ELECTRICAL SYSTEM

B60HD2 [C262];B80ZHD2 [C257];B60ZAC2 [E230]

PART NO. 4214650 2200 SRM 2102

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or
exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 WARNING

California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can
expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and birth defects or other reproductive harm. For
more information, go to www.P65Warnings.ca.gov.
 Table of Contents

TABLE OF CONTENTS
General................................................................................................................................................................... 1
Accessing the Drive Unit Compartment............................................................................................................ 4
Special Precautions................................................................................................................................................5
Discharging the Internal Capacitors................................................................................................................. 5
Electromagnetic Shield ......................................................................................................................................5
Electrical System Checks...................................................................................................................................... 6
Safety Precautions.............................................................................................................................................. 6
Dash Display..........................................................................................................................................................9
Description...........................................................................................................................................................9
Operation.......................................................................................................................................................... 9
Remove.................................................................................................................................................................9
Install.................................................................................................................................................................10
Controller............................................................................................................................................................. 11
Controller, Replace............................................................................................................................................11
Remove............................................................................................................................................................ 12
Install.............................................................................................................................................................. 12
Contactor Coil, Check....................................................................................................................................... 13
Fuses.....................................................................................................................................................................13
Horn......................................................................................................................................................................13
Replace...............................................................................................................................................................13
Brake Sensor Operation...................................................................................................................................... 14
Brake Sensor........................................................................................................................................................14
Removal............................................................................................................................................................. 14
Height Limit.........................................................................................................................................................15
Control Handle (Standard)..................................................................................................................................15
Disassemble.......................................................................................................................................................15
Assemble............................................................................................................................................................16
Control Handle (HD Option)............................................................................................................................... 18
Disassemble.......................................................................................................................................................18
Top Cover........................................................................................................................................................ 18
Remove Function Switches............................................................................................................................ 18
Remove Throttle Sensor Assembly................................................................................................................ 19
Remove Handle Shaft Assembly....................................................................................................................19
Remove the Coast Control Switches..............................................................................................................19
Assemble............................................................................................................................................................20
Install the Coast Control Switches................................................................................................................20
Install Switches Side Glide............................................................................................................................ 20
Install Handle Shaft Assembly......................................................................................................................20
Install Throttle Sensor Assembly.................................................................................................................. 20
Install Function Switches.............................................................................................................................. 21
Install Top Cover............................................................................................................................................ 21
Power Assist Steering (EPAS)............................................................................................................................ 22
Steer Motor........................................................................................................................................................22
Proximity Switch...............................................................................................................................................22
Remove...............................................................................................................................................................22
Install.................................................................................................................................................................22
Calibration.........................................................................................................................................................23
Smart Steer.......................................................................................................................................................... 24
Remove...............................................................................................................................................................24
Install.................................................................................................................................................................24
Aux Control Box Switches...................................................................................................................................25
Remove...............................................................................................................................................................25

©2022 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Install.................................................................................................................................................................25
Lights ...................................................................................................................................................................26
Work Light.........................................................................................................................................................26
Remove............................................................................................................................................................ 26
Install.............................................................................................................................................................. 26
Strobe Light.......................................................................................................................................................26
Remove............................................................................................................................................................ 26
Install.............................................................................................................................................................. 27
Platform Lights................................................................................................................................................. 27
Remove............................................................................................................................................................ 27
Install.............................................................................................................................................................. 27
Trailer Unloading Lights..................................................................................................................................28
Remove............................................................................................................................................................ 28
Install.............................................................................................................................................................. 28
Telemetry Wireless Asset Management System................................................................................................29
General.............................................................................................................................................................. 29
Level 1 - Wireless Monitoring (WIFI Group)...................................................................................................29
Communication Module................................................................................................................................. 33
Basic Operations.............................................................................................................................................33
ID Card / ID Reader.....................................................................................................................................33
Interlock Relay................................................................................................................................................34
Buzzer............................................................................................................................................................. 34
Wakeup........................................................................................................................................................... 34
Checklist......................................................................................................................................................... 35
Locate and Install the Communication Module.............................................................................................. 35
Install the Power Harness................................................................................................................................ 36
Install the Interlock Harness........................................................................................................................... 38
Install the Access Control Kit, Antenna and Buzzer...................................................................................... 39
Install the antenna.........................................................................................................................................40
Install buzzer.................................................................................................................................................. 40
Install the ID Card Reader............................................................................................................................ 41
Install the Checklist Display and Harness......................................................................................................43
First Switch On................................................................................................................................................. 44
Tool Operation................................................................................................................................................ 45
Connection...................................................................................................................................................... 46
Wireless Settings............................................................................................................................................ 48
Telemetry Tool Communication Problems....................................................................................................49
Truck Activation.................................................................................................................................................. 53
DC to DC Converter.............................................................................................................................................54
Troubleshooting................................................................................................................................................... 54

ii
2200 SRM 2102 General

General
Legend for Figure 1.
WARNING
1. AUX CONTROL BOX
DO NOT make repairs or adjustments unless you 2. START SWITCH
have been properly trained and authorized to do 3. DISPLAY
so. Improper repairs and adjustments can create 4. MANUAL COAST SELECTOR (OPTIONAL)
dangerous operating conditions. DO NOT operate 5. TILLER HANDLE
6. PLATFORM LIGHTS
a lift truck that needs repairs. Report the need for 7. TRAILER LIGHTS
repairs to your supervisor immediately. If repair is 8. BATTERY
necessary, attach a DO NOT OPERATE tag to the 9. BATTERY CONNECTOR
control handle and disconnect the battery.
This section describes the electrical systems used on
the motorized hand lift trucks. Procedures are
outlined for the maintenance, adjustment, and
repair that may be required when servicing these
lift trucks. See Figure 2.

Figure 1. Lift Truck Components

1
General 2200 SRM 2102

Figure 2. Electrical Components (Manual Steer Shown)

2
2200 SRM 2102 General

Legend for Figure 2.

1. GRAB RAIL 6. FUSE

2. AUX CONTROL BOX 7. TRACTION CONTROLLER
3. TILLER HANDLE 8. DIAGNOSTIC PORT
4. HYDRAULIC PUMP MOTOR 9. CONTACTOR
5. TRACTION MOTOR 10. ELECTRIC BRAKE

3
General 2200 SRM 2102

ACCESSING THE DRIVE UNIT

COMPARTMENT
The drive unit compartment is concealed behind a
molded cover which fits securely around the drive
unit and steer support to the frame. The floor mat
fits snugly in the operator platform after the drive
unit cover is installed.
To remove the drive unit cover, pull floor mat away
from the drive unit using recessed section in front of
mat. See Figure 3. Next, reach under the side of the
drive unit cover near the bottom and find the grip
slot. With both hands, pull up and away from the
truck until the bottom of the cover kicks out from
the retaining clips. See Figure 4. Repeat this for the
other side of the cover. Work around the edge of the
cover until it is freed from the truck.

1. CAPSCREW 10. PAD, LH

2. NUT 11. PAD, RH
3. ACCESS COVER, 12. WASHER
RH 13. LOCKNUT
4. ACCESS COVER, 14. CAPSCREW
LH 15. CAPSCREW
5. HELMET COVER 16. DRIVE UNIT
6. CAPSCREW COMPARTMENT
7. CAPSCREW COVER
8. STAND OFF 17. FRAME
9. MAIN COVER
1. FLOOR MAT
2. DRIVE UNIT COMPARTMENT COVER
3. FRAME Figure 4. Drive Unit Compartment Cover
4. CASTER ADJUSTMENT ACCESS
To install the drive unit cover, make sure the floor
Figure 3. Floor Mat mat is pulled away from the drive unit. Place the
bottom of the drive unit cover onto the operator
platform and position the lower edges partially into
the lower retaining clips. Push the top of the cover
partially into the upper retaining clips. Do not push
either edge of the cover in completely before starting
all edges into the proper place. When the cover is
aligned and started properly, press the cover
completely into the retaining clips and place the
floor mat into the operator platform around the
cover.

4
2200 SRM 2102 Special Precautions

Special Precautions
DISCHARGING THE INTERNAL
CAPACITORS
When working with the electrical systems of the
truck, it is necessary to discharge the internal
capacitors of the controllers associated with each
circuit affected.

WARNING
Capacitors inside the controllers can hold an
electrical charge after the battery is disconnected.
Discharge the internal capacitors before servicing
the electrical system to prevent injury or electronic
damage.

1. Move the lift truck to a safe, level area and

completely lower the mast. Turn the key switch
to the OFF position and attach a DO NOT
OPERATE tag to the control handle. Block the
drive wheel to prevent unexpected movement.

2. Disconnect the battery power cable connector

from the truck connector located on the right
side of the frame. Pull the battery cable 1. CONTROLLER
connector handle to separate the battery 2. POSITIVE CONNECTION (B+)
3. INSULATED JUMPER WIRES
connector from the truck connector. 4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTIONS (B−)
3. Remove the operator compartment cover.
Figure 5. Discharging the Controller
4. Discharge the internal capacitor in the
controllers by connecting a 200-ohm, 2-watt ELECTROMAGNETIC SHIELD
resistor across the controller B+ and B−
terminals of the motor controller for 10
seconds. Remove the resistor after discharging WARNING
the capacitors. See Figure 5. Never operate Power Assist Steering models with
the Electromagnetic Shield removed.

