Sistema Elétrico

ELECTRICAL SYSTEM
PART NO. 4204129 2200 SRM 2065

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
instructions 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
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 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.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................1
Electrical Schematic and System Description ....................................................................................................... 1
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 ................................................................................................................................. 6
Electrical Connectors .......................................................................................................................................... 8
Connector Types .............................................................................................................................................. 8
Connector Identification ..................................................................................................................................8
Connector Pin Numbers .................................................................................................................................. 9
Connector Description ..................................................................................................................................... 9
Fuses .................................................................................................................................................................... 9
Relays .................................................................................................................................................................14
Flyback Diodes ...................................................................................................................................................15
CAN (Controller Area Network) ....................................................................................................................... 15
Diagnostic ...................................................................................................................................................... 17
Central Warning Lights and Instrument Panel .............................................................................................. 17
Instrument Panel Connector ........................................................................................................................ 20
LCD Display ...................................................................................................................................................... 21
Hourmeter Mode ............................................................................................................................................21
Fault Code Mode ............................................................................................................................................21
Transmission Calibration ............................................................................................................................. 22
Fault Code Log Mode .....................................................................................................................................22
Access ......................................................................................................................................................... 22
Clear ........................................................................................................................................................... 22
Exit ............................................................................................................................................................. 22
General Fault Finding ...................................................................................................................................... 22
Preparation .................................................................................................................................................... 23
Define the Problem Area ...............................................................................................................................23
Identify Possible Causes of Malfunction ...................................................................................................... 23
Determine the Most Probable Cause ............................................................................................................23
Fuse Check .....................................................................................................................................................23
Wiring Check ................................................................................................................................................. 23
Component Check ..........................................................................................................................................23
Repair and Test ............................................................................................................................................. 23
Wire Harness Identification and Connector Location .........................................................................................23
Frame Harness Connectors (Tier 3/Stage IIIA) ...............................................................................................33
Side Console Harness Connectors .................................................................................................................... 35
Mast Harness Connectors ................................................................................................................................. 38
Closed Cab Harness Connectors .......................................................................................................................39
Cab Underfloor Harness Connectors ................................................................................................................42
Steering Column Harness Connectors ............................................................................................................. 43
Power Cab Tilt Harness Connectors ................................................................................................................ 43
Armrest Harness Connectors ............................................................................................................................44
Cab Lights Harness Connectors ....................................................................................................................... 46
Cab Auto Tip Up Connectors ............................................................................................................................ 47
ECM Harness Connectors (Tier 3/Stage IIIA) ................................................................................................. 47
©2017 HYSTER COMPANY i

Table of Contents
TABLE OF CONTENTS (Continued)

ECM / After Treatment Harness Connectors (Tier 4F/Stage IV) ................................................................... 48
Powertrain Harness Connectors .......................................................................................................................50
Rear Harness Connectors ................................................................................................................................. 51
Wash Pump Harness Connectors ..................................................................................................................... 53
Telemetry Harness Connectors ........................................................................................................................ 53
This section is for the following models:
ii
2200 SRM 2065 Series Code / Model Designation Reference Table
Series Code / Model Designation Reference Table

This section is for the following models:
Series Code European Model Americas Model

H8XM-EC6, H8XM-EC7, H9XM-EC7, H180HD-EC6, H180HD-EC7, H200HD-
H9XM-EC8, H9XM-ECD7, H9XM-ECD8, EC7, H200HD-EC8, H200HD-ECD7,
E214
H10XM-ECD8, H11XM-ECD8, H11XM- H190HD-ECD8, H210HD-ECD8,
ECD9 H230HD-ECD8, H230HD-ECD9
General
This manual provides general information on the relevant manual for the component. An example
electrical system of E214 lift trucks. This manual would be a transmission solenoid, which is shown in
provides a link between the electrical schematic and Transmission Repair (ZF-WG211)
the actual location of the electrical components on 1300SRM1718.
the lift truck.
The actual electrical schematic drawings are shown
The description and replacement procedures for the in Diagrams 8000SRM2071.
electrical system components are located in the
1
Electrical Schematic and System Description 2200 SRM 2065
Electrical Schematic and System Description

ELECTRICAL SCHEMATIC The layout of the schematic is function driven,
which means that each sheet represents one
The electrical schematic is laid out over several particular function or area as indicated by the title
pages in Diagrams 8000SRM2071. Each page of the sheet. The index of the electrical schematic is
shows the electrical connection between the shown in Table 1.
components, connectors, and wires.
Table 1. Electrical Schematic Index

Number Title Contents
1 Index Sheet Title Index
2 Main Power Battery, Key Switch, Start Enable, Main Power Distribution
3 Engine Common / T3 Engine controller, Tier 3 and common components
4 T4F/EAS Fan Clutch, Tier 4F/Stage IV sensors, Tier 4F controller
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 Light Fuses, Battery/ING Jumper Marker Lights, Main
Light Relay, Hazard/Indicator Lights, Flasher Unit
10 Cab Tilt/Auto Tip-up ECO-eLo/HIP , Powered Cab Tilt , Auto Cab Tip-up
11 Monitoring Instrument cluster, senders, alarms, diagnostics, Display
Spreader functions
12 OPS/Park Brake Park brake switch and solenoid, suspension seat, Operator
Presence System
13 Hydraulic Controls Cab Hydraulic controller, levers, Operator Presence, Service
Switch
14 Auxiliary Functions Spreader, Tilt Angle/Lift Hight Sensors
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/Teleme- Lubrication switch and pump, Telemetry System (FM1A,
try FM1B, Display Card Reader)
19 Connector Overview Connector codes, names and applied harness.
20 - 24 Wire List List of used wires and their functions
25 Fuse/Relay Index List of fuses and relays and their functions
2
2200 SRM 2065 Electrical Schematic and System Description
Figure 1. Schematic Example
3
Legend for Figure 1.
1. ROW LETTER - A 7. SHEET NAME - ENGINE

2. COLUMN NUMBER - 30 8. SPLICE - S750A
3. WIRE HARNESS NAME - SIDE CONSOLE 9. CONNECTOR - CPS07
4. WIRE HARNESS NAME - FRAME 10. CONNECTOR - CRP07
5. WIRE CONTINUATION LOCATION- [20, H] 11. FUSE
6. WIRE NUMBER AND COLOR - 5-C-RD (RED) 12. HARNESS DIVIDING LINE
SCHEMATIC LOCATION NUMBER and a color indication of the wire insulation. If a

wire continues on a different sheet, then the solid
The schematic is divided into rows with a letter line ends with an arrow and receives in addition the
from A to J and into columns numbered 0 to 9 for schematic location number where this wire
each sheet. See Figure 1. continues.
The column numbering consists of the sheet number
plus the column number. For example, column 57 is Wire Identification Number
the 7th column on sheet 5.
Each electrical wire in the electrical schematic has
The schematic location number is the combination an identification number that is also printed on the
of a row letter and column number, which allows insulation of the wires.
quick identification of a point on the schematic. For
The wire identification numbers consist of a
example, [57,A] is the 7th column on sheet 5, row A.
function ID number and when needed a suffix letter.
ELECTRICAL COMPONENTS The function ID numbers are numbered from 1
through 999. Specific ranges of numbers are
Electrical components are indicated by a symbol and assigned for different function ID groups. See
a description that are placed close to each other on Table 2.
the schematic. An example is the starter relay on
[38,C]. See Figure 1. Wires with the same number are interconnected
through splices and connectors, and therefore have
ELECTRICAL WIRES the same electrical function.
Each electrical wire is indicated by a solid line and

has been identified with an identification number
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
4
Table 2. Function ID Numbers (Continued)

Function Group Number Range
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
When a circuit is spliced into several wires, or when There is a wire number overview in Diagrams
a wire passes a connector, each wire number 8000SRM2071. In this overview each wire is listed
receives the next unique suffix letter. An example is with the wire harness it is part of, and with the
42-a, 42-b. connector identification number and pin numbers it
connects to. The actual location of a connector code
To simplify the schematic, sometimes the
can be looked up in Connector Overview.
identification has been omitted for a spliced
function. It may concern an intersection between a
switch and a splice, or a right-hand component
operating simultaneously with a left hand
component.
5
Electrical Wire Colors

In addition to the function ID numbers on the
electrical 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
Dark Green Signal Grounds
White Other Circuits
Yellow (Twisted Pair) CAN Hi
Light Green (Twisted Pair) CAN Lo
Orange 5 Volt
Pink 12 Volt
Wire Harnesses There are four different jumper options:

