Hyster H300HD2 Service & Repair Manual
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Hyster H300HD2 Service & Repair Manual

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

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Summary of Contents for Hyster H300HD2

  • Page 1 Hyster K019 (H300HD2, H330HD2, H360HD2, H360HD2-EC, H210-48HD2, H230-48HD2, H250-48HD2) Forklift Service Repair Manual...
  • Page 2 ELECTRICAL SYSTEM PART NO. 4133478 2200 SRM 1936...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 4: Table Of Contents

    Top Cab Harness Connectors ........................... 39 Side Console Harness Connectors ........................41 Cab Underfloor Harness Connectors ....................... 44 Armrest Harness Connectors ........................... 46 ECM Harness Connectors (Tier 3/Stage IIIA) ....................48 EAS/ECM Harness Connectors (Tier 4F/Stage IV) ..................49 DEF Tank Harness Connectors ........................50 ©2015 HYSTER COMPANY...
  • Page 5 Table of Contents TABLE OF CONTENTS (Continued) Powertrain Harness Connectors ........................51 Hoodspine Harness Tier 3/Stage IIIA Connectors ..................52 Hoodspine Harness Tier 4F/Stage IV Connectors ...................53 This section is for the following models:...
  • Page 6 2200 SRM 1936 Series Code / Model Designation Reference Table Series Code / Model Designation Reference Table This table consist of the following Series Codes used in this manual. Series European Model Americas Model Code K019 H13.00-16.00XM-6 H210-250-48HD2, H300-360HD2 K019EC H6.00-7.00XM-12EC H360HD2-EC L007...

  • Page 7: Series Code / Model Designation Reference Table

    General 2200 SRM 1936 General This manual provides general information on the would be a transmission solenoid, which is shown electrical system of B238, K019, and L007 lift Transmission Repair (ZF-WG161) trucks. This manual provides a link between the 1300SRM1456. electrical schematic and the actual location of the electrical components on the lift truck.

  • Page 8: General

    2200 SRM 1936 Electrical Schematic and System Description Table 1. Electrical Schematic Index Number Title Contents Index Sheet Title Index Main Power Battery, Key Switch Engine Common / T3 Engine controller and components T4F/EAS Fan Clutch, Tier 4F/Stage IV sensors DEF Sensors, DEF Supply Module XMSN Transmission controller and components...
  • Page 9 Electrical Schematic and System Description 2200 SRM 1936 Figure 1. Schematic Example...
  • Page 10 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...

  • Page 11: Schematic Location Number

    2200 SRM 1936 Electrical Schematic and System Description Legend for Figure 1 1. ROW LETTER - A 9. SHEET NAME - ENGINE 2. COLUMN NUMBER - 30 10. SPLICE - S761A 3. WIRE HARNESS NAME - SIDE CONSOLE 11. DIODE BLOCK 4.
  • Page 12 Electrical Schematic and System Description 2200 SRM 1936 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...

  • Page 13: Electrical Wire Colors

    2200 SRM 1936 Electrical Schematic and System Description Wires with the same number are interconnected There is a wire number overview in Diagrams through splices and connectors, and therefore have 8000SRM1938 for L007 and K019, and in Dia- the same electrical function. grams 8000SRM1982 for B238.
  • Page 14 Electrical Schematic and System Description 2200 SRM 1936 Figure 2. Harnesses Overview...
  • Page 15 2200 SRM 1936 Electrical Schematic and System Description Legend for Figure 2 1. FRAME 12. MAST 23. ECO-ELO/HIP 2. SIDE CONSOLE 13. FRONT-END 24. ARM REST 3. CAB POWER 14. MAST ECH 25. ECH ADAPTOR 4. CAB SIGNALS 15. FRONT LIGHTS LH 26.

  • Page 16: Harness Interconnection

    Electrical Schematic and System Description 2200 SRM 1936 Not shown in the harness overview and in the 3D- location [98, H]. This harness is to be plug- views are harnesses that are merely an extension ged into connector CPS650, which connects cord for some of the connectors, or jumpers that pin B with pin C.

