Hyster H4.0FT5 Operating instructions

Hyster F187 (S40FT, S50FT, S60FT, S70FT, S55FTS)
Forklift Service Repair Manual

DIAGRAMS AND
SCHEMATICS
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299];
S30FT-S35FT, S40FTS [E010];
H1.6FT-1.8FT, H2.0FTS (H30-35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S6.0-7.0FT (S135-155FT) [E024];
H6.0-7.0FT (H135-155FT) [J006];
H2.0-3.5FT (H40-70FT) [L177];
S4.0-5.50FT; S5.5FTS (S80-120FT; S80-100FTBCS, S120FTS,
S120FTPRS) [G004];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) [P005]
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. 4000701 8000 SRM 1409

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 Maintenance 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 ex-
ceed 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 flamma-
ble. 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 hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General Information About Diagrams and Schematics ........................................................................................ 1
Symbol Definitions ..............................................................................................................................................2
Diagrams Manual Applications ..........................................................................................................................2
Diagrams, Schematics or Arrangements................................................................................................................ 4
Figure 1. Type S Option Electrical Schematic................................................................................................... 4
Figure 2. Mazda (2007) 2.0L and 2.2L Gas Engine............................................................................................5
Figure 3. Mazda (2007) 2.0L and 2.2L LPG Engine Electrical Schematic....................................................... 7
Figure 4. GM 2.4L Gas Engine Electrical Schematic........................................................................................ 9
Figure 5. GM 2.4L LPG Engine Electrical Schematic..................................................................................... 11
Figure 6. Yanmar 2.6L and 3.3L Diesel Engine Electrical Schematic............................................................13
Figure 7. GM 4.3L Gas Engine Electrical Schematic...................................................................................... 14
Figure 8. GM 4.3L LPG Engine Electrical Schematic..................................................................................... 16
Figure 9. Cummins 3.3L Diesel Engine Electrical Schematic.........................................................................18
Figure 10. Mazda (2005-2006) 2.0L and 2.2L Gas Engine Electrical Schematic........................................... 20
Figure 11. Mazda (2005-2006) 2.0L and 2.2L LPG Engine Electrical Schematic.......................................... 22
Figure 12. GM (2010) 5.7L LPG Engine Electrical Schematic........................................................................24
Figure 13. Right Side Truck Devices Electrical Schematic............................................................................. 26
Figure 14. Left Side Truck Devices Electrical Schematic................................................................................27
Figure 15. Cowl Devices Electrical Schematic................................................................................................. 28
Figure 16. Standard (Powershift) Transmission Electrical Schematic...........................................................29
Figure 17. Spicer Off-Highway Transmission 3 Forward/2 Reverse Electrical Schematic........................... 30
Figure 18. Electro-Hydraulic Electrical Schematic..........................................................................................33
Figure 19. Lights and Cab Accessories Electrical Schematic..........................................................................34
Figure 20. Forward Travel Amber Lights With Three-Stage Mast................................................................ 35
Figure 21. MLM Internal Connections............................................................................................................. 36
Figure 22. Vehicle System Manager (VSM) Wiring Diagram......................................................................... 37
Figure 23. Power Distribution Module (PDM) Wiring Diagram..................................................................... 38
Figure 24. Operator Cab Wiring Diagram........................................................................................................39
Figure 25. Transmission Wiring Diagram, Common to ALL Transmissions.................................................40
Figure 26. Engines Directory Wiring Diagram................................................................................................ 41
Figure 27. Rear Signal and Work Lights Wiring Diagram..............................................................................42
Figure 28. Mazda 2.0L and 2.2L Gas Engine Wiring Diagram.......................................................................43
Figure 29. Mazda 2.0L and 2.2L LPG Engine Wiring Diagram......................................................................44
Figure 30. GM 2.4L Gas Engine Wiring Diagram........................................................................................... 45
Figure 31. GM 2.4L LPG Engine Wiring Diagram.......................................................................................... 46
Figure 32. Yanmar 2.6L and 3.3L Diesel Engine Wiring Diagram.................................................................47
Figure 33. GM 4.3L Gas Engine Wiring Diagram........................................................................................... 48
Figure 34. GM 4.3L LPG Engine Wiring Diagram.......................................................................................... 49
Figure 35. Cummins 3.3L Diesel Engine Wiring Diagram..............................................................................50
Figure 36. Mazda (2005-2006) 2.0L and 2.2L Gas Engine Wiring Diagram.................................................. 51
Figure 37. Mazda (2005-2006) 2.0L and 2.2L LPG Engine Wiring Diagram................................................. 52
Figure 38. GM 5.7L LPG Engine (2010) Wiring Diagram...............................................................................53
Figure 39. Standard (Powershift) Transmission Wiring Diagram..................................................................54
Figure 40. Spicer Off-Highway Transmission 3 Forward/2 Reverse Wiring Diagram for Lift
Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (E024) and H6.0FT, H7.0FT (H135FT,
H155FT) (J006).................................................................................................................................................. 55
Figure 41. Spicer Off-Highway Transmission 2 Forward/2 Reverse Wiring Diagram for Lift
truck Models S6.0FT, S7.0FT (S135FT, S155FT) (E024) and H6.0FT, H7.0FT (H135FT, H155FT) (J006)56
Figure 42. Forward Travel Amber Lights With Three-Stage Mast................................................................ 57
Figure 43. Connector Pin Identification........................................................................................................... 58
Table of Contents
i

