Hyster - h40ft, h50ft, h60ft, h70ft - M. Service

FRAME
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]
PART NO. 1580502 100 SRM 1120

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. 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 expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load
being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the
load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure
to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make
sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
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.
Frame Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Hood, Seat, and Side Covers Replacement ....................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 8
Steering Column ................................................................................................................................................ 13
Description ..................................................................................................................................................... 13
Steering Column Repair................................................................................................................................ 13
Remove....................................................................................................................................................... 13
Disassemble ............................................................................................................................................... 15
Clean .......................................................................................................................................................... 15
Inspect........................................................................................................................................................ 15
Assemble .................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
LPG Tank and Bracket Assembly ..................................................................................................................... 19
Counterweight Replacement ............................................................................................................................. 19
Remove ........................................................................................................................................................... 19
Install ............................................................................................................................................................. 22
Tow Pin, Remove and Install ........................................................................................................................ 23
Overhead Guard Replacement .......................................................................................................................... 23
Remove and Install........................................................................................................................................ 23
LED Tail, Backup, and Brake Lights, Replace ............................................................................................ 24
Operator Restraint System Replacement......................................................................................................... 25
Description ..................................................................................................................................................... 25
Automatic Locking Retractor (ALR)......................................................................................................... 25
Emergency Locking Retractor (ELR) ....................................................................................................... 25
Engine Replacement .......................................................................................................................................... 27
Remove ........................................................................................................................................................... 27
Install ............................................................................................................................................................. 32
Transmission Replacement ............................................................................................................................... 34
Remove Transmission with Iron Housing .................................................................................................... 34
Install Transmission with Iron Housing ...................................................................................................... 35
Remove Transmission with Aluminum Housing ......................................................................................... 36
Install Transmission with Aluminum Housing ........................................................................................... 41
Throttle Pedal and Cable Adjustment .............................................................................................................. 43
Mazda Gas/LPG Engines With Basic Power Shift Transmission and Electronic Transmission
(Except Mazda Emission Compliant Engines)............................................................................................. 43
Mazda Gasoline Engine With Electronic Transmission .............................................................................. 46
Throttle Pedal Stop Adjustment ................................................................................................................... 47
Yanmar Diesel Engine With Basic Power Shift Transmission.................................................................... 47
Yanmar Diesel Engine With Electronic Throttle ......................................................................................... 47
Exhaust System Repair ..................................................................................................................................... 49
Lift Trucks With Counterweight Exhaust System ...................................................................................... 49
Mazda Gas and LPG Engines ................................................................................................................... 49
Remove and Disassemble ..................................................................................................................... 49
Inspect ................................................................................................................................................... 49
Assemble and Install ............................................................................................................................ 49
Yanmar Diesel Engine............................................................................................................................... 51
Inspect ................................................................................................................................................... 51
©2012 HYSTER COMPANY i

Table of Contents Frame
TABLE OF CONTENTS (Continued)

Lift Trucks With Overhead Exhaust System............................................................................................... 53
Inspect ................................................................................................................................................... 53
Mazda Gas and LPG Engines................................................................................................................... 55
Inspect ................................................................................................................................................... 57
Cooling System................................................................................................................................................... 58
Description ..................................................................................................................................................... 58
Hydraulic Filter Assembly Repair .................................................................................................................... 58
Remove ........................................................................................................................................................... 58
Clean and Inspect .......................................................................................................................................... 58
Install ............................................................................................................................................................. 58
Fuel and Hydraulic Tanks Repair..................................................................................................................... 60
Inspect ............................................................................................................................................................ 60
Clean .............................................................................................................................................................. 60
Steam Method of Cleaning........................................................................................................................ 60
Chemical Solution Method of Cleaning.................................................................................................... 61
Additional Preparations for Repair .............................................................................................................. 61
Small Leaks, Repair ...................................................................................................................................... 61
Large Leaks, Repair ...................................................................................................................................... 61
Preparations for Use After Repair................................................................................................................ 62
Safety Labels ...................................................................................................................................................... 62
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]
ii
100 SRM 1120 Description
General
Periodic Maintenance 8000 SRM 1207 for lift
WARNING truck models
The lift truck must be put on blocks for some • S30FT, S35FT, S40FTS (E010)
types of maintenance and repairs. The re- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
moval of the following assemblies will cause H40FTS) (F001)
large changes in the center of gravity: mast,
drive axle, engine and transmission, and coun- NOTE: For exhaust system procedure for lift trucks
terweight. When the lift truck is put on blocks, equipped with a Mazda 2007 emissions compliant en-
put additional blocks in the following posi- gine and for lift trucks built after January, 2010 go to
tions to maintain stability: section LPG Fuel System, Mazda 2.0L and 2.2L
• Before removing the mast and drive axle, put Emission Compliant Engines 900 SRM 1326 or
blocks under the counterweight so the lift Gasoline Fuel System, Mazda 2.0L and 2.2LE-
truck cannot fall backward. mission Compliant Engines 900 SRM 1325 for ex-
• Before removing the counterweight, put haust system procedures.
blocks under the mast assembly so the lift
truck cannot fall forward. For lift trucks built after January, 2010 and equipped
with a GM 2.4L engine, go to section LPG Fuel Sys-
The surface must be solid, even, and level when tem, GM 2.4L Engine 900 SRM 1124 for exhaust
the lift truck is put on blocks. Make sure that system procedures.
any blocks used to support the lift truck are
solid, one-piece units. See the Operating Man- This section contains the description of the frame
ual or the section (see Figure 1) and connected parts. Procedures for
removing and installing the counterweight, hood,
Periodic Maintenance 8000 SRM 1150 for lift overhead guard, engine, cooling system, and exhaust
truck models system (see NOTE above) are found in this section.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) Checks for the operator restraint system and pro-
• H2.0-3.5FT (H40-70FT) (L177) cedures for the repair of tanks and installation of
safety labels are also included.
Description
The frame is one weldment and includes the hy- Table 6 for lift truck models
draulic tank and fuel tank for gasoline or diesel fuel. • H2.0-3.5FT (H40-70FT) (L177)
See Figure 1.
The muffler is fastened to the frame inside the coun-
There is a counterweight for each capacity of lift terweight.
truck. The counterweights are similar in appear-
ance, but are different weights. The overhead guard, cowl, and hood are installed
on the frame. The hood is connected to the frame
See Table 3 for lift truck models with hinges. Two gas-controlled springs provide as-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) sistance when raising the hood and hold the hood in
the open position. The floor plate and side covers can
Table 4 for lift truck models be removed for access to the engine, transmission,
• S30FT, S35FT, S40FTS (E010) and other components.
Table 5 for lift truck models
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
1
Hood, Seat, and Side Covers Replacement 100 SRM 1120
1. COWL PLATE 5. COUNTERWEIGHT MOUNTS

2. FENDERS 6. FUEL TANK (GAS OR DIESEL)
3. FRAME 7. HYDRAULIC TANK
4. HOOD MOUNTS
Figure 1. Frame
Hood, Seat, and Side Covers Replacement

REMOVE 5. Remove floor mat and floor plate.
1. Slide seat to the closest position to steering col- See Figure 3 for lift truck models
umn. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
2. Fully tilt steering column forward. H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
3. If your truck is equipped with an LPG tank,
swing tank off to the side. See Figure 4 for lift truck models
• H2.0-3.5FT (H40-70FT) (L177)
4. Raise latch on the left, front corner of the hood to
unlatch and lift up hood. See Figure 2.
2
100 SRM 1120 Hood, Seat, and Side Covers Replacement
NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.

A. SIDE VIEW OF HOOD AND SEAT D. SIDE VIEW OF VENTED HOOD WITH SWIVEL
B. SIDE VIEW OF HOOD SEAT
C. BOTTOM VIEW OF HOOD
1. SEAT 10. ATTACHMENT HOLES ATTACHING HOOD TO
2. HOOD SEAT (SEMI-SUSPENSION)
3. FRAME 11. SEAT WIRE HARNESS BRACKETS
4. SEAT WIRE HARNESS 12. SEAT LINER
5. SEAT WIRE HARNESS CONNECTOR (WITHOUT 13. HOOD LATCH
ELECTRONIC CONTROL) 14. ATTACHMENT HOLES ATTACHING HOOD TO
6. SEAT WIRE HARNESS CONNECTOR (WITH SEAT (NON-SUSPENSION)
7. CABLE CLIPS SEAT (FULL SUSPENSION)
8. HINGE SCREWS 16. SPACER
9. GAS SPRING
Figure 2. Hood and Seat Arrangement
3
1. LOWER STEERING COLUMN COVER 14. LEFT HAND FRONT PANEL

2. UPPER STEERING COLUMN COVER 15. LEFT HAND STEP PANEL
3. INSERT 16. LEFT HAND TREAD PLATE
4. CLIP 17. PLATE ASSEMBLY SEAL
5. DASHBOARD 18. RIGHT HAND FENDER COVER
6. CAPSCREW 19. FLOOR MAT
7. SEAL 20. RIGHT HAND TREAD PLATE
8. GROMMET 21. RIGHT HAND FRONT PANEL
9. LEFT HAND REAR PANEL 22. RIGHT HAND STEP PANEL
10. FLOOR PLATE 23. RIGHT HAND REAR PANEL
11. LEFT HAND FENDER COVER 24. RADIATOR COVER
12. SCREW 25. KICK PANEL
13. NUT 26. PLATE ASSEMBLY
Figure 3. Side Cover, Floor Plate, and Cowl Components, Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001), and S30FT, S35FT,
S40FTS (E010)
4
6. Remove two capscrews holding left and right rear See Figure 4 for lift truck models
side covers to the frame. Remove rear side covers • H2.0-3.5FT (H40-70FT) (L177)
from frame.
13. Remove three capscrews holding the seal plate.
See Figure 3 for lift truck models Remove seal plate. See Figure 6.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 14. Disconnect seat wire harness connector. See Fig-
H40FTS) (F001) ure 2.
• S30FT, S35FT, S40FTS (E010)
CAUTION
See Figure 4 for lift truck models
When removing the seat from the hood, DO
• H2.0-3.5FT (H40-70FT) (L177)
NOT use an impact wrench to remove the cap-
7. Remove two capscrews holding left and right screws. Damage can be caused to the threads
fender covers to front overhead guard leg. Re- on the screws and in the holes.
move covers.
15. If seat is to be removed, and truck is equipped
See Figure 3 for lift truck models with a non-swivel seat, remove seat wire har-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) ness from seat wire harness brackets that are
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, attached to the underside of hood. Remove the
H40FTS) (F001) cable clips from the seat wire harness. If truck
• S30FT, S35FT, S40FTS (E010) is equipped with a swivel seat, remove seat wire
harness from seat wire harness bracket attached
See Figure 4 for lift truck models to underside of the hood and behind the seat (see
• H2.0-3.5FT (H40-70FT) (L177) Figure 2).
8. Remove four capscrews holding left and right 16. Remove four capscrews and washers holding the
front side covers to frame. Remove covers. seat to hood. Lift seat off the hood. Pull seat wire
harness through hood. See Figure 2.
9. Fully lower steering column.
17. Remove capscrews and washers at the top of gas
10. Remove upper steering column cover by pulling springs. Remove gas springs from hood.
up on upper steering column cover to release
latches (one on either side), and pulling cover 18. Remove hinge screws, located in the rear of the
away from steering column. See Figure 5. hood.
11. Remove five fasteners (see Figure 5) securing 19. Lift hood from the truck. See Figure 2.
dash to the top of cowl. Remove four clips, lo-
cated underneath dash, that attach dash to the
kick panel. Lift to remove dash.
12. Lift the kick panel to remove from truck.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
5
Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models H2.0-3.5FT (H40-70FT)
(L177)
6
Legend for Figure 4

1. DASH ASSEMBLY 15. LEFT STEP PANEL
2. UPPER STEERING COLUMN COVER 16. RIGHT STEP PANEL
3. LOWER STEERING COLUMN COVER 17. LEFT STEP PLATE
4. KICK PANEL 18. RIGHT STEP PLATE
5. MUD GUARD (LH) 19. LEFT REAR PANEL
6. MUD GUARD (RH) 20. RIGHT REAR PANEL
7. LOCK NUT 21. FLOOR MAT
8. NUT 22. FLOOR PLATE
9. COVER 23. RADIATOR COVER
10. BRACKET 24. SEALS
11. PLATE ASSEMBLY 25. CAPSCREW
12. GROMMET 26. CLIP NUT
13. LEFT FRONT PANEL 27. INSERT
14. RIGHT FRONT PANEL 28. PLATE ASSEMBLY SEAL
NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN SCREWS 3. UPPER STEERING COLUMN COVER
2. COWL 4. LOWER STEERING COLUMN COVER
Figure 5. Remove Dash From Cowl
7
INSTALL See Figure 7 and Table 1 for lift truck models

1. Place hood onto the lift truck frame. H40FTS) (F001) and S2.0-3.5FT (S40-70FT)
(F187)
2. Install hinge screws, located in the rear of the
hood, and tighten to 38 N•m (28 lbf ft). See Fig- See Figure 8 for lift truck models
ure 2. • S30FT, S35FT, S40FTS (E010)
3. Align top holes in the gas springs with holes See Figure 9 and Table 2 for lift truck models
in hood. Install capscrews and washers to at- • H2.0-3.5FT (H40-70FT) (L177)
tach gas springs to hood. Tighten capscrews to
19.2 N•m (170 lbf in).
1. CAPSCREWS 2. SEAL PLATE
Figure 6. Remove Seal Plate From Dash
8
Legend for Figure 7
NOTE: LEFT SIDE SHOWN

A. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION SEAT
B. MOUNTING LOCATION FOR CYLINDER
END OF GAS SPRING FOR SEMI OR FULL
SUSPENSION SEAT
C. MOUNTING LOCATION FOR CYLINDER
SUSPENSION SEAT WITH CAB*
1. MOUNTING POINTS FOR GAS SPRING ON
HOOD
Figure 7. Gas Spring Installation, Lift Truck
Models H1.6FT, H1.8FT, H2.0FTS (H30FT, *CAB ONLY ON LIFT TRUCK MODELS H1.6FT,
H35FT, H40FTS) (F001) and S2.0-3.5FT H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
(S40-70FT) (F187)
Table 1. Gas Spring Installation, Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001) and S2.0-3.5FT (S40-70FT) (F187)
Full or Semi Non-Suspension Seat

Suspension Seat
Frame Hood Frame Hood
Left Right Left Right Left Right Left Right
Side Side Side Side Side Side Side Side
Seat B B 3 3 A A 1 1
Without
E-Control
Seat With B B 2 2 N/A N/A N/A N/A
E-Control
Cab C C 2 2 N/A N/A N/A N/A
9
Legend for Figure 8
NOTE: LEFT SIDE SHOWN.

1. MOUNTING LOCATION FOR CYLINDER END
2. MOUNTING LOCATION FOR CYLINDER
SUSPENSION SEAT

Models S30FT, S35FT, S40FTS (E010)
Figure 9. Gas Spring Installation, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)
10
Legend for Figure 9

A. LEFT SIDE
B. RIGHT SIDE
C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT
D. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT,
LIFT TRUCKS WITH CAB OR H40-70FT (L177) LIFT TRUCKS WITHOUT CAB
E. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT,
LIFT TRUCKS H2.0-3.5FT (L177) WITHOUT CAB
1. MOUNTING POINTS FOR GAS SPRING ON HOOD
Table 2. Gas Spring Installation, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)

Suspension Seat
Non-Cab D D 3 3 C C 1 1
H40-70FT
(L177)
Non-Cab E E 2 2 C C 1 1
H2.0-3.5FT
(L177)
Cab D D 1 1 N/A N/A N/A N/A
11
4. Install latch striker in highest slot position. 6. Check operation of hood latch. Have an opera-
Check that latch striker is in center of jaws of tor sit in seat. Make sure hood is fully closed
hood latch when hood closes. Open and close (two clicks). Also check that hood touches rub-
hood to ensure that center pin strikes hood latch ber bumper. If necessary, repeat Step 5.
properly and that the stop screw contacts frame.
A properly closed hood MUST click twice on
CAUTION
the hood latch. If the hood latch does not close
properly, loosen capscrews on the back of center When installing the seat to the hood, DO NOT
pin and adjust center pin up or down as required use an impact wrench to install the capscrews.
for correct alignment. See Figure 10. Damage can be caused to the threads on the
screws and in the holes.
5. Push down until hood just touches rubber
bumper. Make sure latch striker is still in center 7. Place seat on the hood and thread seat wire har-
of hood latch. Open hood and tighten capscrews ness through the hole in the hood. See Figure 2.
for latch.
8. Align holes in the seat with the holes in hood. In-
sert washers and capscrews. Tighten capscrews
to 18 N•m (159 lbf in).
9. If truck is equipped with a non-swivel seat, tie ca-

ble clips to seat wire harness and insert harness
into seat wire harness brackets under hood. If
truck is equipped with a swivel seat, secure seat
harness to bracket. See Figure 2.
10. Install seal plate using three capscrews. See Fig-

ure 6.
11. Install kick panel onto truck.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)

• H2.0-3.5FT (H40-70FT) (L177)
12. Install dash to top of cowl. See Figure 5. Install

four clips to attach the dash to kick panel.
13. Install upper steering column cover to dash.
14. Using four capscrews, install left and right front

side covers to frame.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
1. HOOD 3. CENTER PIN • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
2. HOOD LATCH 4. CAPSCREW H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
Figure 10. Hood Latch Adjustment
• H2.0-3.5FT (H40-70FT) (L177)
12
100 SRM 1120 Steering Column
15. Using two capscrews, install left and right fender See Figure 4 for lift truck models
covers to front of overhead guard legs. • H2.0-3.5FT (H40-70FT) (L177)
16. Using two capscrews, install left and right rear 17. Install floor mat and floor plate.
18. If truck is equipped with an LPG tank, swing
See Figure 3 for lift truck models LPG tank into position on back of counterweight.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 19. Adjust the steering column and seat positions.
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
Steering Column
DESCRIPTION NOTE: This procedure is for the removal of all compo-
nents of the steering column assembly. Not all com-
This section describes the repair procedures for the ponents are removed for a repair procedure. Do only
steering column. The steering column assembly those steps of the procedure necessary to remove the
mounts to the cowl inside the operator compart- required component.
ment and is the mechanical connection between the
steering wheel and the steering control unit. The NOTE: Tag wires prior to disconnect.
steering column includes the steering wheel, hous-
ing, bracket and lower shaft. For lift trucks with 3. Remove the horn button assembly and discon-
gas and LPG engines, bolts and bushings attach the nect electrical wires. Remove large hex nut and
steering column to the cowl standoffs. For lift trucks steering wheel from steering column. See Fig-
with diesel engines, bolts, bushings and isolators ure 12.
attach the steering column to the cowl standoffs. See
Figure 11.
STEERING COLUMN REPAIR

Remove
1. Put blocks on each side (front and back) of tires
to prevent lift truck from moving.
WARNING
Disconnect the battery before removing any
covers to avoid injury to personnel.
2. Attach a tag on the battery connector or nega-

tive battery cable stating, DO NOT CONNECT
BATTERY. Move the steering column to the most
FORWARD position.
CAUTION NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

If a puller tool is used to remove steering wheel 1. STEERING WHEEL
from steering column, be careful not to damage 2. STEERING COLUMN
horn wires. 3. COWL
Figure 11. Steering Column and Cowl
13
Steering Column 100 SRM 1120
4. Remove steering column covers. Remove floor

mats and floor plate. See section Hood, Seat, and
Side Covers Replacement.
NOTE: Perform Step 5 for lift trucks equipped with

gas or LPG engines.
5. Remove four capscrews, four bushings and steer-

ing column from cowl standoffs. See Figure 13.

diesel engines.
6. Remove four capscrews, four bushings, four iso-

lators, steering column and four isolators from
cowl standoffs. See Figure 13.
1. HORN BUTTON 4. STEERING

2. HEX NUT COLUMN
3. STEERING WHEEL
Figure 12. Steering Wheel Remove/Install
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

1. CAPSCREW 4. STEERING COLUMN
2. BUSHING 5. COWL STANDOFF
3. ISOLATOR
Figure 13. Steering Column Remove/Install
14
Disassemble Clean
NOTE: Remove and discard snap rings if installed.
WARNING
1. Remove two pins and gas spring from housing. Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
See Figure 14, for lift trucks manufactured be- cleaning solvents, always follow the solvent
fore January, 2012. manufacturer’s recommended safety precau-
tions.
See Figure 15, for lift trucks manufactured after
January, 2012.
WARNING
2. Remove two pivot bolts, two bushings, two nuts Compressed air is used for cleaning and drying
and bracket from housing. purposes, or for cleaning restrictions. Wear
protective clothing (goggles/shields, gloves,
See Figure 14, for lift trucks manufactured be- etc.). Make sure the path of the compressed air
fore January, 2012. is away from all personnel to avoid injury.
See Figure 15, for lift trucks manufactured after 1. Clean metal parts in solvent. Remove all traces
January, 2012. of old lubricant and dirt. Clean nonmetal parts
3. Remove split pin and lower shaft from upper with warm soapy water and a lint free cloth.
shaft. 2. After cleaning, dry parts with compressed air.
See Figure 14, for lift trucks manufactured be- DO NOT dry parts with a cloth.
fore January, 2012.
Inspect
1. Inspect for loose, burned, missing, cracked or
January, 2012.
damaged hardware.
4. Remove connector from connector bracket. Re-
2. Inspect all parts for dents, holes, bends, burrs,
move connector bracket, fastener, four screws
rust, corrosion or marred finishes.
and two horn contacts from housing.
3. Replace all defective or damaged parts.
See Figure 14, for lift trucks manufactured be-
fore January, 2012.

January, 2012.
15
Figure 14. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012
16
Legend for Figure 14

1. PIN 9. CONNECTOR BRACKET
2. LOWER SHAFT 10. PIVOT BOLT
3. SPLIT PIN 11. BUSHING
4. UPPER SHAFT 12. NUT
5. HOUSING 13. GAS SPRING
6. HORN CONTACT 14. BRACKET
7. SCREW 15. CONNECTOR
8. FASTENER
1. BRACKET 9. PIN
2. SPACER 10. LOWER SHAFT
3. JOINT 11. GAS SPRING
4. NUT 12. BOLT
5. WASHER 13. BUSHING
7. UPPER SHAFT 15. FASTENER
8. HOUSING 16. HORN CONTACT
Figure 15. Steering Column Assembly, Lift Trucks Manufactured After January, 2012
17
Assemble Install
NOTE: This procedure is for the installation of all NOTE: Lubricate spline end of lower shaft with multi
components of the steering column assembly. Not all purpose grease. See one of the Service Manuals for
components are removed for a repair procedure. Do procedures
only those steps of the procedure necessary to install
the required component. Periodic Maintenance 8000 SRM 1150 for lift
truck models
NOTE: Perform Step 1 only for lift trucks manufac- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
tured before January, 2012. • H2.0-3.5FT (H40-70FT) (L177)
1. Lubricate the horn contact slip rings with a Periodic Maintenance 8000 SRM 1207 for lift
small amount of conductive grease (Hyster P/N truck models
4032542). • S30FT, S35FT, S40FTS (E010)
2. Install fastener, connector bracket and connector, H40FTS) (F001)
two horn contacts and four screws.
See Figure 14, for lift trucks manufactured be- gas or LPG engines.
fore January 2012.
1. Install steering column, four bushings and four
See Figure 15, for lift trucks manufactured after bolts on cowl standoffs. Tighten bolts to 38 N•m
January 2012. (28 lbf ft). See Figure 13.
3. Assemble lower shaft and upper shaft, secure NOTE: Perform Step 2 for lift trucks equipped with
with spit pin. diesel engines.
See Figure 14, for lift trucks manufactured be- 2. Install four isolators, steering column, four isola-
fore January 2012. tors, four bushings, and four bolts on cowl stand-
offs. Tighten bolts to 38 N•m (28 lbf ft). See Fig-
ure 13.
January 2012.
3. Install floor plate, floor mats, and steering col-
4. Install two pivot bolts, two bushings, two nuts
umn covers. See section Hood, Seat, and Side
and bracket onto housing.
Covers Replacement.
4. Install steering wheel and hex nut on steering
fore January 2012.
column, tighten hex nut to 40 to 54 N•m (30 to
See Figure 15, for lift trucks manufactured after 40 lbf ft). Connect electrical wiring and install
January 2012. horn button. See Figure 12.
5. Install gas spring and two pins on housing. 5. Remove tag from negative battery connector and
connect to battery. Adjust steering column to
See Figure 14, for lift trucks manufactured be- neutral position.
fore January 2012.
6. Remove blocks from each side of tires.
January 2012.
18
100 SRM 1120 Counterweight Replacement
LPG Tank and Bracket Assembly

For procedures to remove and install the LPG tank, • S30FT, S35FT, S40FT (E010)
LPG tank bracket, and the LPG tank alignment pin, • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
see one of the following Service Manuals. H40FTS) (F001)
LPG Fuel System, GM 2.4L Engine 900 SRM 1124 LPG Fuel System, Mazda 2.0L and 2.2L Emis-
for lift truck models sion Compliant Engines 900 SRM 1326 for lift
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) truck models
• H2.0-3.5FT (H40-70FT) (L177) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
LPG Fuel System, Mazda 2.0L and 2.2L Engines • S30FT, S35FT, S40FT (E010)
900 SRM 1125 for lift truck models • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
Counterweight Replacement
REMOVE LPG system. LPG fuel systems can be discon-
nected indoors only if the lift truck is at least
WARNING 8 m (26 ft) from any open flame, motor vehicles,
electrical equipment, or ignition source.
The lift truck must be put on blocks for some
types of maintenance and repair. The removal Close the shutoff valve on the LPG tank before
of the following assemblies will cause large any part of the engine fuel system is discon-
changes in the center of gravity: mast, drive nected. Run the engine until the fuel in the sys-
axle, engine and transmission, and counter- tem is used and the engine stops.
weight. When the lift truck is put on blocks,
put additional blocks in the following posi- If the engine will not run, close the shutoff
tions to maintain stability: valve on the LPG tank. Loosen the fitting on
• Before removing the mast and drive axle, put the supply hose from the LPG tank where it
blocks under the counterweight so the lift enters the filter unit. Permit the pressure in
truck cannot fall backward. the fuel system to decrease slowly. Fuel leav-
• Before removing the counterweight, put ing the fitting removes heat. Use a cloth to
blocks under the mast assembly so the lift protect your hands from the cold fitting.
truck cannot fall forward.
The surface must be solid, even, and level when NOTE: The counterweight is held in position on the
the lift truck is put on blocks. Make sure that frame by two hooks that are part of the frame. See
any blocks used to support the lift truck are Figure 16.
solid, one-piece units. See the procedure How
One M24 × 3 x 140 capscrew holds the counterweight
to Put Lift Truck on Blocks in the Operating
to the lower part of the frame on lift truck models
Manual or the Periodic Maintenance section
• S3.0-3.5FT (S60-70FT, S55FTS) (F187)
for your lift truck.
• H3.0-3.5FT (H60-70FT) (L177)
WARNING One M24 × 3 x 90 capscrew holds the counterweight

DO NOT operate the lift truck if the capscrew to the lower part of the frame on lift truck models
for the counterweight is not installed. When • S2.0-2.75FT (S40-50FT, S55FTS) (F187)
the capscrew is removed, the counterweight • H2.0-2.5FT (H40-50FT) (L177)
can fall from the lift truck. • S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the
19
Counterweight Replacement 100 SRM 1120
NOTE: For exhaust system procedure for lift trucks LPG Fuel System, Mazda 2.0L and 2.2L
equipped with a Mazda 2007 emissions compliant en- Emission Compliant Engines 900 SRM 1326
gine and for lift trucks built after January, 2010 go to for lift truck models
section LPG Fuel System, Mazda 2.0L and 2.2L • S30FT, S35FT, S40FTS (E010)
Emission Compliant Engines 900 SRM 1326 or • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
Gasoline Fuel System, Mazda 2.0L and 2.2LE- H40FTS) (F001)
mission Compliant Engines 900 SRM 1325. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
For exhaust system procedures for lift trucks built
after January, 2010 and equipped with a GM 2.4L
engine, go to section LPG Fuel System, GM 2.4L WARNING
Engine 900 SRM 1124. The counterweight is heavy. Make sure that
the eyebolt and lifting devices have enough
NOTE: For overhead exhaust system procedures for capacity to lift the weight. The approximate
lift trucks equipped with a Mazda 2007 emissions weights of the counterweight castings are
compliant engine and for lift trucks built after Jan- shown in .
uary, 2010 go to section LPG Fuel System, Mazda
2.0L and 2.2L Emission Compliant Engines 900 Table 3 for lift truck models
SRM 1326 or Gasoline Fuel System, Mazda 2.0L • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
and 2.2LEmission Compliant Engines 900 SRM
1325.
• S30FT, S35FT, S40FTS (E010)
NOTE: If lift truck is equipped with an overhead ex-
haust system, remove the overhead exhaust pipe be-
fore removing the counterweight. See the section Ex-
H40FTS) (F001)
haust System Repair for the procedures.
1. If the lift truck has an LPG fuel system, see one
• H2.0-3.5FT (H40-70FT) (L177)
of the following Service Manuals to remove the
LPG tank and bracket, before removing the coun- 2. Install a lifting eye in the lift hole of the coun-
terweight, and for additional information on the terweight. See Figure 16 and Figure 17. Con-
LPG fuel systems nect a crane to the lifting eye and raise the crane
until it holds part of the weight of the counter-
LPG Fuel System, GM 2.4L Engine 900 SRM
weight. Remove the tow pin and remove the cap-
1124 for lift truck model
screw that holds the counterweight to the frame.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
See Figure 16. Use the crane to lift the counter-
• H2.0-3.5FT (H40-70FT) (L177)
weight from the lift truck. Put counterweight on
LPG Fuel System, Mazda 2.0L and 2.2L En- the floor so that it has stability and will not fall
gines 900 SRM 1125 for lift truck models over. Take care not to damage exhaust or cooling
• S30FT, S35FT, S40FTS (E010) components.
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
20
Table 4. Weight of Counterweights, Lift Truck

Model Kg Lb
S30FT 772 1702
S35FT 963 2123
S40FTS 1131 2493
Table 5. Weight of Counterweights, Lift

Truck Models H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001)
Model Kg Lb
H1.6FT (H30FT) 812 1790
H1.8FT (H35FT) 887 1955
H2.0FTS (H40FTS) 1047 2308

Models H2.0-3.5FT (H40-70FT) (L177)
1. FRAME HOOK 4. ROLL PIN
2. LOWER FRAME 5. CAPSCREW Model Kg Lb
MOUNT 6. WASHERS
3. TOW PIN 7. LIFT HOLE H2.0FT (H40FT) 994 2191
Figure 16. Counterweight Installation H2.5FT (H50FT) 1338 2950

H3.0FTS (H60FTS) 1664 3668
Table 3. Weight of Counterweights, Lift Truck H3.5FTS (H70FTS) 1965 4332
Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Model Kg Lb
S2.0FT (S40FT) 1040 2293
S2.5FT (S50FT) 1395 3075
S55FTS 1643 3622
S3.0FT (S60FT) 1819 4010
S3.5FT (S70FT) 2153 4747
21
INSTALL compliant engine and for lift trucks built after Jan-
1. Make sure the seals are on the counterweight. 2.0L and 2.2L Emission Compliant Engines 900
See Figure 17. SRM 1326 or Gasoline Fuel System, Mazda 2.0L
2. Use a crane to install the counterweight on the
1325.
lift truck. When the counterweight is installed,
make sure the hooks on the frame fully engage 5. If lift truck is equipped with an overhead exhaust
the counterweight so it is aligned with the parts system, install the overhead exhaust pipe. See
of the frame. Install and tighten the M24 × 3 the section Exhaust System Repair for the pro-
capscrew to 555 N•m (409 lbf ft). cedures.
3. Install tow pin and roll pin. See Tow Pin, Remove
and Install for procedures.

of the following Service Manuals to install the
LPG tank and bracket, after the counterweight
has been installed.

