ELECTRICAL SYSTEM

H8.0-12.0XM-6 (H190-280HD 2) [J007];

H13.0-14.0XM-6 (H300-330HD 2) [H019];
H16.0XM-6 (H360HD 2) [H019];
H10.0-12.0XM-12EC (H360HD 2-EC) [H019]

PART NO. 4034086 2200 SRM 1499

 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 Maintenance section.

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

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

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Electrical System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Electrical Schematic and System Description.................................................................................................. 1
Electrical Schematic ...................................................................................................................................... 1
Schematic Location Number ......................................................................................................................... 3
Electrical Components .................................................................................................................................. 3
Electrical Wires.............................................................................................................................................. 3
Wire Identification Number...................................................................................................................... 3
Electrical Wire Colors ............................................................................................................................... 4
Wire Harnesses ......................................................................................................................................... 4
Harness Interconnection........................................................................................................................... 5
Electrical Connectors..................................................................................................................................... 5
Connector Types ........................................................................................................................................ 5
Connector Identification ........................................................................................................................... 5
Connector Pin Numbers............................................................................................................................ 6
Connector Description............................................................................................................................... 6
Fuses .............................................................................................................................................................. 6
Relays ............................................................................................................................................................. 9
Flyback Diodes............................................................................................................................................... 10
CAN (Controller Area Network) ................................................................................................................... 10
Diagnostic .................................................................................................................................................. 11
Troubleshooting......................................................................................................................................... 11
Instrument Panel ...................................................................................................................................... 11
General Fault Finding ................................................................................................................................... 14
Preparation ................................................................................................................................................ 14
Define the Problem Area........................................................................................................................... 14
Identify Possible Causes of Malfunction .................................................................................................. 14
Determine the Most Probable Cause........................................................................................................ 14
Fuse Check................................................................................................................................................. 14
Wiring Check ............................................................................................................................................. 14
Component Check...................................................................................................................................... 14
Repair and Test ......................................................................................................................................... 14
Wire Harness Identification and Connector Location ..................................................................................... 15

This section is for the following models:

H8.0-12.0XM-6 (H190-280HD 2) [J007];

H13.0-14.0XM-6 (H300-330HD 2) [H019];
H16.0XM-6 (H360HD 2) [H019];
H10.0-12.0XM-12EC (H360HD 2-EC) [H019]

©2011 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1499 Electrical Schematic and System Description

General
This manual provides general information on the be a transmission solenoid which would be located
electrical system J007 and H019 lift trucks and in Transmission Repair, Dana Spicer 1300 SRM
provides a link between the electrical schematic and 1356.
the actual location of the electrical components on
the lift truck. The actual electrical schematic drawings are located
in Diagrams 8000 SRM 1500.
The description and replacement procedures for the
electrical system components are located in the rele-
vant manual for the component. An example would

Electrical Schematic and System Description

ELECTRICAL SCHEMATIC Table 1. Electrical Schematic Index
(Continued)
The electrical schematic is laid out over several
pages/sheets in Diagrams 8000 SRM 1500. Each Number Title Contents
page shows the electrical connection between the
components, connectors, and wires. 8 Twist Twist Module, Override
Module relay, Powered Cab Tilt
The layout of the schematic is function driven, which
means that each sheet represents one particular 9 Monitor- Instrument cluster,
function or area as indicated by the title of the sheet. ing senders, alarms,
Table 1 shows the index of the different sheets. diagnostics
10 Park Park brake switch and
Table 1. Electrical Schematic Index Brake solenoid, suspension seat
Number Title Contents 11 Hydraulic Hydraulic controller,
Controls levers, Operator Presence
1 Index
12 Auxiliary Auxiliary switches
2 Main Battery, Key Switch Functions
Power
13 Wipers Wipers and washers,
3 Engine Engine controller and switches, timer
components
14 Radio/ Radio, Horn, DC
4 Transmis- Transmission controller, Horn converter, 12V plug
sion senders and controls.
15 HVAC Heating, Air Conditioning
5 Cab Cab roof and interior and Ventilation
Lights lights
16 Front End Front End Fork Lift Truck
6 Frame Front and tail lights, FLT
Lights reverse alarm
17 Front End Front End Container
7 Lights 2 Mast lights, flasher, CH Handler
jumper

1
Electrical Schematic and System Description 2200 SRM 1499

Figure 1. Schematic Example

2
2200 SRM 1499 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. WIRE HARNESS NAME - FRAME 12. CONNECTOR - CPS07
5. WIRE CONTINUATION LOCATION- [20, E] 13. CONNECTOR - CRP07
6. MEGA FUSE - 100 AMP 14. FUSE - 5 AMP
7. WIRE NUMBER AND COLOR - 761-F-WHITE 15. HARNESS DIVIDING LINE
8. RELAY - STARTER

SCHEMATIC LOCATION NUMBER Table 2. Function ID Numbers

The schematic is divided into rows with a letter from Function Group Number
A to J and into columns numbered 0 to 9 for each Range
sheet. See Figure 1.
Grounds 101 - 149
The column numbering consists of the sheet number Current sense ground 150 - 199
plus the column number. For example, column 57 is
the 7th column on sheet 5. Switched B+ 200 - 239
Fused B+ 240 - 249
The schematic location number is the combination of
a row letter and column number, which allows quick Regulated power 5V 250 - 279
identification of a point on the schematic. For exam-
Regulated power 12V 280 - 299
ple, [57, A] is the 7th column on sheet 5, row A.
Analog inputs - hydraulics/mast 300 - 319
ELECTRICAL COMPONENTS
Analog inputs - chassis 320 - 339
Electrical components are indicated by a symbol and Analog inputs - powertrain 340 - 399
a description that are placed close to each other on
the schematic. An example is the starter relay on Analog inputs - CAB/OHG 400 - 419
[38,C]. See Figure 1. Additional analog inputs 420 - 499
ELECTRICAL WIRES Digital inputs - hydraulics/mast 500 - 509

Each electrical wire is indicated by a solid line and Digital inputs - chassis 510 - 539
has been identified with an identification number Digital inputs - powertrain 540 - 559
and a color indication of the wire insulation. If a
wire continues on a different sheet, then the solid Digital inputs - CAB/OHG 560 - 569
line ends with an arrow and receives in addition the Encoder inputs 570 - 599
schematic location number where this wire contin-
Additional digital inputs 600 - 699
ues.
Digital outputs - hydraulics/mast 700 - 719
Wire Identification Number
Digital outputs - chassis 720 - 749
Each electrical wire in the electrical schematic has Digital outputs - powertrain 750 - 779
an identification number that is also printed on the
insulation of the wires. Digital outputs - CAB/OHG 780 - 799
PWM outputs - hydraulics/mast 800 - 829
The wire identification numbers consist of a function
ID number and when needed a suffix letter. PWM outputs - chassis 830 - 839

The function ID numbers are numbered from 1 PWM outputs - powertrain 840 - 889
through 999. Specific ranges of numbers are as- PWM outputs - CAB/OHG 890 - 899
signed for different function ID groups. See Table 2.
Communication (eg., CAN) 900 - 909
Non-standard functions 910 - 999

3
Electrical Schematic and System Description 2200 SRM 1499

Wires with the same number are interconnected Table 3. Electrical Wire Colors (Continued)
through splices and connectors, and therefore have
the same electrical function.
Wire Color Circuit Level
When a circuit is spliced into several wires, or when Black Heavy Current Grounds
a wire passes a connector, then each wire number
receives the next unique suffix letter. An example Green Signal Grounds
is 42-a, 42-b. Pink 12 Volt
To simplify the schematic, sometimes the identifi- Orange 5 Volt Supply
cation has been omitted for a spliced function. It
White Other Circuits
may concern an intersection between a switch and
a splice, or a right-hand component operating simul- Yellow (Twisted CAN Hi
taneously with a left hand component. Pair)

There is a wire number overview in Diagrams 8000 Green (Twisted CAN Lo

SRM 1500, diagrams. In this overview each wire is
listed with the wire harness it is part of, and with the
connector identification number and pin numbers it
connects to. The actual location of a connector code
can be looked up in Table 7.
Electrical Wire Colors
In addition to the function ID numbers on the elec-
trical wires, different wire colors are used to identify
the circuit levels. See Table 3.
Table 3. Electrical Wire Colors
Wire Color Circuit Level
Red Battery Level Power Circuits
Pair)
Wire Harnesses
Wires are bound together in wire harnesses to secure
against the adverse effects of vibration, abrasion and
moisture. The description of wire harnesses follows
from its location in the truck or from the functions it
connects with.
Table 4 provides an overview of the different har-
nesses that belong to the different truck options.
Figure 8 through Figure 14 show a 3D-view of most
of the wire harnesses with their terminals and con-
nectors. The legends for these figures mention the
connector codes and connector description for verifi-
cation. See also Electrical Connectors.

