DIAGRAMSAND SCHEMATICS H8.0FT,H8.0FT9,H9.0FT(H170FT,H175FT36,H190FT)[A299]; S30FT,S35FT,S40FTS[E010];H1.6FT,H1.8FT,H2.0FTS(H30FT, H35FT,H40FTS)[F001];S2.0-3.5FT(S40-70FT,S55FTS)[F187]; S6.0FT,S7.0FT(S135FT,S155FT)[E024];H6.0FT,H7.0FT(H135FT, H155FT)[J006];H2.0-3.5FT(H40-70FT)[L177];S4.0,4.5, 5.50FT;S5.5FTS(S80,100,120FT;S80,100FTBCS,S120FTS, S120FTPRS)[G004];H4.0FT5/FT6,H4.5FTS5,H4.5FT6, H5.0-5.5F T(H80,90,100,110,120FT)[P005] Thismanualcontainsinformationthatisconfidentialand/orproprietarytoHyster Company,itssubsidiariesand/orvendors.Copyingordistributionofanysectionsof thismanualmarked"Confidential/Proprietary"isprohibited. PARTNO.4000701 8000SRM1409 Hyster Forklift Diagrams And Schematics Full download: http://manualplace.com/download/hyster-forklift-diagrams-and-schematics/ This is the cut pages sample. Download all 82 page(s) at: ManualPlace.com
SAFETYPRECAUTIONS
MAINTENANCEANDREPAIR
• TheServiceManualsareupdatedonaregularbasis,butmaynotreflectrecentdesignchangestotheproduct.UpdatedtechnicalserviceinformationmaybeavailablefromyourlocalauthorizedHyster®dealer.Service Manualsprovidegeneralguidelinesformaintenanceandserviceandareintendedforusebytrainedandexperiencedtechnicians.FailuretoproperlymaintainequipmentortofollowinstructionscontainedintheService Manualcouldresultindamagetotheproducts,personalinjury,propertydamageordeath.
• Whenliftingpartsorassemblies,makesureallslings,chains,orcablesarecorrectlyfastened,andthattheload beingliftedisbalanced.Makesurethecrane,cables,andchainshavethecapacitytosupporttheweightofthe load.
• Donotliftheavypartsbyhand,usealiftingmechanism.
• Wearsafetyglasses.
• DISCONNECTTHEBATTERYCONNECTORbeforedoinganymaintenanceorrepaironelectriclifttrucks. Disconnectthebatterygroundcableoninternalcombustionlifttrucks.
• Alwaysusecorrectblockstopreventtheunitfromrollingorfalling.SeeHOWTOPUTTHELIFTTRUCKON BLOCKSinthe OperatingManual orthe PeriodicMaintenance section.
• Keeptheunitcleanandtheworkingareacleanandorderly.
• Usethecorrecttoolsforthejob.
• Keepthetoolscleanandingoodcondition.
• Alwaysuse HYSTERAPPROVED partswhenmakingrepairs.Replacementpartsmustmeetorexceedthe specificationsoftheoriginalequipmentmanufacturer.
• Makesureallnuts,bolts,snaprings,andotherfasteningdevicesareremovedbeforeusingforcetoremoveparts.
• AlwaysfastenaDONOTOPERATEtagtothecontrolsoftheunitwhenmakingrepairs,oriftheunitneeds repairs.
• Besuretofollowthe WARNING and CAUTION notesintheinstructions.
• Gasoline,LiquidPetroleumGas(LPG),CompressedNaturalGas(CNG),andDieselfuelareflammable.Besure tofollowthenecessarysafetyprecautionswhenhandlingthesefuelsandwhenworkingonthesefuelsystems.
• Batteriesgenerateflammablegaswhentheyarebeingcharged.Keepfireandsparksawayfromthearea.Make suretheareaiswellventilated.
NOTE: Thefollowingsymbolsandwordsindicatesafetyinformationinthis manual:
WARNING
Indicatesahazardoussituationwhich,ifnotavoided,couldresultin deathorseriousinjury.
CAUTION
Indicatesahazardoussituationwhich,ifnotavoided,couldresultin minorormoderateinjuryandpropertydamage.
Onthelifttruck,theWARNINGsymbolandwordareonorangebackground.TheCAUTIONsymbolandwordareonyellowbackground.
