ELECTRICAL SYSTEM

(TRUCKS WITH AC
CONTROLLERS)
J2.00-3.20XM (J40-60Z) [A416]; V30ZD [D210];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108]

PART NO. 1534734 2200 SRM 1055

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Electrical System (Trucks With AC Controllers) Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Features of the Display Panels ..................................................................................................................... 2
Other Control Components ........................................................................................................................... 3
Display Panel and Key Switch Replacement ................................................................................................... 3
Display Panel, Replace .................................................................................................................................. 3
Key Switch, Replace ...................................................................................................................................... 5
Motor Controller Replacement .......................................................................................................................... 5
Control Components Replacement.................................................................................................................... 6
Start Switch, Replace .................................................................................................................................... 6
Brake Light Switch, Replace......................................................................................................................... 6
Seat Switch, Replace ..................................................................................................................................... 7
Parking Brake Switch, Replace .................................................................................................................... 8
MONOTROL Pedal Direction Switches, Replace ........................................................................................ 9
Steering Column Direction Control Switches, Replace ............................................................................... 10
Brake Fluid Switch, Replace......................................................................................................................... 11
Brush Wear and Overtemperature Sensors (Optional DC Pump Motor Only).......................................... 11
Rocker Switches for Lights, Replace ............................................................................................................ 11
Accelerator Position Sensor, Replace............................................................................................................ 12
On-Demand Steering Sensor, Replace.......................................................................................................... 14
Lights, Converter, Relay, and Reverse Alarm .............................................................................................. 14
Brake, Tail, and Reverse Light Assembly, Replace ................................................................................. 15
Strobe Light Assembly, Replace ............................................................................................................... 15
Front, Rear Driving Light, or Spot Light Assemblies, Replace .............................................................. 17
Converter, Replace .................................................................................................................................... 17
Relay, Replace............................................................................................................................................ 18
Backup Alarm, Replace............................................................................................................................. 18
Horn and Horn Button, Replace ................................................................................................................... 18
Horn Switch and Cover, Replace .............................................................................................................. 19
Hydraulic Pump Switches............................................................................................................................. 19
Control and Power Fuse Check ......................................................................................................................... 20
Fuse Locations ............................................................................................................................................... 20
Brake Light Switch Adjustment ....................................................................................................................... 24
Seat Switch Check ............................................................................................................................................. 25
Seat Brake Adjustment ..................................................................................................................................... 25
Parking Brake Switch Adjustment ................................................................................................................... 25
Direction Switches Check .................................................................................................................................. 26
MONOTROL Pedal........................................................................................................................................ 26
Steering Column ............................................................................................................................................ 26
MONOTROL Pedal or Accelerator Pedal Adjustment..................................................................................... 27
Accelerator Position Sensor Adjustment and Start Switch Adjustment ........................................................ 28
Acceleration Position Sensor, Adjust ............................................................................................................ 28
Start Switch, Adjust ...................................................................................................................................... 28

This section is for the following models:

J2.00-3.20XM (J40-60Z) [A416];

V30ZD [D210];
E1.50-2.00XM (E25-35Z, E40ZS) [E114];
E2.00-3.20XM (E45-65Z) [G108]

©2004 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1055
General
WARNING
Do not operate a lift truck that needs adjust-
ment or repairs. Report the need for adjust-
ment or repairs immediately. If adjustment or
repair is necessary, put a DO NOT OPERATE
tag in the operator’s area. Remove the key
from the key switch.
Some of the checks and adjustments are done
with the battery connected. Never have any
metal on your fingers, arms, or neck. These
metal items can accidentally make an electri-
cal connection and cause an injury.
Some adjustments in this section must be done
with the battery connected and power applied
to the controller. When making these adjust-
ments, make sure the drive wheels are raised
from the floor. See the Operating Manual or the
Periodic Maintenance 8000 SRM 1060 to raise
the drive wheels.
NOTE: This section does NOT include any compo-
nents of any of the motor controllers. Many of the
components in this section do have inputs to the mas-
ter controller, but are not part of the controller.
This section has the checks, adjustments, and repair
procedures for the parts of the electrical system that
are NOT part of the master controller or AC motor
controllers. This section also does NOT include the
electrical components covered in other sections such
as AC motors:
• See AC Motor Controller Parameter Table in
the AC Motor Controller/Display Panel 2200
SRM 1056 for more information.
See the section AC Motor Repair 620 SRM 1098
or 620 SRM 1053 for maintenance of the AC motor.
See the section Industrial Battery 2240 SRM 1 for
information on the battery.
General
Troubleshooting and Adjustment With a Com-
puter With the AC Controller 2200 SRM 1058 for
information on troubleshooting with a computer.
Some components that have inputs to the controller
have installation adjustments. This section has the
correct procedures for replacement, checks, and ad-
justments of these components. These components
include the following:
• Key Switch
• Start Switch
• Brake Light Switch
• Seat Switch
• Parking Brake Switch
• Direction (FWD REV) Switches
MONOTROL™ Pedal
Direction Control (On Steering Column)
• Brake Fluid Switch
• Rocker Switches for Lights
• Accelerator Position Sensor
• Lights, Converter, Relay, and Reverse Alarm
• Horn and Horn Button
NOTE: Some checks and adjustments are easier to
do if another person can operate the controls. If you
are working alone, put a weight on the seat to close
the seat switch. Put the voltmeter in a position so you
can see it from the operator area. You can usually
operate the controls with your hand and also make
the voltage measurements.
NOTE: The adjustments of the switches on the link-
age for the main control valve are in the Main Con-
trol Valve 2000 SRM 562. Following is a list of the
switches:
• Lift - High Speed
• Lift - Medium Speed
• Tilt - Low Speed
• Third Auxiliary
• Fourth Auxiliary - Medium Speed
• Fourth Auxiliary - Low Speed
1
Description 2200 SRM 1055

Description
FEATURES OF THE DISPLAY PANELS
NOTE: There are two dash display options, Standard
and Premium. Both displays look identical. The dif-
ference is in the display software and the resulting
functionality.
The following features are part of both the Standard
and Premium Display Panels:
• LED (Light Emitting Diode) symbol indicators
• LCD (Liquid Crystal Display) screen
• Battery Discharge Indicator
• Service Reminder (if enabled)
• Status Codes
• Hourmeter of traction and lift pump times
These features are shown in the display panel fea-
tures. See Figure 1. The symbol indicators are
shown and described in the Operating Manual.
Since the indicators are for common features, these
indicators are also combined with the Premium
Display Panel.