Table 4. Harnesses by Option

Common to Truck Side Console, Arm Rest, Cab Underfloor, Steering

Figure 12 A Figure 14 Figure 13 A Column,
Figure 13 B
SOH TE-10 Frame, Figure 8
ZF WG 161 Frame, Figure 9
Cab Open Cab Open Cab - Not Shown
Closed Cab Closed Cab, Cab Lights, Rear Wiper Wash Pumps,
Figure 11 Figure 11 Extension, Figure 12C
Figure 12B
Mast Work Lights Mast Lights Mast Work Lights LH/RH
Figure 10 A Not Shown
Mast Harness Fork Lift Mast Fork Lift Carriage Standard
Truck Figure 10 B Not Shown
Mast Harness Container Mast Container Handler
Handler Not Shown

4
2200 SRM 1499
Not shown in a 3D-view are harnesses that are
merely an extension cord for some of the connectors,
or jumpers that connect between wires. The lay-out
of these harnesses can be read from the electrical
schematic. For the actual location of these har-
nesses, see Table 7 to look up the figure and item
number of the mating connectors.
Connected with the frame harness are:
• Brake temperature harness: Connects to CPS127.
• Powered cab tilt harness: Connects to CPS12.
• Front drive light harness: Connects to CPS60 and
CPS61.
• Side & indicator lights harness: Connects to
CPS49 and CPS67.
• Rear lights harness: Connects to CPS68 and
CPS69.
Connected with the mast light harness is the RH
mast work light extention, which connects to CPS
147. See Figure 10.
There are three different jumper options:
• Jumper Power Supply by Ignition, provides power
supply for side, tail and hazard lights when the ig-
nition switch is turned to the ON position. See
schematic location [77,H]. This harness is to be
plugged into connector CRP05, which connects pin
A with pin B.
• Jumper Power Supply by Battery directly, provides
power supply from the batteries to the circuit for
side, tail and hazard lights, allowing to activate
these lights irrespective of the ignition switch po-
sition. See schematic location [78,H]. This harness
is to be plugged into connector CRP05, which con-
nects pin B with pin C.
• The strobe light jumper allows activation by igni-
tion by connecting a jumper between pin number 2
and pin 3 of the strobe switch. See schematic loca-
tion [52,J].
Harness Interconnection
On the electrical schematic the interconnection be-
tween two harnesses is indicated by a harness divid-
ing line, which will run across the two mating har-
ness connectors. See Figure 1, item 15.
ELECTRICAL CONNECTORS
Connector Types
Connector types are identified by letter codes. Multi-
ple pin or socket connectors have a three letter code.
Electrical Schematic and System Description
Terminators, that are not isolated when detached,
have a two letter code. The explanation of the let-
ter codes is shown in Table 5.
Table 5. Connector Types
Letter Explanation
Code
CRP Connector Receptacle Pin
CRS Connector Receptacle Socket
CPP Connector Plug Pin
CPS Connector Plug Socket
TS Terminal Socket
TP Terminal Pin
Connector Identification
Each connector is identified by the letter code of the
connector type and a unique identification number.
Eg CRP07.
Connectors have the same identification number if
they interconnect between two wire harnesses. Eg
CRP07 interconnects with CPS07.
On the schematic a connector may be represented
complete with all wires it normally contains, or par-
tial, showing the few wires that are relevant for the
particular page of the schematic.
A completely represented connector shows two
rounded corners, as shown on Figure 1, item 11.
A partially represented connector has one curled cor-
ner, as shown on Figure 1, item 12.
As the wires in a connector will relate to different
functions, portions of a connector can be divided over
several schematic pages according the different elec-
trical function of the wires. In general there is no re-
lation between a connector and a schematic location.
The only possibility to look up a schematic location is
through the wire listing.
A connector is not shown on the schematic if the con-
nector is an integral part of a component or if it does
not have a minimum length of wire harness between
the component and the connector. In these cases the
schematic just shows the wire harness connector.
5
Electrical Schematic and System Description
Connector Pin Numbers
On the schematic the pin numbers are indicated by
a number or letter inside the connector symbol, with
the relevant wire ending at the relevant pin number.
On the connector itself pin numbers are shown in re-
lief, but can be as small as 1 mm high. To read the
numbers, clean the housing and provide sufficient
lighting.
Pin numbers can be located on the inside of the con-
nector next to the pin, on the backside of the connec-
tor next to the wires, or on the connector housing.
Connector Description
For orientation purposes each connector has been
provided with a description, which is shown in the
connector overview in Table 7, and in the legend for
the wire harnesses. The description matches the
component it is attached with.
For connectors between harnesses the description is
a combination of the two harness names. For in-
stance CPS139: Frame-Mast. The first part of the
description indicates the wire harness that the con-
nector is part of, the second part indicates the wire
6
2200 SRM 1499
harness that the connector connects with. An excep-
tion is the interconnection between frame and side
console harness, which is through three connectors.
To avoid having three identical descriptions, the de-
scriptions Cab Signals, Cab Power and Aux Signals
have been assigned.
FUSES
The grid heater and alternator have separate fuses
that are located in the engine compartment at the left
hand frame channel. Close to these fuses the starter
relay and grid heater are located. See Figure 2.
Four fuse panels are located behind the cover under
the instrument panel. The four fuse panels contain
the fuses that protect all other electrical circuits.
On the inside of this cover a label is fitted that shows
the location of the fuses in the four fuse panels. See
Figure 3.
In some cases a fuse is not adopted on the electrical
schematic. It concerns fuses that are an integral part
of a component, like retrofitted radio’s or the Twist
Module.
2200 SRM 1499 Electrical Schematic and System Description

Figure 2. Starter and Grid Heater Relays

Legend for Figure 2

Item Description Value Connector Location

1 Engine Fuel Filter ---- CPS125 [32,E]
2 Fuse Grid Heater 125 A TS36 [32,E]
3 Fuse Grid Heater 125 A TS95 [32,E]
4 Fuse Alternator 100 A TS15 [36,B]
5 Fuse Alternator 100 A TS16 [36,B]
6 Starter Relay ---- TS11 [38,C]
7 Starter Relay ---- TS08 [38,C]
8 Starter Relay ---- TS09 [38,C]
9 Starter Relay ---- TS10 [38,C]
10 Starter Relay ---- TS26 [38,C]
11 Grid Heater Relay ---- TS12 [32,G]
12 Grid Heater Relay ---- TS20 [32,G]
13 Grid Heater Relay ---- TS19 [32,G]
14 Grid Heater Relay ---- TS18 [32,G]

7
Electrical Schematic and System Description 2200 SRM 1499

Legend for Figure 3 (Continued)

2. FUSE PANEL #2

30A FLOOD LIGHTS F11 [57,J]

5A STROBE LIGHT B+ F12 [50,I]
10A BRAKE LIGHTS F13 [62,H]
10A FRONT DRIVE LIGHTS F14 [62,E]
5A INTERIOR LIGHTING F15 [50,H]
15A MAST/ATTACHMENT F16 [60,E]
LIGHTS
10A DIRECTION F17 [76,D]
INDICATORS
10A SIDE/TAIL LIGHTS F18 [58,I]
10A REAR DRIVE LIGHTS F19 [58,H]
10A REVERSE LIGHT/ F20 [58,I]
ALARM AND STROBE

3. FUSE PANEL #3
Figure 3. Fuse Panel
10A FRONT WINDSHIELD F21 [131,B]
WASHER/WIPER
Legend for Figure 3
10A ROOF WINDSHIELD F22 [131,B]
FUSE DETAILS WASHER/WIPER
1. FUSE PANEL #1 10A REAR WINDSHIELD F23 [131,C]
WASHER/WIPER
10A ENGINE START F1 [24,B]
10A HORN F24 [145,C]
5A ECM IGNITION F2 [30,H]
20A CAB TILT POWER F25 [84,H]
ASSIST
30A ECM SUPPLY F3 [30,H]
OPEN
7.5A XMSN IGN F4 [27,F]
15A SEAT SUSPENSION F27 [101,F]
7.5A XMSN SUPPLY F5 [44,C] COMPRESSOR
30A HYDRAULIC F6 [119,E] 20A HEATER/AC/ F28 [151,F]
CONTROLLER VENTILATION FAN
15A ATTACHMENT F7 [124,A] 15A AC FAN 1 F29 [158,H]
CONTROLS
15A AC FAN 2 F30 [158,G]
5A PARKING BRAKE F8 [102,A]
SOLENOID
10A INSTRUMENTATION F9 [99,B]
5A OPS SWITCH F10 [117,E]

8
2200 SRM 1499 Electrical Schematic and System Description

Legend for Figure 4

Legend for Figure 3 (Continued) Item Description Connector

1 Flood Lights CPS62
4. FUSE PANEL #4
2 Lights CPS62
10A POWER SOCKET F31 [147,H]
12VDC 3 Start Inhibit CPS13

10A RADIO/CB/INTERCOM F32 [147,G] 4 Neutral CPS13

10A CONVERTER FOR F33 [145,H] 5 Hydraulic CPS36

ACCESSORIES Controller

10A HAZARD LIGHTS F34 [76,D] 6 Reverse Lights/ CPS36

Alarm
10A AIR DRYER F35 [102,A]
7 Main Power CPS16
3A 12V RELAY, F36 [147,G]
8 AC Fan 3 CPS115
OPEN
9 Ignition CPS15
OPEN
10 AC Fan 2 CPS115
15A POWER SOCKET F39 [147,G]
24VDC 11 AC Fan 1 CPS115

OPEN 12 Flasher Unit CPS76

13 Open CPS120
RELAYS 14 Twist Lock/Unlock CPS120
15 12 Volt Relay CPS108
16 CH Override CPS108
17 Horn CPS84
18 Seat Switch CPS84

Except for the grid heater and starter relay, all relays
are fitted on the relay panel that is located left of the
fuse panel. The relay panel contains 15 smaller re-
lays, and the main power relay. The 15 smaller relays
are identical and can be swapped to check function-
ality. The relay panel can also contain a flasher unit.
See Figure 4.

