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DIAGRAMS

H6.00-7.00XL (H135-155XL) [F006, G006]


(SERIAL CODE F6 WITH ELECTRONIC
ENGINE CONTROL)
S6.00-7.00XL (S135-155XL) [B024, C024]
(SERIAL CODE B24 WITH ELECTRONIC
ENGINE CONTROL)

PART NO. 897501 8000 SRM 519


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. Diesel Engine Wiring Schematic (Before 1995)....................................................................... 2
Figure 2. Diesel Engine Wiring Schematic (After 1995)......................................................................... 6
Figure 3. Diesel Engine Wiring Schematic (1104C-44)........................................................................... 10
Figure 4. Diesel Engine Wiring Schematic for US Models B024, F006 ................................................. 14
Figure 5. Diesel Engine Wiring Diagram, Models C024, After November 2005 ................................... 16
Figure 6. Diesel Engine Wiring Diagram, Models G006, After November 2005 ................................... 19
Figure 7. Electrical Schematic (GM V-6, Gasoline With Fuel Injection) Early Production.................. 22
Figure 8. Electrical Schematic (GM V-6, Gasoline With Fuel Injection) 1992 to 1998 ......................... 28
Figure 9. Electrical Schematic - GM V-6, Gasoline With Fuel Injection, 1999 and Later Years.......... 34
Figure 10. Electrical Schematic (GM V-6, LPG With MSTS) 1993 to 1997........................................... 40
Figure 11. Electrical Schematic (GM V-6, LPG With MSTS) 1998 and Later Years ............................ 42
Figure 12. GM V-6 Gas and LPG Engine Electrical Schematic (C024, G006), Before November
2005 ............................................................................................................................................................ 44
Figure 13. GM V-6 Gas and LPG Engine Electrical Schematic, Models C024, After November
2005 ............................................................................................................................................................ 49
Figure 14. GM V-6 Gas and LPG Engine Electrical Schematic, Models G006, After November
2005 ............................................................................................................................................................ 55
Figure 15. Schematic for Lights Option (U.S.) for B024 Trucks ............................................................ 61
Figure 16. Schematic for Lights Option for C024 US/EUR Trucks, Before November 2005................ 62
Figure 17. Schematic for Lights Option for C024 US/EUR Trucks, After November 2005 .................. 63
Figure 18. Schematic for Lights for Models F006, G006 (US Only), Before November 2005............... 64
Figure 19. Schematic for Lights for Models G006 (US Only), After November 2005 ........................... 66
Figure 20. Schematic for European Lights G006, Before November 2005 ............................................ 67
Figure 21. Schematic for European Lights, G006 Trucks, After November 2005 ................................. 69
Figure 22. Wire Schematic, Lights Option for EEC Lift Trucks ............................................................ 71
Figure 23. Hydraulic System Schematic for B024 US/EUR (Early Model Trucks)............................... 72
Figure 24. Hydraulic System Schematic for B024 US/EUR (Later Model Trucks)............................... 75
Figure 25. Hydraulic System Schematic for B024 (1999- 2003), C024 US/EUR................................... 76
Figure 26. Powershift Transmission Diagram ........................................................................................ 78
Figure 27. Transmission Schematic......................................................................................................... 80
Figure 28. Oil Clutch Schematic .............................................................................................................. 81

This section is for the following models:

H6.00-7.00XL (H135-155XL) [F006, G006]


(Serial Code F6 With Electronic Engine Control)S6.00-7.00XL
(S135-155XL) [B024, C024]
(Serial Code B24 With Electronic Engine Control)

2007 HYSTER COMPANY i


"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
8000 SRM 519 Diagrams, Schematics, or Arrangements

NOTES

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Diagrams, Schematics, or Arrangements 8000 SRM 519

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 1. Diesel Engine Wiring Schematic (Before 1995)

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Diagrams, Schematics, or Arrangements 8000 SRM 519

Legend for Figure 1


1. ALTERNATOR, D RATING
2. STARTER
3. BATTERY (2)
4. SHUTOFF, ENGINE
5. SENDER, ENGINE OIL PRESSURE
6. SENDER, COOLANT TEMPERATURE
7. COLD START ELEMENT
8. ALTERNATOR, DS RATING
9. DISCONNECT SWITCH, DS ONLY
10. FUEL LEVEL SENDER
11. TEMPERATURE SWITCH, TRANSMISSION OIL OR OIL PRESSURE SWITCH FOR OIL CLUTCH
12. MONOTROL PEDAL (OPTION)
13. IGNITION SWITCH
14. INSTRUMENT PANEL, RIGHT-HAND CLUSTER
15. HORN BUTTON
16. INSTRUMENT PANEL, LEFT-HAND CLUSTER
17. HORN
18. INDICATOR LIGHT, DS ONLY
19. HORN RELAY
20. SWITCH, COLD START AID
21. PARKING BRAKE SWITCH WHEN EQUIPPED WITH MONOTROL PEDAL

