ELECTRICAL SYSTEM

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

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

PART NO. 1538373

2200 SRM 1065

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE:

The following symbols and words indicate safety information in this

manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Electrical System

Table of Contents

TABLE OF CONTENTS

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

1

Operation............................................................................................................................................................

1

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

1

Location Numbers .....................................................................................................................................

2

Components ...............................................................................................................................................

2

Leads/Wires ...............................................................................................................................................

2

Common Parts ...........................................................................................................................................

2

Electrical Components ..................................................................................................................................

4

Circuit Explanation .......................................................................................................................................

13

Key-Switch in OFF Position .....................................................................................................................

13

Key-Switch in ON Position .......................................................................................................................

13

Key-Switch in Engine START Position ....................................................................................................

13

Engine SHUTDOWN ................................................................................................................................

13

Parking Brake ...........................................................................................................................................

13

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

13

Key Switch ON, Engine Not Running .................................................................................................

13

Manual Selection Transmission Control ..................................................................................................

14

APC 100 Electronic Transmission Control ..............................................................................................

14

Outrigger Circuits .....................................................................................................................................

14

Lights .........................................................................................................................................................

14

Sliding Cab ................................................................................................................................................

15

Boom Up ....................................................................................................................................................

15

Boom Down ................................................................................................................................................

15

Tilting Cab .................................................................................................................................................

15

Spreader Rotation .....................................................................................................................................

15

Spreader Sideshift.....................................................................................................................................

15

Spreader Extend/Retract ..........................................................................................................................

15

Container Seating/Locking/Releasing ......................................................................................................

16

Part Numbers of Electrical Components ..........................................................................................................

16

This section is for the following models:

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

40LS, HR45H [A227]

©2004 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

2200 SRM 1065

Operation

Description

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

Operation

GENERAL

The electrical schematic is laid out on several pages.
The index page shows on which page the different
functions can be found. Not all functions will apply
to your truck. See Diagrams 8000 SRM 784.

Each page of the electrical schematic is divided into
41 columns. The column numbers are shown in a
horizontal bar at the top of each page. The meaning
of the reference numbers depends on its layout and
its location. See Figure 1.

1.

COLUMN NUMBERS

2.

LEAD/WIRE IDENTIFICATION

3.

CABLE LOOM

4.

PLUG CONNECTION, PIN/CONTACT 34 OF
PLUG PC1

5.

FUSE FUNCTION

6.

PAGE NUMBER, INDEXES THE PAGE NUMBER
FOR THE DIFFERENT FUNCTIONS.

7.

REPLACEMENT COMPONENTS (GAUGES,
MOTORS, ALTERNATOR, GENERAL)

8.

FUNCTION INDICATION OF A PARTICULAR
SECTION

9.

(XX,YY) XX IS PAGE NUMBER REFERENCE, YY
IS COLUMN REFERENCE.

10. RELAYS

Figure 1. Example Electrical Schematic

1

Operation

2200 SRM 1065

Location Numbers

All location numbers are placed between brackets.
The number starts with the page number, followed
by the column number. Example: Relay R1-BR1 (3.8)
is shown on page 3 in column 8.

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

Components

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

Leads/Wires

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

Wires with the same number are interconnected and
therefore have the same function. Example: Lead/
wire 15 has function "Battery Ground (negative)".

Common Parts

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

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

The numbers at the pin connections for these com-
mon parts refers to the pin number of that common
part. Check the Parts Manual for separate avail-
ability of these common parts.

Table 1. Symbols and Components

Symbol

Component

Battery

Starter

Fuse

Circuit breaker with reset
function

Pin connection

Connection

Relay

Meter/gauge

2

2200 SRM 1065

Operation

Table 1. Symbols and Components (Continued)

Symbol

Component

Relay contact, normally open
(relay non-energized)

Relay contact, normally closed
(relay non-energized)

Switch

Switch with push button
function

Alternator

Solenoid

Indicator lamp

Pressure switch

Cable loom

Table 1. Symbols and Components (Continued)

Symbol

Component

Temperature switch, switches on
at 120 C (248 F)

Sensor

Sensor/proximity switch

Sensor

Horn, alarm

Diode

DC motor (electrical)

Load limiter

3

Operation

2200 SRM 1065

ELECTRICAL COMPONENTS

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

Figure 4, Figure 5, Table 4, Table 5, Figure 6, Table 6,
Figure 7, Table 7, Figure 8, Table 8, Figure 9, and Ta-
ble 9.