Wires are bound together in wire harnesses to • Jumper Power Supply by Ignition provides
secure against the adverse effects of vibration, power supply for side, tail and hazard lights
abrasion and moisture. The description of wire when the ignition switch is turned to the ON
position. See schematic location [98,G]. This
harnesses follows from its location in the truck or
harness is to be plugged into connector
from the functions it connects with. CPS651, which connects pin A with pin B.
Figure 2 provides an overview of the different • Jumper Power Supply by Battery directly
harnesses that belong to the different truck options provides power supply from the batteries to
and their connector numbers. the circuit for side, tail and hazard lights,
allowing activating these lights irrespective of
Figure 14 through Figure 31 shows a 3D-view of the ignition switch position. See schematic
most of the wire harnesses with their terminals and location [97,G]. This harness is to be plugged
connectors. The legends for these figures mention into connector CPS650, which connects pin B
the connector codes and connector description for with pin C.
verification. See also • The strobe light jumper allows activation by
Wire Harness Identification and Connector Location ignition by connecting a jumper between pin
and Table 11. number 2 and pin 3 of the strobe switch. See
Not shown in the harness overview and in the 3D- schematic location [73,J].
views are harnesses that are merely an extension • Operator Presence Switch Jumper, which is
cord for some of the connectors, or jumpers that removed when connecting the optional
connect between wires. The lay-out of these seatbelt sequencer. See schematic location
harnesses can be read from the electrical schematic. [124,F].
For the actual location of these harnesses, read the
code of the mating connector from the electrical Harness Interconnection
schematic and look up the figure and item number On the electrical schematic the interconnection
from Connector Overview. For example: the Closed between two harnesses is indicated by a harness
Cab harness connects with the Cab Lights RH, dividing line, which will run across the two mating
which connects to CPS 64. See Figure 20. harness connectors. See Figure 1, item 15.
Not shown on the figures for the frame harnesses
are the connectors for engine components such as
sensors, fan clutch and grid heater relays.
6
Figure 2. Harness Overview
7
1. FRAME 12. ECM

2. SIDE CONSOLE 13. ECM/EAS
3. CAB POWER 14. ECO-ELO/HIP
4. CAB SIGNALS 15. ARM REST
5. AUX SIGNALS 16. SWITCHES/JOYSTICK
6. POWERTRAIN 17. CAB UNDERFLOOR
7. POWERED CAB TILT 18. STEERING COLUMN
8. MAST 19. CLOSED CAB
9. FRONT LIGHTS LH 20. CAB LIGHTS LH
10. FRONT LIGHTS RH 21. CAB LIGHTS RH
11. REAR 22. WASH PUMP
ELECTRICAL CONNECTORS code. Terminators, that are not isolated when

detached, have a two letter code. The explanation of
Connector Types the letter codes is shown in Table 4.
Connector types are identified by letter codes.
Multiple pin or socket connectors have a three letter
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
Connector Identification As the wires in a connector will relate to different

functions, portions of a connector can be divided
Each connector is identified by the letter code of the over several schematic pages according the different
connector type and a unique identification number, electrical function of the wires. In general there is
e.g. CRP07. no relation between a connector and a schematic
Connectors have the same identification number if location. The only possibility to look up a schematic
they interconnect between two wire harnesses, e.g. location is through the connector listing.
CRP07 interconnects with CPS07. A connector is not shown on the schematic if the
On the schematic a connector may be represented connector is an integral part of a component or if it
complete with all wires it normally contains, or does not have a minimum length of wire harness
partial, showing the few wires that are relevant for between the component and the connector. In these
the particular page of the schematic. cases the schematic just shows the wire harness
connector.
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.
8
Connector Pin Numbers wire harness that the connector connects with. An
exception is the interconnection between frame and
On the schematic the pin numbers are indicated by side console harness, which is through three
a number or letter inside the connector symbol, with connectors.
the relevant wire ending at the relevant pin
number. To avoid having three identical descriptions, the
descriptions Cab Signals, Cab Power and Aux
On the connector itself pin numbers are shown in Signals have been assigned.
relief, but can be as small as 1 mm high. To read the
numbers, clean the housing and provide sufficient
FUSES
lighting.
The fuse panel is located behind the door at the left
Pin numbers can be located on the inside of the
side of the instrument panel. The relays are located
connector next to the pin, on the backside of the
left of the fuse panel. The fuse box for Cab Tilt, DEF
connector next to the wires, or on the connector
and ECM (Electronic Control Module) is located in
housing.
the battery box. See Figure 3 and Table 5.
Connector Description Five fuse panels are located behind the cover under
the instrument panel. The five fuse panels contain
For orientation purposes each connector has been the fuses that protect all other electrical circuits.
provided with a description, which is shown in the See Figure 4 and Table 6.
connector overview in Table 11, and in the legend
for the wire harnesses. The description matches the On the inside of the instrument cover is a label that
component it is attached with. shows the location of the fuses in the four fuse
panels.
For connectors between harnesses the description is
a combination of the two harness names. For In some cases a fuse is not adopted on the electrical
instance CPS132: Frame-Mast. The first part of the schematic. It concerns fuses that are an integral
description indicates the wire harness that the part of a component, like retrofitted radio’s.
connector is part of, the second part indicates the
9
1. BATTERY DISCONNECT SWITCH

2. BATTERY DISCONNECT SWITCH LOCK
3. BATTERY
4. POWERBOARD (SEE TABLE 5)
Figure 3. Main Fuses and Relays
Table 5. Legend for Main Fuses and Relays

Item Code Description Value Connector Location
5 F1 ALTERNATOR 125A TS15/TS16 [37,A]
6 F9 CAB TILT 30A CPS178 [101,B]
7 F10 ENGINE ECM SUPPLY 30A CPS178 [32,H]
8 REL3 RELAY DEF HOSE - — CPS166 [51,D]
CPS141
9 REL2 RELAY DEF HOSE - — CPS166 [51,C]
CPS140
10 REL5 RELAY DEF PUMP — CPS166 [52,C]
HEATER
11 REL4 RELAY DEF HOSE - — CPS166 [50,C]
CPS146
12 F8 SPARE 10A CPS166 [52,C]
13 F11 SPARE 15A CPS166 [53,C]
14 F7 SPARE 7.5A CPS166 [53,C]
15 F6 DEF MODULE HEATER 10A CPS166 [52,D]
16 F3 GRID HEATER 150A F3 [34,H]
10
Table 5. Legend for Main Fuses and Relays (Continued)

Item Code Description Value Connector Location
17 F5 SPARE 10A CPS166 [52,C]
18 F4 DEF HOSE HEATING 15A CPS166 [51,D]
19 F2 CAB SUPPLY 125A TS10/TS01 [21,B]
20 REL1 RELAY GRID HEATER — TS18/CPS166 [34,H]
1. FUSE PANEL 1
2. FUSE PANEL 2
3. FUSE PANEL 3
4. FUSE PANEL 4
5. FUSE PANEL 5
6. ECO-ELO SWITCH
7. HYDRAULIC SERVICE SWITCH
8. TRANSMISSION CALIBRATION SWITCH
9. RELAY PANEL (SEE FIGURE 5)
10. DIAGNOSTIC PLUG
11. REGENERATION CONTROL SWITCH
12. BUZZER
Figure 4. Fuse Panel, Hydraulic Controller and

Hydraulic Relays
Table 6. Fuse Panel Overview

Fuse Description Value Location
Fuse Panel 1 (CPS37)
F11 Ignition 5A [26,C]
F12 Engine Start 30A [24,B]
F13 Transmission B+ 7.5A [24,B]
F14 Transmission Ignition 7.5A [28,H]
F15 Engine Control Module Ignition 5A [27,H]
F16 Engine Aftertreatment System Sensors 10A [27,H]
F17 Instrumentation/CAN Display Ignition 5A [27,H]
F18 Alternator On 5A [27,H]
F19 Joystick/12V Relay/SW Armrest 5A [27,H]
11
Table 6. Fuse Panel Overview (Continued)

F20 Cab Auto Tip Up 5A [26,H]
F21 Interior Lights 5A [98,C]
F22 Reverse Lights/Alarm/Strobe 5A [98,C]
F23 Brake Lights 5A [98,C]
F24 Front Drive Lights 15A [98,B]
F25 Supply CMD Lights switch 5A [98,B]
F26 Attachment Lights 15A [97,C]
F27 Direction Indicators 5A [97,B]
F28 Rear Drive Lights 10A [97,B]
F29 Side/Tail Lights 5A [97,B]
F30 CMD Lights Relay 30A [97,B]
F31 Front Screen Wash/Wipe 10A [152,A]
F32 Roof Screen Wash/Wipe 10A [152,A]
F33 Rear Screen Wash/Wipe 10A [152,A]
F34 Heater/AC/Ventilation Fan 25A [151,A]
F35 Automatic Greasing 10A [151,A]
F36 Seat Suspension Compressor 15A [151,A]
F37 Horn 10A [168,C]
F38 Sped Power B+ 30A [167,C]
F39 Converter for Accessories 10A [167,C]
F40 Park Brake Warning 5A [123,B]
12
Table 6. Fuse Panel Overview (Continued)

