Hyster A1.3XNT User manual

Hyster D203 (A1.3XNT, A1.5XNT A25XNT, A30NXT)
Forklift

ELECTRICAL SYSTEM
A1.3XNT, A1.5XNT
(A25XNT, A30XNT) [D203]
PART NO. 4038031 2200 SRM 1524

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2014 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Discharging the Capacitors ................................................................................................................................ 2
Display Panel and Key or Keyless Switch Replacement .......................................................................................3
Display Panel, Replace ....................................................................................................................................... 3
Remove ............................................................................................................................................................ 3
Install .............................................................................................................................................................. 5
Electronic and Manual Hydraulic Controls ...........................................................................................................6
General ................................................................................................................................................................ 6
Manual Hydraulic Controls ................................................................................................................................7
Upper Front Cover ..........................................................................................................................................7
Remove and Install .....................................................................................................................................7
Direction Control Switch ................................................................................................................................7
Remove ........................................................................................................................................................7
Install ..........................................................................................................................................................8
Emergency Disconnect Switch ..................................................................................................................... 10
Remove ......................................................................................................................................................10
Install ........................................................................................................................................................10
Attachment Button (Fourth Function) ........................................................................................................11
Remove ......................................................................................................................................................11
Install ........................................................................................................................................................11
E-Hydraulic Controls - Test ............................................................................................................................. 12
Mini-Levers ...................................................................................................................................................12
Full Stroke Test ............................................................................................................................................ 12
Function Returns to Neutral Test ............................................................................................................... 12
Push Button Switch ......................................................................................................................................13
E-Hydraulic Controls ........................................................................................................................................13
Mini-levers, Remove and Install ..................................................................................................................13
Armrest Assembly ........................................................................................................................................ 14
Remove ......................................................................................................................................................14
Install ........................................................................................................................................................16
Horn Button .................................................................................................................................................. 16
Remove ......................................................................................................................................................16
Install ........................................................................................................................................................16
Direction Control Switch ..............................................................................................................................18
Remove ......................................................................................................................................................18
Install ........................................................................................................................................................18
Emergency Disconnect Switch ..................................................................................................................... 18
Remove ......................................................................................................................................................18
Install ........................................................................................................................................................19
Momentary Switches and Function Selection Button ................................................................................ 19
Remove ......................................................................................................................................................20
Install ........................................................................................................................................................20
Sensors and Switches ............................................................................................................................................22
General .............................................................................................................................................................. 22
Hydraulic Motor Speed Sensor .........................................................................................................................22
Remove .......................................................................................................................................................... 22
Install ............................................................................................................................................................ 23
Hydraulic Motor Temperature Sensor .............................................................................................................24
Remove .......................................................................................................................................................... 24
Install ............................................................................................................................................................ 24
Table of Contents
i

