ELECTRICAL SYSTEM

H40.00-52.00XM-16CH

(H1050, 1150HD-CH) [E117]

PART NO. 1578950

2200 SRM 1119

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

General ...............................................................................................................................................................

Description .........................................................................................................................................................

Warning Devices ................................................................................................................................................

General ...........................................................................................................................................................

Description .....................................................................................................................................................

Operator-Controlled Horns .......................................................................................................................

Reverse Warning Horns/Lights ................................................................................................................

Warning Lights..........................................................................................................................................

Beacon Lights........................................................................................................................................

Brake Lights..........................................................................................................................................

Hazard Lights .......................................................................................................................................

Replace .......................................................................................................................................................

General ..................................................................................................................................................

Horns .....................................................................................................................................................

Horn Relay ............................................................................................................................................

Warning Lights/Bulbs ...........................................................................................................................

Light Assemblies...................................................................................................................................

Flashing Unit ........................................................................................................................................

Meters, Senders, System Warning Lights, and Switches ................................................................................

General ...........................................................................................................................................................

Alternator ...........................................................................................................................................................

General ...........................................................................................................................................................

Description .....................................................................................................................................................

Charging System Indicator and Accessory Power Supply ......................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Troubleshooting..................................................................................................................................................

Diagrams, Schematics, or Arrangements .........................................................................................................

Figure 7. Main Wire Harness ...................................................................................................................

This section is for the following models:

H40.00-52.00XM-16CH (H1050, 1150HD-CH) [E117]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

2200 SRM 1119

Description

General

This section has the description and repair procedures for electrical components. The instructions for replacing
parts of the warning devices is included. Also, the instructions for removal and installation of the alternator
is included in this section.

Description

The main part of the electrical system is the one piece
main electrical wire harness. The batteries provide
the main electrical wire harness with electricity and
then the main electrical wire harness transmits the
electricity to several components (senders, warning

lights, etc.). See Figure 1 and the section Instru-
ment Panel Indicators and Senders 2200 SRM
1110 for further information regarding senders and
indicator functions.

Figure 1. Main Electrical Wire Harness

Description

2200 SRM 1119

Legend for Figure 1

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

Item No.

Connector

Description

C120 (black 2-way dt socket housing – DEUTSCH)

Light for night fuel filling

C95 (6.35 Faston terminal – LABINAL)

Hourmeter

C60 (6.35 Faston terminal – LABINAL)

Fuel Sender

C230 (black 3-way dt socket housing – DEUTSCH)

Stair Light Switch

C190 (black 4-way dt socket housing – DEUTSCH)

Lubrication

C235 (black 2-way dt socket housing – DEUTSCH)

Stair Light

C220 (black 2-way j timer socket housing A/B – AMP)

Air Filter

C20 (black 4-way dt socket housing – DEUTSCH)

Front Left-Hand Headlights

C40 (black 2-way j timer socket housing A/B – AMP)

Aux 1

C50 (green 2-way j timer socket housing A/B – AMP)

Aux 2

C30 (black 2-way dt socket housing – DEUTSCH)

Park Brake Solenoid

C150 (6.35 Faston terminal – LABINAL)

Hydraulic Restriction

C25 (90 , 6.35 Faston terminal – LABINAL)

Left-Hand Hub Temperature

C100 (female housing connector – ILME)

Mast 2

C90 (female housing connector – ILME)

Mast 1

C15 (90 , 6.35 Faston terminal – LABINAL)

Right-Hand Hub Temperature

C10 (black 4-way dt socket housing – DEUTSCH)

Front Right-Hand Headlights

C155 (Ø 5.3 mm (0.208 in.) ring terminal csa – G and H)

Brake Filter

C130 (Ø 10.5 mm (0.413 in.) ring terminal csa– G and H)

Disconnect Switch

C275 (Ø 8.4 mm (0.331 in.) ring terminal csa– G and H)

Alternator Fuse

C135 (black 4-way dt socket housing – DEUTSCH)

Fuse Box

C85 (Ø 5.3 mm (0.208 in.) and Ø 8.4 mm (0.331 in.) ring
terminal csa– G and H)

Starter Relay

C160 (black 2-way dtp pin housing – DEUTSCH)

Hydraulic Tank Heater

C240 (black 2-way dt socket housing – DEUTSCH)

Stair Light

C250 (Ø 10.6 mm (0.417 in.) ring terminal csa– LABINAL)

ECM (Engine Control Module)
Ground

C80 (black 12-way dt socket housing – DEUTSCH)

Transmission Harness

C170 (Ø 5.3 mm (0.208 in.) ring terminal csa – G and H)

Engine Oil Pressure

C270 (Ø 6.6 mm (0.260 in.) ring terminal csa– LABINAL)

Alternator +VE

C280 (Ø 5.3 mm (0.208 in.) ring terminal csa – G and H)

Alternator Signals

C290 (Ø 6.6 mm (0.260 in.) ring terminal csa– LABINAL)

Alternator Ground

C305 ( 4.0 mm (0.157 in.) socket terminal – SUMITOMO)

2200 SRM 1119

Warning Devices

Item No.

