ELECTRICAL SYSTEM

H6.0-7.0FT (H135-155FT) [L006];

H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) [ N006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) [C299, D299]

PART NO. 4139182 2200 SRM 1954

 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
instructions 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
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 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.
 WARNING

California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can
expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and birth defects or other reproductive harm. For
more information, go to www.P65Warnings.ca.gov.
 Table of Contents

TABLE OF CONTENTS
General................................................................................................................................................................... 1
Display Switch Cluster..........................................................................................................................................5
Remove.................................................................................................................................................................5
Install...................................................................................................................................................................7
Direction Control and Turn Signal Levers........................................................................................................ 7
Remove.............................................................................................................................................................. 7
Install................................................................................................................................................................ 8
Key Switch...........................................................................................................................................................8
Remove.............................................................................................................................................................. 8
Install................................................................................................................................................................ 9
Display Switch Cluster Panel Bezel and Overlay........................................................................................... 10
Remove............................................................................................................................................................ 10
Install.............................................................................................................................................................. 10
Steering Column Repair......................................................................................................................................11
Remove............................................................................................................................................................ 11
Disassemble.................................................................................................................................................... 13
Assemble......................................................................................................................................................... 13
Install.............................................................................................................................................................. 13
Sensors and Switches.......................................................................................................................................... 14
General.............................................................................................................................................................. 14
Dash and Kick Panel, Remove and Install....................................................................................................14
Remove......................................................................................................................................................... 14
Install............................................................................................................................................................14
Accelerator Pedal Position Sensor....................................................................................................................15
Remove............................................................................................................................................................ 15
Install.............................................................................................................................................................. 18
Brake Fluid Level Switch................................................................................................................................. 18
Remove............................................................................................................................................................ 18
Install.............................................................................................................................................................. 19
Service Brake Pedal Position Sensor............................................................................................................... 19
Remove............................................................................................................................................................ 19
Install.............................................................................................................................................................. 20
Parking Brake Position Sensor........................................................................................................................ 20
Remove............................................................................................................................................................ 20
Install.............................................................................................................................................................. 20
Service Brake Pressure Sensor........................................................................................................................ 21
Remove............................................................................................................................................................ 21
Install.............................................................................................................................................................. 21
Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT ) (C299) and H170-190FT, H175FT36 (D299).................................................................................. 22
Remove............................................................................................................................................................ 22
Install.............................................................................................................................................................. 22
Sensor MicroswitchMonotrol®......................................................................................................................... 23
Remove............................................................................................................................................................ 23
Install.............................................................................................................................................................. 25
Low Coolant Level Sensor................................................................................................................................ 25
Remove............................................................................................................................................................ 25
Install.............................................................................................................................................................. 26
Fuel Level Sensor, Diesel Engines Only..........................................................................................................26
Remove............................................................................................................................................................ 26
Install.............................................................................................................................................................. 27
Seat Sensor (Operator Presence System)........................................................................................................ 27

©2021 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Non-Suspension Seat......................................................................................................................................27
Remove......................................................................................................................................................... 27
Install............................................................................................................................................................29
Full Suspension and Swivel Seats.................................................................................................................29
Remove......................................................................................................................................................... 29
Install............................................................................................................................................................29
Hood Shut Off Switch....................................................................................................................................... 30
Remove............................................................................................................................................................ 30
Install.............................................................................................................................................................. 30
Remote Key Switch........................................................................................................................................... 31
Remove............................................................................................................................................................ 31
Install.............................................................................................................................................................. 31
Hydraulic Filter Pressure Switch.................................................................................................................... 32
Remove............................................................................................................................................................ 32
Install.............................................................................................................................................................. 32
Transmission Speed Sensor..............................................................................................................................32
Remove............................................................................................................................................................ 32
Install.............................................................................................................................................................. 33
Transmission Pressure Sensors....................................................................................................................... 33
Remove............................................................................................................................................................ 33
Install.............................................................................................................................................................. 33
Transmission Temperature Sensor..................................................................................................................34
Remove............................................................................................................................................................ 34
Install.............................................................................................................................................................. 34
Engine Speed Sensor.........................................................................................................................................34
Remove............................................................................................................................................................ 34
Install.............................................................................................................................................................. 34
Intermediate Speed Sensor...............................................................................................................................34
Remove............................................................................................................................................................ 34
Install.............................................................................................................................................................. 34
Return To Set Tilt (Tilt Angle) Sensor.............................................................................................................34
Remove............................................................................................................................................................ 34
Install.............................................................................................................................................................. 35
Rear Horn Button Switch................................................................................................................................. 35
Remove............................................................................................................................................................ 35
Install.............................................................................................................................................................. 35
Impact Sensor....................................................................................................................................................36
Remove............................................................................................................................................................ 36
Install.............................................................................................................................................................. 36
Load Weight Sensor.......................................................................................................................................... 37
Remove............................................................................................................................................................ 37
Install.............................................................................................................................................................. 37
Engine and Fuel Sensors and Switches, GM 4.3L and 5.7L LPG Engines....................................................38
Engine and Fuel Sensors and Switches, PSI 4.3L LPG Engine..................................................................... 39
Engine and Fuel Sensors and Switches, Cummins QSB 3.3L Diesel Engine............................................... 39
Air Filter Restriction Switch..........................................................................................................................39
Remove......................................................................................................................................................... 39
Install............................................................................................................................................................39
Engine Oil Pressure Sensor........................................................................................................................... 40
Remove......................................................................................................................................................... 40
Install............................................................................................................................................................40
Engine Speed Sensor......................................................................................................................................40

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Remove......................................................................................................................................................... 40
Install............................................................................................................................................................41
Engine Coolant Temperature (ECT) Sensor................................................................................................. 41
Remove......................................................................................................................................................... 41
Install............................................................................................................................................................41
Fuel/Water Separator Sensor........................................................................................................................ 41
Remove......................................................................................................................................................... 41
Install............................................................................................................................................................41
Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Engine............................................................ 42
Engine Coolant Temperature (ECT) Sensor................................................................................................. 42
Remove......................................................................................................................................................... 42
Install.............................................................................................................................................................. 42
Throttle Position Sensor.................................................................................................................................43
Engine Oil Pressure Sensor........................................................................................................................... 43
Remove......................................................................................................................................................... 43
Install............................................................................................................................................................43
Fuel Shut Off Solenoid................................................................................................................................... 43
Remove......................................................................................................................................................... 43
Install............................................................................................................................................................44
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine With Diesel Particulate Filter (DPF)
And Kubota 3.8L (Tier 4) 55kW Diesel Engine, With Diesel Oxidation Catalyst (DOC)............................. 44
Intake Air Temperature Sensor.....................................................................................................................45
Remove......................................................................................................................................................... 45
Install............................................................................................................................................................45
Boost Sensor....................................................................................................................................................46
Remove......................................................................................................................................................... 46
Install............................................................................................................................................................46
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater.........................................................47
Remove......................................................................................................................................................... 47
Install............................................................................................................................................................48
Engine Coolant Temperature (ECT) Sensor................................................................................................. 48
Remove......................................................................................................................................................... 48
Install............................................................................................................................................................48
Engine Oil Pressure Sensor........................................................................................................................... 48
Remove......................................................................................................................................................... 48
Install............................................................................................................................................................49
Crankshaft Position Sensor........................................................................................................................... 49
Remove......................................................................................................................................................... 49
Install............................................................................................................................................................49
Adjust Shim Procedure................................................................................................................................49
Camshaft Position Sensor.............................................................................................................................. 51
Remove......................................................................................................................................................... 51
Install............................................................................................................................................................51
Differential Pressure Sensor..........................................................................................................................51
Remove......................................................................................................................................................... 51
Install............................................................................................................................................................52
Oxygen Sensors (Inlet and Outlet)................................................................................................................ 52
Remove......................................................................................................................................................... 52
Install............................................................................................................................................................53
Inlet Temperature Sensor..............................................................................................................................53
Remove......................................................................................................................................................... 54
Install............................................................................................................................................................54

iii
Table of Contents

TABLE OF CONTENTS (Continued)

Mass Air Flow Sensor.....................................................................................................................................54
Remove......................................................................................................................................................... 54
Install............................................................................................................................................................54
Fuel/Water Separator.....................................................................................................................................54
Remove......................................................................................................................................................... 54
Install............................................................................................................................................................55
Air Filter Restriction Switch..........................................................................................................................55
Remove......................................................................................................................................................... 55
Install............................................................................................................................................................55
Vehicle System Manager (VSM)......................................................................................................................... 56
General.............................................................................................................................................................. 56
VSM Replacement.............................................................................................................................................56
Remove............................................................................................................................................................ 56
Install.............................................................................................................................................................. 56
Programming A New VSM And/Or Display Switch Cluster...........................................................................57
Data Transferring...........................................................................................................................................58
New VSM......................................................................................................................................................58
New (Blank) Display Switch Cluster.......................................................................................................... 58
Used (Non-Blank) Display Switch Cluster................................................................................................. 58
PC Service Tool Software..................................................................................................................................59
Power Distribution Module (PDM) and Component Parts................................................................................60
Remove...............................................................................................................................................................60
PDM as a Unit................................................................................................................................................ 60
Install.................................................................................................................................................................61
PDM as a Unit................................................................................................................................................ 61
Remove and Install........................................................................................................................................... 61
PDM Component Parts.................................................................................................................................. 61
Transmission Control Unit (TCU)...................................................................................................................... 62
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured Before December, 2018............... 62
Remove............................................................................................................................................................ 62
Install.............................................................................................................................................................. 63
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured Between December, 2018 and
July, 2021.......................................................................................................................................................... 64
Remove............................................................................................................................................................ 64
Install.............................................................................................................................................................. 65
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured After July, 2021...........................65
Remove............................................................................................................................................................ 65
Install.............................................................................................................................................................. 67
Battery..................................................................................................................................................................69
Remove...............................................................................................................................................................69
Install.................................................................................................................................................................69
Lights....................................................................................................................................................................70
Work Lights (Front and Rear)..........................................................................................................................70
Halogen Bulb Lights.......................................................................................................................................70
Remove......................................................................................................................................................... 70
Install............................................................................................................................................................70
LED Lights......................................................................................................................................................70
Remove......................................................................................................................................................... 70
Install............................................................................................................................................................70
Strobe Light.......................................................................................................................................................71
Remove............................................................................................................................................................ 71
Install.............................................................................................................................................................. 71

iv
 Table of Contents

TABLE OF CONTENTS (Continued)

LED Tail, Backup, and Brake Lights...............................................................................................................72
Remove............................................................................................................................................................ 72
Install.............................................................................................................................................................. 72
Front Marker/Turn Signal Lights.................................................................................................................... 73
Replacing Whole Front Marker/Turn Signal Light Assembly..................................................................... 73
Remove......................................................................................................................................................... 73
Install............................................................................................................................................................73
Replacing Just the Front Marker/Turn Signal Light LED Light Lens....................................................... 74
Remove......................................................................................................................................................... 74
Install............................................................................................................................................................74
Electronic-Hydraulic Controls, Before January, 2020.......................................................................................75
E-Hydraulic Controls - TEST........................................................................................................................... 75
Mini-Levers.....................................................................................................................................................75
Full Stroke Test.............................................................................................................................................. 75
Function Returns to Neutral Test................................................................................................................. 75
Push (Override) Button Switch .....................................................................................................................75
General.............................................................................................................................................................. 76
Mini-levers, Remove and Install...................................................................................................................... 76
Armrest Assembly.............................................................................................................................................77
Remove............................................................................................................................................................ 77
Install.............................................................................................................................................................. 80
Horn Button.......................................................................................................................................................80
Remove............................................................................................................................................................ 80
Install.............................................................................................................................................................. 80
Direction Control Switch.................................................................................................................................. 80
Remove............................................................................................................................................................ 81
Install.............................................................................................................................................................. 81
Push (Override) Button.....................................................................................................................................81
Remove............................................................................................................................................................ 82
Install.............................................................................................................................................................. 83
Electronic-Hydraulic Controls, After January, 2020.........................................................................................84
E-Hydraulic Controls - TEST........................................................................................................................... 84
Mini-Levers.....................................................................................................................................................84
Full Stroke Test.............................................................................................................................................. 84
Function Returns to Neutral Test................................................................................................................. 84
Push Button Switch........................................................................................................................................84
General.............................................................................................................................................................. 85
Mini-levers, Remove and Install...................................................................................................................... 85
Armrest Assembly.............................................................................................................................................86
Remove............................................................................................................................................................ 86
Install.............................................................................................................................................................. 89
Horn Button.......................................................................................................................................................89
Remove............................................................................................................................................................ 89
Install.............................................................................................................................................................. 89
Direction Control Switch.................................................................................................................................. 89
Remove............................................................................................................................................................ 90
Install.............................................................................................................................................................. 90
Push (Override) Buttons...................................................................................................................................90
Remove............................................................................................................................................................ 91
Install.............................................................................................................................................................. 91
Diesel Particulate Filter (DPF) Display............................................................................................................. 92
Remove...............................................................................................................................................................92

v
Table of Contents

TABLE OF CONTENTS (Continued)

Clean and Inspect..............................................................................................................................................93
Install.................................................................................................................................................................93
Special Tools.........................................................................................................................................................94

vi
2200 SRM 1954 General

General
The removal and replacement procedures for the LPG Fuel System, GM 5.7L Engine
following electrical components are covered in this 0900SRM1433 for the following lift truck models
manual: H8.0FT, H8.0FT9, H9.0FT (C299)
•
• Display Switch Cluster • H170-190FT, H175FT36 (D299)
• Vehicle System Manager (VSM)
LPG Fuel System, Kubota 3.8L SI Engine
• Power Distribution Module (PDM) 0900SRM1905 for the following lift truck models
• Mini-lever electronic-hydraulic controls • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
• Lights (H135FT, H155FT, H155FTS, H170FTS)
(P006)
• Sensors and switches
• Battery
• Transmission Control Unit (TCU)
Some of the components used are made of plastic.
When using screws to replace and install plastic
components, the screws should be rotated
counterclockwise until the screw thread turns over
the last thread in the plastic part. The screw can
then be turned clockwise to make a connection. This
prevents "cutting" new threads and damaging the
existing thread in the plastic part.
If any welding must be done, obtain proper
authorization from a Resident Service Engineer. If
authorization is given, be sure to follow the
procedures in the CAUTION below.

CAUTION
When welding, always disconnect the negative
battery cable from battery and disconnect the
ground wire from the ground stud on the frame.
See Figure 1. To prevent damage to the Electronic NOTE: VIEW SHOWN IS FROM LEFT SIDE. MAJOR
Control Module (ECM), remove it from the lift truck. COMPONENTS AND ELECTRICAL CONNECTIONS
NOT SHOWN FOR CLARITY.
See one of the following sections for procedures to
remove ECM from your lift truck 1. GROUND STUD
LPG Fuel System, GM 4.3L Engine With PSI 2. TANK OPENING FOR HYDRAULIC FILTER
3. POWER DISTRIBUTION MODULE (PDM)
0900SRM1556 for the following lift truck models 4. BATTERY
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
Figure 1. Welding Preparation
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS, For more information on how to perform welding
H170FTS) (N006)
repairs to lift truck and overhead guard, refer to one
LPG Fuel System, PSI 4.3L Engine of the following sections:
0900SRM1951 for the following lift truck models
Periodic Maintenance 8000SRM1957 for the
• H6.0FT, H7.0FT (H135FT, H155FT) (L006) following lift truck models
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)

1
General 2200 SRM 1954

• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, Three-Speed Powershift Transmission Repair

H8.0FTS6 (H135FT, H155FT, H155FTS, 1300SRM1317 for lift truck models
H170FTS) (N006)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
Periodic Maintenance 8000SRM2401 for the
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
following lift truck models
H8.0FTS6 (H135FT, H155FT, H155FTS,
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 H170FTS) (N006)
(H135FT, H155FT, H155FTS, H170FTS) • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(P006) (H135FT, H155FT, H155FTS, H170FTS)
Periodic Maintenance 8000SRM1959 for the (P006)
following lift truck models • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299) • H170-190FT, H175FT36 (D299)
Periodic Maintenance 8000SRM2296 Two-Speed Powershift Transmission Repair
1300SRM1343 for lift truck models
• H170-190FT, H175FT36 (D299)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
Additional information concerning the electrical
system may be included in other sections when the • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
information is closely related to other systems. H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
Sections may include: H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
•
Frame 0100SRM1948 for lift truck models (H135FT, H155FT, H155FTS, H170FTS)
(P006)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
Calibration Procedures 8000SRM1134 for lift
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS, truck models
H170FTS) (N006) • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
(H135FT, H155FT, H155FTS, H170FTS) H8.0FTS6 (H135FT, H155FT, H155FTS,
(P006) H170FTS) (N006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299) H175FT36, H190FT ) (C299)
Frame 0100SRM2293 for lift truck models • H170-190FT, H175FT36 (D299)
H170-190FT, H175FT36 (D299) Cooling System 0700SRM1950 for lift truck
Wet Brakes - NMHG/HYG 1800SRM1597 for lift models
truck models • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006) • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS,
•
H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS) (N006)
H170FTS) (N006) • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
H8.0FT, H8.0FT9, H9.0FT (H170FT, (H135FT, H155FT, H155FTS, H170FTS)
•
H175FT36, H190FT ) (C299) (P006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Wet Brake System 1800SRM1977 for the H175FT36, H190FT ) (C299)
following lift truck models
• H170-190FT, H175FT36 (D299)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
(P006)

2
2200 SRM 1954 General

Diagnostic Troubleshooting Manual Kubota 3.8L Diesel Engine (Tier 4), 55kW With
9000SRM1112 or Guided Troubleshooting Tool DOC 0600SRM1961 for lift truck models
for lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (L006)
•
• H6.0FT, H7.0FT (H135FT, H155FT) (L006) • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS,
H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS) (N006)
H170FTS) (N006) • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
• H8.0FT, H8.0FT9, H9.0FT (H170FT, (H135FT, H155FT, H155FTS, H170FTS)
H175FT36, H190FT ) (C299) (P006)
• H170-190FT, H175FT36 (D299) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
User Interface - Service Technician
2200SRM1131 for lift truck models • H170-190FT, H175FT36 (D299)