F41 Not Used ... ...
F42 Power Socket 12V 10A [166,B]
F43 Radio/CB/Intercom 10A [166,B]
F44 CAN Display B+ 5A [179,B]
F45 Hazard Lights 5A [179,B]
F46 AC Condenser Fan 1 15A [179,B]
F47 AC Condenser Fan 2 15A [178,B]
F48 Power Socket 24V 15A [178,B]
F49 Strobe B+ 5A [178,B]
F50 Park Brake Solenoid 5A [178,B]
Fuse Panel 5 (CPS 222)
F51 Hydraulic Controller 20A [137,E]
F52 Attachment Controls 15A [169,C]
F53 Aux. Switches 5A [169,C]
F54 Power Socket Switched 24V 5A [169,C]
F55 Sped Power Ignition 5A [169,C]
F56 Rear View Camera 5A [168,C]
F57 Mast Sensors 5A [168,C]
F58 Brake Pressure Warning 5A [168,C]
F59 Operator Presence System 5A [124,D]
F60 Telemetry 5A [124,D]
13
RELAYS
Except for the main relays shown on Figure 3, all
relays are installed on the relay panel that is
located left of the fuse panel. See Figure 5 and
Table 7.
Figure 5. Relay Panel
Table 7. Relay Panel

Item Description Connector Location
1 Main Power, 24V CPS16 [29,E]
2 Lights, 24V CPS174 [99,A]
3 Horn, 24V CPS84 [166,A]
4 2nd Horn, 24V CPS84 [134,J]
5 CMD Lights, 24 CPS221
6 Flasher Unit, 24V CPS76 [90,B]
7 Start Enable, 24V CPS15 [29,G]
8 Ignition, 24V CPS15 [29,G]
9 Reverse Lights & Alarm, 24V CPS36 [81,E]
10 AC3, 24V CPS36 [178,E]
11 Start Inhibit, 24V CPS13 [29,A]
12 OPS, 24V CPS13 [29,A]
13 AC2, 24V CPS115 [178,E]
14 AC1, 24V CPS115 [178,E]
15 12V CPS120 [164,F]
16 Hydraulic Controller, 24V CPS120 [38,D]
17 -- -- --
14
Table 7. Relay Panel (Continued)

Item Description Connector Location
18 Diode Block CPS195
FLYBACK DIODES diode will not conduct at all. Sometimes a failed

diode causes a short circuit.
Some components induce current surges when they
are switched off. These surges can cause sparking of Replacement diodes are integrated in connectors
mechanical contacts in switches and relays, which that attach the correct diode polarity to the wire
results in premature erosion of these contacts. harnesses. Table 8 provides a complete listing of all
Flyback diodes prevent these symptoms by flyback diodes fitted.
connecting the induced current surge to ground. Side Console Diode Block CPS195 includes the
Always check functionality of a flyback diode when diodes for Main Power (CPS16 and CPS15), Cab
a switch or relay has failed. In most cases a failed Lights (CPS221) and Lights (CPS174).
Table 8. Flyback Diodes

Connector Diode Description Location Harness Name Figure Number
CPS236 Diode_Cab_Tilt_Pump [102,H] Powered Cab Tilt N/A
CPS54 Backup_Diode [85,F] Rear N/A
CPS82 Diode_Horn [160,D] Cab Underfloor 17
CPS195 Diode_Block_Side Console [29,D], [78,J], Side Console 15
[99,C]
CAN (CONTROLLER AREA NETWORK) Communication occurs through sending and

receiving signals. Each separate signal contains the
CANbus is a standard for an electronic system that following information (with example):
allows communication between different controllers
without the need for a host computer. • a code for the type of message: Coolant
Temperature
The truck has 3 different CANbus systems
• the message itself: 83°
according the SAE 1939-15 standard:
• the ID of the controller that has sent the
• Powertrain CANbus (wires 900 and 901) signal: ECM
• Vehicle CANbus (wires 902 and 903) Only two wires per CANbus system are required for
• EAS CANbus (wires 906 and 907) communication. The CAN-High wire (901, 903 and
The different controllers have their own controlled 907) and CAN-Low wire (900, 902 and 906). See
network of sensors, actuators and control devices. Figure 6.
Functioning of these components cannot be The CANbus inverse wire and data wire are twisted
influenced by other controllers unless the together to reduce sensitivity to electromagnetic
programming of a network controller specifically interference. For the same purpose there are
allows. termination resistors at the extreme ends of the
Each controller requires its own voltage supply to string of controllers. The CANbus system will not
feed the controller and to provide signals to the function if both 120 Ohm resistors are faulty or
components that belong to the controller network. disconnected.
Without voltage supply a controller does not The optional Electronic Climate Control has an
function. independent control system that does not
communicate through CANbus wires 900 to 903,
and 906-907.
15
Because the CANbus systems for Vehicle and The diagnostic connector itself is not a controller.
Powertrain are separated, there is one diagnostic Instead, the IFAK cable that leads to the laptop
connector for each of the two CANbus systems. The computer contains the controller that will make a
diagnostic connector for Vehicle CANbus is CPS106. connection with the CANbus system when plugged
The diagnostic connector fir the Powertrain CANbus into one of the two diagnostic connectors.
is CPS19. Both are located above the hydraulic
controller, left of the fuses. See Figure 4.
Figure 6. CANbus Circuit
16
Diagnostic can be recognized in Figure 7, Figure 8, and Table 9

through the indicated pin numbers for connector
Most controllers have a memory that retains codes CPS94.
for situations that occurred within their own
controlled circuit. Also faults in the controller itself To test functionality of the individual warning
are stored as a fault code. Both the IFAK cable and lights, switch the ignition from OFF to ON. All
the instrument cluster contain a controller that lights should light up for one second. As there are
makes these codes visible on a lap top computer, no serviceable components, the entire instrument
respectively on the hour meter display. The panel must be replaced if found defective.
explanation of these codes is shown on the different
fault code tables for engine, transmission, hydraulic
system and Electronic Climate Control.
The CANbus connection itself can be verified by
checking continuity of the data inverse wires 900
(green) and the data wires 901 (yellow), and by
checking the 120 Ohm resistance value of the end
resistor. For schematic location and actual location
see Table 11.
Diagnostics of a faulty CANbus system requires
thorough knowledge and specific software. As
controllers cannot be repaired, there is no other
option than to replace a controller if it is found to be
defective.
CENTRAL WARNING LIGHTS AND

INSTRUMENT PANEL
Most of the lights and instruments on the 1. WARNING LIGHTS
instrument panel are controlled by CANbus signals
through pin 14 (CAN High) and pin 15 (CAN Low). Figure 7. Central Warning Lights
The few lights and instruments that are hard wired
17
Table 9. Central Warning Lights and Instrument Panel

Item Description Pin Number Central Buzzer
Warning Light
1 Central Warning Lights CAN ---- ----
2 Engine Coolant Temperature Gauge & High CAN ● ●
Coolant Temperature Warning Light
3 LCD Display (Hourmeter/Fault Code/Exceed CAN ---- ----
Codes/Fault Code Log/Transmission
Calibration)
4 Engine System Fault/Malfunction Warning CAN ● ----
Light
5 Engine System Urgent Stop Warning Light CAN ● ●
6 Transmission System Fault/Malfunction CAN ● ●
Warning Light
7 Transmission Calibration Warning Light 12 ---- ----
8 Transmission (Sump) Oil Temperature Gauge & CAN ● ●
High Oil Temperature Warning Light
9 Hydraulic System Fault/Malfunction Warning CAN ● ●
Light
10 Hydraulic Oil Filter Restriction warning light CAN ● ----
11 Hydraulic (Tank) Oil High Temperature CAN ● ●
Warning Light
18
Table 9. Central Warning Lights and Instrument Panel (Continued)

