ELECTRICAL SYSTEM

H16.00-22.00XM-12EC (H400-500HD-EC) [B214]

PART NO. 1638483 2200 SRM 1279

 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 ................................................................................................................................................ 4
General ........................................................................................................................................................... 4
Description ..................................................................................................................................................... 4
Operator-Controlled Horn......................................................................................................................... 4
Reverse Warning Horns/Lights ................................................................................................................ 4
Warning Lights.......................................................................................................................................... 5
Strobe Light........................................................................................................................................... 5
Brake Lights.......................................................................................................................................... 5
Hazard Lights ....................................................................................................................................... 5
Replace ....................................................................................................................................................... 5
General .................................................................................................................................................. 5
Horns ..................................................................................................................................................... 5
Horn Relay ............................................................................................................................................ 5
Light Assemblies................................................................................................................................... 7
Flashing Unit ........................................................................................................................................ 7
Meters, Senders, and Switches ......................................................................................................................... 7
General ........................................................................................................................................................... 7
Diagrams, Schematics, or Arrangements ......................................................................................................... 8
Figure 5. Main Wire Harness ................................................................................................................... 8
Figure 6. Oil-Cooler Wiring Harness ....................................................................................................... 10

This section is for the following models:

H16.00-22.00XM-12EC (H400-500HD-EC) [B214]

2006 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1279 Description

Description
The main part of the electrical system is the
one-piece, main electrical wire harness. The batter-
ies provide the main electrical wire harness with
electricity and then the main electrical wire har-
ness transmits the electricity to several components
(senders, warning lights, etc.). See Figure 1 and
the section Instrument Panel Indicators and
Senders 2200 SRM 1278 for further information
regarding senders and indicator functions.

Figure 1. Main Electrical Wire Harness

Legend for Figure 1

NOTE: SEE FIGURE 5 AND FIGURE 6 FOR DETAILED INFORMATION REGARDING CONNECTOR IDENTIFI-
CATION.

Item No. Connector Description

Main Wiring Harness
1 C410 (black 3-way dt socket housing (ins 1.35 - 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

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Description 2200 SRM 1279

Item No. Connector Description

4 C144 (60(0-12-48)-way drb socket housing key A - Powertrain Signs
DEUTSCH)
5 C395 (black 6-way dt socket housing (ins 1.35 - 3.05) - Aircon condensor
DEUTSCH)
6 C190 (black 6-way dt socket housing (ins 1.35 - 3.05) - Rear Right-Hand Lamp
DEUTSCH)
7 C55 (4-way 090 sealed housing - SUMITOMO) Diode
8 C270 (2-way dt pin housing - DEUTSCH) Reverse Alarm
9 C200 (black 6-way dt socket housing (ins 1.35 - 3.05) - Rear Left-Hand Lamp
DEUTSCH)
10 C230 (black 2-way dt socket housing (ins 1.35 - 3.05) - Cab Power Tilt
DEUTSCH)
11 C305 (black 1-way female AMP super seal- AMP) AC
12 C280 (4-way anti back out 150 series - DELPHI) Alternator Signs
13 C146 (insulated boot - DELPHI) Alternator VE+
14 C155 ( 10.5 mm (0.394 in.) ring terminal csa 10-16 Ground
sq.mm - G and H)
15 C110 (5.4 ring terminal 2.5 - 6 - G and H) Starter Solenoid
16 C120 (black 3-way dt socket housing (ins 1.35 - 3.05) - Engine Speed
DEUTSCH)
17 C70 (6.35 faston terminal 0.35 - 1.0 mm - LABINAL) Transmission Temp Switch
C160 (black 2-way dt socket housing (ins 1.35 - 3.05) - Turbine Speed
DEUTSCH)
18 C60 (6.35 faston terminal 0.35 - 1.0 mm - LABINAL) Fuel Sender
19 C85 ( 5.3 mm (0.209 in.) and 8.4 mm (0.331 in) ring Starter Relay
terminal csa - G and H)
20 C145 (8.4 ring terminal 8 - 16 csa - G and H) Fuse Alt.
21 C115 (8.4 ring terminal 16 - 25 sq.mm - G and H) +24V
22 C290 ( 5.3 mm (0.209 in.) and 8.4 mm (0.331 in) ring Grid Heater Relay
terminal csa - G and H)
23 C130 (10.5 ring terminal 10 - 16 sq.mm - G and H) Disconnect Switch
24 C135 (black 6-way dt socket housing (ins 1.35 - 3.05) - Fuse Box
DEUTSCH)
25 C45 (4-way 090 sealed housing - SUMITOMO) Diode
26 C25 (90 6.35 faston terminal - LABINAL) Left-Hand Hub Temperature
27 C150 (black 2-way dt socket housing (ins 1.35 - 3.05) - Output Speed
DEUTSCH)
28 C20 (black 4-way dt socket housing (ins 1.35 - 3.05) - Frond Left-Hand Headlights
DEUTSCH)