1124 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
LPG Fuel System, Mazda 2.0L and 2.2L En-

gines 900 SRM 1125 for lift truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
LPG Fuel System, Mazda 2.0L and 2.2L

Emission Compliant Engines 900 SRM 1326
for lift truck models 1. CAPSCREW 7. ROLL PIN
• S30FT, S35FT, S40FTS (E010) 2. LOCKWASHER 8. SEAL
3. WASHER 9. LIFT HOLE
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 4. COUNTERWEIGHT 10. LPG ACCESS
H40FTS) (F001) 5. LIFTING EYEBOLT HOLE
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 6. TOW PIN
• H2.0-3.5FT (H40-70FT) (L177)
Figure 17. Counterweight
NOTE: For overhead exhaust system procedures for
lift trucks equipped with a Mazda 2007 emissions
22
100 SRM 1120 Overhead Guard Replacement
TOW PIN, REMOVE AND INSTALL

1. Remove the tow pin from the counterweight by
driving the roll pin out. See Figure 18.
2. Install tow pin into counterweight and install roll

pin.
1. TOW PIN 2. ROLL PIN
Figure 18. Tow Pin
Overhead Guard Replacement

REMOVE AND INSTALL choices are a four point sling connected to all four
corners on the top of the overhead guard, or a two
WARNING point sling connected to two opposite corners of the
overhead guard. If a single point hoist is used, make
DO NOT operate the lift truck without the over-
sure that the lift point is as close to the center of the
head guard correctly fastened to the lift truck.
overhead guard. If during the initial start of the lift
the overhead guard is off balance lower immediately
WARNING and move the hoist to a more centered point.
DO NOT weld mounts for lights or accessories
to legs of the overhead guard. Changes that are 1. Connect a lifting device to remove or install the
made by welding, or by drilling holes that are overhead guard. Loosen clamp and disconnect
too big or in the wrong location, can reduce the the air intake hose from the elbow. Remove bolts,
strength of the overhead guard. elbow, retainer, and grommet from the overhead
guard rear leg. See Figure 19.
See your dealer for Hyster lift trucks BEFORE
performing any changes to the overhead 2. Disconnect any wires between the frame and the
guard. overhead guard. When the overhead guard is
lifted from the frame, make sure that any elec-
NOTE: The lift trucks covered in this SRM are trical wires are moved through the holes in the
equipped with either a high or low overhead guard. frame so that they are not damaged.
The removal and installation procedures for both
types of overhead guards are the same. 3. The rear legs of the overhead guard have two cap-
screws that are located under the hood inside the
No welding or drilling on legs of overhead guard is engine compartment, next to the radiator. Re-
permitted as per previous WARNING. move and install the capscrews. See Figure 20.
NOTE: The lifting device can be connected to any

number of positions on the overhead guard depend-
ing upon the lifting device available. The ideal
23
Overhead Guard Replacement 100 SRM 1120
4. Remove the fender cover, dash, and kick panel LED TAIL, BACKUP, AND BRAKE LIGHTS,
to remove and install the three capscrews on the REPLACE
front legs of the overhead guard. See Hood, Seat,
and Side Covers Replacement for the removal These light assemblies are nonrepairable and must
procedures. be replaced as an assembly. See the section Elec-
trical System 2200 SRM 1142 for the procedures to
5. When installing the overhead guard, tighten the replace these lights.
capscrews for the overhead guard legs to 66 N•m
(49 lbf ft). See Figure 20.
1. CAPSCREWS - FRONT LEGS

2. HANDLE
3. CAPSCREWS - REAR LEGS
1. CLAMP 4. ELBOW 4. FRAME
2. AIR INTAKE HOSE 5. RETAINER
3. BOLTS 6. GROMMET
Figure 20. Overhead Guard
Figure 19. Disconnect Air Intake Hose
24
100 SRM 1120 Operator Restraint System Replacement
Operator Restraint System Replacement

DESCRIPTION Replace the seat belt if damage or wear is seen. See
Figure 21 and Figure 22.
The seat belt, hip restraint brackets, seat and mount-
ing, hood, and latches are all part of the operator re- NOTE: The following seat belt operation checks must
straint system. Each item must be checked to make be performed three times before replacing the seat
sure it is attached securely, functions correctly, and belt assembly.
is in good condition. See Figure 21. • With the hood closed and in the locked position,
pull the seat belt slowly from the retractor assem-
Automatic Locking Retractor (ALR) bly. Make sure the seat belt pulls out and retracts
smoothly. If the seat belt cannot be pulled from the
NOTE: S2.0-3.5FT (S40-70FT, S55FTS) (F187) lift retractor assembly or the belt will not retract, re-
trucks produced before November 2005 are equipped place the seat belt assembly.
with the ALR type seat belts. • With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. Make sure the
The seat belt must fasten securely. Make sure the
seat belt will not pull from the retractor assembly.
seat belt extends and retracts smoothly and is not
If the seat belt can be pulled from the retractor,
frayed or torn. If the seat belt is damaged or does not
when it is pulled with a sudden jerk, replace the
operate properly, it must be replaced. See Figure 21.
seat belt assembly.
Emergency Locking Retractor (ELR) • With the hood in the open position, make sure the
NOTE: Lift trucks produced after November 2005 If the seat belt can be pulled from the retractor,
are equipped with the Emergency Locking Retractor with the hood in the open position, replace the seat
(ELR) style seat belt. belt assembly.
When the ELR style seat belt is properly buckled Make sure the seat rails and latch striker are not
across the operator, the belt will permit slight op- loose. The seat rails must lock securely in position
erator repositioning without activating the locking but move freely when unlocked. The seat rails must
mechanism. If the truck tips, travels off a dock, or be securely attached to the mounting surface. The
comes to a sudden stop, the locking mechanism will hood must be fully closed. Lift the hood to make sure
be activated and hold the operator’s lower torso in it is closed and will not move.
the seat.
Adjust hood, hood latch, and latch striker when any
A seat belt that is damaged worn or does not oper- of the parts of the operator restraint system are in-
ate properly will not provide protection when it is stalled or replaced. See the section Hood, Seat, and
needed. The end of the belt must fasten correctly in Side Covers Replacement in this manual for the ad-
the latch. The seat belt must be in good condition. justment procedures for the hood.
25
Operator Restraint System Replacement 100 SRM 1120
A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR

1. LATCH STRIKER 7. ARM REST
2. HOOD LATCH 8. SEAT BELT
3. FORWARD/BACKWARD ADJUSTMENT 9. SEAT
4. HOOD 10. HIP RESTRAINT
5. OPERATOR WEIGHT ADJUSTMENT 11. HOOD HINGE
6. SEAT RAIL
Figure 21. Operator Restraint System
26
100 SRM 1120 Engine Replacement

A. STANDARD, NON-SUSPENSION SEAT B. FULL SUSPENSION SEAT
1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 6. ARMREST
3. RIDE POSITION INDICATOR 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER
Engine Replacement
REMOVE WARNING
WARNING sparks or permit flammable material near the
The lift truck must be put on blocks for some LPG system. LPG fuel systems can be discon-
types of maintenance and repairs. The re- nected indoors only if the lift truck is at least
moval of the following assemblies will cause 8 m (26 ft) from any open flame, motor vehicles,
large changes in the center of gravity: mast, electrical equipments, or ignition source.
drive axle, engine and transmission, and coun-
terweight. When the lift truck is put on blocks, 1. For lift trucks equipped with an LPG fuel system,
put additional blocks in the following posi- close the shutoff valve on the tank and run engine
tions to maintain stability: until all fuel is gone and engine stops.
• Before removing the mast and drive axle, put
2. If lift truck is equipped with an LPG fuel tank,
blocks under the counterweight so the lift
swing tank to the side. See one of the following
truck cannot fall backward.
Service Manuals for procedures:
• Before removing the counterweight, put
blocks under the mast assembly so the lift LPG Fuel System, GM 2.4L Engine 900 SRM
truck cannot fall forward. 1124 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
The surface must be solid, even, and level when
• H2.0-3.5FT (H40-70FT) (L177)
the lift truck is put on blocks. Make sure that
any blocks used to support the lift truck are LPG Fuel System, Mazda 2.0L and 2.2L En-
solid, one-piece units. See the Operating Man- gines 900 SRM 1125 for lift truck models
ual or the section • S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• H2.0-3.5FT (H40-70FT) (L177)
truck models
for lift truck models
• S30FT, S35FT, S40FTS (E010)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
WARNING • H2.0-3.5FT (H40-70FT) (L177)
Always disconnect the cables at the battery be-
fore you make repairs to the engine. Discon- 3. Remove overhead guard. See section Overhead
nect the cable at the negative terminal first. Guard Replacement for procedures.
4. Remove the floor mat and floor plate.
27
Engine Replacement 100 SRM 1120
linkage (see the section Powershift Transmis-

WARNING sion, Repair 1300 SRM 1129). Disconnect the
DO NOT remove the radiator cap from the radi- exhaust system.
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from 14. Remove the radiator fan pulley, shroud, and fan
the system. If the system is hot, the steam and assembly. See the section Cooling System 700
boiling coolant can cause burns. SRM 1123 for the removal procedures.
5. Let coolant cool to ambient temperature. Place a

drain pan with a capacity greater than the capac-
WARNING
ity of the cooling system under radiator. Remove All fuels are very flammable and can burn or
radiator cap. cause an explosion. DO NOT use an open flame
to check the fuel level or to check for leaks in
the fuel system.
CAUTION
Disposal of lubricants and fluids must meet lo- No smoking.
cal environmental regulations.
Breathing fuel vapor may cause nausea, uncon-
6. Open the drain plug or disconnect the bottom ra- sciousness or death. Long term exposure to
diator hose to drain coolant from radiator and en- gasoline vapors may cause liver or kidney dam-
gine. age and cancer. Avoid breathing vapor.
7. Remove the hood and seat combination and rear 15. Disconnect the fuel lines at the engine. Put caps
side covers. See the section Hood, Seat, and Side on fuel lines to prevent fuel leakage.
Covers Replacement for procedures.
NOTE: Trucks equipped with a Yanmar Diesel En-

gine do not have an ECM.
8. On lift trucks with the GM 2.4L engine, discon-

nect the ECM from air filter and remove two bolts
holding ECM and mounting bracket to air filter,
before removing the air filter.
9. On lift trucks equipped with a Mazda 2.0L or

2.2L engine, disconnect ECM connector from
ECM. Remove two bolts and ECM bracket, with
ECM attached, from engine block.
10. Disconnect the ground strap from the frame and

remove the power distribution module (PDM)
from the battery tray. See Figure 23.
11. Remove three capscrews from the battery tray

and remove the battery and battery tray. See
Figure 23. 1. BATTERY
2. BATTERY TRAY
3. PDM
12. Disconnect the remaining coolant hoses from the 4. BATTERY LOCKDOWN BAR
radiator and cap them to prevent leakage. 5. GROUND STRAP
13. On lift trucks equipped with a Mazda engine Figure 23. Power Distribution Module,
(except Mazda 2007 emission compliant en- Disconnection
gines and lift trucks built after January, 2010
equipped with a Mazda engine) and Basic Pow-
ershift Transmission, disconnect the throttle
28
NOTE: Lift trucks equipped with Yanmar diesel en- 19. Use the access port on the side of engine and re-
gine do not have an ECM. move the four bolts that attach the flywheel to
the torque converter. See Figure 24.
NOTE: Lift trucks equipped with 2007 Mazda emis-
sion compliant engines and lift trucks built after Jan- 20. Connect a lifting device to the engine. Put a block
uary, 2010 equipped with Mazda engines, do not have under the transmission housing to support the
a governor controller and the ECM for these engines transmission.
is mounted on the side of the engine.
16. For lift trucks built before 2007, equipped iron housing transmission.
with Mazda engines - Disconnect the electronic
control module (ECM) connector and governor 21. Remove capscrews from transmission bell hous-
controller from the side of the frame before re- ing.
moving the engine from the truck.
NOTE: Perform Step 22 through Step 24 for lift
17. 2007 Mazda emission compliant engines trucks equipped with aluminum housing transmis-
only - Disconnect the engine harness connectors sion.
from the right hand chassis harness connectors
22. Remove two capscrews, two washers, and con-
before removing the engine from the truck.
verter housing cover from torque converter hous-
18. Lift trucks built after January, 2010 ing. See Figure 25.
equipped with Mazda engines - Discon-
23. Remove four flange bolts from torque converter
nect the engine harness connectors from the
housing and flywheel housing on transmission
right hand chassis harness connectors before
side. See Figure 25.
removing the engine from the truck.
A. TYPICAL FOR MAZDA AND YANMAR ENGINES B. TYPICAL FOR GM ENGINES

1. ACCESS PORT 2. FLYWHEEL HOUSING
Figure 24. Torque Converter Bolt Access
29
NOTE: TYPICAL FOR ALL ENGINES. GM 2.4L LPG AND ALUMINUM CASE TRANSMISSION SHOWN.
1. CONVERTER HOUSING COVER 7. FLYWHEEL HOUSING
2. CAPSCREW 8. TRANSMISSION ASSEMBLY
3. WASHER 9. FLANGE BOLT
4. TORQUE CONVERTER HOUSING 10. LOCKWASHER
5. EYEBOLT BRACKET 11. ENGINE ASSEMBLY
6. HEX HEAD CAPSCREW
Figure 25. Flywheel and Torque Converter Housings
30
24. Remove six hex head capscrews and six lock

washers from flywheel housing and torque con-
verter housing on flywheel housing side. See
Figure 25.
WARNING
The engine is heavy. Make sure that any lifting
device has enough capacity to lift the engine.
The engine can weigh approximately 194 kg
(428 lb).
25. Remove the flange nuts, washers, bolts, and

isolators from the engine mounts. Remove en-
gine adapter to transmission bolts. On trucks
equipped with a GM 2.4L engine, remove one
starter bolt. See Figure 26 and Figure 27.
A. MAZDA AND YANMAR ENGINE MOUNT

B. GM ENGINE MOUNT
1. LEFT ENGINE MOUNT
2. RIGHT ENGINE MOUNT
3. WASHER
A. MAZDA ENGINE B. GM 2.4L ENGINE 4. CAPSCREW
5. CROSSMEMBER
1. FRAME 3. FLANGE NUT 6. ISOLATOR
2. ENGINE MOUNT 7. FLANGE NUT
Figure 26. Engine Removal Figure 27. Engine Mounts
31
5. Align transmission bell housing holes with

CAUTION flywheel housing holes and install capscrews.
When separating the engine away from the Tighten capscrews to 38 N•m (28 lbf ft).
transmission, place a piece of plywood in front
of radiator. This will keep the engine from NOTE: Perform Step 6 through Step 9 for lift trucks
damaging the radiator. equipped with aluminum transmission housing.
6. Install six lock washers and six capscrews on

CAUTION flywheel housing and torque converter housing
Keep the engine level when the engine is sepa- from flywheel housing side. Tighten capscrews
rated from the transmission so the drive plate to 38 N•m (28 lbf ft). See Figure 25.
is not damaged.
7. Install four flange bolts on torque converter hous-
26. Use the lifting device to carefully move the ening and flywheel housing from transmission side.
gine away from the torque converter. Make sure Tighten bolts to 38 N•m (28 lbf ft). See Figure 25.
all hoses, wires, and cables are disconnected from
the engine, then lift the engine from the frame 8. On trucks equipped with a GM 2.4L engine, in-
and place engine on blocks. stall starter bolt.
27. Remove torque converter from torque converter 9. Install converter housing cover, two washers,
housing. and two capscrews on torque converter housing.
Tighten capscrews to 19 N•m (168 lbf in). See
INSTALL Figure 25.
NOTE: For procedures to install exhaust pipe to ex-

WARNING haust manifold for lift trucks equipped with a Mazda
The engine is heavy. Make sure that any lifting 2007 emissions compliant engine and for lift trucks
device has enough capacity to lift the engine. built after January, 2010 equipped with a Mazda en-
The engine can weigh approximately 194 kg gine, see Gasoline Fuel System, Mazda 2.0L and
(428 lb). 2.2LEmission Compliant Engines 900 SRM 1325
or LPG Fuel System, Mazda 2.0L and 2.2L Emis-
CAUTION sion Compliant Engines 900 SRM 1326.
Keep the engine level when installing the en- 10. Install exhaust pipe to exhaust manifold. See
gine to the transmission so the drive plate is Exhaust System Repair.
not damaged.
11. For lift trucks built before 2007, equipped
1. Install torque converter in torque converter with Mazda engines - Connect the ECM con-
housing. nector and governor controller to lift truck frame.
2. Connect lifting device to engine and lift engine 12. On lift trucks equipped with a Mazda 2.0L or
into frame. 2.2L engine, install ECM bracket with ECM at-
tached and two bolts on engine block.
3. Install isolators on engine mounts. Install the
nuts and bolts for the engine mounts to secure
engine to frame. See Figure 26 and Figure 27. WARNING
Tighten the nuts to 150 N•m (110 lbf ft). All fuels are very flammable and can burn or
cause an explosion. DO NOT use an open flame
4. Use access port on side of engine and install bolts to check the fuel level or to check for leaks in
to hold torque converter to flywheel. Tighten bolt the fuel system.
to 56 N•m (41 lbf ft). See Figure 24.
No smoking.
iron transmission housing. Breathing fuel vapor may cause nausea, uncon-
sciousness or death. Long term exposure to
gasoline vapors may cause liver or kidney dam-
age and cancer. Avoid breathing vapor.
32
13. Connect the wires and wiring harnesses at the 19. Install the rear side covers, floor plates, floor
engine. Remove caps from fuel lines and connect mat, and hood and seat combination. See the sec-
the fuel lines at the engine. tion Hood, Seat, and Side Covers Replacement
for the procedures.
NOTE: On trucks equipped with the GM 2.4L en-
gine, connect the ECM and install ECM and mount- 20. If removed, install Overhead guard. See section
ing bracket to air filter with two bolts, before in- Overhead Guard Replacement for procedures.
stalling the air filter to lift truck.
21. Check all fluid levels as described in the section
14. On lift trucks equipped with a Mazda engine (ex-
cept Mazda 2007, and later, emission compliant Periodic Maintenance 8000 SRM 1150 for lift
engines) and Basic Powershift Transmission, truck models
connect the throttle linkage (see the section • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Powershift Transmission, Repair 1300 SRM • H2.0-3.5FT (H40-70FT) (L177)
1129). Install the air filter assembly.
15. Connect the coolant hoses and lines to the trans- truck models
mission. Fill cooling system with a mixture of 50 • S30FT, S35FT, S40FTS (E010)
percent deionized water and 50 percent ethylene • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
glycol boron-free antifreeze. H40FTS) (F001)
16. Install the radiator shroud, fan pulley, and fan

CAUTION
assembly. See the section Cooling System 700
SRM 1123 for the installation procedures. Disposal of lubricants and fluids must meet lo-
17. Connect the PDM and connect the ground strap
to lift truck frame and attach it to battery. Install 22. Empty drain pan contents.
the battery and battery tray. See Figure 23. 23. If lift truck is equipped with an LPG fuel tank,
18. If lift truck is equipped with an LPG tank, swing swing tank into position on back of counter-
tank into position on truck. See one of the follow- weight and open shutoff valve on tank. See one
ing Service Manuals for procedures: of the following Service Manuals.
LPG Fuel System, GM 2.4L Engine 900 SRM LPG Fuel System, GM 2.4L Engine 900 SRM
1124 for lift truck models 1124 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
LPG Fuel System, Mazda 2.0L and 2.2L En- LPG Fuel System, Mazda 2.0L and 2.2L En-
gines 900 SRM 1125 for lift truck models gines 900 SRM 1125 for lift truck models
• S30FT, S35FT, S40FTS (E010) • S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
LPG Fuel System, Mazda 2.0L and 2.2L LPG Fuel System, Mazda 2.0L and 2.2L
Emission Compliant Engines 900 SRM 1326 Emission Compliant Engines 900 SRM 1326
for lift truck models for lift truck models
H40FTS) (F001) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
33
Transmission Replacement 100 SRM 1120
Transmission Replacement
REMOVE TRANSMISSION WITH IRON 5. Remove the hydraulic hose between the hy-
HOUSING draulic pump and the tank. Put a cap on the
tank fitting. Remove the supply line from hy-
draulic pump to the main control valve.
WARNING
The lift truck must be put on blocks for some NOTE: Step 6 and Step 7 apply to lift truck models
types of maintenance and repairs. The re- H2.0-3.5FT (L177) equipped with a variable displace-
moval of the following assemblies will cause ment pump (VDP):
drive axle, engine, transmission, and counter- 6. Remove the hydraulic supply (suction) hose be-
weight. When the lift truck is put on blocks put tween the variable displacement pump and hy-
additional blocks in the following positions to draulic tank. Put a cap on the hydraulic tank
maintain stability: fitting. See Figure 28.
blocks under the counterweight so the lift 7. Remove the hydraulic supply hose, load sense
truck cannot fall backward. line, drain case line, and hydraulic inlet line from
• Before removing the counterweight, put the variable displacement pump. Put cap on all
blocks under the mast assembly so the lift variable displacement pump and hose openings.
truck cannot fall forward. See Figure 28.

solid, one-piece units. See the Operating Man-
ual or
See section Periodic Maintenance 8000 SRM

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
1. Remove engine from lift truck. See section Re-

move, Engine Replacement for procedures.
2. Remove the seal plate for the brake and throttle

pedals. See Figure 6.
NOTE: When disconnecting wiring harness connec-

tors during removal, tag each connector to aid in con- 1. TRANSMISSION HOUSING
necting wiring harness during installation. 2. VARIABLE DISPLACEMENT PUMP
3. LOAD SENSE LINE
3. Disconnect the engine wiring harness from 4. HYDRAULIC INLET LINE
transmission wiring harness. 5. DRAIN CASE LINE
6. HYDRAULIC SUPPLY (SUCTION) HOSE
4. Disconnect transmission cooling lines.
Figure 28. Hydraulic Hose Connections, Lift
NOTE: Step 5 applies to lift truck models equipped Truck Models H2.0-3.5FT (L177) Equipped With
with a hydraulic gear pump. Variable Displacement pump
34
100 SRM 1120 Transmission Replacement
10. Use a lifting device to carefully lift the transmis-

WARNING sion out of the frame. Slip the transmission out-
The transmission is heavy. Make sure that any put yoke out of the transmission. Make sure to
lifting device has enough capacity to lift the not damage the seal.
weight. The transmission can weigh approxi-
mately 317 kg (699 lb). INSTALL TRANSMISSION WITH IRON
8. Connect a lifting device to support the transmis-
HOUSING
sion.
WARNING
9. Remove the capscrew, washer, snubbing washers, The transmission is heavy. Make sure that any
and isolators from the mount bracket at the rear lifting device has enough capacity to lift the
of the transmission. See Figure 29. weight. The transmission can weigh approxi-
mately 317 kg (699 lb).
1. Using a lifting device, install transmission in lift

truck frame. Place a block under the transmis-
sion housing to support the transmission.
2. Install the transmission output yoke on the

transmission. Be sure to not damage the seal.
Tighten the bolt to 38 N•m (28 lbf ft).
3. Install the isolators, snubbing washers, washer,

and capscrew on the mounting bracket at the
rear of the transmission. See Figure 29. Tighten
capscrew to 225 to 250 N•m (166 to 184 lbf ft).
4. Remove lifting device from the transmission.
NOTE: Step 5 applies to lift truck models equipped

with a hydraulic gear pump.
5. Install the hydraulic hose between the pump and

the tank. Install the hydraulic filter and hoses.
Connect the supply line to the main control valve.
See Hydraulic Gear Pump 1900 SRM 1136 for
more information on installing hydraulic hoses
to gear pump.
NOTE: Step 6 and Step 7 apply to lift truck models

H2.0-3.5FT (L177) equipped with a variable displace-
ment pump (VDP).
6. Install the hydraulic supply hose between the

variable displacement pump and hydraulic tank.
See Figure 28.
7. Install the hydraulic supply hose, load sense

line, drain case line, and hydraulic inlet line on
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. the variable displacement pump. See Figure 28.
1. MOUNT BRACKET 4. SNUBBING See Hydraulic Gear Pump 1900 SRM 1136 for
2. CAPSCREW WASHER more information on installing hydraulic hoses
3. WASHER 5. ISOLATOR to variable displacement pump.
Figure 29. Rear Mount - Transmission
35
8. Connect the transmission wiring harness to en- 1. Remove engine from lift truck. See section Re-
gine wiring harness. Connect transmission cool- move, Engine Replacement for procedures.
ing lines.
9. Install the seal plate for the brake and throttle pedals. See Figure 6.
10. Install engine in lift truck. See section Install, tors during removal, tag each connector to aid in con-
Engine Replacement for procedures. necting wiring harness during installation.
REMOVE TRANSMISSION WITH 3. Disconnect the engine wiring harness from

ALUMINUM HOUSING transmission wiring harness.
4. Disconnect transmission cooling lines from

WARNING transmission.
types of maintenance and repairs. The re- See Figure 30 and Figure 31 for the following
moval of the following assemblies will cause lift truck models equipped with a hydraulic gear
large changes in the center of gravity: mast, pump
drive axle, engine, transmission, and counter- • S30FT, S35FT, S40FTS (E010)
weight. When the lift truck is put on blocks put • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
additional blocks in the following positions to H40FTS) (F001)
maintain stability: • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• Before removing the mast and drive axle, put • H2.0-3.5FT (H40-70FT) (L177)
blocks under the counterweight so the lift See Figure 32 and Figure 33 for lift truck models
truck cannot fall backward. H2.0-3.5FT (H40-70FT) (L177) equipped with a
• Before removing the counterweight, put hydraulic gear pump.
truck cannot fall forward. See Figure 34 and Figure 35 for lift truck models
H2.0-3.5FT (L177) equipped with a variable dis-
The surface must be solid, even, and level when placement pump.
solid, one-piece units. See the Operating Man- CAUTION
ual or Disposal of lubricants and fluids must meet lo-
1207 for lift truck models NOTE: Perform Step 5 for lift trucks equipped with
• S30FT, S35FT, S40FTS (E010) dry brakes.
H40FTS) (F001) 5. Place a suitable container under transmission;
remove drain fitting from transmission housing
See section Periodic Maintenance 8000 SRM and drain transmission oil.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) See Figure 30 and Figure 31 for the following
• H2.0-3.5FT (H40-70FT) (L177) lift truck models equipped with a hydraulic gear
pump
• S30FT, S35FT, S40FTS (E010)
WARNING • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
The transmission is heavy. Make sure that any H40FTS) (F001)
lifting device has enough capacity to lift the • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
weight. The transmission can weigh approxi- • H2.0-3.5FT (H40-70FT) (L177)
mately 83.8 kg (184.7 lb).
See Figure 34 for lift truck models H2.0-3.5FT
NOTE: Make sure the transmission is supported by (L177) equipped with a variable displacement
blocks or a lifting device before removing the engine. pump.
36
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND

ADAPTERS NOT SHOWN.
1. TRANSMISSION HOUSING
2. DRAIN FITTING
3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
5. HYDRAULIC GEAR PUMP INLET PORT
6. HYDRAULIC GEAR PUMP OUTLET PORT
7. HYDRAULIC INLET HOSE
8. TRANSMISSION COOLING LINE
2. DRAIN FITTING
4. SUCTION HOSE
Figure 30. Hydraulic Hose, Dry Brakes

(Aluminum Transmission Prior to January,
2011)
2. WET DISK BRAKE HOSE ASSEMBLY
4. SUCTION HOSE
8. HIGH TEMP HOSE ASSEMBLY
9. TRANSMISSION COOLING SUPPLY PORT
Figure 32. Hydraulic Hose, Wet Brakes

2011)

(Aluminum Transmission After January, 2011)
37

ADAPTERS NOT SHOWN.
1. TRANSMISSION HOUSING 1. TRANSMISSION HOUSING
2. WET DISK BRAKE HOSE ASSEMBLY 2. DRAIN FITTING
3. HYDRAULIC GEAR PUMP 3. VARIABLE DISPLACEMENT PUMP
4. SUCTION HOSE 4. LOAD SENSE LINE
5. HYDRAULIC GEAR PUMP INLET PORT 5. DRAIN CASE LINE
6. HYDRAULIC GEAR PUMP OUTLET PORT 6. HYDRAULIC INLET HOSE
7. HYDRAULIC INLET HOSE 7. TRANSMISSION COOLING LINES
8. HIGH TEMP HOSE ASSEMBLY 8. SUCTION HOSE
9. TRANSMISSION COOLING SUPPLY PORT 9. PUMP INLET PORT
10. PUMP OUTLET PORT
(Aluminum Transmission After January, 2011) Figure 34. Hydraulic Hose, Dry Brakes
(Aluminum Transmission After January, 2011),
Lift Truck Models H2.0-3.5FT (L177) Equipped
With Variable Displacement Pump
38
See Figure 32 and Figure 33 for lift truck models

H2.0-3.5FT (H40-70FT) (L177) equipped with a
hydraulic gear pump.

(L177) equipped with a variable displacement
pump.
7. Disconnect and cap high temp hose assembly

from transmission cooling support port. Cap
transmission cooling supply port.


pump.
8. Disconnect and cap suction hose from hydraulic

gear pump inlet port. Cap hydraulic gear pump
inlet port.
See Figure 30 and Figure 31 for the following

lift truck models equipped with a hydraulic gear
pump
• S30FT, S35FT, S40FTS (E010)
1. TRANSMISSION HOUSING H40FTS) (F001)
2. VARIABLE DISPLACEMENT PUMP • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
3. LOAD SENSE LINE • H2.0-3.5FT (H40-70FT) (L177)
4. DRAIN CASE LINE
5. HYDRAULIC INLET HOSE See Figure 32 and Figure 33 for the following
6. HIGH TEMPERATURE LINE lift truck models equipped with a hydraulic gear
7. TRANSMISSION COOLING SUPPLY PORT pump
8. TRANSMISSION COOLING HOSES
9. WET DISK BRAKE HOSE ASSEMBLY • H2.0-3.5FT (H40-70FT) (L177)
10. PUMP INLET PORT
11. PUMP OUTLET PORT See Figure 34 and Figure 35 for lift truck models
12. SUCTION HOSE H2.0-3.5FT (L177) equipped with a variable dis-
placement pump.
(Aluminum Transmission After January, 2011), NOTE: Perform Step 9 for lift truck models
Lift Truck Models H2.0-3.5FT (L177) Equipped H2.0-3.5FT (H40-70FT) (L177) equipped with a
With Variable Displacement Pump Quick-Lok™ hydraulic hose and adapter.
NOTE: Perform Step 6 and Step 7 for lift trucks 9. Remove adapter and Quick-Lok hydraulic hose
equipped with wet brakes. from hydraulic gear pump outlet port. Cap hy-
draulic gear pump outlet port.
6. Place a suitable container under transmis-
sion; disconnect wet disk brake hose assembly
from transmission and drain transmission and
transaxle oil.
39
10. For lift trucks not equipped with Quick-Lok hy-

draulic hose and adapters, disconnect and cap
hydraulic inlet hose from hydraulic gear pump
outlet port. Cap hydraulic gear pump outlet port.

pump
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)


placement pump.
NOTE: Step 11 applies only to lift truck models H2.0-

3.5FT (L177) equipped with a variable displacement
pump.
11. Disconnect and cap the load sense line and drain
case line from the variable displacement pump.
See Figure 34 and Figure 35.
12. Remove the capscrew, washer, snubbing washers,

and isolators from the mount bracket at the rear
of the transmission. See Figure 36.
13. Use the lifting device to carefully lift the trans-

mission from the frame. Slip the transmission
output yoke out of the transmission. Make sure NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.
to not damage the seal. 1. MOUNT BRACKET
2. CAPSCREW
14. Remove flange head capscrew, yoke, and spacer 3. WASHER
from transmission. Make sure to not damage the 4. SNUBBING WASHER
seal. See Figure 37. 5. ISOLATOR
NOTE: Note position of oil seal prior to removal to aid Figure 36. Rear Mount- Transmission
in installation.
15. Remove oil seal from transmission housing. See

Figure 37.
40
NOTE: Perform Step 7 for lift truck models

Quick-Lok™ hydraulic hose and adapter.
7. Remove cap and install adapter and Quick-Lok

hydraulic hose to hydraulic gear pump outlet
port. Tighten adapter to 59 to 69 N•m (44 to
51 lbf ft).
8. For lift truck not equipped with Quick-Lok hy-

draulic hose and adapters, connect hydraulic in-
let hose to fitting on hydraulic gear pump outlet
port.
1. FLANGE HEAD CAPSCREW
2. STAT-O-SEAL See Figure 30 and Figure 31 for the following
3. YOKE lift truck models equipped with a hydraulic gear
4. OIL SEAL pump
5. SPACER • S30FT, S35FT, S40FTS (E010)
6. TRANSMISSION HOUSING • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
Figure 37. Drive Shaft Yoke
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
INSTALL TRANSMISSION WITH • H2.0-3.5FT (H40-70FT) (L177)
ALUMINUM HOUSING See Figure 32 and Figure 33 for lift truck models
WARNING hydraulic gear pump.
The transmission is heavy. Make sure that any
lifting device has enough capacity to lift the
placement pump.
mately 83.8 kg (184.7 lb).
9. Connect suction hose to hydraulic gear pump in-
let port.
sion housing to support the transmission. See Figure 30 and Figure 31 for the following
2. Install oil seal on back of transmission housing.
pump
See Figure 37.
• S30FT, S35FT, S40FTS (E010)
3. Install new stat-o-seal on yoke. See Figure 37. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
4. Install spacer, yoke, and flange head capscrew on • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
back of transmission. See Figure 37. Tighten • H2.0-3.5FT (H40-70FT) (L177)
capscrew to 77 N•m (57 lbf ft).
5. Install isolators, snubbing washers, washer, and H2.0-3.5FT (H40-70FT) (L177) equipped with a
capscrew on mounting bracket at the rear of the hydraulic gear pump.
transmission. See Figure 36. Tighten capscrew
to 225 to 250 N•m (166 to 184 lbf ft). See Figure 34 and Figure 35 for lift truck models
6. Remove lifting device from transmission. placement pump.
41
NOTE: Perform Step 10 for lift trucks equipped with See Figure 32 and Figure 33 for lift truck models
dry brakes. H2.0-3.5FT (H40-70FT) (L177) equipped with a
10. Install drain fitting on transmission housing.
See Figure 30 and Figure 31 for the following H2.0-3.5FT (L177) equipped with a variable dis-
lift truck models equipped with a hydraulic gear placement pump.
pump
• S30FT, S35FT, S40FTS (E010) NOTE: Step 14 applies only to lift truck models H2.0-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 3.5FT (L177) equipped with a variable displacement
H40FTS) (F001) pump.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) 14. Connect the load sense line and drain case line to
the variable displacement pump. See Figure 34
See Figure 34 for lift truck models H2.0-3.5FT and Figure 35.
pump. 15. Connect transmission wiring harness to engine
wiring harness.
NOTE: Perform Step 11 and Step 12 for lift trucks
equipped with wet brakes. 16. Install the seal plate for the brake and throttle
11. Connect high temp hose assembly to transmis-
sion cooling support port.
WARNING
See Figure 32 and Figure 33 for lift truck models The transmission is heavy. Make sure that any
H2.0-3.5FT (H40-70FT) (L177) equipped with a lifting device has enough capacity to lift the
hydraulic gear pump. weight. The transmission can weigh approxi-
mately 83.8 kg (184.7 lb).
(L177) equipped with a variable displacement NOTE: Make sure the transmission is supported by
pump. blocks or a lifting device before installing the engine.
12. Connect wet disk brake hose assembly to trans- 17. Install engine to lift truck. See section Install,
mission. Engine Replacement for procedures.
See Figure 32 and Figure 33 for lift truck models NOTE: Perform Step 18 for lift trucks equipped with
H2.0-3.5FT (H40-70FT) (L177) equipped with a dry brakes.
variable displacement pump.
18. Fill transmission oil. For fill instruction, oil type,
See Figure 35 for lift truck models H2.0-3.5FT and amount,
pump. See section Periodic Maintenance 8000 SRM
13. Connect transmission cooling lines to transmis- • S30FT, S35FT, S40FTS (E010)
sion. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
lift truck models equipped with a hydraulic gear See section Periodic Maintenance 8000 SRM
pump 1150 for lift truck models
• S30FT, S35FT, S40FTS (E010) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
42
100 SRM 1120 Throttle Pedal and Cable Adjustment
NOTE: Perform Step 19 for lift truck equipped with 19. Fill transmission and transaxle oil. For fill in-
wet brakes. struction, oil type, and amount, see section Peri-
odic Maintenance 8000 SRM 1150 for lift truck
model H2.0-3.5FT (H40-70FT) (L177).
Throttle Pedal and Cable Adjustment