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TABLE OF CONTENTS (Continued)
Traction Motor Temperature Sensor ............................................................................................................... 25
Remove .......................................................................................................................................................... 25
Install ............................................................................................................................................................ 25
Traction Motor Speed Sensor ........................................................................................................................... 26
Remove .......................................................................................................................................................... 26
Install ............................................................................................................................................................ 26
Low Level Brake Fluid Switch ......................................................................................................................... 26
Remove .......................................................................................................................................................... 26
Install ............................................................................................................................................................ 26
Service Brake Pressure Sensor ........................................................................................................................ 27
Remove .......................................................................................................................................................... 27
Install ............................................................................................................................................................ 27
Accelerator Pedal Position Sensor ................................................................................................................... 29
Remove .......................................................................................................................................................... 29
Install ............................................................................................................................................................ 29
Seat Sensor (Operator Presence System) ........................................................................................................ 30
Full Suspension and Swivel Seats ...............................................................................................................30
Remove ......................................................................................................................................................30
Install ........................................................................................................................................................30
Seat Belt Sequence Module .............................................................................................................................. 30
Remove .......................................................................................................................................................... 30
Install ............................................................................................................................................................ 31
Steering Wheel Position Sensor ....................................................................................................................... 31
Remove .......................................................................................................................................................... 31
Install ............................................................................................................................................................ 32
Horn Switch .......................................................................................................................................................32
Remove .......................................................................................................................................................... 32
Install ............................................................................................................................................................ 33
Rear Horn Button Switches ..............................................................................................................................34
Remove .......................................................................................................................................................... 34
Install ............................................................................................................................................................ 34
Tilt Position Sensor ...........................................................................................................................................35
Remove .......................................................................................................................................................... 35
Install ............................................................................................................................................................ 35
Parking Brake Position Sensor ........................................................................................................................ 36
Remove .......................................................................................................................................................... 36
Install ............................................................................................................................................................ 36
Hydraulic Tank Level Sensor ...........................................................................................................................38
Remove .......................................................................................................................................................... 38
Install ............................................................................................................................................................ 38
Hydraulic Filter Sensor; Lift Trucks Prior to November, 2013 ......................................................................39
Remove .......................................................................................................................................................... 39
Install ............................................................................................................................................................ 39
Hydraulic Pressure Switch; Lift Trucks After November, 2013 .................................................................... 39
Remove .......................................................................................................................................................... 39
Install ............................................................................................................................................................ 39
Hydraulic Oil Temperature Sensor ..................................................................................................................40
Remove .......................................................................................................................................................... 40
Install ............................................................................................................................................................ 40
Impact Sensor ....................................................................................................................................................40
Table of Contents
ii

TABLE OF CONTENTS (Continued)
Remove .......................................................................................................................................................... 40
Install ............................................................................................................................................................ 42
Load Weight Sensor ..........................................................................................................................................42
Remove .......................................................................................................................................................... 42
Install ............................................................................................................................................................ 42
Motor Controllers Replacement ............................................................................................................................44
General .............................................................................................................................................................. 44
Hydraulic Motor Controller ..............................................................................................................................45
Remove .......................................................................................................................................................... 45
Install ............................................................................................................................................................ 48
Traction Motor Controllers ...............................................................................................................................49
Remove .......................................................................................................................................................... 49
Install ............................................................................................................................................................ 50
Motor Controller Fans ...................................................................................................................................... 51
Hydraulic Motor Controller Fan ..................................................................................................................51
Remove ......................................................................................................................................................51
Install ........................................................................................................................................................51
Traction Motor Controller Fan .................................................................................................................... 51
Remove ......................................................................................................................................................51
Install ........................................................................................................................................................51
Line Contactor ...................................................................................................................................................54
Remove .......................................................................................................................................................... 54
Install ............................................................................................................................................................ 54
Vehicle Systems Manager .....................................................................................................................................55
General .............................................................................................................................................................. 55
Remove .............................................................................................................................................................. 55
Install .................................................................................................................................................................55
Programming a New VSM and/or Display Panel ............................................................................................58
General ..........................................................................................................................................................58
PC Service Tool Software ................................................................................................................................. 58
Fuses ...................................................................................................................................................................... 59
Audible Alarm ....................................................................................................................................................... 61
Battery Connection ............................................................................................................................................... 62
Inspect ............................................................................................................................................................... 62
Replacing Cables ...............................................................................................................................................62
Lights ..................................................................................................................................................................... 64
General .............................................................................................................................................................. 64
Front Work Lights (LED Lights) ..................................................................................................................... 66
Remove .......................................................................................................................................................... 66
Install ............................................................................................................................................................ 66
Strobe Light .......................................................................................................................................................67
Remove .......................................................................................................................................................... 67
Install ............................................................................................................................................................ 67
LED Tail, Backup, and Brake Lights .............................................................................................................. 68
Remove .......................................................................................................................................................... 68
Install ............................................................................................................................................................ 68
Front Marker/Turn Signal Lights ....................................................................................................................69
Remove .......................................................................................................................................................... 69
Install ............................................................................................................................................................ 70
Converter ...........................................................................................................................................................71
Table of Contents
iii