Figure 2. Electrical Components/Solenoids on the Yardmaster

4

2200 SRM 1065

Operation

Table 2. Solenoids on the Yardmaster

Item

Description

Location

Figure

Part Number

E1

40 L hydraulic flow

(34.38)

Figure 2

1520299

E5

Winch up (option)

(33.31)

Figure 2

1520299

E6

Winch down (option)

(33.34)

Figure 2

1520299

E7

Boom enable up movement

(21.40)

Figure 2

1520299

E8

Boom enable down movement

(30.23)

Figure 2

1520299

E9

Joystick flow 17 bar

(32.35)

Figure 2

1520299

E10

Joystick flow 15 bar

(32.15)

Figure 2

1520299

E11

Joystick flow 13 bar

(32.30)

Figure 2

1520299

E12

3 wraps remaining (winch option)

(33.25)

Figure 2

1520299

E13

Hydraulic oil cooling

(32.6)

Figure 2

1520299

E138

Throttle cutoff

(10.31)

Figure 2

1520299

E152

Speed limit 25 25 km/h (15.5 mph) maximum

(10.25)

Figure 2

1520299

E227

Parking brake

(4.35)

Figure 2

1520299

EV1 - 6

Transmission solenoids

(11.10)

Figure 2

1342504

5

Operation

2200 SRM 1065

Figure 3. Electrical Solenoids on the Spreader

Table 3. Solenoids on the Spreader

Item

Description

Location

Figure

Part Number

E14

Telescope extension out

(36.18)

Figure 3

1520299

E15

Telescope extension in

(36.21)

Figure 3

1520299

E16

Left sideshift (RTG)

(35.27)

Figure 3

1520299

E17

Right sideshift (RTD)

(35.30)

Figure 3

1520299

E18

Powered Pile Slope Left

(42.23)

Figure 3

1520299

E19

Powered Pile Slope Right

(42.26)

Figure 3

1520299

E20

Rotation to left (ROG)

(34.22)

Figure 3

1520299

E21

Rotation to right (ROD)

(34.24)

Figure 3

1520299

E22

Rotation brake release

(34.26)

Figure 3

1520299

E23

Telescope low speed

(36.38)

Figure 3

1520299

E24

Container locking

(38.25)

Figure 3

1520299

E25

Container release

(38.28)

Figure 3

1520299

6

2200 SRM 1065

Operation

Figure 4. Dampening Lock on Boom

Figure 5. Hydraulic Valve on Boom

Table 4. Solenoids on the Boom

Item

Description

Location

Figure

Part Number

E49

Dampening override

(41.20)

Figure 4

1520299

E50

Right dampening locking

(41.30)

Figure 4

1520299

E51

Left dampening locking

(41.38)

Figure 4

1520299

E54

Spreader leveling

(21.4)

Figure 5

1520299

7

Operation

2200 SRM 1065

Table 5. Components on the Yardmaster

Item

Description

Location

Figure

Part

Number

S21

Transmission clutch oil pressure gauge

(7.24)

Figure 2, Pos. 1

1469333

S92

Clutch oil pressure warning

(6.37)

Figure 2, Pos. 2

1469329

Engine - frame connection

(3.17)

Figure 2, Pos. 3

BAT

Batteries

(3.6)

Figure 2, Pos. 4

1492663

S3

Electronic main switch

(1.24)

Figure 2, Pos. 5

1469834

R2

Starter relay

(4.8)

Figure 2, Pos. 6

1469836

S50

Engine fuel gauge

(7.13)

Figure 2, Pos. 7

1470614

S6

Engine shutdown valve

(4.28)

Figure 2, Pos. 8

Cummins

part

S57

Compressor (A/C option)

(28.17)

Figure 2, Pos. 9

1488022

S15

Hydraulic oil temperature contact

(7.21)

Figure 2, Pos. 10

1469146

S40

Horn

(18.39)

Figure 2, Pos. 11

1488123

S141

Tank level, hydraulic oil

(6.19)

Figure 2, Pos. 12

1470615

S43

50 degree boom hoisting limit switch

(20.17)

