1190.
Figure 6. Setup Menu
9
LIFT SETTINGS Lower Maximum Speed (N35ZDR, N45ZR,

N30ZDR, N35-40ZR)
This menu allows the service technician to set vari-
ous lift/lower settings on the lift truck. Upon enter- This setting adjusts the maximum speed of the lift
ing the Lift Settings menu (see Figure 7), the follow- motor during lowering. This setting adjusts the max-
ing settings are available to the service technician: imum speed of the lift motor during lowering. This
• Lift Maximum Speed parameter can be set between 100 and 50. A setting
• Lower Maximum Speed of 100% will allow the lift motor to lower at the max-
imum rate. Setting the parameter below 100% will
Lift Maximum Speed (N35ZDR, N45ZR, cause the motor speed to be reduced. Use the number
N30ZDR, N35-40ZR) keys to increase or decrease the count value shown on
the dash display.
This setting adjusts the maximum speed of the lift
motor during lifting. This parameter can be set be- Lift Acceleration
tween 100 and 50. A setting of 100% will allow the lift
motor to operate at the maximum rate. Setting the This setting adjusts the acceleration rate of the lift
parameter below 100% will cause the motor speed to motor during lifting. A setting of 100% will allow the
be reduced. Use the number keys to increase or de- lift motor to accelerate at the maximum rate. Set-
crease the count value shown on the dash display. ting the parameter below 100% will cause the accel-
eration rate to be reduced. Use the number keys to
increase or decrease the count value shown on the
dash display.
Figure 7. Lift Settings Menu
10
AUXILIARY SETTINGS Slow Extend Speed

This menu allows the service technician to set vari- Use this setting to adjust the maximum extend speed
ous auxiliary function settings on the lift truck. Upon of the reach attachment when the slow extend control
entering the Auxiliary Settings menu, the following is activated. Setting the parameter to 50% will allow
settings are available to the service technician. See the reach attachment to extend at the slowest speed.
Figure 8. Setting the parameter above 50% will increase the
• Fast Extend Speed extend speed of the reach attachment. The minimum
• Slow Extend Speed setting is 50%. The maximum setting is 100%. Use
• Fast Retract Speed the number keys to increase or decrease the count
• Slow Retract Speed value shown on the dash display. The parameter may
• Tilt Up Speed not be set higher than the fast extend speed param-
• Tilt Down Speed eter.
• Sideshift Speed
• Reach Cushioning Fast Retract Speed
Fast Extend Speed Use this setting to adjust the maximum retract speed
of the reach attachment when the fast retract con-
Use this setting to adjust the maximum extend speed trol is activated. Setting the parameter to 100% will
of the reach attachment when the fast extend con- allow the reach attachment to retract at maximum
trol is activated. Setting the parameter to 100% will speed. Setting the parameter below 100% will reduce
allow the reach attachment to extend at maximum the retract speed of the reach attachment. Use the
speed. Setting the parameter below 100% will re- number keys to increase or decrease the count value
duce the extend speed of the reach attachment. the shown on the dash display.
minimum setting is 50%. Use the number keys to in-
crease or decrease the count value shown on the dash
display.
Figure 8. Auxiliary Settings Menu
11
Slow Retract Speed in maximum tilt down speed. Setting the parame-
ter below 100% will reduce the speed of the tilt down
Use this setting to adjust the maximum retract speed function. The minimum setting is 30%. The maxi-
of the reach attachment when the slow retract con- mum setting is 100%. Use the number keys to in-
trol is activated. Setting the parameter to 30% will crease or decrease the count value shown on the dash
allow the reach attachment to retract at the slow- display.
est speed. Setting the parameter above 30% will in-
crease the retract speed of the reach attachment. The Sideshift Speed
minimum setting is 30%. The maximum setting is
100%. The parameter may not be set higher than Use this setting to adjust the speed of the sideshift.
the fast retract speed parameter. Setting the parameter to 70% will result in maximum
sideshift speed. Setting the parameter below 70%
Tilt Up Speed will reduce the speed of the sideshift. The minimum
setting is 40%. The maximum setting is 70%. Use
Use this setting to adjust the speed of the tilt up func- the number keys to increase or decrease the count
tions. Setting the parameter to 100% will result in value shown on the dash display. Use the number
maximum tilt up speed. Setting the parameter be- keys to increase or decrease the count value shown
low 100% will reduce the speed of the tilt up func- on the dash display.
tion. The minimum setting is 30%. The maximum
setting is 100%. Use the number keys to increase or Reach Cushioning
decrease the count value shown on the dash display.
This menu sets the speed of the auxiliary pump
Tilt Down Speed motor for cushioning the reach carriage mechanism.
The minimum speed is 300 RPM. The maximum
Use this setting to adjust the speed of the tilt down speed is 1800 RPM.
function. Setting the parameter to 100% will result
12
STEER SETTINGS facing and the aft controls are activated, the steer-
ing changes such that it becomes “automotive,” from
This menu allows the service technician to adjust that orientation.
various steering function settings on the lift truck.
Upon entering the Steer Setting menu (see Figure 9), NOTE: The FORE/AFT AUTO parameter can be ac-
the following settings are available to the service tivated only if the lift truck is equipped with the Aft
technician: Travel Control Handle option.
• Steer Mode
• Steer Effort Steer Effort
• Steer Ratio
Use this setting to adjust the amount of effort re-
Steer Mode quired to turn the steering wheel. Setting the param-
eter to STIFF will result in maximum steer effort.
Use this menu to select the action of the steering sys- Setting the parameter below STIFF will reduce the
tem. Setting the parameter to AUTO will cause the amount of effort required to turn the steering wheel.
steering system to turn the lift truck in the direction The effort settings available are STIFF, MED STIFF,
the steer disk is turned when moving in the direc- MED, MED LIGHT, and LIGHT.
tion of the forks, much the same as driving an auto-
mobile (automotive style). Setting the parameter to Steer Ratio
REVERSE will cause the steering system to turn the
lift truck in the opposite direction of the steer disk Use this setting to increase or decrease the number of
when moving in the direction of the forks, opposite of lock-to-lock turns of the steering function. The min-
AUTO. Setting the parameter to FORE/AFT AUTO imum setting is 40%. The maximum setting is 65%.
will cause the steering to function the same as AUTO Setting the parameter to a higher number increases
when driving in the forward stance. When rearward the number of lock-to-lock turns.
Figure 9. Steer Setting Menu
13
DISPLAY SETTINGS • Second
This menu allows the service technician to adjust Display Language

various display settings on the lift truck upon enter-
ing the Display Settings menu (see Figure 10), the Use this setting to select the language used to display
following settings are available to the service techni- information on the dash display.
cian:
• Display Language Year, Month, Date, Hour, Minute, and
• Year Second
• Month
• Date Use these settings to enter the correct time and date
• Hour information into the dash display.
• Minute
Figure 10. Display Settings Menu
TRUCK SETTINGS • Lift Limit W/O Override

• Lift Limit With Override
This menu allows the service technician to adjust • Audible Alarm
various truck settings. Upon entering the Truck Set- • Visible Alarm Option
tings menu (see Figure 11), the following settings are • Fork Height Display
available to the service technician: • Auto Tilt Option
• Serial Number • Laser Option
• Voltage • Carry Level Option
• Capacity Lbs • Slow Extended
• Battery Type • Simultaneous Hydraulics
• BDI Adjust Calibration • Password Option
• Extended Shift • Shutdown Timeout
• Shelf Height Selection • Truck Inspection
• Load Weight Option
14
Serial Number BDI Adjust Calibration

This menu is used to store and display the truck se- Use the BDI (Battery Discharge Indicator) Adjust
rial number. Calibration to adjust the Lift Interrupt setting. Ad-
justing the value higher will increase the level of bat-
Voltage tery voltage at which Lift Interrupt will occur. Low-
ering the value will allow the battery to discharge to
This menu is used to store and display the truck volt- a lower voltage before Lift Interrupt will occur. The
age. minimum setting is 0%. The maximum setting is
70%.
Capacity Lbs
This menu is used to store and display the truck max-
Extended Shift
imum capacity. Use this setting to enable or disable the Extended
Shift option. Setting the parameter to ON will enable
Battery Type the option, OFF will disable the option.
This menu is used to store and display the type of bat-
tery installed on the lift truck. Select either flooded
or maintenance free.
Figure 11. Truck Settings Menu
15
Shelf Height Selection Load Weight Option (N35ZDR, N45ZR,

N30ZDR, N35-40ZR)
Use this setting to activate the Shelf Height Selection
feature. See Figure 12. Once activated, the Shelf Use this setting to enable or disable the load weight
Height Selector System operates as follows: display functions. Setting the parameter to ON will
enable the options.
Lift Limit Without Override (N35ZDR,

Use this setting to enable or disable the Lift Limit
Without Override option. Setting the parameter to
ON will enable the option, OFF will disable the op-
tion. The encoder hardware must be correctly in-
stalled along with the settings made for the free lift
and lift limit heights. These settings can be made
with ETACC.
Figure 12. Shelf Height Selector System Screen
NOTE: If Lift Limit Without Override and Lift Limit
NOTE: The Shelf Height Selector System will only With Override are both enabled then Lift Limit With-
function for shelf heights above the freelift range (af- out Override will have priority.
ter the mast begins to extend out from the top) of the
mast installed on the lift truck. Lift Limit With Override
1. The → (right arrow) key activates the PICK func- Use this setting to enable or disable the Lift Limit
tion. The ← (left arrow) key activates the PLACE With Override option. Setting the parameter to ON
function. Press PICK to retrieve a load from a will enable the option, OFF will disable the option.
shelf or press PLACE to place a load on a shelf. The encoder hardware must be correctly installed
along with the settings made for the free lift and
2. Enter the number assigned to the desired shelf lift limit heights. These settings can be made with
height by using the number keys on the display. ETACC.
3. The selected shelf height and the selected opera-
tion will then be shown on the dash display. Move
Audible Alarm
the control handle to lift or lower the forks to the Use this setting to select the mode of operation of
desired elevation. the motion alarm. Setting the parameter to OFF
disables the audible alarm. Setting the parameter
4. When the forks are within the control zone of the
to BACK UP allows the audible alarm to sound only
system, the Shelf Height Selector System will
when the truck is traveling in the reverse direction.
control the Lift/Lower function and smoothly
Setting the parameter to FWD/REV allows the au-
bring the forks to a stop at the target height.
dible alarm to sound only when the truck is travel-
5. PICK or PLACE the load. ing, regardless of direction. Setting the parameter
to FWD/REV AND L/L allows the audible alarm to
6. Repeat Step 1 through Step 5 to PICK or PLACE sound whenever the truck is traveling, and whenever
another load. the truck is lifting or lowering.
16
Visible Alarm Option the slow lower speed when the forks reach the preset
carry level and will activate the audible alarm.
Use this setting to select the mode of operation of
the visible alarm. Setting the parameter to OFF dis- Slow Extended
ables the visible alarm. Setting the parameter to
BACK UP allows the visible alarm to operate only NOTE: This is a paid option and will be initially
when the truck is traveling in the reverse direction. enabled with an option code (models N35ZDRS,
Setting the parameter to FWD/REV allows the vis- N45ZRS, N30ZDRS, N35-40ZRS must also be
ible alarm to operate only when the truck is travel- equipped with specific hardware for this option).
ing, regardless of direction. Setting the parameter
to FWD/REV AND L/L allows the visible alarm to This menu will allow the service technician to view
sound whenever the truck is traveling, and/or when- the steer controller software version identifier for the
ever the truck is lifting or lowering. Setting the pa- main steering controller.
rameter to CONTINUOUS enables the visible alarm
to operate continuously after the truck key switch is Simultaneous Hydraulics
turned to the ON position. Use this setting to select the mode of operation for
simultaneous operation of certain hydraulic func-
Fork Height Display tions. Setting the parameter to NONE will disable
Use this setting to enable or disable the Fork Height any simultaneous operation. Setting the parameter
Display option. Setting the parameter to ON will en- to FULL will allow simultaneous operation of hy-
able the option, OFF will disable the option. The draulic functions at full operating speed. Setting
encoder hardware must be correctly installed along the parameter to LIMITED will allow simultaneous
with the settings made for the free lift and lift limit operation at reduced operating speed only.
heights. These settings can be made with ETACC.
Password Option
Auto Tilt Option Use this setting to enable or disable the password op-
Use this setting to enable or disable the Auto Tilt tion. Set the parameter to ON to enable the password
option. Setting the parameter to ON will enable the option. Set the parameter to OFF to disable the pass-
option. word option.
Laser Option Shutdown Timeout
Use this setting to enable or disable the Laser option. Use this setting to adjust the amount of time the
Setting the parameter to ON will enable the option, lift truck can remain inactive before activating au-
OFF will disable the option. tomatic power shutdown. Set the parameter to any
value between 1 minute and 35 minutes.
Carry Level Option
Truck Inspection
Use this setting to enable and set the Carry Level
option. Setting the parameter to OFF will disable Use this setting to turn the operator checklist option
the Carry Level option. Setting the parameter to ON or OFF.
STOP will stop the forks at the preset carry level
when the forks are being lowered. Setting the pa-
rameter to BEEP will reduce the lowering speed to
17
TRACTION SETTINGS • High Speed

• High Accel
This menu allows the service technician to adjust • Mid Speed
various traction functions settings on the lift truck. • Mid Accel
Upon entering the Traction Settings menu (see Fig- • Turtle Speed
ure 13), the following settings are available to the • Turtle Accel
service technician: • Neutral Braking
• Rabbit Speed • Plug Braking
• Rabbit Accel
Figure 13. Traction Settings Menu
Rabbit Speed High Speed

Use this setting to adjust the maximum speed of the Use this setting to adjust the maximum speed of
lift truck when the rabbit mode is selected. Setting the lift truck when the battery saver mode is se-
the parameter to 100% will allow the lift truck to lected. Setting the parameter to 100% will allow
travel at maximum speed. Setting the parameter be- the lift truck to travel at maximum speed. Setting
low 100% will cause the lift truck to operate at a re- the parameter below 100% will cause the lift truck
duced top speed. The parameter setting cannot be to operate at a reduced top speed. The parameter
reduced below the setting for the mid speed parame- setting cannot be reduced below the setting for the
ter. mid speed parameter.
Rabbit Acceleration High Acceleration

Use this setting to adjust the rate at which the lift Use this setting to adjust the rate at which the lift
truck will accelerate when the rabbit mode has been truck will accelerate when the battery saver mode
selected. Setting the parameter to 100% will allow has been selected. Setting the parameter to 100%
the lift truck to accelerate at the maximum rate. Set- will allow the lift truck to accelerate at the maximum
ting the parameter below 100% will cause the accel- rate. Setting the parameter below 100% will cause
eration rate to be reduced. The parameter setting the acceleration rate to be reduced. The parameter
cannot be reduced below the setting for the mid ac- setting cannot be reduced below the setting for the
celeration parameter. mid acceleration parameter.
18
Mid Speed Turtle Acceleration

Use this setting to adjust the maximum speed of the Use this setting to adjust the maximum acceleration
lift truck when the Mid Speed mode is selected. The of the lift truck when the Turtle Speed mode is se-
parameter may be set up to 80% of the maximum lected. The parameter may be adjusted from 40% to
speed of the lift truck, but cannot be reduced below 60% of the maximum acceleration of the lift truck.
the setting for the Turtle Speed parameter.
Neutral Braking
Mid Acceleration
Use this setting to adjust the maximum braking rate
Use this setting to adjust the rate at which the lift when the control handle is returned to the neutral
truck will accelerate when the Mid Accel mode has position. Setting the parameter to 50% will cause the
been selected. The parameter may be set up to 80% truck to brake at the maximum rate set by the motor
of the maximum acceleration rate of the lift truck, controller. Setting the parameter to a setting below
but cannot be reduced below the setting for the Turtle 50% will cause the lift truck to brake at a slower rate.
Acceleration parameter. The minimum setting is 0%, which allows the truck
to coast.
Turtle Speed
Plug Braking
Use this setting to adjust the maximum speed of the
lift truck when the Turtle Speed mode is selected. Use this setting to adjust the maximum braking rate
The parameter may be adjusted from 0% to 60% of when the control handle is fully reversed causing the
the maximum acceleration of the lift truck. lift truck to enter the plugging mode. Setting the
parameter to 70% will cause the truck to brake at the
maximum rate set by the motor controller. Setting
the parameter at a setting below 70% will cause the
lift truck to brake at a slower rate. The minimum
setting is 40%. The maximum setting is 70%.

