Electrical System: Replacement, Checks, and Adjustments Trucks With Ev-100/200Zx or SR (Sem) and SP Motor Controllers

ELECTRICAL SYSTEM
REPLACEMENT, CHECKS, AND

ADJUSTMENTS
TRUCKS WITH EV-100/200ZX OR SR
(SEM) AND SP MOTOR CONTROLLERS
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];
E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098];
N30XMH, N30XMH 2 [C210];
E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];
E2.00XMS (E40XMS, E40XM 2S) [D114];
E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108]
PART NO. 897640 2200 SRM 560

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Electrical System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
ZX Series Display Panels .............................................................................................................................. 2
Display Panel............................................................................................................................................. 2
Basic Display Panels ................................................................................................................................. 2
Early Display Panel .............................................................................................................................. 2
Later Display Panel .............................................................................................................................. 2
Performance Display ................................................................................................................................. 4
Brush Wear Indicators .............................................................................................................................. 8
SEM Display Panels - Features .................................................................................................................... 8
Descriptions of Common Features ........................................................................................................... 9
LED Symbol Indicators - SEM ............................................................................................................. 9
LCD Screen ........................................................................................................................................... 9
Battery Discharge Indicator (BDI)....................................................................................................... 9
Service Reminder .................................................................................................................................. 10
Status Codes.......................................................................................................................................... 10
Hourmeter ............................................................................................................................................. 10
Additional Features of Premium Display Panel...................................................................................... 10
Descriptions of Additional Features......................................................................................................... 10
LCD Screen ........................................................................................................................................... 10
Operator Passwords .............................................................................................................................. 10
Daily Checklist and Service Items ....................................................................................................... 11
Performance Modes............................................................................................................................... 11
Status Code Lists .................................................................................................................................. 11
Adjustment of BDI ................................................................................................................................ 11
SEM Display Panel Indicators...................................................................................................................... 11
All Indicator Symbols................................................................................................................................ 11
Hourmeter Indicator Symbol .................................................................................................................... 12
Wrench Symbol.......................................................................................................................................... 12
Battery Symbol.......................................................................................................................................... 12
Battery Discharge Indicator (BDI) ........................................................................................................... 12
Brake Fluid Too Low Symbol.................................................................................................................... 12
Parking Brake Symbol .............................................................................................................................. 12
Fasten Seat Belt Symbol........................................................................................................................... 12
LCD Screen (Standard Display Panel)..................................................................................................... 12
Additional Components of Premium Display Panel .................................................................................... 12
Alpha Numerical Screen ........................................................................................................................... 12
STAR Push Button .................................................................................................................................... 13
Push Buttons #1 Through #5 - SEM ........................................................................................................ 13
Other Control Components ........................................................................................................................... 13
Display Panel Components Replacement ......................................................................................................... 14
ZX Panel Replacement .................................................................................................................................. 14
Display Panel Assembly ................................................................................................................................ 14
Key Switch, Replace ...................................................................................................................................... 15
Indicator LEDs .............................................................................................................................................. 15
Battery Indicators.......................................................................................................................................... 15
Digital Display (Performance Display Panel Only) ..................................................................................... 15
Status Code or Performance Level Switches and Indicator LEDs (Performance Display Panel
Only) ............................................................................................................................................................... 15
Basic Display Panel, Replace Parts .............................................................................................................. 15
Performance Display Panel, Replace Parts.................................................................................................. 17
©2004 HYSTER COMPANY i

Table of Contents Electrical System
TABLE OF CONTENTS (Continued)

SEM Display Panel Replacement ..................................................................................................................... 18
Motor Controller (SR or SP) Replacement........................................................................................................ 20
Remove ........................................................................................................................................................... 20
Install ............................................................................................................................................................. 20
Control Components Replacement.................................................................................................................... 21
Start Switch, Replace .................................................................................................................................... 21
Brake Light Switch, Replace......................................................................................................................... 21
Seat Switch, Replace ..................................................................................................................................... 22
External Seat Switch, Adjust........................................................................................................................ 23
Switch for Optional Seat Brake, Replace ..................................................................................................... 23
Parking Brake Switch, Replace .................................................................................................................... 24
Direction Switches (MONOTROL Pedal), Replace ...................................................................................... 25
Direction Control Switches (Steering Column), Replace............................................................................. 26
Direction Control Switches, E70-120XL 3 (Steering Column) ..................................................................... 27
Brake Fluid Switch, Replace......................................................................................................................... 27
Brush Wear and Overtemperature Sensors ................................................................................................. 27
Rocker Switches for Lights ........................................................................................................................... 27
Accelerator Position Sensor, Replace............................................................................................................ 28
On-Demand Steering Components ............................................................................................................... 30
Lights, Converter, Relay, and Reverse Alarm .............................................................................................. 32
Incandescent Brake, Tail, and Reverse Light Assembly, Replace .......................................................... 32
LED Brake, Tail, and Reverse Light Assembly, Replace ........................................................................ 32
Remove .................................................................................................................................................. 32
Install..................................................................................................................................................... 32
Flashing Light Assembly, Replace............................................................................................................ 34
Front, Rear Driving Light, or Spot Light Assemblies, Replace .............................................................. 34
Operator Compartment Light Assembly, Replace ................................................................................... 36
Converter, Replace .................................................................................................................................... 36
Relay, Replace............................................................................................................................................ 37
Reverse Alarm, Replace ............................................................................................................................ 37
Horn and Horn Button .................................................................................................................................. 37
Horn Switch and Cover ............................................................................................................................. 38
Hydraulic Pump Switches............................................................................................................................. 38
Control and Power Fuses Check ....................................................................................................................... 38
ZX Motor Controllers..................................................................................................................................... 38
SEM Motor Controllers ................................................................................................................................. 43
SEM Controller Field Diagnostic Procedure ................................................................................................ 43
Armature FET Test ................................................................................................................................... 43
Field FET Test ........................................................................................................................................... 43
Brush Wear and Overtemperature Sensors Check - ZX Motor Controllers ................................................... 47
Thermal Sensors - SEM Motor Controllers Check........................................................................................... 48
Start Switch Adjustment ................................................................................................................................... 49
Accelerator Potentiometer and Start Switch, E70-120XL, E70-120XL 3 Lift Trucks................................. 50
E70-120XL ................................................................................................................................................. 50
E70-120XL 3................................................................................................................................................ 50
Direction Switches (MONOTROL) ............................................................................................................... 50
Brake Light Switch Adjustment ....................................................................................................................... 52
Seat Switch Check ............................................................................................................................................. 53
Optional Seat Brake Switch Adjustment ......................................................................................................... 53
Parking Brake Switch Adjustment ................................................................................................................... 54
Direction Switches Check .................................................................................................................................. 54
ii
Electrical System Table of Contents
TABLE OF CONTENTS (Continued)

Monotrol Pedal............................................................................................................................................... 54
Steering Column ............................................................................................................................................ 55
Hydraulic Pump Switch Adjustment ................................................................................................................ 55
MONOTROL or Accelerator Pedal Adjustment ............................................................................................... 55
Accelerator Position Sensor Adjustment .......................................................................................................... 56
This section is for the following models:
J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];

E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098];
N30XMH, N30XMH 2 [C210];
E1.50-1.75XM (E25-35XM, E25-35XM 2) [D114];
E2.00XMS (E40XMS, E40XM 2S) [D114];
E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
2200 SRM 560 General
General
See the section Battery Indicators 2260 SRM 138
WARNING to adjust the battery indicator. See the section DC
Do not operate a lift truck that needs adjust- Motor Maintenance 620 SRM 294 for maintenance
ment or repairs. Report the need for adjust- of the motors. See the section Industrial Battery
ment or repairs immediately. If adjustment or 2240 SRM 1 for information on the battery.
repair is necessary, put a DO NOT OPERATE
tag in the operator’s area. Remove the key Some components that have inputs to the controller
from the key switch. have installation adjustments. This section has the
correct procedures for replacement, checks, and ad-
Some of the checks and adjustments are done justments of these components. These components
with the battery connected. Never have any include the following:
metal on your fingers, arms, or neck. These • Key Switch
metal items can accidentally make an electri- • Start Switch
cal connection and cause an injury. • Brake Light Switch
• Seat Switch
Some adjustments in this section must be done
• Switch for Optional Seat Brake
with the battery connected and power applied
• Parking Brake Switch
to the controller. When making these adjust-
• Direction (FWD REV) Switches
ments, make sure the drive wheels are raised
MONOTROL® pedal
from the floor. See the Operator’s Manual or
Direction Control Lever (On Steering Column)
the service section Periodic Maintenance for
• Brake Fluid Switch
your lift truck model to raise the drive wheels.
• Motor Temperature Switches
NOTE: This section does NOT include any compo- • Rocker Switches for Lights
nents of any of the motor controllers. Many of the • Accelerator Position Sensor
components in this section do have inputs to the • On-Demand Steering Components
EV-100ZX™ or EV-T100™ motor controllers, but • Lights, Converter, Relay, and Reverse Alarm
are not part of the controller. • Horn and Horn Button
This section has the checks, adjustments, and repair NOTE: Some checks and adjustments are easier to
procedures for the parts of the electrical system that do if another person can operate the controls. If you
are NOT part of the EV-100ZX, EV-T100, or Sepa- are working alone, put a weight on the seat to close
rately Excited Motor (SEM) motor controllers. This the seat switch. If your lift truck has a seat brake,
section also does NOT include the electrical compo- use a block behind the lower actuator bar to release
nents covered in other sections such as motors and the seat brake when the operator in not in the seat.
battery indicators. To check, adjust, or repair the Put the voltmeter in a position so that you can see it
parts of the EV-100ZX, EV-T100, or TRANSISTOR from the operator area. You can usually operate the
(SEM) motor controller, see one of the following sec- controls with your hand and also make the voltage
tions: measurements.
• EV-100ZX™ SCR Motor Controller, Descrip-
NOTE: The adjustments of the switches on the link-
tion, Adjustments, Troubleshooting, Repairs,
age for the main control valve are included in the sec-
and Theory 2200 SRM 557
tion Main Control Valve for your unit. Following is
• EV-T100™ Transistor Motor Controller, De-
a list of the switches; however, all of the switches are
scription, Adjustments, Troubleshooting, Re-
not on all units:
pairs, and Theory 2200 SRM 581
• Lift - High Speed
• SR/SP Transistor Motor Controllers, Descrip-
• Lift - Low Speed
tion, Checks and Adjustments, Troubleshoot-
• Tilt
ing, Repairs, and Theory of Operation 2200
• Third Auxiliary
SRM 724
• Fourth Auxiliary - Medium Speed
• Transistor Motor Controllers (SR and SP),
• Fourth Auxiliary - Low Speed
Description, Checks, Adjustments, Trou-
bleshooting, Repairs, and Theory of Opera-
tion 2200 SRM 808 - (E70-120XL 3)
1
Description 2200 SRM 560
Description
ZX SERIES DISPLAY PANELS (load) to check the battery charge. Hold the tilt lever
in the tilt BACKWARD position or for the N30XMH/
Display Panel XMH 2, hold the rotate lever in the ROTATE position
and look at the indicator. If the needle is in the red
WARNING band, charge the battery. Operating the lift truck
with the needle in the red band can decrease battery
Some adjustments can cause the lift truck to
life. Continued operation with a discharged battery
operate differently than normal. This different
can damage the battery, motors, or the contactors.
operation of the truck can result in personal
injury or damage. Do NOT try to make adjust- (3) Warning light, parking brake indicator. The
ments for the instrument panel display without red light is on when the parking brake is applied and
using the procedures in the section EV-100ZX™ the seat switch is closed, and goes off when the park-
SCR Motor Controller, Parameter Tables 2200 ing brake is released.
SRM 595.
(4) Warning light, brake fluid reservoir is low
There are two display panels available on lift trucks (Early Only). The red light is on for 1 second when
with the EV-100ZX Silicon Controlled Rectifier the key switch is turned to the START position and
(SCR) motor controller. The lift trucks can only have must go off after 1 second. If the warning light is on
one of the two display panels: during operation, the brake fluid level in the reser-
• A basic display that gives the operator basic infor- voir is too low.
mation about the operation of the lift truck.
• A performance display that includes diagnostic ca- (5) Warning light, fasten seat belt. The red light
pabilities similar to the handset. is on for 8 to 10 seconds after the key switch is turned
to the ON position.
Basic Display Panels
Later Display Panel
The EV-100 ZX Series motor controller can have two
Basic Display Panels that include one of two types of When the key switch is turned to the ON position, a
Battery Indicators. start program will cause each warning light to illu-
minate to show that the function is operating. This
Early Display Panel later display panel has the following functions:
When the key switch is turned to the ON position, a (1) Battery Charge Indicator With Lift Inter-
start program will cause each warning light to illu- rupt. Later Basic Display Panels have a battery
minate to show that the function is operating. This indicator that is a scale with a series of 5 round
later display panel has the following functions: LEDs in three colors (green, orange, and red). See
Figure 1 and Figure 2. There are two green LEDs
(1) Hourmeter. The hourmeter display shows the and bars at the top, two orange LEDs and bars in
operating time of 0000 to 9999 hours. The time for the center, and a red LED and bar at the bottom.
the traction circuit is shown for 4 seconds after the As the battery voltage decreases during operation,
lift truck has been operating and the key is turned to different LEDs illuminate to indicate a discharged
the OFF position. battery. No more than two LEDs are illuminated
at one time. When the battery is fully charged, the
(2) Voltmeter. The earlier Basic Display Panel has
two green LEDs of the scale are illuminated. When
a battery indicator without lift interrupt (voltmeter).
the battery discharges during operation, the LEDs
This meter has a green, yellow, and red band on the
illuminate from top to bottom (green to red). The red
meter face to indicate the voltage of the battery. The
LED indicates that the battery is discharged. The
needle starts in the green band with a fully charged
battery must be charged or a charged battery must
battery and moves to the red band as the battery
be installed before lift truck operation can continue.
discharges. The battery must have a current draw
2
2200 SRM 560 Description
Standard Display 18-Pin Connector

Pin Function Pin Function
1-11 No Connection 15 Hyd. Contactor Coil
12 Battery Negative ( ) 16 Seat Switch
13 Parking Brake Switch 17 Key Switch (IGN)
14 Brake Fluid Switch 18 Battery Positive (+) (from Fuse 6)
1. HOURMETER 6. KEY SWITCH LEADS

2. BATTERY METER 7. BRN BAT TERMINAL
3. PARKING BRAKE INDICATOR 8. RED/BRN IGN TERMINAL
4. BRAKE FLUID TOO LOW INDICATOR 9. 18-PIN CONNECTOR
5. SEAT BELT INDICATOR
Figure 1. Basic (Early) Display Panels for EV-100/200ZX Motor Controllers
1. BATTERY DISCHARGE INDICATOR 3. FASTEN SEAT BELT SYMBOL AND LED