Figure 2, Pos. 13

1470947

S130

Boom hoisting limit switch

(21.19)

Figure 2, Pos. 14

1470943

S90

Derricking down sensor, Dampening

(40.4)

Figure 2, Pos. 15

1470526

S91

Derricking up sensor, Dampening

(40.7)

Figure 2, Pos. 16

1470526

S88

Pressure switch 170 bar (pilot pressure control)

(32.20)

Figure 2, Pos. 17

1520303

S89

Pressure switch 210 bar (pilot pressure control)

(32.24)

Figure 2, Pos. 18

1520303

S84

Anti-tipping indicator switch

(30.8)

Figure 2, Pos. 19

1471902

S1

Alternator

(3.16)

Figure 2, Pos. 20

1469716

S13

Engine coolant temperature gauge

(7.36)

Figure 2, Pos. 21

1469696

S129

Hydraulic oil filter clogging

(6.31)

Figure 2, Pos. 22

1502348

S128

Axle oil filter clogging

(6.30)

Figure 2, Pos. 23

1502348

S86

Hydraulic oil cooling switch, 45 C (113 F)

(7.6)

Figure 2, Pos. 24

1470814

S87

Hydraulic oil cooling switch, 45 C (113 F)

(7.9)

Figure 2, Pos. 25

1470814

S12

Engine oil pressure warning

(6.7)

Figure 2, Pos. 26

1469701

S11

Engine coolant temperature warning

(6.16)

Figure 2, Pos. 27

1469700

S17

Engine speed (APC 100)

(9.15)

Figure 2, Pos. 28

1469338

S68

Torque converter oil temperature and warning

(7.10/11)

Figure 2, Pos. 29

1469146

S132

Air filter clogging

(6.26)

Figure 2, Pos. 30

1469807

S18

Turbine speed

(10.20)

Figure 2, Pos. 31

1475358

8

2200 SRM 1065

Operation

Figure 6. Service and Parking Brake Switches and Sensors

Table 6. Service and Parking Brake Switches and Sensors

Item

Description

Location

Figure

Part Number

S77

Parking brake sensor

(10.3)

Figure 6, Pos. 1

1469193

S75

Parking brake pressure switch for indicators

(6.40)

Figure 6, Pos. 1

1469193

S79

Stop light sensor

(17.30)

Figure 6, Pos. 3

1469193

S78

Minimum pressure switch

(6.35)

Figure 6, Pos. 3

1469194

S139

Brake sensor

(10.6)

Figure 6, Pos. 4

1469118

9

Operation

2200 SRM 1065

Figure 7. Relays and Fuses in the Cab

Table 7. Relays in the Cab

Item

Description

Location

Figure

Part Number

R1 - BR1

Battery voltage, main switch control

(3.8)

Figure 7

1469315

R1 - BR7

Air conditioning pressure control

(27.35)

Figure 7

1469315

R2-BR7

Air conditioning motor control

(27.39)

Figure 7

1469315

R4 - BR1

Suspension

(31.16)

Figure 7

Not Used

R1 - BR2

Joystick pressure control E9

(32.11)

Figure 7

1469315

R2 - BR2

Joystick pressure control E10

(32.35)

Figure 7

1469315

R5 - BR2

Stoplights

(17.35)

Figure 7

1469315

R3 - BR2

High beam lights

(18.14)

Figure 7

1469315

R5 - BR1

Horn

(18.10)

Figure 7

1469315

R1 - BR3

Transmission neutral position indicator

(8.31)

Figure 7

1469316

R2 - BR1

Reverse lights

(19.15)

Figure 7

1469315

R1/2 - BR5

APC 100 override

(8.11/17)

Figure 7

1469316

BR8 - S32

Blinker unit

(16.5)

Figure 7

1472507

10

2200 SRM 1065

Operation

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

Table 8. Spreader Relays and Components in Spreader Electrical Box

Item

Description

Location

Figure

Part

Number

R1 - BR3

Container released on right side. Red light

(39.40)

Figure 8, D1

1469316

R2 - BR3

Container released on left side. Red light

(39.19)

Figure 8, SD

1469316

R1 - BR2

Container seated on right side. White light

(37.31)

Figure 8, P1

1469316

R2 - BR2

Container seated on left side. White light

(37.19)

Figure 8, SP

1469316

R1 - BR4

Container locked on right side. Green light

(39.31)

Figure 8, V1

1469316

R2 - BR4

Container locked on left side. Green light

(39.13)

Figure 8, SV

1469316

R3 - BR5

Spreader horizontal

Figure 8, BK1

1469315

R2 - BR5

Slow speed at end extension range

Figure 8, DT50

1469315

R1 - BR5

Flow selection. 40L/20L

Figure 8, DEB

1469316

11

Operation

2200 SRM 1065

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

Table 9.