TABLE OF CONTENTS (Continued)
Remove .......................................................................................................................................................... 71
Install ............................................................................................................................................................ 71
12 Volt Outlet ....................................................................................................................................................73
Remove .......................................................................................................................................................... 73
Install ............................................................................................................................................................ 74
This section is for the following models:
A1.3XNT, A1.5XNT (A25XNT, A30XNT) [D203]
Table of Contents
iv

General
The removal and replacement procedures for the
following electrical components are covered in this
service manual:
• Display panel
• Manual hydraulic and E-Hydraulic control
components
• Motor controllers
• Sensors and switches
• Lights
• Fuses, alarm and horn
• Battery
• Vehicle System Manger (VSM)
For adjustment procedures of switches located on
the linkage for the manual control valve, or for
switches located on the E-Hydraulic control valve,
see Main Control Valves 2000SRM1520.
See AC Motor Repair 0620SRM1515 for
information on servicing and maintaining the AC
hydraulic pump and traction motors and
Industrial Battery 2240SRM0001 for information
on the battery.
If any of the wire harnesses need to be repaired, see
the section Wire Harness Repair 2200SRM1128
for repair procedures.
Some of the components used are made of plastic.
When using screws to replace and install plastic
components, the screws should be rotated
counterclockwise until screw thread turns over the
last thread in the plastic part. The screw can then
be turned clockwise to make a connection. This
prevents "cutting" new threads and damaging the
existing thread in the plastic part.
If any welding must be done, obtain proper
authorization from a Resident Service Engineer. If
authorization is given, be sure to follow the
procedures in the WARNING and CAUTIONS
below.
WARNING
Forklift frames and components may be painted
with a catalyzed paint such as polyurethane or a
two-part primer. Welding, burning, or other heat
sufficient to cause thermal decomposition of the
paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory
tract and overexposure may occur without odor
warning. Should work be performed, utilize good
industrial hygiene practices including removal of
all paint (prime and finish coats) to the metal
around the area to be welded, local ventilation,
and/or supplied-air respiratory protection.
CAUTION
When an arc welder is used, always disconnect
the battery connector on the lift truck. This action
will prevent damage to the motor controllers.
Connect the ground clamp for the arc welder as
close as possible to the weld area. This action will
prevent damage to a bearing from the large
current from the welder.
Before performing arc welding repairs, disconnect
the motor controller and VSM connections to
prevent damage to motor controllers and VSM. See
sections Motor Controllers Replacement and
Vehicle Systems Manager for procedures.
2200 SRM 1524 General
1

DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag on the
steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to
discharge before opening any compartment
covers or inspecting or repairing the electrical
system. DO NOT place tools on top of the battery.
If a tool causes a short circuit, the high current
flow from the battery can cause personal injury or
property damage.
Some checks and adjustments are performed with
the battery connected. DO NOT connect the
battery until the procedure instructs you to do so.
Never wear any metallic items 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 capacitors in the transistor controller(s) can
hold an electrical charge for about 10 seconds
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 drive unit compartment. Make
certain that the battery has been disconnected.
DO NOT short across the motor controller
terminals with a screwdriver or jumper wire.
Make certain the Emergency-Disconnect switch
has not been activated. This will isolate the
controller and prevent the capacitors from
discharging properly. The proper way to
disconnect the battery is by separating the battery
connectors.
1. Ensure capacitors are discharged by performing
Step 2 through Step 6 below.
2. Turn key or keyless switch to OFF position.
3. Disconnect battery by separating the
connectors.
4. Block drive wheels to prevent lift truck from
moving.
5. Make sure Emergency-Disconnect switch HAS
NOT been activated. If Emergency-Disconnect
switch is activated, rotate switch to right until
it pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
If a torque value is not specified, go to Metric and
Inch (SAE) Fasteners 8000SRM0231 for torque
values.
General 2200 SRM 1524
2

