DIAGRAMS AND

SCHEMATICS
H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) [U005];
S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120STPRS) [J004]

PART NO. 4128428 8000 SRM 1904

 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.
 Table of Contents

TABLE OF CONTENTS

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

Symbol Definitions ..............................................................................................................................................2
Diagrams Manual Applications ..........................................................................................................................2
Diagrams and Schematics ...................................................................................................................................... 4

This section is for the following models:

H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) [U005];

S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS, S120STPRS) [J004]

©2015 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 1904 General Information About Diagrams and Schematics

General Information About Diagrams and Schematics

The chassis wiring used in these vehicles conforms identification located on schematic circuits. When
to the electrical circuit identification standard viewing a color version of the diagrams and
ES-1359 and in addition to surface marked ID schematics, the white chassis wires are seen as
circuit numbers, generally utilizes the colors that yellow. Other wires are shown in colors similar to
are indicated in Table 1. actual colors, i.e. tan shows as yellow. Use circuit
identification for true wire color.
MONOTROL®, engine harnesses, wiring to sensors,
and other applications vary with respect to wire Refer to Diagnostic Troubleshooting Manual
colors. 9000SRM1112 Section 9030, Group 03 - General
Maintenance and Diagnostic Data, for further
Diagrams and schematics in this manual can be information.
viewed and printed in color. If not printed or
viewed in color, refer to the electrical circuit

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 CANbus (Mazda) CAN-Hi CAN-Lo
Blue/Pink Dk Blue/White
Letter on the VSM BUS Use/Function
R Regulated Output Voltage
D Driver
I Input

1
General Information About Diagrams and Schematics 8000 SRM 1904

Table 2. Symbol Definitions SYMBOL DEFINITIONS

Symbol Name Definition See Table 2 for description of symbol definitions.
Type S Identifies information
for UL Safety rated DIAGRAMS MANUAL APPLICATIONS
trucks. Applicable
trucks are rated for GS, See Table 3 for the correct diagrams service
LPS, and DS depending manual for your lift truck.
on fuel type.
Go to specified page of
schematic, located in
Arrow Symbol lower right corner in the
hexagon symbol.
-----X Go to specified sheet of
diagram. Sheet number
is located in lower right
corner of figure.

Table 3. 1-9 Ton Diagrams Manual Applications

Electrical Wiring Diagrams Manual

Unit Code Production Date
Schematic Diagram 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 1688540 1688539 8000 SRM 1409
2012
January, 2013 to April 4051618 4051617 8000 SRM 1585
2014
April, 2014 ===> 4100474 4100473 8000 SRM 1689
Prior to August 2008 8525590 8516519 8000 SRM 1152
August, 2008 to April, 2009 1665405 1665404 8000 SRM 1387
F187, L177 May, 2009 to December 1688540 1688539 8000 SRM 1409
2012
January, 2013 ===> 4051618 4051617 8000 SRM 1585
Prior to August 2008 8525590 8516519 8000 SRM 1152
August, 2008 to December 1665405 1665404 8000 SRM 1387
2009
G004
January 2010 to January 1688540 1688539 8000 SRM 1409
2012
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

2
8000 SRM 1904 General Information About Diagrams and Schematics

Table 3. 1-9 Ton Diagrams Manual Applications (Continued)

Electrical Wiring Diagrams Manual

Unit Code Production Date
Schematic Diagram 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
Prior to April 2014 4051618 4051617 8000 SRM 1585
G024 April 2014 to March 2015 4100474 4100473 8000 SRM 1689
April 2015 ===> 4119055 4119054 8000 SRM 1904
Prior to April 2014 4051618 4051617 8000 SRM 1585
S005
April 2014 ===> 4100474 4100473 8000 SRM 1689
Prior to April 2014 4051618 4051617 8000 SRM 1585
H004
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, January 2015 ===> 4119055 4119054 8000 SRM 1753
H187, P177
J004, U005 April 2015 ===> 4119055 4119054 8000 SRM 1904