Fuses

Item

Description

Location

Figure

Part Number

F100

100 Amp. Main fuse. Provides protection to all
functions behind the battery shutoff.

(3.35)

Figure 9

1500512

F80

80 Amp. Main fuse. Provides protection to the
starter motor behind the battery shutoff.

(3.30)

Figure 9

1500514

F50

50 Amp. Main fuse. Provides general protection
for the direct battery supplies.

(3.36)

Figure 9

1500516

F1

10 Amp. Main protection switch, parking brake

(5.4)

Figure 7

1469237

F2

20 Amp. Front and roof windshield wiper, cab
hoist up, ceiling light

(5.6)

Figure 7

1469239

F3

20 Amp Spreader working lights, chassis
working lights

(5.9)

Figure 7

1469239

F4

20 Amp Boom working lights

(5.12)

Figure 7

1469239

F5

20 Amp Beacon working lights

(5.14)

Figure 7

1469239

F6

15 Amp Gear selector, reverse relay and lights

(5.16)

Figure 7

1469238

F7

10 Amp Parking lights, hazard lights

(3.38)

Figure 7

1469237

F8

15 Amp Spreader sensors locking/unlocking,
speedometer. Telescoping low speed.

(5.19)

Figure 7

1469238

F9

15 Amp Boom hoist up/down, spreader leveling,
telescope extend

(5.21)

Figure 7

1469238

F10

15 Amp Stoplights, blinkers

(5.24)

Figure 7

1469238

F11

10 Amp Spreader telescope extension/
retraction, container locking/releasing

(5.27)

Figure 7

1469237

F12

20 Amp Low/high beam, horn

(5.29)

Figure 7

1469239

12

2200 SRM 1065

Operation

Table 9. Fuses (Continued)

Item

Description

Location

Figure

Part Number

F13

10 Amp Main switch, tachometer/hourmeter

(3.37)

Figure 7

1469237

F14

15 Amp Air conditioning motor

(3.39)

Figure 7

1469238

F15

5 Amp Engine warning lights and gauges,
transmission warning lights and gauges, brake
warning lights and gauges

(5.32)

Figure 7

1469236

F16

20 Amp Cab air conditioning

(5.34)

Figure 7

1469239

F17

15 Amp. Sliding cab (option)

(5.37)

Figure 7

1469237

F18

5 Amp Front outrigger (option)

(5.39)

Figure 7

1469236

CIRCUIT EXPLANATION

NOTE:

For the location of the following components

see Diagrams 8000 SRM 784.

Key-Switch in OFF Position

The ignition starting switch S4 (4.17) is in Pos. 0.

Battery voltage (positive) is supplied to:

• Main switch S3 (3.25).
• Tachometer/hourmeter circuit, via fuses F50, and

F13 (3.36).

• Parking lights, hazard warning lights, via fuses

F50, and F7 (3.38).

• Air conditioning motor, via fuses F50, and F14

(3.39).

The battery voltage (negative) is connected by
Lead/15 to the battery ground M10 (3.3).

Key-Switch in ON Position

The ignition starting switch (4.17) is in Pos. 1.

Via contact 30/15 of S4, lead 125 (4.19), lead 125
(3.28), the main switch is energized, and battery volt-
age is supplied to:

• Starter (Cummins engine), S14 (3.26).
• Fuse F100 (3.34) and the fuses in Diagrams 8000

SRM 784 on PPM page 5.

Key-Switch in Engine START Position

Via contact 30/50 of S4, lead 41, contact 31/34 of
RB-BR3 (Transmission in neutral), the engine start
relay R2 (4.8) is energized. Contact 30/30 (3.30) of
relay R2 activates the starter.

The alternator S1

(3.16) generates the voltage to charge the batteries,
and will energize relay R1-BR1. Contact 30/87 (4.23)
of R1-BR1 provides the holding circuit for the main
switch, and prohibits switching OFF the engine by
means of the key-switch.