1. HOURMETER INDICATOR SYMBOL 8. LCD SCREEN

2. WRENCH INDICATOR SYMBOL 9. STAR PUSH BUTTON
3. BATTERY INDICATOR SYMBOL 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR 11. PUSH BUTTON #2
5. BRAKE FLUID SYMBOL 12. PUSH BUTTON #3
6. PARKING BRAKE SYMBOL 13. PUSH BUTTON #4
7. FASTEN SEAT BELT SYMBOL 14. PUSH BUTTON #5

Figure 1. Features of the Standard and Premium Display Panels

2
2200 SRM 1055
OTHER CONTROL COMPONENTS
Following is a short description of the other control
components and their function:
• Key switch is in the steering column housing and
connects battery voltage to all of the control circuits
except the horn.
• Start switch is actuated by the accelerator pedal
and is part of the SRO circuit. If the start switch
is closed before the seat switch, the controller will
not permit the lift truck to move.
• Brake light switch is actuated by the brake pedal
to energize the brake lights on the rear legs of the
overhead guard.
• Seat switch is inside the seat and is open if the
operator is not on the seat. The seat switch sends
a signal to the master controller.
• Parking brake switch operates if the parking brake
is applied. The parking brake switch is fastened
near the linkage for applying the parking brake.
The switch sends a signal to the master controller
to illuminate the parking brake indicator on the
display panel.
An alarm is also operated by the master controller
if the operator leaves the truck without applying
the parking brake. The master controller will ac-
tivate the alarm after getting the signal from the
parking brake switch. The alarm is activated if the
operator leaves the seat of the lift truck when the
Display Panel and Key Switch Replacement
DISPLAY PANEL, REPLACE
WARNING
Before replacing the Display Panels, fully
lower all parts of the mast and tilt it forward
until the tips of the forks touch the ground.
This action will prevent the mast from lower-
ing suddenly if the control lever is accidently
moved.
Always disconnect the battery, remove the key,
and discharge the capacitor(s) of the motor
controllers before replacing the Display Pan-
els. Discharge the capacitor(s) by holding the
horn button down until the horn stops making
a sound.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally make
an electrical connection and cause an injury.
Display Panel and Key Switch Replacement
key is in the ON position and the parking brake is
not applied. The alarm is also activated if the key
is moved to the OFF position when the brake is not
applied.
• Direction control switches in the MONOTROL
pedal or steering column send battery voltage to
the master controller.
• Brake fluid switch sends voltage to the master con-
troller. The LED in the display panel is displayed
when the fluid in the brake master cylinder is low.
• Rocker switches for lights control all the optional
lights on the lift truck.
• The accelerator position sensor is the input to the
master controller for speed control.
• The On-Demand steering components allow the
steering pump to operate only when the steering
wheel is moved.
• The rear lights on the legs of the overhead guard
are similar to automobile rear lights. The brake
lights come on when the brake pedal is depressed.
The reverse lights come on when the truck is set for
travel in reverse. If there are also driving lights
installed, the tail lights come on with the driving
lights. There can also be an operator compartment
light. A flashing light can be located at the top or
rear of the overhead guard and the reverse alarm.
• The horn switch at the center of the steering wheel
operates the horn under the floor plates.
CAUTION
A short circuit and damage can occur if wires
are not installed correctly. Make sure wire
connectors do not touch the other meter termi-
nals or wire connectors, metal brackets, or the
bracket mounting nuts. Make sure the wires
are not pulled tight and are not touching other
parts to damage the insulation.
The Display Panel is in the dash cover. The Display
Panel cannot be repaired and must be replaced if it
has a malfunction. These Display Panels must be
replaced as a unit. See Figure 2.
1. Disconnect the battery connector. Make sure
the capacitors of the motor controller(s) are
discharged as described in the previous WARN-
ING.
3
Display Panel and Key Switch Replacement
2. Remove the two nuts that fasten the Display
Panel and mount bracket. See Figure 2. Remove
the nuts and bracket. Lift the Display Panel up
out of the instrument panel.
3. Disconnect the plug connector on the back of the
Display Panel.
1. DISPLAY PANEL
2. MOUNT BRACKET
Figure 2. Mounting of Display Panel
4
2200 SRM 1055
4. On the replacement Display Panel, install the
plug connector on the back of the Display Panel.
5. Put the replacement Display Panel back into the
instrument panel.
6. Install the mounting bracket and mounting nuts.
Tighten the nuts that fasten the Display Panel in
the instrument panel.
3. MOUNT NUT
4. 8-PIN CONNECTOR
2200 SRM 1055 Motor Controller Replacement

KEY SWITCH, REPLACE

NOTE: The key switch is replaced as one of the com-
ponents of the steering column. See Steering Wheel
and Column Assembly Repair for more information.

1. Disconnect the battery, discharge capacitors, and

attach a tag to the truck battery connector stat-
ing DO NOT CONNECT BATTERY.

2. Remove the key switch from the housing of the

steering column. See Figure 3. Make an identifi-
cation of the electrical wires and disconnect them
from the key switch.
1. STEERING 3. NUT
3. Install the electrical wires on the key switch that COLUMN 4. RED/BRN
were identified during removal. Install the new 2. KEY SWITCH 5. BRN
key switch into the housing of the steering col-
Figure 3. Key Switch
umn.

4. Remove the DO NOT CONNECT BATTERY tag

from the truck battery connector and reconnect
the battery.

Motor Controller Replacement

Make sure the battery is disconnected and the capac-
itor is discharged using the horn as previously de-
scribed. Replace the motor controller as described in
the following procedure. See Figure 18 or Figure 19.
1. Make an identification for correct connection of
the power cables on the power terminals of the
motor controller. Disconnect the power cables
and the connector plug for the control wires.
CAUTION
Do not remove the small screws that fasten the
cover of the motor controller.
Make sure there is no dirt between the plate of
the motor controller and the mount surface of
the lift truck frame.
2. Remove the traction or pump mounting screws
that fasten the motor controller to the lift truck
heat sink. Carefully remove the motor controller.
3. Put an even coat of the silicone compound (Hys-
ter Part No. 1198757) or equivalent on the plate
of the motor controller. Make sure there are no
air spaces between the plate and mount surface
of the lift truck frame. The motor controller must
make full contact with the lift truck heatsink. In-
stall the mount screws that fasten the motor con-
troller to the lift truck heatsink.
4. Install the power cables at the power terminals
of the motor controller as identified during re-
moval. Install the connector plug for the control
wires on the connector of the motor controller.

5
Control Components Replacement 2200 SRM 1055

Control Components Replacement

START SWITCH, REPLACE Legend for Figure 4

The start switch is a small switch fastened to the 1. MONOTROL PEDAL OR ACCELERATOR PEDAL
mount plate for the MONOTROL pedal or accelera- 2. TO ACCELERATOR POSITION SENSOR
3. START SWITCH
tor pedal. The switch operates as soon as the pedal 4. TO DIRECTION CONTROL LEVER IF INSTALLED
starts to move, for an input to the master controller to 5. ACTUATOR OF START SWITCH
energize the traction motor. Replace the start switch 6. RED/PINK
as follows: 7. BLU-LT
8. WHT
1. Disconnect the battery, discharge capacitors, and 9. GRN
remove the key. 10. WHT OR WHT/BLK
11. RED/YEL, RED/PINK
2. Remove the floor plates. The start switch is un-
5. Adjust the start switch as described in Start
der the accelerator or MONOTROL pedal. See
Switch Adjustment. Install the floor plates.
Figure 4.

3. Install tags on the wires of the start switch for
correct connection during installation. Remove
the wires and the mount screws for the start
switch.
4. Install the replacement start switch in the same
position. Do not bend or damage the leaf of the
switch during installation. Connect the wires as
tagged during removal.
BRAKE LIGHT SWITCH, REPLACE
The brake light switch is a small switch fastened to
the mount plate for the brake pedal assembly. This
switch is normally open. The brake light switch is op-
erated by the brake pedal to energize the brake lights
on the rear legs of the overhead guard. These lights
are standard on U.S. units and optional on European
units. Replace the brake light switch as follows:

1. Disconnect the battery, discharge capacitors, and

remove the key.

