Hyster D210 Operating instructions

Hyster D210 (V30ZMD) Forklift

ELECTRICAL SYSTEM (TRUCKS
WITH AC CONTROLLERS)
J2.00-3.20XM (J40-65Z) [A416/B416];
V30ZMD [D210/E210];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) [D098/E098]
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.
•Donotliftheavypartsbyhand,usealiftingmechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

Electrical System (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 ................................................................................................... 4
Display Panel, Replace.................................................................................................................................. 4
Key Switch, Replace ...................................................................................................................................... 6
Controller Replacement..................................................................................................................................... 6
Traction and Pump Motor Controller Replacement..................................................................................... 6
Master Controller, Replace............................................................................................................................ 12
Master Controller, Remove J2.00-3.20XM (J40-60Z) (A416/B416)......................................................... 12
Master Controller, Install J2.00-3.20XM (J40-60Z) (A416/B416)........................................................... 12
Master Controller, Remove E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); E2.00-3.20XM
(E45-65Z) (G108); and (V30ZMD) (D210/E210)....................................................................................... 14
Master Controller, Install E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); E2.00-3.20XM
(E45-65Z) (G108); and (V30ZMD) (D210/E210)....................................................................................... 14
Master Controller, Remove E3.50-5.50XL E4.50XLS (E70-120Z,E100ZS) (D098/E098) ...................... 16
Master Controller, Install E3.50-5.50XL E4.50XLS (E70-120Z,E100ZS) (D098/E098) ........................ 16
Control Components Replacement.................................................................................................................... 17
General........................................................................................................................................................... 17
Start Switch, Replace .................................................................................................................................... 17
Brake Light Switch, Replace......................................................................................................................... 18
Seat Switch, Replace ..................................................................................................................................... 18
Parking Brake Switch, Replace .................................................................................................................... 19
MONOTROL Pedal Direction Switches, Replace ........................................................................................ 21
Steering Column Direction Control Switches, Replace ............................................................................... 24
Remove....................................................................................................................................................... 24
Install......................................................................................................................................................... 24
Brake Fluid Switch, Replace......................................................................................................................... 25
Brush Wear and Over Temperature Sensors (DC Pump Motor Only)........................................................ 25
Rocker Switches for Lights, Replace ............................................................................................................ 27
Accelerator Position Sensor, Replace............................................................................................................ 28
On-Demand Steering Sensor, Replace.......................................................................................................... 28
Lights, Converter, Relay, and Reverse Alarm .............................................................................................. 29
Brake, Tail, and Reverse Light Assembly, Replace ................................................................................. 29
Incandescent Assembly......................................................................................................................... 29
LED Assembly - Remove ...................................................................................................................... 33
LED Assembly - Install......................................................................................................................... 34
Strobe Light Assembly, Replace ............................................................................................................... 34
Wire Harness Repair................................................................................................................................. 35
Del-City Crimp-Solder-Shrink Splice .................................................................................................. 35
Front, Rear Driving Light or Spot Light Assemblies, Replace ............................................................... 36
Converter, Replace .................................................................................................................................... 37
Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416) .................................................... 37
Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416) ...................................................... 37
Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD (D210/E210); and
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) .................................................................................... 39
Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD (D210/E210); and
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) .................................................................................... 39
Remove, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)................ 41
Install, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) .................. 41
©2009 HYSTER COMPANY i