Engine SHUTDOWN

Pushing the "engine shutdown" button S5 (4.28) will
cause solenoid S6 (4.28) to be de-energized and the
engine will shut down.

Parking Brake

Operating the parking brake switch S72 (4.36) will
activate solenoid E227 (4.36). When solenoid E227
is energized, the parking brake is released.

Warning Lights

Key Switch ON, Engine Not Running

BV3 (6.11) Relay R5-BR7 (6.6) will be energized via
the oil pressure switch S12 (6.6). Warning light BV3
(6.11) will be ON. This indicates "low engine oil pres-
sure." With engine running, the Warning light should
be OFF.

BV3 (6.13) Alternator S1 (3.15) will not generate a
voltage. Warning Light BV3 (6.13) will be ON. This
indicates "No battery charge." With the engine run-
ning, the Warning light should be OFF.

BV3 (6.17) Under normal conditions, the Temper-
ature sensor will not be activated. Warning Light
BV3 (6.17) will be OFF. This indicates temperature
below maximum permissible. With coolant tempera-
ture above maximum temperature, sensor S11 (6.15)
will be closed and Warning light will be ON.

13

Operation

2200 SRM 1065

BV4 (6.20) Under normal conditions, the Warning
light BV4 (6.20) will be OFF. This indicates hydraulic
oil level is correct. With hydraulic oil level below min-
imum level, sensor S141 (6.19) will close and BV4
will be ON.

BV4 (6.26) Indicates the condition of the filters:

• Air filter clogging S132 (6.26)
• Transmission oil filter clogging S127 (6.28)
• Axle oil filter clogging S128 (6.29)
• Hydraulic oil filter clogging (6.31)

With engine not running, the Warning light BV4
(6.26) will be OFF.

With the engine running, and with one of the men-
tioned filters clogged, the Warning light will be ON.

BV3 (6.35) Indicates low front brake oil pressure.
With engine not running, BV3 will be ON. With the
engine running, the warning light will be OFF.

BV3 (6.38) Indicates low clutch oil pressure. With
engine not running, BV3 will be ON. With the engine
running, the Warning light will be OFF.

BV3 (6.40) Low parking brake pressure or parking
brake applied causes BV3 (6.40) to be ON.

Manual Selection Transmission Control

The selection "manual" is only possible with the
transmission control in position NEUTRAL. In
this position relay R1-BR3 (8.31) will be energized
and when manual is selected, via contact 3-4 S121
(8.4) Relay R1-BR5 (8.12) will be energized. Relay
R2-BR5 provides a holding circuit.

The contacts of R1-BR3 will close and gear box
solenoids 1 (9.10), 2 (9.16), 3 (9.21) will be activated,
and first gear is selected. Selection of Forward or
Reverse is with the transmission control via the
APC 100 and is conditional upon outriggers being in
the up position. With outriggers in the up position,
relay R2-BR3 is energized. The table (9.6) provides
details on gear selection/solenoids selection.

APC 100 Electronic Transmission Control

The APC 100 provides automatic gear selection
within the range selected by the transmission con-
trol lever.

The Input/Output signals for the APC 100 are:

• Throttle sensor S30 (10.10)
• Engine speed sensor S17 (10.17)
• Turbine speed sensor S18 (10.21)
• Throttle cut off, solenoid E138 (10.31)
• Speed limit (25 km/h (15.53 mph)), solenoid E152

(10.25).

Speed limit when the container is at-

tached, in the manual mode E152 and E138 will
not be activated. Contacts of R2-BR5 prohibit the
selection.

Outrigger Circuits

Outrigger down and up is given by the Front outrig-
ger switch S71 (14.15).

Outrigger down is only possible with the transmis-
sion in Neutral. Contact 11/14 R1-BR3 (14.15) will
be closed and Solenoids E198 and E172 can be ac-
tivated. The down position is detected by Pressure
switch S93 (14.3). This causes relay R3-BR7 to be en-
ergized. Contact 30/87 R3-BR7 creates a holding cir-
cuit, and ensures that the Outrigger down status is
present until the status Outrigger up R4-BR7 (14.28)
is present.