Display Panel and Key or Keyless Switch Replacement
DISPLAY PANEL, REPLACE
Remove
WARNING
Before replacing the display panel, fully lower all
parts of the mast and tilt it forward until the tips of
the forks touch the ground. This action will pre-
vent the mast from lowering suddenly if the con-
trol lever is accidently moved.
WARNING
Disconnect the battery before doing any work on
the electrical system. Serious injury to personnel
and/or damage to lift truck components can occur
if battery is not disconnected.
Discharge capacitors as directed in Discharging
the Capacitors in General section of this manual.
CAUTION
A short circuit and damage can occur if wires are
not installed correctly. Make sure wire connectors
do not touch the other meter terminals or wire
connectors, metal brackets, or the bracket mount-
ing nuts. Make sure the wires are not pulled tight
and are not touching other parts to damage the in-
sulation.
NOTE: The display panel cannot be repaired and
must be replaced as a unit, if it has a malfunction.
See the Parts Manual for replacement part num-
ber. The key or keyless switch can be replaced with-
out replacing the whole display panel.
The display panel is mounted inside of a display
panel cover. The display panel cover is mounted to
a bracket on upper right corner of overhead guard.
See Figure 1.
NOTE: STANDARD KEY SWITCH SHOWN.
1. OVERHEAD GUARD
2. DISPLAY PANEL
3. DISPLAY PANEL COVER
4. KEY OR KEYLESS SWITCH
5. SLOT
Figure 1. Display Panel Arrangement
1. Read and follow the WARNING and CAU-
TION above.
2. Insert a flat head screwdriver in slot on bottom
of display panel. See Figure 1.
3. Pull screwdriver down to loosen display panel
from slot. When display panel is loose from slot,
pull display panel out of the display panel
cover. See Figure 2.
2200 SRM 1524 Display Panel and Key or Keyless Switch Replacement
3

1. TOP NOTCHES
2. TOP SLOTS
3. DISPLAY PANEL COVER
4. BOTTOM NOTCH
5. BOTTOM SLOT
6. DISPLAY PANEL
Figure 2. Display Panel Removal
Display Panel and Key or Keyless Switch Replacement 2200 SRM 1524
4

4. When display panel is pulled from the display
panel cover, the warning buzzer will disconnect
from the rear of the display panel. See Figure 3.
NOTE: REAR OF DISPLAY PANEL AND DISPLAY
PANEL COVER SHOWN. SOME ELECTRICAL
COMPONENTS AND CONNECTIONS OMITTED
FOR CLARITY.
1. WARNING BUZZER
2. DISPLAY PANEL
3. DISPLAY PANEL COVER
4. PIN CONNECTOR
5. WARNING BUZZER ELECTRICAL CONNEC-
TION
Figure 3. Warning Buzzer
5. Disconnect display wire harness from pin con-
nector on the back of the display panel. Remove
display panel from lift truck. See Figure 4.
6. Remove key or keyless switch from display
panel by pinching in on pinch points and pull-
ing key or keyless switch from display panel.
See Figure 5.
Install
NOTE: If switch being installed uses a key, insert
key into switch first.
This will help install the switch into the display
panel. If switch is keyless, use the knob to help in-
stall switch into display panel.
1. Take new key or keyless switch and install into
display panel. Match the notches on the switch
with the holes on the switch cover. See Figure 5
and Figure 6. Switch will snap into place.
2. Connect display wire harness to pin connector
on back of the display panel. See Figure 4.
3. Connect warning buzzer to back of display
panel. See Figure 3.
4. Insert notches on the top of display panel into
slots on the top of display panel cover. See Fig-
ure 2.
5. Push in the bottom of display panel until notch
on the bottom slides into slot on the bottom and
display panel locks into place inside the cover.
See Figure 2.
1. PIN CONNECTOR
2. KEYSWITCH
Figure 4. Disconnecting Display Panel
2200 SRM 1524 Display Panel and Key or Keyless Switch Replacement
5