Table of Contents Electrical System (Trucks With AC Controllers)
TABLE OF CONTENTS (Continued)
Reverse Relay, Replace.............................................................................................................................. 42
Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416); V30ZMD (D210/E210);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and E2.00-3.20XM (E45-65Z) (G108)...................... 42
Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) ............................... 44
Backup Alarm, Replace............................................................................................................................. 44
Horn and Horn Button, Replace ................................................................................................................... 44
Horn Replacement for Lift Trucks J2.0-3.20XM (J40-65Z) (A416/B416), V30ZMD (D210/E210),
E1.5-2.0XM (E25.35Z, E40ZS) (E114/F114), and E2.00-3.20XM (E45-65Z) (G108) ............................. 44
Horn Replacement for Lift Trucks E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)......... 47
Horn Switch and Cover, Replace .............................................................................................................. 48
Hydraulic Pump Switches............................................................................................................................. 49
Fan Power Supply, Replace........................................................................................................................... 49
Remove, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098/E098) ....................................... 49
Install, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098/E098) ......................................... 49
Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)......................................................... 50
Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)........................................................... 50
Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108)................................................................. 52
Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108)................................................................... 53
Control and Power Fuse Check......................................................................................................................... 53
Fuse Locations ............................................................................................................................................... 53
Brake Light Switch Adjustment ....................................................................................................................... 59
Seat Switch Check ............................................................................................................................................. 60
Seat Brake Adjustment ..................................................................................................................................... 60
Parking Brake Switch Adjustment................................................................................................................... 61
Direction Switches Check.................................................................................................................................. 61
MONOTROL Pedal........................................................................................................................................ 61
Steering Column............................................................................................................................................ 62
MONOTROL Pedal or Accelerator Pedal Adjustment..................................................................................... 62
Accelerator Position Sensor Adjustment and Start Switch Adjustment ........................................................ 63
Acceleration Position Sensor, Adjust ............................................................................................................ 63
Start Switch, Adjust ...................................................................................................................................... 65
This section is for the following models:
J2.00-3.20XM (J40-65Z) [A416/B416];
V30ZMD [D210/E210];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
E2.00-3.20XM (E45-65Z) [G108];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]
ii

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2200 SRM 1055 General
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
section Periodic Maintenance 8000 SRM 1060
for lift truck models J2.00-3.20XM (J40-65Z)
(A416); V30ZMD (D210/E210); E1.50-2.00XM
(E25-35Z, E40ZS) (E114/F114); and E2.00-3.20XM
(E45-65Z) (G108), the section Periodic Main-
tenance 8000 SRM 1226 for lift truck model
J2.00-3.20XM (J40-65Z) (B416), or the sec-
tion Periodic Maintenance 8000 SRM 1201
for lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098) to raise the
drive wheels.
This section has the checks, adjustments, and repair
procedures for the parts of the electrical system that
areNOTpartofthemastercontrollerorACmotor
controllers. This section also does NOT include the
electrical components covered in other sections such
as AC motors and Electro-Hydraulic Control Valve:
•If lift truck is equipped with an Electro-Hydraulic
Control Valve, see Electro-Hydraulic Control
Valve 2000 SRM 1224 for replacement procedures
on the Electro-Hydraulic Valve Driver Module.
•See AC Motor Controller Parameter Table
in the AC Motor Controllers/Display Panel,
Description, Checks, Adjustments, and Trou-
bleshooting 2200 SRM 1056 for more informa-
tion.
See the section AC Motor Repair 620 SRM
1098 for lift truck models V30ZMD (D210/E210);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114);
E2.00-3.20XM (E45-65Z) (G108); and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098) or AC
Motor Repair 620 SRM 1053 for lift truck models
J2.00-3.20XM (J40-65Z) (A416/B416) for mainte-
nance of the AC motor. See the section Industrial
Battery 2240 SRM 1 for information on the battery.
See the section Troubleshooting and Adjust-
ments Using the AC Controls Program (ETACC)
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 (All models except E1.50-
2.00XM (E25-35Z, E40ZS) (E114/F114)
•Rocker Switches for Lights
•Accelerator Position Sensor
•Lights, Converter, Relay, and Reverse Alarm
•Horn and Horn Button
•Fan Power Supply
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-
ageforthem
ain control valve are in the section Man-
ual hydraulic Control Valve 2000 SRM 562 for lift
truck models J2.00-3.20XM (J40-65Z) (A416/B416);
V30ZMD (D210/E210); E1.50-2.00XM (E25-35Z,
E40ZS) (E114/F114); and E2.00-3.20XM (E45-65Z)
(G108) or Manual hydraulic Control Valve
2000 SRM 77 for lift truck models E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (D098/E098). Fol-
lowing is a list of the switches:
•Lift - High Speed
•Lift - Medium Speed
1

