ELECTRICAL SYSTEM

HR45-25, HR45-27, HR45-31, HR45-40S,

HR45-36L, HR45-40LS, HR45H [A227]

PART NO. 1538373 2200 SRM 1065

 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
Operation............................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Location Numbers ..................................................................................................................................... 2
Components ............................................................................................................................................... 2
Leads/Wires ............................................................................................................................................... 2
Common Parts ........................................................................................................................................... 2
Electrical Components .................................................................................................................................. 4
Circuit Explanation ....................................................................................................................................... 13
Key-Switch in OFF Position ..................................................................................................................... 13
Key-Switch in ON Position ....................................................................................................................... 13
Key-Switch in Engine START Position .................................................................................................... 13
Engine SHUTDOWN ................................................................................................................................ 13
Parking Brake ........................................................................................................................................... 13
Warning Lights.......................................................................................................................................... 13
Key Switch ON, Engine Not Running ................................................................................................. 13
Manual Selection Transmission Control.................................................................................................. 14
APC 100 Electronic Transmission Control .............................................................................................. 14
Outrigger Circuits ..................................................................................................................................... 14
Lights ......................................................................................................................................................... 14
Sliding Cab ................................................................................................................................................ 15
Boom Up .................................................................................................................................................... 15
Boom Down ................................................................................................................................................ 15
Tilting Cab ................................................................................................................................................. 15
Spreader Rotation ..................................................................................................................................... 15
Spreader Sideshift..................................................................................................................................... 15
Spreader Extend/Retract .......................................................................................................................... 15
Container Seating/Locking/Releasing ...................................................................................................... 16
Part Numbers of Electrical Components .......................................................................................................... 16

This section is for the following models:

HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-

40LS, HR45H [A227]

©2004 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1065 Operation

Description
This manual provides information on the Operation, Schematics, Wiring, Connectors, and location of the elec-
trical system components.

Operation
GENERAL Each page of the electrical schematic is divided into
41 columns. The column numbers are shown in a
The electrical schematic is laid out on several pages. horizontal bar at the top of each page. The meaning
The index page shows on which page the different of the reference numbers depends on its layout and
functions can be found. Not all functions will apply its location. See Figure 1.
to your truck. See Diagrams 8000 SRM 784.

1. COLUMN NUMBERS 7. REPLACEMENT COMPONENTS (GAUGES,

2. LEAD/WIRE IDENTIFICATION MOTORS, ALTERNATOR, GENERAL)
3. CABLE LOOM 8. FUNCTION INDICATION OF A PARTICULAR
4. PLUG CONNECTION, PIN/CONTACT 34 OF SECTION
PLUG PC1 9. (XX,YY) XX IS PAGE NUMBER REFERENCE, YY
5. FUSE FUNCTION IS COLUMN REFERENCE.
6. PAGE NUMBER, INDEXES THE PAGE NUMBER 10. RELAYS
FOR THE DIFFERENT FUNCTIONS.

Figure 1. Example Electrical Schematic

1
Operation 2200 SRM 1065

Location Numbers The numbers at the pin connections for these com-
mon parts refers to the pin number of that common
All location numbers are placed between brackets. part. Check the Parts Manual for separate avail-
The number starts with the page number, followed ability of these common parts.
by the column number. Example: Relay R1-BR1 (3.8)
is shown on page 3 in column 8. Table 1. Symbols and Components

The location number shows at which location a re- Symbol Component

lated function or connection exists. When a compo-
nent is shown with several location numbers, then Battery
a function or connection exists at each of the indi-
cated locations. A location number shown at a relay
refers to the contact belonging to that relay. A lo-
cation number shown next to a contact refers to the
relay belonging to that contact. A location number Starter
shown at the end of a line refers to the location where
this line continues.

Components
Components that can be replaced are indicated by Fuse
an encircled reference number. See Figure 1, pos.
7. Some of these reference numbers are listed in the
tables in section Part Numbers of Electrical Compo-
nents to identify the spare part number. Normally
the identifiable components are to be selected from Circuit breaker with reset
the spare parts manual. function

Leads/Wires
Numbers shown just above a line are used to identify
leads/wires. The same numbers are also printed on Pin connection
the wires themselves. Example: 430 = wire marked
"430".

