ELECTRICAL SYSTEM

H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236]

PART NO. 1652064 2200 SRM 1311

 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 ..................................................................................................................................................... 6
Operator-Controlled Horn......................................................................................................................... 6
Reverse Warning Horns/Lights ................................................................................................................ 6
Warning Lights.......................................................................................................................................... 6
Strobe Light........................................................................................................................................... 7
Brake Lights.......................................................................................................................................... 8
Hazard Lights ....................................................................................................................................... 8
Replace ....................................................................................................................................................... 8
General .................................................................................................................................................. 8
Horns ..................................................................................................................................................... 8
Horn Relay ............................................................................................................................................ 8
Light Assemblies................................................................................................................................... 9
Flashing Unit ........................................................................................................................................ 9
Meters, Senders, and Switches ......................................................................................................................... 9
General ........................................................................................................................................................... 9
Diagrams, Schematics, or Arrangements ......................................................................................................... 10
Figure 7. Main Wire Harness ................................................................................................................... 10
Figure 8. Oil-Cooler Wiring Harness ....................................................................................................... 12
Figure 9. Rear Wiring Harness ................................................................................................................ 14

This section is for the following models:

H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236]

©2006 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1311 Description

Description
The main part of the electrical system is the An oil cooler is connected to the main electrical wire
one-piece, main electrical wire harness. The batter- harness at location C240 and a rear harness is con-
ies provide the main electrical wire harness with nected to the main electrical wire harness at location
electricity and then the main electrical wire har- C190. See Figure 1. The oil cooler harness provides
ness transmits the electricity to several components the hydraulic oil cooler with electricity. See Figure 2.
(senders, warning lights, etc.). See Figure 1 and The rear harness provides the rear lights and alarm
the section Instrument Panel Indicators and with electricity. See Figure 3.
Senders 2200 SRM 1278 for further information
regarding senders and indicator functions.

Figure 1. Electrical Wire Harness

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Description 2200 SRM 1311

Legend for Figure 1

NOTE: SEE FIGURE 7, FIGURE 8, AND FIGURE 9 FOR DETAILED INFORMATION REGARDING CONNECTOR
IDENTIFICATION.

Item No. Connector Description

1 C410 (black 3-way dt socket housing (ins Ø1.35 - 3.05) - Acc. Pedal
DEUTSCH)
2 C405 (0-23 hdp free socket housing - DEUTSCH) Attachment Signal
3 C140 (0-16 hdp free socket clamped housing - DEUTSCH) Powertrain Power
4 C144 (60(0-12-48)-way drb socket housing key ’A’ - Powertrain Signs
DEUTSCH)
5 C170 (Ø5.3 ring 0.75 - 1.5 sq.mm csa - G and H) Engine Oil Pressure
6 C300 (9-way hd 10 series connector - DEUTSCH) Diagnostic Plug
7 C260 (black 3-way dt socket housing (ins Ø1.35 - 3.05) - Terminating Resistor
DEUTSCH)
8 C390 (2-way dtp socket housing - DEUTSCH) Engine Harness
9 C400 (50-way drc socket housing - DEUTSCH) Engine Control
10 C147 (Ø10.5 ring terminal 10 - 16 sq.mm - G and H) Grid Heater
11 C220 (black 2-way j timer socket housing with A/B - AMP) Air Filter
12 C215 (2-way packard housing - DELPHI) Radiator Coolant
13 C305 (black 1-way female AMP super seal- AMP) AC
C280 (4-way anti back out 150 series - DELPHI) Alternator Signs
C146 (insulated boot - DELPHI) Alternator VE+
14 C190 (black 12-way dt socket housing (ins Ø1.35 - 3.05) - Rear Harness Connection
DEUTSCH)
15 C105 (Ø 10.5 mm (0.394 in.) ring terminal csa – 10-16 Ground
sq.mm - G and H)
16 C110 (Ø5.4 ring terminal 2.5 - 6 - G and H) Starter Solenoid
17 C230 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Cab Power Tilt
DEUTSCH)
18 C60 (6.35 faston terminal 0.35 - 1.0 mm - LABINAL) Fuel Sender
19 C120 (black 3-way dt socket housing (ins Ø1.35 - 3.05) - Engine Speed
DEUTSCH)
20 C70 (6.35 faston terminal 0.35 - 1.0 mm - LABINAL) Transmission Temp Switch
C160 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Turbine Speed
DEUTSCH)
21 C85 (Ø 5.3 mm (0.209 in.) and 8.4 mm (0.331 in) ring Starter Relay
terminal csa - G and H)
22 C45 (4-way 090 sealed housing - SUMITOMO) Diode
23 C145 (Ø8.4 ring terminal 8 - 16 csa - G and H) Fuse Alt.

