ELECTRICAL SYSTEM

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH,

RS46-30IH, RS46-36CH, RS46-33IH First Used

on 1563, 1566, 1567, 1568, 1570, and Up [A222]

PART NO. 1589731

2200 SRM 1184

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Electrical System

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

Description .........................................................................................................................................................

Main Control Box ...............................................................................................................................................

Amplifier.............................................................................................................................................................

Electrical Wiring Harnesses..............................................................................................................................

Warning Devices ................................................................................................................................................

General ...........................................................................................................................................................

Description .....................................................................................................................................................

Operator-Controlled Horn.........................................................................................................................

Reverse Warning Horn/Lights ..................................................................................................................

Warning Lights..........................................................................................................................................

Beacon Lights........................................................................................................................................

Brake Lights..........................................................................................................................................

Replace ...........................................................................................................................................................

General.......................................................................................................................................................

Horns..........................................................................................................................................................

Horn Relay.................................................................................................................................................

Warning Lights/Bulbs ...............................................................................................................................

Light Assemblies .......................................................................................................................................

Flashing Unit.............................................................................................................................................

Backup Alarm/Light Relay .......................................................................................................................

Meters, Senders, System Warning Lights, and Switches ................................................................................

General ...........................................................................................................................................................

3B6 Load Limiter System..................................................................................................................................

Alternator ...........................................................................................................................................................

General ...........................................................................................................................................................

Description .....................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Adjustments .......................................................................................................................................................

Amplifier ........................................................................................................................................................

Troubleshooting..................................................................................................................................................

Diagrams, Schematics, or Arrangements .........................................................................................................

Schematics..........................................................................................................................................................

This section is for the following models:

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH,

RS46-33IH First Used on 1563, 1566, 1567, 1568, 1570, and Up [A222]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

2200 SRM 1184

Electrical Wiring Harnesses

General

This section has the description and repair proce-
dures for electrical components. The instructions for
replacement of parts for the warning devices are in-
cluded. Also, the instructions for removal and instal-
lation of the alternator is included in this section.
There is a separate section for the load limiter sys-
tem. See the section 3B6 Load Limiter System
1900 SRM 1213.

The electrical components located on the boom or
attachment are covered in the section Extendable
Container Attachment (Elme) 5000 SRM 776,
Intermodal Container Attachment 5000 SRM
777, or Boom, ReachStacker 4500 SRM 0649.

See the section Diagrams, Tier 2 Engine 8000 SRM
1182 for more information of the electrical schematic
and wiring diagrams.

Description

The electrical system is built up by several wire
harnesses. The batteries provide the separate wire
harnesses with electricity and the wire harnesses
will transmit the electricity to several components,

senders, warning lights, etc. See the section Instru-
ment Panel, Indicators, and Senders 2200 SRM
1178 for further information regarding senders and
indicator functions.

Main Control Box

CAUTION

Verify replacement of the relays with the same
type or damage to the relays may occur.

All of the relays and flasher relays in the main con-
trol box plug into sockets. These relays cannot be re-
paired and must be replaced if they malfunction. See
Figure 1.

Always verify the socket pins and wires to the socket
pins are not damaged before replacing a relay. Verify
the relay is fully inserted into the socket.

The electrical wire harnesses are connected under-
neath the mail control box. See Figure 1.

Amplifier

The amplifier module contains the necessary elec-
tronics for the control of two proportional solenoids
(A and B). Depending on the input polarity, either
solenoid A or solenoid B is operated. The solenoid
current is measured and compared with the exter-
nal input value. Differences between feedback and
input values, for example caused by changes in so-
lenoid temperature and supply voltage, are compen-
sated.

The module also generates a direction-dependent
voltage signal (solenoid A, solenoid B) as soon as the
solenoid current is up to 10% value.

The current 10% and 90% values can be adjusted
from by means of assigned trimming potentiometers
(setscrew R1 and R2). See Adjustments in this sec-
tion.

Electrical Wiring Harnesses

From the main control box, several wiring harnesses are split up and are positioned in the ReachStacker

. See

Figure 1.

