ELECTRICAL SYSTEM

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004, H004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) [N005, P005, R005, S005];
S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024, F024, G024];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299,
B299]

This manual contains information that is confidential and/or proprietary to Hyster

Company, its subsidiaries and/or vendors. Copying or distribution of any sections
of this manual marked "Confidential/Proprietary" is prohibited.

PART NO. 1580520 2200 SRM 1142

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General .....................................................................................................................................................................1
Display Switch Cluster ........................................................................................................................................... 3
Remove ................................................................................................................................................................ 3
Install ...................................................................................................................................................................5
Direction Control and Turn Signal Levers ........................................................................................................ 6
Remove ............................................................................................................................................................ 6
Install .............................................................................................................................................................. 7
Key Switch ...........................................................................................................................................................7
Remove ............................................................................................................................................................ 7
Install .............................................................................................................................................................. 8
Display Switch Cluster Panel Bezel and Overlay ............................................................................................. 8
Remove ............................................................................................................................................................ 8
Install .............................................................................................................................................................. 8
Steering Column Repair ......................................................................................................................................... 9
Remove ................................................................................................................................................................ 9
Disassemble .......................................................................................................................................................11
Assemble ............................................................................................................................................................11
Install .................................................................................................................................................................11
Sensors and Switches ............................................................................................................................................12
General .............................................................................................................................................................. 12
Dash and Kick Panel, Remove and Install ..................................................................................................12
Remove ......................................................................................................................................................12
Install ........................................................................................................................................................13
Accelerator Pedal Position Sensor ................................................................................................................... 13
Remove .......................................................................................................................................................... 13
Install ............................................................................................................................................................ 17
Brake Fluid Level Switch ................................................................................................................................. 18
Remove .......................................................................................................................................................... 18
Install ............................................................................................................................................................ 19
Service Brake Pedal Position Sensor ............................................................................................................... 21
Remove .......................................................................................................................................................... 21
Install ............................................................................................................................................................ 23
Parking Brake Sensor .......................................................................................................................................24
Remove .......................................................................................................................................................... 24
Install ............................................................................................................................................................ 26
Service Brake Pressure Sensor ........................................................................................................................ 26
Remove .......................................................................................................................................................... 26
Install ............................................................................................................................................................ 28
Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)................................................................................................................... 29
Remove .......................................................................................................................................................... 29
Install ............................................................................................................................................................ 29
Sensor Microswitch MONOTROL®.................................................................................................................. 29
Remove .......................................................................................................................................................... 29
Install ............................................................................................................................................................ 32
Low Coolant Level Sensor ................................................................................................................................ 33
Remove .......................................................................................................................................................... 33
Install ............................................................................................................................................................ 36
Fuel Level Sensor, Gas and Diesel Engines Only ........................................................................................... 37
Remove .......................................................................................................................................................... 37

©2016 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Install ............................................................................................................................................................ 38
Armrest Switch ................................................................................................................................................. 38
Remove .......................................................................................................................................................... 38
Install ............................................................................................................................................................ 40
Seat Sensor (Operator Presence System) ........................................................................................................ 40
Non-Suspension and Semi-Suspension Seats; For Lift truck Models , , , , , , S30-35FT,
S40FTS (E010)...............................................................................................................................................40
Remove ......................................................................................................................................................40
Install ........................................................................................................................................................41
Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006).... 41
Remove ......................................................................................................................................................41
Install ........................................................................................................................................................41
Full Suspension Seats; All Lift Truck Models ............................................................................................ 42
Remove ......................................................................................................................................................42
Install ........................................................................................................................................................42
Hood Shut Off Switch ....................................................................................................................................... 42
Remove .......................................................................................................................................................... 42
Install ............................................................................................................................................................ 44
Remote Key Switch ........................................................................................................................................... 45
Remove .......................................................................................................................................................... 45
Install ............................................................................................................................................................ 45
Hydraulic Filter Pressure Switch .................................................................................................................... 45
Remove .......................................................................................................................................................... 45
Install ............................................................................................................................................................ 48
Transmission Speed Sensor ..............................................................................................................................48
Remove .......................................................................................................................................................... 48
Install ............................................................................................................................................................ 52
Transmission Pressure Sensors ....................................................................................................................... 52
Remove .......................................................................................................................................................... 52
Install ............................................................................................................................................................ 53
Transmission Temperature Sensor ..................................................................................................................54
Remove .......................................................................................................................................................... 54
Install ............................................................................................................................................................ 57
Engine Speed Sensor ........................................................................................................................................ 58
Remove .......................................................................................................................................................... 58
Install ............................................................................................................................................................ 59
Intermediate Speed Sensor .............................................................................................................................. 59
Remove .......................................................................................................................................................... 59
Install ............................................................................................................................................................ 59
Return to Set Tilt (Tilt Angle) Sensor ..............................................................................................................59
Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177)....... 59
Remove ......................................................................................................................................................60
Install ........................................................................................................................................................60
Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024); S4.0,
5.0, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006),
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)................................................ 60
Remove ......................................................................................................................................................61

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Install ........................................................................................................................................................61
Rear Horn Button Switch ................................................................................................................................. 62
Remove .......................................................................................................................................................... 62
Install ............................................................................................................................................................ 63
Impact Sensor ....................................................................................................................................................63
Lift Truck Models S30FT-35FT, S40FTS (E010), H1.6-1.8FT, H2.0FTS (H30-35FT,
H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT (H40-70FT)
(L177), S4.0-5.5FT, S5.5FTS (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS)
(G004, H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (N005,
P005, R005, S005), and S6.0-7.0FT (S135-155FT) (D024, E024, F024, G024)...........................................63
Remove ......................................................................................................................................................63
Install ........................................................................................................................................................65
Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)............................................................... 65
Remove ......................................................................................................................................................65
Install ........................................................................................................................................................66
Load Weight Sensor .......................................................................................................................................... 67
Remove .......................................................................................................................................................... 67
Install ............................................................................................................................................................ 68
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda
Engines 2.0L and 2.2L....................................................................................................................................... 69
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines .......................69
Crankshaft Position (CKP) Sensor .............................................................................................................. 69
Camshaft Position (CMP) Sensor ................................................................................................................ 69
Oil Pressure Sensor ...................................................................................................................................... 69
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor ........................................ 69
Engine Coolant Temperature (ECT) Sensor ............................................................................................... 69
Air Flow Restriction Switch ......................................................................................................................... 70
Remove for GM 2.4L Gas and LPG Trucks .............................................................................................70
Install for GM 2.4L Gas and LPG Trucks ...............................................................................................70
Oxygen Sensor .............................................................................................................................................. 70
Remove ......................................................................................................................................................70
Install ........................................................................................................................................................73
Engine and Fuel Sensors and Switches, PSI 4.3L LPG Engine .....................................................................74
Crankshaft Position (CKP) Sensor .............................................................................................................. 74
Camshaft Position (CMP) Sensor ................................................................................................................ 74
Oil Pressure Sensor ...................................................................................................................................... 74
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor ........................................ 74
Engine Coolant Temperature (ECT) Sensor ............................................................................................... 74
Air Flow Restriction Switch ......................................................................................................................... 74
Oxygen Sensor .............................................................................................................................................. 74
Engine and Fuel Switches, GM 2.4L LPG Trucks Only ................................................................................. 74
Low LPG Pressure Switch ............................................................................................................................74
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks ................................................................... 74
Air Filter Restriction Switch ........................................................................................................................74
Remove ......................................................................................................................................................74
Install ........................................................................................................................................................75
Oil Pressure Sensor ...................................................................................................................................... 75
Remove ......................................................................................................................................................75
Install ........................................................................................................................................................75

iii
Table of Contents

TABLE OF CONTENTS (Continued)

Engine Speed Sensor .................................................................................................................................... 75
Remove ......................................................................................................................................................75
Install ........................................................................................................................................................75
Engine Coolant Temperature (ECT) Sensor ............................................................................................... 75
Remove ......................................................................................................................................................75
Install ........................................................................................................................................................75
Throttle Position Sensor (TPS) .................................................................................................................... 78
Remove ......................................................................................................................................................78
Install ........................................................................................................................................................79
Fuel/Water Separator Sensor .......................................................................................................................79
Remove ......................................................................................................................................................79
Install ........................................................................................................................................................79
Glow Plug Relay ............................................................................................................................................80
Remove ......................................................................................................................................................80
Install ........................................................................................................................................................82
Engine and Fuel Sensors and Switches, Cummins Diesel Engines ...............................................................82
Air Filter Restriction Switch ........................................................................................................................82
Remove ......................................................................................................................................................82
Install ........................................................................................................................................................82
Engine Oil Pressure Sensor ......................................................................................................................... 86
Remove ......................................................................................................................................................86
Install ........................................................................................................................................................86
Engine Speed Sensor .................................................................................................................................... 86
Remove ......................................................................................................................................................86
Install ........................................................................................................................................................87
Engine Coolant Temperature (ECT) Sensor ............................................................................................... 87
Remove ......................................................................................................................................................87
Install ........................................................................................................................................................88
Throttle Position Sensor (TPS) (Cummins 4.5L Only) ............................................................................... 88
Remove ......................................................................................................................................................88
Install ........................................................................................................................................................89
Fuel/Water Separator Sensor .......................................................................................................................89
Remove ......................................................................................................................................................89
Install ........................................................................................................................................................90
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine Without DPF .....................................90
Intake Air Temperature Sensor ...................................................................................................................91
Remove ......................................................................................................................................................91
Install ........................................................................................................................................................92
Intake Air Pressure Sensor ..........................................................................................................................92
Remove ......................................................................................................................................................92
Install ........................................................................................................................................................92
Air Inlet Heater ............................................................................................................................................ 92
Remove ......................................................................................................................................................92
Install ........................................................................................................................................................93
Engine Oil Pressure Sensor ......................................................................................................................... 93
Remove ......................................................................................................................................................93
Install ........................................................................................................................................................93
Engine Coolant Temperature (ECT) Sensor ............................................................................................... 93
Remove ......................................................................................................................................................93
Install ........................................................................................................................................................93

iv
 Table of Contents

TABLE OF CONTENTS (Continued)

Crankshaft Position Sensor ......................................................................................................................... 94
Remove ......................................................................................................................................................94
Install ........................................................................................................................................................94
Adjust Shim Procedure ............................................................................................................................ 95
Camshaft Position Sensor ............................................................................................................................ 96
Remove ......................................................................................................................................................96
Install ........................................................................................................................................................96
Air Flow Restriction Sensor ......................................................................................................................... 97
Remove ......................................................................................................................................................97
Install ........................................................................................................................................................97
Fuel/Water Separator ...................................................................................................................................97
Remove ......................................................................................................................................................97
Install ........................................................................................................................................................98
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine With DPF .......................................... 98
Intake Air Temperature Sensor .................................................................................................................102
Remove ....................................................................................................................................................102
Install ......................................................................................................................................................103
Boost Sensor ................................................................................................................................................103
Remove ....................................................................................................................................................103
Install ......................................................................................................................................................103
Throttle Valve Assembly and Air Intake Heater ......................................................................................104
Remove ....................................................................................................................................................104
Install ......................................................................................................................................................104
Engine Coolant Temperature (ECT) Sensor ............................................................................................. 104
Remove ....................................................................................................................................................104
Install ......................................................................................................................................................105
Engine Oil Pressure Sensor ....................................................................................................................... 105
Remove ....................................................................................................................................................105
Install ......................................................................................................................................................105
Crankshaft Position Sensor ....................................................................................................................... 106
Remove ....................................................................................................................................................106
Install ......................................................................................................................................................106
Adjust Shim Procedure .......................................................................................................................... 106
Camshaft Position Sensor .......................................................................................................................... 108
Remove ....................................................................................................................................................108
Install ......................................................................................................................................................108
Differential Pressure Sensor ......................................................................................................................109
Remove ....................................................................................................................................................109
Install ......................................................................................................................................................109
Mass Air Flow Sensor .................................................................................................................................110
Remove ....................................................................................................................................................110
Install ......................................................................................................................................................111
Fuel/Water Separator .................................................................................................................................111
Remove ....................................................................................................................................................111
Install ......................................................................................................................................................112
Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Engine .......................................................... 112
Engine Coolant Temperature (ECT) Sensor ............................................................................................. 113
Remove ....................................................................................................................................................113
Install ......................................................................................................................................................113
Throttle Position Sensor .............................................................................................................................114

v
Table of Contents

TABLE OF CONTENTS (Continued)

Engine Oil Pressure Sensor ....................................................................................................................... 114
Remove ....................................................................................................................................................114
Install ......................................................................................................................................................114
Engine Speed Sensor .................................................................................................................................. 114
Remove ....................................................................................................................................................114
Install ......................................................................................................................................................114
Fuel Shut Off Solenoid ............................................................................................................................... 114
Remove ....................................................................................................................................................114
Install ......................................................................................................................................................114
Vehicle System Manager (VSM) .........................................................................................................................115
General ............................................................................................................................................................ 115
VSM Replacement ...........................................................................................................................................115
Remove ........................................................................................................................................................ 115
Install .......................................................................................................................................................... 117
Programming a New VSM and/or Display Switch Cluster ...........................................................................117
General ........................................................................................................................................................117
PC Service Tool Software ........................................................................................................................... 118
Data Transferring .......................................................................................................................................118
New VSM ................................................................................................................................................ 118
New (Blank) Display Switch Cluster .................................................................................................... 118
Used (Non-Blank) Display Switch Cluster ........................................................................................... 118
Power Distribution Module (PDM) and Component Parts ............................................................................... 120
Remove ............................................................................................................................................................ 120
PDM as a Unit ............................................................................................................................................ 120
Install ...............................................................................................................................................................124
PDM as a Unit ............................................................................................................................................ 124
Remove and Install ......................................................................................................................................... 125
PDM Component Parts ...............................................................................................................................125
Transmission Control Unit ................................................................................................................................. 125
Remove ............................................................................................................................................................ 125
Install ...............................................................................................................................................................126
Battery ................................................................................................................................................................. 127
Remove ............................................................................................................................................................ 127
Install ...............................................................................................................................................................127
Lights ................................................................................................................................................................... 128
Work Lights (Front and Rear) ........................................................................................................................128
Remove ........................................................................................................................................................ 128
Install .......................................................................................................................................................... 128
Strobe Light .....................................................................................................................................................129
Remove ........................................................................................................................................................ 129
Install .......................................................................................................................................................... 129
LED Tail, Backup, and Brake Lights ............................................................................................................ 130
Remove ........................................................................................................................................................ 130
Install .......................................................................................................................................................... 130
Front Marker/Turn Signal Lights ..................................................................................................................132
Replacing Whole Front Marker/Turn Signal Light Assembly ................................................................. 132
Remove ....................................................................................................................................................132
Install ......................................................................................................................................................132
Replacing Just the Front Marker/Turn Signal Light LED Light Lens ................................................... 132
Remove ....................................................................................................................................................132

vi
 Table of Contents

TABLE OF CONTENTS (Continued)

Install ......................................................................................................................................................133
Diesel Particulate Filter (DPF) Display .............................................................................................................133
Remove ............................................................................................................................................................ 133
Clean and Inspect ........................................................................................................................................... 133
Install ...............................................................................................................................................................134
Electronic-Hydraulic Controls - Generation 1 ................................................................................................... 134
E-Hydraulic Controls - Test ........................................................................................................................... 134
Mini-Levers ................................................................................................................................................. 134
Full Stroke Test .......................................................................................................................................... 134
Function Returns to Neutral Test ............................................................................................................. 134
Push Button Switch ....................................................................................................................................135
General ............................................................................................................................................................ 135
Mini-Lever Replacement ................................................................................................................................ 135
Remove ........................................................................................................................................................ 135
Clean and Inspect ....................................................................................................................................... 137
Install .......................................................................................................................................................... 137
Push Button Switch Replacement ..................................................................................................................138
Remove ........................................................................................................................................................ 138
Install .......................................................................................................................................................... 139
Mini-Lever Module (MLM) ............................................................................................................................. 140
Remove ........................................................................................................................................................ 140
Install .......................................................................................................................................................... 140
Joystick ............................................................................................................................................................140
Remove and Disassemble ........................................................................................................................... 140
Inspect ......................................................................................................................................................... 141
Assemble and Install .................................................................................................................................. 141
Electronic-Hydraulic Controls - Generation 2 ................................................................................................... 141
General ............................................................................................................................................................ 141
Mini-levers, Remove and Install .................................................................................................................... 142
Armrest Assembly ...........................................................................................................................................143
Remove ........................................................................................................................................................ 143
Install .......................................................................................................................................................... 145
Horn Button .................................................................................................................................................... 145
Remove ........................................................................................................................................................ 145
Install .......................................................................................................................................................... 145
Direction Control Switch ................................................................................................................................ 146
Remove ........................................................................................................................................................ 146
Install .......................................................................................................................................................... 146
Momentary Switches and Toggle Switch .......................................................................................................146
Remove ........................................................................................................................................................ 147
Install .......................................................................................................................................................... 148
Joystick ............................................................................................................................................................149
Remove and Disassemble ........................................................................................................................... 149
Inspect ......................................................................................................................................................... 149
Assemble and Install .................................................................................................................................. 149
Joystick Armrest Slider Assembly ................................................................................................................. 149
Remove ........................................................................................................................................................ 149
Install .......................................................................................................................................................... 150

vii
Table of Contents

This section is for the following models:

(S30FT, S35FT, S40FTS) [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [G004, H004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
[N005, P005, R005, S005];
S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024, F024, G024];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299]

viii
2200 SRM 1142
General
NOTE: The joystick option identified in this
manual is not available for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
The removal and replacement procedures for the
following electrical components are covered in this
manual:
• Display Switch Cluster
• Vehicle System Manager (VSM)
• Power Distribution Module (PDM)
• Joystick and mini-lever electronic-hydraulic
controls
• Lights
• Sensors and switches
• Battery
• Transmission Control Unit (TCU) for lift
truck models
• S6.0FT, S7.0FT, (S135FT,S155FT)
(D024, E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
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.
Confidential/Proprietary - Do Not Copy or Duplicate
General
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
Control Unit (ECU), remove it from the lift truck.
See one of the following sections for procedures to
remove ECU from your lift truck
Gasoline Fuel System 0900SRM1126 for lift
truck models
• H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
LPG Fuel System 0900SRM1124 for lift truck
models
• H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Gasoline Fuel System 0900SRM1244 for lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
Gasoline Fuel System PSI GM 4.3L
0900SRM1570 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (F024,
G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006,
K006)
1
General 2200 SRM 1142

LPG Fuel System, GM 4.3L Engine with GFI • H2.0-3.5FT (H40-70FT) (L177)
0900SRM1242 for lift trucks
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, Gasoline Fuel System 0900SRM1325 for lift
E024) truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT; • H2.0-3.5FT (H40-70FT) (L177)
S80, 100FTBCS; S120FTS; S120FTPRS) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(G004)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, LPG Fuel System 0900SRM1326 for lift truck
J006) models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • S30FT, S35FT, S40FTS (E010)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
(N005, P005) H40FTS) (F001)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H175FT36, H190FT) (A299) • H2.0-3.5FT (H40-70FT) (L177)
LPG Fuel System, GM 4.3L Engine With PSI
0900SRM1556 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006,
K006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (E024,
F024, G024)

LPG Fuel System, PSI 4.3L Engine

0900SRM1951 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (G024)

LPG Fuel System, GM 5.7L Engine

0900SRM1433 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Gasoline Fuel System 0900SRM1127 for lift
truck models
• H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
LPG Fuel System 0900SRM1125 for lift truck
models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
NOTE: VIEW SHOWN IS FROM LEFT SIDE. MAJOR
COMPONENTS AND ELECTRICAL CONNECTIONS
NOT SHOWN FOR CLARITY.
1. GROUND STUD
2. TANK OPENING FOR HYDRAULIC FILTER
3. POWER DISTRIBUTION MODULE (PDM)
4. BATTERY
Figure 1. Welding Preparation
For more information on how to perform welding
repairs to lift truck and overhead guard, refer to
one of the following sections:

2 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
Periodic Maintenance 8000SRM1150 for lift
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Periodic Maintenance 8000SRM1207 for lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
Periodic Maintenance 8000SRM1248 for lift
truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
Periodic Maintenance 8000SRM1319 for lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
Periodic Maintenance 8000SRM1322 for lift
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
Periodic Maintenance 8000SRM1407 for lift
truck model
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299)
Periodic Maintenance 8000SRM1558 for lift
truck models
Display Switch Cluster
REMOVE
NOTE: The Display Switch Cluster is a nonrepair-
able part. See Parts Manual for replacement part
number.
1. Disconnect ground wire.
Confidential/Proprietary - Do Not Copy or Duplicate
General
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)
Periodic Maintenance 8000SRM1571 for lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
Periodic Maintenance 8000SRM1583 for lift
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
Periodic Maintenance 8000SRM1586 for lift
truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
Periodic Maintenance 8000SRM1598 for lift
truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(H004)
Periodic Maintenance 8000SRM1604 for lift
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
Periodic Maintenance 8000SRM1606 for lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (G024)
2. Lift up on steering wheel slightly and pull up
on tilt lever. Fully lower steering column.
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.
3
Display Switch Cluster 2200 SRM 1142

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

4. Remove horn button and disconnect horn wires.

NOTE: A puller tool may be required to remove

steering wheel.

5. Remove lock nut securing steering wheel and

remove steering wheel from steering column.
Take care to not damage horn wires. See Fig-
ure 3.

Figure 3. Steering Wheel Removal

4 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Display Switch Cluster

Legend for Figure 3 6. Disconnect Display Switch Cluster harness

from Display Switch Cluster. Remove four bolts
1. HORN BUTTON securing Display Switch Cluster. Slide display
2. LOCK NUT
panel off of steering column. See Figure 4.

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

INSTALL 3. Install steering wheel onto steering shaft and

tighten lock nut until steering wheel is fully
NOTE: When a new Display Switch Cluster is in- seated. Final torque for lock nut is 40 to
stalled on a lift truck, the data that controls all 54 N•m (30 to 40 lbf ft). See Figure 3.
functions and features unique to that lift truck,
needs to be transferred to new Display Switch Clus- 4. Connect horn wires to horn button. Install horn
ter. See section Vehicle System Manager (VSM), lo- lock nut and horn button into steering wheel.
cated in the back of this manual, for procedures to
5. Install upper steering column cover by aligning
transfer data to a new Display Switch Cluster.
two latches and pushing down until latched.
1. Install Display Switch Cluster onto steering See Figure 2.
column. Install four bolts to secure panel to
steering column and tighten bolts to
19 N•m (168 lbf in). See Figure 4.

2. Connect Display Switch Cluster to display har-

ness.

Confidential/Proprietary - Do Not Copy or Duplicate 5

Display Switch Cluster 2200 SRM 1142

DIRECTION CONTROL AND TURN Remove

SIGNAL LEVERS
Direction control lever and turn signal lever are
similar in design, but perform different functions.
Turn signal lever is located on right side of the Dis-
play Switch Cluster. Direction control lever is loca-
ted on left side of Display Switch Cluster.
NOTE: There are no repairs for direction control
lever and turn signal lever. If a lever malfunctions,
replace with new lever. See Parts Manual for re-
placement part numbers.
1. Insert two small flat-blade or Phillips screw-
drivers, with a 3.175 mm (0.125 in.) or less,
wide blade or die end, into opening on Display
Switch Cluster on an outward angle enough to
compress spring tab on direction control lever
or turn signal lever. See A, Figure 5.

Figure 5. Direction Control and Turn Signal Removal

6 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Display Switch Cluster

Legend for Figure 5

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

2. Pry spring tab toward body of direction control
lever or turn signal lever and, at the same time,
pull on handle of lever enough to free the tab of
interior lock of Display Switch Cluster. See B,
Figure 5.
3. Repeat previous steps on opposite side of direc-
tion control lever or turn signal lever. Remove
direction control lever or turn signal lever from
Display Switch Cluster.
Install
Install direction control lever or turn signal lever
into opening of Display Switch Cluster until locking
tabs are engaged in Display Switch Cluster.
KEY SWITCH
NOTE: Lift truck models below may be equipped
with an optional remote key switch in engine com-
partment. See Sensors and Switches section in this
service manual for replacement procedures.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
1. Fully lower steering column and remove upper
steering column cover by pushing in on both
sides of cover to release latches (one on either
side), and pulling cover away from steering col-
umn. See Figure 2.
2. Remove torx head capscrews. Slide key switch
assembly out of Display Switch Cluster. See
Figure 6.

Remove
NOTE: Lift truck models covered in this section
can be equipped with an optional key switch or
Power ON/OFF button. The Power ON/OFF but-
ton is a nonrepairable part. See Parts Manual for
replacement parts. If truck is equipped with a key
switch, follow steps below to remove and replace
key switch.

Confidential/Proprietary - Do Not Copy or Duplicate 7

Display Switch Cluster 2200 SRM 1142

1. BEZEL 4. TORX HEAD SCREW

2. OVERLAY 5. INSERT SCREWDRIVER IN SLOT AT THIS LO-
3. KEY SWITCH CATION
Figure 6. Display Switch Cluster Panel Bezel, Grid, and Key Switch Removal

Install Be careful to not damage bezel and overlay

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.
2. Install upper steering cover on steering column.
Align latches on upper steering cover to holes
on steering column and push upper steering
cover into place on steering column.
when removing bezel. Lift bezel off of Display
Switch Cluster. See Figure 6.
2. Remove overlay from Display Switch Cluster.
Install
Place new overlay on display panel and install a
new bezel by inserting outer edge in display and
then pressing down inner edge.

DISPLAY SWITCH CLUSTER PANEL

BEZEL AND OVERLAY

Remove
1. Insert a small, flat-bladed screwdriver into top
slot on inner edge of bezel and pry outward. Re-
peat procedure at the lower slot on the bezel.

8 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Steering Column Repair

Steering Column Repair

REMOVE 7. Remove two washers from two lower bolts hold-
ing steering column to cowl.
1. On lift truck models below, to access battery,
remove floor mat and floor plate. Disconnect 8. Raise steering column to disengage steering
battery. shaft from the steering control unit.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

On lift truck models below, to access battery,

raise the hood. Disconnect battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

2. 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.

3. Remove steering wheel and instrument display

panel. See section Display Switch Cluster for
removal procedures.

4. Remove two screws and remove lower steering

column cover. See Figure 7.

5. Disconnect Display Switch Cluster harness

from display panel. Remove harness from steer-
ing column.
1. SCREWS
6. Remove four bolts (1, Figure 8) holding steering 2. LOWER STEERING COLUMN COVER
column to cowl.
Figure 7. Lower Steering Column Cover Removal
NOTE: Step 7 only applies to lift truck models
S6.0FT, S7.0FT (S135FT, S155FT) (E024, F024,
G024).