Figure 4. Relay Panel

9
Electrical Schematic and System Description 2200 SRM 1499

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

Some components induce current surges when they
are switched off. These surges can cause sparking
of mechanical contacts in switches and relays, which
results in premature erosion of these contacts. Fly-
back diodes prevent these symptoms by connecting
the induced current surge to ground.
diode causes a short circuit.
Replacement diodes are integrated in connectors,
that attach the correct diode polarity to the wire
harnesses. Table 6 provides a complete listing of all
flyback diodes fitted.

Always check functionality of a flyback diode when

a switch or relay has failed. In most cases a failed

Table 6. Flyback Diodes ZF and TE-10 Transmissions

Connector Diode Description Location Figure Item

CPS1 Calibration TE-10 [45,H] Figure 12 A 78
CPS11 Relays [32,F] Figure 8 and Figure 9 59
CPS17 Main Power [24,A] [27,D] Figure 12 A 63
CPS34 Calibration ZF [42,C] Figure 12 78
CPS39 Lights [103,C] [55,I] Figure 12 79
CPS54 Backup [65,F] Figure 8 and Figure 9 67
CPS82 Horn [143,D] Figure 13 97
CPS123 Cab Tilt Pump [88,F] ---- ----

CAN (CONTROLLER AREA NETWORK)
CAN bus is a standard for an electronic system that
allows communication between different controllers
without the need for a host computer.
The different controllers have their own controlled
network of sensors, actuators and control devices.
Functioning of these components cannot be influ-
enced by other controllers unless the programming
of a network controller specifically allows.
Each controller requires it’s own connection to volt-
age supply, to feed the controller and also to provide
signals to the components that belong to the con-
troller network. Without voltage supply a controller
does not function.
Communication occurs through sending and receiv-
ing signals. Each signal contains amongst others a
code for the type of message (eg coolant temperature),
the message itself (83°) and the ID of the controller
(ECM) that has sent the signal. Each controller has
been programmed to react only to certain messages
from certain controllers. All other messages are ig-
nored.
Only two wires are required for communication: The
data wire and the data inverse wire. Integrity of sig-
nal transfer is verified by comparing the return sig-
nal of the data inverse wire with the original signal
of the data wire.
The can bus system includes the following controllers
:
Transmission controller
Hydraulic controller
Instrument cluster
Diagnostic connector*
Engine Control Module
(*)The diagnostic connector itself is not a controller.
Instead, the IFAK cable that leads to the lap top com-
puter contains the controller that will make contact
with the CAN bus system when plugged into the di-
agnostic connector.

10
2200 SRM 1499
Diagnostic
Interconnection between the controllers is schemat-
ically shown in Figure 5. The controllers are con-
nected through data inverse wire number 900 (green)
and data wire number 901 (yellow) that are twisted
together. The purpose of twisting is to reduce sensi-
tivity to electromagnetic interference. For the same
purpose there are termination resistors at the ex-
treme ends of the string of controllers. The system
will not function if both 120 Ohm resistors are faulty
or disconnected.
For trucks with a ZF transmission controller the end
resistor CPS66 is included in the ZF transmission
controller.
The sensors that relate to the different controllers
are primarily shown on sheet 9 of the electrical
schematic. Sensors for the transmission are shown
on sheet 4.
The optional electronic climate control has an inde-
pendent control system that does not communicate
through can bus wires 900 and 901.
Figure 5. CAN Bus Circuit
Troubleshooting
Most controllers have a memory that retains codes
for situations that occurred within their own con-
trolled circuit. Also faults in the controller itself are
stored as fault codes. Both the IFAK cable and the
instrument cluster contain a controller that makes
these codes visible on a lap top computer, respec-
tively on the hour meter display. The explanation of
these codes is shown on the different fault code ta-
bles for engine, transmission, hydraulic system and
Electronic Climate Control.
Electrical Schematic and System Description
The can bus connection itself can be verified by
checking continuity of the data inverse wires 900
(green) and the data wires 901 (yellow), and by
checking the 120 Ohm resistance value of the two
termination resistors. For schematic and actual
location see Table 7.
Diagnostics of a faulty CAN bus systems requires
thorough knowledge and specific software. As con-
trollers cannot be repaired there is no other option
than to replace a controller if it is found to be defec-
tive.
Instrument Panel
The lights and instruments that are shaded in Fig-
ure 6 and Figure 7 are controlled by CAN bus sig-
nals. The legend also shows the related pin numbers
of connector CPS94, which is shown on schematic lo-
cation [96,B]. To test functionality of the individual
warning lights, switch the ignition from OFF to ON.
All lights should light up for one second.
As there are no serviceable components, the entire
instrument panel must be replaced if found defective.
1. CENTRAL WARNING LIGHT
Figure 6. Instrument Panel
11
Electrical Schematic and System Description 2200 SRM 1499

Figure 7. Instrument Panel

12
2200 SRM 1499 Electrical Schematic and System Description

Legend for Figure 7

Item Description Pin Number

1 Central Warning Lights CAN
2 Coolant Temperature Gauge. See NOTE 2. CAN
3 Hour Meter/Fault Code Display CAN
4 Engine Warning Light/Wait To Start CAN
5 Engine Stop Warning Light CAN
6 Transmission Warning Light CAN
7 Transmission Pressure Warning Light CAN
8 Transmission Oil Temperature Gauge. See NOTE 2. CAN
9 Transmission Calibration Warning Light. CAN
10 Hydraulic System Malfunction Warning Light CAN
11 Hydraulic Oil Filter Restriction Warning Light CAN
12 Hydraulic Oil High Temperature Warning Light 6
13 Brake System Low Pressure Warning Light 13
14 Parking Brake Warning Light 7
15 Voltmeter Gauge. See NOTE 2. 1
16 Fuel Level Gauge 24
17 Engine Oil Pressure Gauge. See NOTE 2. 23
18 Seat Belt Warning Light 2
19 Fuel Filter/Water Separator Warning Light CAN
20 Engine Air Filter Warning Light 9
21 Engine Oil Level Warning Light. See NOTE 1. 8
22 Coolant Level Warning Light 5
23 Engine Maintenance Warning Light CAN
NOTE 1: To obtain functionality provide both the sensor and wiring.
NOTE 2: The icon in the gauge will flash after receiving a CAN signal.
CAN: Connection with CAN signals is through pin 14 and 15.

13
Electrical Schematic and System Description
GENERAL FAULT FINDING
Below procedure is a guideline to facilitate fault find-
ing in electrical circuits. Following the entire proce-
dure is not always practical. Use common sense. For
instance, if only one light out of a set of two has failed,
you will first check the bulb of the failed light.
The procedure is not suited for electronic circuits like
CANbus, which requires specific knowledge and soft-
ware. Fortunately, defective electric components and
connections that are part of a CANbus circuit will
generate a fault code in the controller. The fault code
guide provides further detail about the defect. Al-
ways verify presence of fault codes.
Preparation
1. Have the electrical Schematic available. See Di-
agrams 8000 SRM 1500.
2. Identify the symptoms of the defect.
3. Establish how the relevant switches and levers
should operate. See the Operating Manual.
4. Observe the condition of the truck. Look for
signs of mechanical damage, overheating, un-
usual sounds, burnt smells.
Define the Problem Area
1. Determine the schematic location of the failed
function. See Table 7.
2. Establish which sections of the failed function
operate correctly. Identify these sections on the
schematic.
Identify Possible Causes of Malfunction
1. Make a list of every possible fault. Use your ini-
tial observations to help you writing down these
faults.
Determine the Most Probable Cause
1. Prioritize each of the listed possible faults.
2. Perform a Fuse Check, a Wiring Check and a
Component Check for each of the listed faults.
14
2200 SRM 1499
Fuse Check
Determine which fuse protects the component in the
failed circuit. See Table 7 to look up the related page
of the schematic and find the fuse reference number.
Investigate if an overload condition or a short circuit
caused the fuse to fail. First make repairs to solve
the short circuit or overload condition. See Wiring
Check.
Replace the fuse after the repair has been made. The
actual location of the fuse is indicated on Figure 3.
Wiring Check
Check signal presence at the component.
If no signal is present, check the signal at the next
component closer to the battery (relay, fuse, switch,
ignition switch). See electric diagram.
Check for damaged wire insulation especially when
there are erratic failures.
Check connection to battery ground. Establish virtu-
ally zero resistance for battery ground connections.
Component Check
Isolate the component and check electrical function-
ality according the electric schematic.
Switches and connectors must have virtually zero re-
sistance when closed.
Check for open circuits, short circuits and insulation
breakdown.
Check if coils and relays do not overheat, which indi-
cates a defect.
Repair and Test
Remove the ground cable from the battery when do-
ing repairs. Replace or repair the defective compo-
nents after the cause of failure has been established.
Replace the fuse found defective.
After the repair, do a test to make sure that the
proper repair has been made and that there are no
other faults in the circuit.
2200 SRM 1499 Wire Harness Identification and Connector Location