2. Remove the floor plates. The brake light switch

is between the pedal arm and the mount for the
brake pedal. See Figure 5.

3. Install tags on the wires of the brake light switch

for correct connection during installation. Re-
move the wires and the mount screws for the
switch.

4. Install the replacement switch in the same posi-

tion. Do not bend or damage the actuator arm
and roller of the switch during installation. Con-
nect the wires as tagged during removal.

5. Adjust the brake light switch as described in

Brake Light Switch Adjustment. Install the
floor plates.

Figure 4. Start Switch

6
2200 SRM 1055 Control Components Replacement

from the hole in the hood for enough clearance to

get the connector through the grommet.

3. Remove the screws that fasten the seat to the

hood and hood frame. Close and latch the hood
and put the seat on its side for access to the seat
switch.

4. Use a flat blade screwdriver or other tool with

a flat blade to carefully lift the switch free of the
seat pan. Slide the switch out of the seat cushion.

5. Carefully slide the replacement switch into the

cavity of the seat cushion until the end of the
switch with the wires is aligned over the hole in
the pan. Push on the switch until the clips of the
switch are fastened to the seat.

6. Carefully install the grommet over the wire con-

nector. Install the seat on the hood and tighten
the nuts. Install the grommet in the hole of the
hood, connect the wire connector, and push the
connector back inside the hood frame.
1. BRAKE PEDAL 3. SWITCH
2. BRAKE LIGHT ACTUATOR
SWITCH 4. YEL/RED
5. BRN/PUR

Figure 5. Brake Light Switch

SEAT SWITCH, REPLACE

NOTE: If the lift truck has a seat brake, there is no
seat switch. There is a switch on the seat brake link-
age that must be adjusted by moving it in slots of the
mount bracket.

The seat switch has no adjustments. See Figure 6.

The seat switch is inside the cushion of the opera-
tor seat and must be replaced if it is damaged. The
switch is normally open. Replace the seat switch as
follows:

1. Disconnect the battery, discharge capacitors, and

remove the key.
NOTE: SEAT CAN BE DIFFERENT THAN SHOWN.
2. Open the hood. Disconnect the connector for the
1. SEAT PAN 3. WIRE
seat switch wires near the rear of the hood frame. 2. SEAT SWITCH CONNECTOR
Push the connector through the grommet in the
hood. It can be necessary to remove the grommet Figure 6. Seat Switch Replacement

7
Control Components Replacement 2200 SRM 1055

PARKING BRAKE SWITCH, REPLACE

The parking brake switch is fastened near the link-
age for applying the parking brake. This switch oper-
ates the indicator in the display panel and the alarm
through the control card for the display panel. See
Figure 7, Figure 8, or Figure 9.

1. RELEASE KNOB
2. PARKING BRAKE PEDAL IN RELEASED
POSITION
3. PARKING BRAKE PEDAL IN APPLIED POSITION
4. PARKING BRAKE INDICATOR SWITCH
5. LINKAGE
6. ADJUSTMENT NUT
7. LEVER ASSEMBLY
8. PARKING BRAKE PEDAL ASSEMBLY

Figure 8. Parking Brake Assembly, Lift Trucks

E1.50-2.00XM (E25-35Z, E40ZS)

The park brake alarm will operate for 10 seconds

when the operator gets off the seat or the key is
moved to the OFF position if the park brake is not
applied. The alarm is operated by the display panel
from the switch signal and is located within the
1. RELEASE KNOB display panel housing. The alarm will not operate if
2. PARKING BRAKE PEDAL IN RELEASED
POSITION the parking brake switch is damaged or not adjusted
3. PARKING BRAKE PEDAL IN APPLIED POSITION correctly. An alarm that does not operate cannot be
4. PARKING BRAKE INDICATOR SWITCH repaired and must be replaced as part of the display
5. LINKAGE panel. See Display Panel Assembly. Replace the
6. ADJUSTMENT NUT parking brake switch as follows:
7. LEVER ASSEMBLY
8. PARKING BRAKE PEDAL ASSEMBLY
9. SWITCH MOUNTING PLATE 1. Disconnect the battery, discharge capacitors, and
remove the key.
Figure 7. Parking Brake Assembly, Lift Trucks
J2.00-3.20XM (J40-60Z)

8
2200 SRM 1055
1. RELEASE KNOB
2. PARKING BRAKE PEDAL IN RELEASED
POSITION
3. PARKING BRAKE PEDAL IN APPLIED POSITION
4. LEVER ASSEMBLY
5. ADJUSTMENT NUT
6. PARKING BRAKE INDICATOR SWITCH
Figure 9. Parking Brake Assembly, Lift Trucks
V30ZD, E2.00-3.20XM (E45-65Z)
2. Install blocks on each side of a steering wheel to
prevent movement of the lift truck. Release the
parking brake.
3. Remove the floor plate under the parking brake
pedal. Remove the screws and nuts that fasten
the switch to the bracket. Do not lose the screws,
nuts, or washers.
4. Turn the switch so that you can see the termi-
nals. Make a note of the wires fastened to the
Control Components Replacement
switch terminals for correct connection during in-
stallation. Remove the wires from the switch ter-
minals. Connect the wires to the replacement
switch as disconnected during removal.
5. Install the replacement switch using the same
screws, nuts, or washers. Do not damage the
leaf of the switch during installation. Tighten the
screws and nuts.
6. Check for correct operation and, if necessary,
adjust the switch as described in Parking Brake
Switch Adjustment. Install the floor plates.
Apply the parking brake and remove the wheel
blocks.
MONOTROL PEDAL DIRECTION
SWITCHES, REPLACE
There is a small direction switch under each pad
of the MONOTROL pedal. The direction control
switches send a signal to the master controller to
select the direction of travel. Both switches must
function correctly because both switches are used to
close the circuit. Each switch controls one direction.
If both sides of the MONOTROL pedal are pushed at
the same time, the direction circuit is de-energized
and the lift truck will not move. The contacts of the
two direction switches are in a series and parallel
arrangement so that both direction contactors can-
not be energized at the same time.
NOTE: The direction switches used in the
MONOTROL pedal are made for Hyster Company
with a special contact clearance and materials.
Other switches look the same and will fit in the
same space in the MONOTROL pedal. These other
switches will not operate the same and will often not
provide good service. The switches must be replaced
as an assembly that includes two switches and the
wire cable with connectors. Use only replacement
switches in the assembly with the Hyster part
number. Replace the direction switch assembly as
follows:
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Remove the floor plates. Make a note of the
location of the wire for correct connection dur-
ing installation. Disconnect the wires for the
MONOTROL pedal. Disconnect and remove the
return spring for the pedal.
9
Control Components Replacement 2200 SRM 1055

3. Remove the nut and washer from the pivot cap-
screw of the pedal. Carefully move the pedal as-
sembly to the right to disengage the arm of the
accelerator position sensor. This movement must
also make clearance between the pedal assembly
and the leaf of the start switch. Remove the pedal
assembly.
4. Turn the pedal assembly upside down and re-
move the pedal pad.
5. Remove the nuts that fasten the switches. Re-
move the screws and special washers that fasten
the wires to the pedal. Cut the cable ties that fas-
ten the cable wires to the pedal casting. Remove
the switch assembly from the pedal.
6. Install the replacement switch assembly on the
pedal. Make sure that the Forward switch with
wire 8 (light blue) is on the right of the back side
of the pedal. The Reverse switch with wire 6
(white) is on the left of the back side of the pedal.
STEERING COLUMN DIRECTION
CONTROL SWITCHES, REPLACE
NOTE: The direction switches used in the direction
control are made for Hyster Company with a special
contact clearance and materials. Other switches look
the same and will fit in the same space. These other
switches will not operate the same and will often not
provide good service.
The direction control switches send a signal to the
master controller to select the direction of travel.
This direction control has a pair of small switches
in the steering column. See Figure 10. Each po-
sition of the two switches controls one direction.
Both switches must function correctly because both
switches are used to close the circuit. A bad switch
must be replaced. Refer to the Steering Wheel and
Column Assembly Repair section in the Steering
System for AC Electric Lift Trucks 1600 SRM
1054 to replace these switches.

