Hyster B262 Operating instructions

Hyster B262 (B60ZHD, B80ZHD) Forklift

ELECTRICAL SYSTEM
B60ZAC [C230];
B60ZHD [B262];
B80ZHD [B257]
PART NO. 4096092 2200 SRM 1640

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Upda-
ted technical service information may be available from your local authorized Hyster® dealer. Service Manuals pro-
vide general guidelines for maintenance and service and are intended for use by trained and experienced technicians.
Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in dam-
age 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. Dis-
connect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifi-
cations of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2013 HYSTER COMPANY
TABLE OF CONTENTS
General ......................................................................................................................................................................................... 1
Accessing the Drive Unit Compartment ..................................................................................................................................2
Special Precautions .......................................................................................................................................................................3
Discharging the Internal Capacitors ........................................................................................................................................ 3
Electromagnetic Shield ............................................................................................................................................................3
Electrical System Checks ............................................................................................................................................................. 4
Safety Precautions ................................................................................................................................................................... 4
Calibration .................................................................................................................................................................................... 7
Power Assist Steering Sensor .................................................................................................................................................. 7
Repairs ..........................................................................................................................................................................................7
Controller, Replace .................................................................................................................................................................. 8
Remove ............................................................................................................................................................................... 8
Install ...................................................................................................................................................................................8
Contactor Coil, Check ............................................................................................................................................................. 9
Fuses ............................................................................................................................................................................................. 9
Horn ............................................................................................................................................................................................10
Replace .................................................................................................................................................................................. 10
Brake Switch Operation ............................................................................................................................................................. 10
Brake and Interlock Switches .....................................................................................................................................................11
Standard Steering ...................................................................................................................................................................11
Power Assist Steering ............................................................................................................................................................ 11
Height Limit ............................................................................................................................................................................... 12
Control Handle (Standard) ......................................................................................................................................................... 12
Disassemble ........................................................................................................................................................................... 12
Assemble ................................................................................................................................................................................13
Control Handle (HD Option) ......................................................................................................................................................15
Disassemble ........................................................................................................................................................................... 15
Remove Top Cover ...........................................................................................................................................................15
Remove Function Switches ...............................................................................................................................................15
Remove Throttle Sensor Assembly .................................................................................................................................. 15
Remove Handle Shaft Assembly ...................................................................................................................................... 16
Remove Side Glide............................................................................................................................................................ 16
Remove the Coast Control Switches .................................................................................................................................17
Assemble ................................................................................................................................................................................17
Install the Coast Control Switches ....................................................................................................................................17
Install Side Glide................................................................................................................................................................17
Install Handle Shaft Assembly ..........................................................................................................................................17
Install Throttle Sensor Assembly ......................................................................................................................................18
Install Function Switches ..................................................................................................................................................18
Install Top Cover .............................................................................................................................................................. 18
Control Module .......................................................................................................................................................................... 19
Check ..................................................................................................................................................................................... 19
Remove .................................................................................................................................................................................. 20
Install ..................................................................................................................................................................................... 20
Proximity Switch (Power Assist Steering) ................................................................................................................................. 22
Remove .................................................................................................................................................................................. 22
Install ..................................................................................................................................................................................... 22
Remote Control Box Switches ................................................................................................................................................... 23
Remove .................................................................................................................................................................................. 23
Install ..................................................................................................................................................................................... 23
Electrical System Table of Contents
i

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TABLE OF CONTENTS (Continued)
Troubleshooting ..........................................................................................................................................................................24
This section is for the following models:
(B60ZAC) [C230];
(B60ZHD) [B262];
(B80ZHD) [B257]
Table of Contents Electrical System
ii

General
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 to the
control handle and disconnect the battery.
This section describes the electrical systems used on the
motorized hand lift trucks. Procedures are outlined for the
maintenance, adjustment, and repair that may be required
when servicing these lift trucks. See Figure 1.
1. GRAB RAIL
2. CONTROL BOX
3. BATTERY DISCHARGE INDICATOR
4. FUSE
5. DIAGNOSTIC CONNECTOR
6. KEY SWITCH
7. HORN
8. PUMP MOTOR
9. BRAKE
10. STEER MOTOR
11. TRACTION MOTOR
12. CONTACTOR
13. CONTROLLER
14. PROXIMITY SENSOR
Figure 1. Drive Unit Compartment (Power Assist Shown)
2200 SRM 1640 General
1

