7-FUNCTION JOYSTICK

YARDMASTER®
HR45-25, HR45-27, HR45-31, HR45-40S,
HR45-36L, HR45-40LS, HR45-45LSX,
HR45H [B227]

PART NO. 1595265 2200 SRM 1204

 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!
7-Function Joystick Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Conversion.......................................................................................................................................................... 2
Diagrams, Schematics, or Arrangements ......................................................................................................... 4
Figure 3. Joystick Wire Harness .............................................................................................................. 4
Figure 4. Spreader Rotation/401 Hydraulic Flow ................................................................................... 6
Figure 5. Spreader Sideshift Function..................................................................................................... 8
Figure 6. Spreader Tilt Function ............................................................................................................. 10

This section is for the following models:

HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,

HR45-45LSX, HR45H [B227]

©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1204 General

General
This service manual provides the electrical diagram Legend for Figure 1
for YardMasters® with a optional 7-function joystick
and instructions how to convert from a 5-function joy- 1. LEFT-HAND PILE SLOPE
2. LEFT-HAND SIDESHIFT
stick to a 7-function joystick. 3. RIGHT-HAND SIDESHIFT
4. RIGHT-HAND PILE SLOPE
On YardMasters with a 5-function joystick, the pow- 5. COUNTERCLOCKWISE ROTATION
ered pile slope function is activated by a separate 6. CLOCKWISE ROTATION
switch on the right-hand side panel. The additional 7. HORN
two buttons on a 7-function joystick allows activating
the powered pile slope function without releasing the
joystick.

The electrical diagram for rotation, 40 liter (10.6 gal)

hydraulic flow, and sideshift function are similar
with those in the section Diagrams, YardMaster®
8000 SRM 784. The difference is, that in the dia-
grams for the 7-function joystick, the switches S142
to S148 have been provided with numbers (1 to 7) in
rectangular boxes, that refer to the legend numbers
of the 7-function joystick buttons. See Figure 1.
Figure 2 shows the wire locations of the joystick
connector PMH7B. Pin Wires Switches
1 Red (+)
2 Grey 5 Counterclockwise
rotation
3 White 6 Clockwise rotation
4 Black 1 Pile slope left
5 Blue 2 Sideshift left
6 Green 3 Sideshift right
7 Yellow-Green 7 Horn
8 Yellow 4 Pile slope right

Figure 2. Joystick Connector

The diagrams shown in Figure 4, Figure 5, and Fig-

ure 6, apply to the 7-function joystick and replace the
5-function joystick diagrams found in the section Di-
agrams, YardMaster® 8000 SRM 784. Figure 6 also
shows how to disconnect the pile slope switch (S96),
that is to be made redundant.

Figure 1. 7-Function Joystick

1
Conversion
Conversion
These instructions describe the conversion from a
5-function joystick, to a 7-function joystick. The
required parts are available as a kit, part number
1592833. The kit consists of the following:
• 7-function joystick
• Joystick wire harness
1. Remove connector PMH from the 5-function joy-
stick.
2. Remove the 5-function joystick and replace with
the 7-function joystick.
3. Remove the connection from the separate pile
slope switch by cutting the wires 644, 15, 208,
and 209 at a distance of about 100 mm (4 in.)
from connector CTGD. Related connector num-
bers are 2, 7, 1, and 3.
4. Isolate the wires at the switch side.
2
2200 SRM 1204
5. Plug connector PMH7B of the wire harness into
the plug of the 7-function joystick. The layout of
the wire harness is shown in Figure 3.
6. Connect the previously cut wires 644, 15, 208,
and 209 on the harness side (location SCTGD)
with the wires with the same number coming
from wire harness. Isolate with red shrink tube
hose.
7. Insert connector PMH from the side console har-
ness into connector PMH of the joystick harness.
8. Mount the two relays at the inside of the side
panel.
9. Start the engine and check correct operation of
the joystick switches.
 NOTES

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Diagrams, Schematics, or Arrangements 2200 SRM 1204

4
2200 SRM 1204 Diagrams, Schematics, or Arrangements

Figure 3. Joystick Wire Harness

5
Diagrams, Schematics, or Arrangements 2200 SRM 1204

6
2200 SRM 1204 Diagrams, Schematics, or Arrangements

Figure 4. Spreader Rotation/401 Hydraulic Flow

7
Diagrams, Schematics, or Arrangements 2200 SRM 1204

8
2200 SRM 1204 Diagrams, Schematics, or Arrangements

Figure 5. Spreader Sideshift Function

9
Diagrams, Schematics, or Arrangements 2200 SRM 1204

10
2200 SRM 1204 Diagrams, Schematics, or Arrangements

Figure 6. Spreader Tilt Function

11
 NOTES

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 TECHNICAL PUBLICATIONS

2200 SRM 1204 1/05 Printed in United Kingdom