  • Page 17: Connector Identification

    2200 SRM 1936 Electrical Schematic and System Description Pin numbers can be located on the inside of the con- Connector Identification nector next to the pin, on the backside of the con- nector next to the wires, or on the connector hous- Each connector is identified by the letter code of the ing.
  • Page 18 Electrical Schematic and System Description 2200 SRM 1936 Legend Code Description Value Connector Location Item BATTERY DISCONNECT SWITCH BATTERY DISCONNECT SWITCH LOCK BATTERY POWERBOARD ALTERNATOR 125A TS15/TS16 [38,A] RELAY GRID HEATER TS18/ [35,H] CPS166 CAB SUPPLY 125A TS10/TS01 [22,D] DEF HOSE HEATING CPS166 [52D] GRID HEATER...
  • Page 19 2200 SRM 1936 Electrical Schematic and System Description Legend Code Description Value Connector Location Item ENGINE ECM SUPPLY CPS178 [33,H] CAB TILT CPS178 [105,F] Figure 3. Main Fuses and Main Relays Legend for Figure 4 1. FUSE PANEL 1 2. FUSE PANEL 2 3.
  • Page 20 Electrical Schematic and System Description 2200 SRM 1936 Table 6. Fuse Panel Overview (Continued) Fuse Description Value Location Park Brake Solenoid [123,A] Instrumentation [120,B] Alternator On [34,A] Fuse Panel 2 Flood Lights [78,J] Strobe Light B+ [71,I] Brake Lights [82,H] Front Drive Lights [71,G] Interior Lights...

  • Page 21: Relays

    2200 SRM 1936 Electrical Schematic and System Description RELAYS Except for the main relays shown on Figure 3, all relays are installed on the relay panel that is loca- ted left of the fuse panel. See Figure 5 and Table 7. Figure 5.

  • Page 22: Flyback Diodes

    Electrical Schematic and System Description 2200 SRM 1936 Always check functionality of a flyback diode when FLYBACK DIODES a switch or relay has failed. In most cases a failed diode will not conduct at all. Sometimes a failed di- Some components induce current surges when they ode causes a short circuit.
  • Page 23 2200 SRM 1936 Electrical Schematic and System Description The can bus system includes the following control- The optional Electronic Climate Control has an in- lers: dependent control system that does not communi- cate through can bus wires 900 to 903. •...

  • Page 24: Troubleshooting

    Electrical Schematic and System Description 2200 SRM 1936 To test functionality of the individual warning Troubleshooting lights, switch the ignition from OFF to ON. All lights should light up for one second. As there are Most controllers have a memory that retains codes no serviceable components, the entire instrument for situations that occurred within their own con- panel must be replaced if found defective.
  • Page 25 2200 SRM 1936 Electrical Schematic and System Description Table 9. Legend for Central Warning Lights and Instrument Panel Item Description Pin Number Central Buzzer Warning Light Central Warning Lights ---- ---- ● ● Engine Coolant Temperature Gauge & High Coolant Temperature Warning Light Hour Meter / Active Fault code Display/ Fault Log ---- ----...

  • Page 26: Instrument Panel Connectors

    Electrical Schematic and System Description 2200 SRM 1936 Table 9. Legend for Central Warning Lights and Instrument Panel (Continued) Item Description Pin Number Central Buzzer Warning Light ● Battery Voltage Gauge & Low Battery Voltage ---- Warning Light ● Fuel Level Gauge & Low Fuel Level Warning light ---- ●...
  • Page 27 2200 SRM 1936 Electrical Schematic and System Description Table 10. Pin Descriptions Description Battery positive input (Diagnostic Switch) Seat switch input NOT USED Ground NOT USED NOT USED Park Brake Warning Light Input NOT USED NOT USED NOT USED Brake System Low Pressure Light Transmission Calibration Warning Light NOT USED Can - H...

  • Page 28: Lcd Display

    Electrical Schematic and System Description 2200 SRM 1936 • Hydraulic Control System (L007) LCD DISPLAY 1900SRM1935, Hydraulic Control System (K019) 1900SRM1964 and for B238 Hy- The LCD display can show values for different draulic Control System 2200SRM1980 for modes: hydraulic system fault codes. •...