ACCESSING THE DRIVE UNIT
COMPARTMENT
The drive unit compartment is concealed behind a molded
cover which fits securely around the drive unit and steer
support to the frame. The floor mat fits snugly in the
operator platform after the drive unit cover is installed.
To remove the drive unit cover, first lift the corners of the
floor mat and pull it out away from the drive unit. See
Figure 2. Next, reach under the side of the drive unit cover
near the bottom and find the grip slot. With both hands,
pull up and away from the truck until the bottom of the
cover kicks out from the retaining clips. See Figure 3.
Repeat this for the other side of the cover. Work around the
edge of the cover until it is freed from the truck.
1. FLOOR MAT
2. DRIVE UNIT COMPARTMENT COVER
3. FRAME
4. CASTER ADJUSTMENT ACCESS
Figure 2. Floor Mat
1. DRIVE UNIT COMPARTMENT COVER
2. RETAINING CLIPS
3. GRIP SLOT
4. FRAME
Figure 3. Drive Unit Compartment Cover
To install the drive unit cover, make sure the floor mat is
pulled away from the drive unit. Place the bottom of the
drive unit cover onto the operator platform and position the
lower edges partially into the lower retaining clips. Push
the top of the cover partially into the upper retaining clips.
Do not push either edge of the cover in completely before
starting all edges into the proper place. When the cover is
aligned and started properly, press the cover completely
into the retaining clips and place the floor mat into the
operator platform around the cover.
General 2200 SRM 1640
2

Special Precautions
DISCHARGING THE INTERNAL
CAPACITORS
When working with the electrical systems of the truck, it is
necessary to discharge the internal capacitors of the con-
trollers associated with each circuit affected.
WARNING
Capacitors inside the controllers can hold an elec-
trical charge after the battery is disconnected.
Discharge the internal capacitors before servicing
the electrical system to prevent injury or elec-
tronic damage.
1. Move the lift truck to a safe, level area and completely
lower the mast. Turn the key switch to the OFF posi-
tion and attach a DO NOT OPERATE tag to the con-
trol handle. Block the drive wheel to prevent unexpec-
ted movement.
2. Disconnect the battery power cable connector from the
truck connector located on the right side of the frame.
Pull the battery cable connector handle to separate the
battery connector from the truck connector.
3. Remove the operator compartment cover.
4. Discharge the internal capacitor in the controllers by
connecting a 200-ohm, 2-watt resistor across the con-
troller B+ and B− terminals of the motor controller for
10 seconds. Remove the resistor after discharging the
capacitors. See Figure 4.
ELECTROMAGNETIC SHIELD
WARNING
Never operate Power Assist Steering models with
the Electromagnetic Shield removed.
A metallic shield is installed between the MDU and brake
assembly and the steering assembly on power assist steer-
ing units. This shield deflects the electromagnetic field gen-
erated by the MDU and brake assembly which can interfere
with the operation of the torque sensor. Make certain that
the Electromagnetic Shield is reinstalled before operating
the lift truck after servicing to prevent erratic operation of
the power assist steering function.
1. CONTROLLER
2. POSITIVE CONNECTION (B+)
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTIONS (B−)
Figure 4. Discharging the Controller
2200 SRM 1640 Special Precautions
3