TABLE OF CONTENTS (Continued)
Figure 44. Circuit Identification....................................................................................................................... 59
Figure 45. Electronic Control Valve Hydraulic Schematic for Lift Truck Models S30FT,
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), Equipped With
Hydraulic Gear Pump........................................................................................................................................60
Figure 46. Electronic Control Valve Hydraulic Schematic for Lift Truck Models
H2.0-3.5FT (L177), Equipped With Variable Displacement Pump.................................................................61
Figure 47. Electronic Control Valve Hydraulic Schematic for Lift Truck Models S4.0, 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).................................... 62
Figure 48. Electronic Control Valve Hydraulic Schematic for Lift Truck Models H4.0FT5/
FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (P005), Equipped With Variable Displacement Pump.................... 63
Figure 49. Manual Control Valve Hydraulic Schematic for Lift Truck Models S30FT,
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)...................................................... 64
Figure 50. Manual Control Valve Hydraulic Schematic for Lift Truck Models S4.0, 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).................................... 65
Figure 51. Powershift Transmission Hydraulic Schematic............................................................................. 66
Figure 52. Transmission Hydraulic Schematic for Lift Truck Models S6.0FT, S7.0FT
(S135FT, S155FT) (E024) and H6.0FT, H7.0FT (H135FT, H155FT) (J006)..................................................69
Figure 53. Electronic Control Valve Hydraulic Schematic, Lift Truck Models S6.0FT,
S7.0FT (S135FT, S155FT) (E024) and H6.0FT, H7.0FT (H135FT, H155FT) (J006).....................................72
Figure 54. Manual Control Valve Hydraulic Schematic for Lift Truck Models S6.0FT,
S7.0FT (S135FT, S155FT) (E024) and H6.0FT, H7.0FT (H135FT, H155FT) (J006).....................................73
Figure 55. Electronic Control Valve Hydraulic and Brake System Schematic H8.0FT,
H8.0FT9,H9.0FT (H170FT, H175FT36) H190FT)(A299)................................................................................74
Figure 56. Hydraulic Transmission and Brake Cooling Schematic H8.0FT,
H8.0FT9,H9.0FT (H170FT, H175FT36) H190FT)(A299)................................................................................76
This section is for the following models:
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299];
(S30FT-S35FT, S40FTS) [E010];
H1.6FT-1.8FT, H2.0FTS (H30-35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S6.0-7.0FT (S135-155FT) [E024];
H6.0-7.0FT (H135-155FT) [J006];
H2.0-3.5FT (H40-70FT) [L177];
S4.0-5.50FT; S5.5FTS (S80-120FT; S80-100FTBCS, S120FTS, S120FTPRS)
[G004];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) [P005]
Table of Contents
ii