2. PARKING BRAKE SYMBOL AND LED 4. DIGITAL DISPLAY
Figure 2. Basic (Later) Display Panels for EV-100/200ZX Motor Controllers
3
The battery charge indicator uses the traction control The indicator lights for the traction motor (8) and for
shunt to measure the current during operation. This the hourmeter (12) will also be illuminated during
current and battery voltage are checked at the same this time. If there is an SCR control card for the hy-
time for an accurate reading of battery voltage with draulic pump motor, this time will then be shown on
a load (during use). This method can make operation the hourmeter for another 4 seconds. The indicator
of the lift truck different when the battery is low or a lights for the hydraulic motor (9) and for the hourme-
different battery is connected. This method permits ter (12) will also be illuminated during this time.
better use of the battery charge.
Performance Display
The controller also checks the battery voltage each
time a battery is connected. The traction control will When the key switch is turned to the ON position,
prevent lift truck operation if the battery voltage is a start program will cause each warning and indi-
not correct as set by traction function 15. A status cator light to illuminate to show that the function is
code of -16 (voltage too high) or -15 (voltage too low) operating. The functions and operation of the indi-
will indicate on the display panel. The battery can cators for these early and later display panels is the
have a voltage that is too high or too low. A battery same. These display panels have the following func-
with the correct voltage can also be deeply discharged tions (see Figure 3 and Figure 4):
from use or other reasons and can have a voltage that
is less than the minimum of the voltage range. (1) Battery Charge Indicator With Lift Inter-
rupt. This battery charge indicator shows the
Batteries that have different ampere hour ratings or battery charge with an LED bar graph. There are
are of different ages can sometimes be used in the four green bars, four orange bars, and two red bars.
same lift truck. It can be necessary to adjust trac- When the battery is discharged during operation, the
tion Function 14 so that the weakest battery is not LED bar that is illuminated decreases sequentially
damaged. Follow the procedure for adjusting trac- from the top green bar through the orange bars to
tion Function 14 in the Checks and Adjustments. the red bars. When the battery is discharged to the
red LED bars, the battery is 73% discharged and the
(2) Warning light, parking brake indicator. The lift interrupt function will not permit operation of
red light is on when the parking brake is applied and the hydraulic motor. The battery must be charged
the seat switch is closed, and goes off when the park- or a charged battery must be installed before lift
ing brake is released. truck operation can continue. The top green bar will
be illuminated when the battery is more than 90%
(3) Warning light, fasten seat belt. The red light
charged.
is on for 8 to 10 seconds after the key switch is turned
to the ON position. The battery charge indicator uses the traction control
shunt to measure the current during operation. This
(4) Digital Display. This indicator is blank when
current and battery voltage are checked at the same
the lift truck is operating correctly. The status codes
time for an accurate reading of battery voltage with
and the hourmeter values are shown on this four-
a load (during use). This method can make operation
digit LCD display. When a fault occurs, the status
of the lift truck different when the battery is low or a
code will be shown with a dash (-) in the left digit
different battery is connected. This method permits
position. The warning light, Service Interval (11) will
better use of the battery charge.
also be illuminated when a fault occurs.
The controller also checks the battery voltage each
When it is time for periodic maintenance, the warn-
time a battery is connected. The traction control will
ing light, Service Interval (11) will be illuminated
prevent lift truck operation if the battery voltage is
and a status code -99 will be indicated. The regis-
not correct as set by traction function 15. A status
ter in the controller card must be reset by the service
code of -16 (voltage too high) or -15 (voltage too low)
person before this warning light will go off.
will indicate on the display panel. The battery can
The hourmeter display shows the operating time of have a voltage that is too high or too low. A battery
0000 to 9999 hours. The time for the traction circuit with the correct voltage can also be deeply discharged
is shown for 4 seconds after the lift truck has been from use or other reasons and can have a voltage that
operating and the key is turned to the off position. is less than the minimum of the voltage range.
4
Enhanced Display 18-Pin Connector

1 Traction Card PY 5 10 Pump Card PY 4
2 Pump Card PY 5 11 Brush Wear Indicator and Temperature Jumper*
3 No Connection 12 *
4 Traction Card PY 14 13 Parking Brake Switch
5 Traction Card PY 13 14 Brake Fluid Switch
6 Pump Card PY 14 15 No Connection
7 Pump Card PY 13 16 No Connection
8 No Connection 17 Key Switch (IGN)
9 Traction Card PY 4 18 No Connection
*Pin 11 to 12 jumper (in wire harness). BWI and temperature LEDs disabled if cut.
1. BATTERY DISCHARGE INDICATOR 11. STATUS CODE/MAINTENANCE INDICATOR

2. DIGITAL DISPLAY 12. HOURMETER INDICATOR
3. FASTEN SEAT BELT INDICATOR 13. STATUS CODE BUTTON
4. BRAKE FLUID TOO LOW INDICATOR 14. PERFORMANCE LEVEL BUTTON
5. PARKING BRAKE INDICATOR 15. PERFORMANCE LEVEL LEDS
6. STEERING PUMP MOTOR INDICATOR 16. KEY SWITCH LEADS
7. BRUSH WEAR INDICATOR 17. BRN BAT TERMINAL
8. TRACTION MOTOR INDICATOR 18. RED/BRN IGN TERMINAL
9. LIFT PUMP MOTOR INDICATOR 19. 18-PIN CONNECTOR
10. MOTOR TEMPERATURE INDICATOR
Figure 3. Performance Display Panels (Early) for EV-100/200ZX Motor Controllers
Batteries that have different ampere hour ratings or and the hourmeter values are shown on this four-
are of different ages can sometimes be used in the digit LCD display. When a fault occurs, the status
same lift truck. It can be necessary to adjust trac- code will be shown with a dash (-) in the left digit
tion Function 14 so that the weakest battery is not position. The warning light, Service Interval (11) will
damaged. Follow the procedure for adjusting trac- also be illuminated when a fault occurs.
tion Function 14 in the Checks And Adjustments.
(2) Digital Display. This indicator is blank when

the lift truck is operating correctly. The status codes
5
1. BATTERY DISCHARGE INDICATOR 9. LIFT PUMP MOTOR INDICATOR

2. DIGITAL DISPLAY 10. MOTOR TEMPERATURE INDICATOR
3. FASTEN SEAT BELT INDICATOR 11. STATUS CODE/MAINTENANCE INDICATOR
4. BRAKE FLUID TOO LOW INDICATOR 12. HOURMETER INDICATOR
5. PARKING BRAKE INDICATOR 13. STATUS CODE BUTTON
6. STEERING PUMP MOTOR INDICATOR 14. PERFORMANCE LEVEL BUTTON
7. BRUSH WEAR INDICATOR 15. PERFORMANCE LEVEL LEDS
8. TRACTION MOTOR INDICATOR
Figure 4. Performance Display Panels (Later) for EV-100/200ZX Motor Controllers
The hourmeter display shows the operating time of A warning buzzer will make a noise if the opera-
0000 to 9999 hours. The time for the traction circuit tor leaves the seat (key switch ON) and the parking
is shown for 4 seconds after the lift truck has been brake is not applied.
operating and the key is turned to the OFF position.
The indicator lights for the traction motor (8) and for (6) Indicator Light, Steering Pump Motor. This
the hourmeter (12) will also be illuminated during light will illuminate with another warning light if a
this time. If there is an SCR control card for the hy- fault occurs in the steering pump motor. If the brush
draulic pump motor, this time will then be shown on wear sensor is activated in the motor, the warning
the hourmeter for another 4 seconds. The indicator light, brush wear (7) will go on and the indicator light
lights for the hydraulic motor (9) and for the hourme- for the steering pump motor will show which motor
ter (12) will also be illuminated during this time. has the problem.
(3) Warning Light, Fasten Seat Belt. The red light (7) Warning Light, Motor Brushes Are Worn.
is on for 8 to 10 seconds after the key switch is turned When the sensor for brush wear closes, this warning
to the ON position. light and the indicator light for the motor that has
the problem will both illuminate.
(4) Warning Light, Brake Fluid Reservoir Is
Low (Early Only). The red light is on for 1 second (8) Indicator Light, Traction Motor. This light
when the key switch is turned to the START posi- will illuminate with another warning light if a fault
tion and must go off when the key switch is in the occurs in the traction motor. Example: If the brush
ON position. If the warning light is on when the key wear sensor is activated in the motor, the warning
switch is in the ON position, the brake fluid level in light, brush wear (7) will go on and the indicator light
the reservoir is too low. for the traction motor will show which motor has the
problem.
(5) Warning Light, Parking Brake Indicator.
The red light is on when the parking brake is applied (9) Indicator Light, Hydraulic Motor. This light
and the seat switch is closed, and goes off when the will illuminate with another warning light if a fault
parking brake is released. occurs in the hydraulic pump motor. Example: If the
temperature over limit switch closes in the motor, the
warning light, motor temperature over limit (10) will
6
go on and the indicator light for the hydraulic motor will be indicated on the Status Code Indicator (2). If
will show which motor has the problem. the key switch is turned to OFF, the status code will
be removed from the four-digit display.
(10) Warning light, Motor Temperature Over
Limit. The traction motor and the hydraulic pump The push button (13) will cause the status codes for
motor have thermal switches inside the motors. the faults to be shown on the Status Code Indicator
When the temperature increases to the limit set by (2). When the button is pushed and held down, the
the manufacturer of the motor, the thermal switch indicator light for the traction motor (8) will illumi-
closes and the warning light on the display panel nate. The status codes in memory for the detected
illuminates. The indicator light for traction motor faults will be displayed, starting with the most re-
(8) or for the hydraulic motor (9) will show which cent fault. If the push button is released, the display
motor has the problem. will stop. If the button is pushed again, the display
will start from the beginning again. The hourmeter
(14, 15) Set Lift Truck Performance. The lift time and the battery charge at the time of the fault
truck can be set to four performance levels by the will not be shown. A Handset or a PC must be used
operator. (If the customer does not want this func- to show this additional information. A Handset or
tion available to the operator, a service person can a PC must be used to clear the status code from the
set all four levels to the same setting.) Each time the register.
operator pushes the button (14), performance level
will increase by one step. At the maximum (rabbit) If the button is pushed twice and then held down,
level, the performance levels will begin at the lowest the indicator light for the hydraulic pump motor (9)
(turtle) level again. The four performance levels set will illuminate. The status codes in memory for the
by the manufacturer are: detected faults will be displayed, starting with the
• Low performance for handling fragile loads. most recent fault. If the push button is released, the
• Medium speed for less consumption of battery display will stop. If the button is pushed twice to
charge during a work shift. start the sequence again, the display will start from
• Higher performance with higher consumption of the beginning. The hourmeter time and the battery
battery charge during a work shift. charge at the time of the fault will not be shown. A
• Maximum lift truck performance with maximum Handset or a PC must be used to show this additional
consumption of battery charge. information. A Handset or a PC must be used to clear
the status code from the register.
The performance settings can be made with either
the PC or the Handset (Functions 11, 12, and 13). There can be 16 status codes in the memory for each
system (traction or lift). Push and hold the push but-
The four performance levels can be set to any level up ton to display all the status codes in the memory for
to the maximum limits. Two or more adjacent per- detected faults of the traction system. The Traction
formance levels can be set to the same limits. The Motor Indicator will be on to show that the status
performance levels must be set at the same or in as- codes are for the traction system. If the push button
cending order (from turtle to rabbit). The register is released, then pushed and held again, the digital
interlocks will not permit a higher performance level display will start over, showing all the status codes
setting toward the turtle than the adjacent registers for the traction system. Push the button twice and
toward the rabbit. hold the push button to display all the status codes
in the memory for detected faults of the lift system.
Fault Code Memory. The control cards for the trac-
The Lift Pump Motor Indicator will be on to show
tion motor controller and hydraulic pump motor each
that the status codes are for the lift system. If the
have memory registers in which the last 16 status
push button is released, then pushed twice and held
codes can be stored. Each status code is stored with
again, the digital display will start over, showing all
the hourmeter time and the battery charge at the
the status codes for the lift system.
time of the fault. The status code for the last fault
7
Brush Wear Indicators wears within approximately 1.5 mm (0.060 in.) of the
brush lead, the insulation between the sensor wire
WARNING and the brush material is destroyed. The connection
between the brush and the sensor wire causes the in-
Before replacing any components, fully lower
dicator to illuminate.
all parts of the mast and tilt it forward until the
tips of the forks touch the ground. This action The operation of the brush wear indicators can be
will prevent the mast from lowering suddenly checked during periodic maintenance. The battery
if the control lever is accidently moved. must be removed from the lift truck for access to the
motors.
ALWAYS disconnect the battery and remove
the key before replacing components.
SEM DISPLAY PANELS - FEATURES
Never have any metal on your fingers, arms, or
The following features are part of both the Standard
neck. These metal items can accidentally make
and Premium Display Panels:
an electrical connection and cause an injury.
• LED (Light Emitting Diode) symbol indicators
NOTE: None of the electrical components of this sec- • LCD (Liquid Crystal Display) screen
tion can be repaired. All bad components must be • Battery Discharge Indicator (BDI) (with lift inter-
replaced. rupt when enabled)
• Service Reminder (if enabled)
The brush wear indicators illuminate when the mo- • Status Codes
tor brushes must be replaced. The sensor wires for • Hourmeter of traction and lift pump times
the brush wear indicators are an insert in the brush
material when it is made. The sensor wires are in- These features are shown in the Standard Display
sulated from the brush material. When the brush Panel. See Figure 5.
1. HOURMETER SYMBOL 5. BRAKE FLUID TOO LOW SYMBOL

2. WRENCH SYMBOL 6. PARKING BRAKE SYMBOL
3. BATTERY SYMBOL 7. SEAT BELT SYMBOL
4. BATTERY DISCHARGE INDICATOR (BDI) 8. LCD SCREEN
Figure 5. Standard Display Panel - SEM
8
The symbol indicators are shown and described in indicators are for common features, these indicators
SEM Display Panel Indicators of this manual. The are also shown in the Premium Display Panel. See
symbol indicators are also shown at the descriptions Figure 6. Descriptions of these features follows.
for these indicators following Figure 5. Since the
1. HOURMETER SYMBOL 8. LCD SCREEN