• H6.0FT, H7.0FT (H135FT, H155FT) (L006) LPG Fuel System, GM 4.3L Engine With PSI
0900SRM1556 for the following lift truck models
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, equipped with a GM 4.3L LPG engine
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006) • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
(H135FT, H155FT, H155FTS, H170FTS) H8.0FTS6 (H135FT, H155FT, H155FTS,
(P006) H170FTS) (N006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
H175FT36, H190FT ) (C299) H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
• H170-190FT, H175FT36 (D299) H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
Kubota Diesel 3.6L Engine 0600SRM1579 for lift
LPG Fuel System, PSI 4.3L Engine
truck models
0900SRM1951 for the following lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS, • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H170FTS) (N006) H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) LPG Fuel System, GM 5.7L Engine
(P006) 0900SRM1433 for the following lift truck models
equipped with a GM 5.7L LPG engine
Kubota Diesel 3.8L Engine (Tier 4 Final), 78/82
KW 0600SRM1962 for lift truck models • H8.0FT, H8.0FT9, H9.0FT (C299)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006) • H170-190FT, H175FT36 (D299)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, High Voltage Switch (HVS) Ignition; GM4.3L
H8.0FTS6 (H135FT, H155FT, H155FTS, EPA Compliant Engines and GM5.7L LPG EPA
H170FTS) (N006) Compliant Engine 2200SRM1097 for the following
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 lift truck models equipped with a GM 4.3L and 5.7L
(H135FT, H155FT, H155FTS, H170FTS) LPG engine
(P006)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299) • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
• H170-190FT, H175FT36 (D299)

3
General 2200 SRM 1954

High Voltage Switch (HVS) Ignition; PSI 4.3L • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
EPA Compliant Engines 2200SRM1955 for the (H135FT, H155FT, H155FTS, H170FTS)
following lift truck models (P006)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
• H170-190FT, H175FT36 (D299)
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006) If your lift truck is equipped with a Cummins QSB
Operator's Cab 0100SRM1892 for lift truck 3.3L diesel engine, contact your local Hyster
models dealer, or see Hyster Hypass® Online for any
repair or service procedures.
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)

4
2200 SRM 1954 Display Switch Cluster

Display Switch Cluster

REMOVE 4. Remove horn button and disconnect horn wires.
NOTE: The Display Switch Cluster (DSC) is a non- NOTE: A puller tool may be required to remove
repairable part. See Parts Manual for replacement steering wheel.
parts.
5. Remove lock nut securing steering wheel and
1. Disconnect ground wire. remove steering wheel from steering column.
Take care to not damage horn wires. See
2. Lift up on steering wheel slightly and pull up Figure 3.
on tilt lever. Fully lower steering column.
6. Disconnect Display Switch Cluster harness
3. Remove upper steering column cover by pulling from Display Switch Cluster. Remove four bolts
up on upper steering column cover to release securing Display Switch Cluster. Slide display
latches (one on either side), and pulling cover panel off of steering column. See Figure 4.
away from steering column. See Figure 2.

NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH

1. UPPER STEERING COLUMN COVER 3. LOWER STEERING COLUMN COVER

2. STEERING COLUMN TILT LEVER

Figure 2. Upper Steering Column Cover Removal

5
Display Switch Cluster 2200 SRM 1954

Legend for Figure 3.

1. HORN BUTTON
2. LOCK NUT

Figure 3. Steering Wheel Removal

NOTE: TOP DOWN VIEW SHOWN.

1. BOLTS 3. STEERING COLUMN

2. DISPLAY SWITCH CLUSTER HARNESS 4. HORN WIRES (CONTACT PADS)

Figure 4. Display Switch Cluster Removal

6
2200 SRM 1954 Display Switch Cluster

INSTALL The turn signal lever is located on right side of the

Display Switch Cluster. The direction control lever
NOTE: When a new Display Switch Cluster is is located on left side of Display Switch Cluster.
installed on a lift truck, the data that controls all
functions and features unique to that lift truck,
Remove
needs to be transferred to new Display Switch
Cluster. See section Vehicle System Manager NOTE: The direction control lever and turn signal
(VSM), located in the back of this manual, for lever are not repairable. If one of these levers
procedures to transfer data to a new Display Switch malfunctions, replace with new lever. See Parts
Cluster. Manual for replacement part numbers.
1. Insert two small flat-blade or Phillips
1. Install Display Switch Cluster onto steering
screwdrivers, with a 3.175 mm (0.125 in.) or
column. Install four bolts to secure panel to
less, wide blade or die end, into opening on
steering column and tighten bolts to
Display Switch Cluster on an outward angle
19 N•m (168 lbf in). See Figure 4.
enough to compress spring tab on direction
control lever or turn signal lever. See A,
2. Connect Display Switch Cluster to display
Figure 5.
harness.
2. Pry spring tab toward body of direction control
3. Install steering wheel onto steering shaft and
lever or turn signal lever and, at the same time,
tighten lock nut until steering wheel is fully
pull on handle of lever enough to free the tab of
seated. Final torque for lock nut is
interior lock of Display Switch Cluster. See B,
40 to 54 N•m (30 to 40 lbf ft). See Figure 3.
Figure 5.
4. Connect horn wires to horn button. Install horn
3. Repeat previous steps on opposite side of
lock nut and horn button into steering wheel.
direction control lever or turn signal lever.
5. Install upper steering column cover by aligning Remove direction control lever or turn signal
two latches and pushing down until latched. lever from Display Switch Cluster.
See Figure 2.

DIRECTION CONTROL AND TURN

SIGNAL LEVERS
Direction control lever and turn signal lever are
similar in design, but perform different functions.

7
Display Switch Cluster 2200 SRM 1954

NOTE: DISPLAY SWITCH CLUSTER SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY. FLAT-BLADE
SCREWDRIVERS SHOWN.

A. STEP 1 B. STEP 2

1. DIRECTION CONTROL AND TURN SIGNAL 3. DISPLAY SWITCH CLUSTER

LEVERS
2. FLAT-BLADE SCREWDRIVER

Figure 5. Direction Control and Turn Signal Levers, Remove

Install NOTE: Lift truck models covered in this manual

can be equipped with an optional key switch or
Install direction control lever or turn signal lever Power ON/OFF button. The Power ON/OFF button
into opening of Display Switch Cluster until locking is a nonrepairable part. See Parts Manual for
tabs are engaged in Display Switch Cluster. replacement parts. If truck is equipped with a key
switch, follow steps below to remove and replace key
KEY SWITCH switch.
Remove 1. Fully lower steering column and remove upper
NOTE: The lift truck models covered in this manual steering column cover by pushing in on both
may be equipped with an optional remote key sides of cover to release latches (one on either
switch in the engine compartment. See Sensors and side), and pulling cover away from steering
Switches section in this service manual for column. See Figure 2.
replacement procedures.

8
2200 SRM 1954 Display Switch Cluster

2. Remove torx head capscrews. Slide key switch 2. Install upper steering cover on steering column.
assembly out of Display Switch Cluster. See Align latches on upper steering cover to holes
Figure 6. on steering column and push upper steering
cover into place on steering column. See
Install Figure 2.
1. Install new key switch assembly into Display
Switch Cluster. Install torx head capscrews
(T-15) to secure key switch to Display Switch
Cluster. Tighten torx head capscrews to
1.1 N•m (9.7 lbf in). See Figure 6.

1. BEZEL 4. TORX HEAD SCREW

2. OVERLAY 5. INSERT SCREWDRIVER IN SLOT AT THIS
3. KEY SWITCH LOCATION

Figure 6. Display Switch Cluster Panel Bezel, Grid, and Key Switch Removal

9
Display Switch Cluster 2200 SRM 1954

DISPLAY SWITCH CLUSTER PANEL 2. Remove overlay from Display Switch Cluster.
BEZEL AND OVERLAY
Install
Remove
Place new overlay on display panel and install a
1. Insert a small, flat-bladed screwdriver into top new bezel by inserting outer edge in display and
slot on inner edge of bezel and pry outward. then pressing down inner edge.
Repeat procedure at the lower slot on the bezel.
Be careful to not damage bezel and overlay
when removing bezel. Lift bezel off of Display
Switch Cluster. See Figure 6.

10
2200 SRM 1954 Steering Column Repair

Steering Column Repair

Remove 7. Remove four bolts (1, Figure 9) holding steering
column to cowl.
1. Remove floor mat and floor plate for access to
battery. 8. Raise steering column to disengage steering
shaft from the steering control unit.
2. Disconnect the battery. See Figure 7.

1. BATTERY POSITIVE CABLE

2. BATTERY NEGATIVE CABLE
3. BATTERY

Figure 7. Disconnect The Battery

3. Remove upper steering column cover by pulling

up on upper steering column cover to release
latches (one on either side), and pulling cover
away from steering column. See Figure 2.

4. Remove steering wheel and instrument display

panel. See Display Switch Cluster section for
procedures.

5. Remove two screws and remove lower steering

column cover. See Figure 8.

6. Disconnect Display Switch Cluster harness 1. SCREWS

from display panel. Remove harness from 2. LOWER STEERING COLUMN COVER
steering column.
Figure 8. Lower Steering Column Cover Removal

11
Steering Column Repair 2200 SRM 1954

NOTE: STEERING COLUMN ASSEMBLY FOR LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT)
(L006) SHOWN. STEERING COLUMN ASSEMBLY FOR LIFT TRUCK MODELS H6.0FT, H7.0FT, H7.0FTS6,
H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS) (N006), H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299), AND H170-190FT, H175FT36 (D299) H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) (P006) IS SIMILAR.
NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN. STEERING COLUMN ARRANGEMENT IS
THE SAME WITH MANUAL HYDRAULIC CONTROL VALVE.

1. BOLTS 8. COWL
2. PIVOT BOLTS 9. LOWER STRUT PIVOT PIN
3. HORN WIRES 10. HYDRAULIC CONTROL VALVE
4. STEERING SHAFT RETENTION CLIP 11. STEERING CONTROL UNIT (SCU)
5. HORN HARNESS 12. STEERING SHAFT
6. STEERING COLUMN 13. HORN CONTACT PADS
7. GAS CYLINDER

Figure 9. Steering Column Disassembly

12
2200 SRM 1954 Steering Column Repair

Disassemble 2. Install steering column to cowl using four bolts.

Tighten bolts to 38 N•m (28 lbf ft). See
1. Remove steering shaft retention clip (4, Figure 9.
Figure 9)
3. Connect Display Switch Cluster harness to
2. Remove horn contact pads. Display Switch Cluster panel. Install Display
Switch Cluster harness on steering column. See
3. Remove lower strut pivot pin from the gas
Display Switch Cluster section for procedures.
cylinder. See Figure 9.
4. Install upper steering column cover by aligning
4. Remove steering column pivot bolts and
the two latches and pushing down until
steering shaft.
latched. See Figure 8.
Assemble 5. Install steering wheel and instrument display
1. Install steering column pivot bolts and install panel. See Display Switch Cluster section for
steering shaft. procedures.

2. Install lower strut pivot pin in the gas cylinder. 6. Move steering column to its lowest position and
See Figure 9. install upper steering column cover. See
Figure 2.
3. Install horn contact pads. See Figure 9.
7. Connect the battery. See Figure 7.
4. Install steering shaft retention clip.

Install
1. Lubricate end of steering shaft with
multipurpose grease. Install end of steering
shaft into steering control unit.

13
Sensors and Switches 2200 SRM 1954

Sensors and Switches

GENERAL • Service brake pedal position sensor
• Park brake sensor

CAUTION The dash and kick panel need to be removed and

Before removing and replacing any sensors or installed on lift truck after a sensor or switch has
switches, ALWAYS disconnect the battery (see been replaced.
Figure 7). Failure to disconnect the battery can
cause damage to the sensor or switch and other Remove
electrical components. Always cover or protect the 1. Lower steering column to its lowest position
sensor or switch connector from contamination and remove upper steering column cover by
after disconnecting the harness mating part. pulling up on upper steering column cover to
DO NOT use solvent-based cleaners to clean area release latches (one on either side), and pulling
around sensors or switches. cover away from steering column. See Figure 2.

All sensors and switches used on these trucks are 2. Remove Allen screws from dash and top of
non-repairable parts. Replace with new sensors or cowl. Remove dash from clips, located
switches whenever a sensor or switch malfunctions underneath dash, that attach dash to kick
and is not operating correctly. See Parts Manual panel. Lift to remove the dash. See Figure 10.
for replacement part numbers. Before installing new
sensors or switches, use a clean cloth and make sure 3. Lift kick panel from seal plate and remove from
the area around the sensor or switch is clean and lift truck. See Figure 10.
free of oils and contaminates.
Install
When removing and replacing sensors or switches,
be sure to tag connectors to aid in correct 1. Install kick panel onto seal plate.
reconnecting.
2. Install dash into clips, located underneath
Dash and Kick Panel, Remove and Install dash, that attach dash to kick panel. Install
Allen screws into dash and top of cowl.
Before removing and replacing the following sensors
and switches: 3. Install upper steering column cover by aligning
• Accelerator pedal position sensor two latches and pushing down until latched.
See Figure 2.
• Brake fluid level switch

14
2200 SRM 1954 Sensors and Switches

1. KICK PANEL 3. ALLEN SCREW

2. COWL 4. DASH

Figure 10. Dash and Kick Panel Removal

ACCELERATOR PEDAL POSITION Electronic hydraulic control valve.

SENSOR • Disconnect valve harness from Vehicle
System Manager (VSM). Remove two bolts
Remove and remove valve harness bracket. See
1. Remove floor mat and floor plate and Figure 12.
disconnect battery. See Figure 7.

2. Remove upper steering column cover and dash

and kick panel. See Dash and Kick Panel,
Remove and Install for procedures.

NOTE: Lift truck models H8.0FT, H8.0FT9, H9.0FT

(H170FT, H175FT36, H190FT ) (C299) and
H170-190FT, H175FT36 (D299) are only equipped
with an electronic hydraulic control valve.
3. If lift truck is equipped with:
Manual hydraulic control valve (with or
without Operator Presence System
[OPS]).
• Remove lever bracket capscrews and move
hydraulic lever assembly toward operator's
seat. See Figure 11.

15
Sensors and Switches 2200 SRM 1954

Legend for Figure 11.

1. LEVER BRACKET CAPSCREWS

2. COWL

4. Disconnect accelerator pedal position sensor.

5. Remove three bolts, throttle base plate, and

pedal assembly from cowl. See Figure 13.

6. Remove two pan head screws, lockwashers, and

accelerator pedal position sensor from throttle
base plate. See Figure 12.

Figure 11. Manual Hydraulic Control Valve

Removal

16
2200 SRM 1954 Sensors and Switches

NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN.

1. ACCELERATOR PEDAL POSITION SENSOR 6. COWL

2. BOLTS (THROTTLE BASE PLATE) 7. VEHICLE SYSTEMS MANAGER (VSM)
3. VALVE HARNESS MOUNTING BRACKET 8. CONTROL VALVE HARNESS
(ELECTRONIC VALVE) 9. SENSOR COVER
4. BOLTS (VALVE HARNESS MOUNTING
BRACKET)
5. THROTTLE BASE PLATE

Figure 12. Accelerator Pedal Position Sensor

17
Sensors and Switches 2200 SRM 1954

• Install lever bracket to cowl. Install clevis and

retention pins and connect manual levers to
control valve. See Figure 11.
Electronic hydraulic control valve.
• Insert two bolts into valve harness bracket
and install valve harness bracket. Connect
valve harness to VSM. See Figure 12.

7. Install kick panel and dash. Install upper

steering column cover. See Dash and Kick
Panel, Remove and Install for procedures.

8. Connect the battery and install the floor plate

and floor mat.

9. If throttle pedal needs to be adjusted, see the

Frame manual listed in the General section of
1. BOLTS this manual for procedures.
2. PEDAL ASSEMBLY
3. COWL
BRAKE FLUID LEVEL SWITCH
Figure 13. Accelerator Pedal and Throttle Base
Plate Removal
Remove
NOTE: Lift truck models H8.0FT, H8.0FT9, H9.0FT
Install (H170FT, H175FT36, H190FT ) (C299) and
H170-190FT, H175FT36 (D299) DO NOT have a
1. Insert new accelerator pedal position sensor
brake fluid level switch.
into opening on throttle base plate. See
Figure 13. NOTE: Brake fluid level switch is a component of
master brake cylinder reservoir and is located inside
2. Rotate sensor so that the D shaped throttle reservoir. When switch is replaced, reservoir must
shaft end slides into accelerator pedal position be replaced as well.
sensor. Rotate sensor counterclockwise until 1. Remove floor mat and floor plate. Disconnect
locating pin on sensor lines up with hole in the battery. See Figure 7.
throttle base plate.
2. Remove upper steering column cover and dash
3. Insert two pan head screws and lockwasher and kick panel. See Dash and Kick Panel,
and install accelerator pedal position sensor to Remove and Install for procedures.
throttle base plate. Tighten screws to
2.25 N•m (20 lbf in). 3. Disconnect brake fluid level switch from cowl
harness.
4. Install throttle base plate and pedal assembly
to cowl using three bolts. Tighten capscrews to
19 to 25 N•m (168 to 221 lbf in).
CAUTION
5. Connect accelerator pedal position sensor. Disposal of lubricants and fluids must meet local
environmental regulations.
NOTE: Lift truck models H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT ) (C299) and 4. Remove reservoir from bracket and drain fluid
H170-190FT, H175FT36 (D299) are only equipped from reservoir. Disconnect master cylinder
with an electronic hydraulic control valve. supply hose from reservoir. Make sure air does
not get into hose. See Figure 14.
6. Manual hydraulic control valve (with or
without Operator Presence System
[OPS]).

