DIAGRAMS

LIFT TRUCKS EQUIPPED WITH

TRANSISTOR MOTOR CONTROLLERS
E/J2.00-3.20XM [F108/A216];
E1.50-2.00XMS [D114]

PART NO. 897781 8000 SRM 589

 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!
Diagrams Table of Contents

TABLE OF CONTENTS

Diagrams, Schematics, or Arrangements ......................................................................................................... 1

Figure 1. Transistor Controllers for Traction Motor and Hydraulic Pump Motors
J2.00-3.20XM............................................................................................................................................. 1
Figure 2. Transistor Controllers for Traction Motor and Hydraulic Pump Motors
E1.25-3.20XM ............................................................................................................................................ 2
Figure 3. Transistor Controllers for Traction Motor and Hydraulic Pump Motor Schematic
Diagram ..................................................................................................................................................... 4
Figure 4. Transistor Controllers for Traction Motor and Hydraulic Pump Motors Wiring
Diagram J2.00-3.20XM ............................................................................................................................. 6
Figure 5. Transistor Controller for Traction Motor, Contactor Control for Hydraulic Pump
Wiring Diagram J2.00-3.20XM................................................................................................................. 8
Figure 6. Transistor Controllers for Traction Motor and Hydraulic Pump Motor Wiring
Diagram E1.50-3.20XM ............................................................................................................................ 10
Figure 7. Transistor Controller for Traction Motor, Contactor Control for Hydraulic Pump
Motor Wiring Diagram E1.50-3.20XM ..................................................................................................... 12
Figure 8. Wire Harness J2.00-3.20XM..................................................................................................... 14
Figure 9. Power Cables and Battery Connector J2.00-3.20XM.............................................................. 16
Figure 10. Truck Wiring E1.50-3.20XM................................................................................................... 18
Figure 11. Truck Power Cables North America....................................................................................... 20
Figure 12. Truck Power Cables Europe ................................................................................................... 22
Figure 13. Hydraulic Linkage Switch and Chassis Wiring Details ....................................................... 24
Figure 14. Instrument Panel Wiring Schematic E/J2.00-3.20XM.......................................................... 26
Figure 15. Display Panels and Plug Connectors ..................................................................................... 28
Figure 16. Configuration of the EV-T100 Motor Controller Module...................................................... 29
Figure 17. Control Card Connections ...................................................................................................... 30
Figure 18. Truck Management Module (TMM1) ..................................................................................... 35
Figure 19. Transistor Controllers for Traction Motor and Hydraulic Pump Motor Wiring
Schematic E2.00-3.20XM .......................................................................................................................... 38
Figure 20. Detail of Battery Connector With +12 Volt Tap .................................................................... 39
Figure 21. Hydraulic Schematic E/J2.00-3.20XM, E1.50-2.00XMS ....................................................... 40
Figure 22. Wiring Diagram for Lights ..................................................................................................... 42

This section is for the following models:

E/J2.00-3.20XM [F108/A216];
E1.50-2.00XMS [D114]

©2006 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 1. Transistor Controllers for Traction Motor and Hydraulic Pump Motors J2.00-3.20XM

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Legend for Figure 1

1. CONTROL CARD, TRACTION 10. POWER STEERING CONTACTOR
2. POWER CABLE P5 11. POWER CABLE P3
3. POWER CABLE P13 12. POWER CABLE P3
4. FIELD WEAKENING RESISTOR 13. PLUG PB (HYDRAULIC PUMP)
5. POWER CABLE P14 14. PLUG PA (HYDRAULIC PUMP)
6. POWER CABLE P9 15. CONTROL CARD, HYDRAULIC PUMP
7. POWER STEERING CONNECTION (TAN) 16. PLUG PZ (TRACTION)
8. POWER CABLE IP2 17. PLUG PY (TRACTION)
9. POWER CABLE 2PI