NOTE: BACK SIDE OF DISPLAY PANEL SHOWN.
1. PIN CONNECTOR
2. PINCH POINTS
3. KEY OR KEYLESS SWITCH COVER
Figure 5. Key or Keyless Switch Removal
NOTE: KEY SWITCH SHOWN.
1. KEY SWITCH
2. DISPLAY PANEL
3. NOTCH
Figure 6. Key or Keyless Switch Installation
Electronic and Manual Hydraulic Controls
GENERAL
WARNING
Before replacing any part of the manual hydraulic
control assembly, 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
lowering suddenly if the control lever is acci-
dently moved.
WARNING
Discharge capacitors as directed in Discharging
the Capacitors in General section of this manual.
Disconnect the battery before doing any work on
the electrical system. Serious injury to personnel
and/or damage to lift truck components can occur
if battery is not disconnected.
WARNING
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidently make an
electrical connection and cause an injury.
CAUTION
A short circuit and damage can occur if wires are
not installed correctly. Make sure wire connectors
do not touch the other metal terminals or wire
connectors, metal brackets, or the bracket mount-
ing nuts. Make sure the wires are not pulled tight
and are not touching other parts to damage the in-
sulation.
The lift trucks covered in this service manual come
standard with manual hydraulic control levers, but
have the option of using electronic-hydraulic (E-Hy-
draulic) mini-lever controls.
Electronic and Manual Hydraulic Controls 2200 SRM 1524
6

In each hydraulic control arrangement, there are
several electronic component parts that can be re-
placed if they are no longer working properly.
These components are:
•Direction Control Switch - The Direction
Control Switch (DCS) is an optional feature
and is used to select the direction of travel
when lift truck is equipped with a standard
accelerator pedal.
•Emergency Disconnect Switch - The
emergency disconnect switch is used to dis-
connect power from the controllers. The
switch is operated by pushing the button
down until it clicks. To reset (re-connect) the
emergency disconnect switch and energize
the electrical circuits, turn the switch clock-
wise until button pops up.
•Attachment (Fourth Function) Button -
The attachment button is only on manual hy-
draulic control levers. If lift truck is equipped
with a four function control valve with at-
tachment and three levers, the last (3rd)
lever controls the attachment (4th function).
To engage the attachment, press and hold
button on the left top side of the lever and
move lever forward. To disengage the attach-
ment press and hold button on the left top
side of the lever and move lever backward.
See Figure 13.
When removing and replacing sensors or switches,
be sure to tag connectors to aid in correct installa-
tion.
MANUAL HYDRAULIC CONTROLS
Upper Front Cover
Remove and Install
NOTE: To replace the direction control switch and
emergency disconnect switch, the upper front cover
must be removed first from the manual hydraulic
control lever assembly as described below.
1. Read and follow the WARNING and CAU-
TION section in the General section above.
2. Remove four capscrews and upper front cover
from hydraulic lever assembly. See Figure 7.
NOTE: OPTIONAL DIRECTION CONTROL SWITCH
SHOWN.
1. UPPER FRONT COVER
2. CAPSCREWS
3. LOWER COVER
4. UPPER REAR COVER
5. DIRECTION CONTROL SWITCH
6. EMERGENCY DISCONNECT SWITCH
Figure 7. Manual Hydraulic Control Lever
Assembly
3. Using four capscrews, install front cover on hy-
draulic lever assembly. See Figure 7.
Direction Control Switch
Remove
1. Read and follow the WARNING and CAU-
TION section in the General section above.
2. Remove upper front cover. See section Upper
Front Cover for procedures. Disconnect manual
control valve wire harness from direction con-
trol switch. See Figure 8.
2200 SRM 1524 Electronic and Manual Hydraulic Controls
7