A metallic shield is installed between the MDU and

brake assembly and the steering assembly on power
assist steering units. This shield deflects the
electromagnetic field generated by the MDU and
brake assembly which can interfere with the
operation of the torque sensor. Make certain that
the Electromagnetic Shield is reinstalled before
operating the lift truck after servicing to prevent
erratic operation of the power assist steering
function.

5
Electrical System Checks 2200 SRM 2102

Electrical System Checks

1. Block lift truck so the drive tire is raised
WARNING slightly off the floor to prevent unexpected
Disconnect the battery before opening the movement when making checks.
compartment cover or inspecting or repairing the
electrical system. If a tool causes a short circuit,
the high current flow from the battery can cause WARNING
personal injury or property damage. DO NOT put the lift truck on blocks unless the
The capacitor in the transistor controller can hold surface is solid, even, and level. Make sure that all
an electrical charge after the battery is blocks used to support the lift truck are solid, one-
disconnected. To prevent electrical shock and piece units. Put a block in front and back of the tire
personal injury, discharge the capacitor before or wheels touching the ground to prevent
inspecting or repairing any component in the drive unexpected movement of the lift truck.
unit compartment. Wear safety glasses. Make
certain the battery has been disconnected.
WARNING
All checks, adjustments, and repairs in the drive DO NOT raise the lift truck by attaching an
unit compartment are done with the compartment overhead crane to areas that will be damaged.
cover removed. Remove the drive unit compartment Some of these points are not designed to support
cover for access to the electrical components. the weight of the lift truck. The lift truck can be
damaged or it can fall, causing serious injury.
SAFETY PRECAUTIONS Attach the chain or sling to a support structure of
the lift truck frame.
WARNING
Some checks require the battery to be
reconnected. DO NOT connect the battery until the WARNING
procedure tells you to do so. Make sure the drive Never raise the forks any higher than necessary to
wheel is raised to prevent truck movement and change the load wheels. Always raise both forks at
possible injury. Raise the drive wheel. The blocks the same time. Raising the forks too high or
must prevent the lift truck from falling and causing unevenly can cause the lift truck tip over and
personal injury or property damage. cause personal injury or property damage.

2. Use a crane or jack to raise the forks or motor

compartment assembly. Put blocks under the
CAUTION forks or the edge plates of the motor
To avoid controller damage, always disconnect the compartment assembly. See Figure 6. Make
battery before disconnecting any cables from the sure the lifting device has a capacity of at least
controller. Discharge the capacitor, and never put two-thirds (2/3) of the combined weight of the
power to the controller with any power wire lift truck and the battery as listed on the
disconnected. Never short any controller terminal nameplate.
or motor terminal to the battery. Make sure to use
proper procedure when servicing the controller.

6
2200 SRM 2102 Electrical System Checks

Figure 6. Putting the Lift Truck on Blocks

3. Turn the key switch to the OFF position and each battery terminal and a clean connection
disconnect the battery. on the frame. Remove any circuit paths
between the controller and the frame of the lift
4. Discharge the capacitors. See Special truck, such as a dirty battery case. Carbon dust
Precautions in this section. in a motor or other parts can cause a circuit
path. Check for additional equipment that may
NOTE: These checks require a volt-ohmmeter with cause a circuit path to the frame.
a meter movement. Most digital meters will not
operate correctly for some of these checks. Specific 7. Check for voltage between each terminal of the
checks require additional equipment. connector that fastens to the battery and a
NOTE: The correct meter polarity is necessary for clean connection on the frame. Normally, there
the checks. The voltage checks are made between is small voltage (less than 30 percent of the
the point indicated in Table 1 and battery negative. battery voltage) between the battery and the
Connect the meter negative to battery negative. frame, even though the resistance is very high.
A higher voltage can indicate a dirty battery or
NOTE: The battery does not have to be removed to a damaged battery. Clean the battery and
check the specific gravity. battery compartment as necessary.
5. Using a hydrometer, check the specific gravity
of the battery. If the specific gravity is less than 8. Visually check for parts or wires that are loose
1.260, the battery is not fully charged or is or damaged.
damaged. A fully-charged battery has a specific
gravity of 1.270 to 1.290. A discharged battery NOTE: Make an identification of any wires before
has a specific gravity of approximately 1.165. you disconnect them. The wires must be
reconnected correctly after checks or repairs.
6. The electric lift truck has a two-wire system.
The frame must not be a common electrical
path. Check for 50,000 ohms or more between

7
Electrical System Checks 2200 SRM 2102

Table 1. Voltage Checks

LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION.
NO FAULT IS DISPLAYED ON THE CONTROLLER.

Possible Causes:

1. Battery not connected.

2. Control fuse is damaged.

3. Key switch or brake switch is damaged.

4. Transistor controller connector unplugged.

5. Transistor controller is damaged.

1.0 Check for battery voltage on the battery ― ― ― ―▸ 1.01 Battery voltage at control fuse.
side of control fuse. ―― Check for open control fuse.
|
| 1.02 No battery voltage at control fuse. Connect
| ― ―▸ battery or check wiring between battery and
fuse.

Check for battery voltage at control fuse ― ― ― ―▸ Battery voltage at key switch. Check for
1.1 1.1.1
terminal of key switch. ―― damaged key switch. Check connector.
|
| 1.1.2 No voltage at key switch. Wire to key switch
| ― ―▸ or connections is damaged.

1.3 Key switch closed. Brake switch closed. 1.3.1 Battery voltage at B+ terminal. Check fault
Check for battery voltage at ― ― ― ―▸ code. If no fault code, possible damaged
B+ terminal of transistor controller. ―― control handle card.
|
| 1.3.2 No voltage at B+ terminal. Check B−
| ― ―▸ terminal. Check fault code.

8
2200 SRM 2102 Dash Display

Dash Display
DESCRIPTION REMOVE
The dash display has a LCD screen for displaying Perform the following procedure when servicing the
truck system information. The display has five display assembly:
indicator lights for truck function status. There are
five number keys for password input if the lift truck 1. Remove two capscrews from the top of frame
is equipped for passwords. Number keys are also securing the dash cover assembly to the truck.
used for navigating the on-board setup and service See Figure 7.
menus. The dash display also contains a battery
state-of-charge indicator and is equipped to allow
operator selectable drive modes.

Operation
The following is the normal sequence that occurs
after the operator is in the operating position with
the battery connected to the lift truck:
• After the key is moved to the START position,
ENTER PASSWORD will be shown on the
LCD screen if the passwords function has
been enabled.
• After a correct password has been entered or
the passwords function is disabled, the
indicator symbols will light up from left to 1. COVER
right. 2. DISPLAY
• The truck horn will beep. 3. FRAME
4. CAPSCREW
• The bar graph for the battery-state-of-charge
is illuminated on the LCD screen. If the Figure 7. Dash Assembly
battery is discharged to lift interrupt, the
battery indicator symbol will be flashing. If a 2. From the top, slightly pull the dash cover
battery of the wrong voltage has been
assembly forward and lift from the truck.
installed, the wrench indicator symbol will be
flashing. If necessary, have these problems
corrected before attempting to operate the lift 3. Remove four capscrews from the display, see
truck. Figure 8.
• Performance mode will be displayed. 4. Disconnect the electrical connector from the
• Steer angle indicator will be displayed. (Only back of the display.
on trucks equipped with power steering).
• Truck speed indicator will be displayed.
• Truck hours will be displayed.
• The lift truck is now ready for operation.

9
Dash Display 2200 SRM 2102

3. CAPSCREW
4. DASH COVER
5. DISPLAY
6. DISPLAY BRACKET

Figure 8. Display Assembly

INSTALL
Refer to Figure 7 and Figure 8 when performing the
following procedures:

1. Connect display electrical connector.

2. Install display assembly and four capscrews.

3. Install dash assembly cover.

4. Install two capscrews securing cover to frame.

1. CAPSCREW
2. ELECTRICAL CONNECTOR

10
2200 SRM 2102 Controller

Controller

WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the
control handle and disconnect the battery.
Disconnect the battery and separate the connector
before opening the drive unit compartment cover
or inspecting or repairing the electrical system. If a
tool causes a short circuit, the high current flow
from the battery can cause personal injury or
property damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component in the drive
unit compartment. See Discharging the Internal
Capacitors in this section.