Outrigger up is only possible when the outrigger up
permission relay R3-BR1 (15.20) is energized. This
is conditional upon one of the following:

• No container attached. Contacts 31/34 of R1-BR3

and R2-BR3 (15.29) are closed. Relay R3-RB1 will
be energized.

• Boom is retracted. Sensor S28 (15.17) is activated.

Relay R3-RB1 will be energized.

• Boom is up. Sensor S27 (15.10) is activated. Relay

R3-RB1 will be energized.

NOTE: With the outrigger in the down position an
audible alarm S26 (14.40) will be given, when moving
transmission control out of Neutral.

Lights

Schematics for the blinkers, hazard warning lights,
parking lights, low and high beam lights, and reverse
lights are located in Diagrams 8000 SRM 784 on
PPM pages 16, 17, 18, and 19.

The blinkers (16,XX) are controlled by the Blinker
unit. When the blinkers are activated the audible
alarm S33 (16.8) will sound.

The high beam is switched ON by means of relay
R3-BR2 (18.14). The horn is switched ON by means
of relay R5-BR1 (18.10).

14

2200 SRM 1065

Operation

When in reverse, audible alarm S25 (19.34) will
sound.

Sliding Cab

Sliding the cab toward the rear is conditional upon
the following:

• Both cabin doors being closed. Sensor S41 (20.3)

and S42 (20.7) are activated and switch through
the voltage supply.

• Cab not in the rear position.

Relay R1-BR10

(21.32) is not activated.

When the above conditions are met, the cab sliding
permission relay R1-BR30 (20.15) is energized and
via contact 30/87 R1-BR30 (20.31), and Sliding cab
switch S67, Solenoid E188 can be activated, and the
cab will be moved toward the rear.

Sliding the cab toward the front is conditional upon
the following:

• Both cabin doors being closed. Sensor S41 (20.3)

and S42 (20.7) are activated and switch through
the voltage supply.

• Boom angle within 0 to 5 degrees. Relay R2 BR10

(22.15) is not activated. The relays R3

BR30, R2

BR30, and R4

BR30 (21/23/25) are not ener-

gized as the boom angle sensor S43 is not activated
with the boom within 0 to 5 degrees angle.

When the above conditions are met, the cab sliding
permission/enable relay R1 BR30 (20.15) is ener-
gized and via contact 30/87 R1 BR30 (20.31), sliding
cab switch S67, contact 30/87a R2 BR30, solenoid
E187 can be activated, and the cab will be moved
towards the front.

Boom Up

Boom hoist up is conditional upon:

• Container is properly locked (relay contacts 21/14

of R1 BR4 and R2 BR4 (21.19) are closed), or con-
tainer fully released (relay contacts R1 BR3 and
R2 BR3 (21.13) are closed).

• Boom not in the 60 degrees position (contact of

the maximum boom angle sensor S130 (21.19) is
closed).

• Cab is in the rear position (sensor S134 (21.37) is

closed), or boom angle is in the 0 to 5 degrees range.

When the above conditions are met, solenoid E7 will
be activated, and enables boom up.

Should the cab not be in the rear position and the
boom angle gets larger than 5 degrees, solenoid E7
will be deactivated (contact 30/87a R4 BR30 (21.29)
opens), and stops boom up.

Boom Down

The LMI unit (30.22) provides information on the
load status. It calculates the load status using boom
angle, boom extension, and the load.

It is possible to override the LMI by means of S138.
When using the override function, buzzer S110 and
warning light BV4 will come ON.

The anti-tipping safety feature will, in case tipping
occurs, activate the buzzer S83 and light BV4.

Solenoid E8 activated, enables operation of the boom
down and the extend.

Tilting Cab

The cab tilting up or down movement is activated by
switch S70 (23.21). Solenoid E226 (23.21) is used for
cab down and solenoid E225 (23.9) is used for cab up.

Spreader Rotation

Rotation to the left is via; joystick S147 (34.5), relay
ROG, and solenoid E20.

Rotation to the right is via; joystick S146 (34.9), relay
ROD, and solenoid E21.

Spreader Sideshift

Spreader sideshift to the left is via; joystick S145
(35.5), relay RTG, and solenoid E16.

Spreader sideshift to the right is via; joystick S144
(35.9), relay RTD, and solenoid E17.

