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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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.
2200 SRM 1936 Electrical Schematic and System Description
5

Table 2. Function ID Numbers
Function Group Number Range
Dedicated Circuits 001 - 100
Grounds 101 - 149
Current sense ground 150 - 199
Switched B+ 200 - 239
Fused B+ 240 - 249
Regulated power 5V 250 - 279
Regulated power 12V 280 - 299
Analog inputs - hydraulics/mast 300 - 319
Analog inputs - chassis 320 - 339
Analog inputs - powertrain 340 - 399
Analog inputs - CAB/OHG 400 - 419
Additional analog inputs 420 - 499
Digital inputs - hydraulics/mast 500 - 509
Digital inputs - chassis 510 - 539
Digital inputs - powertrain 540 - 559
Digital inputs - CAB/OHG 560 - 569
Encoder inputs 570 - 599
Additional digital inputs 600 - 699
Digital outputs - hydraulics/mast 700 - 719
Digital outputs - chassis 720 - 749
Digital outputs - powertrain 750 - 779
Digital outputs - CAB/OHG 780 - 799
PWM outputs - hydraulics/mast 800 - 829
PWM outputs - chassis 830 - 839
PWM outputs - powertrain 840 - 889
PWM outputs - CAB/OHG 890 - 899
Communication (e.g., CAN) 900 - 909
Non-standard functions 910 - 999
Electrical Schematic and System Description 2200 SRM 1936
6

Wires with the same number are interconnected
through splices and connectors, and therefore have
the same electrical function.
When a circuit is spliced into several wires, or
when a wire passes a connector, each wire number
receives the next unique suffix letter. An example
is 42-a, 42-b.
To simplify the schematic, sometimes the identifi-
cation has been omitted for a spliced function. It
may concern an intersection between a switch and
a splice, or a right-hand component operating si-
multaneously with a left hand component.
There is a wire number overview in Diagrams
8000SRM1938 for L007 and K019, and in Dia-
grams 8000SRM1982 for B238. In this overview
each wire is listed with the wire harness it is part
of, and with the connector identification number
and pin numbers it connects to. The actual location
of a connector code can be looked up in Connector
Overview.
Electrical Wire Colors
In addition to the function ID numbers on the elec-
trical wires, different wire isolation colors are used
to identify the circuit levels. See Table 3.
Table 3. Electrical Wire Colors
Wire Color Circuit Level
Red Battery Level Power Circuits
Black Heavy Current Grounds
Green Signal Grounds
White Other Circuits
Yellow (Twisted Pair) CAN Hi
Green (Twisted Pair) CAN Lo
Orange 5 Volt
Pink 12 Volt
Wire Harnesses
Wires are bound together in wire harnesses to se-
cure against the adverse effects of vibration, abra-
sion and moisture. The description of wire har-
nesses follows from its location in the truck or from
the functions it connects with.
Figure 2 provides an overview of the different har-
nesses that belong to the different truck options
and their connector numbers.
Figure 14 through Figure 23 shows a 3D-view of
most of the wire harnesses with their terminals
and connectors. The legends for these figures men-
tion the connector codes and connector description
for verification. See also Wire Harness Identifica-
tion and Connector Location.
2200 SRM 1936 Electrical Schematic and System Description
7

Figure 2. Harnesses Overview
Electrical Schematic and System Description 2200 SRM 1936
8

Legend for Figure 2
1. FRAME
2. SIDE CONSOLE
3. CAB POWER
4. CAB SIGNALS
5. AUX SIGNALS
6. REAR
7. POWERTRAIN
8. POWERED CAB TILT
9. MAST WORK LIGHTS
10. MAST WORK LIGHTS RH
11. MAST WORK LIGHTS LH
12. MAST
13. FRONT-END
14. MAST ECH
15. FRONT LIGHTS LH
16. FRONT LIGHTS RH
17. HOOD SPINE
18. ENGINE
19. DEF
20. ECM
21. EAS/ECM
22. TWIST MODULE
23. ECO-ELO/HIP
24. ARM REST
25. ECH ADAPTOR
26. CAB UNDERFLOOR
27. STEERING COLUMN
28. CLOSED CAB
29. CAB LIGHTS LH
30. CAB LIGHTS RH
31. REAR WIPER EXTENSION
32. WASH PUMPS
2200 SRM 1936 Electrical Schematic and System Description
9