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 2. Diesel Engine Wiring Schematic (After 1995)

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Diagrams, Schematics, or Arrangements 8000 SRM 519

Legend for Figure 2


1. ALTERNATOR, D RATING
2. STARTER
3. BATTERY (2)
4. SHUTOFF, ENGINE
5. SENDER, ENGINE OIL PRESSURE
6. SENDER, COOLANT TEMPERATURE
7. COLD START ELEMENT
8. POWERSHIFT TRANSMISSION TEMPERATURE SENDER
9. DISCONNECT SWITCH, DS ONLY
10. FUEL LEVEL SENDER
11. TEMPERATURE SWITCH, TRANSMISSION OIL OR OIL PRESSURE SWITCH FOR OIL CLUTCH
12. MONOTROL PEDAL (OPTION)
13. IGNITION SWITCH
14. INSTRUMENT PANEL, RIGHT-HAND CLUSTER
15. HORN BUTTON
16. INSTRUMENT PANEL, LEFT-HAND CLUSTER
17. HORN
18. STARTER RELAY
19. HORN RELAY
20. SWITCH, COLD START AID
21. PARKING BRAKE SWITCH WHEN EQUIPPED WITH MONOTROL PEDAL
22. COOLANT TEMPERATURE SWITCH (N.C.)
23. COLD START ADVANCE

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Diagrams, Schematics, or Arrangements 8000 SRM 519

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 3. Diesel Engine Wiring Schematic (1104C-44) (Sheet 1 of 2)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 3. Diesel Engine Wiring Schematic (1104C-44) (Sheet 2 of 2)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 4. Diesel Engine Wiring Schematic for US Models B024, F006

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Figure 5. Diesel Engine Wiring Diagram, Models C024, After November 2005 (Sheet 1 of 3)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 5. Diesel Engine Wiring Diagram, Models C024, After November 2005 (Sheet 2 of 3)

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Figure 5. Diesel Engine Wiring Diagram, Models C024, After November 2005 (Sheet 3 of 3)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 6. Diesel Engine Wiring Diagram, Models G006, After November 2005 (Sheet 1 of 3)

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Figure 6. Diesel Engine Wiring Diagram, Models G006, After November 2005 (Sheet 2 of 3)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 6. Diesel Engine Wiring Diagram, Models G006, After November 2005 (Sheet 3 of 3)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 7. Electrical Schematic (GM V-6, Gasoline With Fuel Injection) Early Production (Sheet 1 of 2)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 7. Electrical Schematic (GM V-6, Gasoline With Fuel Injection) Early Production (Sheet 2 of 2)

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Diagrams, Schematics, or Arrangements 8000 SRM 519

Legend for Figure 7


1. GROUND NO. 2, ENGINE HEAD
2. FUEL PUMP RELAY
3. ASSEMBLY LINE DIAGNOSTIC LINK
4. MAP SENSOR
5. PRESSURE SWITCH, ENGINE OIL SENSOR TO ECM
6. THROTTLE BODY INJECTOR ASSEMBLY
7. GOVERNOR MOTOR
8. IDLE AIR CONTROL (IAC)
9. THROTTLE POSITION SENSOR (TPS)
10. ELECTRONIC SPARK TIMING (EST) DISTRIBUTOR
11. IGNITION COIL
12. COOLANT TEMPERATURE SENSOR TO ECM
13. GOVERNOR CONTROLLER
14. ALDL POWER CONNECTOR
15. GROUND NO. 1, ENGINE INLET MANIFOLD
16. FUEL TANK
17. FUEL PUMP INSIDE OF FUEL TANK
18. BATTERY
19. STARTER
20. ALTERNATOR
21. COOLANT TEMPERATURE SENDER, GAUGE
22. PRESSURE SWITCH, ENGINE OIL (LIGHT)
23. SWITCHES USED WITH POWERSHIFT TRANSMISSION AND MONOTROL
24. TEMPERATURE SWITCH, POWERSHIFT TRANSMISSION AND MONOTROL
25. PRESSURE SWITCH, OIL CLUTCH PRESSURE OR TEMPERATURE SWITCH, POWERSHIFT
TRANSMISSION WITH FORWARD/REVERSE LEVER
26. SWITCHES USED WITH POWERSHIFT TRANSMISSION AND FORWARD/REVERSE LEVER OR OIL
CLUTCH TRANSMISSION
27. PARKING BRAKE SWITCH, MONOTROL ONLY
28. SWITCH ARRANGEMENT, MONOTROL ONLY
29. IGNITION SWITCH
30. INDICATOR LIGHTS AND GAUGE, RIGHT-HAND CLUSTER
31. GAUGES, LEFT-HAND CLUSTER
32. HORN BUTTON
33. HORN
34. HORN RELAY
35. FUSE BLOCK, COWL