Upon entering the View Software Versions menu DISPLAY
are visible to the service technician: This menu will allow the service technician to view
• Master Controller the display software version identifier.
• Display
• Traction Controller TRACTION CONTROLLER
• Hydraulic Controller
• Control Handle
the traction controller software version identifier.
• Steer Controller HYDRAULIC CONTROLLER
• Caster Controller
• Aux Pump This menu will allow the service technician to view
See Figure 14. the hydraulic controller software version identifier.
MASTER CONTROLLER CONTROL HANDLE

This menu will allow the service technician to view This menu will allow the service technician to view
the master controller software version identifier. the control handle software version identifier.
19
Figure 14. View SW Versions Menu
REMOTE CAN MODULE (N35ZDR, N45ZR, CASTER CONTROLLER

N30ZDR, N35-40ZR)
This menu will allow the service technician to view the caster controller software version identifier for
the CAN module software version identifier. the optional caster steering controller.
STEER CONTROLLER AUX PUMP

This menu will allow the service technician to view This menu will allow the service technician to view
the steer controller software version identifier for the the Aux Pump controller software version identifier.
main steering controller.
20
Passwords Menu
Within the Passwords menu, the technician has ac-
cess to the following dash display functions:
• View Operator Log
words.
• Add Password
• Delete Password
• Edit Password
erator password. See Figure 15.
display.
Figure 15. Passwords Menu
21
FUNCTIONS password into the dash display. See Figure 16. This
provides the following information:
View Operator Log • Password
• Time
Entering this function allows the technician to view
the login information of all users who have entered a
Figure 16. Operator Log Menu
22
Add Password the → (right arrow) key to move the cursor to the next
the dash display.
Within the Passwords menu, use the ↑ (scroll up) or section of the screen. Use the ↑ (scroll up) and ↓
↓ (scroll down) key to highlight the Add Passwords (scroll down) keys to select a number from 1 to 4 that
word is made up of five numbers from 1 to 5 (example: NOTE: Technicians can add Technician, Supervisor,
12345, 25314, 22222, etc.). Use the ↑ (scroll up) and and Operator passwords.
↓ (scroll down) keys (or numeric keys) to change the
individual digits of the password at the cursor posi- Use the → (right arrow) key to move to the type sec-
tion. Use the → (right arrow) key to move the cursor tion of the screen. Use the ↑ (scroll up) and ↓ (scroll
to the next position and continue the process until all down) keys to select OPERATOR, TECHNICIAN, or
five digits are selected. See Figure 17. SUPERVISOR.
A user identifier may be entered under the user sec- The ← (left arrow) key can be used to move the cursor
tion. Use the → (right arrow) key to move the cursor to the left to make any corrections to the data that
to the first position in the user area of the screen. has been entered. If the information is correct, press
Digits 0 through 9 and letters A through Z are avail- the (enter) key to save the information and return
able for use within this section. Use the ↑ (scroll up) to the Passwords menu. Press the (pencil) key to
and ↓ (scroll down) keys to cycle through the selec- go back and edit the information. Press the ← (left
tions until the desired character is displayed. Use arrow) key to return to the Main Menu.
23
Delete Password All passwords currently active on the lift truck will be
displayed. Use the ↑ (scroll up) and ↓ (scroll down)
NOTE: Service Technicians can delete their own keys to select the password to be deleted. See Fig-
Technician level password as well as all Supervisor ure 18.
and Operator passwords.
Press the X (delete) key to delete the selected pass-
Within the Passwords menu, use the ↑ (scroll up) or word. Press the ← (left arrow) key to return to the
↓ (scroll down) key to highlight the Delete Password Main Menu.
menu and press the → (right arrow) key to enter the
Delete Password Menu.
Figure 18. Delete Password Menu
Edit Password Digits 0 through 9 and letters A through Z are avail-

NOTE: Service Technicians can edit their own Tech- (scroll up) or ↓ (scroll down) key to cycle through the
nician level password as well as all Supervisor and selections until the desired character is displayed.
Operator passwords. Use the → (right arrow) key to move the cursor to the
next position and repeat the process until the correct
Within the Passwords menu, use the ↑ (scroll up) or
information is displayed.
↓ (scroll down) key to highlight the Edit Password
menu and press the (pencil) key to enter the Edit The ← (left arrow) key can be used to move the cursor
Password menu. to the left to make any further correction to the data
that has been entered. If the information is correct,
All passwords currently active on the lift truck will
press the (enter) key to save the information. Press
be displayed. Use the ↑ (scroll up) and ↓ (scroll down)
the ← (left arrow) key to return to the Main Menu.
keys to select the password to be edited. Use the →
See Figure 19.
(right arrow) and ← (left arrow) keys to move the
cursor to the information that needs to be changed.
24
2200 SRM 1241 Setup Shelf Height
Figure 19. Edit Password Menu
Setup Shelf Height

ber to be associated with the preset elevation. Enter
the elevation in inches using the number keys on the
dash display and press the (enter) key to save the
preset height. See Figure 20.
25
Learn Shelf Height

ber to be associated with the preset elevation. Ele-
vate the forks to the desired elevation and press the
(enter) key to save the fork elevation and associate
it to the pick height number. See Figure 21.
Impact Sensor
• Impact Sound
The Impact Sensor function should never be • Hard Duration
turned ON unless the truck is equipped with • Hard Acceleration
impact sensor hardware. • Soft Duration
• Impact Action
26
Impact
Sensor Press → Key Impact Action
Off Press → Key Impact Action
Off
Press * key to save
↑ Scroll ↓

Log Only Press ← key to cancel
↑ Scroll ↓

↑ Scroll ↓
Reduced Speed Press ← key to cancel
↑ Scroll ↓

No Lift Press ← key to cancel
Impact Sound Press * key to save

↑ Scroll ↓
Clear Impact Press * key to save

↑ Scroll ↓
Hard Duration Press * key to save

↑ Scroll ↓
Hard Accel Press * key to save

↑ Scroll ↓
Soft Duration Press * key to save

↑ Scroll ↓
Soft Accel Press * key to save

27
FUNCTIONS log and initiate the action set by the IMPACT AC-
Impact Action sustained over the period of time set with the HARD
DURATION parameter. This parameter may be set
Entering this function allows the service technician from 0 to 255. Increasing the parameter number will
to change how the lift truck will react after sensing increase the amount of deceleration that must be sus-
an impact. This function may be set for the following tained to be recorded as an impact.
actions:
• OFF - No action will be taken Soft Duration
• Log Only - The impact will be logged in the truck
Error Log This function increased or decreased the amount of
• Reduced Speed - The lift truck will operate at "Tur- time the impact must be sustained at the level set
tle" speed until reset with the SOFT ACCELERATION parameter in order
• No Lift - Lifting will be disabled until reset and the to set a soft impact in the error log and initiate the
lift truck will operate at "Turtle" speed action set by the IMPACT ACTION parameter. This
parameter may be set from 0 to 255. Increasing the
Impact Sound parameter number will increase the amount of time
Entering this function allows the service technician impact. For SOFT impacts, this parameter will be
to set the duration of the audible alarm. Select a set higher than the HARD DURATION parameter.
alarm ON for 15 seconds. Each additional number Soft Acceleration
will increase the alarm time by 15 seconds. A setting
of 9 will cause the alarm to be continuous. This function increases or decreased the severity
of the impact required to set a SOFT impact in the
Clear Impact error log and initiate the action set by the IMPACT
ACTION parameter. This severity of impact must
Entering this function allows the service technician be sustained over the period of time set with the
to clear the impact sensor after an impact has oc- SOFT DURATION parameter. This parameter may
curred and restore normal truck operation. be set from 0 to 255. Increasing the parameter value
will increase the amount of deceleration that must
Hard Duration be sustained to be recorded as an impact. For SOFT
This function increases or decreases the amount of impacts, this parameter will be set lower than the
time the impact must be sustained at the level set HARD ACCELERATION parameter.
with the Hard Acceleration parameter in order to set
a HARD impact in the error log and initiate the ac-
Impact Events
tion set by the IMPACT ACTION parameter. This Lift trucks equipped with the optional impact sensor
parameter may be set from 0 to 255. Increasing the leave the factory with the sensor deactivated and set
parameter number will increase the amount of time with default parameter values. The impact sensor is
the impact must be sustained to be recorded as an equipped with an accelerometer that measures the
impact. For HARD impacts, this parameter will be rate and time of truck deceleration continuously and
set lower than the SOFT DURATION parameter. monitors how strong the deceleration is and how long
it lasts. A HARD impact is defined as a high rate of
Hard Acceleration deceleration occurring over a short period of time. A
This function increases or decreases the severity of SOFT impact is defined as a lower rated of decelera-
the impact required to set a Hard impact in the error tion occurring over a longer period of time.
28
2200 SRM 1241 Maintenance Reminder
Maintenance Reminder
Within the Maintenance Reminder menu, the service • Maintenance Reminder
technician can enable or disable the next truck ser- • Maintenance Interval
vice reminder and set the number of hours until the These functions are available only to a service tech-
reminder is set on the dash display from the follow- nician and cannot be accessed using an operator or
ing functions: supervisor password. See Figure 22.
Figure 22. Maintenance Reminder Menu
FUNCTIONS Maintenance Interval

Maintenance Reminder Entering this function allows the service technician
to select the reminder interval at 200, 350, 500, 750,
Entering this function allows the service technician or 1000 hours.
to turn the service reminder ON, OFF, or to reset the
reminder time interval.
29
NOTES
____________________________________________________________
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____________________________________________________________
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____________________________________________________________
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____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
30
USER INTERFACE
SUPERVISOR PASSWORD FUNCTIONS
(STANDARD DISPLAY)
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
PART NO. 1590942 2200 SRM 1192

TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
Menu Navigation ............................................................................................................................................... 2
Standard Display ........................................................................................................................................... 2
Main Menu ......................................................................................................................................................... 2
Traction System ............................................................................................................................................. 7
Steer System .................................................................................................................................................. 11
Error Log ........................................................................................................................................................ 12
View Hourmeters ............................................................................................................................................... 12
Display ........................................................................................................................................................... 13
Control Handle .............................................................................................................................................. 14
Aux Pump....................................................................................................................................................... 16
Impact Sensor .................................................................................................................................................... 17
Functions........................................................................................................................................................ 18
Impact Action ............................................................................................................................................ 18
Impact Sound............................................................................................................................................. 18
Clear Impact .............................................................................................................................................. 18
Hard Duration ........................................................................................................................................... 18
Soft Duration ............................................................................................................................................. 18
Impact Events............................................................................................................................................ 19
Passwords Menu ................................................................................................................................................ 19
Add Password ................................................................................................................................................ 20
Delete Password ............................................................................................................................................ 21
Edit Password ................................................................................................................................................ 22
N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];

General
DESCRIPTION with operator password level access. Menu items
covering optional equipment will only be displayed
NOTE: Initial setup of operator/supervisor pass- for those options installed on the lift truck. Access to
words must be done by a qualified dealer technician display panel functions is through the ↑ (up arrow),
with service level menu access. Other truck func- the ↓ (down arrow), the → (right arrow), the ← (left
tions may be adjusted through the dash display by arrow), and the (enter) key on the dash display. Af-
a qualified dealer technician. These functions may ter successfully entering your supervisor password
include: truck speed, acceleration rate, hydraulic into the dash display, push the (enter) key for ac-
function speeds, and optional motion alarm opera- cess to the Main Menu.
tion.
DASH DISPLAY MENU ACCESS
This section contains information to allow a supervi-
sor access to the password functions of the dash dis- When the key is turned to the ON position, the menu
play. With a proper supervisor password, the super- access keys are activated. See Figure 1.
visor can access menu items not visible to persons
Figure 1. Standard Dash Display
1
Main Menu 2200 SRM 1192
Upon initialization, the Password screen will be standard dash display. Press the (enter) key twice
shown on the dash display. Enter your five-digit su- to enable all dash display menu options allowed for
pervisor password using the five number keys on the supervisor password access. See Figure 2.
Figure 2. Enter Password
Menu Navigation
STANDARD DISPLAY include the menus that are accessible with a super-
visor password.
Upon successful entry of your supervisor password,
you will be directed to the Main Menu. Using the The ↑ (up arrow) and the ↓ (down arrow) keys allow
↑ (up arrow) and the ↓ (down arrow) keys, scroll you to move up and down within a menu. The →
through the menu choices until you see the selection (right arrow) key and the ← (left arrow) key allow
you want to access. Press the → (right arrow) key you to move from menu to menu. The (enter) key
to access that selection. The Main Menu will only allows you to enter or save a parameter.
Main Menu
Upon entering the Main Menu from the password en- • View SW Versions
try screen, the following menu functions are visible • Impact Sensor*
to the supervisor: • Password Menu
• Diagnostics * denotes optional item.
• View Hourmeters
2
Diagnostics Menu
Upon entering the Diagnostics menu from the Main percentage. All motor speeds will be shown in RPM.
Menu, the following menu functions are visible to the Motor current will be shown in amps. All tempera-
service technician: tures will be shown in degrees Celsius. See Table 2,
• Static Diagnostics Table 3, and Table 4.
• Traction System
• Hydraulic System Use the scroll keys to move to the desired function
• Steer System and press the → (right arrow) key to select the func-
• Error Log tion.
For a complete description of the diagnostic func- STATIC DIAGNOSTICS

tions accessible through the dash display, see AC
Motor Controllers/Display Panel, Description, The Static Diagnostics menu allows the service tech-
Checks, Adjustments, and Troubleshooting nician to check various truck functions while the
2200 SRM 1190 or AC Motor Controllers/Display truck is stationary with the traction and hydraulic
Panel, Description, Checks, Adjustments, and functions not operating. Use these menus to check
Troubleshooting 2200 SRM 1308. the status of system inputs and outputs from truck
switches and controls. Digital inputs and outputs
Use these menus to check the various operating sys- will be displayed as ON or OFF depending upon the
tems of the lift truck. All PWM (Pulse Width Mod- state of the switch. Analog inputs or outputs will be
ulation) outputs from controllers will be shown as a shown as a voltage. See Table 1.
Static Brake Pedal Switch Press ← Key to return to

Diagnostics Press → Key Press → Key
Diagnostics 0 or 1 / 1 = On main menu
↑
SCROLL
↓
Oper Sensing Switch Press ← Key to return to
↑
SCROLL
↓
Steer OK Press ← Key to return to
↑
SCROLL
↓
↑
SCROLL
↓
3

↑
SCROLL
↓
Free Lift Prox SW Press ← Key to return to
↑
SCROLL
↓
XXXXX Count main menu
↑
SCROLL
↓
Hyd Level Switch Press ← Key to return to
↑
SCROLL
↓
Tilt Up Switch Press ← Key to return to
↑
SCROLL
↓
Tilt Down Switch Press ← Key to return to
↑
SCROLL
↓
Extend Switch Press ← Key to return to
↑
SCROLL
↓
4
Retract Switch Press ← Key to return to

↑
SCROLL
↓
SS Right Switch Press ← Key to return to
↑
SCROLL
↓
SS Left Switch Press ← Key to return to
↑
SCROLL
↓
Horn Switch Press ← Key to return to
↑
SCROLL
↓
Traction Throttle Press ← Key to return to
XXX % main menu
↑
SCROLL
↓
Hydraulic Throttle Press ← Key to return to
XXX % main menu
↑
SCROLL
↓
Reach Throttle Press ← Key to return to
XXX % main menu
↑
SCROLL
↓
Aft Throttle Press ← Key to return to
XXX % main menu
↑
SCROLL
↓
5
Aft Sensor Press ← Key to return to

↑
SCROLL
↓
Aft Horn Press ← Key to return to
6
TRACTION SYSTEM
traction functions.
Table 2. Traction System Diagnostics Menu
↑
SCROLL
↓
Traction Motor Speed Press ← Key to return

Traction System Press → Key
XXXX RPM to main menu
↑
SCROLL
↓
Traction Motor Current Press ← Key to return

XXX AMPS to main menu
↑
SCROLL
↓
Traction Motor Temp Press ← Key to return

XXX C to main menu
↑
SCROLL
↓
Traction Control Temp Press ← Key to return

XXX C to main menu
↑
SCROLL
↓
Traction Throttle Press ← Key to return

XXX % to main menu
↑
SCROLL
↓
Brake Coil Press ← Key to return

↑
SCROLL
↓
Aft Throttle Press ← Key to return

XXX % to main menu
↑
SCROLL
↓
Aft Sensor Press ← Key to return

7
HYDRAULIC SYSTEM
check various truck functions while operating the hy-
draulic functions.
Table 3. Hydraulic System Diagnostics Menu
↑
SCROLL
↓
Pump Motor Speed Press ← Key to return to

Hydraulic System Press → Key
XXX RPM main menu
↑
SCROLL
↓
Pump Motor Current Press ← Key to return to

XXX AMPS main menu
↑
SCROLL
↓
Pump Motor Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Pump Control Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Pump Throttle Press ← Key to return to

XXX % main menu
↑
SCROLL
↓
Load Hold Coil Press ← Key to return to

1=On 0=Off main menu
↑
SCROLL
↓
Pressure Transducer Press ← Key to return to

XXX main menu
↑
SCROLL
↓
8
Auxiliary Motor SPD Press ← Key to return to

XXXX RPM main menu
↑
SCROLL
↓
Auxiliary Motor CURR Press ← Key to return to

XXX AMPS main menu
↑
SCROLL
↓
Auxiliary Motor Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Forward Coil Press ← Key to return to

↑
SCROLL
↓
Reverse Coil Press ← Key to return to

↑
SCROLL
↓
Reach Coil Press ← Key to return to

↑
SCROLL
↓
Tilt Coil Press ← Key to return to

↑
SCROLL
↓
Sideshift Coil Press ← Key to return to

↑
SCROLL
↓
Aux Direction Press ← Key to return to

0 or 1 / 1 = EXT main menu
↑
SCROLL
↓
9
Reach Sensor Press ← Key to return to

XXX COUNT main menu
↑
SCROLL
↓

XXX COUNT main menu
↑
SCROLL
↓
Lift PV Press ← Key to return to

XXX COUNT main menu
↑
SCROLL
↓
Lower PV Press ← Key to return to

XXX COUNT main menu
10
STEER SYSTEM
steering functions.
Table 4. Steering System Diagnostics Menu
↑
SCROLL
↓
Steer Motor Speed Press ← Key to return to

Steer System Press → Key
XXX RPM main menu
↑
SCROLL
↓
Steer Motor Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Steer Control Temp Press ← Key to return to

XXX C main menu
↑
SCROLL
↓
Steer OK? Press ← Key to return to

↑
SCROLL
↓
Steer Motor Angle Press ← Key to return to

XXX DEG main menu
11
ERROR LOG and ↓ (scroll down) keys. The display can store up to
16 errors. See Table 5. The Error Log is also used to
Upon entering the Error Log from the Main Menu, store impact event errors. These errors are displayed
the last error recorded will be displayed. The error as "Hard Impact" or "Soft Impact" depending on the
code, the number of times the error has occurred, and truck settings and reaction.
the truck hourmeter reading at the last time the er-
ror occurred can be accessed using the ↑ (scroll up)
Table 5. Error Log
Diagnostics Press → Static

Menus Key Diagnostics
↑
SCROLL
↓
Press Error #1 Press Last HM Press Count Press First HM
Error Log
→ Key Message → Key XXX → Key XXX → Key XXXXX
View Hourmeters
Upon entering the View Hourmeters menu from the • Auxiliary Hours
Main Menu, the following menu functions are visible
to the service technician: Use the ↑ (scroll up) and the ↓ (scroll down) keys to
• Truck Hours move to the desired function. When finished, press
• Traction Hours the ← (left arrow) key to return to the Main Menu.
• Pump Hours

Upon entering the View Software Versions Menu • Aux Pump
are visible to the service technician: Use the scroll keys to move to the desired function.
• Master Controller When finished, press the ← (left arrow) key to return
• Display to the Main Menu.
• Traction Controller
• Hydraulic Controller MASTER CONTROLLER
• Control Handle
the Master Controller software version identifier.
• Steer Controller
See Table 6.
• Caster Controller (Optional)
Table 6. Master Controller Software Version

