Hyster C236 Operating instructions

Hyster C236 (H400HD, H400HDS, H450HD, H450HDS)
Internal Combustion Engine Trucks Service Repair Manual

ELECTRICAL SYSTEM
H18-20XM-9, H18-20XMS-9 (H400HD, H450HD,
H400HDS, H450HDS) [C236]
PART NO. 4135453 2200 SRM 1944

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
•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 ex-
ceed 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 flamma-
ble. 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 hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2016 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Electrical Schematic and System Description .......................................................................................................2
Electrical Schematic ........................................................................................................................................... 2
Schematic Location Number ..............................................................................................................................4
Electrical Components ........................................................................................................................................4
Electrical Wires ...................................................................................................................................................4
Wire Identification Number ...........................................................................................................................4
Electrical Wire Colors .....................................................................................................................................6
Wire Harnesses ...............................................................................................................................................6
Harness Interconnection ..............................................................................................................................10
Electrical Connectors ........................................................................................................................................10
Connector Types ........................................................................................................................................... 10
Connector Identification ...............................................................................................................................11
Connector Pin Numbers ...............................................................................................................................11
Connector Description ..................................................................................................................................11
Fuses ..................................................................................................................................................................12
Relays ................................................................................................................................................................ 16
Flyback Diodes ..................................................................................................................................................17
CAN (Controller Area Network) .......................................................................................................................17
Diagnostic ......................................................................................................................................................19
Central Warning Lights and Instrument Panel ..............................................................................................19
Instrument Panel Connector ........................................................................................................................21
LCD Display ......................................................................................................................................................22
Hourmeter Mode ...........................................................................................................................................22
Fault Code Mode ...........................................................................................................................................23
Transmission Calibration .............................................................................................................................23
Fault Code Log Mode ....................................................................................................................................23
Access ........................................................................................................................................................23
Clear ..........................................................................................................................................................24
Exit ............................................................................................................................................................24
General Fault Finding ......................................................................................................................................24
Preparation ...................................................................................................................................................24
Define the Problem Area ..............................................................................................................................24
Identify Possible Causes of Malfunction .....................................................................................................24
Determine the Most Probable Cause ...........................................................................................................24
Fuse Check ....................................................................................................................................................24
Wiring Check ................................................................................................................................................ 25
Component Check .........................................................................................................................................25
Repair and Test .............................................................................................................................................25
Wire Harness Identification and Connector Location .........................................................................................25
Frame Harness Connectors ..............................................................................................................................35
Mast Harness Connectors .................................................................................................................................37
Top Cab Harness Connectors ...........................................................................................................................39
Side Console Harness Connectors ....................................................................................................................41
Cab Underfloor Harness Connectors ...............................................................................................................44
Armrest Harness Connectors ...........................................................................................................................46
ECM Harness Connectors (Tier 3/Stage IIIA) .................................................................................................48
EAS/ECM Harness Connectors (Tier 4F/Stage IV) .........................................................................................49
Powertrain Harness Connectors ......................................................................................................................51
Hoodspine Harness (Tier 3/Stage IIIA) Connectors ........................................................................................52
Table of Contents
i

TABLE OF CONTENTS (Continued)
Hoodspine Harness (Tier 4F/Stage IV) Connectors ........................................................................................53
This section is for the following models:
H18-20XM-9, H18-20XMS-9 (H400HD, H450HD, H400HDS, H450HDS) [C236]
Table of Contents
ii

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General
This manual provides general information on the
electrical system of C236 lift trucks. This manual
provides a link between the electrical schematic
and the actual location of the electrical components
on the lift truck.
The description and replacement procedures for the
electrical system components are located in the
relevant manual for the component. An example
would be a transmission solenoid, which is shown
in Transmission Repair (ZF-WG211)
1300SRM1718.
The actual electrical schematic drawings are shown
in Diagrams 8000SRM1725.
2200 SRM 1944 General
1