Wires with the same number are interconnected and

therefore have the same function. Example: Lead/
wire 15 has function "Battery Ground (negative)". Connection

Common Parts
Components starting with a letter followed by a num-
ber concern one of the following common parts: Relay

• B = Square type plug base

• E = Electrovalve, solenoid
• M = Ground
• P = Plug (Round type)
• BR = Relay base, board for the relays Meter/gauge
• EP = Splice in harness
• F = Fuse
• R = Relay

2
2200 SRM 1065 Operation

Table 1. Symbols and Components (Continued) Table 1. Symbols and Components (Continued)

Symbol Component Symbol Component

Relay contact, normally open Temperature switch, switches on
(relay non-energized) at 120 C (248 F)

Relay contact, normally closed Sensor

(relay non-energized)

Switch Sensor/proximity switch

Switch with push button Sensor

function

Alternator Horn, alarm

Solenoid Diode

Indicator lamp DC motor (electrical)

Pressure switch Load limiter

Cable loom

3
Operation 2200 SRM 1065

ELECTRICAL COMPONENTS Figure 4, Figure 5, Table 4, Table 5, Figure 6, Table 6,

Figure 7, Table 7, Figure 8, Table 8, Figure 9, and Ta-
The following tables give an item number, descrip- ble 9.
tion, reference, and figure location of the electrical
components. See Figure 2, Table 2, Figure 3, Table 3,

Figure 2. Electrical Components/Solenoids on the Yardmaster

4
2200 SRM 1065 Operation

Table 2. Solenoids on the Yardmaster

Item Description Location Figure Part Number

E1 40 L hydraulic flow (34.38) Figure 2 1520299
E5 Winch up (option) (33.31) Figure 2 1520299

E6 Winch down (option) (33.34) Figure 2 1520299

E7 Boom enable up movement (21.40) Figure 2 1520299
E8 Boom enable down movement (30.23) Figure 2 1520299
E9 Joystick flow 17 bar (32.35) Figure 2 1520299
E10 Joystick flow 15 bar (32.15) Figure 2 1520299
E11 Joystick flow 13 bar (32.30) Figure 2 1520299
E12 3 wraps remaining (winch option) (33.25) Figure 2 1520299
E13 Hydraulic oil cooling (32.6) Figure 2 1520299
E138 Throttle cutoff (10.31) Figure 2 1520299
E152 Speed limit 25 25 km/h (15.5 mph) maximum (10.25) Figure 2 1520299
E227 Parking brake (4.35) Figure 2 1520299
EV1 - 6 Transmission solenoids (11.10) Figure 2 1342504

5
Operation 2200 SRM 1065

Figure 3. Electrical Solenoids on the Spreader

Table 3. Solenoids on the Spreader

Item Description Location Figure Part Number

E14 Telescope extension out (36.18) Figure 3 1520299

E15 Telescope extension in (36.21) Figure 3 1520299
E16 Left sideshift (RTG) (35.27) Figure 3 1520299
E17 Right sideshift (RTD) (35.30) Figure 3 1520299
E18 Powered Pile Slope Left (42.23) Figure 3 1520299
E19 Powered Pile Slope Right (42.26) Figure 3 1520299
E20 Rotation to left (ROG) (34.22) Figure 3 1520299
E21 Rotation to right (ROD) (34.24) Figure 3 1520299
E22 Rotation brake release (34.26) Figure 3 1520299
E23 Telescope low speed (36.38) Figure 3 1520299
E24 Container locking (38.25) Figure 3 1520299
E25 Container release (38.28) Figure 3 1520299