Electrical Wiring Harnesses

2200 SRM 1184

Figure 1. Circuit Breakers, Relays, and Bottom Connectors

2200 SRM 1184

Electrical Wiring Harnesses

Legend for Figure 1

A. THERMAL SWITCHES
B. TRANSMISSION SWITCHES
C. FUSES

D. RELAYS
E. BOTTOM CONNECTORS FOR HARNESSES

Thermal Switches

Air-conditioning (12A)

Starting circuit and horn (15A)

Rotating Beacon (10A)

Air-conditioning (12A)

Transmission, Park brake, Indicator Lights/Meters, Warning Lights, Cab Lights, and Cab
Fan (9A)

Backup Alarm/Lights, and Rear Work Lights (10A)

Start Circuit (7A)

Brakes and Brake Lights (12A)

Emergency Stop and Hydraulic Oil Cooler (15A)

Wipers, Attachment, and Rear Work Lights (9A)

Load Limiter (7A)

ELME Attachment Control Box (15A)

Joystick, Attachment Controls, and Cab Shifting (9A)

Attachment Control Lights (7A)

Control Lights, Chassis Work Lights, and Boom Work Lights (12A)

Chassis Work Lights (12A)

Transmission Switches

APC-100 Transmission Override Switch

Auto/Manual Transmission Switch

Fuses

Engine ECM (10A)

Engine ECM (5A)

Electrical Wiring Harnesses

2200 SRM 1184

Legend for Figure 1 (Continued)

Relays

(1)

R1 Start Relay

(2)

R5 Contact Relay

(3)

R21 Horn Relay

(4)

R14 Rotating Beacon Relay

(5)

R10 Indicator Lights Flasher Relay

(6)

R22 Backup Alarm Relay

(7)

R2 Start Permission Relay

(8)

R30 Lift Interrupt Override Relay

(9)

R16 20’ Boom Work Lights Relay

(10)

R15 40’ Boom Work Lights Relay

(11)

R17 Chassis Work Lights Relay

(12)

R60 Backup Lights Flasher Relay

(13)

R11 Backup Rear Work Lights Relay

(14)

R55 Transmission Relay

(15)

R19 Rear Work Lights Relay

(16)

R50 Air-conditioning Relay

(17)

R0 Main Relay

(18)

R12 Boom Cut-out Relay

(19)

R13 Boom Cut-out Relay

(20)

R56 Transmission Relay

(21)

R57 Transmission Relay

(22)

R18 Attachment Work Lights Relay

2200 SRM 1184

Warning Devices

Legend for Figure 1 (Continued)

Bottom Connectors

Power Supply Cable

Right-Hand Side Hydraulic (9 pin)

Engine (44 pin)

Left-Hand Side Hydraulic (21 pin)

Standard Spreader 2 (21 pin)

Optional Intermodal Handler (21 pin)

Rear Lights, Backup Alarm, and Fuel Level (9 pin)

Front Lights and Load Limiter (21 pin)

None (9 pin)

Optional Air-conditioning (3 pin)

Boom Lights (9 pin)

Cab 1 (44 pin)

Transmission Control Valve and Oil Filter Restriction (9 pin)

Cab 2 (44 pin)

Standard Spreader (21 pin)

Cab Connections (Attachment Controls) (44 pin)

Cab Connections (Hydraulic Controls and Sliding Cab) (21 pin)

Warning Devices

GENERAL

Electrical warning devices used on the Reach-
Stacker

are as follows:

• Operator-controlled horn
• Reverse warning horn/lights
• Warning lights

The operator-controlled horn permits the operator to
warn personnel that the equipment is near. System
warning lights and buzzers make an important sys-
tem condition known to the operator. They do this
by illuminating an indicator that is not normally il-
luminated or by energizing a buzzer to sound. The
reverse warning horn automatically sounds a warn-
ing that the equipment is moving in the reverse di-
rection. Warning lights automatically illuminate to
warn personnel that the equipment is operating in
a special way. Warning lights are also used to warn
personnel that the equipment is near. Some of these

warning devices need to be energized and de-ener-
gized at a fast rate. A separate flashing device does
this. Most equipment does not need each of these
warning devices.

DESCRIPTION

Operator-Controlled Horn

The operator-controlled horn has a horn switch, a re-
lay, and horn. The horn switch energizes the relay
to close the power contacts and energize the horn.
This makes the horn sound. The lower sound level
of equipment operation results in a horn that is less
loud and uses less current. This horn current is di-
rectly controlled by the switch. The horn switch is lo-
cated at the operator’s position. The horn is located
just above and to the left of the drive axle center. The
horn relay is installed in the control box, located in-
side the fuel tank platform (right side).