Connector

Description

C400 (0-47 hd socket housing – DEUTSCH)

Engine Control

C390 (0-31 hd socket housing – DEUTSCH)

Engine Harness

C260 (56 series single housing – DELPHI)

Water Temperature Sender

C105 (Ø 13.5 mm (0.531 in.) ring terminal csa– G and H)

Ground

C110 (Ø 6.4 mm (0.252 in.) ring terminal csa – UTA)

Start

C115 (Ø 13.5 mm (0.531 in.) ring terminal csa– G and H)

+24V

C215 (Ø 5.3 mm (0.208 in.) ring terminal csa – G and H)

Radiator Coolant

C210 (black 6-way dt socket housing – DEUTSCH)

Rear Lights

C180 (black 4-way dt socket housing – DEUTSCH)

Wash Pumps

C395 (black 6-way dt socket housing – DEUTSCH)

AC Condenser

C410 (6-way housing – AMP)

Accelerator. Pedal

C144 (60 (0-12-48)-way drb socket housing key A -
DEUTSCH)

Cab Signals

C140 (0-16 hdp free socket clamped housing – DEUTSCH)

Cab Supplies

C405 (0-23 hdp free socket housing – DEUTSCH)

Cab CH

Warning Devices

GENERAL

Electrical warning devices used on the lift truck are
as follows:
• Operator-controlled horns
• Reverse warning horns/lights
• Warning lights

Operator-controlled horns permit the operator to
warn personnel that the equipment is near. System
warning lights and buzzers make an important sys-
tem condition known to the operator. They do this
by illuminating an indicator that is not normally
illuminated or by energizing a buzzer to sound.
Reverse warning horns automatically sound a warn-
ing that the equipment is moving in the reverse
direction. Warning lights automatically illuminate
to warn personnel that the equipment is operating
in a special way. Warning lights are also used to
warn personnel that the equipment is near. Some

of these warning devices need to be energized and
de-energized at a fast rate.

A separate flashing

device does this. Most equipment does not need each
of these warning devices.

DESCRIPTION

Operator-Controlled Horns

The operator controlled horn has a horn switch, a re-
lay, and horn. See Figure 2. The horn switch ener-
gizes the relay to close the power contacts and ener-
gize 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 cur-
rent is directly controlled by the switch. The horn
switch is located at the operators position. The horn
is frequently installed near the front of the equip-
ment. The horn relay is installed in the side console.

Warning Devices

2200 SRM 1119

A. ELECTRICAL HORN
B. AIR HORN

ELECTRICAL HORN

COMPRESSOR, 24V

AIR HORN

Figure 2. Operator-Controlled Horns

Reverse Warning Horns/Lights

The reverse warning horns are operated by a switch.
See Figure 3. They often use a flashing device to
make the sound of the horn begin and end repeat-
edly. This flashing device is part of the reverse warn-
ing horn. The switch is energized to the ON posi-
tion when the equipment is set to operate in the re-
verse direction. The switch will then energize the re-
lay to energize the horn. The switch is usually near
the transmission or shift linkage. The horn is most
frequently located under the back of the equipment.
The relay is located in the side console.

HORN

TRANSMISSION
SWITCH

FLASHER

BASE

Figure 3. Reverse Warning Horn Components

Warning Lights

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

Beacon Lights

These warning lights indicate a particular type of
equipment operation. See Figure 4. They warn oth-
ers that the equipment is in the area or that the op-
erators view is limited by the particular operation.
These lights can be flashing lights or lights that look
as if they are flashing. A switch and a flashing device

2200 SRM 1119

Warning Devices

are used to operate the flashing light. The flashing
device is part of the light assembly. Lights that look
as if they are flashing have a disc that rotates around
the bulb. The disc directs the illumination away from
its surface. As the disc rotates, the directed illumina-
tion touches a fixed point once each revolution. This
makes the light look as if it flashes. Either type of

light can be connected to operate when the key switch
is in the ON position. They can also be connected to
operate with a particular operation of the equipment
such as: (1) equipment is set for reverse operation
or (2) operators platform is above 610 mm (24 in.).
When connected in this way, a separate switch is op-
erated automatically by the equipment function.