NOTE: There are no throttle pedal and cable adjust- 4. Connect throttle cable to bellcrank and engine.
ments for lift trucks equipped with the GM 2.4L en- See Figure 38.
gine. The GM 2.4L engines have an electronic throt-
tle that is self-adjusting and self-calibrating. 5. With throttle pedal in full up position, adjust
throttle cable, using the jam nuts (item #10 in
NOTE: For the Mazda 2007 emission compliant en- Figure 38) to remove all slack from the cable. Ca-
gines and for lift trucks built after January, 2010 ble should be adjusted to the point where addi-
and equipped with a Mazda engine, there is only a tional adjustment will pull the throttle crank off
throttle pedal stop adjustment. The engine has an the idle stop. Tighten jam nuts to 8 to 15 N•m
electronic throttle that is self-adjusting and self-cali- (71 to 133 lbf in).
brating. See Throttle Pedal Stop Adjustment for pro-
cedures. NOTE: If lift truck is equipped with a Electronic Con-
trol Transmission, see the section Calibration Pro-
MAZDA GAS/LPG ENGINES WITH BASIC cedures 8000 SRM 1134 for additional adjustment
POWER SHIFT TRANSMISSION AND procedures before going onto Step 7.
ELECTRONIC TRANSMISSION (EXCEPT 6. Fully depress pedal and verify that full pedal
MAZDA EMISSION COMPLIANT ENGINES) stroke brings the throttle crank to within 3.0 mm
(0.12 in.) of the wide open throttle stop. See Fig-
1. Remove floor plate and disconnect throttle cable ure 38.
from the bellcrank and engine. See Figure 38.
7. Install floor plate. Fully depress throttle pedal
2. Fully depress throttle pedal and verify that the and adjust pedal stop so that it touches floor
dimension between the bellcrank and cowl plate plate. Tighten jam nuts 8 to 15 N•m (71 to
is 6 ±2 mm (0.24 ±0.08 in.). 133 lbf in) (item #12 in Figure 38).
3. If dimension is not correct, adjust ball ends on
push rod so that a minimum of 6 mm (0.24 in.) of
threaded rod screws into each ball end.
43
Throttle Pedal and Cable Adjustment 100 SRM 1120
Figure 38. Throttle Pedal and Cable Adjustment; Mazda Gas/LPG Engines With Basic Power Shift
Transmission, and Mazda LPG Engine With Electronic Transmission
44
NOTE: THROTTLE PEDAL SHOWN IN WIDE OPEN POSITION (FULLY DEPRESSED POSITION).
A. MAZDA GAS ENGINE B. MAZDA LPG ENGINE
1. BELL CRANK 7. FLOOR PLATE
2. COWL 8. THROTTLE CABLE
3. PUSH ROD 9. BRACKET
4. BALL END 10. JAM NUTS
5. PEDAL STOP 11. THROTTLE CRANK
6. THROTTLE PEDAL 12. JAM NUT
45
MAZDA GASOLINE ENGINE WITH the idle stop. Tighten jam nuts 8 to 15 N•m (71
ELECTRONIC TRANSMISSION to 133 lbf in).
1. Remove floor plate. If necessary, remove throttle NOTE: See the section Calibration Procedures
cable from bellcrank follower and throttle crank. 8000 SRM 1134 for additional adjustment proce-
dures before going onto Step 6.
2. Back out bellcrank screw to ensure clearance
when accelerator pedal is fully released, and 5. Fully depress pedal and verify that full pedal
the bellcrank follower is pulled against the stop stroke brings the throttle crank to within 3.0 mm
block located on bracket. See Figure 39. (0.12 in.) of the wide open throttle stop. See Fig-
ure 39.
3. If removed, connect throttle cable to bellcrank
follower and throttle crank. 6. Install floor plate. Fully depress throttle pedal
and adjust pedal stop so that it touches floor
4. With throttle pedal in full up position, adjust plate. Tighten jam nuts 8 to 15 N•m (71 to
throttle cable, using the jam nuts (item #12 in 133 lbf in). See Figure 39.
Figure 39) to remove all slack from the cable. Ca-
ble should be adjusted to the point where addi-
tional adjustment will pull the throttle crank off
1. BELLCRANK 6. BALL END 11. BRACKET

2. BELLCRANK FOLLOWER 7. FLOOR PLATE 12. JAM NUTS
3. COWL 8. THROTTLE CABLE 13. THROTTLE CRANK
4. THROTTLE PEDAL 9. SCREW 14. STOP BLOCK
5. PUSH ROD 10. JAM NUT 15. PEDAL STOP
Figure 39. Throttle Pedal and Cable Adjustment; Mazda Gasoline Engine With Electronic
Transmission
46
THROTTLE PEDAL STOP ADJUSTMENT

Fully depress throttle pedal and adjust pedal stop
so that it touches floor plate. Tighten jam nut to
10 N•m (88.5 lbf in). See Figure 40.
YANMAR DIESEL ENGINE WITH BASIC

POWER SHIFT TRANSMISSION
1. Remove floor plate and disconnect throttle cable
from the bellcrank and engine.
2. Fully depress throttle pedal and verify that the

dimension between the bellcrank and cowl plate
is 5 ±1 mm (0.20 ±0.04 in.). See Figure 41.

threaded rod screws into each ball end. After ad-
justing push rod, tighten jam nuts to 8 to 15 N•m
(71 to 133 lbf in).
4. Connect throttle cable to bellcrank and engine.

See Figure 41.
5. With throttle pedal in full up position, adjust

tional adjustment will pull the control lever off
the idle stop. Tighten jam nuts to 8 to 15 N•m
(71 to 133 lbf in).

and adjust pedal stop so that it touches floor 1. THROTTLE PEDAL POSITION SENSOR
2. JAM NUT
plate. Tighten jam nuts to 8 to 15 N•m (71 to 3. PEDAL STOP
133 lbf in) (item #6 in Figure 41). 4. FLOOR PLATE
YANMAR DIESEL ENGINE WITH Figure 40. Throttle Pedal Stop Adjustment
ELECTRONIC THROTTLE
If lift truck is equipped with an electronic throttle,
see the section Yanmar Diesel Engines, 2.6L, 3.0L
and 3.3L 600 SRM 1205 for adjustment procedures.
47
NOTE: THROTTLE PEDAL NOT SHOWN IN FULLY DEPRESSED POSITION (WIDE OPEN POSITION).
1. COWL 7. PEDAL STOP
2. BELLCRANK 8. THROTTLE CABLE
3. PUSH ROD 9. CABLE BRACKET
5. THROTTLE PEDAL 11. THROTTLE CRANK
6. JAM NUT
Figure 41. Throttle Pedal and Cable Adjustment, Yanmar Diesel Engine
48
100 SRM 1120 Exhaust System Repair
Exhaust System Repair

LIFT TRUCKS WITH COUNTERWEIGHT 5. Remove the plain flanged nuts that attach the
EXHAUST SYSTEM muffler to the frame of the lift truck. Remove the
muffler from the lift truck.
Mazda Gas and LPG Engines
Inspect
NOTE: The Mazda engines covered in this section
are non-emissions compliant engines ONLY. For Inspect the following items in the exhaust system:
exhaust system repair procedures for Mazda 2007 • Exhaust pipes for damage, corrosion, and rust and
emissions compliant engines and for lift trucks built replace as needed.
after January, 2010, see LPG Fuel System, Mazda • If equipped, inspect all exhaust wraps for wear,
2.0L and 2.2L Emission Compliant Engines 900 proper fit, contamination with oil or antifreeze,
SRM 1326 or Gasoline Fuel System, Mazda 2.0L gaps in coverage, failed fasteners and replace as
and 2.2LEmission Compliant Engines 900 SRM needed. If replacing an exhaust pipe section that
1325. has a wrap, also replace the wrap. DO NOT reuse
wraps if they have been removed for a service
NOTE: Remove the counterweight before removing operation.
the muffler and other parts of the exhaust system. • Catalytic converter and muffler for damage, corro-
See the section Counterweight Replacement for the sion, and rust. Replace as needed.
removal procedures for the counterweight.
Assemble and Install
Remove and Disassemble
1. Place the muffler onto the frame of the truck and
The muffler is installed inside the cavity of the coun- install the plain flanged nuts. Tighten the nuts
terweight. A short exhaust pipe sends the exhaust to 39 N•m (29 lbf ft).
gases out of the lift truck through a grille in the coun-
terweight. 2. Install the exhaust pipes (8 and 11, Figure 42)
onto the muffler. Install the clamps on the pipes
to hold them onto the muffler.
WARNING
Exhaust system components are hot to touch. 3. Install the exhaust pipe (15, Figure 42) onto the
Be sure exhaust system components are cool engine exhaust manifold.
before starting disassembly, or personal injury
4. Place the catalytic converter on the lift truck
may occur.
frame. For lift trucks equipped with a Mazda
1. Remove the bracket that attaches the catalytic gas or LPG engine, make sure that the embossed
converter to the frame. See Figure 42. Discon- F is facing up. Install new gaskets onto the
nect the oxygen sensor. catalytic converter and install the exhaust pipes
onto the catalytic converter.
2. Disconnect the exhaust pipes (11 and 15 in Fig-
ure 42) from the catalytic converter and remove 5. Install the bracket that attaches the catalytic
and discard the gaskets from the catalytic con- converter to the frame. See Figure 42. Connect
verter. Remove the catalytic converter from the the oxygen sensor.
lift truck.
6. Install the counterweight. See the section
3. Remove the exhaust pipe (15 in Figure 42) from Counterweight Replacement for installation
the engine exhaust manifold. procedures.
4. Remove the clamps that hold the two exhaust

pipes (8 and 11, Figure 42) to the muffler. Re-
move the exhaust pipes from the muffler.
49
Exhaust System Repair 100 SRM 1120
NOTE: THE EXHAUST WRAPS SHOWN ARE NOT ON ALL LIFT TRUCK MODELS.
1. CAPSCREW 10. MUFFLER
2. WASHER 11. EXHAUST PIPE
3. SPACER 12. LOCKWASHER
4. ISOLATOR 13. GASKET
5. BRACKET 14. CATALYTIC CONVERTER
6. FLANGE NUT 15. EXHAUST PIPE
7. NUT 16. EXHAUST WRAP
8. EXHAUST PIPE 17. OXYGEN SENSOR
9. CLAMP
Figure 42. Counterweight Exhaust System - Mazda
50
Yanmar Diesel Engine and catalytic converter. Remove lower exhaust

pipe from catalytic converter.
Inspect
WARNING Inspect the following items in the exhaust system:
Exhaust system components are hot to touch. • Inspect all exhaust pipes for damage, corrosion,
Be sure exhaust system components are cool and rust and replace as needed.
before starting disassembly, or personal injury • If equipped, inspect all exhaust wraps for wear,
may occur. proper fit, contamination with oil or antifreeze,
gaps in coverage, failed fasteners and replace as
1. Remove the counterweight. See the section
needed. If replacing an exhaust pipe section that
Counterweight Replacement for the removal
has a wrap, also replace the wrap. DO NOT reuse
procedures.
2. Remove clamp that attaches exhaust pipe to muf- operation.
fler (Figure 43). Remove exhaust pipe. • Inspect the catalytic converter (if equipped) and
muffler for damage, corrosion, and rust. Replace
3. Remove clamp that attaches the lower exhaust as needed.
pipe to muffler. On lift truck models H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) Assemble and Install
(F001) the muffler is positioned vertically and
1. Install engine exhaust pipe to engine ex-
lower exhaust pipe is on the bottom. On lift
haust manifold. Tighten locknuts to 22 N•m
truck models H2.0-3.5FT (H40-70FT) (L177),
(195 lbf in).
the muffler is positioned horizontally and the
lower exhaust pipe protrudes from the side (see 2. If lift truck is equipped with a catalytic converter,
Figure 43). install catalytic converter to engine exhaust pipe
and lower exhaust pipe to catalytic converter us-
4. Remove the washers, isolators, spacers, and cap-
ing two clamps. If lift truck is not equipped with
screws that fasten the muffler to the lift truck
catalytic converter, install lower exhaust pipe to
frame and remove muffler from lift truck.
engine exhaust pipe with clamp.
5. If lift truck is not equipped with a catalytic con-
3. Place muffler onto the frame of lift truck and
verter, remove four locknuts attaching engine ex-
install the washers, isolators, spacers, and cap-
haust pipe to engine exhaust manifold and re-
screws to secure muffler to lift truck. Tighten
move engine exhaust pipe from engine manifold
capscrews to 22 N•m (195 lbf in).
and lower exhaust pipe. Remove lower exhaust
pipe. 4. Install lower exhaust pipe to muffler with clamp.
If lift truck is equipped with a catalytic con- 5. Install exhaust pipe on muffler with clamp.
verter, remove clamps securing engine exhaust
pipe and lower exhaust pipe to catalytic con- 6. Install the counterweight. See the section
verter. Remove four locknuts attaching engine Counterweight Replacement for installation
exhaust pipe to engine exhaust manifold and re- procedures.
51
Figure 43. Counterweight Exhaust System Yanmar Diesel Engine
52
NOTE: EXHAUST SYSTEM FOR H2.0-3.5FT (H40-70FT) (L177) LIFT TRUCKS SHOWN. OVERHEAD EXHAUST
SYSTEM FOR H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) IS SIMILAR.
NOTE: EXHAUST SYSTEM WITH CATALYTIC CONVERTER SHOWN.

1. CAPSCREW 8. ENGINE EXHAUST PIPE
2. WASHER 9. CLAMP
3. SPACER 10. CATALYTIC CONVERTER
4. ISOLATOR 11. SOCK
5. LOCKNUT 12. LOWER EXHAUST PIPE
6. MUFFLER 13. COUNTERWEIGHT EXHAUST PIPE
7. GASKET
LIFT TRUCKS WITH OVERHEAD EXHAUST truck models H2.0-3.5FT (H40-70FT) (L177),
SYSTEM the muffler is positioned horizontally and the
lower exhaust pipe protrudes from the side (see
The muffler is installed inside the cavity of the coun- Figure 44).
terweight. A long exhaust pipe, located above the
overhead guard, sends the exhaust gases out of the 5. Remove the washers, isolators, spacers, and cap-
lift truck. screws that fasten the muffler to the lift truck
Yanmar Diesel Engine
Remove and Disassemble verter, remove four locknuts attaching engine ex-
WARNING move engine exhaust pipe from engine manifold
Exhaust system components are hot to touch.
pipe.
Be sure exhaust system components are cool
before starting disassembly, or personal injury If lift truck is equipped with a catalytic con-
may occur. verter, remove clamps securing engine exhaust
pipe and lower exhaust pipe to catalytic con-
1. On trucks equipped with overhead exhaust
verter. Remove four locknuts attaching engine
system, lift cover and remove three capscrews
exhaust pipe to engine exhaust manifold and re-
that attach the overhead exhaust pipe to coun-
terweight. Remove clamp between overhead
and catalytic converter. Remove lower exhaust
exhaust pipe and exhaust pipe (13 in Figure 44)
and remove overhead exhaust pipe.
Inspect
Counterweight Replacement for the removal Inspect the following items in the exhaust system:
procedures. • Inspect all exhaust pipes for damage, corrosion,
and rust and replace as needed.
3. On lift trucks with overhead exhaust system, re-
• If equipped, inspect all exhaust wraps for wear,
move clamp that attaches exhaust pipe to muf-
proper fit, contamination with oil or antifreeze,
fler (13 in Figure 44). On lift trucks with coun-
terweight exhaust system, remove clamp that at-
taches exhaust pipe to muffler (17 in Figure 44).
Remove exhaust pipe.
4. Remove clamp that attaches the lower exhaust operation.
pipe to muffler. On lift truck models H1.6FT, • Inspect the catalytic converter (if equipped) and
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) muffler for damage, corrosion, and rust. Replace
(F001) the muffler is positioned vertically and as needed.
53
Figure 44. Exhaust System - Yanmar Diesel Engine
54

1. CAPSCREW 10. CATALYTIC CONVERTER
2. WASHER 11. SOCK
3. SPACER 12. LOWER EXHAUST PIPE
4. ISOLATOR 13. EXHAUST PIPE
5. LOCKNUT 14. COVER
6. MUFFLER 15. OVERHEAD EXHAUST PIPE
7. GASKET 16. FASTENER*
8. ENGINE EXHAUST PIPE 17. COUNTERWEIGHT EXHAUST PIPE*
9. CLAMP 18. COVER*
*ITEMS USED ONLY ON COUNTERWEIGHT EXHAUST SYSTEM
Assemble and Install Mazda Gas and LPG Engines

1. Install engine exhaust pipe to engine ex- NOTE: The Mazda engines covered in this section
haust manifold. Tighten locknuts to 22 N•m are non-emissions compliant engines ONLY. For
(195 lbf in). exhaust system repair procedures for Mazda 2007
emissions compliant engines and for lift trucks built
2. If lift truck is equipped with a catalytic converter, after January, 2010, see LPG Fuel System, Mazda
install catalytic converter to engine exhaust pipe 2.0L and 2.2L Emission Compliant Engines 900
and lower exhaust pipe to catalytic converter us- SRM 1326 or Gasoline Fuel System, Mazda 2.0L
ing two clamps. If lift truck is not equipped with and 2.2LEmission Compliant Engines 900 SRM
catalytic converter, install lower exhaust pipe to 1325.
WARNING
capscrews to 22 N•m (195 lbf in). Exhaust system components are hot to touch.
4. Install lower exhaust pipe to muffler with clamp. before starting disassembly, or personal injury
may occur.
5. Install exhaust pipe (13 for overhead exhaust or
17 for counterweight exhaust in Figure 44) to 1. Lift cover and remove three capscrews that at-
muffler with clamp. tach the overhead exhaust pipe to counterweight.
Remove clamp between overhead exhaust pipe
6. Install the counterweight. See the section and exhaust pipe (20 in Figure 45) and remove
Counterweight Replacement for installation overhead exhaust pipe.
procedures.
7. On trucks equipped with overhead exhaust sys- Counterweight Replacement for procedures.
tem, insert overhead exhaust pipe in hole of coun-
terweight. Attach overhead exhaust pipe to ex- 3. Remove clamp that attaches exhaust pipe to muf-
haust pipe and secure with clamp. Install and fler (20 in Figure 45). Remove exhaust pipe.
tighten three capscrews to 22 N•m (195 lbf in) to
secure overhead exhaust pipe to counterweight. 4. Remove bracket that attaches the catalytic con-
Cover capscrews with cover. verter to the frame. Disconnect the oxygen sen-
sor.
55
Figure 45. Overhead Exhaust System - Mazda Gas and LPG Engines
56
NOTE: OVERHEAD EXHAUST SYSTEM FOR H2.0-3.5FT (H40-70FT) (L177) LIFT TRUCKS SHOWN. OVERHEAD
EXHAUST SYSTEM FOR H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) IS SIMILAR.
1. CAPSCREW 12. GASKET
2. WASHER 13. CATALYTIC CONVERTER
3. SPACER 14. PLUG
4. ISOLATOR 15. COPPER RING
5. LOCKNUT 16. ENGINE EXHAUST PIPE
6. MUFFLER 17. LOWER EXHAUST PIPE
7. CLAMP 18. BRACKET
8. UPPER EXHAUST PIPE 19. FLANGE NUT
9. NUT 20. EXHAUST PIPE
10. LOCKWASHER 21. OVERHEAD EXHAUST PIPE
11. EXHAUST FLANGE 22. COVER
5. Disconnect upper and lower exhaust pipes from Assemble and Install
catalytic converter and remove and discard the
gaskets from catalytic converter. Remove cat- 1. Install washers, isolators, spacer, and capscrews
alytic converter from lift truck. See Figure 45. to secure muffler to lift truck frame. Tighten cap-
screws to 39 N•m (29 lbf ft).
6. Remove engine exhaust pipe from engine ex-
haust manifold. 2. Install the exhaust pipes (8 and 20, Figure 45)
7. Remove clamp securing exhaust pipe (8, in Fig- to hold them onto the muffler.
ure 45) to muffler and remove pipe from muffler.
3. Install engine exhaust pipe to engine exhaust
8. Remove the washers, isolators, spacers, and cap- manifold using four locknuts. Tighten locknuts
screws that fasten the muffler to the lift truck to 22 N•m (195 lbf in). See Figure 45.
NOTE: Make sure that the embossed F on catalytic
Inspect converter is facing up.
Inspect the following items in the exhaust system: 4. Use new gaskets and install catalytic converter
• Inspect all exhaust pipes for damage, corrosion, to upper and lower exhaust pipes. Tighten nuts
and rust and replace as needed. to 66 N•m (49 lbf ft).
proper fit, contamination with oil or antifreeze, 5. Install the counterweight. See the section Coun-
gaps in coverage, failed fasteners and replace as terweight Replacement for the installation pro-
needed. If replacing an exhaust pipe section that cedures.
6. Insert overhead exhaust pipe in hole of counter-
weight. Attach overhead exhaust pipe to exhaust
operation.
pipe and secure with clamp. Install and tighten
• Inspect the catalytic converter and muffler for
three capscrews to 22 N•m (195 lbf in) to secure
damage, corrosion, and rust. Replace as needed.
overhead exhaust pipe to counterweight. Cover
capscrews with cover.
57
Hydraulic Filter Assembly Repair 100 SRM 1120
Cooling System
DESCRIPTION For the procedures to repair, clean, inspect, and in-
stall the radiator and cooling system components, re-
The cooling system is used to cool the engine and fer to Cooling System 700 SRM 1123.
keep it at the correct operating temperature. The
cooling system is comprised of the following main
components:
• Radiator
• Fan and belt
• Fan shroud
• Coolant hoses and lines
• Coolant reservoir
Hydraulic Filter Assembly Repair

REMOVE foreign material from getting into the hydraulic
tank. See Figure 46.
WARNING 4. After filter element has drained, discard filter el-
At operating temperature, the hydraulic oil is ement and O-ring.
HOT. DO NOT permit the hot oil to touch the
skin and cause a burn. 5. Remove and discard O-ring from top of bowl. See
Figure 46.
CAUTION 6. Remove and discard quad ring from head. See
DO NOT permit dirt to enter the hydraulic sys- Figure 46.
tem when the oil level is checked or the filter
is changed. Dirt can cause damage to the com- CLEAN AND INSPECT
ponents of the hydraulic system.
1. Clean housing and cover plate as necessary.
Never operate they hydraulic pump without
oil in the hydraulic system. The operation of 2. Inspect filter housing, especially sealing sur-
the hydraulic pump without oil will damage faces, for damage. Replace if damaged.
the pump.
3. Inspect dipstick plug. Replace O-ring and plug
as necessary.
CAUTION
Disposal of lubricants and fluids must meet lo- INSTALL
1. Lubricate sealing surfaces on filter housing and
1. Put lift truck on level surface and lower carriage. cover plate with clean hydraulic oil.
2. Unscrew and remove lid and spring from head. 2. Lubricate new quad ring with clean hydraulic oil
Remove and discard O-ring from lid. See Fig- and install onto head. See Figure 46.
ure 46.
3. Lubricate new O-ring with clean hydraulic oil
NOTE: Have container large enough to hold filter el- and install onto top of bowl. See Figure 46.
ement and allow for final hydraulic oil draining.
NOTE: Note placement of filter element and handle and install on bottom of new filter element. See
prior to removal to aid in installation. Figure 46.
3. Remove filter element and O-ring from bowl and 5. Install new filter element into bowl as noted dur-
place in container. Cover head to prevent any ing removal. See Figure 46.
58
100 SRM 1120 Hydraulic Filter Assembly Repair

and install on lid. See Figure 46.
7. Install spring and lid onto head. See Figure 46.

Hand tighten lid.
CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
8. Start lift truck, and allow it to run for 30 seconds.

Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
indicated in

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

truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
1. O-RING 6. FILTER ELEMENT

2. SPRING 7. BOWL
3. LID 8. DIPSTICK PLUG
4. HEAD 9. FILTER HOUSING
5. QUAD RING 10. COVER PLATE
Figure 46. Hydraulic Filter
59
Fuel and Hydraulic Tanks Repair 100 SRM 1120
Fuel and Hydraulic Tanks Repair

INSPECT WARNING
Compressed air can move particles so that they
WARNING cause injury to the user or to other personnel.
Special procedures must be followed when Make sure that the path of the compressed air
large leaks or other repairs need welding or is away from all personnel. Wear protective
cutting. All work must be done by authorized goggles or a face shield to prevent injury to the
personnel. If the tank is cleaned inside a build- eyes.
ing, make sure there is enough ventilation.
See the following manuals for additional infor-
WARNING
mation:
• Safe Practices for Welding and Cutting Con- Be careful when cleaning with steam. Steam
tainers That Have Held Combustibles by the can cause serious burns. Wear protective cloth-
American Welding Society, F4.1 - 1999. ing, gloves, and eye protection. Never expose
• Safety in Welding and Cutting, American Na- your skin to steam.
tional Standard, AWS Z 49.1 - 1999. When cleaning with steam, use a hose with a mini-
mum diameter of 19 mm (0.75 in.). Control the pres-
WARNING sure of the steam by a valve installed at the nozzle of
DO NOT use tools that can make sparks, heat, the hose. If a metal nozzle is used, it must be made of
or static electricity. The vapors in the tank can a material that does not make sparks. Make an elec-
cause an explosion. trical connection between the nozzle and the tank.
Connect a ground wire to the tank to prevent static
electricity.
CAUTION
Additives may damage the hydraulic system. Steam Method of Cleaning
ter dealer.
WARNING
Make a visual inspection of all sides of the tank. In- Compressed air can move particles so that they
spect the welds for cracks and leakage. Check for cause injury to the user or to other personnel.
wet areas, accumulation of dirt, and loose or miss- Make sure that the path of the compressed air
ing paint caused by leakage. Areas of the tank that is away from all personnel. Wear protective
are not easily seen can be checked with an inspection goggles or a face shield to prevent injury to the
mirror and a light that is approved for locations with eyes.
flammable vapors.
1. Place a drain pan with enough capacity to hold WARNING

all the fluid from the tank under the tank’s drain Be careful when cleaning with steam. Steam
plug. can cause serious burns. Wear protective cloth-
ing, gloves, and eye protection. Never expose
2. Remove the drain plug and drain contents of the your skin to steam.
tank into drain pan.
Use the following procedure to clean the tank with
3. After all fluid has been drained, reinstall drain steam:
plug and remove drain pan from under lift truck.
1. Remove all the parts from the tank. Install the
CLEAN drain plug.
2. Fill the tank 1/4 full with a solution of water and

WARNING sodium bicarbonate or sodium carbonate. Mix
When cleaning the tank, DO NOT use solutions 0.5 kg (1 lb) per 4 liter (1 gal) of water.
that make dangerous gases at normal temper-
atures or when heated. Wear eye and face pro- 3. Mix the solution in the tank using air pressure.
tection. Protect the body from burns. Make sure all the surfaces on the inside of the
60
100 SRM 1120 Fuel and Hydraulic Tanks Repair
tank are flushed with the solution. Drain the 3. Drain the tank. Flush the inside of the tank with
tank. hot (boiling) water. Make sure all the cleaning
compound is removed.
4. Put steam into the tank until the tank does not
have odors and the metal is hot. Steam vapors 4. Make an inspection of the inside of the tank.
must come from all the openings. If the tank is not clean, repeat Step 1 through
Step 3. Make another inspection of the tank.
5. Flush the inside of the tank with boiling water. When making inspections, use a light that is ap-
Make sure all the loose material is removed from proved for locations with flammable vapors.
the inside of the tank.
5. Check the tank for flammable vapors using
6. Make an inspection of the inside of the tank. If it special indicator for gas vapors. If the amount
is not clean, repeat Step 4 and Step 5 and make of flammable vapors is not below the lower
another inspection. When making inspections, flammable limit, repeat the cleaning procedures.
use a light that is approved for locations with
flammable vapors. ADDITIONAL PREPARATIONS FOR
7. Put plugs in all the openings in the tank. Wait REPAIR
15 minutes, then remove the inlet and outlet If nitrogen gas or carbon dioxide gas is available, pre-
plugs. Test a sample of the vapor with a spe- pare the tank for welding using these gases. See the
cial indicator for gas vapors. If the amount of manual Safe Practices for Welding and Cutting Con-
flammable vapors is above the lower flammable tainers That Have Held Combustibles by the Ameri-
limit, repeat the cleaning procedures. can Welding Society, F4.1 - 1999. If these gases are
not available, another method using water can be
Chemical Solution Method of Cleaning used as follows:
WARNING 1. Fill the tank with water to just below the point
where the work will be done. Make sure the
When cleaning the tank, DO NOT use solutions
space above the level of the water has a vent.
atures or when heated. Wear eye and face pro- 2. Use acceptable welding practices to repair the
tection. Protect the body from burns. tank. See the American National Standard
Safety in Welding and Cutting, AWS Z 49.1 -
WARNING 1999.
cause injury to the user or to other personnel. SMALL LEAKS, REPAIR
Make sure that the path of the compressed air
Use the following procedure to repair small leaks:
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the 1. Use steam to clean the area around the leak. Re-
eyes. move all paint and dirt around the leak.
2. Apply Loctite® 290 to the leak. Follow the in-

CAUTION structions of the manufacturer.
Disposal of lubricants, fluids, and chemicals
must meet local environmental regulations. LARGE LEAKS, REPAIR
If the tank cannot be cleaned with steam, use the 1. Use one of the procedures described under Clean
following procedure: to clean and prepare the tank for repairs.
1. Mix a solution of water and trisodium phosphate 2. Contact your dealer for Hyster lift trucks for
or a cleaning compound with an alkaline base. welding instructions.
Follow the instructions given by the manufac-
turer. 3. Use acceptable welding practices to repair the
tank. See the American National Standard
2. Fill the tank with the cleaning solution. Use com- Safety in Welding and Cutting, AWS Z 49.1 -
pressed air to mix the solution in the tank. 1999.
61
Safety Labels 100 SRM 1120
PREPARATIONS FOR USE AFTER REPAIR 2. If there are no leaks coming from the tank, re-
move all the water from the tank.
1. Add more water to the tank so that the water
goes above the point of where the work was done.
Check for any leaks coming from tank.
Safety Labels
If a new label must be installed, use the following
WARNING procedure to install a new label.
Safety labels are installed on the lift truck to
provide information about operation and pos- See Figure 47 for lift truck models
sible hazards. It is important that all safety la- • S30FT, S35FT, S40FTS (E010)
bels are installed on the lift truck and can be • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
read.
DO NOT add to or modify the lift truck. Any • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
change to the lift truck, the tires, or its equip- H40FTS) (F001)
ment can change the lifting capacity. The lift • H2.0-3.5FT (H40-70FT) (L177)
truck must be rated as equipped, and the name-
plate must show the new capacity rating. Con- 1. Make sure the surface is dry and has no oil or
tact your dealer for a new nameplate. grease. DO NOT use solvent on new paint. Clean
the surface of old paint with a cleaning solvent.
WARNING 2. Remove the paper from the back of the label. DO

Cleaning solvents can be flammable and toxic NOT touch the adhesive surface.
cleaning solvents, always follow the recom- 3. Carefully hold the label in the correct position
mendations of the manufacturer. above the surface. The label cannot be moved
after it touches the surface. Put the label on the
NOTE: Not all labels that are used on the lift trucks surface. Make sure that all air is removed from
covered in this manual are shown in Figure 47 and under the label, and the corners and edges are
Figure 48. See the Parts Manual for a complete tight.
listing of all labels used on these lift trucks and their
part numbers.
62
100 SRM 1120 Safety Labels
Figure 47. Safety Label Positions for Lift Truck Models S30FT, S35FT, S40FTS (E010) and
S2.0-3.5FT (S40-70FT, S55FTS) (F187)
63

1. OPERATOR RESTRAINT 17. FUEL TYPE LABEL*
2. OVERHEAD GUARD LABEL 18. OIL FILTER LABEL
3. OPERATOR WARNING 19. COMPANY AND MODEL LOGO
4. NO RIDERS LABEL 20. RADIATOR FAN WARNING
5. PARKING BRAKE WARNING LABEL 21. ANTIFREEZE LABEL
6. MAST WARNING LABEL 22. FLAMMABLE LPG LABEL
7. INSPECTION PLATE 23. LPG TANK NAMEPLATE
8. NOTICE TO USER LABEL 24. BRAKE FLUID WARNING **
9. COMPANY LOGO LABEL 25. LOCKING GAS SPRING CAUTION
10. NAMEPLATE 26. HOOD OPENING CAUTION
11. NAMEPLATE COVER 27. ETHER WARNING (DIESEL ONLY)
12. DRIVE TRAIN PROTECTION LABEL 28. SOOT TRAP WARNING (DIESEL ONLY)
13. MAST WARNING LABEL 29. GRIP NAIL
14. PINCH POINT WARNING 30. STABILITY SYSTEM LABEL***
15. LIFT AND TILT LABEL 31. PARKING BRAKE WARNING LABEL****
16. JOYSTICK LABEL
* U.S. LIFT TRUCK MODELS ONLY.

** THIS LABEL APPLIES TO WET BRAKE SYSTEMS ONLY.
*** THIS LABEL APPLIES ONLY TO U.S. LIFT TRUCK MODELS MANUFACTURED AFTER JANUARY, 2012.
**** THIS LABEL USED ONLY ON LIFT TRUCKS MANUFACTURED AFTER JANUARY, 2012.