Description 2200 SRM 1055
•Tilt - Low Speed
•Third Auxiliary •Fourth Auxiliary - Medium Speed •Fourth Auxiliary - Low Speed
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. See AC Motor Controllers/Display
Panel,Description, Checks, Adjustments, and
Troubleshooting 2200 SRM 1056.
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
shownanddescribedintheOperating Manual.
Since the indicators are for common features, these
indicators are also combined with the Premium
Display Panel.
1. HOURMETER INDICATOR SYMBOL
2. WRENCH INDICATOR SYMBOL
3. BATTERY INDICATOR SYMBOL
4. BATTERY DISCHARGE INDICATOR
5. BRAKE FLUID SYMBOL
6. PARKING BRAKE SYMBOL
7. FASTEN SEAT BELT SYMBOL
8. LCD SCREEN
9. STAR PUSH BUTTON
10. PUSH BUTTON #1
11. PUSH BUTTON #2
12. PUSH BUTTON #3
13. PUSH BUTTON #4
14. PUSH BUTTON #5
Figure 1. Standard and Premium Display Panels Features
2

2200 SRM 1055 Description
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 "Static Return to OFF" (SRO)
circuit. The SRO circuit prevents travel of the lift
truck if the starting sequence is not correct. See
the Operating Manual for procedures on how to
check the SRO circuit. If the start switch is closed
before the seat switch, the controller will not per-
mit 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
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
aresimilartoautomobilerearlights. Thebrake
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,
for lift trucks J2.0-3.20XM (J40-65Z) (A416/B416),
V30ZMD (D210/E210), E1.5-2.0XM (E25.35Z,
E40ZS) (E114/F114), and E2.00-3.20XM (E45-65Z)
(G108) or attached to the inside of the left-hand
frame rail, for lift trucks E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (D098/E098).
•The AC control panel, located in the rear of the
lift truck and accessed through a removable panel
in the counterweight, has two fans that help keep
it cool during operation. For lift trucks that are
72 or 80 volts, these fans have a separate power
supply. For lift truck models J2.00-3.20XM (J40-
65Z) (A416/B416) the power supply for the fans
is located between the fans. See Figure 9. For
lift truck models E2.00-3.20XM (E45-65Z) (G108)
and V30ZMD (D210/E210) the power supply for the
fans is located near the converter on the left fender
weldment and towards the front of the lift truck.
See Figure 29. For lift truck models E3.50-5.50XL,
E4.50XLS (D098/E098) the power supply for the
fans is under the floor plate and located on the
same bracket the contains the master controller.
SeeFigure11.
3

Display Panel and Key Switch Replacement 2200 SRM 1055
Display Panel and Key Switch Replacement
DISPLAY PANEL, REPLACE
WARNING
Before replacing the Display Panels, fully
lowerallpartsofthemastandtiltitforward
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.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally 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 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 and discharge the capac-
itors by holding the horn button down until the
horn stops making a sound. Attach a tag to truck
battery connector stating DO NOT CONNECT
BATTERY. Remove the key.
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
and out of the instrument panel.
3. Disconnect the plug connector on the back of the
Display Panel.
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.
4

2200 SRM 1055 Display Panel and Key Switch Replacement
1. DISPLAY PANEL
2. MOUNT BRACKET 3. MOUNT NUT 4. 8-PIN CONNECTOR
Figure 2. Mounting of Display Panel
5

Controller Replacement 2200 SRM 1055
KEY SWITCH, REPLACE
NOTE: The key switch is replaced as one of the
components of the steering column. See the section
Steering Wheel and Column Assembly Repair in
the SRM Steering System for AC Electric Lift
Trucks 1600 SRM 1054 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.
3. Install the electrical wires on the key switch that
were identified during removal. Install the new
key switch into the housing of the steering col-
umn.
4. Remove the DO NOT CONNECT BATTERY tag
from the truck battery connector and reconnect
the battery.
1. STEERING
COLUMN
2. KEY SWITCH
3. NUT
4. RED/BRN
5. BRN
Figure 3. Key Switch
Controller Replacement
TRACTION AND PUMP MOTOR
CONTROLLER REPLACEMENT
Before replacing any motor controllers, disconnect
the battery and discharge the capacitors by holding
thehornbuttondownuntilthehornstopsmakinga
sound. Attach a tag to truck battery connector stat-
ing DO NOT CONNECT BATTERY. Remove the key.
Replace the motor controller as described in the fol-
lowing procedure. See Figure 4 through Figure 8.
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. Putanevencoatofthesiliconecompound(Hys-
ter Part No. 1198757) or equivalent on the plate
ofthemotorcontroller. Makesurethereareno
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. Tighten electrical connections as listed
below:
a. Traction and Pump Controls 18 to 21 N•m
(13to15lbfft)
b. Power Steering Contactor and Fuses 18 to
21 N•m (13 to 15 lbf ft)
c. Line and Pump Contactors 15 to 18 N•m (11
to 13 lbf ft)
5. Install the connector plug for the control wires on
the connector of the motor controller.
6. Remove the DO NOT CONNECT BATTERY tag
from truck battery connector and reconnect the
battery.
6