Wire Harness Identification and Connector Location

Below Figure 8 through Figure 14 show a 3D-view of
most of the wire harnesses with their terminals and
connectors. The legends for these figures mention
the connector codes and connector description for ver-
ification. Related is Table 7, which indicates the item
and figure number to find a connector or terminal.
NOTE: Figure 8 and Figure 9 share the same legend
itemized from 1 to 69.
NOTE: Figure 11 through Figure 14 share the same
legend itemized 1 to 119

Table 7. Connector Overview

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS01 Diode Calibration (SOH [43,C] Figure 12 78 SIDECON-
TE-10) SOLE
CPS01 ZF DIAG (ZF WG161) [46,H] Not shown SIDECON-
SOLE
CPS02 Engine ECM Signals [38,I] [39,I] Figure 8 3 Frame
and
Figure 9
CPS03 Engine ECM Power [38,J] [39,J] Figure 8 4 Frame
and
Figure 9
CPS04 Throttle Pedal [36,I] [37,I] Figure 8 30 Frame
and
Figure 9
CPS05 CAN Termination Resistor [36,F] [37,F] Figure 8 5 Frame
and
Figure 9
CPS06 Cab Power [24,F] [25,F], Figure 8 15 Frame
[33,J], and
[85,G] Figure 9
CPS07 Cab Signals [24,I] [25,I] Figure 8 14 Frame
and
Figure 9
CPS08 Hydraulic Controller [114,B] [115,B] Figure 12 55 Side Console
CPS09 Aux 1 lever [119,J] [120,J] Figure 14 112 Armrest
CPS10 Hydraulic Temperature [90,F] [91,G] Figure 8 19 Frame
and
Figure 9
CPS100 Brake light [63,I] [64,I] Figure 8 31 Frame
and
Figure 9
CPS101 Aux Solenoid [111,J] [112,J] Figure 8 32 Frame
and
Figure 9

15
Wire Harness Identification and Connector Location 2200 SRM 1499

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS102 Tilt Solenoid [112,J] [113,J] Figure 8 41 Frame
and
Figure 9
CPS103 Lift Solenoid 1 [112,J] [113,J] Figure 8 42 Frame
and
Figure 9
CPS104 Lift Solenoid 2 [113,J] [114,J] Figure 8 33 Frame
and
Figure 9
CPS105 Sideconsole - Twist Module [82,D] [83,D] Figure 12 49 Side Console
CPS106 TWIST Module [81,E] [82,E] Not shown Twist
Module
CPS107 DC/DC Convertor [147,I] [148,I] Figure 12 62 Side Console
CPS108 CH Override [144,F] [145,F] Figure 4 15 Side Console
CPS108 12V Relay [86,B] [87,B] Figure 4 16 Side Console
CPS109 Fuses 31-40 Figure 3 Figure 3 Figure 12 34 Side Console
CPS11 Diode Relays [32,F] [33,F] Figure 8 59 Frame
and
Figure 9
CPS110 Radio Power [141,H] [142,H] Figure 11 15 Closed Cab
CPS111 Radio Sound [141,I] [142,I] Figure 11 16 Closed Cab
CPS112 Tilt Lever [117,J] [118,J] Figure 14 107 Armrest
CPS113 Lift Lever [117,J] [118,J] Figure 14 105 Armrest
CPS114 Aux 0 lever [118,J] [119,J] Figure 14 108 Armrest
CPS115 Relay AC Fan 1 and 2 [158,F] [159,F] Figure 4 10,11 Side Console
CPS116 HVAC Unit [152,F] [153,F] Figure 12 47 Side Console
CPS117 Side console - AC [152,C] [153,C] Figure 12 53 Side Console
CPS118 Twist locks [121,G] [122,G], Figure 14 111 Armrest
[123,G]
CPS119 Hydraulic Stop [121,I] [122,I], Figure 14 104 Armrest
[123,I]
CPS12 Frame - Cab Tilt [85,F] [86,F] Figure 8 43 Frame
and
Figure 9
CPS120 Relay TwistLocks [124,E] [125,E] Figure 4 13,14 Side Console
CPS121 Cab Tilt Pump [87,H] [88,H] Not shown Powered Cab
Tilt

16
2200 SRM 1499 Wire Harness Identification and Connector Location

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS122 Cab Tilt Switch [86,G] [87,G] Not shown Powered Cab
Tilt
CPS123 Diode Cab Tilt Pump [88,F] [89,F] Not shown Powered Cab
Tilt
CPS124 Frame - Mast Lights [74,H] [75,H] Figure 8 25 Frame
and
Figure 9
CPS125 Engine-Fuel Filter [37,G] [38,G] Figure 8 58 Frame
and
Figure 9
CPS126 Hoist Pressure [114,J] [115,J] Figure 8 35 Hydraulics
and
Figure 9
CPS127 Frame-Brake Temperature [93,A] Figure 9 28 Frame
(ZF WG161)
CPS128 Frame-Brake Temperature [93,B] Figure 9 39
(ZF WG161)
CPS129 Parkbrake Sol Air brakes [105,H] Figure 8 38 Side Console
(SOH TE-10)
CPS13 Neutral & Startinhibit Relay [28,C] [29,C] Figure 4 3,4 Side Console
CPS130 FWD/REV PROP (SOH [40,C] Figure 8 52 Frame
TE-10)
CPS131 Heating Unit Air Dryer [106,C] Figure 8 10 Frame
(SOH TE-10)
CPS132 2ND PROP (SOH TE-10) [40,D] Figure 8 53 Frame
CPS134 Brake Return Filter (ZF [91,G] Figure 9 24 Frame
WG161)
CPS135 Switches Joystick [121,B] [122,B] Figure 14 110 Armrest
CPS136 ECH Mast-ECH Attachment [174,F] [175,F] Not shown ECH-Mast
CPS137 Aux 2 [120,D] [121,D], Figure 14 109 Armrest
[122,D]
CPS138 Aux 3 [120,E] [121,E], Figure 14 106 Armrest
[122,E]
CPS139 Frame - Mast [129,F] [130,F] Figure 8 27 Frame
and
Figure 9
CPS14 Key Switch [25,B] [26,B] Figure 12 42 Side Console

17
Wire Harness Identification and Connector Location 2200 SRM 1499

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS140 Breather Filter [90,F] [91,F] Figure 8 20 Frame
and
Figure 9
CPS141 Frame-Mast EC [129,H] [130,H] Figure 8 26 Frame
and
Figure 9
CPS142 Sped Signals [119,D] [120,D] Figure 12 54 Side Console
CPS143 Diagnostic Switch (SOH [98,B] Figure 12 77 Side Console
TE-10)
CPS143 XMSN connector (ZF [44,A], Figure 12 77 Side Console
WG161) [44,J]
CPS144 Suspension Seat [101,H] [102,H] Figure 14 102 Armrest
CPS145 Accessory Socket 12V [147,F] [148,F] Figure 12 56 Side Console
CPS146 Mast Lights - RH Mast [77,J] [78,J] Figure 10 1 Mast Lights
Lights
CPS147 Mast Lights - LH Mast [76,I] [77,I] Figure 10 4 Mast Lights
Lights
CPS148 Mast-Front End [163,F] [164,F] Figure 10 5 Mast
CPS149 AUX 0 [167,D] [167,F] Not shown Front End
CPS15 Relay AC Fan 3 [158,G] [159,G] Figure 4 8 Side Console
CPS15 Relay Ignition [26,G] [27,G] Figure 4 9 Side Console
CPS150 AUX 1 [167,E] [167,C] Not shown Front End
CPS151 AUX 2 [167,C] [167,D] Not shown Front End
CPS152 AUX 3 [167,C] [167,E] Not shown Front End
CPS153 SOLENOID B [166,G] [166,G] Not shown DFSSFP
CPS154 SOLENOID A [166,H] [166,H] Not shown DFSSFP
CPS155 SOLENOID B [166,I] [166,I] Not shown DFSSFP
CPS156 Backup Light [68,G] [69,G] Not shown Backup Light
CPS157 Backup Light [68,J] [69,J] Not shown Backup Light
CPS158 Backup Light [68,J] [69,J] Not shown Tail Light
CPS159 Backup Light [67,G] [68,G] Not shown Tail Light
CPS16 Main Power Relay (ZF [27,E] Figure 4 7 Side Console
WG161)
CPS160 1ST/3RD PROP (SOH TE-10) [40,D] Figure 8 54 Frame
CPS160 XMSN connector (ZF [41,F] Figure 9 50 Frame
WG161)