2. WRENCH SYMBOL 9. STAR PUSH BUTTON
3. BATTERY SYMBOL 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR (BDI) 11. PUSH BUTTON #2
5. BRAKE FLUID TOO LOW SYMBOL 12. PUSH BUTTON #3
6. PARKING BRAKE SYMBOL 13. PUSH BUTTON #4
7. SEAT BELT SYMBOL 14. PUSH BUTTON #5
Figure 6. Premium Display Panel - SEM
Descriptions of Common Features Battery Discharge Indicator (BDI)
LED Symbol Indicators - SEM The Battery Discharge Indicator (BDI) uses a bar
graph as a fuel gauge for the battery state-of-charge.
The LED symbol indicators are bright red and indi- As the battery discharges, the bar gets shorter to
cate the function that is shown on the LCD screen. show less fuel. The green band near the bar shows
Some of them are also used as a visual warning for the normal operating range for the battery. The yel-
the operator of a potential problem that needs an ac- low band is the area that the battery can still be op-
tion from the operator. erated in without damage. This band is yellow to
indicate that the battery is nearing the point of dis-
LCD Screen
charge where it can be damaged with continued hard
The LCD screen shows operator messages for the dif- use. The red band indicates the discharge condition
ferent functions. The Standard Display Panel can where battery damage can occur. The battery indica-
show a maximum of 16 numbers (including spaces). tor symbol will come on at this time. Charge the bat-
tery very soon to prevent battery damage. Continued
9
operation will cause Lift-Interrupt (if enabled) to oc- Additional Features of Premium Display
cur to help prevent battery damage. At lift-interrupt, Panel
the last two segments of the bar graph are the only
ones shown and are alternately on and off. The lift The following additional features are part of the Pre-
pump motor will not operate and there will be a re- mium Display Panel:
duction of travel speed. • Operator passwords for restricted use and custom
lift truck operation (if enabled)
Service Reminder • Daily check list and service items shown on LCD
screen (if enabled)
The Service Reminder feature (if enabled) lets the
• Performance modes of operation
operator know when it is time for periodic mainte-
• Status code lists of possible malfunctions or symp-
nance. A status code of 99 will show on the LCD
toms that have occurred
screen and the wrench symbol will be on. If mainte-
• Adjustable battery discharge indicator for condi-
nance is not done within 20 more hours of operating
tion and capacity of battery
time, lift truck operation will be slower until mainte-
nance is done. Have the maintenance done by autho- The additional features of the Premium Display
rized maintenance personnel. The service personnel Panel are described below and shown in Figure 6.
must also set the memory for the next maintenance Also see SEM Display Panel Indicators of this man-
interval to allow normal operation again. ual.
Status Codes Descriptions of Additional Features
Status Codes give an indication to the operator that LCD Screen
a possible malfunction or incorrect truck use has oc-
curred. Status Codes are code numbers for a symp- NOTE: The words shown in all capital letters show
tom or malfunction. The wrench symbol will flash the words that are on the LCD Screen in the following
and the status code number will be shown on the LCD descriptions.
screen if a possible symptom or malfunction occurs
during operation. Have authorized service personnel The LCD Screen shows the information for the addi-
check and repair the lift truck if a status code num- tional features as follows:
ber appears. The symptoms for each status code are • Password request (if enabled)
shown in the Service Manual for your lift truck. • Operator check List (if enabled)
• Status code history
Hourmeter • Information for adjustment of battery discharge
Indicator
The hourmeter shows the operating time in hours on
the LCD screen as a five-digit number. The display The Premium Display Panel can show a maximum
is shown for 4 seconds after the lift truck has been of 20 letters or numbers (including spaces) in each
operating and the key is moved to the OFF position. of two lines. The additional 24 spaces can be used
Traction time is the time that the key has been in for short messages. The messages provide the opera-
the ON position with the operator in the seat. The tor with necessary information for these features and
operating time for the pump motor (with illuminated correct operation.
symbol) will also be displayed as a five-digit number
for 4 seconds following the traction time if there is a Operator Passwords
pump motor controller.
The Operator Passwords are a series of four num-
The Premium Display Panel will show the hours as bers. Each of the four-number digits can be the num-
described above. The words TRACTION HOURS will bers 1 through 5. If enabled, the password number
also be shown on the LCD screen following the trac- series must be entered into the memory by a tech-
tion motor hours. The words PUMP HOURS will also nician and assigned to an operator. Up to 255 pass-
be shown on the LCD screen when the pump motor words can be entered. The password numbers are not
hours are shown. displayed, for security, when entered. Remember the
password. A technician can use a personal computer
(PC), connected to the SEM Display Panel, to check
as well as to assign the passwords.
10
NOTE: The computer does not always respond imme- Status Code Lists
diately for every push button entry. The push but-
ton can also click without an actual change occur- The Status Code Lists are lists of all status codes
ring. Make sure to watch LCD screen and wait for for the malfunctions or symptoms that have occurred
response before requesting another action. since the list was last cleared of entries by a techni-
cian. These status codes are NOT of malfunctions or
The LCD screen will show ENTER PASSWORD af- symptoms that are currently present, but those that
ter the key is moved to the ON position when this have occurred in the past. There are separate lists
function is enabled. Use the numbered push buttons for the Traction Circuit and the Lift Pump Circuit.
to enter your four-digit password. A star symbol will The lists can only be read with the key in the OFF
be shown for each digit. The operator has two tries position.
to enter password correctly. If system does not find
the password after the first entry, REENTER PASS- To access the status code history, wait until after
WORD INPUT PASSWORD ERROR will appear. If the traction and pump hours have been displayed,
system still does not find the password after this sec- then push the STAR push button. The first item in
ond entry, CALL SUPERVISOR INPUT PASSWORD the Menu on the LCD screen is ACTIVATE FAULT
ERROR will appear. CODE DATA KEY 5 NXT 1/4. Now press push
button 5 for a display of: REQUESTING TRACT
Daily Checklist and Service Items 1 HISTORY. All of the status codes in the list for
the traction circuit will now be shown in turn. The
A list of items for Daily Checks and Service will be screen will then show REQUESTING PUMP HIS-
shown on the LCD screen (if enabled) after the pass- TORY, followed by the status codes in the list for the
word is accepted. The Check List has items the oper- lift pump circuit. After the last status code, END
ator needs to check as having been done. This Check FAULT CODE HISTORY will be shown.
List MUST be completed before the lift truck will op-
erate. Press push button 1 for YES and 4 for NO Adjustment of BDI
after each item in Check List. These YES answers
indicate that the operator says the check or mainte- This adjustment allows adjustment for more accu-
nance has been done. The screen will show SERVICE rate indication of Battery-State-of-Charge and Lift-
REQUIRED for a NO answer and the lift truck will Interrupt (if enabled). This adjustment can be nec-
only operate in MODE 1. This operating mode will essary initially and when using batteries in differ-
continue until a service person performs the required ent conditions in your lift truck. The adjustment can
service and clears the message. Additional Check only be made with the key in the OFF position. If
List items will not appear until after service is com- you think the bar graph is not correct for the battery
plete. in your lift truck, have a technician check the battery
with a hydrometer. The technician can then change
Performance Modes the setting as necessary.
Four different Performance Modes of operation can SEM DISPLAY PANEL INDICATORS
be selected. Each mode can change acceleration, top
speed, and lifting speeds. The factory settings in- The following indicators are on both the Standard
crease operating speeds from slowest 1 to fastest 4. Display Panel and the Premium Display Panel. See
After the message MODE #X is on the LCD screen, Figure 5 and Figure 6.
you can change modes. The mode number that was
last activated will appear. If you want to change the All Indicator Symbols
mode, press push button 1, 2, 3, or 4 to select a new
mode. The screen will show REQUESTING MODE The red indicator symbols are on for 1 second after
# Y (Y is the new mode number just entered). The the key is moved to the ON position. This on-time
message will then show MODE #Y unless this mode checks that the indicators are operating on the Stan-
is not permitted under your password. The lift truck dard Display Panel.
will now operate within the parameters set for that The red indicator symbols are on for 1 second after
mode number until you change the operating mode the Check List (if enabled) is complete. If there is
number again. A service person can change the op- no Check List, the indicator is on after password (if
erating parameters of each of the four different levels enabled) or after the key is moved to the ON position.
or modes of operation.
11
This on time checks that the indicators are operating LCD Screen (Standard Display Panel)
on the Premium Display Panel.
The SEM Display Panel, on the right side of the in-
Hourmeter Indicator Symbol strument panel (dash), has an LCD window as an
operator’s screen readout for the SEM motor con-
The hourmeter symbol is on when the traction or lift trollers. The screen is illuminated whenever the key
pump hours are shown on the LCD screen. is in the ON position and for the first 2 minutes after
the key is first moved to the OFF position. Informa-
Wrench Symbol tion with a maximum of 16 characters can be shown.
This information includes the following:
This red indicator is on when status code numbers • Traction operating time in hours
are shown or when maintenance is due (99). • Lift pump operating time in hours
• Status code numbers
Battery Symbol • Service reminder code 99 (if enabled)
This red indicator is on when the battery needs • State-of-charge of the battery
charging or when the wrong voltage battery is con- All of the screen segments are shown as solid blocks
nected to the battery connector of the lift truck. during the indicator check to show that each segment
is operating.
Battery Discharge Indicator (BDI)
The Battery Discharge Indicator Symbol is on and ADDITIONAL COMPONENTS OF PREMIUM
the bar graph is shown on the LCD screen. See Com- DISPLAY PANEL
mon Features for more information.
The Premium Display Panel has a different LCD
The bar graph is on the LCD screen after the indica- screen and additional push buttons as described
tor function check for the Standard Display Panel. below.
The bar graph and the message MODE #X are on the Alpha Numerical Screen
LCD screen after the LED Indicator check is com-
plete for the Premium Display Panel. This LCD screen shows the information for the com-
mon features and information for the additional fea-
Brake Fluid Too Low Symbol tures of the premium SEM Display Panel. Informa-
tion with a maximum of 20 characters per line in two
If this indicator symbol is illuminated during opera- lines can be shown. This additional information in-
tion, the fluid level in the brake fluid reservoir is low cludes the following (display letters shown in all cap-
and the reservoir must be filled. ital letters):
• ENTER PASSWORD (if enabled)
Parking Brake Symbol • Checklist items (if enabled)
• Status code list (history) with number and short
This indicator symbol is illuminated when the park- description
ing brake is applied and the seat switch is closed. • Battery compensation information
The indicator will go off when the parking brake is
released. The hourmeter times are also identified as TRAC-
TION HOURS or PUMP HOURS. MAINTENANCE
If the parking brake is not applied and the operator REQUIRED is also included with the maintenance
leaves the seat or turns the key to the OFF position, reminder code 99 if the function is enabled.
the symbol and a warning tone will be on for approx-
imately 10 seconds. All of the screen segments are shown as solid blocks
during the indicator check to show that each segment
Fasten Seat Belt Symbol is operating.
This indicator symbol will stay illuminated for ap-
proximately 4 seconds, after the indicator check, to
remind the operator to fasten the seat belt.
12
STAR Push Button An alarm is also operated by the control card if

the operator leaves the truck without applying the
This push button is used for MENU access. This parking brake. The card will activate the alarm
push button will ONLY make a change when the key after getting the signal from the parking brake
is in the OFF position. The star button is used to switch. The alarm is activated if the operator
open the Menu from the memory of the SEM Display leaves the seat of the lift truck when the key is
Panel. After the Menu is open, only one Menu item in the ON position and the parking brake is not
is shown on the LCD screen at one time. applied. The alarm is also activated if the key is
moved to the OFF position when the brake is not
Push Buttons #1 Through #5 - SEM applied.
• Direction control switches in the MONOTROL
These push buttons are used as described in Descrip-
pedal or steering column send battery voltage to
tions of Additional Features of this manual.
the control card to close the Forward or Reverse
OTHER CONTROL COMPONENTS contactors.
• Brake fluid switch sends voltage to the indicator
Following is a short description of the other control LED in the display panel when the fluid in the
components and their function: brake master cylinder is low.
• Key switch is in the housing of the display panel • Motor temperature switches send voltage to the in-
and connects battery voltage to all of the control dicator LED in the display panel when either the
circuits except the horn. lift pump or the traction motor is too hot.
• Start switch is actuated by the accelerator pedal • Rocker switches for lights control all the optional
and is part of the Static-Return-To-Off (SRO) cir- lights on the lift truck.
cuit. If the start switch is closed before the seat • The accelerator position sensor is the input to the
switch, the controller will not permit the lift truck control card for speed control.
to move. • The optional On-Demand steering components al-
• Brake light switch is actuated by the brake pedal low the steering pump to operate only when the
to energize the brake lights on the rear legs of the steering wheel is moved. With the other steering
overhead guard. system, the steering pump motor operates when
• Seat switch is inside the seat and is open if the the key is in the ON position and the operator is
operator is not on the seat. The seat switch sends a in the seat.
signal to the control card for operation of the SCR • The rear lights on the legs of the overhead guard
controller and the power steering. are similar to automobile rear lights. The brake
• If the lift truck has a seat brake, the seat brake lights come on when the brake pedal is depressed.
switch is mounted to the front of the front battery The reverse lights come on when the truck is set for
compartment plate. This switch is operated by the travel in reverse. If there are also driving lights
seat brake linkage and has the same function as installed, the tail lights come on with the driving
the seat switch. lights. There can also be an operator compartment
• Parking brake switch operates if the parking brake light. A flashing light at the top or rear of the over-
is applied. The parking brake switch is fastened head guard and the reverse alarm.
near the linkage for applying the parking brake. • The horn switch at the center of the steering wheel
The switch sends a signal to the control card of operates the horn under the floor plates.
the display panel to illuminate the parking brake
indicator.
13
Display Panel Components Replacement 2200 SRM 560
Display Panel Components Replacement

ZX PANEL REPLACEMENT
Each of the two display panel assemblies, Basic and
Performance, can be replaced as a unit.
NOTE: Most parts of the Basic Display Panel can

be replaced. However, the LED indicators cannot be
replaced separately. The LEDs are part of the circuit
board assembly. The major replaceable parts of this
display panel are:
• Key switch
• Top cover housing and O-ring seal
• Light filter and LED warning lights housing
• Hourmeter and gasket
• Battery indicator
• Buzzer and circuit board
• Jumper harness and wires to key switch
NOTE: The only replaceable parts of the Perfor-

mance Display Panel are the O-ring seal, key switch,
wires to the key switch, and the housing that fastens
to the steering column. All other parts of the panel
must be replaced as a single unit. See Display Panel
Assembly of this section.
DISPLAY PANEL ASSEMBLY

Follow this procedure to replace the Basic or Perfor- NOTE: ON = UP AS SHOWN.
mance display panel as an assembly: • 36V SW #1 ON, others OFF
• 48V SW #2 ON, others OFF
1. Disconnect the battery and remove the key. • 72V SW #3 ON, others OFF
2. Remove the front steering column cover with • 80V SW #4 ON, others OFF
the display panel assembly attached. Carefully NOTE: SET DIP SWITCHES TO TRUCK VOLTAGE.
disconnect the 18-pin connector, the key switch IF TRUCK VOLTAGE IS NOT KNOWN, SET 36/48V
wires, and, on the Basic panel, the two-pin con- (U.S.) TRUCKS TO 48V; SET 72/80V (EUR) TRUCKS
nector from inside the column cover. TO 80V.
3. Remove the four screws that fasten the display 1. DISPLAY PANEL
panel to the column cover. 2. STEERING COLUMN
3. ELECTRICAL CONNECTOR
4. Install the replacement display panel assembly 4. DIP SWITCHES
to the cover of the steering column and tighten 5. BRN
the screws. Install the connectors and the key 6. RED/BRN
switch wires. On the Basic panel, set the DIP Figure 7. Dip Switches
switches near the connector for the panel to the
voltage of the lift truck. See Figure 7. Move the
DIP switch for the correct voltage to the up posi-
tion and all others to the down position. Install
the column cover on the steering column.
14
2200 SRM 560 Display Panel Components Replacement
KEY SWITCH, REPLACE See the section Battery Indicators 2260 SRM 138
to adjust these battery indicators.
NOTE: The key switch is replaced as one of the com-
ponents of the display panel. See procedure under DIGITAL DISPLAY (PERFORMANCE
Basic Display Panel, Replace Parts to replace the key DISPLAY PANEL ONLY)
switch of either display panel assembly. See Figure 8.
NOTE: The digital display of the Performance Dis-
play Panel cannot be replaced as a separate compo-
nent. The display must be replaced as part of the
Performance Display Panel. See Display Panel As-
sembly of this section.
STATUS CODE OR PERFORMANCE

LEVEL SWITCHES AND INDICATOR LEDS
(PERFORMANCE DISPLAY PANEL ONLY)
NOTE: These switches of the Performance Display
Panel cannot be replaced as separate components.
The switches must be replaced as part of the Perfor-
mance Display Panel. See Display Panel Assembly
1. DISPLAY PANEL 3. NUT
(REFERENCE) 4. RED/BRN of this section.
2. KEY SWITCH 5. BRN
BASIC DISPLAY PANEL, REPLACE PARTS
Figure 8. Key Switch
NOTE: The parts of the Basic Display Panel can be re-
INDICATOR LEDS placed with the display panel on the steering column.
If the assembly housing will be replaced, remove the
NOTE: The indicator LEDs of the Basic Display complete assembly from the steering column as de-
Panel are part of the circuit board and must be scribed in Display Panel Assembly.
replaced as an assembly. See Basic Display Panel,
Replace Parts of this section. The LED indicators of NOTE: The following is a complete disassembly pro-
the Performance Display Panel cannot be replaced. cedure. Do ONLY those steps necessary to replace
If these LED indicators are bad, replace the display the part you want replaced.
panel. See Display Panel Assembly of this section.
Remove and replace the components of the Basic dis-
BATTERY INDICATORS play panel as follows:
There are two types of battery indicators for these 1. Disconnect the battery and remove the key.
trucks. One type is a meter movement with colored 2. Remove the eight screws that fasten the top cover
bands showing the battery charge (Basic Display to the panel housing. The screws are at the bot-
Panel). The other type is a Light Emitting Diode tom of the housing. See Figure 9. The hourme-
(LED) display with LEDs of different colors showing ter is fastened to the top cover with the electrical
battery charge (Performance Display Panel). connector on the circuit board inside the housing.
NOTE: The battery indicator is replaced as one of the Carefully lift the top cover up off the housing and
components of the display panel. See procedure un- the indicator LEDs without damaging the O-ring
der Basic Display Panel, Replace Parts of this sec- gasket. The gasket for the LED indicators can
tion. The battery indicator of the Performance Dis- stick to the LED housing as the top cover is re-
play Panel cannot be replaced as a separate compo- moved. Do not lose or damage the gasket. Dis-
nent. The indicator must be replaced as part of the connect the three wire connector for the hourme-
Performance Display Panel. See Display Panel As- ter.
sembly of this section.
15
Display Panel Components Replacement 2200 SRM 560
Figure 9. Basic Display Panel
16
2200 SRM 560 Display Panel Components Replacement
Legend for Figure 9