Item Description Pin Number Central Buzzer
Warning Light
12 Wet Brake High Oil Temperature Warning CAN ● ●
Light
13 Brake System Low Oil Pressure Warning Light 11 ● ●
14 Parking Brake Warning Light 7 ---- ----
15 Battery Voltage Gauge & Low Battery Voltage 1 ● ----
Warning Light
16 Fuel Level Gauge & Low Fuel Level Warning 24 ● ----
light
Tier 3/Stage IIIA: Engine Oil Pressure Gauge CAN ● ●
& Low Oil Pressure Warning light
17 Tier 4F/Stage IV: Engine Diesel Emission CAN ● ----
Fluid (DEF) Level Gauge & Low DEF Level
Warning Light
18 Seat Belt Warning Light ---- ---- ----
19 Water in Fuel Filter Warning Light CAN ● ----
20 Engine Coolant Low Level Warning Light CAN ● ●
21 Engine Oil Low Pressure Warning Light CAN ● ●
22 Engine Air Filter Restriction Warning Light 20 ● ----
23 Engine Wait To Start Warning Light CAN ● ----
Figure 8. Instrument Panel
19
Instrument Panel Connector

The instrument panel connects with the system
through connector CPS94, which is located at the
rear of the instrument panel. See Figure 9 and
Table 10.
Figure 9. Instrument Panel Connector
Table 10. Pin Descriptions

Pin Description
1 Battery positive input (Diagnostic Switch)
2 Seat switch input
3 NOT USED
4 Ground
5 NOT USED
6 NOT USED
7 Park Brake Warning Light Input
8 NOT USED
9 NOT USED
10 NOT USED
11 Brake System Low Pressure Light
12 Transmission Calibration Warning Light
13 NOT USED
14 CAN - H
15 CAN - L
16 NOT USED
17 Buzzer output 10 mA
18 NOT USED
19 Central Warning Light output 25 mA
20 Engine Air Filter Restriction Warning Light input
20
Table 10. Pin Descriptions (Continued)

Pin Description
21 NOT USED
22 NOT USED
23 NOT USED
24 Fuel Level Gauge input
LCD DISPLAY Fault Code Mode

The LCD display can show values for different If a control system detects an error, the LCD display
modes: switches between Hour Meter and Error Mode every
Hourmeter Mode 2 seconds. Fault codes start with a letter that relate
•
to the controller that signal the fault. Fault codes
• Fault Code Mode starting with ‘E’ refer to the engine, ‘T’ to the
• Transmission Calibration transmission, ‘H’ to hydraulics. See Figure 11.
• Fault Code Log Mode An explanation and suggested corrective action for
the fault codes is provided in below manuals:
Hourmeter Mode • Cummins Engine Fault Code Guide
Under normal conditions an hourglass is shown, 0600SRM1101 for engine fault codes.
indicating that the LCD display shows engine • Transmission Repair (ZF-WG211)
running hours. The running hours are stored every 1300SRM1718 for Transmission fault codes.
6 minutes when the engine is above 300 rpm. The • Hydraulic Control System 1900SRM2108
maximum number of hours that can be displayed is for fault codes in hydraulics, central greasing
99,999 hours. See Figure 10. and attachment.
Figure 11. LCD Display Engine Fault Code

1. HOUR GLASS
Figure 10. Hourmeter Display
21
Transmission Calibration Recorded faults are shown in batches of four

numbers, each being displayed during three
The display is a convenient replacement for a PC, seconds. The numbers represent the following:
when performing some of the transmission
calibration and test procedures. See Transmission • Fault code
Operations and Diagnostics 1300SRM1717 for a • Hourmeter reading at most recent occurrence
description of these procedures. of this fault
• Hourmeter reading at first occurrence of this
fault
• Number of occurrences of this fault
The batches with fault code information are shown
in sequence of occurrence. The most recently
occurred fault code is shown first.
When all recorded fault codes have been shown, the
display will continue to repeat these recorded fault
Figure 12. LCD Display Transmission Calibration codes until the user exists the fault log mode.
Fault Code Log Mode Clear

The instrument panel stores all fault codes received To clear the fault codes logged in the display,
from the engine, transmission and hydraulic proceed as follows:
controller. The instrument panel does not store
calibration and exceed codes from the transmission. 1. Access into the fault log mode. See Access.
Faults that have occurred can be reviewed at a later
2. Press-and-release the service switch three more
point in time by entering into the Fault Code Log
cycles. This is a repetition of the access
Mode. The display will show Err_H. See Figure 13.
procedure.
The data erasing process will start and confirm
successful completion by showing ‘clear’ on the
display.
If data-erasing is not successful, the display
will continue to show fault code data.
Exit
Figure 13. LCD Display Error Log Mode To exit the fault log mode, turn the ignition OFF
and ON and leave ignition ON for more than 2
Access seconds.
1. Apply the parking brake. An alternative procedure to return to normal mode

is by releasing the park brake or by starting the
2. Turn the key switch into the ON position, but engine.
do not start the engine.
GENERAL FAULT FINDING
3. Press and release the service switch 3 times. Below procedure is a guideline to facilitate fault
finding in electrical circuits. Following the entire
Press approximately for one second and release for procedure is not always practical. Use common
one second. After each press-and-release cycle the sense. For instance, if only one light out of a set of
display will show a number that increases with each two has failed, you will first check the bulb of the
cycle. After the third cycle the display will show a 3. failed light.
The display is now in fault log mode.
When no faults have been recorded, the LCD
display shows "clear."
22
The procedure is not suited for electronic circuits page of the schematic and find the fuse reference
like CANbus, which requires specific knowledge and number.
software. Fortunately, defective electric components
Investigate if an overload condition or a short circuit
and connections that are part of a CANbus circuit
caused the fuse to fail. First make repairs to solve
will generate a fault code in the controller. The fault
the short circuit or overload condition. See
code guide provides further detail about the defect.
Wiring Check.
Always verify presence of fault codes.
Replace the fuse after the repair has been made.
Preparation The actual location of the fuse is indicated on
Figure 4.
1. Have the Electrical Schematic available. See
Diagrams 8000SRM2071. Wiring Check
2. Identify the symptoms of the defect. Check signal presence at the component.
If no signal is present, check the signal at the next
3. Establish how the relevant switches and levers
component closer to the battery (relay, fuse, switch,
should operate. See the Operating Manual.
ignition switch). See Diagrams 8000SRM2071.
4. Observe the condition of the truck. Look for Check for damaged wire insulation in particular
signs of mechanical damage, overheating, when there are erratic failures.
unusual sounds, burn smells. Check connection to battery ground. Establish
virtually zero resistance for battery ground
Define the Problem Area connections.
1. Determine the schematic location of the failed
function. See Table 11. Component Check
Isolate the component and check electrical
2. Establish which sections of the failed function
functionality according the electric schematic.
operate correctly. Identify these sections on the
schematic. Switches and connectors must have virtually zero
resistance when closed.
Identify Possible Causes of Malfunction Check for open circuits, short circuits and insulation
Make a list of every possible fault. Use your initial breakdown.
observations to help you writing down these faults. Check if coils and relays do not overheat, which
indicates a defect.
Determine the Most Probable Cause
1. Prioritize each of the listed possible faults. Repair and Test
Remove the ground cable from the battery when
2. Perform a Fuse Check, a Wiring Check and a doing repairs. Replace or repair the defective
Component Check for each of the listed faults. components after the cause of failure has been
established. Replace the fuse found defective.
Fuse Check
After the repair, do a test to make sure that the
Determine which fuse protects the component in the proper repair has been made and that there are no
failed circuit. See Table 11 to look up the related other faults in the circuit.
23
Wire Harness Identification and Connector Location 2200 SRM 2065
Wire Harness Identification and Connector Location

Below Figure 14 through Figure 31 show a 3D-view description for verification. Related is Table 11,
of most of the wire harnesses with their terminals which indicates the item to find a connector or
and connectors. The legends for these figures terminal.
mention the connector codes and connector
Table 11. Connector Overview