6
2200 SRM 1065 Operation

Figure 4. Dampening Lock on Boom

Figure 5. Hydraulic Valve on Boom

Table 4. Solenoids on the Boom

Item Description Location Figure Part Number

E49 Dampening override (41.20) Figure 4 1520299

E50 Right dampening locking (41.30) Figure 4 1520299

E51 Left dampening locking (41.38) Figure 4 1520299

E54 Spreader leveling (21.4) Figure 5 1520299

7
Operation 2200 SRM 1065

Table 5. Components on the Yardmaster

Part
Item Description Location Figure
Number

S21 Transmission clutch oil pressure gauge (7.24) Figure 2, Pos. 1 1469333
S92 Clutch oil pressure warning (6.37) Figure 2, Pos. 2 1469329
Engine - frame connection (3.17) Figure 2, Pos. 3
BAT Batteries (3.6) Figure 2, Pos. 4 1492663
S3 Electronic main switch (1.24) Figure 2, Pos. 5 1469834
R2 Starter relay (4.8) Figure 2, Pos. 6 1469836
S50 Engine fuel gauge (7.13) Figure 2, Pos. 7 1470614
S6 Engine shutdown valve (4.28) Figure 2, Pos. 8 Cummins
part
S57 Compressor (A/C option) (28.17) Figure 2, Pos. 9 1488022
S15 Hydraulic oil temperature contact (7.21) Figure 2, Pos. 10 1469146
S40 Horn (18.39) Figure 2, Pos. 11 1488123
S141 Tank level, hydraulic oil (6.19) Figure 2, Pos. 12 1470615
S43 50 degree boom hoisting limit switch (20.17) Figure 2, Pos. 13 1470947
S130 Boom hoisting limit switch (21.19) Figure 2, Pos. 14 1470943
S90 Derricking down sensor, Dampening (40.4) Figure 2, Pos. 15 1470526
S91 Derricking up sensor, Dampening (40.7) Figure 2, Pos. 16 1470526
S88 Pressure switch 170 bar (pilot pressure control) (32.20) Figure 2, Pos. 17 1520303
S89 Pressure switch 210 bar (pilot pressure control) (32.24) Figure 2, Pos. 18 1520303
S84 Anti-tipping indicator switch (30.8) Figure 2, Pos. 19 1471902
S1 Alternator (3.16) Figure 2, Pos. 20 1469716
S13 Engine coolant temperature gauge (7.36) Figure 2, Pos. 21 1469696
S129 Hydraulic oil filter clogging (6.31) Figure 2, Pos. 22 1502348
S128 Axle oil filter clogging (6.30) Figure 2, Pos. 23 1502348
S86 Hydraulic oil cooling switch, 45 C (113 F) (7.6) Figure 2, Pos. 24 1470814
S87 Hydraulic oil cooling switch, 45 C (113 F) (7.9) Figure 2, Pos. 25 1470814
S12 Engine oil pressure warning (6.7) Figure 2, Pos. 26 1469701
S11 Engine coolant temperature warning (6.16) Figure 2, Pos. 27 1469700
S17 Engine speed (APC 100) (9.15) Figure 2, Pos. 28 1469338
S68 Torque converter oil temperature and warning (7.10/11) Figure 2, Pos. 29 1469146
S132 Air filter clogging (6.26) Figure 2, Pos. 30 1469807
S18 Turbine speed (10.20) Figure 2, Pos. 31 1475358

8
2200 SRM 1065 Operation

Figure 6. Service and Parking Brake Switches and Sensors

Table 6. Service and Parking Brake Switches and Sensors

Item Description Location Figure Part Number

S77 Parking brake sensor (10.3) Figure 6, Pos. 1 1469193

S75 Parking brake pressure switch for indicators (6.40) Figure 6, Pos. 1 1469193
S79 Stop light sensor (17.30) Figure 6, Pos. 3 1469193
S78 Minimum pressure switch (6.35) Figure 6, Pos. 3 1469194
S139 Brake sensor (10.6) Figure 6, Pos. 4 1469118

9
Operation 2200 SRM 1065

Figure 7. Relays and Fuses in the Cab

Table 7. Relays in the Cab

Item Description Location Figure Part Number

R1 - BR1 Battery voltage, main switch control (3.8) Figure 7 1469315

R1 - BR7 Air conditioning pressure control (27.35) Figure 7 1469315
R2-BR7 Air conditioning motor control (27.39) Figure 7 1469315
R4 - BR1 Suspension (31.16) Figure 7 Not Used
R1 - BR2 Joystick pressure control E9 (32.11) Figure 7 1469315
R2 - BR2 Joystick pressure control E10 (32.35) Figure 7 1469315
R5 - BR2 Stoplights (17.35) Figure 7 1469315
R3 - BR2 High beam lights (18.14) Figure 7 1469315
R5 - BR1 Horn (18.10) Figure 7 1469315
R1 - BR3 Transmission neutral position indicator (8.31) Figure 7 1469316
R2 - BR1 Reverse lights (19.15) Figure 7 1469315
R1/2 - BR5 APC 100 override (8.11/17) Figure 7 1469316
BR8 - S32 Blinker unit (16.5) Figure 7 1472507