Electrical System Checks
WARNING
Disconnect the battery before opening the com-
partment cover or inspecting or repairing the elec-
trical system. If a tool causes a short circuit, the
high current flow from the battery can cause per-
sonal injury or property damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
All checks, adjustments, and repairs in the drive unit com-
partment are done with the compartment cover removed.
Remove the drive unit compartment cover for access to the
electrical components.
SAFETY PRECAUTIONS
WARNING
Some checks require the battery to be reconnec-
ted. DO NOT connect the battery until the proce-
dure tells you to do so. Make sure the drive wheel
is raised to prevent truck movement and possible
injury. Raise the drive wheel. The blocks must
prevent the lift truck from falling and causing per-
sonal injury or property damage.
CAUTION
To avoid controller damage, always disconnect
the battery before disconnecting any cables from
the controller. Discharge the capacitor, and never
put power to the controller with any power wire
disconnected. Never short any controller terminal
or motor terminal to the battery. Make sure to use
proper procedure when servicing the controller.
1. Block lift truck so the drive tire is raised slightly off
the floor to prevent unexpected movement when mak-
ing checks.
WARNING
DO NOT put the lift truck on blocks unless the
surface is solid, even, and level. Make sure that all
blocks used to support the lift truck are solid,
one-piece units. Put a block in front and back of
the tire or wheels touching the ground to prevent
unexpected movement of the lift truck.
WARNING
DO NOT raise the lift truck by attaching an over-
head crane to areas that will be damaged. Some
of these points are not designed to support the
weight of the lift truck. The lift truck can be dam-
aged or it can fall, causing serious injury. Attach
the chain or sling to a support structure of the lift
truck frame.
WARNING
Never raise the forks any higher than necessary
to change the load wheels. Always raise both
forks at the same time. Raising the forks too high
or unevenly can cause the lift truck tip over and
cause personal injury or property damage.
2. Use a crane or jack to raise the forks or motor compart-
ment assembly. Put blocks under the forks or the edge
plates of the motor compartment assembly. See Fig-
ure 5. Make sure the lifting device has a capacity of at
least two-thirds (2/3) of the combined weight of the lift
truck and the battery as listed on the nameplate.
3. Turn the key switch to the OFF position and discon-
nect the battery.
4. Discharge the capacitors. See Special Precautions in
this section.
NOTE: These checks require a volt-ohmmeter with a me-
ter movement. Most digital meters will not operate cor-
rectly for some of these checks. Specific checks require ad-
ditional equipment.
NOTE: The correct meter polarity is necessary for the
checks. The voltage checks are made between the point in-
dicated in Table 1 and battery negative. Connect the meter
negative to battery negative.
NOTE: The battery does not have to be removed to check
the specific gravity.
5. Using a hydrometer, check the specific gravity of the
battery. If the specific gravity is less than 1.260, the
battery is not fully charged or is damaged. A fully-
charged battery has a specific gravity of 1.270 to
1.290. A discharged battery has a specific gravity of
approximately 1.165.
Electrical System Checks 2200 SRM 1640
4

6. The electric lift truck has a two-wire system. The
frame must not be a common electrical path. Check for
50,000 ohms or more between each battery terminal
and a clean connection on the frame. Remove any cir-
cuit paths between the controller and the frame of the
lift truck, such as a dirty battery case. Carbon dust in a
motor or other parts can cause a circuit path. Check for
additional equipment that may cause a circuit path to
the frame.
7. Check for voltage between each terminal of the con-
nector that fastens to the battery and a clean connection
on the frame. Normally, there is small voltage (less
than 30 percent of the battery voltage) between the bat-
tery and the frame, even though the resistance is very
high. A higher voltage can indicate a dirty battery or a
damaged battery. Clean the battery and battery com-
partment as necessary.
8. Visually check for parts or wires that are loose or dam-
aged.
NOTE: Make an identification of any wires before you
disconnect them. The wires must be reconnected correctly
after checks or repairs.
Figure 5. Putting the Lift Truck on Blocks
2200 SRM 1640 Electrical System Checks
5

Table 1. Voltage Checks
LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION.
NO FAULT IS DISPLAYED ON THE CONTROLLER.
Possible Causes:
1. Battery not connected.
2. Control fuse is damaged.
3. Key switch or brake switch is damaged.
4. Transistor controller connector unplugged.
5. Transistor controller is damaged.
1.0 Check for battery voltage on the battery
side of control fuse.
― ― ― ―▸
― ―
1.01 Battery voltage at control fuse.
Check for open control fuse.
|
|
|― ―▸
1.02 No battery voltage at control fuse. Connect bat-
tery or check wiring between battery and fuse.
1.1 Check for battery voltage at control fuse
terminal of key switch.
― ― ― ―▸
― ― 1.1.1 Battery voltage at key switch. Check for dam- aged key switch. Check connector.
|
|
|― ―▸
1.1.2 No voltage at key switch. Wire to key switch or
connections is damaged.
1.3 Key switch closed. Brake switch closed.
Check for battery voltage at
B+ terminal of transistor controller.
― ― ― ―▸
― ―
1.3.1 Battery voltage at B+ terminal. Check fault code.
If no fault code, possible damaged control handle
card.
|
|
|― ―▸
1.3.2 No voltage at B+ terminal. Check B− terminal.
Check fault code.
Electrical System Checks 2200 SRM 1640
6