1. TOP COVER 9. CIRCUIT BOARD (LH) FOR BATTERY
2. FILTER FOR LED INDICATORS INDICATOR
3. HOUSING FOR LED INDICATORS 10. BATTERY INDICATOR
4. KEY SWITCH 11. JUMPER HARNESS
5. ASSEMBLY HOUSING 12. HOURMETER
6. O-RING GASKET 13. GASKET FOR HOURMETER
7. BUZZER 14. CIRCUIT BOARD FOR LED INDICATORS
8. FIBER INSULATING WASHERS 15. GASKET FOR LED INDICATORS
3. If the housing or filter for the indicators will be replacement circuit board. Make sure the pins
replaced, remove the screws that fasten the LED are correctly aligned on the back of the meter
housing to the cover. If the hourmeter or hourme- before pushing the meter on the pins. Connect
ter gasket will be replaced, remove the screws the electrical connector to the circuit board and
that fasten it to the top cover. Install the replace- install the circuit board assembly in the housing.
ment parts to the top cover. Make sure that the
hourmeter is installed so that it can be read after 8. If the LED indicator assembly will be replaced,
the cover is installed. first remove the 18-pin connector. It is necessary
to remove the front steering column cover with
4. Remove the nut that fastens the key switch. See the display panel assembly attached for access
Figure 8. Remove the key switch from the hous- to the connector. After removing the screws that
ing. Make a note of which wires are on which fasten the front cover, carefully disconnect the
terminals and disconnect the wires. Install the connector. It can be necessary to disconnect the
wires on the same terminals of the replacement key switch wires (Step 4) and the two-wire con-
switch. nector for enough clearance to disconnect the 18
pin connector. Remove the two screws that fas-
5. Align the notch in the shaft housing of the key ten the LED assembly to the housing. Install the
switch with the tab in the housing of the display replacement LED assembly, carefully connecting
panel. Install the replacement switch. Tighten all connectors and wires. Install the front steer-
the nut and connect the wires. ing column cover with the display panel assem-
bly attached. Install the LED gasket over the
NOTE: It is not necessary to do Step 7 if only the
LED indicators.
meter movement of the battery indicator will be re-
placed on the existing circuit board. 9. If necessary, install a new O-ring gasket. Care-
fully install the O-ring gasket in the groove of
6. Carefully lift the meter movement up off the pins
the top cover. Carefully install the top cover as-
of the circuit board without bending the pins. See
sembly over the LED indicators and assembly
Figure 9. Carefully install the replacement me-
housing without damaging either the LED gas-
ter movement on the pins. Make sure the pins
ket or O-ring gasket. Make sure the O-ring gas-
are correctly aligned on the back of the meter be-
ket is still correctly aligned with the cover and
fore pushing the meter on the pins.
housing before installing the screws. Install the
7. If the battery indicator, circuit board for the eight screws that fasten the top cover to the panel
hourmeter, or the buzzer will be replaced, re- housing and tighten them in a cross pattern.
move the screws that fasten the circuit board
to the housing. Disconnect the connector from PERFORMANCE DISPLAY PANEL,
the circuit board. Remove the buzzer from the REPLACE PARTS
bottom of the circuit board. Make sure to install
the fiber washer when installing the replace- NOTE: The only replaceable parts of the display
ment buzzer on the replacement circuit board. If panel are the O-ring seal, key switch, wires to the
necessary, carefully lift the meter movement up key switch, and the housing that fastens to the
off the pins of the circuit board without bending steering column. All other parts of the panel must
the pins. See Figure 9. Carefully install the be replaced as a single unit. See Display Panel
replacement meter movement on the pins of the Assembly of this section.
17
SEM Display Panel Replacement 2200 SRM 560
SEM Display Panel Replacement

The SEM Display Panel is in the instrument panel
WARNING (dash). The SEM Display Panel cannot be repaired
Before replacing the SEM Display Panels, fully and must be replaced if it has a malfunction. These
lower all parts of the mast and tilt it forward SEM Display Panels must be replaced as a unit. See
until the tips of the forks touch the ground. Figure 10.
This action will prevent the mast from lower-
ing suddenly if the control lever is accidently 1. Disconnect the battery connector. Make sure
moved. the capacitors of the motor controller(s) are dis-
charged as described in the WARNING.
Always disconnect the battery, remove the key,
and discharge the capacitor(s) of the motor 2. Disconnect the plug connector on the back of the
controllers before replacing the SEM Display SEM Display Panel. Access is under the instru-
Panels. Discharge the capacitor(s) by holding ment panel.
the horn button down until the horn stops
making a sound. 3. Remove the two nuts that fasten the SEM Dis-
play Panel and mount bracket. Remove the nuts
Never have any metal on your fingers, arms, or and bracket. Lift the SEM Display Panel up out
neck. These metal items can accidentally make of the instrument panel.
4. Install the replacement SEM Display Panel in
the instrument panel.
CAUTION
A short circuit and damage can occur if wires 5. Install the mount bracket and mount nuts.
are not installed correctly. Make sure wire Tighten the nuts that fasten the SEM Display
connectors do not touch the other meter termi- Panel in the instrument panel and install the
nals or wire connectors, metal brackets, or the plug connector.
bracket mounting nuts. Make sure the wires
are not pulled tight and are not touching other
parts to damage the insulation.
18
2200 SRM 560 SEM Display Panel Replacement
Figure 10. Mounting of SEM Display Panel - SEM
19
Motor Controller (SR or SP) Replacement 2200 SRM 560
Legend for Figure 10
18-Pin Connector
1 No Connection 9 Battery Negative ( )
2 Battery Shunt 10-12 No Connection
3 No Connection 13 Parking Brake Switch
4 Traction Control TRX 14 Brake Fluid Switch
5 Traction Control RCV 15 Seat Switch Output
6 Pump Control TRX 16 Seat Switch B+ Input
7 Pump Control RCV 17 Key Switch (IGN)
8 No Connection 18 Battery Positive (+)
1. SEM DISPLAY PANEL 5. CONNECTOR FOR PERSONAL COMPUTER

2. INSTRUMENT PANEL CONNECTION
3. MOUNT BRACKET 6. 18-PIN CONNECTOR
4. MOUNT NUT
Motor Controller (SR or SP) Replacement

REMOVE 3. Clean any old silicone compound off of the mount-
ing surface of the truck.
Make sure the battery is disconnected and the capac-
itor is discharged using the horn as previously de- INSTALL
scribed. Replace the motor controller as described in
the following procedure. See Figure 31 or Figure 32. 1. Put a thin, even coat of the silicone compound
(Hyster Part No. 1198757) or equivalent on the
1. Make an identification for correct connection of plate of the motor controller. Make sure there
the power cables on the power terminals of the are no air spaces between the plate and mount
motor controller. Disconnect the power cables surface of the lift truck frame. The plate of the
and the connector plug for the control wires. motor controller must make full contact with the
lift truck frame. Install the mount screws that
CAUTION fasten the motor controller to the lift truck frame.
Do not remove the small screws that fasten the 2. Install the power cables at the power termi-
cover of the motor controller. nals of the motor controller as identified during
removal. Install the connector plug for the
Make sure there is no dirt between the plate of
control wires on the connector of the motor con-
the motor controller and the mount surface of
troller. MAKE SURE THE PLUG COVER IS
the lift truck frame.
INSTALLED ON THE SMALL CONNECTOR
2. Remove the eight (traction) or six (pump) mount- OF THE MOTOR CONTROLLER.
ing screws that fasten the plate of the motor con-
troller to the lift truck frame. Carefully remove
the motor controller.
20
2200 SRM 560 Control Components Replacement
NOTE: The information for the new controller can- 3. Plug in the battery and hook up a computer lap-
not be inputed using the handset. A laptop computer top to the truck. The controller must have the pa-
must be used to enter the truck information, either rameters adjusted to the factory specifications.
hooked up to the controller directly or through the
dash. 4. Enter the unit’s serial number and current hour
meter reading into the appropriate boxes on the
computer.
Control Components Replacement

START SWITCH, REPLACE Legend for Figure 11
The start switch is a small switch fastened to the 1. MONOTROL PEDAL OR ACCELERATOR PEDAL
mount plate for the MONOTROL pedal or accelera- 2. TO ACCELERATOR POSITION SENSOR
3. START SWITCH
tor pedal. This switch is in the normally open posi- 4. TO DIRECTION CONTROL LEVER IF INSTALLED
tion when the pedal is in the UP position. The switch 5. ACTUATOR OF START SWITCH
operates as soon as the pedal starts to move, for an 6. RED/PINK
input to the control card to energize the traction mo- 7. BLU-LT
tor. Replace the start switch as follows: 8. WHT
9. GRN
1. Disconnect the battery and remove the key. 10. WHT OR WHT/BLK
11. RED/YEL, RED/PINK
2. Remove the floor plates. The start switch is un-
3. Install tags on the wires of the start switch for
der the accelerator or MONOTROL pedal. See
correct connection during installation. Remove
Figure 11.
the wires and the mount screws for the start
switch.
4. Install the replacement start switch in the same

position. Do not bend or damage the leaf of the
switch during installation. Connect the wires as
removed during removal.
5. Adjust the start switch as described in Start

Switch Adjustment. Install the floor plates.
BRAKE LIGHT SWITCH, REPLACE

The brake light switch is a small switch fastened to
the mount plate for the brake pedal assembly. This
switch is normally open. The brake light switch is op-
erated by the brake pedal to energize the brake lights
on the rear legs of the overhead guard. These lights
are standard on U.S. units and optional on European
units. Replace the brake light switch as follows:
1. Disconnect the battery and remove the key.
2. Remove the floor plates. The brake light switch

is between the pedal arm and the mount for the
brake pedal. See Figure 12.
Figure 11. Start Switch 3. Install tags on the wires of the brake light switch
for correct connection during installation. Re-
move the wires and the mount screws for the
switch.
21
Control Components Replacement 2200 SRM 560
4. Install the replacement switch in the same posi- 1. Disconnect the battery and remove the key.
tion. Do not bend or damage the actuator arm
and roller of the switch during installation. Con- 2. Open the hood. Disconnect the connector for the
nect the wires as removed during removal. seat switch wires near the rear of the hood frame.
Push the connector through the grommet in the
5. Adjust the brake light switch as described in hood. It can be necessary to remove the grommet
Brake Light Switch Adjustment. Install the from the hole in the hood for enough clearance to
floor plates. get the connector through the grommet.
3. Remove the screws that fasten the seat to the

hood and hood frame. Close and latch the hood,
and put the seat on its side for access to the seat
switch.
4. Use a flat blade screwdriver or other tool with

a flat blade to carefully lift the switch free of the
seat pan. Slide the switch out of the seat cushion.
5. Carefully slide the replacement switch into the

cavity of the seat cushion until the end of the
switch with the wires is aligned over the hole in
the pan. Push on the switch until the clips of the
switch are fastened to the seat.
6. Carefully install the grommet over the wire con-

nector. Install the seat on the hood and tighten
the nuts. Install the grommet in the hole of the
hood, connect the wire connector, and push the
connector back inside the hood frame.
NOTE: E45-65XM/XM 2 AND N30XMH/XMH MOD-

ELS SHOWN. J40-65XM/XM 2, E25-35XM/XM 2, AND
E40XMS/XMS 2 MODELS SIMILAR.
1. BRAKE PEDAL
2. BRAKE LIGHT SWITCH
3. SWITCH ACTUATOR
4. YEL/RED
5. BRN/PUR
Figure 12. Brake Light Switch
SEAT SWITCH, REPLACE

NOTE: If the lift truck has a seat brake, there is no
seat switch. There is a switch on the seat brake link-
age that must be adjusted by moving it in slots of the
mount bracket. To replace this switch, see Switch for
Optional Seat Brake, Replace.
NOTE: SEAT CAN BE DIFFERENT THAN SHOWN.
The seat switch has no adjustments. See Figure 13.
The seat switch is inside the cushion of the opera- 1. SEAT PAN 3. WIRE
2. SEAT SWITCH CONNECTOR
tor seat and must be replaced if it is damaged. The
switch is normally open. Replace the seat switch as Figure 13. Seat Switch Replacement
follows:
22
EXTERNAL SEAT SWITCH, ADJUST 3. Adjust the jam nuts to move the switch. Adjust
the switch so that there is 1.52 mm (0.06 in.)
1. The standard seat switch has no adjustments. It clearance between the switch barrel and the
can be checked with an ohmmeter. The correct plate as shown in Figure 14.
resistance is less than 50 ohms when the seat
switch is closed. SWITCH FOR OPTIONAL SEAT BRAKE,
2. Lift trucks equipped with an optional seat brake REPLACE
have a seat switch installed as shown in Fig- NOTE: The seat brake is a factory option on the E25-
ure 14. This seat switch has a higher current rat- 65XM/XM 2 and N30XMH/XMH 2 models only.
ing than the standard seat switch.
This switch has the same function as the seat switch
and is located near the bottom of the linkage that
operates the seat brake. See Figure 15 or Figure 16.
Replace this switch as follows:
2. Remove the cover over the linkage under the

seat. Remove the mount screws for the switch.
3. Make a note of which wires are connected to

which terminals for correct connection during
installation. Remove the wires and install them
on the replacement switch.
1. LINKAGE LEVER
2. FRONT PLATE OF BATTERY COMPARTMENT
1. SEAT 4. JAM NUTS 3. SWITCH
2. PLATE 5. SWITCH 4. SWITCH ACTUATOR
3. SWITCH BARREL
Figure 15. Seat Brake Assembly (E45-65XM/XM 2
Figure 14. External Seat Switch Adjustment and N30XMH/XMH 2 Only)
for Lift Trucks With Seat Brake
23
2. Install blocks on each side of a steer wheel to

prevent movement of the lift truck. Release the
parking brake.
3. Remove the floor plate under the parking brake

pedal. Remove the screws and nuts that fasten
the switch to the bracket. Do not lose the screws,
nuts, or washers.
1. LINKAGE LEVER
2. FRONT PLATE OF BATTERY COMPARTMENT
3. SWITCH
4. SWITCH ACTUATOR
Figure 16. Seat Brake Assembly (E25-

35XM/XM 2, E40XMS/XMS 2 Only)
4. Install the switch using the same screws and

nuts.
5. Adjust the switch as described in Optional Seat

Brake Switch Adjustment. Install the cover over
the linkage.
PARKING BRAKE SWITCH, REPLACE

The parking brake switch is fastened near the link-
age for applying the parking brake. This switch oper-
ates the indicator in the display panel and the alarm
through the control card for the display panel. See NOTE: E45-65XM/XM 2 AND N30XMH/XMH 2 MOD-
Figure 17 or Figure 18. ELS SHOWN. J40-65XM/XM 2 SWITCH MOUNTING
IS SIMILAR.
The park brake alarm will operate for 10 seconds
when the operator gets off the seat, or the key is 1. RELEASE KNOB 5. SWITCH
moved to the OFF position if the park brake is not 2. PEDAL 6. ADJUSTMENT
applied. The alarm is operated by the display panel 3. ACTUATOR OF KNOB
SWITCH 7. ACTUATOR
from the switch signal and is located within the dis- 4. LINKAGE MECHANISM
play panel housing. The alarm will not operate if the
parking brake switch is damaged or not adjusted cor- Figure 17. Parking Brake Assembly
rectly. An alarm that does not operate cannot be re-
paired and must be replaced as part of the display
panel. See Display Panel Assembly. Replace the
parking brake switch as follows:
24
DIRECTION SWITCHES (MONOTROL

PEDAL), REPLACE
There is a small direction switch under each pad
of the MONOTROL pedal. See Figure 22. Each
switch controls one direction. If both sides of the
MONOTROL pedal are pushed at the same time, the
direction circuit is de-energized and the lift truck
will not move. The contacts of the two direction
switches are in a series and parallel arrangement so
that both direction contactors cannot be energized
at the same time.
NOTE: The direction switches used in the

MONOTROL pedal are made for Hyster Company
with a special contact clearance and materials.
Other switches look the same and will fit in the
same space in the MONOTROL pedal. These other
switches will not operate the same and will often not
provide good service. The switches must be replaced
as an assembly that includes two switches and the
wire cable with connectors. Use only replacement
switches in the assembly with the Hyster part
number. Replace the direction switch assembly as
follows:

1. RELEASE KNOB
2. PEDAL WELDMENT 2. Remove the floor plates. Make a note of the
3. SWITCH ACTUATOR location of the wire for correct connection dur-
4. LINKAGE ing installation. Disconnect the wires for the
5. SWITCH
MONOTROL pedal. Disconnect and remove the
Figure 18. Parking Brake Assembly return spring for the pedal.
(E25-35XM/XM 2 and E40XMS/XMS 2 Only)
3. Remove the nut and washer from the pivot cap-
4. Turn the switch so that you can see the termi- screw of the pedal. Carefully move the pedal as-
nals. Make a note of the wires fastened to the sembly to the right to disengage the arm of the
switch terminals for correct connection during in- accelerator position sensor. This movement must
stallation. Remove the wires from the switch ter- also make clearance between the pedal assembly
minals. Connect the wires to the replacement and the leaf of the start switch. Remove the pedal
switch as disconnected during removal. assembly.
5. Install the replacement switch using the same 4. Turn the pedal assembly upside down and re-
screws, nuts, or washers. Do not damage the move the pedal pad.
leaf of the switch during installation. Tighten the
5. Remove the nuts that fasten the switches. Re-
screws and nuts.
move the screws and special washers that fasten
6. Check for correct operation and, if necessary, the wires to the pedal. Cut the cable ties that fas-
adjust the switch as described in Parking Brake ten the cable wires to the pedal casting. Remove
Switch Adjustment. Install the floor plates. the switch assembly from the pedal.
Apply the parking brake and remove the wheel
6. Install the replacement switch assembly on the
blocks.
pedal. Make sure that the Forward switch with
wire 8 (light blue) is on the right of the back side
of the pedal. The Reverse switch with wire 6
(white) is on the left of the back side of the pedal.
25
7. Temporarily install the nuts that fasten the Both switches must function correctly because both
switches, but do not tighten the nuts. switches are used to close the circuit. A bad switch
must be replaced. Replace the switches as follows:
8. Align the wires as shown in Figure 22. Put Loc-
tite® 222 on the screws for the special washers Replace the direction switch assembly as follows:
that fasten the wires. Install the screws and
washers, and tighten the screws to 0.8 to 1 N•m 1. Disconnect the battery and remove the key.
(7 to 9 lbf in).
2. Move the steering column to the FORWARD po-
9. Install cable ties as removed during removal. sition and remove the rear cover of the steering
Make sure the tie lock of the cable tie is com- column for access to the switches.
pletely inside the U channel of the casting.
3. Make a note of the location of the wires for cor-
10. Before installing the pedal pad, adjust the direc- rect connection during installation and discon-
tion switches as described in Direction Switches nect the three wires from the switch. Replace the
Check. Install the pedal pad on the pedal after switch and connect the wires to the replacement
adjustments are complete. switch.
11. If removed, install the pivot capscrew and 4. There is no adjustment for these switches. In-
washer in the pedal casting. Carefully install stall the cover for the steering column.
the pedal assembly on the truck while aligning
the pin in the slot of the arm of the accelerator
position sensor.
12. Make sure the pedal is down low enough so that

the leaf of the start switch is not damaged. In-
stall the lockwasher and nut on the pivot cap-
screw.
13. Install the return spring and connect the wires

as disconnected. Install the floor plates.
DIRECTION CONTROL SWITCHES

(STEERING COLUMN), REPLACE
NOTE: The direction switches used in the direction
control are made for Hyster Company with a spe-
cial contact clearance and materials. Other switches
look the same and will fit in the same space in the
MONOTROL pedal. These other switches will not
operate the same and will often not provide good ser-
vice. The switches must be replaced as an assembly
that includes two switches and the wire cable with
connectors. Use only replacement switches in the as-
sembly with the Hyster part number. 1. FORWARD AND 4. FORWARD
REVERSE LEVER SWITCH
The direction control switches send a signal to the 2. INDICATOR 5. MOUNT BRACKET
traction control card to close the Forward or Reverse 3. REVERSE SWITCH 6. SHUTTLE
contactors. This direction control has a pair of small
switches in the steering column. See Figure 19. Each Figure 19. Direction Control (Forward and
position of the two switches controls one direction. Reverse) Switches
26
DIRECTION CONTROL SWITCHES, is part of the reservoir. To replace the reservoir, see
E70-120XL 3 (STEERING COLUMN) the Brake System for your unit.
The direction control switches send battery voltage to BRUSH WEAR AND OVERTEMPERATURE
close the Forward or Reverse contactors. This control SENSORS
has a pair of microswitches in the steering column.
See Figure 20. Each microswitch controls one direc- The Brush Wear Indicators illuminate when the mo-
tion. Remove the cover of the steering column so that tor brushes must be replaced. The sensor wires for
you can disconnect the three wires from the switch. the brush wear indicators are an insert in the brush
Replace the switch and reconnect the wires. Adjust material when it is made. The sensor wires are in-
the switch in its mount bracket so that the switch sulated from the brush material. When the brush
opens and closes correctly when that direction is se- wears within approximately 1.5 mm (0.06 in.) of the
lected. Install the cover for the steering column. brush lead, the insulation between the sensor wire
and the brush material is destroyed. The connection
between the brush and the sensor wire causes the
warning indicator to illuminate if the circuit is oper-
ating correctly. Motor indicators on the display panel
will also illuminate to show which motor has worn
brushes.
The Overtemperature Sensors are thermal switches.

These switches are in the traction and lift pump mo-
tors. They send a signal to the control card of the
Performance Display Panel to illuminate the correct
indicators to tell the operator that the motor is too
hot. The Overtemperature warning indicator will il-
luminate if the circuit is operating correctly. Motor
indicators on the display panel will also illuminate
to show which motor is too hot. The control card of
the Performance Display Panel sends a signal to the
traction control card for a slower travel speed if ei-
ther motor is too hot.
ROCKER SWITCHES FOR LIGHTS

These switches are ON/OFF switches that control
the optional front, rear, and operator compartment
1. DIRECTION CONTROL LEVER lights. See Figure 21. Rocker switches for the op-
2. SWITCH BRACKET tional lights are mounted to the instrument panel to
3. REVERSE SWITCH the right of the steering column. Remove the cover
4. SPRING under the instrument panel for access to the under
5. FORWARD SWITCH side of the instrument panel or switch mounting sur-
6. MOUNT BRACKET
face. Replace a switch as described in the following
Figure 20. Direction Control Lever and paragraphs:
Switches (E70-120XL 3)
BRAKE FLUID SWITCH, REPLACE 2. Put tags on the switch wires or wire harness
for correct identification during installation. Re-
This switch is a magnetic switch on the reservoir of
move the wires from the switch terminals.
the master cylinder for the service brakes. It sends
a signal to the control card of the display panel to il-
luminate the indicator for low fluid level. The switch
27
6. Install the cover under the instrument panel.
ACCELERATOR POSITION SENSOR,

REPLACE
The accelerator position sensor is a voltage divider
that sends a signal to the control card. The acceler-
ator position sensor has a link to the MONOTROL
pedal or accelerator pedal. As the MONOTROL
pedal or accelerator pedal position changes, the
signal changes to change the speed. The accelerator
position sensor and start switch must be adjusted as
shown in Figure 22.
NOTE: If you must replace an accelerator position

sensor, make sure that you use the correct part num-
ber. Many potentiometers look the same and will fit
in the same position, but they will NOT work.
2. Remove the floor plates. The accelerator position

sensor is under the accelerator or MONOTROL
pedal. See Figure 22. Disconnect the electrical
connector for the sensor.
1. SWITCH ASSEMBLY 3. Remove the capscrews, washers, and nuts that
2. LENS AND FUNCTION SYMBOL (NOT ON ALL fasten the mount plate for the sensor. Carefully
SWITCHES)
3. INSTRUMENT PANEL move the sensor assembly down while pushing
4. RETAINER CLIP down on the MONOTROL pedal so that the pin
5. SWITCH LIGHT AND OTHER TERMINALS of the pedal assembly will come out of the arm of
6. POWER TERMINALS the sensor. Remove the sensor assembly.
Figure 21. Rocker Switch 4. Cut the cable tie that fastens the wires for the
sensor. Remove the two screws, washers, and
3. Use a flat blade screw driver or other similar tool
nuts that fasten the sensor to the mount plate.
and press in on the retainer clips at each side of
the switch. Remove the switch from the face of 5. Install the replacement sensor on the mount
the instrument panel or switch mounting surface plate using the same screws, washers, and nuts.
while holding the retainer clips in the released Rotate the sensor as far as possible clockwise on
position. the slots. Tighten the nuts to hold the sensor so
that it can still be moved on the plate but will
4. Remove the switch and install the replacement
stay in position. Install a cable tie to fasten the
switch in the panel. Make sure the switch is in
wires.
the correct position for reading by the operator.
6. Install the mount plate in the truck using the
CAUTION reverse of the removal procedure. Make sure the
pin of the MONOTROL assembly is in the sensor
Make sure wire connectors do not touch other
arm.
switch or meter terminal wire connectors,
metal brackets, or the bracket mounting nuts. 7. Install the capscrews, washers, and nuts that
Make sure there is no tension or binding on fasten the mount plate so that it can still be
the wires or connectors. moved but will stay in position.
5. Connect the wires or wire harness to the electri-
cal terminals on the switch as removed during
removal.
28
Figure 22. MONOTROL or Accelerator Pedal Adjustment and Repair
29
NOTE: ADJUST THE FWD/REV SWITCHES BEFORE INSTALLING THE PEDAL PAD. ADJUST THE PEDAL FULLY
DEPRESSED (DOWN) POSITION FIRST. THEN ADJUST THE START SWITCH AND THEN THE ACCELERATOR
OR MONOTROL PEDAL POSITION SENSOR. SEE THE TEXT FOR THE ADJUSTMENT PROCEDURES.
1. ACCELERATOR OR MONOTROL PEDAL 9. CLAMP SCREW
2. FLOOR PLATE 10. CABLE TIES
3. PEDAL MOUNT PLATE 11. PIN
4. ELECTRICAL CONNECTIONS 12. PIVOT CAPSCREW
5. SENSOR MOUNT PLATE 13. SENSOR ARM
6. SPRING 14. ACCELERATOR POSITION SENSOR
7. MOUNT NUT 15. PEDAL UP STOP
8. FORWARD/REVERSE SWITCH AND CABLE 16. PEDAL DOWN STOP
ASSEMBLY 17. START SWITCH
8. Adjust the MONOTROL pedal or accelerator covers. Fasten the front cover to prevent damage
pedal movement and the position sensor as de- to the wires of the display panel on the cover.
scribed in MONOTROL or Accelerator Pedal See Figure 23.
Adjustment. Install the floor plates.
3. Remove the eight screws that fasten the cover
ON-DEMAND STEERING COMPONENTS over the cowl. Move the cover for access to the ac-
tivator. Fasten the cowl cover to prevent damage
For the optional On-Demand steering, there is an en- to the wires of the rocker switches if installed.
coder to sense steering wheel movement, an activator
assembly to energize the contactor for the steering 4. Make a note of the location of the wires fastened
pump motor, and a pressure switch on the steering to the activator for correct connection during in-
pump to tell the system that the steering pump is op- stallation. Remove the wires.
erating. The encoder is in the steering column. The
5. Remove the two screws that fasten the activa-
activator assembly is under the instrument panel to
tor and remove the activator. Install the replace-
the left of the steering column.
ment activator in the same alignment as the old
A gear on the shaft of the steering wheel drives the activator.
gear of the optical encoder as the steering wheel is
6. Carefully remove the spring that fastens the op-
moved to steer the lift truck. The optical encoder
tical encoder assembly to the cover over the steer-
sends a signal to the activator. The activator com-
ing shaft. Remove the encoder assembly. Re-
pletes the battery negative circuit for the steering
move the encoder from the encoder housing and
contactor to energize the steering pump motor. See
remove the gear from the shaft of the encoder.
the section Diagrams for your lift truck for the
electrical connections for On-Demand steering. For 7. If damaged, replace the gear at this time. Install
additional information on the On-Demand steering, the gear on the replacement encoder in the same
see the section Steering System for Electric Lift location on the shaft. Put a coating of multipur-
Trucks 1600 SRM 485. pose grease on the new gear or a gear without
grease. Install the encoder in the housing. In-
NOTE: The following procedure has the steps to re-
stall the housing in the hole of the shaft cover so
place the optical encoder and the actuator assembly.
that the encoder cannot move. Install the spring
It is not usually necessary to replace both compo-
to hold the encoder assembly in correct align-
nents at the same time. Do only the steps of the pro-
ment.
cedure necessary to replace each part separately. Re-
place the parts of the On-Demand steering as follows: 8. Connect the wires to the activator as removed
during removal. Install the cover over the cowl.
Install the covers on the steering column. There
2. Move the steering column to the fully FOR- are no adjustments.
WARD position and remove the steering column
30
Figure 23. Horn Switch and On-Demand Steering Components
31