Not shown in the harness overview and in the 3D-
views are harnesses that are merely an extension
cord for some of the connectors, or jumpers that
connect between wires. The lay-out of these har-
nesses can be read from the electrical schematic.
For the actual location of these harnesses, read the
code of the mating connector from the electrical
schematic and look up the figure and item number
from Connector Overview. For example: the Closed
Cab harness connects with the Cab Lights RH,
which connects to CPS 64. See Top Cab Harness
Connectors.
Not shown on the figures for the frame harnesses
are the connectors for engine components such as
sensors, fan clutch and grid heater relays.
There are four jumper options:
•Jumper Power Supply by Ignition provides
power supply for side, tail and hazard lights
when the ignition switch is turned to the ON
position. See schematic location [99, H]. This
harness is to be plugged into connector
CPS651, which connects pin A with pin B.
•Jumper Power Supply by Battery directly
provides power supply from the batteries to
the circuit for side, tail and hazard lights, al-
lowing activating these lights irrespective of
the ignition switch position. See schematic
location [98, H]. This harness is to be plug-
ged into connector CPS650, which connects
pin B with pin C.
•The strobe light jumper allows activation by
ignition by connecting a jumper between pin
number 2 and pin 3 of the strobe switch. See
schematic location [72, L].
•Operator Presence Switch Jumper, which is
removed when connecting the optional seat-
belt sequencer.
Harness Interconnection
On the electrical schematic the interconnection be-
tween two harnesses is indicated by a harness di-
viding line, which will run across the two mating
harness connectors. See Figure 1, item 15.
ELECTRICAL CONNECTORS
Connector Types
Connector types are identified by letter codes. Mul-
tiple pin or socket connectors have a three letter
code. Terminators, that are not isolated when de-
tached, have a two letter code. The explanation of
the letter codes is shown in Table 4.
Table 4. Connector Types
Letter Code Explanation
CRP Connector Receptacle Pin
CRS Connector Receptacle Socket
CPP Connector Plug Pin
CPS Connector Plug Socket
TS Terminal Socket
TP Terminal Pin
Electrical Schematic and System Description 2200 SRM 1936
10

Connector Identification
Each connector is identified by the letter code of the
connector type and a unique identification number,
e.g. CRP07.
Connectors have the same identification number if
they interconnect between two wire harnesses, e.g.
CRP07 interconnects with CPS07.
On the schematic a connector may be represented
complete with all wires it normally contains, or
partial, showing the few wires that are relevant for
the particular page of the schematic.
A completely represented connector shows two
rounded corners, as shown on Figure 1, item 11.
A partially represented connector has one curled
corner, as shown on Figure 1, item 12.
As the wires in a connector will relate to different
functions, portions of a connector can be divided
over several schematic pages according the differ-
ent electrical function of the wires. In general there
is no relation between a connector and a schematic
location. The only possibility to look up a schematic
location is through the connector listing.
A connector is not shown on the schematic if the
connector is an integral part of a component or if it
does not have a minimum length of wire harness
between the component and the connector. In these
cases the schematic just shows the wire harness
connector.
Connector Pin Numbers
On the schematic the pin numbers are indicated by
a number or letter inside the connector symbol,
with the relevant wire ending at the relevant pin
number.
On the connector itself pin numbers are shown in
relief, but can be as small as 1 mm high. To read
the numbers, clean the housing and provide suffi-
cient lighting.
Pin numbers can be located on the inside of the con-
nector next to the pin, on the backside of the con-
nector next to the wires, or on the connector hous-
ing.
Connector Description
For orientation purposes each connector has been
provided with a description, which is shown in the
connector overview in Table 11, and in the legend
for the wire harnesses. The description matches the
component it is attached with.
For connectors between harnesses the description
is a combination of the two harness names. For in-
stance CPS139: Frame-Mast. The first part of the
description indicates the wire harness that the con-
nector is part of, the second part indicates the wire
harness that the connector connects with. An ex-
ception is the interconnection between frame and
side console harness, which is through three con-
nectors.
To avoid having three identical descriptions, the
descriptions Cab Signals, Cab Power and Aux Sig-
nals have been assigned.
FUSES
The grid heater, cab and alternator have separate
fuses and relays that are located on the powerboard
in the battery box attached to the fuel tank on the
left-hand side of the truck. See Figure 3 and Ta-
ble 5.
Four fuse panels are located behind the cover under
the instrument panel. The four fuse panels contain
the fuses that protect all other electrical circuits.
See Figure 4 and Table 6.
On the inside of the instrument cover is a label that
shows the location of the fuses in the four fuse pan-
els.
In some cases a fuse is not adopted on the electrical
schematic. It concerns fuses that are an integral
part of a component, like retrofitted radio’s or the
Twist Module.
2200 SRM 1936 Electrical Schematic and System Description
11