Confidential/Proprietary - Do Not Copy or Duplicate 9

Steering Column Repair 2200 SRM 1142

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 8. Steering Column Disassembly

10 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Steering Column Repair

DISASSEMBLE 5. Install upper steering column cover by aligning

the two latches and pushing down until
1. Remove steering shaft retention clip (4, Fig- latched. See Figure 7.
ure 8).
6. Install steering wheel and instrument display
2. Remove horn contact pads. panel. See section Display Switch Cluster.

3. Remove lower strut pivot pin from the gas cyl- 7. Move steering column to its lowest position and
inder. install upper steering column cover. See Fig-
ure 2.
4. Remove steering column pivot bolts and steer-
ing shaft. 8. For lift truck models below, connect battery and
close hood.
ASSEMBLE • S30FT, S35FT, S40FTS (E010)
1. Install steering column pivot bolts and install • H1.6FT, H1.8FT, H2.0FTS (H30FT,
steering shaft. H35FT, H40FTS) (F001)

2. Install lower strut pivot pin in the gas cylinder. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
See Figure 8. • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
3. Install horn contact pads.
120FT; S80, 100FTBCS; S120FTS;
4. Install steering shaft retention clip. S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
INSTALL H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
1. Lubricate end of steering shaft with multipur-
pose grease. Install end of steering shaft into • S6.0FT, S7.0FT (S135FT, S155FT)
steering control unit. (D024, E024, F024, G024)

NOTE: Step 2 only applies to lift truck models
S6.0FT, S7.0FT (S135FT, S155FT) (E024, F024,
G024).
2. Install two washers onto two lower bolts hold-
ing steering column to cowl.
3. Install steering column to cowl using four bolts.
Tighten bolts to 38 N•m (28 lbf ft). See Fig-
ure 8.
For lift truck models below, connect battery, in-
stall floor plate and floor mat.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

4. Connect Display Switch Cluster harness to Dis-

play Switch Cluster panel. Install Display
Switch Cluster harness on steering column.

Confidential/Proprietary - Do Not Copy or Duplicate 11

Sensors and Switches
Sensors and Switches
GENERAL
CAUTION
Before removing and replacing any sensors or
switches, ALWAYS disconnect the battery. Failure
to disconnect the battery can cause damage to
the sensor or switch and other electrical compo-
nents. Always cover or protect the sensor or
switch connector from contamination after dis-
connecting the harness mating part.
DO NOT use solvent-based cleaners to clean area
around sensors or switches.
All sensors and switches used on these trucks are
non-repairable parts. Replace with new sensors or
switches whenever a sensor or switch malfunctions
and is not operating correctly. See Parts Manual
for replacement part numbers. Before installing
new sensors or switches, use a clean cloth and
make sure the area around the sensor or switch is
clean and free of oils and contaminates.
When removing and replacing sensors or switches,
be sure to tag connectors to aid in correct recon-
necting.
Dash and Kick Panel, Remove and Install
Before removing and replacing the following sen-
sors and switches:
12
2200 SRM 1142
• Accelerator pedal position sensor
• Brake fluid level switch
• Service brake pedal position sensor
• Park brake sensor
The dash and kick panel need to be removed and
installed on lift truck after a sensor or switch has
been replaced.
Remove
1. Lower steering column to its lowest position
and 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.
2. Remove Allen screws securing dash to top of
cowl. Remove dash from clips, located under-
neath dash, that attach dash to kick panel. Lift
to remove the dash. See Figure 9.
3. Lift kick panel from seal plate and remove from
lift truck. See Figure 9.
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142 Sensors and Switches

NOTE: KICK PANEL AND DASH PANEL FOR S2.0-3.5FT (S40-70FT, S55FTS) (F187) AND H2.0-3.5FT
(H40-70FT) (L177) MODELS SHOWN.
1. KICK PANEL 3. FASTENERS
2. COWL 4. DASH

Figure 9. Dash and Kick Panel Removal

Install ACCELERATOR PEDAL POSITION

SENSOR
1. Install kick panel onto seal plate.

2. Install dash into clips, located underneath Remove

dash, that attach dash to kick panel. Install Al-
len screws securing dash to top of cowl. 1. For lift truck models below, to access battery,
remove floor mat and floor plate. Disconnect
3. Install upper steering column cover by aligning battery.
two latches and pushing down until latched. • H6.0FT, H7.0FT (H135FT, H155FT)
See Figure 2. (H006, J006, K006)

Confidential/Proprietary - Do Not Copy or Duplicate 13

Sensors and Switches 2200 SRM 1142

• H8.0FT, H8.0FT9, H9.0FT (H170FT,

H175FT36, H190FT) (A299, B299)

For lift truck models below, to access battery,

raise hood. Disconnect battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

2. Remove upper steering column cover and dash

and kick panel. See Dash and Kick Panel, Re-
move and Install for procedures.

NOTE: Lift truck model shown below is equipped

only with an electronic hydraulic control valve.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

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 opera-
tor's seat. See Figure 10.
Electronic hydraulic control valve.
• Disconnect valve harness from Vehicle
System Manager (VSM). Remove two bolts
and remove valve harness bracket. See
Figure 12.
NOTE: MANUAL HYDRAULIC CONTROL VALVE
WITHOUT OPS SHOWN. REMOVAL OF MANUAL
HYDRAULIC CONTROL VALVE WITH OPS IS THE
SAME.
1. LEVER BRACKET CAPSCREWS
2. COWL
Figure 10. Manual Hydraulic Control Valve
Removal

14 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

4. Disconnect accelerator pedal position sensor.

5. Remove three bolts, throttle base plate, and

pedal assembly from cowl. See Figure 11.

6. Remove two pan head screws, lockwashers, and

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

1. BOLTS
2. PEDAL ASSEMBLY
3. COWL

Figure 11. Accelerator Pedal and Throttle Base

Plate Removal

Confidential/Proprietary - Do Not Copy or Duplicate 15

Sensors and Switches 2200 SRM 1142

NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN.

1. ACCELERATOR PEDAL POSITION SENSOR 6. BOLTS (THROTTLE BASE PLATE)

2. BOLTS (THROTTLE BASE PLATE) 7. COWL
3. VALVE HARNESS MOUNTING BRACKET 8. VEHICLE SYSTEMS MANAGER (VSM)
(ELECTRONIC VALVE) 9. CONTROL VALVE HARNESS
4. BOLTS (VALVE HARNESS MOUNTING 10. SENSOR COVER
BRACKET)
5. THROTTLE BASE PLATE

Figure 12. Accelerator Pedal Position Sensor

16 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Install • S30FT, S35FT, S40FTS (E010)

• H1.6FT, H1.8FT, H2.0FTS (H30FT,
1. Insert new accelerator pedal position sensor
H35FT, H40FTS) (F001)
into opening on throttle base plate. See Fig-
ure 12. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
2. Rotate sensor so that the D shaped throttle
shaft end slides into accelerator pedal position • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
sensor. Rotate sensor counterclockwise until lo- 120FT; S80, 100FTBCS; S120FTS;
cating pin on sensor lines up with hole in throt- S120FTPRS) (G004, H004)
tle base plate. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
3. Insert two pan head screws and lockwasher and (N005, P005, R005, S005)
install accelerator pedal position sensor to
throttle base plate. Tighten screws to • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
2.25 N•m (20 lbf in). E024, F024, G024)

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). See Figure 11.
5. Connect accelerator pedal position sensor.
NOTE: Lift truck model shown below is equipped
only with an electronic hydraulic control valve.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
9. If throttle pedal needs to be adjusted, see one of
the following sections for procedures:
Frame 0100SRM1120 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

6. If lift truck is equipped with Frame 0100SRM1243 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
Manual hydraulic control valve (with or
120FT; S80, 100FTBCS; S120FTS;
without Operator Presence System [OPS]).
S120FTPRS) (G004, H004)
• Install lever bracket to cowl. Install clevis
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
and retention pins and connect manual
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
levers to control valve. See Figure 10.
(N005, P005, R005, S005)
Electronic hydraulic control valve.
Frame 0100SRM1316 for lift truck models
• Insert two bolts into valve harness bracket
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
and install valve harness bracket. Connect
E024, F024, G024)
valve harness to VSM. See Figure 12.
Frame 0100SRM1321 for lift truck models
7. Install kick panel and dash. Install upper steer-
ing column cover. See Dash and Kick Panel, Re- • H6.0FT, H7.0FT (H135FT, H155FT)
move and Install for procedures. (H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
8. Connect battery. For lift truck models below, H175FT36, H190FT) (A299)
install floor plate and floor mat.
• H6.0FT, H7.0FT (H135FT, H155FT) Frame 0100SRM1581 for lift ruck model
(H006, J006, K006) • H6.0FT, H7.0FT (H135FT, H155FT)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, (K006)
H175FT36, H190FT) (A299, B299) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
Connect battery. For lift truck models below,
lower hood.

Confidential/Proprietary - Do Not Copy or Duplicate 17

Sensors and Switches
BRAKE FLUID LEVEL SWITCH
Remove
NOTE: Brake fluid level switch is a component of
master brake cylinder reservoir and is located in-
side reservoir. When switch is replaced, reservoir
must be replaced as well.
NOTE: Lift truck model shown below DOES NOT
have a brake fluid level switch.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
1. For lift truck models below, to access battery,
remove floor mat and floor plate. Disconnect
battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
For lift truck models below, to access battery,
raise hood. Disconnect battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
18
2200 SRM 1142
2. Remove upper steering column cover and dash
and kick panel. See Dash and Kick Panel, Re-
move and Install for procedures.
3. Disconnect brake fluid level switch from cowl
harness.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
4. Remove reservoir from bracket and drain fluid
from reservoir. Disconnect master cylinder sup-
ply hose from reservoir. Make sure air does not
get into hose.
See Figure 13 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 14 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142
1. RESERVOIR SUPPLY HOSE
2. BRAKE FLUID RESERVOIR
3. COWL
4. BRAKE FLUID LEVEL SWITCH (INSIDE RESER-
VOIR)
5. BRAKE FLUID RESERVOIR MOUNTING
BRACKET
Figure 13. Brake Fluid Level Switch, Lift Truck
Models S30FT, S35FT, S40FTS (E010); H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); and
H2.0-3.5FT (H40-70FT) (L177)
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
1. SERVICE BRAKE PRESSURE SENSOR
2. MASTER CYLINDER (BOOSTED)
3. SERVICE BRAKE PEDAL POSITION SENSOR
4. BRAKE FLUID LEVEL SWITCH (INSIDE RESER-
VOIR)
5. BRAKE FLUID RESERVOIR MOUNTING
BRACKET
6. COWL
7. BRAKE FLUID RESERVOIR
Figure 14. Brake Fluid Level Switch, Service Brake
Pedal Position Sensor, and Service Brake
Pressure Sensor For Lift Truck Models S4.0, 5.0,
5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004, H004); H4.0FT5/
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005, S005); S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024); and H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
Install
1. Connect the master cylinder supply hose to a
new reservoir.
19
Sensors and Switches 2200 SRM 1142

See Figure 13 for lift truck models • H6.0FT, H7.0FT (H135FT, H155FT)
• S30FT, S35FT, S40FTS (E010) (H006, J006)

• H1.6FT, H1.8FT, H2.0FTS (H30FT, Periodic Maintenance 8000SRM1558 for lift

H35FT, H40FTS) (F001) truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
• H2.0-3.5FT (H40-70FT) (L177) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)
See Figure 14 for lift truck models
Periodic Maintenance 8000SRM1571 for lift
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
truck models
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004) • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, Periodic Maintenance 8000SRM1583 for lift
H5.0-5.5FT (H80, 90, 100, 110, 120FT) truck models
(N005, P005, R005, S005)
• H6.0FT, H7.0FT (H135FT, H155FT)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, (K006)
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT) Periodic Maintenance 8000SRM1598 for lift
(H006, J006, K006) truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
2. Install new reservoir onto bracket and fill with 120FT; S80, 100FTBCS; S120FTS;
new brake fluid. See one of the following sec- S120FTPRS) (H004)
tions for brake fluid specifications:
Periodic Maintenance 8000SRM1604 for lift
Periodic Maintenance 8000SRM1150 for lift truck models
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• H2.0-3.5FT (H40-70FT) (L177) (S005)

Periodic Maintenance 8000SRM1207 for lift Periodic Maintenance 8000SRM1606

truck models • S6.0FT, S7.0FT (S135FT, S155FT) (G024)
• S30FT, S35FT, S40FTS (E010)
3. Connect brake fluid level switch to cowl har-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, ness.
H35FT, H40FTS) (F001)
4. Install kick panel and dash. Install upper steer-
Periodic Maintenance 8000SRM1248 for lift ing column cover. See Dash and Kick Panel, Re-
truck models move and Install for procedures.
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; 5. Connect battery. For lift truck models below,
S120FTPRS) (G004) install floor plate and floor mat.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • H6.0FT, H7.0FT (H135FT, H155FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (H006, J006, K006)
(N005, P005)

Periodic Maintenance 8000SRM1319 for lift

truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)

Periodic Maintenance 8000SRM1322 for lift

truck models

20 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Connect battery. For lift truck models below, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
lower hood. E024, F024, G024)
• S30FT, S35FT, S40FTS (E010)
2. Remove upper steering column cover and dash
• H1.6FT, H1.8FT, H2.0FTS (H30FT, and kick panel. See Dash and Kick Panel, Re-
H35FT, H40FTS) (F001) move and Install for procedures.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
3. Disconnect brake pedal position sensor from
• H2.0-3.5FT (H40-70FT) (L177) cowl harness.
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
See Figure 14 for lift truck models
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004) • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
S120FTPRS) (G004, H004)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
(N005, P005, R005, S005)
E024, F024, G024)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
SERVICE BRAKE PEDAL POSITION E024, F024, G024)
SENSOR • H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
Remove
See Figure 15 for lift truck models
1. For lift truck models below, to access battery, • S30FT, S35FT, S40FTS (E010)
remove floor mat and floor plate. Disconnect
battery. • H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • H2.0-3.5FT (H40-70FT) (L177)
H175FT36, H190FT) (A299, B299)
See Figure 16 for lift truck models
For lift truck models below, to access battery, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
raise hood. Disconnect battery. H175FT36, H190FT) (A299, B299)
• S30FT, S35FT, S40FTS (E010)
See Figure 17 for lift truck models
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H35FT, H40FTS) (F001) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (R005, S005)
• H2.0-3.5FT (H40-70FT) (L177) • S6.0FT, S7.0FT (S135FT, S155FT) (F024,
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, G024)
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)

Confidential/Proprietary - Do Not Copy or Duplicate 21

Sensors and Switches 2200 SRM 1142

NOTE: SERVICE BRAKE PEDAL POSITION SEN-

SOR FOR LIFT TRUCK MODELS H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
SHOWN. SERVICE BRAKE PEDAL POSITION SEN-
SORS FOR ALL LIFT TRUCKS COVERED IN THIS
MANUAL ARE MOUNTED THE SAME WAY.

1. MOUNTING BRACKET CAPSCREW

2. MOUNTING BRACKET
3. CAPSCREWS AND NUTS
4. SERVICE BRAKE PEDAL POSITION SENSOR
5. SERVICE BRAKE PEDAL POSITION SENSOR
1. MOUNTING BRACKET CAPSCREW CONNECTOR
2. BRAKE PEDAL POSITION SENSOR 6. BRAKE PEDAL
3. MASTER CYLINDER 7. PARKING BRAKE
4. SERVICE BRAKE PRESSURE SENSOR
5. PARKING BRAKE SENSOR CONNECTOR (TO Figure 16. Service Brake Pedal Position Sensor
COWL HARNESS) Location, Prior to December, 2009
Figure 15. Service Brake Pedal Position Sensor
and Service Brake Pressure Sensor For Lift Truck
Models S30FT, S35FT, S40FTS (E010); H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT
(H40-70FT) (L177)

22 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

1. NUTS
1. MOUNTING BRACKET CAPSCREW 2. MOUNTING BRACKET
2. MOUNTING BRACKET 3. SERVICE BRAKE PEDAL POSITION SENSOR
3. CAPSCREWS AND NUTS CONNECTOR
4. SERVICE BRAKE PEDAL POSITION SENSOR 4. SERVICE BRAKE PEDAL POSITION SENSOR
5. SERVICE BRAKE PEDAL POSITION SENSOR 5. CAPSCREWS
CONNECTOR
6. BRAKE PEDAL Figure 18. Brake Pedal Position Sensor
7. PARKING BRAKE Disassembly, Prior to December, 2009
Figure 17. Service Brake Pedal Position Sensor
Location, After December, 2009

4. Remove mounting bracket capscrew, mounting

bracket, and brake pedal position sensor from
lift truck.

See Figure 16 for lift trucks built prior to Decem-

ber, 2009.

See Figure 17.for lift trucks built after Decem-

ber, 2009.
1. NUTS
2. MOUNTING BRACKET
5. Remove two capscrews, two nuts, and brake 3. SERVICE BRAKE PEDAL POSITION SENSOR
pedal position sensor from mounting bracket. CONNECTOR
4. SERVICE BRAKE PEDAL POSITION SENSOR
See Figure 18 for lift trucks built prior to Decem- 5. CAPSCREWS
ber, 2009.
Figure 19. Brake Pedal Position Sensor
See Figure 19 for lift trucks built after Decem- Disassembly, After December, 2009
ber, 2009.

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

Confidential/Proprietary - Do Not Copy or Duplicate 23

Sensors and Switches 2200 SRM 1142

See Figure 18 for lift trucks built prior to Decem- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
ber, 2009. H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005)
See Figure 19, for lift trucks built after Decem-
ber, 2009. 4. Install kick panel and dash. Install upper steer-
ing column cover. See Dash and Kick Panel, Re-
2. Install mounting bracket and service brake move and Install for procedures.
pedal position sensor to lift truck using mount-
ing bracket capscrew. Connect service brake 5. Connect battery. For lift truck models below,
pedal position sensor to cowl harness. install floor plate and floor mat.
• H6.0FT, H7.0FT (H135FT, H155FT)
See Figure 16 for lift trucks built prior to Decem-
(H006, J006, K006)
ber, 2009.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
See Figure 17 for lift trucks built after Decem- H175FT36, H190FT) (A299, B299)
ber, 2009.
Connect battery. For lift truck models below
3. After new service brake pedal position sensor lower hood.
has been installed, check the gap between the
• S30FT, S35FT, S40FTS (E010)
sensor arm and tab. See one of the following
sections for procedures: • H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
Brake System 1800SRM1135 for lift truck mod- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
els
• H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
• H1.6FT, H1.8FT, H2.0FTS (H30FT, 120FT; S80, 100FTBCS; S120FTS;
H35FT, H40FTS) (F001) S120FTPRS) (G004, H004)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H2.0-3.5FT (H40-70FT) (L177) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
Brake System - DANA 1800SRM1247 for lift
truck models • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024) PARKING BRAKE SENSOR
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; Remove
S120FTPRS) (G004)
1. For lift truck models below, to access battery,
• H6.0FT, H7.0FT (H135FT, H155FT)
remove floor mat and floor plate. Disconnect
(H006, J006, K006)
battery.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H6.0FT, H7.0FT (H135FT, H155FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(H006, J006, K006)
(N005, P005, R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (A299, B299)

Wet Brakes - NMHG 1800SRM1597 for lift

truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004)

24 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

For lift truck models below, to access battery,

raise hood. Disconnect battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

2. Remove upper steering column cover and dash

and kick panel. See Dash and Kick Panel, Re-
move and Install for procedures.

3. Disconnect parking brake sensor from cowl har-

ness. Remove torx capscrews from sensor and
remove sensor from parking brake handle as-
sembly. See Figure 20 or Figure 21.

1. PARKING BRAKE SENSOR

2. PARKING BRAKE HANDLE ASSEMBLY
3. PARKING BRAKE SENSOR CONNECTOR (TO
COWL HARNESS)
4. TORX CAPSCREWS

Figure 20. Parking Brake Sensor (Early Design)

Confidential/Proprietary - Do Not Copy or Duplicate 25

Sensors and Switches 2200 SRM 1142

Connect battery. For lift truck models below,

lower hood.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

SERVICE BRAKE PRESSURE SENSOR

1. PARKING BRAKE SENSOR Remove
2. PARKING BRAKE HANDLE ASSEMBLY
3. PARKING BRAKE SENSOR CONNECTOR (TO 1. For lift truck models below, to access battery,
COWL HARNESS)
4. TORX CAPSCREWS remove floor mat and floor plate. Disconnect
battery.
Figure 21. Parking Brake Sensor, Lift Truck Model • H6.0FT, H7.0FT (H135FT, H155FT)
(Late Design) (H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Install
For lift truck models below, to access battery,
1. Install new sensor by using torx capscrews to raise hood. Disconnect battery.
secure sensor to parking brake handle assem-
bly. • S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
2. Visually inspect sensor to ensure sensor arm H35FT, H40FTS) (F001)
and parking brake lever maintain continuous
contact throughout full range of lever opera- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
tion. • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
3. Connect sensor to cowl harness. See Figure 20
120FT; S80, 100FTBCS; S120FTS;
or Figure 21.
S120FTPRS) (G004, H004)
4. Install kick panel and dash. Install upper steer- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
ing column cover. See Dash and Kick Panel, Re- H5.0-5.5FT (H80, 90, 100, 110, 120FT)
move and Install for procedures. (N005, P005, R005, S005)
5. Connect battery. For lift truck models below, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
install floor plate and floor mat. E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

26 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

2. Remove floor mat and floor plate to access serv-

ice brake pressure sensor for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024, G024)

3. Disconnect the sensor from the cowl harness

and remove it from the master cylinder.

See Figure 14 for lift truck models

• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)

See Figure 15 for lift truck models

• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

NOTE: Perform Step 4 for lift truck models

H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299).

4. Disconnect the sensor from the cowl harness

and remove it from the modulating brake valve.
See Figure 22. Figure 22. Brake Pressure Sensor and
Accumulator Pressure Switch, Lift Truck Models
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)

Confidential/Proprietary - Do Not Copy or Duplicate 27

Sensors and Switches 2200 SRM 1142

Legend for Figure 22 • H6.0FT, H7.0FT (H135FT, H155FT)

(H006, J006, K006)
1. PARKING BRAKE SENSOR
2. ACCUMULATOR PRESSURE SWITCH See Figure 15 for lift truck models
3. BRAKE PRESSURE SENSOR
4. MODULATING BRAKE VALVE • S30FT, S35FT, S40FTS (E010)
5. ACCUMULATOR • H1.6FT, H1.8FT, H2.0FTS (H30FT,
6. ACCUMULATOR CHARGE VALVE
7. PARKING BRAKE H35FT, H40FTS) (F001)
8. BRAKE PEDAL • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Install See Figure 16 for lift truck models

1. Install a new sensor on master cylinder. • H8.0FT, H8.0FT9, H9.0FT (H170FT,

Tighten sensor to 23 to 28 N•m (204 to H175FT36, H190FT) (A299, B299)
248 lbf in) for lift truck models 4. Bleed the brake system as described in the sec-
• S30FT, S35FT, S40FTS (E010) tion:
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
Brake System 1800SRM1135 for lift truck mod-
H35FT, H40FTS) (F001)
els
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S30FT, S35FT, S40FTS (E010)
• H2.0-3.5FT (H40-70FT) (L177)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, H35FT, H40FTS) (F001)
120FT; S80, 100FTBCS; S120FTS;
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
S120FTPRS) (G004, H004)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) Brake System - DANA 1800SRM1247 for lift
(N005, P005, R005, S005) truck models
• S6.0FT, S7.0FT (S135FT, S155FT) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
(D024, E024, F024, G024) E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT) • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
(H006, J006, K006) 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004)
NOTE: Perform Step 2 for lift truck models
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, • H6.0FT, H7.0FT (H135FT, H155FT)
H190FT) (A299, B299). (H006, J006, K006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
2. Install a new sensor on modulating brake H5.0-5.5FT (H80, 90, 100, 110, 120FT)
valve. Tighten sensor to 23 to 28 N•m (204 to (N005, P005, R005)
248 lbf in). See Figure 22.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
3. Connect new sensor to cowl harness. H175FT36, H190FT) (A299, B299)

See Figure 14 for lift truck models Wet Brakes - NMHG 1800SRM1597 for lift
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, truck models
120FT; S80, 100FTBCS; S120FTS; • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (G004, H004) 120FT; S80, 100FTBCS; S120FTS;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, S120FTPRS) (H004)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
(N005, P005, R005, S005) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, (R005, S005)
E024, F024, G024)

28 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
5. Connect battery. For lift truck models below,
install floor plate and floor mat.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect battery. For lift truck models below
lower hood.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
ACCUMULATOR PRESSURE SWITCH
FOR LIFT TRUCK MODELS H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
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 serv-
ice brakes from stopping the lift truck. Serious in-
jury to personnel can result.
During operation of lift truck, if the red, low accu-
mulator pressure light illuminates and an audible
alarm sounds (see Operating Manual), accumula-
tor 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 condi-
tion has been corrected.
Remove
1. Remove floor mat and floor plate and discon-
nect battery.
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
2. Disconnect accumulator pressure switch from
the cowl harness and remove it from the accu-
mulator charge valve. See Figure 22.
Install
1. Install new accumulator pressure switch into
accumulator charge valve. Connect cowl har-
ness to accumulator pressure switch. See Fig-
ure 16.
2. Connect battery and install floor plate and floor
mat.
3. Bleed brake system as described in service
manual Brake System - DANA
1800SRM1247.
MONOTROL® SENSOR MICROSWITCH
Remove
1. For lift truck models below, to access battery,
remove floor mat and floor plate. Disconnect
battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
For lift truck models below, to access battery,
raise hood. Disconnect battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
2. Remove MONOTROL® pedal assembly from
throttle base plate and cowl. Follow removal
procedures in one of the following sections:
29
Sensors and Switches 2200 SRM 1142

Powershift Transmission 1300SRM1129 for Two-Speed Powershift Transmission Re-

lift truck models pair 1300SRM1343 for lift truck models
• S30FT, S35FT, S40FTS (E010) • S6.0FT, S7.0FT (S135FT, S155FT) (G024)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
Single Speed PowerShift, Aluminum Gear
H35FT, H40FTS) (F001)
Drive Transmission 1300SRM1421 for lift
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) truck models
• H2.0-3.5FT (H40-70FT) (L177) • S30FT, S35FT, S40FTS (E010)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, • H1.6FT, H1.8FT, H2.0FTS (H30FT,
120FT; S80, 100FTBCS; S120FTS; H35FT, H40FTS) (F001)
S120FTPRS) (G004)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H2.0-3.5FT (H40-70FT) (L177)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) Single Speed Powershift 1300SRM1447 for
lift truck models
One and Two Speed Transmissions
1300SRM1569 for lift truck models • S30FT, S35FT, S40FTS (E010)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • H1.6FT, H1.8FT, H2.0FTS (H30FT,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) H35FT, H40FTS) (F001)
(R005, S005) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, • H2.0-3.5FT (H40-70FT) (L177)
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004) 3. Remove u-clip, foam lock seal, and wiring har-
ness from the pedal frame. Remove four pan
Three-Speed Powershift Transmission Re- head screws, lockwashers, washers, pedal pad,
pair 1300SRM1317 for lift truck models and springs from pedal frame. If any metal in-
• H6.0FT, H7.0FT (H135FT, H155FT) serts in pedal pad are damaged, replace as nec-
(H006, J006, K006) essary. See Figure 23.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 4. Remove two hex head screws 19 mm (3/4 in.),
E024, F024, G024) lockwashers, nuts, and microswitch from pedal
• H8.0FT, H8.0FT9, H9.0FT (H170FT, pad. Repeat for remaining microswitch and re-
H175FT36, H190FT) (A299, B299) move wiring harness from pedal frame.