All checks, adjustments, and repairs in the drive

unit compartment are done with the compartment
cover removed. Remove the drive unit compartment
cover for access to the electrical components and
discharge the capacitor. See Accessing the Drive
Unit Compartment in this section.
1. MAIN CONTACTOR TERMINAL (OUT)
CONTROLLER, REPLACE 2. MAIN CONTACTOR
3. TERMINAL W, CABLE
4. ELECTRICAL CONNECTOR, TRACTION
5. GROUND, HYDRAULIC PUMP
WARNING 6. TERMINAL U, CABLE
Some checks require the battery to be connected. 7. FUSED B(+)
DO NOT connect the battery until the procedure 8. FUSE, 400A
tells you to do so. Make sure the drive wheel is 9. CONTROLLER B(-)
10. TERMINAL V, CABLE
raised to prevent movement and possible injury. 11. MAIN CONTACTOR TERMINAL (IN)
Raise the drive wheel. See the section Periodic 12. TRACTION CONTROLLER
Maintenance 8000SRM2105 - How to Put a Lift
Truck on Blocks. The blocks must prevent the lift Figure 9. Controller Wiring (Prior to July 2018)
truck from falling and causing personal injury or
property damage.

11
Controller 2200 SRM 2102

3. Discharge the capacitor. See Discharging the

Internal Capacitors in this section.

4. Tag and disconnect wires from the controller.

See Figure 9.

1. MAIN CONTACTOR TERMINAL (OUT)

2. MAIN CONTACTOR
3. TERMINAL W, CABLE
4. ELECTRICAL CONNECTOR, TRACTION 1. TRACTION CONTROLLER
5. GROUND, HYDRAULIC PUMP 2. CAPSCREW
6. TERMINAL U, CABLE 3. WASHER
7. FUSED B(+) 4. NUT
8. FUSE, 400A 5. LOCKWASHER
9. CONTROLLER B(-)
10. TERMINAL V, CABLE
11. MAIN CONTACTOR TERMINAL (IN) Figure 11. Traction Controller
12. TRACTION CONTROLLER
5. Remove nuts securing shield box to controller if
Figure 10. Controller Wiring (July 2018 and After) equipped.

DO NOT replace the controller until you have 6. Remove mounting screws and remove
thoroughly checked all other electrical components controller.
and are sure the controller is malfunctioning. .
Install
Remove 1. Install replacement controller on lift truck
1. Move the truck to a safe, level location. Turn using mounting hardware.
the key switch to the OFF position, disconnect
the battery, and block the drive tire to prevent 2. Connect wires and cables to the proper
unexpected movement. terminals as identified during the removal
procedure.
2. Remove the drive unit compartment covers.

12
2200 SRM 2102 Fuses

3. Connect battery and turn the key switch to the

ON position. Test the brake for proper
operation. Turn the key switch to the OFF
position and disconnect the battery again to
continue installation.

4. The Traction Controller must be reprogramed.

Run Field Service tool to program and
download the CDF.

5. Install the drive unit compartment covers.

CONTACTOR COIL, CHECK

Disconnect coil wires. Test contactor coil using an
ohmmeter to measure the resistance. The coil
should read 23 ohms ±10%. Remove and replace
contactor if resistance readings indicate a short
circuit in both directions or if there is an open
circuit in both directions. Make sure coil wires are
connected to the proper terminals. See Figure 12.

Figure 12. Contactor

NOTE: The contactor contains no serviceable parts

and must be replaced as a complete assembly.

Fuses
400-amp (FU 1) fuse mounted on the controller for
both the drive motor and the hydraulic pump motor.
WARNING
Trucks with power assisted steering have a 30-amp
The capacitor in the transistor controller can hold
in-line fuse in the steering motor circuit. Remove
an electrical charge after the battery is
and replace as required. Refer to Figure 9.
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before If it cannot be determined visually that a fuse has
inspecting or repairing any component in the drive failed, check for continuity using an ohmmeter.
unit compartment. Wear safety glasses. Make Make certain that any replacement fuse is of the
certain the battery has been disconnected. right amperage before installation.

The motorized hand trucks use a single 4-amp in-

line fuse (FU 5) for the control circuit, and a single

Horn
REPLACE 2. Remove the drive unit compartment covers. See
in this section.
1. Move the truck to a safe, level location; turn
the key switch to the OFF position; and 3. Disconnect the horn wiring from the main
disconnect the battery. Block the drive tire to wiring harness.
prevent unexpected movement.

13
Brake Sensor Operation 2200 SRM 2102

6. Connect the battery, turn the key switch to the

CAUTION ON position, and test for proper operation.
DO NOT overtighten horn mounting hardware. Turn the key switch back to the OFF position
and disconnect the battery again to finish
4. Remove nuts and washers from bolts securing repairs.
horn to frame. Remove horn from bolts.
Position new horn onto bolts as removed and 7. Install the drive unit compartment covers as
install washers and nut. removed. See in this section. Return the lift
truck to service.
5. Install wiring to horn as removed.

Brake Sensor Operation

The brake is applied when the control handle is in
the full up or full down position. The brake is
released by lowering the control handle to the RUN
position and selecting a direction with the speed/
direction control. See Figure 13. The parking brake
is controlled by a proximity sensor that monitors the
control arm position. If the parking brake does not
release or apply properly, check the operation of the
brake proximity sensor.

A. BRAKE ZONE
B. RUN ZONE
C. BRAKE ZONE

Figure 13. Brake Operation

Brake Sensor
REMOVAL 3. Tag all wiring connections to the sensor for
later use when assembling the sensor to the
1. Position the lift truck on a level surface. Turn steer swivel.
the key switch to the OFF position and
disconnect the battery.

2. Remove the two screws and remove wire guard

assembly. See Figure 14.

14
2200 SRM 2102 Height Limit

5. Loosen Jamnuts and remove sensor.

6. Install new sensor into steer swivel. See

Figure 14.

7. Set brake sensor gap to 3 to 4.0 mm and

tighten set screw.

8. Tighten jamnuts.

CAUTION
Overtightening the screws can damage the sensor.

9. Install wire guard and secure with two screws.

10. Connect battery and turn the key switch to the

1. BRAKE SENSOR 3. WIRE GUARD ON position.
2. CAPSCREW 4. SET SCREW
5. STEER SWIVEL 11. Test for proper operation before returning the
truck to service.
Figure 14. Brake Sensor

4. Loosen set screw, see Figure 14.

Height Limit
Height limiting is controlled by the height limit is when the lift cylinder reaches maximum height,
switch in the controller. When the controller senses and the second is when the load exceeds the rated
a high current draw from the hydraulic pump, it capacity. In either case, the controller will shut
will shut down the pump. There are two separate down the pump.
incidents that will cause this current draw: The first

Control Handle (Standard)

DISASSEMBLE 1. Move the lift truck to a safe, level area and
block the drive wheel to prevent movement of
the lift truck. Refer to Figure 6.
WARNING
DO NOT make repairs or adjustments unless you 2. Turn the key switch to the OFF position and
have been properly trained and authorized to do disconnect the battery.
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate 3. The handle is comprised of two molded-plastic
a lift truck that needs repairs. Report the need for halves and is held together by capscrews.
repairs to your supervisor immediately. If repair is Remove the screws.
necessary, attach a DO NOT OPERATE tag to the
control handle and disconnect the battery. 4. Disengage the hooks under the auto-reverse
switch. Slide the upper half off of the lower half
NOTE: It is not always necessary to remove and using a gentle rocking motion while lifting and
disassemble all the components that make up the pulling the upper half away from lower half.
control section of the steering handle to replace a
damaged part. Perform only the steps necessary to 5. Unplug the handle wiring harness from the
replace the damaged parts. See Figure 15. control handle card.

15
Control Handle (Standard) 2200 SRM 2102

6. Place upper half of the handle upside down on 3. Connect the switches and wire harness
a secure, level work surface so the internal connectors.
parts are facing up.
4. Plug handle wiring harness into control handle
NOTE: Make note of the position of the butterfly card.
knobs relative to the handle BEFORE removal.
7. Remove one of the butterfly knobs by removing
the screw that holds it to the handle (8). CAUTION
DO NOT force the upper half onto the lower half as
8. Using the remaining butterfly knob, slide the this will cause damage to the retaining hooks of
shaft out of the handle. Be careful not to rotate the upper half.
the shaft within the control handle card.
5. To install upper half of handle onto the lower
9. Refer to the wiring diagram, or draw a sketch half:
of where each of the push button switches are
plugged into the control handle card. Unplug a. Tip the upper half up and align the hooks
switches from the control handle card and under the auto-reverse switch.
remove the card.
b. Lower the upper half onto the lower half.
ASSEMBLE 6. Install capscrews to retain upper half of control
1. Install control handle card in the upper half of handle to lower half.
control handle. See Figure 15.
7. Connect battery cable and test control handle
NOTE: When inserting knobs, make sure that operation.
flange on one of the butterfly knobs inserts between
spring on handle (9).
2. Slide shaft and butterfly knob into control
handle card. Be careful not to rotate the shaft
inside the control handle card.

