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

1
2
4
4
6
8
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

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

2200 SRM 1204

General

General
This service manual provides the electrical diagram
for YardMasters with a optional 7-function joystick
and instructions how to convert from a 5-function joystick to a 7-function joystick.
On YardMasters with a 5-function joystick, the powered pile slope function is activated by a separate
switch on the right-hand side panel. The additional
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 diagrams 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.

Legend for Figure 1

LEFT-HAND PILE SLOPE
LEFT-HAND SIDESHIFT
RIGHT-HAND SIDESHIFT
RIGHT-HAND PILE SLOPE
COUNTERCLOCKWISE ROTATION
CLOCKWISE ROTATION
HORN

1.
2.
3.
4.
5.
6.
7.

Pin

Wires

Switches

Red (+)

Grey

Counterclockwise
rotation

White

Clockwise rotation

Black

Pile slope left

Blue

Sideshift left

Green

Sideshift right

Yellow-Green

Horn

Yellow

Pile slope right

Figure 2. Joystick Connector

The diagrams shown in Figure 4, Figure 5, and Figure 6, apply to the 7-function joystick and replace the
5-function joystick diagrams found in the section Diagrams, 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

Conversion

2200 SRM 1204

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

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.

1. Remove connector PMH from the 5-function joystick.

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.

2. Remove the 5-function joystick and replace with

the 7-function joystick.

7. Insert connector PMH from the side console harness into connector PMH of the joystick harness.

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 numbers are 2, 7, 1, and 3.

8. Mount the two relays at the inside of the side

panel.

4. Isolate the wires at the switch side.

9. Start the engine and check correct operation of

the joystick switches.

NOTES
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Diagrams, Schematics, or Arrangements

2200 SRM 1204

2200 SRM 1204

Diagrams, Schematics, or Arrangements

Figure 3. Joystick Wire Harness

Diagrams, Schematics, or Arrangements

2200 SRM 1204

2200 SRM 1204

Diagrams, Schematics, or Arrangements

Figure 4. Spreader Rotation/401 Hydraulic Flow

Diagrams, Schematics, or Arrangements

2200 SRM 1204

2200 SRM 1204

Diagrams, Schematics, or Arrangements

Figure 5. Spreader Sideshift Function

Diagrams, Schematics, or Arrangements

10

2200 SRM 1204

2200 SRM 1204

Diagrams, Schematics, or Arrangements

Figure 6. Spreader Tilt Function

11

NOTES
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12

TECHNICAL PUBLICATIONS
2200 SRM 1204

1/05 Printed in United Kingdom