1. HORN SWITCH AND COVER 10. ACTIVATOR
2. ENCODER HOUSING 11. COWL COVER
3. SPRING 12. WHT/BLK
4. SHAFT COVER 13. WHT (ENC.)
5. DIRECTION CONTROL LEVER (NOT ON ALL 14. RED (MARKED) (+5V)
UNITS) 15. BLK (BATT. )
6. OPTICAL ENCODER 16. WHT (START SW.)
7. GEAR 17. YEL (SOLENOID)
8. DISPLAY PANEL HOUSING 18. RED (BATT. +)
9. STEERING COLUMN
LIGHTS, CONVERTER, RELAY, AND 4. If the complete light assembly is being replaced,
REVERSE ALARM remove the light assembly from the bracket.
The lights are all fastened to the overhead guard. 5. If necessary, install the grommet on the wires
The brake, tail, and reverse light assemblies are on of the replacement light assembly. Install the
the rear legs of the overhead guard and are standard connector, wire cable, and grommet in the leg of
in North America and optional in Europe. These the overhead guard leg.
light sets operate on 12, 36, or 48 volts. The flash-
6. Put the wire and connector in the same position
ing light is fastened to the top or rear of the overhead
as the old wire and connector. Connect the light
guard and is optional on all units. This 12-volt light
assembly and wire harness connectors. Close the
operates from the battery of the lift truck and is on
hood.
when the key is in the ON position. The rear driving
light (optional) is also fastened to the top or rear of 7. Assemble the base and lens of the light assembly
the overhead guard. An optional light for the oper- and install the two screws. Align the assembly
ator compartment is also fastened to the top of the in the brackets and tighten the screws.
overhead guard. The optional spot light (not avail-
able in North America) and the optional front driving LED Brake, Tail, and Reverse Light
lights are all fastened to the front legs of the over-
Assembly, Replace
head guard. All of these lights operate on 12, 36, or
48 volts. Remove
NOTE: It is not necessary to replace the complete NOTE: Newer models of lift trucks are equipped
light assemblies to replace a bulb. Do only the steps with LED (Light Emitting Diode) backup and brake
necessary for your replacement needs. tail lights. These light assemblies are non-repairable
and must be replaced as a complete unit. See the
Incandescent Brake, Tail, and Reverse Parts Manual for replacement LED lights.
Light Assembly, Replace
1. Disconnect negative terminal of battery and re-
1. Disconnect the battery and remove the key. move the key.
2. Open the hood for access to the electrical plug of 2. Disconnect the LED light from the chassis light
the light assembly. See Figure 24. Disconnect harness. See Figure 25.
the rectangular six-pin plug for the light assem-
bly. 3. Remove LED light assembly and harness from
mounting bracket.
3. Remove the two screws in the lens of the light as-
sembly. To replace a bulb only, remove the lens 4. If the LED mounting bracket must be removed
from the base. Push and turn the bulb 1/4 turn from the overhead guard leg, remove the plug,
counterclockwise. Make sure you are replacing screw and bracket from the overhead guard leg.
the correct bulb of the set. Make sure the replace-
Install
ment bulb is the correct voltage and has the cor-
rect pin configuration. Install the replacement 1. If the mounting bracket was removed, install it
bulb in the socket using the reverse procedure. onto the overhead guard leg. Insert the plug and
Go to Step 7 if the assembly will not be replaced.
32
screw to attach mounting bracket to overhead 3. Connect the LED light to the chassis light har-
guard leg. ness. See Figure 25.
2. Install the LED light assembly and harness on 4. Connect the negative terminal of battery and
the mounting bracket. close the hood.
Figure 24. Lights
33
NOTE: SPOT LIGHTS ARE NOT INSTALLED IN THE UNITED STATES OR CANADA. INCANDESCENT BRAKE,
TAIL, AND REVERSE LIGHTS SHOWN.
NOTE: E25-65XM/XM 2 AND N30XMH/XMH 2 MODELS SHOWN. J40-65XM/XM 2 MODELS SIMILAR.
NOTE: SEE THE DIAGRAMS SECTION FOR YOUR LIFT TRUCK MODEL, FOR THE CORRECT CONNECTIONS.
A. FRONT LIGHTS B. REAR LIGHTS
1. SPOT LIGHT (REPLACES RIGHT DRIVING 8. CONTROL CIRCUIT CONNECTOR
LIGHT WHEN INSTALLED) 9. 12-VOLT CONVERTER
2. DRIVING LIGHT 10. RELAY
3. OPERATOR’S COMPARTMENT LIGHT 11. BLK
4. FLASHING LIGHT 12. BRN/WHT
5. REVERSE ALARM 13. BRN/PUR
6. BRAKE, TAIL, AND REVERSE LIGHT ASSEMBLY 14. BLK/PUR
7. LIGHT SWITCH CONNECTOR
Flashing Light Assembly, Replace 8. Install the lens and guard on the base. Install
the two mount screws.
Front, Rear Driving Light, or Spot Light
2. Remove the two screws, nuts, and washers that
fasten the flashing light. Assemblies, Replace
3. Remove the wire guard. 1. Disconnect the battery and remove the key.
4. To replace a bulb only, remove the lens from the 2. Replace the bulb only by carefully moving the
base. Carefully remove the bulb. Go to Step 8 if rubber housing away from the edge of the lens
the assembly will not be replaced. to get the light assembly out of the housing. Re-
move the socket assembly from the back of the
5. Carefully pull the wires away from the lift truck light assembly. Turn the socket assembly 1/4
for as much length as possible. It can be neces- turn counterclockwise. Push and turn the bulb
sary to loosen the wire clamp (top mounted units 1/4 turn counterclockwise. Make sure the re-
only). If the complete light assembly is being replacement bulb is the correct voltage and has
placed, cut each of the wires as close to the splice the correct pin configuration. Use a cloth to in-
connectors (lift truck end) as possible. stall the replacement quartz bulb of the spot light
without touching the bulb with your fingers. In-
6. Carefully remove 6 mm (0.25 in.) of insulation stall the replacement bulb and socket assembly
from the ends of both the lift truck and flashing using the reverse procedure. Install the light as-
light wires. Install a 50 mm (2.00 in.) length sembly in the housing.
of heat-shrink tubing on each wire of the pair.
Connect the red and red/green wires using a butt 3. Carefully remove the wire cable from the leg of
splice (Hyster P/N 201950). Connect the black the overhead guard. It can be necessary to re-
and black/tan wires using another butt splice. move the grommet for enough clearance to re-
Slide the tubing over each butt splice so that they move the electrical connector.
are centered. Use a hot air-device to heat and
"shrink" the tubing onto each splice. 4. Remove the nut that fastens the housing to the
lift truck. Carefully pull the wires away from the
7. Align the flashing light in the correct position on lift truck for as much length as possible. Cut each
the lift truck and push the excess wire into the of the light wires as close to the splice connectors
leg of the overhead guard. If necessary, tighten (lift truck end) as possible.
the wire clamp.
34
Figure 25. Lights
35
NOTE: SPOT LIGHTS ARE NOT INSTALLED IN THE UNITED STATES OR CANADA. LED BRAKE, TAIL, AND
REVERSE LIGHTS SHOWN.
NOTE: SEE THE DIAGRAMS SECTION FOR YOUR LIFT TRUCK MODEL, FOR THE CORRECT CONNECTIONS.
A. FRONT VIEW B. REAR VIEW
1. SPOT LIGHT (REPLACES RIGHT DRIVING 7. RELAY
LIGHT WHEN INSTALLED) 8. DC/DC CONVERTER
2. DRIVING LIGHT 9. LIGHT HARNESS
3. FLASHING LIGHT 10. BATTERY POSITIVE (12 VOLTS)
4. REVERSE ALARM 11. BATTERY NEGATIVE
5. LED BRAKE, TAIL, AND REVERSE LIGHT 12. 12 VOLT NEGATIVE
6. CONTROL CIRCUIT CONNECTOR
5. Carefully remove 6 mm (0.25 in.) of insulation light assembly. Make sure the replacement as-
from the ends of both the lift truck and flash- sembly is the correct voltage. Install the replace-
ing light wires. Install a 50 mm (2 in.) length ment assembly in the housing and push until the
of heat-shrink tubing on each wire of the pair. clips hold the assembly securely. Connect the two
For the front driving light or spot light, connect wires to the spade terminals.
the white and yellow/black wires using a butt
splice (Hyster P/N 201950). Connect the black 5. Install the housing and light assembly on the
and black/green wires using another butt splice. overhead guard using the four screws.
Slide the tubing over each butt splice so that they
are centered. Use a hot air-device to heat and Converter, Replace
shrink the tubing onto each splice.
The Converter changes the lift truck voltage (36, 48,
6. Install the light assembly on the lift truck using 72, or 80 volts) to 12 volts for the 12-volt light system.
the nut and push the extra wire into the leg of The converter must be replaced as a unit. Replace
the overhead guard. the converter as follows:

Operator Compartment Light Assembly,
Replace 2. Remove the battery as described in the section
Periodic Maintenance or Operator Manual
1. Disconnect the battery and remove the key. for your lift truck.
2. Remove the four screws that fasten the assembly 3. Remove the front left access plate for access to
black plastic housing to the overhead guard. See the converter.
Figure 24.
4. Remove the M8 capscrews, nuts, and washers
3. Replace the bulb only by removing the socket as- that fasten the bottom of the bracket to the lift
sembly from the back of the light assembly. Turn truck frame. See Figure 24. Move the converter
the socket assembly 1/4-turn counterclockwise. assembly for better access to the terminals.
Push and turn the bulb 1/4-turn counterclock-
wise. Make sure the replacement bulb is the cor- 5. Make a note of the wires fastened to the termi-
rect voltage and has the correct pin configura- nals for correct installation. Remove the wires
tion. Install the replacement bulb and socket as- from the terminals.
sembly using the reverse procedure.
6. Remove the four #10 screws, nuts, and washers
4. If necessary, replace the complete light assem- that fasten the converter to the bracket. Install
bly in the black plastic housing. Disconnect the the replacement converter on the bracket using
two wires. Pull on the light assembly while care- the same screws, washers, and nuts. Make sure
fully pushing the clip away from the edge of the the converter is installed so that the wires can be
connected.
36
7. Install the wires on the correct terminals as re- 1. Disconnect the battery and remove the key.
moved.
2. Remove the floor plates.
8. Install the converter assembly on the lift truck
frame using the same M8 capscrews, washers, 3. Disconnect the wires fastened to the horn termi-
and nuts. Tighten the nuts and capscrews. nals. Do not lose the screws.
9. Install the access plate. Install the battery as 4. Hold the horn and remove the capscrew, nut,
described in the section Periodic Maintenance washers, and insert that fasten the horn to the
or Operator Manual for your lift truck. lift truck frame. Do not lose the parts. Remove
the horn.
Relay, Replace
5. Install the capscrews and washers on the horn
The Relay is an electrical switch that is energized bracket as shown in Figure 26. Keep the insert
with the Reverse contactor coil to operate the Reverse in the hole of the bracket during installation.
lights. The relay is in the top cavity of the counter-
weight. Replace the relay as follows:
2. Open the hood for access to the relay.
3. Pull the relay away from the relay socket.
4. Install the replacement relay on the socket and

close the hood.
Reverse Alarm, Replace

The Reverse Alarm is fastened to the left rear leg of
the overhead guard. The alarm operates from sig-
nals from the traction control card to let people know
the lift truck is traveling in the reverse direction. Re-
place the reverse alarm as follows:
2. Open the hood for access to the electrical plug of

the alarm. See Figure 24. Disconnect the square
six pin plug for the alarm.
3. Turn the special round nut on the rear of the

bracket that fastens the reverse alarm coun-
terclockwise to remove it. Remove the reverse
alarm.
4. Align and install the replacement alarm on the

bracket and tighten the special round nut.
1. HORN 7. INSULATING
5. Put the wire and connector in the same position 2. TERMINALS INSERT
as the old wire and connector. Connect the alarm 3. HORN BRACKET 8. CAPSCREW
and wire harness connectors. Close the hood. 4. LIFT TRUCK 9. COVER
FRAME 10. CONTACT PLATE
5. NUT 11. CONTACT SET
HORN AND HORN BUTTON 6. INSULATING AND SETSCREW
WASHER 12. SPRING
The Horn is under the brake pedal and floor plate.
Replace the horn as follows: Figure 26. Horn and Horn Button
37
Control and Power Fuses Check 2200 SRM 560
6. Align the horn assembly to install the capscrew 4. Pull the horn wires out of the contact set and
in the hole of the frame and install the nut. Make remove the assembly.
sure the insert is in the hole of the bracket be-
fore tightening the nut to prevent damaging the
WARNING
insert.
If the steering wheel has been removed, make
7. Align the horn in the same position as the old sure the steering wheel nut has been tightened.
horn and tighten the capscrew and nut. The correct torque is 40.7 to 54.2 N•m (30 to
40 lbf ft).
8. Install the wires on the horn terminals and in-
stall the floor plates. 5. Put the replacement assembly in position over
the steering wheel and install the wires in the
Horn Switch and Cover contacts. Tighten the setscrews to fasten the
wires.
The Horn Switch and Cover (button) is in the center
of the steering wheel. See Figure 23. Replace the NOTE: If the contact set, spring, contact plate, and
horn button assembly as follows: cover are separated, make sure they are installed
and aligned correctly.
6. Carefully push the wires into the shaft bore as far
2. Carefully lift the cover and horn button assem- as possible. Align the horn button assembly and
bly up off the steering wheel. Lift the assembly press down on the edges of the cover to install it
far enough for access to the setscrews that fas- in the steering wheel.
ten the horn wires. There is some extra length
of the horn wires, but the assembly will not come HYDRAULIC PUMP SWITCHES
up very far. If necessary for additional clearance,
the cover, contact plate, and spring can be re- See the section Main Control Valve for your unit to
moved from the contact set. replace and adjust these switches.
3. Loosen the setscrews that fasten the contact set

to the horn wires.
Control and Power Fuses Check

ZX MOTOR CONTROLLERS CAUTION
The SEM Display Panel must be adjusted using
WARNING a computer to allow lift truck operation. Re-
Some checks and adjustments in this section fer to the section SEM Display Panel (Windows
must be done with the battery connected and Version) Display Panel for SEM Controls, (Win-
power applied to the controller. Lift truck dows Version) 2200 SRM 942 for the adjustment
movement during checks or adjustments can procedure.
cause personal injury. Raise the drive wheels
to prevent lift truck movement. See the Oper-
ating Manual or the section Periodic Mainte- CAUTION
nance of the Service Manual for your lift truck Correct meter polarity is necessary for some
to raise the drive wheels. checks. Meter correct positive is indicated as
(+). Meter correct negative is indicated as ( ).
neck. These metal items can accidentally make Use a meter with a minimum rating of 20,000
an electrical connection and cause an injury. ohms per volt to make measurements. Most
digital volt meters are good.
ALWAYS disconnect the battery before making
checks or adjustments that do not need power
applied.
38
2200 SRM 560 Control and Power Fuses Check
The condition of fuses can normally be checked by the capacitors before checking fuses. Sizes and loca-
looking at them. Some fuses do not change in appear- tions of the fuses are shown in Figure 27, Figure 28,
ance and must be checked with an ohmmeter. Dis- Figure 29, and Figure 30.
connect the battery and connect a jumper to the ter-
minals of the SCR controller capacitors to discharge Replace all bad fuses. Check to see what caused the
fuse to open before connecting the battery.
1. FUSE 1 - TRACTION POWER FUSE (500 AMP) 5. FUSE 5 - AUXILIARY FUSE (15 AMP)
2. FUSE 2 - LIFT PUMP POWER FUSE (325 AMP) 6. FUSE 6 - AUXILIARY FUSE (15 AMP)
(ON LIFT PUMP CONTACTOR WITHOUT SCR 7. FUSE 7 - FORWARD/REVERSE CONTACTOR
PUMP CONTROLLER) COIL FUSE (3 AMP)
3. FUSE 3 - CONTROL FUSE (15 AMP) 8. CAPACITOR
4. FUSE 4 - POWER STEERING POWER FUSE
(40 AMP)
Figure 27. Fuse Locations for EV-100ZX SCR Motor Controller of E1.50-3.20XM (E25-65XM) and
N30XMH
39
2. FUSE 2 - LIFT PUMP POWER FUSE (325 AMP) 6. FUSE 6 - AUXILIARY FUSE (15 AMP)
(ON LIFT PUMP CONTACTOR WITHOUT SCR 7. FUSE 7 - FORWARD/REVERSE CONTACTOR
PUMP CONTROLLER) COIL FUSE (3 AMP)
3. FUSE 3 - CONTROL FUSE (15 AMP)
(40 AMP)
Figure 28. Fuse Locations for EV-100ZX SCR Motor Controller of J2.00-3.20XM (J40-60XM)
40
2. FUSE 2 - LIFT PUMP POWER FUSE (325 6. FUSE 6 - AUXILIARY FUSE (15 AMP)
AMP) (ON LIFT PUMP CONTACTOR WITHOUT 7. FUSE 7 - FORWARD/REVERSE CONTACTOR
TRANSISTOR PUMP CONTROLLER) COIL FUSE (3 AMP)
3. FUSE 3 - CONTROL FUSE (15 AMP)
(40 AMP)
Figure 29. Fuse Locations for EV-T100 Transistor Motor Controller of J2.00-3.20XM (J40-60XM)
41
1. FUSE 1 - TRACTION POWER FUSE (800 AMP) 6. FUSE 6 - LIFT PUMP POWER FUSE (325 AMP)
2. FUSE 4 - POWER STEERING POWER FUSE (40 (FOR LIFT PUMP MOTOR #2)
AMP) (TWO EACH) 7. FUSE 2 - LIFT PUMP POWER FUSE (325 AMP)
3. FUSE 3 - CONTROL FUSE (15 AMP) (FOR LIFT PUMP MOTOR #1)
4. FUSE 5 - AUXILIARY FUSE (15 AMP) 8. CAPACITOR
5. FUSE 7 - FORWARD/REVERSE CONTACTOR
FUSE (3 AMP)
Figure 30. Fuse Locations for EV-100ZX SCR Motor Controller of E3.50-5.50XL (E70-120XL)
42
SEM MOTOR CONTROLLERS SEM CONTROLLER FIELD DIAGNOSTIC

PROCEDURE
WARNING
If a problem is suspected with a SEM controller,
Some checks and adjustments in this section
follow the below test procedure for diagnosing field
must be done with the battery connected and
and armature transistor (FET) failures in SEM
power applied to the controller. Lift truck
controllers.
movement during checks or adjustments can
Armature FET Test
to prevent lift truck movement. See the Oper-
ating Manual or the section Periodic Mainte- 1. Remove all cables and wiring harnesses from the
nance of the Service Manual for your lift truck controller.
to raise the drive wheels.
2. Set the digital meter to the diode test function.
neck. These metal items can accidentally make 3. Attach the red lead to the NEG terminal and the
an electrical connection and cause an injury. black lead to the A2 terminal.
ALWAYS disconnect the battery before making 4. If the reading is higher or lower than 0.4 to 0.5
checks or adjustments that do not need power volts, replace the controller.
applied.
5. Attach the red lead to the A2 terminal and the
black to the POS terminal.
CAUTION
The SEM Display Panel must be adjusted using 6. If the reading is higher or lower than 0.4 to 0.5
a computer to allow lift truck operation. Re- volts, replace the controller.
fer to the section SEM Display Panel (Windows
Version) Display Panel for SEM Controls, (Win- Field FET Test
dows Version) 2200 SRM 942 for the adjustment
1. Attach the red lead to the NEG terminal and the
procedure.
black to the F1 terminal.
CAUTION 2. If the reading is higher or lower than 0.4 to 0.5

volts, replace the controller.
Correct meter polarity is necessary for some
checks. Meter correct positive is indicated as 3. Attach the black lead to the F2 terminal.
4. If the reading is higher or lower than 0.4 to 0.5
Use a meter with a minimum rating of 20,000 volts, replace the controller.
ohms per volt to make measurements. Most
digital volt meters are good. 5. Attach the black lead to the POS terminal and
the red lead to the F1 terminal.
The condition of fuses can normally be checked by
looking at them. Some fuses do not change in ap- 6. If the reading is higher or lower than 0.4 to 0.5
pearance and must be checked with an ohmmeter. volts, replace the controller.
Disconnect the battery, and push and hold the horn
button until the horn stops making a sound before 7. Attach the red lead to the F2 terminal.
checking fuses. This action will discharge the capac-
8. If the reading is higher or lower than 0.4 to 0.5
itors in the motor controllers. Sizes and locations of
volts, replace the controller.
the fuses are shown in Figure 31 or Figure 32.
Replace all bad fuses. Check to see what caused the

fuse to open before connecting the battery.
43
Figure 31. Traction and Pump Motor Controllers - SEM
44