Item

No.

Connector

Description

N/A

Working Light (Halogen or HID)

N/A

Rotating Flashing Light

N/A

Cab

C10 (black 8 way dt socket housing – DEUTSCH)

Mate to connector on cab assembly.

C30 (4 mm socket terminal and 4 mm male bullet terminal
– SUMITOMO)

Beacon/Strobe

C20 (black 2 way dt socket housing – DEUTSCH)

Rear Drive Light

C50 (black 2 way dt socket housing – DEUTSCH)

Outer Front Flood Light

C40 (black 2 way dt socket housing – DEUTSCH)

Inner Front Flood Light

Figure 4. Light Assemblies

Warning Devices

2200 SRM 1119

Brake Lights

These warning lights indicate that the speed of the
lift truck will slow down. They warn others that the
lift truck will stop or decrease the speed severely.
These lights are positioned on the backside of the lift
truck and will be activated by operating the brake
pedal.

Hazard Lights

These warning lights will be used when the lift truck
has problems with driving or when the lift truck is
placed at a dangerous location.

Replace

General

Horns, light assemblies, flashing devices, buzzers,
and switches are not repairable items. The most ac-
curate and usually easiest checks for proper opera-
tion of individual items is direct replacement. How-
ever, the most common cause of failure are poor con-
nections or defective or improper wiring. Also, there
are no adjustments to perform. Therefore, only re-
placement procedures are given. Before replacing an
item, verify the following:
• Other electrical circuits are operating correctly.
• Battery is fully charged and the cable terminals are

clean and correctly connected.

• Wiring and connections to device are tight and in

good condition.

Horns

CAUTION

Audible alarms and horns have various levels
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.

Verify the key switch is in the OFF position or
the battery is disconnected.

Mark the horn wires for reconnection and discon-
nect them.

Remove the screws, nuts, or other items fasten-
ing the horn to the equipment.

Remove the horn and install the replacement.

Tighten the screws, nuts, or other items fasten-
ing the horn to the equipment.

Connect the wires, as marked, to the electrical
terminals.

Horn Relay

The horn relay, if used, is frequently located in the
side console in the cab. If necessary, follow the horn
electrical leads to find the relay. Replace the relay as
follows:

Disconnect the battery or batteries to remove all
voltage from the terminals.

Mark the wires for reconnection.

Disconnect the wires.

Remove the screws, nuts, or other items fasten-
ing the unit to the equipment.

Remove the unit and install the replacement
unit.

Tighten the screws, nuts, or other items fasten-
ing the unit to the equipment.

Connect the marked wires to the correct termi-
nals or connectors.

Warning Lights/Bulbs

Access the different assemblies/bulbs as follows,
see Figure 4 and Figure 5:

a. Large instrument panel assemblies – push

the assembly base toward the lens and turn.
Do not let spring fall.

b. Small instrument panel assemblies – twist

the bulb assembly free of the lens tube.

Exterior assemblies - remove the screws fas-
tening the lens.

Push the bulb toward the base while turning the
bulb to the left.

After the bulb is released, slowly remove it and
check position of pins on the base of the bulb.

2200 SRM 1119

Meters, Senders, System Warning Lights, and Switches

BULB ASSEMBLY

BULB PINS

BULB

LENS TUBE

LENS

LENS PIN

BASE

SLOT

Figure 5. Instrument Panel Lights Replacement

Position new bulb so that the pin position is the
same.

Align pins with slots in light assembly.

Push the bulb toward the base. Turn to the right
until locked.

Light Assemblies

Disconnect the battery or batteries to remove all
voltage from the terminals.

NOTE: Do Step 4 before Step 2 and Step 3 if there is
no access to assembly wire terminals.

Mark the wires for reconnection.

Disconnect the wires at the wire connectors or
light terminals.

Remove the screws, nuts, or other items fasten-
ing the assembly to the equipment.

Remove the assembly and put the new assembly
in the correct position.

NOTE: Some assemblies have no access to the wire
terminals after it is fastened to the equipment. If so,
do Step 7 before Step 6.

Install the screws, nuts, or other items to fasten
the assembly to the equipment.