Warning Devices

2200 SRM 1184

Reverse Warning Horn/Lights

The reverse warning horns are operated by a switch
on the gear selector. See Figure 2. They often use a
flashing device to make the sound of the horn begin
and end repeatedly. This flashing device is part of the
reverse warning horn. The switch is energized to the
ON position when the equipment is set to operate in
the reverse direction. The switch will then energize
the relay to energize the horn. The switch is usually
near the transmission or shift linkage. The reverse
warning horn is located at the backside under the
ReachStacker between the cooling system and the
steering axle. The horn relay is installed in the con-
trol box, located inside the fuel tank platform (right
side).

HORN

GEAR SELECTOR

FLASHER

BASE

Figure 2. Reverse Warning Horn Components

Warning Lights

The following types of warning lights are attached to
the ReachStacker:
• Beacon Lights
• Brake Lights

Beacon Lights

These warning lights indicate a particular type of
equipment operation. See Figure 3. They warn oth-
ers that the equipment is in the area or that the op-
erators view is limited by the particular operation.
These lights can be flashing lights or lights that look
as if they are flashing. A switch and a flashing device
are used to operate the flashing light. The flashing
device is part of the light assembly. Lights that look
as if they are flashing have a disc that rotates around
the bulb. The disc directs the illumination away from
its surface. As the disc rotates, the directed illumina-
tion touches a fixed point once each revolution. This
makes the light look as if it flashes. Either type of
light can be connected to operate when the key switch
is in the ON position. They can also be connected to
operate with a particular operation of the equipment
such as: (1) equipment is set for reverse operation
or (2) operator’s platform is above 610 mm (24 in.).
When connected in this way, a separate switch is op-
erated automatically by the equipment function.

Brake Lights

These warning lights indicate that the speed of the
lift truck will slow down. They warn others that the
lift truck will stop or decrease the speed severely.
These lights are positioned on the backside of the lift
truck and will be activated by operating the brake
pedal containing a pressure switch.

REPLACE

General

Horns, light assemblies, flashing devices, buzzers,
and switches are not repairable items. The most ac-
curate and usually easiest checks for proper opera-
tion of individual items is direct replacement. How-
ever, the most common cause of failure are poor con-
nections or defective or improper wiring. Also, there
are no adjustments to perform. Therefore, only re-
placement procedures are given. Before replacing an
item, verify the following:
• Other electrical circuits are operating correctly.
• Battery is fully charged and the cable terminals are

clean and correctly connected.

• Wiring and connections to device are tight and in

good condition.

2200 SRM 1184

Warning Devices

A. DRIVE DIRECTION

BOOM

ROTATING BEACON LIGHT

BOOM LIGHT HARNESS

BLACK WIRE

RED WIRE

BOOM WORK LIGHT

Figure 3. Light Assemblies

Horns

CAUTION

Audible alarms and horns have various levels
of output.

Be certain that any replacement

alarm or horn has an output that can be heard
in the area where the lift truck will be used.

Verify the key switch is in the OFF position or
the battery is disconnected.

Mark the horn wires for reconnection and discon-
nect them.

Remove the screws, nuts, or other items fasten-
ing the horn to the equipment.

Remove the horn and install the replacement.

Tighten the screws, nuts, or other items fasten-
ing the horn to the equipment.

Connect the wires, as marked, to the electrical
terminals.

Horn Relay

The horn relay is installed in the control box, located
inside the fuel tank platform (right side). Replace
the horn relay by holding the base and pulling the
unit until the pins are out of the base clips. Align
the replacement horn relay pins. Push the relay into
position on the base.

Warning Devices

2200 SRM 1184

Warning Lights/Bulbs

Access the different assemblies/bulbs as follows
(see Figure 4):

a. Remove the four screws from the instrument

panel cover.

b. Remove the instrument panel cover to gain

access to the back of the instrument panel
cover.

Push the bulb toward the light module while
turning the bulb to the left.

d. After the bulb is released, slowly remove it.

Position the new bulb in the light module.

Push the bulb toward the light module and
turn to the right until locked.

Light Assemblies

Disconnect the battery or batteries to remove all
voltage from the terminals.

NOTE: Do Step 4 before Step 2 and Step 3 if there is
no access to assembly wire terminals.

Mark the wires for reconnection.

Disconnect the wires at the wire connectors or
light terminals.