TABLEOFCONTENTS
GeneralInformationAboutDiagramsandSchematics................................................................................... 1
SymbolDefinitions........................................................................................................................................1
DiagramsManualApplications....................................................................................................................2
Diagrams,Schematics,orArrangements.........................................................................................................3
Figure1.TypeSOptionElectricalSchematic......................................................................................... 3
Figure2.Mazda(2007)2.0Land2.2LGasEngine.................................................................................3
Figure3.Mazda(2007)2.0Land2.2LLPGEngineElectricalSchematic............................................5
Figure4.GM2.4LGasEngineElectricalSchematic.............................................................................7
Figure5.GM2.4LLPGEngineElectricalSchematic............................................................................9
Figure6.Yanmar2.6Land3.3LDieselEngineElectricalSchematic...................................................12
Figure7.GM4.3LGasEngineElectricalSchematic.............................................................................12
Figure8.GM4.3LLPGEngineElectricalSchematic............................................................................14
Figure9.Cummins3.3LDieselEngineElectricalSchematic................................................................16
Figure10.Mazda(2005-2006)2.0Land2.2LGasEngineElectricalSchematic..................................18
Figure11.Mazda(2005-2006)2.0Land2.2LLPGEngineElectricalSchematic.................................20
Figure12.GM(2010)5.7LLPGEngineElectricalSchematic...............................................................22
Figure13.RightSideTruckDevicesElectricalSchematic....................................................................25
Figure14.LeftSideTruckDevicesElectricalSchematic.......................................................................26
Figure15.CowlDevicesElectricalSchematic........................................................................................ 27
Figure16.Standard(Powershift)TransmissionElectricalSchematic..................................................28
Figure17.SpicerOff-HighwayTransmission3Forward/2ReverseElectricalSchematic...................28
Figure18.Electro-HydraulicElectricalSchematic.................................................................................32
Figure19.LightsandCabAccessoriesElectricalSchematic.................................................................33
Figure20.ForwardTravelAmberLightsWithThree-StageMast........................................................34
Figure21.MLMInternalConnections....................................................................................................35
Figure22.VehicleSystemManager(VSM)WiringDiagram.................................................................36
Figure23.PowerDistributionModule(PDM)WiringDiagram............................................................37
Figure24.OperatorCabWiringDiagram...............................................................................................38
Figure25.TransmissionWiringDiagram,CommontoALLTransmissions........................................39
Figure26.EnginesDirectoryWiringDiagram.......................................................................................40
Figure27.RearSignalandWorkLightsWiringDiagram.....................................................................41
Figure28.Mazda2.0Land2.2LGasEngineWiringDiagram..............................................................42 Figure29.Mazda2.0Land2.2LLPGEngineWiringDiagram.............................................................43 Figure30.GM2.4LGasEngineWiringDiagram..................................................................................44 Figure31.GM2.4LLPGEngineWiringDiagram.................................................................................45 Figure32.Yanmar2.6Land3.3LDieselEngineWiringDiagram........................................................46 Figure33.GM4.3LGasEngineWiringDiagram..................................................................................47 Figure34.GM4.3LLPGEngineWiringDiagram.................................................................................48