Electrical Schematic and System Description
ELECTRICAL SCHEMATIC
The electrical schematic is laid out over several pa-
ges in Diagrams 8000SRM1725. Each page shows
the electrical connection between the components,
connectors, and wires.
The layout of the schematic is function driven,
which means that each sheet represents one partic-
ular function or area as indicated by the title of the
sheet. The index of the electrical schematic is
shown in Table 1.
Table 1. Electrical Schematic Index
Number Title Contents
1 Index Sheet Title Index
2 Main Power Battery, Key Switch
3 Engine Common and T3 Engine controller and components
4 T4F/EAS Fan Clutch, Tier 4F/Stage IV sensors
5 DEF DEF Sensors, DEF Supply Module
6 XMSN Transmission controller and components
7 Cab Lights Cab roof and interior lights
8 Frame Lights Front and tail lights, reverse alarm
9 Lights Mast lights, flasher, jumper
10 Powered Cab Tilt Powered Cab Tilt
11 Monitoring Instrument cluster, senders, alarms, diagnostics
12 OPS/Park Brake Park brake switch and solenoid, suspension seat
13 Hydraulic Controls Cab Hydraulic controller, levers, Operator Presence
14 Auxiliary Functions Hydraulic Stop Lock-, Twist Lock-, Joystick switches
15 Wipers Wipers and washers, switches, timer
16 Radio/Horn Radio, Horn, DC converter, 12V plug
17 HVAC Heating, Air Conditioning and Ventilation
18 Automatic Greasing Lubrication pump, Lubrication Display
19 Front End FLT Carriage, Slide Shift
20 Connect Overview Connector codes, names and applied harness
21 Wire List List of used wires and their functions
22 Wire List List of used wires and their functions
23 Wire List List of used wires and their functions
24 Wire List List of used wires and their functions
25 Wire List List of used wires and their functions
26 Fuse/Relay Index List of used fuses and their functions
Electrical Schematic and System Description 2200 SRM 1944
2

Figure 1. Schematic Example
2200 SRM 1944 Electrical Schematic and System Description
3

Legend for Figure 1
1. ROW LETTER - A
2. COLUMN NUMBER - 30
3. WIRE HARNESS NAME - SIDE CONSOLE
4. WIRE HARNESS NAME - FRAME
5. WIRE CONTINUATION LOCATION- [20, E]
6. MEGA FUSE - 100 AMP
7. WIRE NUMBER AND COLOR - 761-F-WHITE
8. RELAY - STARTER
9. SHEET NAME - ENGINE
10. SPLICE - S761A
11. DIODE BLOCK
12. CONNECTOR - CPS07
13. CONNECTOR - CRP07
14. FUSE - 5 AMP
15. HARNESS DIVIDING LINE
SCHEMATIC LOCATION NUMBER
The schematic is divided into rows with a letter
from A to J and into columns numbered 0 to 9 for
each sheet. See Figure 1.
The column numbering consists of the sheet num-
ber plus the column number. For example, column
57 is the 7th column on sheet 5.
The schematic location number is the combination
of a row letter and column number, which allows
quick identification of a point on the schematic. For
example, [57,A] is the 7th column on sheet 5, row
A.
ELECTRICAL COMPONENTS
Electrical components are indicated by a symbol
and a description that are placed close to each
other on the schematic. An example is the starter
relay on [38,C]. See Figure 1.
ELECTRICAL WIRES
Each electrical wire is indicated by a solid line and
has been identified with an identification number
and a color indication of the wire insulation. If a
wire continues on a different sheet, then the solid
line ends with an arrow and receives in addition
the schematic location number where this wire con-
tinues.
Wire Identification Number
Each electrical wire in the electrical schematic has
an identification number that is also printed on the
insulation of the wires.
The wire identification numbers consist of a func-
tion ID number and when needed a suffix letter.
The function ID numbers are numbered from 1
through 999. Specific ranges of numbers are as-
signed for different function ID groups. See Table 2.
Electrical Schematic and System Description 2200 SRM 1944
4