ELECTRICAL SYSTEM
H8.00-12.00XM (H170-280HD) [H007];
H13.00-14.00XM (H300-330HD) [G019];
H16.00XM-6 (H360HD) [G019];
H10.00-12.00XM-12EC (H360HD-EC) [G019]
PART NO. 1665779 2200 SRM 1351
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
Description ......................................................................................................................................................... 1
Warning Devices ................................................................................................................................................ 6
General ........................................................................................................................................................... 6
Description ..................................................................................................................................................... 7
Operator-Controlled Horn......................................................................................................................... 7
Reverse Warning Horns/Lights ................................................................................................................ 7
Warning Lights.......................................................................................................................................... 7
Strobe Light........................................................................................................................................... 7
Brake Lights.......................................................................................................................................... 9
Hazard Lights ....................................................................................................................................... 9
Replace ....................................................................................................................................................... 9
General .................................................................................................................................................. 9
Horns ..................................................................................................................................................... 9
Horn Relay ............................................................................................................................................ 9
Light Assemblies................................................................................................................................... 9
Flashing Unit ........................................................................................................................................ 10
Meters, Senders, and Switches ......................................................................................................................... 10
General ........................................................................................................................................................... 10
Diagrams, Schematics, or Arrangements ......................................................................................................... 10
Figure 6. Diesel Main Wire Harness (H007) ........................................................................................... 12
Figure 7. Diesel Main Wire Harness (G019) ........................................................................................... 14
Figure 8. LPG Main Wire Harness (H007) .............................................................................................. 16
Figure 9. LPG Main Wire Harness (G019) .............................................................................................. 18
This section is for the following models:
H8.00-12.00XM (H170-280HD) [H007];
H13.00-14.00XM (H300-330HD) [G019];
H16.00XM-6 (H360HD) [G019];
H10.00-12.00XM-12EC (H360HD-EC) [G019]
©2007 HYSTER COMPANY i
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
2200 SRM 1351 Description
Description
The main part of the electrical system is the (senders, warning lights, etc.). See Figure 1 and
one-piece, main electrical wire harness. The batter- Figure 2 and the section Instrument Panel Indi-
ies provide the main electrical wire harness with cators and Senders 2200 SRM 1105 for further
electricity and then the main electrical wire har- information regarding senders and indicator func-
ness transmits the electricity to several components tions.
Figure 1. Main Electrical Wire Harness (Diesel)
1
Description 2200 SRM 1351
Legend for Figure 1
Item No. Connector Description
Main Wiring Harness
1 C390 Reverse Alarm
2 C380 LH Rear Lamp
3 C100 Backup Diode
4 C280 Alternator Signs
5 C270 Alternator +
6 C290 Alternator Ground
7 C105 Ground
8 C420 Pre-excitation Diode
9 C70 +24V
10 C415 Grid Heater Relay
11 C110 Starter Solenoid
12 C115 +24V
13 C425 Fuse
14 C85 Starter Relay
15 C80 Valve
16 C90 Drum Speed
17 C470 Fuel Filter to Filter
18 C150 Engine Speed
19 C82 Cab Tilt Power
20 C60 Fuel Sender
21 C350 Low
22 C120 Output Speed
23 C370 Tilt
24 C360 Aux
25 C25 LH Hub Brake Temp
26 C30 Tilt
27 C20 Front Lamps
28 C40 Aux
29 C50 Lift
30 C310 Park Brake Solenoid
31 C450 Accelerator Pedal
32 C15 RH Hub Brake Temp (wet brake option)
Hydraulic Tank Temp (dry brake option)
2
2200 SRM 1351 Description
Item No. Connector Description