30 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

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 23. Microswitch Removal

Confidential/Proprietary - Do Not Copy or Duplicate 31

Sensors and Switches 2200 SRM 1142

Install pan head screws with Loctite 222 (Hyster P/N

0360387). Install pan head screws, lockwash-
1. Install microswitch and two hex head screws in ers, and washers in pedal pad. Tighten pan
pedal pad. Coat exposed threads of hex head head screws to 2.25 to 2.50 N•m (19 to
screws with Loctite™ 222 (Hyster P/N 22 lbf in).
0360387). Install two lockwashers and nuts on
hex head screws. DO NOT tighten nuts at this 4. Install MONOTROL® pedal assembly onto the
time. Repeat for the other microswitch. truck. Follow installation procedures in one of
the following sections:
2. Put wires through hole in pedal frame. The
white banded wire is for the reverse micro- Powershift Transmission 1300SRM1129 for
switch, and the blue banded wire is for the for- lift truck models
ward microswitch. Adjust each microswitch in • S30FT, S35FT, S40FTS (E010)
its mount so that the measurement between
the edge of the mount and the base of the mi- • H1.6FT, H1.8FT, H2.0FTS (H30FT,
croswitch equals 0.0 to 0.5 mm (0.0 to 0.02 in.). H35FT, H40FTS) (F001)
Tighten mounting nuts of each microswitch as • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
adjustment is completed. See Figure 24. • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)

One and Two Speed Transmissions

1300SRM1569 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004)

Three-Speed Powershift Transmission Re-

pair 1300SRM1317 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

Two-Speed Powershift Transmission Re-

pair 1300SRM1343 for lift truck models
1. MICROSWITCH MOUNT • S6.0FT, S7.0FT (S135FT, S155FT) (G024)
2. MICROSWITCH BASE
Figure 24. Microswitch Adjustment

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

32 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Single Speed PowerShift, Aluminum Gear Remove

Drive Transmission 1300SRM1421 for lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Single Speed Powershift 1300SRM1447 for
lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
5. Connect battery. For lift truck models below,
install floor plate and floor mat.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect battery. For lift truck models below
lower hood.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
1. For lift truck models below, to access battery,
remove floor mat and floor plate. Disconnect
battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
For lift truck models below, to access battery,
raise hood. Disconnect battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
2. Drain coolant from radiator and disconnect
electrical connector from low coolant level sen-
sor.
3. Remove low coolant level sensor from radiator.

LOW COOLANT LEVEL SENSOR

NOTE: The low coolant level sensor is an optional
feature on these lift trucks and is a part of the Elec-
tronic 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 25.

Confidential/Proprietary - Do Not Copy or Duplicate 33

Sensors and Switches 2200 SRM 1142

See Figure 25 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,

• H6.0FT, H7.0FT (H135FT, H155FT) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(H006, J006, K006) (N005, P005, R005, S005)

• S30FT, S35FT, S40FTS (E010) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,

E024, F024, G024)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001) See Figure 26 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H2.0-3.5FT (H40-70FT) (L177) H175FT36, H190FT) (A299, B299)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)

34 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Figure 25. Low Level Coolant Sensor

Confidential/Proprietary - Do Not Copy or Duplicate 35

Sensors and Switches
A. GM 2.4L ENGINES, RADIATOR WITH EXTER-
NAL COOLER SHOWN
B. MAZDA 2.0L AND 2.2L ENGINES EXCEPT 2007
EMISSION COMPLIANT ENGINES (MODINE
SHOWN), RADIATOR WITH INTERNAL
COOLER SHOWN
C. CUMMINS 4.5L AND YANMAR DIESEL EN-
GINES AND GM 4.3L AND PSI 4.3L ENGINES
WITH INTERNAL COOLER SHOWN
1. RADIATOR
NOTE: CUMMINS QSB 3.3L DIESEL ENGINE WITH
CHARGE AIR INTERCOOLER SHOWN.
1. RADIATOR
2. LOW LEVEL COOLANT SENSOR
Figure 26. Low Coolant Level Sensor, Lift Truck
Models H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Install
1. Install new low coolant level sensor into radia-
tor.
See Figure 25 for lift truck models
• H6.0FT, H7.0FT (H135FT,
(H006, J006, K006)
• S30FT, S35FT, S40FTS (E010)
36
2200 SRM 1142
Legend for Figure 25
D. CUMMINS 4.5L AND YANMAR DIESEL EN-
GINES AND GM 4.3L AND 5.7L ENGINES AND
PSI 4.3L ENGINES AND KUBOTA 3.8L DIESEL
ENGINES WITH EXTERNAL COOLER SHOWN
E. MAZDA 2007 EMISSION COMPLIANT 2.0L AND
2.2L ENGINES (MODINE SHOWN), RADIATOR
WITH INTERNAL COOLER SHOWN
F. CUMMINS QSB 3.3L DIESEL ENGINE WITH IN-
TERNAL COOLER SHOWN, LIFT TRUCK MOD-
ELS H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
2. LOW LEVEL COOLANT SENSOR
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
See Figure 26 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
2. Connect the electrical connector to the low cool-
ant level sensor. Refill radiator with correct
coolant of 50% water and 50% Ethylene Glycol
Boron-Free Antifreeze.
3. Seal threads with Loctite PST 567 (Hyster P/N
273338) thread sealant and torque to
7 N•m (62 lbf in).
4. Connect battery. For lift truck models below,
install floor plate and floor mat.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
H155FT)
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142 Sensors and Switches

Connect battery. For lift truck models below

lower hood.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

FUEL LEVEL SENSOR, GAS AND DIESEL

ENGINES ONLY
NOTE: If lift truck is equipped with a Mazda 2007
emissions compliant 2.0L or 2.2L gas engine, or if
lift truck was built after January, 2010 and equip-
ped with Mazda gas engine, see the following serv-
ice manual to replace fuel level sensor.

• Gasoline Fuel System 0900SRM1325

Remove
1. To access the battery, raise the hood, on lift
truck models below. Disconnect the battery.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

2. Disconnect the electrical connector from the

sensor on the fuel pump cover.
NOTE: GAS FUEL PUMP SHOWN. FUEL LEVEL
3. Unscrew the sensor and remove sensor and SENSOR LOCATED IN SAME POSITION FOR DIE-
sender unit from fuel pump assembly. See Fig- SEL FUEL PUMP.
ure 27.
1. BRACKET
2. FUEL SENDER UNIT
3. FUEL LEVEL SENSOR
4. FUEL PUMP COVER

Figure 27. Fuel Pump and Sensor

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Sensors and Switches 2200 SRM 1142

Install
1. Install new fuel level sensor and sender unit
through hole in fuel pump cover. Be sure that
the bracket in the fuel pump engages the plas-
tic piece on the bottom of the fuel sender unit.
Tighten fuel level sensor and sender unit onto
fuel pump cover. See Figure 27.
2. Connect the fuel level sensor electrical connec-
tor.
Remove
1. Raise the hood and disconnect the battery.
2. Unlatch and raise armrest.
3. Remove arm pad by removing four screws from
underside of armrest. Disconnect armrest
switch from seat harness. See Figure 28. Re-
move screws securing armrest switch to arm-
rest bracket and remove switch.

3. Connect the battery and lower the hood, on lift

truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

ARMREST SWITCH
NOTE: Lift truck models shown below are NOT
equipped with an armrest switch
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

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2200 SRM 1142 Sensors and Switches

Figure 28. Armrest Switch

Confidential/Proprietary - Do Not Copy or Duplicate 39

Sensors and Switches 2200 SRM 1142

Legend for Figure 28

NOTE: NON-SWIVEL SEAT SHOWN.

A. FRONT VIEW B. BOTTOM VIEW

1. ARMREST SWITCH 4. ARMREST SCREWS
2. SWITCH ACTUATOR 5. SEAT HARNESS
3. ARMREST PAD

Install
1. Install new armrest switch on bracket. Connect
switch to seat harness. See Figure 28.

2. Install arm pad by inserting four screws into

underside of armrest.

3. Close and latch armrest.

4. Connect the battery and lower the hood.

SEAT SENSOR (OPERATOR PRESENCE

SYSTEM)

Non-Suspension and Semi-Suspension

Seats; For Lift truck Models S30-35FT,
S40FTS (E010), H1.6-1.8FT, H2.0FTS
(H30-35FT, H40FTS) (F001), S2.0-3.5FT
(S40-70FT, S55FTS) (F187), H2.0-3.5FT
(H40-70FT) (L177), S4.0-5.5FT, S5.5FTS
(S80-120FT; S80-100FTBCS; S120FTS;
S120FTPRS) (G004, H004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT)
(N005, P005, R005, S005), S6.0-7.0FT
(S135-155FT) (D024, E024, F024, G024)
Remove
1. Raise hood for access to battery and disconnect
battery.
2. Disconnect seat harness from chassis harness.
Remove seat harness from brackets that are at-
tached to hood. See Figure 29.
NOTE: BOTTOM VIEW OF HOOD SHOWN.
1. CAPSCREWS
2. SEAT HARNESS BRACKET
3. SEAT HARNESS
Figure 29. Seat Removal, Non-Suspension and
Semi-Suspension Seats
3. Remove four capscrews and washers holding
seat to hood. Remove seat from hood.
4. Disconnect seat sensor. See Figure 30.
5. Remove two capscrews and seat sensor from
seat.

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2200 SRM 1142 Sensors and Switches

Remove
1. For access to battery, remove floor plate and
floor mat. Disconnect battery.

2. Disconnect seat harness from chassis harness.

Remove the seat harness from the bracket that
is attached to the seat surround plate. See Fig-
ure 31.

1. CAPSCREWS
2. SEAT SENSOR
3. SEAT SENSOR ELECTRICAL CONNECTOR
4. SEAT GROUND WIRE
5. SEAT HARNESS
NOTE: BOTTOM VIEW SHOWN.
Figure 30. Seat Sensor, Non-Suspension and
Semi-Suspension Seats 1. HARNESS BRACKET
2. SEAT HARNESS
3. SEAT SURROUND PLATE
Install 4. FLANGE NUTS
5. SEAT PLATE
1. Insert two capscrews and install sensor to seat.
See Figure 30. Figure 31. Seat Removal, Non-Suspension Seat,
Lift Truck Models H6.0FT, H7.0FT (H135FT,
2. Connect new seat sensor to seat harness. H155FT) (H006, J006, K006)

3. Install seat onto hood using four capscrews and

washers. Tighten capscrews to 3. Remove the four flange nuts holding the seat to
18 N•m (156 lbf in). See Figure 29. the seat plate. Remove seat from seat plate.

4. Install seat harness to brackets on hood. 4. Disconnect the seat sensor. See Figure 30.

5. Connect seat harness to chassis harness. 5. Remove two capscrews and seat sensor from
the seat.
6. Connect the battery and close hood.
Install
Non-Suspension Seats; Lift Truck Models
H6.0FT, H7.0FT (H135FT, H155FT) (H006, 1. Insert two capscrews and install new sensor to
J006, K006) seat. See Figure 30.

NOTE: Lift truck model shown below is NOT 2. Connect new seat sensor to seat harness.
equipped with a non-suspension seat. 3. Install seat onto seat plate using four flange
• H8.0FT, H8.0FT9, H9.0FT (H170FT, nuts. Tighten flange nuts to 18 N•m (156 lbf in)
H175FT36, H190FT) (A299, B299) See Figure 31.

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Sensors and Switches 2200 SRM 1142

4. Install seat harness to bracket on seat sur- 2. Connect seat sensor to seat harness. See Fig-
round plate. ure 32.

5. Connect seat harness to chassis harness.
6. Connect the battery and install the floor plate
and floor mat.
Full Suspension Seats; All Lift Truck Models
Remove
3. Place bottom seat cushion onto seat base and
secure cushion to base with two clips.
HOOD SHUT OFF SWITCH
NOTE: The hood shut off switch is found on certain
lift truck models manufactured for use in Europe
only.

1. Remove two clips that secure the bottom seat Remove

cushion to seat base. See Figure 32.
1. To access the battery, remove the floor mat and
2. Lift bottom seat cushion up and disconnect the floor plate, on lift truck models below. Discon-
seat sensor from harness. nect the battery.
3. Use a small, flat-bladed screwdriver and re- • H6.0FT, H7.0FT (H006, J006)
move the seat sensor from bottom seat cushion. • H8.0FT, H8.0FT9, H9.0FT (A299)

To access the battery, raise the hood, on lift

truck models below. Disconnect the battery.
• H1.6FT, H1.8FT, H2.0FTS (F001)
• S2.0-3.5FT (F187)
• H2.0-3.5FT (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (N005, P005)
• S6.0FT, S7.0FT (D024, E024, F024, G024)

2. Raise the hood and disconnect switch from rear

harness to chassis harness connector and re-
move capscrews to remove switch from bracket.

See Figure 33 for lift truck models

• S4.0, 5.0, 5.5FT, S5.5FTS (G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (N005, P005)
• S6.0FT, S7.0FT (D024, E024, F024, G024)
1. SEAT SENSOR
2. SEAT HARNESS • H1.6FT, H1.8FT, H2.0FTS (F001)
3. TO CHASSIS HARNESS • S2.0-3.5FT (F187)
4. CLIPS
5. BOTTOM SEAT CUSHION • H2.0-3.5FT (L177)
6. SEAT BASE
Figure 32. Seat Sensor, Full-Suspension Seat See Figure 34 for lift truck models
• H6.0FT, H7.0FT (H006, J006)
Install • H8.0FT, H8.0FT9, H9.0FT (A299)

1. Install new seat sensor into bottom seat cush-

ion.

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2200 SRM 1142 Sensors and Switches

NOTE: BOTTOM VIEW OF HOOD SHOWN.

1. REAR HARNESS TO CHASSIS HARNESS CON- 3. BRACKET CAPSCREW

NECTOR 4. ACTUATOR MAGNET SWITCH
2. HOOD SHUT OFF SWITCH
Figure 33. Hood Shut Off Switch, Lift Truck Models S4.0, 5.0, 5.5FT, S5.5FTS (G004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (N005, P005), S6.0FT, S7.0FT (D024, E024, F024, G024), H1.6FT, H1.8FT,
H2.0FTS (F001), S2.0-3.5FT (F187), and H2.0-3.5FT (L177)

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Sensors and Switches 2200 SRM 1142

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

1. HINGE BRACKET 4. REAR HARNESS TO CHASSIS HARNESS CON-

2. ACTUATOR MAGNET NECTOR
3. HOOD SHUT OFF SWITCH 5. KEY SWITCH

Figure 34. Hood Shut Off Switch, Lift Truck Models H6.0FT, H7.0FT (H006, J006) and H8.0FT, H8.0FT9,
H9.0FT (A299)

Install • S2.0-3.5FT (F187)

• H2.0-3.5FT (L177)
1. Install new switch on bracket using the cap-
screws and connect switch to rear harness to See Figure 34 for lift truck models
chassis harness connector.
• H6.0FT, H7.0FT (H006, J006)
See Figure 33 for lift truck models • H8.0FT, H8.0FT9, H9.0FT (A299)
• S4.0, 5.0, 5.5FT, S5.5FTS (G004)
2. Connect the battery, install the floor plate and
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, floor mat, on lift truck models
H5.0-5.5FT (N005, P005)
• H6.0FT, H7.0FT (H006, J006)
• S6.0FT, S7.0FT (D024, E024, F024, G024)
• H8.0FT, H8.0FT9, H9.0FT (A299)
• H1.6FT, H1.8FT, H2.0FTS (F001)

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2200 SRM 1142 Sensors and Switches

Connect the battery and lower the hood, on lift Legend for Figure 35
truck models
1. BOOT PROTECTOR
• H1.6FT, H1.8FT, H2.0FTS (F001) 2. MOUNTING BRACKET
• S2.0-3.5FT (F187) 3. REMOTE KEY SWITCH ASSEMBLY
4. NUT
• H2.0-3.5FT (L177) 5. KEY
• S4.0, 5.0, 5.5FT, S5.5FTS (G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, 3. Loosen the nut and remove remote key switch
H5.0-5.5FT (N005, P005) assembly from mounting bracket.
• S6.0FT, S7.0FT (D024, E024, F024, G024)
Install
REMOTE KEY SWITCH
1. Install new remote key switch assembly into
NOTE: Lift truck models shown below may be mounting bracket. Tighten nut to secure the as-
equipped with an optional remote key switch on the sembly to mounting bracket.
right side of the engine compartment.
2. Connect boot protector to remote key switch as-
• H6.0FT, H7.0FT (H006, J006)
sembly. See Figure 35.
• H8.0FT, H8.0FT9, H9.0FT (A299)
3. Close the hood. Connect the battery and install
Remove floor plate and floor mat.

1. Remove the floor mat and floor plate for access
to the battery. Disconnect the battery.
2. Raise the hood and pull back the boot protector
and disconnect boot protector from the remote
key switch assembly. See Figure 35.
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 Moni-
toring package option.

Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

Figure 35. Remote Key Switch Replacement, Lift

Truck Models H6.0FT, H7.0FT (H006, J006) and
H8.0FT, H8.0FT9, H9.0FT (A299)

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Sensors and Switches 2200 SRM 1142

To access the battery, raise the hood, on lift • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
truck models below. Disconnect the battery. H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S30FT, S35FT, S40FTS (E010) (N005, P005, R005, S005)

• H1.6FT, H1.8FT, H2.0FTS (H30FT, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,

H35FT, H40FTS) (F001) E024, F024, G024)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
2. Disconnect the hydraulic filter pressure switch
from the chassis harness. Remove switch from
hydraulic filter head assembly and discard
switch and O-ring. See Figure 36.

46 Confidential/Proprietary - Do Not Copy or Duplicate

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Figure 36. Hydraulic Filter Pressure Switch

Confidential/Proprietary - Do Not Copy or Duplicate 47

Sensors and Switches 2200 SRM 1142

Legend for Figure 36

A. HYDRAULIC FILTER USED ON LIFT TRUCK MODELS S30-35FT, S40FTS (E010), H1.6-1.8FT, H2.0FTS
(H30-35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), AND H2.0-3.5FT (H40-70FT) (L177)
B. HYDRAULIC FILTER USED ON LIFT TRUCK MODELS S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004, H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005, P005, R005, S005), S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
1. HYDRAULIC FILTER PRESSURE SWITCH 3. FILTER HEAD ASSEMBLY
2. O-RING (NOT SHOWN)

Install TRANSMISSION SPEED SENSOR

1. Insert new switch, with new O-ring, into hy-
draulic filter head assembly. Torque switch to
20 N•m (177 lbf in). Connect hydraulic filter
pressure switch to chassis harness. See Fig-
ure 36.
2. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood, on lift
truck models below. Disconnect the battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
NOTE: Perform Step 2 for lift trucks equipped with
an iron transmission housing.

2. Disconnect sensor from transmission harness

and remove bolt securing sensor to transmis-
sion housing. Discard the O-rings.

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2200 SRM 1142 Sensors and Switches

See Figure 37 for lift truck models

• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

See Figure 38 for lift truck models

• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

NOTE: TWO-SPEED TRANSMISSION SHOWN FOR

LIFT TRUCK MODELS
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005, R005, S005)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

1. PRESSURE SENSORS
2. PRESSURE SENSOR (TWO-SPEED ONLY)
3. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
4. TRANSMISSION INPUT SPEED SENSOR
(TISS)
5. BOLTS
6. TEMPERATURE SENSOR

Figure 37. Transmission Sensors - Iron Housing

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Sensors and Switches 2200 SRM 1142

NOTE: THREE-SPEED TRANSMISSION SHOWN.

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

1. TEMPERATURE SENSOR 5. TRANSMISSION OUTPUT SPEED SENSOR
2. ENGINE SPEED SENSOR (THREE-SPEED (TOSS)**
TRANSMISSION ONLY) 6. PRESSURE SENSORS
3. INTERMEDIATE SPEED SENSOR (THREE- 7. TRANSMISSION INPUT SENSOR (TISS)
SPEED TRANSMISSION ONLY)
4. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)*

*TOSS SENSOR LOCATION, THREE-SPEED TRANSMISSION ONLY.

**TOSS SENSOR LOCATION, TWO-SPEED TRANSMISSION ONLY.

Figure 38. Transmission Sensors, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)

NOTE: Perform Step 3 for lift trucks built prior to • H1.6FT, H1.8FT, H2.0FTS (H30FT,
January, 2011 equipped with an aluminum trans- H35FT, H40FTS) (F001)
mission housing. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
3. Remove capscrew, washer, and shield from the • H2.0-3.5FT (H40-70FT) (L177)
top of the transmission housing. See Figure 39.
See Figure 40 for lift truck models
NOTE: Perform Step 4 and Step 5 for lift truck • S30FT, S35FT, S40FTS (E010)
equipped with an aluminum housing.
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
4. Disconnect sensor from transmission harness. H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
5. Remove capscrew, washer, and sensor from
transmission housing. Remove and discard O- • H2.0-3.5FT (H40-70FT) (L177)
ring from sensor.

See Figure 39 for lift truck models

• S30FT, S35FT, S40FTS (E010)

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NOTE: ALUMINUM TRANSMISSION SHOWN FOR

LIFT TRUCKS S30FT, S35FT, S40FTS (E010),
NOTE: ALUMINUM TRANSMISSION SHOWN FOR
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
LIFT TRUCKS S30FT, S35FT, S40FTS (E010),
(F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
AND H2.0-3.5FT (H40-70FT) (L177).
(F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
AND H2.0-3.5FT (H40-70FT) (L177). 1. CAPSCREW
2. WASHER
1. CAPSCREW 3. TRANSMISSION SENSOR
2. WASHER 4. TRANSMISSION SPEED SENSOR
3. SHIELD 5. PRESSURE SENSOR
4. TRANSMISSION SENSOR 6. TEMPERATURE SENSOR
5. TRANSMISSION SPEED SENSOR
6. PRESSURE SENSOR Figure 40. Transmission Sensors - Aluminum
7. TEMPERATURE SENSOR Housing Built After January, 2011
Figure 39. Transmission Sensors - Aluminum
Housing Built Prior to January, 2011

Confidential/Proprietary - Do Not Copy or Duplicate 51

Sensors and Switches
Install
NOTE: Perform Step 1 for lift trucks equipped with
an iron transmission housing.
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.
See Figure 37 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 38 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
NOTE: Perform Step 2 and Step 3 for lift trucks
equipped with an aluminum transmission housing.
2. Install new O-ring on sensor. Install sensor,
washer, and capscrew on transmission housing.
See Figure 39 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 40 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
52
2200 SRM 1142
3. Connect sensor to transmission harness.
NOTE: Perform Step 4 for lift trucks built prior to
January, 2011 equipped with an aluminum trans-
mission housing.
4. Install shield, washer, and capscrew onto top of
transmission housing. See Figure 39.
5. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
TRANSMISSION PRESSURE SENSORS
Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142
To access the battery, raise the hood, on lift
truck models below. Disconnect the battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
NOTE: Perform Step 2 for lift truck equipped with
an iron transmission housing.
2. Disconnect the pressure sensors from the trans-
mission harness. Remove sensors from fitting
on the control valve.
See Figure 37 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 38 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
NOTE: Perform Step 3 for lift trucks shown below,
built prior to January, 2011, equipped with an alu-
minum transmission housing.
3. Remove capscrew, washer, and shield from the
top of the transmission housing.
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
See Figure 39 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
NOTE: Perform Step 4 and Step 5 for lift trucks
built after January, 2011, equipped with an alumi-
num transmission housing.
4. Disconnect pressure sensor from transmission
harness.
5. Remove pressure sensor from transmission
housing.
See Figure 39 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 40 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Install
NOTE: When new transmission pressure sensors
are installed, calibration is required for transmis-
sions with an iron housing. See the section Cali-
bration Procedures 8000SRM1134 for calibration
procedures.
NOTE: Perform Step 1 for lift trucks equipped with
an iron transmission housing.
1. Install new sensors on control valve. Connect
sensors to transmission harness.
53
Sensors and Switches
See Figure 37 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 38 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
NOTE: Perform Step 2 and Step 3 for lift trucks
built after January, 2011, equipped with an alumi-
num transmission housing.
2. Install pressure sensor on transmission hous-
ing.
See Figure 39 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 40 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
3. Connect pressure sensor to transmission har-
ness.
NOTE: Perform Step 4 for lift trucks built prior to
January, 2011 equipped with an aluminum trans-
mission housing.
54
2200 SRM 1142
4. Install shield, washer, and capscrew onto top of
transmission housing. See Figure 39.
5. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
TRANSMISSION TEMPERATURE
SENSOR
Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142 Sensors and Switches

To access the battery, raise the hood, on lift Periodic Maintenance 8000SRM1571 for lift
truck models below. Disconnect the battery. truck models
• S30FT, S35FT, S40FTS (E010) • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
Periodic Maintenance 8000SRM1322 for lift
H35FT, H40FTS) (F001)
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H6.0FT, H7.0FT (H135FT, H155FT)
• H2.0-3.5FT (H40-70FT) (L177) (H006, J006)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
Periodic Maintenance 8000SRM1407 for lift
120FT; S80, 100FTBCS; S120FTS;
truck models
S120FTPRS) (G004, H004)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H175FT36, H190FT) (A299)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005) Periodic Maintenance 8000SRM1586 for lift
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, truck models
E024, F024, G024) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
2. Put the lift truck on blocks. See the Operating
Manual or one of the following sections for the Periodic Maintenance 8000SRM1583 for lift
procedures: truck models
Periodic Maintenance 8000SRM1150 for lift • H6.0FT, H7.0FT (H135FT, H155FT)
truck models (K006)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) Periodic Maintenance 8000SRM1598 for lift
• H2.0-3.5FT (H40-70FT) (L177) truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
Periodic Maintenance 8000SRM1207 for lift
120FT; S80, 100FTBCS; S120FTS;
truck models
S120FTPRS) (H004)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, Periodic Maintenance 8000SRM1604 for lift
H35FT, H40FTS) (F001) truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Periodic Maintenance 8000SRM1248 for lift H5.0-5.5FT (H80, 90, 100, 110, 120FT)
truck models (S005)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; Periodic Maintenance 8000SRM1606 for lift
S120FTPRS) (G004) truck models