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NOTES

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Figure 8. Electrical Schematic (GM V-6, Gasoline With Fuel Injection) 1992 to 1998 (Sheet 1 of 2)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 8. Electrical Schematic (GM V-6, Gasoline With Fuel Injection) 1992 to 1998 (Sheet 2 of 2)

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Diagrams, Schematics, or Arrangements 8000 SRM 519

Legend for Figure 8


1. ENGINE HEAD GROUND
2. FUEL PUMP RELAY
3. FUEL PUMP PRIME
4. DIAGNOSTIC CONNECTOR (ALDL)
5. MAP SENSOR
6. PRESSURE SWITCH, ENGINE OIL (ECM)
7. FUEL PUMP
8. FUEL LEVEL SENDER
9. FUEL TANK
10. THROTTLE BODY INJECTOR (TBI)
11. FUEL INJECTOR 1
12. FUEL INJECTOR 2
13. GOVERNOR MOTOR
14. ENGINE INLET MANIFOLD GROUND
15. POWER PLUG FOR ALDL
16. GOVERNOR CONTROLLER
17. COOLANT TEMPERATURE SENSOR (ECM)
18. TACHOMETER CONNECTION
19. COIL
20. EST DISTRIBUTOR
21. FUSE, FUEL PUMP
22. FUSE, ECM
23. FUSE, STARTER SOLENOID
24. BATTERY (TYPE G)
25. DISCONNECT SWITCH (EEC ONLY)
26. ALTERNATOR (TYPE G)
27. STARTER SOLENOID
28. SENDER FOR GAUGE, ENGINE TEMPERATURE
29. SWITCH FOR WARNING LIGHT, ENGINE OIL PRESSURE
30. CHASSIS GROUND
31. ALTERNATOR (TYPE GS)
32. INDICATOR LIGHT, KEY SWITCH ON OR SHORT-CIRCUIT SWITCH
33. DISCONNECT SWITCH
34. BATTERY (TYPE GS)
35. POWERSHIFT TRANSMISSION WITH MONOTROL
36. SERVICE BRAKE SWITCH
37. NEUTRAL START SWITCH
38. POWERSHIFT TRANSMISSION WITH FORWARD/REVERSE LEVER
39. NEUTRAL START SWITCH
40. PARKING BRAKE SWITCH (MONOTROL)
41. IGNITION SWITCH
42. RIGHT-HAND GAUGE CLUSTER
43. FUEL GAUGE (GASOLINE ONLY)
44. WARNING LIGHT, ENGINE OIL PRESSURE
45. WARNING LIGHT, DISCHARGE INDICATOR
46. WARNING LIGHT, TRANSMISSION OIL TEMPERATURE
47. WARNING LIGHT, CHECK ENGINE
48. OIL TEMPERATURE SWITCH, TRANSMISSION
49. COWL GROUND
50. HORN BUTTON
51. LEFT-HAND GAUGE CLUSTER
52. HOURMETER
53. COOLANT TEMPERATURE GAUGE
54. HORN
55. HORN RELAY
56. FUSE, INJECTOR 7.5A
57. FUSE, ECM 15A
58. FUSE, LIGHTS 25A
59. FUSE, LIGHTS 25A
60. FUSE, HORN 10A
61. FUSE, RIGHT-HAND GAUGE CLUSTER
62. FUSE, LEFT-HAND GAUGE CLUSTER

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 9. Electrical Schematic - GM V-6, Gasoline With Fuel Injection,


1999 and Later Years (Sheet 1 of 3)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 9. Electrical Schematic - GM V-6, Gasoline With Fuel Injection,