Press → Key Press ← key to return to main menu
Versions XXXX
12
DISPLAY
the display software version identifier. See Table 7.
Table 7. Display Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Display
XXXX
TRACTION CONTROLLER
the Traction Controller software version identifier.
See Table 8.
Table 8. Traction Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Traction Controller
XXXX
13
HYDRAULIC CONTROLLER
the Hydraulic Controller software version identifier.
See Table 9.
Table 9. Hydraulic Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Hydraulic Controller Press ← key to return to main
XXXX menu
CONTROL HANDLE
the Control Handle software version identifier. See
Table 10.
Table 10. Control Handle Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Control Handle Press ← key to return to main
XXXX menu
14
REMOTE CAN MODULE (N35ZDR, N45ZR,

N30ZDR, N35-40ZR)
the Remote CAN Module software version identifier.
See Table 11.
Table 11. Remote CAN Module Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Remote CAN Module
XXXX
STEER CONTROLLER
main steering controller. See Table 12.
Table 12. Steer Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Steer Controller
XXXX
15
CASTER CONTROLLER
the Steer Controller software version identifier. See
Table 13.
Table 13. Caster Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Caster Controller
XXXX
AUX PUMP
the Aux Pump controller software version identifier.
See Table 14.
Table 14. Aux Pump Controller Software Version

Press → Key
Versions XXXX
↑
SCROLL
↓
Aux Pump Controller
XXXX
16
Impact Sensor
• Impact Sound
The Impact Sensor function should never be • Hard Duration
turned ON unless the truck is equipped with • Hard Acceleration
impact sensor hardware. • Soft Duration
• Impact Action
Impact Impact Action Impact Action Press *

Sensor
Press → Key Off
Press → Key Off key to save
Press ← key
to cancel
↑ Scroll ↓
↑ Scroll ↓ Impact Action Press *

Log Only key to save
Press ← key
to cancel
↑ Scroll ↓

Reduced Speed key to save
Press ← key
to cancel
↑ Scroll ↓

No Lift key to save
Press ← key
to cancel
Impact Sound Press * key

001 to save
Press ← key
to cancel
↑ Scroll ↓
Clear Impact Press * key

to save
Press ← key
to cancel
↑ Scroll ↓
Hard Duration Press * key

100 to save
Press ← key
to cancel
↑ Scroll ↓
17
Table 13. Impact Sensor Data Display (Continued)
Hard Accel Press * key

160 to save
Press ← key
to cancel
↑ Scroll ↓
Soft Duration Press * key

70 to save
Press ← key
to cancel
↑ Scroll ↓
Soft Accel Press * key

250 to save
Press ← key
to cancel
FUNCTIONS with the Hard Acceleration parameter in order to set

a HARD impact in the error log and initiate the ac-
Impact Action tion set by the IMPACT ACTION parameter. This
parameter may be set from 0 to 255. Increasing the
Entering this function allows the service technician parameter number will increase the amount of time
to change how the lift truck will react after sensing the impact must be sustained to be recorded as an
an impact. This function may be set for the following impact. For HARD impacts, this parameter will be
actions: set lower than the SOFT DURATION parameter.
• OFF - No action will be taken
• Log Only - The impact will be logged in the truck Hard Acceleration
Error Log
• Reduced Speed - The lift truck will operate at "Tur- This function increased or decreases the severity of
tle" speed until reset the impact required to set a Hard impact in the error
• No Lift - Lifting will be disabled until reset and the log and initiate the action set by the IMPACT AC-
lift truck will operate at "Turtle" speed TION parameter. This severity of impact must be
sustained over the period of time set with the HARD
Impact Sound DURATION parameter. This parameter may be set
from 0 to 255. Increasing the parameter number will
Entering this function allows the service technician increase the amount of deceleration that must be sus-
to set the duration of the audible alarm. Select a tained to be recorded as an impact.
alarm on for 15 seconds. Each additional number will Soft Duration
increase the alarm time by 15 seconds. A setting of 9
will cause the alarm to be "continuous." This function increased or decreased the amount of
Clear Impact with the SOFT ACCELERATION parameter in order
to set a soft impact in the error log and initiate the
Entering this function allows the service technician action set by the IMPACT ACTION parameter. This
to clear the impact sensor after an impact has oc- parameter may be set from 0 to 255. Increasing the
curred and restore normal truck operation. parameter number will increase the amount of time
Hard Duration impact. For SOFT impacts, this parameter will be
This function increased or decreased the amount of set higher than the HARD DURATION parameter.
18
Soft Acceleration Impact Events

This function increases or decreased the severity Lift trucks equipped with the original impact sensor
of the impact required to set a SOFT impact in the leave the factory with the sensor deactivated and set
error log and initiate the action set by the IMPACT with default parameter values. The impact sensor is
ACTION parameter. This severity of impact must equipped with an accelerometer that measures the
be sustained over the period of time set with the rate and time of truck deceleration continuously and
SOFT DURATION parameter. This parameter may monitors how strong the deceleration is and how long
be set from 0 to 255. Increasing the parameter value it lasts. A HARD impact is defined as a high rate of
will increase the amount of deceleration that must deceleration occurring over a short period of time. A
be sustained to be recorded as an impact. For SOFT SOFT impact is defined as a lower rated of deceler-
impacts, this parameter will be set lower than the ation occurring over a longer period of time. There-
HARD ACCELERATION parameter. fore a SOFT impact would have the SOFT ACCEL
parameter set to a low level and the Soft Duration
parameter set at a high level.
Passwords Menu
Within the Passwords menu, the supervisor has ac-
cess to the following dash display functions:
• Add Password
words.
• Delete Password
• Edit Password
erator password.
display.
19
ADD PASSWORD the → (right arrow) key to move the cursor to the next
the dash display.
Within the Password Menu, use the ↑ (up arrow) or section of the screen. Use the ↑ (up arrow) and ↓
↓ (down arrow) key to highlight the Add Passwords (down arrow) keys to select a number from 1 to 4 that
word is made up of five numbers from 1 to 5 (example: Use the → (right arrow) key to move to the type sec-
12345, 25314, 22222, etc.). Use the ↑ (up arrow) and tion of the screen. Use the ↑ (up arrow) and ↓ (down
↓ (down arrow) keys to change the individual digits arrow) keys to select Operator or Supervisor.
of the password at the cursor position. Use the →
(right arrow) key to move the cursor to the next posi- The ← (left arrow) key can be used to move the cur-
tion and continue the process until all five digits are sor to the left to make any corrections to the data
selected. See Figure 3. that has been entered. If the information is correct,
press the (enter) key to save the information and re-
A user identifier may be entered under the user sec- turn to the Passwords menu. Press the ← (left arrow)
tion. Use the → (right arrow) key to move the cursor key to cancel the entry and return to the Passwords
to the first position in the user area of the screen. Menu. See Figure 3.
able for use within this section. Use the ↑ (up arrow)
and ↓ (down arrow) keys to cycle through the selec-
Figure 3. Add Passwords Menu Screen
20
DELETE PASSWORD arrow) and ↓ (down arrow) keys to select the pass-
word to be deleted. See Figure 4.
↓ (down arrow) key to highlight the Delete Password Press the (enter) key. Press the (enter) key again
menu and press the → (right arrow) key to enter the to confirm and delete the password. Press the ← (left
Delete Password Menu. arrow) key twice to return to the Main Menu.
All operator passwords and the currently active su-

pervisor password will be displayed. Use the ↑ (up
Figure 4. Delete Password Menu Screen
21
EDIT PASSWORD (up arrow) or ↓ (down arrow) key to cycle through the
selections until the desired character is displayed.
Within the Passwords menu, use the ↑ (up arrow) or Use the → (right arrow) key to move the cursor to the
↓ (down arrow) key to highlight the Edit Password next position and repeat the process until the correct
menu and press the → (right arrow) key to enter the information is displayed.
Edit Password menu.
The ← (left arrow) key can be used to move the cursor
All passwords currently active on the lift truck will be to the left to make any further correction to the data
displayed. Use the ↑ (up arrow) and ↓ (down arrow) that has been entered. If the information is correct,
keys to select the password to be edited. Use the → press the (enter) key to save the information. Press
(right arrow) and ← (left arrow) keys to move the the ← (left arrow) key twice to return to the Main
curser to the information that needs to be changed. Menu. See Figure 5.
Figure 5. Edit Password Menu Screen
22
WIRE HARNESS REPAIR
S6.0FT, S7.0FT
(S135FT,S155FT) [D024, E024];
S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; S4.0, 4.5,
5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004]; H6.0FT, H7.0FT
(H135FT, H155FT) [H006, J006];
H2.0-3.5FT (H40-70FT) [L177]; H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) [N005, P005];
E2.2-3.5XN (E45-70XN) [A268];
J2.2-3.5XN (J40-70XN) [A276];
J1.5-2.0XNT (J30-70XNT) [K160];
J1.6-2.0XN [A935]
PART NO. 1580517 2200 SRM 1128

Wire Harness Repair Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Deutsch Crimping Tool ........................................................................................................................................ 1
How to Strip a Wire for Use With Deutsch Crimping Tool............................................................................ 1
How to Crimp With the Deutsch Crimping Tool ............................................................................................ 2
Calibration Test for the Deutsch Crimping Tool ............................................................................................ 3
Deutsch Connectors ............................................................................................................................................. 5
DT, DTM, and DTP Series Connectors ........................................................................................................... 5
Connector Receptacle Replacement.......................................................................................................... 13
Connector Plug Replacement.................................................................................................................... 18
Connector Receptacle Pin Replacement................................................................................................... 24
Connector Plug Socket Replacement........................................................................................................ 30
HD Series Connectors ................................................................................................................................... 38
Connector Receptacle Replacement.......................................................................................................... 40
Connector Plug Replacement.................................................................................................................... 43
Connector Receptacle Pin Replacement................................................................................................... 46
Connector Plug Socket Replacement........................................................................................................ 51
Sealing Plugs ................................................................................................................................................. 55
Metri-Pack Connectors ...................................................................................................................................... 57
Remove and Install........................................................................................................................................ 57
Micro-Pack Connectors ...................................................................................................................................... 59
Weather-Pack Connectors ................................................................................................................................. 60
Weather-Pack Terminal Repair .................................................................................................................... 60
AMPSEAL Crimping Tools ................................................................................................................................ 61
AMP Hand Crimping Tool With Certi-Crimp .............................................................................................. 61
Description................................................................................................................................................. 61
Stripping Wire for Use With AMP Hand Crimping Tool......................................................................... 62
Insulation Crimp Adjustment................................................................................................................... 62
Maintenance and Inspection for AMP Hand Crimping Tool................................................................... 63
AMP Hand Crimping Tool .................................................................................................................... 63
Crimp Height Inspection ...................................................................................................................... 63
How to Use AMP Hand Crimping Tool......................................................................................................... 64
AMP Pro-Crimper II Tool .............................................................................................................................. 64
Description................................................................................................................................................. 64
Remove and Install Die Set and Locator Assembly ............................................................................ 65
Stripping Wire for Use With AMP PRO-CRIMPER II Tool .................................................................... 66
Contact Support Adjustment .................................................................................................................... 66
Crimp Height Adjustment ........................................................................................................................ 67
Maintenance and Inspection Procedures ................................................................................................. 67
PRO-CRIMPER II Tool ......................................................................................................................... 67
How to Use AMP PRO-CRIMPER II Tool .................................................................................................... 68
AMPSEAL Connector Assemblies..................................................................................................................... 69
Description for Plug Connector Assembly.................................................................................................... 69
Seal Plug .................................................................................................................................................... 69
Contact Crimping ...................................................................................................................................... 70
Contact Removal ....................................................................................................................................... 70
Contact Insertion....................................................................................................................................... 72
Description for Plug Connector and Header Assembly ............................................................................... 74
Voltage Reading......................................................................................................................................... 75
Seal Plug .................................................................................................................................................... 75
Contact Crimping ...................................................................................................................................... 76

Table of Contents Wire Harness Repair

Contact Removal ....................................................................................................................................... 78
Contact Insertion....................................................................................................................................... 80
AMP Superseal 1.5 Crimping Tools .................................................................................................................. 82
Mini Mic Receptacle and Tab Contacts ........................................................................................................ 82
Description................................................................................................................................................. 82
Crimping Conditions and Measurements ................................................................................................ 82
Insertion of Rubber Seal on Cable............................................................................................................ 84
Correction or Replacement of Parts ......................................................................................................... 85
AMP Hand Application Tool.......................................................................................................................... 89
Description................................................................................................................................................. 89
Maintenance and Inspection..................................................................................................................... 89
Crimp Height Adjustment ........................................................................................................................ 90
How to Use AMP Hand Application Tool ..................................................................................................... 90
AMP Pro-Crimper II Tool .............................................................................................................................. 91
Description................................................................................................................................................. 91
Remove and Install Die Set and Locator Assembly ............................................................................ 91
Adjustments............................................................................................................................................... 92
Contact Support .................................................................................................................................... 92
Crimp Height......................................................................................................................................... 92
Inspections and Maintenance ................................................................................................................... 94
Visual Inspection................................................................................................................................... 94
Maintenance .......................................................................................................................................... 94
How to Use Pro-Crimper II Tool ................................................................................................................... 94
AMP Superseal 1.5 Connector Assemblies ....................................................................................................... 95
Description ..................................................................................................................................................... 95
Harness Assembly ..................................................................................................................................... 95
Positioning of anti-backout device ....................................................................................................... 96
Removal of Contacts ............................................................................................................................. 98
Repair and Maintenance ............................................................................................................................. 102
Panel Mount Option .................................................................................................................................... 102
AMP Fastin-Faston Hand Tools ...................................................................................................................... 102
Description - AMP Double Action Hand Tool ............................................................................................. 102
Maintenance and Inspection Procedures ................................................................................................... 104
Daily Maintenance .................................................................................................................................. 104
Periodic Tool Inspection .......................................................................................................................... 104
Lubrication .......................................................................................................................................... 104
Visual Inspection................................................................................................................................. 104
Crimp Height Inspection......................................................................................................................... 105
Certi-Crimp Ratchet Inspection ............................................................................................................. 105
How to Use AMP Double Action Hand Tool ............................................................................................... 106
Description - AMP Extraction Tool ............................................................................................................. 107
Maintenance and Inspection....................................................................................................................... 107
How to Use AMP Extraction Tool ............................................................................................................... 108
AMP Fastin-Faston Receptacles and Housings ............................................................................................. 109
Description ................................................................................................................................................... 109
Wire Repair ...................................................................................................................................................... 115
Wire Splicing Requirements ....................................................................................................................... 115
Deutsch Jiffy Splice ..................................................................................................................................... 116
Assemble .................................................................................................................................................. 116
ii
Wire Harness Repair Table of Contents

Disassemble ............................................................................................................................................. 118
Del-City Crimp-Solder-Shrink Splice ......................................................................................................... 120
Twisted/Shielded Cable and Leads Repair ..................................................................................................... 121
Twisted/Shielded Cable Repair ................................................................................................................... 121
Twisted Leads Repair .................................................................................................................................. 123
Special Tools ..................................................................................................................................................... 124
S6.0FT, S7.0FT (S135FT,S155FT) [D024, E024];

S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006];
H2.0-3.5FT (H40-70FT) [L177];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) [N005, P005];
E2.2-3.5XN (E45-70XN) [A268];
J2.2-3.5XN (J40-70XN) [A276];
J1.5-2.0XNT (J30-70XNT) [K160];
J1.6-2.0XN [A935]
iii
2200 SRM 1128 Deutsch Crimping Tool
General
This section covers the repair of the wire harness connectors, pins, sockets, and splicing of wires.
Deutsch Crimping Tool

HOW TO STRIP A WIRE FOR USE WITH
DEUTSCH CRIMPING TOOL
1. Choose the correct AWG for the contact being
used. See Table 1.
2. See Table 1 for recommended strip length for con-

tact size. Measure strip length from end of wire
as shown in Figure 1.
3. Strip the wire to the recommended strip length.