18
2200 SRM 1499 Wire Harness Identification and Connector Location

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS161 1ST/3RD SELECT (SOH [40,E] Figure 8 55 Frame
TE-10)
CPS161 Turbine speed (ZF WG161) [41,B] Figure 9 12 Frame
CPS162 SERVICE SWITCH (SOH [116,F] Figure 12 80 Side Console
TE-10)
CPS162 XMSN Filter Switch (ZF [41,H] Figure 9 49 Frame
WG161)
CPS163 CALIBRATION SWITCH [43,B] Figure 12 81 Side Console
(SOH TE-10)
CPS17 Diode Main Power [24,A] [25,A], Figure 12 63 Side Console
[28,D]
CPS18 Brake Pressure Switch [90,H] [93,H] Figure 8 34 Frame
and
Figure 9
CPS19 Diagnostic Connector [98,G] [99,G] Figure 12 45 Side Console
CPS20 Washer Front [138,J] [139,J] Figure 12 74 Wash Pumps
CPS21 XMSN J1 (SOH TE-10) [43,J] Figure 12 64 Side Console
CPS21 ZF Display (ZF WG161) [46,I] Not shown Side Console
CPS22 Engine Speed [40,F] [41,C] Figure 8 48 Frame
and
Figure 9
CPS23 Output Speed Sensor [40,A] [41,A] Figure 9 47 Frame
CPS24 Drum Speed (SOH TE-10) [40,A] Figure 8 11 Frame
CPS24 Internal Speed (ZF WG161) [41,B] Figure 8 11 Frame
and
Figure 9
CPS25 FWD SELECTOR (SOH [40,B] Figure 8 51 Frame
TE-10)
CPS25 Diagnostic Switch (ZF [100,B], [99,C] Figure 12 77 Side Console
WG161)
CPS26 Turbine Speed (SOH TE-10) [40,F] Figure 8 12 Frame
CPS26 SERVICE SWITCH (ZF [117,F] Figure 12 80 Side Console
WG161)
CPS27 XMSN J2 (SOH TE-10) [44,A] Figure 12 81 Side Console
CPS27 CALIBRATION SWITCH [43,B] Figure 12 81 Side Console
(ZF WG161)
CPS28 Side console - Washer Pump [135,G] [136,G] Figure 12 72 Side Console

19
Wire Harness Identification and Connector Location 2200 SRM 1499

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS29 Shift Lever [49,B] [50,B] Figure 13 88 Steering
Column
CPS30 Underfloor - Steer Column [49,D] [50,D] Figure 13 93 Cab
Underfloor
CPS300 BACKUP ALARM-FRAME [67,G] [68,G] Not shown Back-Up
Alarm
Extension
CPS301 BACKUP ALARM [67,G] [68,G] Not shown Back-Up
Alarm
Extension
CPS31 Monotrol Pedal [49,H] [50,H] Figure 13 90 Cab
Underfloor
CPS32 Inching Pedal [48,H] [49,I] Figure 13 96 Cab
Underfloor
CPS33 Side console - Under Floor [26,I] [27,I] Figure 12 61 Side Console
CPS34 XMSN Resistors (SOH [46,I] Figure 12 78 Side Console
TE-10)
CPS34 Diode Calibration (ZF [43,C] Figure 12 78 Side Console
WG161)
CPS35 Aux Signals [88,C] [89,C] Figure 8 16 Frame
and
Figure 9
CPS36 Hydr contr. Relay [26,H] [27,H] Figure 4 5 Side Console
CPS36 Reverse Lights relay [61,I] [62,I] Figure 4 5 Side Console
CPS37 Fuses 1-10 Figure 3 Figure 3 Figure 12 32 Side Console
CPS38 Washer Roof [138,I] [139,I] Figure 12 76 Wash Pumps
CPS39 Lights Diode [55,I] [104,C], Figure 12 79 Side Console
[56,I]
CPS40 RH Rear Drive Lts [58,C] [59,C] Figure 11 5 Cab Lights
CPS41 RH Outer Flood Light [58,D] [59,D] Figure 11 1 Cab Lights
CPS42 RH Inner Flood Light [58,D] [59,D] Figure 11 2 Cab Lights
CPS43 LH Rear Drive Lts [58,F] [59,F] Figure 11 8 Cab Lights
CPS44 LH Outer Flood Light [58,G] [59,G] Figure 11 11 Cab Lights
CPS45 LH Inner Flood Light [58,G] [59,G] Figure 11 12 Cab Lights
CPS46 12v Plug [146,F] [147,F] Figure 12 43 Side Console
CPS47 Strobe Switch [52,J] [53,J], [54,J] Figure 12 39 Side Console

20
2200 SRM 1499 Wire Harness Identification and Connector Location

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS48 Flood /RR Drive LTS Switch [55,G] [56,G], Figure 12 38 Side Console
[57,G]
CPS49 Front Lts-LH Marker Lts [67,B] [68,B] Not shown Front Drive
Light
CPS50 Fuses 11-20 Figure 3 Figure 3 Figure 12 33 Side Console
CPS51 Fuses 21-30 Figure 3 Figure 3 Figure 12 35 Side Console
CPS52 Side/Front Lights Switch [60,D] [61,D],[61,E] Figure 12 37 Side Console
CPS53 Mast/Att Lights Switch [60,F] [61,F],[61,G] Figure 12 36 Side Console
CPS54 Backup Diode [65,F] [66,F] Figure 8 67 Frame
and
Figure 9
CPS55 Reverse Selector Valve [40,C] Not shown Frame-
CPS56 LH Drive Light [68,D] [69,D] Not shown Front Drive
Light
CPS57 LH Mast Light [77,J] [69,D] Not shown Mast Light
Extension
CPS59 RH Drive Light [68,E] [69,E] Not shown Front Drive
Light
CPS60 Frame - LH Front Lights [66,C] [67,C] Figure 8 40 Frame
and
Figure 9
CPS61 Frame - RH Front Lights [66,E] [67,E] Figure 8 29 Frame
and
Figure 9
CPS62 Relay Main / Flood Lights [55,I] [56,I] Figure 4 1,2 Side Console
CPS63 Closed Cab - Side Console [53,G] [54,F] Figure 11 30 Closed
Cab/Open
Cab
CPS64 RH Cab Lights [56,D] [57,D] Figure 11 6 Cab Lights
CPS65 LH Cab Lights [56,G] [57,G] Figure 11 7 Cab Lights
CPS66 End Resistor (SOH TE-10) [42,J] Figure 12 67 Side Console
CPS67 Front Lts-RH Marker Lts [67,F] [68,F] Not shown Front Drive
Light
CPS68 Frame-RH rear lamp [66,H] [67,H] Figure 8 1 Frame
and
Figure 9
CPS69 Rear Lights - LH Tail Lights [66,J] [67,J] Figure 8 65 Rear Lights
and
Figure 9

21
Wire Harness Identification and Connector Location 2200 SRM 1499

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS70 Engine Shut Down Jumper [25,C] [26,C] Figure 12 60 Side Console
CPS71 Wiper Timer [131,F] [132,F] Figure 12 48 Side Console
CPS72 Inhibit Aux 1 [119,J] [120,J] Figure 14 113 Armrest
CPS73 Lowering Solenoid [110,I] [111,I] Figure 8 36 Frame
and
Figure 9
CPS74 Side console - Wiper Rear [130,G] [131,G] Figure 12 51 Side Console
CPS75 Roof Wiper [133,J] [134,J] Figure 11 20 Closed Cab
CPS76 Flasher Unit [71,B] [72,B] Figure 4 12 Side Console
CPS77 Hazard Switch [71,D] [72,D], Figure 12 36 Side Console
[73,D]
CPS78 Front Wiper [136,I] [137,I] Figure 13 91 Cab
Underfloor
CPS79 Pressure Filter [90,E] [91,E] Figure 8 9 Frame
and
Figure 9
CPS80 Horn Switch Armrest [148,C] [149,C], Figure 14 114 Armrest
[150,C]
CPS81 Armrest-Side console [102,G] [103,G] Figure 14 119 Armrest
CPS82 Diode Horn [143,D] [144,D] Figure 13 97 Cab
Underfloor
CPS83 Horn Button [140,B] [141,B] Figure 13 82 Steering
Column
CPS84 Seat Switch/Horn Relay [115,I] [116,I], Figure 4 17,18 Side Console
[147,C]
CPS85 Main Filter [90,D] [91,D] Figure 8 18 Frame
and
Figure 9
CPS86 Front Wiper Switch [137,B] [138,B], Figure 14 116 Armrest
[139,B]
CPS87 Hub Temp Switch (ZF [92,A] Not shown Brake
WG161) Temperature
CPS88 Hub Temp Switch (ZF [92,B] Not shown Brake
WG161) Temperature
CPS89 Front Washer Switch [137,C] [138,C], Figure 14 115 Armrest
[139,C]
CPS90 Roof Wiper/Washer Switch [137,E] [138,E], Figure 14 117 Armrest
[139,E]