3
Diagrams and Schematics 8000 SRM 1904

Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 1 of 42)

4
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 2 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 3 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 4 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 5 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 6 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 7 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 8 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 9 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 10 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 11 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 12 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 13 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 14 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 15 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 16 of 42)

19
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 17 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 18 of 42)

21
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 19 of 42)

22
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 20 of 42)

23
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 21 of 42)

24
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 22 of 42)

25
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 23 of 42)

26
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 24 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 25 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 26 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 27 of 42)

30
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 28 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 29 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 30 of 42)

33
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 31 of 42)

34
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 32 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 33 of 42)

36
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 34 of 42)

37
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 35 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 36 of 42)

39
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 37 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 38 of 42)

41
Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 39 of 42)

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8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 40 of 42)

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Diagrams and Schematics 8000 SRM 1904

Figure 1. Electrical Schematic (Sheet 41 of 42)

44
8000 SRM 1904 Diagrams and Schematics

Figure 1. Electrical Schematic (Sheet 42 of 42)

45
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 1 of 28)

46
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 2 of 28)

47
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 3 of 28)

48
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 4 of 28)

49
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 5 of 28)

50
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 6 of 28)

51
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 7 of 28)

52
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 8 of 28)

53
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 9 of 28)

54
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 10 of 28)

55
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 11 of 28)

56
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 12 of 28)

57
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 13 of 28)

58
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 14 of 28)

59
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 15 of 28)

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8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 16 of 28)

61
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 17 of 28)

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8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 18 of 28)

63
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 19 of 28)

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8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 20 of 28)

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Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 21 of 28)

66
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 22 of 28)

67
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 23 of 28)

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8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 24 of 28)

69
Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 25 of 28)

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8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 26 of 28)

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Diagrams and Schematics 8000 SRM 1904

Figure 2. Wiring Diagram (Sheet 27 of 28)

72
8000 SRM 1904 Diagrams and Schematics

Figure 2. Wiring Diagram (Sheet 28 of 28)

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Diagrams and Schematics 8000 SRM 1904

Figure 3. NMHG 4-5T Wet Drive Axle - Hydraulic Schematic

74
8000 SRM 1904 Diagrams and Schematics

Figure 4. Hydraulic Schematic - Dana 4-5T Wet Drive Axle

75
Diagrams and Schematics 8000 SRM 1904

Figure 5. Hydraulic Schematic - Cast Iron Transmission

76
8000 SRM 1904 Diagrams and Schematics

Figure 6. Hydraulic Schematic - Manual Control Valve

77
Diagrams and Schematics 8000 SRM 1904

Figure 7. Hydraulic Schematic - Electronic Control Valve with Variable Displacement Pump for Lift Truck
Models S4.0-5.5FT, S5.5FTS, (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) (J004) (Sheet 1 of 2)

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8000 SRM 1904 Diagrams and Schematics

Figure 7. Hydraulic Schematic - Electronic Control Valve with Variable Displacement Pump for Lift Truck
Models S4.0-5.5FT, S5.5FTS, (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) (J004) (Sheet 2 of 2)

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Diagrams and Schematics 8000 SRM 1904

Figure 8. Hydraulic Schematic - Electronic Control Valve with Variable Displacement Pump for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005) (Sheet 1 of 2)

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8000 SRM 1904 Diagrams and Schematics

Figure 8. Hydraulic Schematic - Electronic Control Valve with Variable Displacement Pump for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005) (Sheet 2 of 2)

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Diagrams and Schematics 8000 SRM 1904

Figure 9. Hydrualic Schematic - Electronic Hydraulic Fan Drive (Sheet 1 of 2)

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8000 SRM 1904 Diagrams and Schematics

Figure 9. Hydrualic Schematic - Electronic Hydraulic Fan Drive (Sheet 2 of 2)

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 NOTES

84
 TECHNICAL PUBLICATIONS

8000 SRM 1904 4/15