1. EMERGENCY DISCONNECT SWITCH CON-
NECTOR
2. MANUAL CONTROL VALVE WIRE HARNESS
3. DIRECTION CONTROL SWITCH CONNECTOR
Figure 8. Manual Control Levers Assembly
Electrical Components
3. Remove two outer capscrews and lift/lower with
Direction Control Switch handle from manual
lift/lower lever. See Figure 9.
4. Remove one inner capscrew and palm side grip
handle from manual lift lever. See Figure 9.
5. Remove Direction Control Switch cable from ca-
ble track. See Figure 9.
6. Remove two screws, Direction Control Switch
retainer, Direction Control Switch cup, and Di-
rection Control Switch from lift/lower with Di-
rection Control Switch handle. See Figure 10.
Install
1. Install DCS into DCS cup. See Figure 10.
2. Install DCS cup and DCS into lift/lower Direc-
tion Control Switch handle. See Figure 10.
3. Install DCS retainer onto back side of DCS cup,
inside lift/lower with DCS handle. See Fig-
ure 10.
4. Install two screws through retainer and DCS
cup into DCS. See Figure 10.
5. Route DCS cable through cable track on man-
ual lift/lower lever. See Figure 9.
6. Install palm side handle and one capscrew on
manual lift/lower lever. See Figure 9.
7. Install lift/lower with DCS handle and two
outer capscrews on manual lift/lower lever.
Tighten outer capscrews 1.35 to 1.65 N•m (11.9
to 14.6 lbf in). See Figure 9.
8. Install upper front cover. See section Upper
Front Cover for procedures.
Electronic and Manual Hydraulic Controls 2200 SRM 1524
8

A. AUX HANDLE WITH DUAL FUNCTION B. LIFT/LOWER WITH DIRECTION CONTROL
SWITCH
1. PALM SIDE GRIP HANDLE
2. ATTACHMENT SWITCH HANDLE
3. LIFT/LOWER WITH DIRECTION CONTROL
SWITCH HANDLE
4. MANUAL AUX 2 LEVER
5. MANUAL LIFT LEVER
6. DIRECTION CONTROL SWITCH
7. ATTACHMENT PUSH-BUTTON
8. INNER CAPSCREW
9. OUTER CAPSCREW
10. CABLE TRACK
11. SCREW
12. DIRECTION CONTROL SWITCH RETAINER
13. DIRECTION CONTROL SWITCH CUP
14. PUSH-BUTTON CABLE
15. DIRECTION CONTROL SWITCH CABLE
Figure 9. Manual Hydraulic Control Handles
2200 SRM 1524 Electronic and Manual Hydraulic Controls
9

1. SCREW
2. DIRECTION CONTROL SWITCH RETAINER
3. DIRECTION CONTROL SWITCH CUP
4. DIRECTION CONTROL SWITCH CABLE
Figure 10. Direction Control Switch
Emergency Disconnect Switch
Remove
1. Read and follow the WARNING and CAU-
TION section in the General section above.
2. Remove upper front cover. See section Upper
Front Cover above for procedures.
3. Remove five socket head capscrews from upper
rear cover. See Figure 11. Pull cover forward to
generate enough space to disconnect the emer-
gency disconnect switch wires. See Figure 8.
1. SOCKET HEAD SCREWS
2. UPPER REAR COVER
3. LEVER LINKAGE
4. MANUAL HYDRAULICS WIRE HARNESS
Figure 11. Upper Rear Cover Removal
4. Disconnect the Direction Control Switch if lift
truck is equipped with this feature. See Fig-
ure 8.
5. Insert screwdriver or other flat tipped tool into
slot on side of switch. Pull tool up to remove the
emergency disconnect switch, switch adapter,
and lock from upper rear cover. See Figure 12.
6. Remove nut from upper rear cover. Remove
emergency disconnect button and bushing from
hole in upper rear cover. See Figure 12.
Install
1. Insert the emergency disconnect button and
bushing into hole in upper rear cover. See Fig-
ure 12. Place nut on button and turn it clock-
wise to secure emergency disconnect button and
bushing in hole. Tighten nut to
2 N•m (18 lbf in).
2. Connect wires to emergency disconnect switch.
Tighten screws to 0.8 N•m (8.55 lbf in) typical;
1.2 N•m (10.7 lbf in) maximum.
Electronic and Manual Hydraulic Controls 2200 SRM 1524
10

