ELECTRICAL WARNING DEVICES

GENERAL

Electrical warning devices used on Hyster equipment

are: (1) operator controlled horns, (2) system warning
lights, buzzers and bells, (3) reverse warning horns and
(4) warning lights. Operator controlled horns permit the
operator to make it known that the equipment is near.
System warning lights, buzzers and bells make an im-
portant system condition known to the operator. They
do this by illuminating an indicator that is not normally
illuminated or by energizing a buzzer or bell to make a
noise. Reverse warning horns automatically sound a
warning that the equipment is moving in the reverse di-
rection. Warning lights automatically illuminate to warn
personnel that the equipment is operating in a special
way. One such method of operation is the operator’s
platform is above 24 inches or 610 mm. Warning lights
are also used to warn personnel that the equipment is
near. Some of these warning devices need to be ener-
gized and deenergized at a fast rate. A separate flashing
device does this. Most equipment does not need each of
these warning devices.

DESCRIPTION
FIGURE 1. OPERATOR CONTROLLED HORN

System Warning Lights, Buzzers And Bells

Operator Controlled Horns
(See FIGURE 1.)
The operator controlled horn has a horn switch, a relay
and the horn. The horn switch energizes the relay to
close the power contacts and energize the horn. This
makes the horn sound. Battery powered equipment uses
no relay. 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 frequently installed near the front of the
equipment. The horn relay can be installed under the in-
strument panel or near the horn.
(See FIGURE 2.)
System warning lights, buzzers and bells use the light
and/or a buzzer or bell and a switch for operation. Some-
times an electrical flashing device is also used. The
switch is energized to the “ON” position when a system
condition occurs. Such conditions as low air pressure,
low oil pressure, or high engine temperature can be
equipped with a warning device. The switch causes the
light to illuminate, or the buzzer or bell to sound. For
some conditions, both a light and buzzer or bell are ener-
gized. The light can also have a flashing device in its cir-
cuit. This will cause the light to flash. More warning de-
vices are used as the importance of the condition in-
creases. The switch is located where it can be operated

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by the system. The warning light, buzzer or bell and, if
used, the flashing device are most frequently located at
the operator’s position.
FIGURE 2. SYSTEM WARNING LIGHTS,
BUZZERS AND BELLS
Reverse Warning Horns (See FIGURE 3.)
Reverse warning horns need a switch to operate. They
often also use a flashing device to make the sound of the
horn begin and end repeatedly. The switch is energized
to the ”ON” position when the equipment is set to oper-
ate in the reverse direction. This energizes the horn.
Some horns need a relay. The switch will then energize
the relay to energize the horn. If a flashing device is used
it is energized by the switch. The flashing device will
then energize and deenergize the horn or relay. This will
make the sound of the horn begin and end repeatedly.
The switch is usually close to the transmission or shift
linkage. The horn is most frequently located near the
back of the equipment. The flasher and relay if used, can
be located under the instrument panel or near the horn.
2
1. HORN
2. FASTENING HOLES
3. ELECTRICAL CONNECTIONS
4. HORN RELAY
5. FLASHING UNIT
6. BASE
FIGURE 3. COMPONENTS, REVERSE
WARNING HORN
Warning Lights (See FIGURE 4.)
These warning lights indicate a particular type of equip-
ment operation. They warn others that the equipment is
in the area or that the operator’s view is limited by the
particular operation. These lights can be flashing lights
or lights that look as if they are flashing. A switch and a
flashing device are used to operate the flashing light.
The flashing device is part of the light assembly. Lights
that look as if they are flashing, have a disc that rotates
around the bulb. The disc directs the illumination away
from its surface. As the disc rotas, the directed illumina-
tion touches a fixed point once each revolution. This
makes the light look as if it flashes. Either type of 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 equipment such as: (1)
equipment is set for reverse operation or (2) operator’s
platform is above 24 inches or 610mm. When connected
in this way, a separate switch is operated automatically
by the equipment function.
1. LENS SCREW
2. FASTENING NUT
FIGURE 4. WARNING LIGHTS
REPLACEMENT
General
Horns, light assemblies, flashing devices, buzzers and
switches are not repairable items. The most accurate and
usually easiest checks for proper operation of individual
items is direct replacement. However, the most common
cause of failure is poor connections or defective or im-
proper wiring. Also, there are no adjustments to per-
form. Therefore, only replacement procedures are giv-
en. Before replacing an item, make sure of the follow-
ing:
a. Other electrical circuits are operating correctly.
b. Battery is fully charged and the cable terminals
are clean and correctly connected.
c. Wiring and connections to device are tight and in
good condition.
Replacing Horns Or Bells (See FIGURE 5.)
1. Make sure the KEY switch is in the “OFF” position or
the battery is electrically disconnected.
2. Mark the horn or bell wires for reconnection and dis-
connect them.
3. Remove the screws, nuts or other items fastening the
horn or bell to the equipment.
4. Remove the horn or bell and install the replacement.
5. Tighten the screws, nuts, or other items fastening the
horn or bell to the equipment.
6. Connect the wires as marked, to the electrical termi-
nals.
1. BULB ASSEMBLY 5. LENS
2. BULB PINS 6. LENS PIN
3. BULB 7. BASE
4. LENS TUBE 8. SLOT
FIGURE 5. REPLACEMENT OF INSTRUMENT
PANEL LIGHTS
Replacing Horn Relay Or Buzzer
The horn relay if used, is frequently located under the in-
strument panel or near the horn. Electrically powered
equipment does not use relays. 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 volt-
age from the terminals.
2. Mark the wires for reconnection.
3. Disconnect the wires.
4. Remove the screws, nuts, or other items fastening the
unit to the equipment.
5. Remove the unit and install the replacement unit.
6. Connect the marked wires to the correct terminals or
connectors.
Replacing Warning Lights BULBS
(See FIGURE 2., FIGURE 4. and FIGURE 5.)
1. Access the different assemblies’ bulbs as follows:
a. Large instrument panel assemblies – push the as-
sembly base toward the lens and turn. Do not let
spring fall.
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 b. Small instrument panel assemblies – twist the
bulb assembly free of the lens tube.
c. Exterior assemblies – remove the screws fasten-
ing the lens.
2. Push the bulb toward the base while turning the bulb
to the left.
3. After the bulb is released, slowly remove it and check
position of pins on the base of the bulb.
4. Position new bulb so that the pin position is the same.
5. Align pins with slots in light assembly.
6. Push the bulb toward the base. Turn to the right until
locked.
Light Assemblies
(See FIGURE 4. and FIGURE 5.)
1. Disconnect the battery or batteries, to remove all volt-
age from the terminals.
NOTE: Do step 4 before steps 2 and 3 if there is no ac-
cess 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 fastening the
assembly to the equipment.
5. Remove the assembly and put the new assembly in the
correct position.
NOTE: Some assemblies have no access to the wire ter-
minals 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 as-
sembly to the equipment.
7. Connect the marked wires to the correct terminals or
connectors.
Replacing Flashing Units
Replace the flashing unit by holding the base and pull-
ing the unit until the pins are out of the base clips. Align
the replacement flashing unit pins. Push the unit into po-
sition on the base.