Hyster D264 Service & Repair Manual Download | Manualshive

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This section is for the following models:

(N35ZDR2, N45ZR2) [D264];

(N30ZDR2, N35-40ZR2) [E470];

(N30ZDRS2, N35-40ZRS2) [B265]

Table of Contents

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Summary of Contents for 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: ...dic 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 ma...

Page 4: ...oder Integrity 9 Test Encoders 9 Proximity Switches 9 Key Switch 10 Multifunction Displays 10 BDI 10 Speed 10 Steer Angle 10 Truck Hours 10 Operational Mode 10 Setup 10 Setup Instructions 10 ACE2 ACE3...

Page 5: ...mb Grip Pad Replacement 28 Handle Grip and Switch Repairs 29 Handle Grip Support Mounting 29 Handle Disassembly 30 Forward Stance Controls 33 Control Handle Functions 33 Repair 34 Aft Travel Control H...

Page 6: ...ore 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 pl...

Page 7: ...63 Adjust 63 Load Transport Proximity Switch 64 Replace 65 Adjust 65 Fork Height Sensor Option 66 Remove 66 Encoder Assembly 66 Timing Belt 67 Install 68 Encoder Assembly 68 Timing Belt 68 Reach Posi...

Page 8: ...This section is for the following models N35ZDR2 N45ZR2 D264 N30ZDR2 N35 40ZR2 E470 N30ZDRS2 N35 40ZRS2 B265 Table of Contents iv...

Page 9: ...pacities to handle the output of the electrical components they are used to check Never wire aftermarket components to this truck without factory approval The electrical system is an alternating curre...

Page 10: ...seconds Remove the resistor after discharging the capacitors See Figure 2 1 POSITIVE CONNECTION B 2 NEGATIVE CONNECTIONS B 3 INSULATED JUMPER WIRES 4 200 OHM 2 WATT RESISTOR Figure 2 Discharging the I...

Page 11: ...N position Remove the safety chains from the mast Refer to Periodic Maintenance 8000SRM1617 Battery Connection The battery cables supply power from the battery terminals through the battery cable conn...

Page 12: ...contactor b Discharge the capacitors in the motor con trollers Refer to Discharging the Internal Capacitors NOTE Make note of position of cables for proper reinstallation c Remove the nuts securing t...

Page 13: ...cause injury or parts damage The key switch is used to power ON and OFF the lift truck operating systems including the dash dis play and integrated fuse board REPLACE CAUTION Check the electrical con...

Page 14: ...over from the bottom of the arm rest console on sidestance models See Figure 20 NOTE Make note of the position of the key switch before removal 5 Remove the nut retaining the key switch to the mountin...

Page 15: ...Increased reliability Substantial reduction in connections and wiring complexity Extensive function monitoring capability Serial bus simplicity two wires Easy information exchange between subsys tems...

Page 16: ...xiliary transistor outputs that control the traction main contactor lift pump contactor lower solenoid valve brake coil and horn CAN I O The CAN I O connects the following devices to the CANbus networ...

Page 17: ...n the encoder is OK See Setup PROXIMITY SWITCHES These are noncontact devices which sense the pres ence of steel They have three wires going to them battery negative supply voltage and an output sig n...

Page 18: ...nu choose Battery Type Flooded Cell or Maintenance Free Check with your battery manufacturer for recommended settings SPEED The traction throttle command is shown by 8 step bars at the top of the disp...

Page 19: ...justing all setup parameters refer to Steering Sys tem 1600SRM1610 for the Steer Calibration procedure NORMAL OPERATION Display Password Access Following truck startup if the Operator Password feature...

Page 20: ...de the lift truck MUST BE stopped with the control handle in the neutral position The last mode selected will be retained and will be displayed on the dash even after the key has been recycled If the...

Page 21: ...ilent control of motor speed and tor que Three phase winding control stage provides solid state motor control and full regenerative braking without additional relays or contactors See Figure 8 There a...

Page 22: ...s cannot be recovered to lower hour level readings Additionally non programmed devi ces may assume the truck serial number that they are installed in 2 Disconnect and separate battery connector Re mov...

Page 23: ...sion hex It is recommended the files be saved to the computer desktop default loca tion or another file directory where it can be easily located 2 Connect to the truck with the IFAK cable With the tru...

Page 24: ...e located in the electrical compart ment See Figure 10 Remove cover over electrical compartment for access The condition of some fuses can be checked by looking at them Other fuses do not change in lo...

Page 25: ...ity since spike suppressors on some coils make them polarity sensitive Compare ohm reading against ohm value for the type contactor Use the highest rating See Table 2 Table 2 Coil Resistance Device Lo...

Page 26: ...ings 3 Replace two fixed contacts in contactor covers 4 Remove plunger assembly and movable contact and replace fixed contact bar Replace contact of plungers 5 If a coil will be replaced remove cover...

Page 27: ...wheel to prevent truck from rolling 3 Disconnect battery connectors and turn the key switch to the OFF position 4 Remove instrument panel See Instrument Panel Removal and Installation 5 Remove cover 6...

Page 28: ...12 Integrated Fuse Board IFB NOTE The integrated fuse board is not repairable If damaged it must be replaced Check the IFB for signs of damaged or burned components Fuses are the only replaceable com...

Page 29: ...moved 8 Install the plastic cover s to the operator com partment as removed 9 Engage the battery cable connectors Install the key and turn the key switch to the ON position Test for proper operation R...

Page 30: ...ess adjacent to the IFB board and is installed from the factory in the 3 pin location of the IFB board with the other side of the diode connecting to the 033A wire of the main harness Before replac in...

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