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2200 SRM 1311 Description

Item No. Connector Description

24 C115 (Ø8.4 ring terminal 16 - 25 sq.mm - G and H) +24V
25 C290 (Ø 5.3 mm (0.209 in.) and 8.4 mm (0.331 in) ring Grid Heater Relay
terminal csa - G and H)
26 C135 (black 6-way dt socket housing (ins Ø1.35 - 3.05) - Fuse Box
DEUTSCH)
27 C130 (Ø10.5 ring terminal 10 - 16 sq.mm - G and H) Disconnect Switch
28 C150 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Output Speed
DEUTSCH)
29 C20 (black 4-way dt socket housing (ins Ø1.35 - 3.05) - Frond Left-Hand Headlights
DEUTSCH)
30 C25 (90 6.35 faston terminal - LABINAL) Left-Hand Hub Temperature
31 C180 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Drum Speed
DEUTSCH)
32 C55 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Aux A
DEUTSCH)
33 C250 (6.35 faston terminal 0.35 - 1.0 mm - LABINAL) Low Brake Pressure
34 C50 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Aux B
DEUTSCH)
35 C80 (14-way dt bsa connector F - DEUTSCH) Valve
36 C90 (black 3-way dtm socket housing - DEUTSCH) Alternate Idle Sensor
37 C35 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Low
DEUTSCH)
38 C40 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Lift
DEUTSCH)
39 C210 (6.35 faston terminal 0.35 - 1.0 mm - LABINAL) Brake Light Switch
40 C30 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Parkbrake Solenoid
DEUTSCH)
41 C15 (90 6.35 faston terminal - LABINAL) Right-Hand Hub Temperature
42 C100 (0 - 23 hd pin housing - DEUTSCH) Front End
43 C270 (black 2-way dt socket housing (ins Ø1.35 - 3.05) - Light Work Mast
DEUTSCH)
44 C240 (2-way dtp socket housing - DEUTSCH) Oil Cooler Harness connection.
45 C10 (black 4-way dt socket housing (ins Ø1.35 - 3.05) - Front Right-Hand Headlights
DEUTSCH)

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Description 2200 SRM 1311

Item No. Connector Description

1 C30 (2-way dt socket housing - DEUTSCH) Fan L
2 C40 (2-way dt socket housing - DEUTSCH) Fan M
3 C50 (2-way dt socket housing - DEUTSCH) Fan R
4 C20 (4-way 090 sealed housing - SUMITOMO) Diodes
5 C70 (Pos. lock receptacle trml 0.7 - 2.0 sq.mm - AMP) Thermostat
6 C90 (Relay socket - G and H) Relay
7 C10 (2-way dtp pin housing - DEUTSCH) Oil cooler harness connection to
C240 frame harness connection.

Figure 2. Oil Cooler Wire Harness

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2200 SRM 1311 Description

Item No. Connector Description

1 C60 (4-way 090 sealed housing - SUMITOMO) Diode
2 C40 (black 2-way dt pin housing - DEUTSCH) Reverse Alarm
3 C50 (black 6-way dt socket housing - DEUTSCH) Air-conditioning condensor
4 C20 (black 6-way dt socket housing - DEUTSCH) Rear Right-Hand Lamp
5 C30 (black 6-way dt socket housing - DEUTSCH) Rear Left-Hand Lamp
6 C10 (black 12-way dt pin housing - DEUTSCH) Rear harness connection to C190
frame harness connection.

Figure 3. Rear Wire Harness

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Warning Devices 2200 SRM 1311

Warning Devices
GENERAL
Electrical warning devices used on the lift truck are
as follows:
• Operator-controlled air horn
• Reverse warning horn/lights
• Warning lights

Operator-controlled horns permit 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
illuminated or by energizing a buzzer to sound. A
reverse warning horn automatically sounds a warn-
ing that the equipment is moving in the reverse 1. ELECTRICAL HORN
direction. Warning lights automatically illuminate
Figure 4. Operator-Controlled Horns
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-energized 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. See Figure 4. 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
Reverse Warning Horns/Lights 2. TRANSMISSION SHIFTER OR MONOTROL®
PEDAL
3. RELAY
The reverse warning horn is operated by the 4. BASE
MONOTROL® pedal or the shifter. See Figure 5.
They use a flashing device to make the sound of the Figure 5. Reverse Warning Horn Components
horn begin and end repeatedly. This flashing device
is part of the reverse warning horn. The switch is Warning Lights
energized to the ON position when the equipment is
set to operate in the reverse direction. The switch The following types of warning lights are attached to
will then energize the relay to energize the horn. the lift truck:
The horn is most frequently located under the back • Strobe Light
of the equipment. The relay is located in the side • Brake Lights
console. • Hazard Lights