33 C10 Front End
34 C130 Battery
35 C340 Turbine Speed
36 C330 Conv Out Temp Sensor
37 C146 Cab Supplies
38 C144 Cab Signals
39 C175 Air Dryer
40 C75 Park Brake and Air Dryer Diode
41 C460 Fuel Filter to Engine
42 C170 Engine Oil Pressure
43 C405 Terminating Resistor
44 C401 Engine Supply
45 C300 Diagnostics
46 C400 ECM
47 C220 Air Filter
48 C148 Grid Heater
49 C305 AC
50 C210 RH Rear Lamp
51 C215 Coolant Level
3
Description 2200 SRM 1351
Figure 2. Main Electrical Wire Harness (LPG)
Legend for Figure 2
Item No. Connector Description
Main Wiring Harness
1 C390 Reverse Alarm
2 C380 LH Rear Lamp
3 C100 Backup Diode
4 C270 Alternator +
5 C280 Alternator Signs
6 C290 Alternator Ground
4
2200 SRM 1351 Description
Item No. Connector Description
7 C105 Ground
8 C70 +24V
9 C115 +24V
10 C110 Starter Solenoid
11 C425 Fuse
12 C85 Starter Relay
13 C480 LPG Relay
14 C490 Fuse Box 1
15 C500 Fuse Box 2
16 C510 Fuse Box 3
17 C440 LPG Solenoid
18 C460 Low Pressure Switch
19 C82 Cab Tilt Power
20 C520 Resistor
21 C470 DC/DC Converter
22 C150 Engine Speed
23 C80 Valve
24 C90 Drum Speed
25 C35 Hydraulic Cooler
26 C350 Low
27 C120 Output Speed
28 C370 Tilt
29 C360 Aux
30 C25 LH Hub Brake Temp
31 C30 Tilt
32 C20 Front Lamps
33 C40 Aux
34 C50 Lift
35 C310 Park Brake Solenoid
36 C450 Acc Pedal
37 C15 RH Hub Brake Temp (wet brake option)
Hydraulic Tank Temp (dry brake option)
38 C10 Front End
39 C130 Battery
40 C340 Turbine Speed
5
Warning Devices 2200 SRM 1351
Item No. Connector Description
41 C330 Conv Out Temp Sensor
42 C146 Cab Supplies
43 C144 Cab Signals
44 C175 Air Dryer
45 C410 Engine
46 C400 ECM
C405 Terminating Resistor
47 C430 Can Connector
48 C75 Park Brake and Air Dryer Diode
49 C86 Pressure Switch
50 C170 Engine Oil Pressure
51 C220 Air Filter
52 C210 RH Rear Lamp
53 C305 AC
54 C215 Coolant Level
Warning Devices
GENERAL illuminated or by energizing a buzzer to sound. A
reverse warning horn automatically sounds a warn-
Electrical warning devices used on the lift truck are ing that the equipment is moving in the reverse
as follows: direction. Warning lights automatically illuminate
• Operator-controlled air horn to warn personnel that the equipment is operating
• Reverse warning horn/lights in a special way. Warning lights are also used to
• Warning lights warn personnel that the equipment is near. Some
of these warning devices need to be energized and
Operator-controlled horns permit the operator to
de-energized at a fast rate. A separate flashing
warn personnel that the equipment is near. System
device does this. Most equipment does not need each
warning lights and buzzers make an important sys-
of these warning devices.
tem condition known to the operator. They do this
by illuminating an indicator that is not normally
6
2200 SRM 1351 Warning Devices
DESCRIPTION
Operator-Controlled Horn
The operator-controlled horn has a horn switch, a re-
lay, and horn. See Figure 3. The horn switch ener-
gizes the relay to close the power contacts and en-
ergize 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 directly controlled by the switch. The
horn switch is located at the operator’s position. The
horn is installed underneath the cab. The horn relay
is installed in the side console.
1. HORN
2. TRANSMISSION SHIFTER OR MONOTROL®
PEDAL
3. RELAY
4. BASE
Figure 4. Reverse Warning Horn Components
Warning Lights
1. ELECTRICAL HORN The following types of warning lights are attached to
the lift truck:
Figure 3. Operator-Controlled Horns • Strobe Light
• Brake Lights
Reverse Warning Horns/Lights • Hazard Lights
The reverse warning horn is operated by the Strobe Light
MONOTROL® pedal or the shifter. See Figure 4.
They use a flashing device to make the sound of the These warning lights indicate a particular type of
horn begin and end repeatedly. This flashing device equipment operation. See Figure 5. They warn oth-
is part of the reverse warning horn. The switch is ers that the equipment is in the area or that the op-
energized to the ON position when the equipment is erator’s view is limited by the particular operation.
set to operate in the reverse direction. The switch These lights can be flashing lights. A switch and a
will then energize the relay to energize the horn. flashing device are used to operate the flashing light.
The horn is most frequently located under the back The flashing device is part of the light assembly. The
of the equipment. The relay is located in the side light can be connected to operate when the key switch
console. is in the ON position. They can also be connected
to operate with a particular operation of the equip-
ment such as: Equipment is set for reverse opera-
tion. When connected in this way, a separate switch
is operated automatically by the equipment function.
7
Warning Devices 2200 SRM 1351
Item Connector Description
No.
1 N/A Working Light (Halogen or HID)
2 N/A Strobe Light
3 N/A Cab
4 C10 (black 8 way dt socket housing – DEUTSCH) Mate to connector on cab assembly.
5 C30 (4 mm socket terminal and 4 mm male bullet terminal – Strobe
SUMITOMO)
6 C20 (black 2 way dt socket housing – DEUTSCH) Rear Drive Light
7 C50 (black 2 way dt socket housing – DEUTSCH) Outer Front Flood Light
8 C40 (black 2 way dt socket housing – DEUTSCH) Inner Front Flood Light
Figure 5. Light Assemblies
8
2200 SRM 1351 Warning Devices
Brake Lights 4. Remove the horn and install the replacement.