Remove the screws, nuts, or other items fasten-
ing the assembly to the equipment.

Remove the assembly and put the new assembly
in the correct position.

NOTE: Some assemblies have no access to the wire
terminals after it is fastened to the equipment. If so,
do Step 7 before Step 6.

Install the screws, nuts, or other items to fasten
the assembly to the equipment.

Connect the marked wires to the correct termi-
nals or connectors.

LIGHT MODULES

SCREW

INSTRUMENT PANEL COVER

Figure 4. Instrument Panel Lights Replacement

2200 SRM 1184

3B6 Load Limiter System

Flashing Unit

The flashing unit is installed in the control box, lo-
cated inside the fuel tank platform (right side).

Replace the flashing unit by holding the base and
pulling the unit until the pins are out of the base
clips. Align the replacement flashing unit pins. Push
the unit into position on the base.

Backup Alarm/Light Relay

The backup alarm/light relay is installed in the con-
trol box, located inside the fuel tank platform (right
side).

Replace the backup alarm/light relay by holding the
base and pulling the relay until the pins are out of the
base clips. Align the replacement backup alarm/light
relay pins. Push the relay into position on the base.

Meters, Senders, System Warning Lights, and Switches

GENERAL

Meters, senders, and switches cannot be repaired.
The fan and wiper motors of the operator compart-
ment also cannot be repaired. These components are
replaced when they are defective. The most com-
mon cause of failure is a bad connection or defec-
tive wiring. There are no adjustments. See the sec-
tion Instrument Panel, Indicators, and Senders
2200 SRM 1178 for replacement procedures. Before
a meter or sender is replaced, make the following
checks:

Make sure that the other meters and electrical
circuits are operating correctly.

Make sure that the battery is charged, correctly
installed, and the cable terminals are clean and
tight.

Make sure that the wires and connections to the
unit are tight and in good condition.

3B6 Load Limiter System

NOTE: See the section 3B6 Load Limiter System
1900 SRM 1213 for information on the 3B6 load lim-
iter system.

This electrical system prevents lifting loads that are
over capacity as well as preventing moving the load

over the operator compartment. The system has a
small computer (main unit) using inputs from pres-
sure transducers in the lift circuit to determine the
weight of the container.

Alternator

2200 SRM 1184

Alternator

GENERAL

CAUTION

Always disconnect the battery before making
repairs. The diodes and resistors in the elec-
trical system can be damaged if the following
cautions are not followed:
• Do not disconnect the battery when the en-

gine is running. The voltage surge can dam-
age the diodes and resistors in the electrical
system.

• Do not disconnect an electric wire before the

engine is stopped and the switches are OFF.

• Do not cause a short circuit by connection

of the electric wires to the wrong terminals.
Verify correct identification is made of the
wire before it is connected.

• Verify the battery is the correct voltage and

polarity before it is connected.

• Do not check for current flow by making a

spark because the electronic components can
be damaged.

• These lift trucks have a 24-volt electrical sys-

tem (two 12-volt batteries in series). Use cau-
tion when working on the electrical system.

CAUTION

When using an arc welder, always disconnect
the ground lead from the lift truck battery to
prevent alternator or battery damage. Attach
the welding ground clamp as close to the weld
area as possible to prevent welding current
from damaging the bearings.

This section has the remove and install procedures
for the alternator with an internal regulator. The
replacement procedures for meters and gauges is in
the section Instrument Panel, Indicators, and
Senders 2200 SRM 1178. The electrical schematic
diagram for the lift truck is shown in the section
Diagrams, Tier 2 Engine 8000 SRM 1182.

DESCRIPTION

The Delco Remy model 22-SI alternator generates
a 24-volt alternating current when the engine is
running. See Figure 5. The alternating current is

changed to a 70-ampere direct current by six silicon
diodes contained in a rectifier assembly (rectifier
bridge).

The diode set continues the process of

changing the alternating current to direct current
(DC). The rectifier bridge, diode set, and regulator
are all mounted in the end frame for the slip rings.

Output from the alternator is controlled by the regu-
lator. The regulator controls the alternator output
by controlling the voltage of the field. Voltage for
the regulator is supplied as part of the output volt-
age from the alternator.

The alternator has these main parts:
• Stator
• Rotor
• Two end frames
• Solid-state voltage regulator

The direct current, from the diodes, flows to the out-
put or battery (BAT, B+) terminal. The voltage is con-
trolled by the amount of current flowing through the
field winding in the alternator and the rpm of the ro-
tor. The voltage regulator inside the frame contains
a transistor, diodes, and capacitors. The voltage reg-
ulator must be replaced, if faulty.