Legend for Figure 2

1. 1A CONTACTOR 10. FORWARD CONTACTOR
2. REGENERATIVE BRAKING CONTACTOR 11. FIELD WEAKENING RESISTOR (NOT USED ON
3. FUSE PANEL (FU 7, FU 3, FU 5, FU 6) THESE MODELS)
4. POWER STEERING CONTACTOR (UNDER 12. FIELD WEAKENING CONTACTOR (NOT USED
FUSE PANEL 3) ON THESE MODELS)
5. FUSE 4 POWER STEERING CIRCUIT 13. TRANSISTOR CONTROLLER FOR LIFT PUMP
6. FUSE 1, TRACTION MOTOR CIRCUIT MOTOR
7. LINE CONTACTOR 14. TRANSISTOR CONTROLLER FOR TRACTION
8. FUSE 2, HYDRAULIC PUMP CIRCUIT MOTOR
9. REVERSE CONTACTOR

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 2. Transistor Controllers for Traction Motor and Hydraulic Pump Motors E1.25-3.20XM

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Diagrams, Schematics, or Arrangements 8000 SRM 589

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 3. Transistor Controllers for Traction Motor and Hydraulic Pump Motor Schematic
Diagram

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Diagrams, Schematics, or Arrangements 8000 SRM 589

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 4. Transistor Controllers for Traction Motor and Hydraulic Pump Motors Wiring Diagram
J2.00-3.20XM

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Diagrams, Schematics, or Arrangements 8000 SRM 589

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 5. Transistor Controller for Traction Motor, Contactor Control for Hydraulic Pump Wiring
Diagram J2.00-3.20XM

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Diagrams, Schematics, or Arrangements 8000 SRM 589

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 6. Transistor Controllers for Traction Motor and Hydraulic Pump Motor Wiring Diagram
E1.50-3.20XM

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Diagrams, Schematics, or Arrangements 8000 SRM 589

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 7. Transistor Controller for Traction Motor, Contactor Control for Hydraulic Pump Motor
Wiring Diagram E1.50-3.20XM

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 8. Wire Harness J2.00-3.20XM (Sheet 1 of 2)

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 8. Wire Harness J2.00-3.20XM (Sheet 2 of 2)

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Legend for Figure 8

1. WIRE HARNESS, BRUSH WEAR INDICATORS 11. TO HORN
2. EMERGENCY STOP KNOW 12. BRUSH WEAR INDICATOR, HYDRAULIC PUMP
3. WIRE HARNESS, EMERGENCY DISCONNECT MOTOR
4. WIRE FOR SEAT SWITCH 13. BRUSH WEAR INDICATOR, STEERING PUMP
5. MAIN WIRE HARNESS, CONTROLLER MOTOR
6. WIRE HARNESS, INSTRUMENT PANEL 14. TEMPERATURE SWITCH HYDRAULIC PUMP
DISPLAY MOTOR
7. SEE DETAIL C 15. WARNING LEVEL INDICATOR, MASTER
8. SEE DETAIL A CYLINDER FLUID
9. COWL (REFERENCE) 16. PARKING BRAKE SWITCH
10. TERMINAL STRIP (ALL WIRES WITH RED GO 17. TEMPERATURE SWITCH TRACTION MOTOR
INTO THE TOP TERMINALS. ALL WIRES WITH 18. BRUSH WEAR INDICATOR, TRACTION MOTOR
BLACK GO INTO THE BOTTOM TERMINALS)

Legend for Figure 9

1. TRACTION MOTOR 4. HYDRAULIC PUMP MOTOR
2. EMERGENCY DISCONNECT KNOB 5. POWER STEERING MOTOR
3. BATTERY CONNECTOR

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 9. Power Cables and Battery Connector J2.00-3.20XM

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 10. Truck Wiring E1.50-3.20XM

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Legend for Figure 10

1. TRACTION MOTOR 7. MOTOR CONTROLLERS COMPARTMENT
2. LIFT PUMP MOTOR 8. BATTERY COMPARTMENT
3. STEERING PUMP MOTOR 9. CONNECTOR FOR BRUSH WEAR INDICATOR
4. HORN (BWI)
5. MONOTROL PEDAL 10. CONNECTOR FOR TEMPERATURE INDICATOR
6. CONTROL LEVER SWITCHES 11. PARKING BRAKE SWITCH