Legend
Item Code Description Value Connector Location
1. BATTERY DISCONNECT
SWITCH -- -- --
2. BATTERY DISCONNECT
SWITCH LOCK -- -- --
3. BATTERY -- -- --
4. POWERBOARD -- -- --
5. F1 ALTERNATOR 125A TS15/TS16 [38,A]
6. R1 RELAY GRID HEATER -- TS18/
CPS166 [35,H]
7. F2 CAB SUPPLY 125A TS10/TS01 [22,D]
8. F4 DEF HOSE HEATING 15A CPS166 [52D]
9. F3 GRID HEATER 150A F3 [35,H]
10. F5 SPARE 10A CPS166 [53,C]
11. F6 DEF MODULE HEATER 10A CPS166 [53,D]
12. F7 SPARE 7.5A CPS166 [53,C]
13. F8 SPARE 10A CPS166 [53,C]
14. F11 SPARE 15A CPS166 [54,C]
15. R4 RELAY DEF HOSE CPS146 -- CPS166 [51,C]
16. R5 RELAY DEF PUMP HEATER -- CPS166 [52,D]
17. R3 RELAY DEF HOSE CPS141 -- CPS166 [51,D]
18. R2 RELAY DEF HOSE CPS140 -- CPS166 [52,C]
Electrical Schematic and System Description 2200 SRM 1936
12

Legend
Item Code Description Value Connector Location
19. F10 ENGINE ECM SUPPLY 30A CPS178 [33,H]
20. F9 CAB TILT 30A CPS178 [105,F]
Figure 3. Main Fuses and Main Relays
Figure 4. Fuse Panel, Hydraulic Controller and
Hydraulic Relays
Legend for Figure 4
1. FUSE PANEL 1
2. FUSE PANEL 2
3. FUSE PANEL 3
4. FUSE PANEL 4
5. ECO-ELO SWITCH
6. HYDRAULIC SERVICE SWITCH
7. TRANSMISSION CALIBRATION SWITCH
8. RELAY PANEL (SEE FIGURE 5)
9. DIAGNOSTIC PLUG
10. REGENERATION SWITCH (TIER 4 ONLY)
Table 6. Fuse Panel Overview
Fuse Description Value Location
Fuse Panel 1
F1 Engine Start 30A [25,B]
F2 ECM Ignition 5A [31,E]
F3 Low Brake Pressure Warning 5A [29,F]
F4 Ignition 7.5A [29,F]
F5 Transmission B+ 7.5A [64,C]
F6 Hydraulic Controller 30A [138,E]
F7 Attachment Controls 15A [145,A]
2200 SRM 1936 Electrical Schematic and System Description
13

Table 6. Fuse Panel Overview (Continued)
Fuse Description Value Location
F8 Park Brake Solenoid 5A [123,A]
F9 Instrumentation 10A [120,B]
F10 Alternator On 5A [34,A]
Fuse Panel 2
F11 Flood Lights 30A [78,J]
F12 Strobe Light B+ 5A [71,I]
F13 Brake Lights 10A [82,H]
F14 Front Drive Lights 15A [71,G]
F15 Interior Lights 5A [71,H]
F16 Mast/Attachment Lights 15A [81,E]
F17 Direction Indicators 10A [97,D]
F18 Side/Tail Lights 10A [82,E]
F19 Rear Drive Lights 10A [79,I]
F20 Reverse Lights/Alarm/Strobe 10A [79,I]
Fuse Panel 3
F21 Front Screen Wash/Wipe 10A [152,B]
F22 Roof Screen Wash/Wipe 10A [152,B]
F23 Rear Screen Wash/Wipe 10A [152,C]
F24 Horn 10A [166,C]
F25 Sped Power Ignition 5A [168,G]
F26 Automatic Greasing (opt) 10A [182,F]
F27 Seat Suspension Compressor 15A [122,F]
F28 Heater/AC/Ventilation Fan 25A [171,F]
F29 AC Condenser, Fans 30A [179,H]
F30 Parkbrake Warning Buzzer 5A [179,G]
Fuse Panel 4
F31 Power Socket 12V DC 10A [168,H]
F32 Radio/CB/Intercom 10A [168,H]
F33 12V Converter for Accessories 10A [166,H]
F34 Hazard Lights 10A [97,D]
F35 Sped Power B+ 25A [168,G]
F36 12V Relay 3A [168,H]
F37 OPS System 5A [126,C]
F38 EAS Sensor 10A [43,A]
F39 Power Socket Switched 24V B+ 15A [168,G]
F40 Power Socket 24V ign 5A [168,G]
Electrical Schematic and System Description 2200 SRM 1936
14