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Summary of Contents for Hyster D264
- Page 1 Hyster D264 (N45ZR2, N35ZDR2) Forklift...
- Page 2 ELECTRICAL SYSTEM N35ZDR2, N45ZR2 [D264]; N30ZDR2, N35-40ZR2 [E470]; N30ZDRS2, N35-40ZRS2 [B265] PART NO. 4075037 2200 SRM 1612...
- Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
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Page 4: Table Of Contents
AC Motor Controllers ............................13 Controller Removal ............................14 Install .................................14 Low-Voltage Protection Function ........................14 CDF File Installation Procedure .......................... 15 LOW-VOLTAGE PROTECTION FUNCTION ....................15 Contactor and Electrical Panel Checks ........................16 Fuses ..................................16 Contactors ................................16 General ................................16 ©2015 HYSTER COMPANY... - Page 5 Table of Contents TABLE OF CONTENTS (Continued) Test ................................17 Tips ................................17 Disassemble and Assemble .......................... 17 Instrument Panel Removal and Installation ....................... 19 Key Switch Removal and Installation ........................19 Remove ................................19 Install .................................19 Integrated Fuse Board (IFB) ..........................20 Fuses ................................20 Replace ................................20 Diodes ................................
- Page 6 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
- Page 7 Table of Contents TABLE OF CONTENTS (Continued) Rear Work and Caution Light ..........................54 Rear Work Light ............................54 Caution Light ..............................54 Light Switches ..............................55 Cooling Fans ................................56 Electrical Compartment Fans .......................... 56 Replace ................................57 Operator Fan ..............................58 Repair ................................58 Impact Sensor ................................60 Remove ................................
- Page 8 Table of Contents This section is for the following models: (N35ZDR2, N45ZR2) [D264]; (N30ZDR2, N35-40ZR2) [E470]; (N30ZDRS2, N35-40ZRS2) [B265]...
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Page 9: General
2200 SRM 1612 General General WARNING This electrical system utilizes capacitors that maintain a charge on the electrical system even after the battery is disconnected. Damage to the truck components and injury from electrical shock may occur if the capacitors are not properly discharged prior... -
Page 10: Discharging The Internal Capacitors
General 2200 SRM 1612 DISCHARGING THE INTERNAL CAPACITORS When working with the electrical systems of the truck, it is necessary to discharge the internal capacitors of the controllers associated with each circuit affected. WARNING Capacitors inside the controllers can hold an electrical charge after the battery is disconnected. -
Page 11: Inspect
2200 SRM 1612 General Inspect Check that the static strap is present and is in good working condition before operating the lift truck. Inspect the static strap for wear, cracks, tears, or missing length. Inspect the strap for cleanliness and clean if necessary with a mild, soapy detergent if dirty or oily. - Page 12 Battery Connection 2200 SRM 1612 1. Move the lift truck to a safe, level area and c. Install new cables. completely lower the mast. Turn the key switch d. Reinstall the battery to the lift truck. to the OFF position and attach a DO NOT OP- ERATE tag to the control handle.
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Page 13: Key Switch
2200 SRM 1612 Key Switch Key Switch WARNING The key switch does not remove electrical power from the main contactor and controllers of the lift truck. Before servicing the truck, disconnect the battery and discharge the capacitors. See Dis- charging the Internal Capacitors. WARNING Making repairs with the battery connected can cause a short circuit. -
Page 14: Remove
Key Switch 2200 SRM 1612 1. Move the lift truck to a safe, level area, and 9. Install the jam nut onto the key switch as re- completely lower the mast. Turn the key switch moved. to the OFF position and remove the key. Attach 10. -
Page 15: Major Electrical System Features
2200 SRM 1612 Major Electrical System Features Major Electrical System Features CANBUS COMMUNICATIONS • Keep It Simple philosophy - a simple hard- ware design with fewer parts - better relia- bility Electronic controllers connected by the CANbus data link are as follows: •... -
Page 16: Centering Proximity Sensor
Major Electrical System Features 2200 SRM 1612 Centering Proximity Sensor Input Devices • Proximity Sensor - The Proximity Sensor is a CAUTION sourcing PNP sensor that provides a voltage It is very important that the proximity sensor be input signal to the CAN I/O when the sensor connected to the harness and that the sensor air senses ground. -