10
2200 SRM 1065 Operation

Figure 8. Spreader Relays and Components (Located in the Electrical Box on the PPM Spreader)

Table 8. Spreader Relays and Components in Spreader Electrical Box

Part
Item Description Location Figure
Number

R1 - BR3 Container released on right side. Red light (39.40) Figure 8, D1 1469316
R2 - BR3 Container released on left side. Red light (39.19) Figure 8, SD 1469316
R1 - BR2 Container seated on right side. White light (37.31) Figure 8, P1 1469316
R2 - BR2 Container seated on left side. White light (37.19) Figure 8, SP 1469316
R1 - BR4 Container locked on right side. Green light (39.31) Figure 8, V1 1469316
R2 - BR4 Container locked on left side. Green light (39.13) Figure 8, SV 1469316
R3 - BR5 Spreader horizontal Figure 8, BK1 1469315
R2 - BR5 Slow speed at end extension range Figure 8, DT50 1469315
R1 - BR5 Flow selection. 40L/20L Figure 8, DEB 1469316

11
Operation 2200 SRM 1065

Figure 9. General Fuse Panel (Located in the Battery Box)

Table 9. Fuses

Item Description Location Figure Part Number

F100 100 Amp. Main fuse. Provides protection to all (3.35) Figure 9 1500512
functions behind the battery shutoff.
F80 80 Amp. Main fuse. Provides protection to the (3.30) Figure 9 1500514
starter motor behind the battery shutoff.
F50 50 Amp. Main fuse. Provides general protection (3.36) Figure 9 1500516
for the direct battery supplies.
F1 10 Amp. Main protection switch, parking brake (5.4) Figure 7 1469237
F2 20 Amp. Front and roof windshield wiper, cab (5.6) Figure 7 1469239
hoist up, ceiling light
F3 20 Amp Spreader working lights, chassis (5.9) Figure 7 1469239
working lights
F4 20 Amp Boom working lights (5.12) Figure 7 1469239
F5 20 Amp Beacon working lights (5.14) Figure 7 1469239
F6 15 Amp Gear selector, reverse relay and lights (5.16) Figure 7 1469238
F7 10 Amp Parking lights, hazard lights (3.38) Figure 7 1469237
F8 15 Amp Spreader sensors locking/unlocking, (5.19) Figure 7 1469238
speedometer. Telescoping low speed.
F9 15 Amp Boom hoist up/down, spreader leveling, (5.21) Figure 7 1469238
telescope extend
F10 15 Amp Stoplights, blinkers (5.24) Figure 7 1469238
F11 10 Amp Spreader telescope extension/ (5.27) Figure 7 1469237
retraction, container locking/releasing
F12 20 Amp Low/high beam, horn (5.29) Figure 7 1469239

12
2200 SRM 1065 Operation

Table 9. Fuses (Continued)

Item Description Location Figure Part Number

F13 10 Amp Main switch, tachometer/hourmeter (3.37) Figure 7 1469237
F14 15 Amp Air conditioning motor (3.39) Figure 7 1469238
F15 5 Amp Engine warning lights and gauges, (5.32) Figure 7 1469236
transmission warning lights and gauges, brake
warning lights and gauges
F16 20 Amp Cab air conditioning (5.34) Figure 7 1469239
F17 15 Amp. Sliding cab (option) (5.37) Figure 7 1469237
F18 5 Amp Front outrigger (option) (5.39) Figure 7 1469236

CIRCUIT EXPLANATION (3.16) generates the voltage to charge the batteries,

and will energize relay R1-BR1. Contact 30/87 (4.23)
NOTE: For the location of the following components of R1-BR1 provides the holding circuit for the main
see Diagrams 8000 SRM 784. switch, and prohibits switching OFF the engine by
means of the key-switch.
Key-Switch in OFF Position
Engine SHUTDOWN
The ignition starting switch S4 (4.17) is in Pos. 0.
Pushing the "engine shutdown" button S5 (4.28) will
Battery voltage (positive) is supplied to:
cause solenoid S6 (4.28) to be de-energized and the
engine will shut down.
• Main switch S3 (3.25).
• Tachometer/hourmeter circuit, via fuses F50, and
Parking Brake
F13 (3.36).
• Parking lights, hazard warning lights, via fuses Operating the parking brake switch S72 (4.36) will
F50, and F7 (3.38). activate solenoid E227 (4.36). When solenoid E227
• Air conditioning motor, via fuses F50, and F14 is energized, the parking brake is released.
(3.39).
Warning Lights
The battery voltage (negative) is connected by
Lead/15 to the battery ground M10 (3.3). Key Switch ON, Engine Not Running