18
2200 SRM 1954 Sensors and Switches

1. SERVICE BRAKE PRESSURE SENSOR 7. BRAKE FLUID RESERVOIR

2. MASTER CYLINDER (BOOSTED) 8. NUTS
3. SERVICE BRAKE PEDAL POSITION SENSOR 9. SERVICE BRAKE PEDAL POSITION SENSOR
4. BRAKE FLUID LEVEL SWITCH (INSIDE MOUNTING BRACKET
RESERVOIR)* 10. SERVICE BRAKE PEDAL POSITION SENSOR
5. BRAKE FLUID RESERVOIR MOUNTING CONNECTOR
BRACKET 11. CAPSCREWS
6. COWL
*Brake fluid level switch not used on lift truck models H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT )
(C299) and H170-190FT, H175FT36 (D299)

Figure 14. Brake Fluid Level Switch, Service Brake Pedal Position Sensor, and Service Brake Pressure
Sensor

Install 4. Install kick panel and dash. Install upper

steering column cover. See Dash and Kick
1. Connect the master cylinder supply hose to a Panel, Remove and Install for procedures.
new reservoir. See Figure 14
5. Connect the battery. Install floor plate and
2. Install new reservoir onto bracket and fill with floor mat.
new brake fluid. See the Periodic
Maintenance manual listed in the General
SERVICE BRAKE PEDAL POSITION
section of this manual for brake fluid
specifications. SENSOR
Remove
3. Connect brake fluid level switch to cowl
harness. 1. Remove floor mat and floor plate. Disconnect
the battery. See Figure 7.

19
Sensors and Switches 2200 SRM 1954

2. Remove upper steering column cover and dash

and kick panel. See Dash and Kick Panel,
Remove and Install for procedures.

3. Disconnect brake pedal position sensor from

cowl harness. See Figure 14.

4. Remove mounting bracket capscrew, mounting

bracket, and brake pedal position sensor from
lift truck. See Figure 14.

5. Remove two capscrews, two nuts, and brake

pedal position sensor from mounting bracket.
See Figure 14.

Install
1. Install new service brake pedal position sensor
to mounting bracket using two capscrews and
two nuts. See Figure 14.

2. Install mounting bracket and service brake

pedal position sensor to lift truck using
mounting bracket capscrew. Connect service
brake pedal position sensor to cowl harness.
See Figure 14.
1. PARKING BRAKE SENSOR CONNECTOR
3. After new service brake pedal position sensor 2. PARKING BRAKE POSITION SENSOR
has been installed, check the gap between the 3. LOCKWASHER
sensor arm and tab. See the Brake System 4. TORX CAPSCREWS
5. PARKING BRAKE ASSEMBLY
manual listed in the General of this manual for
procedures. Figure 15. Parking Brake Sensor
4. Install kick panel and dash. Install upper
steering column cover. See Dash and Kick
Install
Panel, Remove and Install for procedures. 1. Install new sensor by using torx capscrews to
secure sensor to parking brake handle
5. Connect the battery. Install floor plate and assembly. See Figure 15.
floor mat.
2. Visually inspect sensor to ensure sensor arm
PARKING BRAKE POSITION SENSOR and parking brake lever maintain continuous
contact throughout full range of lever
Remove operation.
1. Remove floor mat and floor plate. Disconnect
the battery. See Figure 7. 3. Connect sensor to cowl harness. See Figure 15.

2. Remove upper steering column cover and dash 4. Install kick panel and dash. Install upper
and kick panel. See Dash and Kick Panel, steering column cover. See Dash and Kick
Remove and Install for procedures. Panel, Remove and Install for procedures.

3. Disconnect parking brake sensor from cowl 5. Connect the battery. Install floor plate and
harness. Remove torx capscrews from sensor floor mat.
and remove sensor from parking brake handle
assembly. See Figure 15.

20
2200 SRM 1954 Sensors and Switches

SERVICE BRAKE PRESSURE SENSOR Install

Remove NOTE: Perform Step 1 for lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (L006) and H6.0FT,
1. Disconnect the battery. H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT,
H155FT, H155FTS, H170FTS) (N006). H6.0FT,
2. Remove floor mat and floor plate for access to
H7.0FT, H7.0FTS9, H8.0FTS6 (H135FT, H155FT,
service brake pressure sensor.
H155FTS, H170FTS) (P006).
3. Disconnect the sensor from the cowl harness 1. Install a new sensor on master cylinder.
and remove it from the master cylinder. Tighten sensor to
23 to 28 N•m (204 to 248 lbf in). See Figure 14.
See Figure 14 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (L006) NOTE: Perform Step 2 for lift truck models H8.0FT,
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT )
H8.0FTS6 (H135FT, H155FT, H155FTS, (C299) and H170-190FT, H175FT36 (D299).
H170FTS) (N006) 2. Install a new sensor on modulating brake
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 valve. Tighten sensor to
(H135FT, H155FT, H155FTS, H170FTS) 23 to 28 N•m (204 to 248 lbf in). See Figure 16.
(P006)
See Figure 16 for lift truck models 3. Connect new sensor to cowl harness.
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 4. Bleed the brake system as described in the
H175FT36, H190FT ) (C299)
Brake System manual listed in the General
• H170-190FT, H175FT36 (D299) section of this manual.

NOTE: Perform Step 4 for lift truck models H8.0FT, 5. Connect the battery. Install floor plate and
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT ) floor mat.
(C299) and H170-190FT, H175FT36 (D299) .
4. Disconnect the sensor from the cowl harness
and remove it from the modulating brake valve.
See Figure 16.

21
Sensors and Switches 2200 SRM 1954

Legend for Figure 16.

1. PARKING BRAKE SENSOR

2. ACCUMULATOR PRESSURE SWITCH
3. SERVICE BRAKE PRESSURE SENSOR
4. MODULATING BRAKE VALVE
5. ACCUMULATOR
6. ACCUMULATOR CHARGE VALVE
7. PARKING BRAKE
8. BRAKE PEDAL

ACCUMULATOR PRESSURE SWITCH FOR

LIFT TRUCK MODELS H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT )
(C299) AND H170-190FT, H175FT36 (D299)

WARNING
DO NOT continue to operate the lift truck if the
light and audible alarm are on during operation.
Low accumulator pressure will prevent the service
brakes from stopping the lift truck. Serious injury
to personnel can result.

During operation of lift truck, if the red, low

accumulator pressure light illuminates and an
audible alarm sounds (see Operating Manual),
accumulator pressure switch has detected that
hydraulic pressure is below 7240 kPa (1050 psi).
Move lift truck to level ground and/or apply the
parking brake. Turn lift truck power OFF
immediately and DO NOT restart engine until low
pressure condition has been corrected.

Remove
1. Remove floor mat and floor plate and
disconnect battery.

2. Disconnect accumulator pressure switch from

the cowl harness and remove it from the
accumulator charge valve. See Figure 16.

Install
1. Install new accumulator pressure switch into
accumulator charge valve. Connect cowl
harness to accumulator pressure switch. See
Figure 16.
Figure 16. Service Brake Pressure Sensor and 2. Connect battery and install floor plate and floor
Accumulator Pressure Switch, Lift Truck Models mat.
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT ) (C299) and H170-190FT, H175FT36 (D299)

22
2200 SRM 1954 Sensors and Switches

3. Bleed brake system as described in the Brake 3. Remove u-clip, foam lock seal, and wiring
System manual listed in the General section of harness from the pedal frame. Remove four pan
this manual. head screws, lockwashers, washers, pedal pad,
and springs from pedal frame. If any metal
SENSOR MICROSWITCHMONOTROL® inserts in pedal pad are damaged, replace as
necessary. See Figure 17.
Remove
1. Remove floor mat and floor plate and 4. Remove two hex head screws, lockwashers,
disconnect battery. nuts, and microswitch from pedal pad. Repeat
for remaining microswitch and remove wiring
2. Remove Monotrol® pedal assembly from harness from pedal frame.
throttle base plate and cowl. See Accelerator
Pedal Position Sensor, Remove for procedures.

23
Sensors and Switches 2200 SRM 1954

1. WIRING HARNESS 9. METAL INSERT

2. FOAM LOCK SEAL 10. NUT
3. U-CLIP 11. LOCKWASHER
4. PAN HEAD SCREW 12. MICROSWITCH
5. LOCKWASHER 13. HEX HEAD SCREW
6. WASHER 14. SPRING
7. STOP SCREW 15. PEDAL PAD
8. NUT 16. PEDAL FRAME.

Figure 17. RemovalMonotrol Microswitch

24
2200 SRM 1954 Sensors and Switches

Install
1. Install microswitch and two hex head screws in
pedal pad. Coat exposed threads of hex head
screws with Loctite™ 222 (Hyster P/N
0360387) . Install two lockwashers and nuts on
hex head screws. DO NOT tighten nuts at this
time. Repeat for the other microswitch.

2. Put wires through hole in pedal frame. The

white banded wire is for the reverse
microswitch, and the blue banded wire is for
the forward microswitch. Adjust each
microswitch in its mount so that the
measurement between the edge of the mount
and the base of the microswitch equals
0.0 to 0.5 mm (0.0 to 0.02 in.). Tighten
mounting nuts of each microswitch as
adjustment is completed. See Figure 18.

3. Install wiring harness in pedal frame. Install

foam lock seal and u-clip. Install pedal pad and
springs in pedal frame. Coat threads of four
pan head screws with Loctite™ 222 (Hyster
P/N 0360387) . Install pan head screws,
lockwashers, and washers in pedal pad.
Tighten pan head screws to
2.25 to 2.50 N•m (19 to 22 lbf in).

4. Install Monotrol® pedal assembly onto lift 1. MICROSWITCH MOUNT

truck. See Accelerator Pedal Position Sensor, 2. MICROSWITCH BASE
Install for procedures.
Figure 18. Microswitch Adjustment
5. Connect the battery. Install floor plate and
floor mat. LOW COOLANT LEVEL SENSOR
NOTE: The low coolant level sensor is an optional
feature on these lift trucks and is a part of the
Electronic Monitoring package option. If the lift
truck does not have a low coolant sensor, a plug will
be in place of where the sensor goes. See Figure 19.

Remove
1. Remove floor mat and floor plate and
disconnect battery.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

2. Drain coolant from radiator and disconnect

electrical connector from low coolant level
sensor.

25
Sensors and Switches 2200 SRM 1954

3. Remove low coolant level sensor from radiator.

See Figure 19.

A. GM 4.3L AND 5.7L LPG ENGINES, PSI 4.3L LPG C. KUBOTA 3.8L DIESEL, CHARGE AIR COOLER
ENGINE, AND KUBOTA 3.6L DIESEL [LIFT SHOWN.
TRUCK MODELS H6.0-7.0FT (H135-155FT)
(L006) AND H6.0FT, H7.0FT, H7.0FTS6,
H7.0FTS9, H8.0FTS6 (H135FT, H155FT,
H155FTS, H170FTS) (N006) H6.0FT, H7.0FT,
H7.0FTS9, H8.0FTS6 (H135FT, H155FT,
H155FTS, H170FTS) (P006) ], EXTERNAL
COOLER SHOWN
B. CUMMINS QSB 3.3L DIESEL ENGINE WITH
INTERNAL COOLER SHOWN

1. RADIATOR 2. LOW LEVEL COOLANT SENSOR

Figure 19. Low Level Coolant Sensor

Install FUEL LEVEL SENSOR, DIESEL ENGINES

1. Install new low coolant level sensor into ONLY
radiator. See Figure 19. Remove
2. Connect the electrical connector to the low 1. Remove floor mat and floor plate and
coolant level sensor. Refill radiator with correct disconnect battery.
coolant of 50% water and 50% Ethylene Glycol
Boron-Free Antifreeze. 2. Disconnect the electrical connector from the
sensor on the fuel pump cover.
3. Seal threads with Loctite™ PST 567 (Hyster
P/N 273338) thread sealant and torque to 3. Unscrew the sensor and remove sensor and
7 N•m (62 lbf in). sender unit from fuel pump assembly. See
Figure 20.
4. Connect the battery. Install floor plate and
floor mat.

26
2200 SRM 1954 Sensors and Switches

Install SEAT SENSOR (OPERATOR PRESENCE

1. Install new fuel level sensor and sender unit SYSTEM)
through hole in fuel pump cover. Be sure that Non-Suspension Seat
the bracket in the fuel pump engages the
plastic piece on the bottom of the fuel sender NOTE: Lift truck models H8.0FT, H8.0FT9, H9.0FT
unit. Tighten fuel level sensor and sender unit (H170FT, H175FT36, H190FT ) (C299) and
onto fuel pump cover. See Figure 20. H170-190FT, H175FT36 (D299) are not equipped
with a non-suspension seat.
2. Connect the fuel level sensor electrical
connector. Remove
1. Remove floor mat and floor plate and
3. Connect the battery. Install floor plate and
disconnect battery.
floor mat.
2. Remove two capscrews and washers from cover
plate and remove seat box. See Figure 21.

1. BRACKET
2. FUEL SENDER UNIT
3. FUEL LEVEL SENSOR
4. FUEL PUMP COVER

Figure 20. Fuel Pump and Sensor

27
Sensors and Switches 2200 SRM 1954

A. FULL SUSPENSION SEAT B. NON-SUSPENSION SEAT

1. CAPSCREWS 4. SEAT WIRE HARNESS CONNECTOR

2. WASHERS 5. COVER PLATE
3. SEAT BOX

Figure 21. Seat Wire Harness Connector

3. Disconnect seat wire harness connector from

chassis harness. See Figure 21.

4. Remove the four flange nuts holding the seat to

the seat plate. Remove seat from seat plate.

5. Remove capscrew and grounding wire from

seat. See Figure 22.

6. Turn seat sensor approximately 1/4 turn

counterclockwise and remove sensor from seat.

28
2200 SRM 1954 Sensors and Switches

Full Suspension and Swivel Seats

Remove
1. Remove floor mat and floor plate and
disconnect battery.

2. Remove two capscrews and washers from cover

plate and remove seat box. See Figure 21.

3. Disconnect seat wire harness connector from

chassis harness. See Figure 21.

4. Pull out two pins that secure bottom seat

cushion to seat base. See Figure 23.

5. Lift bottom seat cushion up and disconnect the

seat wire harness from seat sensor. See
Figure 23.

6. Use a small, flat-bladed screwdriver and

remove the seat sensor from seat base.

1. GROUND WIRE 2. SEAT SENSOR

Figure 22. Seat Sensor Replacement, Non-

Suspension Seat

Install
NOTE: DO NOT force seat sensor into seat base.
Seat sensor is made of plastic and will break if not
installed properly.
1. Install new seat sensor into opening in seat
base. Turn sensor 1/4 turn clockwise and sensor
should lock into place. See Figure 22.

2. Connect new seat sensor ground wire to seat.

3. Install seat to seat plate and install four flange

nuts to secure seat to seat plate. 1. SEAT SENSOR
2. SEAT WIRE HARNESS
3. SEAT BASE
4. Connect seat wire harness to chassis harness. 4. CUSHION PINS
See Figure 21.
Figure 23. Seat Sensor, Full Suspension and
5. Install seat box to cover plate using two Swivel Seats
capscrews and washers. See Figure 21.
Install
6. Connect the battery and install floor plate and
floor mat. 1. Install new seat sensor into seat base.

2. Connect seat wire harness to seat sensor. See

Figure 23.

29
Sensors and Switches 2200 SRM 1954

3. Place bottom seat cushion onto seat base and Remove

attach cushion to seat base with pins. See
Figure 23. 1. Remove floor mat and floor plate and
disconnect battery.
4. Connect seat wire harness to chassis harness.
See Figure 21. 2. Raise the hood and disconnect switch from rear
harness to chassis harness connector and
5. Install seat box to cover plate using two remove capscrews to remove switch from
capscrews and washers. See Figure 21. bracket. See Figure 24.

6. Connect the battery and install floor plate and Install

floor mat. 1. Install new switch on bracket using the
capscrews and connect switch to rear harness
HOOD SHUT OFF SWITCH to chassis harness connector. See Figure 24.
NOTE: The hood shut off switch is found on certain
lift truck models manufactured for use in Europe 2. Connect the battery, install the floor plate and
only. floor mat.

30
2200 SRM 1954 Sensors and Switches

NOTE: BOTTOM VIEW OF HOOD SHOWN. KEY AND HOOD SWITCHES ARE OPTIONAL FEATURES.

1. HINGE BRACKET 4. REAR HARNESS TO CHASSIS HARNESS

2. ACTUATOR MAGNET CONNECTOR
3. HOOD SHUT OFF SWITCH 5. REMOTE KEY SWITCH

Figure 24. Hood Shut Off Switch And Remote Key Switch

REMOTE KEY SWITCH Install

Remove 1. Install new remote key switch assembly into
mounting bracket. Tighten nut to secure the
1. Remove the floor mat and floor plate for access assembly to mounting bracket.
to the battery. Disconnect the battery.
2. Connect boot protector to remote key switch
2. Raise the hood and pull back the boot protector assembly. See Figure 25.
and disconnect boot protector from the remote
key switch assembly. See Figure 25. 3. Close the hood. Connect the battery and install
floor plate and floor mat.
3. Loosen the nut and remove remote key switch
assembly from mounting bracket.

31
Sensors and Switches 2200 SRM 1954

1. BOOT PROTECTOR
2. MOUNTING BRACKET
3. REMOTE KEY SWITCH ASSEMBLY
4. NUT
5. KEY

Figure 25. Remote Key Switch Replacement

HYDRAULIC FILTER PRESSURE SWITCH

NOTE: The hydraulic filter pressure switch is an
optional feature on the lift trucks covered in this
service manual and is a part of the Electronic
Monitoring package option.

Remove
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery. 1. HYDRAULIC FILTER PRESSURE SWITCH
2. O-RING (NOT SHOWN)
2. Disconnect the hydraulic filter pressure switch
from the chassis harness. Remove switch from Figure 26. Hydraulic Filter Pressure Switch
hydraulic filter head assembly and discard
switch and O-ring. See Figure 26. TRANSMISSION SPEED SENSOR
Install Remove
1. Insert new switch, with new O-ring, into 1. Remove the floor mat and floor plate for access
hydraulic filter head assembly. Torque switch to the battery. Disconnect the battery.
to 20 N•m (177 lbf in). Connect hydraulic filter
2. Disconnect sensor from transmission harness
pressure switch to chassis harness. See
and remove bolt securing sensor to
Figure 26.
transmission housing. Discard the O-rings. See
2. Connect the battery and install floor plate and Figure 27.
floor mat.

32
2200 SRM 1954 Sensors and Switches

Install 2. Connect the battery and install floor plate and

floor mat.
1. Install new O-rings on sensor and install
sensor into transmission housing with the bolt.
Tighten bolt to 6.9 N•m (61 lbf in). Connect
sensor to transmission harness.

