DIAGRAMS AND

SCHEMATICS
S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT
(S40-70FT, S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, 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) [N005];
S6.0FT, S7.0FT (S135FT, S155FT) [D024]; H6.0FT,
H7.0FT (H135FT, H155FT) [H006]

This manual contains information that is confidential and/or proprietary to Hyster

Company, its subsidiaries and/or vendors. Copying or distribution of any sections of
this manual marked "Confidential/Proprietary" is prohibited.

PART NO. 1580527 8000 SRM 1152

 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 and Schematics Table of Contents

TABLE OF CONTENTS

General Information About Diagrams and Schematics................................................................................... 1

Symbol Definitions .................................................................................................................................... 1
Diagrams, Schematics, or Arrangements ......................................................................................................... 2
Figure 1. Electrical Schematic Type S Option......................................................................................... 2
Figure 2. Mazda 2.0L and 2.2L Gas Engine Electrical Schematic......................................................... 3
Figure 3. Mazda 2.0L and 2.2L LPG Engine Electrical Schematic........................................................ 5
Figure 4. GM 2.4L Gas Engine Electrical Schematic ............................................................................. 7
Figure 5. GM 2.4L LPG Engine Electrical Schematic ............................................................................ 9
Figure 6. Yanmar 2.6L and 3.3L Diesel Engine Electrical Schematic ................................................... 11
Figure 7. GM 4.3L Gas Engine Electrical................................................................................................ 12
Figure 8. GM 4.3L LPG Engine Electrical System ................................................................................. 14
Figure 9. Cummins 4.5L Diesel Engine Electrical System .................................................................... 16
Figure 10. Right Side Truck Devices Electrical Schematic .................................................................... 17
Figure 11. Left Side Truck Devices Electrical Schematic ....................................................................... 18
Figure 12. Cowl Devices Electrical Schematic ........................................................................................ 19
Figure 13. Standard (Powershift) Transmission Electrical Schematic .................................................. 20
Figure 14. Spicer Off-Highway Transmission Electrical Schematic for Lift Truck Models
S6.0FT, S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006) ............. 21
Figure 15. Electro-Hydraulics Electrical Schematic ............................................................................... 24
Figure 16. Lights and Cab Accessories Electrical Schematic................................................................. 25
Figure 17. Vehicle System Manager (VSM) Wiring Diagram................................................................. 26
Figure 18. Power Distribution Module (PDM) Wiring Diagram ............................................................ 27
Figure 19. Operator Cab Wiring Diagram............................................................................................... 28
Figure 20. Transmission Wiring Diagram, Common to ALL Transmissions......................................... 29
Figure 21. Engines Directory Diagram.................................................................................................... 30
Figure 22. Rear Signal and Work Lights Wiring Diagram ..................................................................... 31
Figure 23. Mazda 2.0L and 2.2L Gas Engine Wiring Diagram.............................................................. 32
Figure 24. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram............................................................. 33
Figure 25. GM 2.4L Gas Engine Wiring Diagram................................................................................... 34
Figure 26. GM 2.4L LPG Engine Wiring Diagram ................................................................................. 35
Figure 27. Yanmar 2.6L and 3.3L Diesel Engine Wiring Diagram ........................................................ 36
Figure 28. GM 4.3L Gas Engine Wiring Diagram................................................................................... 37
Figure 29. GM 4.3L LPG Engine Wiring Diagram ................................................................................. 38
Figure 30. Cummins 4.5L Engine Wiring Diagram ................................................................................ 39
Figure 31. Standard (Powershift) Transmission Wiring Diagram ......................................................... 40
Figure 32. Spicer Off-Highway Transmission 3 Forward/2 Reverse Wiring Diagram for Lift
Truck Models S6.0FT, S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT,
H155FT) (H006) ........................................................................................................................................ 41
Figure 33. Spicer Off-Highway Transmission 2 Forward/2 Reverse Wiring Diagram for Lift
truck Models S6.0FT, S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT,
H155FT) (H006) ........................................................................................................................................ 42
Figure 34. Connector Pin Identification ................................................................................................. 43
Figure 35. Circuit Identification ............................................................................................................. 44
Figure 36. Electronic Control Valve Hydraulic Schematic ..................................................................... 45
Figure 37. Manual Control Valve Hydraulic Schematic ......................................................................... 46
Figure 38. Transmission Hydraulic Schematic ....................................................................................... 47

©2006 HYSTER COMPANY i

Table of Contents Diagrams and Schematics

TABLE OF CONTENTS (Continued)

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, 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) [N005];
S6.0FT, S7.0FT (S135FT, S155FT) [D024];
H6.0FT, H7.0FT (H135FT, H155FT) [H006]

ii
8000 SRM 1152 General Information About Diagrams and Schematics

General Information About Diagrams and Schematics

The chassis wiring used in these vehicles conforms to and in addition to surface marked ID circuit num-
the electrical circuit identification standard ES-1359 bers, generally utilizes the colors that are indicated
in Table 1.