Spreader Extend/Retract

Spreader extend is via; S95 (36.6), and solenoid E14.

Spreader retract is via; S95 (36.6), and solenoid E15.

Before reaching the 9.14 m (30 ft) position, the speed
of the extend or retract movement is lowered. The
proximity switch S94 (36.31) is activated, energizes
relay R2 BR5 and via contact 30/87 R2 BR5 sole-
noid E23 (36.38) will be activated.

15

Part Numbers of Electrical Components

2200 SRM 1065

Container Seating/Locking/Releasing

Left front sensor S105 (37.23) and left rear sensor
S106 (37.26) will, when container is seated, energize
relay R2 BR2 (37.18). This represents the container
is seated on the left hand side.

Right front sensor S107 (37.34) and right rear sensor
S108 (37.39) will, when container is seated, energize
relay R1 BR2 (37.31). This represents the container
is seated on the right hand side.

In the event that the seated signals cannot be ob-
tained, the pushbutton container seated override
S109 (37.4) can be activated.

Warning light BV4

(37.10) will be ON.

Contacts 21/24 of R2 BR2 and R1 BR2 (38.6) will
be closed and the container lock/release switch S142
can be used to lock the container. Solenoids E24 and

E25 provide locking when activated and provide re-
leasing when not activated.

Sensor S101 (39.6) detects that the container is
locked on the left side and will energize relay
R2 BR4. Sensor 103 (39.27) detects that the con-
tainer is locked on the right side and will energize
relay R1 BR4.

Sensor S102 (39.13) detects that the container is
released on the left side and will energize R2 BR3.
Sensor S104 (39.34) detects that the container is
released on the right side and will energize relay
R1 BR3.

Indication of seating, locking, and releasing is by
means of the lights on (40,XX). The green indicator
lights will be ON when locked. The red indicator
lights will be ON when released/unlocked. The white
indicator lights will be ON when seated.

Part Numbers of Electrical Components

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

Item

Description

Part Number

Schematic Page

APC100

APC100 Electronic unit

1476484

8

BV14

Side dashboard

relay connection

1480679

34

C1 BR1

5 Relay board

1469314

3

C1 BR2

5 Relay board

1469314

32

C1 BR3

2 Relay board

1469318

8

C1 BR5

2 Relay board

1469318

8

C1 BR7

5 Relay board

1469314

27

C1 BR30

5 Relay board

1469314

20

C11

Fuse board

1469233

3

C13

Diode board (option)