A. REAR VIEW OF TRANSMISSION B. FRONT VIEW OF TRANSMISSION

1. TRANSMISSION OUTPUT SPEED SENSOR 5. TEMPERATURE SENSOR

(TOSS)* 6. TRANSMISSION OUTPUT SPEED SENSOR
2. PRESSURE SENSORS (TOSS)**
3. TRANSMISSION INPUT SENSORS (TISS) 7. INTERMEDIATE SPEED SENSOR (THREE-SPEED
4. ENGINE SPEED SENSOR (THREE-SPEED TRANSMISSION)
TRANSMISSION)
*TOSS sensor location, Two-Speed Transmission Only
**TOSS sensor location, Three-Speed Transmission Only

Figure 27. Transmission Sensors

TRANSMISSION PRESSURE SENSORS Install

Remove NOTE: When new transmission pressure sensors
are installed, calibration is required for
1. Remove the floor mat and floor plate for access transmissions with an iron housing. See the
to the battery. Disconnect the battery. Calibration manual listed in the General section of
this manual for procedures.
2. Disconnect the pressure sensors from the
transmission harness. Remove sensors from 1. Install new sensors on control valve. Connect
fitting on the control valve. See Figure 27. sensors to transmission harness. See Figure 27.

33
Sensors and Switches 2200 SRM 1954

2. Connect the battery and install floor plate and 2. Disconnect engine speed sensor from
floor mat. transmission harness and remove bolt securing
sensor to transmission housing. Discard the O-
TRANSMISSION TEMPERATURE SENSOR ring. See Figure 27.

Remove Install
1. Remove the floor mat and floor plate for access 1. Install new O-ring on sensor and install sensor
to the battery. Disconnect the battery. into transmission housing with the bolt.
Tighten bolt to 6.9 N•m (61 lbf in). Connect
2. Put the lift truck on blocks. See the Operating
sensor to transmission harness. See Figure 27.
Manual or the Periodic Maintenance
manual listed in the General section of this 2. Connect the battery and install floor plate and
manual for procedures. floor mat.

INTERMEDIATE SPEED SENSOR

WARNING
At operating temperature, the transmission oil is NOTE: The intermediate speed sensor is used only
HOT. DO NOT permit the hot oil to touch the skin on lift trucks equipped with a three-speed
and cause a burn. Make sure oil is cool before transmission.
draining.
Remove
3. Drain the transmission oil. See the Periodic 1. Remove the floor mat and floor plate for access
Maintenance manual listed in the General to the battery. Disconnect the battery.
section of this manual for procedures.
2. Disconnect intermediate speed sensor from
4. Disconnect temperature sensor from transmission harness and remove bolt securing
transmission harness and remove sensor from sensor to transmission housing. Discard the O-
transmission. See Figure 27. ring. See Figure 27.
Install Install
1. Install new temperature sensor and connect 1. Install new O-ring on intermediate speed
sensor to transmission harness. See Figure 27. sensor and install intermediate speed sensor
into transmission housing with the bolt.
2. Remove lift truck from blocks.
Tighten bolt to 6.9 N•m (61 lbf in). Connect
3. Connect the battery and install floor plate and intermediate speed sensor to transmission
floor mat. harness. See Figure 27.

4. Fill transmission with oil. Run the lift truck 2. Connect the battery and install floor plate and
and check oil level. See the Periodic floor mat.
Maintenance manual listed in the General
section of this manual for transmission oil RETURN TO SET TILT (TILT ANGLE)
specifications and for the procedures to check SENSOR
the transmission oil level.
Remove
ENGINE SPEED SENSOR NOTE: Before working on or near the mast, see the
section Safety Procedures When Working Near
Remove Mast in the Periodic Maintenance manual listed
1. Remove the floor mat and floor plate for access in the General of this manual.
to the battery. Disconnect the battery.
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.

34
2200 SRM 1954 Sensors and Switches

2. Disconnect sensor harness from cowl harness. Install

See Figure 28.
1. Install new tilt sensor onto sensor bracket
3. Remove harness bracket from cowl and remove using two torx capscrews and nuts. See
harness from bracket. Figure 28.

4. Remove capscrew (4, Figure 28) that attaches 2. Secure sensor bracket and tilt sensor to mast
tilt sensor bracket to mast. using capscrew. Tighten capscrew to
90 to 99 N•m (66 to 73 lbf ft).
5. Remove sensor bracket and tilt sensor from
mast. 3. Place sensor harness in harness bracket and
install bracket onto cowl. Tighten capscrew to
6. Remove two torx capscrews and nuts holding 38 N•m (28 lbf ft).
tilt sensor to sensor bracket. Remove sensor
from bracket. See Figure 28. 4. Connect sensor harness connector to cowl
harness.

5. Connect the battery and install floor plate and

floor mat.

6. Tilt the mast completely forward and backward

to ensure that the tilt sensor is correctly
installed and connected.

REAR HORN BUTTON SWITCH

Remove
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.

2. Disconnect rear horn button switch electrical

NOTE: MAST ASSEMBLY FOR LIFT TRUCK MOD- connector from chassis harness. See Figure 29.
ELS H6.0FT, H7.0FT (H135FT, H155FT) (L006)
SHOWN. RETURN TO SET TILT SENSOR IN SAME 3. Remove two capscrews and inserts that attach
LOCATION ON MAST ASSEMBLY FOR LIFT TRUCK rear horn button switch and handle to the right
MODELS H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, rear overhead guard leg.
H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS)
(N006), H8.0FT, H8.0FT9, H9.0FT (H170FT, 4. Remove switch and handle assembly from
H175FT36, H190FT ) (C299), AND H170-190FT, overhead guard leg, pulling the wire and
H175FT36 (D299) H6.0FT, H7.0FT, H7.0FTS9, connector through the holes in the overhead
H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS) guard leg.
(P006)
Install
1. TILT SENSOR 1. Insert wire and connector in the hole in
2. TORX HEAD CAPSCREW
3. TILT SENSOR BRACKET overhead guard leg and thread wire until
4. CAPSCREW connector can be pulled through bottom hole in
5. TILT SENSOR CONNECTOR TO COWL the overhead guard leg.
HARNESS
6. TILT CYLINDER 2. Attach handle and switch assembly to overhead
7. TILT SENSOR HARNESS BRACKET guard leg with two capscrews and inserts. See
Figure 29.
Figure 28. Return To Set Tilt (Tilt Angle) Sensor
3. Connect rear horn switch electrical connector to
chassis harness.

35
Sensors and Switches 2200 SRM 1954

4. Connect the battery and install floor plate and IMPACT SENSOR
floor mat.
Remove
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.

2. Disconnect impact sensor connector from right

chassis harness connector. See Figure 30.

3. Remove two capscrews that secure impact

sensor to bracket and remove sensor from lift
truck. See Figure 30.

Install
1. Install new impact sensor to sensor bracket
using two capscrews. Tighten capscrews to
26 N•m (230 lbf in).

2. Insert the push-in fastener into the connector

clip, then connect the correct chassis harness
connector to the impact sensor connector. See
Figure 30.

3. Connect the battery and install the floor plate

and floor mat.

1. CAPSCREW
2. INSERT
3. HANDLE AND SWITCH ASSEMBLY
4. HOLE
5. HANDLE
6. REAR HORN BUTTON SWITCH
7. ELECTRICAL CONNECTOR
8. OVERHEAD GUARD LEG

Figure 29. Rear Horn Button Switch

36
2200 SRM 1954 Sensors and Switches

1. IMPACT SENSOR 5. CAPSCREW

2. SENSOR BRACKET 6. SENSOR CONNECTOR
3. FLOOR PLATE 7. PUSH-IN FASTENER
4. FLOOR MAT 8. RIGHT CHASSIS HARNESS CONNECTOR

Figure 30. Impact Sensor Replacement

LOAD WEIGHT SENSOR Install

Remove 1. Insert new load weight sensor into special
fitting. Tighten sensor by hand, and then
1. Remove the floor mat and floor plate for access torque sensor to 37 N•m (27 lbf ft).
to the battery. Disconnect the battery.
2. Connect the harness connector to the load
2. Disconnect the harness connector from the load weight sensor. See Figure 31.
weight sensor. See Figure 31.
3. Connect the battery, install the floor plate and
3. Remove the load weight sensor from the special floor mat.
fitting on hydraulic control valve.

37
Sensors and Switches 2200 SRM 1954

NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN. LOAD WEIGHT SENSOR IS IN SAME POSI-
TION ON MANUAL HYDRAULIC CONTROL VALVE.

1. SPECIAL FITTING 4. VEHICLE SYSTEM MANAGER (VSM)

2. LOAD WEIGHT SENSOR 5. COWL
3. HARNESS CONNECTOR 6. MAIN CONTROL VALVE

Figure 31. Load Weight Sensor

ENGINE AND FUEL SENSORS AND • Engine Coolant Temperature (ECT) sensor
SWITCHES, GM 4.3L AND 5.7L LPG • Air flow restriction switch
ENGINES See the LPG Fuel System manual listed in the
See the High Voltage Switch (HVS) Ignition General section of this manual for lift truck models
manual listed in the General section of this manual H8.0FT, H8.0FT9, H9.0FT (C299) and H170-190FT,
to replace the following engine sensors and switches H175FT36 (D299) equipped with a GM 5.7L LPG
used on the GM 4.3L and 5.7L LPG engines engine to replace the following LPG fuel sensors and
switches
• Crankshaft Position (CKP) sensor
• Low pressure switch
• Camshaft Position (CMP) sensor
• Low fuel sensor
• Oil pressure sensor
• Oxygen sensors
• Manifold Absolute Pressure (MAP) sensor
See the LPG Fuel System manual listed in the
• Manifold Air Temperature (MAT) sensor
General section of this manual for lift truck models

38
2200 SRM 1954 Sensors and Switches

H6.0FT, H7.0FT (H135FT, H155FT) (L006) and • LP vapor sensor

H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) ENGINE AND FUEL SENSORS AND
(N006) H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 SWITCHES, CUMMINS QSB 3.3L DIESEL
(H135FT, H155FT, H155FTS, H170FTS) (P006)
ENGINE
equipped with a GM 4.3L LPG engine to replace the
following LPG fuel sensors and switches NOTE: The Cummins QSB 3.3L diesel engine is
used only on lift truck models H8.0FT, H8.0FT9,
• Low pressure switch
H9.0FT (C299) and H170-190FT, H175FT36
• Low fuel sensor (D299) .
• Oxygen sensors
• LP vapor sensor Air Filter Restriction Switch
NOTE: The air filter restriction switch is an
ENGINE AND FUEL SENSORS AND optional feature on these lift trucks and is a part of
SWITCHES, PSI 4.3L LPG ENGINE the Electronic Monitoring package option.
See High Voltage Switch (HVS) Ignition manual
Remove
listed in the General section of this manual to
replace the following engine sensors and switches 1. Remove the floor mat and floor plate for access
used on PSI 4.3L LPG engine to the battery. Disconnect the battery.
• Crankshaft Position (CKP) sensor
2. Disconnect the electrical connector from air
• Camshaft Position (CMP) sensor filter restriction switch.
• Oil pressure sensor
3. Remove air filter restriction switch from air
• Manifold Absolute Pressure (MAP) sensor
cleaner. See Figure 32.
• Manifold Air Temperature (MAT) sensor
• Engine Coolant Temperature (ECT) sensor Install
• Air flow restriction switch 1. Install new air filter restriction switch onto air
See LPG Fuel System manual listed in the cleaner. See Figure 32.
General section of this manual to replace the
2. Connect air filter electrical connector.
following LPG fuel sensors and switches
• Low pressure switch 3. Connect the battery, install the floor plate and
• Low fuel sensor floor mat.
• Oxygen sensors

39
Sensors and Switches 2200 SRM 1954

1. AIR FILTER RESTRICTION SWITCH 5. FUEL/WATER SEPARATOR DRAIN PLUG

2. ENGINE COOLANT TEMPERATURE SENSOR 6. ENGINE SPEED SENSOR
3. AIR CLEANER 7. ENGINE OIL PRESSURE SENSOR
4. FUEL/WATER SEPARATOR ELECTRICAL
CONNECTOR AND SENSOR

Figure 32. Cummins QSB 3.3L Diesel Engine Sensors and Switches

Engine Oil Pressure Sensor 2. Connect the electrical connector for the engine
oil pressure sensor. See Figure 32.
Remove
1. Remove the floor mat and floor plate for access 3. Connect the battery, install the floor plate and
to the battery. Disconnect the battery. floor mat.

2. Disconnect the electrical connector from engine Engine Speed Sensor

oil pressure sensor.
Remove
3. Unscrew and remove the oil pressure sensor 1. Remove the floor mat and floor plate for access
from adapter. Adapter does not need to be to the battery. Disconnect the battery.
removed from engine. Discard O-ring. See
Figure 32. 2. Disconnect the electrical connection from
engine speed sensor. See Figure 32.
Install
3. Remove capscrew from engine speed sensor
1. Apply 50 ml (1.7 oz) of Loctite 592™ thread bracket and remove bracket and engine speed
sealant on O-ring. Install new oil pressure sensor.
sensor into adapter. Tighten sensor
9 N•m (80 lbf in).

40
2200 SRM 1954 Sensors and Switches

Install 2. Remove drain plug from bottom of fuel filter

element body and drain water from fuel filter.
1. Install engine speed sensor bracket to engine. See Figure 33.
Tighten capscrew to 7 N•m (62 lbf in). Install
new engine speed sensor onto bracket. See 3. Disconnect fuel/water separator sensor from
Figure 32. harness.
2. Connect electrical connector to engine speed 4. Remove sensor from bottom of fuel filter
sensor. element body. See Figure 33.
3. Connect the battery, install the floor plate and
Install
floor mat.
1. Install new sensor into bottom of fuel filter
Engine Coolant Temperature (ECT) Sensor element body. See Figure 33.

Remove 2. Connect fuel/water separator sensor to harness.

1. Remove the floor mat and floor plate for access
3. Install drain plug and new O-ring into bottom
to the battery. Disconnect the battery.
of fuel filter element body. See Figure 33.
2. Drain the engine coolant from radiator before
4. Connect the battery, install the floor plate and
removing the ECT sensor. Refer to the Cooling
floor mat.
System manual listed in the General section of
this manual for procedures.

3. Disconnect the ECT sensor connector. See

Figure 32.

4. Remove the ECT sensor and packing from the

intake manifold. Discard the O-ring.

Install
1. Install new O-ring onto ECT sensor. Install
new ECT sensor and new packing and tighten
the ECT sensor to 20 N•m (177 lbf in).

2. Connect the ECT sensor connector. See

Figure 32.

3. Refill the radiator with engine coolant after

replacing the ECT sensor. See the Periodic
Maintenance manual listed in the General
section of this manual for procedures and
coolant specifications.

4. Connect the battery, install the floor plate and

floor mat.

Fuel/Water Separator Sensor

Remove
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.

41
Sensors and Switches 2200 SRM 1954

H155FT) (L006) and H6.0FT, H7.0FT, H7.0FTS6,

H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006). H6.0FT, H7.0FT, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS)
(P006).

Engine Coolant Temperature (ECT) Sensor

Remove
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.

2. Drain the engine coolant from radiator before

removing the ECT sensor. Refer to the Cooling
System manual listed in the General section of
this manual for procedures.

3. Disconnect the ECT sensor connector from ECT

sensor. See Figure 34.

4. Remove the ECT sensor and O-ring. Discard

the O-ring.

Install
1. Install new O-ring onto new ECT sensor.

2. Install new ECT sensor. Tighten ECT sensor to

20 N•m (177 lbf in).
1. FUEL FILTER ELEMENT BODY
2. DRAIN PLUG 3. Connect the ECT sensor connector. See
3. ELECTRICAL CONNECTOR
4. FUEL/WATER SEPARATOR SENSOR Figure 34.
5. FUEL FILTER
4. Refill the radiator with engine coolant after
Figure 33. Fuel/Water Separator Sensor, Cummins replacing the ECT sensor. See the Periodic
QSB 3.3L Diesel Engine Maintenance manual listed in the General
section of this manual for procedures and
ENGINE AND FUEL SENSORS AND coolant specifications.
SWITCHES, KUBOTA 3.6L DIESEL 5. Connect the battery, install the floor plate and
ENGINE floor mat.
NOTE: The Kubota 3.6L diesel engine is used only
on lift truck models H6.0FT, H7.0FT (H135FT,

42
2200 SRM 1954 Sensors and Switches

A. RIGHT SIDE OF ENGINE B. LEFT SIDE OF ENGINE

1. ENGINE COOLANT TEMPERATURE (ECT) 3. FUEL SHUT OFF SOLENOID

SENSOR 4. SOCKET HEAD BOLTS
2. ENGINE OIL PRESSURE SENSOR

Figure 34. Kubota 3.6L Diesel Engine Sensors and Switches

Throttle Position Sensor Install

For procedures to remove and install the throttle 1. Lubricate new O-ring with multipurpose
position sensor, see the Kubota 3.6L Diesel grease, and install on engine oil pressure
Engine manual listed in the General section of this sensor.
manual.
2. Apply 50 ml (1.7 oz) of Loctite 592™ thread
Engine Oil Pressure Sensor sealant on O-ring. Install new oil pressure
sensor into adapter. Tighten sensor
Remove 9 N•m (80 lbf in).
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery. 3. Connect electrical connector for engine oil
pressure sensor. See Figure 34.
2. Disconnect electrical connector from oil
pressure sensor. 4. Connect the battery, install the floor plate and
floor mat.
3. Unscrew and remove oil pressure sensor and O-
ring from adapter. Discard O-ring. See Fuel Shut Off Solenoid
Figure 34.
Remove
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.

43
Sensors and Switches 2200 SRM 1954

2. Disconnect electrical connector from fuel shut 4. Connect the battery, install the floor plate and
off solenoid. See Figure 34. floor mat.

3. Remove two socket head bolts from fuel shut off ENGINE AND FUEL SENSORS AND
solenoid. See Figure 34. SWITCHES, KUBOTA 3.8L DIESEL
4. Remove fuel shut off solenoid and O-ring. ENGINE WITH DIESEL PARTICULATE
Discard O-ring. FILTER (DPF) AND KUBOTA 3.8L (TIER 4)
55KW DIESEL ENGINE, WITH DIESEL
Install OXIDATION CATALYST (DOC)
1. Lubricate new O-ring with multipurpose grease See Figure 35 for the location of engine sensors and
and install onto new fuel shut off solenoid. switches for the Kubota 3.8L diesel engine equipped
with either a DPF or DOC.
2. Install fuel shut off solenoid. See Figure 34.

