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DIAGRAMSS2.00-3.20XM (S40-65XM) [D187]
PART NO. 1483161 8000 SRM 807
SAFETY PRECAUTIONSMAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctlyfastened, and that the load being lifted is balanced. Make sure the crane, cables, andchains 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 repairon electric lift trucks. Disconnect the battery ground cable on internal combustion lifttrucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUTTHE 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 partsmust meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed beforeusing 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 fuelare flammable. Be sure to follow the necessary safety precautions when handling thesefuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparksaway from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in thismanual:
WARNINGIndicates a condition that can cause immediate death or injury!
CAUTIONIndicates a condition that can cause property damage!
Diagrams Table of Contents
TABLE OF CONTENTS
Diagrams, Schematics, or Arrangements ......................................................................................................... 1Figure 1. GM 3.0L Gasoline Engine Wiring Diagram (Early Models) ................................................... 2Figure 2. GM 3.0L Gasoline Engine Wiring Diagram (Late Models)..................................................... 6Figure 3. GM 3.0L LPG Engine With MSTS Wiring Diagram (Early Models) ..................................... 10Figure 4. GM 3.0L LPG Engine With MSTS Wiring Diagram - IMPCO System.................................. 12Figure 5. GM 3.0L LPG Engine With MSTS Wiring Diagram - Aisan System..................................... 14Figure 6. GM 3.0L LPG Engine Without MSTS Wiring Diagram (Early Models) ................................ 16Figure 7. GM 3.0L LPG Engine Without MSTS Wiring Diagram - IMPCO System ............................ 18Figure 8. GM 3.0L LPG Engine Without MSTS - Aisan System............................................................ 20Figure 9. GM 3.0L LPG Engine Wiring Diagram ................................................................................... 22Figure 10. GM 3.0L LPG Engine Closed Loop ........................................................................................ 28Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic................................. 32Figure 12. Mazda 2.0L and 2.2L Gasoline Engine Wiring Diagram...................................................... 36Figure 13. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram - IMPCO Closed-Loop........................ 38Figure 14. Mazda 2.0L and 2.2L Gasoline and LPG Engine Wiring Diagram...................................... 40Figure 15. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram - Aisan Open-Loop............................. 44Figure 16. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram - Aisan Closed-Loop........................... 46Figure 17. Mazda 2.0L and 2.2L Engine With Dual Fuel System Wiring Diagram ............................. 48Figure 18. Mazda 2.0L and 2.2L Engine Wiring Diagram - Powertrain Protection ............................. 50Figure 19. GM 3.0L Engine With Dual Fuel System Wiring Diagram (Late Models) .......................... 52Figure 20. GM 3.0L Gasoline Engine Electrical Schematic (Late Models) ........................................... 56Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models) .................................................. 60Figure 22. Mazda 2.0L and 2.2L Gasoline Engine Electrical Schematic (Late Models)....................... 66Figure 23. Mazda 2.0L and 2.2L LPG Engine Electrical Schematic - Aisan System............................ 68Figure 24. Mazda 2.0L and 2.2L Gasoline and LPG Engine Electrical Schematic (Late Models) ....... 70Figure 25. Chassis Wiring Diagram (Late Models)................................................................................. 74Figure 26. UL Safety Classification Wiring Diagram............................................................................. 76Figure 27. Lights Wiring Diagram (Early Models) ................................................................................. 78Figure 28. Wiring Diagram Chassis and Cluster (Late Models) ............................................................ 80Figure 29. Hydraulic System Schematic ................................................................................................. 88Figure 30. Hydraulic System Arrangement ............................................................................................ 89Figure 31. Hydraulic Schematic for Transmission (Neutral) ................................................................. 90
This section is for the following models:
S2.00-3.20XM (S40-65XM) [D187]
©2005 HYSTER COMPANY i
"THEQUALITYKEEPERS"
HYSTERAPPROVEDPARTS
8000 SRM 807 Diagrams, Schematics, or Arrangements
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Figure 1. GM 3.0L Gasoline Engine Wiring Diagram (Early Models) (Sheet 1 of 2)
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Figure 1. GM 3.0L Gasoline Engine Wiring Diagram (Early Models) (Sheet 2 of 2)
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Figure 2. GM 3.0L Gasoline Engine Wiring Diagram (Late Models) (Sheet 1 of 2)
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Figure 2. GM 3.0L Gasoline Engine Wiring Diagram (Late Models) (Sheet 2 of 2)
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Figure 3. GM 3.0L LPG Engine With MSTS Wiring Diagram (Early Models)
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Figure 4. GM 3.0L LPG Engine With MSTS Wiring Diagram - IMPCO System
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Figure 5. GM 3.0L LPG Engine With MSTS Wiring Diagram - Aisan System
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Figure 6. GM 3.0L LPG Engine Without MSTS Wiring Diagram (Early Models)
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Figure 7. GM 3.0L LPG Engine Without MSTS Wiring Diagram - IMPCO System