1. OPERATOR RESTRAINT 18. OIL FILTER LABEL
2. OVERHEAD GUARD LABEL 19. COMPANY AND MODEL LOGO
3. OPERATOR WARNING 20. RADIATOR FAN WARNING
4. NO RIDERS LABEL 21. ANTIFREEZE LABEL
5. PARKING BRAKE WARNING LABEL 22. FLAMMABLE LPG LABEL
6. MAST WARNING LABEL 23. LPG TANK NAMEPLATE
7. INSPECTION PLATE 24. BRAKE FLUID WARNING **
8. NOTICE TO USER LABEL 25. LOCKING GAS SPRING CAUTION
9. COMPANY LOGO LABEL 26. HOOD OPENING CAUTION
10. NAMEPLATE 27. ETHER WARNING (DIESEL ONLY)
11. NAMEPLATE COVER 28. RADIAL TIRES AND WHEELS WARNING
13. MAST WARNING LABEL 30. SPLIT WHEEL WARNING
14. PINCH POINT WARNING 31. GRIP NAIL
15. LIFT AND TILT LABEL 32. STABILITY SYSTEM LABEL***
16. JOYSTICK LABEL 33. PARKING BRAKE WARNING LABEL****
17. FUEL TYPE LABEL*

64
Figure 48. Safety Label Positions for Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) and H2.0-3.5FT (H40-70FT) (L177)
65
NOTES
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66
TECHNICAL PUBLICATIONS
100 SRM 1120 12/12 (12/11)(8/11)(6/11)(11/10)(2/10)(12/09)(8/09)(8/06)(1/07)(9/06) Printed in U.S.A.

OPERATOR’S CAB
H1.6FT, H1.8FT, 2.0FTS [F001];
H2.0-3.5FT (H40-70FT) [L177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005,
R005]; H6.0FT, H7.0FT (H135FT, H155FT) [H006,
J006, K006]; H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) [A299, B299]
PART NO. 1673866 100 SRM 1290

SAFETY PRECAUTIONS
• 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.
• 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.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
manual:
WARNING
CAUTION
Operator’s Cab Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Cab Replacement ............................................................................................................................................... 2
Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT (H40-70FT) (L177);
and H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) .............................................................................................................................................................. 2
Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT (H40-70FT) (L177);
R005) .............................................................................................................................................................. 16
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) ................................................. 18
Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)................................................................ 24
Door Assemblies ................................................................................................................................................. 25
Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177); and H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005, R005) ........................................................................................................................... 25
Remove....................................................................................................................................................... 25
Disassemble ............................................................................................................................................... 33
Door Cover With Heater Unit .............................................................................................................. 33
Door Cover With Air Conditioner/Heater Unit ................................................................................... 33
Heater Assembly ................................................................................................................................... 33
Air Conditioner and Heater Unit Assembly ........................................................................................ 37
Door Lock Assembly.............................................................................................................................. 38
Windows ................................................................................................................................................ 39
Clean .......................................................................................................................................................... 39
Inspect........................................................................................................................................................ 39
Assemble .................................................................................................................................................... 39
Windows ................................................................................................................................................ 39
Heater Assembly ................................................................................................................................... 39
Door Cover With Air Conditioner and Heater Unit ............................................................................ 40
Install ......................................................................................................................................................... 40
Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
120FT) (N005, P005, R005) ........................................................................................................................... 41
Remove....................................................................................................................................................... 41
Disassemble ............................................................................................................................................... 41
Door Cover............................................................................................................................................. 41
Windows ................................................................................................................................................ 41
Clean .......................................................................................................................................................... 41
Inspect........................................................................................................................................................ 41
Assemble .................................................................................................................................................... 41
Windows ................................................................................................................................................ 41
Door Cover............................................................................................................................................. 42
Install ......................................................................................................................................................... 42
Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) ............... 43

Table of Contents Operator’s Cab

Remove....................................................................................................................................................... 43
Disassemble ............................................................................................................................................... 44
Door Cover............................................................................................................................................. 44
Windows ................................................................................................................................................ 44
Clean .......................................................................................................................................................... 45
Inspect........................................................................................................................................................ 45
Assemble .................................................................................................................................................... 46
Windows ................................................................................................................................................ 46
Door Cover............................................................................................................................................. 46
Install ......................................................................................................................................................... 47
Window Wipers Replacement............................................................................................................................ 47
General ........................................................................................................................................................... 47
Front Wiper Assembly and Motor................................................................................................................. 47
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0-3.5FT (H40-70FT)
(L177) ......................................................................................................................................................... 47
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0-3.5FT (H40-70FT) (L177) ........ 47
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006),
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) ............................................. 49
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005, R005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), and
Rear Wiper Assembly and Motor .................................................................................................................. 54
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) ................................................................. 54
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) ................................................................... 54
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)................................................................... 56
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)..................................................................... 56
110, 120FT) (N005, P005, R005)............................................................................................................... 59
120FT) (N005, P005, R005)....................................................................................................................... 59
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) ........................................................... 61
Install, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) and
Window Replacement ........................................................................................................................................ 63
General ........................................................................................................................................................... 63
Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
120FT) (N005, P005, R005) ........................................................................................................................... 63
Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
120FT) (N005, P005, R005) ........................................................................................................................... 64
Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006) and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) ............................... 64
Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) .......................................... 66
Heater Replacement .......................................................................................................................................... 66
ii

Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) and
Heater and Air Conditioner Assembly.............................................................................................................. 70
Air Conditioner Condenser Unit................................................................................................................... 70
Remove....................................................................................................................................................... 70
Install ......................................................................................................................................................... 71
Air Conditioner Receiver/Drier Unit ............................................................................................................ 72
Remove....................................................................................................................................................... 72
Install ......................................................................................................................................................... 72
Air Conditioner Compressor ......................................................................................................................... 73
Light Replacement............................................................................................................................................. 74
Work Lights (Front and Rear)....................................................................................................................... 74
Remove....................................................................................................................................................... 74
Install ......................................................................................................................................................... 74
Strobe Light ................................................................................................................................................... 75
Remove....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Turn, Stop, Tail, and Backup Light .............................................................................................................. 75
Remove....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Front Marker/Turn Signal Lights................................................................................................................. 77
Remove....................................................................................................................................................... 77
Install ......................................................................................................................................................... 78
Display Switches ................................................................................................................................................ 78
Electrical Schematics......................................................................................................................................... 78
Optional Equipment .......................................................................................................................................... 81
Heavy Duty Pre-Cleaner ............................................................................................................................... 81
Remove....................................................................................................................................................... 81
Clean .......................................................................................................................................................... 81
Inspect........................................................................................................................................................ 81
Install ......................................................................................................................................................... 81
Fan.................................................................................................................................................................. 84
Remove....................................................................................................................................................... 84
Install ......................................................................................................................................................... 84
Mirror ............................................................................................................................................................. 84
Remove....................................................................................................................................................... 84
Install ......................................................................................................................................................... 84
Label Replacement............................................................................................................................................. 86
H1.6FT, H1.8FT, 2.0FTS [F001];

H2.0-3.5FT (H40-70FT) [L177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) [N005, P005, R005];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
100 SRM 1290 General
General
The overhead guard is an integral part of the opera- cab. The operator cab is a separate unit and can
tor cab. The operator cab is installed on a platform be removed as a complete unit from the module and
above the main frame members. Step plates on both frame of the lift truck. See Figure 1.
sides of the lift truck provide access to the operator
Figure 1. Operator Cab
1
Cab Replacement 100 SRM 1290
Cab Replacement
REMOVE, FOR LIFT TRUCK MODELS boiling coolant can cause burns. Wait 30 min-
H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT utes for the engine to cool. Do a touch test by
(H40-70FT) (L177); AND H4.0FT5/FT6, touching the radiator with your hand. If the
radiator is still hot to the touch, wait another
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 30 minutes before attempting to remove, check,
100, 110, 120FT) (N005, P005, R005) or fix any part of the cooling system.
NOTE: The EZXchange bracket used on these trucks NOTE: Removing the radiator cap will help depres-
to mount the LPG tank onto the counterweight come surize the cooling system.
in two styles. One style of bracket swings out to the
side of the truck and the other swings out to the side 4. Remove radiator cover to access radiator cap. Re-
and drops down. move radiator cap. See Figure 5.
NOTE: On lift trucks equipped with LPG, make sure

to release the EZXchange bracket before opening the CAUTION
hood. DO NOT allow any fluid to drain when discon-
necting the heater hose from the engine. The
1. For lift truck models H1.6FT, H1.8FT, 2.0FTS method will help when purging the system dur-
(F001), tilt the steering column to the UP posi- ing installation.
tion, slide seat assembly forward, open rear door,
and open hood to disconnect battery. See Fig- 5. Disconnect and cap the heater hoses from engine.
ure 2. See Figure 6.
2. Tilt the steering column to the UP position, slide

seat assembly forward, open rear sliding window,
and open the hood to disconnect battery.

• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
3. Disconnect the air filter hose from the rear left

corner leg of the cab frame. See Figure 4.
WARNING
DO NOT disconnect the heater hoses from the
engine when the engine is hot or when the cool-
ing system is under pressure, to do so could
cause serious injury.
WARNING 1. LATCH 3. REAR DOOR

DO NOT remove the radiator cap from the ra- 2. HINGE
diator when the engine is hot. When the radia-
tor is hot and the cap is removed, the pressure Figure 2. Rear Door and Latch for Lift Truck
is released from the system and the steam and Models H1.6FT, H1.8FT, 2.0FTS (F001)
2
100 SRM 1290 Cab Replacement
A. LIFT TRUCKS MODELS H2.0-3.5FT (H40-70FT) (L177) AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005) WITHOUT AIR CONDITIONING.
B. LIFT TRUCKS MODELS H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005,
R005) WITH AIR CONDITIONING.
1. REAR BOTTOM WINDOW 3. AC HOSE
2. RELEASE LATCH
Figure 3. Rear Bottom Window for Lift Trucks Models H2.0-3.5FT (H40-70FT) (L177) and
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
Legend for Figure 4
1. CAPSCREW
2. AIR FILTER HOSE
Figure 4. Air Filter Hose Removal
3
Figure 5. Radiator Cover and Cap Location
4
Legend for Figure 5

A. H1.6FT, H1.8FT, 2.0FTS (F001) C. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
B. H2.0-3.5FT (H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
1. RADIATOR COVER 2. RADIATOR CAP
NOTE: Step 6 is for lift truck models H4.0FT5/FT6; 9. Disconnect heater hose quick disconnect fittings.
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (P005, R005) with a Cummins QSB 3.3L or a a. For Lift truck models H1.6FT, H1.8FT,
Kubota diesel engine. 2.0FTS (F001), open right side door and
push the buttons on quick disconnect fit-
6. If lift truck cab is equipped with an air condi- tings to disconnect the heater hoses from the
tioner/heater unit, disconnect the AC refrigerant heater assembly hoses (see Figure 6). Dis-
hoses from the refrigerant compressor. connect the heater wire harness connection.
See Figure 11.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- b. For lift truck models H2.0-3.5FT (H40-70FT)
5.5FT (H80, 90, 100, 110, 120FT) (P005) (L177), open right side door and remove radi-
ator cover to access the quick disconnect fit-
See Figure 8 for lift truck models tings. Push the buttons on the quick discon-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- nect fittings to disconnect the heater hoses
5.5FT (H80, 90, 100, 110, 120FT) (R005) from heater assembly (see Figure 6). Discon-
nect the heater wire harness connection. See
NOTE: Removing the door assemblies requires two
Figure 11.
people.
c. For lift truck models H4.0FT5/FT6;
7. Open left side door, remove lock nut, and discon-
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
nect gas spring from the cab mounting bracket.
100, 110, 120FT) (N005, P005, R005), open
See Figure 9.
right side door and located on inner rear
8. Lift left side door up and over hinge pin and set cover there are two port holes (see Figure 6).
aside. See Figure 10. Push the buttons on the quick disconnect
fittings to disconnect the heater hoses from
heater assembly and disconnect the heater
WARNING wire harness connection. See Figure 11.
quick disconnect fittings (inside operator cab)
or engine when the engine is hot or under pres-
sure, to do so could cause serious injury.
5
NOTE: MAJOR COMPONENTS OF THE CAB HAVE BEEN REMOVED FOR CLARITY.
A. LIFT TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS (F001)
B. LIFT TRUCK MODELS H2.0-3.5FT (H40-70FT) (L177)
C. LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005)
D. LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
1. QUICK DISCONNECT FITTING 4. RIGHT SIDE DOOR ASSEMBLY
2. INNER REAR COVER 5. HEATER HOSES
3. RADIATOR COVER
Figure 6. Heater Hose Connection
6
1. HOSE FITTING 3. AC/HEATER UNIT
2. REFRIGERANT COMPRESSOR 4. ENGINE
Figure 7. AC Refrigerant Hose Connections, Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005) with Cummins QSB 3.3L Engine
7
NOTE: MAJOR COMPONENTS OF THE CAB HAVE BEEN REMOVED FOR CLARITY. KUBOTA 3.8L DIESEL
ENGINE SHOWN, 3.6L DIESEL ENGINE SIMILAR.
Figure 8. AC Refrigerant Hose Connection, Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) with Kubota Diesel Engine
Legend for Figure 9
NOTE: RIGHT SIDE DOOR SHOWN.

1. GAS SPRING
2. CAB MOUNTING BRACKET
3. LOCK NUT
Figure 9. Gas Spring Mounting Removal
8
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN

REMOVED FOR CLARITY.
1. HEATER WIRE HARNESS CONNECTOR
2. REAR GRAB HANDLE HORN BUTTON
CONNECTOR (TO RIGHT-HAND CHASSIS
HARNESS)
10. For lift truck models H4.0FT5/FT6; H4.5FTS5,

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(P005, R005) with a Cummins QSB 3.3L or Kub-
ota diesel engine, if lift truck cab is equipped with
an air conditioner/heater unit, disconnect the AC
hoses.
a. Remove six fasteners and remove rear cover.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
NOTE: RIGHT SIDE DOOR HINGE SHOWN. See Figure 13 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
1. HINGE PIN 2. DOOR HINGE 5.5FT (H80, 90, 100, 110, 120FT) (R005)
Figure 10. Door Removal b. Disconnect the air conditioner hoses at the
bulkhead bracket and at the receiver/drier.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
c. Disconnect the air conditioner wire harness.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
Figure 11. Heater Wire Harness and Rear Grab

Handle Horn Button Connectors
9
A. FRONT VIEW B. TOP VIEW
1. HOSE WRAP 5. BULKHEAD BRACKET
2. FASTENERS 6. RECEIVER/DRIER
3. REAR COVER 7. FITTINGS
4. AIR CONDITIONER HOSES 8. AIR CONDITIONER WIRE HARNESS
Figure 12. AC System Arrangement and Hose Connections, Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005) With a Cummins QSB 3.3L Diesel
Engine
10
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) With a Kubota Diesel Engine
11
Figure 14. Dash Installation
12
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.

A. H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001) AND H2.0-3.5FT (H40-70FT) (L177)
B. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
1. CAPSCREWS 5. COWL PANEL
2. FRONT WIPER MOTOR COVER 6. FRONT OPERATOR CAB LEGS
3. DASH ASSEMBLY 7. LOCK NUT
4. KICK PANEL 8. FLANGE BOLT
11. Remove lock nut and disconnect gas spring from right rear corner leg of the cab frame. See Fig-
cab mounting bracket. See Figure 9. ure 11.
12. Lift door up and over hinge pin and set aside. See 22. Disconnect the light harness connector from the
Figure 10. Vehicle Systems Manager (VSM) and right-hand
chassis harness connector. See Figure 16.
NOTE: Wiper motor cover must be removed before
the dash assembly can be removed. 23. Remove rear panels, front panels, and fender cov-
ers to access the cab mounting capscrews and
13. Unclip and remove front wiper motor cover. See flange nuts. See Figure 17.
Figure 14 for lift truck models
• H1.6FT, H1.8FT, 2.0FTS (F001) 24. Remove front and rear cab capscrews and flange
• H2.0-3.5FT (H40-70FT) (L177) nuts from lift truck frame. See Figure 18.

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) WARNING
(N005, P005), remove two lock nuts from front Make sure that the lifting device has a mini-
wiper motor cover. Remove front wiper motor mum capacity to lift 500 kg (1100 lb).
cover. See Figure 14.
25. Connect a lifting device to a spreader bar or lift
15. For lift truck models H4.0FT5/FT6; H4.5FTS5, strap, that is through the door openings at the
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) top of the operator’s cab (under the overhead
(R005), remove three lock nuts from front wiper guard structure). Place material that will be a
motor cover. Remove front wiper motor cover. cushion at the top of the door opening to prevent
damage. Operate the lifting device just enough
16. Remove five capscrews from top of dash assembly to correctly position the spreader bar or lifting
and cowl panel. strap on the operator’s cab. See Figure 19.
17. Remove two flange bolts securing the cowl panel
to the front operator cab legs. CAUTION
Lift the operator cab carefully. Check that all
18. Unclip the dash assembly from kick panel. Re- electrical wires and attachments are discon-
move dash assembly. nected and are not damaged.
19. Remove kick panel from seal plate assembly. See 26. Carefully lift the operator cab away from the lift
Figure 15. truck. Set the operator cab in a storage area
and place blocks under the operator cab to make
20. Remove capscrews and seal plate assembly from
it stable and prevent damage to parts still at-
lift truck frame.
tached.
21. Disconnect rear grab handle horn button connec-
tor from right-hand chassis harness, located in
13
Figure 15. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
14
NOTE: CAB REMOVED FOR CLARITY.

A. H1.6FT, H1.8FT, 2.0FTS (F001) AND H2.0-3.5FT B. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
1. CAPSCREWS 5. FLOOR PLATE (LEFT SIDE)
2. KICK PANEL 6. FLOOR PLATE (RIGHT SIDE)
3. SEAL PLATE ASSEMBLY 7. FLOOR PLATE
4. SEAL
NOTE: LEFT SIDE DOOR REMOVED FOR CLARITY.

NOTE: KICK PANEL REMOVED FOR CLARITY. 1. REAR PANEL (LPG)
1. VSM 2. REAR PANEL (GAS AND DIESEL)
2. LIGHT HARNESS CONNECTOR (TO VSM) 3. FRONT PANEL
3. HARNESS CONNECTOR (TO RIGHT-HAND 4. FENDER COVER
CHASSIS HARNESS) 5. SCREWS
6. CAPSCREWS
Figure 16. Light Harness Connection to Vehicle
Figure 17. Front and Rear Panels and Fender
System Manager (VSM)
Cover Removal
15
Figure 19. Lift Strap Connection
INSTALL, FOR LIFT TRUCK MODELS

H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177); AND H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005)
strap, that is through the door openings at the
top of the operator’s cab (under the overhead
guard structure). Place material that will be a
NOTE: ILLUSTRATION FOR REFERENCE PUR- cushion at the top of the door opening to prevent
POSES ONLY. ACTUAL LIFT TRUCK MAY BE damage. Operate the lifting device just enough
SLIGHTLY DIFFERENT. to correctly position the spreader bar or lifting
strap on the operator’s cab. See Figure 19.
A. FRONT VIEW B. REAR VIEW
1. CAPSCREWS 2. FLANGE NUTS 2. Carefully lift the operator cab onto the lift truck
frame making sure that the front and rear leg
Figure 18. Front and Rear Cab Mounting mounting holes are aligned with the frame
mounting holes.
16
3. Install the capscrews and flange nuts to the rear 18. Connect the heater hoses to the heater assembly
operator cab legs. Tighten capscrews to 66 N•m and connect the heater wire harness connection.
(49 lbf ft). See Figure 18. See Figure 6 and Figure 11.
4. Install the capscrews and lock nuts to the front 19. For lift truck models H4.0FT5/FT6; H4.5FTS5,
operator’s cab legs. Tighten capscrews to 66 N•m H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(49 lbf ft). (P005) with a Cummins QSB 3.3L engine and
equipped with an air conditioner/heater unit,
5. Install the fender covers, front panel, and rear connect the AC hoses. Tighten the AC hose at
panels to the frame. See Figure 17. Tighten cap- the bulkhead bracket to 29 to 37 N•m (21 to
screws to 10.8 N•m (7.96 lbf ft). 27 lbf ft) and the AC hose to the receiver/drier to
15 to 18 N•m (133 to 159 lbf in). See Figure 12.
6. Connect light harness connector to the VSM (Ve-
hicle Systems Manager) and right-hand chassis 20. For lift truck models H4.0FT5/FT6; H4.5FTS5,
harness. See Figure 16. H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005) with a Kubota engine and equipped with
7. Connect the right-hand chassis harness to rear
an air conditioner/heater unit, connect the AC
grab handle horn button connector. See Fig-
hoses. Tighten the AC hose at the bulkhead
ure 11.
bracket to 29 to 37 N•m (21 to 27 lbf ft) and the
8. Install seal plate assembly to the lift truck frame AC hose to the receiver/drier to 20 to 27 N•m
and tighten capscrews. See Figure 15. (177 to 239 lbf in). See Figure 13.
9. Install floor plate and floor mat. Tighten cap- 21. Install left side door onto cab by lifting door up
screws to 10.8 N•m (7.96 lbf ft). and over the top and bottom hinge pins. See Fig-
ure 10.
10. Install kick panel onto seal plate assembly.
22. Connect gas spring and lock nut to cab mounting
11. Install two flange bolts securing the cowl to the bracket. See Figure 9.
front operator cab legs. See Figure 14.
23. Uncap and connect heater hoses at the engine.
12. Install dash assembly onto kick panel and install See Figure 6.
five capscrews to secure dash assembly to cowl
panel. 24. For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
13. Install and clip front wiper motor cover for lift (P005, R005) with a Cummins QSB 3.3L or a
truck models Kubota diesel engine and equipped with an air
• H1.6FT, H1.8FT, 2.0FTS (F001) conditioner/heater unit, connect the AC refriger-
• H2.0-3.5FT (H40-70FT) (L177) ant hoses to the refrigerant compressor.
14. Install front wiper motor cover and tighten two See Figure 7 for lift truck models
lock nuts for lift truck models H4.0FT5/FT6, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 5.5FT (H80, 90, 100, 110, 120FT) (P005)
110, 120FT) (N005, P005).
See Figure 8 for lift models
15. Install front wiper motor cover and tighten three • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
lock nuts for lift truck models H4.0FT5/FT6, 5.5FT (H80, 90, 100, 110, 120FT) (R005)
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (R005). 25. Check coolant level, fill if necessary.
16. Install right side door onto cab by lifting door 26. Install radiator cap and radiator cover. See Fig-
up and over the top and bottom hinge pins. See ure 5.
Figure 10.
27. Connect the air filter hose onto the rear left cor-
17. Connect gas spring and lock nut to cab mounting ner leg of the cab frame. Tighten capscrews to
bracket. See Figure 9. 66 N•m (49 lbf ft). See Figure 4.
17
28. Connect battery and close hood. 5. Remove front floor mat and floor plate. See Fig-
ure 22.
29. Start engine and turn on the heater to the ON po-
sition, run engine approximately 1 to 2 minutes 6. Disconnect battery.
or until heater supply hose is fully purged.
7. Remove two screws holding the right side rear
cover to the rear overhead guard leg. See Fig-
WARNING ure 23.
Contact an authorized technician or company
to charge the AC system. DO NOT charge the 8. Remove two screws holding the right side front
AC system if you don’t have the experience or cover to frame. Remove right side rear cover.
authorization. To do so can result in serious
injury. 9. Remove two screws securing the right side front
cover to the front overhead guard leg. Remove
30. On lift trucks equipped with an air conditioner/ right side front cover.
heater unit, start engine and turn on the heater
to the ON position, run engine approximately 1 10. Repeat Step 7 through Step 9 to remove the left
to 2 minutes or until heater supply hose is fully side covers.
purged.
NOTE: The EZXchange bracket used on these trucks

to mount the LPG tank onto the counterweight comes
side of the truck and the other swings out to the side
and drops down.
31. Lift trucks equipped with a LPG engine, swing

EZXchange bracket back to its original and
locked position.
REMOVE, FOR LIFT TRUCK MODELS

H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) AND H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
NOTE: Removing the door assemblies from operators
cab requires two people.
1. Open right side door and remove hair pin from

rod pin. See Figure 20.
NOTE: RIGHT SIDE DOOR SHOWN
2. Remove rod pin and spacers from link. 1. ROD PIN 5. GAS SPRING
2. SPACERS 6. LOCK NUT
3. Remove right side door from cab frame by lifting 3. HAIR PIN 7. WASHER
door up and over the hinge pin and set door aside. 4. DOOR ASSEMBLY 8. LINK
See Figure 21.
Figure 20. Door Link Removal
4. Repeat Step 1 through Step 3 for the removal of
left side door.
18
14. Unclip the dash assembly from kick panel. Re-

move dash assembly.
15. Remove kick panel from seal plate assembly. See

Figure 22.
16. Remove two flange bolts securing cowl panel to

front operator cab legs.
See Figure 24 for early model H6.0FT, H7.0FT

(H135FT, H155FT) (H006, J006) lift trucks.
See Figure 25 for later model lift trucks

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
17. Disconnect three harness connectors from right

side front operator cab leg that are connected to
the Vehicle Systems Manager (VSM) and right
hand chassis harness connectors. See Figure 26.
NOTE: RIGHT SIDE DOOR HINGE SHOWN 18. Remove four flange bolts securing right and left
1. HINGE PIN 2. DOOR HINGE side of the front operator cab legs to module. See
Figure 27.
Figure 21. Door Removal
19. From inside the cab, remove the six flange bolts
NOTE: Perform Step 11 for early model H6.0FT, securing right and left side rear operator cab legs
H7.0FT (H135FT, H155FT) (H006, J006). to module.
11. Remove two lock nuts from front wiper motor 20. Open right side hood door and remove both wiper
cover. Remove front wiper motor cover. See Fig- motor washer tubes from t-fitting and disconnect
ure 24. washer pump harness connector from washer
fluid reservoir.
NOTE: Perform Step 12 on later model lift trucks
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, 21. Disconnect rear grab handle horn button connec-
K006) tor from right hand chassis harness.
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299) 22. Remove the bottom flange bolt securing right
side rear operator cab leg to module.
12. Remove three lock nuts from front wiper motor
cover. Remove front wiper motor cover. See Fig- 23. Open left side hood door and remove the bottom
ure 25. flange bolt securing rear left side operator cab leg
to module.
13. Remove five capscrews from top of dash assembly
and cowl panel.
19
1. DASH ASSEMBLY 6. FLANGE BOLT

2. KICK PANEL 7. REAR FLOOR PLATE
3. SEAL PLATE ASSEMBLY 8. FRONT FLOOR PLATE
4. FRONT FLOOR MAT 9. MODULE
5. REAR FLOOR MAT
20
NOTE: RIGHT SIDE VIEW SHOWN.

1. RIGHT SIDE REAR COVER
2. RIGHT SIDE FRONT COVER
3. SCREWS
4. REAR FLOOR PLATE 1. CAPSCREWS
5. FRONT FLOOR PLATE 2. FRONT WIPER MOTOR COVER
6. CLIP NUTS 3. DASH ASSEMBLY
4. KICK PANEL
Figure 23. Side Cover Removal 5. COWL PANEL
6. FRONT OPERATORS CAB LEGS
7. LOCK NUT
8. FLANGE BOLT
Figure 24. Dash Removal, Early Model H6.0FT,

H7.0FT (H135FT, H155FT) (H006, J006) Lift
Trucks
21

2. FRONT WIPER MOTOR COVER 6. FRONT OPERATORS CAB LEGS
Figure 25. Dash Removal, Later Model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) Lift
Trucks and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) Lift Truck Models
22
NOTE: KICK PANEL REMOVED FOR CLARITY.

1. VSM
2. HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT HAND
CHASSIS HARNESS)

NOTE: RIGHT SIDE SHOWN. WIPER COVER AND

ASSEMBLY FOR EARLY MODEL H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006) LIFT TRUCKS
SHOWN. THE FRONT AND REAR CAB MOUNT-
ING IS THE SAME FOR LATER MODEL H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006, K006) LIFT
TRUCKS AND ON H8.0FT, H8.0FT9, H9.0FT (H170FT, Figure 27. Front and Rear Cab Mounting
H175FT36, H190FT) (A299, B299) LIFT TRUCK MOD-
ELS.
A. REAR VIEW B. FRONT VIEW
1. FLANGE BOLTS
2. REAR OPERATOR CAB LEG
3. REAR LIGHT HARNESS
4. WASHER PUMP HARNESS CONNECTOR
5. WASHER FLUID RESERVOIR
6. MODULE
7. COWL PANEL
23

WARNING
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Make sure that the lifting device has a mini-
mum capacity to lift 500 kg (1100 lb).
J006, K006), H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
strap, that is through the door openings at the 1. Connect a lifting device to a spreader bar or lift
top of the operator’s cab (under the overhead strap, that is through the door openings at the
guard structure). Place material that will be a top of the operator’s cab (under the overhead
cushion at the top of the door opening to prevent guard structure). Place material that will be a
damage. Operate the lifting device just enough cushion at the top of the door opening to prevent
to correctly position the spreader bar or lifting damage. Operate the lifting device just enough
strap on the operator’s cab. See Figure 28. to correctly position the spreader bar or lifting
CAUTION 2. Carefully lift the operator cab onto the lift truck
Lift the operator cab carefully. Check that all frame making sure that the front and rear leg
electrical wires and attachments are discon- mounting holes are aligned with the module
nected correctly and are not damaged. mounting holes.
25. Carefully lift the operator cab up and away from 3. Open left side hood door and install the bottom
the lift truck. Set the operator cab in a storage flange bolt to secure rear left side operator cab
area and place blocks under the operator cab to leg to module. Tighten flange bolt to 165 N•m
make it stable and prevent damage to the wire (122 lbf ft). See Figure 27.
harness and parts still attached.
4. Open right side hood door and install bottom
flange bolt to secure rear right side operator cab
leg to module. Tighten flange bolt to 165 N•m
(122 lbf ft).
5. Connect rear grab handle horn button harness

connector to right hand chassis harness.
6. Connect both wiper motor washer tubes to t-fit-

ting and connect washer pump harness connector
to washer fluid reservoir.
7. Install two flange bolts to secure right and left

side front operator cab legs to module. Tighten
flange bolt to 165 N•m (122 lbf ft).
8. From inside the cab, install the four remaining

flange bolts to right and left side rear opera-
tor cab legs to module. Tighten flange bolt to
165 N•m (122 lbf ft).
9. Connect the three harness connectors on the

front right side operator cab leg to Vehicle Sys-
tem Manager (VSM) and right hand chassis
harness. See Figure 26.
10. Install two flange bolts to secure cowl panel to


24
100 SRM 1290 Door Assemblies
See Figure 25 for later model lift trucks 17. Install right side rear cover to right side front
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, cover and install and tighten two screws to
J006, K006) frame.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) 18. Align right side rear cover to rear overhead guard
leg and install and tighten two screws to rear
11. Install kick panel to seal plate assembly. See Fig- overhead guard leg and install and tighten two
ure 22. screws to rear overhead guard leg.
12. Install and clip dash assembly onto kick panel. 19. Repeat Step 16 through Step 18 to install left side
See Figure 24. covers.
13. Install five capscrews to top of dash assembly 20. Connect battery.
to secure dash assembly onto the cowl panel.
Tighten capscrew to 3.5 N•m (30 lbf in). 21. Install front floor plate and floor mat. See Fig-
ure 22.
NOTE: Perform Step 14 on early model H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006) lift trucks. NOTE: Installing the door assemblies onto operator
14. Install front wiper motor cover using two lock
nuts. See Figure 24. 22. Lift door up and over the top and bottom hinge
pins. See Figure 21.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, 23. Align link and spacers into guide and install rod
K006) pin. See Figure 20.
24. Install hair pin into rod pin.
H190FT) (A299, B299)
25. Repeat steps Step 22 through Step 24 for instal-
15. Install front wiper motor cover using three lock
lation of left side door.
nuts. See Figure 25.
16. Install right side front cover to front overhead

guard leg using two screws. See Figure 23.
Door Assemblies
RIGHT SIDE DOOR ASSEMBLY, LIFT is removed, the pressure is released from cool-
TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS ing system. If cooling system is hot, the steam
(F001); H2.0-3.5FT (H40-70FT) (L177); and boiling coolant can cause burns.
AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, Wait 30 minutes for the engine to cool. Do a
H5.0-5.5FT (H80, 90, 100, 110, 120FT) touch test by touching the radiator with your
(N005, P005, R005) hand. If the radiator is still hot to the touch,
wait another 30 minutes before attempting to
Remove remove the radiator cap.
NOTE: Removing the radiator cap will help depres-

WARNING surize the cooling system.
DO NOT remove the radiator cap from the radi-
ator when the engine is hot. When radiator cap 1. Remove radiator cover to access radiator cap. Re-
move radiator cap. See Figure 29.
25
Door Assemblies 100 SRM 1290
26

B. H2.0-3.5FT (H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
WARNING H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
DO NOT disconnect the heater hoses from the (P005, R005) with a Cummins QSB 3.3L or Kub-
quick disconnect fittings (inside operator cab) ota diesel engine, if lift truck cab is equipped with
or engine when the engine is hot or under pres- an air conditioner/heater unit, disconnect the AC
sure. Serious injury can occur. hoses.
NOTE: Removing the right side door assembly re- a. Remove six fasteners and remove rear cover.
quires two people.
2. Disconnect heater hose quick disconnect fittings. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
See Figure 30. 5.5FT (H80, 90, 100, 110, 120FT) (P005)
a. For Lift truck models H1.6FT, H1.8FT, See Figure 33 for lift truck models
2.0FTS (F001), open right side door and • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
push the buttons on quick disconnect fit- 5.5FT (H80, 90, 100, 110, 120FT) (R005)
tings to disconnect the heater hoses from the
heater assembly hoses. See Figure 30. Dis- b. Disconnect the air conditioner hoses at the
connect the heater wire harness connection. bulkhead bracket and at the receiver/drier.
See Figure 31.
b. For lift truck models H2.0-3.5FT (H40-70FT) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
(L177), open right side door and remove radi- 5.5FT (H80, 90, 100, 110, 120FT) (P005)
tings. Push the buttons on the quick discon- See Figure 33 for lift truck models
nect fittings to disconnect the heater hoses • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
from the heater assembly hoses. See Fig- 5.5FT (H80, 90, 100, 110, 120FT) (R005)
ure 30. Disconnect the heater wire harness
connection. See Figure 31.
c. For lift truck models H4.0FT5/FT6,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80,
5.5FT (H80, 90, 100, 110, 120FT) (P005)
90, 100, 110, 120FT) (N005, P005, R005)
equipped with a heater unit, open right side See Figure 33 for lift truck models
door and locate the two port holes on inner • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
rear cover. Push the buttons on the quick 5.5FT (H80, 90, 100, 110, 120FT) (R005)
disconnect fittings to disconnect the heater
hoses from heater assembly. See Figure 30. 4. Disconnect the gas spring. See Figure 34.
Disconnect the heater wire harness connec-
tion. See Figure 31. 5. Remove right side door from cab frame by lifting
door up and over hinge pin. See Figure 35.
27
A. H1.6FT, H1.8FT, 2.0FTS (F001)
B. H2.0-3.5FT (H40-70FT) (L177)
C. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
D. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
3. RADIATOR COVER
28