A small piece of insulation should come off the
wire after stripping. See Figure 2.
4. Check for any broken strands or for a nick in the

wire. If either exists, the wires are damaged and Figure 2. Stripped Wire
should be cut and stripped again.
5. Measure the exposed strands to verify strip

length is correct. See Figure 3.
Figure 3. Strip Length Measurement

Verification
Figure 1. Strip Length Measurement
1
Deutsch Crimping Tool 2200 SRM 1128
Table 1. Wire Strip Length Specifications
Contact Recommended
Type Wire Gauge Range
Part Number Strip Length
1463136 Pin 20 AWG (0.5 mm 2) 3.96 to 5.54 mm (0.156 to 0.218 in.)
2
1463137 Socket 20 AWG (0.5 mm ) 3.96 to 5.54 mm (0.156 to 0.218 in.)
2
1330433 Pin 16 to 20 AWG (1.0 to 0.5 mm ) 6.35 to 7.92 mm (0.250 to 0.312 in.)
1330434 Socket 16 to 20 AWG (1.0 to 0.5 mm 2) 6.35 to 7.92 mm (0.250 to 0.312 in.)
2
2
1579860 Socket 16 to 20 AWG (1.0 to 0.5 mm ) 6.4 to 7.9 mm (0.252 to 0.311 in.)
2
1653804 Socket 14 AWG (2.0 mm 2) 6.4 to 7.9 mm (0.252 to 0.311 in.)
2
HOW TO CRIMP WITH THE DEUTSCH 3. Loosen lock nut and turn adjusting screw until it
CRIMPING TOOL stops. See Figure 5.
1. Strip the insulation from the wire. See How to 4. Insert the contact into the crimping tool; for pin
Strip a Wire for Use With Deutsch Crimping Tool. contacts, insert short end into crimping tool; for
socket contacts, insert long end into crimping
2. Raise the selector knob and rotate until arrow tool. See Figure 6.
is aligned with wire gauge to be crimped. See
Figure 4. 5. Turn the adjusting screw clockwise until the con-
tact is flush or slightly above flush with the in-
dentor cover (cover around insertion point). See
Figure 6. Tighten the lock nut.
1. LOCK NUT
2. ADJUSTING SCREW
Figure 5. Adjusting Screw and Lock Nut

Figure 4. Selector Knob
2
2200 SRM 1128 Deutsch Crimping Tool
1. INSERTION POINT 1. INSPECTION HOLE

2. INDENTOR COVER 2. CRIMP
3. INSULATION GAP, 0.635 to 2.54 mm (0.025 to
Figure 6. Insertion Point 0.100 in.)
Figure 8. Proper Crimp
10. If any of the conditions in Step 9 are not met,

discard the contact, re-cut and strip the wire, and
start the crimping process over.
CALIBRATION TEST FOR THE DEUTSCH

CRIMPING TOOL
The G454 testing tool is needed for the following pro-
cedures. The G454 testing tool is for use with the
Deutsch hand crimping tool only. See Figure 9.
NOTE: Testing for all wire sizes should be #20 wire

Figure 7. Wire Insertion size, selector number 4. This ensures proper calibra-
6. Insert the wire into the contact. There should be tion for all settings and further testing is not needed
no loose strands. All strands should be contained for the other selections.
in the contact barrel. The contact must be cen- 1. Set the Deutsch hand crimp tool to #20 wire size,
tered between indicators. See Figure 7. selector number 4. See Figure 10.
7. Close handles until handles stop.
8. Release handles and remove crimped contact.
9. Visually check the crimped contact for the follow-

ing:
a. The conductor is inserted to the proper depth

and is visible through the inspection hole.
See Figure 8.
b. There is about 0.635 to 2.54 mm (0.025 to

0.100 in.) of conductor between the contact
and the insulator.
1. GO END (GREEN)
c. There are no damaged wire strands. 2. NO-GO END (RED)
d. There are no frayed wires or wires not enter- Figure 9. G454 Testing Tool
ing the contact barrel.
3
Deutsch Crimping Tool 2200 SRM 1128
The No-Go end (red) should not insert. If it does

insert, the calibration is incorrect and the crimp
tool must be replaced. See Figure 13.
1. SELECTOR SET AT #20 WIRE SIZE, SELECTOR

NUMBER 4
Figure 10. Selector Test Setting

1. GO END (GREEN)
2. GO END COMPLETELY INSERTED
Figure 12. Go End Test
Figure 11. Insertion Point
2. Squeeze the handles of the crimp tool completely

together. See Figure 11.
3. Insert the Go end (green) of the G454 testing tool

into the insertion point of the crimp tool while
the handles are completely closed. The Go end
(green) should insert easily. If it does not in-
sert, the calibration is incorrect and the crimp
tool must be replaced. See Figure 12. 1. NO-GO END (RED)
2. NO-GO END SHOULD NOT INSERT ANY
4. Insert the No-Go end (red) of the G454 testing FURTHER
tool into the insertion point of the crimp tool
while the handles are still completely closed. Figure 13. No-Go End Test
4
2200 SRM 1128 Deutsch Connectors
Deutsch Connectors
DT, DTM, AND DTP SERIES CONNECTORS Figure 17 for the different connector plug secondary
locks.
All Deutsch DT, DTM, and DTP series pin- and
socket-type connectors are repaired in the same For examples of the DTM and DTP connectors, see
manner. Figure 18 for the different connector receptacles,
Figure 19 for the different connector receptacle sec-
For examples of the DT connectors, see Figure 14 ondary locks, Figure 20 for the different connector
for the different connector receptacles, Figure 15 for plugs, and Figure 21 for the different connector plug
the different connector receptacle secondary locks, secondary locks.
Figure 16 for the different connector plugs, and
NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE AA G. CONNECTOR TYPE AB-A (SIMILAR TO TYPE
B. CONNECTOR TYPE AB AB)
C. CONNECTOR TYPE AC H. CONNECTOR TYPE AB-B (SIMILAR TO TYPE
D. CONNECTOR TYPE AD AB)
E. CONNECTOR TYPE AE I. CONNECTOR TYPE AB-C (SIMILAR TO TYPE
F. CONNECTOR TYPE AF AB)
Figure 14. DT Connector Receptacles
5
Deutsch Connectors 2200 SRM 1128
A. SECONDARY LOCK TYPE BA E. SECONDARY LOCK TYPE BE

B. SECONDARY LOCK TYPE BB F. SECONDARY LOCK TYPE BF
C. SECONDARY LOCK TYPE BC G. SECONDARY LOCK TYPE BG
D. SECONDARY LOCK TYPE BD H. SECONDARY LOCK TYPE BH
Figure 15. DT Connector Receptacle Secondary Locks
6
NOTE: ALL CONNECTOR PLUGS ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE CA E. CONNECTOR TYPE CE
B. CONNECTOR TYPE CB F. CONNECTOR TYPE CF
C. CONNECTOR TYPE CC G. CONNECTOR TYPE CH (SIMILAR TO TYPE CB)
D. CONNECTOR TYPE CD H. CONNECTOR TYPE CG
Figure 16. DT Connector Plugs
7
A. SECONDARY LOCK TYPE DA E. SECONDARY LOCK TYPE DE

B. SECONDARY LOCK TYPE DB F. SECONDARY LOCK TYPE DF
C. SECONDARY LOCK TYPE DC G. SECONDARY LOCK TYPE DG
D. SECONDARY LOCK TYPE DD H. SECONDARY LOCK TYPE DH
Figure 17. DT Connector Plug Secondary Locks

A. DTP CONNECTOR TYPE EA D. DTP CONNECTOR TYPE ED
B. DTM CONNECTOR TYPE EB E. DTM CONNECTOR TYPE EE
C. DTM CONNECTOR TYPE EC F. DTM CONNECTOR TYPE EF
8
Figure 18. DTM and DTP Connector Receptacles
9
A. DTP SECONDARY LOCK TYPE FA D. DTP SECONDARY LOCK TYPE FD

B. DTM SECONDARY LOCK TYPE FB E. DTM SECONDARY LOCK TYPE FE
C. DTM SECONDARY LOCK TYPE FC F. DTM SECONDARY LOCK TYPE FF
Figure 19. DTM and DTP Connector Receptacle Secondary Locks
10
A. DTM CONNECTOR TYPE GA E. DTM CONNECTOR TYPE GF

B. DTM CONNECTOR TYPE GB F. DTM CONNECTOR TYPE GE
C. DTM CONNECTOR TYPE GC G. DTP CONNECTOR TYPE GG
D. DTP CONNECTOR TYPE GD H. DTM CONNECTOR TYPE GH
Figure 20. DTM and DTP Connector Plugs
11
A. DTM SECONDARY LOCK TYPE HA F. DTM SECONDARY LOCK TYPE HF

B. DTM SECONDARY LOCK TYPE HB G. DTM SECONDARY LOCK TYPE HG
C. DTM SECONDARY LOCK TYPE HC H. DTP SECONDARY LOCK TYPE HH
D. DTP SECONDARY LOCK TYPE HD I. DTM SECONDARY LOCK TYPE HJ
E. DTM SECONDARY LOCK TYPE HE
Figure 21. DTM and DTP Connector Plug Secondary Locks
12
Connector Receptacle Replacement

STEP 1.
Release the external locking clip(s) and separate the
connector plug from the connector receptacle.
13
STEP 2.
Using a small hook end tool (Hyster Part No.
866404), or needle nose pliers, remove the secondary
lock from the connector receptacle.
STEP 3.
Using a small, flat-blade screwdriver (Hyster Part
No. 866404), release the locking finger by moving it
away from the pin.
14
STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver (Hyster Part No. 866404).
15
STEP 5.
Tag the wire and mark it with the corresponding
number or letter on the back of the connector from
which the wire was removed.
STEP 6.
Repeat STEP 3 through STEP 5 for the removal of the remaining wires.
STEP 7.
Insert the wires into the new connector receptacle ac-
cording to the number or letter on the tag and connec-
tor receptacle. Push the wires straight into the back
of the receptacle until a click is felt. Slightly tug each
wire to verify the wire is properly locked in place. Re-
move tags.
16
NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.
STEP 8.
Install the secondary lock. Push the lock straight in
until the lock snaps into place.
17
STEP 9.
Push the connector plug into the connector receptacle
until the external locking mechanism(s) snap(s) into
place.
Connector Plug Replacement

STEP 1.
18
STEP 2.
No. 866404), remove the secondary lock from the
connector plug.
19
STEP 3.
away from the socket.
STEP 4.
20
STEP 5.
STEP 6.
21
STEP 7.
Insert the wires into the back of the new connector
plug according to the number or letter on the tag and
connector plug. Push the wires straight into the back
of the plug until a click is felt. Slightly tug each wire
to verify the wire is properly locked in place. Remove
tags.
STEP 8.
until the lock snaps into place. On 3-way secondary
locks, the arrow on the lock must be oriented toward
the exterior locking mechanism.
1. SEAL
22
1. SEAL
STEP 9.
place.
23
Connector Receptacle Pin Replacement

STEP 1.
STEP 2.
Using a small hook end tool (Hyster Part No.
866404), or needle nose pliers, remove the secondary
lock from the connector receptacle.
24
STEP 3.
away from the pin.
25
STEP 4.
STEP 5.
If more than one pin is being replaced, tag the wire
and mark it with the corresponding number or letter
on the back of the connector from which the wire was
removed.
26
STEP 6.
Using wire cutters, cut the wire behind the old pin
and discard old pin.
STEP 7.
Using wire strippers (Hyster Part No. 866411, strip
the wire to the recommended length shown in Ta-
ble 1.
27
STEP 8.
Using the Deutsch Crimping Tool (Hyster Part No.
867888), crimp the new pin on the wire as shown in
How to Crimp With the Deutsch Crimping Tool.
STEP 9.
Insert the wire into the connector receptacle accord-
ing to the number or letter on the tag and connector
receptacle. Push the wire straight into the back of the
receptacle until a click is felt. Slightly tug the wire
tag.
28
STEP 10.
until the lock snaps into place.
29
STEP 11.
place.
Connector Plug Socket Replacement

STEP 1.
30
STEP 2.
No. 866404), remove the secondary lock from the
connector plug.
31
STEP 3.
away from the socket.
STEP 4.
32
STEP 5.
If more than one socket is being removed, tag the wire
removed.
33
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
STEP 7.
Using wire strippers Hyster Part No. 866411, strip
ble 1.
STEP 8.
867888), crimp the new socket on the wire as shown
in How to Crimp With the Deutsch Crimping Tool.
34
STEP 9.
Insert the wire into the back of the new connector
connector plug. Push the wire straight into the back
of the plug until a click is felt. Slightly tug the wire
tag.
35
STEP 10.
until the lock snaps into place. On 3-way secondary
locks, the arrow on the lock must be oriented toward
the exterior locking mechanism.
1. SEAL
1. SEAL
36
STEP 11.
place.
37
HD SERIES CONNECTORS For examples of the HD connectors, see Figure 22 for

the different connector receptacles and Figure 23 for
All Deutsch HD series pin-type connectors are re- the different connector plugs.
paired in the same manner.
A. TYPE A B. TYPE B
Figure 22. HD Connector Receptacles
38
A. TYPE 1 B. TYPE 2
Figure 23. HD Connector Plugs
39
Connector Receptacle Replacement

STEP 1.
Separate the connector plug from the connector re-
ceptacle.
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.
STEP 3.
Insert a Deutsch extraction tool over the wire being
removed.
40
NOTE: Do not twist the tool or insert the tool at an angle.
STEP 4.
Push the tool into the connector about 25 mm (1 in.)
until it bottoms on the contact flange.
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert
the tool into the connector.
STEP 5.
Hold the tool on the contact flange and pull the wire
and the connection pin out of the connector.
41
STEP 6.
STEP 7.
STEP 8.
Insert the wires into the back of the new connector re-
ceptacle according to the number or letter on the tag
and connector receptacle. Push the wire straight into
the back of the receptacle until a click is felt. Slightly
tug each wire to verify the wire is properly locked in
place. Remove tags.
42
STEP 9.
Install receptacle into mounting structure. Install
the lock nut and washer to retain the receptacle to
the mounting structure.
STEP 10.
Connect the connector plug to the connector recepta-
cle.
Connector Plug Replacement

STEP 1.
ceptacle.
43
STEP 2.
removed.
STEP 3.
44
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert
STEP 4.
and the connection socket out of the connector.
STEP 5.
45
STEP 6.
STEP 7.
of the plug until a click is felt. Slightly tug each wire
tags.
STEP 8.
cle.
Connector Receptacle Pin Replacement

STEP 1.
ceptacle.
46
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
STEP 3.
removed.
47
STEP 4.
STEP 5.
and the connection pin out of the connector.
STEP 6.
If more than one wire is being removed, tag the wire
removed.
48
STEP 7.
Using wire cutters, cut the wire behind the old pin
and discard old pin.
STEP 8.
Using wire strippers, Hyster Part No. 866411, strip
ble 1.
49
STEP 9.
867888), crimp the new pin on the wire as shown in
How to Crimp With the Deutsch Crimping Tool.
NOTE: The rear seal/grommet must be seated properly before inserting wires.
STEP 10.
Insert the wires into the back of the new connector re-
ceptacle according to the number or letter on the tag
and connector receptacle. Push the wire straight into
the back of the receptacle until a click is felt. Slightly
tug each wire to verify the wire is properly locked in
place. Remove tags.
STEP 11.
Install receptacle into mounting structure. Install
the lock nut and washer to retain the receptacle to
the mounting structure.
50
STEP 12.
cle.
Connector Plug Socket Replacement

STEP 1.
ceptacle.
51
STEP 2.
removed.
STEP 3.
52
STEP 4.
and the connection socket out of the connector.
STEP 5.
If more than one wire is being removed, tag the wire
removed.
53
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
STEP 7.
Using wire strippers, Hyster Part No. 866411, strip
ble 1.
STEP 8.
867888), crimp the new socket on the wire as shown
in How to Crimp With the Deutsch Crimping Tool.
54
NOTE: The rear seal/grommet must be seated properly before inserting wires.
STEP 9.
of the plug until a click is felt. Slightly tug wire to
verify the wire is properly locked in place. Remove
tags.
STEP 10.
cle.
SEALING PLUGS
All empty contact cavities must be filled with a sealing plug. See Figure 24.
A. 6 AWG (DARK RED) C. 12 TO 18 AWG (WHITE)

B. 8 AWG (CLEAR WHITE) D. 20 AWG (RED)
Figure 24. Sealing Plugs
55
STEP 1.
Hold the sealing plug with the large diameter end
away from the connector.
STEP 2.
Insert the sealing plug into the connector contact
cavity. Gently apply downward pressure to force the
sealing plug into the cavity.
56
2200 SRM 1128 Metri-Pack Connectors
STEP 3.
Apply pressure until sealing plug is forced to stop
by the connector rear grommet. Visually inspect
the sealing plug to ensure it is flush with the cavity
opening.
Metri-Pack Connectors
Some connectors use terminals called Metri-Pack Se- REMOVE AND INSTALL
ries 150. These may be used at the coolant sensor and
TBI units on ICE lift trucks. 1. Slide the seal back on the wire.
They are also called push-to-seat terminals because 2. Hold the wire and use it to push the terminal to
to install a terminal on a wire, the wire is first in- its forward position in the connector body. Hold
serted through the seal and connector. The terminal the terminal in this position. See Figure 25.
is then crimped on the wire and the terminal pulled
3. Find the lock tab for the terminal in the connec-
back into the connector to seat it in place.
tor channel. Push a removal tool (pick) (HYSTER
NOTE: DO NOT cut contacts from reel, use loose con- Part No. 866420) of the correct size into the con-
tacts only. nector channel. See Figure 26 and Figure 27.
1. FEMALE TERMINAL 4. CONNECTOR BODY

2. LOCKING TAB 5. SEAL
3. TOOL KIT
Figure 25. Metri-Pack Terminal Removal
57
Metri-Pack Connectors 2200 SRM 1128
5. Inspect the terminal and connector for damage.

See Figure 29.
NOTE: If reusing the terminal, reshape the locking

tab.
6. If the terminal will be used again, make sure the

lock tab is correctly bent so that the terminal will
be locked in the connector again.
7. Push the terminal into the connector channel.