1999 and Later Years (Sheet 2 of 3)

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Figure 9. Electrical Schematic - GM V-6, Gasoline With Fuel Injection,


1999 and Later Years (Sheet 3 of 3)

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Figure 10. Electrical Schematic (GM V-6, LPG With MSTS) 1993 to 1997

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 11. Electrical Schematic (GM V-6, LPG With MSTS) 1998 and Later Years

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Figure 12. GM V-6 Gas and LPG Engine Electrical Schematic (C024, G006),
Before November 2005 (Sheet 1 of 5)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 12. GM V-6 Gas and LPG Engine Electrical Schematic (C024, G006),
Before November 2005 (Sheet 2 of 5)

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Figure 12. GM V-6 Gas and LPG Engine Electrical Schematic (C024, G006),
Before November 2005 (Sheet 3 of 5)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 12. GM V-6 Gas and LPG Engine Electrical Schematic (C024, G006),
Before November 2005 (Sheet 4 of 5)

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Figure 12. GM V-6 Gas and LPG Engine Electrical Schematic (C024, G006),
Before November 2005 (Sheet 5 of 5)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 13. GM V-6 Gas and LPG Engine Electrical Schematic, Models C024,
After November 2005 (Sheet 1 of 6)

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Figure 13. GM V-6 Gas and LPG Engine Electrical Schematic, Models C024,
After November 2005 (Sheet 2 of 6)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 13. GM V-6 Gas and LPG Engine Electrical Schematic, Models C024,
After November 2005 (Sheet 3 of 6)

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Figure 13. GM V-6 Gas and LPG Engine Electrical Schematic, Models C024,
After November 2005 (Sheet 4 of 6)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 13. GM V-6 Gas and LPG Engine Electrical Schematic, Models C024,
After November 2005 (Sheet 5 of 6)

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Figure 13. GM V-6 Gas and LPG Engine Electrical Schematic, Models C024,
After November 2005 (Sheet 6 of 6)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 14. GM V-6 Gas and LPG Engine Electrical Schematic, Models G006,
After November 2005 (Sheet 1 of 6)

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Figure 14. GM V-6 Gas and LPG Engine Electrical Schematic, Models G006,
After November 2005 (Sheet 2 of 6)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 14. GM V-6 Gas and LPG Engine Electrical Schematic, Models G006,
After November 2005 (Sheet 3 of 6)

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Figure 14. GM V-6 Gas and LPG Engine Electrical Schematic, Models G006,
After November 2005 (Sheet 4 of 6)

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Figure 14. GM V-6 Gas and LPG Engine Electrical Schematic, Models G006,
After November 2005 (Sheet 5 of 6)

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Figure 14. GM V-6 Gas and LPG Engine Electrical Schematic, Models G006,
After November 2005 (Sheet 6 of 6)

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Figure 15. Schematic for Lights Option (U.S.) for B024 Trucks

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Legend for Figure 15


1. LIGHT SWITCH 5. BRAKE PRESSURE SWITCH
2. RIGHT-HAND TAIL AND STOP LIGHT 6. LEFT-HAND TAIL AND STOP LIGHT
3. FUSE PANEL 7. LEFT-HAND WORK LIGHT
4. REAR DRIVING LIGHT 8. RIGHT-HAND WORK LIGHT

1. RIGHT-HAND WORK LIGHT 5. WORK/REAR DRIVE LIGHT SWITCH


2. LEFT-HAND WORK LIGHT 6. RIGHT-HAND STOP TAIL LIGHT
3. BATTERY 7. REAR DRIVE LIGHT
4. BRAKE PRESSURE SWITCH 8. LEFT-HAND STOP TAIL LIGHT

Figure 16. Schematic for Lights Option for C024 US/EUR Trucks, Before November 2005

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Figure 17. Schematic for Lights Option for C024 US/EUR Trucks, After November 2005

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Figure 18. Schematic for Lights for Models F006, G006 (US Only), Before November 2005

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8000 SRM 519 Diagrams, Schematics, or Arrangements

Legend for Figure 18


1. RIGHT WORK LIGHT 5. BRAKE PRESSURE SWITCH
2. LEFT WORK LIGHT 6. RIGHT-HAND STOP TAIL DIRECTION
3. LIGHT SWITCH 7. REAR DRIVING LIGHT
4. FUSE PANEL 8. LEFT-HAND STOP TAIL DIRECTION