16
2200 SRM 2102 Control Handle (Standard)

1. LOWER HALF 12. SPRING

2. UPPER HALF 13. SWITCH
3. CONTROL HANDLE CARD ASSEMBLY 14. HORN SWITCH COVER
4. SHAFT 15. SWITCH ASSEMBLY
5. BUSHING 16. LABEL
6. LH BUTTERFLY KNOB 17. LABEL
7. WASHER 18. LABEL
8. SCREW 19. ACTUATOR
9. SPRING 20. ACTUATOR
10. RH BUTTERFLY KNOB 21. SPRING
11. SWITCH COVER 22. MICROSWITCH

Figure 15. Control Handle

17
Control Handle (HD Option) 2200 SRM 2102

Control Handle (HD Option)

DISASSEMBLE 2. The switch mount is held to the switch retainer
by four tabs - two on each side of the switch
Top Cover mount. See Figure 17.
NOTE: Cover screws near the traction reverse
switch are shorter than the cover screws near the
control handle arm. See Figure 16.
1. While holding the top cover in place, remove
the four cover screws securing the top cover to
the base from the bottom of the handle
assembly.

1. BELLY SWITCH 10. LOCKING PLATE

2. SPRING, BELLY 11. SCREW
3. ASSEMBLY, TOP 12. HORN TAB
COVER 13. SCREW
4. LIFT / LOWER 14. ROCKER SWITCH
SWITCH ASSEMBLY
5. HORN SWITCH 15. DUMMY SWITCH
6. MOLEX CONN. 16. SCREW
SWITCH 17. COAST SWITCH,
7. SPRING, SIDE LEFT
TRACKER
8. COAST SWITCH,
1. TOP COVER 4. CAPSCREW, COVER RIGHT
2. TILLER HEAD 5. CAPSCREW, SIDE 9. COVER
3. TILLER ARM COVER
6. GRIP HANDLE
Figure 17. Switch Mounting
Figure 16. Handle Assembly
3. Remove the switch mount from the switch
2. Slowly lift the top cover from the base. retainer by lightly applying pressure to the
tabs on one side of the switch mount and
3. Tag, identify, and disconnect the wiring slightly lifting the switch mount away from the
connecting the top cover switches to the control retainer. Once clear, remove the switch mount
handle. from the top cover.

4. Remove the pin retaining the traction switch at

Remove Function Switches
the front of the switch mount.
1. Remove the top cover. See Top Cover in this
section. 5. Slide each switch from the switch mount and
remove the switches with the attached wiring.

18
2200 SRM 2102 Control Handle (HD Option)

NOTE: The switches are not individually

serviceable. The switch assembly must be serviced
as a unit.

Remove Throttle Sensor Assembly

1. Remove the top cover. See Top Cover in this
section.

NOTE: Position the handle vertically to access the

screws securing it to the base. Hold the switch while
removing screws from the base. 1. HANDLE GRIP, 5. E-RING
RIGHT 6. SHAFT
2. Remove the two screws from the bottom center 2. BUSHING 7. PRINTED CIRCUIT
of the handle base. 3. SPRING, BOARD
DIRECTIONAL 8. HANDLE GRIP, LEFT
3. While lifting the throttle sensor assembly, CONTROL
RETURN
remove the pin securing the link to the throttle 4. WASHER
sensor assembly using needle-nose pliers.
Figure 18. Handle Shaft
4. Maneuver the link to disconnect it from the
throttle sensor assembly. 3. Install an M6 capscrew into the threaded end of
the handle shaft pin and remove the pin from
5. Disconnect the wiring connected to the throttle the handle casting.
sensor.
4. Lift the handle shaft assembly from the handle
6. Remove the two capscrews, washers, spacers, casting and maneuver the link to disconnect it
and nuts securing the sensor to the throttle from the throttle sleeve.
sensor and remove the sensor.
5. Slide the grips from the shaft. Recover the
7. Remove the inner bushing supporting the locking rods from inside the grips if equipped.
throttle sensor end of the throttle cam.
6. Move the butterfly actuators as required to
8. Slide the cam out of the outer bushing. Take remove the spiral pins from the shaft (2 pins
care to ensure the throttle return spring tangs per side).
slide off the sensor mounting bracket and
remain in the cam. Remove the cam and spring 7. Remove the butterfly actuators from the shaft.
from bracket.
Remove the Coast Control Switches
9. Remove the outer spring from the bracket.
1. Remove the top cover. Refer to Top Cover in
10. Inspect the bushings for excessive wear and this section.
replace as needed.
2. Tag, identify, and disconnect the wiring from
Remove Handle Shaft Assembly the coast control switches.

1. Remove the top cover. Refer to Top Cover in 3. Disconnect the two leads from the switch at the
this section. wiring connector. The individual switch wires
must be removed from the connector body to
2. Remove the retaining rings from either side of remove the switch from the lift truck.
the handle to access the handle shaft pins. See
Figure 18. 4. Remove the locking nut and washer from the
switch body and remove the switch from the top
cover.

19
Control Handle (HD Option) 2200 SRM 2102

ASSEMBLE 5. Install the handle shaft pins through the

handle, shims, and into the ends of the handle
Install the Coast Control Switches shaft. Ensure the butterfly actuators rotate
1. Install the switch and wiring through the freely.
mounting hole in the top cover.
6. Install the retaining pin in the link at the
2. Install washer and lock nut removed during throttle sensor end of the link.
disassembly.
7. Install the retaining rings removed during
3. Connect leads from the switch wiring to the disassembly into the handle. Replace the
connector body and reconnect the connector. retaining rings if the rings show any sign of
damage.
Install Switches Side Glide
8. Install the top cover assembly. See Top Cover
1. Install the switch to the switch base with the in this section.
two screws removed during disassembly.
Install Throttle Sensor Assembly
2. Connect the wiring removed during
disassembly. NOTE: Re-calibration is required when changing or
servicing the throttle assembly.
3. Install the actuator and two springs into the
cover. 1. Install the outer cam shaft bushing into the
mounting bracket.
4. Place the switch base on the cover and install
the assembly to the handle with the two screws 2. Install the cam and spring assembly removed
and washers removed during disassembly. during disassembly. Insert the spring end into
the outer bushing and spread the spring tangs
Install Handle Shaft Assembly over the tab on the mounting bracket.

1. Slide the butterfly actuators onto the handle 3. While holding the cam shaft in place, slide the
shaft and engage the spiral pins in the shaft. inner bushing over the shaft and install into
the mounting bracket.

CAUTION 4. Apply a light coating of white lithium grease

Make sure the lock rods are installed opposite one onto the throttle return spring.
another in capped slots of the butterfly actuators.
5. Apply a light coating of white lithium grease to
both ends of the link and maneuver the link
NOTE: Locking rods can be installed or removed
into the throttle sensor assembly and the
depending on operational preference.
handle shaft sleeve. Install the retaining pin
Align the grips with the locking rods and into the link and the throttle sensor end of the
2.
install the grips onto the handle shaft. link.

Install the link from the throttle sensor into the 6. Install the throttle sensor to the base using the
3.
shaft sleeve and the throttle sensor assembly. capscrews, washers, and nuts removed during
disassembly. Ensure the tang on the sensor
4. Position the handle shaft assembly into the aligns correctly with the shaft on the bottom
handle. assembly.

NOTE: The pins are a slight press fit to the handle 7. Torque the capscrews to 2 N•m (17.7 lbf in).
and may require slight tapping with a hammer and
8. Install the wiring connector into the base of the
punch to install.
throttle sensor.

20
2200 SRM 2102 Control Handle (HD Option)

9. Install the two capscrews and washers to retain 7. Install top cover. See Top Cover in this section.
the sensor assembly to the handle base.
Install Top Cover
10. Operate the linkage to ensure there is no
binding. 1. Reconnect any wiring disconnected during
disassembly.
11. Install the top cover. See Top Cover in this
section. 2. Install the traction reversing switch actuator
and springs into the top cover. The springs
mount between the actuator and the front of
Install Function Switches
the switch retainer plate. See for position of
1. Slide each switch into its mounting slot in the actuator.
switch mount.
3. Hold the traction reversing actuator and
NOTE: The retaining pin must be installed from the springs in place in the top cover and install the
bottom of the switch mount. traction reversing actuator into the recess in
2. Install the retaining pin for the traction the bottom half of the handle. Lower the cover
reversing switch into the switch mount. onto the handle base.

3. Spread the retaining pin legs and ensure the 4. Ensure no wiring is pinched between the cover
legs lay as flat as possible against the top of the and the handle base.
switch mount for correct fit up with the switch
NOTE: Exercise caution when installing the four
retainer.
self tapping screws into the top cover. The screws
4. Install two of the mounting tabs on one side of must be installed into the existing threads. Ensure
the switch mount into the corresponding the screws are started into the existing threads of
mounting slots of the switch retainer. the top cover or stripping of the threads may occur.
5. Install the four screws in the corners of the
5. Snap the opposite side tabs into the switch handle base to retain the top cover.
retainer.

6. Reconnect any wiring disconnected during

disassembly.

21
Power Assist Steering (EPAS) 2200 SRM 2102

Power Assist Steering (EPAS)

STEER MOTOR MDU when the control handle is in the straight-
ahead position.
The steer motor assembly consists of the electric
motor and the steer motor gear.