Key-Switch in ON Position BV3 (6.11) Relay R5-BR7 (6.6) will be energized via
the oil pressure switch S12 (6.6). Warning light BV3
The ignition starting switch (4.17) is in Pos. 1. (6.11) will be ON. This indicates "low engine oil pres-
sure." With engine running, the Warning light should
Via contact 30/15 of S4, lead 125 (4.19), lead 125
be OFF.
(3.28), the main switch is energized, and battery volt-
age is supplied to: BV3 (6.13) Alternator S1 (3.15) will not generate a
voltage. Warning Light BV3 (6.13) will be ON. This
• Starter (Cummins engine), S14 (3.26). indicates "No battery charge." With the engine run-
• Fuse F100 (3.34) and the fuses in Diagrams 8000 ning, the Warning light should be OFF.
SRM 784 on PPM page 5.
BV3 (6.17) Under normal conditions, the Temper-
Key-Switch in Engine START Position ature sensor will not be activated. Warning Light
BV3 (6.17) will be OFF. This indicates temperature
Via contact 30/50 of S4, lead 41, contact 31/34 of below maximum permissible. With coolant tempera-
RB-BR3 (Transmission in neutral), the engine start ture above maximum temperature, sensor S11 (6.15)
relay R2 (4.8) is energized. Contact 30/30 (3.30) of will be closed and Warning light will be ON.
relay R2 activates the starter. The alternator S1

13
Operation 2200 SRM 1065

BV4 (6.20) Under normal conditions, the Warning • Throttle sensor S30 (10.10)
light BV4 (6.20) will be OFF. This indicates hydraulic • Engine speed sensor S17 (10.17)
oil level is correct. With hydraulic oil level below min- • Turbine speed sensor S18 (10.21)
imum level, sensor S141 (6.19) will close and BV4 • Throttle cut off, solenoid E138 (10.31)
will be ON. • Speed limit (25 km/h (15.53 mph)), solenoid E152
(10.25). Speed limit when the container is at-
BV4 (6.26) Indicates the condition of the filters: tached, in the manual mode E152 and E138 will
not be activated. Contacts of R2-BR5 prohibit the
• Air filter clogging S132 (6.26) selection.
• Transmission oil filter clogging S127 (6.28)
• Axle oil filter clogging S128 (6.29) Outrigger Circuits
• Hydraulic oil filter clogging (6.31)
Outrigger down and up is given by the Front outrig-
With engine not running, the Warning light BV4 ger switch S71 (14.15).
(6.26) will be OFF.
Outrigger down is only possible with the transmis-
With the engine running, and with one of the men- sion in Neutral. Contact 11/14 R1-BR3 (14.15) will
tioned filters clogged, the Warning light will be ON. be closed and Solenoids E198 and E172 can be ac-
tivated. The down position is detected by Pressure
BV3 (6.35) Indicates low front brake oil pressure.
switch S93 (14.3). This causes relay R3-BR7 to be en-
With engine not running, BV3 will be ON. With the
ergized. Contact 30/87 R3-BR7 creates a holding cir-
engine running, the warning light will be OFF.
cuit, and ensures that the Outrigger down status is
BV3 (6.38) Indicates low clutch oil pressure. With present until the status Outrigger up R4-BR7 (14.28)
engine not running, BV3 will be ON. With the engine is present.
running, the Warning light will be OFF.
Outrigger up is only possible when the outrigger up
BV3 (6.40) Low parking brake pressure or parking permission relay R3-BR1 (15.20) is energized. This
brake applied causes BV3 (6.40) to be ON. is conditional upon one of the following:

Manual Selection Transmission Control • No container attached. Contacts 31/34 of R1-BR3

and R2-BR3 (15.29) are closed. Relay R3-RB1 will
The selection "manual" is only possible with the be energized.
transmission control in position NEUTRAL. In • Boom is retracted. Sensor S28 (15.17) is activated.
this position relay R1-BR3 (8.31) will be energized Relay R3-RB1 will be energized.
and when manual is selected, via contact 3-4 S121 • Boom is up. Sensor S27 (15.10) is activated. Relay
(8.4) Relay R1-BR5 (8.12) will be energized. Relay R3-RB1 will be energized.
R2-BR5 provides a holding circuit.
NOTE: With the outrigger in the down position an
The contacts of R1-BR3 will close and gear box audible alarm S26 (14.40) will be given, when moving
solenoids 1 (9.10), 2 (9.16), 3 (9.21) will be activated, transmission control out of Neutral.
and first gear is selected. Selection of Forward or
Reverse is with the transmission control via the Lights
APC 100 and is conditional upon outriggers being in
the up position. With outriggers in the up position, Schematics for the blinkers, hazard warning lights,
relay R2-BR3 is energized. The table (9.6) provides parking lights, low and high beam lights, and reverse
details on gear selection/solenoids selection. lights are located in Diagrams 8000 SRM 784 on
PPM pages 16, 17, 18, and 19.
APC 100 Electronic Transmission Control
The blinkers (16,XX) are controlled by the Blinker
The APC 100 provides automatic gear selection unit. When the blinkers are activated the audible
within the range selected by the transmission con- alarm S33 (16.8) will sound.
trol lever.
The high beam is switched ON by means of relay
The Input/Output signals for the APC 100 are: R3-BR2 (18.14). The horn is switched ON by means
of relay R5-BR1 (18.10).

14
2200 SRM 1065 Operation

When in reverse, audible alarm S25 (19.34) will Should the cab not be in the rear position and the
sound. boom angle gets larger than 5 degrees, solenoid E7
will be deactivated (contact 30/87a R4 BR30 (21.29)
Sliding Cab opens), and stops boom up.

Sliding the cab toward the rear is conditional upon Boom Down
the following:
The LMI unit (30.22) provides information on the
• Both cabin doors being closed. Sensor S41 (20.3) load status. It calculates the load status using boom
and S42 (20.7) are activated and switch through angle, boom extension, and the load.
the voltage supply.
• Cab not in the rear position. Relay R1-BR10 It is possible to override the LMI by means of S138.
(21.32) is not activated. When using the override function, buzzer S110 and
warning light BV4 will come ON.
When the above conditions are met, the cab sliding
permission relay R1-BR30 (20.15) is energized and The anti-tipping safety feature will, in case tipping
via contact 30/87 R1-BR30 (20.31), and Sliding cab occurs, activate the buzzer S83 and light BV4.
switch S67, Solenoid E188 can be activated, and the
Solenoid E8 activated, enables operation of the boom
cab will be moved toward the rear.
down and the extend.
Sliding the cab toward the front is conditional upon
the following: Tilting Cab
The cab tilting up or down movement is activated by
• Both cabin doors being closed. Sensor S41 (20.3)
switch S70 (23.21). Solenoid E226 (23.21) is used for
and S42 (20.7) are activated and switch through
cab down and solenoid E225 (23.9) is used for cab up.
the voltage supply.
• Boom angle within 0 to 5 degrees. Relay R2 BR10 Spreader Rotation
(22.15) is not activated. The relays R3 BR30, R2
BR30, and R4 BR30 (21/23/25) are not ener- Rotation to the left is via; joystick S147 (34.5), relay
gized as the boom angle sensor S43 is not activated ROG, and solenoid E20.
with the boom within 0 to 5 degrees angle.
Rotation to the right is via; joystick S146 (34.9), relay
When the above conditions are met, the cab sliding ROD, and solenoid E21.
permission/enable relay R1 BR30 (20.15) is ener-
gized and via contact 30/87 R1 BR30 (20.31), sliding Spreader Sideshift
cab switch S67, contact 30/87a R2 BR30, solenoid
E187 can be activated, and the cab will be moved Spreader sideshift to the left is via; joystick S145
towards the front. (35.5), relay RTG, and solenoid E16.

Boom Up Spreader sideshift to the right is via; joystick S144

(35.9), relay RTD, and solenoid E17.
Boom hoist up is conditional upon:
Spreader Extend/Retract
• Container is properly locked (relay contacts 21/14
of R1 BR4 and R2 BR4 (21.19) are closed), or con- Spreader extend is via; S95 (36.6), and solenoid E14.
tainer fully released (relay contacts R1 BR3 and Spreader retract is via; S95 (36.6), and solenoid E15.
R2 BR3 (21.13) are closed).
• Boom not in the 60 degrees position (contact of Before reaching the 9.14 m (30 ft) position, the speed
the maximum boom angle sensor S130 (21.19) is of the extend or retract movement is lowered. The
closed). proximity switch S94 (36.31) is activated, energizes
• Cab is in the rear position (sensor S134 (21.37) is relay R2 BR5 and via contact 30/87 R2 BR5 sole-
closed), or boom angle is in the 0 to 5 degrees range. noid E23 (36.38) will be activated.
When the above conditions are met, solenoid E7 will
be activated, and enables boom up.