These warning lights indicate that the speed of the 5. Tighten the screws, nuts, or other items fasten-
lift truck will slow down. They warn others that the ing the horn to the equipment.
lift truck will stop or decrease the speed severely.
These lights are positioned on the backside of the lift 6. Connect the wires, as marked, to the electrical
truck and will be activated by operating the brake terminals.
pedal.
Horn Relay
Hazard Lights
The horn relay is located in the side console in the
These warning lights will be used when the lift truck cab. If necessary, follow the horn electrical leads to
has problems with driving or when the lift truck is find the relay. Replace the relay as follows:
placed at a dangerous location.
1. Disconnect the battery or batteries to remove all
voltage from the terminals.
Replace
2. Mark the wires for reconnecting.
General
3. Disconnect the wires.
Horns, light assemblies, flashing devices, buzzers,
and switches are not repairable items. The most ac- 4. Remove the screws, nuts, or other items fasten-
curate and usually easiest checks for proper opera- ing the unit to the equipment.
tion of individual items is direct replacement. How-
ever, the most common cause of failure are poor con- 5. Remove the unit and install the replacement
nections or defective or improper wiring. Also, there unit.
are no adjustments to perform. Therefore, only re-
placement procedures are given. Before replacing an 6. Tighten the screws, nuts, or other items fasten-
item, verify the following: ing the unit to the equipment.
• Other electrical circuits are operating correctly.
7. Connect the marked wires to the correct termi-
• Battery is fully charged and the cable terminals are
nals or connectors.
clean and correctly connected.
• Wiring and connections to device are tight and in Light Assemblies
good condition.
1. Disconnect the battery or batteries to remove all
Horns voltage from the terminals.
CAUTION NOTE: Do Step 4 before Step 2 and Step 3 if there is
no access to assembly wire terminals.
Audible alarms and horns have various levels
of output. Be certain that any replacement 2. Mark the wires for reconnecting.
alarm or horn has an output that can be heard
in the area where the lift truck will be used. 3. Disconnect the wires at the wire connectors or
light terminals.
1. Make sure the key switch is in the OFF position
or the battery is disconnected. 4. Remove the screws, nuts, or other items fasten-
ing the assembly to the equipment.
2. Mark the horn wires for reconnecting and discon-
nect them. 5. Remove the assembly and put the new assembly
in the correct position.
3. Remove the screws, nuts, or other items fasten-
ing the horn to the equipment.
9
Diagrams, Schematics, or Arrangements 2200 SRM 1351
NOTE: Some assemblies have no access to the wire Flashing Unit
terminals after it is fastened to the equipment. If so,
do Step 7 before Step 6. Replace the flashing unit by holding the base and
pulling the unit until the pins are out of the base
6. Install the screws, nuts, or other items to fasten clips. Align the replacement flashing unit pins. Push
the assembly to the equipment. the unit into position on the base.
7. Connect the marked wires to the correct termi-
nals or connectors.
Meters, Senders, and Switches
GENERAL 2. Make sure that the battery is charged, correctly
installed, and the cable terminals are clean and
Meters, senders, and switches cannot be repaired. tight.
The fan and wiper motors of the operator compart-
ment also cannot be repaired. These components are 3. Make sure that the wires and connections to the
replaced when they are defective. The most com- unit are tight and in good condition.
mon cause of failure is a bad connection or defective
wiring. There are no adjustments. See the section for NOTE: See your Cummins engine dealer for starter
replacement procedures. Before a meter or sender is and alternator repair.
replaced, make the following checks:
1. Make sure that the other meters and electrical
circuits are operating correctly.
10
NOTES
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Diagrams, Schematics, or Arrangements 2200 SRM 1351
12
2200 SRM 1351 Diagrams, Schematics, or Arrangements
Figure 6. Diesel Main Wire Harness (H007)
13
Diagrams, Schematics, or Arrangements 2200 SRM 1351
14
2200 SRM 1351 Diagrams, Schematics, or Arrangements
Figure 7. Diesel Main Wire Harness (G019)
15
Diagrams, Schematics, or Arrangements 2200 SRM 1351
16
2200 SRM 1351 Diagrams, Schematics, or Arrangements
Figure 8. LPG Main Wire Harness (H007)
17
Diagrams, Schematics, or Arrangements 2200 SRM 1351
18
2200 SRM 1351 Diagrams, Schematics, or Arrangements
Figure 9. LPG Main Wire Harness (G019)
19
NOTES
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TECHNICAL PUBLICATIONS
2200 SRM 1351 4/07 Printed in United Kingdom
