ELECTRICAL SYSTEM

RS45-27CH, RS45-31CH, RS46-36CH,

RS46-40CH, RS46-41S CH, RS46-41L CH,
RS46-41LS CH, RS45-24IH, RS45-28IH,
RS46-33IH, RS46-37IH, RS46-38S IH, RS46-38L
IH, RS46-38LS IH (HR45-27, HR45-31,
HR45-36, HR45-40, HR45-41S, HR45-41L,
HR45-41LS) [B222]

PART NO. 1638191 2200 SRM 1259

 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
Warning Devices ................................................................................................................................................ 7
General ........................................................................................................................................................... 7
Description ..................................................................................................................................................... 8
Operator-Controlled Air Horn .................................................................................................................. 8
Reverse Warning Horns/Lights ................................................................................................................ 8
Warning Lights.......................................................................................................................................... 8
Strobe Lights ......................................................................................................................................... 8
Brake Lights.......................................................................................................................................... 10
Hazard Lights ....................................................................................................................................... 10
Replace ....................................................................................................................................................... 10
General .................................................................................................................................................. 10
Horns ..................................................................................................................................................... 10
Horn Relay ............................................................................................................................................ 10
Light Assemblies................................................................................................................................... 11
Flashing Unit ........................................................................................................................................ 11
Meters, Senders, and Switches ......................................................................................................................... 11
General ........................................................................................................................................................... 11
Diagrams, Schematics, or Arrangements ......................................................................................................... 11
Figure 7. Frame Harness.......................................................................................................................... 12
Figure 8. Transmission Harness .............................................................................................................. 14
Figure 9. Engine Harness......................................................................................................................... 16
Figure 10. Controller Harness.................................................................................................................. 18

This section is for the following models:

RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L

CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222]

©2007 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1259 Description

Description
The main part of the electrical system is the (senders, warning lights, etc.). See Figure 1 and
one-piece, main electrical wire harness. The batter- the section Instrument Panel Indicators and
ies provide the main electrical wire harness with Senders 2200 SRM 1234 for further information
electricity and then the main electrical wire har- regarding senders and indicator functions.
ness transmits the electricity to several components

Figure 1. Main Electrical Wire Harness

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Description 2200 SRM 1259

Legend for Figure 1

NOTE: SEE FIGURE 7 FOR DETAILED INFORMATION REGARDING CONNECTOR IDENTIFICATION.

Item No. Connector Description

1 C95 (positive lock receptacle trml - AMP) Hourmeter
2 C60 (positive lock receptacle trml - AMP) Fuel Sender
3 C230 (black 2-way dt socket housing - DEUTSCH) Stair Light Switch
4 CPS151 (0-47 hdp free socket housing - DEUTSCH) Controller 1
5 CPS152 (0-31 hdp free clamped socket housing - Controller 2
DEUTSCH)
6 C235 (black 2-way dt socket housing - DEUTSCH) Stair Light
7 CPS174 (black 12-way dt socket housing - DEUTSCH) Transmission Sensors
(Connector)
8 C150 (positive lock receptacle trml - AMP) Hydraulic Restriction
9 CPS193 (black 8-way dt socket housing - DEUTSCH) Hydraulic Valve
10 C20 (black 4-way dt socket housing - DEUTSCH) Front Left-Hand Headlights
11 CPS201 (black DIN46350-A housing - HIRSCHMANN) LH-2 LH
12 CPS202 (grey DIN46350-A housing - HIRSCHMANN) LH-1 LH
13 CPS197 (grey DIN46350-A housing - HIRSCHMANN) Press Trans 2
14 CPS196 (black DIN46350-A housing - HIRSCHMANN) Press Trans 1
15 C25 (90 , 6.35 Faston terminal - LABINAL) Left-Hand Hub Temperature
16 C15 (90 , 6.35 Faston terminal - LABINAL) Right-Hand Hub Temperature
17 C155 (Ø 5.3 mm (0.209 in.) ring terminal csa -G and H) Brake Filter
18 CPS166 (0-18 hd socket housing - DEUTSCH) Power Train (Connector)
19 C250 (Ø 10.6 mm (0.417 in.) ring csa - G and H) ECM Ground
20 CRP208 (0-23 hdp jam pin housing - DEUTSCH) Attachment Signal
CRP207 (0-16 hdp socket housing - DEUTSCH) Power Train Power
CRP205 (hdp jam pin housing - DEUTSCH) Power Train Signals 1
CRP206 (0-31 hdp socket housing - DEUTSCH) Power Train Signals 2
CRP204 (3-way dt pin housing with flange - DEUTSCH) Can Conn Powertrain
CRP203 (3-way dt pin housing with flange - DEUTSCH) Can Conn - LM 1
21 C65 (4-way 090 sealed housing - SUMITOMO) Relay Diode
22 C85 (Ø 5.3 mm (0.209 in.) and 8.4 mm (0.331 in.) ring Starter Relay
terminal csa - G and H)
23 C130 (Ø 10.5 mm (0.413 in.) ring terminal csa - G and H) Disconnect Switch
24 C275 (Ø 8.4 mm (0.331 in.) ring terminal csa - G and H) Alternator Fuse
25 C135 (black 4-way dt socket housing - DEUTSCH) Fuse Box
26 C240 (black 2-way dt socket housing - DEUTSCH) Stair Light