The voltage regulator is installed in the end of the
alternator with the slip rings. The voltage regulator
controls the current at the output or BAT B+ termi-
nal. The voltage is set by controlling the current in
the field winding of the alternator. The voltage is set
by the manufacturer and is not adjustable. When the
key switch is turned to the IGN position, the voltage
regulator is energized.

REMOVE

WARNING

Always disconnect the battery terminals be-
fore doing any disassembly or repair to the
parts of the electrical system.

CAUTION

Before disassembling the alternator, make
marks on all housings to make sure of the
correct parts alignment during assembly.

2200 SRM 1184

Alternator

REGULATOR

BATTERY (B+)
TERMINAL

F+

DIODE SET

INDICATOR LIGHT
TERMINAL

ROTOR FIELD
COIL

RELAY TERMINAL

BRIDGE DIODE
RECTIFIER (6)

10. GROUND (B )

TERMINAL

11. STATOR

Figure 5. Alternator Diagram

Disconnect the wires at the alternator. Use a
socket to move the arm of the belt tensioner and
remove the drive belt from the pulley. Remove
the capscrews that fasten the alternator to the
bracket.

Remove the nut, pulley, and fan from the shaft.
Make alignment marks on the stator and frames.
Then remove the bolts that fasten the frames and
stator together.

Remove the drive end frame and rotor from the
stator. If the bearing will be replaced, remove the
rotor from the drive end frame. Use a gear puller
or press and remove the bearing from the drive
end frame.

Remove the nuts and screws that connect the sta-
tor leads, diode set, regulator, capacitor, termi-
nals, and rectifier assembly. Make a note of the
location, disassembly sequence, and the correct
connections of the nuts, insulators, screws, and
components for correct assembly.

INSTALL

Install the nuts and screws that connect the sta-
tor leads, diode set, regulator, capacitor, termi-
nals, and rectifier assembly. Make sure to install
the parts in the brush end frame as noted during
disassembly. Make sure to align the alignment
marks on the stator to the brush end frame.

Install the rotor in the stator and brush end
frame. Install the drive end frame on the rotor
and stator. Make sure to align the alignment
marks on the drive end frame and the stator. In-
stall the bolts that fasten the frames and stator
together.

CAUTION

Verify the drive belt is correctly installed and
aligned on ALL pulleys before releasing the
belt tensioner. Belt damage will occur if not
correctly installed.

Install the fan, pulley, washer, and nut on the ro-
tor shaft. Tighten the shaft nut to 95 to 108 N•m
(70 to 80 lbf ft). Install the alternator on the
bracket. Tighten the mount bolt to 81 to 95 N•m
(60 to 70 lbf ft). Use a socket to move the arm
of the belt tensioner and install the drive belt on
the pulley. Set the belt to the proper tension and
tighten the adjusting strap bolt.

Install the electrical connectors on the correct
terminals. Tighten the terminal nuts and ground
screw to the following torque values:

Battery (B+) terminal - 9.0 to 13.6 N•m (80 to
120 lbf in)
Indicator (I) terminal - 1.7 to 2.8 N•m (15 to
25 lbf in)
Ground (B ) terminal - 5.6 to 6.8 N•m (50 to
60 lbf in)

Adjustments

2200 SRM 1184

Adjustments

AMPLIFIER

Open the main control box.

Remove relay R12 and R13.

Turn ignition ON.

Connect the measuring pins to wire 156 and 151.
See Figure 6.

Move the joystick forward (LIFTING IN) until
LED A on the amplifier is ON and keep it in po-
sition.

Check if current is 0.2 Amps. If necessary adjust
to 0.2 Amps by turning setscrew R1.

Move the joystick to the maximum forward posi-
tion and hold.

CAUTION

Use caution never to adjust the maximum cur-
rent to more than 0.6 Amps or the solenoid will
be damaged.

Check if current is 0.6 Amps. If necessary, adjust
to 0.6 Amps by turning setscrew R2.

Replace relay R12 and R13.

10. Close the main control box.

11. Repeat Step 1 through Step 10 for wire 155 and

152 (LIFTING IN).

12. Repeat Step 1 through Step 10 for wire 157 and

153 (TELESCOPING OUT).