1. CAPSCREW
2. PROXIMITY SWITCH
3. BRACKET
4. NUT
5. STEER SUPPORT

Figure 20. Proximity Switch

1. ELECTRICAL 6. PINION GEAR
CONNECTOR 7. RETAINER REMOVE
2. STEER MOTOR 8. CAPSCREW
3. STEER MOUNT 9. KEY 1. Disconnect the proximity switch wiring from
4. WASHER main wiring harness.
5. CAPSCREW
2. Loosen the jam nut from against the proximity
Figure 19. Steer Motor switch bracket, see Figure 20.

PROXIMITY SWITCH 3. Unscrew the proximity switch from the

bracket.
A proximity switch is located on the steer support
assembly on power assist steering models. This
switch signals to the controller that the control arm INSTALL
is in the straight ahead position. After startup, the 1. Install the jam nut onto the proximity switch
controller will wait for the signal from the proximity and position it near the end of the threads
switch that the handle has passed through the nearest the wiring harness end of the switch.
straight-ahead position before it will allow rabbit
speed to be activated. If rabbit speed is not 2. Turn the control handle and MDU to the
functioning properly, check that the proximity "straight ahead" position.
switch is adjusted properly. The sensor should be
set 2.00 mm (0.08 in.) from its target plate on the

22
2200 SRM 2102 Power Assist Steering (EPAS)

3. Screw the proximity switch into the bracket 3. Turn the key switch to the OFF position and
until the face of the sensor is 2.00 mm (0.08 in.) remove the drive unit compartment cover.
from its target plate on the MDU.
4. The Calibration Tab is an unconnected wire
with a female spade connector hanging near
CAUTION the Diagnostic Port Connector. Attach the
DO NOT overtighten jam nut. Calibration Tab to the B+ terminal (right post)
of the contactor, using a 914 mm (36 in.) 14 Ga.
4. Hold the proximity switch in position, and turn jumper wire with an alligator clip on one end
the jam nut down against the MDU housing and a male spade connector on the other.
and snug to secure switch in place.
NOTE: DO NOT interfere with the lift truck or
5. Connect the proximity switch wiring to main tiller handle during the calibration cycle.
wiring harness and secure harness as removed. Attempting to operate the truck during calibration
command will abort the calibration process.
CALIBRATION 5. Standing clear of the steer handle, turn the key
switch to the ON position.
WARNING NOTE: Not applicable to new EPAS system.
If at any time a tiller handle slowly moves in one
6. The lift truck will start up in calibration mode
direction during startup, it is likely calibration
and the tiller handle will begin to move under
needs to be performed.
its own power during the calibration cycle. Be
Power assist steering calibration should be aware that the tiller arm will move through a
performed if either the torque sensor or EPAS unit range of motion that will vary, from a few
is serviced or replaced or anytime the drive tire is degress to full range of motion.
replaced.
7. Wait at least 5 seconds after the calibration
cycle has ended (the tiller has stopped moving)
and remove the jumper wire.
CAUTION
The brake will be disengaged while in calibration NOTE: Not applicable to new EPAS system.
mode. Perform calibration only on a level surface.
Do not perform calibration on an incline. 8. Wait at least 5 seconds after the jumper wire is
removed and cycle the key switch to the OFF
1. Position the lift truck on a normal, smooth position and then back to the ON position.
surface floor away from personnel or other
equipment. 9. Check the lift truck for proper operation.
Reinstall the drive unit compartment cover.
2. Turn on User Interface Display and follow
steps for calibration procedure. Read and
accept the user agreement. See Calibrating
EPAS , section in User Interface
2200SRM2161 .

23
Smart Steer 2200 SRM 2102

Smart Steer
The Smart Steer Sensor is located on the front of Legend for Figure 21.
the MDU. This sensor signals to the controller when
the steering system has changed in angle 15° in A. PROXIMITY RANGE
either direction. When sensed, the system will
reduce truck speed and acceleration while 1. MDU PLATE
cornering. If smart steer is not functioning properly, 2. CAPSCREW
3. NUT
check that the sensor is adjusted properly. The 4. SENSOR TARGET
sensor should be set 5.00 mm (0.19 in.) from its 5. JAM NUT
target plate on the mdu when the control handle is 6. SMART STEER SENSOR
in the straight-ahead position. 7. MOUNTING BRACKET

REMOVE 3. Unscrew the proximity switch from bracket.

1. Disconnect the smart steer sensor wiring from INSTALL

main wiring harness.
1. Install the lower jam nut onto the smart steer
2. Loosen the jam nut from against the sensor sensor and position it near the end of the
mounting bracket. threads nearest the wiring harness end of the
switch.

2. Turn the control handle and MDU to the

"straight ahead" position.

3. Screw the sensor into the mounting bracket

until the face of the sensor is 5.00 mm (0.19 in.)
from its target plate. See Figure 21.

CAUTION
DO NOT overtighten jam nut.

4. Install and tighten upper jam nut.

5. Connect the smart steer sensor wiring to main

wiring harness and secure harness as removed.

Figure 21. Smart Steer Sensor

24
2200 SRM 2102 Aux Control Box Switches

Aux Control Box Switches

REMOVE 4. Remove two Allen head screws and washers
retaining control box cover to handrail.
1. Turn key to OFF position. Disconnect battery.
5. Remove control box Allen head screw and
2. Remove drive unit compartment cover. remove switch assembly. See Figure 22
3. Unplug aux control box wiring harness and 6. Gently pull wiring harness out of grab rail a
gently push some of the wiring up inside the couple of inches or just enough to allow switch
tube of the grab rail. wiring to be unplugged.

7. Test switches for continuity. Replace any

switches found to be damaged or inoperative.

8. Inspect actuator springs for damage. Replace

any damaged springs.

INSTALL
1. Connect control box electrical connector. See
Figure 22.

2. Install control box assembly into grab handle

and install Allen head screw.

3. Install control box cover.

4. Install two Allen head screws to retain cover

and switches to rail.

5. Reconnect battery and test operation of lift

1. COVER 6. LOWER BUTTON truck before returning truck to service.
2. CAPSCREW 7. LIFT BUTTON
3. RABBIT BUTTON 8. HANDRAIL
4. CONTROL BOX 9. ELECTRICAL
5. CAPSCREW CONNECTOR

Figure 22. Aux Control Box

25
Lights 2200 SRM 2102

Lights
WORK LIGHT 2. Connect battery.

Remove STROBE LIGHT

1. Disconnect the battery and discharge
Remove
capacitors. Refer to Figure 5.
1. Disconnect the battery and discharge
2. Disconnect work light wiring harness from capacitors. Refer to Discharging the Internal
wiring harness. See Figure 23. Capacitors

2. Disconnect strobe light electrical connector

CAUTION from cab wiring harness.
Clean any dirt or oil from the lamp surface with
alcohol and a lint-free cloth or tissue. Any foreign
particles or materials on the bulb surface can
cause hot spots on the bulb and result in lamp
failure.

3. Remove work light mounting nut, lockwasher,

and lens assembly.

1. STROBE LIGHT GUARD

2. STROBE LIGHT LENS
3. ELECTRICAL CONNECTOR
4. NUT
5. GROMMET
6. CAPSCREW
1. LENS ASSEMBLY
2. NUT / LOCKWASHER Figure 24. Strobe Light Assembly
3. ELECTRICAL CONNECTOR
4. GROMMET, ELECTRICAL HARNESS 3. Remove capscrews, washers, and flange nuts
securing strobe light and light guard to strobe
Figure 23. Work Light Assembly
light mounting bracket. Remove strobe light
and guard from lift truck. See Figure 24.
Install
1. Using the washer and lock nut, install work
light to mounting bracket. See Figure 23.
Connect work light to pole harness.

26
2200 SRM 2102 Lights

Install 3. Remove three capscrews and nuts from

platform light assembly.
1. Place strobe light assembly and strobe light
guard onto mounting bracket. Secure assembly 4. Remove platform light assembly and disconnect
to mounting bracket with capscrews, washers, electrical connector.
and flange nuts.
Install
2. Connect strobe light electrical connector.
1. Connect platform light assembly electrical
3. Connect battery. connector and install light.

PLATFORM LIGHTS 2. Install three capscrews and nuts.

NOTE: Lights can be programmed to flash when 3. Install floor mat and connect battery.
low battery conditions are present. Ensure proper
battery charge when replacing platform lights.

Remove
1. Disconnect battery and discharge the
capacitors. See Discharging the Internal
Capacitors.

2. Remove floor mat, refer to Accessing the Drive

Unit Compartment.

1. FLOOR MAT
2. CAPSCREW
3. LIGHT ASSEMBLY
4. NUT

Figure 25. Platform Lights

27
Lights 2200 SRM 2102

TRAILER UNLOADING LIGHTS 4. Disconnect trailer light assembly wiring

harness from main wiring harness.
NOTE: The following steps are used to remove and
install either right or left front marker/turn signal
Install
light assembly.
1. Connect front trailer unloading light wiring
Remove harness to main wiring harness.
1. Disconnect battery and discharge capacitors. 2. Using the capscrew and nut, install light
See Discharging the Internal Capacitors. assembly onto mounting bracket.
2. If needed, place lift truck on blocks. Refer to 3. Connect the battery.
How to Put a Lift Truck on Blocks.