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 11. Truck Power Cables North America

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Legend for Figure 11

1. BATTERY CONNECTOR 9. POWER CABLE P13
2. POWER CABLE 2P1 10. TRACTION MOTOR
3. NEGATIVE TERMINAL POST 11. STEERING PUMP MOTOR
4. POWER CABLE P3 12. POWER CABLE 2P2
5. POWER CABLE 1P1 13. POWER CABLE P9
6. POWER CABLE P10 14. POWER CABLE P14
7. LIFT PUMP MOTOR 15. POWER CABLE 2P3
8. POWER CABLE P5

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 12. Truck Power Cables Europe

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Legend for Figure 12

1. BATTERY CONNECTOR 9. POWER CABLE P13
2. POWER CABLE 2P1 10. TRACTION MOTOR
3. NEGATIVE TERMINAL POST 11. STEERING PUMP MOTOR
4. POWER CABLE P3 12. POWER CABLE 2P2
5. POWER CABLE 1P1 13. POWER CABLE P9
6. POWER CABLE P10 14. POWER CABLE P14
7. LIFT PUMP MOTOR 15. POWER CABLE 2P3
8. POWER CABLE P5

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 13. Hydraulic Linkage Switch and Chassis Wiring Details

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Legend for Figure 13

1. CABLE CONNECTOR 11. #4, BLK/YEL
2. #1, RED/WHT & RED/BRN 12. NEGATIVE TERMINAL POST
3. #5, RED/GRN-DK (LIGHTS) 13. 2P1
4. #7, RED/YEL & RED/BLUE-LT 14. 2P3
5. #9, RED 15. 2P2
6. #11, RED/TAN 16. BLK/WHT
7. #12, BLACK 17. SWITCH
8. #10, BLACK 18. BLACK & GRAY
9. #8, BLK/GRN-DK (LIGHTS) 19. BLACK & BLUE-DK/GRN
10. #6, BLK/WHT 20. BLACK & BLUE-DK

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 14. Instrument Panel Wiring Schematic E/J2.00-3.20XM

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Legend for Figure 14

1. ENCODER ASSEMBLY, ON-DEMAND STEERING 5. KEY SWITCH
2. INSTRUMENT PANEL 6. HORN SWITCH
3. STEERING COLUMN 7. TERMINAL STRIP, INSTRUMENT PANEL
4. ACTIVATOR ASSEMBLY, POWER STEERING

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 15. Display Panels and Plug Connectors

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Legend for Figure 15

1. BATTERY CHARGE INDICATOR WITH LIFT
INTERRUPT
2. DIGITAL DISPLAY
3. FASTEN SEAT BELT WARNING LIGHT
4. BRAKE FLUID RESERVOIR IS LOW WARNING
LIGHT
5. PARKING BRAKE INDICATOR WARNING LIGHT
6. STEERING PUMP MOTOR INDICATOR LIGHT
7. MOTOR BRUSHES ARE WORN (TRACTION,
HYDRAULIC, OR STEERING) WARNING LIGHT
8. TRACTION MOTOR INDICATOR LIGHT
9. HYDRAULIC MOTOR INDICATOR LIGHT
10. MOTOR TEMPERATURE OVER LIMIT
(TRACTION OR HYDRAULIC) WARNING LIGHT
11. SERVICE INTERVAL WARNING LIGHT
12. HOURMETER INDICATOR LIGHT
13. DISPLAY STATUS CODES PUSH BUTTON
14. SET PERFORMANCE LEVEL PUSH BUTTON
15. PERFORMANCE LEVEL INDICATORS (4 LEDS)
16. HOURMETER
17. VOLTMETER