13. Repeat Step 1 through Step 10 for wire 158 and

154 (TELESCOPING OUT).

14. Repeat Step 1 through Step 10 for wire 162 and

147 (TELESCOPING IN).

15. Repeat Step 1 through Step 10 for wire 161 and

148 (TELESCOPING IN).

16. Repeat Step 1 through Step 10 for wire 160 and

149 (LIFTING OUT).

17. Repeat Step 1 through Step 10 for wire 159 and

150 (LIFTING OUT).

AMP METER

RELAY (R12)

RELAY (R13)

Figure 6. Amplifier Adjustment

2200 SRM 1184

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

STARTING SYSTEM

Starter does not run or has
slow speed.

The batteries are not fully charged or
are damaged.

Recharge or replace battery.

The power disconnect switch is in the
Off position.

Place power disconnect switch in the
On position.

The connections at the batteries or
starter are loose or corroded.

Tighten connections to battery or
starter. Remove corrosion.

Key switch is damaged.

Replace key switch.

Start switch is damaged or circuit
breaker is open.

Replace start switch or close circuit
breaker.

Start relay is damaged.

Replace start relay.

Solenoid coil or switch contacts are
damaged.

Repair or replace solenoid coil or
switch contacts.

Brush springs in starter are dam-
aged.

Replace brush springs.

Brush leads are broken or have a
short circuit.

Replace brush leads or repair short
circuit.

Commutator in starter is dirty or
worn.

Clean or replace commutator.

Armature winding in starter is dam-
aged.

Repair or replace winding.

Field windings in starter are dam-
aged.

Repair or replace field windings.

Worn or damaged starter gears.

Replace starter gears.

Bearings in starter are worn or dam-
aged.

Replace bearings.

Starter operates, but engine
crankshaft does not rotate.

Wiring

connections

are

broken,

loose, or have corrosion.

Replace or tighten wiring connec-
tions. Remove corrosion.

Starter clutch assembly is damaged.

Repair or replace starter clutch as-
sembly.

Solenoid is damaged and will not
keep the clutch assembly engaged.

Repair or replace solenoid.

Troubleshooting

2200 SRM 1184

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Starter operates, but engine
crankshaft does not rotate.
(Cont.)

Starter clutch assembly will not
move freely.

Repair or replace starter.

Gear teeth on starter clutch assem-
bly are damaged.

Replace gear teeth.

Gear teeth on ring gear are damaged.

Replace gear teeth.

Starter continues to run.

Contacts of solenoid are welded to-
gether.

Repair or replace solenoid.

Solenoid coil has a short circuit.

Replace solenoid.

Spring that disengages the starter
clutch is broken.

Replace spring.

Key switch is damaged.

Replace key switch.

CHARGING SYSTEM

Batteries

not

stay

charged.

Battery terminals have corrosion.

Clean battery terminals to remove
corrosion.

A battery has damage inside the
case.

Replace battery.

Drive belt for alternator is loose.

Tighten drive belt.

Wiring

connections

are

broken,

loose, or have corrosion.

Replace or tighten wiring connec-
tions. Remove corrosion.

Short circuit between wiring connec-
tor(s).

Repair or replace wiring connectors.

Alternator brushes are worn.

Replace brushes.

Alternator

brushes

have

weak

springs.

Replace springs.

Alternator has dirty slip rings.

Clean or replace slip rings.

Stator coil for alternator has a short
circuit.

Replace stator coil.

Voltage regulator is damaged.

Replace voltage regulator.

2200 SRM 1184

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Batteries are charged more
than necessary.

Wiring

connections

are

broken,

loose, or corroded.

Replace or tighten wiring connec-
tions. Remove corrosion.

Short circuit between wiring connec-
tor(s).

Repair or replace wiring connectors.

Field coil in alternator is damaged.

Repair or replace alternator.

Regulator in alternator is damaged.

Repair or replace alternator.

High resistance in the circuit.

Repair or replace parts.

Batteries use more water
than normal.

Batteries are being charged more
than normal.

Replace voltage regulator.

Alternator has damaged stator wind-
ings, diodes, rectifier bridge, rotor, or
voltage regulator.

Repair or replace parts.

Battery or batteries are damaged.

Replace battery or batteries.

There is no charge from the
alternator.

The indicator

light indicates a discharge
condition when the rpm is
high and the load is high.