3. Install two socket head bolts into fuel shut off

solenoid. See Figure 34.

44
2200 SRM 1954 Sensors and Switches

NOTE: KUBOTA 3.8L DIESEL ENGINE WITH THROTTLE VALVE ASSEMBLY SHOWN. KUBOTA 3.8L DIESEL
ENGINE WITHOUT THROTTLE VALVE ASSEMBLY SIMILAR.

A. LEFT SIDE B. RIGHT SIDE

1. CRANKSHAFT POSITION SENSOR 6. BOOST SENSOR

2. ENGINE OIL PRESSURE SENSOR 7. THROTTLE VALVE ASSEMBLY
3. CAMSHAFT POSITION SENSOR 8. EGR VALVE LIFT SENSOR
4. ENGINE COOLANT TEMPERATURE (ECT) 9. FUEL RAIL PRESSURE SENSOR
SENSOR
5. INTAKE AIR TEMPERATURE SENSOR

Figure 35. Kubota 3.8L Diesel Engine With DPF and DOC Sensors and Switches

Intake Air Temperature Sensor Install

Remove 1. Install new gasket and new intake air
temperature sensor into air intake housing.
1. Remove the floor mat and floor plate for access Tighten to 16 to 23 N•m (12 to 17 lbf ft). See
to the battery. Disconnect the battery. Figure 36 or Figure 37
2. Disconnect electrical connector from intake air 2. Connect intake air temperature sensor
temperature sensor. electrical sensor.
3. Remove intake air temperature sensor and 3. Connect the battery, install the floor plate and
gasket from intake air intake housing. Discard floor mat.
gasket. See Figure 36 or Figure 37.

45
Sensors and Switches 2200 SRM 1954

Boost Sensor Install

Remove 1. Install new boost sensor onto air intake
housing. See Figure 36 or Figure 37.
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery. 2. Install two capscrews to boost sensor. Tighten
capscrews to 30 to 39 N•m (22 to 28 lbf ft).
2. Disconnect electrical connector from boost
sensor. 3. Install hose and two hose clamps to boost
sensor and air intake housing. See Figure 36 or
3. Remove two hose clamps and hose from boost Figure 37.
sensor and air intake housing. See Figure 36 or
Figure 37. 4. Connect electrical connector to boost sensor.
4. Remove two capscrews from boost sensor. 5. Connect the battery, install the floor plate and
floor mat.
5. Remove boost sensor from air intake housing.
See Figure 36 or Figure 37.

1. BOOST SENSOR 8. FLANGE NUTS

2. CAPSCREW 9. FLANGE BOLTS
3. CLAMP 10. THROTTLE VALVE ASSEMBLY
4. HOSE 11. STUD
5. INTAKE AIR TEMPERATURE SENSOR 12. AIR INTAKE HEATER
6. GASKET 13. INTAKE MANIFOLD
7. AIR INTAKE HOUSING 14. AIR HEATER TERMINAL NUTS

Figure 36. Air Intake Housing and Throttle Valve Assembly

46
2200 SRM 1954 Sensors and Switches

1. BOOST SENSOR 7. GASKET

2. CAPSCREW 8. AIR INTAKE HOUSING
3. CLAMP 9. FLANGE BOLT
4. HOSE 10. INTAKE AIR TEMPERATURE SENSOR
5. BOOST SENSOR BRACKET 11. AIR INTAKE ADAPTER
6. HOSE FITTING 12. AIR INTAKE HEATER

Figure 37. Air Intake Housing without Throttle Valve Assembly

Throttle Valve Assembly, Air Intake 3. Disconnect electrical connections from air
Adapterand Air Intake Heater intake heater terminal nuts. See Figure 36 or
Figure 37.
Remove
NOTE: Perform Step 4 on lift trucks equipped with
1. Remove the floor mat and floor plate for access
throttle valve assembly.
to the battery. Disconnect the battery.
4. Remove two flange nuts and two flange bolts
2. Disconnect electrical connector from air intake from air intake housing. See Figure 36.
sensor and boost sensor.
NOTE: Perform Step 5 on lift trucks not equipped
with throttle valve assembly.

47
Sensors and Switches 2200 SRM 1954

5. Remove four flange bolts from air intake 8. Connect electrical connectors to air intake
housing. See Figure 37. heater terminal nuts. Torque nuts to
4 to 5 N•m (35 to 44 lbf in). See Figure 36 or
6. Remove air intake housing and gasket from Figure 37.
throttle valve assembly. Discard gasket. See
Figure 36 or Figure 37. 9. Connect electrical connectors to boost sensor
and air temperature sensor.
7. Remove throttle valve assembly or air intake
adapter and gasket from air intake heater. 10. Connect the battery, install the floor plate and
Discard gasket. See Figure 36 or Figure 37. floor mat.

8. Remove air intake heater and gasket from Engine Coolant Temperature (ECT) Sensor
intake manifold. Discard gasket. See Figure 36
or Figure 37. Remove
1. Remove the floor mat and floor plate for access
9. Remove two studs from intake manifold. See to the battery. Disconnect the battery.
Figure 36.
2. Drain engine coolant from radiator before
Install removing ECT sensor. Refer to the Cooling
NOTE: If throttle valve assembly, air intake System manual listed in the General section
adapter, or air intake heater have been identified as for procedures.
faulty, replace with new one.
3. Disconnect the ECT sensor electrical connector
1. Install two studs into intake manifold. See from the ECT sensor. See Figure 35.
Figure 36.
4. Remove the ECT sensor and O-ring. Discard O-
2. Install new gasket and air intake heater onto ring.
studs and intake manifold.
Install
NOTE: Perform Step 3 through Step 6 on lift trucks
equipped with throttle valve assembly. 1. Install new O-ring onto new ECT sensor.
3. Install new gasket and throttle valve assembly 2. Install ECT sensor. Tighten sensor to
onto two studs and air intake heater. See 16 to 23 N•m (12 to 17 lbf ft).
Figure 36.
3. Connect ECT sensor connector. See Figure 35.
4. Install new gasket and air intake housing onto
two studs and throttle valve assembly. 4. Refill the radiator with engine coolant. See the
Periodic Maintenance manual listed in the
5. Install two flange bolts through air intake General section of this manual for coolant
housing, throttle valve assembly and air intake specification and procedures.
heater into intake manifold. See Figure 36.
5. Connect the battery, install the floor plate and
6. Install two flange nuts onto two studs at air floor mat.
intake housing.
Engine Oil Pressure Sensor
NOTE: Perform Step 7 on lift trucks not equipped
with throttle valve assembly. Remove
7. Using four flange bolts, install air intake 1. Remove the floor mat and floor plate for access
housing, new gasket, air intake adapter, new to the battery. Disconnect the battery.
gasket, air intake heater and a new gasket onto
intake manifold. See Figure 37. 2. Disconnect electrical connector from oil
pressure sensor.

48
2200 SRM 1954 Sensors and Switches

3. Unscrew and remove oil pressure sensor and O- 4. Install crankshaft position sensor mounting
ring from adapter. Discard O-ring. See capscrew. Tighten capscrew to
Figure 35. 4 to 5 N•m (35 to 45 lbf in).

Install 5. Connect crankshaft position sensor electrical

connector to crankshaft position sensor.
1. Lubricate new O-ring with multipurpose
grease, and install onto engine oil pressure 6. Connect the battery, install the floor plate and
sensor. floor mat.
2. Apply thread locker to threads of oil pressure
sensor. Install oil pressure sensor into adapter.
Tighten to 15 to 19 N•m (11 to 14 lbf ft). See
Figure 35.

3. Connect electrical connector for oil pressure

sensor.

4. Connect the battery, install the floor plate and

floor mat.

Crankshaft Position Sensor

Remove
1. Remove the floor mat and floor plate for access
1. PULSAR GEAR
to the battery. Disconnect the battery. 2. AIR GAP
3. SHIM
2. Disconnect crankshaft position sensor electrical 4. CRANKSHAFT POSITION SENSOR
connector from the crankshaft position sensor. 5. GEAR CASE
See Figure 35. 6. SHIM 0.25 mm (0.0098 in.)
7. SHIM 0.50 mm (0.0200 in.)
8. SHIM 1.00 mm (0.0394 in.)
3. Remove crankshaft position sensor mounting
capscrew. Figure 38. Crankshaft Position Sensor Air Gap
4. Remove crankshaft position sensor and O-ring.
Discard O-ring.
Adjust Shim Procedure
NOTE: This procedure uses special tools JIG 1 and
Install JIG 2 or a combination tool Hyster P/N 4047774 .
Where JIG 1 or JIG 2 is specified the combination
1. Lubricate new O-ring with multipurpose
tool may be used instead. See section Special Tools
grease. Install O-ring on new crankshaft
in this manual for additional tool information.
position sensor. See Figure 38.
1. Align TC mark of flywheel with flywheel
NOTE: An air gap of housing timing window. See the Kubota 3.8L
0.25 to 1.4 mm (0.0098 to 0.055 in.) is needed Diesel Engine manual listed in the General
between the crankshaft position sensor and the section of this manual. The procedures can be
pulsar gear. The air gap is achieved by using shims found in the Fuel System Repair section in the
shown in Figure 38 and procedure outlined in Kubota manual.
Adjust Shim Procedure.
2. Install measurement JIG 1 into sensor
2. Add the appropriate amount of air gap by
mounting position. See Figure 39.
adding shims to the crankshaft position sensor.
See Figure 38. 3. Set dial gauge at measurement JIG 2, then
measure protrusion of JIG 1. See Figure 40 and
3. Install crankshaft position sensor. See
Figure 41.
Figure 35.

49
Sensors and Switches 2200 SRM 1954

4. Use the protrusion measurement for the proper

shim combination required to set the air gap.
See Table 1.

1. JIG 1
2. PROTRUSION
3. GEAR CASE
4. PULSE GEAR
1. MEASUREMENT JIG 1 Figure 41. Protrusion Measurement
Figure 39. Measurement JIG 1

1. MEASUREMENT JIG 2
2. DIAL GAUGE

Figure 40. Measurement JIG 2

50
2200 SRM 1954 Sensors and Switches

Table 1. Adjustment Shim Combinations

Protrusion Thickness and Number of Shims
0.25 mm (0.0098 in.) 0.50 mm (0.020 in.) 1.00 mm (0.0394 in.)
2.25 to 2.50 mm 1 2
(0.0886 to 0.0984 in.)
2.00 to 2.25 mm 2
(0.01788 to 0.0885 in.)
1.75 to 2.00 mm 1 1 1
(0.0689 to 0.0787 in.)
1.50 to 1.75 mm 1 1
(0.0591 to 0.0688 in.)
1.25 to 1.50 mm 1 1
(0.0493 to 0.0590 in.)
1.00 to 1.25 mm 1
(0.0394 to 0.0492 in.)
0.750 to 1.00 mm 1 1
(0.0296 to 0.0393 in.)
0.500 to 0.750 mm 1
(0.0197 to 0.0295 in.)
0.250 to 0.500 mm 1
(0.00985 to 0.0196 in.)

Camshaft Position Sensor 4. Connect camshaft position sensor electrical

connector to camshaft position sensor.
Remove
1. Remove the floor mat and floor plate for access 5. Connect the battery, install the floor plate and
to the battery. Disconnect the battery. floor mat.

2. Disconnect camshaft position sensor electrical Differential Pressure Sensor

connector from camshaft position sensor. See NOTE: Only the Kubota 3.8L diesel engine with
Figure 35. DPF is equipped with a differential pressure sensor.
The differential pressure sensor is located on the
3. Remove camshaft position sensor mounting Diesel Particulate Filter (DPF) which is mounted in
capscrew. the engine compartment on the right rear plate. See
Figure 42.
4. Remove camshaft position sensor and O-ring.
Discard O-ring.
Remove
Install 1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.
1. Lubricate new O-ring with multipurpose
grease. Install O-ring on new camshaft position 2. Disconnect electrical connector from
sensor. See Figure 35. differential pressure sensor.
2. Install camshaft position sensor. 3. Remove two clamps and two hoses from bottom
of differential pressure sensor. See Figure 42.
3. Install camshaft position sensor mounting
capscrew. Tighten to 4. Remove two capscrews and differential
4 to 5 N•m (35 to 45 lbf in). pressure sensor from bracket. See Figure 42.

51
Sensors and Switches 2200 SRM 1954

Install Oxygen Sensors (Inlet and Outlet)

1. Using two capscrews, install new differential Only the Kubota 3.8L diesel engine with DPF is
pressure sensor onto bracket. See Figure 42. equipped with oxygen sensors. The oxygen sensors
are located on the catalytic converter. See Figure 43.
2. Connect electrical connector to differential
pressure sensor. Remove
3. Install two hoses and two clamps onto bottom 1. Remove the floor mat and floor plate for access
of sensor. See Figure 42. to the battery. Disconnect the battery.

4. Connect the battery, install the floor plate and 2. Raise the hood for access to the catalytic
floor mat. converter. See the Frame manual listed in the
General section of this manual for procedures.

3. Disconnect each oxygen sensor electrical

connector from engine wire harness. See
Figure 43.

4. Using a special tool, an oxygen sensor socket

(see Figure 44), remove oxygen sensor.

1. DIFFERENTIAL PRESSURE SENSOR

2. BRACKET
3. CAPSCREW
4. CLAMP
5. HOSE

Figure 42. Differential Pressure Sensor

52
2200 SRM 1954 Sensors and Switches

1. DIESEL PARTICULATE FILTER (DPF) 5. INLET OXYGEN SENSOR

2. RIGHT REAR PLATE 6. INLET TEMPERATURE SENSOR
3. CATALYTIC CONVERTER 7. SENSOR ELECTRICAL CONNECTORS
4. OUTLET OXYGEN SENSOR

Figure 43. DPF Location and Catalytic Converter Sensors

Install
1. Before installing new oxygen sensors, coat each
sensor sparingly with an antiseize compound,
then install oxygen sensor into the inlet and
outlet pipes on the catalytic converter. See
Figure 43. Using a special tool, an oxygen
sensor socket (see Figure 44), tighten sensor to
40 to 60 N•m (30 to 44 lbf ft).

2. Connect the electrical connectors to engine wire

harness. Verify that the connectors click/lock
into place. See Figure 43.

3. Close the hood.

4. Connect the battery and install floor plate and Figure 44. Oxygen Sensor Socket
floor mat.
Inlet Temperature Sensor
Only the Kubota 3.8L diesel engine with DPF is
equipped with an inlet temperature sensor. The

53
Sensors and Switches 2200 SRM 1954

inlet temperature sensor is located on the catalytic

converter. See Figure 43.

Remove
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.

2. Raise the hood for access to the catalytic

converter. See the Frame manual listed in the
General section of this manual for procedures.

3. Disconnect inlet temperature sensor electrical

connector from engine wire harness. See
Figure 43.

4. Remove inlet temperature sensor from catalytic

converter. See Figure 43.

Install
1. Install new inlet temperature sensor into
catalytic converter. See Figure 43.
1. MASS AIR FLOW SENSOR
2. CAPSCREW
2. Connect inlet temperature sensor connector to
engine wire harness. See Figure 43. Figure 45. Mass Air Flow Sensor

3. Close the hood. Fuel/Water Separator

4. Connect the battery and install floor plate and Remove
floor mat.
1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.
Mass Air Flow Sensor
Remove
Remove the floor mat and floor plate for access
CAUTION
1.
to the battery. Disconnect the battery. Disposal of lubricants and fluids must meet local
environmental regulations.
2. Disconnect mass air flow sensor electrical
2. Attach a small hose to hose barb on drain valve
connector.
at bottom of fuel filter element and route hose
3. Remove two capscrews and mass air flow into a suitable container to collect fuel and
sensor. See Figure 45. contaminants.

3. Open drain valve. See Figure 46.

Install
1. Install new mass air flow restriction sensor and 4. Disconnect electrical connector.
two capscrews. See Figure 45.
5. Once all fuel and contaminants have been
2. Connect electrical connector for mass air flow drained from fuel filter element housing,
sensor. remove drain hose.

3. Connect the battery and install floor plate and 6. Remove fuel filter element housing. See
floor mat. Figure 46.

54
2200 SRM 1954 Sensors and Switches

5. Connect the battery and install floor plate and

CAUTION floor mat.
DO NOT over tighten the vice. If over tightening of
the vice occurs, the fuel filter element housing will Air Filter Restriction Switch
become misshapen and not seal correctly. NOTE: The air filter restriction switch is an
optional feature on these lift trucks and is a part of
7. Place fuel filter element housing in soft jawed the Electronic Monitoring package option.
vice.

NOTE: The fuel/water sensor, drain, and electrical

Remove
connection are one piece and will be removed as an 1. Remove the floor mat and floor plate for access
assembly. to the battery. Disconnect the battery.
8. Remove fuel/water sensor, drain, and electrical
2. Disconnect engine wire harness from air filter
connection from fuel filter housing.
restriction switch.

3. Remove air filter restriction switch from air

filter. See Figure 47.

Install
1. Install new air filter restriction switch into
elbow on air filter. Tighten air filter restriction
switch two to three turns past finger tight. See
Figure 47.

2. Connect engine wire harness to air filter

restriction switch.

3. Connect the battery and install floor plate and

floor mat.

1. FUEL FILTER ELEMENT HOUSING

2. FUEL/WATER SENSOR ASSEMBLY
3. DRAIN VALVE
4. ELECTRICAL CONNECTOR

Figure 46. Fuel/Water Separator

Install
1. Install new fuel/water sensor assembly into
fuel filter element housing and tighten one half
turn past hand tight.