15
Part Numbers of Electrical Components 2200 SRM 1065

Container Seating/Locking/Releasing E25 provide locking when activated and provide re-
leasing when not activated.
Left front sensor S105 (37.23) and left rear sensor
S106 (37.26) will, when container is seated, energize Sensor S101 (39.6) detects that the container is
relay R2 BR2 (37.18). This represents the container locked on the left side and will energize relay
is seated on the left hand side. R2 BR4. Sensor 103 (39.27) detects that the con-
tainer is locked on the right side and will energize
Right front sensor S107 (37.34) and right rear sensor relay R1 BR4.
S108 (37.39) will, when container is seated, energize
relay R1 BR2 (37.31). This represents the container Sensor S102 (39.13) detects that the container is
is seated on the right hand side. released on the left side and will energize R2 BR3.
Sensor S104 (39.34) detects that the container is
In the event that the seated signals cannot be ob- released on the right side and will energize relay
tained, the pushbutton container seated override R1 BR3.
S109 (37.4) can be activated. Warning light BV4
(37.10) will be ON. Indication of seating, locking, and releasing is by
means of the lights on (40,XX). The green indicator
Contacts 21/24 of R2 BR2 and R1 BR2 (38.6) will lights will be ON when locked. The red indicator
be closed and the container lock/release switch S142 lights will be ON when released/unlocked. The white
can be used to lock the container. Solenoids E24 and indicator lights will be ON when seated.

Part Numbers of Electrical Components

The following tables show the electrical components,
part numbers, and schematic page number refer-
ences. See Diagrams 8000 SRM 784.

Item Description Part Number Schematic Page

APC100 APC100 Electronic unit 1476484 8
BV14 Side dashboard relay connection 1480679 34
C1 BR1 5 Relay board 1469314 3
C1 BR2 5 Relay board 1469314 32
C1 BR3 2 Relay board 1469318 8
C1 BR5 2 Relay board 1469318 8
C1 BR7 5 Relay board 1469314 27
C1 BR30 5 Relay board 1469314 20
C11 Fuse board 1469233 3
C13 Diode board (option) 1469321 31
E172 Outrigger rod side decompression 1520299 14
E173 Not used 1520299 15
E187 Sliding cab front position 1520299 20
E188 Sliding cab rear position 1520299 20
E198 Outrigger down 1520299 14
E199 Outrigger up 1520299 14
E225 Cab up 1520299 23

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2200 SRM 1065 Part Numbers of Electrical Components

Item Description Part Number Schematic Page

E226 Cab down 1520299 23
E310 Boom hoist down 1520299 22
ROD Relay, spreader right rotation 1469315 34
ROG Relay, spreader left rotation 1469315 34
RTD Relay, spreader right sideshift 1469315 35
RTG Relay, spreader left sideshift 1469315 35
RT1 Windshield wiper timer 1488335 29
R1 Front windshield wiper relay 1488336 29
R1 BR10 Cab rear position 1469316 21
R1 BR30 Cab sliding permission 1469315 20
R2 BR3 Outrigger up position 1469316 14
R2 BR10 Boom hoist down permission 1469316 22
R2 BR30 Sliding cab front travel cutoff 1469315 20
R3 BR1 Outrigger up permission 1469315 15
R3 BR7 Outrigger down 1469315 14
R3 BR30 Boom retraction 1469315 20
R4 BR7 Outrigger up 1469315 14
R4 BR30 Boom hoist up cutoff 1469315 20
R5 BR7 Engine oil pressure 1469315 6
R11 0 to 5 Boom angle 1469315 22
S4 Ignition starting switch 1469263 4
S5 Engine shutdown 1487218 4
S7 Tachometer/hourmeter 1526102 3
S8 Fuel gauge/oil temperature converter 1468923 7
S9 Clutch pressure/hydraulic oil temperature 1468917 7
S10 Voltmeter/engine coolant temperature 1468922 7
S14 Starter 1469710 3
S17 Engine speed sensor 1469338 10
S20 Transmission control 1470377 8
S22 Left reverse light 1468374 19
S23 Right reverse light 1468374 19
S25 Reverse gear audible alarm 1468929 19
S26 Travel forbidden audible alarm 1477409 14
S27 Boom up position sensor 1477407 15
S28 Boom retraction position sensor 1469129 15