7. Temporarily install the nuts that fasten the

switches, but do not tighten the nuts.

8. Align the wires as shown in Figure 12. Put Loc-

tite® 222 on the screws for the special washers
that fasten the wires. Install the screws and
washers and tighten the screws to 0.8 to 1 N•m
(7 to 9 lbf in).

9. Install cable ties as removed during removal.

Make sure the tie lock of the cable tie is com-
pletely inside the U channel of the casting.

10. Before installing the pedal pad, adjust the direc-

tion switches as described in Direction Switches
Check. Install the pedal pad on the pedal after
adjustments are complete.

11. If removed, install the pivot capscrew and

washer in the pedal casting. Carefully install
the pedal assembly on the truck while aligning
the pin in the slot of the arm of the accelerator 1. DIRECTION SWITCHES
position sensor. 2. SHIFT LEVER ASSEMBLY
3. SCREW
12. Make sure the pedal is down low enough so that 4. ELECTRICAL CONNECTORS
the leaf of the start switch is not damaged. In-
Figure 10. Direction Control Handle Assembly
stall the lockwasher and nut on the pivot cap-
screw. 1. Go to the ,Assembly Components, RemoveSteer-
ing Wheel and Column Assembly Repair section
13. Install the return spring and connect the wires
of the service manual Steering System for AC
as disconnected. Install the floor plates.
Electric Lift Trucks 1600 SRM 1054 to remove

10
2200 SRM 1055 Control Components Replacement

the direction control switches. Follow Step 1

through Step 4 for this procedure.

2. Go to the ,Assembly Components, InstallSteer-

ing Wheel and Column Assembly Repair section
of the service manual Steering System for AC
Electric Lift Trucks 1600 SRM 1054 to install
the directional control switches. Follow Step 6
through Step 12 of this procedure.

BRAKE FLUID SWITCH, REPLACE

This switch is a magnetic switch on the reservoir of
the master cylinder for the service brakes. It sends
a signal to the control card of the display panel to il-
luminate the indicator for low fluid level. The switch
is part of the reservoir. To replace the reservoir, see
the Brake System SRM for your lift truck model.

BRUSH WEAR AND OVERTEMPERATURE

SENSORS (OPTIONAL DC PUMP MOTOR
ONLY)
On the optional DC Pump Motor when brush wear
is detected, the dash display shows a status code of
Code 95 to indicated that the brushes need to be re-
placed.
The overtemperature sensors are thermal switches.
These switches are in the lift pump motors. They
send a signal to the master controller. The dash dis-
play shows a status code of Code 91 to indicate that
the motor is too hot. The master controller sends a
signal to the traction control for a slower travel speed
if the pump motor is too hot.
ROCKER SWITCHES FOR LIGHTS,
REPLACE
These switches are ON/OFF switches that control
the optional front, rear, and operator compartment
lights. See Figure 11. Rocker switches for the lights
are mounted to the instrument panel to the right of
the steering column. Remove the cover under the in-
strument panel for access to the under side of the in-
strument panel or switch mounting surface. Replace
a switch as described in the following paragraphs:
1. Disconnect the battery, discharge capacitors, and
remove the key.
1. SWITCH ASSEMBLY
2. LENS AND FUNCTION SYMBOL (NOT ON ALL
SWITCHES)
3. INSTRUMENT PANEL
4. RETAINER CLIP
5. SWITCH LIGHT AND OTHER TERMINALS
6. POWER TERMINALS
Figure 11. Rocker Switch
2. Put tags on the switch wires or wire harness
for correct identification during installation. Re-
move the wires from the switch terminals.
3. Use a flat blade screwdriver or other similar tool
and press in on the retainer clips at each side of
the switch. Remove the switch from the face of
the instrument panel or switch mounting surface
while holding the retainer clips in the released
position.
4. Remove the switch and install the replacement
switch in the panel. Make sure the switch is in
the correct position for reading by the operator.

11
Control Components Replacement
CAUTION
Make sure wire connectors do not touch other
switch or meter terminal wire connectors,
metal brackets, or the bracket mounting nuts.
Make sure there is no tension or binding on
the wires or connectors.
5. Connect the wires or wire harness to the electri-
cal terminals on the switch as tagged during re-
moval.
6. Install the cover under the instrument panel.
ACCELERATOR POSITION SENSOR,
REPLACE
The accelerator position sensor is a voltage di-
vider that sends a signal to the master controller.
The accelerator position sensor has a link to the
MONOTROL pedal or accelerator pedal. As the
MONOTROL pedal or accelerator pedal position
changes, the signal changes to change the speed.
The accelerator position sensor and start switch
must be adjusted as shown in Figure 12.
NOTE: If you must replace an accelerator position
sensor, make sure that you use the correct part num-
ber. Many potentiometers look the same and will fit
in the same position, but they will NOT work.
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Remove the floor plates. The accelerator position
sensor is under the accelerator or MONOTROL
12
2200 SRM 1055
pedal. See Figure 12. Disconnect the electrical
connector for the sensor.
3. Remove the capscrews, washers, and nuts that
fasten the mount plate for the sensor. Carefully
move the sensor assembly down while pushing
down on the MONOTROL pedal so the pin of the
pedal assembly will come out of the arm of the
sensor. Remove the sensor assembly.
4. Cut the cable tie that fastens the wires for the
sensor. Remove the two screws, washers, and
nuts that fasten the sensor to the mount plate.
5. Install the replacement sensor on the mount
plate using the same screws, washers, and nuts.
Rotate the sensor as far as possible clockwise on
the slots. Tighten the nuts to hold the sensor so
that it can still be moved on the plate, but will
stay in position. Install a cable tie to fasten the
wires.
6. Install the mount plate in the truck using the
reverse of the removal procedure. Make sure the
pin of the MONOTROL pedal assembly is in the
sensor arm.
7. Install the capscrews, washers, and nuts that
fasten the mount plate so that it can still be
moved, but will stay in position.
8. Adjust the MONOTROL pedal or accelerator
pedal movement and the position sensor as de-
scribed in MONOTROL Pedal or Accelerator
Pedal Adjustment. Install the floor plates.
2200 SRM 1055 Control Components Replacement