Calibration
POWER ASSIST STEERING SENSOR
WARNING
If at any time a tiller handle slowly moves in one
direction during startup, it is likely calibration
needs to be performed.
Power assist steering calibration should be performed if ei-
ther the torque sensor or EPAS unit is serviced or replaced
or anytime the drive tire is replaced.
1. Position the lift truck on a normal, smooth surface
floor away from personnel or other equipment.
2. Turn the key switch to the OFF position and remove
the drive unit compartment cover.
3. The Calibration Tab is an unconnected wire with a fe-
male spade connector hanging near the ETACC CAN
connector. Attach the Calibration Tab to the B+ termi-
nal of the controller, using a 914 mm (36 in.) 14 Ga.
jumper wire with an alligator clip on one end and a
male spade connector on the other.
WARNING
DO NOT interfere with the lift truck or tiller handle
during the calibration cycle.
4. Standing clear of the steer handle, turn the key switch
to the ON position.
5. The lift truck will start up in calibration mode and the
tiller handle will begin to move on its own power dur-
ing the calibration cycle.
6. Wait at least 5 seconds after the calibration cycle has
ended (the tiller has stopped moving) and remove the
jumper wire.
7. Wait at least 5 seconds after the jumper wire is re-
moved and cycle the key switch to the OFF position
and then back to the ON position.
8. Check the lift truck for proper operation. Reinstall the
drive unit compartment cover.
Repairs
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 to the
control handle and disconnect the battery.
Disconnect the battery and separate the connec-
tor before opening the drive unit compartment
cover or inspecting or repairing the electrical sys-
tem. If a tool causes a short circuit, the high cur-
rent flow from the battery can cause personal in-
jury or property damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. See Discharging the Internal Capacitors
in this section.
All checks, adjustments, and repairs in the drive unit com-
partment are done with the compartment cover removed.
Remove the drive unit compartment cover for access to the
electrical components and discharge the capacitor. See Ac-
cessing the Drive Unit Compartment in this section.
2200 SRM 1640 Calibration
7

CONTROLLER, REPLACE
WARNING
Some checks require the battery to be connected.
DO NOT connect the battery until the procedure
tells you to do so. Make sure the drive wheel is
raised to prevent movement and possible injury.
Raise the drive wheel. See the section Periodic
Maintenance 8000SRM1644 - How to Put a Lift
Truck on Blocks. The blocks must prevent the lift
truck from falling and causing personal injury or
property damage.
DO NOT replace the controller until you have thoroughly
checked all other electrical components and are sure the
controller is malfunctioning. .
Remove
1. Move the truck to a safe, level location. Turn the key
switch to the OFF position, disconnect the battery, and
block the drive tire to prevent unexpected movement.
2. Remove the drive unit compartment covers.
3. Discharge the capacitor. See Discharging the Internal
Capacitors in this section.
4. Tag and disconnect wires from the controller. See Fig-
ure 6.
5. Remove nuts securing shield box to controller if equip-
ped.
6. Remove mounting screws and remove controller.
Install
1. Install replacement controller on lift truck using
mounting hardware.
2. Connect wires and cables to the proper terminals as
identified during the removal procedure.
3. Connect battery and turn the key switch to the ON po-
sition. Test the brake for proper operation.
Turn the key switch to the OFF position and discon-
nect the battery again to continue installation.
4. Install the drive unit compartment covers.
1. B+ CONTROLLER TERMINAL
2. MAIN FUSE
3. MAIN CONNECTOR
4. TRACTION MOTOR POS (TERMINAL U)
5. TRACTION MOTOR POS (TERMINAL W)
6. CABLE CLAMP
7. TRACTION MOTOR POS (TERMINAL V)
8. MAIN CONTACTOR (IN)
9. BATTERY POS
10. MAIN CONTACTOR (OUT)
11. BATTERY NEG
12. PUMP MOTOR POS (TERMINAL P)
13. IN-LINE FUSE
14. BATT POS (FROM CONTACTOR)
15. BATT NEG (FROM CONTROLLER)
16. B– CONTROLLER TERMINAL
Figure 6. Controller Wiring (Manual Steer Shown)
Repairs 2200 SRM 1640
8