22
2200 SRM 1499 Wire Harness Identification and Connector Location

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CPS91 Rear Wiper/Washer Switch [137,F] [138,F], Figure 14 118 Armrest
[139,F]
CPS92 Wiper Rear [131,H] [132,H] Figure 12 65 Rear Wiper
Extension
CPS93 Coolant Level [90,I] [91,I] Not shown Frame
CPS94 Instrument Cluster [97,B] [98,B] Figure 12 41 Side Console
CPS95 Washer Rear [138,H] [139,H] Figure 12 75 Wash Pumps
CPS96 Map Light [51,I] [52,I] Figure 12 57 Side Console
CPS97 Air Filter [90,C] [91,C] Figure 8 46 Frame
and
Figure 9
CPS98 Parkbrake Solenoid (ZF [106,F] Figure 9 38 Frame
WG161)
CPS99 Accumulator Charge Disable [113,J] [114,J] Figure 8 37 Frame
Solenoid and
Figure 9
CRP01 AC Clutch [157,C] [158,C] Figure 8 2 Frame
and
Figure 9
CRP02 OPS Switch [116,I] [117,I] Figure 14 101 Armrest
CRP03 1st 3rd p Sensor (SOH [40,H] Figure 8 56 Frame
TE-10)
CRP05 Lights Jumper [78,G] [78,G] Figure 12 58 Side Console
CRP06 Cab Power [25,F] [25,F] Figure 12 70 Side Console
CRP07 Cab Signals [24,F] Figure 12 69 Side Console
CRP08 Fuel Filter-Engine [39,G] [40,G] Figure 8 6 Frame
and
Figure 9
CRP09 XMSN Sump Temp [40,G] Figure 8 68 Frame
CRP09 Convertor Temp (ZF WG161) [42,G] Figure 9 13 Frame
CRP10 Closed Cab - Condensor Unit [151,B] [151,B] Figure 11 26 Closed Cab
CRP105 TWIST Mod-Side console [83,D] [83,D] Not shown Twist
Module
CRP11 2nd p Sensor (SOH TE-10) [40,G] Figure 8 57 Frame
CRP117 AC - Side Console [153,C] [153,C] Figure 11 31 Closed Cab
CRP12 Cab Tilt-Frame [85,F] [86,F] Not shown Powered Cab
Tilt

23
Wire Harness Identification and Connector Location 2200 SRM 1499

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CRP124 Mast Lights - Frame [75,H] [75,H] Figure 10 3 Mast Work
Lights
CRP127 Brake Temperature-Frame [93,A] Not shown Brake
(ZF WG161) Temperature
CRP128 Brake Temperature-Frame [93,B] Not shown Brake
(ZF WG161) Temperature
CRP139 Mast-Frame [160,F] [161,F] Figure 10 2 Mast
CRP141 Mast ec-Front End [171,F] [171,F] Not shown ECH-MAST
CRP147 Mast Lts LH-Mas Lts [76,I] [77,I] Not shown Mast Lights
Extention
CRP148A Front-End [163,E] [164,E] Not shown Front End
CRP148B DFSSFP [163,H] [164,H] Not shown DFSSFP
CRP148C Frame-ECH Mast [171,D] [171,D] Not shown ECH-MAST
CRP156 Backup Light [67,G] [68,G] Not shown Tail LIght
CRP157 Backup Light [68,J] [69,J] Not shown Tail LIght
CRP158 Backup Light [68,J] [69,J] Not shown Backup Light
CRP159 Backup Light [68,G] [69,G] Not shown Backup Light
CRP28 Washer Pump - Side Console [135,H] [136,H] Figure 12 72 Wash Pumps
CRP30 Steer Column - Underfloor [72,J] [73,J] Figure 13 92 Steering
Column
CRP300 FRAME-BACKUP ALARM [66,G] [67,G] Figure 8 66 Frame
and
Figure 9
CRP33 Underfloor - Side console [26,J] [27,J] Figure 13 89 Cab
Underfloor
CRP35 Aux Signals [88,C] [128,F], Figure 12 71 Side Console
[89,C],
[95,D]
CRP49 LH Marker Lts-LH Lts [67,B] [68,B] Not shown Side and
Indicator
Light
CRP60 LH Front Lights-Frame [66,C] [67,C] Not shown Front Drive
Light
CRP61 RH Front Lights-Frame [66,E] [67,E] Not shown Front Drive
Light
CRP63 Side console - Closed Cab [53,G] [55,G] Figure 12 50 Side Console

24
2200 SRM 1499 Wire Harness Identification and Connector Location

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
CRP64 RH Cab Lights [56,D] [57,D] Figure 11 25 Closed
Cab/Open
Cab
CRP65 LH Cab Lights [56,G] [57,G] Figure 11 17 Closed
Cab/Open
Cab
CRP67 RH Marker Lts-RH-Lts [67,F] [68,F] Not shown Side and
Indicator
Light
CRP68 RH rear lamp-Frame [66,H] [67,H] Not shown Tail Lights
CRP69 LH Rear lights-Frame [66,J] [67,J] Not shown Tail Lights
CRP70 Engine Shut Down Jumper [25,D] [26,D] Figure 12 59 Side Console
CRP74 Wiper Rear - Side console [130,G] [131,G] Figure 12 51 Rear Wiper
Extention
CRP81 Side console - Armrest [102,F] [103,F] Figure 12 66 Side Console
CRS01 Park Brake Switch Element [101,B] [102,B] Figure 12 46 Side Console
TS01 Groundpoint Frame [33,B] [34,B] Figure 8 21 Frame
and
Figure 9
TS02 Battery+ [22,I] [23,I] Not shown Battery
Cable +
TS03 Battery- [20,I] [21,I] Not shown Battery
Cable -
TS04 Battery+ [21,I] [22,I] Not shown Battery
Cable +
TS05 Battery- [21,I] [22,I] Not shown Battery
Cable +
TS06 Alternator B+ [36,C] [37,C] Figure 8 63 Frame
and
Figure 9
TS07 Alternator Ground [36,D] [37,D] Figure 8 64 Frame
and
Figure 9
TS08 Starter Relay [38,B] [39,B] Figure 2 7 Frame
TS09 Starter Relay [38,C] [39,C] Figure 2 8 Frame
TS10 Starter Relay [38,B] [39,B] Figure 2 9 Frame
TS100 Ground Starter motor [38,E] [39,E] Not shown Battery
Cable
TS102 Armrest Ground [148,D] [149,D] Figure 14 100 Armrest

25
Wire Harness Identification and Connector Location 2200 SRM 1499

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
TS103 Armrest Ground [149,D] [150,D] Figure 14 103 Armrest
TS11 Starter Relay [38,C] [39,C] Figure 2 6 Frame
TS12 Gridheater Relay [32,G] [33,G] Figure 2 11 Frame
TS13 Starter Motor Solenoid [38,E] [39,E] Figure 8 62 Frame
and
Figure 9
TS14 Ground Starter motor [38,E] [39,E] Figure 8 60 Frame
and
Figure 9
TS15 Fuse Alternator 100A [36,A] [37,A] Figure 2 4 Frame
TS16 Fuse Alternator 100A [36,A] [37,A] Figure 2 5 Frame
TS17 Grid Heater [32,H] [33,H] Figure 8 69 Frame
and
Figure 9
TS18 Gridheater Relay [32,G] [33,G] Figure 2 14 Frame
TS19 Gridheater Relay [32,G] [33,G] Figure 2 13 Frame
TS20 Gridheater Relay [32,G] [33,G] Figure 2 12 Frame
TS23 Groundpoint Frame [33,A] Not shown Battery
Cable -
TS24 Groundpoint Frame [33,A] Not shown Battery
Cable -
TS25 Starter Motor+ [38,D] [39,D] Figure 8 61 Frame
and
Figure 9
TS26 Starter Relay [38,B] [39,B] Figure 2 10 Frame
TS27 XMSN Temp Switch (SOH [40,I] Figure 8 13 Frame
TE-10)
TS29 Starter Motor+ [38,D] [39,D] Figure 8 61 Frame
and
Figure 9
TS34 Inching Switch [25,J] [26,J] Figure 13 95 Cab
Underfloor
TS35 Inching Switch [25,J] [26,J] Figure 13 94 Cab
Underfloor
TS36 Fuse Grid heater 125 A [32,D] [33,D] Figure 2 2 Frame
TS39 Starter Motor+ [38,D] [39,D] Figure 8 61 Frame
and
Figure 9