Connector Description Location Harness
CPP02 POWERTRAIN-FRAME [36,C], [61,H] Powertrain
CPP03 Engine_ECM_Signals [37,G], [41,G], [49,C], [52,A] EAS
CPP04 MAST-FRAME [146,B], ECH-MAST
CPS02 ECM_TIER3 [39,H] Tier3 Adaptor
CPS04 Throttle_Pedal [30,J], [34,G] Cab Underfloor
CPS05 ECM_Power_Tier3 [39,J] Tier3 Adaptor
CPS06 Cab_Power [24,G], [34,C] Frame
CPS07 Cab_Signals [31,G], [34,C], [34,D], [40,C], Frame
[63,E], [81,B], [101,D], [125,B,
[132,E], [144,H], [175,B], [184,F]
CPS08 Hydraulic_Controller [132,A] Side Console
CPS09 Height Sensor [147,E] Frame
CPS10 Hydraullic_Temperature [110,C] Frame
CPS12 Convertor_Temp [61,J] Powertrain
CPS13 Start_inhibit/OPS [29,B], [134,J] Side Console
CPS14 Key_Switch [26,B] Side Console
CPS15 Start_Enable/IGN [29,G], [30,D] Side Console
CPS16 Main_Power_Relay [29,F] Side Console
CPS19 Diag_Powertrain_CAN [113,E] Side Console
CPS20 Washer_Front [158,I] Wash_Pumps
CPS21 DISPLAY [111,F] CAN Display
CPS22 Engine_Speed [60,C] Powertrain
CPS23 Output_Speed [60,A] Powertrain
CPS24 Internal_Speed [60,B] Powertrain
CPS25 Diagnostic_Switch [119,B] Side Console
CPS26 SERVICE_SWITCH [118,C], [134,F] Side Console
CPS27 Calibration Switch [62,B] Side Console
CPS28 SideConsole/Wash_Pumps [155,G] Side Console
CPS29 Shift_Lever [69,B] , Steer Column
CPS30 Underfloor-SteerColumn [68,D], [92,I], [117,J], [162,B], Cab Underfloor
[182,I]
24
2200 SRM 2065 Wire Harness Identification and Connector Location
Table 11. Connector Overview (Continued)

CPS31 Monotrol_Pedal [69,I] Cab Underfloor
CPS32 Inching_Pedal [68,I] Cab Underfloor
CPS33 Sideconsole-Underfloor [30,H], [91,G], [116,H], [154,G], Side Console
[163,B], [182,G]
CPS34 V_CAN_Termination_Resistor [110,F] CAN Display
CPS35 Aux_Signals [40,B], [113,C], [144,E] Frame
CPS36 Reverse Lights/Alarm [82,F], [179,G] Frame
CPS37 Fuses_1-10 [28,H], [24,B], [27,B] Side Console
CPS38 Washer_Roof [158,I] Wash_Pumps
CPS40 Rear Drive Lights [78,B], [78,E] Cab Lights
CPS41 Outer Flood Light [78,C], [78,E] Cab Lights
CPS42 Inner Flood Light [78,C], [78,F] Cab Lights
CPS43 LED Beacon [78,A], [78,D] Cab Lights
CPS46 12V_Plug [166,F] Side Console
CPS47 Beacon/Strobe_Switch [72,J], [73,J] Side Console
CPS48 Flood/RR_Drive_LTS_Switch [75,G], [76,G] Side Console
CPS49 Side/Indicator-Lights [88,E], [88,B] Front Drive
Light
CPS50 Fuses_21-30 [98,H] Side Console
CPS51 Fuses_31-40 [123,B], [152,A], [152,B], [167,C] Side Console
CPS52 Side/Front_Lights_Switch [81,G], [81,H] Side Console
CPS53 Att_Lights_Switch [82,G], [82,H] Side Console
CPS54 Backup_Diode [88,F] Rear
CPS56 Drive_Light [89,D], [89,C] Front Drive
Light
CPS57 TBAP_SENSOR [41,J] Frame
CPS58 CAN_termination_resistor [39,G] Tier3 Adaptor
CPS59 Drive_Light [89,D], [89,B] Front Drive
Lights
CPS60 Frame-LH_Front_Lights [86,B] Frame
CPS61 Frame-RH_Front_Lights [86,D] Frame
CPS62 TBAP_SENSOR_TO_ENGINE [44,J] Frame
CPS63 Closed_Cab-SideConsole [73,F], [153,G], [153,H], [172,E] Closed Cab/
Open Cab
CPS64 Cab Lights [76,C] Cab Lights
CPS65 Cab Lights [76,E] Cab Lights
25

CPS68 Frame-Rear [85,I] Frame
CPS69 RH_Tail_lights [88,I] Rear
CPS71 Wiper_Timer [151,F] Side Console
CPS72 LH_Tail_lights [88,J] Rear
CPS73 SPED [167,J] Side Console
CPS74 Sideconsole-Wiper_Rear [150,G] Side Console
CPS75 Roof_Wiper [153,J] Closed Cab/
Open Cab
CPS76 Flasher_Unit [90,B] Side Console
CPS77 Hazard_Switch [91,D], [92,D] Side Console
CPS78 Front_Wiper [156,I] Cab Underfloor
CPS80 Horn_Switch_Armrest [168,A], [169,A] Armrest
CPS81 Armrest-Sideconsole [122,G], [123,I], [136,H], [167,B], Armrest
[155,C]
CPS82 Diode_Horn [160,D] Cab Underfloor
CPS83 Horn_Button [160,B] Steer Column
CPS84 Second Horn/Horn [138,B], [166,A] Side Console
CPS85 Joystick [136,J] Armrest
CPS86 Front_Wiper_Switch [157,B], [158,B] Armrest
CPS87 REGEN_EN/DISABLE_SW [42,A], [43,A] Side Console
CPS88 WIF_Sensor [36,F] Frame
CPS89 Front_Washer_Switch [157,C], [158,C] Armrest
CPS90 Roof Wiper/Washer_Switch [157,E], [158,E] Armrest
CPS91 Rear Wiper/Washer_Switch [157,F], [158,F] Armrest
CPS92 Wiper_Rear [151,H] Rear Wiper
Extension
CPS93 Hoist_Pressure [134,J] Frame
CPS94 Instrument_Cluster [118,A] Side Console
CPS95 Washer_Rear [158,H] Wash_Pumps
CPS96 Map_Light [70,J] Side Console
CPS97 Air_filter [110,A] Frame
CPS98 Parkbrake_Solenoid [126,B] Frame
CPS99 Lift_Solenoid2 [134,J] Frame
CPS101 Lift_Solenoid1 [133,J] Frame
CPS102 Lift and Tilt Sensor [144,I] Frame
CPS103 COOLANT_LEVEL [32,E] Frame
26

CPS106 Diag_Vehicle_CAN [134,E] Side Console
CPS107 DC/DC_Convertor [164,I] Side Console
CPS109 Fuses_41-50 [166,C], [179,B] Side Console
CPS110 Radio_Power [161,H] Closed Cab/
Open Cab
CPS111 Radio_Sound [161,J] Closed Cab/
Open Cab
CPS112 SIDECONSOLE_DISPLAY [111,I] Side Console
CPS115 AC1/AC2 [179,F] Side Console
CPS116 HVAC_Unit [173,F] Side Console
CPS117 Sideconsole-AC_cond [172,D] Side Console
CPS119 Move_Twistlocks [137,I], [138,I] Armrest
CPS120 12V_HYDR_CONTR [164,G], [138,D] Side Console
CPS121 Tilt_Sensor [140,I] Proximity
Switch
CPS122 Frame-Cab_Tilt [102,E] Frame
CPS124 ACTUATOR_LEFT_POWER [107,F] Auto Tip Up
CPS125 ACTUATOR_RIGHT_SIGNALS [107,H] Auto Tip Up
CPS126 ACTUATOR_RIGHT_POWER [107,H] Auto Tip Up
CPS129 Tilt_Solenoid [132,J] Frame
CPS130 Aux_Solenoid [131,J] Frame
CPS131 Accum_Charge_disable_Sol [131,I] Frame
CPS132 Lowering_Solenoid [130,I] Frame
CPS133 FAN_CLUTCH [40,H] EAS
CPS134 CAN_termination_resistor [48,B] EAS
CPS136 Mast-Front_End_Equipm. [148,C] ECH Mast
CPS137 ACTUATOR_LEFT_SIGNALS [107,F] Auto Tip Up
CPS140 HOSE 3 INLET [54,C] EAS
CPS141 HOSE 2 BACKFLOW [54,D] EAS
CPS143 XMSN_connector [63,A], [65,J] Side Console
CPS144 Suspension_Seat [120,G] Armrest
CPS145 Accessory_Socket_24V [177,B] Side Console
CPS146 HOSE 1 OUTLET [54,E] EAS
CPS147 CAC_Temp [33,E] FRAME
CPS149 DEF_TANK_HEATING_VALVE [57,I] EAS
CPS151 DEF DOSING MODULE [59,I] EAS
27