Figure 12. MONOTROL Accelerator Pedal Adjustment and Repair

13
Control Components Replacement 2200 SRM 1055

Legend for Figure 12

NOTE: ADJUST THE FWD/REV SWITCHES BEFORE INSTALLING THE PEDAL PAD. ADJUST THE PEDAL FULLY
DEPRESSED (DOWN) POSITION FIRST. THEN ADJUST THE START SWITCH AND THEN THE ACCELERATOR
OR MONOTROL PEDAL POSITION SENSOR. SEE ACCELERATOR POSITION SENSOR ADJUSTMENT AND
START SWITCH ADJUSTMENT SECTION FOR THESE ADJUSTMENT PROCEDURES.
1. ACCELERATOR OR MONOTROL PEDAL 9. CLAMP SCREW
2. FLOOR PLATE 10. CABLE TIES
3. PEDAL MOUNT PLATE 11. PIN
4. ELECTRICAL CONNECTIONS 12. PIVOT CAPSCREW
5. SENSOR MOUNT PLATE 13. SENSOR ARM
6. SPRING 14. ACCELERATOR POSITION SENSOR
7. MOUNT NUT 15. PEDAL UP STOP
8. FORWARD/REVERSE SWITCH AND WIRING 16. PEDAL DOWN STOP
ASSEMBLY 17. START SWITCH

ON-DEMAND STEERING SENSOR,

REPLACE
See Diagrams 8000 SRM 1059 for the electrical con-
nections for On-Demand steering. For additional in-
formation on the On-Demand steering, see Steering
System 1600 SRM 1054.

NOTE: The following procedure has the steps to re-

place the steering sensor.

1. Disconnect the battery, discharge capacitors, and

remove the key.

2. Move the steering column to the fully FOR-

WARD position and remove the upper access
cover and lower access cover. See Steering Col-
umn Assembly in Steering System for AC
Electric Lift Trucks 1600 SRM 1054. 1. STEERING WHEEL 4. STEERING
2. STEERING SENSOR
3. Disconnect the connector and remove the two COLUMN 5. LARGE HEX NUT
capscrews holding the steering sensor to the 3. HORN SWITCH 6. HORN BUTTON
steering column. Remove the steering sensor Figure 13. Steering Sensor
from the steering column. See Figure 13.

4. Connect the connector and install the two cap-

screws that hold the steering sensor to the steer-
ing column.
5. Install the cover over the cowl. Install the upper
and lover access covers on the steering column.
6. Connect the battery and insert the key.
LIGHTS, CONVERTER, RELAY, AND
REVERSE ALARM
The lights are all fastened to the overhead guard.
The brake, tail, and reverse light assemblies are
on the rear legs of the overhead guard and are
standard in North America and optional in Europe.

14
2200 SRM 1055
These light sets operate at 12 volts with a DC/DC
converter. The strobe light is fastened to the top or
rear of the overhead guard and is optional on all
units. On North American models, the strobe light
operates from the battery of the lift truck and is ON
when the key is in the ON position. On European
models, the strobe light is 12 volts, and is turned
on using the strobe light switch. The rear driving
light (optional) is also fastened to the top or rear
of the overhead guard. An optional light for the
operator compartment is also fastened to the top
of the overhead guard. The optional spot light (not
available in North America) and the optional front
driving lights are all fastened to the front legs of the
overhead guard.
Brake, Tail, and Reverse Light Assembly,
Replace
NOTE: It is not necessary to replace the complete
light assemblies to replace a bulb. Do only the steps
necessary for your replacement needs.
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Open the hood for access to the electrical plug of
the light assembly. See Figure 14. Disconnect
the rectangular six-pin plug for the light assem-
bly.
3. Remove the two screws in the lens of the light as-
sembly. To replace a bulb only, remove the lens
from the base. Push and turn the bulb 1/4 turn
counterclockwise. Make sure you are replacing
the correct bulb of the set. Make sure the replace-
ment bulb is the correct voltage and has the cor-
rect pin configuration. Install the replacement
bulb in the socket using the reverse procedure.
Go to Step 7 if the assembly will not be replaced.
4. If the complete light assembly is being replaced,
remove the light assembly from the bracket.
5. If necessary, install the grommet on the wires
of the replacement light assembly. Install the
connector, wire cable, and grommet in the leg of
the overhead guard leg.
Control Components Replacement
6. Put the wire and connector in the same position
as the old wire and connector. Connect the light
assembly and wire harness connectors. Close the
hood.
7. Assemble the base and lens of the light assembly
and install the two screws. Align the assembly
in the brackets and tighten the screws.
Strobe Light Assembly, Replace
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Remove the two screws, nuts, and washers that
fasten the flashing light.
3. Remove the wire guard.
4. To replace a bulb only, remove the lens from the
base. Carefully remove the bulb. Go to Step 8 if
the assembly will not be replaced.
5. Carefully pull the wires away from the lift truck
for as much length as possible. It may be neces-
sary to loosen the wire clamp (top mounted units
only). If the complete light assembly is being re-
placed, cut each of the wires as close to the splice
connectors (lift truck end) as possible.
6. Carefully remove 6 mm (0.25 in.) of insulation
from the ends of both the lift truck and flashing
light wires. Install a 50 mm (2.00 in.) length
of heat-shrink tubing on each wire of the pair.
Connect the red and red/green wires using a butt
splice Hyster part number 201950. Connect the
black and black/tan wires using another butt
splice. Slide the tubing over each butt splice so
that they are centered. Use a hot-air device to
heat and "shrink" the tubing onto each splice.
7. Align the flashing light in the correct position on
the lift truck and push the excess wire into the
leg of the overhead guard. If necessary, tighten
the wire clamp.
8. Install the lens and guard on the base. Install
the two mount screws.
15
Control Components Replacement 2200 SRM 1055