2200 SRM 1055 Controller Replacement
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP
2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE
SOLENOID
3. FUSE 3 (15A) LIGHTS
4. FUSE 4 (5A) KEYSWITCH
5. POWER STEERING CONTACTOR
6. FUSE 5 (40A) POWER STEERING
7. AC TRACTION MOTOR CONTROLLER
8. LINE CONTACTOR
9. AC PUMP MOTOR CONTROLLER
10. POSITIVE TEMPERATURE COEFFICIENT
RESISTOR (PTC)
11. LED INDICATOR
Figure 4. AC Traction and Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for J2.00-3.20XM
(J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models Only and for J2.00-3.20XM
(J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and V30ZMD (D210/E210) Lift Truck
Models
7

Controller Replacement 2200 SRM 1055
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP
2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE
3. FUSE 3 (15A) LIGHTS
4. FUSE 4 (5A) KEYSWITCH
5. POWER STEERING CONTACTOR
6. FUSE 5 (40A) POWER STEERING
7. LINE CONTACTOR
8. POSITIVE TEMPERATURE COEFFICIENT
RESISTOR (PTC)
9. AC TRACTION MOTOR CONTROLLER
10. FUSE (PUMP) (325A)
11. CONTACTOR FOR DC PUMP MOTOR
12. LED INDICATOR
Figure 5. AC Traction Motor Controller and Contactor Control for DC Pump Motor (Gen V) (36v/48v
or 72v/80v) for J2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108), Later Models
Only and for J2.00-3.20XM (J40-65Z) (B416); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); and
V30ZMD (D210/E210) Lift Truck Models
8

2200 SRM 1055 Controller Replacement
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP
2. FUSE 5 (15A) LIGHTS
3. FUSE 3 (5A) KEYSWITCH
4. POWER STEERING CONTACTOR
5. FUSE 4 (40A) POWER STEERING
6. LINE CONTACTOR
7. AC TRACTION MOTOR CONTROLLER
8. AC PUMP MOTOR CONTROLLER
9. LED INDICATOR
10. POSITIVE TEMPERATURE COEFFICIENT
RESISTOR (PTC)
Figure 6. AC Traction and Pump Motor Controllers (72v/80v) (Gen IV) for Early ModelJ2.00-3.20XM
(J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks
9