Make sure that the lock tab correctly locks the
terminal in position.
1. TOOL (PICK) 4. CONNECTOR 8. Push the seals into their position and install any
2. LOCK TAB BODY secondary locks.
3. TERMINAL
Figure 26. Metri-Pack Push-to-Seat Connector
1. TOOL (PICK) 4. CONNECTOR

2. LOCK TAB BODY
3. TERMINAL
Figure 27. Metri-Pack Pull-to-Seat Connector
4. Use the removal tool (HYSTER Part No. 866420)

to move the lock tab to release the terminal from
its seat.
Push-to-Seat - Gently pull the wire to remove

the terminal from the back of the connector.
1. TERMINAL 4. CONNECTOR
Pull-to-Seat - Gently push the wire to remove 2. LOCK TAB BODY
the terminal through the front of the connector. 3. TOOL KIT 5. SEAL
See Figure 28.
Figure 28. Metri-Pack Pull-to-Seat Terminal
Removal
CAUTION
Work carefully and do not use enough force to
damage the terminal or the connector.
58
2200 SRM 1128 Micro-Pack Connectors
NOTE: THE GREATER DISTANCE D, A FAULT CAN

OCCUR IN THE CONNECTION.
1. CONTACT TAB
Figure 29. Metri-Pack Terminal Inspection
Micro-Pack Connectors
The Micro-Pack connector is shown in Figure 30.
This connector is normally used to connect the
wire harness to the ECM. The repair procedures
for the Micro-Pack connectors are the same as
the Metri-Pack connectors. Refer to the section
Metri-Pack Connectors for the repair procedures.
1. CABLE 4. TOOL KIT (HYSTER

2. TERMINAL PART NO. 866422
3. LOCKING TAB
Figure 30. Micro-Pack Connector
59
Weather-Pack Connectors 2200 SRM 1128
Weather-Pack Connectors
A Weather-Pack connector can be identified by a rub- these terminals cannot be straightened once they
ber seal at the rear of the connector. This connector, are bent.
which is used in the engine compartment, protects
against moisture and dirt which could create oxida- Make certain that the connectors are properly seated
tion and deposits on the terminals. This protection and all of the sealing rings are in place when connect-
is important because of the very low voltage and curing leads. The hinge-type flap provides a backup or
rent levels found in the electronic system. secondary locking feature for the connector. They are
used to improve the connector reliability by retaining
Repair of a Weather-Pack terminal is shown in the terminals if the small terminal lock tabs are not
Weather-Pack Terminal Repair. Use the tool kit to positioned properly.
remove the pin and sleeve terminals. See Special
Tools. Weather-Pack connections cannot be replaced with
standard connections. Instructions are provided
If removal is attempted with an ordinary pick, there with Weather-Pack connector and terminal pack-
is a good chance that the terminal will be bent or ages.
deformed. Unlike standard blade-type terminals,
WEATHER-PACK TERMINAL REPAIR

STEP 1.
Open secondary lock hinge on connector.
1. FEMALE CONNECTOR
2. MALE CONNECTOR
3. SECONDARY LOCK HINGE
STEP 2.
Remove terminal, using tool HYSTER Part No.
866421.
1. TERMINAL
2. TOOL
60
2200 SRM 1128 AMPSEAL Crimping Tools
STEP 3.
Cut wire immediately behind cable seal.
1. WIRE
2. SEAL
STEP 4.
Replace terminal.
a. Slip new seal onto wire.
b. Strip 5 mm (0.2 in.) of insulation from wire.
c. Crimp terminal over wire and seal.
STEP 5.
Push terminal and connector onto wire and engage locking tabs.
STEP 6.
Close secondary lock hinge.
1. SEAL
AMPSEAL Crimping Tools

AMP HAND CRIMPING TOOL WITH and a CERTI-CRIMP ratchet. The contact is inserted
CERTI-CRIMP into the FRONT of the tool. The wire is inserted into
the BACK of the tool. See Figure 31.
Description
The insulation adjust lever regulates the crimp
The tool, Hyster Part No. 1698557, features two up- height. See Insulation Crimp Adjustment.
per inserts, two anvils, an insulation crimp adjust-
ment lever, a contact support, a locator, an ejector,
61
AMPSEAL Crimping Tools 2200 SRM 1128
The contact support prevents the contact from bend-

ing during crimping.
The locator functions two ways:

• position the contact between the upper insert and
the anvil before crimping
• limits the insertion distance of the stripped wire
into the contact.
The ejector pulls the locator down, and ejects the

crimped contact when the tool handles are fully
opened.
CAUTION
The crimping jaws bottom before the CERTI-
CRIMP ratchet releases. This is a design fea-
ture that ensures maximum electrical and ten-
sile performance of the crimp DO NOT readjust
the ratchet.
The CERTI-CRIMP ratchet assures full crimping of

the contact. Once engaged, the ratchet will not re-
lease until the handles have been fully closed.
Stripping Wire for Use With AMP Hand

Crimping Tool
1. Choose the correct AWG for the contact being
used.
2. See Table 2 for recommended strip length.
CAUTION
DO NOT cut or nick the wire strands.
3. Strip wire to recommended strip length. A small

piece of insulation should come off the wire after
stripping. See Figure 32.
Insulation Crimp Adjustment

The insulation barrel crimp height is regulated by
A. FRONT OF TOOL B. BACK OF TOOL the insulation adjustment lever. To determine the
proper setting, test crimp a contact using the setting
1. UPPER INSERT 4. CONTACT which approximates the insulation size: 1) small, 2)
2. ANVIL SUPPORT medium, or 3) large. If the crimped insulation barrel
3. INSULATION 5. LOCATOR
CRIMP 6. CERTI-CRIMP is too tight or too loose, change the setting accord-
ADJUSTMENT RATCHET ingly. The crimp should hold the insulation firmly
LEVER 7. STRIPPED WIRE without cutting into it.
Figure 31. AMP Hand Crimping Tool
62
NOTE: SEE TABLE 2 FOR WIRE STRIP LENGTH.

1. STRIPPED WIRE
2. LOCATOR SLOT
Figure 32. Strip Length
Table 2. Wire Size (AWG)
Wire Size Insulation Tool Wire Size Contact Wire

(AWG) Diameter Range Marking Strip Length
16 1.7 to 2.7 mm 16 5.5 mm (0.215 in.)
(0.067 to 0.106 in.)
20 - 18 20 - 18 4.7 mm (0.185 in.)
Maintenance and Inspection for AMP Hand

Crimping Tool
AMP Hand Crimping Tool
1. Perform maintenance and inspections as speci-

fied by AMP.
Crimp Height Inspection
1. This inspection requires the use of a micrometer

with a modified anvil as shown in Figure 33.
2. Refer to Table 3 and select contact and wire (max-

imum size) for each crimp section listed.
3. Crimp a contact on to the wire according to How

to Use AMP Hand Crimping Tool procedure.
4. Using a modified micrometer, measure wire bar-

rel crimp height as shown in Figure 33. If the
crimp height conforms to measurement in Ta-
ble 3 the tool is correct. If not, replace tool.

A. CRIMP HEIGHT - SEE TABLE 3
1. TOOL CRIMP SECTION MARKING
2. WIRE SLOT IN LOCATOR
3. WIRE BARREL
4. LOCATOR SLOT IN CONTACT
5. MODIFIED ANVIL ON MICROMETER Figure 33. AMP Crimp Tool Inspection
63
Table 3. Crimp Height
Contact Part No Wire Size (AWG) Tool Crimp Section Crimp Height
Marking
20 20-18 1.22 ±0.05 mm
(0.048 ±0.002 in.)
18 20-18 1.22 ±0.05 mm
Hyster Part No. 2035276
(0.048 ±0.002 in.)
16 16 1.40 ± 0.05 mm
(0.055 ±0.002 in.)
HOW TO USE AMP HAND CRIMPING TOOL NOTE: Make sure wire barrel is not deformed during
crimping procedure.
1. Strip insulation from wire. See Stripping Wire
for Use With AMP Hand Crimping Tool. 5. Holding contact in this position, squeeze tool
handles together.
2. Hold tool so BACK side (wire side) faces you.
6. Insert properly stripped wire through locator and
3. Release tool ratchet by squeezing tool handles into wire barrel of contact.
then allowing them to open.
7. Crimp contact onto wire while holding wire in
4. Holding contact by its mating portion and look- place by squeezing tool handles together until
ing straight into crimp section, insert contact ratchet releases.
from the FRONT of tool into BACK of crimp
section. Position contact as shown in Figure 34. 8. Allow tool handles to open fully and remove
crimped contact from tool.
AMP PRO-CRIMPER II TOOL

Description
This tool has a tool frame with stationary jaw and
handle, a moving jaw and handle, and an adjustable
ratchet to ensure full contact crimping. The tool
frame contains a die assembly with two crimping
sections.
The die assembly contains a wire anvil, an insulation

anvil, a wire crimper and an insulation crimper. See
Figure 35.
The locator assembly, on the outside of the frame,

contains a locator, a spring retainer, and a contact
support.
The dies are secured to the frame with retaining pins

1. BACK OF TOOL 4. CONTACT and retaining screws. A nut on the upper retaining
2. STRIPPED WIRE 5. LOCATOR
3. WIRE BARREL screw holds the locator assembly in place.
Figure 34. Crimp Contact to Wire
64
7. Insert wire crimper and insulation crimper into

stationary jaw, with chamfered sides and marked
surfaces facing outward. See Figure 36.
8. Insert upper die retaining pins. See Figure 36.
9. Insert upper die retaining screw through sta-

tionary jaw and both crimpers. See Figure 36.
Tighten screw enough to hold crimpers in place,
but DO NOT tighten completely.
10. Carefully close tool handles. Make sure anvils

and crimpers align properly. Completely close
tool handles until ratchet is engaged enough to
hold anvils and crimpers in position. Tighten up-
per and lower die retaining screws.
11. Install locator assembly over the end of upper die

retaining screw and position against the side of
A. TOOL FRONT B. TOOL BACK the tool jaw. See Figure 36.
1. STATIONARY JAW 4. MOVING HANDLE 12. Install nut onto the end of upper die retaining
2. STATIONARY 5. DIE ASSEMBLY screw and tighten enough to hold locator assem-
HANDLE 6. LOCATOR bly in place while allowing the locator to slide up
3. MOVING JAW ASSEMBLY
and down. See Figure 36.
Figure 35. AMP PRO-CRIMPER II Tool
Remove and Install Die Set and Locator Assembly
NOTE: Perform Step 1 through Step 3 for removal of

die set and locator assembly. Follow Step 4 through
Step 12 for installation of die set and locator assem-
bly.
1. Close tool handles until ratchet releases.
2. Remove nut, locator assembly, upper and lower

die retaining screws, and upper and lower die
retaining pins. See Figure 36.
3. Slide wire anvil, insulation anvil, wire crimper, 1. UPPER DIE 6. WIRE CRIMPER
RETAINING 7. INSULATION
and insulation crimper out of tool frame. See Fig- SCREW CRIMPER
ure 36. 2. LOWER DIE 8. UPPER DIE
RETAINING RETAINING PIN
4. Install wire anvil and insulation anvil into mov- SCREW 9. LOCATOR
ing jaw of tool frame, with chamfered sides and 3. WIRE ANVIL ASSEMBLY
marked surfaces facing outward. See Figure 36. 4. INSULATION ANVIL 10. NUT
5. LOWER DIE 11. LOCATOR
5. Insert lower die retaining pins. See Figure 36. RETAINING PIN 12. TOOL FRAME
6. Insert lower die retaining screw through mov- Figure 36. Die Set and Locator Assembly
ing jaw and both anvils. Tighten screw enough
to hold the anvils in place, but DO NOT tighten
completely. See Figure 36.
65
Stripping Wire for Use With AMP Contact Support Adjustment

PRO-CRIMPER II Tool
1. Make a sample crimp. Determine if contact is
1. Choose the correct AWG for the contact being straight, bent upward or downward.
used.
2. If adjustment is required, loosen adjustment
2. See Table 4 for recommended strip length. screw, DO NOT remove screw. See Figure 38.
Table 4. Strip Length for PRO-CRIMPER II Tool 3. Insert contact and wire into tool as shown in
Figure 37. Close tool handles until the ratchet
Wire Wire Insulation Strip Length reaches the sixth clip or the contact support
Size Diameter touches the contact.
(AWG)
4. Loosen the nut, slightly, that holds the locator
16 1.7 to 2.7 mm 5.1 ± 0.4 mm assembly onto the tool frame. See Figure 38.
18-20 (0.07 to 0.11 in.) (0.20 ± 0.02 in.)
5. Move the contact support to eliminate bending
the contact.
CAUTION 6. Tighten the nut and squeeze handles until
DO NOT cut or nick the wire strands. ratchet releases.
3. Strip wire to recommended strip length. See Fig- 7. Remove and inspect the contact.
ure 37.
8. Make another sample crimp. If the contact is
straight, tighten the adjustment screw. If the
contact is bent, repeat Step 2 through Step 8.
1. CONTACT
2. LOCATOR (IN WIRE STOP SLOT)
3. WIRE (INSERTED TO STOP)
4. STRIP LENGTH
Figure 37. Contact and Wire Strip 1. ADJUSTMENT SCREW

2. CONTACT SUPPORT
3. LOCATOR
4. WIRE
5. BACK OF TOOL
Figure 38. Contact Support Adjustment
66
Crimp Height Adjustment 2. Inspect the crimping dies on a regular basis to

ensure they are not worn or damaged. If crimp
1. Remove lockscrew from ratchet adjustment sections are flattened, chipped, worn or broken
wheel. See Figure 39. replace tool.
2. Using screwdriver, adjust ratchet wheel as indi- Crimp Height Inspection
cated in Step 3 or Step 4.
1. This inspection requires the use of a micrometer
3. To tighten crimp, rotate ratchet adjustment with a modified anvil as shown in Figure 40.
wheel COUNTERCLOCKWISE. See Figure 39.
4. To loosen crimp, rotate ratchet adjustment wheel

CLOCKWISE. See Figure 39.
5. Replace lockscrew onto ratchet adjustment

wheel. See Figure 39.
6. Make a sample crimp and measure the crimp

height.
A. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM.
1. MODIFIED ANVIL ON MICROMETER
2. CRIMP HEIGHT, SEE TABLE 5
Figure 40. Crimp Height
2. Refer to Table 5 to select wire for each crimp sec-

tion listed.
3. Crimp a contact onto the selected wire according

to How to Use AMP PRO-CRIMPER II Tool pro-
cedure.
Table 5. Crimp Measurement

1. LOCKSCREW
2. RATCHET ADJUSTMENT WHEEL Wire Size Crimp Height
3. SCREWDRIVER (AWG)
Figure 39. Ratchet Adjustment Wheel 1.22 ± 0.05 mm

18
(0.048 ±0.002 in.)
Maintenance and Inspection Procedures 1.41 ± 0.05 mm
16
(0.056 ±0.002 in.)
PRO-CRIMPER II Tool
1. Make sure the tool and dies are clean by wip- 4. Using a modified micrometer, measure wire bar-
ing them with a clean, soft cloth. If debris is rel height as shown in Figure 40. If the crimp
present, clear away with a soft brush. Keep han- height matches measurement shown in Table 5
dles closed when not in use to prevent objects the tool is correct. If not, follow Crimp Height
from becoming stuck in crimping dies. Store in Adjustment procedure.
clean, dry area.
67
HOW TO USE AMP PRO-CRIMPER II TOOL slot in the contact. Butt the front end of the wire
barrel against locator.
1. Strip insulation from wire. See Stripping Wire
for Use With AMP PRO-CRIMPER II Tool proce- NOTE: Make sure neither wire barrel nor insulation
dure. barrel are damaged.
2. Hold PRO-CRIMPER II tool so BACK side (wire 6. Hold contact in position and squeeze tool handles
side) is facing you. until ratchet engages enough to hold contact.
3. Squeeze tool handles together, then allow to fully 7. Insert stripped wire into contact insulation and
open. wire barrels until butted against wire stop.
4. Holding contact by mating end, insulation barrel 8. Squeeze tool handles, while holding wire in posi-
first, insert contact through front of tool and into tion, until ratchet releases.
appropriate crimp section.
9. Allow tool handles to open and remove crimped
5. Mating end of contact should be on locator side contact from tool.
of tool; the open "U" of wire barrel and insulation
barrel should face the top of the tool. The contact 10. Check crimp height as described in Crimp Height
to be placed to that movable locator drips into Inspection.
68
2200 SRM 1128 AMPSEAL Connector Assemblies
AMPSEAL Connector Assemblies

DESCRIPTION FOR PLUG CONNECTOR For current ratings of special use connectors,
ASSEMBLY AMPSEAL, refer to Table 6.
The plug assembly consists of a housing, a wedge Table 6. Current Rating

lock, a wire seal, and a mating seal. See Figure 41.
Single Wire Size Current Rating
Circuit (AWG) (Max.)
Plating
Tin 16, 18, and 20 8A
Gold 16 14.5A
18 13A
20 11.5A
Seal Plug
All circuits are sealed by a diaphragm in the rubber
wire seal. When assembling the connector, the di-
aphragm is pierced as the contact passes through it.
Unused circuit cavities will remain sealed unless per-
forated by accidental insertion and removal of con-
tact in the wrong cavity. The seal plug is designed to
keep out contaminants if the diaphragm is pierced.
1. Insert the seal plug, large end first, into the cir-
cuit cavity as far as it will go. No insertion tool
is usually required for this procedure. See Fig-
ure 42.
1. HOUSING 5. DIAPHRAGM
2. WEDGE LOCK 6. CONTACT
3. WIRE SEAL 7. RETENTION 1. PLUG CONNECTOR
4. MATING SEAL FINGERS 2. SEAL PLUG
3. CIRCUIT CAVITY
Figure 41. AMPSEAL Plug Connector
Figure 42. Seal Plug
69
AMPSEAL Connector Assemblies 2200 SRM 1128
Contact Crimping
Information on contact crimping can be found in
AMPSEAL Crimping Tools.
Contact Removal
NOTE: The wedge lock should never be removed from
the housing for insertion or removal of the contacts.
STEP 1.
Insert a screwdriver blade between the mating seal
and one of the red wedge lock tabs. Pry open the
wedge lock to the OPEN position.
NOTE: SCREWDRIVER TO BE MOVED IN DIREC-

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
70
STEP 2.
While rotating the wire back and forth over a half
turn (1/4 turn each direction), gently pull the wire
until the contact is removed.
STEP 3.
Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the
wire was removed.
STEP 4.
Repeat STEP 2 and STEP 3 to remove remaining wires.
71
Contact Insertion
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
NOTE: Check to be sure the wedge lock is in the OPEN position. Perform STEP 1 if wedge lock is closed
STEP 1.

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
72
STEP 2.
Insert contact by pushing it straight into the appro-
priate circuit cavity as far as it will go.
STEP 3.
Pull back on the contact wire with a force of 4 to 9 N
(1 to 2 lbf) to be sure the retention fingers are holding
the contact.
NOTE: PULL WIRE IN DIRECTION OF ARROW.