HARNESS)

29
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)
30
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
31
NOTE: RIGHT SIDE DOOR SHOWN. NOTE: RIGHT SIDE DOOR HINGE SHOWN.
1. GAS SPRING 1. HINGE PIN 2. DOOR HINGE
2. MOUNTING BRACKET
3. LOCK NUT Figure 35. Door Removal
Figure 34. Gas Spring Mounting Installation
32
Disassemble See Figure 33 for lift truck models

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
Door Cover With Heater Unit 5.5FT (H80, 90, 100, 110, 120FT) (R005)
1. Remove the four screws and washers that attach 3. Remove the fan and heater/AC knobs from knob
the handle to the door cover. Remove the handle plate. Remove four screws that fasten the knob
and two handle plates. See Figure 36. plate to heater valve and switch plate. Remove
knob plate and heater valve from door cover. See
2. Remove the fan and heater knobs from knob
Figure 37.
plate. Remove four screws that fasten the knob
plate to heater valve and switch plate. Remove 4. Remove the two fasteners from top of door cover.
knob plate from door cover.
5. Remove four capscrews that fasten the AC rocker
3. Remove the two fasteners from top of door cover. switch plate to door cover. Remove AC rocker
switch plate from door cover. See Figure 37.
4. Remove the five plugs along the sides and front
of the door cover. Remove the two capscrews and 6. Remove the five plugs, washers, and star nuts
washers from the bottom of door cover. Remove along the sides and front of the door cover. Re-
door cover from door frame. move the two capscrews and washers from the
bottom of door cover. Remove door cover from
5. Remove the prefilter, located on the bottom of
door frame.
door frame.
Door Cover With Air Conditioner/Heater Unit
door frame. See Figure 37.
NOTE: Only lift truck models H4.0FT5/FT6;
Heater Assembly
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (P005, R005) with a Cummins QSB NOTE: The heater assembly is non-repairable, re-
3.3L or Kubota diesel engine may be equipped with place as a complete unit. See the Parts Manual.
an air conditioner/heater unit.
1. Remove lock nut from heater valve and switch
NOTE: The procedures in this section remove the air plate. See Figure 38.
conditioner/heater unit assembly door cover from the
right side door. For the procedures to remove or re- 2. Disconnect heater switch connector from heater
place the other components of the air conditioner/ switch.
heater unit assembly, go to Heater and Air Condi-
tioner Assembly section. 3. Remove two screws from heater valve and switch
plate and remove plate.
1. Remove the four screws and washers that attach
the handle to the door cover. Remove the handle. 4. Disconnect supply hose at heater valve and dis-
See Figure 37. connect return hose from the heater coil.
2. Remove the hose wrap from the AC hoses. 5. Remove two nuts and washers from heater as-
sembly bracket. Remove heater assembly and
See Figure 32 for lift truck models bracket from door frame.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
33
Figure 36. Right Side Door Cover Removal, Heater Unit
34

1. PLUG 9. WASHER
2. FASTENER 10. HEATER/FAN LOUVER
3. GAS SPRING 11. CAPSCREW
4. FAN AND HEATER KNOBS 12. DOOR COVER
5. SCREW 13. PRE-FILTER
6. KNOB PLATE 14. HEATER VALVE AND SWITCH PLATE
7. HANDLE 15. STAR NUT
8. HANDLE PLATES
1. CAPSCREW 8. HEATER, FAN, AND AC LOUVER

2. AC ROCKER SWITCH PLATE 9. PRE-FILTER
3. AC ROCKER SWITCH 10. DOOR COVER
4. HEATER/AC KNOBS 11. WASHER
5. HANDLE 12. PLUG
6. HEATER VALVE AND SWITCH PLATE 13. WASHER
7. FASTENER 14. STAR NUT
Figure 37. Right Side Door Cover Removal, Air Conditioner/Heater Unit
35
1. LOCK NUT 7. HEATER VALVE AND SWITCH PLATE

2. NUT 8. HEATER VALVE
3. WASHER 9. HEATER SWITCH
4. HEATER ASSEMBLY BRACKET 10. RETURN HOSE
5. SUPPLY HOSE 11. SCREWS
6. HEATER ASSEMBLY 12. HEATER COIL
Figure 38. Heater Assembly Removal
36
Air Conditioner and Heater Unit Assembly 2. Disconnect heater switch connector from heater
switch.
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 3. Remove two screws from heater valve and switch
110, 120FT) (P005, R005) with a Cummins QSB plate and remove plate.
3.3L or Kubota diesel engine may be equipped with
an air conditioner/heater unit. 4. Disconnect the AC rocker switch. See Figure 39.
NOTE: The procedures in this section remove the air 5. Disconnect supply hose at heater valve and dis-
conditioner/heater unit assembly from the right side connect return hose from the heater coil.
door. For the procedures to remove or replace the
6. Disconnect the AC hoses from the AC expansion
other components of the air conditioner/heater unit
valve. See Figure 39.
assembly, go to Heater and Air Conditioner Assembly
section. 7. Remove four nuts and capscrews from AC/heater
assembly mounting bracket. Remove AC/heater
NOTE: The air conditioner and heater assembly is
assembly and mounting bracket from door frame.
non-repairable, replace as a complete unit. See the
Parts Manual.

plate. See Figure 39.
1. HEATER RETURN HOSE 8. AC/HEATER UNIT

2. HEATER SUPPLY HOSE 9. HEATER VALVE
3. AC HOSES 10. AC ROCKER SWITCH
4. HEATER VALVE AND SWITCH PLATE 11. HEATER SWITCH
5. LOCKNUT 12. HEATER COIL
6. MOUNTING BRACKET 13. AC EXPANSION VALVE
7. CAPSCREW
Figure 39. Air Conditioner/Heater Unit Assembly Removal, Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005, R005)
37
Door Lock Assembly 5. Remove two nuts and capscrews from door lock
assembly. Remove door lock assembly from door
1. Remove inside lever handle cover. See Figure 40. frame.
2. Place the inside lever handle in the closed posi- 6. Remove the screw and washer from the release
tion. Remove the lock nut from the release bar at lever and release lever from outside door handle
the inside lever handle. Pull inside lever handle assembly. See Figure 40 and Figure 41.
to open position. Remove release bar from inside
lever handle. 7. Remove four capscrews that fasten the outside
door handle to door. Remove outside door handle
3. Remove two capscrews and inside lever handle from door.
and mounting plate.
8. Remove seal and grip from outside handle assem-
4. Remove lock nut from release bar and release bar bly. Discard seal. See Figure 41.
from door lock assembly.
A. LEVER IN CLOSED POSITION B. LEVER IN OPEN POSITION

1. INSIDE LEVER HANDLE 7. DOOR LOCK ASSEMBLY
2. CAPSCREWS 8. RELEASE LEVER
3. INSIDE LEVER HANDLE COVER 9. NUT
4. CAPSCREW (OUTSIDE HANDLE) 10. MOUNTING PLATE
5. LOCK NUT 11. SCREWS
6. RELEASE BAR 12. WASHER
Figure 40. Door Lock and Lever Disassembly
38
Windows 5. Install inside lever handle and mounting plate

to door frame. Tighten capscrews to 19.2 N•m
For procedures to remove and install door windows, (170 lbf in).
see the section Window Replacement.
6. Place the inside lever handle in the closed posi-
Clean tion (see Figure 40). Insert release bar into door
lock assembly end and into the inside lever han-
WARNING dle. Secure release bar with lock nuts.
Compressed air can move particles so that they 7. Install cover onto inside lever assembly.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air Heater Assembly
goggles or a face shield to prevent injury to the 1. Secure heater assembly to door frame with
eyes. mounting bracket. Insert washers and two lock
nuts onto mounting bracket, and tighten to
Check door assembly and parts for oil, grease, dirt, 19.2 N•m (170 lbf in). See Figure 38.
and other debris. Clean door assembly and parts
with a clean cloth, soap, and water. Compressed air 2. Connect supply and return hoses to heater valve.
can be used to dry door assembly and parts.
3. Install heater valve and switch plate using two
Inspect screws.
Inspect all hoses for cracks and wear. Replace dam- 4. Connect heater switch connector to heater
aged hoses. Inspect the seals around door window switch.
and door lock assembly and replace if damaged. 5. Secure heater valve and switch plate with lock
Check the door lock and latch assembly. Make sure nut.
it opens, shuts, and locks door securely and there
is no rust, grease, oil, or dirt on door lock and latch
assembly parts. Inspect windows for cracks or chips.
Replace windows if damaged.
Assemble
Windows
For procedures to remove and install door windows,

Door Lock Assembly
1. Install new seal and grip to outside handle as-

sembly. See Figure 41.
2. Apply Loctite® 242 to the threads of the four cap-

screws and secure outside door handle to door
(see Figure 40). Tighten capscrews to 19.2 N•m
(170 lbf in).
3. Apply Loctite® 242 to capscrew and install re-

lease lever to rear of outside door handle assem- 1. LATCH STRIKER ASSEMBLY
bly. Tighten capscrew to 5.0 N•m (44 lbf in). 2. SEAL
3. OUTSIDE HANDLE ASSEMBLY
4. Install door lock assembly onto door frame using 4. GRIP
two capscrews and nuts. Tighten capscrews to
19.2 N•m (170 lbf in). Figure 41. Outside Handle Disassembly
39
Air Conditioner and Heater Unit Assembly 1. Install the pre-filter on the bottom of door frame.
See Figure 37.
NOTE: The procedures in this section install the
air conditioner/heater unit assembly to the right 2. Align holes on door cover with holes that are on
side door. For the procedures to install or replace door frame. Install the five plugs into holes that
the other components of the air conditioner/heater are along the sides and front of door cover. Secure
unit assembly, go to Heater and Air Conditioner the bottom of door cover using two capscrews and
Assembly section. washers.
1. Insert four nuts and capscrews and secure air 3. Install AC rocker switch plate to door cover using
conditioner/heater unit assembly to door frame four capscrews.
and mounting bracket.
4. Install two fasteners into holes on top of door
2. Connect the AC hoses to AC expansion valve. See cover. See Figure 37.
Figure 39.
5. Install the knob plate on heater valve and switch
3. Connect supply and return hoses to heater valve. plate with four screws. Install the fan and
AC/heater knobs on knob plate.
4. Connect the AC rocker switch.
6. Install the hose wrap around the AC hoses. See
5. Install heater valve and switch plate using two Figure 32.
screws. See Figure 39.
7. Install handle and handle plates on door with
6. Connect heater switch connector to heater four screws and washers.
switch.
Install
7. Secure heater valve and switch plate with lock
nut. 1. Install right side door onto cab by lifting door
over the top and bottom hinge pins. See Fig-
Door Cover With Heater Unit
ure 35.
1. Install the pre-filter on the bottom of door frame.
2. Connect gas spring and lock nut to mounting
See Figure 36.
bracket on operator cab frame. See Figure 34.
2. Align holes on door cover with holes that are on
3. Connect the heater hoses to the heater assembly
door frame. Install the five plugs into holes that
and connect the heater wire harness connection.
are along the sides and front of door cover. Secure
the bottom of door cover using two capscrews and
washers. 4. On lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
ota diesel engine and equipped with an air con-
4. Install the knob plate on heater valve and switch ditioner/heater unit:
plate with four screws. Install the fan and heater
a. Connect the AC hoses at the bulkhead
knobs on knob plate.
bracket and to the receiver/drier.
four screws and washers.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
Door Cover With Air Conditioner and Heater Unit 5.5FT (H80, 90, 100, 110, 120FT) (P005)
NOTE: The procedures in this section install the air See Figure 33 for lift truck models
conditioner/heater unit assembly door cover onto the • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
right side door. For the procedures to install or re- 5.5FT (H80, 90, 100, 110, 120FT) (R005)
place the other components of the air conditioner/
tioner Assembly section.
40
b. Install rear cover with six fasteners. Windows
See Figure 32 for lift truck models For procedures to remove and install door windows,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- see the section Window Replacement.
5.5FT (H80, 90, 100, 110, 120FT) (P005)
Clean
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
WARNING
5.5FT (H80, 90, 100, 110, 120FT) (R005)
5. Install radiator cover. See Figure 29. cause injury to the user or to other personnel.
LEFT SIDE DOOR ASSEMBLY, LIFT is away from all personnel. Wear protective
TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS goggles or a face shield to prevent injury to the
eyes.
(F001); H2.0-3.5FT (H40-70FT) (L177);
AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, Check door assembly and parts for oil, grease, dirt,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) and other debris. Clean door assembly and parts
(N005, P005, R005) with a clean cloth and soap and water. Compressed
air can be used for drying door assembly and parts.
Remove
Inspect
NOTE: Removing the left side door assembly requires
two people. Inspect the seals around the window, door, and door
lock assembly and replace if damaged. Check the
1. Open left side door and disconnect the gas spring. door lock and latch assembly. Make sure it opens,
See Figure 34. shuts, and locks door securely and there is no rust,
grease, oil, or dirt on door lock and latch assembly
2. Remove left side door from cab frame by lifting parts. Inspect window for cracks or chips. Replace
door over hinge pin. See Figure 35. window if damaged.
Disassemble Assemble
Door Cover Windows
1. Remove cover from rear of handle and remove For procedures to remove and install door windows,
screw. Remove capscrew from door lock cover and see the section Window Replacement.
remove door lock cover from lock assembly. See
Figure 42. Door Lock Assembly
2. Remove two capscrews that secure handle to door 1. Install seal and grip (see Figure 41) onto outside
lock assembly. Remove handle from door. door handle. Place outside door handle onto door
frame. Apply Loctite® 242 to threads of four cap-
3. Remove two fasteners from top of door cover. Re- screws and secure outside handle to door frame
move five plugs along the edges of door cover and using capscrews and washers. The washers go on
remove door cover from door frame. right side from inside the cab. Tighten capscrews
to 19.2 N•m (170 lbf in).
Door Lock Assembly
2. Apply Loctite® 242 to capscrew and install
1. Remove capscrew and washer from release lever.
release lever to rear of outside door handle.
Remove release lever from door. See Figure 43.
Tighten capscrew and washer to 5.0 N•m
2. Remove four capscrews and two washers (right (44 lbf in). See Figure 43.
side only) from rear of outside handle. Remove
outside door handle from door.
3. Remove the grip and seal from outside handle.

Discard seal. See Figure 41.
41
Door Cover 3. Secure handle to rear of door cover with screw.

Tighten screw to 5.0 N•m (44 lbf in). Push cover
1. Place door cover onto door frame. Install two fas- into place over screw.
teners onto top of door cover and install five plugs
along edges of door cover. See Figure 42. Install
2. Install handle to latch assembly with two 1. Install left side door onto cab by lifting door over
capscrews. Tighten capscrews to 19.2 N•m the top and bottom hinge pins. See Figure 35.
(170 lbf in). Secure lock cover to door lock as-
sembly with capscrew. 2. Connect gas spring to mounting bracket on oper-
ator cab frame. See Figure 9.
1. FASTENER 5. CAPSCREW
2. PLUG 6. DOOR LOCK COVER
3. COVER 7. HANDLE
4. SCREW 8. DOOR LOCK ASSEMBLY
Figure 42. Left Side Door Cover Removal
42
RIGHT AND LEFT SIDE DOOR

ASSEMBLIES, LIFT TRUCK MODELS
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006), H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
NOTE: The right and left doors are identical and are
repaired and serviced in the same manner on lift
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006)
H190FT) (A299, B299)
Remove
NOTE: Removing the door assemblies from the oper-
ators cab requires two people.

2. Remove rod pin and spacers from link.
1. ROD PIN 5. GAS SPRING
3. Remove right side door from cab frame by lifting 2. SPACERS 6. LOCK NUT
3. HAIR PIN 7. WASHER
door up and over the hinge pin. See Figure 35. 4. DOOR ASSEMBLY 8. LINK
4. To remove the left door, repeat Step 1 through Figure 44. Door Link Removal
Step 3.
1. CAPSCREW 3. RELEASE LEVER

2. WASHER
Figure 43. Release Lever Removal
43
Disassemble Door Lock Assembly
Door Cover 1. Remove capscrew and washer from release lever.

Remove release lever from rear of outside door
1. Remove cover from rear of handle and remove handle. See Figure 46.
screw. Remove capscrew from door lock cover
and remove cover from lock assembly. Remove 2. Remove four screws from rear of outside door
two capscrews and washers that secure handle handle. Remove outside door handle from door.
to door lock assembly. Remove handle and door
lock assembly from door frame. See Figure 45. 3. Remove the grip and seal from outside door han-
dle. See Figure 47.
2. Remove the five plugs that secure door cover to
door frame and remove cover from frame. Windows


1. COVER 5. DOOR LOCK
2. SCREW 6. WASHER
3. CAPSCREW 7. HANDLE
4. LOCK COVER 8. PLUG
Figure 45. Door Cover Removal
44
Clean clean cloth, soap, and water. Compressed air can be

used for drying door assembly and parts.
WARNING
Inspect
cause injury to the user or to other personnel. Inspect the seals around the window, door, and door
Make sure that the path of the compressed air lock assembly and replace if damaged. Check the
is away from all personnel. Wear protective door lock and latch assembly. Make sure it opens,
goggles or a face shield to prevent injury to the shuts, and locks door securely and there is no rust,
eyes. grease, oil, or dirt on door lock and latch assembly
parts. Inspect window for cracks or chips. Replace
Check door assembly parts for oil, grease, dirt, and
window if damaged.
other debris. Clean door assembly and parts with a

1. SCREW 3. RELEASE LEVER
2. WASHER 4. CAPSCREW
45
Assemble 3. Apply Loctite® 242 to threads of capscrew for re-

lease lever and install release lever to rear of out-
Windows side door handle assembly. Tighten capscrew to
5.0 N•m (44 lbf in).
see the section Window Replacement. Door Cover
Door Lock Assembly 1. Place door cover onto door frame. Install two fas-
teners onto top of door cover. Install five plugs
1. Install grip and seal to outside door handle as-
along edges of door cover. See Figure 45.
2. Install handle to lock assembly with two cap-
2. Apply Loctite® 242 to threads of four screws.
screws and washers. Tighten capscrews to
Use screws to install outside door handle to door
19.2 N•m (170 lbf in). Install lock cover to lock
frame. Tighten screws to 19.2 N•m (170 lbf in).
assembly with capscrew. See Figure 45.
See Figure 46.
3. Secure handle to rear of door cover with screw.
into place over screw.

1. LATCH STRIKER ASSEMBLY 3. OUTSIDE DOOR HANDLE
2. SEAL 4. GRIP
Figure 47. Outside Handle Removal
46
100 SRM 1290 Window Wipers Replacement
Install 2. Align link and spacers into guide and install rod
pin. See Figure 44.
NOTE: The installation procedures outlined below
apply to both the left and right side doors. 3. Install hair pin into rod pin.
1. Lift door over the top and bottom hinge. See Fig-
ure 35.
Window Wipers Replacement

GENERAL that pass through two holes in window. Remove
wiper motor from front window.
Two window wiper motor assemblies are installed in
the operator cab. The front window motor assembly Install, Lift Truck Models H1.6FT, H1.8FT,
has two wiper arms connected to a single wiper blade. 2.0FTS (F001) and H2.0-3.5FT (H40-70FT)
The rear window has a wiper motor assembly that
has one wiper arm attached to a single wiper blade. (L177)
1. Install wiper motor to front window using one
FRONT WIPER ASSEMBLY AND MOTOR flange nut (right side) and two grommets onto
threaded shafts on wiper motor. Insert shafts
Remove, Lift Truck Models H1.6FT, H1.8FT, through two holes in the front window. See Fig-
2.0FTS (F001) and H2.0-3.5FT (H40-70FT) ure 48.
(L177)
2. Install cap and jam nut.
1. Remove wiper motor cover from wiper motor. See
Figure 48. NOTE: Inspect the wiper blade. If it is cracked, split,
or worn, replace with new blade before installing
2. Disconnect cab harness connector from wiper mo- wiper arms onto front window.
tor.
3. Install the wiper arms and blade to front window
3. Open hardware covers at base of wiper arms and using two lock nuts and lockwashers. Close hard-
remove the two lock nuts and lockwashers from ware covers at base of wiper arms.
wiper arms. Remove wiper arms and blade from
wiper motor. 4. Connect the cab harness connector to wiper mo-
tor.
4. Remove cap and jam nut.
5. Install wiper motor cover to wiper motor.
5. Remove one flange nut (right side) and two grom-
mets from the threaded shafts on wiper motor
47
Window Wipers Replacement 100 SRM 1290
1. FRONT WINDOW 8. CAP

2. WIPER BLADE 9. FLANGE NUT
3. WIPER ARM 10. GROMMET
4. LOCKWASHER 11. WIPER MOTOR COVER
5. LOCK NUT 12. CAB HARNESS CONNECTOR (WIPER MOTOR)
6. WIPER HOSE 13. WIPER MOTOR
7. JAM NUT 14. HARDWARE COVERS
Figure 48. Front Wiper and Motor Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)
and H2.0-3.5FT (H40-70FT) (L177)
48
Remove, Lift Truck Models H4.0FT5/FT6, 6. Disconnect cab harness from wiper motor har-
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, ness.
90, 100, 110, 120FT) (N005, P005, R005), 7. Remove wiper motor and bracket from wiper mo-
H6.0FT, H7.0FT (H135FT, H155FT) (H006, tor housing.
J006, K006), H8.0FT, H8.0FT9, H9.0FT
8. Remove three capscrews and external tooth lock-
(H170FT, H175FT36, H190FT) (A299, B299)
washers and remove wiper motor from wiper mo-
1. Open hardware covers at base of wiper arms and tor bracket assembly.
remove two nuts and external tooth lockwashers
See Figure 49 for early lift truck models
from wiper arms.
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
See Figure 49 for early model lift trucks 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0- • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, J006)
R005)
See Figure 50 for later lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
J006, K006)
See Figure 50 for later lift truck models • H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 5.5FT (H80, 90, 100, 110, 120FT) (R005)
H175FT36, H190FT) (A299, B299) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, H175FT36, H190FT) (A299, B299)
J006, K006)
Install, Lift Truck Models H4.0FT5/FT6,
2. Remove wiper blade and wiper arm from wiper H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80,
motor threaded shafts. 90, 100, 110, 120FT) (N005, P005, R005),
3. Remove the two hardware covers, nuts, washers, H6.0FT, H7.0FT (H135FT, H155FT) (H006,
and lockwashers from two threaded shafts that J006, K006), and H8.0FT, H8.0FT9, H9.0FT
pass through two holes in the wiper motor hous- (H170FT, H175FT36, H190FT) (A299, B299)
ing. Remove wiper arms from front window.
1. Install wiper motor to wiper motor bracket using
4. Remove the two lock nuts that secure front wiper three capscrews and external tooth lockwashers.
motor cover to wiper motor housing. Remove
cover. See Figure 49 for lift truck models
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
See Figure 49 for lift truck models 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0- • Early model H6.0FT, H7.0FT (H135FT,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) H155FT) (H006, J006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) See Figure 50 for later lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
5. Remove the three lock nuts that secure front J006, K006)
wiper motor cover to wiper motor housing. Re- H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
move cover. 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) 2. Install wiper motor and bracket into wiper motor
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0- housing.
5.5FT (H80, 90, 100, 110, 120FT) (R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 3. Connect wiper motor harness to cab harness.
H175FT36, H190FT) (A299, B299)
49
4. Attach front wiper motor cover to wiper motor • H8.0FT, H8.0FT9, H9.0FT (H170FT,
housing with two lock nuts. H175FT36, H190FT) (A299, B299)
See Figure 49 for lift truck models 6. Install two washers, nuts, and hardware covers
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0- onto threaded shafts.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
• Early model H6.0FT, H7.0FT (H135FT, NOTE: Inspect the wiper blade. If it is cracked, split,
H155FT) (H006, J006) or worn, replace with new blade before installing
wiper arms onto front window.
5. Attach front wiper motor cover to wiper motor
housing with three lock nuts. 7. Install wiper arms onto wiper motor threaded
shafts, using two external tooth lockwashers
See Figure 50 for later lift truck models and nuts. Close hardware cover at base of wiper
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, arms.
J006, K006)
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)

A. OUTSIDE OF CAB B. INSIDE OF CAB
1. WIPER BLADE 9. FRONT WIPER MOTOR COVER
2. WIPER ARM 10. WIPER MOTOR
3. LOCKWASHERS 11. WIPER MOTOR BRACKET ASSEMBLY
4. WASHERS 12. CAPSCREWS
5. NUTS 13. THREADED SHAFTS
6. HARDWARE COVER 14. WIPER MOTOR HOUSING
7. EXTERNAL TOOTH LOCKWASHER 15. CAB HARNESS
8. LOCK NUTS
50
Figure 49. Front Wiper and Motor Remove, H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005, P005) Lift Trucks and Early Model H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) Lift Trucks
51
Figure 50. Front Wiper and Motor Remove, Later Model H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006), H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005), H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) Lift Truck Models
52

1. WIPER BLADE 9. THREADED SHAFTS
2. WIPER ARM 10. WIPER MOTOR BRACKET ASSEMBLY
3. LOCKWASHER 11. WIPER MOTOR
4. WASHER 12. FRONT WIPER MOTOR COVER
5. NUTS 13. LOCKNUTS
6. HARDWARE COVER 14. CAPSCREW AND EXTERNAL TOOTH
7. EXTERNAL TOOTH LOCKWASHER LOCKWASHER
8. WIPER MOTOR HOUSING
53
REAR WIPER ASSEMBLY AND MOTOR pass through the window from the back side. Re-
move wiper motor from rear window.
Remove, Lift Truck Models H1.6FT, H1.8FT,
2.0FTS (F001) Install, Lift Truck Models H1.6FT, H1.8FT,
2.0FTS (F001)
1. To replace the rear wiper motor assembly, open
hardware covers at base of wiper arms and re- 1. Insert wiper motor mounting studs through holes
move the nut and lockwasher from wiper arm. in window. Place motor on mounting studs and
Remove the wiper arm and blade. See Figure 51. secure motor to mounting studs with two wash-
ers and nuts. See Figure 51.
2. Remove the hardware cover, nut, retainer,
washer, and grommet from the threaded shaft 2. Install washer reservoir onto reservoir mounting
that passes through the window of the operator bracket and connect the wiring harness connec-
cab. tor and the water tube.
3. Remove the wiper motor cover by pulling back- 3. Install the wiper motor cover. The cover snaps
ward. The cover is held in place by plastic tabs into place with plastic tabs.
on the inside of the cover.
4. Install the grommet, washer, retainer, nut, and
4. Disconnect the wiring harness connector and re- hardware cover on threaded shaft that passes
move the water tube. Remove washer reservoir through the window of the operator cab.
from reservoir mounting bracket.
NOTE: Inspect the wiper blade. If it is worn or
NOTE: The left mounting stud is also the spray noz- cracked, replace with new wiper blade.
zle for the window washer. See Figure 51.
5. Attach wiper arm to threaded shaft with lock-
5. From inside the cab, remove the nuts and wash- washer and nut. Install wiper blade onto wiper
ers from the wiper motor mounting studs that arm.
54
1. REAR WINDOW 13. WIPER BLADE

2. GROMMET 14. SPRAY NOZZLE MOUNTING STUD
3. WASHER 15. WASHER RESERVOIR
4. MOUNTING STUD 16. RESERVOIR MOUNTING BRACKET
5. GROMMET 17. WATER TUBE
6. WASHER 18. WIRE HARNESS CONNECTOR
7. RETAINER 19. WIPER MOTOR COVER
8. NUT 20. NUT
9. HARDWARE COVER 21. WASHER
10. WASHER 22. WIPER MOTOR
11. NUT 23. THREADED SHAFT
12. WIPER ARM
Figure 51. Rear Wiper and Reservoir Bottle Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS
(F001)
55
Remove, Lift Truck Models H2.0-3.5FT Install, Lift Truck Models H2.0-3.5FT
(H40-70FT) (L177) (H40-70FT) (L177)
1. Disconnect the washer tube connector. See Fig- 1. Place wiper motor mount stud through hole. In-
ure 52. stall rear wiper motor to lift truck using motor
mount grommet, flange nut, and cover. See Fig-
2. Open hardware cover at base of wiper arm and ure 52.
remove the nut and washer from the wiper arm.
Remove wiper arm and blade from window. Re- 2. Install reservoir onto mounting bracket with
move wiper blade from wiper arm. washer and nut. See Figure 53.
3. Remove the cap, nut, and wiper arm grommet 3. Connect the washer pump connectors to cab wire
from wiper motor shaft. harness.
4. Disconnect the wiper motor connector from cab 4. Insert washer tube through hole and secure tube
wire harness. See Figure 53. to window with nut and washer.
5. Remove the cover, flange nut, and motor mount 5. Connect the rear wiper motor connector to cab
grommet from the motor mount stud. See Fig- wire harness.
ure 52.
6. Install the wiper arm grommet, nut, and cap onto
6. Disconnect the rear wiper motor connector, and rear wiper motor shaft.
remove rear wiper motor from the window. See
Figure 52. NOTE: Inspect wiper blade for cracks and wear. Re-
place with new blade if old blade is worn or damaged.
7. Remove the nut and washer and remove washer
tube from hole. See Figure 53. 7. Install wiper blade onto wiper arm. Install wiper
blade and arm to window using nut and washer.
8. Disconnect the washer pump connectors from cab See Figure 52. Close hardware cover.
wire harness.
8. Connect the washer tube to wiper arm.
9. Remove the nut and washer from mounting
bracket and remove washer reservoir from
mounting bracket.
56
1. WIPER BLADE 8. NUT

2. WIPER ARM 9. HARDWARE COVER
3. WASHER TUBE 10. WIPER ARM GROMMET
4. WASHER TUBE CONNECTOR 11. FLANGE NUT
5. NUT 12. MOTOR MOUNT GROMMET
6. WASHER 13. MOTOR MOUNT STUD
7. CAP 14. WIPER MOTOR SHAFT
Figure 52. Rear Wiper Removal, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)
57
1. WASHER TUBE 6. WIPER MOTOR CONNECTOR

2. NUT 7. REAR WIPER MOTOR
3. WASHER 8. CAB WIRE HARNESS
4. WASHER RESERVOIR 9. MOUNTING BRACKET
5. WASHER PUMP CONNECTORS
Figure 53. Washer Bottle and Wiper Motor Removal
58
Remove, Lift Truck Models H4.0FT5/FT6, Install, Lift Truck Models H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005) 100, 110, 120FT) (N005, P005, R005)
1. Disconnect the washer tube connector. See Fig- 1. From inside of cab, install the washer reservoir
ure 54. and mounting bracket using four capscrews,
nuts, and washers. See Figure 54.
2. Lift up hardware cover at base of wiper arm and
remove the nut and washer from the wiper arm. 2. Connect the washer reservoir pump connectors
Remove wiper arm and blade from rear window. and washer fluid hose. Install radiator cover. See
Remove wiper blade from wiper arm. See Fig- Figure 5.
ure 52.
3. Place wiper motor onto wiper motor mount and
3. Remove the cap, nut, and wiper arm grommet secure using nut and washer. Connect the wiper
from wiper motor shaft. motor to the cab harness.
4. Open both doors of cab. From inside of cab, re- 4. Install the inner cover using five screws.
move the five screws from inner cover and re-
move inner cover from cab. 5. Install the cap, nut, and wiper arm grommet onto
threaded wiper motor shaft that passes through
5. Disconnect the wiper motor from cab harness the window of the operator’s cab.
from inside the cab. From the outside of cab, re-
move nut and washer from wiper motor mount. NOTE: Inspect wiper blade for cracks and wear. Re-
Remove wiper motor from cab. place with new blade if old blade is worn or damaged.
6. Remove radiator cover (see Figure 5) and discon- 6. Install wiper blade to wiper arm. Install wiper
nect the washer reservoir pump connectors and arm and blade to window using nut and washer.
disconnect the washer fluid hose. Close hardware cover at base of wiper arm.
7. From inside the cab, remove four capscrews, 7. Connect the washer tube connector.
nuts, and washers from washer reservoir mount-
ing bracket. Remove washer reservoir and
mounting bracket from lift truck.
59
Figure 54. Washer Reservoir and Rear Wiper Removal, Lift Truck Models H4.0FT5/FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
60

A. INNER REAR COVER C. WIPER ARM
B. WASHER RESERVOIR AND PUMP
1. SCREWS 9. WASHER RESERVOIR PUMP CONNECTOR
2. INNER REAR COVER 10. WASHER RESERVOIR PUMP
3. WASHER RESERVOIR 11. WASHER FLUID HOSE
4. WASHER 12. CAB HARNESS
5. WIPER MOTOR 13. WASHER TUBE CONNECTOR
6. NUT 14. WIPER ARM
7. CAPSCREW 15. WIPER MOTOR MOUNT
8. WASHER MOUNTING BRACKET
Remove, Lift Truck Models H6.0FT, Install, Lift Truck Models H6.0FT, H7.0FT
H7.0FT (H135FT, H155FT) (H006, J006, (H135FT, H155FT) (H006, J006, K006)
K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) H175FT36, H190FT) (A299, B299)
1. Open hardware cover at base of wiper arm and 1. Install washer reservoir using four flange bolts.
remove nut and washer. Remove wiper arm and Connect the water tubes at T-fitting and cab har-
blade. See Figure 55. ness to washer reservoir. See Figure 55.
2. Disconnect water tube from water tube nozzle. 2. Install wiper motor to rear window using two
grommets, washers, and mounting studs. Con-
3. Remove hardware cover, nut, retainer, washer, nect cab harness to wiper motor.
and grommet from threaded shaft on wiper mo-
tor. 3. Install the wiper motor cover. The cover snaps
into place with plastic tabs.
4. Remove the wiper motor cover by pulling back-
ward. The cover is held in place by plastic tabs 4. Install grommet, washer, retainer, nut, and hard-
on the inside of the cover. ware cover onto threaded shaft of wiper motor.
See Figure 55.
5. Disconnect cab harness from wiper motor. Re-
move the two mounting studs, washers, and NOTE: Inspect wiper blade for cracks and wear. Re-
grommets that attached wiper motor to window. place with new blade if old blade is worn or damaged.
Remove wiper motor from window.
5. Install wiper arm and blade with washer and
6. Disconnect the water tubes at T-fitting and cab nut.
harness from the washer reservoir. Remove the
four flange bolts from washer reservoir and re- 6. Connect the water tube onto water tube nozzle.
move reservoir from lift truck.
61
1. COVER 11. CAB HARNESS

2. NUT 12. WATER TUBE NOZZLE
3. WASHER 13. WATER TUBE
4. WIPER MOTOR 14. FRONT WATER TUBE
5. REAR WINDOW 15. T-FITTING
6. GROMMET 16. FLANGE BOLTS
7. MOUNTING STUD 17. WASHER RESERVOIR
8. RETAINER 18. RESERVOIR PUMP
9. HARDWARE COVER 19. WIPER BLADE
10. WIPER MOTOR CONNECTOR 20. WIPER ARM
Figure 55. Rear Wiper, Motor, and Washer Reservoir Removal, Lift Truck Models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)
62
100 SRM 1290 Window Replacement
Window Replacement
GENERAL 1. Slide window open half way. Grab window sides
and lift window off window guide. See Figure 56.
See the Parts Manual for window replacement part
numbers for the front, back, and top windows. To 2. Remove two setscrews from window mounting
replace the door windows, see the procedures below. bracket and remove window from mounting
bracket.
REMOVE DOOR WINDOW, LIFT TRUCK
MODELS H1.6FT, H1.8FT, 2.0FTS (F001); 3. Remove side seal from side of sliding window.
H2.0-3.5FT (H40-70FT) (L177); AND 4. Remove two capscrews from window handle and
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, remove handle from window.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
To remove the non-sliding window, repeat Step 1
(N005, P005, R005) through Step 4.
NOTE: The procedures described below apply to the NOTE: The lower window on the left side door is
sliding and non-sliding right side door windows. The glued into place on the door frame.
procedures to remove the sliding and non-sliding left
side door windows are the same as the right side. 5. On the outside of the door, cut the seal that holds
To remove the lower window on the left side door, the window in place on the door frame. See Fig-
perform Step 5 and Step 6. ure 57.