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2200 SRM 1259 Description

Item No. Connector Description

27 C10 (black 4-way dt socket housing - DEUTSCH) Front Right-Hand Headlights
28 CPS198 (grey DIN46350-A housing - HIRSCHMANN) Press Trans 5
29 CPS199 (black DIN46350-A housing - HIRSCHMANN) Press Trans 6
30 CPS181 (black DIN46350-A housing - HIRSCHMANN) LH-2 RH
31 CPS184 (grey DIN46350-A housing - HIRSCHMANN) LH-1 RH
32 C105 (Ø 13 mm (0.512 in.) ring terminal csa - G and H) Ground
C115 (Ø 13.5 mm (0.531 in.) ring terminal csa - G and H) +24V
33 C170 (3-way dt pin housing - DEUTSCH) Can Conn
34 C400 (0-47 hd socket housing - DEUTSCH) Engine Control
C390 (0-31 hd socket housing - DEUTSCH) Engine Harness
C110 (16-way bsa connector - DEUTSCH) Valve
35 CPS187 (2-way dtm housing M with endcap - DEUTSCH) Engine Compartment Light
36 CPS195 (black 6-way dt socket housing - DEUTSCH) Powered Sliding Cab
CPS189 (3-way dt socket housing - DEUTSCH) Proximity Switch
C35 (4-way 090 sealed housing - SUMITOMO) Diode Alarm
37 C215 (Ø 5.3 mm (0.209 in.) ring terminal csa - DEUTSCH) Radiator Coolant
38 C220 (black 2-way timer socket housing A/B - AMP) Air Filter
39 CPS200 (8-way dtm socket housing - DEUTSCH) Boom Valves
40 C210 (black 6-way dt socket housing - DEUTSCH) Rear Lights
41 CPS188 (connector housing female - ILME) Boom 1 - Boom Lights
CPS190 (16-way insert housing (screw in) - ILME) Boom 2 - Std Spreader (1)
CPS191 (NM16 housing - ILME) Boom 3 - Std Spreader (2)
CPS192 (16-way insert housing (screw in) - ILME) Boom 4 - IH

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Description 2200 SRM 1259

A power train harness is connected to the main elec- A controller wire harness is connected to the main
trical wire harness at location CPS166 and a trans- wire harness at location CPS15 and CPS152. See
mission harness is connected to the mail electrical Figure 3.
wire harness at location CPS174. See Figure 1. The
power train and transmission harnesses provide the See the section Stabilizer 2120 SRM 1361 for
engine and transmission with electricity. See Fig- further information regarding the Stabilizer (if
ure 2 and the section Instrument Panel Indica- equipped).
tors and Senders 2200 SRM 1234 for further infor-
mation regarding senders and indicator functions.

Figure 2. Power Train Wire Harness

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2200 SRM 1259 Description

Legend for Figure 2

Item No. Connector Description

1 CRP166 (16-way jam pin housing - DEUTSCH) Frame Harness - Transmission
Connector
2 TS167 (Ø 13.0 mm (0.512 in.) ring csa - G and H) Ground
TS168 (Ø 6.4 mm (0.252 in.) ring csa - UTA) Start
3 TS169 ( 4.0 mm (0.157 in.) socket terminal - SUMITOMO) AC
4 TS170 (Ø 6.5 mm (0.256 in.) ring csa - G and H) Alternator Ground
TS171 (taxi asm connector m/p - DELPHI) Alternator Signals
TS172 (Ø 8.4 mm (0.331 in.) ring csa - G and H) Alternator +VE
5 TS173 (Ø 5.3 mm (0.209 in.) ring csa - G and H) Engine Oil Pressure
6 CRP174 (black 12-way dt pin housing T.wall - DEUTSCH) Frame Harness - Power Train
Connector
7 CPS179 (black 3-way superseal female - AMP) Engine Speed
8 CPS175 ( 6.3 mm (0.252 in.) receptacle - AMP) Temperature switch
9 CPS176 (black 2-way superseal female - AMP) Output Speed
10 CPS177 (black 2-way superseal female - AMP) Drum Speed
11 CPS178 (black 2-way superseal female - AMP) Turbine Speed

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Description 2200 SRM 1259

Figure 3. Controller Wire Harness

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2200 SRM 1259 Warning Devices

