Hyster D264 Operating instructions

Hyster D264 (N45ZR2, N35ZDR2) Forklift

ELECTRICAL SYSTEM
N35ZDR2, N45ZR2 [D264];
N30ZDR2, N35-40ZR2 [E470];
N30ZDRS2, N35-40ZRS2 [B265]
PART NO. 4075037 2200 SRM 1612

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.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Discharging the Internal Capacitors ................................................................................................................. 2
Static Strap ......................................................................................................................................................... 2
Inspect ............................................................................................................................................................. 3
Replace ............................................................................................................................................................ 3
Battery Connection ................................................................................................................................................. 3
Inspect ................................................................................................................................................................. 3
Replacing Cables .................................................................................................................................................3
Key Switch ...............................................................................................................................................................5
Replace .................................................................................................................................................................5
Major Electrical System Features ..........................................................................................................................7
Integrated System ...............................................................................................................................................7
CANbus Advantages ...........................................................................................................................................7
CANbus Communications .................................................................................................................................. 7
Electric Steering / Steer Caster (Optional) ................................................................................................... 7
Centering Proximity Sensor ...................................................................................................................... 8
Traction ........................................................................................................................................................... 8
CAN I/O ...........................................................................................................................................................8
Input Devices ..............................................................................................................................................8
Output Devices ........................................................................................................................................... 8
Encoder Integrity ................................................................................................................................................ 9
Test Encoders ......................................................................................................................................................9
Proximity Switches ............................................................................................................................................. 9
Key Switch .........................................................................................................................................................10
Multifunction Displays ..................................................................................................................................... 10
BDI .....................................................................................................................................................................10
Speed ..................................................................................................................................................................10
Steer Angle ........................................................................................................................................................ 10
Truck Hours ...................................................................................................................................................... 10
Operational Mode ..............................................................................................................................................10
Setup ...................................................................................................................................................................... 10
Setup Instructions .............................................................................................................................................10
ACE2 / ACE3 Traction and Hydraulic Controllers .....................................................................................11
Normal Operation ............................................................................................................................................. 11
Display ...........................................................................................................................................................11
Password Access ....................................................................................................................................... 11
Startup Checklist ..................................................................................................................................... 11
Truck Operation Mode ............................................................................................................................. 12
Diagnostics ........................................................................................................................................................ 12
Calibrations ........................................................................................................................................................... 13
AC Motor Controllers ............................................................................................................................................13
Controller Removal ........................................................................................................................................... 14
Install .................................................................................................................................................................14
Low-Voltage Protection Function .....................................................................................................................14
CDF File Installation Procedure .......................................................................................................................... 15
LOW-VOLTAGE PROTECTION FUNCTION ............................................................................................15
Contactor and Electrical Panel Checks ................................................................................................................16
Fuses ..................................................................................................................................................................16
Contactors ..........................................................................................................................................................16
General ..........................................................................................................................................................16
Table of Contents
i

TABLE OF CONTENTS (Continued)
Test ................................................................................................................................................................17
Tips ................................................................................................................................................................17
Disassemble and Assemble .......................................................................................................................... 17
Instrument Panel Removal and Installation .......................................................................................................19
Key Switch Removal and Installation ..................................................................................................................19
Remove .............................................................................................................................................................. 19
Install .................................................................................................................................................................19
Integrated Fuse Board (IFB) ................................................................................................................................ 20
Fuses ..............................................................................................................................................................20
Replace ...............................................................................................................................................................20
Diodes ................................................................................................................................................................ 22
Power Disconnect Switch ......................................................................................................................................23
Replace ...............................................................................................................................................................23
Side-Stance Controls .............................................................................................................................................24
Multifunction Control Handle ..........................................................................................................................24
Horn ...............................................................................................................................................................25
Inspection ......................................................................................................................................................26
Remove .............................................................................................................................................................. 26
Install .................................................................................................................................................................28
Control Handle Disassembly and Repair .............................................................................................................28
Thumb Grip Pad Replacement .........................................................................................................................28
Handle Grip and Switch Repairs ..................................................................................................................... 29
Handle Grip Support Mounting ...................................................................................................................29
Handle Disassembly ......................................................................................................................................... 30
Forward-Stance Controls ......................................................................................................................................33
Control Handle Functions ................................................................................................................................ 33
Repair ............................................................................................................................................................ 34
Aft Travel Control Handle Option ................................................................................................................... 35
Repair ............................................................................................................................................................ 36
Aft Handle Sensor Adjustment ....................................................................................................................37
Steering Handle .....................................................................................................................................................38
Steering Unit Repair .........................................................................................................................................38
Foot Switches .........................................................................................................................................................42
Brake Switch ..................................................................................................................................................... 43
Operator Sensing .............................................................................................................................................. 43
Repair ................................................................................................................................................................ 43
Freezer Floor Plate Repair ............................................................................................................................... 44
General ..........................................................................................................................................................44
Heater Harness .............................................................................................................................................48
Dash Display Assembly .........................................................................................................................................48
Description ........................................................................................................................................................ 48
Remove .............................................................................................................................................................. 49
Test .................................................................................................................................................................... 49
Install .................................................................................................................................................................50
Horn ....................................................................................................................................................................... 51
Audible Alarm ................................................................................................................................................... 51
Light Assemblies ................................................................................................................................................... 52
Front Lights ...................................................................................................................................................... 52
Bulb Replacement .........................................................................................................................................52
Assembly Replacement .................................................................................................................................52
Table of Contents
ii