CONTACTOR COIL, CHECK
Disconnect coil wires. Test contactor coil using an ohmme-
ter to measure the resistance. The coil should read 23 ohms
±10%. Remove and replace contactor if resistance readings
indicate a short circuit in both directions or if there is an
open circuit in both directions. Make sure coil wires are
connected to the proper terminals. See Figure 7.
NOTE: The contactor contains no serviceable parts and
must be replaced as a complete assembly.
Figure 7. Contactor
Fuses
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
The motorized hand trucks use a single 4-amp in-line fuse
(FU 5) for the control circuit, and a single 400-amp (FU 1)
fuse mounted on the controller for both the drive motor and
the hydraulic pump motor. Trucks with power assisted
steering have a 30-amp in-line fuse in the steering motor
circuit. Remove and replace as required.
If it cannot be determined visually that a fuse has failed,
check for continuity using an ohmmeter. Make certain that
any replacement fuse is of the right amperage before instal-
lation.
2200 SRM 1640 Fuses
9

Horn
REPLACE
1. Move the truck to a safe, level location; turn the key
switch to the OFF position; and disconnect the battery.
Block the drive tire to prevent unexpected movement.
2. Remove the drive unit compartment covers. See Gen-
eralGeneral in this section.
3. Discharge the capacitor. See Special Precautions in
this section.
4. Disconnect the horn wiring from the main wiring har-
ness.
CAUTION
DO NOT overtighten horn mounting hardware.
5. Remove nuts and washers from bolts securing horn to
frame. Remove horn from bolts. Position new horn
onto bolts as removed and install washers and nut.
6. Install wiring to horn as removed.
7. Connect the battery, turn the key switch to the ON po-
sition, and test for proper operation. Turn the key
switch back to the OFF position and disconnect the
battery again to finish repairs.
8. Install the drive unit compartment covers as removed.
See GeneralGeneral in this section. Return the lift
truck to service.
Brake Switch Operation
The brake is applied when the control handle is in the full
up or full down position. The brake is released by lowering
the control handle to the Brake Off (operating position) and
selecting a direction with the speed/direction control. Re-
gen braking is activated when the control arm approaches
full up or full down position. This slows the truck using the
traction motor before applying the parking brake. See Fig-
ure 8. The parking brake is controlled by a switch(es)
and/or a potentiometer (depending on model) that monitors
the control arm position. If the parking brake does not re-
lease or apply properly, check the operation of the brake
switches and/or potentiometer.
A. BRAKE ON
B. REGEN BRAKING
C. BRAKE OFF
Figure 8. Brake Operation
Horn 2200 SRM 1640
10

Brake and Interlock Switches
STANDARD STEERING
1. Position the lift truck on a level surface. Turn the key
switch to the OFF position and disconnect the battery.
NOTE: The screws have been installed using Loctite®
290.
2. Remove the two screws and the nut plate retaining the
switches to the control handle hub. See Figure 9.
3. Tag all wiring connections to the switches for later use
when assembling the switches to the hub. Remove the
switch wires.
4. Attach wiring to correct switch terminals as noted dur-
ing removal.
CAUTION
Overtightening the screws can damage the
switches.
5. Position switches to the hub as removed and secure
with two screws and nutplate. Apply Loctite® 290 to
the screws, install, and tighten.
1. NUTPLATE
2. SCREW
3. REGEN SWITCH
4. BRAKE SWITCH
Figure 9. Brake and Interlock Switches
6. Connect battery and turn the key switch to the ON po-
sition.
7. Test for proper operation before returning the truck to
service.
POWER ASSIST STEERING
Truck may be equipped with one or two brake switches de-
pending on model. To replace the brake switch(es):
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.
1. Move the truck to a safe, level location, turn the key
switch to the OFF position, and disconnect the battery.
Block the drive tire to prevent unexpected movement.
2. Remove two screws securing the cover to the steer
support and lift the cover off. See Figure 10.
3. Tag and disconnect the wiring from the brake
switch(es).
4. Remove the two screws and nutplate securing the
brake switch(es) to the steer swivel. Remove the brake
switch(es). See Figure 11.
CAUTION
DO NOT overtighten switch mounting hardware.
5. Position the brake switch(es) to the steer swivel as re-
moved. Align the switch holes with the mounting holes
in the steer swivel and install screws and nutplate.
Make sure the switch actuator is aligned properly
within the control arm notches.
6. Install wiring to switch(es) as removed.
2200 SRM 1640 Brake and Interlock Switches
11