1. POWER TRANSISTOR TR1 5. SUPPRESSOR ASSEMBLY FOR DIODES D3

2. SUPPRESSOR ASSEMBLY FOR TR1 AND D4
3. CAPACITOR C1 (C1A, C1B, C1C) 6. LOCATION OF DIODES D3 AND D4
4. CONTROL CARD 7. LOCATION OF DIODES D3 AND D4

Figure 16. Configuration of the EV-T100 Motor Controller Module

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Diagrams, Schematics, or Arrangements 8000 SRM 589

1. CONTROL CARD (TRACTION OR HYDRAULIC 4. PLUG PA (6-PIN) (WIDE GUIDES)

PUMP) 5. PLUG PB (6-PIN) (CLOSE GUIDES)
2. TB SCREW TERMINALS (6) 6. PLUG PY (14-PIN)
3. PLUG GUIDES 7. PLUG (PZ (14-PIN)

Figure 17. Control Card Connections

Table 1. Terminal and Plug Wire Connections for Control Card JH

With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium
Display, GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature Indicators
NOTE: Table 1 and Table 2 are components of the same controller option.
Plug or Wire Color Function
Terminal or Wire
No. Number
PA1 37 To coil for Field Weakening contactor.
PA2 50 To BLU-L and then to PB3 on hydraulic pump control card.
PA3 — Not used.
PA4 — Not used.
PA5 — Not used.
PA6 — Not used.
PB1 12 Battery positive from Fuse 5.
PB2 24 To coil for Line contactor.
PB3 60 To contactor coil for Steering pump motor.
PB4 27 Forward contactor coil negative.
PB5 23 Reverse contactor coil negative.
PB6 41 1A contactor coil negative.

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Table 1. Terminal and Plug Wire Connections for Control Card JH (Continued)

With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium
Display, GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature Indicators
NOTE: Table 1 and Table 2 are components of the same controller option.
Plug or Wire Color Function
Terminal or Wire
No. Number
TB1 YEL/PNK Accelerator potentiometer input.
TB2 GRN Start switch input.
15 Voltage supply from Fuse 7.
TB3 PNK Seat switch input.
TB4 RED/BLU-L Key switch input. Battery voltage supply from key switch.
TB5 10 Battery supply voltage to TB4 on hydraulic pump control card.
TB6 10-1 Battery supply voltage.
RED/WHT Battery voltage supply to seat switch.
WHT-5 FORWARD direction switch input.
BLU-L REVERSE direction switch input.
PY1 — Not used.
PY2 — Not used.
PY3 — Not used.
PY4 BLK-1 To instrument panel display number 9 (TGND) input (ground).
PY5 WHT-1 To instrument panel display number 1 (T5) input.
PY6 — Not used.
PY7 — Not used.
PY8 BRN/WHT Signal wire from PY12 on hydraulic pump control card.
PY9 BRN/PNK Signal wire from PY11 on hydraulic pump control card.
PY10 BRN/ORN Signal wire from PY10 on hydraulic pump control card.
PY11 YEL/GRN
PY12 — Not used.
PY13 WHT-2 To instrument panel display number 5 (PY13) input.
PY14 BLK-2 To instrument panel display number 4 (PY14) input.
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 32 to GRN/ Voltage supply to accelerator potentiometer.
PZ7 WHT
PZ8 17 Battery positive. (Voltage check across Regenerative Braking Diode D7.)
PZ9 31 Regenerative braking contactor negative.
PZ10 BLU Signal wire for voltage check across TR1.
PZ11 GRN to 22 Signal wire from current sensor for Regenerative Braking.
PZ12 YEL to 21 Signal wire from current sensor for Regenerative Braking.
PZ13 GRN Signal wire from motor current sensor.
PZ14 YEL Signal wire from motor current sensor.
WHT Signal wire for battery voltage check.