Connect the marked wires to the correct termi-
nals or connectors.

Flashing Unit

Replace the flashing unit by holding the base and
pulling the unit until the pins are out of the base
clips. Align the replacement flashing unit pins. Push
the unit into position on the base.

Meters, Senders, System Warning Lights, and Switches

GENERAL

Meters, senders, and switches cannot be repaired.
The fan and wiper motors of the operator compart-
ment also cannot be repaired. These components are
replaced when they are defective. The most com-
mon cause of failure is a bad connection or defective
wiring. There are no adjustments. See the section
Instrument Panel Indicators and Senders 2200
SRM 1110 for replacement procedures. Before a me-
ter or sender is replaced, make the following checks:

Make sure that the other meters and electrical
circuits are operating correctly.

Make sure that the battery is charged, correctly
installed, and the cable terminals are clean and
tight.

Make sure that the wires and connections to the
unit are tight and in good condition.

NOTE: See your dealer of Cummins engines for
starter repair.

Alternator

2200 SRM 1119

Alternator

GENERAL

CAUTION

Always move the battery disconnect switch
to the disconnected position before making
repairs. The diodes and resistors in the elec-
trical system can be damaged if the following
cautions are not followed:
• Do not disconnect the battery when the en-

gine is running. The voltage surge can dam-
age the diodes and resistors in the electrical
system.

• Do not disconnect an electric wire before the

engine is stopped and the switches are OFF.

• Do not cause a short circuit by connection

of the electric wires to the wrong terminals.
Verify correct identification is made of the
wire before it is connected.

• Verify the battery is the correct voltage and

polarity before it is connected.

• Do not check for current flow by making a

spark because the electronic components can
be damaged.

• These lift trucks have a 24-volt electrical sys-

tem (two 12-volt batteries in series). Use cau-
tion when working on the electrical system.

CAUTION

When using an arc welder, always disconnect
the ground lead from the lift truck battery to
prevent alternator or battery damage. Attach
the welding ground clamp as close to the weld
area as possible to prevent welding current
from damaging the bearings.

This section has the remove and install procedures
for the alternator with an internal regulator. Contact
your dealer for Cummins engines for starter repair.
The replacement procedures for meters and gauges is
in the section Instrument Panel Indicators and
Senders 2200 SRM 1110. The electrical schematic
diagram for the lift truck is shown in the section Di-
agrams 8000 SRM 1153.

DESCRIPTION

The Delco Remy model 22-SI alternator generates
a 24-volt alternating current when the engine is
running. See Figure 6. The alternating current is
changed to a 70-ampere direct current by six silicon

diodes contained in a rectifier assembly (rectifier
bridge).

The diode set continues the process of

changing the alternating current to direct current
(DC). The rectifier bridge, diode set, and regulator
are all mounted in the end frame for the slip rings.

Output from the alternator is controlled by the regu-
lator. The regulator controls the alternator output
by controlling the voltage of the field. Voltage for
the regulator is supplied as part of the output volt-
age from the alternator.

The alternator has these main parts:
• Stator
• Rotor
• Two end frames
• Solid-state voltage regulator

The direct current, from the diodes, flows to the out-
put or battery (BAT, B+) terminal. The voltage is con-
trolled by the amount of current flowing through the
field winding in the alternator and the rpm of the ro-
tor. The voltage regulator inside the frame contains
a transistor, diodes, and capacitors. The voltage reg-
ulator must be replaced, if faulty.

The voltage regulator is installed in the end of the
alternator with the slip rings. The voltage regulator
controls the current at the output or BAT B+ termi-
nal. The voltage is set by controlling the current in
the field winding of the alternator. The voltage is set
by the manufacturer and is not adjustable. When the
key switch is turned to the IGN position, the voltage
regulator is energized.

Charging System Indicator and Accessory
Power Supply

The I terminal, which is connected to the ignition key
through an indicator light, supplies power to turn on
the regulator and supply field current. The I termi-
nal lines includes a bulb used as a charging indicator
light located on the instrument panel. As long as the
light is not ON, the alternator is functioning prop-
erly. If the indicator light comes ON while the engine
is running, the alternator is not charging properly,
which may be due to an alternator problem, wiring
problem, or other issue in the charging system. The
R or relay terminal is not used. The B or ground ter-
minal is connected to chassis ground.