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • S6.0FT, S7.0FT (S135FT, S155FT) (G024)

H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) WARNING
Periodic Maintenance 8000SRM1558 for lift At operating temperature, the transmission oil is
truck models HOT. DO NOT permit the hot oil to touch the skin
and cause a burn. Make sure oil is cool before
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; draining.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005) 3. Drain the transmission oil. See one of the fol-
lowing sections for the procedures:
Periodic Maintenance 8000SRM1319 for lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)

Confidential/Proprietary - Do Not Copy or Duplicate 55

Sensors and Switches 2200 SRM 1142

Periodic Maintenance 8000SRM1150 for lift • H6.0FT, H7.0FT (H135FT, H155FT)

truck models (K006)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) Periodic Maintenance 8000SRM1598
• H2.0-3.5FT (H40-70FT) (L177) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
Periodic Maintenance 8000SRM1207 for lift 120FT; S80, 100FTBCS; S120FTS;
truck models S120FTPRS) (H004)

• S30FT, S35FT, S40FTS (E010) Periodic Maintenance 8000SRM1604 for lift

• H1.6FT, H1.8FT, H2.0FTS (H30FT, truck models
H35FT, H40FTS) (F001) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
Periodic Maintenance 8000SRM1248 for lift (S005)
truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, Periodic Maintenance 8000SRM1606 for lift
120FT; S80, 100FTBCS; S120FTS; truck models
S120FTPRS) (G004) • S6.0FT, S7.0FT (S135FT, S155FT) (G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
NOTE: Perform Step 4 for lift trucks built prior to
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
January, 2011 equipped with an aluminum trans-
(N005, P005)
mission housing.
Periodic Maintenance 8000SRM1558 for lift
4. Remove capscrew, washer, and shield from the
truck models
top of the transmission housing. See Figure 39.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 5. Disconnect temperature sensor from transmis-
(R005) sion harness and remove sensor from transmis-
sion.
Periodic Maintenance 8000SRM1319 for lift
truck models See Figure 37 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
E024) 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
Periodic Maintenance 8000SRM1571 for lift
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
truck models
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) (N005, P005, R005, S005)
Periodic Maintenance 8000SRM1322 for lift • S30FT, S35FT, S40FTS (E010)
truck models • H1.6FT, H1.8FT, H2.0FTS (H30FT,
• H6.0FT, H7.0FT (H135FT, H155FT) H35FT, H40FTS) (F001)
(H006, J006) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Periodic Maintenance 8000SRM1407 for lift • H2.0-3.5FT (H40-70FT) (L177)
truck models
See Figure 38 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
H175FT36, H190FT) (A299)
E024, F024, G024)
Periodic Maintenance 8000SRM1586 for lift • H6.0FT, H7.0FT (H135FT, H155FT)
truck models (H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) H175FT36, H190FT) (A299, B299)

Periodic Maintenance 8000SRM1583 for lift

truck models

56 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
See Figure 39 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 40 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Install
1. Install new temperature sensor and connect
sensor to transmission harness.
See Figure 37 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 38 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
See Figure 39 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 40 for lift truck models
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
NOTE: Perform Step 2 for lift trucks built prior to
January, 2011 equipped with an aluminum trans-
mission housing.
2. Install shield, washer, and capscrew onto top of
transmission housing. See Figure 39.
3. Remove lift truck from blocks.
4. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
5. Fill transmission with oil. Run the lift truck
and check oil level. See one of the following sec-
tions for transmission oil specifications and for
the procedures to check the transmission oil
level:
Periodic Maintenance 8000SRM1150 for lift
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
57
Sensors and Switches 2200 SRM 1142

Periodic Maintenance 8000SRM1207 for lift • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
truck models 120FT; S80, 100FTBCS; S120FTS;
• S30FT, S35FT, S40FTS (E010) S120FTPRS) (H004)

• H1.6FT, H1.8FT, H2.0FTS (H30FT, Periodic Maintenance 8000SRM1604 for lift

H35FT, H40FTS) (F001) truck models

Periodic Maintenance 8000SRM1248 for lift • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

truck models H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; Periodic Maintenance 8000SRM1606 for lift
S120FTPRS) (G004) truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • S6.0FT, S7.0FT (S135FT, S155FT) (G024)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) ENGINE SPEED SENSOR
Periodic Maintenance 8000SRM1558 for lift NOTE: The engine speed sensor is used only on lift
truck models truck models shown below, equipped with three-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; speed transmission.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
See Figure 38 for lift truck models
(R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
Periodic Maintenance 8000SRM1319 for lift E024, F024, G024)
truck models • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, J006, K006)
E024) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
Periodic Maintenance 8000SRM1571 for lift H175FT36, H190FT) (A299, B299)
truck models
Remove
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
1. Remove the floor plate and mat from frame and
Periodic Maintenance 8000SRM1322 for lift disconnect the battery for lift truck models
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) • H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) (H006, J006, K006)

Periodic Maintenance 8000SRM1407 for lift • H8.0FT, H8.0FT9, H9.0FT (H170FT,

truck models H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 2. To access the battery, raise the hood, on lift
H175FT36, H190FT) (A299) truck models below. Disconnect the battery.
Periodic Maintenance 8000SRM1586 for lift • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
truck models E024, F024, G024)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) 3. Disconnect engine speed sensor from transmis-
sion harness and remove bolt securing sensor to
Periodic Maintenance 8000SRM1583 for lift transmission housing. Discard the O-ring. See
truck models Figure 38.
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)

Periodic Maintenance 8000SRM1598

58 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
Install
1. Install new O-ring 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. See Figure 38.
2. Connect the battery and place floor plate and
mat onto frame for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
3. Connect battery and lower hood, on lift truck
models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
INTERMEDIATE SPEED SENSOR
NOTE: The intermediate speed sensor is used only
on lift truck models shown below, equipped with
three-speed transmission.
See Figure 38 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood, on lift
truck models below. Disconnect the battery.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
2. Disconnect intermediate speed sensor from
transmission harness and remove bolt securing
sensor to transmission housing. Discard the O-
ring. See Figure 38.
Install
1. Install new O-ring on intermediate speed sen-
sor and install intermediate speed sensor into
transmission housing with the bolt. Tighten
bolt to 6.9 N•m (61 lbf in). Connect intermedi-
ate speed sensor to transmission harness. See
Figure 38.
2. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
RETURN TO SET TILT (TILT ANGLE)
SENSOR
Lift Truck Models S30FT, S35FT, S40FTS
(E010); H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001); S2.0-3.5FT
(S40-70FT, S55FTS) (F187); H2.0-3.5FT
(H40-70FT) (L177)
NOTE: Before working on or near the mast, see the
section Safety Procedures When Working Near
MastSafety Procedures When Working Near Mast
in the section:
Periodic Maintenance 8000SRM1150 for lift
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Periodic Maintenance 8000SRM1207 for lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
59
Sensors and Switches
Remove
1. Raise hood and disconnect the battery.
2. Disconnect mast harness from cowl harness.
3. Remove two torx capscrews and nuts holding
the tilt sensor to the sensor bracket on the mast
and remove sensor and mast harness from sen-
sor and harness brackets. See Figure 41.
NOTE: MAST SHOWN MAY BE DIFFERENT, BUT
LOCATION OF TILT SENSOR IS THE SAME FOR
ALL LIFT TRUCKS COVERED IN THIS SECTION.
1. TORX CAPSCREWS
2. RETURN TO SET TILT (TILT ANGLE) SENSOR
3. SENSOR BRACKET
4. COWL
5. MAST HARNESS (TO COWL HARNESS)
6. HARNESS BRACKET
Figure 41. Return to Set Tilt (Tilt Angle) Sensor
Install
1. Install new sensor onto sensor bracket and in-
sert two torx capscrews and nuts to secure sen-
sor to bracket. Secure mast harness to harness
bracket. See Figure 41.
2. Connect mast harness to cowl harness.
3. Connect battery and close hood.
60
2200 SRM 1142
4. Tilt mast completely forward and backward to
ensure that tilt sensor is correctly installed and
connected.
Lift Truck Models S6.0FT, S7.0FT (S135FT,
S155FT) (D024, E024, F024, G024); S4.0, 5.0,
5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004,
H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005, R005, S005), H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006), H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299,
B299)
NOTE: Before working on or near the mast, see the
section Safety Procedures When Working Near
Mast in the section:
Periodic Maintenance 8000SRM1248 for lift
truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
Periodic Maintenance 8000SRM1558 for lift
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)
Periodic Maintenance 8000SRM1319 for lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
Periodic Maintenance 8000SRM1571 for lift
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
Periodic Maintenance 8000SRM1322 for lift
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142 Sensors and Switches

Periodic Maintenance 8000SRM1407 for lift 3. Remove harness bracket from cowl and remove
truck models harness from bracket.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
4. Remove capscrew that attaches tilt sensor
H175FT36, H190FT) (A299) bracket to mast. See Figure 42.
Periodic Maintenance 8000SRM1586 for lift
5. Remove sensor bracket and tilt sensor from
truck models mast.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) 6. Remove two torx capscrews and nuts holding
tilt sensor to sensor bracket. Remove sensor
Periodic Maintenance 8000SRM1583 for lift from bracket.
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)

Periodic Maintenance 8000SRM1598

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(H004)

Periodic Maintenance 8000SRM1604 for lift

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)

Periodic Maintenance 8000SRM1606 for lift

truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (G024)

Remove
1. To access the battery, remove floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
NOTE: S6.0FT, S7.0FT (S135FT, S155FT) (F024)
• H6.0FT, H7.0FT (H135FT, H155FT) SHOWN.
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 1. TILT SENSOR
2. TILT SENSOR BRACKET
H175FT36, H190FT) (A299, B299) 3. CAPSCREW
4. SENSOR HARNESS BRACKET
To access the battery, raise hood, on lift truck 5. SENSOR CONNECTOR TO COWL HARNESS
models below. Disconnect the battery. 6. COWL
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 7. TILT CYLINDERS
120FT; S80, 100FTBCS; S120FTS; Figure 42. Return to Set Tilt (Tilt Angle) Sensor
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) Install
(N005, P005, R005, S005)
1. Install new tilt sensor onto sensor bracket us-
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, ing two torx capscrews and nuts.
E024, F024, G024)
2. Secure sensor bracket and tilt sensor to mast
2. Disconnect sensor harness from cowl harness. using capscrew. Tighten capscrew to 90 to
See Figure 42. 99 N•m (66 to 73 lbf ft). See Figure 42.

Confidential/Proprietary - Do Not Copy or Duplicate 61

Sensors and Switches 2200 SRM 1142

3. Place sensor harness in harness bracket and in- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
stall bracket onto cowl. Tighten capscrew to H5.0-5.5FT (H80, 90, 100, 110, 120FT)
38 N•m (28 lbf ft). (N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
4. Connect sensor harness connector to cowl har-
E024, F024, G024)
ness.

5. Connect the battery, install floor plate and floor 2. Disconnect rear horn button switch electrical
mat, on lift truck models connector from chassis harness. See Figure 43.

• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
3. Remove two capscrews and inserts that attach
rear horn button switch and handle to the right
rear overhead guard leg.
4. Remove switch and handle assembly from over-
head guard leg, pulling the wire and connector
through the holes in the overhead guard leg.

• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,

120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

6. Tilt the mast completely forward and backward

to ensure that the tilt sensor is correctly instal-
led and connected.

REAR HORN BUTTON SWITCH

Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

To access the battery, raise the hood, on lift 1. CAPSCREW

truck models below. Disconnect the battery. 2. INSERT
3. HANDLE AND SWITCH ASSEMBLY
• S30FT, S35FT, S40FTS (E010) 4. HOLE
• H1.6FT, H1.8FT, H2.0FTS (H30FT, 5. HANDLE
6. REAR HORN BUTTON SWITCH
H35FT, H40FTS) (F001) 7. ELECTRICAL CONNECTOR
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 8. OVERHEAD GUARD LEG
• H2.0-3.5FT (H40-70FT) (L177) Figure 43. Rear Horn Button Switch
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)

62 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
Install
1. Insert wire and connector in the hole in over-
head guard leg and thread wire until connector
can be pulled through bottom hole in the over-
head guard leg.
2. Attach handle and switch assembly to overhead
guard leg with two capscrews and inserts. See
Figure 43.
3. Connect rear horn switch electrical connector to
chassis harness.
4. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
IMPACT SENSOR
The impact sensor is located under the right step
plate.
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
Lift Truck Models S30FT-35FT, S40FTS
(E010), H1.6-1.8FT, H2.0FTS (H30-35FT,
H40FTS) (F001), S2.0-3.5FT (S40-70FT,
S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177),
S4.0-5.5FT, S5.5FTS (S80-120FT;
S80-100FTBCS; S120FTS; S120FTPRS)
(G004, H004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80-120FT) (N005, P005,
R005, S005), and S6.0-7.0FT (S135-155FT)
(D024, E024, F024, G024)
Remove
1. Raise the hood and disconnect the battery.
2. Remove floor mat and floor plate. Remove right
rear panel, right panel, right fender cover, and
right step plate. See one of the following sec-
tions for removal procedures:
Frame 0100SRM1120 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Frame 0100SRM1243 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
Frame 0100SRM1316 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
Frame 0100SRM1321 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
3. Disconnect impact sensor from right chassis
harness. See Figure 44.
4. Remove two capscrews that attach the impact
sensor to mounting bracket. Remove sensor
from lift truck.
63
Sensors and Switches 2200 SRM 1142

NOTE: THE FRAME SHOWN IN FIGURE 44 MAY BE DIFFERENT, BUT LOCATION OF IMPACT SENSOR IS
THE SAME. ON LIFT TRUCK MODEL S4.0-5.5FT, S5.5FTS (S80-120FT; S80-100FTBCS; S120FTS;
S120FTPRS) (H004), SINGLE HYDRAULIC TANK SHOWN, DUAL HYDRAULIC TANK SIMILAR.

A. SIDE VIEW B. VIEW UNDERNEATH RIGHT STEP PLATE.

1. RIGHT STEP PLATE 4. RIGHT CHASSIS HARNESS CONNECTOR
2. SENSOR MOUNTING BRACKET 5. IMPACT SENSOR
3. ELECTRICAL CONNECTOR 6. CAPSCREW
Figure 44. Impact Sensor Replacement, Lift Truck Models S30FT-35FT, S40FTS (E010), H1.6-1.8FT,
H2.0FTS (H30-35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177),
S4.0-5.5FT, S5.5FTS (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) (G004, H004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (N005, P005, R005, S005), and S6.0-7.0FT (S135-155FT) (D024,
E024, F024, G024)

64 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
Install
1. Install new impact sensor to mounting bracket.
Tighten capscrews to 26 N•m (19 lbf ft).
2. Connect impact sensor to right chassis harness.
See Figure 44.
3. Install floor mat and floor plate. Install right
rear panel, right panel, right fender cover, and
right step plate. See one of the following sec-
tions for installation procedures:
Frame 0100SRM1120 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Frame 0100SRM1243 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
Frame 0100SRM1316 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
Frame 0100SRM1321 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
4. Connect the battery and close hood.
Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006), H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299,
B299)
Remove
1. Remove floor mat and floor plate and discon-
nect the battery.
2. Disconnect impact sensor connector from right
chassis harness connector. See Figure 45.
3. Remove two capscrews that secure impact sen-
sor to bracket and remove sensor from lift
truck. See Figure 45.
65
Sensors and Switches 2200 SRM 1142

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 45. Impact Sensor Replacement, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)

Install 3. Connect the battery and install the floor plate

and floor mat.
1. Install new impact sensor to sensor bracket us-
ing two capscrews. Tighten capscrews to
26 N•m (230 lbf in).

2. Insert the push-in fastener into the connector

clip, then connect the right chassis harness con-
nector to the impact sensor connector. See Fig-
ure 45.

66 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

LOAD WEIGHT SENSOR • S2.0-3.5FT (S40-70FT, S55FTS) (F187)

• H2.0-3.5FT (H40-70FT) (L177)
Remove • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
1. To access the battery, remove the floor mat and 120FT; S80, 100FTBCS; S120FTS;
floor plate, on lift truck models below. Discon- S120FTPRS) (G004, H004)
nect the battery. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H6.0FT, H7.0FT (H135FT, H155FT) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(H006, J006, K006) (N005, P005, R005, S005)

• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,

H175FT36, H190FT) (A299, B299) E024, F024, G024)

To access the battery, raise the hood, on lift 2. Disconnect the harness connector from the load
truck models below. Disconnect the battery. weight sensor. See Figure 46.

• S30FT, S35FT, S40FTS (E010) 3. Remove the load weight sensor from the special
• H1.6FT, H1.8FT, H2.0FTS (H30FT, fitting on hydraulic control valve.
H35FT, H40FTS) (F001)

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Sensors and Switches 2200 SRM 1142

NOTE: THE POSITION OF THE VEHICLE SYSTEM MANAGER SHOWN IN FIGURE 46 MAY BE DIFFERENT,
BUT LOCATION OF LOAD WEIGHT SENSOR IS THE SAME FOR ALL LIFT TRUCKS COVERED IN THIS
SRM.

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

NOTE: COWL COMPONENTS OMITTED FOR CLARITY. COWL SHOWN MAY BE DIFFERENT FOR SOME
LIFT TRUCKS COVERED IN THIS SRM, BUT THE LOCATION FOR THE COMPONENTS OF THE LOAD
WEIGHT SENSOR IS THE SAME.

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

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

Figure 46. Load Weight Sensor

Install 3. Connect the battery, install the floor plate and

floor mat, on lift truck models
1. Insert new load weight sensor into special fit-
• H6.0FT, H7.0FT (H135FT, H155FT)
ting. Tighten sensor by hand, and then torque
(H006, J006, K006)
sensor to 37 N•m (27 lbf ft).
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
2. Connect the harness connector to the load H175FT36, H190FT) (A299, B299)
weight sensor. See Figure 46.

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2200 SRM 1142
Connect the battery and lower the hood, on lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
ENGINE AND FUEL SENSORS AND
SWITCHES, GAS AND LPG TRUCKS
EQUIPPED WITH MAZDA 2.0L AND 2.2L
ENGINES
For lift trucks equipped with a Mazda engine, see
the following service manuals for procedures to re-
place the engine and fuel sensors and switches. The
list below is for Mazda engines built prior to 2007:
• Electrical System 2200SRM1143
• Gasoline Fuel System 0900SRM1127
• LPG Fuel System 0900SRM1125
The list of service manuals below are for Mazda en-
gines that are 2007 emissions compliant and for lift
trucks built after January, 2010:
• Electrical System 2200SRM1327
• Gasoline Fuel System 0900SRM1325
• LPG Fuel System 0900SRM1326
ENGINE AND FUEL SENSORS AND
SWITCHES, GAS AND LPG TRUCKS
EQUIPPED WITH GM ENGINES
Crankshaft Position (CKP) Sensor
NOTE: To replace crankshaft position sensor on
GM 4.3L engine, see section High Voltage Switch
(HVS) Ignition; GM4.3L EPA Compliant En-
gines and GM5.7L LPG EPA Compliant En-
gine 2200SRM1097.
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
NOTE: To replace the crankshaft position sensor
on GM 2.4L engine, see section GM Engine Re-
pair 0600SRM1121.
Camshaft Position (CMP) Sensor
NOTE: On the GM 4.3L engine, the camshaft posi-
tion sensor cannot be replaced separately from the
distributor. If the CMP sensor fails, the whole dis-
tributor must be replaced. See the section High
Voltage Switch (HVS) Ignition; GM4.3L EPA
Compliant Engines and GM5.7L LPG EPA
Compliant Engine 2200SRM1097 for procedures
to replace the distributor.
NOTE: To replace the camshaft position sensor on
the GM 2.4L engine, see section GM Engine Re-
pair 0600SRM1121.
Oil Pressure Sensor
NOTE: To replace oil pressure sensor on GM 4.3L
engine, see section High Voltage Switch (HVS)
Ignition; GM4.3L EPA Compliant Engines and
GM5.7L LPG EPA Compliant Engine
2200SRM1097.
NOTE: To replace oil pressure sensor on GM 2.4L
engine, see section GM Engine Repair
0600SRM1121.
Manifold Absolute Pressure (MAP)/Manifold
Air Temperature (MAT) Sensor
NOTE: To replace manifold absolute pressure
(MAP)/manifold air temperature (MAT) sensor on
GM 4.3L engine, see section High Voltage Switch
(HVS) Ignition; GM4.3L EPA Compliant En-
gines and GM5.7L LPG EPA Compliant En-
gine 2200SRM1097.
NOTE: To replace manifold absolute pressure
(AMP)/manifold air temperature (MAT) sensor on
GM 2.4L engine, see sections LPG Fuel System
0900SRM1124 for LPG or Gasoline Fuel System
0900SRM1126 for gas.
Engine Coolant Temperature (ECT) Sensor
NOTE: To replace engine coolant temperature
(ECT) sensor on GM 4.3L engine, see section High
Voltage Switch (HVS) Ignition; GM4.3L EPA
Compliant Engines and GM5.7L LPG EPA
Compliant Engine 2200SRM1097.
69
Sensors and Switches
NOTE: To replace engine coolant temperature
(ECT) sensor on GM 2.4L engine, see sections LPG
Fuel System 0900SRM1124 for LPG or Gasoline
Fuel System 0900SRM1126 for gas.
Air Flow Restriction Switch
NOTE: To replace engine air flow restriction switch
on GM 4.3L or GM 5.7L engine, see section High
Voltage Switch (HVS) Ignition; GM4.3L EPA
Compliant Engines and GM5.7L LPG EPA
Compliant Engine 2200SRM1097.
NOTE: The air flow restriction switch is an op-
tional feature on these lift trucks and is a part of
the Electronic Monitoring package option.
Remove for GM 2.4L Gas and LPG Trucks
1. Raise hood and disconnect the battery.
2. Disconnect the air flow restriction switch elec-
trical connection. See Figure 47.
3. Remove air filter restriction switch from air
cleaner.
NOTE: AIR CLEANER HOSE NOT SHOWN FOR
CLARITY. SWITCH NOT SHOWN, BUT ITEM #4
POINTS TO ITS LOCATION.
1. ECT SENSOR
2. AIR FLOW RESTRICTION ELECTRICAL CON-
NECTOR
3. AIR CLEANER
4. AIR FLOW RESTRICTION SWITCH
Figure 47. Air Flow Restriction Switch
70
2200 SRM 1142
Install for GM 2.4L Gas and LPG Trucks
1. Install new air flow restriction switch into air
cleaner.
2. Connect the air flow restriction switch electri-
cal connection. See Figure 47.
3. Connect the battery and lower the hood.
Oxygen Sensor
NOTE: The procedures below cover GM 4.3L en-
gine, for lift trucks built before January, 2010. For
procedures to replace oxygen sensor on GM 4.3L
engine on lift trucks built after January, 2010, see
one of the following service manuals:
• LPG Fuel System, GM 4.3L Engine with
GFI 0900SRM1242
• LPG Fuel System, GM 4.3L Engine With
PSI 0900SRM1556
• Gasoline Fuel System 0900SRM1244
• Gasoline Fuel System PSI GM 4.3L
0900SRM1570 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT)
(F024, G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H6.0FT, H7.0FT (H135FT, H155FT)
(J006, K006)
NOTE: For procedures to replace oxygen sensors on
GM 2.4L engine, see sections
• LPG Fuel System 0900SRM1124
• Gasoline Fuel System 0900SRM1126
Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
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2200 SRM 1142 Sensors and Switches

To access the battery, raise the hood, on lift See Figure 48 for lift truck models
truck models below. Disconnect the battery. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
120FT; S80, 100FTBCS; S120FTS; (N005, P005, R005, S005)
S120FTPRS) (G004, H004)
See Figure 49 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
(N005, P005, R005, S005) E024, F024, G024)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, • H6.0FT, H7.0FT (H135FT, H155FT)
E024, F024, G024) (H006, J006, K006)

NOTE: The GM 4.3L engine has two oxygen sen- See Figure 50 for lift truck models
sors and two electrical connectors. • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
2. Disconnect the oxygen sensor electrical connec- S120FTPRS) (G004, H004)
tor.

NOTE: EXHAUST SYSTEM FOR LIFT TRUCK MODELS S4.0, 5.0, 5.5FT, (S80, 100, 120FT) (G004, H004) IS
SIMILAR.

NOTE: SEE FIGURE 50 FOR OXYGEN SENSOR LOCATION ON LIFT TRUCK MODEL S5.5FTS (S80,
100FTBCS; S120FTS; S120FTPRS) (G004, H004)

1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD

2. ELECTRICAL CONNECTOR
Figure 48. Oxygen Sensor, GM 4.3L Engine, Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)

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Sensors and Switches 2200 SRM 1142

NOTE: OVERHEAD EXHAUST IS AN OPTIONAL FEATURE.

1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD

2. ELECTRICAL CONNECTOR

Figure 49. Oxygen Sensor, GM 4.3L Engine, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)

NOTE: Perform Step 3 for lift truck models 3. Remove the clip connector retaining each wire
S5.5FTS (S80, 100FTBCS; S120FTS; S120FTPRS) harness to the oxygen sensor brackets. See Fig-
(G004, H004), equipped with the GM 4.3L engine. ure 50.

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2200 SRM 1142 Sensors and Switches

Figure 51. Oxygen Sensor Socket

Install
1. OXYGEN SENSOR (POST-CATALYTIC)
2. MUFFLER
3. OXYGEN SENSOR (PRE-CATALYTIC) 1. Before installing the sensor, coat sensor spar-
4. SENSOR ELECTRICAL CONNECTORS ingly with an antiseize compound, then install
5. CLIP CONNECTOR oxygen sensor into the exhaust pipes to the ex-
6. BRACKET haust manifold for GM 4.3L engines. Using a
special tool, oxygen sensor socket (see Fig-
Figure 50. Oxygen Sensor, GM 4.3L Engine for Lift
ure 51), tighten oxygen sensors to 40 to
Truck Models (BCS/PRS Only) S5.5FTS (S80,
60 N•m (30 to 44 lbf ft).
100FTBCS; S120FTS; S120FTPRS) (G004, H004)
See Figure 48 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
4. Using a special tool, oxygen sensor socket (see
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
Figure 51), remove the oxygen sensor.
(N005, P005, R005, S005)
See Figure 48 for lift truck models
See Figure 49 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
E024, F024, G024)
(N005, P005, R005, S005)
• H6.0FT, H7.0FT (H135FT, H155FT)
Figure 49 for lift truck models (H006, J006, K006)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
Figure 50 for lift truck models
E024, F024, G024)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
• H6.0FT, H7.0FT (H135FT, H155FT)
120FT; S80, 100FTBCS; S120FTS;
(H006, J006, K006)
S120FTPRS) (G004, H004)
See Figure 50 for lift truck models
NOTE: Perform Step 2 for lift truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, S5.5FTS (S80, 100FTBCS; S120FTS; S120FTPRS)
120FT; S80, 100FTBCS; S120FTS; (G004, H004) equipped with the GM 4.3L engine.
S120FTPRS) (G004, H004)
2. Install the clip connector to attach oxygen sen-
sor wiring harness to oxygen sensor brackets.