Legend for Figure 3

Item No. Connector Description

1 CPS159 (black 3-way dt socket housing t-wall - DEUTSCH) Diagnostic Plug - MIDAC
2 CPS158 (black 3-way dt socket housing t-wall - DEUTSCH) Diagnostic Plug - XMSN
CPS160 (black 2-way dt socket housing - DEUTSCH) Service Power
CPS161 (4-way flanged socket housing CPCS12E11 - AMP) XMSN Diagnostic
3 CPS162 (positive lock receptacle TRML - AMP) Pre-Excitation
4 CPS155 (metri pack 18-way connector - DELPHI) Transmission Controller
5 CPS156 (metri pack 30-way connector - DELPHI) Transmission Controller
6 CPS165 (black contra switch 10-way housing - Switch Sliding Cab
CARLINGSWITCH)
7 CRP152 (0-31 hdp jam pin housing - DEUTSCH) Frame Harness - Controller 2
connector
8 CRP151 (0-47 hdp jam pin housing - DEUTSCH) Frame Harness - Controller 1
connector
9 CPS700 (relay socket - G & H) Speed Limiter Relay
10 CPS610 (relay socket - G & H) Alternate Idle Relay
11 CPS163 (black 24-way female housing - FCI) MIDAC 256
12 CPS157 (4-way 090 sealed housing - SUMITOMO) Resistor 1
CPS615 (4-way 090 sealed housing - SUMITOMO) Resistor 2
CPS616 (4-way 090 sealed housing - SUMITOMO) Resistor 3
13 CPS164 (black 3-way dt socket housing t-wall - DEUTSCH) Terminating Resistor
14 CPS166 (6-way dt socket housing - DEUTSCH) Harness Jumper

Warning Devices
GENERAL illuminated or by energizing a buzzer to sound. A
reverse warning horn automatically sounds a warn-
Electrical warning devices used on the lift truck are ing that the equipment is moving in the reverse
as follows: direction. Warning lights automatically illuminate
• Operator-controlled air horn to warn personnel that the equipment is operating
• Reverse warning horn/lights in a special way. Warning lights are also used to
• Warning lights warn personnel that the equipment is near. Some
of these warning devices need to be energized and
Operator-controlled horns permit the operator to
de-energized at a fast rate. A separate flashing
warn personnel that the equipment is near. System
device does this. Most equipment does not need each
warning lights and buzzers make an important sys-
of these warning devices.
tem condition known to the operator. They do this
by illuminating an indicator that is not normally

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Warning Devices 2200 SRM 1259

DESCRIPTION the horn. The switch is on the steering column. The

horn is most frequently located under the back of the
Operator-Controlled Air Horn equipment. The relay is located in the side console.

The operator-controlled horn has a horn switch, a re-

lay, and a horn. See Figure 4. The horn switch en-
ergizes the relay to close the power contacts and en-
ergize the horn. This makes the horn sound. The
lower sound level of equipment operation results in
a horn that is less loud and uses less current. This
horn current is directly controlled by the switch. The
horn switch is located at the operator’s position. The
horn is installed underneath the cab. The horn relay
is installed in the side console.

1. HORN
2. TRANSMISSION SHIFTER
3. RELAY
4. BASE

Figure 5. Reverse Warning Horn Components

Warning Lights
The following types of warning lights are attached to
the lift truck:
• Strobe Lights
• Brake Lights
• Hazard Lights

Strobe Lights

These warning lights indicate a particular type of

1. 24V COMPRESSOR equipment operation. See Figure 6. They warn oth-
2. AIR HORN ers that the equipment is in the area or that the op-
erator’s view is limited by the particular operation.
Figure 4. Operator-Controlled Horns These lights can be flashing lights. A switch and a
flashing device are used to operate the flashing light.
Reverse Warning Horns/Lights The flashing device is part of the light assembly. The
The reverse warning horn is operated by the shifter. light can be connected to operate when the key switch
See Figure 5. They use a flashing device to make is in the ON position. They can also be connected
the sound of the horn begin and end repeatedly. This to operate with a particular operation of the equip-
flashing device is part of the reverse warning horn. ment such as: Equipment is set for reverse opera-
The switch is energized to the ON position when the tion. When connected in this way, a separate switch
equipment is set to operate in the reverse direction. is operated automatically by the equipment function.
The switch will then energize the relay to energize

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2200 SRM 1259 Warning Devices

Item No. Connector Description

1 N/A Working Light (Halogen or HID)
2 N/A Rotating Flashing Light
3 N/A Cab
4 C10 (black 8 way dt socket housing – DEUTSCH) Mate to connector on cab
assembly.
5 C30 (4 mm socket terminal and 4 mm male bullet terminal Beacon/Strobe
– SUMITOMO)
6 C20 (black 2 way dt socket housing – DEUTSCH) Rear Drive Light
7 C50 (black 2 way dt socket housing – DEUTSCH) Outer Front Flood Light
8 C40 (black 2 way dt socket housing – DEUTSCH) Inner Front Flood Light