Figure 14. Lights

16
2200 SRM 1055
Legend for Figure 14
NOTE: SPOT LIGHTS ARE NOT INSTALLED IN THE UNITED STATES OR CANADA.
NOTE: SEE DIAGRAMS 8000 SRM 1059 FOR THE CORRECT CONNECTIONS.
1. STROBE LIGHT
2. HEADLIGHTS
3. SPOTLIGHT
4. REVERSE/BRAKE LIGHT
5. BACKUP ALARM
6. BATTERY VOLTAGE TO 12-VDC CONVERTER
7. SPOTLIGHT HARNESS
8. HEADLIGHT HARNESS
Front, Rear Driving Light, or Spot Light
Assemblies, Replace
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Replace the bulb only by carefully moving the
rubber housing away from the edge of the lens
to get the light assembly out of the housing. Re-
move the socket assembly from the back of the
light assembly. Turn the socket assembly 1/4
turn counterclockwise. Push and turn the bulb
1/4 turn counterclockwise. Make sure the re-
placement bulb is the correct voltage and has
the correct pin configuration. Use a cloth to in-
stall the replacement quartz bulb of the spot light
without touching the bulb with your fingers. In-
stall the replacement bulb and socket assembly
using the reverse procedure. Install the light as-
sembly in the housing.
3. Carefully remove the wire cable from the leg of
the overhead guard. It can be necessary to re-
move the grommet for enough clearance to re-
move the electrical connector.
4. Remove the nut that fastens the housing to the
lift truck. Carefully pull the wires away from the
lift truck for as much length as possible. Cut each
of the light wires as close to the splice connectors
(lift truck end) as possible.
5. Carefully remove 6 mm (0.25 in.) of insulation
from the ends of both the lift truck and flashing
light wires. Install a 50 mm (2 in.) length of
heat-shrink tubing on each wire of the pair. For
the front driving light or spot light, connect the
white and yellow/black wires using a butt splice
Hyster part number 201950. Connect the black
and black/green wires using another butt splice.
Slide the tubing over each butt splice so that they
Control Components Replacement
9. LIGHT SWITCH CONNECTOR
10. MAIN HARNESS
11. WIRE 3
12. WIRE 13J
13. WIRE 13
14. WIRE 13A
15. LIGHT HARNESS
are centered. Use a hot-air device to heat and
shrink the tubing onto each splice.
6. Install the light assembly on the lift truck using
the nut and push the extra wire into the leg of
the overhead guard.
Converter, Replace
The converter changes the lift truck voltage (36, 48,
72, or 80 volts) to 12 volts for the 12-volt light system.
The converter must be replaced as a unit. Replace
the converter as follows:
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Remove the battery as described in the Periodic
Maintenance 8000 SRM 1060 or the Operat-
ing Manual.
3. Remove the front left access plate for access to
the converter.
4. Remove the capscrews, nuts, and washers that
fasten the bottom of the bracket to the lift truck
frame. See Figure 14. Move the converter assem-
bly for better access to the terminals.
5. Make a note of the wires fastened to the termi-
nals for correct installation. Remove the wires
from the terminals.
6. Remove the four screws, nuts, and washers that
fasten the converter to the bracket. Install the
replacement converter on the bracket using the
same screws, washers, and nuts. Make sure the
converter is installed so that the wires can be
connected.
7. Install the wires on the correct terminals as re-
moved.
17
Control Components Replacement
8. Install the converter assembly on the lift truck
frame using the same capscrews, washers, and
nuts. Tighten the nuts and capscrews.
9. Install the access plate. Install the battery as
described in the Periodic Maintenance 8000
SRM 1060 or the Operating Manual.
Relay, Replace
The relay is an electrical switch that is energized
with the Reverse contactor coil to operate the Reverse
lights. The relay is in the top cavity of the counter-
weight. Replace the relay as follows:
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Open the hood for access to the relay.
3. Pull the relay away from the relay socket.
4. Install the replacement relay on the socket and
close the hood.
Backup Alarm, Replace
The backup alarm is fastened to the right rear leg
next to the reverse/brake light assembly. The alarm
operates from signals from the master controller to
let people know the lift truck is traveling in the re-
verse direction. Replace the backup alarm as follows:
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Open the hood for access to the electrical plug of
the alarm. See Figure 14. Disconnect the square
six-pin plug for the alarm.
3. Turn the special round nut on the rear of the
bracket that fastens the backup alarm coun-
terclockwise to remove it. Remove the backup
alarm.
18
2200 SRM 1055
4. Align and install the replacement alarm on the
bracket and tighten the special round nut.
5. Put the wire and connector in the same position
as the old wire and connector. Connect the alarm
and wire harness connectors. Close the hood.
HORN AND HORN BUTTON, REPLACE
The horn is under the brake pedal and floor plate.
Replace the horn as follows:
1. Disconnect the battery, discharge capacitors, and
remove the key.
2. Remove the floor plates.
3. Disconnect the wires fastened to the horn termi-
nals. Do not lose the screws.
4. Hold the horn and remove the capscrew, nut,
washers, and insert that fasten the horn to the
lift truck frame. Do not lose the parts. Remove
the horn.
5. Install the capscrews and washers on the horn
bracket as shown in Figure 15. Keep the insert
in the hole of the bracket during installation.
6. Align the horn assembly to install the capscrew
in the hole of the frame and install the nut. Make
sure the insert is in the hole of the bracket be-
fore tightening the nut to prevent damaging the
insert.
7. Align the horn in the same position as the old
horn and tighten the capscrew and nut.
8. Install the wires on the horn terminals and in-
stall the floor plates.
2200 SRM 1055 Control Components Replacement

Horn Switch and Cover, Replace

The Horn Switch and Cover (button) is in the center
of the steering wheel. See Figure 15. Replace the
horn button assembly as follows:

1. Disconnect the battery, discharge capacitors, and

remove the key.

2. Carefully lift the cover and horn button assem-

bly up off the steering wheel. Lift the assembly
far enough for access to the setscrews that fas-
ten the horn wires. There is some extra length
of the horn wires, but the assembly will not come
up very far. If necessary for additional clearance,
the cover, contact plate, and spring can be re-
moved from the contact set.

3. Loosen the setscrews that fasten the contact set

to the horn wires.

4. Pull the horn wires out of the contact set and

remove the assembly.

WARNING
If the steering wheel has been removed, make
sure the steering wheel nut has been tightened.
The correct torque is 40.7 to 54.2 N•m (30 to
40 lbf ft).

5. Put the replacement assembly in position over

1. HORN 7. INSULATING the steering wheel and install the wires in the
2. TERMINALS INSERT contacts. Tighten the setscrews to fasten the
3. HORN BRACKET 8. CAPSCREW wires.
4. LIFT TRUCK 9. COVER
FRAME 10. CONTACT PLATE
5. NUT 11. CONTACT SET NOTE: If the contact set, spring, contact plate, and
6. INSULATING AND SETSCREW cover are separated, make sure they are installed
WASHER 12. SPRING and aligned correctly.

Figure 15. Horn and Horn Button 6. Carefully push the wires into the shaft bore as far
as possible. Align the horn button assembly and
press down on the edges of the cover to install it
in the steering wheel.

HYDRAULIC PUMP SWITCHES

See Main Control Valve 2000 SRM 562 to replace
and adjust the hydraulic pump switches.

19
Control and Power Fuse Check 2200 SRM 1055

Control and Power Fuse Check

FUSE LOCATIONS
The condition of fuses can normally be checked by
looking at them. Some fuses do not change in ap-
pearance and must be checked with an ohmmeter.
Disconnect the battery and honk the horn to dis-
charge the capacitors before checking fuses. This
action will discharge the capacitors in the motor con-
trollers. Sizes and locations of the fuses are shown
in Figure 16, Figure 17, Figure 18, and Figure 19.
Replace all bad fuses. Check to see what caused the
fuse to open before connecting the battery.

1. FUSE 1 (15A) 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) 8. LINE CONTACTOR
3. FUSE 3 (15A) 9. AC PUMP MOTOR CONTROLLER
4. FUSE 4 (15A) 10. POSITIVE TEMPERATURE COEFFICIENT
5. POWER STEERING CONTACTOR RESISTOR (PTC)
6. FUSE 4 (POWER STEERING) (40A)

Figure 16. AC Traction and Pump Motor Controllers (36v/48v)

20
2200 SRM 1055 Control and Power Fuse Check

1. FUSE 1 (15A) 7. LINE CONTACTOR

2. FUSE 2 (15A) 8. POSITIVE TEMPERATURE COEFFICIENT
3. FUSE 3 (15A) RESISTOR (PTC)
4. FUSE 4 (15A) 9. AC TRACTION MOTOR CONTROLLER
5. POWER STEERING CONTACTOR 10. FUSE (PUMP) (325A)
6. FUSE 4 (POWER STEERING) (40A) 11. CONTACTOR FOR DC PUMP MOTOR

Figure 17. AC Traction Motor Controller and Contactor Control for DC Pump Motor (36v/48v)