2. Install fuel filter element housing to casting

mounted on engine. See Figure 46.
1. AIR FILTER RESTRICTION SWITCH
3. Tighten housing one quarter turn past hand 2. CLEAN AIR HOSE
tight. 3. DIRTY AIR HOSE
4. AIR FILTER ASSEMBLY
4. Connect electrical connector. See Figure 46.
Figure 47. Air Filter Restriction Switch

55
Vehicle System Manager (VSM) 2200 SRM 1954

Vehicle System Manager (VSM)

GENERAL 5. Remove the three bolts securing the VSM and
harness bracket to the cowl. Remove VSM from
The Vehicle System Manager (VSM) is a lift truck cowl. See Figure 48.
microprocessor- powered controller which controls
or monitors, directly or indirectly, every electrical
Install
device on the lift truck, except for the Electronic
Control Module (ECM) and the Governor Control 1. Install VSM and harness bracket onto lift truck
Unit (GCU). These devices are controlled by the cowl with three bolts. Tighten bolts to
engine. 19 N•m (168 lbf in). See Figure 48.

VSM REPLACEMENT 2. Connect all electrical connections to the VSM.

The connectors are color coded for easy
NOTE: The VSM is not a serviceable part. If the connection. See Figure 48.
VSM malfunctions, replace with a new VSM. See
the Parts Manual for replacement part number. 3. Install the dash and kick panel. See the section
Dash and Kick Panel, Remove and Install for
Remove procedures.
1. To access the battery, remove the floor mat and
4. Install the upper steering column cover. See
floor plate. Disconnect the battery.
the section Steering Column Repair for
2. Fully lower the steering column and remove installation procedures.
the upper steering column cover. See the
5. Connect the battery and install floor plate and
section Steering Column Repair for removal
floor mat.
procedures.

3. Remove the dash and kick panel. See the

section Dash and Kick Panel, Remove and
Install for procedures.

4. Disconnect all electrical connections from the

VSM. These connections include the chassis
harness, cowl harness, and electronic hydraulic
(e-hydraulic) controls, if lift truck is equipped
with this feature. See Figure 48.

56
2200 SRM 1954 Vehicle System Manager (VSM)

1. BOLTS 4. CHASSIS HARNESS

2. COWL HARNESS 5. COWL
3. E-HYDRAULIC HARNESS 6. VSM

Figure 48. Vehicle System Manager

PROGRAMMING A NEW VSM AND/OR • Configuration Data File (CDF) - This file
contains a unique set of data values that
DISPLAY SWITCH CLUSTER represent how a truck is equipped, how
NOTE: See the Diagnostic Troubleshooting systems are controlled, and what options are
Manual listed in the General of this manual, for enabled. The CDF is also linked and unique to
information on how delete and reset fault codes to the truck serial number. An example of a lift
the VSM, how to use the PC Service Tool software, truck serial number is G001V12345A001. The
first 11 characters (G001V12345A001)
and for the procedures to troubleshoot the VSM,
represent the truck’s serial number and the
Display Switch Cluster, and other electrical last 3 digits (001) represent the CDF revision
components used on these trucks. loaded on the truck. The serial number of a
NOTE: When installing a new VSM or Display use lift truck is stored in the display panel. See
PC Service Tool to upload Application Code and the User Interface Service Technician
correct Configuration Data File. manual listed in the General section of this
manual for the procedures to find the serial
Two file types are required to operate the VSM; number. The CDF can be found online at
Application Code File and Configuration Data File Hypass Online® using the serial number.
(CDF). New VSMs will have the Application Code The CDF revision will change every time a
loaded but you will need to upload a truck specific new version is ordered and transferred to
CDF. Hypass Online® . The CDF cannot be
modified by a service technician. However, a
• Application Code File - These are operating
replacement file (with alternate options
files for the VSM and Display.
[SEF]) can be loaded into a truck VSM by a
service technician.

57
Vehicle System Manager (VSM) 2200 SRM 1954

Data Transferring automatically upload the Operating Data and CDF

to the Display Switch Cluster using the PC Service
New VSM Tool software. If the PC Service Tool is not used
NOTE: Data transfer to a used VSM is not possible. there will be a mismatch. See Table 2.
Only a new VSM can be used.
Used (Non-Blank) Display Switch Cluster
If the VSM is being replaced, the lift truck's CDF
and Operating Data files must be retrieved from the If the replacement Display Switch Cluster has been
Display Switch Cluster using the PC Service Tool used on another truck, the PC Service Tool software
software or the data will be overwritten. This also must be used to perform the data copying sequence
includes the truck hourmeters. See Table 2. discussed in New (Blank) Display Switch Cluster.
Detailed instructions can be found in the PC Service See Table 2.
Tool (PCST) Truck Reprogramming Guide. Depending on the part being replaced and the tools
available, different methods of transferring the
New (Blank) Display Switch Cluster needed data exist. Refer to Table 2 for the best
If the Display Switch Cluster is being replaced with method to use to transfer data based on the tools
a new (blank) display, the PC Service Tool software available.
will match the VSM to the display. The VSM will

Table 2. VSM and Display Switch Cluster Replacement

Repair Location Conditions
PC Not Available PC Available, No PC and Internet
Internet Available
Field Repair VSM Replaced, Not allowed - PC Read back up CDF Read back up
Original Display required from Display, Display, download
Intact download into new into new VSM
VSM
VSM and Display Not allowed - PC Not allowed - PC Read back up CDF
Replaced and Internet and Internet from Hypass Online,
required required download into new
VSM, new blank
display auto
updated after
installation
Display Replaced New blank display New blank display New blank display
With New Blank auto updated after auto updated after auto updated after
Display installation installation installation
Display Replaced Not allowed - PC PC Service Tool PC Service Tool
With Previously required enables over write of enables over write of
Used Display old CDF in display old CDF in display

58
2200 SRM 1954 Vehicle System Manager (VSM)

PC SERVICE TOOL SOFTWARE

The PC Service Tool software is not used to transfer
backup copies whenever a new VSM or display
panel is installed on a lift truck. Backup copies are
generated automatically when the system detects
that a blank (new) VSM or display panel has been
installed.
A non-blank VSM or display panel is one that has
been used previously. A non-blank VSM or display
panel is not usable outside of the system it was
originally connected to. In other words, a VSM or
display panel cannot be removed from one lift truck
and installed onto another lift truck. If a VSM or
display panel must be replaced, a new part (blank)
must be used. See the Parts Manual for part
numbers for replacement parts.
To connect the PC Service Tool, remove the plug
that covers the PC service tool diagnostic connector
on the right side of the steering column and connect
the interface cable (Hyster P/N 1534010) to the PC
service tool diagnostic connector. See Figure 49. For
minimum PC requirements to run the software,
refer to the PC Service Tool Installation and User
Guide, Systems Requirements section.

1. STEERING COLUMN
2. PC SERVICE TOOL DIAGNOSTIC CONNECTOR

Figure 49. Connecting PC Service Tool

59
Power Distribution Module (PDM) and Component Parts 2200 SRM 1954

Power Distribution Module (PDM) and Component Parts

REMOVE
1. Remove the floor mat and floor plate and
PDM as a Unit disconnect the battery.
NOTE: The PDM as a unit, is not a serviceable
2. Disconnect the chassis harness from the main
part. The component parts of the PDM (relays,
power connection terminals on the PDM.
fuses, and resistors), can be replaced without
replacing the PDM. If the PDM malfunctions,
3. Remove bolts and PDM from PDM mounting
replace with a new PDM. See the Parts Manual for
bracket. See Figure 50.
replacement part number.

1. BATTERY 4. CHASSIS HARNESS

2. BATTERY CONNECTIONS 5. BOLTS
3. MAIN POWER TERMINALS 6. PDM

Figure 50. PDM Removal and Installation

60
2200 SRM 1954 Power Distribution Module (PDM) and Component Parts

INSTALL
PDM as a Unit
1. For lift truck models below, install PDM and
bolts onto PDM mounting bracket. Tighten
bolts to 8 N•m (71 lbf in). See Figure 50.

2. Connect the chassis harness to the main power

connection terminals on the PDM.

3. Connect the lift truck battery.

4. Install floor plate and floor mat.

REMOVE AND INSTALL

PDM Component Parts
1. RESISTOR (68 OHM)
If lift truck is equipped with a key switch, turn key 2. START RELAY
to ON position. If lift truck is equipped with a 3. STARTER (30 AMP)
Power ON/OFF button, press button to turn system 4. IGNITION 3 RELAY
power ON. Check all indicator lights for correct 5. BACKUP RELAY
operation as described in the Operating Manual. 6. BACKUP (20 AMP)
7. IGNITION (30 AMP)
Check the operation of the horn. Start the engine by 8. SPARE FUEL PUMP (20 AMP)
turning the key switch to the Start position, if truck 9. SPARE FUEL PUMP RELAY
is equipped with a key switch, or press the Power 10. BATTERY (20 AMP)
ON/OFF button, if lift truck is equipped with this 11. FRONT WORK LIGHT (20 AMP)
button. If any indicator lights do not operate 12. FRONT/REAR WORK LIGHT RELAYS
13. BATTERY (25 AMP)
correctly, check the fuses. See Figure 51. The fuses 14. REAR WORK LIGHT (20 AMP)
are located in the Power Distribution Module 15. IGNITION 1 (20 AMP)
(PDM). See Figure 50. 16. IGNITION 1 RELAY
17. BATTERY (25 AMP)
18. TRANSZORB

Figure 51. PDM Component Parts

61
Transmission Control Unit (TCU) 2200 SRM 1954

Transmission Control Unit (TCU)

LIFT TRUCKS EQUIPPED WITH A 3- aid in connecting transmission harness connectors
SPEED TRANSMISSION AND correctly during installation.
MANUFACTURED BEFORE DECEMBER, 2. Disconnect transmission harness connectors
2018 from TCU. See Figure 52.

Remove 3. Remove four flange capscrews from bracket and

TCU. See Figure 52.
WARNING 4. Remove TCU from bracket.
Always disconnect the cables at the battery before
disconnecting the transmission control unit (TCU). 5. If the TCU is being replaced, remove old
Disconnect the cable at the negative terminal first. mounting bracket and TCU cover from front
side plate by removing flange capscrew and
1. Remove floor mat and floor plate and foldover nut from plate. See Figure 53.
disconnect the battery.

NOTE: When disconnecting transmission harness

connectors during removal, tag each connector to

1. FLANGE CAPSCREWS 4. TRANSMISSION HARNESS CONNECTOR

2. TRANSMISSION CONTROL UNIT (TCU) (CRP128)
3. TRANSMISSION HARNESS CONNECTOR 5. BRACKET
(CRP129)

Figure 52. Transmission Control Unit, Lift Trucks Manufactured Before December, 2018

62
2200 SRM 1954 Transmission Control Unit (TCU)

Legend for Figure 53.

1. CAPSCREW
2. MOUNTING BRACKET
3. FRONT SIDE PLATE
4. PLATE
5. FOLDOVER NUT
6. TCU COVER

Install
1. If TCU is being replaced with a new TCU,
(Hyster kit, P/N 4239657), install new
mounting bracket to front side plate using
flange capscrew and foldover nut. See
Figure 53.

2. Install TCU onto bracket using four flange

capscrews. See Figure 52.

3. Connect transmission harness connectors to

Figure 53. TCU Mounting Brackets TCU as tagged during removal. See Figure 52.

4. If the TCU was replaced with TCU shown in

Figure 52 using (Hyster kit, P/N 4239657),
replace two 5.0 amp fuses with two 7.5 amp
fuses and replace label on fuse covers. See
Figure 54.

63
Transmission Control Unit (TCU) 2200 SRM 1954

1. FUSE COVER (7.5 AMP) 4. TRANSMISSION WIRE HARNESS

2. FUSE LABEL 5. TRANSMISSION OIL FILTER
3. RIGHT CHASSIS WIRE HARNESS

Figure 54. TCU Fuse and Label Replacement

5. Connect battery and install floor plate and floor

1. Remove floor mat and floor plate and
mat.
disconnect the battery.
6. Calibrate the transmission. See Calibration
NOTE: When disconnecting transmission harness
Procedures 8000SRM1134 for procedures.
connectors during removal, tag each connector to
aid in connecting transmission harness connectors
LIFT TRUCKS EQUIPPED WITH A 3- correctly during installation.
SPEED TRANSMISSION AND
2. Disconnect transmission harness connectors
MANUFACTURED BETWEEN DECEMBER, from TCU. See Figure 55.
2018 AND JULY, 2021
3. Remove three flange capscrews and foldover
Remove nuts from mounting bracket and TCU. See
Figure 55.
WARNING
Always disconnect the cables at the battery before 4. Remove TCU from bracket.
disconnecting the transmission control unit (TCU).
Disconnect the cable at the negative terminal first.

64
2200 SRM 1954 Transmission Control Unit (TCU)

1. CAPSCREW 5. TRANSMISSION WIRE HARNESS

2. FOLDOVER NUT 6. TRANSMISSION HARNESS CONNECTOR
3. MOUNTING BRACKET (CPS128)
4. TRANSMISSION CONTROL UNIT 7. TRANSMISSION HARNESS CONNECTOR
(CPS129)

Figure 55. Transmission Control Unit, Lift Trucks Manufactured Between December, 2018 and July, 2021

Install LIFT TRUCKS EQUIPPED WITH A 3-

1. Install TCU onto bracket using three flange SPEED TRANSMISSION AND
capscrews and foldover nuts. See Figure 55. MANUFACTURED AFTER JULY, 2021
2. Connect transmission harness connectors to Remove
TCU as tagged during removal. See Figure 55.
WARNING
3. Connect battery and install floor plate and floor
Always disconnect the cables at the battery before
mat.
disconnecting the transmission control unit (TCU).
4. Calibrate the transmission. See Calibration Disconnect the cable at the negative terminal first.
Procedures 8000SRM1134 for procedures.
1. Remove floor mat and floor plate and
disconnect the battery.

NOTE: When disconnecting transmission harness

connectors during removal, tag each connector to
aid in connecting transmission harness connectors
correctly during installation.
2. Disconnect transmission harness connectors
from TCU. See Figure 56.

65
Transmission Control Unit (TCU) 2200 SRM 1954

3. Remove four flange capscrews from bracket and 5. If the TCU is being replaced, remove old
TCU. See Figure 56. mounting bracket and TCU cover from front
side plate by removing flange capscrew and
4. Remove TCU from bracket. foldover nut from plate. See Figure 57.

1. FLANGE CAPSCREWS 4. TRANSMISSION HARNESS CONNECTOR

2. TRANSMISSION CONTROL UNIT (TCU) (CRP128)
3. TRANSMISSION HARNESS CONNECTOR 5. BRACKET
(CRP129)

Figure 56. Transmission Control Unit, Lift Trucks Manufactured After July, 2021

66
2200 SRM 1954 Transmission Control Unit (TCU)

Legend for Figure 57.

1. CAPSCREW
2. MOUNTING BRACKET
3. FRONT SIDE PLATE
4. PLATE
5. FOLDOVER NUT
6. TCU COVER

Install
1. If TCU is being replaced with a new TCU,
using (Hyster kit, P/N 4239657), install new
mounting bracket to front side plate using
flange capscrew and foldover nut. See
Figure 57.

2. Install TCU onto bracket using four flange

capscrews. See Figure 56.

3. Connect transmission harness connectors to

Figure 57. TCU Mounting Brackets TCU as tagged during removal. See Figure 56.

4. If the TCU was replaced with TCU shown in

Figure 56 using (Hyster kit, P/N 4239657),
replace two 5.0 amp fuses with two 7.5 amp
fuses and replace label on fuse covers. See
Figure 58.

67
Transmission Control Unit (TCU) 2200 SRM 1954

1. FUSE COVER (7.5 AMP) 4. TRANSMISSION WIRE HARNESS

2. FUSE LABEL 5. TRANSMISSION OIL FILTER
3. RIGHT CHASSIS WIRE HARNESS

Figure 58. TCU Fuse and Label Replacement

5. Connect battery and install floor plate and floor 6. Calibrate the transmission. See Calibration
mat. Procedures 8000SRM1134 for procedures.

68
2200 SRM 1954 Battery

Battery
REMOVE
1. Remove floor mat and floor plate for access to
battery. Disconnect the battery.

2. Remove the battery lockdown bar securing

battery to battery tray. Remove battery from
lift truck. See Figure 59.

INSTALL
1. Install new battery onto battery tray. Secure
battery to battery tray with battery lockdown
bar. See Figure 59.

2. Connect the battery and install the floor plate

and floor mat.

1. BATTERY
2. BATTERY TRAY
3. BATTERY LOCKDOWN BAR

Figure 59. Battery, Remove/Install

69
Lights 2200 SRM 1954

Lights
NOTE: The lights described in this section are used
on lift truck models equipped with an overhead
guard. If lift truck is equipped with a cab, see the
Operator's Cab manual listed in the General
section of this manual for procedures to remove and
install the lights used on a lift truck equipped with
a cab.

WORK LIGHTS (FRONT AND REAR)

Halogen Bulb Lights
Remove
1. Remove floor mat and floor plate. Disconnect
the battery.

CAUTION
DO NOT touch the Halogen bulb surface or inside
reflectors with your bare hands. Oils from skin can 1. CAPSCREWS (LENS ASSEMBLY)
lead to breakage or shorten the life of the lamp. 2. LENS ASSEMBLY
Use clean gloves or lint free cloth for installation 3. NUT (ATTACHES LIGHT TO OVERHEAD
and removal. GUARD)
Clean any dirt or oil, from the lamp surface with Figure 60. Halogen Bulb Work Lights
alcohol and a lint free cloth or tissue. Any foreign
particles or materials on the bulb surface can LED Lights
cause hot spots on the bulb and result in lamp
failure. NOTE: LED work lights are an optional feature on
lift trucks covered in this service manual. If LED
2. To replace the bulb, remove the lens assembly work light malfunctions, the whole LED work light
by removing the four capscrews. See Figure 60. assembly must be replaced.
Replace the bulb and reinstall the lens
assembly. Remove
1. Remove floor mat and floor plate. Disconnect
3. To replace the work light assembly, disconnect
the battery.
the light from the overhead guard harness and
remove the capscrew, washer, and nut 2. Disconnect overhead guard harness from work
attaching the work light to the overhead guard. light.
See Figure 60.
3. Remove locknut, washer, and capscrew and
Install remove LED work light from overhead guard.
1. Install work light to overhead guard using the See Figure 61.
capscrew, washer, and nut. Tighten nut to
20 N•m (177 lbf in). Connect work light to Install
overhead guard harness. See Figure 60. 1. Install new LED work light assembly by using
capscrew, washer, and locknut. Tighten nut to
2. Connect the battery and install floor plate and 20 N•m (177 lbf in) . See Figure 61.
floor mat.
2. Connect overhead guard harness to work light.