Figure35.Cummins3.3LDieselEngineWiringDiagram.....................................................................49 Figure36.Mazda(2005-2006)2.0Land2.2LGasEngineWiringDiagram.........................................50 Figure37.Mazda(2005-2006)2.0Land2.2LLPGEngineWiringDiagram........................................51 Figure38.GM5.7LLPGEngine(2010)WiringDiagram......................................................................52
Figure39.Standard(Powershift)TransmissionWiringDiagram.........................................................53
Figure40.SpicerOff-HighwayTransmission3Forward/2ReverseWiringDiagramforLift TruckModelsS6.0FT,S7.0FT(S135FT,S155FT)(E024)andH6.0FT,H7.0FT(H135FT, H155FT)(J006).........................................................................................................................................54
Figure41.SpicerOff-HighwayTransmission2Forward/2ReverseWiringDiagramfor LifttruckModelsS6.0FT,S7.0FT(S135FT,S155FT)(E024)andH6.0FT,H7.0FT(H135FT, H155FT)(J006).........................................................................................................................................55 Figure42.ForwardTravelAmberLightsWithThree-StageMast........................................................56 Figure43.ConnectorPinIdentification..................................................................................................57
DiagramsandSchematicsTableofContents
©2013HYSTERCOMPANY i
TABLEOFCONTENTS(Continued)
Figure44.CircuitIdentification..............................................................................................................58
Figure45.ElectronicControlValveHydraulicSchematicforLiftTruckModelsS30FT,S35FT, S40FTS(E010),H1.6FT,H1.8FT,2.0FTS(H30FT,H35FT,H40FTS)(F001),S2.0-3.5FT (S40-70FT,S55FTS)(F187),H2.0-3.5FT(H40-70FT)(L177),EquippedWithHydraulicGear Pump..........................................................................................................................................................59
Figure46.ElectronicControlValveHydraulicSchematicforLiftTruckModelsH2.0-3.5FT (L177),EquippedWithVariableDisplacementPump............................................................................60
Figure47.ElectronicControlValveHydraulicSchematicforLiftTruckModelsS4.0,4.5, 5.5FT,S5.5FTS(S80,100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)and H4.0FT5/FT6;H4.5FTS5,H4.5FT6,H5.0-5.5FT(H80,90,100,110,120FT)(P005)...........................61
Figure48.ElectronicControlValveHydraulicSchematicforLiftTruckModelsH4.0FT5/FT6, H4.5FTS5,H4.5FT6,H5.0-5.5FT(P005),EquippedWithVariableDisplacementPump.....................62
Figure49.ManualControlValveHydraulicSchematicforLiftTruckModelsS30FT,S35FT, S40FTS(E010),H1.6FT,H1.8FT,2.0FTS(H30FT,H35FT,H40FTS)(F001),S2.0-3.5FT (S40-70FT,S55FTS)(F187),H2.0-3.5FT(H40-70FT)(L177).................................................................63
Figure50.ManualControlValveHydraulicSchematicforLiftTruckModelsS4.0,4.5, 5.5FT,S5.5FTS(S80,100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)and H4.0FT5/FT6;H4.5FTS5,H4.5FT6,H5.0-5.5FT(H80,90,100,110,120FT)(P005)...........................64
Figure51.PowershiftTransmissionHydraulicSchematic....................................................................64
Figure52.TransmissionHydraulicSchematicforLiftTruckModelsS6.0FT,S7.0FT(S135FT, S155FT)(E024)andH6.0FT,H7.0FT(H135FT,H155FT)(J006)..........................................................67
Figure53.ElectronicControlValveHydraulic Schematic,LiftTruckModelsS6.0FT,S7.0FT (S135FT,S155FT)(E024)andH6.0FT,H7.0FT(H135FT,H155FT)(J006)..........................................71
Figure54.ManualControlValveHydraulicSchematicforLiftTruckModelsS6.0FT,S7.0FT (S135FT,S155FT)(E024)andH6.0FT,H7.0FT(H135FT,H155FT)(J006)..........................................72
Figure55.ElectronicControlValveHydraulicandBrakeSystemSchematic.....................................72 Figure56.HydraulicTransmissionandBrakeCoolingSchematicH8.0FT,H8.0FT9,H9.0FT (H170FT,H175FT36)H190FT)(A299).....................................................................................................74
Thissectionisforthefollowingmodels:
H8.0FT,H8.0FT9,H9.0FT(H170FT,H175FT36,H190FT)[A299]; S30FT,S35FT,S40FTS[E010];
H1.6FT,H1.8FT,H2.0FTS(H30FT,H35FT,H40FTS)[F001]; S2.0-3.5FT(S40-70FT,S55FTS)[F187]; S6.0FT,S7.0FT(S135FT,S155FT)[E024]; H6.0FT,H7.0FT(H135FT,H155FT)[J006]; H2.0-3.5FT(H40-70FT)[L177];
S4.0,4.5,5.50FT;S5.5FTS(S80,100,120FT;S80,100FTBCS, S120FTS,S120FTPRS)[G004]; H4.0FT5/FT6,H4.5FTS5,H4.5FT6,H5.0-5.5FT(H80,90, 100,110,120FT)[P005]
TableofContentsDiagramsandSchematics
ii
GeneralInformationAboutDiagramsandSchematics
Thechassiswiringusedinthesevehiclesconformsto theelectricalcircuitidentificationstandard ES-1359 andinadditiontosurfacemarkedIDcircuitnumbers,generallyutilizesthecolorsthatareindicated inTable1.
MONOTROL®,engineharnesses,wiringtosensors, andotherapplicationsvarywithrespecttowirecolors.