Page 17: Encoder Integrity
2200 SRM 1612 Major Electrical System Features ENCODER INTEGRITY then connect to one output channel and battery negative, and rotate the encoder very slowly to see Steering and height encoders are tested continu- if the input channel goes on/off/on (0 then 5 volts ously for current draw. -
Page 18: Key Switch
Major Electrical System Features 2200 SRM 1612 KEY SWITCH There are 10 steps shown on the left of the display. Flooded cell and maintenance-free battery types The key switch receives battery voltage provided by can be accommodated by changing the setup pa- the Integrated Fuse Board and is protected by a 10 rameters. -
Page 19: Ace2 / Ace3 Traction And Hydraulic Controllers
2200 SRM 1612 Setup NORMAL OPERATION ACE2 / ACE3 Traction and Hydraulic Controllers Display NOTE: For all the display examples shown below, x's represent numerical values which will vary with Password Access parameter adjustments. Following truck startup, if the Operator Password NOTE: Controllers and dash displays should not be feature is enabled, the operator will be prompted to exchanged between other trucks for periods of lon-... -
Page 20: Truck Operation Mode
Setup 2200 SRM 1612 3. When this feature is enabled, the following • The factory performance modes are num- items will show on the display each time the bered 1, 2, 3, and 4. Mode 1 corresponds to key is turned ON. Display button 1 (Up Arrow) slowest performance mode and 4 corresponds is used to answer "OK."... -
Page 21: Calibrations
2200 SRM 1612 Calibrations Calibrations Refer to User Interface Service Technician Steering calibrations must be performed NOTE: 2200SRM1614 for calibration of the steering, rear with the operator brake switch in the activated con- handle and mast tare weight calibration proce- dition. -
Page 22: Controller Removal
AC Motor Controllers 2200 SRM 1612 The controller checks the following functions: 2. Disconnect and separate battery connector. Re- move the cover and discharge the capacitors. • Checks the temperature and gives both low- Refer to Discharging the Internal Capacitors. and high-temperature thermal protection to the controller. -
Page 23: Cdf File Installation Procedure
2200 SRM 1612 CDF File Installation Procedure CDF File Installation Procedure NOTE: Installation of a CDF file requires the CCS Field Tool from HYPASS or Access. A CDF file download is required whenever a controller or other module device is replaced or a new option feature is added to the truck. -
Page 24: Contactor And Electrical Panel Checks
Contactor and Electrical Panel Checks 2200 SRM 1612 Contactor and Electrical Panel Checks Fuses Circuit Rating WARNING FU 10 Key Switch DO NOT operate a lift truck that needs adjustment E-Stop or repairs. Report the need for adjustment or re- Start pairs immediately. -
Page 25: Test
2200 SRM 1612 Contactor and Electrical Panel Checks Test Table 2. Coil Resistance WARNING 24v Coil Resistanc Parts of this procedure require working on the Device Location Notes e @ 21°C truck with full electric current present. To prevent (70°F) personal injury or property damage, DO NOT wear a watch, rings, or jewelry while working around Truck main... - Page 26 Contactor and Electrical Panel Checks 2200 SRM 1612 The contactor contacts are made of special silver al- loy. The contacts may look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Clean- ing is not necessary.
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Page 27: Remove
2200 SRM 1612 Instrument Panel Removal and Installation Instrument Panel Removal and Installation 3. Remove four screws that fasten instrument WARNING panel to console. Always disconnect the battery ground cable be- 4. Align instrument panel on console and install fore making repairs to prevent possible damage capscrews. -
Page 28: Replace
Integrated Fuse Board (IFB) 2200 SRM 1612 Integrated Fuse Board (IFB) The Integrated Fuse Board (IFB) is located on the NOTE: The integrated fuse board is not repairable. inside of the front frame wall, beside the traction If damaged, it must be replaced. Check the IFB for and lift motor controllers. -
Page 29: Install
2200 SRM 1612 Integrated Fuse Board (IFB) NOTE: Some fuses for accessories may be located WARNING in a separate fuse holder such as the heater option fuses. Trucks with camera options also have fuses Making repairs with the battery connected can located in the camera power module located on the cause a short circuit. - Page 30 Integrated Fuse Board (IFB) 2200 SRM 1612 DIODES ness adjacent to the IFB board and is installed from the factory in the #3 pin location of the IFB An internal IFB board diode (D6) and the external board with the other side of the diode connecting to diode (D 5) are used to prevent fly-back voltage the 033A wire of the main harness.
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