3. Connect the electrical connectors. Verify that

the connectors click/lock into place.

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Sensors and Switches
4. Verify that the wire is pulled up toward the
thermostat and away from any hot exhaust
components.
5. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
Connect the battery and lower the hood, on lift
truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
6. Connect the battery; install the floor plate and
floor mat for lift truck model
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
ENGINE AND FUEL SENSORS AND
SWITCHES, PSI 4.3L LPG ENGINE
Crankshaft Position (CKP) Sensor
NOTE: To replace crankshaft position sensor on
PSI 4.3L engine, see section High Voltage Switch
(HVS) Ignition; PSI 4.3L EPA Compliant En-
gines 2200SRM1955.
Camshaft Position (CMP) Sensor
NOTE: On the PSI 4.3L engine, the camshaft posi-
tion sensor cannot be replaced separately from the
distributor. If the CMP sensor fails, the whole dis-
tributor must be replaced. See the section High
Voltage Switch (HVS) Ignition; PSI 4.3L EPA
Compliant Engines 2200SRM1955 for procedures
to replace the distributor.
Oil Pressure Sensor
NOTE: To replace oil pressure sensor on PSI 4.3L
engine, see section High Voltage Switch (HVS)
Ignition; PSI 4.3L EPA Compliant Engines
2200SRM1955
74
2200 SRM 1142
Manifold Absolute Pressure (MAP)/Manifold
Air Temperature (MAT) Sensor
NOTE: To replace manifold absolute pressure
(MAP)/manifold air temperature (MAT) sensor on
PSI 4.3L engine, see section High Voltage Switch
(HVS) Ignition; PSI 4.3L EPA Compliant En-
gines 2200SRM1955
Engine Coolant Temperature (ECT) Sensor
NOTE: To replace engine coolant temperature
(ECT) sensor on PSI 4.3L engine, see High Volt-
age Switch (HVS) Ignition; PSI 4.3L EPA Com-
pliant Engines 2200SRM1955
Air Flow Restriction Switch
NOTE: To replace engine air flow restriction switch
on PSI 4.3L engine, see High Voltage Switch
(HVS) Ignition; PSI 4.3L EPA Compliant En-
gines 2200SRM1955.
Oxygen Sensor
NOTE: See LPG Fuel System, PSI 4.3L Engine
0900SRM1951 for procedures to replace oxygen
sensor on PSI 4.3L engine.
ENGINE AND FUEL SWITCHES, GM 2.4L
LPG TRUCKS ONLY
Low LPG Pressure Switch
NOTE: For procedures to replace Low LPG pres-
sure switch on GM 2.4L LPG engine, see section
LPG Fuel System 0900SRM1124.
ENGINE AND FUEL SENSORS AND
SWITCHES, YANMAR DIESEL TRUCKS
Air Filter Restriction Switch
NOTE: The air filter restriction switch is an op-
tional feature on these lift trucks and is a part of
the Electronic Monitoring package option.
Remove
1. Raise hood and disconnect the battery.
2. Disconnect the electrical connector from air fil-
ter restriction switch.
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142
3. Remove air filter restriction switch from air
cleaner. See Figure 52.
Install
1. Install new air filter restriction switch into air
cleaner.
2. Connect air filter electrical connector.
3. Connect the battery and close hood.
Oil Pressure Sensor
Remove
1. Raise hood and disconnect the battery.
2. Disconnect the electrical connector for the oil
pressure sensor.
3. Remove the oil pressure sensor. See Figure 52.
Install
1. Install new oil pressure sensor onto engine.
Tighten sensor to 9 N•m (80 lbf in).
2. Connect the electrical connector for the oil pres-
sure sensor. See Figure 52.
3. Connect the battery and close hood.
Engine Speed Sensor
Remove
1. Raise the hood and disconnect the battery.
2. Disconnect the electrical connection from en-
gine speed sensor.
3. Remove capscrew from engine speed sensor
bracket and remove bracket and engine speed
sensor. See Figure 52.
Install
1. Install engine speed sensor bracket and install
new engine speed sensor.
2. Connect electrical connector to engine speed
sensor.
3. Connect the battery and close hood.
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
Engine Coolant Temperature (ECT) Sensor
Remove
1. Raise hood and disconnect the battery.
2. Drain the engine coolant from radiator before
removing the ECT sensor. Refer to the section
Cooling System 0700SRM1123.
3. Disconnect the ECT sensor connector. See Fig-
ure 52.
4. Remove the ECT sensor and packing from the
intake manifold. Discard the copper washer.
See Figure 52.
Install
1. Install new copper washer onto ECT sensor. In-
stall new ECT sensor and new packing and
tighten the ECT sensor to 25 to 34 N•m (18 to
25 lbf ft).
2. Connect the ECT sensor connector.
3. Refill the radiator with engine coolant after re-
placing the ECT sensor. See one of the follow-
ing sections for coolant specifications and proce-
dures:
Periodic Maintenance 8000SRM1150 for lift
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Periodic Maintenance 8000SRM1207 for lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
Periodic Maintenance 8000SRM1248 for lift
truck models
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
75
Sensors and Switches 2200 SRM 1142

Periodic Maintenance 8000SRM1598 4. Connect the battery and close hood.

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (H004)

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2200 SRM 1142 Sensors and Switches

Figure 52. Yanmar Diesel Engine Sensors and Switches

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Sensors and Switches 2200 SRM 1142

Legend for Figure 52

A. FRONT VIEW B. SIDE VIEW

1. AIR FILTER RESTRICTION SWITCH ELECTRI- 6. ENGINE COOLANT TEMPERATURE SENSOR
CAL CONNECTOR 7. THROTTLE POSITION SENSOR
2. AIR CLEANER 8. ENGINE OIL PRESSURE SENSOR
3. AIR FILTER RESTRICTION SWITCH 9. FUEL/WATER SEPARATOR SENSOR
4. AIR CLEANER BRACKET
5. ENGINE SPEED SENSOR

Throttle Position Sensor (TPS)

Remove
1. Open hood and disconnect the battery.

2. Disconnect the electrical connector from the

throttle position sensor (TPS).

3. Remove Torx-head screws securing the TPS to

TPS bracket. See Figure 53. Remove TPS sen-
sor from TPS bracket.

1. LOCKWASHER
2. TORX-HEAD SCREW (BRACKET)
3. TPS BRACKET
4. WASHER
5. TORX-HEAD SCREW (SENSOR)
6. THROTTLE POSITION SENSOR (TPS)
7. TPS ROTOR
8. THROTTLE LEVER
9. FUEL PUMP

Figure 53. Throttle Position Sensor (TPS)

Assembly

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2200 SRM 1142 Sensors and Switches

Install
NOTE: When installing the TPS, rotate the sensor
rotor clockwise to match D-shape on the TPS rotor.
See Figure 54.

1. Install new TPS sensor on TPS bracket and se-

cure with Torx-head screws. Tighten Torx-head
screws to 2.25 N•m (20 lbf in).

2. Connect the throttle position sensor (TPS) elec-

trical connector.

3. Connect the battery and close hood.

1. SENSOR ROTOR
2. TPS
3. TPS ROTOR
4. D-SHAPE

Figure 54. TPS and Rotor

Fuel/Water Separator Sensor 1. DRAIN PLUG

2. O-RING
3. FUEL/WATER SEPARATOR SENSOR
Remove 4. FUEL FILTER ELEMENT BODY
5. FUEL FILTER
1. Open hood and disconnect the battery. 6. FUEL FILTER COVER
2. Remove drain plug from bottom of fuel/water Figure 55. Fuel/Water Separator Sensor
separator sensor and drain water from fuel fil-
ter. See Figure 55.

3. Disconnect sensor from harness. Install

4. Remove sensor from bottom of fuel filter ele- 1. Install new sensor into bottom of fuel filter ele-
ment body. ment body. See Figure 55.

2. Connect sensor to harness.

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Sensors and Switches 2200 SRM 1142

3. Install drain plug and O-ring into bottom of

fuel/water separator sensor.

4. Connect the battery and close hood.

Glow Plug Relay

Remove

WARNING
Always disconnect the cables at the battery be-
fore you make repairs to the engine. Disconnect
the cable at the negative terminal first. Install a
tag on the battery terminals so that no one con-
nects the cables on the terminals.

1. Open hood and disconnect the battery.

2. Tag and disconnect the wiring connectors at

terminals E and S. See Figure 56.

1. M TERMINAL
2. E TERMINAL
3. B TERMINAL
4. S TERMINAL

Figure 56. Glow Plug Relay Terminals

3. Slide the protective boots back on the wires for

terminals B and M. See Figure 56 and Fig-
ure 57.

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2200 SRM 1142 Sensors and Switches

1. B TERMINAL 5. NUT
2. M TERMINAL 6. S TERMINAL WIRING
3. M TERMINAL WIRING 7. E TERMINAL WIRING
4. WASHER 8. B TERMINAL WIRING

Figure 57. Glow Plug Relay and Wiring

4. Place tags on the wires for terminals B and M
to properly identify them for reinstallation.
5. Remove the nuts and washers retaining the
wires to terminals B and M. See Figure 57.
6. Remove the nuts retaining the glow plug relay
to the mounting bracket and remove the glow
plug relay. See Figure 58.

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Sensors and Switches 2200 SRM 1142

Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

To access the battery, raise the hood, on lift

truck models below. Disconnect the battery.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)

NOTE: ENGINE NOT SHOWN FOR CLARITY. 2. Disconnect the electrical connector from air fil-
ter restriction switch.
1. MOUNTING BRACKET
2. GLOW PLUG RELAY 3. Remove air filter restriction switch from air
3. NUT cleaner.
Figure 58. Glow Plug Relay and Mounting Bracket See Figure 59 for lift trucks equipped with Cum-
mins 4.5L diesel engine.

Install See Figure 60 for lift trucks equipped with Cum-

1. Place the glow plug relay in position on the
mounting bracket and install retaining nuts.
Tighten retaining nuts to 2.50 to
2.75 N•m (22.13 to 24.34 lbf in). See Figure 58.
2. Connect the wiring connections to terminals B
and M. Install the nuts and washers. Tighten
the nuts to 2.9 to 4.0 N•m (25.67 to
35.40 lbf in). See Figure 56 and Figure 57.
3. Install the protective boots over the terminals B
and M. See Figure 57.
4. Connect the electrical connectors at terminals
E and S. See Figure 56.
mins QSB 3.3L diesel engine.
Install
1. Install new air filter restriction switch onto air
cleaner.
2. Connect air filter electrical connector.
3. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

5. Connect the battery and close the hood. Connect the battery and lower the hood, on lift
truck models
ENGINE AND FUEL SENSORS AND • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
SWITCHES, CUMMINS DIESEL ENGINES H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
Air Filter Restriction Switch • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
NOTE: The air filter restriction switch is an op-
tional feature on these lift trucks and is a part of
the Electronic Monitoring package option.

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2200 SRM 1142 Sensors and Switches

Figure 59. Cummins 4.5L Diesel Engine Sensors and Switches

Confidential/Proprietary - Do Not Copy or Duplicate 83

Sensors and Switches 2200 SRM 1142

Legend for Figure 59

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

1. ENGINE SPEED SENSOR 5. FUEL/WATER SEPARATOR SENSOR
2. AIR FILTER RESTRICTION SWITCH 6. ENGINE OIL PRESSURE SENSOR
3. AIR CLEANER 7. THROTTLE POSITION SENSOR (TPS)
4. WATER (COOLANT) TEMPERATURE SENSOR

84 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Figure 60. Cummins QSB 3.3L Diesel Engine Sensors and Switches

Confidential/Proprietary - Do Not Copy or Duplicate 85

Sensors and Switches 2200 SRM 1142

Legend for Figure 60

A. CUMMINS QSB 3.3L DIESEL ENGINE USED ON B. CUMMINS QSB 3.3L DIESEL ENGINE USED ON
LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, LIFT TRUCK MODELS H6.0FT, H7.0FT
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (H135FT, H155FT) (H006, J006), H8.0FT,
(N005, P005) H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)
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 SWITCH
4. FUEL/WATER SEPARATOR ELECTRICAL CON-
NECTOR AND SENSOR

Engine Oil Pressure Sensor See Figure 59 for lift trucks equipped with Cum-
mins 4.5L diesel engine.
Remove
See Figure 60 for lift trucks equipped with Cum-
1. To access the battery, remove the floor mat and mins QSB 3.3L diesel engine.
floor plate, on lift truck models below. Discon-
3. Connect the battery, install the floor plate and
nect the battery.
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood, on lift
Connect the battery and lower the hood, on lift
truck models below. Disconnect the battery.
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
(N005, P005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
E024)
2. Disconnect the electrical connector from the oil
pressure sensor. Engine Speed Sensor

3. Unscrew and remove the oil pressure sensor Remove

from adapter. Adapter does not need to be re-
moved from engine. Discard O-ring. 1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
See Figure 59 for lift trucks equipped with Cum- nect the battery.
mins 4.5L diesel engine.
• H6.0FT, H7.0FT (H135FT, H155FT)
See Figure 60 for lift trucks equipped with Cum- (H006, J006)
mins QSB 3.3L diesel engine. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Install
To access the battery, raise the hood, on lift
1. Apply 50 ml (1.7 oz) of Loctite 592™ thread truck models below. Disconnect the battery.
sealant on O-ring. Install new oil pressure sen- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
sor into adapter. Tighten sensor two to three H5.0-5.5FT (H80, 90, 100, 110, 120FT)
turns past finger tight. (N005, P005)
2. Connect the electrical connector for the oil pres- • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
sure sensor. E024)

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2200 SRM 1142 Sensors and Switches

2. Disconnect the electrical connection from en-
gine speed sensor.
See Figure 59 for lift trucks equipped with Cum-
mins 4.5L diesel engine.
See Figure 60 for lift trucks equipped with Cum-
mins QSB 3.3L diesel engine.
3. Remove capscrew from engine speed sensor
bracket and remove bracket and engine speed
sensor.
To access the battery, raise the hood, on lift
truck models below. Disconnect the battery.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
2. Drain the engine coolant from radiator before
removing the ECT sensor. Refer to the section
Cooling System 0700SRM1123.

Install 3. Disconnect the ECT sensor connector.

1. Install engine speed sensor bracket to engine. See Figure 60 for lift trucks equipped with Cum-
Tighten capscrew to 7 N•m (62 lbf in). Install mins QSB 3.3L diesel engine.
new engine speed sensor onto bracket.
See Figure 61 for lift trucks equipped with Cum-
2. Connect electrical connector to engine speed mins 4.5L diesel engine.
sensor.
4. Remove the ECT sensor and packing from the
See Figure 59 for lift trucks equipped with Cum- intake manifold. Discard the O-ring.
mins 4.5L diesel engine.

See Figure 60 for lift trucks equipped with Cum-

mins QSB 3.3L diesel engine.

3. Connect the battery, install the floor plate and

floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

Connect the battery and lower the hood, on lift

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)

Engine Coolant Temperature (ECT) Sensor

Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon- Figure 61. Engine Coolant Temperature Sensor,
nect the battery. Cummins 4.5L Diesel Engine
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

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Sensors and Switches 2200 SRM 1142

Legend for Figure 61 Periodic Maintenance 8000SRM1586 for lift

truck models
NOTE: TOP VIEW SHOWN.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
1. ENGINE COOLANT TEMPERATURE SENSOR H175FT36, H190FT) (B299)
(ECT)
2. ECT ELECTRICAL CONNECTOR 4. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
Install (H006, J006)
1. Install new O-ring onto ECT sensor. Install • H8.0FT, H8.0FT9, H9.0FT (H170FT,
new ECT sensor and new packing and tighten H175FT36, H190FT) (A299, B299)
the ECT sensor to 20 N•m (177 lbf in).
Connect the battery and lower the hood, on lift
2. Connect the ECT sensor connector. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
See Cummins QSB 3.3L Diesel Engine Sensors
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
and Switches for Cummins QSB 3.3L diesel en-
(N005, P005)
gine.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
See Engine Coolant Temperature Sensor, Cum- E024)
mins 4.5L Diesel Engine for Cummins 4.5L die-
sel engine. Throttle Position Sensor (TPS) (Cummins
4.5L Only)
3. Refill the radiator with engine coolant after re-
placing the ECT sensor. See one of the follow-
ing sections for coolant specification and proce- Remove
dures: 1. To access the battery, remove the floor mat and
Periodic Maintenance 8000SRM1248 for lift floor plate, on lift truck models below. Discon-
truck models nect the battery.

• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, • H6.0FT, H7.0FT (H135FT, H155FT)
120FT; S80, 100FTBCS; S120FTS; (H006, J006)
S120FTPRS) (G004) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H175FT36, H190FT) (A299)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) To access the battery, raise the hood, on lift
(N005, P005) truck models below. Disconnect the battery.
Periodic Maintenance 8000SRM1319 for lift • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
truck models H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, (N005, P005)
E024) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
Periodic Maintenance 8000SRM1322 for lift
truck models 2. Disconnect the electrical connector from the
• H6.0FT, H7.0FT (H135FT, H155FT) throttle position sensor (TPS).
(H006, J006) 3. Remove Torx-head screws and washers secur-
Periodic Maintenance 8000SRM1407 for lift ing the TPS to TPS bracket. See Figure 62. Re-
truck models move TPS sensor from TPS bracket.

• H8.0FT, H8.0FT9, H9.0FT (H170FT,

H175FT36, H190FT) (A299)

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2200 SRM 1142 Sensors and Switches

2. Connect the throttle position sensor (TPS) elec-

trical connector. See Figure 62.

3. Connect the battery, install the floor plate and

floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299)

Connect the battery and lower the hood, on lift

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)

Fuel/Water Separator Sensor

Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
1. TORX-HEAD SCREW To access the battery, raise the hood, on lift
2. WASHER truck models below. Disconnect the battery.
3. TPS ELECTRICAL CONNECTOR
4. TPS COVER • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
5. THROTTLE POSITION SENSOR (TPS) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
6. TPS BRACKET (N005, P005)
7. FUEL PUMP
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
Figure 62. Throttle Position Sensor (TPS) E024)
Assembly, Cummins 4.5L Diesel Engine
2. Remove drain plug from bottom of fuel filter el-
ement body and drain water from fuel filter.
Install See Figure 63.

NOTE: The TPS mounting screws are non-mag- 3. Disconnect sensor from harness.
netic stainless steel to avoid interference with the 4. Remove sensor from bottom of fuel filter ele-
sensor magnet and must be reused if the TPS is re- ment body.
placed.

1. Install new TPS sensor on TPS bracket and se-

cure with Torx-head screws and washers.
Tighten Torx-head screws to
2.25 N•m (20 lbf in).

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Sensors and Switches 2200 SRM 1142

Install
1. Install new sensor into bottom of fuel filter ele-
ment body. See Figure 63.

2. Connect sensor to harness.

3. Install drain plug and new O-ring into bottom

of fuel filter element body.

4. Connect the battery, install the floor plate and

floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

Connect the battery and lower the hood, on lift

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)

ENGINE AND FUEL SENSORS AND

SWITCHES, KUBOTA 3.8L DIESEL
1. FUEL FILTER ELEMENT BODY ENGINE WITHOUT DPF
2. DRAIN PLUG
3. ELECTRICAL CONNECTOR Refer to Figure 64 for location of engine sensors
4. FUEL/WATER SEPARATOR SENSOR and switches.
5. FUEL FILTER
Figure 63. Fuel/Water Separator Sensor

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2200 SRM 1142 Sensors and Switches

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

1. INTAKE AIR TEMPERATURE SENSOR 5. EGR VALVE LIFT SENSOR
2. INTAKE AIR PRESSURE SENSOR 6. CRANKSHAFT POSITION SENSOR
3. RAIL PRESSURE SENSOR 7. CAMSHAFT POSITION SENSOR
4. COOLANT TEMPERATURE SENSOR 8. OIL PRESSURE SENSOR

Figure 64. Kubota 3.8L Diesel Engine without DPF Sensors and Switches

Intake Air Temperature Sensor • S6.0FT, S7.0FT (S135FT, S155FT)

(F024)
Remove
2. Disconnect electrical connector from intake air
1. To access battery, raise hood, on lift truck mod- temperature sensor.
els below. Disconnect the battery.
3. Remove intake air temperature sensor from in-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; take air inlet elbow. See Figure 65.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)

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Sensors and Switches 2200 SRM 1142

• S6.0FT, S7.0FT (S135FT, S155FT)

(F024)

2. Disconnect electrical connector from intake

pressure sensor.

3. Remove two capscrews and intake air pressure

sensor. See Figure 65.

Install
NOTE: If intake air pressure sensor has been iden-
tified as faulty, replace sensor with new one.

1. Install two capscrews and intake air pressure

sensor. Tighten capscrews to 30 to 39 N•m (22
to 29 lbf ft).

1. AIR INLET ELBOW 2. Connect intake air pressure sensor electrical

2. INTAKE AIR TEMPERATURE SENSOR connector.
3. AIR HEATER TERMINAL NUTS
4. AIR INLET HEATER 3. Connect battery and lower the hood on lift
5. INTAKE AIR PRESSURE SENSOR truck models
Figure 65. Intake Air Inlet Elbow • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)
Install • S6.0FT, S7.0FT (S135FT, S155FT)
(F024)
NOTE: If intake air temperature sensor has been
identified as faulty, replace sensor with new one. Air Inlet Heater
1. Install intake air temperature sensor. Tighten Remove
to 16 to 23 N•m (12 to 17 lbf ft).
1. To access battery, raise hood, on lift truck mod-
2. Connect intake air temperature sensor electri- els below. Disconnect the battery.
cal sensor.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. Connect battery and lower the hood on lift H5.0-5.5FT (H80, 90, 100, 110, 120FT)
truck models (R005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • S6.0FT, S7.0FT (S135FT, S155FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (F024)
(R005)
2. Disconnect electrical connections from air inlet
• S6.0FT, S7.0FT (S135FT, S155FT) heater terminal nuts. See Figure 65.
(F024)
3. Remove four capscrews from intake air inlet el-
Intake Air Pressure Sensor bow.

Remove 4. Remove intake air inlet elbow and set aside for
later installation.
1. To access battery, raise hood, on lift truck mod-
els below. Disconnect the battery. 5. Remove air intake heater from air intake mani-
fold.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)

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2200 SRM 1142 Sensors and Switches

Install 2. Apply thread locker to threads of oil pressure

sensor. Install oil pressure sensor into adapter.
NOTE: If intake air heater has been identified as Tighten to 15 to 19 N•m (11 to 14 lbf ft).
faulty, replace air intake heater with new one.
3. Connect electrical connector for oil pressure
1. Install air inlet heater into air intake manifold. sensor. See Figure 64.
2. Using four capscrews, install intake air inlet el- 4. Connect battery and lower the hood on lift
bow to air intake manifold, cover the air intake truck models
heater. See Figure 65.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. Connect electrical connections for air intake H5.0-5.5FT (H80, 90, 100, 110, 120FT)
heater to terminal nuts. (R005)
• S6.0FT, S7.0FT (S135FT, S155FT)
4. Tighten terminal nuts to 3.5 to 5.3 N•m (31 to (F024)
44 lbf in). See Figure 65.

5. Connect battery and lower the hood on lift Engine Coolant Temperature (ECT) Sensor
truck models
Remove
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 1. To access battery, raise hood, on lift truck mod-
(R005) els below. Disconnect the battery.
• S6.0FT, S7.0FT (S135FT, S155FT) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
(F024) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)
Engine Oil Pressure Sensor • S6.0FT, S7.0FT (S135FT, S155FT)
(F024)
Remove
2. Drain engine coolant from radiator before re-
1. To access battery, raise hood, on lift truck mod- moving ECT sensor. Refer to the section Cool-
els below. Disconnect the battery. ing System 0700SRM1123.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 3. Disconnect the ECT sensor electrical connector
(R005) from the ECT sensor. See Figure 64.
• S6.0FT, S7.0FT (S135FT, S155FT) 4. Remove the ECT sensor and O-ring. Discard O-
(F024) ring.
2. Disconnect electrical connector from oil pres-
Install
sure sensor.
NOTE: If ECT sensor has been identified as faulty,
3. Unscrew and remove oil pressure sensor and O-
replace ECT sensor with new one.
ring from adapter. See Figure 64.
1. Install new O-ring onto ECT sensor.
4. Discard O-ring.
2. Install ECT sensor. Tighten sensor to 16 to
Install 23 N•m (12 to 17 lbf ft).
NOTE: If oil pressure sensor has been identified as 3. Connect ECT sensor connector. See Figure 64.
faulty, replace oil pressure sensor with new one.
4. Refill the radiator with engine coolant. See one
1. Lubricate new O-ring with multipurpose of the following sections for coolant specifica-
grease, and install on oil pressure sensor. tion and procedures

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Sensors and Switches 2200 SRM 1142

Periodic Maintenance 8000SRM1558 for lift

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)

Periodic Maintenance 8000SRM1571 for lift

truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)

5. Connect battery and lower the hood on lift

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 1. PULSAR GEAR
(R005) 2. AIR GAP
• S6.0FT, S7.0FT (S135FT, S155FT) 3. SHIM
4. CRANKSHAFT POSITION SENSOR
(F024) 5. GEAR CASE
6. SHIM 0.25 mm (0.0098 in.)
Crankshaft Position Sensor 7. SHIM 0.50 mm (0.020 in.)
8. SHIM 1.00 mm (0.0394 in.)
Remove Figure 66. Crankshaft Position Sensor Air Gap
1. To access battery, raise hood, on lift truck mod-
els below. Disconnect the battery.
NOTE: An air gap of 0.25 to 1.4 mm (0.0098 to
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 0.055 in.) is needed between the crankshaft posi-
H5.0-5.5FT (H80, 90, 100, 110, 120FT) tion sensor and the pulsar gear. The air gap is ach-
(R005) ieved by using shims shown in Figure 66 and proce-
• S6.0FT, S7.0FT (S135FT, S155FT) dure outlined in Adjust Shim Procedure.
(F024)
2. Add the appropriate amount of air gap by add-
2. Disconnect crankshaft position sensor electrical ing shims to the crankshaft position sensor. See
connector from the crankshaft position sensor. Figure 66.
See Figure 64.
3. Install crankshaft position sensor.
3. Remove crankshaft position sensor mounting
capscrew. 4. Install crankshaft position sensor mounting
capscrew. Tighten to 4 to 5 N•m (35 to
4. Remove crankshaft position sensor and O-ring. 45 lbf in).
Discard O-ring.
5. Connect crankshaft position sensor electrical
Install connector to crankshaft position sensor.