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General Information About Diagrams and Schematics
The chassis wiring used in these vehicles conforms
to the electrical circuit identification standard
ES-1359 and in addition to surface marked ID
circuit numbers, generally utilizes the colors that
are indicated in Table 1.
MONOTROL®, engine harnesses, wiring to sensors,
and other applications vary with respect to wire
colors.
Diagrams and schematics in this manual can be
viewed and printed in color. If not printed or
viewed in color, refer to the electrical circuit
identification located on schematic circuits. When
viewing a color version of the diagrams and
schematics, the white chassis wires are seen as
yellow. Other wires are shown in colors similar to
actual colors, i.e. tan shows as yellow. Use circuit
identification for true wire color.
Refer to Diagnostic Troubleshooting Manual
9000SRM1112 Section 9030, Group 03 - General
Maintenance and Diagnostic Data, for further
information.
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) Yellow Green CANbus CAN-Hi CAN-Lo
Twisted Pair (Dk Blue/Pink and Dk Blue/White) Dk
Blue/Pink Dk Blue/White
CANbus (Mazda) CAN-Hi CAN-Lo
Letter on the VSM BUS Use/Function
R Regulated Output Voltage
D Driver
I Input
8000 SRM 1409 General Information About Diagrams and Schematics
Confidential/Proprietary - Do Not Copy or Duplicate 1

SYMBOL DEFINITIONS
See Table 2 for description of symbol definitions.
Table 2. Symbol Definitions
Symbol Name Definition
Type S Identifies information for UL Safety rated trucks.
Applicable trucks are rated for GS, LPS, and DS
depending on fuel type.
Arrow Symbol
Go to specified page of schematic, located in lower
right corner in the hexagon symbol.
-----X Go to specified sheet of diagram. Sheet number is
located in lower right corner of figure.
DIAGRAMS MANUAL APPLICATIONS
See Table 3 for the correct diagrams service manual for your lift truck.
Table 3. 1-9 Ton Diagrams Manual Applications
Unit Code Production Date Electrical
Schematic
Wiring
Diagram
Diagrams Manual
Number
E010, F001
Prior to August 2008 8525590 8516519 8000 SRM 1152
August, 2008 to April, 2009 1665405 1665404 8000 SRM 1387
May, 2009 to December
2012
1688540 1688539 8000 SRM 1409
January, 2013 to April
2014
4051618 4051617 8000 SRM 1585
April, 2014 ===> 4100474 4100473 8000 SRM 1689
F187, L177
Prior to August 2008 8525590 8516519 8000 SRM 1152
August, 2008 to April, 2009 1665405 1665404 8000 SRM 1387
May, 2009 to December
2012
1688540 1688539 8000 SRM 1409
January, 2013 ===> 4051618 4051617 8000 SRM 1585
G004
Prior to August 2008 8525590 8516519 8000 SRM 1152
August, 2008 to December
2009
1665405 1665404 8000 SRM 1387
January 2010 to January
2012
1688540 1688539 8000 SRM 1409
January 2012 ===> 4051618 4051617 8000 SRM 1585
N005, D024, H006 All 8525590 8516519 8000 SRM 1152
E024 August, 2008 to April, 2009 1665405 1665404 8000 SRM 1387
May, 2009 ===> 1688540 1688539 8000 SRM 1409
General Information About Diagrams and Schematics 8000 SRM 1409
2 Confidential/Proprietary - Do Not Copy or Duplicate