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Table 2. Terminal and Plug Wire Connections for Hydraulic Pump Control Card LP

With Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium
Display, GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature Indicators
NOTE: Table 1 and Table 2 are components of the same controller option.
Plug or Wire Color Function
Terminal or Wire
No. Number
PA1 GRN/GRY Signal wire between pump control card and brush wear indicator, steering pump.
PA2 BLU-D/YEL Signal wire between pump control card and brush wear indicator, steering pump.
PA3 ORN/PNK Signal wire between pump control card and temperature switch, traction motor.
PA4 BLU-D/PNK Signal wire between pump control card and brush wear indicator, traction motor.
PA5 GRN/PUR Signal wire between pump control card and brush wear indicator, traction motor.
PA6 ORN/YEL Signal wire between pump control card and temperature switch, hydraulic pump motor.
PB1 BRN Supply voltage from Fuse 3.
PB2 — Not used.
PB3 BLU-L To 50 and then to PA2 on traction control card.
PB4 — Not used.
PB5 — Not used.
PB6 — Not used.
TB1 — Not used.
TB2 GRY To circuit board for control lever, hydraulic pump.
TB3 BLU-D/GRN To circuit board for control lever, hydraulic pump.
TB4 10 Key switch input. Battery supply voltage from TB4 on traction control card.
TB5 — Not used.
TB6 BLU-D To circuit board for control lever, hydraulic pump.
PY1 — Not used.
PY2 — Not used.
PY3 — Not used.
PY4 BLK-3 To instrument panel display number 10 (PGND) input (ground).
PY5 WHT-3 To instrument panel display number 2 (P5) input.
PY6 — Not used.
PY7 — Not used.
PY8 — Not used.
PY9 — Not used.
PY10 BRN/ORN Signal wire to PY10 on traction control card.
PY11 BRN/PNK Signal wire to PY9 on traction control card.
PY12 BRN/WHT Signal wire to PY8 on traction control card.
PY13 WHT-4 To instrument panel display number 7 (P13) input.
PY14 BLK-4 To instrument panel display number 6 (P14) input.
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 — Not used.
PZ7 — Not used.
PZ8 — Not used.
PZ9 BLU Signal wire for voltage check across TR1.
PZ10 98 BLU-D/ Signal wire between pump control card and brush wear indicator, hydraulic pump motor.
PZ11 GRY Signal wire between pump control card and brush wear indicator, hydraulic pump motor.
PZ12 99 GRN/PNK Signal wire from motor current sensor.
PZ13 GRN Signal wire from motor current sensor.
PZ14 YEL Signal wire for battery voltage check.
WHT

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Table 3. Terminal and Plug Wire Connections for Control Card JH

With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium
Display, GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature Indicators,
and TMM1 module (see Table 4).
Plug or Wire Color Function
Terminal or Wire
No. Number
PA1 37 To coil for Field Weakening contactor.
PA2 50 To BLU-L and then to PB3 on hydraulic pump control card.
PA3 — Not used.
PA4 — Not used.
PA5 — Not used.
PA6 — Not used.
PB1 12 Battery positive from Fuse 5.
PB2 24 To coil for Line contactor.
PB3 60 To contactor coil for Steering pump motor.
PB4 27 Forward contactor coil negative.
PB5 23 Reverse contactor coil negative.
PB6 41 1A contactor coil negative.
TB1 YEL/PNK Accelerator potentiometer input.
TB2 GRN Start switch input.
TB3 15 Voltage supply from Fuse 7.
TB4 PNK Seat switch input.
TB5 10-1 Battery supply voltage.
TB6 RED/BLU-L Key switch input. Battery voltage supply from key switch.
RED/WHT Battery voltage supply to seat switch.
WHT-5 FORWARD direction switch input.
BLU-L REVERSE direction switch input.