A. INSERT SCREWDRIVER HERE
1. EMERGENCY DISCONNECT SWITCH
2. SWITCH ADAPTER
3. LOCK
4. NUT
5. EMERGENCY DISCONNECT BUTTON
6. BUSHING
7. UPPER REAR COVER
8. HOLE
Figure 12. Emergency Disconnect Switch
Replacement
3. Install switch adapter and lock onto emergency
disconnect button assembly. Install switches,
by pushing switches onto switch adapter until
switches clicks into place. Connect main wire
harness to emergency disconnect switch. See
Figure 8.
4. Connect the Direction Control Switch if lift
truck is equipped with this function. See Fig-
ure 8.
5. Install and tighten five socket head capscrews
to secure upper rear cover to manual lever as-
sembly. See Figure 12.
6. Install upper front cover. See section Upper
Front Cover for procedures.
Attachment Button (Fourth Function)
Remove
1. Read and follow the WARNING and CAU-
TION section in the General section above.
2. Remove upper front cover. See section Upper
Front Cover for procedures. Disconnect manual
control valve wire harness from direction con-
trol switch. See Figure 8.
3. Remove two outer capscrews and attachment
switch handle from manual aux 2 lever. See
Figure 9.
4. Remove one inner capscrew and palm side grip
handle from manual aux 2 lever. See Figure 9.
5. Remove push-button cable from cable track.
See Figure 9 and Figure 13.
Install
1. Route push-button cable through cable track on
manual aux 2 lever. See Figure 9 and Fig-
ure 13.
2. Install palm side handle and one inner cap-
screw on manual aux 2 lever. See Figure 9.
1. ATTACHMENT BUTTON
2. THIRD MANUAL CONTROL LEVER
Figure 13. Attachment Button
2200 SRM 1524 Electronic and Manual Hydraulic Controls
11

NOTE: Ensure attachment push-button is in cor-
rect position on attachment switch handle by align-
ing notches and flats during assembly.
3. Install attachment switch handle and two outer
capscrews on manual aux 2 lever. Tighten outer
capscrews 1.35 to 1.65 N•m (11.9 to 14.6 lbf in).
4. Install upper front cover. See section Upper
Front Cover for procedures.
E-HYDRAULIC CONTROLS - TEST
Mini-Levers
Perform all of the following test procedures to be
sure mini-levers operate properly.
See User Interface Service Technician
2200SRM1336 instructions to view Lever output
Value. With Service Password, view Diagnostics –
Hydraulic Data Display – Hydraulic Input.
Full Stroke Test
Check for full stroke of mini-lever. Use DSC or in-
stall the Service Tool to monitor functions.
1. Stroke each lever to full stroke, forward and
backward, and allow lever to snap back to cen-
ter.
2. Turn key switch to ON position.
3. Display electro-hydraulic diagnostics menu on
dash display panel. Operate each lever to full
stroke forward and read input.
• Is lever output = -92%?
•YES: Go to Step 4.
•NO: Mini-lever not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun test.
4. Operate each lever to full stroke backward and
read input.
• Is lever output = +92%?
•YES: Mini-lever is supplying full stroke.
•NO: Mini-lever not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun test.
5. If mini-lever continues to not function properly,
contact your local Hyster dealer or see Hyster
Hypass Online.
Function Returns to Neutral Test
Check to confirm function returns to neutral (0%).
Use DSC or install Service Tool to monitor func-
tions.
1. Stroke each lever to full stroke, forward and
backward, and allow lever to snap back to cen-
ter.
2. Turn key switch to ON position.
3. Display electro-hydraulic diagnostics menu on
dash display panel.
• Is each lever output = 0%?
•YES: Go to Step 4.
•NO: Mini-lever is not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun test.
4. Operate each lever to full stroke forward and
slowly release (1-2 seconds from full stroke).
Read output when fully released.
• Is each lever output = 0%?
•YES: Go to Step 5.
•NO: Mini-lever is not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun test.
5. Operate each lever to full stroke back and
slowly release (1-2 seconds from full stroke).
Read output when fully released.
• Is each lever output = 0%?
•YES: Mini-lever function is returning to
neutral.
•NO: Mini-lever is not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun test.
6. If mini-lever continues to not function, contact
your local Hyster dealer or see Hyster Hy-
pass Online.
Electronic and Manual Hydraulic Controls 2200 SRM 1524
12