DIAGRAMS

H2.00-3.20XM (H40-65XM) [H177]

PART NO. 1456998 8000 SRM 709

 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. GM 3.0L Gasoline Engine Wiring Schematic (Early Models) ................................................ 2
Figure 2. GM 3.0L Gasoline Engine Wiring Schematic (Late Models) .................................................. 4
Figure 3. GM 3.0L LPG Engine With MSTS Wiring Schematic (Early Models) ................................... 6
Figure 4. GM 3.0 LPG Engine With MSTS Wiring Schematic (Late Models) ....................................... 8
Figure 5. GM 3.0L LPG Engine Without MSTS Wiring Schematic (Late Models) ............................... 10
Figure 6. GM 3.0L Engine Wiring Harness LPG Closed Loop ............................................................... 12
Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic................................... 16
Figure 8. Mazda EGI Gas EPA Compliant Engine Wiring Diagram .................................................... 20
Figure 9. Mazda Gasoline or LPG Engine Wiring Schematic (Early Models)....................................... 22
Figure 10. Mazda Gasoline or LPG Engine Wiring Schematic (Late Models) ...................................... 23
Figure 11. Mazda 2.0L and 2.2L LPG Engine Wiring Schematic - Aisan Closed-Loop ........................ 24
Figure 12. Perkins 2.6L Diesel Engine Wiring Schematic (Early Models) ............................................ 25
Figure 13. Perkins 2.6L Diesel Engine Wiring Schematic (Late Models).............................................. 26
Figure 14. Dual Fuel Option on GM 3.0L Engine Electrical Schematic................................................ 27
Figure 15. Dual Fuel Option on Mazda 2.0L and 2.2L Engine Electrical Schematic ........................... 27
Figure 16. UL Safety Classification Wiring Schematic .......................................................................... 28
Figure 17. UL Safety Classification Wiring Schematic .......................................................................... 29
Figure 18. Chassis Wiring Schematic (Early Models) ............................................................................ 30
Figure 19. GM 3.0L Engine Chassis Wiring Schematic (Early Models) ................................................ 32
Figure 20. Cab Wiring Schematic ............................................................................................................ 34
Figure 21. Lights Wiring Schematic (Early Models)............................................................................... 36
Figure 22. Lights Wiring Schematic (Late Models) ................................................................................ 38
Figure 23. Chassis and Lights Wiring Schematic - Late Models ........................................................... 40
Figure 24. Instrument Cluster Harness (Later Models)......................................................................... 44
Figure 25. Instrument Cluster Wiring Schematic .................................................................................. 45
Figure 26. Hydraulic System Schematic ................................................................................................. 46
Figure 27. Hydraulic System Arrangement ............................................................................................ 47
Figure 28. Transmission Control Lever Schematic................................................................................. 48
Figure 29. Powershift Transmission (Neutral) Hydraulic Schematic.................................................... 49
Figure 30. Hydraulic Schematic for Hydrostatic Drive System ............................................................. 50
Figure 31. Electrical Schematic for Hydrostatic Transmission.............................................................. 51
Figure 32. Hydrostatic Transmission Throttle Up Wiring Diagram...................................................... 52

This section is for the following models:

H2.00-3.20XM (H40-65XM) [H177]

©2004 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 709 Diagrams, Schematics, or Arrangements

NOTES

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Diagrams, Schematics, or Arrangements 8000 SRM 709

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 1. GM 3.0L Gasoline Engine Wiring Schematic (Early Models)

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Diagrams, Schematics, or Arrangements 8000 SRM 709

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 2. GM 3.0L Gasoline Engine Wiring Schematic (Late Models)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 3. GM 3.0L LPG Engine With MSTS Wiring Schematic (Early Models)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 4. GM 3.0 LPG Engine With MSTS Wiring Schematic (Late Models)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 5. GM 3.0L LPG Engine Without MSTS Wiring Schematic (Late Models)

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Figure 6. GM 3.0L Engine Wiring Harness LPG Closed Loop (Sheet 1 of 2)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 6. GM 3.0L Engine Wiring Harness LPG Closed Loop (Sheet 2 of 2)

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Diagrams, Schematics, or Arrangements 8000 SRM 709

Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 1 of 4)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 2 of 4)

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Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 3 of 4)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 7. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 4 of 4)

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Figure 8. Mazda EGI Gas EPA Compliant Engine Wiring Diagram (Sheet 1 of 2)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 8. Mazda EGI Gas EPA Compliant Engine Wiring Diagram (Sheet 2 of 2)

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Figure 9. Mazda Gasoline or LPG Engine Wiring Schematic (Early Models)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 10. Mazda Gasoline or LPG Engine Wiring Schematic (Late Models)

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Figure 11. Mazda 2.0L and 2.2L LPG Engine Wiring Schematic - Aisan Closed-Loop

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 12. Perkins 2.6L Diesel Engine Wiring Schematic (Early Models)

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Figure 13. Perkins 2.6L Diesel Engine Wiring Schematic (Late Models)