NOTE: If crankshaft position sensor has been iden- 6. Connect battery and lower the hood on lift
tified as faulty, replace crankshaft position sensor truck models
with new one. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
1. Lubricate new O-ring with multipurpose (R005)
grease. Install O-ring on crankshaft position
• S6.0FT, S7.0FT (S135FT, S155FT)
sensor. See Figure 66.
(F024)

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Adjust Shim Procedure

1. Align TC mark of flywheel with flywheel hous-
ing timing window. See procedure in Fuel Sys-
tem Repair section of Kubota Diesel 3.8L
Engines with Diesel Particulate Filter
(DPF) 0600SRM1590.

2. Install measurement jig 1 into sensor mounting

position. See Figure 67.

1. JIG 1
2. PROTRUSION
3. GEAR CASE
4. PULSE GEAR

Figure 69. Protrusion Measurement

4. Using the protrusion measurement, see Table 1

for the proper shim combination required to set
the air gap.
1. MEASUREMENT JIG 1
Figure 67. Measurement JIG 1

3. Set dial gauge at measurement jig 2, then

measure protrusion of jig 1. See Figure 68 and
Figure 69.

1. MEASUREMENT JIG 2
2. DIAL GAUGE
Figure 68. Measurement JIG 2

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Sensors and Switches 2200 SRM 1142

Table 1. Adjustment Shim Combinations

Thickness and Number of Shims

Protrusion
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
(0.0788 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 3. Remove camshaft position sensor mounting

capscrew.
Remove
4. Remove camshaft position sensor and O-ring.
1. To access battery, raise hood, on lift truck mod- Discard O-ring.
els below. Disconnect the battery.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Install
H5.0-5.5FT (H80, 90, 100, 110, 120FT) NOTE: If camshaft position sensor has been identi-
(R005) fied as faulty, replace camshaft position sensor
• S6.0FT, S7.0FT (S135FT, S155FT) with new one.
(F024)
1. Lubricate new O-ring with multipurpose
2. Disconnect camshaft position sensor electrical grease. Install O-ring on camshaft position sen-
connector from camshaft position sensor. See sor. See Figure 64.
Figure 64.
2. Install camshaft position sensor.

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3. Install camshaft position sensor mounting cap- Install

screw. Tighten to 4 to 5 N•m (35 to 45 lbf in).
NOTE: If air flow restriction sensor has been iden-
4. Connect camshaft position sensor electrical con- tified as faulty, replace air flow restriction sensor
nector to camshaft position sensor. with new one.
5. Connect battery and lower the hood on lift 1. Install air flow restriction sensor. Tighten sen-
truck models sor two to three turns past finger tight.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
2. Connect electrical connector for air flow restric-
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
tion sensor. See Figure 70.
(R005)
• S6.0FT, S7.0FT (S135FT, S155FT) 3. Connect battery and lower the hood on lift
(F024) truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Air Flow Restriction Sensor H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)
Remove • S6.0FT, S7.0FT (S135FT, S155FT)
1. To access battery, raise hood, on lift truck mod- (F024)
els below. Disconnect the battery.
Fuel/Water Separator
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
Remove
(R005)
• S6.0FT, S7.0FT (S135FT, S155FT) 1. To access battery, raise hood, on lift truck mod-
(F024) els below. Disconnect the battery.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
2. Disconnect air flow restriction sensor electrical
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
connector. See Figure 70.
(R005)
• S6.0FT, S7.0FT (S135FT, S155FT)
(F024)

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

2. Attach a small hose to hose barb on drain valve

at bottom of fuel filter element and route hose
into a suitable container to collect fuel and con-
taminants. See Figure 71.

1. AIR FLOW RESTRICTION SENSOR

2. ELECTRICAL CONNECTOR
Figure 70. Air Flow Restriction Sensor

3. Remove the air flow restriction sensor. See Fig-

ure 70.

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Install
NOTE: If fuel/water sensor has been identified as
faulty, replace fuel/water sensor with new one.

1. Apply Loctite 567 or equivalent to threads on

fuel/water sensor assembly.

2. Install fuel/water sensor assembly into fuel fil-

ter element housing and tighten one half turn
past hand tight.

3. Apply Loctite 567 or equivalent to threads on

fuel filter element housing.

4. Install fuel filter element housing to casting

mounted on engine. See Figure 71.

5. Tighten housing one quarter turn past hand

1. FUEL FILTER ELEMENT HOUSING tight.
2. FUEL/WATER SENSOR ASSEMBLY
3. DRAIN 6. Connect electrical connector. See Figure 71.
4. ELECTRICAL CONNECTOR
7. Connect battery and lower the hood on lift
Figure 71. Fuel/Water Separator truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
3. Open drain valve. See Figure 71.
(R005)
4. Disconnect electrical connector. • S6.0FT, S7.0FT (S135FT, S155FT)
(F024)
5. Once all fuel and contaminants have been
drained from fuel filter element housing, re- ENGINE AND FUEL SENSORS AND
move drain hose. SWITCHES, KUBOTA 3.8L DIESEL
6. Remove fuel filter element housing. See Fig- ENGINE WITH DPF
ure 71.
See Figure 72 for location of engine sensors and
switches on lift truck models
CAUTION
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
DO NOT over tighten the vice. If over tightening of
the vice occurs, the fuel filter element housing will • H8.0FT, H8.0FT9, H9.0FT (H170FT,
become misshapen and not seal correctly. H175FT36, H190FT) (B299)
.
7. Place fuel filter element housing in soft jawed
vice. See Figure 73 for location of engine sensors and
switches on lift truck models
NOTE: The fuel/water sensor, drain, and electrical
connection are one piece and will be removed as an • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
assembly. H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
8. Remove fuel/water sensor, drain, and electrical
• S6.0FT, S7.0FT (S135FT, S155FT) (G024)
connection from fuel filter housing.

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Figure 72. Kubota 3.8L Diesel Engine with DPF Sensors and Switches for Lift Truck Models H6.0FT,
H7.0FT (H135FT, H155FT) (K006) And H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (B299)

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Sensors and Switches 2200 SRM 1142

Legend for Figure 72

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

1. INTAKE AIR TEMPERATURE SENSOR 7. CRANKSHAFT POSITION SENSOR
2. THROTTLE VALVE ASSEMBLY 8. CAMSHAFT POSITION SENSOR
3. FUEL RAIL PRESSURE SENSOR 9. OIL PRESSURE SENSOR
4. COOLANT TEMPERATURE SENSOR 10. DIFFERENTIAL PRESSURE SENSOR
5. EGR VALVE LIFT SENSOR 11. DIESEL PARTICULATE FILTER
6. BOOST SENSOR

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Figure 73. Kubota 3.8L Diesel Engine with DPF Sensors and Switches for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005) And S6.0FT, S7.0FT (S135FT, S155FT)
(G024)

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Sensors and Switches 2200 SRM 1142

Legend for Figure 73

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

1. INTAKE AIR TEMPERATURE SENSOR 7. DIESEL PARTICULATE FILTER (DPF)
2. BOOST SENSOR 8. CAMSHAFT POSITION SENSOR
3. THROTTLE VALVE ASSEMBLY 9. OIL PRESSURE SENSOR
4. EGR VALVE LIFT SENSOR 10. CRANKSHAFT POSITION SENSOR
5. FUEL RAIL PRESSURE SENSOR 11. COOLANT TEMPERATURE SENSOR
6. DIFFERENTIAL PRESSURE SENSOR

Intake Air Temperature Sensor • S6.0FT, S7.0FT (S135FT, S155FT)

(G024)
Remove
2. Disconnect electrical connector from intake air
1. To access battery, raise hood, on lift truck mod- temperature sensor.
els below. Disconnect the battery.
3. Remove intake air temperature sensor and gas-
• H6.0FT, H7.0FT (H135FT, H155FT) ket from intake air intake housing. See Fig-
(K006) ure 74. Discard gasket.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)

Figure 74. Air Intake Housing and Throttle Valve

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2200 SRM 1142 Sensors and Switches

Legend for Figure 74

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

Install 3. Remove two hose clamps and hose from boost

NOTE: If intake air temperature sensor has been
identified as faulty, replace sensor with new one.
1. Install new gasket and intake air temperature
sensor. Tighten to 16 to 23 N•m (12 to
17 lbf ft).
sensor and air intake housing. See Figure 74.
4. Remove two capscrews from boost sensor. See
Figure 74.
5. Remove boost sensor from air intake housing.
See Figure 74.

2. Connect intake air temperature sensor electri- Install

cal sensor.
NOTE: If boost sensor has been identified as
3. Connect battery and lower the hood on lift faulty, replace boost sensor with new one.
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) 1. Install boost sensor onto air intake housing.
(K006) See Figure 74.

• H8.0FT, H8.0FT9, H9.0FT (H170FT, 2. Install two capscrews to boost sensor. Torque to
H175FT36, H190FT) (B299) 30 to 39 N•m (22 to 28 lbf ft). See Figure 74.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. Install hose and two hose clamps to boost sen-
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
sor and air intake housing. See Figure 74.
(S005)
• S6.0FT, S7.0FT (S135FT, S155FT) 4. Connect electrical connector to boost sensor.
(G024)
5. Connect battery and lower the hood on lift
Boost Sensor truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
Remove (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
1. To access battery, raise hood, on lift truck mod- H175FT36, H190FT) (B299)
els below. Disconnect the battery.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
• H6.0FT, H7.0FT (H135FT, H155FT) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(K006) (S005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S6.0FT, S7.0FT (S135FT, S155FT)
H175FT36, H190FT) (B299) (G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
• S6.0FT, S7.0FT (S135FT, S155FT)
(G024)

2. Disconnect electrical connector from boost sen-

sor.

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Throttle Valve Assembly and Air Intake 4. Install new gasket and air intake housing onto
Heater two studs and throttle valve assembly. See Fig-
ure 74.
Remove
5. Install two flange bolts through air intake
1. To access battery, raise hood, on lift truck mod- housing, throttle valve assembly and air intake
els below. Disconnect the battery. heater into intake manifold. See Figure 74.
• H6.0FT, H7.0FT (H135FT, H155FT) 6. Install two flange nuts onto two studs at air in-
(K006) take housing. See Figure 74.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
7. Connect electrical connectors to air intake
H175FT36, H190FT) (B299)
heater terminal nuts. Torque nuts to 3.5 to
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 5.3 N•m (30.9 to 46.9 lbf in).
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005) 8. Connect electrical connectors to boost sensor
• S6.0FT, S7.0FT (S135FT, S155FT) and air temperature sensor.
(G024) 9. Connect battery and lower the hood on lift
2. Disconnect electrical connector from air intake truck models
sensor and boost sensor. • H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
3. Disconnect electrical connections from air in-
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
take heater terminal nuts.
H175FT36, H190FT) (B299)
4. Remove two flange nuts and two flange bolts • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
from air intake housing. See Figure 74. H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
5. Remove air intake housing and gasket from
throttle valve assembly. Discard gasket. See • S6.0FT, S7.0FT (S135FT, S155FT)
Figure 74. (G024)

6. Remove throttle valve assembly and gasket Engine Coolant Temperature (ECT) Sensor
from air intake heater. Discard gasket. See Fig-
ure 74. Remove
7. Remove air intake heater and gasket from in- 1. To access battery, raise hood, on lift truck mod-
take manifold. Discard gasket. See Figure 74. els below. Disconnect the battery.
8. Remove two studs from intake manifold. See • H6.0FT, H7.0FT (H135FT, H155FT)
Figure 74. (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Install H175FT36, H190FT) (B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
NOTE: If throttle valve assembly or air intake
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
heater have been identified as faulty, replace with
(S005)
new one.
• S6.0FT, S7.0FT (S135FT, S155FT)
1. Install two studs into intake manifold. See Fig- (G024)
ure 74.
2. Drain engine coolant from radiator before re-
2. Install new gasket and air intake heater onto moving ECT sensor. Refer to the section Cool-
studs and intake manifold. See Figure 74. ing System 0700SRM1123.
3. Install new gasket and throttle valve assembly 3. Disconnect the ECT sensor electrical connector
onto two studs and air intake heater. See Fig- from the ECT sensor. See Figure 72.
ure 74.

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4. Remove the ECT sensor and O-ring. Discard O- Engine Oil Pressure Sensor
ring.
Remove
Install
1. To access battery, raise hood, on lift truck mod-
NOTE: If ECT sensor has been identified as faulty, els below. Disconnect the battery.
replace ECT sensor with new one.
• H6.0FT, H7.0FT (H135FT, H155FT)
1. Install new O-ring onto ECT sensor. (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
2. Install ECT sensor. Tighten sensor to 16 to H175FT36, H190FT) (B299)
23 N•m (12 to 17 lbf ft).
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. Connect ECT sensor connector. See Figure 72. H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
4. Refill the radiator with engine coolant. See one
• S6.0FT, S7.0FT (S135FT, S155FT)
of the following sections for coolant specifica-
(G024)
tion and procedures
2. Disconnect electrical connector from oil pres-
Periodic Maintenance 8000SRM1583 for lift
sure sensor.
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) 3. Unscrew and remove oil pressure sensor and O-
(K006) ring from adapter. See Figure 72.

Periodic Maintenance 8000SRM1586 for lift 4. Discard O-ring.

truck model
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Install
H175FT36, H190FT) (B299) NOTE: If oil pressure sensor has been identified as
Periodic Maintenance 8000SRM1604 for lift faulty, replace oil pressure sensor with new one.
truck models 1. Lubricate new O-ring with multipurpose
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; grease, and install on oil pressure sensor.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005) 2. Apply thread locker to threads of oil pressure
sensor. Install oil pressure sensor into adapter.
Periodic Maintenance 8000SRM1606 Tighten to 15 to 19 N•m (11 to 14 lbf ft).
• S6.0FT, S7.0FT (S135FT, S155FT) (G024)
3. Connect electrical connector for oil pressure
5. Connect battery and lower the hood on lift sensor. See Figure 64.
truck models
4. Connect battery and lower the hood on lift
• H6.0FT, H7.0FT (H135FT, H155FT) truck models
(K006)
• H6.0FT, H7.0FT (H135FT, H155FT)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, (K006)
H175FT36, H190FT) (B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H175FT36, H190FT) (B299)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
(S005)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S6.0FT, S7.0FT (S135FT, S155FT) (S005)
(G024)
• S6.0FT, S7.0FT (S135FT, S155FT)
(G024)

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Crankshaft Position Sensor Legend for Figure 75

1. PULSAR GEAR
Remove 2. AIR GAP
3. SHIM
1. To access battery, raise hood, on lift truck mod- 4. CRANKSHAFT POSITION SENSOR
els below. Disconnect the battery. 5. GEAR CASE
6. SHIM 0.25 mm (0.0098 in.)
• H6.0FT, H7.0FT (H135FT, H155FT) 7. SHIM 0.50 mm (0.020 in.)
(K006) 8. SHIM 1.00 mm (0.0394 in.)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
NOTE: An air gap of 0.25 to 1.4 mm (0.0098 to
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
0.055 in.) is needed between the crankshaft posi-
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
tion sensor and the pulsar gear. The air gap is ach-
(S005)
ieved by using shims shown in Figure 75 and proce-
• S6.0FT, S7.0FT (S135FT, S155FT) dure outlined in Adjust Shim Procedure.
(G024)
2. Add the appropriate amount of air gap by add-
2. Disconnect crankshaft position sensor electrical ing shims to the crankshaft position sensor. See
connector from the crankshaft position sensor. Figure 75.
See Figure 72.
3. Install crankshaft position sensor.
3. Remove crankshaft position sensor mounting
capscrew. 4. Install crankshaft position sensor mounting
capscrew. Tighten to 4 to 5 N•m (35 to
4. Remove crankshaft position sensor and O-ring. 45 lbf in).
Discard O-ring.
5. Connect crankshaft position sensor electrical
Install connector to crankshaft position sensor.

NOTE: If crankshaft position sensor has been iden- 6. Connect battery and lower the hood on lift
tified as faulty, replace crankshaft position sensor truck models
with new one. • H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
1. Lubricate new O-ring with multipurpose
grease. Install O-ring on crankshaft position • H8.0FT, H8.0FT9, H9.0FT (H170FT,
sensor. See Figure 75. H175FT36, H190FT) (B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
• S6.0FT, S7.0FT (S135FT, S155FT)
(G024)

Adjust Shim Procedure

1. Align TC mark of flywheel with flywheel hous-
ing timing window. See procedure in Fuel Sys-
tem Repair section of Kubota Diesel 3.8L
Engines with Diesel Particulate Filter
(DPF) 0600SRM1590.

2. Install measurement jig 1 into sensor mounting

Figure 75. Crankshaft Position Sensor Air Gap position. See Figure 76.

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1. MEASUREMENT JIG 1 1. JIG 1

2. PROTRUSION
Figure 76. Measurement JIG 1 3. GEAR CASE
4. PULSE GEAR
3. Set dial gauge at measurement jig 2, then
Figure 78. Protrusion Measurement
measure protrusion of jig 1. See Figure 77 and
Figure 78.
4. Using the protrusion measurement, see Table 2
for the proper shim combination required to set
the air gap.

1. MEASUREMENT JIG 2
2. DIAL GAUGE
Figure 77. Measurement JIG 2

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Table 2. Adjustment Shim Combinations

Thickness and Number of Shims

Protrusion
0.25 mm (0.0098 in.) 0.50 mm (0.020 in.) 1.00 mm (0.0394 in.)
2.25 to 2.50 mm (0.0886
1 2
to 0.0984 in.)
2.00 to 2.25 mm (0.0788
2
to 0.0885 in.)
1.75 to 2.00 mm (0.0689
1 1 1
to 0.0787 in.)
1.50 to 1.75 mm (0.0591
1 1
to 0.0688 in.)
1.25 to 1.50 mm (0.0493
1 1
to 0.0590 in.)
1.00 to 1.25 mm (0.0394
1
to 0.0492 in.)
0.750 to 1.00 mm (0.0296
1 1
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 Install

Remove NOTE: If camshaft position sensor has been identi-

fied as faulty, replace camshaft position sensor
1. To access battery, raise hood, on lift truck mod- with new one.
els below. Disconnect the battery.
1. Lubricate new O-ring with multipurpose
• H6.0FT, H7.0FT (H135FT, H155FT) grease. Install O-ring on camshaft position sen-
(K006) sor. See Figure 72.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) 2. Install camshaft position sensor.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 3. Install camshaft position sensor mounting cap-
H5.0-5.5FT (H80, 90, 100, 110, 120FT) screw. Tighten to 4 to 5 N•m (35 to 45 lbf in).
(S005)
4. Connect camshaft position sensor electrical con-
• S6.0FT, S7.0FT (S135FT, S155FT)
nector to camshaft position sensor.
(G024)

2. Disconnect camshaft position sensor electrical

connector from camshaft position sensor. See
Figure 72.

3. Remove camshaft position sensor mounting

capscrew.

4. Remove camshaft position sensor and O-ring.

Discard O-ring.

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2200 SRM 1142 Sensors and Switches

5. Connect battery and lower the hood on lift

truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
• S6.0FT, S7.0FT (S135FT, S155FT)
(G024)

Differential Pressure Sensor

Remove
1. DIFFERENTIAL PRESSURE SENSOR
1. To access battery, raise hood, on lift truck mod- 2. BRACKET
3. CAPSCREW
els below. Disconnect the battery. 4. CLAMP
• H6.0FT, H7.0FT (H135FT, H155FT) 5. HOSE
(K006)
Figure 79. Differential Pressure Sensor
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; Install
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005) NOTE: If differential pressure sensor has been
• S6.0FT, S7.0FT (S135FT, S155FT) identified as faulty, replace differential pressure
(G024) sensor with new one.

2. Disconnect electrical connector from differential 1. Using two capscrews, install differential pres-
pressure sensor. sure sensor onto bracket. See Figure 79.

3. Remove two clamps and two hoses from bottom 2. Connect electrical connector to differential
of differential pressure sensor. See Figure 79. pressure sensor.

4. Remove two capscrews and differential pres- 3. Install two hoses and two clamps onto bottom of
sure sensor from bracket. See Figure 79. sensor. See Figure 79.

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Sensors and Switches 2200 SRM 1142

4. Connect battery and lower the hood on lift

truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
• S6.0FT, S7.0FT (S135FT, S155FT)
(G024)

Mass Air Flow Sensor

Remove
1. To access battery, raise hood, on lift truck mod-
els below. Disconnect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006) 1. MASS AIR FLOW SENSOR
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 2. CAPSCREW
H175FT36, H190FT) (B299)
Figure 80. Mass Air Flow Sensor for Lift Truck
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; Models H6.0FT, H7.0FT (H135FT, H155FT) (K006)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) And H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
(S005) H190FT) (B299)
• S6.0FT, S7.0FT (S135FT, S155FT)
(G024)

2. Disconnect mass air flow sensor electrical con-

nector.

See Figure 80 for lift truck models

• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)

See Figure 81 for lift truck models

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (G024)

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2200 SRM 1142 Sensors and Switches

See Figure 80 for lift truck models

• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)

See Figure 81 for lift truck models

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (G024)

3. Connect battery and lower the hood on lift

truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
1. MASS AIR FLOW SENSOR H5.0-5.5FT (H80, 90, 100, 110, 120FT)
2. CAPSCREW
(S005)
Figure 81. Mass Air Flow Sensor for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • S6.0FT, S7.0FT (S135FT, S155FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005) And (G024)
S6.0FT, S7.0FT (S135FT, S155FT) (G024)
Fuel/Water Separator
3. Remove two capscrews and mass air flow sen-
Remove
sor.
1. To access battery, raise hood, on lift truck mod-
See Figure 80 for lift truck models
els below. Disconnect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
(K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
H175FT36, H190FT) (B299)
See Figure 81 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005)
(S005) • S6.0FT, S7.0FT (S135FT, S155FT)
• S6.0FT, S7.0FT (S135FT, S155FT) (G024) (G024)

Install
NOTE: If mass air flow sensor has been identified
as faulty, replace mass air flow sensor with new
one.
1. Install mass air flow restriction sensor and two
capscrews.
2. Connect electrical connector for mass air flow
sensor.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
2. Attach a small hose to hose barb on drain valve
at bottom of fuel filter element and route hose
into a suitable container to collect fuel and con-
taminants. See Figure 82.

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Sensors and Switches 2200 SRM 1142

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

connection are one piece and will be removed as an
assembly.

8. Remove fuel/water sensor, drain, and electrical

connection from fuel filter housing.

Install
NOTE: If fuel/water sensor has been identified as
faulty, replace fuel/water sensor with new one.

1. Install fuel/water sensor assembly into fuel fil-

ter element housing and tighten one half turn
past hand tight.

2. Install fuel filter element housing to casting

mounted on engine. See Figure 82.

1. FUEL FILTER ELEMENT HOUSING 3. Tighten housing one quarter turn past hand
2. FUEL/WATER SENSOR ASSEMBLY tight.
3. DRAIN
4. ELECTRICAL CONNECTOR 4. Connect electrical connector. See Figure 82.
Figure 82. Fuel/Water Separator 5. Connect battery and lower the hood on lift
truck models
3. Open drain valve. See Figure 82. • H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
4. Disconnect electrical connector. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
5. Once all fuel and contaminants have been
drained from fuel filter element housing, re- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
move drain hose. H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(S005)
6. Remove fuel filter element housing. See Fig-
• S6.0FT, S7.0FT (S135FT, S155FT)
ure 82.
(G024)

CAUTION ENGINE AND FUEL SENSORS AND

DO NOT over tighten the vice. If over tightening of SWITCHES, KUBOTA 3.6L DIESEL
the vice occurs, the fuel filter element housing will ENGINE
become misshapen and not seal correctly.
Refer to Figure 83 for location of engine sensors
7. Place fuel filter element housing in soft jawed and switches.
vice.

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2200 SRM 1142 Sensors and Switches

NOTE: H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) ENGINE SHOWN,
H6.0FT, H7.0FT (H135FT, H155FT) (K006) AND H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (S005) SIMILAR.

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

1. COOLANT TEMPERATURE SENSOR 3. ENGINE SPEED SENSOR (H4.0FT5/FT6;
2. OIL PRESSURE SENSOR H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (R005, S005) ONLY
4. FUEL SHUT OFF SOLENOID

Figure 83. Kubota 3.6L Diesel Engine Sensors and Switches

Engine Coolant Temperature (ECT) Sensor Install

Remove NOTE: If ECT sensor has been identified as faulty,

1. Raise hood and disconnect the battery.
2. Drain engine coolant from radiator before re-
moving ECT sensor. Refer to the section Cool-
ing System 0700SRM1123.
3. Disconnect the ECT sensor electrical connector
from the ECT sensor. See Figure 83.
4. Remove the ECT sensor and O-ring. Discard O-
ring.
replace ECT sensor with new one.
1. Install new O-ring onto ECT sensor.
2. Install ECT sensor.
3. Connect ECT sensor connector. See Figure 83.
4. Refill the radiator with engine coolant. For cool-
ant specification and procedure
See Periodic Maintenance 8000SRM1558 for
lift truck model
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005)

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Sensors and Switches 2200 SRM 1142

See Periodic Maintenance 8000SRM1583 for Engine Speed Sensor

lift truck model
• H6.0FT, H7.0FT (H135FT, H155FT) Remove
(K006)
1. Raise hood and disconnect the battery.
See Periodic Maintenance 8000SRM1604 for
lift truck models 2. Disconnect electrical connector from engine
speed sensor. See Figure 83.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 3. Remove engine speed sensor mounting cap-
(S005) screw.

5. Connect battery and lower the hood.
Throttle Position Sensor
See section Kubota Diesel 3.6L Engine
0600SRM1579, Electronic Throttle System for pro-
cedures to remove and install throttle position sen-
sor.
4. Remove engine speed sensor and O-ring. Dis-
card O-ring.
Install
NOTE: If engine speed sensor has been identified
as faulty, replace camshaft position sensor with
new one.

1. Lubricate new O-ring with multipurpose

Engine Oil Pressure Sensor grease. Install O-ring on engine speed sensor.
Remove 2. Install engine speed sensor. See Figure 83.
1. Raise hood and disconnect the battery. 3. Install engine speed sensor mounting capscrew.
2. Disconnect electrical connector from oil pres- 4. Connect engine speed sensor electrical connec-
sure sensor. tor.

3. Unscrew and remove oil pressure sensor and O-
ring from adapter. See Figure 83.
4. Discard O-ring.
Install
NOTE: If oil pressure sensor has been identified as
faulty, replace oil pressure sensor with new one.
1. Lubricate new O-ring with multipurpose
grease, and install on oil pressure sensor.
2. Apply thread locker to threads of oil pressure
sensor. Install oil pressure sensor into adapter.
Tighten two to three turns past finger tight.
3. Connect electrical connector for oil pressure
sensor. See Figure 83.
4. Connect battery and lower the hood.
5. Connect battery and lower hood on lift truck.
Fuel Shut Off Solenoid
Remove
1. Raise hood and disconnect battery.
2. Disconnect electrical connector from fuel shut
off solenoid. See Figure 83.
3. Remove two socket head bolts from fuel shut off
solenoid.
4. Remove fuel shut off solenoid and O-ring. Dis-
card O-ring.
Install
NOTE: If fuel shut off solenoid has been identified
as defective, replace fuel shut off solenoid with new
one.