  • Page 29: Access

    2200 SRM 1936 Electrical Schematic and System Description Clear To clear the fault codes logged in the display, pro- ceed as follows: 1. Access into the fault log mode. See Access. 2. Press-and-release the service switch three more cycles. This is a repetition of the access proce- Figure 13.

  • Page 30: Preparation

    Electrical Schematic and System Description 2200 SRM 1936 Replace the fuse after the repair has been made. Preparation The actual location of the fuse is indicated on Fig- 1. Have the Electrical Schematic available. See ure 4. Diagrams 8000SRM1938 for L007 and K019, and in Diagrams 8000SRM1982 for B238.

  • Page 31: Wire Harness Identification And Connector Location

    2200 SRM 1936 Wire Harness Identification and Connector Location Wire Harness Identification and Connector Location Below Figure 14 through Figure 23 show a 3D-view for verification. Related is Table 11, which indi- of most of the wire harnesses with their terminals cates the item and figure number to find a connec- and connectors.
  • Page 32 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 11. Connector Overview (Continued) Connector Description Location Harness CPS112 Tilt_Lever [137,J] Armrest CPS113 Lift_Lever [136,J] Armrest CPS114 Aux0_Lever [138,J] Armrest CPS115 Relays_AC [178,F] Sideconsole CPS116 HVAC_unit [173,F] Sideconsole CPS117 Sideconsole-AC_cond [173,C] Sideconsole CPS118...
  • Page 33 2200 SRM 1936 Wire Harness Identification and Connector Location Table 11. Connector Overview (Continued) Connector Description Location Harness CPS147 CAC_Temp [35,F] Hoodspine CPS148 Mast-Front_End [193,E] Mast CPS149 Aux 0 [197,A], [197,F] DFSSFP CPS15 Start_Enable/IGN [28,G], [31,E] Sideconsole CPS150 Aux 1 [197,C], [197,G] DFSSFP CPS151...
  • Page 34 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 11. Connector Overview (Continued) Connector Description Location Harness CPS178 Frame-PDM_box [32,I], [104,F] Frame CPS179 Inhibit_Aux1 [139,J] Armrest CPS18 Diode_Hydraulic_cont [138,D] Sideconsole roller CPS180 Alternator Connector [40,D] Frame CPS181 Lub_Display_Frame [183,D] Sideconsole CPS182 Lub_Display_Att...
  • Page 35 2200 SRM 1936 Wire Harness Identification and Connector Location Table 11. Connector Overview (Continued) Connector Description Location Harness CPS32 Inching_Pedal [68,I] Cab Underfloor CPS33 Sideconsole- [115,H], [154,G], [164,B], [26,I], [30,I], Sideconsole Underfloor [67,G], [82,G], [91,G] CPS34 Diode_Calibration [62,C] Sideconsole CPS35 Aux_Signals [108,D], [113,D], [147,F], [42,E] Frame...
  • Page 36 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 11. Connector Overview (Continued) Connector Description Location Harness CPS58 CAN_termination_res [39,F] Tier3 Adaptor istor CPS60 Frame- [86,C] Frame LH_Front_Lights CPS61 Frame- [86,E] Frame RH_Front_Lights CPS62 Frame-Hydraulics [42,F], [127,A], [131,F] Frame CPS63 Closed_Cab- [153,H], [163,G], [172,D], [73,G]...
  • Page 37 2200 SRM 1936 Wire Harness Identification and Connector Location Table 11. Connector Overview (Continued) Connector Description Location Harness CPS83 Horn_Button [160,B] Steer Column CPS84 Seat_Switch/ [135,I], [166,C] Sideconsole Horn_Relay CPS86 Front_Wiper_Switch [157,B], [158,B] Armrest CPS87 REGEN_EN/ [41,H], [41,I] Sideconsole DISABLE_SW CPS88 WIF_Sensor [36,E]...
  • Page 38 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 11. Connector Overview (Continued) Connector Description Location Harness CRP142 End_Resistor [137,G] Sideconsole CRP148 Front-End [194,G] Front End CRP14 Reverse_Light [88,I], [89,G] Tail Light CRP15 Rear Light [88,I], [89,G] Tail Light CRP155 OPS_JUMPER [127,E]...
  • Page 39 2200 SRM 1936 Wire Harness Identification and Connector Location Table 11. Connector Overview (Continued) Connector Description Location Harness CRP69/72 Tail_Lights [87,I] Tail light CRP70 Eng_Shut- [25,C], [27,C] Sideconsole down_Jumper CRP72 LH_Tail_Lights [87,J], [151,F] Tail light CRP74 Wiper_Rear- [150,G] Rear Wiper Extension Sideconsole CRP81 Sideconsole-Armrest...
  • Page 40 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 11. Connector Overview (Continued) Connector Description Location Harness TS21 Ground_Startermotor [36,A] Battery Cable - TS22 Buzzer [125,B] Side Console TS23 Groundpoint_Frame [36,A] Battery Cable - TS24 Groundpoint_Frame [36,A] Battery Cable - TS25 Buzzer [125,B]...