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2200 SRM 1279 Description

Item No. Connector Description

29 C240 (2-way dtp socket housing - DEUTSCH) Hydraulic Cooler
30 C90 (black 3-way dtm socket housing - DEUTSCH) Alternate Idle Sensor
31 C80 (14-way dt bsa connector F - DEUTSCH) Valve
32 C180 (black 2-way dt socket housing (ins 1.35 - 3.05) - Drum Speed
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 1.35 - 3.05) - Aux B
DEUTSCH)
35 C15 (90 6.35 faston terminal - LABINAL) Right-Hand Hub Temperature
36 C100 (0 - 23 hd pin housing - DEUTSCH) Front End
37 C10 (black 4-way dt socket housing (ins 1.35 - 3.05) - Front Right-Hand Headlights
DEUTSCH)
38 C30 (black 2-way dt socket housing (ins 1.35 - 3.05) - Parkbrake Solenoid
DEUTSCH)
39 C210 (6.35 faston terminal 0.35 - 1.0 mm - LABINAL) Brake Light Switch
40 C40 (black 2-way dt socket housing (ins 1.35 - 3.05) - Lift
DEUTSCH)
41 C35 (black 2-way dt socket housing (ins 1.35 - 3.05) - Low
DEUTSCH)
42 C220 (black 2-way j timer socket housing with A/B - AMP) Air Filter
43 C260 (black 3-way dt socket housing (ins 1.35 - 3.05) - Terminating Resistor
DEUTSCH)
44 C300 (9-way hd 10 series connector - DEUTSCH) Diagnostic Plug
45 C170 (5.3 ring 0.75 - 1.5 sq.mm csa - G and H) Engine Oil Pressure
46 C390 (2-way dtp socket housing - DEUTSCH) Engine Harness
47 C400 (50-way drc socket housing - DEUTSCH) Engine Control
48 C147 (10.5 ring terminal 10 - 16 sq.mm - G and H) Grid Heater
49 C215 (2-way packard housing - DELPHI) Radiator Coolant
Oil Cooler Wire Harness
A1 C60 (Pos. lock receptacle trml 0.7 - 2.0 sq.mm - AMP) Thermostat 1
C70 (Pos. lock receptacle trml 0.7 - 2.0 sq.mm - AMP) Thermostat 2
C80 (Relay socket - G and H) Relay 1
C90 (Relay socket - G and H) Relay 2
A2 C20 (4 way 090 sealed housing - SUMITOMO) Diodes
A3 C50 (2 way dt socket housing - DEUTSCH) Fan R
A4 C40 (2 way dt socket housing - DEUTSCH) Fan M
A5 C30 (2 way dt socket housing - DEUTSCH) Fan L

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Warning Devices
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
direction. 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-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 2.
1. ELECTRICAL HORN
Figure 2. Operator-Controlled Horns
4
2200 SRM 1279
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 directly controlled
by the switch. The horn switch is located at the oper-
ators position. The horn is installed underneath the
cab. The horn relay is installed in the side console.
Reverse Warning Horns/Lights
The reverse warning horn is operated by the
MONOTROL pedal or the shifter. See Figure 3.
They 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 horn is most frequently located under the back
of the equipment. The relay is located in the side
console.
1. HORN
2. TRANSMISSION SHIFTER OR MONOTROL
PEDAL
3. RELAY
4. BASE
Figure 3. Reverse Warning Horn Components
2200 SRM 1279
Warning Lights
The following types of warning lights are attached to
the lift truck:
Strobe Light
Brake Lights
Hazard Lights
Strobe Light
These warning lights indicate a particular type of
equipment operation. See Figure 4. 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. A switch and a
flashing device are used to operate the flashing light.
The flashing device is part of the light assembly. The
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 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.
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.
Hazard Lights
These warning lights will be used when the lift truck
has problems with driving or when the lift truck is
placed at a dangerous location.
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.
Warning Devices
Battery is fully charged and the cable terminals are
clean and correctly connected.
Wiring and connections to device are tight and in
good condition.
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.
1. Verify the key switch is in the OFF position or
the battery is disconnected.
2. Mark the horn wires for reconnection and discon-
nect them.
3. Remove the screws, nuts, or other items fasten-
ing the horn to the equipment.
4. Remove the horn and install the replacement.
5. Tighten the screws, nuts, or other items fasten-
ing the horn to the equipment.
6. Connect the wires, as marked, to the electrical
terminals.
Horn Relay
The horn relay is located in the side console in the
cab. If necessary, follow the horn electrical leads to
find the relay. Replace the relay as follows:
1. Disconnect the battery or batteries to remove all
voltage from the terminals.
2. Mark the wires for reconnection.
3. Disconnect the wires.
4. Remove the screws, nuts, or other items fasten-
ing the unit to the equipment.
5. Remove the unit and install the replacement
unit.
6. Tighten the screws, nuts, or other items fasten-
ing the unit to the equipment.
7. Connect the marked wires to the correct termi-
nals or connectors.
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Warning Devices 2200 SRM 1279

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 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 4. Light Assemblies

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2200 SRM 1279
Light Assemblies
1. 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.
2. Mark the wires for reconnection.
3. Disconnect the wires at the wire connectors or
light terminals.
4. Remove the screws, nuts, or other items fasten-
ing the assembly to the equipment.
5. Remove the assembly and put the new assembly
in the correct position.
Meters, Senders, 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 defective
wiring. There are no adjustments. See the section for
replacement procedures. Before a meter or sender is
replaced, make the following checks:
1. Make sure that the other meters and electrical
circuits are operating correctly.
Meters, Senders, and Switches
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.
6. Install the screws, nuts, or other items to fasten
the assembly to the equipment.
7. Connect the marked wires to the correct termi-
nals or connectors.
Flashing Unit
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.
2. Make sure that the battery is charged, correctly
installed, and the cable terminals are clean and
tight.
3. Make sure that the wires and connections to the
unit are tight and in good condition.
NOTE: See your Cummins engine dealer for starter
and alternator repair.
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Diagrams, Schematics, or Arrangements 2200 SRM 1279

8
2200 SRM 1279 Diagrams, Schematics, or Arrangements

Figure 5. Main Wire Harness

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Diagrams, Schematics, or Arrangements 2200 SRM 1279

10
2200 SRM 1279 Diagrams, Schematics, or Arrangements

Figure 6. Oil-Cooler Wiring Harness

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 NOTES

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 TECHNICAL PUBLICATIONS

2200 SRM 1279 5/06 Printed in United Kingdom