26
2200 SRM 1499 Wire Harness Identification and Connector Location

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
TS40 Ground Starter motor [33,A] [34,A] Figure 8 22 Frame
and
Figure 9
TS41 Fuel Sender- [90,C] [91,C] Figure 8 44 Frame
and
Figure 9
TS43 RH Interior Light [53,A] [54,A] Figure 11 28 Closed Cab
TS44 RH Interior Light [53,A] [54,A] Figure 11 27 Closed Cab
TS45 LH Interior Light [53,B] [54,B] Figure 11 13 Closed Cab
TS46 LH Interior Light [53,B] [54,B] Figure 11 14 Closed Cab
TS48 Strobe Light [58,C] [59,C] Figure 11 3 Cab Lights
TS49 RH Rear Lights [67,H] [68,H] Not shown Tail Lights
TS50 RH Rear Lights [67,H] [68,H] Not shown Tail Lights
TS51 RH Rear Lights [67,H] [68,H] Not shown Tail Lights
TS52 RH Rear Lights [67,H] [68,H] Not shown Tail Lights
TS53 LH Rear Lights [67,I] [68,I] Not shown Tail Lights
TS54 LH Rear Lights [67,I] [68,I] Not shown Tail Lights
TS55 LH Brake Lights [67,I] [68,I] Not shown Tail Lights
TS56 LH Rear Lights [67,J] [68,J] Not shown Tail Lights
TS57 RH Indicator [68,E] [69,E] Not shown Side and
Indicator
Light
TS58 RH Side Light [68,F] [69,F] Not shown Side and
Indicator
Light
TS59 RH Side/Indicator Ground [68,F] [69,F] Not shown Side and
Indicator
Light
TS60 LH Side/Indicator Ground [68,D] [69,D] Not shown Side and
Indicator
Light
TS61 LH Side Light [68,C] [69,C] Not shown Side and
Indicator
Light
TS62 LH Indicator Light [68,C] [69,C] Not shown Side and
Indicator
Light

27
Wire Harness Identification and Connector Location 2200 SRM 1499

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
TS64 Indicator Switch 54 [73,G] [74,G] Figure 13 84 Steering
Column
TS65 Strobe Light [58,E] [59,E] Figure 11 10 Cab Lights
TS66 Indicator Switch L [73,H] [74,H] Figure 13 83 Steering
Column
TS67 Indicator Switch R [73,H] [74,H] Figure 13 87 Steering
Column
TS68 Horn [143,E] [144,E] Figure 13 99 Cab
Underfloor
TS69 Horn [143,E] [144,E] Figure 13 98 Cab
Underfloor
TS76 Fuel Sender + [90,C] [91,C] Figure 8 45 Frame
and
Figure 9
TS77 Starter Motor+ [38,E] Not shown Batery Cable
+
TS78 Engine Oil Pressure + [90,I] [91,J] Figure 8 7 Frame
and
Figure 9
TS79 Engine Oil Pressure - [90,J] [91,J] Figure 8 8 Frame
and
Figure 9
TS80 Master Warning [97,J] [98,J] Figure 13 86 Steering
Column
TS81 Master Warning [97,J] [98,J] Figure 13 85 Steering
Column
TS82 Buzzer [94,G] [95,G] Figure 12 44 Side Console
TS83 Buzzer [94,G] [95,G] Figure 12 44 Side Console
TS84 Groundpoint Frame [33,A] [34,A] Figure 8 23 Frame
and
Figure 9
TS89 Radio Coms [141,F] [142,F] Figure 11 24 Closed Cab
TS90 Radio Coms [141,F] [142,F] Figure 11 23 Closed Cab
TS91 Right Speaker + [142,J] [143,J] Figure 11 21 Closed Cab
TS92 Right Speaker - [142,J] [143,J] Figure 11 22 Closed Cab
TS93 Left Speaker + [143,J] [144,J] Figure 11 18 Closed Cab
TS94 Left Speaker - [143,J] [144,J] Figure 11 19 Closed Cab
TS95 Fuse Grid heater 125 A [32,D] [33,D] Figure 2 3 FRAME

28
2200 SRM 1499 Wire Harness Identification and Connector Location

Table 7. Connector Overview (Continued)

Code Description Location Location Figure Item Harness

TE-10 ZF Name
TS96 Strobe Light [58,B] [59,B] Figure 11 4 Cab Lights
TS97 Strobe Light [58,E] [59,E] Figure 11 9 Cab Lights
TS98 Ventilation Fan [151,D] [152,D] Figure 11 29 Closed Cab
TS99 ECM Power Connection [22,I] [23,I] Figure 8 17 Frame
and
Figure 9

29
Wire Harness Identification and Connector Location 2200 SRM 1499

Figure 8. TE-10 Transmission Frame Harness

A. TE-10 TRANSMISSION HARNESS B. ZF TRANSMISSION HARNESS

Figure 9. ZF Transmission Frame Harness

30
2200 SRM 1499 Wire Harness Identification and Connector Location

Legend for Figure 8 and Figure 9

NOTE: These items will have either (SOH TE-10) or (ZF WG161) to specify which application it
applies to.
Number Connector Description
1 CPS68 CPS68/Frame-RH rear lamp
2 CRP01 AC-Clutch
3 CPS02 Engine ECM signals
4 CPS03 Engine ECM Power
5 CPS05 CAN termination resistor
6 CRP08 Fuelfilter-Engine
7 TS78 Engine Oil Pressure+
8 TS79 Engine Oil Pressure-
9 CPS79 Pressure Filter
10 CPS131 Heating Unit Air Dryer (SOH TE-10)
11 CPS24 Drum Speed (SOH TE-10)
CPS24 Internal Speed (ZF WG161)
12 CPS26 Turbine Speed (SOH TE-10)
CPS161 Turbine speed (ZF WG161)
13 TS27 XMSN Temp Switch (SOH TE-10)
CRP09 Convertor Temp (ZF WG161)
14 CPS07 Cab Signals
15 CPS06 Cab Power
16 CPS35 Aux Signals
17 TS99 ECM Power Connection
18 CPS85 Main Filter
19 CPS10 Hydraullic Temperature
20 CPS140 Breather Filter
21 TS01 Groundpoint Frame
22 TS40 Groundpoint Frame
23 TS84 Groundpoint Frame
24 CPS134 Brake Return Filter (ZF WG161)
25 CPS124 Frame-Mast Lts
26 CPS141 Frame-Mast EC
27 CPS139 Frame-Mast
28 CPS127 Frame-Brake Temperature (ZF WG161)
29 CPS61 Frame-RH Front Lights

31
Wire Harness Identification and Connector Location 2200 SRM 1499

Legend for Figure 8 and Figure 9 (Continued)

NOTE: These items will have either (SOH TE-10) or (ZF WG161) to specify which application it
applies to.
Number Connector Description
30 CPS04 Trottle Pedal
31 CPS100 Brake light
32 CPS101 Aux Solenoid
33 CPS104 Lift Solenoid2
34 CPS18 Brake Pressure Switch
35 CPS126 Hoist Pressure
36 CPS73 Lowering Solenoid
37 CPS99 Accum Charge disable Sol
38 CPS129 Parkbrake Sol Air brakes (SOH TE-10)
CPS98 Parkbrake Solenoid (ZF WG161)
39 CPS128 Frame-Brake Temperature (ZF WG161)
40 CPS60 Frame-LH Front Lights
41 CPS102 Tilt Solenoid
42 CPS103 Lift Solenoid1
43 CPS12 Frame-Cab Tilt
44 TS41 Fuel Sender-
45 TS76 Fuel Sender+
46 CPS97 Air filter
47 CPS23 Output Speed
48 CPS22 Engine Speed
49 CPS162 XMSN Filter Switch (ZF WG161)
50 CPS160 XMSN connector (ZF WG161)
51 CPS25 FWD SELECTOR (SOH TE-10)
52 CPS130 FWD/REV PROP (SOH TE-10)
53 CPS132 2ND PROP (SOH TE-10)
54 CPS160 1ST/3RD PROP (SOH TE-10)
55 CPS161 1ST/3RD SELECT (SOH TE-10)
56 CRP03 1st 3rd p Sensor (SOH TE-10)
57 CRP11 2nd p Sensor (SOH TE-10)
58 CPS125 CPS125/Engine-Fuelfilter
59 CPS11 Diode Relays
60 TS14 Ground Startermotor