A. E2.00-3.20XM (E45-65XM 2) B. E3.50-5.50XL (E70-120XL 3)
1. FUSE 7 (15A) 10. FUSE 2 (LIFT PUMP MOTOR)
2. FUSE 6 (15A) 11. MOTOR CONTROLLER FOR LIFT PUMP MOTOR
3. FUSE 5 (15A) 12. PUMP FUSE
4. FUSE 3 (15A) 13. FUSE
5. POWER STEERING CONTACTOR 14. 1A CONTACTOR
6. FUSE 4 (POWER STEERING) (40A) 15. LINE CONTACTOR
7. LINE CONTACTOR 16. PUMP #2 CONTACTOR
8. TRACTION MOTOR CONTROLLER 17. PUMP #2 FUSE
9. FUSE 1 (TRACTION MOTOR)
45
Figure 32. Traction Motor Controller and Contactor Control for Lift Pump Motor - SEM
46
2200 SRM 560 Brush Wear and Overtemperature Sensors Check - ZX Motor Controllers

A. E45-65XM 2 B. E70-120XL 3
1. FUSE 7 (15A) 10. CONTACTOR FOR LIFT PUMP MOTOR
2. FUSE 6 (15A) 11. CONTACTOR DRIVER MODULE
3. FUSE 5 (15A) 12. FUSE 2 (LIFT PUMP MOTOR) (325A)
4. FUSE 3 (15A) 13. FUSE
5. POWER STEERING CONTACTOR 14. 1A CONTACTOR
6. FUSE 4 (POWER STEERING) (40A) 15. PUMP #1 CONTACTOR
7. LINE CONTACTOR 16. PUMP #2 CONTACTOR (DUAL PUMPS ONLY)
8. TRACTION MOTOR CONTROLLER 17. PUMP #2 FUSE (DUAL PUMPS ONLY)
9. FUSE 1 (TRACTION MOTOR) 18. PUMP #1 FUSE
Brush Wear and Overtemperature Sensors Check -

ZX Motor Controllers
The operation of the brush wear and overtempera-
WARNING ture indicators can be checked during periodic main-
Some checks and adjustments in this section tenance. The battery must be removed from the lift
must be done with the battery connected and truck for access to the motors.
movement during checks or adjustments can The Brush Wear Indicators illuminate when the mo-
cause personal injury. Raise the drive wheels tor brushes must be replaced. The sensor wires for
to prevent lift truck movement. See the Oper- the brush wear indicators are an insert in the brush
ating Manual or the section Periodic Mainte- material when it is made. The sensor wires are in-
nance of the Service Manual for your lift truck sulated from the brush material. When the brush
to raise the drive wheels. wears within approximately 1.5 mm (0.060 in.) of the
brush lead, the insulation between the sensor wire
Never have any metal on your fingers, arms, or and the brush material is destroyed. The connection
neck. These metal items can accidentally make between the brush and the sensor wire causes the
an electrical connection and cause an injury. warning indicator to illuminate if the circuit is oper-
ating correctly. Motor indicators on the Performance
Display Panel will also illuminate to show which mo-
tor has worn brushes. Check that the correct indica-
applied.
tor comes on for each motor as well as the warning
indicator.
CAUTION
The Overtemperature Sensors are thermal switches
that complete a circuit to send a signal to the display
a computer to allow lift truck operation. Re-
panel if the motor gets too hot. The Overtempera-
fer to the section SEM Display Panel (Windows
ture warning indicator will illuminate if the circuit
Version) Display Panel for SEM Controls, (Win-
is operating correctly. Motor indicators on the dis-
dows Version) 2200 SRM 942 for the adjustment
play panel will also illuminate to show which motor
procedure.
is too hot. Check that the correct indicator comes on
for each motor as well as the warning indicator. The
CAUTION motor for the power steering pump does not have a
Correct meter polarity is necessary for some thermal switch.
checks. Meter correct positive is indicated as
Use a jumper cable so that the battery can be con-
nected for operation of the motors. See Figure 33.
Use a meter with a minimum rating of 20,000 Remove the battery as described in the section Peri-
ohms per volt to make measurements. Most odic Maintenance or Operator Manual for your
digital voltmeters are good. lift truck. Raise the drive wheels. See How To Raise
47
Thermal Sensors - SEM Motor Controllers Check 2200 SRM 560
Drive Tires in the same Periodic Maintenance sec-

tion.
Disconnect the sensor wires from the outside of

the motor case. Touch the ends of the sensor wires
together. The warning and motor light will illumi-
nate if the circuit is operating correctly. The thermal
switch can be replaced if it is damaged. However, the
motor must be disassembled to replace the thermal
switch. See the section DC Motor Maintenance
620 SRM 294.
1. BATTERY NEXT TO LIFT TRUCK

2. JUMPER CABLE
3. CONNECT TO BATTERY CONNECTOR ON LIFT
TRUCK
Figure 33. Connect Battery for Motor Operation
Thermal Sensors - SEM Motor Controllers Check

to the section Display Panel for SEM Controls,
WARNING (Windows Version) 2200 SRM 942 for the adjust-
Some checks and adjustments in this section ment procedure.
movement during checks or adjustments can CAUTION
cause personal injury. Raise the drive wheels Correct meter polarity is necessary for some
to prevent lift truck movement. See the Oper- checks. Meter correct positive is indicated as
ating Manual or the section Periodic Mainte- (+). Meter correct negative is indicated as ( ).
nance of the Service Manual for your lift truck
to raise the drive wheels. Use a meter with a minimum rating of 20,000
Never have any metal on your fingers, arms, or digital voltmeters are good.
an electrical connection and cause an injury. The thermal sensors indicate to the motor controller
that the motor is too hot. When a motor gets too hot,
ALWAYS disconnect the battery before making the sensor makes an electrical connection to send a
checks or adjustments that do not need power signal to the motor controller.
applied.
CAUTION
a computer to allow lift truck operation. Refer
48
2200 SRM 560 Start Switch Adjustment
Use a jumper cable so that the battery can be con-

WARNING nected for operation of the motors. See Figure 33.
To help prevent damage or injury, raise the Disconnect the sensor wires from the outside of the
drive wheels before doing these checks. Raise motor case. Touch the ends of the sensor wires to-
the drive wheels as described in the Operating gether. The warning light will illuminate if the cir-
Manual or the section Periodic Maintenance cuit is operating correctly. The thermal switch can be
of the Service Manual. replaced if it is damaged. However, the motor must
be disassembled to replace the thermal switch.
Start Switch Adjustment

the start switch. See MONOTROL or Accelera-
WARNING tor Pedal Adjustment of this section to adjust
Some checks and adjustments in this section the pedal movement.
power applied to the controller. Lift truck The start switch is a small switch fastened to the
movement during checks or adjustments can mount for the accelerator pedal assembly. See Fig-
cause personal injury. Raise the drive wheels ure 22. The normally open and common contacts of
to prevent lift truck movement. See the Oper- the start switch are closed when the pedal is in the
ating Manual or the section Periodic Mainte- up position.
to raise the drive wheels. The accelerator or MONOTROL pedal actuates the
start switch through the leaf of the switch. The start
Never have any metal on your fingers, arms, or switch prevents the operation of the lift truck until
neck. These metal items can accidentally make the SRO circuit is complete. The start switch must
an electrical connection and cause an injury. be adjusted so that the switch normally closed con-
tacts close as soon as the accelerator or MONOTROL
ALWAYS disconnect the battery before making pedal start to move. The adjustment of the start
checks or adjustments that do not need power switch must be checked after the MONOTROL pedal
applied. or accelerator position adjustment is correct. See
MONOTROL or Accelerator Pedal Adjustment of
CAUTION this section to adjust the pedal position.
The SEM Display Panel must be adjusted using NOTE: The following check can be NOT accurate if
a computer to allow lift truck operation. Re- the MONOTROL pedal or accelerator position sensor
fer to the section SEM Display Panel, (Dos Ver- also needs adjustment. If the position sensor was
sion) 2200 SRM 725 or Display Panel for SEM also replaced or needs adjustment, adjust the start
Controls, (Windows Version) 2200 SRM 942 for switch to make sure it is correctly adjusted.
the adjustment procedure.
Check that the start switch operates as soon as
the pedal moves off the UP stop (lift truck starts to
CAUTION move). If it doesn’t, adjust the switch. Disconnect
Correct meter polarity is necessary for some the battery and remove the key. Remove the floor
checks. Meter correct positive is indicated as plates. If you can’t hear the switch operate, check the
(+). Meter correct negative is indicated as ( ). switch with an ohmmeter. Temporarily disconnect
the wires to the switch, and connect the ohmmeter
Use a meter with a minimum rating of 20,000
between the common (COM) and normally closed
(NC) terminals at the switch. A good switch will
indicate less than 50 ohms between the terminals as
soon as the pedal moves off the stop.
CAUTION
The MONOTROL pedal or accelerator pedal To adjust the start switch, the mount screws for the
movement MUST be adjusted before adjusting switch must be tight enough to hold the switch in po-
sition, but loose enough to permit switch movement.
49
Start Switch Adjustment 2200 SRM 560
See Figure 22. Move the switch so that the normally 4. Adjust the position of the START switch so that
open contacts just close. Tighten the switch mount it will actuate when the 1.5 mm (0.06 in.) shim is
screws without moving the switch. Check that the in position between the pedal and the pedal stop.
normally open (NO) contacts of the start switch close
as soon as the pedal moves. If necessary, adjust the E70-120XL 3
switch again until the switch operates correctly. Con-
nect the switch wires and install the floor plates. 1. Rotate the potentiometer housing to the end of
the mount slots as shown in Figure 34. Tighten
ACCELERATOR POTENTIOMETER AND the mounting screws.
START SWITCH, E70-120XL, E70-120XL 3 2. Loosen the crank on the shaft of the accel-
LIFT TRUCKS erator potentiometer. Push the accelerator
(MONOTROL) pedal down and install a 10 mm
NOTE: Adjustment of the accelerator linkage will (0.40 in.) shim between the pedal and the mount
make necessary the adjustment of the START bracket. See Figure 34. Adjust the shaft of the
switch. accelerator potentiometer so that the voltage be-
The accelerator potentiometer has a range of 0-6000 tween terminals B and C drops below 0.54 volts,
ohms. If you must replace an accelerator po- just as the pedal contacts the 10 mm (0.40 in.)
tentiometer, make sure you use the correct part shim. Tighten the crank on the potentiometer
number. Many potentiometers have approximately shaft and check the voltage again.
290 mechanical rotation, but the accelerator poten- 3. Adjust the position of the start switch so that,
tiometer has approximately 70 electrical rotation. while slowly depressing the pedal, the normally
The accelerator potentiometer is connected to the open circuit opens when the voltage between ter-
accelerator pedal. minals B and C is 3.6 to 3.9 volts. If the switch
The start switch is only used on units without a adjustment range does not permit this adjust-
MONOTROL pedal. The start switch and accelera- ment, repeat Step 2.
tor potentiometer must be adjusted together. Adjust 4. Rotate the pedal stop until there is a 1 to 2 mm
the accelerator potentiometer and start switch as (0.04 to 0.08 in.) gap between the pedal and the
follows: See Figure 34. pedal stop when the switch normally open circuit
opens. If the pedal stop adjustment range does
E70-120XL not permit this adjustment, repeat Step 2 and
1. Rotate the potentiometer housing to the end of Step 3.
the mount slots as shown in Figure 34. Tighten
the mounting screws. DIRECTION SWITCHES (MONOTROL)
2. Loosen the crank on the shaft of the accel- There is a small direction switch under each pad of
erator potentiometer. Push the accelerator the MONOTROL pedal. See Figure 35. Each switch
(MONOTROL) pedal down and install a 10 mm controls one direction. A capacitor is in parallel with
(0.40 in.) shim between the pedal and the mount each direction switch to decrease arcs at the switch
bracket. See Figure 34. Adjust the shaft of the contacts. If both sides of the MONOTROL pedal
accelerator potentiometer so that the resistance are pushed at the same time, the direction circuit is
between terminals B and C is 100-200 ohms (R × de-energized and the lift truck will not move. The
1 scale). Tighten the crank on the potentiometer contacts of the two direction switches are in a series
shaft and check the resistance again. and parallel arrangement so that both direction
contactors cannot be energized at the same time.
3. Loosen the bolt that holds the pedal stop. Raise
the pedal to the pedal stop. Install a 1.5 mm Each direction switch must be adjusted so that one
(0.06 in.) shim between the pedal and the pedal set of switch contacts is closed when the pedal pad
stop. Adjust the pedal stop so that the resistance is at each position of its travel. The pedal pad must
between terminals B and C is 4100-4300 ohms be removed from the pedal assembly to make adjust-
(R × 100 scale). Tighten the bolt that holds the ments. Each switch is normally adjusted so that the
pedal stop and check the resistance again. body of the switch is even with the stop on the pedal
pad.
50
2200 SRM 560 Start Switch Adjustment
1. PEDAL STOP 8. POTENTIOMETER HOUSING

2. PIVOT CAPSCREW 9. A TERMINAL, E70-120XL
3. START SWITCH 10. B TERMINAL E70-120XL
4. ACCELERATOR (MONOTROL) PEDAL 11. C TERMINAL E70-120XL
5. SPRING 12. A TERMINAL E70-120XL 3
6. CRANK 13. B TERMINAL E70-120XL 3
7. POTENTIOMETER SHAFT 14. C TERMINAL E70-120XL 3
Figure 34. Accelerator Potentiometer and Start Switch Adjustment (E70-120XL, E70-120XL 3)
1. PEDAL PAD
2. FORWARD DIRECTION SWITCH
3. CAPACITOR
4. REVERSE DIRECTION SWITCH
5. SPRING
Figure 35. MONOTROL Pedal
51
Brake Light Switch Adjustment 2200 SRM 560
Brake Light Switch Adjustment

switch so that the switch operates from the normally
WARNING open position to the closed position. Tighten the
Some checks and adjustments in this section switch mount screws and nuts to 2.0 to 2.3 N•m (18
must be done with the battery connected and to 20 lbf in) without moving the switch. Remove the
power applied to the controller. Lift truck shim and check that the switch operates correctly.
cause personal injury. Raise the drive wheels If you can’t hear the switch operate, check the switch
to prevent lift truck movement. See the Oper- with an ohmmeter. Separate the connector and con-
ating Manual or the section Periodic Mainte- nect the ohmmeter between the common (COM) and
nance of the Service Manual for your lift truck normally closed (NC) terminals at the switch. A good
to raise the drive wheels. switch will indicate less than 50 ohms between the
terminals as soon as the pedal moves off the stop.
Never have any metal on your fingers, arms, or Connect the switch connector after the switch opera-
neck. These metal items can accidentally make tion is correct and install the floor plates.

applied.
CAUTION
a computer to allow lift truck operation. Refer
to the section Display Panel for SEM Controls,
(Windows Version) 2200 SRM 942 for the adjust-
ment procedure.
CAUTION
checks. Meter correct positive is indicated as

Check the brake light switch by checking that the

brake lights come on when the brake pedal is de-
pressed. Adjust the switch by first disconnecting NOTE: E2.00-3.20XM (E45-65XM/XM 2) AND
the battery and removing the key. Remove the floor N30XMH/XMH 2 MODELS SHOWN, J2.00-3.20XM
plates. The brake light switch is between the pedal (J40-60XM/XM 2) MODELS SIMILAR.
arm and the mount for the brake pedal. Make sure 1. BRAKE PEDAL
the brake pedal height is correctly adjusted as shown 2. BRAKE LIGHT SWITCH
in Figure 36. If the pedal adjustment is not correct, 3. SWITCH ACTUATOR
adjust the pedal height and master cylinder push 4. PEDAL ADJUSTMENT - 81 to 83 mm (3.19 to
rod as described in the Brake System for your unit. 3.27 in.) E SERIES AND 94.0 mm (3.7 in.) J
SERIES
After the pedal and push rod are correctly adjusted, 5. FLOOR PLATE
6. ADJUSTMENT SCREW AND JAM NUT
loosen the screws and nuts that fasten the switch to 7. INSTALL SHIM HERE
the plate. Install a 0.4 to 0.6 mm (0.016 to 0.024 in.)
shim between the adjustment screw for the pedal Figure 36. Brake Light Switch
stop and the stop surface. Move the brake light
52
2200 SRM 560 Optional Seat Brake Switch Adjustment
Seat Switch Check

Controls, (Windows Version) 2200 SRM 942 for
WARNING the adjustment procedure.
power applied to the controller. Lift truck CAUTION
movement during checks or adjustments can Correct meter polarity is necessary for some
cause personal injury. Raise the drive wheels checks. Meter correct positive is indicated as
to prevent lift truck movement. See the Oper- (+). Meter correct negative is indicated as ( ).
ating Manual or the section Periodic Mainte-
nance of the Service Manual for your lift truck Use a meter with a minimum rating of 20,000
to raise the drive wheels. ohms per volt to make measurements. Most
neck. These metal items can accidentally make NOTE: There is no adjustment for the seat switch
an electrical connection and cause an injury. located in the cushion of the operator seat. Check
that the seat switch is good.
checks or adjustments that do not need power Check as follows:
applied. 1. Sit on the seat.
2. Turn the key to the START and ON positions.