21
Control and Power Fuse Check 2200 SRM 1055

1. FUSE 7 (15A) 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 5 (15A) 8. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (15A) 9. LED INDICATOR
4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT
5. FUSE 4 (POWER STEERING) (40A) RESISTOR (PTC)
6. LINE CONTACTOR

Figure 18. AC Traction and Pump Motor Controllers (72v/80v)

22
2200 SRM 1055 Control and Power Fuse Check

1. FUSE 7 (15A) 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 5 (15A) RESISTOR (PTC)
3. FUSE 3 (15A) 8. AC TRACTION MOTOR CONTROLLER
4. POWER STEERING CONTACTOR 9. FUSE 2 (PUMP) (325A)
5. FUSE 4 (POWER STEERING) (40A) 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR

Figure 19. AC Traction Motor Controller and Contactor Control for DC Pump Motor (72v/80v)

23
Brake Light Switch Adjustment 2200 SRM 1055

Brake Light Switch Adjustment

normally closed (NC) terminals at the switch. A good
WARNING switch will indicate less than 50 ohms between the
Some checks and adjustments in this section terminals as soon as the pedal moves off the stop.
must be done with the battery connected and Connect the switch connector after the switch opera-
power applied to the controller. Lift truck tion is correct and install the floor plates.
movement during checks or adjustments can
cause personal injury. Raise the drive wheels
to prevent lift truck movement. See the Op-
erating Manual or Periodic Maintenance 8000
SRM 1060 to raise the drive wheels.

Never have any metal on your fingers, arms, or

neck. These metal items can accidentally make
an electrical connection and cause an injury.

ALWAYS disconnect the battery before making

checks or adjustments that do not need power
applied.

Check the brake light switch by checking that the

brake lights come on when the brake pedal is de-
pressed. Adjust the switch by first disconnecting
the battery and removing the key. Remove the floor
plates. The brake light switch is between the pedal
arm and the mount for the brake pedal. Make sure
the brake pedal height is correctly adjusted as shown
in Figure 20. If the pedal adjustment is not correct,
adjust the pedal height and master cylinder push
rod as described in the Brake System SRM for your
lift truck model.
1. BRAKE PEDAL
After the pedal and push rod are correctly adjusted, 2. BRAKE LIGHT SWITCH
loosen the screws and nuts that fasten the switch to 3. SWITCH ACTUATOR
the plate. Place a 0.4 to 0.6 mm (0.016 to 0.024 in.) 4. PEDAL ADJUSTMENT - 81 to 83 mm (3.19 to
3.27 in.) AND 94.0 mm (3.7 in.) FOR THE J
shim between the adjustment screw for the pedal SERIES TRUCK.
stop and the stop surface. Move the brake light 5. FLOOR PLATE
switch so the switch operates from the normally 6. ADJUSTMENT SCREW AND JAM NUT
open position to the closed position. Tighten the 7. SHIM
switch mount screws and nuts to 2.0 to 2.3 N•m (18
to 20 lbf in) without moving the switch. Remove the Figure 20. Brake Light Switch
shim and check that the switch operates correctly.

If you can’t hear the switch operate, check the switch

with an ohmmeter. Separate the connector and con-
nect the ohmmeter between the common (COM) and

24
2200 SRM 1055
Seat Switch Check
WARNING
Some checks and adjustments in this section
must be done with the battery connected and
power applied to the controller. Lift truck
movement during checks or adjustments can
cause personal injury. Raise the drive wheels
to prevent lift truck movement. See the Op-
erating Manual or the Periodic Maintenance
8000 SRM 1060 of the Service Manual for your
lift truck to raise the drive wheels.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally make
an electrical connection and cause an injury.
Seat Brake Adjustment
Lift truck models E1.50-2.00XM (E25-35Z, E40ZS)
(E114), V30ZD (D210), and E2.00-3.20XM (E45-65Z)
(G108) have a seat brake that is adjustable. The
seat brake adjustment procedures for V30ZD (D210),
E2.00-3.20XM (E45-65Z) (G108) lift trucks is located
Parking Brake Switch Adjustment
WARNING
Some checks and adjustments in this section
must be done with the battery connected and
power applied to the controller. Lift truck
movement during checks or adjustments can
cause personal injury. Raise the drive wheels
to prevent lift truck movement. See the Op-
erating Manual or the Periodic Maintenance
8000 SRM 1060 to raise the drive wheels.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally make
an electrical connection and cause an injury.
ALWAYS disconnect the battery before making
checks or adjustments that do not need power
applied.
Parking Brake Switch Adjustment
ALWAYS disconnect the battery before making
checks or adjustments that do not need power
applied.
NOTE: There is no adjustment for the seat switch
located in the cushion of the operator seat. Check
that the seat switch is good.
Check as follows:
1. Sit on the seat.
2. Turn the key to the START and ON positions.
3. Depress the MONOTROL pedal or accelerator
pedal. If the seat switch is bad, the lift truck will
not operate. Replace the seat switch. See Seat
Switch, Replace of this section.
in Brake System 1800 SRM 574. The seat brake
adjustment procedures for E1.50-2.00XM (E25-35Z,
E40ZS) (E114) lift trucks is located in Brake Sys-
tem 1800 SRM 620, for the procedures to adjust the
seat brake.
Check the operation of the switch for the parking
brake by applying the parking brake with the key in
the ON position. The indicator on the display panel
will be ON if the switch is good and correctly ad-
justed.
The parking brake switch is fastened near the link-
age for applying the parking brake. The switch must
be adjusted so that it is closed when the parking
brake is applied. The parking brake must also be
correctly adjusted before the switch is adjusted. See
the Brake System SRM for your lift truck model, to
adjust the parking brake linkage.
25
Direction Switches Check 2200 SRM 1055

Direction Switches Check

WARNING
Some checks and adjustments in this section
must be done with the battery connected and
power applied to the controller. Lift truck
movement during checks or adjustments can
cause personal injury. Raise the drive wheels
to prevent lift truck movement. See the Op-
erating Manual or the Periodic Maintenance
8000 SRM 1060 to raise the drive wheels.
contacts. If both sides of the MONOTROL pedal
are pushed at the same time, the direction circuit is
de-energized and the lift truck will not move. The
contacts of the two direction switches are in a series
and parallel arrangement so that both direction
contactors cannot be energized at the same time.

Never have any metal on your fingers, arms, or

neck. These metal items can accidentally make
an electrical connection and cause an injury.

ALWAYS disconnect the battery before making

checks or adjustments that do not need power
applied.

This information applies to both the MONOTROL

pedal and Steering Column Direction Control
Switches.

