Hyster E004 Operating instructions

Hyster E004 (S70XM S80XM S100XM S120XM
S120XMS) Forklift

DIAGRAMS
S3.50-5.50XM (S70-120XM) [E004, F004]
PART NO. 1510481 8000 SRM 989

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
General ............................................................................................................................................................... 1
Diagrams, Schematics, or Arrangements......................................................................................................... 1
Figure 1. Electrical Schematic LPG (REV 1) (E004)............................................................................... 2
Figure 2. Electrical Schematic LPG (REV 2-5) (E004) ........................................................................... 5
Figure 3. Wiring Diagram LPG (REV 1) (E004)...................................................................................... 7
Figure 4. Wiring Diagram LPG (REV 2 and 3) (E004) ........................................................................... 11
Figure 5. Electrical Schematic Gas (REV 1) (E004)................................................................................ 15
Figure 6. Electrical Schematic Gas (REV 2-4) (E004) ............................................................................ 18
Figure 7. Wiring Diagram Gas (REV 1) (E004) ...................................................................................... 20
Figure 8. Wiring Diagram Gas (REV 2) (E004)....................................................................................... 24
Figure 9. GM V-6 Gas and LPG Engine Electrical Schematic (F004) ................................................... 28
Figure 10. Electrical Schematic Diesel (REV 1) (E004).......................................................................... 32
Figure 11. Electrical Schematic Diesel (REV 2-4) (E004)....................................................................... 35
Figure 12. Wiring Diagram Diesel (REV 1) (E004)................................................................................. 37
Figure 13. Wiring Diagram Diesel (REV 2) (E004)................................................................................. 41
Figure 14. Hydraulic System Schematic ................................................................................................. 45
Figure 15. Single-Speed Powershift Transmission Schematic ............................................................... 45
This section is for the following models:
S3.50-5.50XM (S70-120XM) [E004, F004]
©2003 HYSTER COMPANY i

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APPROVED
PARTS

8000 SRM 989 Diagrams, Schematics, or Arrangements
General
This service repair manual contains electrical, hydraulic, and transmission diagrams for S3.50-5.50XM (S70-
120XM) model lift trucks.
1

Diagrams, Schematics, or Arrangements 8000 SRM 989
Figure 1. Electrical Schematic LPG (REV 1) (E004) (Sheet 1 of 3)
2

8000 SRM 989 Diagrams, Schematics, or Arrangements
Figure 1. Electrical Schematic LPG (REV 1) (E004) (Sheet 2 of 3)
3

Diagrams, Schematics, or Arrangements 8000 SRM 989
Figure 1. Electrical Schematic LPG (REV 1) (E004) (Sheet 3 of 3)
4

8000 SRM 989 Diagrams, Schematics, or Arrangements
Figure 2. Electrical Schematic LPG (REV 2-5) (E004) (Sheet 1 of 2)
5

Diagrams, Schematics, or Arrangements 8000 SRM 989
Figure 2. Electrical Schematic LPG (REV 2-5) (E004) (Sheet 2 of 2)
6

8000 SRM 989 Diagrams, Schematics, or Arrangements
Figure 3. Wiring Diagram LPG (REV 1) (E004) (Sheet 1 of 4)
7

Diagrams, Schematics, or Arrangements 8000 SRM 989
Figure 3. Wiring Diagram LPG (REV 1) (E004) (Sheet 2 of 4)
8

8000 SRM 989 Diagrams, Schematics, or Arrangements
Figure 3. Wiring Diagram LPG (REV 1) (E004) (Sheet 3 of 4)
9

Diagrams, Schematics, or Arrangements 8000 SRM 989
Figure 3. Wiring Diagram LPG (REV 1) (E004) (Sheet 4 of 4)
10

8000 SRM 989 Diagrams, Schematics, or Arrangements
Figure 4. Wiring Diagram LPG (REV 2 and 3) (E004) (Sheet 1 of 4)
11

Diagrams, Schematics, or Arrangements 8000 SRM 989
Figure 4. Wiring Diagram LPG (REV 2 and 3) (E004) (Sheet 2 of 4)
12

8000 SRM 989 Diagrams, Schematics, or Arrangements
Figure 4. Wiring Diagram LPG (REV 2 and 3) (E004) (Sheet 3 of 4)
13