DIAGRAMS

AC MOTOR CONTROL SYSTEM

E3.50-5.50XL, E4.50XLS

(E70-120Z, E100ZS) [D098]

PART NO. 1596605

8000 SRM 1203

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. Wiring Schematic Diagram for E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098).........................................................................................................................................................

1

Figure 2. Schematic Wiring Diagram 12 Volt Lights E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (D098) .........................................................................................................................................

6

Figure 3. Hydraulic Schematic E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) .......................

7

Figure 4. Lift Truck Power Cables E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) ..................

8

Figure 5. Control Panel Wiring E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) .......................

9

Figure 6. Wiring Schematic Diagram for AC Traction and Pump Motor Controllers, Gen V,
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098)............................................................................

10

Figure 7. Lights Wiring Arrangement E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) ............

13

This section is for the following models:

E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098]

©2005 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

8000 SRM 1203

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Schematic Diagram for E3.50-5.50XL, E4.50XLS (E70-

120Z, E100ZS) (D098) (Sheet 1 of 5)

1

Diagrams, Schematics, or Arrangements

8000 SRM 1203

Figure 1. Wiring Schematic Diagram for E3.50-5.50XL, E4.50XLS (E70-

120Z, E100ZS) (D098) (Sheet 2 of 5)

2

8000 SRM 1203

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Schematic Diagram for E3.50-5.50XL, E4.50XLS (E70-

120Z, E100ZS) (D098) (Sheet 3 of 5)

3

Diagrams, Schematics, or Arrangements

8000 SRM 1203

Figure 1. Wiring Schematic Diagram for E3.50-5.50XL, E4.50XLS (E70-

120Z, E100ZS) (D098) (Sheet 4 of 5)

4

8000 SRM 1203

Diagrams, Schematics, or Arrangements

Figure 1. Wiring Schematic Diagram for E3.50-5.50XL, E4.50XLS (E70-

120Z, E100ZS) (D098) (Sheet 5 of 5)

5

Diagrams, Schematics, or Arrangements

8000 SRM 1203

Figure 2. Schematic Wiring Diagram 12 Volt Lights E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)

(D098)

6

8000 SRM 1203

Diagrams, Schematics, or Arrangements

Figure 3. Hydraulic Schematic E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098)

7

Diagrams, Schematics, or Arrangements

8000 SRM 1203

1.

BATTERY CONNECTOR

2.

TRACTION MOTOR

3.

SEAT BRAKE

4.

TRACTION MOTOR CABLE (UT)

5.

TRACTION MOTOR CABLE (VT)

6.

TRACTION MOTOR CABLE (WT)

7.

MAIN WIRING HARNESS

8.

HYDRAULIC PUMP MOTOR CABLE (UP)

9.

HYDRAULIC PUMP MOTOR CABLE (VP)

10. HYDRAULIC PUMP MOTOR CABLE (WP)
11. HYDRAULIC PUMP MOTOR
12. STEERING PUMP MOTOR

Figure 4. Lift Truck Power Cables E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098)

8

8000 SRM 1203

Diagrams, Schematics, or Arrangements

1.

TRACTION MOTOR CABLE (UT)

2.

TRACTION MOTOR CABLE (VT)

3.

TRACTION MOTOR CABLE (WT)

4.

MAIN WIRING HARNESS

5.

TRACTION MOTOR CONTROLLER

6.

BATTERY POSITIVE CABLE (B+)

7.

BATTERY NEGATIVE CABLE (B-)

8.

HYDRAULIC PUMP MOTOR CONTROLLER

9.

HYDRAULIC PUMP MOTOR CABLE (UP)

10. HYDRAULIC PUMP MOTOR CABLE (VP)
11. HYDRAULIC PUMP MOTOR CABLE (WP)
12. KEY SWITCH FUSE (5A)
13. LIGHTS FUSE (15A)
14. ELECTRIC SEAT BRAKE FUSE (15A)
15. TERMINAL STRIP FUSE (15A)

Figure 5. Control Panel Wiring E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098)

9

Diagrams, Schematics, or Arrangements

8000 SRM 1203

10

8000 SRM 1203

Diagrams, Schematics, or Arrangements

Figure 6. Wiring Schematic Diagram for AC Traction and Pump Motor Controllers, Gen

V, E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) (Sheet 1 of 2)

11

Diagrams, Schematics, or Arrangements

8000 SRM 1203

Figure 6. Wiring Schematic Diagram for AC Traction and Pump Motor Controllers, Gen

V, E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) (Sheet 2 of 2)

12

8000 SRM 1203

Diagrams, Schematics, or Arrangements

Figure 7. Lights Wiring Arrangement E3.50-5.50XL, E4.50XLS (E70-120Z,

E100ZS) (D098) (Sheet 1 of 2)

13

Diagrams, Schematics, or Arrangements

8000 SRM 1203

A. SIDE VIEW
B. FRONT VIEW

C. REAR VIEW

1.

REVERSE/BRAKE LIGHT

2.

MAIN WIRING HARNESS

3.

DC CONVERTER

4.

FRONT HEADLIGHT ASSEMBLY

5.

STROBE LIGHT

6.

HEADLIGHT WIRING HARNESS

7.

CONTROL PANEL

8.

TRACTION MOTOR POWER CABLES

9.

BATTERY POSITIVE CABLE (B+)

10. BATTERY NEGATIVE CABLE (B-)
11. HYDRAULIC PUMP MOTOR POWER CABLES
12. 24 VOLT RELAY
13. REAR HEADLIGHT

Figure 7. Lights Wiring Arrangement E3.50-5.50XL, E4.50XLS (E70-120Z,

E100ZS) (D098) (Sheet 2 of 2)

14

TECHNICAL PUBLICATIONS

8000 SRM 1203

7/05 (3/05) Printed in United Kingdom