1. RETENTION FINGERS
STEP 4.
After all required contacts have been inserted, the
wedge lock must be closed to its LOCKED position.
Release the locking latches by squeezing them in-
ward.
1. LOCKING LATCHES
STEP 5.
Slide the wedge lock into the housing until it is flush
with the housing.
1. WEDGE LOCK
73
DESCRIPTION FOR PLUG CONNECTOR

AND HEADER ASSEMBLY
The plug assembly will accept multiple socket con-
tacts. The head assembly is designed to be fastened
to the enclosure by four self-tapping screws. The
screw length will depend on panel thickness.
Panel mounting cutout requirements shown in

Figure 44. Maximum panel thickness to be 2 mm
(.08 in.) for proper clearance.
Use screwdriver slot to lift latch for un-mating. To

mate the plug and head must be identical in color.
Securely fasten the locking latch when mating plug
and header. See Figure 45.
The wedge lock has slotted openings in the mating, NOTE: PLUG AND HEADER ASSEMBLY COLORS
forward, end. The slots are for circuit test tabs ap- ARE MECHANICALLY KEYED TO MATE ONLY WITH
proximately 3.3 × 0.6 mm (0.13 × 0.02 in.), which pre- IDENTICAL COLORS.
vent damage to the receptacle. Circuit testing in the
field to be done by a flat probe, DO NOT use a sharp A. PLUG ASSEMBLY B. HEADER
point. ASSEMBLY
1. MATING SEAL 3. WEDGE LOCK
2. HOUSING 4. RETENTION LEG
Figure 43. AMPSEAL Plug and Header

Assembly
Figure 44. AMPSEAL Plug and Header Assembly Panel Mounting
74
A. WIRE STRANDS MUST BE VISIBLE IN THIS AREA

B. WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA
C. CUTOFF TAB MUST BE VISIBLE
1. SCREWDRIVER SLOT
2. LOCKING LATCH
3. PLUG AND HEADER
Figure 45. Contact, Plug, and Header
Voltage Reading Seal Plug

All circuits are sealed by a diaphragm in the rub-
CAUTION ber wire seal. This diaphragm is pierced when the
DO NOT pierce wire insulation to take voltage contact is pressed through it. Unused circuit cavities
readings. will remain sealed unless perforated by accidental in-
sertion and removal of contact in the wrong cavity.
When using AMPSEAL plug assembly DO NOT The seal plug is designed to keep out contaminants
pierce wire insulation with a sharp point. Pin holes if the diaphragm is accidentally pierced.
in the insulation allow moisture to invade the sealed
connector system nullifying effectiveness and result- 1. Insert the seal plug, large end first, into the cir-
ing in possible system failure. cuit cavity as far as it will go. No insertion tool
is required for this procedure. See Figure 46.
75

1. PLUG CONNECTOR
2. SEAL PLUG
3. CIRCUIT CAVITY
Contact Crimping
1. Information on contact crimping can be found in
AMPSEAL Crimping Tools.
NOTE: DO NOT cut contacts from "reel", use loose

contacts only.
2. Crimped contacts to meet conditions shown in

Figure 47 and Table 7.
Figure 46. Seal Plug
A. WIRE STRAND ENDS MUST BE VISIBLE IN THIS AREA

B. WIRE BARREL SHALL BE CLOSED AT SEAM WITH NO STRANDS PROTRUDING OR SHOWING
C. WIRE STRANDS AND INSULATION SHALL BOTH BE VISIBLE
D. FRONT BELLMOUTH SHALL BE 0.25 mm (0.01 in.)MAX; 0.13 mm (0.005 in.)MIN
E. REAR BELLMOUTH SHALL BE 0.13 to 0.75 mm (0.005 to 0.03 in.)
F. CUTOFF TAB SHALL BE 0.25 mm (0.01 in.)MAX
Figure 47. Crimp Conditions
76
Table 7. Crimp Conditions
Wire Wire Barrel Insulation Barrel

Size Insulation Strip Crimp Crimp Width Crimp Crimp Width
(AWG) Diameter Length Height (Nom) Height ±0.1
Range Max
20 1.17 ±0.08
18 1.7 to 2.7 5.1 1.27 ±0.05 2.03 3.2 3.1
16 1.40 ±0.05
contact tip must be smooth and free of indentations.

CAUTION Ensure wire insulation is not damaged during crimp-
Cable far end to be sealed or isolated from the ing procedure. The insulation bars to be wrapped
environment. DO NOT damage insulation. around the wire insulation, leaving not sharp points
to damage rubber wire seal.
NOTE: Wire stripping tools may leave indentations
on the surface of the wire insulation. If these inden- 3. The crimped contact to be a 2 mm (.08 in.) diam-
tations are present at the wire seal, leakage can oc- eter cylinder. See Figure 48.
cur. Insulation surface within 26 mm (1.02 in.) of
A. CENTERLINE B. DIA 2 mm (0.08 in.)

1. CONTACT (PARTIALLY INSERTED) 4. DIAPHRAGM
2. WIRE SEAL 5. MATING SEAL
3. RETENTION FINGERS 6. WEDGE LOCK (OPEN POSITION)
Figure 48. Contact Concentricity
77
Contact Removal
STEP 1.

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
78
STEP 2.
Wile rotating the wire back and forth over a half turn
(1/4 turn each direction), gently pull the wire until
the contact is removed.
STEP 3.
Repeat STEP 2 to remove remaining wires.
79
Contact Insertion
NOTE: Check to be sure the wedge lock is in the OPEN position. Perform STEP 1 if wedge lock is closed.
STEP 1.
Insert a screw driver blade between the mating seal

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
80
STEP 2.
Insert contact straight into circuit cavity as far as it
will go.
STEP 3.
Pull back on contact wire with 4 to 9 N•m (1 to 2 lbf)
to be sure the retention fingers are holding the con-
tact.
1. RETENTION FINGERS
STEP 4.
After all required contacts have been inserted, the
wedge lock must be closed to the LOCKED position.
Release the locking latches by squeezing them in-
ward.
1. LOCKING LATCHES
STEP 5.
Slide the wedge lock into the housing until it is flush
with the housing.
1. WEDGE LOCK
81
AMP Superseal 1.5 Crimping Tools 2200 SRM 1128
AMP Superseal 1.5 Crimping Tools

MINI MIC RECEPTACLE AND TAB 4. Bend up = 5 max. See Figure 51.
CONTACTS
5. Bend down = 5 max. See Figure 51.
Description 6. Bend right = 5 max. See Figure 50.
Contacts are for 16-22 AWG wire, with single wire 7. Bend left = 5 max. See Figure 50.
seals. Each wire is inserted into a discrete wire seal
before crimping into contact. Insulation barrel is 8. Rolling = 5 max. See Figure 50.
crimped so wire seal is gripped to avoid any move-
ment of seal. Contacts are suitable for single wires 9. Cable end protrusion = 0.2 to 0.7 mm (0.008 to
only. 0.03 in.). See Figure 49.
Crimping Conditions and Measurements 10. Insulation stripping length = 3.0 to 3.5 mm (0.12
to 0.14 in.).
1. Cut-off tab length = 0.3 mm (0.01 in.) max. See
Figure 49. 11. Wire barrel seam must be neatly closed. See Fig-
ure 49.
2. Front bellmouth = 0.10 mm (0.004 in.) × 45 max.
See Figure 49.
3. Rear bellmouth = 0.25 mm (0.009 in.) × 45 max.

See Figure 49.
82
2200 SRM 1128 AMP Superseal 1.5 Crimping Tools

1. WIRE BARREL SEAM 8. INSULATION BARREL
2. WIRE BARREL 9. FRONT BELLMOUTH
3. CABLE END PROTRUSION LENGTH 10. REAR BELLMOUTH
4. WIRE BARREL CRIMP WIDTH 11. INSULATION BARREL CRIMP HEIGHT
5. INSULATION BARREL CRIMP WIDTH 12. CUT-OFF TAB LENGTH
6. RUBBER SEAL 13. WIRE BARREL CRIMP HEIGHT
7. CABLE
Figure 49. Crimping Conditions
83
1. BEND RIGHT 3. ROLLING

2. BEND LEFT 4. DATUM LINE
Figure 50. Crimping Conditions Bend Right/Left
1. BEND UP 2. BEND DOWN 3. DATUM LINE
Figure 51. Crimping Conditions Bend Up/Down
Insertion of Rubber Seal on Cable

NOTE: Rubber seals are lubricated, lubrication must
not be removed.
The end of cable insulation to be positioned from edge

of rubber seal when rubber seal is installed on cable.
See Figure 52.
A. 0.5 mm (0.02 in.)MAX

1. WIRE INSULATION 2. RUBBER SEAL
Figure 52. Rubber Seal Installed on Cable
84
Correction or Replacement of Parts

STEP 1.
When defects or improper applications are found on parts to be installed, rework or replace with new parts.
STEP 2.
Cut end of wire shall appear neat without any bend
or stranded conductor.
STEP 3.
Conductor shall be free from nick, cut or scrape.
STEP 4.
Wire insulation must have smooth surface in a round
form without damage, groove, or recessed surface.
85
STEP 5.
wire end shall be straight without bend or untidiness
after insertion of rubber seal.
STEP 6.
Flanges of rubber seal to be free of cuts or damage.
STEP 7.
Insertion of rubber seal to be done straight and even.
If flanges are tilted, plug must be corrected so flanges
are perpendicular to contact center line.
STEP 8.
After crimping, cable insulation inside rubber seal to
be in good condition and within requirements as spec-
ified in Crimping Conditions and Measurements in
this section.
A. 0.2 to 0.7 mm (0.008 to 0.03 in.)

B. 0.2 mm (0.008 in.)
86
STEP 9.
Rubber seal must protrude from insulation crimp
without damage. Check by visual inspection in the
transition area (between wire and insulation barrel)
as shown.
1. RUBBER SEAL
STEP 10.
No parts of insulation or rubber are allowed in the
wire crimp, after crimping.
STEP 11.
Part of rubber seal must stick out of transition hole.
1. RUBBER SEAL
STEP 12.
Tilt shape of rubber seal is unacceptable.
A. 8 MAX
87
STEP 13.
Crimped contacts should appear as shown.
88
AMP HAND APPLICATION TOOL Crimp Height Inspection
Description 1. This inspection requires the use of a micrometer

with a modified anvil. See Figure 54.
This tool is designed for use with AMP Superseal 1.5
series contacts. The tool has two crimp sections, con-
tact locator, wire stop, and ratchet.
A. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM.
1. MODIFIED ANVIL
2. CRIMP HEIGHT (SEE TABLE 8)
2. Use Table 8 to select wire for crimp height inspec-

tion.
1. FRONT OF TOOL (LOCATOR SIDE)
2. BACK OF TOOL (WIRE SIDE) 3. Crimp a contact onto the selected wire according
3. DIE SET to How to use AMP Hand Application Tool proce-
4. MOVABLE LOCATOR dure.
5. RATCHET ADJUSTMENT WHEEL
6. PIVOT PIN
4. Using crimp height comparator, measure wire
Figure 53. AMP Hand Application Tool for barrel crimp height as shown in Figure 54. If
AMP Superseal 1.5 Contacts crimp height matches that shown in Table 8, the
tool is considered dimensionally correct. If not,
Maintenance and Inspection follow Crimp Height Adjustment procedure.
1. Ensure tool and dies are clean by wiping with a Table 8. Wire Strip Lengths
clean, soft cloth. Remove any debris with clean,
soft brush. DO NOT use objects that could dam- Wire Size Strip Crimp Height
age tool. When not in use, keep handles closed (AWG) Length ± 0.05 mm
to prevent debris from lodging in dies. Store in (0.002 in.)
clean, dry area. 3.0 to 3.5 mm 1.12 mm
20
(0.12 to 0.13 in.) (0.044 in.)
2. Crimping dies to be inspected on a regular basis
for wear or damage. Inspect crimp sections for 3.0 to 3.5 mm 1.30 mm
18
flattened, chipped, worn, or broken areas. Re- (0.12 to 0.13 in.) (0.051 in.)
place tool if damaged. 3.0 to 3.5 mm 1.45 mm
16
(0.12 to 0.13 in.) (0.057 in.)
89
Crimp Height Adjustment

1. Remove lockscrew from ratchet adjustment
wheel. See Figure 55.

2. LOCKSCREW
3. LOOSEN-TIGHTEN 1. WIRE STRIP LENGTH
4. BACK OF TOOL 2. WIRE SEAL
5. FRONT OF TOOL 3. INSULATION BARREL
6. SCREWDRIVER 4. WIRE BARREL
5. WIRE STOP SLOT
6. MATING END
Figure 55. Ratchet Wheel Adjustment
Figure 56. Wire and Receptacle
2. Using a screwdriver, adjust ratchet wheel from
front of tool. See Figure 55. Table 9. Wire Strip Lengths
3. To tighten crimp, rotate ratchet adjustment
Wire Size Insulation Strip
wheel COUNTERCLOCKWISE. See Figure 55.
(AWG) Diameter Length
4. To loosen crimp, rotate ratchet adjustment wheel 1.7 to 2.4 mm 3.0 to 3.5 mm
CLOCKWISE. See Figure 55. 20-16
(0.07 to 0.09 in.) (0.12 to 0.13 in.)
5. Make a sample crimp and measure crimp height. 1.7 to 2.4 mm 3.0 to 3.5 mm
22-20
If crimp height is acceptable, replace and tighten (0.07 to 0.09 in.) (0.12 to 0.13 in.)
lockscrew. If crimp height is unacceptable, follow
Step 3 or Step 4 until acceptable crimp height is NOTE: Insert contact with open side of insulation and
achieved. wire barrel toward movable crimping jaw.
HOW TO USE AMP HAND APPLICATION 4. Holding contact by insulation barrel, insert it
TOOL through back of tool into appropriate crimp sec-
tion, receptacle/tab end first.
1. Strip insulation from wire. See Figure 56 and
Table 9. NOTE: Ensure both sides of insulation barrel are
started evenly into the crimper jaws. DO NOT
2. Hold tool so BACK (wire side) faces you. attempt to crimp improperly positioned contacts.
3. Release tool handles by squeezing them together 5. Align contact wire stop slot with the wire stop
then allowing them to open fully. in the crimping jaws. Contact insulation and
wire barrels must be position in crimp section as
shown in Figure 57.
90
Remove and Install Die Set and Locator Assembly
1. Close tool handles until ratchet releases, remove

the nut, locator assembly, upper retaining screw,
lower retaining screw and four die retaining pins
from tool frame. See Figure 59.
2. Slide wire anvil, insulation anvil, wire crimper,

and insulation crimper out of tool frame. See Fig-
ure 59.
3. Install wire anvil and insulation anvil, with

chamfered sides and marked surfaces facing
outward, into moving jaw. See Figure 59.
4. Insert two die retaining pins. See Figure 59.
1. WIRE INSERTED 2. STRIP LENGTH

TO STOP (SEE TABLE 9)
Figure 57. Wire Stop Slot
6. Squeeze handles together until ratchet engages

sufficiently to hold contact in position. DO NOT
deform insulation or wire barrel.
7. Insert stripped wire into contact insulation and

wire barrels until butted against wire stop. See
Figure 57.
8. Holding wire in position, squeeze tool handles to-

gether until ratchet releases. Allow tool handles
to open and remove crimped contact.
AMP PRO-CRIMPER II TOOL

Description
This tool has a tool frame with stationary jaw and
handle, a moving jaw and handle, and an adjustable
ratchet to endure full contact crimping. The tool
frame contains a die assembly with three crimping A. FRONT OF TOOL (LOCATOR SIDE)
B. BACK OF TOOL (WIRE SIDE)
sections.
1. LOCATOR ASSEMBLY
The die assembly contains a wire anvil, an insulation 2. STATIONARY JAW
anvil, a wire crimper and an insulation crimper. See 3. DIE ASSEMBLY
Figure 58. 4. MOVING JAW
Die retaining pins and retaining screws are used to 6. PIVOT PIN
7. STATIONARY HANDLE
position and secure the dies in the tool frame. A nut 8. MOVING HANDLE
is used on upper retaining screw to hold locator as-
sembly in place. See Figure 58. Figure 58. AMP PRO-CRIMPER II Tool and Die
91
5. Insert lower retaining screw through moving jaw, the sixth click, or until the contact support
insulation anvil, and wire anvil. Tighten lower touches the contact.
retaining screw just enough to hold anvils in po-
sition. DO NOT tighten lower retaining screw
completely. See Figure 59.
6. Install wire crimper and insulation crimper, with

chamfered sides and marked surfaces facing out-
ward, into stationary jaw. See Figure 59.
7. Insert two die retaining pins. See Figure 59.
8. Install upper die retaining screw through

stationary jaw, insulation crimper, and wire
crimper. Tighten upper retaining screw just
enough to hold crimpers in position. DO NOT
tighten upper retaining screw completely. See 1. TOOL FRAME 7. WIRE CRIMPER
Figure 59. 2. LOCATOR 8. WIRE ANVIL
ASSEMBLY 9. CHAMFER
9. Carefully close tool handles making sure anvils 3. NUT 10. OFFSET
and crimpers align properly. Continue closing 4. DIE RETAINING 11. INSULATION
PIN CRIMPER
tool handles until ratchet in tool frame engages 5. UPPER RETAINING 12. INSULATION ANVIL
enough to hold anvils and crimpers in position. SCREW 13. CHAMFER
Tighten upper and lower retaining screws. 6. LOWER 14. MOVING JAW
RETAINING 15. STATIONARY JAW
10. Install locator assembly over the end of upper SCREW
retaining screw and position against tool frame.
See Figure 59. Figure 59. Die Set and Locator Assembly
11. Install nut onto end of upper retaining screw and 4. Slightly loosen the nut holding the locator assem-
tighten enough to hold locator assembly in posi- bly onto the tool frame.
tion while allowing locator to slide up and down.
5. Move the contact support as needed to eliminate
See Figure 59.
the bending of the contact.
Adjustments 6. Tighten the nut and close the handles until the
ratchet releases.
Contact Support
7. Remove and inspect the contact.
NOTE: Contact support is preset prior to shipment
but minor adjustment may be necessary. 8. Make another sample crimp. If the contact is
straight, tighten the adjustment screw. If the
1. Make a sample crimp and determine if the con-
contact is still being bent during crimping, repeat
tact is straight, bending upward, or bending
adjustment procedure.
downward.
Crimp Height
2. If adjustment is required, loosen the adjustment
screw holding contact support onto locator as- 1. Remove lockscrew from ratchet adjustment
sembly. See Figure 60. wheel. See Figure 61.
NOTE: The ratchet has detents that create audible 2. Using a screwdriver, adjust the ratchet wheel
clicks as the tool handles are closed. from locator side of tool. See Figure 61. Observe
ratchet adjustment wheel.
3. Position contact with wire in the proper nest and
close the tool handles until the ratchet reaches
92
A. BACK OF TOOL B. STRIP LENGTH

1. LOCATOR 5. WIRE SEAL
2. CONTACT SUPPORT 6. CONTACT
3. ADJUSTMENT SCREW 7. LOCATOR IN WIRE STOP SLOT
4. WIRE 8. WIRE INSERTED TO STOP
Figure 60. Contact Support and Wire Strip