3. Remove capscrew and nut from light assembly.

1. ELECTRICAL CONNECTOR
2. LIGHT ASSEMBLY
3. NUT
4. CAPSCREW
5. MOUNTING BRACKET

Figure 26. Trailer Unloading Lights

28
2200 SRM 2102 Telemetry Wireless Asset Management System

Telemetry Wireless Asset Management System

GENERAL interlock the starting of lift truck. The main
function of level 1 configuration is reporting
hour meters and impacts through use of WIFI
WARNING or GSM to the communication module.
Failure to follow the instructions in this section • Level 2 - Wireless Access - This level of
can cause the lift truck to become inoperable or service connects passively to the CANbus and
damaged and result in personal injury, death, or interlocks the lift truck. Only authorized
users are allowed access through use of an
property damage. Read and follow all WARNINGS
RF-ID reader card. Performing maintenance
and CAUTIONS. will require use of a service card to disable all
The communication module and related parts shut down timers.
(harnesses, brackets, and subsystems) MUST be • Level 3 - Wireless Verification - This level
removed and installed by service technicians of service connects passively to the CANbus
trained in the removal and installation of these and interlocks the lift truck. Only authorized
systems and in accordance with the instructions users are allowed access through use of an
outlined below. RF-ID reader card. Additionally, a checklist
will be displayed and all items must pass
DO NOT modify, tap into, splice, or solder existing inspection before lift truck can be started.
factory harnesses, wiring, or connectors. Except Failing a checklist item can be configured to
for the wire harness clamps, replacement parts disable lift truck. A service card is required to
include all required wiring and hardware for proper start a lift truck that has failed a checklist
installation of new parts without disturbing or item. Performing maintenance will require
modifying the factory installed wiring or use of a service card to disable all shut down
accessories on the lift truck. timers.

ALWAYS disconnect the battery prior to removing The information in this section describes how to
and installing parts of the telemetry system to remove and install new hardware components that
prevent electrical shock or short circuits in the are replaceable, for each level of the Telemetry
electrical system of the lift truck. Wireless Asset Management System. For
information on programming the Telemetry
System reliability is dependent on correct wire Wireless Asset Management System, for diagnostic
harness routing. The wire harness must not and troubleshooting procedures, or for installing,
interfere with other wires, hoses, brackets, or connecting and routing the power (wire) harness,
other components that might contact and rub the Interlock Harness, and checklist display harness,
wire harness. The wire harness must be properly see the Wireless Asset Management manual
secured to lift truck frame to prevent rubbing with located on the Hyster Hypass Online system.
other components during normal vibration while Information on correctly routing and installing the
lift truck is in operation. Clamps should be used to power (wire) harness, Interlock Harness, and
securely fasten harness in place without excessive checklist display harness, can also be found in the
crimping of the wire harness. Diagrams and Schematics service manual listed
in the section of this manual.
The lift trucks covered in this Service Manual may
be equipped with an optional Telemetry Wireless LEVEL 1 - WIRELESS MONITORING (WIFI
Asset Management System. This system is designed
to allow monitoring of key systems for which the lift GROUP)
truck is equipped with. There are three levels of the The level 1 Telemetry Wireless Asset Management
Telemetry Wireless Asset Management System that System is comprised of the following components:
can be installed on your lift truck if this option is
• Power (wire) harness
chosen.
• A WIFI, GSM, or CDMA communication
• Level 1 - Wireless Monitoring (WIFI module
Group) - This level of service connects
passively to the CANbus and does not

29
Telemetry Wireless Asset Management System 2200 SRM 2102

• WIFI antenna (if communication module is • GSM, GPS, or CDMA GPS antenna (if
WIFI supported) communication module is GSM or CDMA
supported)

1. POWER (WIRE HARNESS)

2. COMMUNICATION MODULE
3. WIFI ANTENNA (WHITE)
4. GSM OR CDMA GPS ANTENNA (BLACK)

Figure 27. Level 1 - Wireless Monitoring

30
2200 SRM 2102 Telemetry Wireless Asset Management System

1. POWER (WIRE HARNESS)

2. INTERLOCK HARNESS
3. RFID READER
4. COMMUNICATION MODULE
5. BUZZER
6. WIFI ANTENNA (WHITE)
7. GSM OR CDMA GPS ANTENNA (BLACK)

Figure 28. Level 2 - Wireless Access

31
Telemetry Wireless Asset Management System 2200 SRM 2102

1. POWER (WIRE HARNESS)

2. INTERLOCK WIRE HARNESS
3. DISPLAY READER
4. RFID READER
5. BUZZER
6. COMMUNICATION MODULE
7. WIFI ANTENNA (WHITE)
8. GSM OR CDMA GPS ANTENNA (BLACK)

Figure 29. Level 3 – Wireless Verification

32
2200 SRM 2102 Telemetry Wireless Asset Management System

Communication Module
The Communication Module has two primary
connectors. The GREY connector, and the BLACK
connector are both 12 pin Deutsch connectors.
The GREY connector connects to the power
harness. This connector carries the primary signals
to the truck, the CAN communication lines to and
from the truck’s VSM, the wake up signals, and
carries the positive and negative power rails to feed
the communication module.
The BLACK connector connects to the Interlock
Harness. This connector carries relay contacts for
interlocking the truck’s systems, custom switched
outputs for additional expansion, and the
Figure 31.
communication lines to the Checklist Display or ID
Reader. The ID Reader has a simple 4 pin GREY connector.
The ID Reader detects ID cards presented to it, and
sends communication data to the communication
module. The ID Reader allows the full capability of
the telemetry system to be utilized.
The 4 Pin GREY connector connects to the checklist
display harness (if a checklist display is installed) or
the Interlock Harness (if no checklist display is
installed).

Figure 30.

The Checklist Display has one primary GREEN

connector. The checklist display is considered a
“dumb” unit, as in it simply displays information on
the screen which has been pre-processed by the
communication module. The checklist display allows
for the full capability of the telemetry system to be
utilized.
The GREEN connector connects to the checklist Figure 32.
display harness. The checklist display harness
connects to the Interlock Harness. Basic Operations
ID Card / ID Reader
ID reader interlock will prevent unauthorized
operator access to equipment. A registered ID card
must be swiped against the ID reader to allow
equipment start up.
ID cards are registered to the equipment through
the NTP website. Operator cards IDs are given
standard access to equipment. Technician card IDs
are used to clear equipment lockout and
additionally do not require checklist interlock.

33
Telemetry Wireless Asset Management System 2200 SRM 2102

The ID reader will detect operator cards swiped Buzzer

within close range. After card swipe, the ID Reader
sends card data to the Communication Module for The Buzzer harness exists as feedback to operator of
processing. Communication Module determines if the interlock state. This audible feedback is
access is granted or denied and whether a particularly useful for equipment without a Display
technician or operator card has been swiped. installed.

Before ID card swipe, Display will prompt the During start up sequence:
following text: Please swipe card. • First buzz indicates:
Swipe Valid Operator Card: - Communication Module wakeup.
• Buzzer tone: Single long buzz. - Card ID swipe required.
• Display text: Access granted. • Second buzz indicates:
Swipe valid Technician Card: - Single long buzz – Card ID accepted.
• Buzzer tone: Single long buzz. - Two/Three short buzz – Card ID denied.
• Display text: Access granted. During shutdown sequence:
• Checklist: Disabled. • Periodic buzz during shutdown time-out.
• Lockout: Cleared. • Increasing buzz frequency as time-out
approaches end. Buzzer is driven by 12V
NOTE: Swiping a Operator card during System switched supply from Communications
Lockout will result in 2 short buzzes. module, Interlock Harness, 12pin Black
connector, Pin6.
Swipe invalid Operator/Technician Card:
• Buzzer tone: Three short buzz. Wakeup
• Display text: Access granted.
Communication Module requires constant battery
voltage.
Interlock Relay
A start-up signal is used to trigger wakeup of
Relays control the operation of equipment and allow Communication Module.
interlocks to be enforced.
Successful wakeup is observed through a buzzer and
An equipment’s Ignition system is disabled until powering up of the Display Module.
access is granted by ID reader interlock (excluding
some BE trucks). Depending on equipment type, the start-up trigger
will be one of the following:
Relay 1 Contacts – Interlock Harness, 12pin Black
connector (pin1 and pin2). • honk horn

Before successful card swipe: Contact broken • sit on seat

between pin1 and pin2 (ignition inhibited). • toggle key switch
After successful card swipe: Contact made between Depending on the start-up trigger, a 12v signal can
pin1 and pin2 (ignition uninhibited). be measured on pin3 or a ground signal on pin9 of
the power harness.
An equipment’s start/drive system is disabled until
access is granted by Pre-start checklist interlock. The resulting wakeup is confirmed by hearing the
buzz tone or confirming the 12V power to the
Relay 2 Contacts – Interlock Harness, 12pin Black
Display Module. Measurable by any of the following:
connector (pin3 and pin4).
• Observe Display screen LCD light up (if
Before completing Pre-start checklist: Contact installed).
broken between pin3 and pin4 (start/drive
inhibited). • 12V: Interlock Harness, 12pin Black
connector pin5.
After completing Pre-start checklist: Contact made • 12V: Display harness, 12pin Green connector
between pin3 and pin4 (start/drive uninhibited). pin1.