CPS152 DEF_SUPPLY_MODULE [57,I] EAS
CPS153 SCR_TEMP [52,E] EAS
CPS154 DEF Sensors [54,I] EAS
CPS155 OPS [127,E] Side Console
CPS156 DOC_TEMP [51,J] EAS
CPS157 NOx_Sensor_DOC [52,J] EAS
CPS158 CAN_termination_resistor [53,F] DEF
CPS159 NOx_Sensor_SCR [53,J] EAS
CPS160 XMSN_connector [60,G] Powertrain
CPS161 Turbine_speed [60,C] Powertrain
CPS162 XMSN_Filter_Switch [60,J] Powertrain
CPS163 2nd Pump Disable [130,H] Frame
CPS164 FM1A [183,A] FM1A
CPS165 Fuel Level Sender [110,B] Frame
CPS166 PDM [51,B], [35,H] Frame
CPS168 Brake_light_Switch [83,J] Frame
CPS171 Brake_Temperature_Sensor [110,B] Frame
CPS173 Low_Brake_Pressure [110,D] Frame
CPS174 Lights [98,A] Side Console
CPS175 ECO-eLo/HiP [100,D] Side Console
CPS178 Frame-PDM_box [32,I], [102,B] Frame
CPS180 Alternator Connector [38,D] Frame
CPS183 LUBRICATION PUMP [187,D] Frame
CPS184 LUBRICATION SWITCH [188,D] Frame
CPS185 LUBRICATION SWITCH [187,B] Lubrication
Switch
CPS186 LUBRICATION PUMP [186,B] Lubrication
Pump
CPS187 RH_REVERSE-LIGHTS [88,H] Rear
CPS188 LH_REVERSE-LIGHTS [88,I] Rear
CPS190 RELAY_AUTO_TIP_UP [107,C] Auto Tip Up
CPS195 DIODE_BLOCK [29,D], [78,I], [78,J], [99,C] Side Console
CPS200 ZF_DIAG [67,H] Side Console
CPS201 Power_Auto_Tip_Up [104,B] Frame
CPS202 Signals_Auto_Tip_Up [104,A] Frame
CPS204 Buzzer+ [124,B] Side Console
28

CPS205 Buzzer- [124,B] Side Console
CPS206 FUSEBOX_AUTO_TIP_UP [107,D] Auto Tip Up
CPS213 OPTIONAL_INPUTS [135,C] Side Console
CPS214 Buzzer- [115,D] Side Console
CPS215 Buzzer+ [115,D] Side Console
CPS221 CMD Lights [78,H] Side Console
CPS222 Fuses 51-60 [124,D], [137,E], [168,C] Side Console
CPS233 Cab_Tilt_Switch [103,F] Powered Cab
Tilt
CPS234 Cab_Tilt [103,G] Powered Cab
Tilt
CPS235 Cab_Tilt_Pump [104,I] Powered Cab
Tilt
CPS236 Diode_Cab_Tilt_Pump [103,H] Powered Cab
Tilt
CPS237 SIDECONSOLE_FM1A [181,A] Side Console
CPS238 SIDECONSOLE_FM1B [181,C] Side Console
CPS239 SteerColumn_FM2A [184,H] Steer Column
CPS240 FM1B [183,C] FM1B
CPS241 BUZZER [183,E] FM1B
CPS242 FM2A [188,G] FM2A
CPS243 CARD_READER [187,J] FM2A
CPS244 Horn [160,E] Cab Underfloor
CPS245 Horn [160,E] Cab Underfloor
CPS250 P_CAN_Termination_Resistor [113,E] CAN Display
CPS256 OVERRIDE_KEY_SWITCH [138,G] Side Console
CPS350 Rear View Camera [168,G] Side Console
CPS450 Seat_Belt_Sequencer [128,F] Australian_OPS
CPS540 12V Plug [166,H] second socket
CPS541 12V Plug [167,H] second socket
CPS650 by_battery [95,C] Jumper_Lights/
Battery
CPS651 by_ign [96,C] Jumper_Lights/
Ignition
CPS670 Camera_Display [168,J] Adaptor
CRP01 AC-Clutch [176,B] Frame
29

CRP02 Condenser_Unit [173,B] Extension
HVAC
CRP03 ECM_T4 [49,C], [57,A] EAS
CRP04 AC_cond-Sideconsole [174,B] Extension
HVAC
CRP06 Cab_Power [24,G], [33,C] Side Console
CRP07 Cab_Signals [31,G], [33,D], [33,C],[41,C], Side Console
[63,E], [81,B], [101,D],[124,B],
[132,E], [144,H], [175,C], [184,F]
CRP10 Condensor_Unit [170,B] Closed Cab/
Open Cab
CRP12 ECM_Cross-over [50,F], [40,I] EAS
CRP28 Wsh_Pumps-SideConsole [155,G] Wash_Pumps
CRP30 SteerColumn-Underfloor [68,D], [92,I], [117,J], [161,B], Steer Column
[183,I]
CRP33 Underfloor-Sideconsole [30,I], [67,H], [91,G], [116,I], Cab Underfloor
[154,G], [163,B], [182,G]
CRP35 Aux_Signals [41,B], [114,D], [144,E] Side Console
CRP46 SECOND SOCKET [166,F] Second Socket
CRP49 TURNSIGNAL&MARKER LIGHTS [88,B], [88,E] TURNSIGNAL
&MARKER
LIGHTS
CRP60/61 Front_Lights-Frame [86,B], [86,D] Front Drive
Light
CRP63 SideConsole-Closed_Cab [73,G], [153,G], [163,H], [172,E] Side Console
CRP64 RH_Cab_Lights [76,C] Closed Cab/
Open Cab
CRP65 LH_Cab_Lights [76,E] Closed Cab/
Open Cab
CRP68 Rear-Frame [85,I] Rear
CRP74 Wiper_Rear-Sideconsole [150,G] Rear Wiper
Extension
CRP81 Sideconsole-Armrest [122,F], [124,I], [136,H], [155,C], Side Console
[166,A]
CRP88 WIF_Sensor [39,F] Tier3 Adapter
CRP102 Lift_&_Tilt_Sensor [144,I] Proximity
Switch
CRP112 DISPLAY_SIDECONSOLE [112,I] CAN Display
CRP117 AC_cond-Sideconsole [172,D] Closed Cab/
Open Cab
30

CRP122 Cab_Tilt-Frame [102,E] Powered Cab
Tilt
CRP155 Australian_OPS [127,E], [127,F] Unset
CRP175 ECO-eLo/HIP [100,D] ECO-Elo/HIP
CRP183 LUBRICATION PUMP [187,D] Lubrication
Pump
CRP184 LUBRICATION SWITCH [188,D] Lubrication
Switch
CRP201 Power_Auto_Tip_Up [104,B] Auto Tip Up
CRP202 Signals_Auto_Tip_Up [104,A] Auto Tip Up
CRP237 SIDECONSOLE_FM1A [182,A] FM1A
CRP238 SIDECONSOLE_FM1B [182,C] FM1B
CRP238A Jumper [182,F] Side Console
CRP239 FM2A_Sideconsole [184,H] FM2A
CRP300 FRAME-BACKUP_ALARM [88,G] Rear
CRP350 REAR_VIEW_CAMERA [168,G] Adaptor
CRP420 Seat_Belt_Switch [122,H] Armrest
CRP440 Seat_Switch [122,J] Armrest
CRP650 Lights_Jumper [96,F] Side Console
CRS01 Parkbrake_Switch_Element [120,D] Side Console
CRS02 FRAME-POWERTRAIN [35,D], [62,H] Frame
CRS03 Frame-Engine [36,J], [40,G], [52,A] Frame
CRS04 Frame-Mast [146,B] Frame
TS01 FUSE_CAB_125A [21,C] Frame
TS02 Battery+ [22,J] Battery Cable +
TS03 Battery- [20,J] Battery Cable -
TS04 Battery+ [21,J] Battery Cable +
TS05 Battery- [21,J] Battery Cable +
TS06 Alternator_B+ [38,D] Frame
TS07 Alternator_Ground [38,D] Battery Cable -
TS08 ECO-eLo/HIP Switch [100,B] ECO-eLo/HIP
TS09 ECO-eLo/HIP Switch [100,B] ECO-eLo/HIP
TS10 Supply_PDM [21,C] Supply_PDM
TS13 Startermotor_Solenoid [36,D] Powertrain
TS14 Ground_Startermotor [36,A] Battery Cable -
TS15 Fuse_Alternator_125A [37,B] Frame
31