1. Lubricate new O-ring with multipurpose grease

and install onto fuel shut off solenoid.

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2200 SRM 1142
2. Install fuel shut off solenoid. See Figure 83.
3. Install two socket head bolts into fuel shut off
solenoid.
Vehicle System Manager (VSM)
GENERAL
The Vehicle System Manager (VSM) is a microproc-
essor-powered controller which controls or moni-
tors, directly or indirectly, every electrical device on
the lift truck, except for the Electronic Control Unit
(ECU) and the Governor Control Unit (GCU).
These devices are controlled by the engine.
VSM REPLACEMENT
NOTE: The VSM is not a serviceable part. If the
VSM malfunctions, replace with a new VSM. See
the Parts Manual for replacement part number.
Remove
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood, on lift
truck models below. Disconnect the battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
Confidential/Proprietary - Do Not Copy or Duplicate
Sensors and Switches
4. Connect battery and close hood.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
2. Fully lower the steering column and remove the
upper steering column cover. See the section
Steering Column Repair for the removal proce-
dures.
3. Remove the dash and kick panel. See the sec-
tion Dash and Kick Panel, Remove and Install
for removal procedures.
4. Disconnect all electrical connections from the
VSM. These connections include the chassis
harness, cowl harness, transmission harness,
and electronic hydraulic (e-hydraulic) controls,
if lift truck is equipped with this feature. See
Figure 84.
5. Remove the three bolts securing the VSM and
harness bracket to the cowl. Remove VSM from
lift truck cowl.
115
Vehicle System Manager (VSM) 2200 SRM 1142

A. VSM ARRANGEMENT FOR ALL LIFT TRUCK MODELS EXCEPT FOR S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024, G024) AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
B. VSM ARRANGEMENT FOR LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024)
C. VSM ARRANGEMENT FOR LIFT TRUCK MODELS H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
1. BOLTS 4. E-HYDRAULIC CONTROLS HARNESS
2. COWL HARNESS 5. COWL
3. VSM

Figure 84. Vehicle System Manager

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2200 SRM 1142
Install
1. Install VSM and harness bracket onto lift truck
cowl. Tighten bolts to 19.2 N•m (14 lbf ft).
2. Connect all electrical connections to the VSM.
The connectors are color coded for easy connec-
tion.
3. Install the dash panel and kick panel. See the
section Dash and Kick Panel, Remove and In-
stall for installation procedures.
4. Install the upper steering column cover. See the
section Steering Column Repair for the instal-
lation procedures.
5. Connect the battery, install the floor plate and
floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
PROGRAMMING A NEW VSM AND/OR
DISPLAY SWITCH CLUSTER
NOTE: See the section Diagnostic Troubleshoot-
ing Manual 9000SRM1112 for information on how
delete and reset fault codes to the VSM, how to use
the PC Service Tool software, and for the proce-
dures to troubleshoot the VSM, Display Switch
Cluster, and other electrical components used on
these trucks.
Confidential/Proprietary - Do Not Copy or Duplicate
Vehicle System Manager (VSM)
General
Whenever a new VSM or Display Switch Cluster is
installed (see Display Switch Cluster for procedures
to remove and install the Display Switch Cluster)
on a lift truck, the data that controls all the func-
tions and features unique to that lift truck needs to
be transferred to the new VSM or Display Switch
Cluster.
There are two types of data files that may be re-
quired to be transferred when a new VSM or Dis-
play Switch Cluster is installed:
• Configuration Data File (CDF).
This data file has the configuration and op-
tional details specific to a given truck. For
example, configuration information may in-
clude data that shows the truck's lifting ca-
pacity and base type (e.g., 2-3 Ton Cushion
tire truck). Optional information may include
data defining the type of engine the truck
has and whether any Software Enabled Op-
tions (SEO) have been installed (e.g., opera-
tor passwords). Adding new SEO will require
that new CDF be downloaded and transfer-
red into the VSM and Display Switch Clus-
ter. This data information is directly linked
to the truck's serial number. An example of a
lift truck serial number is F187V12345A001.
The first 11 characters (F187V12345A) rep-
resent the truck's serial number and the last
3 digits (001) represent the CDF revision loa-
ded on the truck. The serial number of a lift
truck is stored in the Display Switch Cluster.
See the section User Interface - Service
Technician 2200SRM1131 for the proce-
dures to find the serial number. A lift truck's
serial number can be found online at Hypass
Online. The CDF revision will change every
time a new version is loaded and transferred
to either the VSM or Display Switch Cluster.
The CDF for a particular truck cannot be
modified by a service technician. However, a
replacement file (with alternate options
[SEO]) can be loaded into a truck's controller
by a service technician. The operational copy
of the CDF is stored in the VSM and a
backup copy is stored in the Display Switch
Cluster.
• Operating Data
117
Vehicle System Manager (VSM)
This includes periodically updated and truck
specific information such as component serial
numbers and hourmeters. It also includes
the specific adjustments that can be made by
the service technician for various parameters
on a given lift truck. Examples are: auto-de-
celeration, which may be set on a scale from
(1to10); and certain features which can be
activated or deactivated.
PC Service Tool Software
The PC Service Tool software (Hyster P/N 1582488)
is required to perform any CDF data file transfers
from the Display Switch Cluster to a new VSM or
from the VSM to a nonblank Display Switch Clus-
ter. A nonblank Display Switch Cluster is one that
has been used on several trucks. If the Display
Switch Cluster is brand new (blank display), the
PC Service Tool software is not used. The CDF data
will automatically be transferred to the new display
from the VSM (see Table 3).
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 85. For
minimum PC requirements to run the software, re-
fer to the PC Service Tool Installation and Use
Guide, Systems Requirements section.
Data Transferring
New VSM
NOTE: Data transfer to a used VSM is not possi-
ble. Only a new VSM can be used.
118
2200 SRM 1142
If the VSM is being replaced, the lift truck's CDF
and Operating Data files must be retrieved from
the Display Switch Cluster using the PC Service
Tool software or the data will be overwritten. This
also includes the truck hourmeters. See Table 3.
Detailed instructions can be found in the PC Serv-
ice Tool (PCST) Truck Reprogramming Guide.
New (Blank) Display Switch Cluster
If the Display Switch Cluster is being replaced with
a new (blank) display, the PC Service Tool software
will match the VSM to the display. If the PC Serv-
ice Tool is not used there will be a mismatch. See
Table 3.
Used (Non-Blank) Display Switch Cluster
If the replacement Display Switch Cluster has been
used on another truck, the PC Service Tool soft-
ware must be used to perform the data copying se-
quence discussed in New (Blank) Display Switch
Cluster. See Table 3.
Depending on the part being replaced and the tools
available, different methods of transferring the nee-
ded data exist. Refer to Table 3 for the best method
to use to transfer data based on the tools available.
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142 Vehicle System Manager (VSM)

Legend for Figure 85

1. STEERING COLUMN
2. PC SERVICE TOOL DIAGNOSTIC CONNEC-
TOR

Figure 85. Connecting PC Service Tool

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Vehicle System Manager (VSM) 2200 SRM 1142

Table 3. VSM and Display Switch Cluster Replacement

Repair Location Conditions

PC Not Available PC Available, No PC and Internet
Internet Available
VSM Replaced, Not allowed - PC re- Read back up CDF Read back up Dis-
Original Display quired from Display, down- play, download into
Intact load into new VSM new VSM
VSM and Display Not allowed - PC Not allowed - PC Read back up CDF
Replaced and Internet re- and Internet re- from Hypass Online,
quired quired download into new
VSM, new blank
Field Repair display auto upda-
ted 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 re- PC Service Tool ena- PC Service Tool ena-
With Previously quired bles over write of old bles over write of old
Used Display CDF in display CDF in display

Power Distribution Module (PDM) and Component Parts

REMOVE • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
PDM as a Unit • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
NOTE: The PDM as a unit, is not a serviceable 120FT; S80, 100FTBCS; S120FTS;
part. The component parts of the PDM (relays, S120FTPRS) (G004, H004)
fuses, and resistors), can be replaced without re- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
placing the PDM. If the PDM malfunctions, replace H5.0-5.5FT (H80, 90, 100, 110, 120FT)
with a new PDM. See the Parts Manual for re- (N005, P005, R005, S005)
placement part number. • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
1. To access the PDM and battery, remove the
floor mat and floor plate, on lift truck models 2. Disconnect the chassis harness from the main
below. Disconnect the battery. power connection terminals on the PDM.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006) 3. Remove bolts and PDM from battery tray for
lift truck models below.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

To access the PDM and battery, raise the steer-

ing column to its highest position, move the seat
all the way forward, and raise the hood on lift
truck models below. Disconnect the battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)

120 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Power Distribution Module (PDM) and Component Parts

See Figure 86 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,

• S30FT, S35FT, S40FTS (E010) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)

Confidential/Proprietary - Do Not Copy or Duplicate 121

Power Distribution Module (PDM) and Component Parts 2200 SRM 1142

Figure 86. PDM Removal, For Lift Truck Models S30-35FT, S40FTS (E010), H1.6-1.8FT, H2.0FTS (H30-35FT,
H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177), S4.0-5.5FT, S5.5FTS
(S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) (G004, H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (N005, P005, R005, S005), 6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024)

122 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Power Distribution Module (PDM) and Component Parts

Legend for Figure 86

NOTE: FRAME FOR YOUR MODEL LIFT TRUCK MAY VARY FROM IMAGE SHOWN.

1. BATTERY 5. MAIN POWER CONNECTIONS

2. BATTERY TRAY 6. BOLTS (SECURE PDM TO BATTERY TRAY)
3. PDM 7. BATTERY LOCKDOWN BAR
4. FUSE CLIP

4. Remove bolts and PDM from PDM mounting • H8.0FT, H8.0FT9, H9.0FT (H170FT,
bracket, for lift truck models below. H175FT36, H190FT) (A299, B299)

See Figure 87 for lift truck models

• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)

1. BATTERY 4. CHASSIS HARNESS

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

Figure 87. PDM Removal, Lift Truck Models H6.0-7.0FT (H135-155FT) (H006, J006, K006) and H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)

Confidential/Proprietary - Do Not Copy or Duplicate 123

Power Distribution Module (PDM) and Component Parts 2200 SRM 1142

INSTALL 5. Close the hood and move the seat and steering
column into position, for lift truck models
PDM as a Unit shown below see section indicated for proce-
dures:
1. For lift truck models below, install PDM and
bolts onto battery tray. Tighten bolts to Frame 0100SRM1120 for lift truck models
8 N•m (71 lbf in). • S30FT, S35FT, S40FTS (E010)

See Figure 86 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS
H35FT, H40FTS) (F001)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(H30FT,
• H2.0-3.5FT (H40-70FT) (L177)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187) Frame 0100SRM1243 for lift truck models
• H2.0-3.5FT (H40-70FT) (L177) • S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
S120FTPRS) (G004, H004) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
(N005, P005, R005, S005)
Frame 0100SRM1316 for lift truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
E024, F024, G024)
2. For lift truck models below, install PDM and
6. Install the floor plate and floor mat for lift
bolts onto PDM mounting bracket. Tighten
truck models shown below, see section indica-
bolts to 8 N•m (71 lbf in).
ted for procedures:
See Figure 87 for lift truck models
Frame 0100SRM1321 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (A299)
3. Connect the chassis harness to the main power
Frame 0100SRM1581 for lift ruck model
connection terminals on the PDM.
• H6.0FT, H7.0FT (H135FT, H155FT)
See Figure 86 for lift truck models (K006)
• H6.0FT, H7.0FT (H135FT, H155FT) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
(H006, J006, K006) H175FT36, H190FT) (B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

See Figure 87 for lift truck models

• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

4. Connect the lift truck battery.

124 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Power Distribution Module (PDM) and Component Parts

REMOVE AND INSTALL

PDM Component Parts

If lift truck is equipped with a key switch, turn key

to ON position. If lift truck is equipped with a
Power ON/OFF button, press button to turn sys-
tem power on. Check all indicator lights for correct
operation as described in the Operating Manual.
Check the operation of the horn. Start the engine
by turning the key switch to the Start position, if
truck is equipped with a key switch, or press the
Power ON/OFF button, if lift truck is equipped
with this button. If any indicator lights do not oper-
ate correctly, check the fuses. The fuses are located
in the Power Distribution Module (PDM) which is
under the hood next to the battery on the right 1. RESISTOR (68 OHM)
side. See Figure 88. 2. START RELAY
3. STARTER (30 AMP)
4. IGNITION 3 RELAY
5. BACKUP RELAY
6. BACKUP (20 AMP)
7. IGNITION (30 AMP)
8. SPARE FUEL PUMP (20 AMP)
9. SPARE FUEL PUMP RELAY
10. BATTERY (25 AMP)
11. FRONT WORK LIGHT (20 AMP)
12. FRONT/REAR WORK LIGHT RELAYS
13. BATTERY (25 AMP)
14. REAR WORK LIGHT (20 AMP)
15. IGNITION 1 (20 AMP)
16. IGNITION 1 RELAY
17. BATTERY (25 AMP)

Figure 88. PDM Component Parts

Transmission Control Unit

NOTE: The transmission control unit (TCU) is REMOVE
used only on lift truck models:
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
WARNING
E024, F024, G024)
Always disconnect the cables at the battery be-
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, fore disconnecting the transmission control unit
J006, K006) (TCU). Disconnect the cable at the negative termi-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, nal first.
H175FT36, H190FT) (A299, B299)
1. Open hood and disconnect battery, for lift truck
models below.
• S6.0FT, S7.0FT, (S135FT, S155FT)
(D024, E024, F024, G024)

Confidential/Proprietary - Do Not Copy or Duplicate 125

Transmission Control Unit 2200 SRM 1142

Remove front and rear floor mat and floor plates
and disconnect battery, for lift truck models be-
low.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
2. Disconnect transmission harness connectors
from TCU. See Figure 89.
3. Remove four flange capscrews from bracket and
TCU.
4. Remove TCU from bracket.

NOTE: When disconnecting transmission harness

connectors during removal, tag each connector to
aid in connecting transmission harness connectors
during installation.

A. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, B. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
K006) AND H8.0FT, H8.0FT9, H9.0FT (H170FT, F024, G024)
H175FT36, H190FT) (A299, B299)
1. FLANGE CAPSCREW 4. TRANSMISSION HARNESS CONNECTOR
2. TRANSMISSION CONTROL UNIT (TCU) (CRP128)
3. TRANSMISSION HARNESS CONNECTOR 5. BRACKET
(CRP129)

Figure 89. Transmission Control Unit Location

INSTALL 4. Connect battery and close hood, for lift truck

models
1. Install TCU into bracket. See Figure 89. • S6.0FT, S7.0FT (S135FT, S155FT)
2. Install four flange capscrews into bracket and (D024, E024, F024, G024)
TCU.

3. Connect transmission harness connectors to

TCU as tagged during removal.

126 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
Connect battery and install front and rear floor
plate and floor mats, for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
Battery
REMOVE
1. To access the battery, remove the floor mat and
floor plate, on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood, on lift
truck models below. Disconnect the battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
2. Remove the battery lockdown bar securing bat-
tery to battery tray. Remove battery from lift
truck.
See Figure 86 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Confidential/Proprietary - Do Not Copy or Duplicate
Transmission Control Unit
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
See Figure 87 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
INSTALL
1. Install new battery onto battery tray. Secure
battery to battery tray with battery lockdown
bar.
2. Connect the battery, install the floor plate and
floor mat, on lift truck models:
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Connect the battery and lower the hood, on lift
truck models:
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)
127
Lights 2200 SRM 1142

Lights
WORK LIGHTS (FRONT AND REAR) 3. To replace the work light assembly, disconnect
the light from the overhead guard harness and
Remove remove the capscrew, washer, and nut attach-
ing the work light to the overhead guard.
1. To access the battery, remove the floor mat and
floor plate on lift truck models below. Discon-
nect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

To access the battery, raise the hood on lift truck

models below. Disconnect the battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
NOTE: REAR WORK LIGHT SHOWN, FRONT
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, WORK LIGHT IS SIMILAR.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005) 1. CAPSCREWS (LENS ASSEMBLY)
2. LENS ASSEMBLY
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 3. NUT (ATTACHES LIGHT TO OVERHEAD
E024, F024, G024) GUARD)

Figure 90. Work Lights

CAUTION
DO NOT touch the Halogen bulb surface or inside
reflectors with your bare hands. Oils from skin Install
can lead to breakage or shorten the life of the
lamp. Use clean gloves or lint free cloth for instal- 1. Install work light to overhead guard using the
lation and removal. capscrew, washer, and nut. See Figure 90. Con-
nect work light to overhead guard harness.
Clean any dirt or oil, from the lamp surface with
alcohol and a lint free cloth or tissue. Any foreign 2. Connect the battery, install the floor plate and
particles or materials on the bulb surface can floor mat, on lift truck models
cause hot spots on the bulb and result in lamp
• H6.0FT, H7.0FT (H135FT, H155FT)
failure.
(H006, J006, K006)
2. To replace the bulb, remove the lens assembly • H8.0FT, H8.0FT9, H9.0FT (H170FT,
by removing the four capscrews. See Figure 90. H175FT36, H190FT) (A299, B299)
Replace the bulb and reinstall the lens assem-
bly.

128 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Lights

Connect the battery and lower the hood, on lift 2. Disconnect the strobe light electrical connector
truck models from the overhead guard harness. See Fig-
• S30FT, S35FT, S40FTS (E010) ure 91.

• H1.6FT, H1.8FT, H2.0FTS (H30FT, 3. Remove the capscrews, washers, lockwasher,

H35FT, H40FTS) (F001) and nuts securing the strobe light and light
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) guard to strobe light mounting bracket. Remove
strobe light and guard from lift truck.
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 4. If the strobe light bulb needs to be replaced, re-
120FT; S80, 100FTBCS; S120FTS; move the strobe light lens from base and re-
S120FTPRS) (G004, H004) move bulb.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
Install
(N005, P005, R005, S005) 1. If bulb is being replaced, install new bulb into
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, strobe light base. Install strobe light lens onto
E024, F024, G024) base.

STROBE LIGHT 2. Place strobe light assembly and 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-moun-
ted). The removal and installation procedures are
the same for both options.
guard onto mounting bracket. Secure the as-
sembly to mounting bracket with capscrews,
washers, lockwasher, and nuts. See Figure 91.
3. Connect strobe light electrical connector to
overhead guard harness.

4. Connect the battery, install the floor plate and

Remove
floor mat, on lift truck models
1. To access the battery, remove the floor mat and • H6.0FT, H7.0FT (H135FT, H155FT)
floor plate on lift truck models below. Discon- (H006, J006, K006)
nect the battery. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H6.0FT, H7.0FT (H135FT, H155FT) H175FT36, H190FT) (A299, B299)
(H006, J006, K006)
Connect the battery and lower the hood, on lift
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
truck models
H175FT36, H190FT) (A299, B299)
• S30FT, S35FT, S40FTS (E010)
To access the battery, raise the hood, on lift • H1.6FT, H1.8FT, H2.0FTS (H30FT,
truck models below. Disconnect the battery. H35FT, H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, • H2.0-3.5FT (H40-70FT) (L177)
H35FT, H40FTS) (F001)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 120FT; S80, 100FTBCS; S120FTS;
• H2.0-3.5FT (H40-70FT) (L177) S120FTPRS) (G004, H004)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
120FT; S80, 100FTBCS; S120FTS; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
S120FTPRS) (G004, H004) (N005, P005, R005, S005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) E024, F024, G024)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

Confidential/Proprietary - Do Not Copy or Duplicate 129

Lights 2200 SRM 1142

To access the battery, raise the hood, on lift

truck models below. Disconnect the battery.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024, G024)

2. If lift truck is equipped with an optional 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.
1. STROBE LIGHT GUARD
2. STROBE LIGHT LENS 4. Disconnect the LED light from the chassis light
3. STROBE LIGHT BULB harness. See Figure 92.
4. LIGHT BASE
5. NUT 5. If the mounting bracket must be removed from
6. LOCKWASHER the overhead guard leg, remove rear crossmem-
7. WASHER ber cover and remove the mounting bracket
8. MOUNTING BRACKET
9. CAPSCREW from the overhead guard leg. See Figure 92.
10. LOCK NUT
11. ELECTRICAL CONNECTOR Install
Figure 91. Strobe Light Assembly 1. If the mounting bracket was removed, install
the rear crossmember cover. Install mounting
bracket to overhead guard leg.
LED TAIL, BACKUP, AND BRAKE LIGHTS
2. Connect the LED light to the chassis light har-
NOTE: These light assemblies are nonrepairable ness. See Figure 92.
and must be replaced as an assembly. See the
Parts Manual for replacement LED lights. 3. Insert the screw and install the LED light to
the mounting bracket. See Figure 92.
Remove 4. Connect the battery, install the floor plate and
1. To access the battery, remove the floor mat and floor mat, on lift truck models
floor plate on lift truck models below. Discon- • H6.0FT, H7.0FT (H135FT, H155FT)
nect the battery. (H006, J006, K006)
• H6.0FT, H7.0FT (H135FT, H155FT) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
(H006, J006, K006) H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

130 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Lights

Connect the battery and lower the hood, on lift • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
truck models H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S30FT, S35FT, S40FTS (E010) (N005, P005, R005, S005)

• H1.6FT, H1.8FT, H2.0FTS (H30FT, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,

H35FT, H40FTS) (F001) E024, F024, G024)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)

• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)

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 92. LED Tail, Backup, and Brake Lights Replacement

Confidential/Proprietary - Do Not Copy or Duplicate 131

Lights 2200 SRM 1142

FRONT MARKER/TURN SIGNAL LIGHTS Legend for Figure 93

NOTE: RIGHT FRONT MARKER/TURN SIGNAL
Replacing Whole Front Marker/Turn Signal LIGHT ASSEMBLY SHOWN. PROCEDURES TO
Light Assembly REMOVE AND REPLACE LEFT FRONT MARKER/
TURNS SIGNAL LIGHT ASSEMBLY ARE THE
Remove SAME.

1. Disconnect light wire harness from front 1. FRONT MARKER/TURN SIGNAL LIGHT AS-
marker/turn signal light connector. See Fig- SEMBLY
ure 93. 2. LIGHT WIRE HARNESS
3. BOLT
4. TRIM
2. Remove two bolts located at the top of the front 5. OVERHEAD GUARD
marker/turn signal light assembly and inside
the corner of the overhead guard. See Fig-
ure 93.
Replacing Just the Front Marker/Turn Signal
3. Remove front marker/turn signal light assem- Light LED Light Lens
bly from overhead guard and trim.
Remove
Install
1. Use a flat head tool and remove the two caps lo-
1. Install new front marker/turn signal light as- cated on each side of the LED lens. See Fig-
sembly to overhead guard and trim using two ure 94.
bolts. See Figure 93.
2. Remove the four capscrews securing the LED
2. Connect light wire harness to front marker/ lens in the front marker/turn signal light as-
turn signal light connector. sembly. Remove LED lens from assembly. See
Figure 94.
3. Connect the battery.

Figure 93. Front Marker/Turn Signal Light

Assembly Removal

Figure 94. LED Lens Replace

132 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Lights

Legend for Figure 94 Install

NOTE: RIGHT LED LENS SHOWN. PROCEDURES 1. Install new LED light into front marker/turn
TO REMOVE AND REPLACE LEFT LED LENS ARE signal light assembly using four capscrews. See
THE SAME. Figure 94.
1. FRONT MARKER/TURN SIGNAL LIGHT AS-
SEMBLY 2. Install two caps on each side of LED lens. Push
2. CAPS caps until they snap into place.
3. CAPSCREWS
4. FRONT MARKER/TURN SIGNAL LIGHT AS- 3. Connect the battery.
SEMBLY CONNECTOR
5. LED LIGHT

Diesel Particulate Filter (DPF) Display

REMOVE
NOTE: Use a flat head screwdriver to help sepa-
rate the cover from base, where the bracket enters
the cover pry point. See Figure 95.

1. Remove cover from base and DPF display. See

Figure 95.

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 95.

3. Disconnect electrical connector from back of

DPF display. See Figure 95.

4. Remove DPF display from lift truck

NOTE: Note position of lock ring and base in rela- 1. DPF DISPLAY
2. COVER
tion to wiring harness and mounting bracket prior 3. BASE
to removal to help in installation. 4. LOCK RING
5. ELECTRICAL CONNECTOR
5. Slide base and lock ring down wiring harness 6. WIRING HARNESS
and remove from lift truck. 7. HOOK TABS
8. MOUNTING BRACKET
6. Remove two capscrews and mounting bracket 9. COVER PRY POINT
from overhead guard. See Figure 95. 10. CAPSCREW
11. OVERHEAD GUARD

Figure 95. DPF Display

CLEAN AND INSPECT

Using a lint free cloth, wipe down components and

inspect for damage or defects.