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Table 3. Terminal and Plug Wire Connections for Control Card JH (Continued)

With: Transistor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand, Premium
Display, GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear and Temperature Indicators,
and TMM1 module (see Table 4).
Plug or Wire Color Function
Terminal or Wire
No. Number
PY1 — Not used.
PY2 — Not used.
PY3 — Not used.
PY4 BLK-1 Instrument panel display number 9 (TGND) input (ground).
PY5 WHT-1 Instrument panel display number 1 (T5) input.
PY6 — Not used.
PY7 — Not used.
PY8 BRN/WHT Signal wire from TB9 on TMM1.
PY9 BRN/PNK Signal wire from TB7 on TMM1.
PY10 Signal wire from TB13 on TMM1.
PY11 BRN/ORN
PY12 YEL/GRN Not used.
PY13 — Instrument panel display number 5 (PY13) input.
PY14 WHT-2 Instrument panel display number 4 (PY14) input.
BLK-2
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire to voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 32 to GRN/ Voltage supply to accelerator potentiometer.
PZ7 WHT Battery positive. (Voltage check across Regenerative Braking Diode D7.)
PZ8 17 Regenerative braking contactor negative.
PZ9 31 Signal wire for voltage check across TR1.
PZ10 BLU Signal wire from current sensor for Regenerative Braking.
PZ11 GRN to 22 Signal wire from current sensor for Regenerative Braking.
PZ12 YEL to 21 Signal wire from motor current sensor.
PZ13 GRN Signal wire from motor current sensor.
PZ14 YEL Signal wire for battery voltage check.
WHT

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Table 4. Terminal and Plug Wire Connections for TMM1 Module

Plug or Wire No. Function

Termi- or Color
nal No.
TB1 ORN/PNK Signal wire for temperature switch, traction motor.
TB2 — Not used.
TB3 ORN/YEL Signal wire for temperature switch, hydraulic pump motor.
TB4 — Not used.
TB5 GRN/GRY Signal wire for brush wear indicator, steering pump.
TB6 BLU-D/ Signal wire for brush wear indicator, steering pump.
TB7 YEL
TB8 BRN/PNK Signal wire for brush wear indicator, traction motor.
TB9 BLU-D/
TB10 PNK Signal wire for brush wear indicator, traction motor.
TB11 BLU-L Signal wire for brush wear indicator, hydraulic pump motor.
TB12 GRN/PUR Signal wire for brush wear indicator, hydraulic pump motor.
TB13 BLU-D/
GRY
GRN/PNK
BRN/ORN

Figure 18. Truck Management Module (TMM1)

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Diagrams, Schematics, or Arrangements 8000 SRM 589

Table 5. Terminal and Plug Wire Connections for Control Card JY

With Contactor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand Option,
Economy Display and Curtis BDI Option, or Partial GE Display Option,
Without: GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear or Temperature Indicators
Plug or Wire Color Function
Terminal or Wire
No. Number
PA1 37 To coil for Field Weakening contactor.
PA2 — Not used.
PA3 — Not used.
PA4 — Not used.
PA5 — Not used.
PA6 — Not used.
PB1 12 Battery positive from Fuse 5.
PB2 24 To coil for Line contactor.
PB3 60 To contactor coil for Steering pump motor. (Not used when equipped with "On Demand"
PB4 27 power steering)
PB5 23
PB6 41 Forward contactor coil negative.
Reverse contactor coil negative.
1A contactor coil negative.
TB1 YEL/PNK Accelerator potentiometer input.
TB2 GRN Start switch input.
TB3 15 Voltage supply from Fuse 7.
PNK Seat switch input.
TB4 10-1 Battery supply voltage.
TB5 RED/BLU-L Key switch input. Battery voltage supply from key switch.
TB6 RED/WHT Battery voltage supply to seat switch.
PNK Input to instrument panel display (Seat Switch SSW 16)
WHT-5 FORWARD direction switch input.
BLU-L REVERSE direction switch input.