Controller Replacement 2200 SRM 1055
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP
2. FUSE 5 (15A) LIGHTS
3. FUSE 3 (5A) KEYSWITCH
4. POWER STEERING CONTACTOR
5. FUSE 4 (40A) POWER STEERING)
6. LINE CONTACTOR
7. POSITIVE TEMPERATURE COEFFICIENT
RESISTOR (PTC)
8. AC TRACTION MOTOR CONTROLLER
9. FUSE 2 (325A) PUMP
10. CONTACTOR FOR DC PUMP MOTOR
11. LED INDICATOR
Figure 7. AC Traction Motor Controller and Contactor Control for DC Pump Motor (72v/80v) (Gen
IV) for Early ModelJ2.00-3.20XM (J40-65Z) (A416) and E2.00-3.20XM (E45-65Z) (G108) Lift Trucks
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2200 SRM 1055 Controller Replacement
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP
2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE
3. FUSE 3 (15A) LIGHTS
4. FUSE 4 (5A) KEYSWITCH
5. POWER STEERING CONTACTOR
6. LINE TRACTION CONTACTOR
7. POSITIVE TEMPERATURE COEFFICIENT
RESISTOR (PTC)
8. AC TRACTION MOTOR CONTROLLER
9. AC PUMP MOTOR CONTROLLER
10. POWER STEERING FUSE (40A)
11. LED INDICATOR
12. LINE PUMP CONTACTOR
Figure 8. AC Traction and Pump Motor Controllers for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098) Lift Trucks Only
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Controller Replacement 2200 SRM 1055
MASTER CONTROLLER, REPLACE
NOTE: If your lift truck is equipped with an Elec-
tro-Hydraulic control valve, see Electro-Hydraulic
Control Valve 2000 SRM 1224 for the location and
procedures to replace the Electro-Hydraulic Valve
Driver Module.
Master Controller, Remove J2.00-3.20XM
(J40-60Z) (A416/B416)
NOTE: The master controller is located behind the
battery and can be removed by performing the steps
below. See Figure 9.
1. Disconnect the battery and discharge the capac-
itors by holding the horn button down until the
horn stops making a sound. Attach a tag to truck
battery connector stating DO NOT CONNECT
BATTERY. Remove the key.
2. Remove the counterweight cover located between
the hood and counterweight.
3. Loosen capscrews and remove fan cover.
4. Remove fan plate assembly.
NOTE: Perform Step 5 if a fan is to be replaced.
5. Remove the four capscrews and fan from fan
plate assembly.
6. Disconnect the power supply cable from master
controller.
7. Remove three capscrews and master controller
from mounting plate.
Master Controller, Install J2.00-3.20XM
(J40-60Z) (A416/B416)
1. Install master controller on mounting plate with
three capscrews.
2. Connect power supply cable to master controller.
NOTE: Perform Step 3 only if fan is to be installed.
3. Install fan on fan bracket assembly with four cap-
screws.
4. Install fan plate assembly.
5. Install fan cover and tighten capscrews.
6. Install counterweight cover.
7. Remove the DO NOT CONNECT BATTERY tag
from truck battery connector and reconnect the
battery.
12

2200 SRM 1055 Controller Replacement
1. MOUNTING PLATE
2. SCREW
3. PLATE
4. FAN PLATE ASSEMBLY
5. POWER SUPPLY
6. FAN COVER
7. CAPSCREW
8. GROMMET
9. MASTER CONTROLLER
10. COVER-COUNTERWEIGHT
Figure 9. AC Master Controller for J2.00-3.20XM (J40-60Z) (A416/B416)
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Controller Replacement 2200 SRM 1055
Master Controller, Remove E1.50-2.00XM
(E25-35Z, E40ZS) (E114/F114);
E2.00-3.20XM (E45-65Z) (G108); and
(V30ZMD) (D210/E210)
NOTE: On the E1.50-2.00XM (E25-35Z, E40ZS)
(E114/F114) lift truck model, the master controller
is located on the right-hand side under the battery
tray. See Figure 10.
NOTE: On the E2.00-3.20XM (E45-65Z) (G108) and
(V30ZMD) (D210/E210), the master controller is lo-
cated on the left-hand side under the battery tray.
1. Disconnect the battery and discharge the capac-
itors by holding the horn button down until the
horn stops making a sound. Attach a tag to truck
battery connector stating DO NOT CONNECT
BATTERY. Remove the key.
2. Remove battery, and battery tray.
3. Remove the two capscrews from bracket located
under the frame.
4. Rotate master controller bracket and master con-
troller assembly, and disconnect the power sup-
ply cable.
5. Remove three capscrews and bracket from mas-
ter controller.
Master Controller, Install E1.50-2.00XM
(E25-35Z, E40ZS) (E114/F114);
E2.00-3.20XM (E45-65Z) (G108); and
(V30ZMD) (D210/E210)
1. Install master controller on bracket with three
capscrews.
2. Connect power supply cable to master controller.
3. Install two capscrews to the bracket located un-
der the frame.
4. Install battery tray, and battery.
5. Remove the DO NOT CONNECT BATTERY tag
from truck battery connector and reconnect the
battery.
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