Confidential/Proprietary - Do Not Copy or Duplicate 133

Diesel Particulate Filter (DPF) Display
If any components are found to have damage or de-
fect replace them. See Parts Manual for part in-
formation.
INSTALL
1. Install mounting bracket and two capscrews
onto overhead guard. See Figure 95.
2. Slide lock ring and base over wiring harness
and into position on mounting bracket as noted
during removal.
3. Connect electrical connector into back of DPF
display. See Figure 95.
Electronic-Hydraulic Controls - Generation 1
E-HYDRAULIC CONTROLS - TEST
Mini-Levers
Perform all of the following test procedures to be
sure mini-levers operate properly.
See User Interface - Service Technician
2200SRM1131 for instructions to view Lever output
Value. With Service Password, view Diagnostics –
Hydraulic Data Display – Hydraulic Input.
Full Stroke Test
Check for full stroke of mini-lever. Use DSC or in-
stall the Service Tool to monitor functions.
1. Stroke each lever to full stroke, forward and
backward, and allow lever to snap back to cen-
ter.
2. (DO NOT start.) Turn key switch to ON posi-
tion.
3. Display the electro-hydraulic diagnostics menu
on the dash display panel. Operate each lever
to full stroke forward and read input.
• Is lever output = -92%?
• YES: Go to Step 4.
• NO: Mini-lever not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun the test.
134
2200 SRM 1142
NOTE: DO NOT overtighten lock ring.
4. Secure DPF display to base and mounting
bracket using lock ring as noted during re-
moval. See Figure 95.
NOTE: Align two hook tabs into openings of base
at top of cover and snap bottom of cover into posi-
tion.
5. Snap cover onto base and DPF display. See Fig-
ure 95.
4. Operate each lever to full stroke backward and
read input.
• Is lever output = +92%?
• YES: Mini-lever is supplying full stroke.
• NO: Mini-lever not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun the test.
5. If mini-lever continues to not function properly,
contact your local HYSTER dealer or see Hys-
ter Hypass Online.
Function Returns to Neutral Test
Check to confirm function returns to neutral (0%).
Use DSC or install the Service Tool to monitor
functions.
1. Stroke each lever to full stroke, forward and
backward, and allow lever to snap back to cen-
ter.
2. (DO NOT start.) Turn key switch to ON posi-
tion.
3. Display the electro-hydraulic diagnostics menu
on the dash display panel.
• Is each lever output = 0%?
• YES: Go to Step 4.
• NO: Mini-lever is not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun the test.
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142
4. Operate each lever to full stroke forward and
slowly release (1-2 seconds from full stroke).
Read output when fully released.
• Is each lever output = 0%?
• YES: Go to Step 5.
• NO: Mini-lever is not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun the test.
5. Operate each lever to full stroke back and
slowly release (1-2 seconds from full stroke).
Read output when fully released.
• Is each lever output = 0%?
• YES: Mini-lever function is returning to
neutral.
• NO: Mini-lever is not working properly.
See procedures for each generation of
MLM for repair or replacement. Upon
completion, rerun the test.
6. If mini-lever continues to not function, contact
your local HYSTER dealer or see Hyster Hy-
pass Online.
Push Button Switch
1. Validate push button switch operates properly
by operating applicable function.
2. If system does not function; see procedures for
each generation of MLM for repair or replace-
ment. 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 hy-
draulic 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 acci-
dently moved.
Confidential/Proprietary - Do Not Copy or Duplicate
Electronic-Hydraulic Controls - Generation 1
WARNING
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidently make an
electrical connection and cause an injury.
CAUTION
A short circuit and damage can occur if wires are
not installed correctly. Make sure wire connectors
do not touch other metal terminals or wire con-
nectors, metal brackets, or bracket mounting
nuts. Make sure wires are not pulled tight and are
not touching other parts to damage the insulation.
NOTE: The information in this section covers lift
trucks equipped with Electronic-Hydraulic Controls
and built before January, 2010.
NOTE: The mini-levers and joystick do not need to
be calibrated.
The line of trucks covered in this manual come
standard with manual hydraulic levers, but have
the option of using electronic-hydraulic controls. If
the joystick, Mini-Levers Module (MLM), or mini-
levers malfunction, replace with new part. See the
Parts Manual for replacement parts.
MINI-LEVER REPLACEMENT
Remove
1. Remove MLM from lift truck. See Mini-Lever
Module (MLM)Remove.
CAUTION
The following procedure should only be per-
formed by Hyster trained and certified techni-
cians. The removal and replacement of the mini-
levers should be done in a clean environment
whenever possible and on an electrically groun-
ded surface. Do not touch any printed circuit
board (PCB) surface to prevent damage from elec-
trostatic voltage.
NOTE: Warranty seal will be broken when the
MLM housing is opened.
2. Remove lower MLM housing screws using a No.
25 torx driver. See Figure 96.
3. Remove lower MLM housing bottom. See Fig-
ure 96.
135
Electronic-Hydraulic Controls - Generation 1 2200 SRM 1142

4. Unplug the mini-lever connector from the main

PCB. See Figure 97.

CAUTION
DO NOT TRY TO REMOVE CONNECTOR BY
PULLING ON THE WIRES.

5. If push button switch connector is attached to

the mini-lever PCB then unplug this connector.
Carefully grip plug with flush cutting wire cut-
ters. Gently work the plug out of the socket. See
Figure 98.

6. Locate the mini-lever mounting screws. See

Figure 99.

1. MAIN PCB BOARD

2. MINI-LEVER CONNECTOR
3. SCREWS
4. METAL BACKING PLATE

Figure 97. MLM Connector

1. LOWER MLM HOUSING

2. TORX HOUSING SCREWS

Figure 96. MLM Housing Screws

Figure 98. MLM Push Button Switch Connector

136 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142
7. Remove screws using a No. 10 torx driver.
Carefully slide lever out of the top of the MLM.
Be sure wires do no catch on any sharp edges.
Clean and Inspect
Remove any grease or dirt from MLM housing exte-
rior.
Install
1. Install seal (supplied in mini-lever kit) onto
base of new mini-lever.
NOTE: Mini-lever will only insert in one direction.
2. Carefully position mini-lever over mounting
hole. Use index pins to align with matching
hole pattern.
3. Insert one mounting screw and hand tighten to
hold mini-lever in place. See Figure 99.
4. Insert the remaining three screws but do not
tighten.
5. Tighten all screws per the tightening sequence
using a No. 10 torx driver. See Figure 99. Tor-
que to 0.62 N•m (5.5 lbf in). If a torque meas-
urement device is not available, tightened
firmly, but DO NOT over tighten.
NOTE: NUMBERS IN PARENTHESES REPRESENT
MINI-LEVER TIGHTENING SEQUENCE.
1. MOUNTING SCREWS
2. MINI-LEVER PCB BOARD
Figure 99. MLM
Confidential/Proprietary - Do Not Copy or Duplicate
Electronic-Hydraulic Controls - Generation 1
CAUTION
Part can be damaged. Use caution when instal-
ling.
6. Apply Nye 760G grease (supplied in lever kit)
to the push button switch connector.
7. Connect push button switch connector (if fitted)
to mini-lever connection using long nosed pli-
ers. See Figure 100.
8. Apply Nye 760G grease (supplied in lever kit)
to the mini-lever connector.
9. Connect the mini-lever harness to the main
PCB. See Figure 97.
10. Confirm mini-lever functions properly. See E-
Hydraulic Controls - Test procedures in this
section.
Figure 100. MLM Push Connector
11. Install lower MLM housing and lower housing
screws. Tighten screws to 2.8 N•m (25 lbf in)
using No. 25 torx driver. See Figure 101.
12. Install MLM on lift truck. See Mini-Lever Re-
placementInstall.
137
Electronic-Hydraulic Controls - Generation 1
1. LOWER MLM HOUSING
2. TORX HOUSING SCREWS
Figure 101. MLM Housing
PUSH BUTTON SWITCH REPLACEMENT
NOTE: The yellow, rectangular button is a toggle
switch and the round, green button(s) is a momen-
tary switch. See Figure 102.
Remove
1. While in the seat, power truck ON. Check to
confirm there is no Hydraulic Interlock or fault
code display messages. If codes exist, clear co-
des using procedures in Diagnostic Trouble-
shooting Manual 9000SRM1112. Repeat
power ON to confirm codes are cleared.
If Hydraulic Interlock appears, perform Opera-
tor Presence System Check, Hydraulic In-
terlock Check, and Armrest Hydraulic In-
terlock Check. See Diagnostic Trouble-
shooting Manual 9000SRM1112, Operational
Checkout.
2. Remove MLM from lift truck. See Mini-Lever
Module (MLM)Remove.
138
2200 SRM 1142
CAUTION
The following procedure should only be per-
formed by Hyster trained and certified techni-
cians. The removal and replacement of the mini-
levers and push button switch should be done in
a clean environment whenever possible and on an
electrically grounded surface. Do not touch any
printed circuit board (PCB) surface to prevent
damage from electrostatic voltage.
NOTE: Warranty seal will be broken when the
MLM housing is opened.
3. Remove the MLM lower housing screws using a
No. 25 torx driver. See Figure 101.
4. Remove the MLM housing bottom.
5. Disconnect all mini-levers from main PCB con-
nectors. See Figure 97.
6. Disconnect the main PCB to MLM wire harness
connector.
7. Remove the screws from the metal MLM back-
ing plate using a No. 20 torx driver. See Fig-
ure 97.
8. Remove metal backing plate. Make sure wires
are clear and not pinched.
CAUTION
DO NOT touch any printed circuit board (PCB)
surface to prevent damage from electrostatic volt-
age. Handle only by edges of the PCB.
9. Remove the screws securing the main PCB us-
ing a No. 10 Torx driver.
10. Remove the main PCB.
CAUTION
DO NOT TRY TO REMOVE THE CONNECTOR BY
PULLING ON THE WIRES.
11. Disconnect push button switch connector from
mini-lever connection. Carefully grip plug with
flush cutting wire cutters. Gently work the plug
out of the socket. See Figure 98.
Confidential/Proprietary - Do Not Copy or Duplicate
2200 SRM 1142 Electronic-Hydraulic Controls - Generation 1

12. If replacing yellow, rectangular toggle switch,
go to Step 13. Remove lock nut from back of
green, round momentary switch. See Fig-
ure 103. Remove push button switch from hous-
ing.
NOTE: Note the position of the yellow rectangular
toggle switch before removal to aid in installation.
See Figure 103.
13. Remove knurl nut. See Figure 102.

14. Rotate red screw to left stop. See Figure 102.

15. Remove blue connector by sliding from black

cylinder.

16. Remove push button switch from front of hous-

ing.

Install
1. If installing yellow rectangular toggle switch,
insert black cylinder portion of switch through
the housing.

2. Slide blue connector onto cylinder.

3. Rotate red screw to right stop. See Figure 102.

4. Adjust position of yellow rectangular toggle

1. TOGGLE SWITCH switch and tighten knurl nut. Go to Step 7.
2. MOMENTARY SWITCH
5. Install a new green round momentary switch
Figure 102. Push Button Switches assembly.

6. Tighten lock nut.

7. Apply Nye 760G grease (supplied in kit) to the

push button switch connector.

8. Connect push button switch connector to mini-

lever connection using long nosed pliers. See
Figure 100.

9. Replace the main PCB without touching the

surface and secure with screws using a No. 10
torx driver. Torque to 0.62 N•m (5.5 lbf in). If
no torque measurement device is available,
tighten firmly. DO NOT over tighten.

10. Replace metal backing plate. Make sure push

button switch wires are routed into channel. Be
sure all wires are clear and not pinched.

11. Install the two mounting screws loosely.

1. LOCKNUT
2. KNURL NUT 12. Temporarily insert lower MLM housing screws
3. BLACK CYLINDER to align metal backing plate.
4. BLUE CONNECTOR
5. RED SCREW 13. Tighten the metal backing plate screws using a
No. 25 torx driver.
Figure 103. Push Button Switch Housing
14. Remove lower MLM housing screws.

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Electronic-Hydraulic Controls - Generation 1 2200 SRM 1142

15. Apply Nye 760G grease (supplied in kit) to the

main MLM wire harness connector.

16. Connect the main MLM wire harness to the

main PCB connector.

17. Apply Nye 760G grease (supplied in lever kit)

to the mini-lever connector.

18. Connect all of the mini-lever to main PCB con-

nectors.

19. Install lower MLM housing with the lower

housing screws. Tighten screws to
2.8 N•m (25 lbf in) using No. 25 torx driver.
See Figure 101.

20. Confirm push button switch operates properly.

See E-Hydraulic Controls - TestPush Button
Switch.

21. Install MLM on lift truck. See Mini-Lever Mod- 1. MINI-LEVER ASSEMBLY
ule (MLM), Install. 2. FLANGE NUTS
3. ELECTRICAL CONNECTOR
MINI-LEVER MODULE (MLM) 4. MINI-LEVER

Figure 104. Mini-Lever Module Removal

Remove
1. If equipped, pull up on armrest lever and put
armrest cover in the up position see Figure 109.
Disconnect the electrical connector. See Fig-
ure 104.
2. Remove flange nuts that secure MLM to arm-
rest and remove MLM from armrest.
Install
1. Install MLM onto armrest and secure with
flange nuts.
NOTE: When closing the armrest cover, make sure
the wires for the electrical connection are inside the
armrest. If they are hanging out, they can be cut
when closing the armrest cover.
JOYSTICK
NOTE: Joystick control used on lift trucks
manufactured prior to 4/7/2014.
Remove and Disassemble
1. Remove four nuts that attach joystick to
mounting bracket.
2. Disconnect the joystick electrical connector. See
Figure 105.
3. Remove four nuts, lockwashers, washers,
screws, and upper housing from the bracket.

2. Connect the electrical connection and if equip-

ped, put armrest cover in the down position.

140 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Electronic-Hydraulic Controls - Generation 1

Inspect

Inspect the components of the joystick to ensure

that there is no damage. If any component is dam-
aged, other than the wiring harness, replace that
component. Inspect the pins of the wiring harness.
If any are damaged, see the section Wire Harness
Repair 2200SRM1128 for the proper repair proce-
dures.

Assemble and Install

1. Install upper housing, four screws, washers,
lockwashers, and nuts to the bracket. See Fig-
ure 105.

2. Install the bottom cover to the bracket using

four screws.

3. Connect the joystick connector.

1. BOTTOM COVER
2. SCREW 4. Using four nuts, attach joystick to mounting
3. ELECTRICAL CONNECTOR
4. MOUNTING BRACKET bracket.
5. WASHER
6. LOCKWASHER
7. NUT
8. SCREW
9. JOYSTICK
10. LOCK NUT
11. UPPER HOUSING
12. BRACKET

Figure 105. Joystick

Electronic-Hydraulic Controls - Generation 2

GENERAL
WARNING
Before replacing any part of the electronic hy-
draulic 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 acci-
dently moved.
WARNING
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidently make an
electrical connection and cause an injury.
CAUTION
A short circuit and damage can occur if wires are
not installed correctly. Make sure wire connectors
do not touch other metal terminals or wire con-
nectors, metal brackets, or bracket mounting
nuts. Make sure wires are not pulled tight and are
not touching other parts to damage the insulation.
NOTE: Prior to performing the following proce-
dures the E-Hydraulic Controls - Test must be per-
formed.
NOTE: The information in this section covers lift
trucks equipped with Electronic-Hydraulic Controls
and built after January, 2010.

Confidential/Proprietary - Do Not Copy or Duplicate 141

Electronic-Hydraulic Controls - Generation 2 2200 SRM 1142

NOTE: The mini-levers and joystick do not need to possible and on an electrically grounded surface.
be calibrated. Do not touch any printed circuit board (PCB) sur-
face to prevent damage from electrostatic voltage.
NOTE: The Direction Control Switch (DCS) is an
optional feature on lift trucks equipped with Elec- 1. Remove the two capscrews that secure the
tronic-Hydraulic Controls. See Figure 106. mini-lever to the armrest. Remove mini-lever
from armrest. See Figure 107.
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 106. If the joystick, Mini-Levers Module
(MLM), or mini-levers malfunction, replace with
new part. See the Parts Manual for replacement
parts.

1. ARMREST
2. TO WIRE HARNESS
3. HORN BUTTON
4. DIRECTION CONTROL SWITCH
5. MINI-LEVERS
6. MOMENTARY SWITCHES
7. TOGGLE SWITCH

Figure 106. E-Hydraulic Controls Arrangement

MINI-LEVERS, REMOVE AND INSTALL

1. CAPSCREWS
2. MINI-LEVER
3. ARMREST
CAUTION 4. MOMENTARY SWITCH
The following procedure should only be per- Figure 107. Mini-Lever Removal
formed by Hyster trained certified technicians.
The removal and replacement of the mini-levers
should be done in a clean environment whenever NOTE: Before installing new mini-lever, check the
Parts Manual for the correct part number to be
sure the correct mini-lever is being installed.

2. Install new mini-lever onto armrest using two

capscrews.

142 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Electronic-Hydraulic Controls - Generation 2

ARMREST ASSEMBLY 2. Remove two capscrews and washers from cover

plate and remove seat box. Disconnect the main
Remove E-Hydraulic control wire harness from E-Hy-
draulic armrest harness. See Figure 108.
1. Disconnect the battery.

NOTE: SOME COMPONENT PARTS AND ELECTRICAL CONNECTIONS OMITTED OR MOVED FOR
CLARITY.
A. FULL SUSPENSION SEATS B. SEMI SUSPENSION SEATS
1. CAPSCREWS 4. E-HYDRAULIC ARMREST HARNESS CONNEC-
2. WASHERS TOR
3. SEAT BOX 5. COVER PLATE

Figure 108. Seat Box Cover Removal

3. Pull up on handle (see Figure 109) and slide

armrest all the way forward and remove the
flange capscrew from under the armrest mount-
ing bracket that attaches the armrest to the
mounting bracket. Pull up on handle and slide
armrest all the way back and remove the other
flange capscrew. See Figure 110.

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Electronic-Hydraulic Controls - Generation 2 2200 SRM 1142

5. Remove six socket head screws that fasten the

bottom and top armrest covers together. See
Figure 111. Remove the bottom armrest cover
from armrest.

A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN
Figure 109. Armrest Adjustment Handles

4. Remove armrest from armrest mounting

bracket.
1. SOCKET HEAD SCREWS
2. BOTTOM ARMREST COVER

Figure 111. Bottom Armrest Cover Removal

NOTE: The momentary switches and toggle switch

are optional features. If lift truck is not equipped
with these features, there will be a plug covering
the electrical connector on the PCB cassette.

6. Disconnect the momentary switches/toggle

switch connector from PCB cassette. See Fig-
ure 112.

7. Remove the three socket screws from PCB cas-

sette and remove PCB cassette from the arm-
rest. See Figure 112.

1. E-HYDRAULIC CONTROL WIRE HARNESS

2. FLANGE CAPSCREWS
3. ARMREST
4. ARMREST MOUNTING BRACKET
5. HOLES FOR FLANGE CAPSCREWS
Figure 110. E-Hydraulic Armrest and Mounting
Bracket

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2200 SRM 1142 Electronic-Hydraulic Controls - Generation 2

2. Remove two Phillips head screws that attach

horn button to armrest. See Figure 113. Re-
move horn button from armrest.

1. TO E-HYDRAULIC CONTROL WIRE HARNESS

2. SOCKET HEAD SCREWS
3. PCB CASSETTE
4. MOMENTARY SWITCHES/TOGGLE SWITCH
CONNECTOR

Figure 112. PCB Cassette Removal

Install
1. Install PCB cassette to armrest with three
socket head screws. See Figure 112.

2. If lift truck is equipped, connect the momentary

switches/toggle switch connector to PCB cas-
sette. See Figure 112. NOTE: MOMENTARY SWITCHES AND TOGGLE
SWITCH CONNECTIONS NOT SHOWN FOR
3. Install bottom armrest cover to armrest with CLARITY.
six socket head screws. See Figure 111.
1. PHILLIPS HEAD SCREWS
4. Install new armrest onto mounting bracket 2. DIRECTION CONTROL SWITCH ADAPTER*
with flange capscrews. Tighten flange cap- 3. HORN BUTTON ADAPTER
screws to 13 to 15 N•m (115 to 132 lbf in). 4. PLUG
5. HORN SWITCH
5. Connect the E-hydraulic wire harness to arm- 6. DIRECTION CONTROL SWITCH CONNECTOR
7. ARMREST
rest. See Figure 110. Install seat box to cover
plate with two capscrews and washers. See Fig- *DIRECTION CONTROL SWITCH IS AN OPTIONAL
ure 108. Tighten capscrews to FEATURE.
1.2 N•m (10.6 lbf in).
Figure 113. Switch Arrangement and Connections,
6. Connect the battery. E-Hydraulic Mini-Levers

HORN BUTTON
Install
Remove
1. Insert new horn switch into armrest and secure
1. Remove the armrest from armrest mounting
switch to armrest with two Phillips head
bracket. Remove bottom armrest and PCB cas-
screws. See Figure 113.
sette. See the section Armrest Assembly for re-
moval procedures.

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Electronic-Hydraulic Controls - Generation 2
2. Install armrest and PCB cassette to armrest
and install armrest to armrest mounting
bracket. See the section Armrest Assembly for
installation procedures.
DIRECTION CONTROL SWITCH
NOTE: The Direction Control Switch (DCS) is an
optional feature on lift trucks covered in this man-
ual that are equipped with electro-hydraulic con-
trols and built after January 2010.
Remove
1. Remove armrest from armrest mounting
bracket. Remove bottom armrest cover. See sec-
tion Armrest Assembly for removal procedures.
2. Remove Direction Control Switch assembly
from armrest by compressing the clips on either
side of the bezel and carefully pulling the as-
sembly out. Disconnect the E-Hydraulic control
wiring harness from the Direction Control
Switch. See Figure 114.
1. DIRECTION CONTROL SWITCH
2. BEZEL
3. ARMREST
4. E-HYDRAULIC CONTROL VALVE WIRING HAR-
NESS
Figure 114. Direction Control Switch Replacement
3. Remove the Direction Control Switch from the
bezel. See Figure 114.
146
2200 SRM 1142
Install
1. Insert new Direction Control Switch into bezel.
See Figure 114.
2. Connect the E-Hydraulic control valve wiring
harness to the Direction Control Switch. Install
the Direction Control Switch assembly into the
armrest by compressing the clips on either side
of the bezel and pushing the assembly into the
armrest until the clips latch. See Figure 114.
3. Install armrest cover to armrest, and install
armrest to armrest mounting bracket. See the
section Armrest Assembly for installation pro-
cedures.
MOMENTARY SWITCHES AND TOGGLE
SWITCH
On lift trucks equipped with E-Hydraulic controls,
there may be two optional momentary switches
(green buttons) and a toggle switch (yellow button)
located behind the second, third, or fourth mini-
lever. See Figure 115. The momentary switch loca-
ted behind the second mini-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 three mini-levers
and a four function control valve, there will be a
toggle switch behind the third mini-lever. Pressing
this button allows the third mini-lever to switch be-
tween the third and fourth functions. If the lift
truck is equipped with four mini-levers and a five
function control valve, the toggle switch will be lo-
cated behind the fourth mini-lever. Pressing the
button allows the fourth mini-lever to switch be-
tween the fourth and fifth functions.
If the lift truck is equipped with a clamp attach-
ment, the last mini-lever on the right controls the
clamp function. Behind this lever will be a momen-
tary switch. To engage the clamp, move the mini-
lever backward. To disengage the clamp, push the
momentary switch behind the mini-lever and move
mini-lever forward.
The different configurations of switches and but-
tons discussed in this section may not be found on
your lift truck.
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2200 SRM 1142 Electronic-Hydraulic Controls - Generation 2

NOTE: Tag wires prior to disconnecting them to

aid in reconnecting.

2. Pull the momentary switches or toggle switch

connectors apart to disconnect them from wire
harness. See Figure 116.

3. If momentary switch is being replaced, remove

lock nut from back of green, round, push but-
ton. Remove push button switch from armrest.
See Figure 116.

NOTE: Note the position of the yellow, rectangular,

toggle switch before removal to aid in installation.
See Figure 115.

4. If function selection button is being replaced:

NOTE: NOT ALL LIFT TRUCK MAY HAVE ALL
SWITCHES AND BUTTONS SHOWN. a. Remove knurl nut. See Figure 116.

1. MINI-LEVERS b. Rotate red screw to left stop. Remove blue

2. MOMENTARY SWITCH (RTST) connector by sliding it from black cylinder.
3. TOGGLE SWITCH See Figure 116.
4. MOMENTARY SWITCH (CLAMP)
5. ARMREST HOUSING
c. Remove toggle switch from armrest.
Figure 115. Momentary Switches and Toggle
Switch Location

Remove
1. Remove the armrest from armrest mounting
bracket. Remove bottom armrest and PCB cas-
sette. See procedures in Armrest Assembly sec-
tion above.

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Electronic-Hydraulic Controls - Generation 2 2200 SRM 1142

1. CLAMP BUTTON CONNECTION 5. LOCK NUT

2. RTST CONNECTION 6. BLUE CONNECTOR
3. TOGGLE SWITCH CONNECTION 7. KNURL NUT
4. RED SCREW 8. BLACK CYLINDER

Figure 116. Momentary Switches and Toggle Switch Replacement

Install d. Adjust position of yellow, rectangular toggle

1. If installing a new toggle switch:
a. Insert black cylinder portion of toggle switch
through armrest housing.
b. Slide blue connector onto cylinder. See Fig-
ure 116.
c. Rotate red screw to right stop.
switch. See Figure 115. Install and tighten
knurl nut to secure toggle switch to armrest.
e. Apply Nye 760G grease (supplied in kit) to
toggle switch connector. Push toggle switch
connector to wire harness. See Figure 116.
2. If installing a momentary switch:

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2200 SRM 1142 Electronic-Hydraulic Controls - Generation 2

a. Install new green, round momentary switch Legend for Figure 117
assembly through armrest housing.
1. BOTTOM COVER
b. Install and tighten lock nut to secure mo- 2. SCREW
mentary switch to armrest. See Figure 116. 3. ELECTRICAL CONNECTOR
4. MOUNTING BRACKET
5. WASHER
c. Push momentary switch connector to wire 6. LOCKWASHER
harness. See Figure 116. 7. NUT
8. SCREW
3. Install armrest and PCB cassette to armrest 9. JOYSTICK
and install armrest to armrest mounting 10. LOCK NUT
bracket. See the section Armrest Assembly for 11. UPPER HOUSING
installation procedures. 12. BRACKET

4. Connect the E-hydraulic wire harness to arm-

rest. See Figure 110.
JOYSTICK
NOTE: Joystick control used on lift trucks
manufactured prior to 4/7/2014.
Remove and Disassemble
1. Remove four nuts that attach joystick to
mounting bracket.
2. Disconnect the joystick electrical connector. See
Figure 117.
3. Remove four nuts, lockwashers, washers,
screws, and upper housing from the bracket.
Inspect
Inspect the components of the joystick to ensure
that there is no damage. If any component is dam-
aged, other than the wiring harness, replace that
component. Inspect the pins of the wiring harness.
If any are damaged, see the section Wire Harness
Repair 2200SRM1128 for the proper repair proce-
dures.
Assemble and Install
1. Install upper housing, four screws, washers,
lockwashers, and nuts to the bracket. See Fig-
ure 117.
2. Install the bottom cover to the bracket using
four screws.

3. Connect the joystick connector.

4. Using four nuts, attach joystick to mounting

bracket.

JOYSTICK ARMREST SLIDER

ASSEMBLY
NOTE: Joystick control used on lift trucks
manufactured prior to 4/7/2014.

The joystick armrest slider assembly covers and

arm pad can be replaced if damaged.

Remove
1. Remove three screws from inner cover that at-
tach inner and outer covers to joystick armrest
Figure 117. Joystick slider assembly. See Figure 118.

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Electronic-Hydraulic Controls - Generation 2 2200 SRM 1142

1. ARM PAD 6. STRAP CLAMP

2. ARM PAD FRAME 7. SCREW
3. JOYSTICK ELECTRICAL CONNECTOR 8. CAPSCREW
4. INNER COVER 9. NUT
5. OUTER COVER 10. JOYSTICK ARMREST SLIDER ASSEMBLY
FRAME

Figure 118. Joystick Armrest Slider Assembly

2. Remove inner and outer covers from joystick Install

armrest slider assembly.
3. Remove capscrew and nut from rear of arm pad
frame. Remove arm pad from arm pad frame.
See Figure 118.
1. Install arm pad to arm pad frame with nut and
capscrew. See Figure 118.
2. Install inner and outer covers onto joystick
armrest assembly frame using three screws.
See Figure 118.

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2200 SRM 1142 11/16 (6/16)(5/16)(4/14)(3/13)(11/12)