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2200 SRM 1311 Warning Devices

Strobe Light The flashing device is part of the light assembly. The
light can be connected to operate when the key switch
These warning lights indicate a particular type of is in the ON position. They can also be connected
equipment operation. See Figure 6. They warn oth- to operate with a particular operation of the equip-
ers that the equipment is in the area or that the op- ment such as: Equipment is set for reverse opera-
erator’s view is limited by the particular operation. tion. When connected in this way, a separate switch
These lights can be flashing lights. A switch and a is operated automatically by the equipment function.
flashing device are used to operate the flashing light.

Item No. Connector Description

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 Strobe
terminal – 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 6. Light Assemblies

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Warning Devices 2200 SRM 1311

Brake Lights 1. Verify the key switch is in the OFF position or

the battery is disconnected.
These warning lights indicate that the speed of the
lift truck will slow down. They warn others that the 2. Mark the horn wires for reconnection and discon-
lift truck will stop or decrease the speed severely. nect them.
These lights are positioned on the backside of the lift
truck and will be activated by operating the brake 3. Remove the screws, nuts, or other items fasten-
pedal. ing the horn to the equipment.

Hazard Lights 4. Remove the horn and install the replacement.

These warning lights will be used when the lift truck 5. Tighten the screws, nuts, or other items fasten-
has problems with driving or when the lift truck is ing the horn to the equipment.
placed at a dangerous location.
6. Connect the wires, as marked, to the electrical
terminals.
Replace
Horn Relay
General
The horn relay is located in the side console in the
Horns, light assemblies, flashing devices, buzzers,
cab. If necessary, follow the horn electrical leads to
and switches are not repairable items. The most ac-
find the relay. Replace the relay as follows:
curate and usually easiest checks for proper opera-
tion of individual items is direct replacement. How- 1. Disconnect the battery or batteries to remove all
ever, the most common cause of failure are poor con- voltage from the terminals.
nections or defective or improper wiring. Also, there
are no adjustments to perform. Therefore, only re- 2. Mark the wires for reconnection.
placement procedures are given. Before replacing an
item, verify the following: 3. Disconnect the wires.
• Other electrical circuits are operating correctly.
4. Remove the screws, nuts, or other items fasten-
• Battery is fully charged and the cable terminals are
ing the unit to the equipment.
clean and correctly connected.
• Wiring and connections to device are tight and in 5. Remove the unit and install the replacement
good condition. unit.
Horns 6. Tighten the screws, nuts, or other items fasten-
ing the unit to the equipment.
CAUTION
7. Connect the marked wires to the correct termi-
Audible alarms and horns have various levels
nals or connectors.
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.

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2200 SRM 1311 Meters, Senders, and Switches

Light Assemblies NOTE: Some assemblies have no access to the wire

terminals after it is fastened to the equipment. If so,
1. Disconnect the battery or batteries to remove all do Step 7 before Step 6.
voltage from the terminals.
6. Install the screws, nuts, or other items to fasten
NOTE: Do Step 4 before Step 2 and Step 3 if there is the assembly to the equipment.
no access to assembly wire terminals.
7. Connect the marked wires to the correct termi-
2. Mark the wires for reconnection. nals or connectors.
3. Disconnect the wires at the wire connectors or Flashing Unit
light terminals.
Replace the flashing unit by holding the base and
4. Remove the screws, nuts, or other items fasten- pulling the unit until the pins are out of the base
ing the assembly to the equipment. clips. Align the replacement flashing unit pins. Push
the unit into position on the base.
5. Remove the assembly and put the new assembly
in the correct position.

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.

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Diagrams, Schematics, or Arrangements 2200 SRM 1311

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2200 SRM 1311 Diagrams, Schematics, or Arrangements

Figure 7. Main Wire Harness

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Diagrams, Schematics, or Arrangements 2200 SRM 1311

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2200 SRM 1311 Diagrams, Schematics, or Arrangements

Figure 8. Oil-Cooler Wiring Harness

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Diagrams, Schematics, or Arrangements 2200 SRM 1311

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2200 SRM 1311 Diagrams, Schematics, or Arrangements

Figure 9. Rear Wiring Harness

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 NOTES

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 TECHNICAL PUBLICATIONS

2200 SRM 1311 12/06 Printed in United Kingdom