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TABLE OF CONTENTS (Continued)
Rear Work and Caution Light ..........................................................................................................................54
Rear Work Light ........................................................................................................................................... 54
Caution Light ................................................................................................................................................54
Light Switches ...................................................................................................................................................55
Cooling Fans .......................................................................................................................................................... 56
Electrical Compartment Fans .......................................................................................................................... 56
Replace .......................................................................................................................................................... 57
Operator Fan .....................................................................................................................................................58
Repair ............................................................................................................................................................ 58
Impact Sensor ........................................................................................................................................................60
Remove .............................................................................................................................................................. 60
Install .................................................................................................................................................................61
Height Proximity Switch .......................................................................................................................................61
Test .................................................................................................................................................................... 62
Remove .............................................................................................................................................................. 62
Install .................................................................................................................................................................63
Adjust .................................................................................................................................................................63
Load Transport Proximity Switch ........................................................................................................................64
Replace .......................................................................................................................................................... 65
Adjust ............................................................................................................................................................ 65
Fork Height Sensor Option ...................................................................................................................................66
Remove .............................................................................................................................................................. 66
Encoder Assembly .........................................................................................................................................66
Timing Belt ................................................................................................................................................... 67
Install .................................................................................................................................................................68
Encoder Assembly .........................................................................................................................................68
Timing Belt ................................................................................................................................................... 68
Reach Position Sensor ...........................................................................................................................................69
Remove .............................................................................................................................................................. 69
Install .................................................................................................................................................................72
Retract Sensor ....................................................................................................................................................... 73
Remove .............................................................................................................................................................. 73
Install .................................................................................................................................................................74
Tilt Leveling ...........................................................................................................................................................75
Remove .............................................................................................................................................................. 75
Install .................................................................................................................................................................76
Laser Option .......................................................................................................................................................... 77
Remove .............................................................................................................................................................. 77
Adjustment ........................................................................................................................................................78
Horizontal Adjustment .................................................................................................................................78
Vertical Adjustment ..................................................................................................................................... 78
Install .................................................................................................................................................................80
Camera Option ...................................................................................................................................................... 80
Description ........................................................................................................................................................ 80
Remove .............................................................................................................................................................. 83
Install .................................................................................................................................................................83
Table of Contents
iii

This section is for the following models:
(N35ZDR2, N45ZR2) [D264];
(N30ZDR2, N35-40ZR2) [E470];
(N30ZDRS2, N35-40ZRS2) [B265]
Table of Contents
iv

General
WARNING
This electrical system utilizes capacitors that
maintain a charge on the electrical system even
after the battery is disconnected. Damage to the
truck components and injury from electrical
shock may occur if the capacitors are not
properly discharged prior to servicing the
electrical systems. Refer to Discharging the
Internal Capacitors in this section.
CAUTION
Electrical components on this truck are polarity
sensitive and may be damaged if wired
incorrectly. Make sure each electrical wire
connection is tagged and properly identified
before removal or installation. If the proper
location for connection is unclear, consult the
wiring diagram for the truck. Make sure testing
meters have adequate voltage and current
capacities to handle the output of the electrical
components they are used to check. Never wire
aftermarket components to this truck without
factory approval.
The electrical system is an alternating current (AC)
system. DC current from the battery is converted
into AC current by a series of transistor motor
controllers to power each AC induction motor. See
Figure 1. Other components of this system include
battery connectors and cables, cooling fans, main
contactor, CAN I/O, display unit, integrated fuse
board (IFB), horn, lights, multifunction control
handle, emergency battery disconnect switch, key
or lever switch, and wiring harnesses.
1. TRACTION CONTROLLER
2. LIFT MOTOR
3. AUX HYDRAULIC MOTOR (BELOW) (N35ZDR,
N45ZR, N30ZDR, N35-40ZR ONLY)
4. CAN I/O AND STEERING CONTROLLERS
5. TRACTION MOTOR
6. STEERING MOTOR
7. CASTER MOTOR (OPTIONAL)
8. HYDRAULIC CONTROLLER
9. INTEGRATED FUSE BOARD (IFB)
Figure 1. Electrical System General Arrangement
2200 SRM 1612 General
1

DISCHARGING THE INTERNAL
CAPACITORS
When working with the electrical systems of the
truck, it is necessary to discharge the internal
capacitors of the controllers associated with each
circuit affected.
WARNING
Capacitors inside the controllers can hold an
electrical charge after the battery is disconnected.
Discharge the internal capacitors before servicing
the electrical system to prevent injury or
electronic damage.
1. Move the lift truck to a safe, level area and
completely lower the mast. Turn the key switch
to the OFF position and attach a DO NOT
OPERATE tag to the control handle. Block the
drive wheel to prevent unexpected 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 controller B+ and B-
terminals of the motor controller for 10 seconds.
Remove the resistor after discharging the
capacitors. See Figure 2.
1. POSITIVE CONNECTION (B+)
2. NEGATIVE CONNECTIONS (B-)
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 2. Discharging the Internal Capacitors
STATIC STRAP
The static strap is a rubber strap molded with non-
sparking metal inside. It is mounted to the frame of
the lift truck near the lower mast mounting plate.
See Figure 3. Static electricity builds during
operation of the lift truck. The tires of the lift truck
isolate the metal components of the truck from the
floor. The strap allows limited conductivity between
the lift truck frame and the floor to disperse the
static charge. If the static strap is removed or
damaged, the static charge may build. This can
cause damage to electronic components of the lift
truck and may discharge with a spark when the
forks or other parts of the lift truck frame contact
items that permit grounding to the floor. Sparks
caused by static electricity can cause an explosion
when it occurs near flammable materials or around
batteries which vent flammable gasses during
normal operation. Check that the static strap is
present and is in good working condition before
operating the lift truck. Replace the strap if
necessary.
General 2200 SRM 1612
2