32
2200 SRM 1499 Wire Harness Identification and Connector Location

Legend for Figure 8 and Figure 9 (Continued)

NOTE: These items will have either (SOH TE-10) or (ZF WG161) to specify which application it
applies to.
Number Connector Description
61 TS25,29,39 Starter Motor+
62 TS13 Startermotor Solenoid
63 TS06 Alternator B+
64 TS07 Alternator Ground
65 CPS69 Frame-LH Rear lights
66 CRP300 FRAME-BACKUP ALARM
67 CPS54 Backup Diode
68 CRP09 Sump Temp (SOH TE-10)
69 TS17 Gridheater

33
Wire Harness Identification and Connector Location 2200 SRM 1499

Figure 10. Mast Harness

34
2200 SRM 1499 Wire Harness Identification and Connector Location

Legend for Figure 10

A. MAST LIGHTS B. MAST FORK LIFT

Number Connector Description

1 CPS147 Mast Lights - RH Mast Lights
2 CRP139 Mast FL - Frame
3 CRP124 Mast Lights - Frame
4 CPS146 Mast Lights - LH mast lights
5 CPS148 Mast FL - Carriage

35
Wire Harness Identification and Connector Location 2200 SRM 1499

A. CLOSED CAB B. RH CAB LIGHTS C. LH CAB LIGHTS

Figure 11. Top Cab Harness

36
2200 SRM 1499 Wire Harness Identification and Connector Location

A. SIDE CONSOLE B. REAR WIPER EXTENSION C. WASHER PUMPS

Figure 12. Cab Harness

37
Wire Harness Identification and Connector Location 2200 SRM 1499

Figure 13. Underfloor Harness

38
2200 SRM 1499 Wire Harness Identification and Connector Location

Legend for Figure 13

A. CAB UNDERFLOOR B. STEERING COLUMN

A. THIS IS THE ACTUAL POSITION OF THE HARNESS IN THE CAB.

Figure 14. Armrest Harness

Legend for Figure 11 through Figure 14

Number Connector Description

NOTE: Some items in this table are specific to TE-10 Transmissions or ZF Transmissions. These
items will have either (SOH TE-10) or (ZF WG161) to specify which application it applies to.
1 CPS41 RH Outer Flood Light
2 CPS42 RH Inner Flood Light
3 TS48 Strobe Light
4 TS96 Strobe Light
5 CPS40 RH Rear Drive Lts
6 CPS64 RH Cab Lights
7 CPS65 LH Cab Lights
8 CPS43 LH Rear Drive Lts
9 TS97 Strobe Light

39
Wire Harness Identification and Connector Location 2200 SRM 1499

Legend for Figure 11 through Figure 14 (Continued)

Number Connector Description

NOTE: Some items in this table are specific to TE-10 Transmissions or ZF Transmissions. These
items will have either (SOH TE-10) or (ZF WG161) to specify which application it applies to.
10 TS65 Strobe Light
11 CPS44 LH Outer Flood Light
12 CPS45 LH Inner Flood Light
13 TS45 LH Interior Light
14 TS46 LH Interior Light
15 CPS110 Radio Power
16 CPS111 Radio Sound
17 CRP65 LH Cab Lights
18 TS93 Left Speaker+
19 TS94 Left Speaker-
20 CPS75 Roof Wiper
21 TS91 Right Speaker+
22 TS92 Right Speaker-
23 TS90 Radio Coms
24 TS89 Radio Coms
25 CRP64 RH Cab Lights
26 CRP10 Condensor Unit
27 TS44 RH Interior Light
28 TS43 RH Interior Light

29 TS98 Ventilation Fan

30 CPS63 Closed Cab-SideConsole
31 CRP117 AC cond-Sideconsole
32 CPS37 Fuses 1-10
33 CPS50 Fuses 11-20
34 CPS51 Fuses 21-30
35 CPS109 Fuses 31-40
36 CPS53 Mast/Att Lights Switch
37 CPS52 Side/Front Lights Switch
38 CPS48 Flood/RR Drive LTS Switch
39 CPS47 Strobe Switch
40 CPS77 Hazard Switch

40
2200 SRM 1499 Wire Harness Identification and Connector Location

Legend for Figure 11 through Figure 14 (Continued)

Number Connector Description

NOTE: Some items in this table are specific to TE-10 Transmissions or ZF Transmissions. These
items will have either (SOH TE-10) or (ZF WG161) to specify which application it applies to.
41 CPS94 Instrument Cluster
42 CPS14 Key Switch

43 CPS46 12V Plug

44 TS82,TS83 Buzzer
45 CPS19 Diag Connector
46 CRS01 Parkbrake Switch Element
47 CPS116 HVAC unit
48 CPS71 Wiper Timer
49 CPS105 Sideconsole-TWIST Mod
50 CRP63 SideConsole-Closed Cab
51 CRP74 Wiper Rear-Sideconsole
52 CPS74 Sideconsole-Wiper Rear
53 CPS117 Sideconsole-AC cond
54 CPS142 Sped Signals
55 CPS08 Hydraulic Controller
56 CPS145 Accessory Socket 24V

57 CRS96 Map Light

58 CRP05 Lights Jumper
59 CRP70 Eng Shut-down Jumper
60 CPS70 Eng Shut-down Jumper
61 CPS33 Sideconsole-Underfloor
62 CPS107 DC/DC Convertor
63 CPS17 Diode Main Power
64 CPS21, CPS27 XMSN J1,2 (SOH TE-10)
CPS143 XMSN connector (ZF WG161)
65 CPS92 Wiper Rear
66 CRP81 Sideconsole-Armrest
67 CPS66 End Resistor (SOH TE-10)
68 CPS34 XMSN Resistors (SOH TE-10)
69 CRP07 Cab Signals
70 CRP06 Cab Power

41
Wire Harness Identification and Connector Location 2200 SRM 1499

Legend for Figure 11 through Figure 14 (Continued)

Number Connector Description

NOTE: Some items in this table are specific to TE-10 Transmissions or ZF Transmissions. These
items will have either (SOH TE-10) or (ZF WG161) to specify which application it applies to.
71 CRP35 Aux Signals
72 CPS28 SideConsole/Wsh Pumps
73 CRP28 Wsh Pumps-SideConsole
74 CPS20 Washer Front
75 CPS95 Washer Rear
76 CPS38 Washer Roof
77 CPS143 Diagnostic Switch (SOH TE-10)
CPS25 Diagnostic Switch (ZF WG161)
78 CPS01 Diode Calibration (SOH TE-10)
CPS34 Diode Calibration (ZF WG161)
79 CPS39 Lights Diode
80 CPS162 SERVICE SWITCH (SOH TE-10)
CPS26 SERVICE SWITCH (ZF WG161)
81 CPS163 CALIBRATION SWITCH (SOH TE-10)
CPS27 CALIBRATION SWITCH (ZF WG161)
82 CPS83 Horn Button
83 TS66 Indicator Switch L
84 TS64 Indicator Switch 54
85 TS81 Master Warning
86 TS80 Master Warning
87 TS67 Indicator Switch R
88 CPS29 Shift Lever
89 CRP33 Underfloor-Sideconsole
90 CPS31 Monotrol Pedal
91 CPS78 Front Wiper
92 CRP30 SteerColumn-Underfloor
93 CPS30 Underfloor-SteerColumn
94 TS35 Inching Switch
95 TS34 Inching Switch
96 CPS32 Inching Pedal
97 CPS82 Diode Horn
98 TS69 Horn

42
2200 SRM 1499 Wire Harness Identification and Connector Location

Legend for Figure 11 through Figure 14 (Continued)

Number Connector Description

NOTE: Some items in this table are specific to TE-10 Transmissions or ZF Transmissions. These
items will have either (SOH TE-10) or (ZF WG161) to specify which application it applies to.
99 TS68 Horn
100 TS102 Armrest Ground
101 CRP02 OPS Switch
102 CPS144 Suspension Seat
103 TS103 Armrest Ground
104 CPS119 Hydr. Stop
105 CPS113 Lift Lever
106 CPS138 Aux3
107 CPS112 Tilt Lever
108 CPS114 Aux0 Lever
109 CPS137 Aux2
110 CPS135 Switches Joystick
111 CPS118 Twist Locks

112 CPS09 Aux1 Lever

113 CPS72 Inhibit Aux1
114 CPS80 Horn Switch Armrest
115 CPS89 Front Washer Switch
116 CPS86 Front Wiper Switch
117 CPS90 Roof Wiper/Washer Switch
118 CPS91 Rear Wiper/Washer Switch
119 CPS81 Armrest-Sideconsole

43
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 TECHNICAL PUBLICATIONS

2200 SRM 1499 4/11 Printed in United Kingdom