1. SETSCREWS 5. WINDOW GUIDE
2. MOUNTING BRACKET 6. WINDOW HANDLE
3. SLIDING WINDOW 7. NON SLIDING WINDOW
4. SIDE SEAL 8. CAPSCREWS
Figure 56. Sliding Window Removal
63
Window Replacement 100 SRM 1290
6. Remove window and seal from door frame. Re- right side door windows are the same as the left side.
move any excess seal material and adhesive from To remove the lower windows, go to Step 5.
door frame.
1. Slide window open half way. Grab window sides
INSTALL DOOR WINDOWS, LIFT TRUCK and lift window off window guide. See Figure 58.
MODELS H1.6FT, H1.8FT, 2.0FTS (F001); 2. Remove two setscrews from window mounting
H2.0-3.5FT (H40-70FT) (L177); AND bracket and remove window from mounting
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, bracket. See Figure 58.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
3. Remove side seal from side of sliding window.
(N005, P005, R005)
4. Remove two capscrews and washers from win-
NOTE: The procedures described below apply to the dow slide/locking handle and remove handle
sliding and non-sliding right side door windows. The from window.
procedures to install the sliding and non-sliding left
side door windows are the same as the right side. To To remove the non-sliding window, repeat Step 1
install the lower window on the left side door, per- through Step 4.
form Step 5 and Step 6.
5. To remove the lower window, remove seal from
NOTE: See the Parts Manual for window replace- window and remove window from door frame.
ment part numbers. See Figure 59.
1. Attach window handle to window with two bolts.

See Figure 57.
2. Install side seal to side of sliding window.
3. Place window in mounting bracket and secure

window to mounting bracket with setscrews.
4. Place window onto window guide. Open and close

window (sliding window only) to ensure it is prop-
erly installed onto window guide.
Perform Step 1 through Step 4 to install the non-slid-

ing window.
5. Apply adhesive to side of new seal that goes

against window and install seal onto new win-
dow. See Figure 57.
6. Apply adhesive to other side of seal and press

seal and window into door frame.

MODELS H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006) AND H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299) 1. DOOR FRAME 3. WINDOW
2. SEAL
NOTE: The procedures described below apply to the
Figure 57. Lower Window Removal (Left Side
sliding and non-sliding left side door windows. The
Door)
procedures to remove the sliding and non-sliding
64
NOTE: LEFT SIDE DOOR SHOWN.

1. SETSCREW 6. WASHER
2. MOUNTING BRACKET 7. SLIDE/LOCKING HANDLE
3. SLIDING WINDOW 8. WINDOW GUIDE
4. SIDE SEAL 9. NON-SLIDING WINDOW
5. CAPSCREW
65
Heater Replacement 100 SRM 1290
INSTALL DOOR WINDOW, LIFT TRUCK Perform Step 2 through Step 5 to install the non-slid-
MODELS H6.0FT, H7.0FT (H135FT, H155FT) ing window.
(H006, J006, K006) AND H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)
procedures to install the sliding and non-sliding right
side door windows are the same as the left side. To
install the lower windows, go to Step 1.
NOTE: See the Parts Manual for window replace-

ment part numbers.
1. Install seal around lower window. Install seal

and window into door frame. See Figure 59.
2. Attach handle to window with two capscrews and

washers. See Figure 58.
3. Install side seal from side of sliding window.
4. Place window onto mounting bracket and secure

window to mounting bracket with setscrews. NOTE: LEFT SIDE DOOR SHOWN.
5. Place window onto window guide. Open and close 1. SEAL 3. DOOR FRAME
window (slide window only) to ensure it is prop- 2. WINDOW
Figure 59. Lower Window Removal
Heater Replacement
REMOVE, FOR LIFT TRUCK MODELS 7. Disconnect heater control harness from heater
H6.0FT, H7.0FT (H135FT, H155FT) (H006, and cab harness and unclip heater control har-
J006, K006) AND H8.0FT, H8.0FT9, H9.0FT ness from seat support.
(H170FT, H175FT36, H190FT) (A299, B299) 8. Remove four screws from heater control at top of
seat surround. Remove Heater control.
1. Remove front and rear floor mat and front floor
plate. See Figure 60. 9. Loosen strap clamps and disconnect front and
rear duct heater hoses at top of surround cover.
2. Remove four flange bolts and rear floor plate. See
Figure 60. 10. Loosen strap clamp and disconnect floor vent
duct hose from rectangle adapter to heater vent.
3. Disconnect battery.
11. Remove two capscrews securing heater vent and
4. Remove right side rear panel. See Figure 61. vent bracket to seat support.
5. Loosen strap clamps and remove formed hose NOTE: Drain supply and return hoses into a suitable
from fresh air intake vent to heater box. See container.
Figure 62.
12. Remove supply and return hoses from heater.
6. Remove flange bolts, clip nuts, and fresh air in-
take vent located outside on module. See Fig- 13. Remove four capscrews from heater and seat sup-
ure 63. port. Remove heater.
66
100 SRM 1290 Heater Replacement
1. FRONT FLOOR MAT 4. REAR FLOOR PLATE

2. REAR FLOOR MAT 5. FRONT FLOOR PLATE
3. FLANGE BOLT 6. MODULE
Figure 60. Floor Plate Removal


1. SCREWS
2. RIGHT SIDE REAR PANEL
Figure 61. Right Side Rear Panel Removal
67
Figure 62. Heater and Hoses
68

1. LOUVERS 15. HEATER CONTROL HARNESS
2. TOP VENT ADAPTERS 16. CONNECTOR TO CAB HARNESS
3. STRAP CLAMPS 17. CONNECTOR TO HEATER
4. REAR DUCT HEATER HOSE 18. FLOOR VENT DUCT HOSE
5. FRONT DUCT HEATER HOSE 19. NUT
6. SCREWS 20. FLOOR VENT
7. HEATER CONTROL 21. INSERT
8. CLIPS 22. BRACKET
9. RETURN HOSE 23. RECTANGLE ADAPTER
10. SUPPLY HOSE 24. FORMED HOSE
11. SWIVEL CLAMP 25. CLIP NUTS
12. CLAMP 26. FRESH AIR INTAKE VENT
13. CAPSCREWS 27. SURROUND COVER
14. HEATER BOX
INSTALL, FOR LIFT TRUCK MODELS 11. Connect battery.

H6.0FT, H7.0FT (H135FT, H155FT) (H006,
12. Install rear floor plate with four flange bolts. See
J006, K006) AND H8.0FT, H8.0FT9, H9.0FT Figure 60.
(H170FT, H175FT36, H190FT) (A299, B299)
13. Install front floor plate and front and rear floor
1. Install heater on seat support with four cap- mats.
2. Connect supply and return hoses from engine to

heater.
3. Pre-install heater vent to bracket and assemble

the bracket with two capscrews to seat support.
4. Install front and rear duct heater hoses and floor

vent hose to heater box.
5. Route front and rear ducts to the respective open-

ings at the top vent adapters.
6. Route floor vent hose to the bottom and connect

to heater vent through the rectangle adapter.
7. Install heater control on top of seat surround

with four screws and route the control cable and
harness firmly held by clips by the side of seat
support and connect middle connector to cab
harness and bottom connector heater.
8. Install air intake vent from outside on module 1. FLANGE BOLTS

with flange bolts and clip nuts. See Figure 63. 2. FRESH AIR INTAKE VENT
3. CLIP NUTS
9. Attach intake vent to heater box and air intake
vent with formed hose. Tighten strap clamps. Figure 63. Fresh Air Intake Vent
10. Install right side rear panel. See Figure 61.
69
Heater and Air Conditioner Assembly 100 SRM 1290
Heater and Air Conditioner Assembly

Lift truck models H4.0FT5/FT6; H4.5FTS5, AIR CONDITIONER CONDENSER UNIT
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(P005, R005) and H6.0FT, H7.0FT (H135FT,H155FT) NOTE: The air conditioner condenser unit is a non-re-
(J006, K006) equipped with a Cummins QSB 3.3L pairable part. Replace as a complete unit. See Parts
or Kubota diesel engine may be equipped with a cab Manual.
that has an heater/air conditioner unit installed. In
the section Door Assemblies, the removal procedures Remove
for the heater/air conditioner unit, control knobs,
1. Open hood and disconnect the battery.
and AC rocker switch from the right side door are
outlined. 2. Disconnect the AC hose connections from AC con-
denser unit. See Figure 64.
The other component parts that make up this heating
and air conditioning system are: 3. Disconnect AC condenser unit fans wire harness
• Air conditioner condenser unit from light harness. See Figure 64.
• Air conditioner receiver/drier unit
• Air conditioner compressor unit.
1. FAN CONNECTION 3. LIGHT WIRE HARNESS

2. AC HOSE CONNECTION 4. AC CONDENSER UNIT
Figure 64. Air Conditioner Condenser Unit Wire/Hose Connections
70
100 SRM 1290 Heater and Air Conditioner Assembly
4. Remove four capscrews from front of AC con- 2. Install four capscrews in front of AC condenser
denser unit. See Figure 65. unit.
5. Remove four capscrews and bushings from top of 3. Connect AC condenser fan wire harness to lights
AC condenser unit. Remove AC condenser unit wire harness. See Figure 64.
from lift truck cab. See Figure 65.
4. Connect AC hoses to AC condenser unit.
Install
5. Connect battery and close hood.
1. Install four bushings and capscrews in holes at
top of AC condenser unit. See Figure 65.
1. CAPSCREW 3. AC CONDENSER UNIT

2. BUSHING
Figure 65. Air Conditioner Condenser Unit, Remove
71
AIR CONDITIONER RECEIVER/DRIER 5. Remove two strap clamps from the air con-
UNIT ditioner receiver/drier unit. Remove air condi-
tioner receiver/drier unit from mounting bracket.
NOTE: The air conditioner receiver/drier unit is a See Figure 67.
non-repairable part. Replace as a complete unit. See
Parts Manual. Install
Remove 1. Attach air conditioner receiver/drier unit to
mounting bracket using two strap clamps. See
1. Raise hood and disconnect the battery. Figure 67.
2. Remove the radiator cover. See Figure 66. 2. Connect AC hoses to air conditioner re-
ceiver/drier unit. See Figure 67.
3. Disconnect the air conditioner wire harness from
the air conditioner receiver/drier unit. See Fig- 3. Connect the air conditioner wire harness to air
ure 67. conditioner receiver/drier unit. See Figure 67.
4. Disconnect the AC hoses from the air conditioner 4. Install radiator cover. See Figure 66.
receiver/drier unit.
Figure 66. Radiator Cover Removal
72
AIR CONDITIONER COMPRESSOR

For removal and replacement instructions on the air
conditioner compressor, contact your local Hyster
dealer or see Hyster Hypass Online.
1. STRAP CLAMP 4. MOUNTING BRACKET

2. AC HOSE CONNECTIONS 5. AC RECEIVER/DRIER UNIT
3. AC WIRE HARNESS 6. COUNTERWEIGHT
Figure 67. Air Conditioner Receiver/Drier Unit
73
Light Replacement 100 SRM 1290
Light Replacement
WORK LIGHTS (FRONT AND REAR) 2. Connect the battery, install the floor plate and
floor mat on lift truck models
Remove • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
1. Disconnect battery. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
To access battery, remove floor mat and floor
plate on lift truck models Connect the battery, lower the hood, on lift truck
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, models
J006, K006) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H40FTS) (F001)
H175FT36, H190FT) (A299, B299) • H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
To access battery, raise the hood, on lift truck
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
models
R005)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
CAUTION
Clean any dirt or oil from the lamp surface with
alcohol and a lint-free cloth or tissue. Any for-
eign particles or materials on the bulb surface
can cause hot spots on the bulb and result in
lamp failure.
NOTE: The work light assembly does not need to be

removed from the lift truck to replace the bulb
2. Remove four capscrews, lens assembly, and bulb.

See Figure 68. Install the bulb, lens assembly,
and four capscrews.
NOTE: REAR WORK LIGHT SHOWN, FRONT WORK
3. Disconnect the work light wiring harness from LIGHT IS SIMILAR.
the cab wiring harness. Remove the lock nut,
washer, and work light from the mounting 1. CAPSCREWS (LENS ASSEMBLY)
bracket located on the cab. See Figure 69. 2. LENS ASSEMBLY
3. NUT
Install Figure 68. Work Lights
1. Using the washer and lock nut, install work light
on the cab mounting bracket. See Figure 69.
Connect work light to overhead guard harness.
74
100 SRM 1290 Light Replacement
STROBE LIGHT • H2.0-3.5FT (H40-70FT) (L177)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
NOTE: The strobe light may either be mounted above 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
the top of the cab assembly (high-mounted) or below R005)
the top of the cab assembly (low-mounted). The re-
moval and installation procedures are the same for TURN, STOP, TAIL, AND BACKUP LIGHT
both options.
NOTE: The turn, stop, tail, and backup light assem-
Remove bly is non-repairable. See the Parts Manual for re-
placement turn, stop, tail, and backup lights.
Remove
To access battery, remove the floor mat and floor
plate on lift truck models 1. Disconnect battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) To access battery, remove the floor mat and floor
• H8.0FT, H8.0FT9, H9.0FT (H170FT, plate on lift truck models
H175FT36, H190FT) (A299, B299) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
To access battery, raise the hood, on lift truck • H8.0FT, H8.0FT9, H9.0FT (H170FT,
models H175FT36, H190FT) (A299, B299)
H40FTS) (F001) To access battery, raise the hood, on lift truck
• H2.0-3.5FT (H40-70FT) (L177) models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, H40FTS) (F001)
R005) • H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
2. Disconnect the strobe light electrical connector 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
from the cab wiring harness. See Figure 70. R005)
3. Remove the capscrews, washers, and flange nuts 2. Remove screw securing the turn, stop, tail, and
securing the strobe light and light guard to strobe backup light to mounting bracket. Pull Turn,
light mounting bracket. Remove strobe light and Stop, Tail, and Backup Light downward to re-
guard from lift truck. See Figure 69. move it from the mounting bracket.
Install 3. Disconnect the turn, stop, tail, and backup light

from the cab wiring harness. See Figure 69.
1. Place strobe light assembly and strobe light
guard onto mounting bracket. Secure the as- 4. If the mounting bracket must be removed from
sembly to mounting bracket with capscrews, the cab, remove rear crossmember cover and re-
washers, and flange nuts. See Figure 70. move the mounting bracket from the cab. See
Figure 69.
2. Connect strobe light electrical connector to over-
head guard wiring harness. Install
3. Connect the battery, install the floor plate and 1. If the mounting bracket was removed, install
floor mat on lift truck models the rear crossmember cover. Install mounting
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, bracket on the cab.
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 2. Connect the turn, stop, tail, and backup light to
H175FT36, H190FT) (A299, B299) the cab wiring harness. See Figure 69.
Connect the battery, lower the hood, on lift truck 3. Install the screw to attach the turn, stop, tail,
models and backup light to the mounting bracket. See
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, Figure 69.
H40FTS) (F001)
75
Figure 69. Cab Light Assemblies
76

1. CAB ASSEMBLY 10. MOUNTING BRACKET
2. RIGHT SIDE WORK LIGHT 11. STROBE LIGHT GUARD
3. RIGHT SIDE MARKER/TURN SIGNAL LIGHT 12. REAR WORK LIGHT
4. LEFT SIDE MARKER/TURN SIGNAL LIGHT 13. LOCKNUT
5. LEFT SIDE WORK LIGHT 14. WASHER
6. RIGHT SIDE TURN, STOP, TAIL, AND BACKUP 15. MOUNTING BRACKET
LIGHT 16. LEFT SIDE TURN, STOP, TAIL, AND BACKUP
7. FLANGE NUT LIGHT
8. CAPSCREW 17. FRONT MOUNTING BRACKET
9. STROBE LIGHT
4. Connect the battery, install the floor plate and NOTE: The following steps are used to remove either
floor mat on lift truck models the right or left side front marker/turn signal light
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, assembly.
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 2. Remove two lock nuts, washers and front
H175FT36, H190FT) (A299, B299) marker/turn signal light assembly from the
front mounting bracket. See Figure 69.
Connect the battery, lower the hood, on lift truck
models
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
FRONT MARKER/TURN SIGNAL LIGHTS

NOTE: The front marker/turn signal light assembly
is non-repairable. See the Parts Manual for replace-
ment front marker/turn signal lights.
Remove

plate on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
To access battery, raise the hood, on lift truck 1. STROBE LIGHT GUARD
models 2. STROBE LIGHT LENS
3. FLANGE NUT
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, 4. LOCKWASHER
H40FTS) (F001) 5. WASHER
• H2.0-3.5FT (H40-70FT) (L177) 6. MOUNTING BRACKET
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- 7. CAPSCREW
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, 8. LOCK NUT
9. ELECTRICAL CONNECTOR
R005)
Figure 70. Strobe Light Assembly
77
Electrical Schematics 100 SRM 1290
3. Disconnect the front marker/turn signal light • H8.0FT, H8.0FT9, H9.0FT (H170FT,
wiring harness from the cab wiring harness. H175FT36, H190FT) (A299, B299)
Install Connect the battery, lower the hood, on lift truck

models
NOTE: The following steps are used to install either • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
the right or left side front marker/turn signal light H40FTS) (F001)
assembly. • H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
1. Connect the front marker/turn signal light 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
wiring harness to the cab wiring harness. R005)
2. Using two lock nuts, and washers, install the
front marker/turn signal light assembly on the
front mounting bracket.
3. Connect the battery, install the floor plate and

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
Display Switches
The lift trucks covered in this manual can have sev- • H1.6FT, H1.8FT, 2.0FTS, H2.0-3.5FT (H40-70FT)
eral different options and configurations. Depending (L177)
on the equipment on the lift truck, warnings and in- • H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
dicator lights on the right side of the Display Switch (H80, 90, 100, 110, 120FT) (N005, P005, R005)
Cluster will vary and the truck may not contain all
the warnings and indicator lights shown in Figure 71 The fuses are located in the Power Distribution Mod-
and Figure 72. ule (PDM), which is under the floor plates mounted
on the right side. See Figure 73 for lift truck models
The fuses are located in the Power Distribution Mod- • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
ule (PDM), which is under the hood next to the bat- K006)
tery on the right side. See Figure 73 for lift truck • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
models H190FT) (A299, B299)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001)
Electrical Schematics
Refer to Diagrams and Schematics 8000 SRM
1409 or Diagrams and Schematics 8000 SRM
1585 for complete lift truck electrical schematics.
78
100 SRM 1290 Electrical Schematics
A. LEFT SIDE B. RIGHT SIDE

1. HOURMETER 10. POWER (ON/OFF)
2. #1 BUTTON (ADMINISTERING PASSWORDS) 11. ENGINE START (KEYLESS REMOTE)
3. #2 BUTTON (ADMINISTERING PASSWORDS) 12. 1ST GEAR LOCKING
4. ENTER BUTTON 13. FRONT WORK LIGHTS
5. #3 BUTTON (ADMINISTERING PASSWORDS) 14. REAR WORK LIGHTS
6. SCROLL DOWN 15. REAR WIPER
7. SCROLL UP 16. FRONT WIPER
8. #4 BUTTON (ADMINISTERING PASSWORDS) 17. FRONT WASHER
9. #5 BUTTON (ADMINISTERING PASSWORDS)
Figure 71. Right and Left Side Display Switch Cluster
79
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator Malfunction Indicator
14 Indicator Light, 1st Gear Locking
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 72. Warning and Indicator Lights
80
100 SRM 1290 Optional Equipment
Optional Equipment
HEAVY DUTY PRE-CLEANER 2. Remove hose clamp securing pre-cleaner to air
duct. Remove pre-cleaner.
The procedure below only pertains to lift truck mod-
els Clean
• H1.6FT, H1.8FT, 2.0FTS (F001)
• H2.0-3.5FT (H40-70FT) (L177)
WARNING
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005) Compressed air can move particles so that they
See section Frame 100 SRM 1321 for the heavy-duty Make sure that the path of the compressed air
pre-cleaner removal and installation procedures for is away from all personnel. Wear protective
lift truck models goggles or a face shield to prevent injury to the
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) eyes.
H190FT) (A299) Clean the heavy-duty pre-cleaner and air duct with
compressed air as necessary.
See section Frame 100 SRM 1581 for the heavy-duty
pre-cleaner removal and installation procedures for Inspect
lift truck models
• H6.0FT, H7.0FT (H135FT,H155FT) (K006) Inspect the air duct and pre-cleaner for excessive
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, wear, cracks, or damage. If damaged, replace.
H190FT) (B299)
Install
In environments with very dirty conditions, the lift
NOTE: Orient ejection port away from operator.
truck may be equipped with a heavy-duty air cleaner
which pre-cleans the air before it enters the standard 1. Install pre-cleaner and hose clamp onto air duct.
air filter. The pre-cleaner is mounted on the rear of Tighten hose clamp.
the cab in place of the air vent. See Figure 74.
2. Install air duct and pre-cleaner onto left side rear
Remove operator cab leg with two washers and socket
head capscrews.
1. Remove two socket head capscrews and washers
securing the air duct to left side rear operator
cab leg. Remove air duct and pre-cleaner. See
Figure 74.
81
Optional Equipment 100 SRM 1290
Figure 73. PDM Showing Fuses and Relays
82

A. H1.6FT, H1.8FT, 2.0FTS (F001), H2.0-3.5FT (H40-70FT) (L177), AND H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
B. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
1. BATTERY 11. SPARE FUEL PUMP RELAY
2. PDM 12. BATTERY (25-AMP FUSE)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20-AMP FUSE)
4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30-AMP FUSE) 15. BATTERY (25-AMP FUSE)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20-AMP FUSE)
7. BACKUP RELAY 17. IGNITION 1 (20-AMP FUSE)
8. BACKUP (20-AMP FUSE) 18. IGNITION RELAY
9. IGNITION (30-AMP FUSE) 19. BATTERY (25-AMP FUSE)
10. SPARE FUEL PUMP (20-AMP FUSE)
1. PRE-CLEANER 5. INSERT
2. AIR DUCT 6. HOSE CLAMP
3. WASHER 7. INJECTION PORT
4. SOCKET HEAD CAPSCREW
Figure 74. Heavy Duty Pre-Cleaner
83
FAN 2. Connect fan assembly wiring harness connector

to cab wiring harness connector.
Remove
3. Connect battery, install the floor plate and floor
1. Disconnect battery. mat on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
To access battery, remove the floor mat and floor J006, K006)
plate on lift truck models • H8.0FT, H8.0FT9, H9.0FT (H170FT,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Connect battery, lower the hood, on lift truck
H175FT36, H190FT) (A299, B299) models
To access battery, raise the hood, on lift truck H40FTS) (F001)
models • H2.0-3.5FT (H40-70FT) (L177)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H40FTS) (F001) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H2.0-3.5FT (H40-70FT) (L177) R005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, MIRROR
R005)
Remove
2. Disconnect fan assembly wiring harness connec-
tor from cab wiring harness connector. See Fig- Remove nut and mirror from the mounting bracket.
3. Remove four nuts, lockwashers, capscrews, and Install
fan assembly from mounting bracket.
Using nut, install mirror on the mounting bracket.
Install See Figure 75.
1. Using four nuts, lockwashers, and capscrews, in-
stall fan assembly on mounting bracket. See Fig-
ure 75.
84
1. MIRROR 6. WASHER
2. MOUNTING BRACKET 7. WIRING HARNESS CONNECTOR
3. NUT 8. MOUNTING BRACKET
4. SCREW 9. FAN ASSEMBLY
5. LOCKNUT
Figure 75. Fan and Mirror Replacement
85
Label Replacement 100 SRM 1290
Label Replacement
2. Remove paper from back of label. Do not touch
WARNING adhesive surface.
Labels that have WARNINGS or CAUTIONS
must be replaced if they are damaged. If a 3. Carefully hold label in correct position above sur-
mast of a different size or an accessory car- face. Label cannot be moved after it touches sur-
riage is installed, the capacity rating can face. Put label on surface. Make sure all air is
change. Changes in the kind of drive tires removed from under label and corners and edges
can change the capacity rating. See a dealer are tight.
for Hyster lift trucks for a replacement name-
plate. The nameplate information is a safety See Parts Manual for correct location and part num-
item and must be correct for the equipment ber.
and configuration of the lift truck.
1. Make sure surface is dry and free of oil or grease.

DO NOT use solvent on new paint. Clean the
surface of old paint using cleaning solvent.
86
100 SRM 1290 9/12 (7/12)(1/12)(7/11)(6/10)(4/09)(7/08)(7/07) Printed in U.S.A.

GM ENGINE REPAIR
GM 2.4 LITER ENGINE
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580503 600 SRM 1121

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
GM Engine Repair Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Engine Serial Number ....................................................................................................................................... 1
Engine Removal and Installation ..................................................................................................................... 3
Intake Manifold.................................................................................................................................................. 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 4
Exhaust Manifold............................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Camshaft and Cylinder Head Repair ............................................................................................................... 6
Rocker Arm Cover.......................................................................................................................................... 6
Remove....................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Camshaft Timing Pulley and/or Front Seal ................................................................................................. 7
Remove....................................................................................................................................................... 7
Install ......................................................................................................................................................... 7
Camshaft Carrier and Cylinder Head .......................................................................................................... 8
Remove....................................................................................................................................................... 8
Disassemble ............................................................................................................................................... 9
Camshaft Carrier .................................................................................................................................. 9
Cylinder Head ....................................................................................................................................... 10
Clean and Inspect...................................................................................................................................... 11
Cylinder Head ....................................................................................................................................... 12
Valve and Valve Seat................................................................................................................................. 14
Assemble .................................................................................................................................................... 14
Cylinder Head ....................................................................................................................................... 14
Install ......................................................................................................................................................... 15
Timing Belt......................................................................................................................................................... 16
Timing Belt Front Cover ............................................................................................................................... 16
Remove....................................................................................................................................................... 16
Install ......................................................................................................................................................... 17
Timing Belt and Timing Belt Tensioner....................................................................................................... 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 19
Timing Belt Rear Cover................................................................................................................................. 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Lubrication System Repair................................................................................................................................ 20
Oil Pan............................................................................................................................................................ 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 20
Oil Pump ........................................................................................................................................................ 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 24
Piston and Piston Rod Assemblies Repair........................................................................................................ 25
Piston Rod Bearings, Replace ....................................................................................................................... 25

Table of Contents GM Engine Repair

Piston and Piston Rod Assemblies................................................................................................................ 27
Remove....................................................................................................................................................... 27
Disassemble ............................................................................................................................................... 28
Pistons, Clean and Inspect........................................................................................................................ 28
Cylinder Bores, Inspect and Repair ......................................................................................................... 29
Piston Rings, Inspect................................................................................................................................. 30
Assemble .................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
Crankshaft and Main Bearings......................................................................................................................... 32
Crankshaft Timing Pulley and/or Front Seal .............................................................................................. 32
Remove....................................................................................................................................................... 32
Install ......................................................................................................................................................... 33
Crankshaft Rear Main Oil Seal .................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Crankshaft/RPM Sensor ............................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 35
Crankshaft Reluctor Wheel........................................................................................................................... 35
Remove and Install ................................................................................................................................... 35
Crankshaft and Main Bearings .................................................................................................................... 35
Remove....................................................................................................................................................... 35
Inspect and Repair .................................................................................................................................... 36
Bearing Selection ...................................................................................................................................... 37
Main Bearings and Journal Clearance, Check ........................................................................................ 38
Install ......................................................................................................................................................... 39
Flywheel and Flywheel Housing ....................................................................................................................... 41
Remove ........................................................................................................................................................... 41
Install ............................................................................................................................................................. 41
Cooling System Repair ...................................................................................................................................... 42
Serpentine Belt .............................................................................................................................................. 42
Remove....................................................................................................................................................... 42
Inspect........................................................................................................................................................ 42
Install ......................................................................................................................................................... 42
Water Pump ................................................................................................................................................... 43
Remove....................................................................................................................................................... 43
Inspect........................................................................................................................................................ 45
Install ......................................................................................................................................................... 45
Thermostat..................................................................................................................................................... 46
Remove....................................................................................................................................................... 46
Check.......................................................................................................................................................... 47
Install ......................................................................................................................................................... 47
Thermostat Housing...................................................................................................................................... 48
Remove....................................................................................................................................................... 48
Install ......................................................................................................................................................... 48
Sensors and Switches ........................................................................................................................................ 50
Crankshaft Position (CKP) Sensor ............................................................................................................... 50
Remove....................................................................................................................................................... 50
Install ......................................................................................................................................................... 50
Camshaft Position (CMP) Sensor ................................................................................................................. 50
ii
GM Engine Repair Table of Contents

Remove for Lift Trucks Built Before January, 2010................................................................................ 50
Assembly................................................................................................................................................ 50
Sensor Only ........................................................................................................................................... 51
Install for Lift Trucks Built Before January, 2010 .................................................................................. 51
Assembly................................................................................................................................................ 51
Sensor Only ........................................................................................................................................... 52
Remove for Lift Trucks Built After January, 2010 .................................................................................. 52
Install for Lift Trucks Built After January, 2010 .................................................................................... 52
Oil Pressure Sensor ....................................................................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 53
Ignition System .................................................................................................................................................. 53
Spark Plug Wire Inspection .......................................................................................................................... 53
Spark Plug Wire Replacement ...................................................................................................................... 53
Remove....................................................................................................................................................... 53
Install ......................................................................................................................................................... 54
Spark Plug Replacement ............................................................................................................................... 54
Remove....................................................................................................................................................... 54
Install ......................................................................................................................................................... 54
Spark Plug Inspection ................................................................................................................................... 55
Usage.......................................................................................................................................................... 55
Inspect........................................................................................................................................................ 55
Visual Inspection ....................................................................................................................................... 57
Coil Pack......................................................................................................................................................... 57
Remove....................................................................................................................................................... 57
Install ......................................................................................................................................................... 57
Alternator Repair............................................................................................................................................... 58
Alternator....................................................................................................................................................... 58
Remove....................................................................................................................................................... 58
Install ......................................................................................................................................................... 58
Alternator Fuse, Replace............................................................................................................................... 58
Starter Repair .................................................................................................................................................... 59
Remove ........................................................................................................................................................... 59
Install ............................................................................................................................................................. 59
Engine Specifications......................................................................................................................................... 60
Engine Data ................................................................................................................................................... 60
Cylinder Bore ................................................................................................................................................. 60
Piston.............................................................................................................................................................. 60
Piston Rings ................................................................................................................................................... 60
Wrist Pin ........................................................................................................................................................ 61
Crankshaft ..................................................................................................................................................... 61
Piston Rod ...................................................................................................................................................... 61
Camshaft and Camshaft Carrier .................................................................................................................. 62
Valve System.................................................................................................................................................. 62
Cylinder Head Warpage ................................................................................................................................ 63
Lubrication System ....................................................................................................................................... 63
Cooling System .............................................................................................................................................. 63
Torque Specifications ......................................................................................................................................... 63
Special Tools ....................................................................................................................................................... 65
iii
Table of Contents GM Engine Repair

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]
iv
600 SRM 1121 Engine Serial Number
General
This section has the repair instructions for the GM
2.4 liter engine.
Engine Serial Number

The location of the engine serial number is shown in
1. ENGINE SERIAL NUMBER
Figure 1. Engine Serial Number Prior to January, 2010
1
Engine Serial Number 600 SRM 1121
1. ENGINE SERIAL NUMBER
Figure 2. Engine Serial Number After January, 2010
2
600 SRM 1121 Intake Manifold
Engine Removal and Installation

• Do not check for current flow by making a
CAUTION spark because the electronic components can
Disconnect the battery cables before doing any be damaged.
disassembly and repair to the engine or parts
of the electrical system.
CAUTION
The diodes and resistors in the electrical sys- Many parts of the engine assembly are made
tem can be damaged if the following cautions of aluminum. Use care not to damage mating
are not followed: surfaces or threads. To prevent possible dam-
• Do not disconnect the battery when the en- age to mating surfaces, do not clean with wire
gine is running. The voltage surge can dam- brushes, steel wool, or sharp objects. Do not
age the diodes and resistors. overtighten parts that are aluminum or mount
• Do not disconnect an electric wire before the to an aluminum part, as this can cause damage
engine is stopped and the switches are OFF. to the threads or part.
• Do not cause a short circuit by connection
of the electric wires to the wrong terminals. The procedures to remove and install the engine are
Make sure a correct identification is made of not included in this section. See the section Frame
the wire before it is connected. 100 SRM 1120 for these procedures.
• Make sure a battery is the correct voltage and
polarity before it is connected.
Intake Manifold
REMOVE 900 SRM 1126. For LPG fuel systems, refer to the
section LPG Fuel System, GM 2.4L Engine 900
NOTE: Step 1 is for gasoline engines only. SRM 1124.
1. Disconnect the electrical connector from the fuel 8. Remove the three bolts that attach the air filter
pump. assembly mounting bracket to the frame and re-
move air filter assembly with mounting bracket.
NOTE: Step 2 is for LPG fuel systems only.
9. Disconnect the electrical connections to the
2. Close the fuel valve on the propane tank.
throttle body.
3. Start the engine and let it idle until the engine
10. Disconnect the fuel delivery hoses and return
shuts down from the lack of fuel.
hoses, or LPG vapor hose.
NOTE: Step 4 is for gasoline engines only.
11. Disconnect the vacuum hose from the intake
4. Crank the engine for approximately five seconds manifold.
for full pressure relief from the fuel system.
12. Disconnect the air intake hoses and positive
5. Disconnect the negative battery cable. crankcase ventilation (PCV) valve hoses from
the intake manifold.
6. Remove the left rear side cover. Refer to the sec-
tion Frame 100 SRM 1120. 13. Disconnect the wiring harness connectors to the
fuel injectors.
7. Disconnect the air intake hoses from the air filter
assembly. 14. Disconnect the electrical connector to the MAP
sensor.
NOTE: The ECM assembly must be disconnected
from the air filter assembly before removing the air 15. Remove the nuts retaining the intake manifold
filter assembly. For gasoline engines, refer to the to the cylinder head. See Figure 3.
section Gasoline Fuel System, GM 2.4L Engine
3
Intake Manifold 600 SRM 1121
4. Place the intake manifold into position on the

cylinder head.
5. Install the retaining nuts on the studs. Tighten

the nuts to 18 to 22 N•m (13 to 16 lbf ft).
6. Connect the electrical connector to the MAP sen-

sor.
7. Connect the wiring harness connectors to the fuel

injectors.
8. Connect the air intake hoses and PCV valve

hoses to the intake manifold.
9. Connect the vacuum hose to the intake manifold.