1469321

31

E172

Outrigger rod side decompression

1520299

14

E173

Not used

1520299

15

E187

Sliding cab front position

1520299

20

E188

Sliding cab rear position

1520299

20

E198

Outrigger down

1520299

14

E199

Outrigger up

1520299

14

E225

Cab up

1520299

23

16

2200 SRM 1065

Part Numbers of Electrical Components

Item

Description

Part Number

Schematic Page

E226

Cab down

1520299

23

E310

Boom hoist down

1520299

22

ROD

Relay, spreader right rotation

1469315

34

ROG

Relay, spreader left rotation

1469315

34

RTD

Relay, spreader right sideshift

1469315

35

RTG

Relay, spreader left sideshift

1469315

35

RT1

Windshield wiper timer

1488335

29

R1

Front windshield wiper relay

1488336

29

R1 BR10

Cab rear position

1469316

21

R1 BR30

Cab sliding permission

1469315

20

R2 BR3

Outrigger up position

1469316

14

R2 BR10

Boom hoist down permission

1469316

22

R2 BR30

Sliding cab front travel cutoff

1469315

20

R3 BR1

Outrigger up permission

1469315

15

R3 BR7

Outrigger down

1469315

14

R3 BR30

Boom retraction

1469315

20

R4 BR7

Outrigger up

1469315

14

R4 BR30

Boom hoist up cutoff

1469315

20

R5 BR7

Engine oil pressure

1469315

6

R11

0 to 5 Boom angle

1469315

22

S4

Ignition starting switch

1469263

4

S5

Engine shutdown

1487218

4

S7

Tachometer/hourmeter

1526102

3

S8

Fuel gauge/oil temperature converter

1468923

7

S9

Clutch pressure/hydraulic oil temperature

1468917

7

S10

Voltmeter/engine coolant temperature

1468922

7

S14

Starter

1469710

3

S17

Engine speed sensor

1469338

10

S20

Transmission control

1470377

8

S22

Left reverse light

1468374

19

S23

Right reverse light

1468374

19

S25

Reverse gear audible alarm

1468929

19

S26

Travel forbidden audible alarm

1477409

14

S27

Boom up position sensor

1477407

15

S28

Boom retraction position sensor

1469129

15

17

Part Numbers of Electrical Components

2200 SRM 1065

Item

Description

Part Number

Schematic Page

S29

Outrigger high position sensor

1469129

14

S30

Throttle sensor

1469129

10

S31

Hazard switch

1463261

16

S33

Blinkers audible alarm

1469226

16

S34

Right rear light unit

1468919

16

S35

Left rear light unit

1468918

16

S36

Right front blinker

1468915

16

S37

Left front blinker

1468915

16

S38

Right front headlamp

1468932

18

S39

Left front headlamp

1468932

18

S41

Cab door closed sensor

1476406

20

S42

Cab door closed sensor

1476406

20

S44

Cab working light

1468374

25

S45

Boom working light

1468374

24

S46

Chassis working light

1468374

24

S47

Chassis working light

1468374

24

S48

Spreader working light

1468374

24

S49

Spreader working light

1468374

24

S51

Boom working light

1468374

24

S52

Boom working light

1468374

24

S53

Boom working light

1468374

24

S54

Cab working light

1468374

25

S55

Rotating beacon

1468924

25

S56

Rotating beacon

1468924

25

S58

Roof windshield wiper

1488325

26

S59

Roof windshield wiper switch

1469056

26

S62

Working light switch

1469051

25

S63

Rotating beacon switch

1469052

25

S64

Working light switch

1469051

24

S65

Working light switch

1469051

24

S66

Parking light switch

1469050

17

S67

Sliding cab switch

1469272

20

S70

Up and down cab switch

1469271

23

S71

Front outrigger switch

1469273

14

S72

Parking brake switch

1469259

4

18

2200 SRM 1065

Part Numbers of Electrical Components

Item

Description

Part Number

Schematic Page

S73

Air condition switch

1488029

27

S74

Stop light sensor

1469193

17

S76

Front brake oil pressure

1469194

6

S80

Front windshield wiper

1488338

29

S81

Winch hydraulic flow

1471222

33

S82

Boom hoist pressure sensor (long chassis)

1472911

30

S83

Anti tipping safety

1469226

30

S85

Dampening switch

1469256

41

S90

Boom hoist up

1470526

41

S91

Boom hoist down

1470526

41

S93

Outrigger down position sensor

1477390

14

S94

Spreader telescope low speed

1469129

36

S95

Spreader telescope switch

1469257

36

S96

Switch, powered pile slope

1469270

42

S97

Spreader controls

1468360

40

S100

Spreader controls

1468360

40

S101

Container locking sensor

1469129

39

S102

Container releasing sensor

1469129

39

S103

Container locking sensor

1469129

39

S104

Container releasing sensor

1469129

39

S105

Container seated sensor

1469129

37

S106

Container seated sensor

1469129

37

S107

Container seated sensor

1469129

37

S108

Container seated sensor

1469129

37

S110

LMI override

1469129

30

S124

Air condition motor

1488053

28

S125

Air condition motor

1488053

28

S126

Boom anti two block sensor

1471113

33

S127

Transmission oil filter clogging

1469222

36

S131

3 Wraps remaining

1471190

33

S131

3 Wraps remaining

1471191

33

S133

0 to 5 boom angle sensor

1470947

22

S134

Cab rear position sensor

1470943

21

S135

Lighting switch

1470355

16

S136

Windshield washer

1488341

29

19

Part Numbers of Electrical Components

2200 SRM 1065

Item

Description

Part Number

Schematic Page

S140

Front windshield wiper switch

1469262

29

S142

Container lock/release switch

1469264

38

S151

Pressure safety, low pressure

1488049

27

S152

Pressure safety, high pressure

1488048

27

S153

Left ceiling light

1488112

26

S154

Right ceiling light

1488115

26

S156

Evaporator

1488035

27

S158

Pressure safety, low pressure

1488056

27

20

TECHNICAL PUBLICATIONS

2200 SRM 1065

2/04 (1/04)(11/03)(2/03) Printed in United Kingdom