7. Connect the battery, turn the key switch to the ON po-
sition, and test for proper operation. Turn the key
switch back to the OFF position and disconnect the
battery again to finish repairs.
8. Position the cover to the steer swivel and install the
two screws to secure.
9. Install the drive unit compartment covers as removed.
Return the lift truck to service.
1. SCREW
2. CONTROL ARM
3. COVER
4. STEER SUPPORT
BASE
5. DASH
Figure 10. Swivel Cover (Power Assist Steering)
1. NUTPLATE
2. SCREW
3. REGEN SWITCH
4. BRAKE SWITCH
Figure 11. Brake Switch(es)
Height Limit
Height limiting is controlled by the height limit switch in
the controller. When the controller senses a high current
draw from the hydraulic pump, it will shut down the pump.
There are two separate incidents that will cause this current
draw: The first is when the lift cylinder reaches maximum
height, and the second is when the load exceeds the rated
capacity. In either case, the controller will shut down the
pump.
Control Handle (Standard)
DISASSEMBLE
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 to the
control handle and disconnect the battery.
Height Limit 2200 SRM 1640
12

NOTE: It is not always necessary to remove and disas-
semble all the components that make up the control section
of the steering handle to replace a damaged part. Perform
only the steps necessary to replace the damaged parts. See
Figure 12.
1. Move the lift truck to a safe, level area and block the
drive wheel to prevent movement of the lift truck.
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. The handle is comprised of two molded-plastic halves
and is held together by capscrews. Remove the screws.
4. Disengage the hooks under the auto-reverse switch.
Slide the upper half off of the lower half using a gentle
rocking motion while lifting and pulling the upper half
away from lower half.
5. Unplug the handle wiring harness from the control
handle card.
6. Place upper half of the handle upside down on a se-
cure, level work surface so the internal parts are facing
up.
NOTE: Make note of the position of the butterfly knobs
relative to the handle BEFORE removal.
7. Remove one of the butterfly knobs by removing the
screw that holds it to the handle (8).
8. Using the remaining butterfly knob, slide the shaft out
of the handle. Be careful not to rotate the shaft within
the control handle card.
9. Refer to the wiring diagram, or draw a sketch of where
each of the push button switches are plugged into the
control handle card. Unplug switches from the control
handle card and remove the card.
ASSEMBLE
1. Install control handle card in the upper half of control
handle. See Figure 12.
NOTE: When inserting knobs, make sure that flange on
one of the butterfly knobs inserts between spring on handle
(9).
2. Slide shaft and butterfly knob into control handle card.
Be careful not to rotate the shaft inside the control han-
dle card.
3. Connect the switches and wire harness connectors.
4. Plug handle wiring harness into control handle card.
CAUTION
DO NOT force the upper half onto the lower half
as this will cause damage to the retaining hooks
of the upper half.
5. To install upper half of handle onto the lower half:
a. Tip the upper half up and align the hooks under the
auto-reverse switch.
b. Lower the upper half onto the lower half.
6. Install capscrews to retain upper half of control handle
to lower half.
7. Connect battery cable and test control handle opera-
tion.
2200 SRM 1640 Control Handle (Standard)
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1. LOWER HALF
2. UPPER HALF
3. CONTROL HANDLE CARD ASSEMBLY
4. SHAFT
5. BUSHING
6. LH BUTTERFLY KNOB
7. WASHER
8. SCREW
9. SPRING
10. RH BUTTERFLY KNOB
11. SWITCH COVER
12. SPRING
13. SWITCH
14. HORN SWITCH COVER
15. SWITCH ASSEMBLY
16. LABEL
17. LABEL
18. LABEL
19. ACTUATOR
20. ACTUATOR
21. SPRING
22. MICROSWITCH
Figure 12. Control Handle
Control Handle (Standard) 2200 SRM 1640
14