TS16 Fuse_Alternator_125A [37,B] Alternator
TS18 Gridheater_Relay [35,H] Frame
TS19 Grid_Heater [36,H] Frame
TS20 Alternator_B+ [39,D] Frame
TS21 Ground_Startermotor [35,A] Battery Cable -
TS23 Groundpoint_Frame [36,A] Battery Cable -
TS24 Groundpoint_Frame [35,B] Battery Cable -
TS40 Groundpoint_Frame [35,A] Frame
TS43 RH_Interior_Light [74,A] Closed Cab/
Open Cab
TS44 RH_Interior_Light [74,A] Closed Cab/
Open Cab
TS45 LH_Interior_Light [74,B] Closed Cab/
Open Cab
TS46 LH_Interior_Light [74,B] Closed Cab/
Open Cab
TS64 Indicator_Switch_54 [93,H] Steer Column
TS66 Indicator_Switch_L [93,I] Steer Column
TS67 Indicator_Switch_R [93,I] Steer Column
TS70 Switch2 [72,J] Strobe_Adaptor
TS71 Switch1 [73,J] Strobe_Adaptor
TS77 Starter_Motor+ [36,D] Battery Cable +
TS80 Master_Warning [119,J] Steer Column
TS81 Master_Warning [119,J] Steer Column
TS84 Groundpoint_Frame [35,B] Frame
TS89 Radio_Coms [161,F] Closed Cab/
Open Cab
TS90 Radio_Coms [161,F] Closed Cab/
Open Cab
TS91 Right_Speaker+ [162,J] Closed Cab/
Open Cab
TS92 Right_Speaker- [162,J] Closed Cab/
Open Cab
TS93 Left_Speaker+ [163,J] Closed Cab/
Open Cab
TS94 Left_Speaker- [163,J] Closed Cab/
Open Cab
32

TS98 Ventilation_Fan [171,D] Closed Cab/
Open Cab
TS100 Ground_Startermotor [36,E] Battery Cable -
TS102 Armrest_Ground [169,A] Armrest
TS103 Armrest_Ground [169,A] Armrest
FRAME HARNESS CONNECTORS (TIER 3/STAGE IIIA)
Figure 14. Frame Harness Connectors (Tier 3/Stage IIIA)
Table 12. Legend for Frame Harness Connectors (Tier 3/Stage IIIA)
Item Connector Description
1 CPS07 Cab Signals
2 CPS06 Cab Power
3 CPS35 Aux Signals
4 CPS68 Frame – Rear
33
Table 12. Legend for Frame Harness Connectors (Tier 3/Stage IIIA) (Continued)
5 CPS202 Auto Tip-Up Signals
6 CPS201 Auto Tip-Up Power
7 CPS122 Frame – Cab Tilt
8 CPS103 Coolant Level
9 CPS62 TBAP Sensor to Engine
10 CPS180 Alternator Connector
11 TS06 Alternator B+
12 TS20 Alternator B+
13 TS07 Alternator Ground
14 TS84/TS40/TS14 Groundpoint Frame
15 Tier 3/Stage IIIA: TBAP Sensor
CPS57
15 Tier 4F/Stage IV: TBAP Sensor
16 Tier 3/Stage IIIA: Air Filter
CPS97
16 Tier 4F/Stage IV: Air Filter
17 CPS165 Fuel Level Sender
18 TS15 Fuse Alternator 125A
19 TS18 Gridheater Relay
20 TS01 Fuse Cab 125A
21 CPS178 Frame – PDM Box
22 CPS166 PDM
23 CPS88 WIF Sensor
24 CPS129 Tilt Solenoid
25 CPS101 Lift Solenoid 1
26 CPS163 2nd Pump Disable
27 CPS98 Park Brake Solenoid
28 CPS93 Hoist Pressure
29 CPS132 Lowering Solenoid
30 CPS131 Accumulator Charge Disable Solenoid
31 CPS173 Low Brake Pressure
32 CPS171 Brake Temperature Sensor
33 CPS99 Lift Solenoid 2
34 CPS130 Aux Solenoid
35 CPS168 Brake Light Switch
36 CPS60 Frame – LH Front Lights
37 CPS61 Frame – RH Front Lights
34
Table 12. Legend for Frame Harness Connectors (Tier 3/Stage IIIA) (Continued)
38 CPS183 Lubrication Pump
39 CPS09 Height Sensor
40 CRS04 Frame Mast
41 CPS184 Lubrication Switch
42 CPS102 Lift & Tilt Sensor
43 CPS10 Hydraulic Temperature
44 CRS02 Frame-Powertrain
45 CRS03 Frame-Engine
46 CPS147 CAC-Temp
47 TS19 Grid Heater
48 CRP01 AC-Clutch
35
SIDE CONSOLE HARNESS CONNECTORS
Figure 15. Side Console Harness Connectors
36
A. FUSES – SEE FUSES

B. RELAYS – SEE RELAYS
Table 13. Legend for Side Console Harness Connectors

1 CRP81 Side Console – Armrest
2 CRP35 Auxiliary Signals
3 CRP06 Cab Power
4 CRP07 Cab Signals
5 CPS175 ECO-ELO/Hip
6 CPS107 DC/DC Convertor
7 CPS238 Side Console FM1B
8 CRP238A Jumper
9 CPS237 Side Console FM1A
10 CPS17 Diode Main Power
11 CPS112 Side Console – Display
12 CPS117 Side Console – AC-Cond
13 CPS74 Side Console – Wiper Rear
14 CRP63 Side Console – Closed Cab
15 CPS71 Wiper Timer
16 CPS256 Override Key Switch
17 CPS46 12V Plug
18 CPS96 Map Light
19 CPS14 Key Switch
20 CPS116 HVAC Unit
21 CPS25 Diagnostic Switch
22 CPS77 Hazard Switch
23 CPS47 Beacon/Strobe Switch
24 CPS48 Flood Drive LTS Switch
25 CPS52 Side/Front Lights Switch
26 CPS53 Attachment Lights Switch
27 CRS01 Park Brake Switch Element
28 CPS106 Diagnostics Vehicle Can
29 CPS08 Hydraulic Controller
30 CPS19 Diagnostics Conn Powertrain CAN
31 CPS94 Instrument Cluster
32 CPS200 ZF Diagnostics
37
Table 13. Legend for Side Console Harness Connectors (Continued)

33 CPS214 Central Warning Buzzer -
34 CPS215 Central Warning Buzzer +
35 CPS204 Park Brake Warning Buzzer +
36 CPS205 Park Brake WarningBuzzer -
37 CPS87 Regeneration Enable/Disable Switch
38 CRP650 Lights Jumper
39 CPS145 Accessory Socket 24V
40 CPS350 Rear View Camera
41 CPS73 SPED
42 CPS213 Optional Inputs
43 CPS33 Side Console – Underfloor
44 CPS26 Service Switch
45 CPS27 Calibration Switch
46 CPS155 OPS
47 CPS28 Side Console Wash Pumps
38
MAST HARNESS CONNECTORS
1. CPS136-CONNECTOR FRONT-END 4. MAST HARNESS

2. CPP04-CONNECTOR FRAME 5. CONNECTOR PIN (SEE TABLE 14).
3. SOCKET
Figure 16. Mast Harness Connectors
Table 14. Mast Harness Connectors Pins

Connector Pin Connector Socket Description
Carriage Mast
--- X CAN shield
1 B CAN L
2 A CAN H
3-6 --- Not Connected
7 E +24V Power Supply Attachment Controls
8-11 --- Not Connected
12 D Ground
13 --- Not Connected
14 F Ground
15 C +24V Power Supply Attachment Lights
16 --- Not Connected
39
CLOSED CAB HARNESS CONNECTORS
Figure 17. Closed Cab Harness Connectors
Table 15. Legend for Closed Cab Harness Connectors

1 CRP117 AC Condenser – Side Console
2 CPS63 Closed Cab – Side Console
3 TS98 Ventilation Fan
4 TS44 RH Interior Light
5 TS43 RH Interior Light
6 CRP10 Condenser Unit
7 CRP64 RH Cab Lights
8 TS89 Radio Coms
9 TS90 Radio Coms
10 TS91 Right Speaker
40
Table 15. Legend for Closed Cab Harness Connectors (Continued)

11 TS92 Right Speaker
12 CPS75 Roof Wiper
13 TS93 Left Speaker
14 TS94 Left Speaker
15 CRP65 LH Cab Lights
16 CPS110 Radio Power
17 CPS111 Radio Sound
18 TS45 LH Interior Lights
19 TS46 LH Interior Lights
41
CAB UNDERFLOOR HARNESS CONNECTORS
Figure 18. Cab Underfloor Harness Connectors
Table 16. Legend for Cab Underfloor Harness Connectors

1 CPS30 Underfloor – Steer Column
2 CPS82 Diode Horn
3 CPS244 Horn
4 CPS245 Horn
5 CPS32 Inching Pedal
6 CPS78 Front Wiper
7 CPS31 Monotrol Pedal
8 CPS04 Throttle Pedal
9 CRP33 Underfloor – Side Console
42
STEERING COLUMN HARNESS CONNECTORS
Figure 19. Steering Column Harness Connectors
Table 17. Legend for Steering Column Harness Connectors