1. LOCKSCREW
3. SCREWDRIVER
3. If a tighter crimp is required, rotate ratchet ad-

justment wheel COUNTERCLOCKWISE to a
higher-numbered setting.
4. If a looser crimp is required, rotate ratchet ad-

justment wheel CLOCKWISE to a lower-num-
bered setting.
5. Replace lockscrew. See Figure 61.
6. Make a sample crimp and measure the crimp

height as specified in Crimp Height Inspection
section. If the dimension is acceptable, secure
Figure 61. Ratchet Adjustment Wheel lockscrew. If the dimension is unacceptable, con-
tinue to adjust the ratchet and measure a sample
crimp.
93
Inspections and Maintenance Visual Inspection
Crimp Height Inspection The crimping dies should be inspected on a regular

basis to ensure they have not become worn or dam-
1. This inspection requires the use of a micrometer aged. Inspect the crimping chamfers for flattened,
with a modifier anvil as shown in Figure 62. chipped, worn or broken areas. If damage or abnor-
mal wear is present, replace tool.
2. See Table 10 and select a wire (maximum size)
for each crimping chamber listed. Maintenance
1. Wipe tool and dies with clean, soft cloth. Remove

any debris with a clean, soft brush. DO NOT use
objects that could damage the tool. When not in
use, keep handles closed to prevent debris from
becoming lodged in the crimping dies, and store
in a clean, dry area.
HOW TO USE PRO-CRIMPER II TOOL

NOTE: This tool is provided with a crimp adjustment
feature. Initially the crimp height should be veri-
fied as stipulated in Crimp Height Inspection and
1. POSITION POINT ON CENTER OF WIRE Crimp Height Adjustment sections to verify height
BARREL OPPOSITE SEAM
2. MODIFIED ANVIL before using the tool to crimp desired contacts and
3. CRIMP HEIGHT (SEE TABLE 10) wire sizes.
Figure 62. Crimp Height 1. Using Table 9 select wire of specified size and in-
sulation diameter. Assemble wire seal onto wire
Table 10. Crimp Height - Dimension as specified in Mini Mic Receptacle and Tab Con-
"3" in Figure 62 tact section.
Wire Size Crimping Crimp Height 2. Strip wire to the length indicated in Table 9 tak-
AWG Chamber ±0.05 mm ing care not to nick or cut wire strands. Select
(Wire Size (0.002 in.) contact and identify appropriate crimping cham-
Marking) ber according to the wire size markings on the
tool.
20 20 1.12 mm (0.044 in.)
18 18 1.30 mm (0.051 in.) 3. Hold tool so that the back (wire side) is facing
you. Squeeze tool handles together and allow
16 16 1.45 mm (0.057 in.) them to open fully.
3. See How to Use AMP Pro-Crimper II Tool section 4. Holding contact by mating end, insert the con-
and crimp contact accordingly. tact, insulation barrel first, through the front of
the tool and into the appropriate crimping cham-
4. Using crimp height comparator, measure the ber.
wire barrel crimp height as shown in Figure 62.
If crimp height conforms to dimensions shown 5. Position the contact tho that the mating end of
in Table 10 the tool is considered dimension- contact is on locator side of tool and the open "U"
ally correct. If not, the tool must be adjusted; of the wire and insulation barrels face the top of
seeCrimp Height section. the tool. Fit the contact into the nest so the mov-
able locator drops into the slot in the contact. See
Figure 60. Butt front end of wire barrel against
movable locator.
94
2200 SRM 1128 AMP Superseal 1.5 Connector Assemblies
NOTE: Make sure both sides of insulation barrel are NOTE: The crimped contact may stick in the crimp-
started evenly into the crimping chamber. DO NOT ing area, but the contact can be easily removed by
attempt to crimp and improperly positioned contact. pushing downward on the top of the locator. See Fig-
ure 60.
6. Hold contact in position and squeeze the tool
handles together until ratchet engages enough 8. Holding wire in position, squeeze tool handles to-
to hold contact in position. DO NOT deform gether until ratchet releases. Allow tool handles
insulation barrel or wire barrel. to open and remove crimped contact.
7. Insert stripped wire, with wire seal, into insula- 9. Check contact crimp height as described in
tion and wire barrels until it is butted against Crimp Height Inspection section. If necessary,
wire stop. See Figure 60. adjust the crimp height as specified in Crimp
Height section.
AMP Superseal 1.5 Connector Assemblies

DESCRIPTION
The AMP Superseal 1.5 connectors are designed to
meet the performance requirements in the automo-
tive field. The following information is intended as
a general guide for the best use of the connectors for
wire harnesses and their maintenance.
Harness Assembly
STEP 1.
Contacts can only be inserted into housing cavities
in one position. The correct placing is shown. After
insertion of a contact, pull back lightly on the wire to
check that the contact is securely locked in position.
STEP 2.
Cavity plug, Hyster Part No. 2069381, must be used
when a cavity is not loaded with a contact. This pre-
vents the ingress of water. Insert cavity plug deeply
into the cavity by means of a pin as shown. If neces-
sary, the cavity plug can be removed by a pin point.
1. CAVITY PLUG
95
AMP Superseal 1.5 Connector Assemblies 2200 SRM 1128
Positioning of anti-backout device
STEP 1.
These connectors are supplied with an anti-backout
device for both receptacle and tab housings. After
loading all of the crimped contacts, these devices
must be pushed into CLOSED position. If one con-
tact is not properly seated in the cavity, the plastic
locking lance remains deflected and the anti-backout
device cannot be closed. This serves as a warning for
the user. If the anti-backout device is not closed, the
mating with a counterpart cannot be completed.
A. CONTACT NOT PROPERLY SEATED

1. TAB HOUSING
2. PLUG HOUSING
3. ANTI-BACK OUT DEVICE
NOTE: Perform STEP 2 for manually operated, position 2 to 6 plugs.
STEP 2.
Rotate the anti-back out device to deflect the central
lances inward then push until the side arms lock.
96
NOTE: Perform STEP 3 for position 2 to 6 plugs inserted by a harness maker machine.
STEP 3.
Push the two lances for position 2 housing, the cen-
tral lance for positions 3 and 5 housing, and the two
central lances for positions 4 and 6 housing inward.
Then push until the side arms lock.
STEP 4.
For position 1, manually or machine operated, push
the anti-backout device until its upper end is the
same level as the housing mating face.
NOTE: Different jigs are needed for position 1 and 2 housings and position 3 to 6 housings.
STEP 5.
To close the anti-backout device for tab housings, ei-
ther manually or by machine, push the device in with
a jig until it meets the stop.
97
Removal of Contacts
Since the locking lance of contacts can be reached from the mating side of the housings, it is necessary to remove
the anti-backout device first.
NOTE: Perform STEP 1 and STEP 2 for removal of receptacle contact.
STEP 1.
Deflect the side arms of the anti-back out device and
pull it away.

2. EXTRACTION TOOL
98
CAUTION
Be careful not to insert the extraction tool in the contacting area of the receptacle.
STEP 2.
Insert the contact extraction tool Hyster Part No.
1698561 between contact and lance nose, then rotate
slightly as shown. Pull the wire.
1. CONTACT
2. CONTACT EXTRACTION TOOL
99
NOTE: Perform STEP 3 and STEP 4 for removal of tab contact.
STEP 3.
Insert the extraction tool Hyster Part No. 1698560
in one of the central holes of the anti-backout device
and pull it away.
NOTE: Pull extraction tool in direction of arrow.

1. EXTRACTION TOOL
100
CAUTION
When rotating the extraction tool, be careful
not to deform the tab.
STEP 4.
Insert the contact extraction tool Hyster Part No.
1698561 between contact and lance note, then rotate
slightly as shown. Pull the wire up as shown.
1. CONTACT EXTRACTION TOOL
101
AMP Fastin-Faston Hand Tools 2200 SRM 1128
REPAIR AND MAINTENANCE

During repair and maintenance operation for wiring,
replacement of contacts may be required. Following
is the recommended procedure.
1. Cut the wire of the defective contact.
2. Strip the wire insulation to appropriate length.
3. Slide a new wire seal onto the wire.
4. Crimp the new contact on the wire using a hand

crimping tool. NOTE: SLIDE CLIP IN DIRECTION OF ARROW.
PANEL MOUNT OPTION Figure 63. Panel Mount Clip Example
The tab housings come with two "L" shaped guides

for the insertion of a special elastic clip, allowing
panel mounting of the connector. The clip can be dif-
ferent shape according to the requirements. See ex-
ample in
AMP Fastin-Faston Hand Tools

DESCRIPTION - AMP DOUBLE ACTION consisting of an anvil and a crimper. When jaws are
HAND TOOL closed they form two crimping chambers, marked on
BACK of tool as "A" and "B". Crimping jaws "bottom"
Hand-crimping tools that accommodate full wire size before ratchet releases. This is a design feature to
range are designed for repair applications. This tool assure maximum electrical and tensile performance
is designed for use with AMP micro and mini relay of crimp; DO NOT readjust ratchet. See Figure 64.
receptacles. The tool has two crimping jaws, each
102
2200 SRM 1128 AMP Fastin-Faston Hand Tools
1. CRIMPER 5. INSULATION CRIMPING JAWS

2. ANVIL 6. BACK OF TOOL
3. CRIMPING CHAMBER MARKINGS 7. CERTI-CRIMP RATCHET
4. WIRE CRIMPING JAW 8. LINK
Figure 64. AMP Double Action Hand Tool
103
MAINTENANCE AND INSPECTION free cloth. DO NOT use objects that could dam-
PROCEDURES age tool.
Daily Maintenance 2. Ensure retaining pins are in place and secured

with retaining rings. See Figure 65.
1. Immerse tool, with handles partially closed, in
reliable commercial de-greasing compound to re- 3. When not in use, keep handles closed to prevent
move accumulated debris. If de-greasing com- debris from lodging in jaws. Store in clean dry
pound is not available, wipe tool with soft, lint- area.
1. RETAINING RING 2. RETAINING PIN 3. HANDLE SPRING
Figure 65. Tool Inspection
Periodic Tool Inspection Visual Inspection
Lubrication NOTE: Manufacturer’s replacement and repair pro-

cedures included in documentation received with
1. Coat all pins, pivot points, and bearing surfaces tool.
with thin layer of SAE 20 motor oil per schedule
below: 1. Close handles until ratchet releases and handles
1. Tool used daily: lubricate weekly open freely. If handles DO NOT open quickly
2. Tool used weekly: lubricate monthly and fully, the spring is defective and must be re-
placed. See Figure 65. If spring is defective, fol-
2. Wipe excess oil from tool paying close attention to low manufacturers’ replacement and repair pro-
crimp area. Oil transferred from crimping area cedures.
onto terminations can affect electrical character-
istics of application. 2. Inspect tool for worn, cracked, or broken jaws. If
jaws are damaged follow manufacturers’ replace-
ment and repair procedures.
104
Crimp Height Inspection 4. Using modified micrometer, measure wire barrel

crimp height as shown in Figure 67. If crimp
1. This inspections requires the use of a modified height matches measurement in Table 11, the
micrometer with modified anvil and spindle. tool is considered dimensionally correct. If not,
Modified micrometer to be used when crimp follow manufacturers’ replacement and repair
height is specified. See Figure 66. procedure.
1. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM
2. MODIFIED ANVIL
3. CRIMP HEIGHT (SEE TABLE 11)

NOTE: SAMPLE READING SHOWN IN ILLUSTRA-
TION EQUALS 3.489 mm (0.1374 in.). Certi-Crimp Ratchet Inspection
1. ANVIL The ratchet on this tool should be checked to ensure
2. SPINDLE it does not release prematurely, allowing jaws to open
3. STATIONARY HANDLE before they have fully bottomed. Use a 0.025 mm
4. MOVABLE HANDLE (0.001 in.) shim suitable for checking clearance be-
5. TYPICAL CONTACT
tween bottoming surfaces of crimping jaws.
Figure 66. Modified Micrometer
1. Select receptacle and maximum size wire for
2. Use Table 11 to select maximum size wire for tool.
each crimping chamber.
2. Position receptacle and wire between jaws as
3. Crimp receptacle onto selected wire according to shown in Figure 68.
How to Use AMP Double Action Hand Tool pro-
3. While holding wire in position, squeeze tool han-
cedure.
dles together until ratchet releases. Hold han-
Table 11. Wire Size and Crimp Height dles in closed position.
4. Check clearance between bottoming surfaces

Crimp Wire Size Crimp
of crimping jaws. If clearance is 0.025 mm
Chamber (AWG) Height
(0.001 in.) or less, the ratchet is satisfactory. If
1.27 ±0.076 mm clearance exceeds 0.025 mm (0.001 in.) follow
A 18-20
(0.05 ±0.003 in.) manufacturers’ replacement and repair proce-
dure.
1.65 ±0.076 mm
B 14-16
(0.065 ±0.003 in.)
105
2. Hold tool so BACK side is facing you.
3. Release tool handles by squeezing them together

until ratchet releases.
4. Insert receptacle barrel into crimping area as

shown in Figure 68.
5. Squeeze tool handles together just enough to hold

receptacle in place.
NOTE: Make sure insulation DOES NOT enter wire

barrel.
6. Insert stripped wire into receptacle crimping bar-

rel from BACK of tool.
7. While holding wire position, squeeze tool handles

together until ratchet releases. Open tool han-
dles and remove crimped receptacle.
A. RECEPTACLE BARREL ALIGNMENT

1. RECEPTACLE CRIMPING BARREL
2. STRIPPED WIRE
3. WIRE CRIMPING JAW
4. INSULATION CRIMPING JAW
5. BACK SIDE OF TOOL
Figure 68. Crimp Alignment
HOW TO USE AMP DOUBLE ACTION

HAND TOOL 1. WIRE BARREL
2. INSULATION BARREL
NOTE: Wire size and insulation diameter must be 3. LOCATOR SLOT
within specified range for receptacle. See Table 12. 4. WIRE STRIP LENGTH (SEE TABLE 12)
1. Strip insulation from wire. See Table 12 and Fig- Figure 69. Wire and Receptacle
ure 69.
Table 12. Wire Strip Length
Crimp Wire Size Strip Insulation

Chamber (AWG) Length Diameter
20-16 4.2 to 5.2 mm (0.16 to 0.20 in.)
B 2.2 to 3.1 mm (0.09 to 0.12 in.)
18-14 5.1 to 6.1 mm (0.20 to 0.24 in.)
106
DESCRIPTION - AMP EXTRACTION TOOL universal handle as shown in Figure 70. Extraction
tip, installed, is aligned with mating face of connector
Extraction tools are designed to release locking lance housing to depress locking lance of receptacle holding
inside connector housing without damaging housing it in housing.
or connectors. The extraction tip is used with the
1. UNIVERSAL HANDLE 2. EXTRACTION TIP 3. DRIVE SCREW
Figure 70. AMP Extraction Tool With Tip
MAINTENANCE AND INSPECTION performed at regular intervals, refer to manufactur-

ers data for specifics.
For proper operation, tool to conform to measure-
ments indicated in Figure 71. Inspections to be
Figure 71. Tool Tip Inspection
107
Clean extraction tool with clean, soft, lint-free cloth 2. Insert tip of extraction tool, aligned in center
and store in clean, dry place. of housing cavity where locking lance is located.
See view B of Figure 72.
HOW TO USE AMP EXTRACTION TOOL
3. Push wire from BACK of housing TOWARD tool
It is necessary to depress locking lance of receptacle and depress locking lance. See view C of Fig-
from its cavity inside connector housing. Procedure ure 72.
below describes steps of extraction.
4. Pull BACK on wire and remove receptacle from
1. Orient extraction tool tip with mating face of con- housing. See view D of Figure 72.
nector. See view A of Figure 72.
5. Remove extraction tool from housing.
A. EXTRACTION TOOL ORIENTATION C. WIRE DEPRESSIONS

B. TOOL TIP ALIGNMENT D. RECEPTACLE REMOVAL
1. EXTRACTION TOOL 3. RECEPTACLE
2. HOUSING 4. LOCKING LANCE
Figure 72. Contact Extraction
108
2200 SRM 1128 AMP Fastin-Faston Receptacles and Housings
AMP Fastin-Faston Receptacles and Housings

DESCRIPTION f. Acceptable dimensions for wire barrel flash
shown in section A-A, Figure 76.
This manual section covers FASTIN-FASTON recep-
tacle installation. These connectors are the multiple g. After crimping, wire conductor and insula-
circuit connectors use primarily as wire harness con- tion to be visible in areas shown in Figure 76.
nectors.
h. Conductor may extend beyond wire barrel to
maximum dimension shown in Figure 76.
CAUTION
DO NOT nick, scrape, or cut the wire conductor i. Wire barrel seam to be closed, no loose wire
during the striping operation. strands visible.
1. Install receptacles as specified in How to Use j. There shall be no twist, roll, deformation, or
AMP Double Action Hand Tool. See Figure 73 other damage to mating portion of crimped
for tool image. receptacle that will prevent proper mating.
See Figure 77.
2. Receptacle contact should appear as shown in
Figure 74.
a. The most critical and compressed area is the

crimp applied to the wire portion of the con-
tact to ensure optimum electrical and me-
chanical performance of crimped receptacle.
See Figure 75 and Table 13.
b. Crimp length must be within dimensions in-

dicated in Table 13.
c. Front and rear bellmouths to match images

and dimensions shown in Figure 76.
d. The cutoff tab to be cut as shown in Figure 76.
e. Max burr on cutoff tab shall not exceed di-

mensions indicated in enlarged view of Fig- Figure 73. AMP Double Action Hand Tool
ure 76.
109
AMP Fastin-Faston Receptacles and Housings 2200 SRM 1128
A. WIRE CONDUCTORS AND INSULATION BOTH B. CONDUCTOR VISIBLE

VISIBLE IN THIS AREA C. INSULATION BARREL CRIMP WIDTH
1. FRONT BELLMOUTH 5. WIRE BARREL CRIMP HEIGHT
2. CRIMP LENGTH 6. WIRE BARREL FLASH
3. REAR BELLMOUTH 7. CUTOFF TAB
4. WIRE BARREL CRIMP WIDTH 8. MAX BURR
Figure 74. Typical Crimped Receptacle