70
2200 SRM 1954 Lights

3. Connect the battery. Install floor plate and 4. If the strobe light bulb needs to be replaced,
floor mat. remove the strobe light lens from base and
remove bulb.

Install
1. If bulb is being replaced, install new bulb into
strobe light base. Install strobe light lens onto
base.

2. Place strobe light assembly and strobe light

guard onto mounting bracket. Install
capscrews, washers, lockwasher, and nuts. See
Figure 62.

3. Connect strobe light electrical connector to

overhead guard harness.

4. Connect the battery and install floor plate and

floor mat.

1. LOCKNUT
2. WASHER
3. CAPSCREW
4. MOUNTING BRACKET
5. LED LIGHT ASSEMBLY

Figure 61. LED Work Lights

STROBE LIGHT
NOTE: The strobe light may either be mounted
above the top of the overhead guard (high-mounted)
or below the top of the overhead guard (low-
mounted). The removal and installation procedures
are the same for both options.

Remove
1. Remove floor mat and floor plate. Disconnect
the battery.

2. Disconnect strobe light electrical connector

from overhead guard harness. See Figure 62.

3. Remove capscrews, washers, lockwasher, and

nuts from strobe light, light guard, and strobe
light mounting bracket. Remove strobe light
and light guard from lift truck.

71
Lights 2200 SRM 1954

Remove
1. Remove floor mat and floor plate. Disconnect
the battery.

2. If lift truck is equipped with a key switch,

remove the key.

3. Remove screw and clip nut securing the LED

light to mounting bracket. Pull LED light
downward to remove it from the mounting
bracket.

4. Disconnect the LED light from the chassis light

harness. See Figure 63.

5. If the mounting bracket must be removed from

the overhead guard leg, remove rear
crossmember cover and remove the mounting
bracket from the overhead guard leg. See
Figure 63.

Install
1. If the mounting bracket was removed, install
the rear crossmember cover. Install mounting
bracket to overhead guard leg.
1. STROBE LIGHT GUARD
2. STROBE LIGHT LENS
3. STROBE LIGHT BULB 2. Connect the LED light to the chassis light
4. LIGHT BASE harness. See Figure 63.
5. NUT
6. LOCKWASHER 3. Insert the screw and install the LED light to
7. WASHER the mounting bracket. See Figure 63.
8. MOUNTING BRACKET
9. CAPSCREW
10. LOCK NUT 4. Connect the battery and install the floor plate
11. ELECTRICAL CONNECTOR and floor mat.

Figure 62. Strobe Light Assembly

LED TAIL, BACKUP, AND BRAKE LIGHTS

NOTE: These light assemblies are nonrepairable
and must be replaced as an assembly. See the Parts
Manual for replacement LED lights.

72
2200 SRM 1954 Lights

1. CHASSIS LIGHT HARNESS 6. SCREW

2. VEHICLE SYSTEM MANAGER 7. CLIP NUT
3. MOUNTING BRACKET 8. CROSSMEMBER
4. REFLEX LENS 9. LED LIGHT HOUSING
5. LED LIGHT LENS 10. INSERT

Figure 63. LED Tail, Backup, and Brake Light Replacement

FRONT MARKER/TURN SIGNAL LIGHTS 3. Remove two bolts located at the top of the front
marker/turn signal light assembly and inside
Replacing Whole Front Marker/Turn Signal the corner of the overhead guard. See
Light Assembly Figure 64.
Remove 4. Remove front marker/turn signal light
1. Remove floor mat and floor plate and assembly from overhead guard and trim.
disconnect the battery.
Install
2. Disconnect light wire harness from front
1. Install new front marker/turn signal light
marker/turn signal light connector. See
assembly to overhead guard and trim using two
Figure 64.
bolts. See Figure 64.

2. Connect light wire harness to front marker/

turn signal light connector.

73
Lights 2200 SRM 1954

3. Connect battery and install floor plate and floor Install

mat.
1. Install new LED light into front marker/turn
signal light assembly using four capscrews. See
Figure 65.

2. Install two caps on each side of LED lens. Push

caps until they snap into place. See Figure 65.

3. Connect battery and install floor plate and floor

mat.

NOTE: RIGHT FRONT MARKER/TURN SIGNAL

LIGHT ASSEMBLY SHOWN. PROCEDURES TO RE-
MOVE AND REPLACE LEFT FRONT MARKER/
TURNS SIGNAL LIGHT ASSEMBLY ARE THE SAME.

1. FRONT MARKER/TURN SIGNAL LIGHT

ASSEMBLY
2. LIGHT WIRE HARNESS
3. BOLT
4. TRIM
5. OVERHEAD GUARD

Figure 64. Front Marker/Turn Signal Light

Assembly Removal

Replacing Just the Front Marker/Turn NOTE: RIGHT LED LENS SHOWN. PROCEDURES
Signal Light LED Light Lens TO REMOVE AND REPLACE LEFT LED LENS ARE
THE SAME.
Remove
1. Remove floor mat and floor plate and 1. FRONT MARKER/TURN SIGNAL LIGHT
disconnect the battery. ASSEMBLY
2. CAPS
2. Use a flat head tool and remove the two caps 3. CAPSCREWS
4. FRONT MARKER/TURN SIGNAL LIGHT
located on each side of the LED lens. See ASSEMBLY CONNECTOR
Figure 65. 5. LED LIGHT

3. Remove the four capscrews securing the LED Figure 65. LED Lens Replace
lens in the front marker/turn signal light
assembly. Remove LED lens from assembly.
See Figure 65.

74
2200 SRM 1954 Electronic-Hydraulic Controls, Before January, 2020

Electronic-Hydraulic Controls, Before January, 2020

NOTE: The information in this section applies to Function Returns to Neutral Test
the electronic-hydraulic controls used on lift truck
models manufactured before January, 2020 Check to confirm function returns to neutral (0%).
Use DSC or install the Service Tool to monitor
functions.
E-HYDRAULIC CONTROLS - TEST
Mini-Levers 1. Stroke each lever to full stroke, forward and
backward, and allow lever to snap back to
Perform all of the following test procedures to be center.
sure mini-levers operate properly.
See the User Interface - Service Technician 2. (DO NOT start). Turn key switch to ON
manual located in the General section of this position.
manual for instructions to view Lever output Value.
With Service Password, view Diagnostics – 3. Display the electro-hydraulic diagnostics menu
Hydraulic Data Display – Hydraulic Input. on the dash display panel.
• Is each lever output = 0%?
Full Stroke Test • YES: Go to Step 4.
Check for full stroke of mini-lever. Use the Display • NO: Mini-lever is not working properly. See
Switch Cluster (DSC) or install the Service Tool to procedures below for repair or replacement.
monitor functions. Upon completion, rerun the test.

1. Stroke each lever to full stroke, forward and 4. Operate each lever to full stroke forward and
backward, and allow lever to snap back to slowly release (1-2 seconds from full stroke).
center. Read output when fully released.
• Is each lever output = 0%?
2. (DO NOT start). Turn key switch to ON
position. • YES: Go to Step 5.
• NO: Mini-lever is not working properly. See
3. Display the electro-hydraulic diagnostics menu procedures below for repair or replacement.
on the dash display panel. Operate each lever Upon completion, rerun the test.
to full stroke forward and read input.
5. Operate each lever to full stroke back and
• Is lever output ≥ -92%?
slowly release (1-2 seconds from full stroke).
• YES: Go to Step 4. Read output when fully released.
• NO: Mini-lever is not working properly. See • Is each lever output = 0%?
procedures below for repair or replacement.
Upon completion, rerun the test. • YES: Mini-lever function is returning to
neutral.
4. Operate each lever to full stroke backward and • NO: Mini-lever is not working properly. See
read input. procedures below for repair or replacement.
Upon completion, rerun the test.
• Is lever output ≥ +92%?
• YES: Mini-lever is supplying full stroke. 6. If mini-lever continues to not function properly,
• NO: Mini-lever is not working properly. See contact your local Hyster dealer or see Hyster
procedures below for repair or replacement. Hypass Online .
Upon completion, rerun the test.
Push (Override) Button Switch
5. If mini-lever continues to not function properly,
1. Validate that push button switch operates
contact your local Hyster dealer or see Hyster
properly by operating applicable function.
Hypass Online .

75
Electronic-Hydraulic Controls, Before January, 2020 2200 SRM 1954

2. If system does not function, see procedures

below for repair or replacement. Upon
completion, rerun the test.

3. If push button switch continues to not function

properly, contact your local Hyster dealer or
see Hyster Hypass Online .

GENERAL

WARNING
Before replacing any part of the electronic
hydraulic control assembly, fully lower all parts of
the mast and tilt it forward until the tips of forks
touch the ground. This action will prevent mast
from lowering suddenly if the control lever is
accidently moved.

1. ARMREST
WARNING 2. TO WIRE HARNESS
Never wear any metallic items on your fingers, 3. HORN BUTTON
4. DIRECTION CONTROL SWITCH
arms, or neck. Metal items can accidently make an 5. MINI-LEVERS
electrical connection and cause an injury. 6. PUSH (OVERRIDE) BUTTON

Figure 66. E-Hydraulic Controls Arrangement

CAUTION
A short circuit and damage can occur if wires are MINI-LEVERS, REMOVE AND INSTALL
not installed correctly. Make sure wire connectors
do not touch other metal terminals or wire CAUTION
connectors, metal brackets, or bracket mounting
The following procedure should only be performed
nuts. Make sure wires are not pulled tight and are
by Hyster trained certified technicians. The
not touching other parts to damage the insulation.
removal and replacement of the mini-levers should
NOTE: Prior to performing the following be done in a clean environment whenever possible
procedures, the E-Hydraulic Controls - TEST must and on an electrically grounded surface. Do not
be performed. touch any printed circuit board (PCB) surface to
prevent damage from electrostatic voltage.
NOTE: The mini-levers do not need to be calibrated.
NOTE: The Direction Control Switch (DCS) is an 1. Remove two capscrews and mini-lever from
optional feature on lift trucks equipped with armrest. See Figure 67.
Electronic-Hydraulic Controls. See Figure 66.
The line of trucks covered in this manual come
standard with manual hydraulic levers, but have
the option of using electronic-hydraulic controls. See
Figure 66. If the Mini-Levers Module (MLM), or
mini-levers malfunction, replace with new part. See
the Parts Manual for replacement parts.

76
2200 SRM 1954 Electronic-Hydraulic Controls, Before January, 2020

Legend for Figure 67.

1. CAPSCREWS
2. MINI-LEVER
3. ARMREST
4. PUSH BUTTON

NOTE: Before installing new mini-lever, check

Parts Manual for correct part number to be sure
correct mini-lever is being installed.
2. Install new mini-lever onto armrest using two
capscrews. See Figure 67.

ARMREST ASSEMBLY
Remove
1. Disconnect the battery.

2. Remove two capscrews and washers from cover

plate and remove seat box. Disconnect the main
E-Hydraulic control wire harness from E-
Hydraulic armrest harness. See Figure 68.

Figure 67. Mini-Lever Removal

77
Electronic-Hydraulic Controls, Before January, 2020 2200 SRM 1954

NOTE: SOME COMPONENT PARTS AND ELECTRICAL CONNECTIONS OMITTED FOR CLARITY.

A. FULL SUSPENSION AND SWIVEL SEATS B. NON SUSPENSION SEATS

1. CAPSCREWS 4. E-HYDRAULIC ARMREST HARNESS

2. WASHERS CONNECTOR
3. SEAT BOX 5. COVER PLATE

Figure 68. Seat Box Cover Removal

3. Pull up on handle (see Figure 69) and slide

armrest all the way forward and remove flange
capscrew from under armrest mounting bracket
that attaches armrest to mounting bracket.
Pull up on handle and slide armrest all the way
back and remove the other flange capscrew. See
Figure 70.

Figure 69. Armrest Adjustment Handles

78
2200 SRM 1954 Electronic-Hydraulic Controls, Before January, 2020

Legend for Figure 69.

A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN

4. Remove armrest from armrest mounting

bracket.

1. SOCKET HEAD SCREWS

2. BOTTOM ARMREST COVER

Figure 71. Bottom Armrest Cover Removal

NOTE: The push button is optional features and lift

truck may be equipped with more than one push
button depending of the number of hydraulic
1. E-HYDRAULIC CONTROL WIRE HARNESS functions on the lift truck. If lift truck is not
2. FLANGE CAPSCREWS equipped with this feature, there will be a plug
3. ARMREST covering the electrical connector on the PCB
4. ARMREST MOUNTING BRACKET
5. HOLES FOR FLANGE CAPSCREWS cassette.
6. Disconnect the push button connector from
Figure 70. E-Hydraulic Armrest and Mounting PCB cassette. See Figure 72.
Bracket
7. Remove three socket screws from PCB cassette
5. Remove six socket head screws that fasten the and remove PCB cassette from armrest. See
bottom and top armrest covers together. See Figure 72.
Figure 71. Remove the bottom armrest cover
from armrest.

79
Electronic-Hydraulic Controls, Before January, 2020 2200 SRM 1954

2. Remove two Phillips head screws that attach

horn button to armrest. See Figure 73. Remove
horn button from armrest.

1. TO E-HYDRAULIC CONTROL WIRE HARNESS

2. SOCKET HEAD SCREWS
3. PCB CASSETTE
4. PUSH BUTTON CONNECTOR

Figure 72. PCB Cassette Removal

Install
1. Install PCB cassette to armrest with three NOTE: PUSH BUTTON CONNECTIONS NOT
socket head screws. See Figure 72. SHOWN FOR CLARITY.

2. If lift truck is equipped, connect the push 1. PHILLIPS HEAD SCREWS

button connector to PCB cassette. See 2. DIRECTION CONTROL SWITCH ADAPTER*
3. HORN BUTTON ADAPTER
Figure 72. 4. PLUG
5. HORN SWITCH
3. Install bottom armrest cover to armrest with 6. DIRECTION CONTROL SWITCH CONNECTOR
six socket head screws. See Figure 72. 7. ARMREST
*Direction Control Switch is an optional feature.
4. Install new armrest onto mounting bracket
with flange capscrews. Tighten flange Figure 73. Switch Arrangement and Connections,
capscrews to 13 to 15 N•m (115 to 132 lbf in). E-Hydraulic Mini-Levers

5. Connect E-hydraulic wire harness to armrest. Install

See Figure 70. Install seat box to cover plate 1. Install new horn switch and two Phillips head
with two capscrews and washers. See screws onto armrest. See Figure 73.
Figure 68. Tighten capscrews to
1.2 N•m (10.6 lbf in). 2. Install armrest and PCB cassette to armrest
and install armrest to armrest mounting
6. Connect the battery. bracket. See the section Armrest Assembly for
installation procedures.
HORN BUTTON
Remove DIRECTION CONTROL SWITCH
1. Remove the armrest from armrest mounting NOTE: The Direction Control Switch (DCS) is an
bracket. Remove bottom armrest and PCB optional feature on lift trucks covered in this
cassette. See section Armrest Assembly for manual that are equipped with electro-hydraulic
removal procedures. controls.

80
2200 SRM 1954 Electronic-Hydraulic Controls, Before January, 2020

Remove 3. Install armrest cover to armrest, and install

armrest to armrest mounting bracket. See
1. Remove armrest from armrest mounting section Armrest Assembly for installation
bracket. Remove bottom armrest cover. See procedures.
section Armrest Assembly for removal
procedures.
PUSH (OVERRIDE) BUTTON
2. Remove Direction Control Switch (DCS) On lift trucks equipped with E-Hydraulic controls,
assembly from armrest by compressing the there may be two optional push (override) button
clips on either side of the bezel and carefully (green buttons) located behind the second, third, or
pulling the assembly out. Disconnect E- fourth mini-lever. See Figure 75. The push button
Hydraulic control wiring harness from the located behind the second mini-lever is used to
Direction Control Switch. See Figure 74. override the Return To Set Tilt (RTST) function. By
pressing this switch, the RTST parameters are
overridden and the mast is allowed to tilt
unrestricted.
If the lift truck is equipped with a clamp
attachment, the last mini-lever on the right controls
the clamp function. Behind this lever will be a push
(override) button. To engage the clamp, move the
mini-lever backward. To disengage the clamp, push
the push (ovrride) button behind the mini-lever and
move mini-lever forward.
The different configurations of push (override)
buttons discussed in this section may not be found
on your lift truck.

1. DIRECTION CONTROL SWITCH

2. BEZEL
3. ARMREST
4. E-HYDRAULIC CONTROL VALVE WIRING
HARNESS

Figure 74. Direction Control Switch Replacement

3. Remove DCS from bezel. See Figure 74.

Install
1. Insert new Direction Control Switch into bezel.
See Figure 74.

2. Connect E-Hydraulic control valve wiring Figure 75. Push (Override) Button Location
harness to the DCS. Install DCS assembly into
armrest by compressing clips on either side of
the bezel and pushing assembly into armrest
until the clips latch. See Figure 74.

81
Electronic-Hydraulic Controls, Before January, 2020 2200 SRM 1954

Legend for Figure 75. NOTE: Tag wires prior to disconnecting them to aid
NOTE: NOT ALL LIFT TRUCKS MAY HAVE ALL in reconnecting.
PUSH (OVERRIDE) BUTTONS SHOWN.
2. Pull push (override) button connectors apart to
disconnect them from wire harness. See
1. MINI-LEVERS
2. PUSH (OVERRIDE) BUTTON (CLAMP) Figure 76.
3. PUSH (OVERRIDE) BUTTON (RTST)
4. BUTTON PLUG 3. If push button is being replaced, remove lock
5. ARMREST HOUSING nut from back of green, round, push button.
Remove push button switch from armrest. See
Remove Figure 76.
1. Remove the armrest from armrest mounting
bracket. Remove bottom armrest and PCB
cassette. See procedures in Armrest Assembly
section above.

1. CLAMP BUTTON (SWITCH) CONNECTION 3. LOCKNUT

2. RTST BUTTON (SWITCH) CONNECTION 4. PUSH (OVERRIDE) BUTTON WIRE HARNESS
AND CONNECTOR

Figure 76. Push (Override) Button Replacement

82
2200 SRM 1954 Electronic-Hydraulic Controls, Before January, 2020

Install 4. Install armrest and PCB cassette to armrest

and install armrest to armrest mounting
1. Install new green, round push button assembly bracket. See the section Armrest Assembly for
through armrest housing. installation procedures.
2. Install and tighten lock nut on push button and 5. Connect the E-hydraulic wire harness to
armrest. See Figure 76. armrest. See Figure 70.
3. Push push button connector to wire harness.
See Figure 76.