  • Page 41: Frame Harness Connectors

    2200 SRM 1936 Wire Harness Identification and Connector Location Table 11. Connector Overview (Continued) Connector Description Location Harness TS77 Starter_Motor+ [37,D] Battery Cable + TS80 Master_Warning [117,J] Steer Column TS81 Master_Warning [117,J] Steer Column TS82 Buzzer [114,G] Sideconsole TS83 Buzzer [114,G] Sideconsole TS84...
  • Page 42 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 12. Legend for Frame Harness Connectors Legend Connector Description CPS184 Lubrication Switch CPS68 Frame-Rear CRP01 AC Clutch CRS03 Frame-Engine TS19 Gridheater CPS183 Lubrication Pump CPS127 Frame-Hoodspine CPS07 Cab Signals CPS06 Cab Power CPS35 Aux Signals...

  • Page 43: Mast Ech Harness Connectors

    2200 SRM 1936 Wire Harness Identification and Connector Location Table 12. Legend for Frame Harness Connectors (Continued) Legend Connector Description CPS167 Fuel Sensor CPS101 Lift Solenoid1 CPS169 Pump Disable CPS122 Frame-Cab Tilt CPS88 WIF Sensor CPS62 TBAP Sensor to Engine TS07 Alternator-Ground TS20...
  • Page 44 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 13. Legend for Mast ECH Harness Connectors Legend Connector Description CPS141A Mast ECH-Frame CPS136 ECH Mast-ECH Attachment, See Table 14 Table 14. Mast ECH Harness Connector Pins Description Description 24V DC Seated LH Ground Seated LH...

  • Page 45: Top Cab Harness Connectors

    2200 SRM 1936 Wire Harness Identification and Connector Location TOP CAB HARNESS CONNECTORS Figure 16. Top Cab Harness Connectors...
  • Page 46 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 15. Top Cab Harness Connectors Item Connector Description CRP117 AC Condenser – Side Console CPS63 Closed Cab – Side Console TS98 Ventilation Fan TS44 RH Interior Light TS43 RH Interior Light CRP10 Condenser Unit CRP64...

  • Page 47: Side Console Harness Connectors

    2200 SRM 1936 Wire Harness Identification and Connector Location SIDE CONSOLE HARNESS CONNECTORS A. FUSES C. SWITCHES B. RELAYS (SEE RELAYS) Figure 17. Side Console Harness Connectors...
  • Page 48 Wire Harness Identification and Connector Location 2200 SRM 1936 Table 16. Legend for Side Console Harness Connectors Item Connector Description CPS28 Side Console Wash Pumps CRP35 Aux Signals CRP06 Cab Power CRP07 Cab Signals CPS107 DC/DC Convertor CPS18 Diode Hydraulic Controller CPS17 Diode Main Power CPS143...
  • Page 49 2200 SRM 1936 Wire Harness Identification and Connector Location Table 16. Legend for Side Console Harness Connectors (Continued) Item Connector Description TS83 Buzzer CPS73 SPED CRP142 CAN End Resistor CRP145 Accessory Socket 24V CPS27 Calibration Switch CPS182 Lubrication Display Attachment CRP175 ECO-eLO/HiP CPS181...