Table 3. 1-9 Ton Diagrams Manual Applications (Continued)
Unit Code Production Date Electrical
Schematic
Wiring
Diagram
Diagrams Manual
Number
J006 August, 2008 to April, 2009 1665405 1665404 8000 SRM 1387
May, 2009 ===> 1688540 1688539 8000 SRM 1409
F024 All 4051618 4051617 8000 SRM 1585
K006 Prior to April 2014 4051618 4051617 8000 SRM 1585
April 2014 ===> 4100474 4100473 8000 SRM 1689
P005 Prior to January 2010 1665405 1665404 8000 SRM 1387
January 2010 ===> 1688540 1688539 8000 SRM 1409
R005 All 4051618 4051617 8000 SRM 1585
G024
Prior to April 2014 4051618 4051617 8000 SRM 1585
April 2014 to March 2015 4100474 4100473 8000 SRM 1689
April 2015 ===> 4119055 4119054 8000 SRM 1904
S005 Prior to April 2014 4051618 4051617 8000 SRM 1585
April 2014 ===> 4100474 4100473 8000 SRM 1689
H004 Prior to April 2014 4051618 4051617 8000 SRM 1585
April 2014 ===> 4100474 4100473 8000 SRM 1689
A299 May, 2009 ===> 1688540 1688539 8000 SRM 1409
B299 Prior to April 2014 4051618 4051617 8000 SRM 1585
April 2014 ===> 4100474 4100473 8000 SRM 1689
G187, N177 April 2014 ===> 4100474 4100473 8000 SRM 1689
F010, G001,
H187, P177
January 2015 ===> 4119055 4119054 8000 SRM 1753
J004, U005 April 2015 ===> 4119055 4119054 8000 SRM 1904
L006 October 2015 ===> 4119055 4119054 8000 SRM 1904
8000 SRM 1409 General Information About Diagrams and Schematics
Confidential/Proprietary - Do Not Copy or Duplicate 3

Diagrams and Schematics
Figure 1. Type S Option Electrical Schematic
Diagrams, Schematics or Arrangements 8000 SRM 1409
4 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 2. Mazda (2007) 2.0L and 2.2L Gas Engine (Sheet 1 of 2)
8000 SRM 1409 Diagrams, Schematics or Arrangements
Confidential/Proprietary - Do Not Copy or Duplicate 5

Figure 2. Mazda (2007) 2.0L and 2.2L Gas Engine (Sheet 2 of 2)
Diagrams, Schematics or Arrangements 8000 SRM 1409
6 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 3. Mazda (2007) 2.0L and 2.2L LPG Engine Electrical Schematic (Sheet 1 of 2)
8000 SRM 1409 Diagrams, Schematics or Arrangements
Confidential/Proprietary - Do Not Copy or Duplicate 7

Figure 3. Mazda (2007) 2.0L and 2.2L LPG Engine Electrical Schematic (Sheet 2 of 2)
Diagrams, Schematics or Arrangements 8000 SRM 1409
8 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 4. GM 2.4L Gas Engine Electrical Schematic (Sheet 1 of 2)
8000 SRM 1409 Diagrams, Schematics or Arrangements
Confidential/Proprietary - Do Not Copy or Duplicate 9

Figure 4. GM 2.4L Gas Engine Electrical Schematic (Sheet 2 of 2)
Diagrams, Schematics or Arrangements 8000 SRM 1409
10 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 5. GM 2.4L LPG Engine Electrical Schematic (Sheet 1 of 2)
8000 SRM 1409 Diagrams, Schematics or Arrangements
Confidential/Proprietary - Do Not Copy or Duplicate 11

Figure 5. GM 2.4L LPG Engine Electrical Schematic (Sheet 2 of 2)
Diagrams, Schematics or Arrangements 8000 SRM 1409
12 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 6. Yanmar 2.6L and 3.3L Diesel Engine Electrical Schematic
8000 SRM 1409 Diagrams, Schematics or Arrangements
Confidential/Proprietary - Do Not Copy or Duplicate 13

Figure 7. GM 4.3L Gas Engine Electrical Schematic (Sheet 1 of 2)
Diagrams, Schematics or Arrangements 8000 SRM 1409
14 Confidential/Proprietary - Do Not Copy or Duplicate