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Figure 19. Schematic for Lights for Models G006 (US Only), After November 2005

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Figure 20. Schematic for European Lights G006, Before November 2005

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Legend for Figure 20


1. RUNNING LIGHT 6. BRAKE PRESSURE SWITCH
2. DRIVING LIGHT 7. FUSE PANEL
3. WORK LIGHT 8. RIGHT-HAND TAIL DIRECTION
4. TURN SIGNAL SWITCH 9. REAR DRIVING LIGHT
5. LIGHT SWITCHES 10. LEFT-HAND TAIL DIRECTION

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Figure 21. Schematic for European Lights, G006 Trucks, After November 2005 (Sheet 1 of 2)

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Figure 21. Schematic for European Lights, G006 Trucks, After November 2005 (Sheet 2 of 2)

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1. SIDE LIGHT AND RIGHT DIRECTION SIGNAL 9. SWITCH, WORK LIGHTS, AND REAR DRIVING
2. RIGHT DRIVING LIGHT LIGHT
3. RIGHT WORK LIGHT 10. SWITCH, MARKER, TAIL, AND DRIVE LIGHTS
4. LEFT WORK LIGHT 11. BRAKE PRESSURE SWITCH
5. LEFT DRIVING LIGHT 12. STOP, TAIL, AND RIGHT DIRECTION LIGHTS
6. SIDE LIGHT AND LEFT DIRECTION SIGNAL 13. REAR DRIVING LIGHT
7. DIRECTION SIGNAL FLASHER 14. STOP, TAIL, AND LEFT DIRECTION LIGHTS
8. DIRECTION SIGNAL SWITCH

Figure 22. Wire Schematic, Lights Option for EEC Lift Trucks

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Figure 23. Hydraulic System Schematic for B024 US/EUR (Early Model Trucks)

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Legend for Figure 23


1. HYDRAULIC TANK
2. STEERING HYDRAULIC PUMP
3. HYDRAULIC PUMP
4. MAIN CONTROL VALVE
5. MANIFOLD BLOCK
6. STEERING CONTROL UNIT
7. STEERING CYLINDER
8. BRAKE VALVE
9. OIL CLUTCH HOUSING
10. TILT CYLINDER
11. LIFT CYLINDER
12. LIFT SYSTEM CHECK PORT
13. CHECK PORT

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Figure 24. Hydraulic System Schematic for B024 US/EUR (Later Model Trucks)

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Figure 25. Hydraulic System Schematic for B024 (1999- 2003), C024 US/EUR

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Figure 26. Powershift Transmission Diagram

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1. TORQUE CONVERTER 12. FORWARD, LOW RANGE


2. TRANSMISSION PUMP 13. FORWARD, HIGH RANGE
3. LUBRICATION FOR PUMP DRIVE CHAIN AND 14. REVERSE, LOW RANGE
BEARING 15. REVERSE, HIGH RANGE
4. SUMP SCREEN 16. HIGH AND LOW SPEED RANGE SPOOL
5. FILTER 17. ACCUMULATION DUMP
6. SOLENOID VALVE, FORWARD 18. ACCUMULATOR
7. SOLENOID VALVE, REVERSE 19. REGULATOR SPOOL, MODULATOR
8. MONOTROL OPTION, FORWARD AND 20. TRANSMISSION CONTROL VALVE
REVERSE SPOOL 21. REGULATOR, TORQUE CONVERTER
9. CONTROL LEVER OPTION, FORWARD AND 22. REGULATOR, CLUTCH PRESSURE
REVERSE SPOOL 23. REGULATOR, TRANSMISSION PUMP
10. INCHING SPOOL 24. COOLER
11. BRAKE EFFORT INCREASE

Figure 27. Transmission Schematic

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1. COOLER 7. PUMP DRIVE CHAIN AND BEARING


2. FILTER 8. SUMP SCREEN
3. CLUTCH OIL PRESSURE SENDER 9. OIL CLUTCH PUMP
4. TRANSMISSION PUMP 10. CLUTCH HOUSING
5. COLD RELIEF VALVE 11. FLYWHEEL HOUSING
6. CLUTCH DISK

Figure 28. Oil Clutch Schematic

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TECHNICAL PUBLICATIONS

8000 SRM 519 6/07 (10/06)(10/05)(5/04)(12/03)(3/03)(9/00)(11/97)(5/94)(3/93)(12/92) Printed in U.S.A.

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