1. WIRE INSULATION
2. STRIP LENGTH (SEE TABLE 13)
Figure 75. Wire Strip Length
110
Table 13. Wire Strip Length and Crimp Measurements
Insulation
Wire Size Insulation Strip Wire Barrel
Barrel
Crimp Width Crimp Height Crimp Width
1.52 to 2.54 mm 2.49 to 2.59 mm
(0.06 to 0.10 in.) 5.82 to 6.48 mm 2.24 to 2.34 mm 1.07 to 1.32 mm (0.98 to 0.102 in.)
20
2.16 to 3.18 mm (0.229 to 0.255 in.) (0.088 to 0.092 in.) (0.042 to 0.052 in.) 3.5 to 3.61 mm
(0.085 to 0.125 in.) (0.138 to 0.142 in.)
3.05 to 4.32 mm 6.23 to 6.48 mm
(0.120 to 0.170 in.) (0.245 to 0.255 in.)
3.05 to 4.06 mm 1.5 to 1.6 mm 4.01 to 4.11 mm
(0.120 to 0.160 in.) (0.059 to 0.063 in.) (0.158 to 0.162 in.)
3.5 to 3.68 mm 2.74 to 2.84 mm
(0.120 to 0.145 in.) 5.41 to 5.66 mm (0.108 to 0.112 in.)
(0.213 to 0.223 in.) 1.37 to 1.42 mm 4.52 to 4.62 mm
2.54 to 4.42 mm (0.054 to 0.058 in.) (0.178 to 0.182 in.)
(0.100 to 0.170 in.) 1.47 to 1.57 mm 4.01 to 4.11 mm
(0.054 to 0.062 in.) (0.158 to 0.162 in.)
18
6.22 to 6.48 mm 1.35 to 1.45 mm
2.16 to 3.18 mm (0.245 to 0.255 in.) (0.053 to 0.057 in.) 3.5 to 3.61 mm
(0.085 to 0.125 in.) 5.82 to 6.07 mm 1.17 to 1.27 mm (0.138 to 0.142 in.)
(0.229 to 0.239 in.) 2.24 to 2.34 mm (0.046 to 0.050 in.)
6.22 to 6.48 mm (0.088 to 0.092 in.) 1.35 to 1.45 mm
1.52 to 2.54 mm (0.245 to 0.255 in.) (0.053 to 0.057 in.) 2.49 to 2.59 mm
(0.060 to 0.100 in.) 5.82 to 6.07 mm 1.17 to 1.27 mm (0.098 to 0.102 in.)
(0.229 to 0.239 in.) (0.046 to 0.050 in.)
2.2 to 4.44 mm 5.1 to 6.1 mm 2.74 to 2.84 mm 1.42 to 1.52 mm 4.52 to 4.62 mm
(0.090 to 0.175 in.) (0.200 to 0.240 in.) (0.108 to 0.112 in.) (0.056 to 0.060 in.) (0.178 to 0.182 in.)
111
Table 13. Wire Strip Length and Crimp Measurements (Continued)
Insulation
Wire Size Insulation Strip Wire Barrel
Barrel
Crimp Width Crimp Height Crimp Width
4.06 to 5.33 mm 1.5 to 1.83 mm 6.3 to 6.4 mm
(0.160 to 0.210 in.) (0.059 to 0.072 in.) (0.248 to 0.252 in.)
3.81 to 4.83 mm 1.73 to 1.83 mm 5.28 to 5.38 mm
5.82 to 6.07 mm 3.0 to 3.11 mm
(0.150 to 0.190 in.) (0.068 to 0.072 in.) (0.208 to 0.212 in.)
(0.229 to 0.239 in.) (0.118 to 0.122 in.)
3.3 mm 1.85 to 2.18 mm 6.3 to 6.4 mm
(0.130 in.)MAX (0.073 to 0.086 in.) (0.248 to 0.252 in.)
(2 Wires)
3.05 to 4.32 mm 6.22 to 6.48 mm
(0.120 to 0.170 in.) (0.245 to 0.255 in.)
16 3.05 to 4.06 mm 1.65 to 1.75 mm 4.01 to 4.11 mm
(0.120 to 0.160 in.) (0.065 to 0.069 in.) (0.158 to 0.162 in.)
3.05 to 3.68 mm
(0.120 to 0.145 in.) 5.41 to 5.66 mm 2.74 to 2.84 mm
(0.213 to 0.223 in.) (0.108 to 0.112 in.) 1.32 to 1.42 mm 4.52 to 4.62 mm
2.54 to 4.32 mm (0.052 to 0.056 in.) (0.178 to 0.182 in.)
(0.100 to 0.170 in.) 1.6 to 1.7 mm 4.01 to 4.11 mm
(0.063 to 0.067 in.) (0.158 to 0.162 in.)
2.2 to 4.44 mm 5.1 to 6.1 mm 1.57 to 1.68 mm 4.52 to 4.62 mm
(0.090 to 0.175 in.) (0.200 to 0.240 in.) (0.062 to 0.066 in.) (0.178 to 0.182 in.)
4.06 to 5.33 mm 1.7 to 2.03 mm 6.3 to 6.4 mm
(0.106 to 0.210 in.) 6.22 to 6.45 mm 3.0 to 3.1 mm (0.067 to 0.080 in.) (0.248 to 0.252 in.)
3.81 to 4.83 mm (0.245 to 0.255 in.) (0.118 to 0.122 in.) 1.93 to 2.03 mm 5.28 to 5.38 mm
(0.150 to 0.190 in.) (0.076 to 0.080 in.) (0.208 to 0.212 in.)
3.05 to 4.32 mm (0.276 to 0.286 in.) (0.108 to 0.112 in.) (0.074 to 0.078 in.) (0.158 to 0.162 in.)
(0.120 to 0.170 in.) 6.60 to 6.86 mm 3.25 to 3.35 mm 1.78 to 1.88 mm 4.52 to 4.62 mm
3.05 to 4.06 mm 4.01 to 4.62 mm
14
(0.120 to 0.160 in.) 1.88 to 1.98 mm (0.158 to 0.182 in.)
3.05 to 3.68 mm (0.074 to 0.078 in.) 4.01 to 4.11 mm
(0.120 to 0.145 in.) 5.82 to 6.07 mm (0.158 to 0.162 in.)
(0.229 to 0.239 in.) 2.74 to 2.84 mm 1.55 to 1.65 mm 4.52 to 4.62 mm
2.54 to 4.32 mm (0.108 to 0.112 in.) (0.061 to 0.065 in.) (0.178 to 0.182 in.)
(0.100 to 0.170 in.) 1.83 to 1.93 mm 4.01 to 4.11 mm
(0.072 to 0.076 in.) (0.158 to 0.162 in.)
112
A. WIRE CONDUCTORS AND INSULATION BOTH VISIBLE IN THIS AREA

B. CONDUCTOR VISIBLE
C. INSULATION BARREL CRIMP WIDTH
1. FRONT BELLMOUTH 5. WIRE BARREL CRIMP HEIGHT (SEE TABLE 13)
2. CRIMP LENGTH (SEE TABLE 13) 6. WIRE BARREL FLASH
3. REAR BELLMOUTH 7. CUTOFF TAB
4. WIRE BARREL CRIMP WIDTH (SEE TABLE 13) 8. MAX BURR
Figure 76. Typical Crimp - Fastin-Faston Receptacle
113
1. FRONT OF RECEPTACLE
2. WIRE BARREL
Figure 77. Mating Portion
k. Force applied during crimping can cause

bending between the crimped wire barrel
and mating portion of receptacle. Bending is NOTE: ANGLES DRAWN FOR CLARIFICATION ONLY,
acceptable within limits shown in Figure 78. NOT TO SCALE. ANGLES ARE MAXIMUM DISTANCE
FROM DATUM LINE.
3. Crimped receptacle should hold wire firmly and
have a pull-test tensile value as specified in Ta- A. UP AND DOWN B. SIDE TO SIDE
ble 14.
1. DATUM LINE
Table 14. Crimp Pull-Out Test
Figure 78. Receptacle Bending Limits
Wire Size Minimum Force

(AWG) Newtons Pounds
20 57.8 13
18 89.0 20
16 133.4 30
14 222.4 50
4. Damaged crimped receptacles or housings must

be removed, discarded, and replaced with new
components. See Figure 79 and Figure 80 for
tools used during removal.
5. For procedure to remove receptacles for connec-

tor housings, see How to Use AMP Extraction
Tool section.
Figure 79. AMP Extraction Tool Universal

Handle
114
2200 SRM 1128 Wire Repair
Figure 80. AM Extraction Tool Tip
Wire Repair
WIRE SPLICING REQUIREMENTS 3. 10 to 20 Gauge wire in area allowing use of a heat
gun - repair using Del-City crimp-solder-shrink
Refer to the following for determining which proce- splice.
dure to use for wire repairs.
4. 12 to 14 Gauge wire in area allowing 12.7 mm
1. 8 Gauge or heavier wire - no splicing, replace full (0.5 in.) diameter × 63.5 mm (2.5 in.) long splice
length of wire or replace harness. - use Deutsch jiffy splice.
2. Wires not meeting requirements of Step 3 5. 14 to 20 Gauge wire in area allowing 9.78 mm
through Step 5 - no splicing, replace full length (0.385 in.) diameter × 62.74 mm (2.47 in.) long
of wire or replace harness. splice - use Deutsch jiffy splice.
Table 15. Wire Strip Length Specifications
Contact Type Wire Gauge Range Recommended

Part Number Strip Length
2
2
2
2
1330435 Pin 14 AWG (2.0 mm ) 6.35 to 7.92 mm (0.250 to 0.312 in.)
1330436 Socket 14 AWG (2.0 mm 2) 6.35 to 7.92 mm (0.250 to 0.312 in.)
2
2
2
1554359 Socket 12 to 14 AWG (3.0 to 2.0 mm ) 5.64 to 7.21 mm (0.222 to 0.284 in.)
115
Wire Repair 2200 SRM 1128
DEUTSCH JIFFY SPLICE

This splicing procedure adds 19.05 mm (0.75 in.) to
the length of the wire and may be used when slight
lengthening of the wire is desired.
Assemble
STEP 1.
Strip both wire ends to the specifications in Table 15.
STEP 2.
On one wire, crimp the appropriate pin onto the wire
using the Deutsch Crimping Tool (Hyster Part No.
867888). See How to Crimp With the Deutsch Crimp-
ing Tool.
STEP 3.
On second wire, crimp the appropriate socket onto
the wire using the Deutsch Crimping Tool (Hyster
Part No. 867888). See How to Crimp With the
Deutsch Crimping Tool.
116
STEP 4.
Insert the wire with the socket contact into one end
of the jiffy splice.
STEP 5.
Push the contact into the jiffy splice until a positive
stop is felt. An audible snap will occur when correctly
installed. Slightly tug the wire to verify the wire is
properly locked in place.
STEP 6.
Insert the wire with the pin contact into opposite end
of the jiffy splice.
STEP 7.
Push the contact into the jiffy splice until a positive
stop is felt. An audible snap will occur when correctly
installed. Slightly tug the wire to verify the wire is
properly locked in place.
117
Disassemble
STEP 1.
Insert appropriate Deutsch extraction tool over the
wire being removed.
118
STEP 2.
Push the tool into the splice connector about 25 mm
(1 in.), until it bottoms on the contact flange.
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees and reinsert
STEP 3.
and the connection socket or pin out of the connector.
STEP 4.
Repeat STEP 1 through STEP 3 on opposite end.
119
DEL-CITY CRIMP-SOLDER-SHRINK SPLICE

Refer to Table 16 for the correct splice part number for the wire gauge being repaired.
Table 16. Wire Splice Size
Part Number Wire Gauge Range

866417 10 to 12 AWG (5.0 to 3.0 mm 2)
866418 14 to 16 AWG (2.0 to 1.0 mm 2)
866419 18 to 20 AWG (0.8 to 0.5 mm 2)
STEP 1.
Strip approximately 9.525 mm (0.375 in.) from both
wire ends.
CAUTION
Do not crimp solder sleeve in the center of the connector. This will make the connector unservice-
able.
STEP 2.
Insert one wire into the connector. Make sure wire
is properly seated and crimp the connector using an
insulated connector crimping tool nest that matches
the color or gauge of the connector.
1. SOLDER SLEEVE 2. CRIMP POINT
CAUTION
Do not crimp solder sleeve in the center of the connector. This will make the connector unservice-
able.
STEP 3.
Insert the second wire into the opposite end of the
connector. Make sure wire is properly seated and
crimp the connector using an insulated connector
crimping tool nest that matches the color or gauge of
the connector.
1. CRIMP POINT
120
2200 SRM 1128 Twisted/Shielded Cable and Leads Repair
STEP 4.
Using a heat gun, apply heat evenly, to approx-
imately 135 C (275 F), around the length of the
tubing (including the crimp area) from the center
out to the ends until the tubing fully recovers and
adhesive flows.
Continue distributing the heat over the solder sleeve

until solder flows into the terminal barrel. Remove
from the heat and let cool for ultimate connection per-
formance.
1. EXPOSED NOTCHES AFTER SOLDER BAND

MELTS
Twisted/Shielded Cable and Leads Repair
TWISTED/SHIELDED CABLE REPAIR

STEP 1.
Remove outer jacket.
STEP 2.
Unwrap aluminum mylar tape. Do not remove mylar
tape.
1. DRAIN WIRE
2. OUTER JACKET
3. MYLAR
121
Twisted/Shielded Cable and Leads Repair 2200 SRM 1128
STEP 3.
Untwist conductors and strip insulation as necessary.
STEP 4.
Splice wires using splice clips and rosin core solder.
Wrap each splice to insulate.
1. SPLICE AND SOLDER
STEP 5.
Splice the drain (uninsulated) wire using splice clip
and rosin core solder.
STEP 6.
Wrap with mylar and drain (uninsulated) wire.
1. DRAIN WIRE
STEP 7.
Apply electrical tape over whole bundle to secure.
122
2200 SRM 1128 Twisted/Shielded Cable and Leads Repair
TWISTED LEADS REPAIR

STEP 1.
Locate damaged wire and remove insulation as re-
quired.
STEP 2.
Splice the two wires using splice clips and rosin core
solder.
1. SPLICE AND SOLDER
STEP 3.
Cover splice with electrical tape to insulate from
other wires.
STEP 4.
Twist and tape with electrical tape.
123
Special Tools 2200 SRM 1128
Special Tools
Illustration Tool Description
Not Illustrated Deutsch Connector Kit
Not Illustrated Deutsch Connector/ Crimp/ Stripper Kit
Wire Stripper
Used for stripping wires.
Wire Stop for Wire Stripper

Wire Crimping Pliers

Used for crimping connectors. (Except
Deutsch and AMP Connectors)
Deutsch Hand Crimping Tool

Used for crimping pins and sockets for
Deutsch connectors.
124
2200 SRM 1128 Special Tools

Deutsch Wedge Removal Tool
Used to remove secondary lock for
Deutsch connectors.
Yellow Extracting Tool

Used to repair Deutsch HD 12 to 14
AWG connectors.
Orange Extracting Tool (E-Seal)

Extra thin wall tool. Used to repair Deutsch
HD 12 to 14 AWG connectors.
Light Blue Extracting Tool

AWG connectors.
Dark Blue Extracting Tool (E-Seal)

Extra thin wall tool. Used to repair Deutsch
HD 16 to 18 AWG connectors.
Red Extracting Tool

AWG connectors.
125

Deutsch G454 Testing Tool
Used to check calibration of Deutsch
Hand Crimping Tool
Flat Blade Screwdriver

Used to open wedge lock for AMP plug connectors
AMP Hand Crimping Tool

(AMP Part No. 58440-1)
Use for crimping AMPSEAL contacts
126

AMP Pro-Crimper II
Hyster Part No. 1698558 with Die Set 1698559
Use for crimping AMPSEAL contacts
AMP Extracting Tool Hyster Part No. 1698561

AMP Receptacle and Tab Contact Extraction
Tool for AMPSeal connectors
127

AMP Extracting Tool
AMP Tab Contact Extraction Tool for
AMPSeal connectors
AMP Hand Application Tool

Hyster Part No. 1698562 with Die Set
Use for crimping AMP Superseal 1.5
Series Contacts
128

AMP Pro-Crimper II
Hyster Part No. 1698565 with Die Set
Used for crimping AMP Superseal 1.5
Series Contacts
Heat Gun
Used to repair connector wires.
Tool Kit for Terminal Repair

Terminals cannot be removed from their
connectors or repaired without special tools.
This kit has the special removal and installation
tools and crimping tools required to make repairs
in Micro-Pack, Metri-Pack, and Weather-Pack
connectors. This repair kit does not have
the terminals or the connectors.
129

AMP Double Action Hand Tool
Use for crimping Fastin-Faston receptacle
connectors.
AMP Universal Handle Assembly with Strap

Use with Extraction Tool Tip for Fastin-Faston
receptacle connector extraction from
connector housings.
AMP Extraction Tool Tip

Hyster Part No 1701711
Use with Universal Handle Assembly for
Fastin-Faston receptacle connector extractions.
130

Hyster n35zdr n45zr (n264) n30zdr n35-40zr-d470

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AC MOTOR

PART NO. 1590940 2200 SRM 1190

©2008 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

N35ZDR, N45ZR [C264];

The AC motors also have thermal sensors embedded

The master controller also manages the operating

AC Transistor Motor Controller Replacement

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 3. AC Traction and AC Pump Motor Controllers (450A)

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 4. AC Traction and AC Pump Motor Controllers (675A)

GENERAL MAINTENANCE During installation of the controller, apply a suffi-

CAUTION Parts of these assemblies not covered in this manual

FUSES Contactor Contacts. The contacts in a contactor

Check the coil with an ohmmeter for an open circuit

Figure 5. Integrated Fuse Board

Figure 6. Main (Line) Contactor

Legend for Figure 7

Figure 7. Replacement Parts of Line Contactor

Master Controller Checks and Adjustments

The following checks and adjustments may be made

Table 1. Factory Parameter Defaults Table 1. Factory Parameter Defaults

Parameter Factory Default Parameter Factory Default

Table 2. Traction Parameter Defaults

CONTROLLER STATUS LIGHT EMITTING AC Motor Controllers

Figure 8. Master Controller LED

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 9. AC Traction and AC Pump Motor Controllers (450A)

1. AC TRACTION MOTOR CONTROLLER 3. MAIN CONTACTOR

Figure 10. AC Traction and AC Pump Motor Controllers (675A)

Table 3. List of Operator Warning Messages

Message Description Explanation

Table 3. List of Operator Warning Messages (Continued)

Message Description Explanation

Table 3. List of Operator Warning Messages (Continued)

Message Description Explanation

Table 3. List of Operator Warning Messages (Continued)

Message Description Explanation

Table 4. List of Fault Messages

Fault Message Description

Table 4. List of Fault Messages (Continued)

Fault Message Description

Table 4. List of Fault Messages (Continued)

Fault Message Description

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit

Status Display Message Circuit