1. INTAKE MANIFOLD 3. CYLINDER HEAD
2. NUT 10. Connect the fuel delivery hose to the intake man-
ifold.
Figure 3. Intake Manifold
11. Connect the breather hose to the intake mani-
16. Remove the intake manifold. fold.
17. Remove the intake manifold gasket and discard. 12. Connect the fuel delivery hoses and return hoses,
or LPG vapor hose.
18. Remove and replace fuel system components as
needed. For gasoline engines, refer to the section 13. Connect the electrical connections to the throttle
Gasoline Fuel System, GM 2.4L Engine 900 body.
SRM 1126. For LPG fuel systems, refer to the
section LPG Fuel System, GM 2.4L Engine NOTE: Step 14 is for gasoline engines only.
900 SRM 1124. 14. Connect the electrical connector to the fuel pump.
CLEAN AND INSPECT NOTE: Step 15 is for LPG fuel systems only.
15. Slowly open the fuel valve on the propane tank.

CAUTION
Use caution not to scratch the gasket mating NOTE: The ECM assembly must be connected to the
surfaces when cleaning the intake manifold air filter assembly after installing the air filter as-
and cylinder head. sembly. For gasoline engines, refer to the section
Gasoline Fuel System, GM 2.4L Engine 900 SRM
Carefully remove all gasket residue from the intake 1126. For LPG fuel systems, refer to the section LPG
manifold and cylinder head. Inspect the intake man- Fuel System, GM 2.4L Engine 900 SRM 1124.
ifold for scratches, cracks, or any other damage. Re-
pair or replace as needed. 16. Place the air filter assembly with mounting
bracket in position on the frame. Install bolts
INSTALL and tighten to 20 N•m (15 lbf ft).
1. Verify the mating surfaces are clean and not 17. Connect the air intake hoses to the air filter as-
damaged. sembly.
2. If necessary, install fuel system components. For 18. Install the left rear side cover. Refer to the sec-
gasoline engines, refer to the section Gasoline tion Frame 100 SRM 1120.
Fuel System, GM 2.4L Engine 900 SRM 1126.
For LPG fuel systems, refer to the section LPG 19. Connect the negative battery cable.
Fuel System, GM 2.4L Engine 900 SRM 1124.
3. Place a new gasket in position between the in-

take manifold and the cylinder head.
4
600 SRM 1121 Exhaust Manifold
WARNING WARNING
During engine operation, be careful not to The radiator or other parts of the cooling sys-
touch the fan, pulleys, or drive belts. Contact tem may be hot or under pressure and can
with these parts can cause serious injury. cause serious injury.
20. Start the engine and check for proper operation

and leaks.
Exhaust Manifold
REMOVE manifold for scratches, cracks, or any other damage.
Repair or replace as needed.
1. Remove the battery, battery tray, and power
distribution module (PDM). Refer to the section INSTALL
Electrical System 2200 SRM 1142.
1. Verify the mating surfaces are clean and not
2. Tag and disconnect the spark plug wires. damaged.
3. Disconnect the electrical connection to the coil 2. Place a new gasket in position between the ex-
pack. haust manifold and the cylinder head.
4. Remove the coil pack and coil pack mounting 3. Place the exhaust manifold into position on the
bracket. cylinder head.
5. Remove the capscrews retaining the exhaust 4. Install new locking nuts on the studs. Tighten
manifold heat shield and remove the heat shield. the nuts to 18 to 22 N•m (13 to 16 lbf ft).
6. Disconnect the oxygen sensor electrical connec- 5. Place a new gasket in position between the ex-
tion. haust manifold adapter and the exhaust mani-
fold.
7. Remove and discard the locking nuts retaining
the exhaust manifold adapter to the exhaust
manifold.
8. Remove and discard the gasket between the ex-

haust manifold adapter and the exhaust mani-
fold.
9. Remove and discard the locking nuts retaining

the exhaust manifold to the cylinder head. See
Figure 4.
10. Remove the exhaust manifold.
11. Remove the gasket and discard.
CLEAN AND INSPECT 1. GASKET

2. EXHAUST MANIFOLD
CAUTION 3. NUT
Use caution not to scratch the gasket mating Figure 4. Exhaust Manifold Removal/
surfaces when cleaning the exhaust manifold Installation
and cylinder head.
Carefully remove all gasket residue from the exhaust

manifold and cylinder head. Inspect the exhaust
5
Camshaft and Cylinder Head Repair 600 SRM 1121
6. Connect the exhaust manifold adapter to the 10. Connect the electrical connection to the coil pack.
exhaust manifold and secure with new locking
nuts. Tighten the nuts to 14 to 20 N•m (10 to 11. Connect the spark plug wires and remove tags.
15 lbf ft).
12. Install the battery, battery tray, and PDM. Re-
7. Connect the oxygen sensor electrical connection. fer to the section Electrical System 2200 SRM
1142.
8. Place the exhaust manifold heat shield in posi-
tion and secure with capscrews. Tighten the cap- 13. Start the engine and check for proper operation
screws to 6 to 8 N•m (53 to 71 lbf in). and leaks.
9. Install the coil pack mounting bracket and coil

pack.
Camshaft and Cylinder Head Repair

ROCKER ARM COVER 5. Connect the crankcase vent tube to the rocker
arm cover.
Remove
6. Connect the two hoses to the PCV valve.
1. Disconnect the two hoses from the PCV valve.
2. Disconnect the crankcase vent tube from the

rocker arm cover.
3. Remove the capscrews retaining the rocker arm

cover to the camshaft carrier assembly. See Fig-
ure 5.
4. Remove the rocker arm cover and gasket. Dis-

card gasket.
Install
1. Clean the mating surfaces of the rocker arm
cover and the camshaft carrier assembly.
2. Place a new gasket in position in the rocker arm

cover.
3. Place the rocker arm cover in position on the

camshaft carrier assembly.
1. CAPSCREW
4. Install the capscrews to retain the rocker arm 2. OIL FILLER CAP
3. ROCKER ARM COVER
cover to the camshaft carrier assembly. Tighten 4. CAMSHAFT CARRIER ASSEMBLY
the capscrews to 8 N•m (71 lbf in).
Figure 5. Rocker Arm Cover
6
600 SRM 1121 Camshaft and Cylinder Head Repair
CAMSHAFT TIMING PULLEY AND/OR Legend for Figure 6

FRONT SEAL 1. CAMSHAFT TIMING PULLEY
2. 22-MM, OPEN-END WRENCH
Remove 3. 17-MM WRENCH
NOTE: Before removing the timing belt, make sure
the alignment mark on the crankshaft timing pulley
is aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark
is aligned with the timing mark on the rear timing
belt cover; and the camshaft pin is in the top hole
of the camshaft timing pulley. See Timing Belt and
Timing Belt Tensioner, Remove.
1. Remove the timing belt. See Timing Belt and

2. Remove the rocker arm cover. See Rocker Arm

Cover, Remove.
3. Use a 22-mm, open-end wrench and lock the

camshaft. Using a 17-mm wrench, remove the
Figure 7. Camshaft Front Seal Removal
bolt retaining the camshaft timing pulley. See
Figure 6. Install
4. Remove the camshaft timing pulley. 1. Using a special tool, a camshaft seal installer,
5. Drill a small hole into the front seal face. Install install new front seal. See Figure 8.
a fine thread screw. Using a pair of pliers, pull 2. Use a 22-mm, open-end wrench and lock the
the seal outward, and remove the seal. See Fig- camshaft.
ure 7.
3. Place the camshaft timing pulley in position. In-
stall the retaining bolt and tighten bolt to 40 to
50 N•m (30 to 37 lbf ft). See Figure 6.
Figure 6. Camshaft Timing Pulley
Figure 8. Camshaft Front Seal Installation
7
NOTE: Before installing the timing belt, verify the 4. Loosen the lower radiator hose and drain the
alignment mark on the crankshaft timing pulley is coolant from the coolant system.
aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion 5. Remove the intake manifold. See Intake Mani-
stroke; the camshaft timing pulley alignment mark fold, Remove.
6. Remove the exhaust manifold. See Exhaust
Manifold, Remove.
Timing Belt Tensioner, Install. 7. Remove the spark plugs.
4. Install the timing belt. See Timing Belt and Tim- 8. Remove the fan belt. See Serpentine Belt, Re-
ing Belt Tensioner, Install. move.
5. Install the rocker arm cover. See Rocker Arm NOTE: Before removing the timing belt, make sure
Cover, Install. the alignment mark on the crankshaft timing pulley
is aligned with the alignment mark on the oil pump
CAMSHAFT CARRIER AND CYLINDER case flange, with the No. 1 cylinder in the combustion
HEAD stroke; the camshaft timing pulley alignment mark
Remove belt cover; and the camshaft pin is in the top hole
1. Turn the ignition switch to the OFF position. Timing Belt Tensioner, Remove.
2. Disconnect the negative battery cable. 9. Remove the timing belt. See Timing Belt and
WARNING
10. Remove the timing belt rear cover. See Timing
DO NOT remove the radiator cap from the ra-
Belt Rear Cover, Remove.
tor cap is removed, pressure will release from 11. Remove the thermostat housing. See Thermostat
the coolant system. If the coolant system is hot, Housing, Remove.
the steam and boiling coolant can cause severe
burns. 12. Disconnect the electrical connector for the
camshaft sensor.
WARNING
13. Remove the rocker arm cover. See Rocker Arm
The radiator or other parts of the cooling sys- Cover, Remove.
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator and engine to cool before performing CAUTION
maintenance to the cooling system. After 30 Since there is spring tension on the camshaft
minutes, do a touch test by touching the radi- and carrier, use caution when removing
ator with your hand. If the radiator is still hot camshaft carrier/cylinder head bolts. Remove
to the touch, wait another 30 minutes before the bolts in the sequence shown in Figure 9 in
attempting any maintenance to the cooling even increments to prevent possible damage
system. to the camshaft and camshaft carrier.
14. Remove and discard the camshaft carrier/cylin-

CAUTION der head bolts in sequence and in even incre-
Disposal of lubricants must meet local environments. See Figure 9 and Figure 10.
mental regulations.
15. Remove the camshaft carrier assembly from the
3. Remove the radiator cap. cylinder head.
8
NOTE: Organize camshaft followers and keepers so

they can be installed in their original positions.
16. Remove the camshaft followers and keepers from

the cylinder head. See Figure 11.
1. CAMSHAFT FOLLOWER
Figure 9. Removal Sequence 2. KEEPERS
3. LIFTERS
4. CYLINDER HEAD
5. CYLINDER HEAD GASKET
6. CYLINDER BLOCK
Figure 11. Cylinder Head
NOTE: Organize camshaft lifters so they can be in-

stalled in their original positions.
17. Remove the camshaft lifters from the cylinder

head.
18. Remove the cylinder head from the engine block.
19. Remove the cylinder head gasket and discard.
Disassemble
Camshaft Carrier
1. Remove the camshaft sensor assembly.
2. Remove the capscrews from the camshaft re-

1. WASHER
2. BOLT tainer. See Figure 12.
3. CAMSHAFT CARRIER ASSEMBLY
4. CYLINDER HEAD 3. Carefully move the camshaft slightly out of the
camshaft carrier and remove the camshaft re-
Figure 10. Camshaft Carrier Assembly tainer.
9
5. Remove the front camshaft seal. See Camshaft

Timing Pulley and/or Front Seal, Remove.
Cylinder Head
NOTE: Keep cylinder head components in order so

they will be installed in the same positions during
assembly.
1. Using a valve spring compressor, compress the

valve spring. See Figure 14.
1. RETAINER 2. CAPSCREW
Figure 12. Camshaft Retainer
CAUTION
All camshaft journals are the same diameter.
Be careful when removing the camshaft to
avoid damage to the camshaft carrier.
1. VALVE SPRING COMPRESSOR
4. Carefully rotate and remove the camshaft out of
the camshaft carrier. See Figure 13. Figure 14. Valve Spring Compressor
2. Remove the valve stem keys. See Figure 15.
3. Remove the retainers from the valve spring.
4. Remove the valve springs.
5. Using a special tool, remove the valve stem oil

seals.
6. Remove valve spring seat (Inlet).
7. Remove the valve spring rotator assembly.
8. Remove the exhaust valve.
9. Remove the inlet valve.
10. Repeat Step 1 through Step 9 for remaining

valves.
1. CAMSHAFT 2. CAMSHAFT
CARRIER
Figure 13. Camshaft Removal/Installation
10
1. THREADED HOLE 3. BOLT HOLE

2. MATING SURFACE
Figure 16. Camshaft Carrier
5. Inspect the bottom mating surface of the

1. VALVE STEM KEYS camshaft carrier for warpage. Replace as needed.
2. RETAINER
3. VALVE SPRING
4. VALVE STEM OIL SEAL 6. Inspect the bores in the camshaft carrier for dam-
5. VALVE SEAT (INLET) age. Replace as needed. See Figure 17.
6. VALVE INLET
7. VALVE EXHAUST 7. Using a dial indicator, measure the camshaft
8. CYLINDER HEAD bore surfaces. See Engine Specifications for the
9. VALVE SPRING ROTATOR ASSEMBLY correct measurements. If not within specifica-
(EXHAUST) tions, replace camshaft carrier.
Figure 15. Valve Removal/Installation
Clean and Inspect

Camshaft Carrier
CAUTION
Use care not to damage the mating sur-
faces when removing old gaskets and sealant
residues.
1. Clean all debris, old gaskets, and sealants from

the mating surfaces of the camshaft carrier. See
Figure 16.
2. Clean the bolt holes and threads in the camshaft 1. CAMSHAFT BORE
carrier.
Figure 17. Camshaft Bores Inspection
3. Inspect the camshaft carrier mating surfaces for
damage. Replace as needed.
4. Inspect the camshaft carrier for cracks or any

other damage. Replace as needed.
11
Cylinder Head d. The maximum clearance between the valve

stems and their valve guides is shown in En-
gine Specifications.
CAUTION
Do not use a wire brush to clean the combus- NOTE: If the valve stem to valve guide clearance can-
tion chambers. This can damage the seats and not be obtained using an oversized valve stem, the
possibly the sealing surface at the edge of the cylinder head must be replaced.
combustion chamber.
e. If the clearance between the valve stem and
Use a soft brush and cleaner to remove the carbon its valve guide is greater than the specifica-
from the combustion chambers and the valve ports. tion, a valve with an oversize stem must be
Be careful not to scuff the chamber. installed. Use a reamer to make the bore the
correct diameter for the next oversize valve.
1. Clean the following areas: See Figure 19. See the Parts Manual for
oversize valves.
a. Carbon and sludge from the lifters, followers,
and keepers. 4. Inspect the valve springs for squareness. See
Figure 20.
b. Valve stems and heads.
5. Measure the valve seat runout. The valve seats
c. Cylinder head and engine block gasket sur-
should be centered to within 0.05 mm (0.002 in.).
faces.
See Figure 21.
d. Bolt holes and threads in the cylinder head
6. Inspect the cylinder head and measure it for
and the engine block.
warpage. A cylinder head with excessive
2. Inspect the following areas: warpage must be repaired or replaced. Refer
to Engine Specifications for cylinder head di-
a. Cylinder head for cracks in the exhaust ports mensions. Also, see Figure 22.
and the combustion chambers.
b. Cylinder head for external cracks in the wa-

ter chamber.
c. Valves for burned heads, cracked faces, or

damaged stems.
3. Check the valve stem-to-bore clearance of each

valve and valve guide. Use the following proce-
dure:
a. Install the dial indicator into the valve guide

and measure the inner diameter of the valve
guide. See Figure 18.
b. Measure the outside diameter of the valve

stem with a micrometer.
c. Determine the difference between the outer

diameter of the valve stem and the inner di- Figure 18. Valve Guide Inner Diameter
ameter of the valve guide. Measurement
12
Figure 19. Valve Guide Reaming

Figure 21. Valve Seat Runout Measurement
Figure 20. Valve Springs Inspection Figure 22. Cylinder Head Measurement
13
Valve and Valve Seat 12. Using a valve spring compressor, compress the
valve spring.
The condition of the valves and alignment of the
valves to their valve seats are important for the NOTE: Make sure the keys seat properly in the upper
correct operation of the engine. Before any work is groove of the valve stem. If necessary, tap the end of
done on the valve seats, make sure the clearance the valve stem with a plastic-faced hammer, making
of the valve stems in their valve guides is within sure the valves will not come into contact with the
specifications. work bench, in order to seat the keys.
A correction for minimum wear and damage to the 13. Install the valve stem keys.
valve and seat can be done by a process called lap-
ping. When the valve seats are lapped, keep the 14. Remove the valve spring compressor.
valve seats within the specifications. Make sure all
15. Repeat Step 1 through Step 14 for remaining
of the lapping compound is removed from the valve
valves.
and valve seat when the process is completed.
Damaged valve seats can be repaired with a 45° ±30’

cutter tool. See Figure 23. If the valve seat cannot
be repaired so that the valve depth is within speci-
fications, the cylinder head must be replaced. The
specifications for the valve seats are listed in Engine
Specifications.
Assemble
Cylinder Head
1. Install the valves into the proper ports. See Fig-

ure 15.
2. Install the valve seat (inlet) on the inlet valve.
3. Install the valve seat (exhaust) on the exhaust

valve.
4. Install the inlet valve and exhaust valve into the

cylinder head.
5. Install the valve spring rotator assembly over the

valve guide.
6. Lubricate the valve stem oil seal with clean en-

gine oil.
7. Using a special tool, install the valve stem oil seal

onto the exhaust valve.
8. Lubricate the valve stem oil seal with clean en-

gine oil.
9. Using a special tool, install the valve stem oil seal

onto the inlet valve.
Figure 23. Valve Seat Repair
10. Install the valve springs.
11. Install the retainers onto the valve spring.
14
Camshaft Carrier 9. Tighten the camshaft carrier/cylinder head bolts

in sequence to 25 N•m (18 lbf ft). See Figure 24.
1. Using a special tool, a camshaft seal installer,
install new front seal. See Figure 8.
CAUTION
All camshaft journals are the same diameter.
Be careful when installing the camshaft to
avoid damage to the camshaft carrier.
2. Carefully rotate and install the camshaft into the

camshaft carrier.
NOTE: The camshaft may need to be pulled slightly

out of the camshaft carrier to place the camshaft re-
tainer in position.
3. Install the camshaft retainer.

Figure 24. Tightening Sequence
4. Install the capscrews to retain the camshaft re-
tainer. Tighten capscrews to 8 N•m (71 lbf in). 10. Tighten the cylinder head bolts in sequence an
additional 180 degrees.
5. Install the camshaft sensor assembly.
11. Tighten the cylinder head bolts in sequence an
Install additional 10 degrees.
NOTE: Verify the cylinder head locators are installed 12. Install the rocker arm cover. See Rocker Arm
in the engine block. Cover, Install.
1. Install the new cylinder head gasket over the lo- 13. Connect the electrical connector for the camshaft
cators onto the engine block with the TOP mark sensor.
facing upward and toward the front end of the
14. Install the thermostat housing. See Thermostat
engine block. See Figure 11.
Housing, Install.
2. Install the cylinder head over the locators onto
15. Install the timing belt rear cover. See Timing
the gasket.
Belt Rear Cover, Install.
3. Coat the bottom of the valve lifters with molyb-
NOTE: Before installing the timing belt, verify the
denum lubricant.
alignment mark on the crankshaft timing pulley is
NOTE: If using the old valve lifters, install the lifters aligned with the alignment mark on the oil pump
in original positions. case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark
4. Install valve lifters. is aligned with the timing mark on the rear timing
5. Install the camshaft follower keepers and follow- of the camshaft timing pulley. See Timing Belt and
ers. Timing Belt Tensioner, Install.
6. Apply RTV sealant (Hyster part number 280472) 16. Install the timing belt. See Timing Belt and Tim-
to the mating surface of the cylinder head for the ing Belt Tensioner, Install.
carrier assembly.
17. Install the fan belt. See Serpentine Belt, Install.
7. Place the camshaft carrier assembly in position
on the cylinder head. 18. Install the spark plugs.
8. Install new camshaft carrier/cylinder head bolts 19. Install the exhaust manifold. See Exhaust Man-
and washers. Tighten bolts finger tight only. ifold, Install.
15
Timing Belt 600 SRM 1121
20. Install the intake manifold. See Intake Manifold, alternator. When the air has been bled from the
Install. system, close the bleed screw.
21. Connect the lower radiator hose and tighten the

clamp. WARNING
diator when the engine is hot. When the radi-
CAUTION ator cap is removed, the pressure is released
Additives may damage the cooling system. Be- from the system. If the system is hot, the steam
fore using additives, contact your local Hyster and boiling coolant can cause burns. DO NOT
dealer. remove the cover for the radiator when the en-
gine is running.
22. Connect the bottom radiator hose. Fill cooling
system with coolant. Refer to the section Peri-
odic Maintenance 8000 SRM 1150 for correct WARNING
coolant amount and type. The radiator or other parts of the cooling sys-
23. Install radiator cap on radiator. cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
WARNING the radiator with your hand. If the radiator is
During engine operation, be careful not to still hot to the touch, wait another 30 minutes
touch the fan, pulleys, or drive belts. Contact before attempting to check or fix any part of
with these parts can cause serious injury. the cooling system.
WARNING CAUTION
The radiator or other parts of the cooling sys- Additives may damage the cooling system. Be-
tem may be hot or under pressure and can fore using additives, contact your local Hyster
cause serious injury. dealer.
24. Start engine and check cooling system for leaks. 26. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
25. Bleed air from the cooling system by opening the tween the ADD and FULL marks on the coolant
bleed screw located on the left side behind the reservoir.
Timing Belt
TIMING BELT FRONT COVER 6. Remove the four bolts retaining the fan assembly.
Remove 7. Remove the fan assembly.
1. Turn the ignition to the OFF position. 8. Remove the serpentine belt. See Serpentine Belt,
Remove.
2. Remove the battery, battery tray, and PDM. Re-
fer to the section Electrical System 2200 SRM 9. Remove the spacer and the pulley.
1142.
10. Disconnect the electrical connections to the alter-
3. Remove the auxiliary coolant reservoir. nator.
4. Remove the fan shroud. Refer to the section 11. Remove the alternator mounting bolts and re-
Cooling System 700 SRM 1123. move the alternator.
5. Place a piece of cardboard over the radiator sur- 12. Remove the alternator bracket bolts, fan hub
face to prevent damage to the radiator. bracket bolts, and fan hub bracket.
16
600 SRM 1121 Timing Belt
NOTE: Before removing the crankshaft pulley and 4. Install alternator bracket and retaining bolts.
the crankshaft pulley hub, make alignment marks Tighten bolts to 38 N•m (28 lbf ft).
on the crankshaft hub, crankshaft pulley, and crank-
shaft spacer. 5. Install the alternator. See the section Alternator
Repair.
13. Remove the bolts retaining the crankshaft fan
pulley and remove the crankshaft fan pulley and 6. Install the fan spacer and the pulley.
the crankshaft pulley spacer. See Figure 25.
7. Install the serpentine belt. See Serpentine Belt,
Install.
8. Place the fan in position on the pulley and in-

stall the four retaining bolts. Tighten the bolts
to 26 N•m (19 lbf ft).
9. Remove cardboard from the radiator surface.
10. Install the fan shroud. Refer to the section Cool-

ing System 700 SRM 1123.
11. Install the auxiliary coolant reservoir.
12. Install the battery, battery tray, and PDM. Re-

fer to the section Electrical System 2200 SRM
1142.
TIMING BELT AND TIMING BELT

TENSIONER
1. CRANKSHAFT PULLEY HUB Remove

2. CRANKSHAFT PULLEY SPACER
3. CRANKSHAFT PULLEY 1. Remove the timing belt front cover. See Timing
4. SERPENTINE BELT Belt Front Cover, Remove.
5. OIL PUMP HOUSING
6. ALIGNMENT MARK 2. Turn the crankshaft until the alignment mark on
the crankshaft timing pulley is aligned with the
Figure 25. Crankshaft Pulley Arrangement
alignment mark on the oil pump case flange, with
14. Remove the front timing belt cover bolts and re- the No. 1 cylinder in the combustion stroke. See
move the front timing belt cover. Figure 26.
Install
1. Place the timing belt cover over the timing
belt and install bolts. Tighten bolts to 6 N•m
(53 lbf in).
NOTE: Before installing the crankshaft pulley and

crankshaft spacer, align these components with the
alignment marks made when disassembled.
2. Install the crankshaft spacer and crankshaft pul-

ley, ensuring that all alignment marks made dur-
ing removal are lined up properly. Tighten crank-
shaft pulley bolts to 15 to 25 N•m (11 to 18 lbf ft).
Figure 26. Crankshaft Timing Pulley
3. Install fan hub bracket and retaining bolts. Alignment Mark
Tighten bolts to 52 N•m (38 lbf ft).
17
Timing Belt 600 SRM 1121
CAUTION
The camshaft pin must be in the top hole of the
camshaft timing pulley.
3. Position the camshaft timing pulley alignment

mark with the timing mark on the rear timing
belt cover. Verify that the camshaft pin is located
in the 12 o’clock position. See Figure 27.
Figure 28. Timing Belt
1. CAMSHAFT PIN
Figure 27. Camshaft Timing Pulley and

Crankshaft Timing Pulley Alignment Marks 1. WATER PUMP BOLT
2. WATER PUMP
3. WATER PUMP TAB (11 O’CLOCK POSITION)
4. Use chalk to mark direction of timing belt rota- 4. TIMING BELT TENSIONER POINTER
tion. See Figure 28. 5. LOCATORS
6. TENSIONER TAB (7 O’CLOCK POSITION)
NOTE: Before removing the timing belt tensioner, 7. USED TIMING BELT MARK
verify the tensioner tab is between the two locator 8. NEW TIMING BELT MARK
tabs at the 7 o’clock position. See Figure 29. 9. TENSIONER
5. Remove the bolt retaining the timing belt ten- Figure 29. Tensioner Tab and Locators
sioner.
6. Remove the timing belt and the timing belt ten-

sioner.
18
600 SRM 1121 Timing Belt
Install belt marks to make sure they are still aligned

correctly.
1. Align the camshaft timing pulley alignment
mark with the timing mark on the rear timing 10. Install the timing belt front cover. See Timing
belt cover. See Figure 27. Belt Front Cover, Install
TIMING BELT REAR COVER

CAUTION
The camshaft pin must be in the top hole of the Remove
camshaft timing pulley.
1. Remove the timing belt front cover. See Timing
2. Verify that the camshaft pin is located in the 12 Belt Front Cover, Remove.
o’clock position. See Figure 27.
NOTE: Before removing the timing belt, verify the
3. Verify the alignment mark on the crankshaft alignment mark on the crankshaft timing pulley is
timing pulley is aligned with the alignment aligned with the alignment mark on the oil pump
mark on the oil pump case flange, with the No. 1 case flange, with the No. 1 cylinder in the combustion
cylinder in the combustion stroke. See Figure 27. stroke, the camshaft timing pulley alignment mark is
aligned with the timing mark on the rear timing belt
NOTE: The timing belt tensioner tab must be placed
cover, and the camshaft pin is in the top hole of the
in the 7 o’clock position between the locators. See
camshaft timing pulley. See Timing Belt and Timing
Figure 29.
Belt Tensioner, Remove.
4. Install the timing belt tensioner, but do not
2. Remove the timing belt and timing belt ten-
tighten the bolt.
sioner. See Timing Belt and Timing Belt Ten-
5. Place the timing belt over the pulleys and the sioner, Remove.
timing belt tensioner.
3. Remove the rocker arm cover.
6. Tighten the tensioner to the appropriate refer-
4. Remove the camshaft timing pulley. See
ence mark with the crankshaft timing pulley hub
Camshaft Timing Pulley and/or Front Seal,
timing mark aligned with the oil pump housing
Remove.
timing mark and the camshaft timing belt pul-
ley timing mark aligned with the timing mark 5. Remove the crankshaft timing pulley. See
located on the plastic timing belt housing. Crankshaft Timing Pulley and/or Front Seal,
Remove.
NOTE: The timing belt tensioner has two markings,
NEW and USED, for the appropriate timing belt. 6. Remove the Torx head capscrews retaining front
The tensioner pointer will need to be aligned with bracket and remove front bracket.
the correct timing belt installed. See Figure 29.
7. Remove the capscrews retaining the timing belt
7. If timing belt is too tight and cannot be adjusted rear cover.
with the tensioner, loosen water pump bolts (see
Figure 29) and turn water pump counterclock- 8. Remove timing belt rear cover.
wise until proper tension is achieved. Tighten
water pump bolts to 20 to 30 N•m (15 to 22 lbf ft). Install
8. If timing belt is too loose and cannot be adjusted 1. Place timing belt rear cover in position on engine.
with the tensioner, loosen water pump bolts and
turn water pump clockwise until proper tension 2. Install bolts to retain timing belt rear cover.
is reached. Tighten water pump bolts to 20 to Tighten capscrews to 6 N•m (53 lbf in).
30 N•m (15 to 22 lbf ft).
3. Place front bracket in position and install Torx
9. Tighten the timing belt tensioner bolt to 20 N•m head capscrews. Tighten Torx head capscrews to
(15 lbf ft). Verify the timing belt tensioner 25 N•m (18 lbf ft).
pointer is aligned with the appropriate mark
4. Install the camshaft timing pulley. See Camshaft
after tightening. Recheck tensioner and timing
Timing Pulley and/or Front Seal, Install.
19
Lubrication System Repair 600 SRM 1121
5. Install crankshaft timing pulley and retaining belt cover; and the camshaft pin is in the top hole
bolt. See Crankshaft Timing Pulley and/or Front of the camshaft timing pulley. See Timing Belt and
Seal, Install. Timing Belt Tensioner, Install.
NOTE: Before installing the timing belt, verify the 6. Install the timing belt and timing belt tensioner.
alignment mark on the crankshaft timing pulley is See Timing Belt and Timing Belt Tensioner, In-
aligned with the alignment mark on the oil pump stall.
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark 7. Install the timing belt front cover. See Timing
is aligned with the timing mark on the rear timing Belt Front Cover, Install.
Lubrication System Repair

OIL PAN CAUTION
Remove Use care not to damage the mating sur-
1. Remove the engine from the lift truck. Refer to residues.
the section Frame 100 SRM 1120 for the proce-
dures to remove the engine. 6. Carefully remove old sealant residue from the
mating surfaces of the oil pan and cylinder block.
2. Remove the oil pan drain plug and drain the en-
gine oil into a suitable container. 7. Thoroughly clean the outside and inside surfaces
of the oil pan.
3. If necessary, remove the oil filter.
Install
4. Remove the capscrews retaining the oil pan to
the engine block. See Figure 30. 1. Apply a 3.175 mm (0.125 in.) continuous bead of
sealant around the sealing surface of the oil pan.
5. Remove the oil pan.
2. Place the oil pan into position on the cylinder
block using the locating pins.
3. Remove the right side bell housing alignment

bushing. See Figure 31.
4. Install special tool, rear flange alignment tool, to

keep the alignment of the oil pan to the cylinder
block. See Figure 32.
5. Install capscrews, except the two capscrews

where the alignment tool is using the mounting
holes.
6. Verify the alignment of the oil pan and cylinder

block is correct. The edge of the oil pan should be
a maximum distance of 0.15 mm (0.006 in.) from
the edge of the cylinder block. See Figure 33.
Adjust the oil pan as needed.
7. Tighten the capscrews to 18 to 22 N•m (13 to

1. OIL PAN 2. DRAIN PLUG 16 lbf ft).
Figure 30. Oil Pan
20
600 SRM 1121 Lubrication System Repair

1. BUSHING
2. BELL HOUSING
3. REMOVAL TOOL
Figure 31. Bell Housing Alignment Bushing
1. OIL PAN 3. BELL HOUSING

2. REAR FLANGE ALIGNMENT TOOL
Figure 32. Rear Flange Alignment Tool
21
5. Remove the oil pressure sensor.
6. Remove the oil filter.
1. CYLINDER BLOCK 2. OIL PAN
Figure 33. Oil Pan Alignment
8. Remove the special tool.
9. Install the remaining two capscrews and tighten

to 18 to 22 N•m (13 to 16 lbf ft). 1. OIL FILTER
2. OIL PRESSURE SENSOR
10. Install the right side bell housing alignment 3. BANJO BOLT
bushing. 4. OIL FILTER ADAPTER
11. Install the drain plug and tighten to 18 to
Figure 34. Oil Pressure Sensor and Oil Filter
22 N•m (13 to 16 lbf ft).
With Adaptor
12. If removed, install new oil filter.
13. Install the engine into the lift truck. Refer to the
section Frame 100 SRM 1120.
14. Fill the engine oil to the correct level. Refer to

the section Periodic Maintenance 8000 SRM
1150 for correct oil amount and type.
OIL PUMP
Remove
1. Remove the oil pan. See Oil Pan, Remove.