83
Electronic-Hydraulic Controls, After January, 2020 2200 SRM 1954

Electronic-Hydraulic Controls, After January, 2020

NOTE: The information in this section applies to Function Returns to Neutral Test
the electronic-hydraulic controls used on lift truck
models manufactured after January, 2020. Check to confirm function returns to neutral (0%).
Use DSC or install the Service Tool to monitor
functions.
E-HYDRAULIC CONTROLS - TEST
Mini-Levers 1. Stroke each lever to full stroke, forward and
backward, and allow lever to snap back to
Perform all of the following test procedures to be center.
sure mini-levers operate properly.
See the User Interface - Service Technician 2. (DO NOT start). Turn key switch to ON
manual located in the General section of this position.
manual for instructions to view Lever output Value.
With Service Password, view Diagnostics – 3. Display the electro-hydraulic diagnostics menu
Hydraulic Data Display – Hydraulic Input. on the dash display panel.
• Is each lever output = 0%?
Full Stroke Test • YES: Go to Step 4.
Check for full stroke of mini-lever. Use the Display • NO: Mini-lever is not working properly. See
Switch Cluster (DSC) or install the Service Tool to procedures below for repair or replacement.
monitor functions. Upon completion, rerun the test.

1. Stroke each lever to full stroke, forward and 4. Operate each lever to full stroke forward and
backward, and allow lever to snap back to slowly release (1-2 seconds from full stroke).
center. Read output when fully released.
• Is each lever output = 0%?
2. (DO NOT start). Turn key switch to ON
position. • YES: Go to Step 5.
• NO: Mini-lever is not working properly. See
3. Display the electro-hydraulic diagnostics menu procedures below for repair or replacement.
on the dash display panel. Operate each lever Upon completion, rerun the test.
to full stroke forward and read input.
5. Operate each lever to full stroke back and
• Is lever output ≥ -92%?
slowly release (1-2 seconds from full stroke).
• YES: Go to Step 4. Read output when fully released.
• NO: Mini-lever is not working properly. See • Is each lever output = 0%?
procedures below for repair or replacement.
Upon completion, rerun the test. • YES: Mini-lever function is returning to
neutral.
4. Operate each lever to full stroke backward and • NO: Mini-lever is not working properly. See
read input. procedures below for repair or replacement.
Upon completion, rerun the test.
• Is lever output ≥ +92%?
• YES: Mini-lever is supplying full stroke. 6. If mini-lever continues to not function properly,
• NO: Mini-lever is not working properly. See contact your local Hyster dealer or see Hyster
procedures below for repair or replacement. Hypass Online.
Upon completion, rerun the test.
Push Button Switch
5. If mini-lever continues to not function properly,
1. Validate that push button switch operates
contact your local Hyster dealer or see Hyster
properly by operating applicable function.
Hypass Online.

84
2200 SRM 1954 Electronic-Hydraulic Controls, After January, 2020

2. If system does not function, see procedures

below for repair or replacement. Upon
completion, rerun the test.

3. If push button switch continues to not function

properly, contact your local Hyster dealer or
see Hyster Hypass Online.

GENERAL

WARNING
Before replacing any part of the electronic
hydraulic control assembly, fully lower all parts of
the mast and tilt it forward until the tips of forks
touch the ground. This action will prevent mast
from lowering suddenly if the control lever is
accidently moved.

1. ARMREST
WARNING 2. TO WIRE HARNESS
Never wear any metallic items on your fingers, 3. HORN BUTTON
4. DIRECTION CONTROL SWITCH
arms, or neck. Metal items can accidently make an 5. MINI-LEVERS
electrical connection and cause an injury. 6. PUSH (OVERRIDE) BUTTON

Figure 77. E-Hydraulic Controls Arrangement

CAUTION
A short circuit and damage can occur if wires are MINI-LEVERS, REMOVE AND INSTALL
not installed correctly. Make sure wire connectors
do not touch other metal terminals or wire CAUTION
connectors, metal brackets, or bracket mounting
The following procedure should only be performed
nuts. Make sure wires are not pulled tight and are
by Hyster trained certified technicians. The
not touching other parts to damage the insulation.
removal and replacement of the mini-levers should
NOTE: Prior to performing the following be done in a clean environment whenever possible
procedures, the E-Hydraulic Controls - TEST must and on an electrically grounded surface. Do not
be performed. touch any printed circuit board (PCB) surface to
prevent damage from electrostatic voltage.
NOTE: The mini-levers do not need to be calibrated.
NOTE: The Direction Control Switch (DCS) is an 1. Remove two capscrews and mini-lever from
optional feature on lift trucks equipped with armrest. See Figure 78.
electronic-hydraulic controls. See Figure 77.
The line of trucks covered in this manual come
standard with manual hydraulic levers, but have
the option of using electronic-hydraulic controls. See
Figure 77. If the Mini-Levers Module (MLM), or
mini-levers malfunction, replace with new part. See
the Parts Manual for replacement parts.

85
Electronic-Hydraulic Controls, After January, 2020 2200 SRM 1954

Legend for Figure 78.

1. CAPSCREWS
2. MINI-LEVER
3. ARMREST
4. PUSH (OVERRIDE) BUTTON

NOTE: Before installing new mini-lever, check

Parts Manual for correct part number to be sure
correct mini-lever is being installed.
2. Install new mini-lever onto armrest using two
capscrews. See Figure 78.

ARMREST ASSEMBLY
Remove
1. Disconnect the battery.

2. Remove two capscrews and washers from cover

plate and remove seat box. Disconnect the main
Figure 78. Mini-Lever Removal
E-Hydraulic control wire harness from E-
Hydraulic armrest harness. See Figure 79.

86
2200 SRM 1954 Electronic-Hydraulic Controls, After January, 2020

NOTE: SOME COMPONENT PARTS AND ELECTRICAL CONNECTIONS OMITTED FOR CLARITY.

A. FULL SUSPENSION AND SWIVEL SEATS B. NON SUSPENSION SEATS

1. CAPSCREWS 4. E-HYDRAULIC ARMREST HARNESS

2. WASHERS CONNECTOR
3. SEAT BOX 5. COVER PLATE

Figure 79. Seat Box Cover Removal

3. Pull up on handle (see Figure 80) and slide

armrest all the way forward and remove flange
capscrew from under armrest mounting bracket
that attaches armrest to mounting bracket.
Pull up on handle and slide armrest all the way
back and remove the other flange capscrew. See
Figure 81.

Figure 80. Armrest Adjustment Handles

87
Electronic-Hydraulic Controls, After January, 2020 2200 SRM 1954

Legend for Figure 80.

A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN

4. Remove armrest from armrest mounting

bracket.

1. SOCKET HEAD SCREWS

2. BOTTOM ARMREST COVER

Figure 82. Bottom Armrest Cover Removal

NOTE: The push (override) button is optional

features and lift truck may be equipped with more
than one push (override) button depending of the
1. E-HYDRAULIC CONTROL WIRE HARNESS number of hydraulic functions on the lift truck. If
2. FLANGE CAPSCREWS lift truck is not equipped with this feature, there
3. ARMREST will be a plug covering the electrical connector on
4. ARMREST MOUNTING BRACKET
5. HOLES FOR FLANGE CAPSCREWS the PCB cassette.
6. Disconnect the push (override) button
Figure 81. E-Hydraulic Armrest and Mounting connector from PCB cassette. See Figure 83.
Bracket
7. Remove three socket screws from PCB cassette
5. Remove six socket head screws that fasten the and remove PCB cassette from armrest. See
bottom and top armrest covers together. See Figure 83.
Figure 82. Remove the bottom armrest cover
from armrest.

88
2200 SRM 1954 Electronic-Hydraulic Controls, After January, 2020

2. Remove two Phillips head screws that attach

horn button to armrest. See Figure 84. Remove
horn button from armrest.

1. TO E-HYDRAULIC CONTROL WIRE HARNESS

2. SOCKET HEAD SCREWS
3. PCB CASSETTE
4. PUSH (OVERRIDE) BUTTON CONNECTOR

Figure 83. PCB Cassette Removal

Install
1. Install PCB cassette to armrest with three NOTE: PUSH (OVERRIDE) BUTTON CONNEC-
socket head screws. See Figure 83. TIONS NOT SHOWN FOR CLARITY.

2. If lift truck is equipped, connect the push 1. PHILLIPS HEAD SCREWS

(override) button connector to PCB cassette. 2. DIRECTION CONTROL SWITCH ADAPTER*
3. HORN BUTTON ADAPTER
See Figure 83. 4. PLUG
5. HORN SWITCH
3. Install bottom armrest cover to armrest with 6. DIRECTION CONTROL SWITCH CONNECTOR
six socket head screws. See Figure 83. 7. ARMREST
*Direction Control Switch is an optional feature.
4. Install new armrest onto mounting bracket
with flange capscrews. Tighten flange Figure 84. Switch Arrangement and Connections,
capscrews to 13 to 15 N•m (115 to 132 lbf in). E-Hydraulic Mini-Levers

5. Connect E-hydraulic wire harness to armrest. Install

See Figure 81. Install seat box to cover plate 1. Install new horn switch and two Phillips head
with two capscrews and washers. See screws onto armrest. See Figure 84.
Figure 79. Tighten capscrews to
1.2 N•m (10.6 lbf in). 2. Install armrest and PCB cassette to armrest
and install armrest to armrest mounting
6. Connect the battery. bracket. See the section Armrest Assembly for
installation procedures.
HORN BUTTON
Remove DIRECTION CONTROL SWITCH
1. Remove the armrest from armrest mounting NOTE: The Direction Control Switch (DCS) is an
bracket. Remove bottom armrest and PCB optional feature on lift trucks covered in this
cassette. See section Armrest Assembly for manual that are equipped with electro-hydraulic
removal procedures. controls.

89
Electronic-Hydraulic Controls, After January, 2020 2200 SRM 1954

Remove 3. Install armrest cover to armrest, and install

armrest to armrest mounting bracket. See
1. Remove armrest from armrest mounting section Armrest Assembly for installation
bracket. Remove bottom armrest cover. See procedures.
section Armrest Assembly for removal
procedures.
PUSH (OVERRIDE) BUTTONS
2. Remove Direction Control Switch (DCS) On lift trucks equipped with E-Hydraulic controls,
assembly from armrest by compressing the there may be two optional push (override) button
clips on either side of the bezel and carefully (green buttons) located behind the second, third, or
pulling the assembly out. Disconnect E- fourth mini-lever. See Figure 86. The push
Hydraulic control wiring harness from the (override) button located behind the second mini-
Direction Control Switch. See Figure 85. lever is used to override the Return To Set Tilt
(RTST) function. By pressing this switch, the RTST
parameters are overridden and the mast is allowed
to tilt unrestricted.
If the lift truck is equipped with a clamp
attachment, the last mini-lever on the right controls
the clamp function. Behind this lever will be a push
(override) button. To engage the clamp, move the
mini-lever backward. To disengage the clamp, push
the push (override) button behind the mini-lever
and move mini-lever forward.
The different configurations of push (override)
button discussed in this section may not be found on
your lift truck.

1. DIRECTION CONTROL SWITCH

2. BEZEL
3. ARMREST
4. E-HYDRAULIC CONTROL VALVE WIRING
HARNESS

Figure 85. Direction Control Switch Replacement

3. Remove DCS from bezel. See Figure 85.

Install
NOTE: NOT ALL LIFT TRUCK MAY HAVE ALL
1. Insert new Direction Control Switch into bezel. PUSH (OVERRIDE) BUTTON SHOWN.
See Figure 85.
1. MINI-LEVERS
2. Connect E-Hydraulic control valve wiring 2. PUSH (OVERRIDE) BUTTON (CLAMP)
harness to the DCS. Install DCS assembly into 3. PUSH (OVERRIDE) BUTTON (RTST)
armrest by compressing clips on either side of 4. BUTTON PLUG
the bezel and pushing assembly into armrest 5. ARMREST HOUSING
until the clips latch. See Figure 85.
Figure 86. Push (Override) Buttons Location

90
2200 SRM 1954 Electronic-Hydraulic Controls, After January, 2020

Remove 2. Pull push (override) button connectors apart to

disconnect them from wire harness. See
1. Remove the armrest from armrest mounting Figure 87.
bracket. Remove bottom armrest and PCB
cassette. See procedures in Armrest Assembly 3. If push (override) button is being replaced,
section above. remove lock nut from back of green, round,
push button. Remove push button switch from
NOTE: Tag wires prior to disconnecting them to aid armrest. See Figure 87.
in reconnecting.

1. CLAMP BUTTON (SWITCH) CONNECTION 3. LOCKNUT

2. RTST BUTTON (SWITCH) CONNECTION 4. PUSH (OVERRIDE) BUTTON WIRE HARNESS
AND CONNECTOR

Figure 87. Push (Override) buttons Replacement

Install 4. Install armrest and PCB cassette to armrest

and install armrest to armrest mounting
1. Install new green, round push (override) button bracket. See the section Armrest Assembly for
assembly through armrest housing. installation procedures.
2. Install and tighten lock nut on push (override) 5. Connect the E-hydraulic wire harness to
button and armrest. See Figure 87. armrest. See Figure 81.
3. Push push (override) button connector to wire
harness. See Figure 87.

91
Diesel Particulate Filter (DPF) Display 2200 SRM 1954

Diesel Particulate Filter (DPF) Display

REMOVE
NOTE: Use a flat head screwdriver to help separate
the cover from base, where the bracket enters the
cover pry point. See Figure 88.
1. Remove cover from base and DPF display. See
Figure 88.

NOTE: Note position of lock ring during removal to

help in installation.
2. Unscrew lock ring from back of DPF display
and base. See Figure 88.

3. Disconnect electrical connector from back of

DPF display. See Figure 88.

4. Remove DPF display from lift truck

NOTE: Note position of lock ring and base in 1. DPF DISPLAY

relation to wiring harness and mounting bracket 2. COVER
prior to removal to help in installation. 3. BASE
4. LOCK RING
5. Slide base and lock ring down wiring harness 5. ELECTRICAL CONNECTOR
and remove from lift truck. 6. WIRING HARNESS
7. HOOK TABS
6. Remove two capscrews and mounting bracket 8. MOUNTING BRACKET
from overhead guard. See Figure 88. 9. COVER PRY POINT
10. CAPSCREW
11. OVERHEAD GUARD

Figure 88. DPF Display

92
2200 SRM 1954 Diesel Particulate Filter (DPF) Display

CLEAN AND INSPECT 3. Connect electrical connector into back of DPF

display. See Figure 88.
Using a lint free cloth, wipe down components and
inspect for damage or defects. NOTE: DO NOT overtighten lock ring.
If any components are found to have damage or 4. Secure DPF display to base and mounting
defect replace them. See Parts Manual for part bracket using lock ring as noted during
information. removal. See Figure 88.

INSTALL NOTE: Align two hook tabs into openings of base at

1. Install mounting bracket and two capscrews top of cover and snap bottom of cover into position.
onto overhead guard. See Figure 88. 5. Snap cover onto base and DPF display. See
Figure 88.
2. Slide lock ring and base over wiring harness
and into position on mounting bracket as noted
during removal.

93
Special Tools 2200 SRM 1954

Special Tools

Tool Name Applicable Model and Tool Size Illustration

Crankshaft A 92 mm (3.6 in.) radius
Position B 13.0 to 13.1 mm (0.0512 to 0.51 in.) dia.
Sensor
Measuring C 10.000 to 10.015 mm (0.39370 to 0.39429 in.) dia.
JIG 1 D 18 mm (0.71 in.) dia.
E 16 mm (0.63 in.)
F Chamfer 0.3 mm (0.01 in.)
G Chamfer 0.5 mm (0.02 in.)
H Chamfer 0.5 mm (0.02 in.)
I Chamfer 0.5 mm (0.02 in.)
J 5.0 to 5.05 mm (0.197 to 0.198 in.)
K 7.0 mm (0.28 in.)
L 39.990 to 40.010 mm (1.5744 to 1.5751 in.)
M 50 mm (2.0 in.)
N 5.0 mm (0.20 in.) radius
O 0.35 rad (20°)
P 0.35 rad (20°)
Q 2.0 mm (0.079 in.)
R 18.380 to 18.393 mm (0.72363 to 0.72413 in.) dia.
S 92 mm (3.6 in.) radius
T Chamfer 0.5 mm (0.02 in.)
U 11 mm (0.43 in.)
V 13 mm (0.51 in.) radius
W 80.0 mm (3.1 in.) dia.
X 8.0 mm (0.31 in.) radius
Y 6.5 mm (0.26 in.) dia.
Z 19.5 mm (0.768 in.)
a 12.8 to 12.9 mm (0.504 to 0.507 in.) dia.
b Chamfer 0.3 mm (0.01 in.)
c Chamfer 0.5 mm (0.02 in.)
d 0.4 mm (0.02 in.) radius
e 12.8 to 12.9 mm (0.504 to 0.507 in.) dia.
f 4.95 to 5.00 mm (0.195 to 0.196 in.) dia.
g 2.0 mm (0.079 in.)
h 0.35 rad (20°)
i 9.978 to 9.987 mm (0.3929 to 0.3931 in.)
Locally Manufactured

94
2200 SRM 1954 Special Tools

Tool Name Applicable Model and Tool Size Illustration

Crankshaft A 8.0 mm (0.31 in.) dia. reamer
Position B 22 mm (0.866 in.)
Sensor
Measuring C M4 X Pitch 0.7
JIG 2 D 6.5 mm (0.26 in.)
E 34.0 mm (1.34 in.)
F 35 mm (1.14 in.) radius
G 20 mm (0.79 in.) radius

H 68.0 mm (2.68 in.)

Locally Manufactured
Crankshaft
Position
Sensor Air
Gap Tool -
JIG 1 and
JIG 2 Hyster P/N 4047774

95
 TECHNICAL PUBLICATIONS

2200 SRM 1954 8/21 (6/21)(3/20)(1/20)(11/19)(12/18)