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8000 SRM 589 Diagrams, Schematics, or Arrangements

Table 5. Terminal and Plug Wire Connections for Control Card JY (Continued)

With Contactor Control of Hydraulic Pump, Regenerative Braking, Power Steering On Demand Option,
Economy Display and Curtis BDI Option, or Partial GE Display Option,
Without: GE Battery Discharge Indicator (BDI) with Lift Interrupt, Brush Wear or Temperature Indicators
Plug or Wire Color Function
Terminal or Wire
No. Number
PY1 WHT-3 Not used.
PY2 BLK-2 Not used.
PY3 WHT-2 Not used.
PY4 BLK-1 Instrument panel display number 2 (PY4) input (GE display option only).
PY5 WHT-1 Instrument panel display number 5 (PY5) input (GE display option only).
PY6 — Input to Handset.
PY7 — Not used.
PY8 — Not used.
PY9 — Not used.
PY10 — Not used.
PY11 — Not used.
PY12 — Not used.
PY13 WHT-2 Instrument panel display number 1 (PY3) input (GE display option only).
PY14 BLK-2 Instrument panel display number 3 (PY2) input (GE display option only).
PZ1 WHT/BRN Battery negative.
PZ2 VIO Signal wire from TR1 thermal protector.
PZ3 BRN Signal wire for voltage check across TR1.
PZ4 RED Signal wire to gate for TR1.
PZ5 WHT/VIO Signal wire from TR1 thermal protector.
PZ6 32 to GRN/ Voltage supply to accelerator potentiometer.
PZ7 WHT Battery positive. (Voltage check across Regenerative Braking Diode D7)
PZ8 17 Regenerative braking contactor negative.
PZ9 31 Signal wire for voltage check across TR1.
PZ10 BLU Signal wire from current sensor for Regenerative Braking.
PZ11 GRN to 22 Signal wire from current sensor to Regenerative Braking.
PZ12 YEL to 21 Signal wire from motor current sensor.
PZ13 GRN Signal wire from motor current sensor.
PZ14 YEL Signal wire for battery voltage check.
WHT

37
Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 19. Transistor Controllers for Traction Motor and Hydraulic Pump Motor Wiring Schematic
E2.00-3.20XM

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8000 SRM 589
1. TRUCK HALF OF BATTERY CONNECTOR
2. RED HOUSING FOR +12 VOLT "BATTERY TAP"
3. LOCK SPRING (TIP OF CONTACT MUST LOCK
OVER TOP OF LOCK SPRING)
4. BLACK CONNECTOR HOUSING (ASSEMBLED
ON RED HOUSING WITH SLOTS FOR LOCK
PINS ALIGNED AS SHOWN - NO WIRE OR
CONTACT IN HOUSING)
Figure 20. Detail of Battery Connector With +12 Volt Tap
Diagrams, Schematics, or Arrangements
5. SLOT FOR LOCK PIN
6. WIRE FROM IN-LINE FUSE (WITH CONNECTOR
CONTACT)
7. KEY (RED AND BLACK CONNECTORS ALIGN
ON KEY)
8. LOCK PINS (MUST INSTALL FROM FRONT OF
CONNECTOR THROUGH RED AND BLACK
CONNECTORS)
39
Diagrams, Schematics, or Arrangements 8000 SRM 589

Figure 21. Hydraulic Schematic E/J2.00-3.20XM, E1.50-2.00XMS

40
8000 SRM 589 Diagrams, Schematics, or Arrangements

Legend for Figure 21

1. HYDRAULIC CONTROL VALVE 10. CHECK PORT, LINE PRESSURE
2. SECONDARY RELIEF VALVE 11. STEERING CONTROL UNIT
3. HYDRAULIC TANK 12. STEERING CYLINDER
4. FILTER 13. LIFT CYLINDER
5. HYDRAULIC PUMP 14. SECONDARY LOWERING CONTROL VALVE
6. CHECK PORT (INTERNAL)
7. STEERING PUMP 15. PRIMARY LOWERING CONTROL VALVE
8. CHECK PORT 16. TILT CYLINDER
9. PRESSURE SWITCH FOR STEERING
ON-DEMAND OPTION. (REPLACES CHECK
PORT WHEN INSTALLED)

41
Diagrams, Schematics, or Arrangements 8000 SRM 589

42
8000 SRM 589 Diagrams, Schematics, or Arrangements

Figure 22. Wiring Diagram for Lights

43
 NOTES

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 TECHNICAL PUBLICATIONS

8000 SRM 589 4/06 (3/06) Printed in United Kingdom