Hyster H300HD2 Operating instructions

Hyster K019 (H300HD2, H330HD2, H360HD2,
H360HD2-EC, H210-48HD2, H230-48HD2,
H250-48HD2) Forklift Service Repair Manual

ELECTRICAL SYSTEM
PART NO. 4133478 2200 SRM 1936

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.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................2
Electrical Schematic and System Description .......................................................................................................2
Electrical Schematic ........................................................................................................................................... 2
Schematic Location Number ..............................................................................................................................5
Electrical Components ........................................................................................................................................5
Electrical Wires ...................................................................................................................................................5
Wire Identification Number ...........................................................................................................................5
Electrical Wire Colors .....................................................................................................................................7
Wire Harnesses ...............................................................................................................................................7
Harness Interconnection ..............................................................................................................................10
Electrical Connectors ........................................................................................................................................10
Connector Types ........................................................................................................................................... 10
Connector Identification ...............................................................................................................................11
Connector Pin Numbers ...............................................................................................................................11
Connector Description ..................................................................................................................................11
Fuses ..................................................................................................................................................................11
Relays ................................................................................................................................................................ 15
Flyback Diodes ..................................................................................................................................................16
CAN (Controller Area Network) .......................................................................................................................16
Troubleshooting ............................................................................................................................................18
Instrument Panel ..............................................................................................................................................18
Instrument Panel Connectors ......................................................................................................................20
LCD Display ......................................................................................................................................................22
Hourmeter Mode ...........................................................................................................................................22
Fault Code Mode ...........................................................................................................................................22
Transmission Calibration .............................................................................................................................22
Fault Code Log Mode ....................................................................................................................................22
Access ........................................................................................................................................................23
Clear ..........................................................................................................................................................23
Exit ............................................................................................................................................................23
General Fault Finding ......................................................................................................................................23
Preparation ...................................................................................................................................................24
Define the Problem Area ..............................................................................................................................24
Identify Possible Causes of Malfunction .....................................................................................................24
Determine the Most Probable Cause ...........................................................................................................24
Fuse Check ....................................................................................................................................................24
Wiring Check ................................................................................................................................................ 24
Component Check .........................................................................................................................................24
Repair and Test .............................................................................................................................................24
Wire Harness Identification and Connector Location .........................................................................................25
Frame Harness Connectors ..............................................................................................................................35
Mast ECH 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
DEF Tank Harness Connectors ....................................................................................................................... 50
Table of Contents
i

TABLE OF CONTENTS (Continued)
Powertrain Harness Connectors ......................................................................................................................51
Hoodspine Harness Tier 3/Stage IIIA Connectors ..........................................................................................52
Hoodspine Harness Tier 4F/Stage IV Connectors ...........................................................................................53
This section is for the following models:
Table of Contents
ii

Series Code / Model Designation Reference Table
This table consist of the following Series Codes
used in this manual.
Series
Code European Model Americas Model
K019 H13.00-16.00XM-6 H210-250-48HD2, H300-360HD2
K019EC H6.00-7.00XM-12EC H360HD2-EC
L007 H8.00-12.00XM-6 H190-280HD2, H250HD2
B238 H16.00XM-9, H18XM-7.5, H16XM-12, H18XM-9 H360-36HD, H360-48HD
2200 SRM 1936 Series Code / Model Designation Reference Table
1

General
This manual provides general information on the
electrical system of B238, K019, and L007 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 rel-
evant manual for the component. An example
would be a transmission solenoid, which is shown
in Transmission Repair (ZF-WG161)
1300SRM1456.
The actual electrical schematic drawings are shown
in Diagrams 8000SRM1938 for L007 and K019,
and in Diagrams 8000SRM1982 for B238.
Electrical Schematic and System Description
ELECTRICAL SCHEMATIC
The electrical schematic is laid out over several pa-
ges in Diagrams 8000SRM1938 for L007 and K019
and in Diagrams 8000SRM1982 for B238. 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. Each page shows the electrical
connection between the components, connectors,
and wires.
General 2200 SRM 1936
2

Table 1. Electrical Schematic Index
Number Title Contents
1 Index Sheet Title Index
2 Main Power Battery, Key Switch
3 Engine Common / 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 Twist Module 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 and Switch
19 Front End FLT Carriage, Slide Shift
20 ECH Attachment Connection between Mast and ECH Attachment
21 Connector Overview Connector codes, names and applied harness
22-26 Wire List List of used wires and their functions
27 Fuses List of used fuses and their functions
2200 SRM 1936 Electrical Schematic and System Description
3

Figure 1. Schematic Example
Electrical Schematic and System Description 2200 SRM 1936
4

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