  • Page 50: Cab Underfloor Harness Connectors

    Wire Harness Identification and Connector Location 2200 SRM 1936 CAB UNDERFLOOR HARNESS CONNECTORS A. CAB UNDERFLOOR B. STEERING COLUMN Figure 18. Cab Underfloor Harness Connectors...
  • Page 51 2200 SRM 1936 Wire Harness Identification and Connector Location Table 17. Legend for Cab Underfloor Harness Connectors Item Connector Description CRP33 Underfloor – Side Console CPS04 Throttle Pedal CPS78 Front Wiper CPS100 Brake Light CPS31 Monotrol Pedal CPS82 Diode Horn TS68 Horn TS69...

  • Page 52: Armrest Harness Connectors

    Wire Harness Identification and Connector Location 2200 SRM 1936 ARMREST HARNESS CONNECTORS Figure 19. Armrest Harness Connectors...
  • Page 53 2200 SRM 1936 Wire Harness Identification and Connector Location Table 18. Legend for Armrest Harness Connectors Item Connector Description TS102 Armrest Ground CPS91 Rear Wiper/Washer Switch CPS90 Roof Wiper/Washer Switch CPS86 Front Wiper Switch CPS80 Horn Switch Armrest CPS118 Twist Locks CPS89 Front Washer Switch CPS179...

  • Page 54: Ecm Harness Connectors (Tier 3/Stage Iiia)

    Wire Harness Identification and Connector Location 2200 SRM 1936 ECM HARNESS CONNECTORS (TIER 3/ STAGE IIIA) Figure 20. ECM Harness Connectors (Tier 3/Stage IIIA) Table 19. Legend for ECM Harness Connectors (Tier 3/Stage IIIA) Item Connector Description CPP03 Tier 3 Adaptor CRP88 WIF Sensor CPS05...

  • Page 55: Eas/Ecm Harness Connectors (Tier 4F/Stage Iv)

    2200 SRM 1936 Wire Harness Identification and Connector Location EAS/ECM HARNESS CONNECTORS (TIER 4F/STAGE IV) Figure 21. EAS/ECM Harness Connectors (Tier 4F/Stage IV) Table 20. Legend for EAS/ECM Harness Connectors (Tier 4F/Stage IV) Item Connector Description CPS189 EAS – DEF CPS153 SCR Thermistor Controller CPS159...

  • Page 56: Def Tank Harness Connectors

    Wire Harness Identification and Connector Location 2200 SRM 1936 DEF TANK HARNESS CONNECTORS Figure 22. DEF Tank Harness Connectors Table 21. Legend for DEF Tank Harness Connectors Item Connector Description CPS146 Line Heater 1 (DEF Hose) CPS140 Line Heater 3 (DEF Hose) CPS141 Line Heater 2 (DEF Hose) CPS03...
  • Page 57 2200 SRM 1936 Wire Harness Identification and Connector Location POWERTRAIN HARNESS CONNECTORS Figure 23. Powertrain Harness Connectors Table 22. Legend for Powertrain Harness Connectors Item Connector Description CRS02 Powertrain – Frame CPS24 Internal Speed CPS161 Turbine Speed CPS162 XMSN Filter Switch CPS150 XMSN Connector CPS22...
  • Page 58 Wire Harness Identification and Connector Location 2200 SRM 1936 HOODSPINE HARNESS TIER 3/STAGE IIIA CONNECTORS Figure 24. Hoodspine Harness Tier 3/Stage IIIA Connectors Table 23. Legend for Hoodspine Harness Tier 3/Stage IIIA Item Connector Description CRP127 Hoodspine – Frame CPS97 Air Filter CPS103 Coolant Level...
  • Page 59 2200 SRM 1936 Wire Harness Identification and Connector Location HOODSPINE HARNESS TIER 4F/STAGE IV CONNECTORS Figure 25. Hoodspine Harness Tier 4F/Stage IV Connectors Table 24. Legend for Hoodspine Harness Tier 4F/Stage IV Item Connector Connector Description L007 B238/K019 CPS147 CPS147 CAC Temperature CPS103 CPS103...
  • Page 60 NOTES...
  • Page 62 TECHNICAL PUBLICATIONS 2200 SRM 1936 12/15 (8/15)

This manual is also suitable for:

H330hd2H360hd2H360hd2-ecH210-48hd2H230-48hd2H250-48hd2

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