34
2200 SRM 2102 Telemetry Wireless Asset Management System

Checklist Pre-start questions will be completed before start/

drive is enabled on the equipment.
NOTE: Level 3 Only
Post-start questions will be completed after start/
Checklist interlock requires a Display module for drive is enabled on the equipment.
operator interaction.
To deter operators from blatantly using equipment
Pre and Post start questions are configured via the during the post-start checklist phase, a question
website. timer can be enabled. This timer will report
The Communications module can be configured to operators to the website which do not complete their
prompt for checklist every set time period, or at checklist.
particular shift times each day, or every key on.
Accessing the equipment by swiping technician ID
card will cause the checklist to be skipped.

LOCATE AND INSTALL THE COMMUNICATION MODULE

Reference Number Hyster part number Quantity Description
8807981 OR 4618251 1 Communication Module with GSM
8831912 OR 4669428 1 Communication Module-Sprint 4G
8807966 4618236 1 Communication Module with WiFi
4217281 4217281 1 Communication Module bracket
293741 293741 4 Capscrew
1527880 1527880 2 Capscrew

WARNING
FAILURE TO FOLLOW THE INSTALLATION
INSTRUCTIONS IN THIS MANUAL CAN CAUSE
THE FORK LIFT TRUCK TO BECOME
INOPERABLE OR DAMAGED AND RESULT IN
PERSONAL INJURY, DEATH OR PROPERTY
DAMAGE. READ AND FOLLOW WARNINGS IN
INSTALLATION INSTRUCTIONS.

1. Remove the main cover. See Figure 4.

2. Use the four capscrews to attach the

communication module to the bracket. See
Figure 33.

1. CAPSCREW
2. BRACKET
3. COMMUNICATION MODULE

Figure 33. Communication Module and Bracket

35
Telemetry Wireless Asset Management System 2200 SRM 2102

3. Allign the two holes and weldnuts of the 4. Insert the two screws into the outside of the
communication module bracket with the frame. frame and attach bracket. See Figure 34.
See Figure 34.

1. CAPSCREW
2. COMMUNICATION MODULE AND BRACKET

Figure 34. Communication Module Installation

INSTALL THE POWER HARNESS

Reference Number Hyster part number Quantity Description
8828145 4662908 1 Power Harness

visible at certain angles, the connectors and sockets

WARNING are all keyed. A gray connector will not go into a
FAILURE TO FOLLOW THE INSTALLATION black socket, just as a black connector will not go
INSTRUCTIONS IN THIS MANUAL CAN CAUSE into a gray socket.
THE FORK LIFT TRUCK TO BECOME 2. Insert the 12 pin grey connector (CPS401) of
INOPERABLE OR DAMAGED AND RESULT IN the Power Harness into the 12 pin grey socket
PERSONAL INJURY, DEATH OR PROPERTY on the communication module.
DAMAGE. READ AND FOLLOW WARNINGS IN
INSTALLATION INSTRUCTIONS. 3. Connect CPS65A of the Power Harness to
CPS65 connector of Main Wire Harness.
1. Disconnect the battery.
4. Connect CRP65A of the Power Harness to
NOTE: Even though the colors of the CRP65 connector of Main Wire Harness.
communication module connectors may not be

36
2200 SRM 2102 Telemetry Wireless Asset Management System

Figure 35. Telemetry Power Harness

37
Telemetry Wireless Asset Management System 2200 SRM 2102

INSTALL THE INTERLOCK HARNESS

Reference Number Hyster part number Quantity Description

8828144 4662747 1 Interlock Harness

3. Remove jumper (CRP414A) from CPS414 on

WARNING the Power Harness. Attach the connector
FAILURE TO FOLLOW THE INSTALLATION (CRP414) on the Interlock Harness (Item 4,
INSTRUCTIONS IN THIS MANUAL CAN CAUSE Figure 1) to CPS414 on the Power Harness.
THE FORK LIFT TRUCK TO BECOME
INOPERABLE OR DAMAGED AND RESULT IN 4. Use the wire loop on CRP414A to attach
PERSONAL INJURY, DEATH OR PROPERTY jumper to the Power Harness for later use. See
DAMAGE. READ AND FOLLOW WARNINGS IN Figure 37.
INSTALLATION INSTRUCTIONS.

1. Disconnect the battery.

NOTE: Even though the colors of the

communication module connectors may not be
visible at certain angles, the connectors and sockets
are all keyed. A gray connector will not go into a
black socket, just as a black connector will not go
into a gray socket.
2. Connect the 12 pin black connector (CPS417) of
the Interlock Harness into the 12 pin black
socket of the communication module. See
Figure 36.

1. INTERLOCK HARNESS Figure 37. Jumper Loop

Figure 36. Install Interlock Harness

38
2200 SRM 2102 Telemetry Wireless Asset Management System

Figure 38. Telemetry Interlock Harness

INSTALL THE ACCESS CONTROL KIT, ANTENNA AND BUZZER

Reference Number Hyster part number Quantity Description
8808045 4618315 1 Antenna with GSM/GPS
8808044 4618314 1 Antenna with WiFi
4167168 4167168 1 Bracket
0370599 0370599 2 Capscrew
1502543 1502543 4 Nut
1695284 1695284 1 Buzzer
296145 296145 2 Capscrew
4167169 4167169 1 Card reader bracket
8808033 4618303 1 ID card reader (ISO Prox)
8808034 4618304 1 ID card reader (Standard)
8808035 4618305 1 ID card reader (MIFARE Prox)
4044956 4044956 2 Capscrew

39
Telemetry Wireless Asset Management System 2200 SRM 2102

Reference Number Hyster part number Quantity Description

320154 320154 2 Washer
1463912 1463912 2 Nut
8810751 4623436 1 Label-ID card reader
8828143 4662732 1 Lower display harness
1360529 1360529 1 Strap clamp

Install the antenna

WARNING
FAILURE TO FOLLOW THE INSTALLATION
INSTRUCTIONS IN THIS MANUAL CAN CAUSE
THE FORK LIFT TRUCK TO BECOME
INOPERABLE OR DAMAGED AND RESULT IN
PERSONAL INJURY, DEATH OR PROPERTY
DAMAGE. READ AND FOLLOW WARNINGS IN
INSTALLATION INSTRUCTIONS.

1. Disconnect the battery.

2. Locate the antenna bracket and allign with the

hole in the frame as shown in Figure 39.

3. Use the two capscrews (item 1) and nuts (item

4) to attach the bracket to the frame. See
Figure 39. Tighten nut.
1. CAPSCREW
4. Locate the antenna and run the antenna cables 2. ANTENNA BRACKET
3. ANTENNA
through the bracket. See Figure 39. 4. NUT
5. Use the nut to attach the antenna to the Figure 39. Install the antenna
bracket.
Install buzzer
6. Connect the two antenna cable connectors to
the communication module. Figure 39. 1. Confirm the battery is still disconnected.

2. Use the two capscrews to install the buzzer

onto the communication module mounting
bracket. See Figure 40.

3. Connect 2 pin PLUG (CPS418) from Interlock

Harness to 2 pin SOCKET (CRP418) of buzzer.
See Figure 40.

40
2200 SRM 2102 Telemetry Wireless Asset Management System

1. CAPSCREW 1. BRACKET
2. BUZZER 2. CAPSCREW
3. CRP418 3. CARD READER
4. CPS418 4. WASHER
5. NUT
Figure 40. Install buzzer
Figure 41. Install the ID Card Reader
Install the ID Card Reader
3. Use the two capscrews and nuts from the
1. Confirm the battery is still disconnected. antenna bracket to install the ID card reader
mounting bracket. See Figure 41.
2. Use the two capscrews, washers and nuts to
install the ID card reader onto the mounting 4. Locate the lower display harness, and insert
bracket. See Figure 41. the 4 pin grey PLUG (CPS419) of the Interlock
Harness into the 4 pin grey SOCKET (CRP419)
of the Lower Display Harness.

41
Telemetry Wireless Asset Management System 2200 SRM 2102

Legend for Figure 42.

1. LOWER DISPLAY HARNESS

2. CRP419
3. CPS422
4. CRP423
5. CRP424

5. Insert the 4 pin grey PLUG (CPS422) of the

Lower Display Harness into the 4 pin grey
SOCKET (CRP422) of the ID card reader. See
Figure 42.

Figure 42. Lower Display Harness, Installed

Figure 43. Lower Display Harness

42
2200 SRM 2102 Telemetry Wireless Asset Management System

INSTALL THE CHECKLIST DISPLAY AND HARNESS

Reference Number Hyster part number Quantity Description
8807954 4618224 1 Checklist Display
1502543 1502543 2 Nut
2048064 2048064 2 Capscrew
8828142 4662731 1 Wire Harness-Upper Display

4. Route the upper display harness from here to

WARNING the Lower Display Harness.
FAILURE TO FOLLOW THE INSTALLATION
INSTRUCTIONS IN THIS MANUAL CAN CAUSE 5. Insert the 2 pin grey PLUG (CPS423) of the
THE FORK LIFT TRUCK TO BECOME Upper Display Harness into the 2 pin grey
INOPERABLE OR DAMAGED AND RESULT IN SOCKET (CRP423) of the Lower Display
PERSONAL INJURY, DEATH OR PROPERTY Harness. See Figure 45.
DAMAGE. READ AND FOLLOW WARNINGS IN
INSTALLATION INSTRUCTIONS.