Diagramsandschematicsinthismanualcanbe viewedandprintedincolor.Ifnotprintedorviewed incolor,refertotheelectricalcircuitidentification
locatedonschematiccircuits.Whenviewingacolor versionofthediagramsandschematics,thewhite chassiswiresareseenasyellow.Otherwiresare shownincolorssimilartoactualcolors,i.e.tan showsasyellow.Usecircuitidentificationfortrue wirecolor.
Referto DiagnosticTroubleshootingManual 9000SRM1112Section9030,Group03-General MaintenanceandDiagnosticData,forfurtherinformation.
Table1.WireColors
8000SRM1409GeneralInformationAboutDiagramsandSchematics
Color Use/Function Red Battery-levelpowercircuitsand5voltsupplycircuits Black Heavycurrentgrounds Green Signalgrounds White Othercircuits TwistedPair(Yellow/Green) Yellow Green CANbus CAN-Hi CAN-Lo TwistedPair(DkBlue/PinkandDkBlue/White) DkBlue/Pink DkBlue/White CANbus(Mazda) CAN-Hi CAN-Lo LetterontheVSMBUS Use/Function R RegulatedOutputVoltage D Driver I Input SYMBOLDEFINITIONS SeeTable2fordescriptionofsymboldefinitions. Table2.SymbolDefinitions SymbolName Definition TypeS Identifiesinformation forULSafetyrated trucks.Applicable trucksareratedforGS, LPS,andDSdepending onfueltype. Table2.SymbolDefinitions(Continued) SymbolName Definition ArrowSymbol Gotospecifiedpageof schematic,locatedin lowerrightcornerin thehexagonsymbol. -----X Gotospecifiedsheetof diagram.Sheetnumber islocatedinlowerright corneroffigure. Confidential/Proprietary-DoNotCopyorDuplicate1
DIAGRAMSMANUALAPPLICATIONS
SeeTable3forthecorrectdiagramsservicemanual foryourlifttruck.
Table3.1-9TonDiagramsManualApplications
UnitCode
E010,F001
F187,L177
DiagramsManual Number
PriortoAugust2008 8525590 8516519 8000SRM1152 August,2008toApril,2009 1665405 1665404 8000SRM1387 May,2009toDecember2012 1688540 1688539 8000SRM1409
January,2013===> 4051618 4051617 8000SRM1585 PriortoAugust2008 8525590 8516519 8000SRM1152 August,2008toApril,2009 1665405 1665404 8000SRM1387 May,2009toDecember2012 1688540 1688539 8000SRM1409
January,2013===> 4051618 4051617 8000SRM1585
PriortoAugust2008 8525590 8516519 8000SRM1152 August,2008toDecember 2009 1665405 1665404 8000SRM1387
January2010toJanuary 2012 1688540 1688539 8000SRM1409 G004 January2012===> 4051618 4051617 8000SRM1585 N005,D024, H006 All 8525590 8516519 8000SRM1152
August,2008toApril,2009 1665405 1665404 8000SRM1387 E024 May,2009===> 1688540 1688539 8000SRM1409 F024 All 4051618 4051617 8000SRM1585 K006 All 4051618 4051617 8000SRM1585 PriortoJanuary2010 1665405 1665404 8000SRM1387 P005 January2010===> 1688540 1688539 8000SRM1409 R005 All 4051618 4051617 8000SRM1585 August,2008toApril,2009 1665405 1665404 8000SRM1387 J006 May,2009===> 1688540 1688539 8000SRM1409 A299 May,2009===> 1688540 1688539 8000SRM1409 B299 All 4051618 4051617 8000SRM1585 G024 All 4051618 4051617 8000SRM1585 S005 All 4051618 4051617 8000SRM1585
GeneralInformationAboutDiagramsandSchematics8000SRM1409
ProductionDate Electrical Schematic Wiring Diagram
2Confidential/Proprietary-DoNotCopyorDuplicate
Figure1.TypeSOptionElectricalSchematic
8000SRM1409Diagrams,Schematics,orArrangements
Confidential/Proprietary-DoNotCopyorDuplicate3
Diagrams,Schematics,orArrangements8000SRM1409
4Confidential/Proprietary-DoNotCopyorDuplicate Hyster Forklift Diagrams And Schematics
This is the cut pages sample. Download all 82 page(s) at: ManualPlace.com
Figure2.Mazda(2007)2.0Land2.2LGasEngine(Sheet1of2)
Full download: http://manualplace.com/download/hyster-forklift-diagrams-and-schematics/