CAUTION
The SEM Display Panel must be adjusted using 3. Depress the MONOTROL pedal or accelerator
a computer to allow lift truck operation. Re- pedal. If the seat switch is bad, the lift truck will
fer to the section SEM Display Panel, (Dos Ver- not operate. Replace the seat switch. See Seat
sion) 2200 SRM 725 or Display Panel for SEM Switch, Replace of this section.
Optional Seat Brake Switch Adjustment

WARNING CAUTION
Some checks and adjustments in this section The SEM Display Panel must be adjusted using
must be done with the battery connected and a computer to allow lift truck operation. Re-
power applied to the controller. Lift truck fer to the section SEM Display Panel, (Dos Ver-
movement during checks or adjustments can sion) 2200 SRM 725 or Display Panel for SEM
cause personal injury. Raise the drive wheels Controls, (Windows Version) 2200 SRM 942 for
to prevent lift truck movement. See the Oper- the adjustment procedure.
to raise the drive wheels. CAUTION
Never have any metal on your fingers, arms, or checks. Meter correct positive is indicated as
neck. These metal items can accidentally make (+). Meter correct negative is indicated as ( ).
ALWAYS disconnect the battery before making ohms per volt to make measurements. Most
checks or adjustments that do not need power digital volt meters are good.
applied.
Check the operation of the switch for the optional
seat brake by leaving the parking brake off, moving
the key to the ON position, and getting off the seat.
If alarm makes a noise, the switch is operating cor-
rectly.
53
Direction Switches Check 2200 SRM 560
This switch is located near the bottom of the link- time the linkage lever contacts the battery compart-
age that operates the seat brake. See Figure 16. ment. Tighten the mount screws without moving the
Make sure the seat brake linkage is correctly ad- switch. Check that the switch operates correctly af-
justed as described in the Frame section for your ter the screws are tight. Install the cover over the
unit. Remove the cover over the linkage under the linkage.
seat. Loosen the mount screws for the switch. Ad-
just the switch so the switch leaf is actuated each
Parking Brake Switch Adjustment

(Windows Version) 2200 SRM 942 for the adjust-
WARNING ment procedure.
power applied to the controller. Lift truck CAUTION
movement during checks or adjustments can Correct meter polarity is necessary for some
cause personal injury. Raise the drive wheels checks. Meter correct positive is indicated as
to prevent lift truck movement. See the Oper- (+). Meter correct negative is indicated as ( ).
nance of the Service Manual for your lift truck Use a meter with a minimum rating of 20,000
to raise the drive wheels. ohms per volt to make measurements. Most
neck. These metal items can accidentally make Check the operation of the switch for the parking
an electrical connection and cause an injury. brake by applying the parking brake with the key in
the ON position. The indicator on the display panel
ALWAYS disconnect the battery before making will be on if the switch is good and correctly adjusted.
applied. The parking brake switch is fastened near the link-
age for applying the parking brake. The switch must
be adjusted so that it is closed when the parking
CAUTION brake is applied. The parking brake must also be
The SEM Display Panel must be adjusted using correctly adjusted before the switch is adjusted. See
a computer to allow lift truck operation. Refer the Brake System for your unit to adjust the park-
to the section Display Panel for SEM Controls, ing brake linkage.
Direction Switches Check

MONOTROL PEDAL Never have any metal on your fingers, arms, or
WARNING an electrical connection and cause an injury.
Some checks and adjustments in this section ALWAYS disconnect the battery before making
must be done with the battery connected and checks or adjustments that do not need power
power applied to the controller. Lift truck applied.
to prevent lift truck movement. See the Oper- CAUTION
ating Manual or the section Periodic Mainte- The SEM Display Panel must be adjusted using
nance of the Service Manual for your lift truck a computer to allow lift truck operation. Re-
to raise the drive wheels. fer to the section SEM Display Panel, (Dos Ver-
sion) 2200 SRM 725 or Display Panel for SEM
Controls, (Windows Version) 2200 SRM 942 for
the adjustment procedure.
54
2200 SRM 560 MONOTROL or Accelerator Pedal Adjustment
be removed from the pedal assembly to make adjust-

CAUTION ments. Move each switch so that the body of the
Correct meter polarity is necessary for some switch is even or within 0.8 mm (0.020 in.) of the
checks. Meter correct positive is indicated as switch mount of the pedal pad. Put Loctite® 222 on
(+). Meter correct negative is indicated as ( ). the screws for the switches and tighten the nuts af-
ter each switch is adjusted. Assemble and install the
Use a meter with a minimum rating of 20,000 pedal assembly as described in .
digital volt meters are good. STEERING COLUMN
Check that the direction switches operate correctly The controller includes logic circuits for an optional
by operating the lift truck in the FORWARD and direction control on the steering column. See Fig-
REVERSE directions. If the lift truck operates cor- ure 19. The Forward and Reverse switches complete
rectly, the switches are good and correctly adjusted. the circuit for the controller card to energize the For-
The pedal assembly must be disassembled to adjust ward or Reverse contactors.
the switches. See Figure 22 and to remove and dis-
assemble the pedal assembly. Check that the direction switches operate correctly
by operating the lift truck in the FORWARD and
Each direction switch must be adjusted so that one REVERSE directions. If the lift truck operates cor-
set of switch contacts is closed when the pedal pad rectly, the switches are good. See and to replace bad
is at each position of its travel. The pedal pad must direction switches. There is no adjustment for these
switches.
Hydraulic Pump Switch Adjustment

See the section Main Control Valve for your lift truck to replace and adjust these switches.
MONOTROL or Accelerator Pedal Adjustment

WARNING CAUTION
Some checks and adjustments in this section The SEM Display Panel must be adjusted using
must be done with the battery connected and a computer to allow lift truck operation. Re-
power applied to the controller. Lift truck fer to the section SEM Display Panel, (Dos Ver-
movement during checks or adjustments can sion) 2200 SRM 725 or Display Panel for SEM
cause personal injury. Raise the drive wheels Controls, (Windows Version) 2200 SRM 942 for
to prevent lift truck movement. See the Oper- the adjustment procedure.
to raise the drive wheels. CAUTION
Never have any metal on your fingers, arms, or checks. Meter correct positive is indicated as
neck. These metal items can accidentally make (+). Meter correct negative is indicated as ( ).
ALWAYS disconnect the battery before making ohms per volt to make measurements. Most
checks or adjustments that do not need power digital volt meters are good.
applied.
If the unit has a MONOTROL pedal, there are direc-
tion switches that must be correctly adjusted. There
is also a start switch for either the MONOTROL
pedal or accelerator pedal. There is also an accel-
erator position sensor for either pedal. Adjust the
pedal movement in this procedure before adjusting
55
Accelerator Position Sensor Adjustment 2200 SRM 560
the switches. See Start Switch Adjustment and Ac- the pedal mount plate to the frame. See Figure 22.
celerator Position Sensor Adjustment of this section The bolts must be tight enough to hold the position,
to adjust these parts. but loose enough to permit plate movement. Move
the plate to the maximum UP position and install
The movement of the MONOTROL pedal or acceler- the floor plate. Slowly push down on the pedal un-
ator pedal must be correctly adjusted before the start til it touches the down stop. Continue to push the
switch or accelerator position sensor is adjusted. The pedal down to move the plate until the pedal is within
floor plate must be in position to check or adjust the 0.2 mm (0.08 in.) of the floor plate. See Figure 22.
pedal movement. Push the pedal down. Check that Tighten the bolts without changing the plate posi-
the pedal arm is against the down stop when the tion. Check that the adjustment is still correct.
pedal is within 0.2 mm (0.08 in.) of the floor plate. If
adjustment is necessary, loosen the bolts that fasten
Accelerator Position Sensor Adjustment

WARNING CAUTION
Some checks and adjustments in this section The MONOTROL pedal or accelerator pedal
must be done with the battery connected and movement and start switch MUST be adjusted
power applied to the controller. Lift truck before adjusting the accelerator position sen-
movement during checks or adjustments can sor. See MONOTROL or Accelerator Pedal
cause personal injury. Raise the drive wheels Adjustment of this section to adjust the pedal
to prevent lift truck movement. See the Oper- movement. See Start Switch Adjustment of
ating Manual or the section Periodic Mainte- this section to adjust the start switch. See
nance of the Service Manual for your lift truck Figure 22.
to raise the drive wheels.
NOTE: The floor plates must be installed to check
Never have any metal on your fingers, arms, or the maximum speed adjustment of the accelerator
neck. These metal items can accidentally make position sensor.
When the position of the MONOTROL pedal or ac-
ALWAYS disconnect the battery before making celerator pedal and the start switch adjustments are
checks or adjustments that do not need power correctly adjusted, adjust the accelerator position
applied. sensor as follows:
1. Raise the drive tires as described in the Oper-

CAUTION ating Manual or the Periodic Maintenance
The SEM Display Panel must be adjusted using section.
a computer to allow lift truck operation. Re-
fer to the section SEM Display Panel, (Dos Ver-
WARNING
sion) 2200 SRM 725 or Display Panel for SEM
Controls, (Windows Version) 2200 SRM 942 for On SCR units, do not touch the terminals of
the adjustment procedure. capacitor C1 of the traction or lift motor con-
trollers. The charge on the capacitors can
cause electrical shock and personal injury.
CAUTION Disconnect the battery and use an insulated
Correct meter polarity is necessary for some screwdriver or jumper wire to discharge the
checks. Meter correct positive is indicated as capacitors before connecting the voltmeter
(+). Meter correct negative is indicated as ( ). leads. Make a short circuit across the capaci-
tor terminals to discharge each capacitor and
Use a meter with a minimum rating of 20,000 prevent electrical shocks.
digital voltmeters are good. 2. Remove the cover from the counterweight for ac-
cess to the traction control card.
56
2200 SRM 560 Accelerator Position Sensor Adjustment
3. Connect a voltmeter between the TB1 terminal

(+) of the traction control card and a battery neg-
ative ( ). See Figure 37. Connect the battery
after the voltmeter is connected.
4. Sit in the seat or put a weight in the seat to close

the seat switch or the switch of the seat brake.
Turn the key to the START and ON position. DO
NOT depress the MONOTROL pedal or acceler-
ator pedal.
5. The correct voltmeter reading is 3.7 volts or

more. If the voltage reading is too low, remove
the top floor plate and adjust the mount plate for
the position sensor. Move the plate to a position
for the correct voltage. Repeat Step 4 and Step 5
until the voltage is correct after the screws have
been tightened with the mount plate in the cor-
rect position.
6. Install the floor plate and sit in the seat or put

a weight in the seat to close the seat switch
or the switch of the seat brake. Turn the key
to the START and ON position. Depress the 1. TERMINAL TB1 OF TRACTION CONTROL CARD
MONOTROL pedal or accelerator pedal to the (METER +)
2. TRACTION CAPACITOR C1 (LIFT CAPACITOR
floor plate. The correct voltmeter reading is 0.4 NOT SHOWN)
volt or more. If the voltage reading is too low, 3. BATTERY NEGATIVE (METER )
remove the top floor plate and adjust the position
sensor on the mount plate for 0.4 volt. Check Figure 37. Voltmeter Connection Points on SCR
that the voltage of Step 5 is correct. Repeat Motor Controllers
Step 4 through Step 6 until both voltages (Step 5
and Step 6) are correct.
7. Install the floor plate, remove the voltmeter and

lower the lift truck off the blocks.
57
NOTES
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58
TECHNICAL PUBLICATIONS
2200 SRM 560 6/04 (11/02)(7/02)(3/99)(6/98)(5/96)(4/95)(1/94) Printed in United Kingdom

Electrical System: Replacement, Checks, and Adjustments Trucks With Ev-100/200Zx or SR (Sem) and SP Motor Controllers

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ELECTRICAL SYSTEM

REPLACEMENT, CHECKS, AND

PART NO. 897640 2200 SRM 560

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2004 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];

Standard Display 18-Pin Connector

1. HOURMETER 6. KEY SWITCH LEADS

Figure 1. Basic (Early) Display Panels for EV-100/200ZX Motor Controllers

1. BATTERY DISCHARGE INDICATOR 3. FASTEN SEAT BELT SYMBOL AND LED

Figure 2. Basic (Later) Display Panels for EV-100/200ZX Motor Controllers

Enhanced Display 18-Pin Connector

1. BATTERY DISCHARGE INDICATOR 11. STATUS CODE/MAINTENANCE INDICATOR

Figure 3. Performance Display Panels (Early) for EV-100/200ZX Motor Controllers

(2) Digital Display. This indicator is blank when

1. BATTERY DISCHARGE INDICATOR 9. LIFT PUMP MOTOR INDICATOR

Figure 4. Performance Display Panels (Later) for EV-100/200ZX Motor Controllers

1. HOURMETER SYMBOL 5. BRAKE FLUID TOO LOW SYMBOL

Figure 5. Standard Display Panel - SEM

1. HOURMETER SYMBOL 8. LCD SCREEN

Figure 6. Premium Display Panel - SEM

Descriptions of Common Features Battery Discharge Indicator (BDI)

STAR Push Button An alarm is also operated by the control card if

Display Panel Components Replacement

NOTE: Most parts of the Basic Display Panel can

NOTE: The only replaceable parts of the Perfor-

DISPLAY PANEL ASSEMBLY

STATUS CODE OR PERFORMANCE

Figure 9. Basic Display Panel

Legend for Figure 9

SEM Display Panel Replacement

Figure 10. Mounting of SEM Display Panel - SEM

Legend for Figure 10

1. SEM DISPLAY PANEL 5. CONNECTOR FOR PERSONAL COMPUTER

Motor Controller (SR or SP) Replacement

Control Components Replacement

4. Install the replacement start switch in the same

5. Adjust the start switch as described in Start

BRAKE LIGHT SWITCH, REPLACE

1. Disconnect the battery and remove the key.

2. Remove the floor plates. The brake light switch

3. Remove the screws that fasten the seat to the

4. Use a flat blade screwdriver or other tool with

5. Carefully slide the replacement switch into the

6. Carefully install the grommet over the wire con-

NOTE: E45-65XM/XM 2 AND N30XMH/XMH MOD-

Figure 12. Brake Light Switch

SEAT SWITCH, REPLACE

1. Disconnect the battery and remove the key.

2. Remove the cover over the linkage under the

3. Make a note of which wires are connected to