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Figure 14. Dual Fuel Option on GM 3.0L Engine Electrical Schematic

Figure 15. Dual Fuel Option on Mazda 2.0L and 2.2L Engine Electrical Schematic

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Diagrams, Schematics, or Arrangements 8000 SRM 709

Figure 16. UL Safety Classification Wiring Schematic

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Figure 17. UL Safety Classification Wiring Schematic

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 18. Chassis Wiring Schematic (Early Models)

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Figure 19. GM 3.0L Engine Chassis Wiring Schematic (Early Models)

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Figure 20. Cab Wiring Schematic

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Figure 21. Lights Wiring Schematic (Early Models)

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Figure 22. Lights Wiring Schematic (Late Models)

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Figure 23. Chassis and Lights Wiring Schematic - Late Models (Sheet 1 of 2)

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8000 SRM 709 Diagrams, Schematics, or Arrangements

Figure 23. Chassis and Lights Wiring Schematic - Late Models (Sheet 2 of 2)

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Diagrams, Schematics, or Arrangements 8000 SRM 709

Figure 24. Instrument Cluster Harness (Later Models)

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Figure 25. Instrument Cluster Wiring Schematic

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Diagrams, Schematics, or Arrangements 8000 SRM 709

1. HYDRAULIC PUMP 11. TILT SPOOL

2. FLOW CONTROL VALVE 12. AUXILIARY FUNCTION SPOOL
3. RELIEF VALVE (STEERING SYSTEM) 13. RELIEF VALVE (TILT AND AUXILIARY CIRCUITS)
4. CHECK PORT (STEERING SYSTEM) 14. TILT CYLINDER
5. STEERING CONTROL UNIT 15. LIFT CYLINDER
6. STEERING CYLINDER 16. LOWERING CONTROL VALVE (INSIDE
7. MAIN CONTROL VALVE CYLINDER)
8. FILTER 17. LOWERING CONTROL VALVE (OUTSIDE
9. RELIEF VALVE (LIFT CIRCUIT) CYLINDER)
10. LIFT/LOWER SPOOL 18. CHECK PORT (LIFT AND TILT CIRCUITS)

Figure 26. Hydraulic System Schematic

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8000 SRM 709 Diagrams, Schematics, or Arrangements

1. HYDRAULIC TANK 7. TO LIFT CYLINDERS

2. BREATHER 8. TILT CYLINDER
3. RETURN LINE 9. STEERING CONTROL UNIT
4. MAIN CONTROL VALVE 10. HYDRAULIC PUMP
5. TILT BACKWARD LINE 11. FILTER
6. TILT FORWARD LINE 12. STEERING CYLINDER

Figure 27. Hydraulic System Arrangement

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COLOR CODES: Y = WHITE, W = GREEN, X = RED, CB = LIGHT GREEN (REV SOLENOID), CC =

ORANGE/BLACK (FWD SOLENOID)
1. REVERSE CONTROL SWITCH 3. FORWARD CONTROL SWITCH
2. NEUTRAL START SWITCH 4. CONNECTOR-TO-COWL WIRING HARNESS

Figure 28. Transmission Control Lever Schematic

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8000 SRM 709 Diagrams, Schematics, or Arrangements

1. SCREEN 13. MODULATOR REGULATOR

2. PUMP 14. INCHING SPOOL
3. PUMP RELIEF VALVE 15. DIRECTION SPOOL
4. FILTER 16. REVERSE SOLENOID
5. CHECK PORT FOR TORQUE CONVERTER 17. FORWARD SOLENOID
6. TORQUE CONVERTER 18. CHECK PORT FOR FORWARD CLUTCH
7. TORQUE CONVERTER REGULATOR PRESSURE
8. OIL COOLER 19. CHECK PORT FOR REVERSE CLUTCH
9. CHECK PORT FOR LUBRICATION CIRCUIT PRESSURE
10. CLUTCH PRESSURE REGULATOR 20. REVERSE CLUTCH
11. CHECK PORT FOR MODULATOR PRESSURE 21. FORWARD CLUTCH
12. MODULATOR CONTROL VALVE 22. CHECK PORT FOR PUMP PRESSURE

Figure 29. Powershift Transmission (Neutral) Hydraulic Schematic

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1. THROTTLE CONTROL 6. SCREEN

2. TRANSMISSION FILTER 7. TRANSMISSION RESERVOIR
3. DIRECTION CONTROL VALVE 8. OIL COOLER
4. BRAKE INCHING VALVE 9. WHEEL MOTORS
5. HYDROSTATIC TRANSMISSION PUMP

Figure 30. Hydraulic Schematic for Hydrostatic Drive System

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Figure 31. Electrical Schematic for Hydrostatic Transmission

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Figure 32. Hydrostatic Transmission Throttle Up Wiring Diagram

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 TECHNICAL PUBLICATIONS

8000 SRM 709 10/04 (12/03)(12/02)(1/02)(6/01)(2/98) Printed in United Kingdom