MONOTROL PEDAL
Check that the direction switches operate correctly
by operating the lift truck in the forward and re-
verse directions. If the lift truck operates correctly, 1. PEDAL PAD
2. FORWARD DIRECTION SWITCH
the switches are good and correctly adjusted. The 3. CAPACITOR
pedal assembly must be disassembled to adjust the 4. REVERSE DIRECTION SWITCH
switches. See Accelerator Position Sensor, Replace 5. SPRING
and Figure 12 to remove and disassemble the pedal
assembly. Figure 21. MONOTROL Pedal

Each direction switch must be adjusted so that one STEERING COLUMN

set of switch contacts are closed when the pedal pad
is at each position of its travel. The pedal pad must
be removed from the pedal assembly to make adjust-
ments. Move each switch so that the body of the
switch is even or within 0.8 mm (0.03 in.) inch of
the switch mount of the pedal pad. Put Loctite® 222
on the screws for the switches and tighten the nuts
after each switch is adjusted. Assemble and install
the pedal assembly as described in MONOTROL Ac-
celerator Pedal Adjustment and Repair.
There is a small directional switch under each pad of
the MONOTROL pedal. See Figure 21. Each switch
controls one direction. A capacitor is in parallel with
each direction switch to decrease arcs at the switch
The controller includes logic circuits for an optional
direction control on the steering column. See Fig-
ure 10. The Forward and Reverse switches complete
the circuit for the controller card to energize the For-
ward or Reverse contactors.
Check that the direction switches operate correctly
by operating the lift truck in the forward and reverse
directions. If the lift truck operates correctly, the
switches are good. See MONOTROL Pedal Direc-
tion Switches, Replace and Steering Column Direc-
tion Control Switches, Replace for the replacement of
direction switches. There is no adjustment for these
switches.

26
2200 SRM 1055
MONOTROL Pedal or Accelerator Pedal Adjustment
WARNING
Some checks and adjustments in this section
must be done with the battery connected and
power applied to the controller. Lift truck
movement during checks or adjustments can
cause personal injury. Raise the drive wheels
to prevent lift truck movement. See the Op-
erating Manual or the Periodic Maintenance
8000 SRM 1060 to raise the drive wheels.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally make
an electrical connection and cause an injury.
ALWAYS disconnect the battery before making
checks or adjustments that do not need power
applied.
If the unit has a MONOTROL pedal, there are direc-
tion switches that must be correctly adjusted. There
is also a start switch for the MONOTROL pedal or
accelerator pedal. There is also an accelerator posi-
tion sensor for either pedal. Adjust the pedal move-
ment in this procedure before adjusting the switches.
MONOTROL Pedal or Accelerator Pedal Adjustment
See Start Switch Adjustment and Accelerator Posi-
tion Sensor Adjustment of this section to adjust these
parts.
The movement of the MONOTROL pedal or acceler-
ator pedal must be correctly adjusted before the start
switch or accelerator position sensor is adjusted. The
floor plate must be in position to check or adjust the
pedal movement. Push the pedal down. Check that
the pedal arm is against the down stop when the
pedal is within 0.2 mm (0.08 in.) of the floor plate. If
adjustment is necessary, loosen the bolts that fasten
the pedal mount plate to the frame. See Figure 12.
The bolts must be tight enough to hold the position,
but loose enough to permit plate movement. Move
the plate to the maximum UP position and install
the floor plate. Slowly push down on the pedal un-
til it touches the down stop. Continue to push the
pedal down to move the plate until the pedal is within
0.2 mm (0.08 in.) of the floor plate. See Figure 12.
Tighten the bolts without changing the plate posi-
tion. Check that the adjustment is still correct.
27
Accelerator Position Sensor Adjustment and Start Switch Adjustment
Accelerator Position Sensor Adjustment and Start
Switch Adjustment
ACCELERATION POSITION SENSOR,
ADJUST
WARNING
Some checks and adjustments in this section
must be done with the battery connected and
power applied to the controller. Lift truck
movement during checks or adjustments can
cause personal injury. Raise the drive wheels
to prevent lift truck movement. See the Op-
erating Manual or Periodic Maintenance 8000
SRM 1060 to raise the drive wheels.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally make
an electrical connection and cause an injury.
ALWAYS disconnect the battery before making
checks or adjustments that do not need power
applied.
CAUTION
The MONOTROL pedal or accelerator pedal
movement MUST be adjusted before adjust-
ing the accelerator position sensor and start
switch. See Start Switch Adjustment of this
section to adjust the start switch. See Fig-
ure 12.
When the position of the MONOTROL pedal or accel-
erator pedal adjustment is correctly adjusted, adjust
the accelerator position sensor as follows:
1. Raise the drive wheels as described in the Oper-
ating Manual or the Periodic Maintenance
8000 SRM 1060.
2. Remove the floor plates for access to the acceler-
ator position sensor.
3. Examine the accelerator position sensor con-
nected to the plate. If the accelerator position
sensor hardware is not positioned at the end of
the slots, loosen the accelerator position sensor
screws from the pot plate. Rotate the accelerator
position sensor so the hardware is positioned at
the end of the slots as shown in Figure 22.
28
2200 SRM 1055
4. Tighten the accelerator position sensor screws to
the pot plate.
5. Loosen the adjustment screws on the accelerator
position sensor plate.
NOTE: Use the display panel while in the diagnos-
tic mode to check voltage of the accelerator position
sensor. See AC Motor Controller/Display Panel
2200 SRM 1056.
NOTE: The floor plate must be installed to check the
maximum speed adjustment of the accelerator posi-
tion sensor.
6. Adjust the position of the pot plate so that when
the pedal is fully up, the voltage on the display
panel should read between 10.70 to 11.00 volts.
When the pedal is fully pressed with the front
floor plate installed, the voltage on the display
panel should read a maximum of 1.40 volts or
less.
7. Tighten the adjustment screws on the pot plate.
Recheck the voltages in Step 6.
NOTE: If the start switch needs to be adjusted, pro-
ceed to Step 2 in the Start Switch, Adjust procedure
and follow the steps. If the start switch does not need
to be adjusted, follow the remaining steps for the Ac-
celeration Position Sensor, Adjust procedure.
8. Replace the floor plate.
9. Lower the drive wheels as described in the Op-
erating Manual or the Periodic Maintenance
8000 SRM 1060.
START SWITCH, ADJUST
NOTE: If the accelerator position sensor needs to be
adjusted, follow Step 1 through Step 7 from the Ac-
celeration Position Sensor, Adjust procedure before
adjusting the start switch. If only the start switch
needs to be adjusted, follow Step 2 through Step 6
that follows.
1. Follow Step 1 through Step 7 from the Accelera-
tion Position Sensor, Adjust procedure.
2200 SRM 1055 Accelerator Position Sensor Adjustment and Start Switch Adjustment

2. When the pedal is fully up, against the upper switch until the correct voltage is displayed on
stop, the normally open contacts on the start the display panel. See Figure 22.
switch should be closed. See Figure 22. When
the pedal is pressed in a downward motion, the 4. Tighten the start switch mounting screws.
normally closed contacts should close when volt- Recheck the voltage in Step 2.
age displayed on the display panel is between
5. Replace the floor plate.
9.80 to 9.30 volts.
6. Lower the drive wheels as described in the Op-
3. If the correct voltage is not displayed on the
erating Manual or the Periodic Maintenance
display panel, loosen the start switch mount-
8000 SRM 1060.
ing screws and adjust the position of the start

A. SIDE VIEW OF ACCELERATOR POSITION B. PEDAL UP

SENSOR C. PEDAL DOWN
1. ACCELERATOR POSITION SENSOR 6. SLOT
2. ADJUSTMENT SCREW 7. SWITCH ACCELERATION POINT
3. ACCELERATOR POSITION SENSOR PLATE 8. START SWITCH
4. ACCELERATOR POSITION SENSOR SCREW 9. START SWITCH MOUNTING SCREWS
5. PLUG TO MAIN HARNESS

Figure 22. Accelerator Position Sensor

29
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 TECHNICAL PUBLICATIONS

2200 SRM 1055 1/04 (11/03)(3/03) Printed in U.S.A.