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Figure 8. GM 3.0L LPG Engine Without MSTS - Aisan System
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Figure 9. GM 3.0L LPG Engine Wiring Diagram (Sheet 1 of 3)
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Figure 9. GM 3.0L LPG Engine Wiring Diagram (Sheet 2 of 3)
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Figure 9. GM 3.0L LPG Engine Wiring Diagram (Sheet 3 of 3)
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Figure 10. GM 3.0L LPG Engine Closed Loop (Sheet 1 of 2)
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Figure 10. GM 3.0L LPG Engine Closed Loop (Sheet 2 of 2)
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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 1 of 4)
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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 2 of 4)
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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 3 of 4)
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Figure 11. GM 3.0L Gas and LPG EPA Compliant Engine Electrical Schematic (Sheet 4 of 4)
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Figure 12. Mazda 2.0L and 2.2L Gasoline Engine Wiring Diagram
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Figure 13. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram - IMPCO Closed-Loop
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Figure 14. Mazda 2.0L and 2.2L Gasoline and LPG Engine Wiring Diagram (Sheet 1 of 2)
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Figure 14. Mazda 2.0L and 2.2L Gasoline and LPG Engine Wiring Diagram (Sheet 2 of 2)
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Figure 15. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram - Aisan Open-Loop
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Figure 16. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram - Aisan Closed-Loop
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Figure 17. Mazda 2.0L and 2.2L Engine With Dual Fuel System Wiring Diagram
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Figure 18. Mazda 2.0L and 2.2L Engine Wiring Diagram - Powertrain Protection
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Figure 19. GM 3.0L Engine With Dual Fuel System Wiring Diagram (Late Models) (Sheet 1 of 2)
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Figure 19. GM 3.0L Engine With Dual Fuel System Wiring Diagram (Late Models) (Sheet 2 of 2)
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Figure 20. GM 3.0L Gasoline Engine Electrical Schematic (Late Models) (Sheet 1 of 2)
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Figure 20. GM 3.0L Gasoline Engine Electrical Schematic (Late Models) (Sheet 2 of 2)
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Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models) (Sheet 1 of 3)
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Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models) (Sheet 2 of 3)
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Figure 21. GM 3.0L LPG Engine Electrical Schematic (Late Models) (Sheet 3 of 3)
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Figure 22. Mazda 2.0L and 2.2L Gasoline Engine Electrical Schematic (Late Models)
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Figure 23. Mazda 2.0L and 2.2L LPG Engine Electrical Schematic - Aisan System
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Figure 24. Mazda 2.0L and 2.2L Gasoline and LPG Engine ElectricalSchematic (Late Models) (Sheet 1 of 2)
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Figure 24. Mazda 2.0L and 2.2L Gasoline and LPG Engine ElectricalSchematic (Late Models) (Sheet 2 of 2)
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Figure 25. Chassis Wiring Diagram (Late Models)
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Figure 26. UL Safety Classification Wiring Diagram
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Figure 27. Lights Wiring Diagram (Early Models)
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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 1 of 4)
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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 2 of 4)
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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 3 of 4)
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Figure 28. Wiring Diagram Chassis and Cluster (Late Models) (Sheet 4 of 4)
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1. HYDRAULIC PUMP2. FLOW CONTROL VALVE3. RELIEF VALVE (STEERING SYSTEM)4. CHECK PORT (STEERING SYSTEM)5. STEERING CONTROL UNIT6. STEERING CYLINDER7. MAIN CONTROL VALVE8. FILTER9. RELIEF VALVE (LIFT CIRCUIT)10. LIFT/LOWER SPOOL
11. TILT SPOOL12. AUXILIARY FUNCTION SPOOL13. RELIEF VALVE (TILT AND AUXILIARY CIRCUITS)14. TILT CYLINDER15. LIFT CYLINDER16. LOWERING CONTROL VALVE (INSIDE
CYLINDER)17. LOWERING CONTROL VALVE (OUTSIDE
CYLINDER)18. CHECK PORT (LIFT AND TILT CIRCUITS)
Figure 29. Hydraulic System Schematic
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1. HYDRAULIC TANK2. BREATHER3. RETURN LINE4. MAIN CONTROL VALVE5. TILT BACKWARD LINE6. TILT FORWARD LINE
7. TO LIFT CYLINDERS8. TILT CYLINDER9. STEERING CONTROL UNIT10. HYDRAULIC PUMP11. FILTER12. STEERING CYLINDER
Figure 30. Hydraulic System Arrangement
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1. SCREEN2. PUMP3. PUMP RELIEF VALVE4. FILTER5. CHECK PORT FOR TORQUE CONVERTER6. TORQUE CONVERTER7. TORQUE CONVERTER REGULATOR8. OIL COOLER9. CHECK PORT FOR LUBRICATION CIRCUIT10. CLUTCH PRESSURE REGULATOR11. CHECK PORT FOR MODULATOR PRESSURE12. MODULATOR CONTROL VALVE
13. MODULATOR REGULATOR14. INCHING SPOOL15. DIRECTION SPOOL16. REVERSE SOLENOID17. FORWARD SOLENOID18. CHECK PORT FOR FORWARD CLUTCH
PRESSURE19. CHECK PORT FOR REVERSE CLUTCH
PRESSURE20. REVERSE CLUTCH21. FORWARD CLUTCH22. CHECK PORT FOR PUMP PRESSURE
Figure 31. Hydraulic Schematic for Transmission (Neutral)
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TECHNICAL PUBLICATIONS
8000 SRM 807 9/05 (12/03)(9/03)(1/02)(12/00)(4/00) Printed in U.S.A.