1. Align the Checklist Display with the two holes

in the frame. See Figure 44.

1. LOWER DISPLAY 4. CRP423

HARNESS 5. CRP424
2. CRP419
3. CPS422
1. CAPSCREW 3. NUT
2. DISPLAY 4. UPPER DISPLAY Figure 45. Attach to Lower Display Harness
HARNESS

Figure 44. Install Display 6. Insert the 3 pin grey PLUG (CPS424) of the
Upper Display Harness into the 3 pin grey
2. Use the capscrew and nut to attach the display SOCKET (CRP424) of the Lower Display
to the frame. See Figure 44. Harness. See Figure 45.

3. Insert the 12 pin green PLUG (CPS421) of the

Upper Display Harness into the 12 pin green
SOCKET of the Checklist Display.

43
Telemetry Wireless Asset Management System 2200 SRM 2102

Figure 46. Upper Display Harness

FIRST SWITCH ON • Gives the user the ability to set the external
communication settings.
• Set the Wi-Fi SSID and Password.
WARNING • Change the regional GSM frequency settings.
FAILURE TO FOLLOW THE INSTALLATION
INSTRUCTIONS IN THIS MANUAL CAN CAUSE HYG standards specify that this diagnostic
THE FORK LIFT TRUCK TO BECOME software tools utilize the standard IFAK
INOPERABLE OR DAMAGED AND RESULT IN communication device and through the truck
PERSONAL INJURY, DEATH OR PROPERTY service connector. See Figure 47 for the current
DAMAGE. READ AND FOLLOW WARNINGS IN adapter:
INSTALLATION INSTRUCTION. The IFAK adapter needs to be installed on the
computer and tested prior to running the PCST
1. Validate installation and change Telemetry Tool
communications settings with PCST
Telemetry Tool.
The PCST Telemetry Tool has been developed
by the HYG software group to assist in the
setup of the Hyster Tracker telemetry systems
on truck. The tool has the following
functionality:
• Assist in validating a truck install by dealer
or factory.
• Validate that a truck is connecting to the
Hyster Tracker .
• Validate the communication module (FM1) is Figure 47. IFAK Adapter
talking to the truck CAN-Bus.
• Read the HUID from the Communication
module (FM1) over the CAN-Bus.

44
2200 SRM 2102 Telemetry Wireless Asset Management System

Tool Operation and Press the start button to initiate

communication with the telemetry module:
This is the screen you will see when the application
is started. Connect the IFAK adapter to the truck

The drop-down control on the bottom left of the

window allows the user to select one of the five
supported languages.

45
Telemetry Wireless Asset Management System 2200 SRM 2102

Connection
To change adapter settings use the Connection
expander: module:

The Vendor and Device drop down boxes are • 125K CanOpen- used for 3-Wheel Stand and
populated by scanning the available RP1210 devices all Class 2 and Class 3 trucks.
installed on the system – select the iFak (assumes • 250K J1939 - used for all Class 4 and Class 5
iFak driver is installed). trucks.
The ‘Bus Type’ drop down selects the protocol and On D456 select Bus Type 125K CanOpen.
baud rate that will be used to establish the All of these settings persist when the application
connection. closes, the user does not need to change them on re-
There are three available: launch unless the IFAK has changed or connecting
250K CanOpen - used for all Class 1 trucks to a different class of truck.
•
(except 3-Wheel Stand).

46
2200 SRM 2102 Telemetry Wireless Asset Management System

When the user presses start the tool queries the the wireless settings, check for proper installation of
FM1. Most parameters are information, but a few the antenna.
are required to have a certain value, if they do not
Unit Install Verified – this will become ‘Verified’
meet the criteria specified then they are
after the FM1 connects to the portal the first time.
highlighted.
CAN Bus Active Status – if the FM1 sees vehicle
Time Since Last Server Connect – the FM1 keeps
CAN traffic then this parameter becomes ‘Active’.
track of the last time it connected wirelessly to the
Note that if the truck is not awake then this will be
portal. If this parameter reports ‘Has Never
‘Not Active’ – a legitimate state on a sleeping
Connected’ this means wireless communications
interlocked truck.
have never functioned properly for this unit. Verify

47
Telemetry Wireless Asset Management System 2200 SRM 2102

Wireless Settings control when the tool connects. So it can be changed,

but the tool will not report the password currently
NOTE: The WiFi password is write-only, the stored.
existing password will not be displayed in the

The Wireless settings expander exposes controls controls will be active - if the FM1 currently
that can be used to change the credentials far Wifi connected communicates via GSM then the Wifi
connection or the GSM frequency. Only the relevant controls will be grayed out.

48
2200 SRM 2102 Telemetry Wireless Asset Management System

When a value in the Wireless Settings has been Update button has been pressed and the value has
modified but not yet sent to the truck it will be been confirmed as received by the truck.
highlighted. The highlight will be removed when the

49
Telemetry Wireless Asset Management System 2200 SRM 2102

Telemetry Tool Communication Problems

This message indicates the selected IFAK is not

presently connected to the system, or is in use by
another application.

50
2200 SRM 2102 Telemetry Wireless Asset Management System

These are things to verify:

• IFAK cable is connected into the service port
on the truck
• The proper bus-type was selected for the
Class of equipment you are connected to
• The FM1 is connected to the truck CAN bus

1. When the truck is switched on for the 1st time

the buzzer will emit a long beep every 5
seconds and the display, if fitted, will show the
following message. See Figure 48.

Figure 48. First Display Message

2. Swipe card past card reader. Once a card has

been swiped past the card reader, the buzzer
will emit 1 long beep for card access granted
and the display (if fitted) will show the
following message. See Figure 49.

51
Telemetry Wireless Asset Management System 2200 SRM 2102

4. Press the right hand green button. The

following message will be displayed. See
Figure 51.

Figure 49. Access Granted

Figure 51. Right Hand Green Button Display
3. Switch truck off.
In the event of no display fitted, this will 5. Press the left hand green button and the
complete the initial set up and the truck should following message will be displayed. See
be switched off. Figure 52.
This will start the Verification process and the
truck will communicate with the portal for the
1st time. When communication process is
complete, the buzzer will emit a series of beeps;
1 short 1 long and again 1 short 1 long.
When a display is fitted the following
additional steps should be taken.
Once Access has been granted, the following
message will be displayed. See Figure 50.

Figure 52. Checklist Complete

6. Switch truck off.

This completes the checklist self-test function
and starts the Verification Process outlined
above in Step 3 above.

Figure 50. Prestart Checklist

52
2200 SRM 2102 Truck Activation

Truck Activation
1. When the installation is completed and the
system verified, it is needed to activate the
WARNING
truck on the c portal.
FAILURE TO FOLLOW THE INSTALLATION
INSTRUCTIONS IN THIS MANUAL CAN CAUSE Open the portal (https://
THE FORK LIFT TRUCK TO BECOME www.hystertracker.com/Login.aspx) on your
INOPERABLE OR DAMAGED AND RESULT IN internet browser.
PERSONAL INJURY, DEATH OR PROPERTY
DAMAGE. READ AND FOLLOW WARNINGS IN 2. Click on “Equipment not activated yet? Click
INSTALLATION INSTRUCTION. Here”.
The activation form will be opened.

3. Fill the activation form with truck details and

submit it.

53
DC to DC Converter 2200 SRM 2102

DC to DC Converter
NOTE: The DC-to-DC Converter has no repairable Replace the DC-to-DC Converter as follows:
parts. Check wiring and plug for proper voltages
and connections. If converter is inoperative, it must 1. Turn the key switch the OFF position and
be replaced. disconnect the battery.

2. Discharge the capacitors. Refer to Discharging

the Internal Capacitors.

3. Remove covers, see Figure Frame Covers.

4. Disconnect the plug from the converter. See

Figure 53.

5. Remove the capscrews retaining the converter

to the frame and remove the converter from the
lift truck.

6. Align the replacement converter and install the

mounting hardware as removed.

7. Tighten the nuts to 1.7 N•m (15 lbf in).

8. Connect the plug to the converter.

9. Reinstall the battery if removed.

10. Connect the battery and turn the lights ON to

test functionality.
1. CAPSCREW
2. DC/DC CONVERTER 11. Install covers.
3. ELECTRICAL CONNECTOR

Figure 53. DC to DC Converter

Troubleshooting
See the Troubleshooting Manual section for
information on using on-board diagnostics for
troubleshooting electrical problems.

54
 TECHNICAL PUBLICATIONS

2200 SRM 2102 3/22 (6/19)(1/19)(10/18)