Table 1. Wire Colors

Color Use/Function
Red Battery-level power circuits and 5 volt supply circuits
Black Heavy current grounds
Green Signal grounds
White Other circuits
Twisted Pair (Yellow/Green) CANbus
Yellow CAN-Hi
Green CAN-Lo
Twisted Pair (Dk Blue/Pink and Dk Blue/White) CANbus (Mazda)
Dk Blue/Pink CAN-Hi
Dk Blue/White CAN-Lo
Letter on the VSM BUS Use/Function
R Regulated Output Voltage
D Driver
I Input

MONOTROL®, engine harnesses, wiring to sensors, Table 2. Symbol Definitions

and other applications vary with respect to wire col-
ors. Symbol Name Definition

Diagrams and schematics in this manual can be Type S Identifies information

viewed and printed in color. If not printed or viewed for UL Safety rated
in color, refer to the electrical circuit identification trucks. Applicable
located on schematic circuits. When viewing a color trucks are rated for GS,
version of the diagrams and schematics, the white LPS, and DS depending
chassis wires are seen as yellow. Other wires are on fuel type.
shown in colors similar to actual colors, i.e. tan Arrow Symbol Go to specified page of
shows as yellow. Use circuit identification for true schematic, located in
wire color. lower right corner in
the hexagon symbol.
Refer to Diagnostic Troubleshooting Manual
9000 SRM 1112 Section 9030, Group 03 - General Hexagon Symbol Page number of the
Maintenance and Diagnostic Data, for further infor- schematic or diagram.
mation. Located in the lower
right corner.
Symbol Definitions
-----X Go to specified sheet of
See Table 2 for description of symbol definitions. diagram. Sheet number
is located in lower right
corner of figure.

Confidential/Proprietary - Do Not Copy or Duplicate 1

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 1. Electrical Schematic Type S Option

2 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 2. Mazda 2.0L and 2.2L Gas Engine Electrical Schematic (Sheet 1 of 2)

Confidential/Proprietary - Do Not Copy or Duplicate 3

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 2. Mazda 2.0L and 2.2L Gas Engine Electrical Schematic (Sheet 2 of 2)

4 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 3. Mazda 2.0L and 2.2L LPG Engine Electrical Schematic (Sheet 1 of 2)

Confidential/Proprietary - Do Not Copy or Duplicate 5

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 3. Mazda 2.0L and 2.2L LPG Engine Electrical Schematic (Sheet 2 of 2)

6 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 4. GM 2.4L Gas Engine Electrical Schematic (Sheet 1 of 2)

Confidential/Proprietary - Do Not Copy or Duplicate 7

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 4. GM 2.4L Gas Engine Electrical Schematic (Sheet 2 of 2)

8 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 5. GM 2.4L LPG Engine Electrical Schematic (Sheet 1 of 2)

Confidential/Proprietary - Do Not Copy or Duplicate 9

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 5. GM 2.4L LPG Engine Electrical Schematic (Sheet 2 of 2)

10 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 6. Yanmar 2.6L and 3.3L Diesel Engine Electrical Schematic

Confidential/Proprietary - Do Not Copy or Duplicate 11

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 7. GM 4.3L Gas Engine Electrical (Sheet 1 of 2)

12 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 7. GM 4.3L Gas Engine Electrical (Sheet 2 of 2)

Confidential/Proprietary - Do Not Copy or Duplicate 13

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 8. GM 4.3L LPG Engine Electrical System (Sheet 1 of 2)

14 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 8. GM 4.3L LPG Engine Electrical System (Sheet 2 of 2)

Confidential/Proprietary - Do Not Copy or Duplicate 15

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 9. Cummins 4.5L Diesel Engine Electrical System

16 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 10. Right Side Truck Devices Electrical Schematic

Confidential/Proprietary - Do Not Copy or Duplicate 17

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 11. Left Side Truck Devices Electrical Schematic

18 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 12. Cowl Devices Electrical Schematic

Confidential/Proprietary - Do Not Copy or Duplicate 19

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 13. Standard (Powershift) Transmission Electrical Schematic

20 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 14. Spicer Off-Highway Transmission Electrical Schematic for Lift Truck Models S6.0FT,
S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006) (Sheet 1 of 3)