2200 SRM 1119

Alternator

REGULATOR

BATTERY (B+)
TERMINAL

F+

DIODE SET

INDICATOR LIGHT
TERMINAL

ROTOR FIELD
COIL

RELAY TERMINAL

BRIDGE DIODE
RECTIFIER (6)

10. GROUND (B )

TERMINAL

11. STATOR

Figure 6. Alternator Diagram

REMOVE

WARNING

Always move the battery disconnect lever to
the "disconnected" position before doing any
disassembly or repair to the parts of the elec-
trical system.

CAUTION

Before disassembling the alternator, make
marks on all housings to make sure of the
correct parts alignment during assembly.

Disconnect the wires at the alternator. Use a
socket to move the arm of the belt tensioner and
remove the drive belt from the pulley. Remove
capscrews that fasten alternator to bracket.

Remove the nut, pulley, and fan from the shaft.
Make alignment marks on the stator and frames.
Then remove the bolts that fasten the frames and
stator together.

Remove the drive end frame and rotor from the
stator. If the bearing will be replaced, remove the
rotor from the drive end frame. Use a gear puller
or press and remove the bearing from the drive
end frame.

Remove the nuts and screws that connect the sta-
tor leads, diode set, regulator, capacitor, termi-
nals, and rectifier assembly. Make a note of the
location, disassembly sequence, and the correct
connections of the nuts, insulators, screws, and
components for correct assembly.

INSTALL

Install the nuts and screws that connect the sta-
tor leads, diode set, regulator, capacitor, termi-
nals, and rectifier assembly. Make sure to install
the parts in the brush end frame as noted during
disassembly. Make sure to align the alignment
marks on the stator to the brush end frame.

Install the rotor in the stator and brush end
frame. Install the drive end frame on the rotor
and stator. Make sure to align the alignment
marks on the drive end frame and the stator. In-
stall the bolts that fasten the frames and stator
together.

CAUTION

Make sure the drive belt is correctly installed
and aligned on ALL pulleys before releasing
the belt tensioner. Belt damage will occur if not
correctly installed.

Install the fan, pulley, washer, and nut on the ro-
tor shaft. Tighten the shaft nut to 95 to 108 N•m
(70 to 80 lbf ft). Install the alternator on the
bracket. Tighten the mount bolt to 81 to 95 N•m
(60 to 70 lbf ft). Use a socket to move the arm
of the belt tensioner and install the drive belt on
the pulley. Set the belt to the proper tension and
tighten the adjusting strap bolt.

Install the electrical connectors on the correct
terminals. Tighten the terminal nuts and ground
screw to the following torque values:

Battery (B+) terminal - 9.0 to 13.6 N•m (80 to
120 lbf in)
Indicator (I) terminal - 1.7 to 2.8 N•m (15 to
25 lbf in)
Ground (B ) terminal - 5.6 to 6.8 N•m (50 to
60 lbf in)

Troubleshooting

2200 SRM 1119

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery is charged above
normal.

Alternator is not charging correctly.

Repair or replace alternator.

Electrical ground in wire to brush or
clip.

Repair ground in wire to brush or
clip.

Battery uses more water
than normal.

Battery is charging more than nor-
mal.

Adjust or replace alternator or volt-
age regulator.

Leaks in the battery.

Replace battery.

Battery

will

not

hold

charge.

Loose wiring or broken connections.

Repair wiring or broken connections.

Alternator has a defect in the field
wiring, diodes, rectifier bridge, or
stator.

Repair or replace alternator.

Battery has a defect.

Replace battery.

There is no charge from the
alternator.

Worn or damaged brushes.

Replace worn or damaged brushes.

Weak springs for brushes.

Replace springs.

Brushes or holders do not move
freely.

Repair brushes or holders.

Dirt on the Brush End Frames.

Clean brush end frames.

There is no charge from the
alternator.

The indicator

light or ammeter indicates
a discharged condition when
the rpm is high and there
is a high current need (high
load).

There is an electrical ground in the
field winding.

Repair electrical ground.

Drive belt is not tight or is broken.

Adjust or replace drive belt.

2200 SRM 1119

Diagrams, Schematics, or Arrangements

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Ammeter or the indicator
light indicates a discharged
condition at all speeds.

There is a short circuit in the diodes.

Repair or replace diodes.

There is an electrical ground at the
end of the windings.

Repair electrical ground.

Voltage regulator has a defect.

Replace voltage regulator.

Diagrams, Schematics, or Arrangements

2200 SRM 1119

Diagrams, Schematics, or Arrangements

Figure 7. Main Wire Harness

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

2200 SRM 1119

8/04 (7/04) Printed in United Kingdom

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