1 CRP30 Steer Column – Underfloor
2 CPS239 Steer Column
3 CPS29 Shift Lever
4 TS81 Master Warning
5 TS80 Master Warning
6 CPS83 Horn Button
7 TS67 Indicator Switch R
8 TS66 Indicator Switch L
9 TS64 Indicator Switch 54
43
POWER CAB TILT HARNESS CONNECTORS
Figure 20. Power Cab Tilt Harness Connectors
Table 18. Legend for Power Cab Tilt Harness Connectors

1 CPS233 Cab Tilt Switch
2 CPS234 Cab Tilt
3 CPS236 Diode Cab Tilt pump
4 CPS235 Cab Tilt Pump
5 CRP122 Cab Tilt – Frame
44
ARMREST HARNESS CONNECTORS
Figure 21. Armrest Harness Connectors
45
Table 19. Legend for Armrest Harness Connectors

1 CPS119 Move Twistlocks
2 CPS80 Horn Switch Armrest
3 CPS86 Front Wiper Switch
4 CPS90 Roof Wiper/Washer Switch
5 CPS91 Rear Wiper/Washer Switch
6 CPS89 Front Washer Switch
7 TS102 Armrest Ground
8 CPS85 Joystick
9 TS103 Armrest Ground
10 CPS144 Suspension Seat
11 CRP440 Seat Switch
12 CRP420 Seat Belt Switch
13 CPS81 Armrest – Side Console
CAB LIGHTS HARNESS CONNECTORS
Figure 22. Cab Lights Harness Connectors
NOTE: The connector numbers for the left-hand

and right-hand lights are equal.
Table 20. Legend for Cab Lights Harness Connectors

1 CPS41 Outer Flood Light
2 CPS42 Inner Flood Light
3 CPS43 LED Beacon
4 CPS64/CPS65 Cab Lights
46
Table 20. Legend for Cab Lights Harness Connectors (Continued)

5 CPS40 Rear Drive Lights
CAB AUTO TIP UP CONNECTORS
Figure 23. Cab Auto Tip Up Connectors
Table 21. Legend for Cab Auto Tip Up Connectors

1 CPS206 Fuse Box Auto Tip Up
2 CPS190 Relay Auto Tip Up
3 CPS137 Actuator Left Signals
4 CPS124 Actuator Left Power
5 CPS125 Actuator Right Signals
6 CPS126 Actuator Right Power
7 CRP201 Power Auto Tip Up
8 CRP202 Signals Auto Tip Up
47
ECM HARNESS CONNECTORS (TIER 3/STAGE IIIA)
Figure 24. ECM Harness Connectors (Tier 3/Stage IIIA)
Table 22. Legend for ECM Harness Connectors (Tier 3/Stage IIIA)
1 CRP02 Engine – ECM Signals
2 CPS58 CAN Termination Resistor
3 CPP03A Tier 3 Adapter
4 CPS05 ECM Power Tier 3
5 CRP88 WIF Sensor
48
ECM / AFTER TREATMENT HARNESS CONNECTORS (TIER 4F/STAGE IV)
Figure 25. ECM / After Treatment Harness Connectors (Tier 4F/Stage IV)
Table 23. Legend for ECM / After Treatment Harness Connectors (Tier 4F/Stage IV)
1 CPS133 Fan Clutch
2 CRP12 ECM Cross-Over
3 CRP03 ECM Tier 4
4 CPP03 Engine ECM Signals
6 CPS157 NOX Sensor DOC
7 CPS156 DOC Temp
8 CPS152 DEF Supply Module
9 CPS140 Hose Heating 3
12 CPS149 DEF Tank Heating Valve
14 CPS154 DEF Sensor
49
Table 23. Legend for ECM / After Treatment Harness Connectors (Tier 4F/Stage IV) (Continued)
15 CPS151 DEF Dosing Module
16 CPS153 SCR Temp
17 CPS159 NOX Sensor SCR
POWERTRAIN HARNESS CONNECTORS
Figure 26. Powertrain Harness Connectors
Table 24. Legend for Powertrain Harness Connectors

1 CPS161 Turbine Speed
2 CPS24 Internal Speed
3 CPP02 Powertrain-Frame
4 CPS22 Engine Speed
5 CPS162 XMSN Filter Switch
6 CPS160 XMSN Connector
7 TS13 Startermotor Solenoid
50
Table 24. Legend for Powertrain Harness Connectors (Continued)

8 CPS12 Convertor Temp
9 CPS23 Output Speed
51
REAR HARNESS CONNECTORS
Figure 27. Rear Harness Connectors
52
Table 25. Legend for Rear Harness Connectors

1 CRP68 Rear Frame
2 CPS54 Backup_Diode
3 CPS187 RH Reverse Lights
4 CPS69 RH Tail Lights
5 CPS72 LH Tail Lights
6 CPS188 LH Reverse Lights
7 CRP300 Frame Backup Alarm
WASH PUMP HARNESS CONNECTORS
Figure 28. Wash Pump Harness Connectors
Table 26. Legend for Wash Pump Harness Connectors

1 CRP28 Wash Pump
2 CPS20 Front Washer
3 CPS95 Rear Washer
4 CPS38 Roof Washer
53
TELEMETRY HARNESS CONNECTORS
Figure 29. Legend for Telemetry Harness Connectors FM1A
Table 27. Legend for Telemetry Harness Connectors FM1A

1 CRP237 FM1A E-Console
2 CPS164 FM1A
54
Figure 30. Legend for Telemetry Harness Connectors FM1B
Table 28. Legend for Telemetry Harness Connectors FM1B

1 CPS241 Buzzer
2 CPS240 FM1B
3 CRP238 FM1B E-Console
Figure 31. Legend for Telemetry Harness Connectors FM2A
Table 29. Legend for Telemetry Harness Connectors FM2A

1 CPS242 FM2A
2 CPS243 Card Reader
3 CRP239 FM2A E-Console
55
NOTES
56
TECHNICAL PUBLICATIONS
2200 SRM 2065 11/17

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ELECTRICAL SYSTEM

PART NO. 4204129 2200 SRM 2065

©2017 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

Series Code / Model Designation Reference Table

Series Code European Model Americas Model

Electrical Schematic and System Description

Table 1. Electrical Schematic Index

Figure 1. Schematic Example

Legend for Figure 1.

1. ROW LETTER - A 7. SHEET NAME - ENGINE

SCHEMATIC LOCATION NUMBER and a color indication of the wire insulation. If a

Each electrical wire is indicated by a solid line and

Table 2. Function ID Numbers

Table 2. Function ID Numbers (Continued)

Electrical Wire Colors

Table 3. Electrical Wire Colors

Wire Harnesses There are four different jumper options:

Figure 2. Harness Overview

Legend for Figure 2.

1. FRAME 12. ECM

ELECTRICAL CONNECTORS code. Terminators, that are not isolated when

Table 4. Connector Types

Connector Identification As the wires in a connector will relate to different

1. BATTERY DISCONNECT SWITCH

Figure 3. Main Fuses and Relays

Table 5. Legend for Main Fuses and Relays

Table 5. Legend for Main Fuses and Relays (Continued)

Legend for Figure 4.

Figure 4. Fuse Panel, Hydraulic Controller and

Table 6. Fuse Panel Overview

Table 6. Fuse Panel Overview (Continued)

Table 6. Fuse Panel Overview (Continued)

Figure 5. Relay Panel

Table 7. Relay Panel

Table 7. Relay Panel (Continued)

FLYBACK DIODES diode will not conduct at all. Sometimes a failed

Table 8. Flyback Diodes

CAN (CONTROLLER AREA NETWORK) Communication occurs through sending and

Figure 6. CANbus Circuit

Diagnostic can be recognized in Figure 7, Figure 8, and Table 9

CENTRAL WARNING LIGHTS AND

Table 9. Central Warning Lights and Instrument Panel

Table 9. Central Warning Lights and Instrument Panel (Continued)

Figure 8. Instrument Panel

Instrument Panel Connector

Figure 9. Instrument Panel Connector

Table 10. Pin Descriptions

Table 10. Pin Descriptions (Continued)

LCD DISPLAY Fault Code Mode

Figure 11. LCD Display Engine Fault Code

Figure 10. Hourmeter Display

Transmission Calibration Recorded faults are shown in batches of four

Fault Code Log Mode Clear

1. Apply the parking brake. An alternative procedure to return to normal mode

Wire Harness Identification and Connector Location

Table 11. Connector Overview

Table 11. Connector Overview (Continued)