Alternator drive belt is not tight or is
broken.

Tighten alternator belt or replace.

Alternator brushes are worn or dam-
aged.

Replace or repair alternator brushes.

Weak

alternator

brush

springs.

Brushes do not move freely in the
brush holders.

Repair or replace brush springs.

Dirt on the alternator slip rings.

Clean slip rings.

Discharge

indicator

indi-

cates a discharge condition
at all engine speeds.

There is an electrical ground in the
field winding.

Repair or replace field winding.

There is a short circuit in the alter-
nator diodes.

Repair or replace alternator.

There is an electrical ground at the
end of the alternator windings.

Repair or replace alternator.

The voltage regulator has damage.

Replace voltage regulator.

Troubleshooting

2200 SRM 1184

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

ELECTRICAL SYSTEM

All indicator lights are out.

Fuse(s) are damaged.

Replace fuse(s).

Connector at attachment is discon-
nected or damaged.

Reconnect or repair connector.

Wiring harness on attachment is
damaged.

Replace or repair wiring harness.

Wiring harness to operator compart-
ment is disconnected or damaged.

Reconnect or repair wiring harness.

Amber light is out.

Switch or switches at interlock
valve(s) or twist lock cylinders are
damaged or not adjusted correctly.

Adjust or replace switches.

Bulb(s) are damaged. Wires are dis-
connected.

Reconnect wires or replace bulb(s).

Green light is out.

Switch or switches at interlock
valve(s) are damaged or not adjusted
correctly.

Adjust or replace switches.

Bulb(s) are damaged. Wires are dis-
connected.

Reconnect wires or replace bulb(s).

Blue light is out.

Switch or switches at interlock
valve(s) or twist lock cylinders are
damaged or not adjusted correctly.

Adjust or replace switches.

Bulb(s) are damaged. Wires are dis-
connected.

Reconnect wires or replace bulb(s).

Indicator lights stay on.

Switches at twist lock cylinders or in-
terlock valves are damaged or not ad-
justed correctly.

Adjust or replace switches.

Hydraulic

function

does

not operate when button is
pushed.

Push button switches, relays, or cir-
cuit breakers for the function have a
malfunction or are damaged.

Repair

replace

push

button

switches, relays, or circuit break-
ers.

2200 SRM 1184

Schematics

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Hydraulic

function

does

not operate when button is
pushed. (Cont.)

Hydraulic component has a mal-
function or is damaged.

See the

section Hydraulic System 1900
SRM 1212, Extendable Container
Attachment (Elme) 5000 SRM
776, Intermodal Container At-
tachment 5000 SRM 777, or Boom,
ReachStacker 4500 SRM 0649.

Repair or replace hydraulic compo-
nent.

Hydraulic

function

does

not operate when handle is
moved.

Joystick, relays, or circuit breakers
for the function have a malfunction
or are damaged.

Replace or repair joystick, relays, or
circuit breakers.

Hydraulic component has a mal-
function or is damaged.

See the

section Hydraulic System 1900
SRM 1212, Extendable Container
Attachment (Elme) 5000 SRM
776, Intermodal Container At-
tachment 5000 SRM 777, or Boom,
ReachStacker 4500 SRM 0649.

Repair or replace hydraulic compo-
nent.

Schematics

For the electrical schematics, see the section Diagrams, Tier 2 Engine 8000 SRM 1182.

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

2200 SRM 1184

3/05 Printed in United Kingdom

Document Outline

Wyszukiwarka

Podobne podstrony:
1586985 2200SRM1178 (03 2005) UK EN
897961 2200SRM0647 (03 2005) UK EN
897825 2200SRM0596 (03 2005) UK EN
897953 1600SRM0639 (03 2005) UK EN
1598459 1900SRM1213 (03 2005) UK EN
897956 1900SRM0642 (03 2005) UK EN
897963 4500SRM0649 (03 2005) UK EN
897435 2200SRM0473 (03 1994) UK EN
1554634 2200SRM1078 (07 2005) UK EN
1573930 0600SRM1172 (03 2005) UK EN
897345 1400SRM0413 (03 2005) UK EN
1531815 1800SRM1040 (03 2005) UK EN
1468474 2200SRM0756 (07 2005) UK EN
899782 2000SRM0077 (03 2005) UK EN

więcej podobnych podstron

1589731 2200SRM1184 (03 2005) UK EN

Document Outline