Figure 6. Light Assemblies

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Warning Devices 2200 SRM 1259

Brake Lights 1. Verify the key switch is in the OFF position or

the battery is disconnected.
These warning lights indicate that the speed of the
lift truck will slow down. They warn others that the 2. Mark the horn wires for reconnection and discon-
lift truck will stop or decrease the speed severely. nect them.
These lights are positioned on the backside of the lift
truck and will be activated by operating the brake 3. Remove the screws, nuts, or other items fasten-
pedal. ing the horn to the equipment.

Hazard Lights 4. Remove the horn and install the replacement.

These warning lights will be used when the lift truck 5. Tighten the screws, nuts, or other items fasten-
has problems with driving or when the lift truck is ing the horn to the equipment.
placed at a dangerous location.
6. Connect the wires, as marked, to the electrical
terminals.
Replace
Horn Relay
General
The horn relay is located in the side console in the
Horns, light assemblies, flashing devices, buzzers,
cab. If necessary, follow the horn electrical leads to
and switches are not repairable items. The most ac-
find the relay. Replace the relay as follows:
curate and usually easiest checks for proper opera-
tion of individual items is direct replacement. How- 1. Disconnect the battery or batteries to remove all
ever, the most common cause of failure are poor con- voltage from the terminals.
nections or defective or improper wiring. Also, there
are no adjustments to perform. Therefore, only re- 2. Mark the wires for reconnection.
placement procedures are given. Before replacing an
item, verify the following: 3. Disconnect the wires.
• Other electrical circuits are operating correctly.
4. Remove the screws, nuts, or other items fasten-
• Battery is fully charged and the cable terminals are
ing the unit to the equipment.
clean and correctly connected.
• Wiring and connections to device are tight and in 5. Remove the unit and install the replacement
good condition. unit.
Horns 6. Tighten the screws, nuts, or other items fasten-
ing the unit to the equipment.
CAUTION
7. Connect the marked wires to the correct termi-
Audible alarms and horns have various levels
nals or connectors.
of output. Be certain that any replacement
alarm or horn has an output that can be heard
in the area where the lift truck will be used.

10
2200 SRM 1259 Diagrams, Schematics, or Arrangements

Light Assemblies NOTE: Some assemblies have no access to the wire

terminals after it is fastened to the equipment. If so,
1. Disconnect the battery or batteries to remove all do Step 7 before Step 6.
voltage from the terminals.
6. Install the screws, nuts, or other items to fasten
NOTE: Do Step 4 before Step 2 and Step 3 if there is the assembly to the equipment.
no access to assembly wire terminals.
7. Connect the marked wires to the correct termi-
2. Mark the wires for reconnection. nals or connectors.
3. Disconnect the wires at the wire connectors or Flashing Unit
light terminals.
Replace the flashing unit by holding the base and
4. Remove the screws, nuts, or other items fasten- pulling the unit until the pins are out of the base
ing the assembly to the equipment. clips. Align the replacement flashing unit pins. Push
the unit into position on the base.
5. Remove the assembly and put the new assembly
in the correct position.

Meters, Senders, and Switches

GENERAL 1. Make sure that the other meters and electrical
circuits are operating correctly.
Meters, senders, and switches cannot be repaired.
The fan and wiper motors of the operator compart- 2. Make sure that the battery is charged, correctly
ment also cannot be repaired. These components are installed, and the cable terminals are clean and
replaced when they are defective. The most com- tight.
mon cause of failure is a bad connection or defective
wiring. There are no adjustments. See the section 3. Make sure that the wires and connections to the
Instrument Panel Indicators and Senders 2200 unit are tight and in good condition.
SRM 1234 for replacement procedures. Before a me-
ter or sender is replaced, make the following checks:

11
Diagrams, Schematics, or Arrangements 2200 SRM 1259

12
2200 SRM 1259 Diagrams, Schematics, or Arrangements

Figure 7. Frame Harness

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Diagrams, Schematics, or Arrangements 2200 SRM 1259

14
2200 SRM 1259 Diagrams, Schematics, or Arrangements

Figure 8. Transmission Harness

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Diagrams, Schematics, or Arrangements 2200 SRM 1259

16
2200 SRM 1259 Diagrams, Schematics, or Arrangements

Figure 9. Engine Harness

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Diagrams, Schematics, or Arrangements 2200 SRM 1259

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2200 SRM 1259 Diagrams, Schematics, or Arrangements

Figure 10. Controller Harness

19
 NOTES

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 TECHNICAL PUBLICATIONS

2200 SRM 1259 7/07 (8/06)(5/06) Printed in United Kingdom