Confidential/Proprietary - Do Not Copy or Duplicate 21

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 14. Spicer Off-Highway Transmission Electrical Schematic for Lift Truck Models S6.0FT,
S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006) (Sheet 2 of 3)

22 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 14. Spicer Off-Highway Transmission Electrical Schematic for Lift Truck Models S6.0FT,
S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006) (Sheet 3 of 3)

Confidential/Proprietary - Do Not Copy or Duplicate 23

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 15. Electro-Hydraulics Electrical Schematic

24 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 16. Lights and Cab Accessories Electrical Schematic

Confidential/Proprietary - Do Not Copy or Duplicate 25

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 17. Vehicle System Manager (VSM) Wiring Diagram

26 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 18. Power Distribution Module (PDM) Wiring Diagram

Confidential/Proprietary - Do Not Copy or Duplicate 27

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 19. Operator Cab Wiring Diagram

28 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 20. Transmission Wiring Diagram, Common to ALL Transmissions

Confidential/Proprietary - Do Not Copy or Duplicate 29

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 21. Engines Directory Diagram

30 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 22. Rear Signal and Work Lights Wiring Diagram

Confidential/Proprietary - Do Not Copy or Duplicate 31

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 23. Mazda 2.0L and 2.2L Gas Engine Wiring Diagram

32 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 24. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram

Confidential/Proprietary - Do Not Copy or Duplicate 33

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 25. GM 2.4L Gas Engine Wiring Diagram

34 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 26. GM 2.4L LPG Engine Wiring Diagram

Confidential/Proprietary - Do Not Copy or Duplicate 35

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 27. Yanmar 2.6L and 3.3L Diesel Engine Wiring Diagram

36 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 28. GM 4.3L Gas Engine Wiring Diagram

Confidential/Proprietary - Do Not Copy or Duplicate 37

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 29. GM 4.3L LPG Engine Wiring Diagram

38 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 30. Cummins 4.5L Engine Wiring Diagram

Confidential/Proprietary - Do Not Copy or Duplicate 39

Diagrams, Schematics, or Arrangements 8000 SRM 1152

NOTE: ALSO SEE FIGURE 20.

Figure 31. Standard (Powershift) Transmission Wiring Diagram

40 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

NOTE: ALSO SEE FIGURE 20.

Figure 32. Spicer Off-Highway Transmission 3 Forward/2 Reverse Wiring Diagram for Lift Truck
Models S6.0FT, S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006)

Confidential/Proprietary - Do Not Copy or Duplicate 41

Diagrams, Schematics, or Arrangements 8000 SRM 1152

NOTE: ALSO SEE FIGURE 20.

Figure 33. Spicer Off-Highway Transmission 2 Forward/2 Reverse Wiring Diagram for Lift truck
Models S6.0FT, S7.0FT, (S135FT, S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006)

42 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 34. Connector Pin Identification

Confidential/Proprietary - Do Not Copy or Duplicate 43

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 35. Circuit Identification

44 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

Figure 36. Electronic Control Valve Hydraulic Schematic

Confidential/Proprietary - Do Not Copy or Duplicate 45

Diagrams, Schematics, or Arrangements 8000 SRM 1152

Figure 37. Manual Control Valve Hydraulic Schematic

46 Confidential/Proprietary - Do Not Copy or Duplicate

8000 SRM 1152 Diagrams, Schematics, or Arrangements

1. SUMP SCREEN 12. FORWARD LOW CLUTCH PRESSURE PORT

2. CHARGE PUMP 13. REVERSE CLUTCH PRESSURE PORT
3. LINE PRESSURE TAP 14. FORWARD HIGH CLUTCH*
4. FILTER 15. FORWARD LOW CLUTCH
5. CHARGE PUMP RELIEF 16. REVERSE CLUTCH
6. TRANSMISSION ENABLE SOLENOID VALVE 17. CONVERTER PRESSURE REGULATOR
7. TRANSMISSION ENABLE SPOOL 18. PACK REGULATOR VALVE
8. PROPORTIONAL VALVE 19. CONVERTER PRESSURE TAP
9. TRANSDUCER 20. TORQUE CONVERTER
10. PROPORTIONAL VALVE* 21. COOLER
11. TRANSDUCER* 22. TRANSMISSION CLUTCH PACKS LUBRICATION

*USED ON TWO-SPEED TRANSMISSION ONLY

Figure 38. Transmission Hydraulic Schematic

Confidential/Proprietary - Do Not Copy or Duplicate 47

 NOTES

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48
 TECHNICAL PUBLICATIONS

8000 SRM 1152 10/06 (6/06)(3/06)(6/05)(5/05)(2/05)(12/04) Printed in U.S.A.