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Part Numbers of Electrical Components 2200 SRM 1065

Item Description Part Number Schematic Page

S29 Outrigger high position sensor 1469129 14
S30 Throttle sensor 1469129 10
S31 Hazard switch 1463261 16
S33 Blinkers audible alarm 1469226 16
S34 Right rear light unit 1468919 16
S35 Left rear light unit 1468918 16
S36 Right front blinker 1468915 16
S37 Left front blinker 1468915 16
S38 Right front headlamp 1468932 18
S39 Left front headlamp 1468932 18
S41 Cab door closed sensor 1476406 20
S42 Cab door closed sensor 1476406 20
S44 Cab working light 1468374 25
S45 Boom working light 1468374 24
S46 Chassis working light 1468374 24
S47 Chassis working light 1468374 24
S48 Spreader working light 1468374 24
S49 Spreader working light 1468374 24
S51 Boom working light 1468374 24
S52 Boom working light 1468374 24
S53 Boom working light 1468374 24
S54 Cab working light 1468374 25
S55 Rotating beacon 1468924 25
S56 Rotating beacon 1468924 25
S58 Roof windshield wiper 1488325 26
S59 Roof windshield wiper switch 1469056 26
S62 Working light switch 1469051 25
S63 Rotating beacon switch 1469052 25
S64 Working light switch 1469051 24
S65 Working light switch 1469051 24
S66 Parking light switch 1469050 17
S67 Sliding cab switch 1469272 20
S70 Up and down cab switch 1469271 23
S71 Front outrigger switch 1469273 14
S72 Parking brake switch 1469259 4

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2200 SRM 1065 Part Numbers of Electrical Components

Item Description Part Number Schematic Page

S73 Air condition switch 1488029 27
S74 Stop light sensor 1469193 17
S76 Front brake oil pressure 1469194 6
S80 Front windshield wiper 1488338 29
S81 Winch hydraulic flow 1471222 33
S82 Boom hoist pressure sensor (long chassis) 1472911 30
S83 Anti tipping safety 1469226 30
S85 Dampening switch 1469256 41
S90 Boom hoist up 1470526 41
S91 Boom hoist down 1470526 41
S93 Outrigger down position sensor 1477390 14
S94 Spreader telescope low speed 1469129 36
S95 Spreader telescope switch 1469257 36
S96 Switch, powered pile slope 1469270 42
S97 Spreader controls 1468360 40
S100 Spreader controls 1468360 40
S101 Container locking sensor 1469129 39
S102 Container releasing sensor 1469129 39
S103 Container locking sensor 1469129 39
S104 Container releasing sensor 1469129 39
S105 Container seated sensor 1469129 37
S106 Container seated sensor 1469129 37
S107 Container seated sensor 1469129 37
S108 Container seated sensor 1469129 37
S110 LMI override 1469129 30
S124 Air condition motor 1488053 28
S125 Air condition motor 1488053 28
S126 Boom anti two block sensor 1471113 33
S127 Transmission oil filter clogging 1469222 36
S131 3 Wraps remaining 1471190 33
S131 3 Wraps remaining 1471191 33
S133 0 to 5 boom angle sensor 1470947 22
S134 Cab rear position sensor 1470943 21
S135 Lighting switch 1470355 16
S136 Windshield washer 1488341 29

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Part Numbers of Electrical Components 2200 SRM 1065

Item Description Part Number Schematic Page

S140 Front windshield wiper switch 1469262 29
S142 Container lock/release switch 1469264 38
S151 Pressure safety, low pressure 1488049 27
S152 Pressure safety, high pressure 1488048 27
S153 Left ceiling light 1488112 26
S154 Right ceiling light 1488115 26
S156 Evaporator 1488035 27
S158 Pressure safety, low pressure 1488056 27

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 TECHNICAL PUBLICATIONS

2200 SRM 1065 2/04 (1/04)(11/03)(2/03) Printed in U.S.A.