Belt Rear Cover, Remove.
3. Disconnect the electrical connector for the crank-

shaft sensor. 1. ELECTRICAL CONNECTOR
4. Disconnect the electrical connector for the oil 3. OIL FILTER
pressure sensor. See Figure 34 and Figure 35.
Figure 35. Oil Pressure Sensor and Oil Filter
Without Adaptor
22
NOTE: Step 7 and Step 8 are for engines with an oil

filter adapter only.
7. Using vise grips, remove the banjo bolt retaining

the oil filter adapter and remove oil filter adapter.
8. Discard the seal washer and the banjo bolt.
9. Remove the capscrew from the oil pump suction

tube bracket. See Figure 36.
10. Remove the capscrews from the suction tube.
NOTE: The oil suction tube and screen are to be ser-

viced as an assembly. Do not attempt to repair the
wire mesh portion of the tube and screen assembly.
11. Remove the suction tube and O-ring. Discard 2. SAFETY VALVE 5. OIL PUMP
O-ring. 3. SPACER
12. Remove the capscrews retaining the oil pump to Figure 37. Oil Pump
the engine block. See Figure 37.
Clean and Inspect
NOTE: Be sure to retain the spacers for installation.
NOTE: The internal components of the oil pump are
13. Remove the oil pump, gasket, and spacers. Dis- not serviceable. If the oil pump components are dam-
card gasket. aged or worn, replace the oil pump as an assembly.
14. Remove the safety valve. 1. Remove the screws retaining the oil pump cover
and remove oil pump cover. See Figure 38.
1. SCREW 2. OIL PUMP COVER

1. O-RING 3. SUCTION TUBE
2. BRACKET 4. CAPSCREWS Figure 38. Oil Pump Cover
Figure 36. Oil Suction Tube
23
5. Attach the oil pump cover to the oil pump. Install

WARNING the retaining screws. Tighten retaining screws to
Cleaning solvents can be flammable and toxic 6 N•m (53 lbf in).
cleaning solvents, always follow the recom- Install
mendations of the manufacturer.
1. Install safety valve with a new O-ring. Tighten
WARNING safety valve to 37 N•m (27 lbf ft).
Compressed air can move particles so that they 2. Install new oil pump gasket.
Make sure that the path of the compressed air 3. Install the oil pump and spacers.
goggles or a face shield to prevent injury to the 4. Install the capscrews to retain the oil pump to
eyes. engine block. Tighten capscrews to 6 to 10 N•m
(53 to 89 lbf in).
NOTE: The internal parts of the oil pump are not
serviced separately. If the oil pump components are 5. Install new O-ring on oil pump suction tube. In-
worn or damaged, replace the oil pump as an assem- stall the oil pump suction tube and capscrews.
bly. If the drive gear and drive shaft are worn, re- Tighten the capscrews to 8 N•m (71 lbf in).
place the entire oil pump.
6. Install the oil pump suction tube bracket cap-
The oil suction tube and screen are to be serviced as screw. Tighten capscrew to 18 to 22 N•m (13 to
an assembly. Do not attempt to repair the wire mesh 16 lbf ft).
portion of the tube and screen assembly.
NOTE: Step 7 is for engines with an oil filter adapter
2. Clean all of the parts in cleaning solvent. Dry the only.
parts with compressed air.
7. Install the oil filter adapter, new seal washer, and
3. Inspect the gears and the pump body for wear new shear banjo bolt. Tighten banjo bolt with an
and damage. If the parts are worn or damaged, open-end, 10-mm wrench until the head of the
replace the oil pump. bolt completely shears off. See Figure 40.
4. Check the gap of the gears with a feeler gauge 8. Install new oil filter.
and a straight edge. The dimension should be
0.03 to 0.10 mm (0.0011 to 0.004 in.). See Fig-
ure 39.
1. SEAL WASHER 4. OIL FILTER

2. BANJO BOLT ADAPTER
1. STRAIGHT EDGE 2. FEELER GAUGE 3. SHEAR HEAD
Figure 39. Gear Inspection Figure 40. Shear Banjo Bolt Installation
24
600 SRM 1121 Piston and Piston Rod Assemblies Repair
9. Install the oil pressure sensor. Tighten sensor to 12. Connect the electrical connector for the crank-
20 N•m (15 lbf ft). shaft sensor.
10. Connect the electrical connector for the oil pres- 13. Install the oil pan. See Oil Pan, Install.
sure sensor.
11. Install the timing belt rear cover. See Timing

Piston and Piston Rod Assemblies Repair

PISTON ROD BEARINGS, REPLACE 9. Use a micrometer to measure the bearing jour-
nal. The bearing journal must be within the fol-
NOTE: The piston rod bearings are available in a lowing specification:
standard size and several undersizes. See the Parts • Out-of-roundness less than 0.004 mm
Manual for bearing sizes. If a bearing on a journal is (0.00016 in.); taper less than 0.005 mm
worn, both the upper and lower halves of the bearing (0.0002 in.)
must be replaced.
If the bearing journals are not within specifica-
1. Remove the oil pan and oil pump. See Lubrica- tions, the crankshaft must be removed and the
tion System Repair. bearing journal ground to an undersize. If the
bearing journal cannot be repaired so that the
2. Remove the capscrews retaining the baffle plate
bearing journal is a correct undersize, the crank-
and remove baffle plate.
shaft must be replaced. See Engine Specifica-
3. Remove the remaining capscrews from the bear- tions.
ing bracket and remove the bearing bracket.
4. Before the cap for the piston rod is removed,

mark the piston rod and cap with the cylinder
number so that the parts will be installed in
their original positions.
5. Remove the capscrews retaining the cap and re-

move cap for the piston rod bearing and the lower
bearing half. See Figure 41.
6. Push the piston rod away from the crankshaft

and remove the upper bearing half. Wipe the oil
from the bearing halves and the bearing journal.
7. Inspect bearings for craters, pockets, excessive

scoring, and dirt or debris imbedded into the
bearing material. Replace as needed. Replace
the upper and lower halves as a set.
8. Inspect the bearings for improper seating indi-

cated by bright, polished sections of the bearing.
Replace as needed. Replace the upper and lower 1. BEARING CAP 3. CRANKSHAFT
halves as a set. 2. BEARING
Figure 41. Piston Rod Cap Removal
25
Piston and Piston Rod Assemblies Repair 600 SRM 1121
10. If the bearing journal is within specifications, b. Measure the clearance between the caps for
measure the clearance between the new bearing the piston rods and the crankshaft. See Fig-
and the crankshaft. Use Plastigage®, or equiva- ure 44.
lent, to check the clearance as described below:
a. Put a piece of Plastigage® across the full

width of the bearing journal as shown in Fig-
ure 42. Do not rotate the crankshaft when
the Plastigage® is between the bearing and
its journal.
b. Install the bearing and bearing cap. Tighten

the capscrews to 30 to 40 N•m (22 to
29.5 lbf ft). Tighten the capscrews an addi-
tional 40 to 45 degrees.
c. Remove the bearing and bearing cap. The

Plastigage® will be compressed and wider
and it will adhere to either the bearing or its
journal. Use the scale on the envelope for the
Plastigage® to measure the width of the plas-
tic at its widest point. The scale will indicate
the clearance in millimeters or thousandths
of an inch. See Figure 43.
1. BEARING CAP 2. PLASTIGAGE®
d. If the clearance is greater than the specifica-
tions, select a new undersize bearing set and Figure 42. Bearing Journal Plastigage®
install it. Measure the clearance again. If Placement
the clearance cannot meet specifications with
the available undersize bearings, the bearing
journal must be ground to a new undersize.
If the bearing journal is already at the max-
imum undersize, the crankshaft must be re-
placed.
e. If the clearance is within specifications,

lubricate the bearing with engine oil and
install the bearing and bearing cap. Tighten
the capscrews to 30 to 40 N•m (22 to
29.5 lbf ft). Tighten the capscrews an addi-
tional 40 to 45 degrees.
11. When all of the connecting rod bearings have

been replaced, use the following procedure to
check the side clearances between the piston
rods and the crankshaft (refer to Engine Specifi-
cations for clearance specifications):
a. Use a hammer to lightly hit the piston rod

parallel to the crankshaft journal to make Figure 43. Bearing Journal Plastigage®
sure there is a clearance. Measurement
26
e. Remove the cloth.
f. Remove the cutting debris.
5. Clean the carbon from the top of each cylinder.
6. Put an identification mark on the top of each pis-

ton.
7. Remove the caps and bearings from each piston

rod. Keep the caps and bearings with their origi-
nal piston assemblies. Mark the caps so that they
will be installed again in their original positions.
Do not mix the parts.
Figure 44. Piston Rods Side Clearance
Measurement 8. Push the piston rod and piston from the cylinder.
Temporarily install the bearing cap on the piston
PISTON AND PISTON ROD ASSEMBLIES rod to keep the parts together.
Remove
1. Remove the oil pan and oil pump. See Lubrica-
tion System Repair.

3. Remove the cylinder head. See Camshaft Carrier

and Cylinder Head, Remove.
4. If the engine has been in service for many hours,

a ridge can be worn in the top of the cylinder.
This ridge can be removed with a ridge reamer
tool (see Figure 45) using the procedures de-
scribed below:
a. Turn the crankshaft to lower the piston to the

bottom of the stroke in its cylinder.
b. Put a cloth on top of the piston to collect

metal particles. Figure 45. Ridge Reamer
c. Remove the ridge at the top of the cylinder.
d. Turn the crankshaft so the piston is at the

top of the stroke.
27
Disassemble goggles or a face shield to prevent injury to the

eyes.
CAUTION 3. Use solvent to clean the pistons and piston rods.
The pistons are aluminum alloy and can be Use compressed air to dry the parts. Make sure
damaged if they are hit with a hard object. The that the holes for oil passages are clean.
grooves for the piston rings are machined to
close tolerances. Use a tool made to clean the Pistons, Clean and Inspect
grooves of the piston rings. Do not use a wire
brush to clean a piston. Inspect the pistons for wear, cracks, and damage. Re-
place a piston that is worn or damaged.
1. Remove the piston rings from the pistons. See
Figure 46. NOTE: If the cylinder bore must be repaired, the pis-
ton must be changed to the correct oversize piston.
Check the clearance of the piston in its cylinder af-
ter the surface of the cylinder bore has been finished
with a hone.
Check the clearance of the wrist pin in the piston.

The normal clearance is shown in Engine Specifica-
tions. The wrist pin will normally fall from the hole
in the piston by its own weight.
The wrist pin is a press fit in the piston rod. The

piston and wrist pin are a matched set and must be
replaced as a unit if the clearances are greater than
the specifications.
1. UPPER COMPRESSION RING

2. LOWER COMPRESSION RING
3. OIL CONTROL RING
4. PISTON
Figure 46. Piston Rings
2. Use a press to remove the wrist pins from the

pistons. See Figure 47.
WARNING
Cleaning solvents can be flammable and toxic
cleaning solvents, always follow the recom-
WARNING
Figure 47. Wrist Pin Removal
28
Cylinder Bores, Inspect and Repair Using an oversize piston in the engine does not af-
fect the dynamic balance of the engine. Replacement
Inspect the cylinder bores for wear and damage. pistons are available in standard size and 0.50 mm
Measure the cylinder bores with a bore gauge in (0.020 in.) oversize. The clearance between a pis-
several positions as shown in Figure 48. Measure ton and its cylinder bore should be between 0.010 to
the cylinder bore at right angles to the centerline 0.030 mm (0.00039 to 0.00118 in.).
to find any distortion from wear. A cylinder that is
out of round greater than 0.127 mm (0.005 in.) will
require that the short block assembly be replaced as
oversized pistons are not available.
A tool called a hone can be used to remove a small

amount of taper from a cylinder bore. Use a boring
machine to repair a badly worn cylinder. The bor-
ing machine will make a more accurate cylinder bore.
The hone is then used to finish the surface of the
cylinder bore.
A cylinder bore that has been repaired with a hone

or a boring machine must be fitted with a piston that
is the correct size.
Use the following procedure to determine the clear-

ance between the pistons and cylinders.
1. Measure the inner diameter of the cylinder bore Figure 49. Bore Gauge Measurement
as shown in Figure 48.
2. Using a micrometer, measure the bore gauge and

record the reading. See Figure 49.
3. Using a micrometer, measure the outer diameter

of the piston. See Figure 50.
4. Subtract the piston diameter from the bore diam-

eter to determine the piston to bore clearance.
Figure 50. Piston Measurement
Figure 48. Cylinder Bore Measurement
29
Piston Rings, Inspect

NOTE: Check the clearance of the piston rings in the
cylinder after the surface of the cylinder has been
finished with a hone. New piston rings are available
for the different piston sizes. See the Parts Manual
for sizes.
The piston rings must match the size of the piston on

which they are installed. Check the side clearance
and the end clearance of the piston rings as described
in the following paragraphs.
Each compression ring has a dimple or orientation

mark on one surface. This mark must be toward the
top of the cylinder when the piston ring is installed.
The lower compression ring also has a bevel edge that
faces the bottom of the piston. The upper compres-
sion ring has a molybdenum filling and no bevelled
edge.
The oil control ring has three pieces. There are two
thin steel rings separated by a spacer. The oil control
ring has no dimple or orientation mark and may be
installed in either direction.
1. Measure the clearance between the piston ring Figure 51. Piston Ring and Groove Clearance
and the groove in the piston as shown in Fig- Check
ure 51. The clearances are shown in Engine
Specifications. Replace the piston if the clear-
ances are greater than the specifications.
2. Measure the end clearance of each piston ring

as shown in Figure 52. The end clearances are
shown in Engine Specifications. Install the pis-
ton ring into the cylinder where it will be used.
Use a thickness gauge to measure the amount
of end clearance. Replace the piston ring if the
clearances are greater than the specifications.
Figure 52. Piston Ring End Clearance Check
30
Assemble
NOTE: There are notches cast in the top of all pis-
tons to indicate the correct assembly and installa-
tion. The pistons must always be installed with this
notch toward the fan end of the engine. See Fig-
ure 56.
The piston rods have a notch cast in the bearing jour-

nal as shown in Figure 53. This notch must be oppo-
site the notch on the top of the piston when the piston
and piston rod are assembled.
B. POSITION OF GAP FOR OIL RING

C. POSITION OF GAP FOR SPACER OF OIL RING
D. POSITION OF GAP FOR OIL RING
E. POSITION OF GAP FOR LOWER
COMPRESSION RING
F. POSITION OF GAP FOR UPPER COMPRESSION
RING
Figure 54. Piston Ring Arrangement

1. NOTCHES ON ROD OPPOSITE NOTCH IN
PISTON Install
Figure 53. Piston Rod Identification 1. Lubricate the assembly with engine oil during in-
stallation. Arrange the piston rings on the piston
1. Assemble the piston rod to the piston. Make sure as shown in Figure 54. Install a ring compressor
the orientation of the piston rod and piston are on the piston as shown in Figure 55.
correct as described in the NOTE above. Use a
press to install the wrist pin into the piston and
piston rod. Lubricate the wrist pin with engine
oil during installation.
NOTE: Each compression ring has a dimple or ori-

entation mark on one surface. This mark must be
toward the top of the cylinder when the piston ring
is installed. The lower compression ring also has a
bevel edge that faces the bottom of the piston. The
upper compression ring has a molybdenum filling
and no bevelled edge.
The oil control rings do not have a dimple or orienta-

tion mark and may be installed in either direction. Figure 55. Ring Compressor Installation
2. Check the clearances of the piston rings as de- 2. Make sure that the notch in the piston is toward
scribed in Piston Rings, Inspect. Install the the fan end of the engine as shown in Figure 56.
piston rings on the piston as shown in Figure 54, Install the piston and piston rod assemblies in
considering that the vertical dash line corre- the cylinder bores.
sponds to the wrist pin position.
31
Crankshaft and Main Bearings 600 SRM 1121
to 29.5 lbf ft). Tighten the capscrews an addi-

tional 40 to 45 degrees. Check the side clear-
ance of each piston rod after the bearing cap is
installed. See the paragraphs in the procedure
Piston Rod Bearings, Replace.
4. Install the cylinder head. See Camshaft Carrier

and Cylinder Head, Install.
5. Place the bearing bracket in position on the en-

NOTE: CAST NOTCH MUST BE TOWARD FAN END gine block.
OF ENGINE.
6. Place the baffle plate in position on the bear-
A. FAN END OF ENGINE ing bracket and install capscrews. Tighten cap-
screws to 20 to 24 N•m (15 to 17.7 lbf ft).
Figure 56. Piston Position Inside Cylinder
7. Install the oil pump and oil pan. See Lubrication
3. Install the bearings and the caps for the piston
System Repair.
rods. Tighten the capscrews to 30 to 40 N•m (22
Crankshaft and Main Bearings

CRANKSHAFT TIMING PULLEY AND/OR 3. Using the special tool, piston flange universal
FRONT SEAL puller, remove the crankshaft timing pulley. See
Figure 58.
Remove
4. Remove the crankshaft keyway and the spacer.
1. Remove the timing belt. See Timing Belt and See Figure 59.
5. With an electric drill and a 2-mm drill bit, drill a
2. Using a special tool to hold the pulley, remove hole in the front face of the seal.
the crankshaft timing pulley retaining bolt. See
Figure 57.
Figure 58. Crankshaft Timing Pulley Removal

Figure 57. Crankshaft Timing Pulley Retaining
Bolt Removal/Installation
32
600 SRM 1121 Crankshaft and Main Bearings
Install
1. Install a special tool, protective sleeve, onto the
crankshaft end with the outer surface lubricated
with clean engine oil and the chamfered end of
the sleeve facing away from the engine. See Fig-
ure 61.
2. Install the front seal onto the protective sleeve.
3. Using a special tool, crankshaft front seal in-

staller, install the front seal into its lodging.
4. Remove the special tools.
5. Install the spacer and the keyway.
6. Install the crankshaft timing pulley onto the

1. KEYWAY 2. SPACER crankshaft end.
Figure 59. Crankshaft Keyway and Spacer 7. Using the special tool to hold the crankshaft
timing pulley, install the retaining bolt. See
6. Install a special tool, crankshaft front seal puller, Figure 57. Initially tighten bolt to 130 N•m
on a universal sliding mallet. Thread the end of (96 lbf ft). Tighten the bolt an additional 45
the special tool into the hole previously drilled in degrees.
the seal. Remove the seal. See Figure 60.
8. Install the timing belt. See Timing Belt and Tim-
ing Belt Tensioner, Install.
1. SEAL PULLER
2. END OF SLIDING MALLET
1. CRANKSHAFT FRONT SEAL INSTALLER
Figure 60. Crankshaft Front Seal Removal 2. SEAL
3. PROTECTIVE SLEEVE
4. CRANKSHAFT END
Figure 61. Crankshaft Front Seal Installation
33
CRANKSHAFT REAR MAIN OIL SEAL

Remove
1. Remove the engine. Refer to the section Frame
100 SRM 1120.
2. Remove the flywheel. See Flywheel and Fly-

wheel Housing.
3. With an electric drill and a 2-mm drill bit, drill a

hole in the front face of the seal.
4. Install a special tool, crankshaft rear main oil

seal puller, on a sliding mallet. Tighten the nut
on the sliding mallet against the special tool.
Thread the end of the special tool into the previ-
ously-drilled hole in the seal. Remove the seal. Figure 63. Crankshaft Rear Main Oil Seal
See Figure 62. Installation
Install 3. Install the flywheel. See Flywheel and Flywheel

Housing.
1. Remove the excess sealer from the oil seal recess.
4. Install the engine. Refer to the section Frame
2. Using a special tool, crankshaft rear main oil seal 100 SRM 1120.
installer, press the new oil seal into the housing.
See Figure 63. CRANKSHAFT/RPM SENSOR
Remove
1. Remove the timing belt front cover. See Timing
Belt Front Cover, Remove.
2. Disconnect the crankshaft/rpm sensor electrical

1. SEAL PULLER
2. NUT
3. END OF SLIDING MALLET
Figure 62. Crankshaft Rear Main Oil Seal

Removal
1. CRANKSHAFT/RPM SENSOR
2. ELECTRICAL HARNESS
Figure 64. Crankshaft Sensor
34
3. Remove the capscrew retaining the crankshaft/ 4. Remove the reluctor wheel.
rpm sensor.
5. Inspect the reluctor wheel for wear and damage.
4. Remove the crankshaft/rpm sensor. Replace as needed.
Install 6. Place the reluctor wheel in position on the crank-

shaft.
1. Install the crankshaft/rpm sensor into the engine
block. 7. Verify the alignment mark on the reluctor wheel
is aligned with the alignment mark on the crank-
2. Install the capscrew to retain the crankshaft/rpm shaft.
sensor. Tighten capscrew to 8 N•m (71 lbf in).
8. Install capscrews to retain reluctor wheel to
3. Connect the crankshaft/rpm sensor electrical the crankshaft. Tighten capscrews to 10 N•m
harness. (88.5 lbf in).
4. Install the timing belt front cover. See Timing 9. Install the crankshaft. See Crankshaft and Main
Belt Front Cover, Install Bearings, Install.
CRANKSHAFT RELUCTOR WHEEL CRANKSHAFT AND MAIN BEARINGS

Remove and Install Remove
1. Remove the crankshaft. See Crankshaft and 1. Remove the engine. Refer to the section Frame
Main Bearings, Remove. 100 SRM 1120.
2. Make an alignment mark on the crankshaft and 2. Remove the flywheel and flywheel housing. See
the reluctor wheel to properly align the reluctor Flywheel and Flywheel Housing.
wheel in the original position during installation.
3. Remove the oil pan and oil pump. See Lubrica-
3. Remove the capscrews retaining the reluctor tion System Repair.
wheel to the crankshaft. See Figure 65.
5. Remove the remaining capscrews from the bear-

ing bracket and remove the bearing bracket.
6. Remove caps for connecting rods. Put identifi-

cation marks on bearing caps so they can be in-
stalled in the original locations during assembly.
See Piston and Piston Rod Assemblies Repair.
7. Remove the capscrews for bearing caps and re-

move caps. See Figure 66.
1. CAPSCREW
2. RELUCTOR WHEEL
3. CRANKSHAFT
Figure 65. Reluctor Wheel
35
9. Remove the bearings from the bearing caps and

from the engine block.
10. If necessary, remove the reluctor wheel. See

Crankshaft Reluctor Wheel, Remove and Install.
Inspect and Repair
WARNING
goggles or a face shield to prevent injury to the
eyes.
WARNING
1. MAIN BEARING 3. CAP CAPSCREWS and can cause skin irritation. When using
2. BEARING CAPS 4. BEARINGS (HALF) cleaning solvents, always follow the recom-
Figure 66. Crankshaft Bearings
1. Clean the crankshaft with solvent and dry it with
8. Remove the crankshaft and rear main oil seal.
compressed air.
Remove and discard rear main oil seal. See Fig-
ure 67. 2. Inspect the crankshaft for cracks, wear, and dam-
age.
3. Inspect bearings for craters, pockets, excessive

scoring, and dirt or debris imbedded into the
bearing material. Replace as needed. Replace
the upper and lower halves as a set.
4. Inspect the bearings for improper seating indi-

cated by bright, polished sections of the bearing.
Replace as needed. Replace the upper and lower
halves as a set.
5. Use a micrometer to measure the journals for the

bearings of the crankshaft. See Figure 68. Take
the measurement at different positions to see if
the surface of the bearing is round. The correct
sizes are given in Engine Specifications.
6. If the crankshaft journals must be repaired, they

can be ground to a smaller (undersize) than the
original size. See the Parts Manual for avail-
1. CRANKSHAFT able bearing sizes.
2. REAR MAIN OIL SEAL
Figure 67. Crankshaft Removal
36
1. MAIN BEARING JOURNAL

2. CONNECTING ROD BEARING JOURNAL
3. CENTER BEARING
4. CRANKSHAFT COLOR CODE
5. BEARING COLOR CODE
6. BEARING IDENTIFICATION
Figure 68. Crankshaft Journal Measurement
Figure 69. Crankshaft and Bearing
Bearing Selection Identification
NOTE: The dimensions of a new crankshaft main
bearing journal, or one that was not subjected to
recondition procedures, can be identified by means
of the crankshaft color code.
The shell selection is performed by matching the

block main bearing diameter, identified by digits 0
and 1, and the crankshaft color code. See Figure 69.
At one end of the main bearing the color code (5)

and standard or oversize [0.25 to 0.50 mm (0.0098
to 0.0197 in.)] identification (6) is located. The iden-
tification code (365N - 366N) is located at the other
end of the bearing.
The diameter of the block main bearings is identified

by means of digits 0 and 1. See Figure 70. The diam-
eter identification numbers engraved on the engine
Figure 70. Engine Block Main Bearing
block main bearing direction are 01001.
Identification
37
The standard crankshaft has a brown color code. 2. Install all the main bearings and caps. Initially
tighten the capscrews to 50 N•m (37 lbf ft). Sec-
For a main bearing having an identification number ond, tighten the capscrews an additional 45 de-
0 on the engine block, and a crankshaft with a brown grees. Finally, tighten the capscrews an addi-
color code, you should install to the engine block main tional 15 degrees.
bearing (with an identification number 0) a brown
color upper bearing half, and to the main bearing cap 3. Check the rear main bearing first. Remove the
a brown color lower bearing half. cap for the rear main bearing. See Figure 66. The
procedure for checking the clearance of the other
For a main bearing having an identification number bearings is similar.
1 on the engine block, and a crankshaft with a brown
color code, you should install to the engine block main 4. Clean the oil from the bearing half and journal
bearing (with an identification number 0) a green to be checked. Put a piece of Plastigage® across
color upper bearing half, and to the main bearing cap the full width of the bearing journal as shown in
a brown color lower bearing half. Figure 71. Do not rotate the crankshaft when the
Plastigage® is between the main bearing and its
For a main bearing having an identification number journal.
0 on the engine block, and a crankshaft with a green
color code, you should install to the engine block main 5. Install the main bearing and main bearing
bearing (with an identification number 0) a brown cap. Initially tighten the capscrews to 50 N•m
color upper bearing half, and to the main bearing cap (37 lbf ft). Second, tighten the capscrews an
a green color lower bearing half. additional 45 degrees. Finally, tighten the cap-
screws an additional 15 degrees. The capscrews
For a main bearing having an identification number must be tightened to their final torque or there
1 on the engine block, and a crankshaft with a green will be an error in the measurement.
color code, you should install to the engine block main
bearing (with an identification number 0) a green
color upper bearing half, and to the main bearing cap
a green color lower bearing half.
Example: For a brown color crankshaft (standard

size) and a block having an identification number
01001 on the main bearings, use:
• For the bearing having identification 0, a brown
upper bearing half and a brown lower bearing half.
• For the bearing having identification 1, a green up-
per bearing half and a brown lower bearing half.
See the Parts Manual for available bearing sizes.
Main Bearings and Journal Clearance,

Check
NOTE: Crankshaft main bearings are a precision-in-
sert type. Main bearing caps are machined with
the engine block for proper clearance and cannot
be shimmed or filed for bearing fit. If crankshaft Figure 71. Bearing Journal Plastigage®
bearing clearances are not within specifications, new Placement
bearings and/or engine block and cap repair may be
required.
1. Place the upper bearing halves in position in the

cylinder block.
38
6. Remove the main bearing cap. The Plastigage®

will be compressed and wider and it will adhere
to either the bearing or its journal. Use the scale
on the envelope for the Plastigage® to measure
the width of the plastic at its widest point. The
scale will indicate the clearance in millimeters or
thousandths of an inch. See Figure 72.
Figure 73. Crankshaft End Clearance

Measurement
Install
1. If removed, install the reluctor wheel. See
Crankshaft Reluctor Wheel, Remove and Install.
2. Lubricate new main bearing halves with engine

Figure 72. Plastigage® Measurement oil and install them in the bearing housing of the
engine block.
7. Refer to Engine Specifications for clearances. If
the clearance is greater than the specifications, 3. Carefully install the crankshaft in the engine
select a new undersize bearing set and install it. block. See Figure 61.
Measure the clearance again. If the clearance
cannot meet specifications with the available 4. Lubricate the lower halves of the main bear-
undersize bearings, the bearing journal must ings and install them in their caps. Fill the
be ground to a new undersize. If the bearing side grooves of the rear main bearing cap with
journal is already at the maximum undersize, sealant. See Figure 74. Install each main bear-
the crankshaft must be replaced. ing cap in its position on the engine block. Make
sure each main bearing cap is installed in its
8. Check the crankshaft end clearance. Install original position. If a main bearing cap is not
a dial indicator so that the probe touches the installed correctly, there can be an alignment
crankshaft end. See Figure 73. Using a flat blade problem, which can cause rapid wear and dam-
screwdriver, push forward and backward and age to the engine.
read the dial gauge. The correct end play clear-
ance is 0.050 to 0.152 mm (0.002 to 0.006 in.). If
clearance is greater than specification, replace
main bearings or crankshaft.
39
the thrust surfaces on the rear main bearing.

Initially tighten the main bearing capscrews to
50 N•m (37 lbf ft). Second, tighten the capscrews
an additional 45 degrees. Finally, tighten the
capscrews an additional 15 degrees.
6. Check the crankshaft end clearance. See Fig-

ure 73.
7. Check the clearance between the main bearing

and its crankshaft journal. See Main Bearings
and Journal Clearance, Check.
8. Install the piston assemblies. See Piston and Pis-

ton Rod Assemblies Repair.
9. Place the bearing bracket in position on the en-

gine block. Install the three central capscrews
and hand tighten only.
10. Place the baffle plate in position on the bearing

bracket and install remaining capscrews. Ini-
tially tighten capscrews to 20 N•m (15 lbf ft).
1. SIDE GROOVE Then tighten the capscrews an additional 45 de-
grees. This includes the three central capscrews
Figure 74. Rear Main Bearing Cap Side previously hand tightened.
Grooves
11. Install the oil pump and oil pan. See Lubrication
5. Install the capscrew for the main bearing caps System Repair.
and tighten the capscrews handtight. Use a soft
hammer or plastic mallet to hit the crankshaft 12. Install the flywheel and flywheel housing. See
lightly and move it forward against the rear main Flywheel and Flywheel Housing.
bearing. Then, use the hammer to hit the crank-
shaft lightly and move it backward against the 13. Install the engine. Refer to the section Frame
rear main bearing. This procedure is to align 100 SRM 1120.
40
600 SRM 1121 Flywheel and Flywheel Housing
Flywheel and Flywheel Housing

REMOVE (28 lbf ft). Tighten M12 capscrews to 66 N•m
(48.7 lbf ft). See Figure 75.
1. Remove the engine. See Engine Removal and
Installation. 2. Install adapter plate on crankshaft. Install the
flywheel.
2. Remove capscrews for flywheel. Then remove fly-
wheel and adapter plate. See Figure 75. 3. Apply Loctite® 222 or equivalent on threads of
capscrews. Then install capscrews for flywheel.
3. If necessary, remove flywheel housing. Tighten capscrews to 52 N•m (38.35 lbf ft) in
proper sequence. See Figure 75.
INSTALL
4. Install the engine. See Engine Removal and In-
1. If flywheel housing was removed, install it on stallation.
engine. Tighten M10 capscrews to 38 N•m
A. TIGHTENING SEQUENCE
1. ENGINE BLOCK 6. CAPSCREW
2. M10 CAPSCREWS 7. FLYWHEEL
3. LOCKWASHERS 8. M12 CAPSCREW
4. FLYWHEEL HOUSING 9. LOCKWASHER
5. ADAPTER PLATE
Figure 75. Flywheel Arrangement
41
Cooling System Repair 600 SRM 1121
Cooling System Repair

SERPENTINE BELT Install
Remove NOTE: The belt tensioner is a nonadjustable, self-
tensioning device with two positions, tension applied
and tension relieved.
WARNING
During engine operation, be careful not to NOTE: The drive tool slot will accommodate the drive
touch the fan, pulleys, or drive belts. Contact end of either a 3/8-in. ratchet or breaker bar.
with these parts can cause serious injury.
1. Using a drive tool, placed in the drive tool slot
located on the self-tensioning device, move the
WARNING self-tensioning device in a downward motion to
The radiator or other parts of the cooling sys- relieve tension on the self-tensioning device. See
tem may be hot or under pressure and can Figure 76.
radiator to cool. Do a touch test by touching 2. Place the serpentine belt over the pulleys, and
the radiator with your hand. If the radiator is release the self-tensioning device.
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of 3. Remove truck from the blocks. Refer to How to
the cooling system. Put a Truck on Blocks in the Operating Man-
ual or to the section Periodic Maintenance
1. Turn the ignition switch to the OFF position. 8000 SRM 1150.
2. Remove the four bolts retaining the fan assembly. 4. Replace the fan assembly.
3. Remove the fan assembly.
4. Place the truck up on blocks. Refer to How to

Put a Truck on Blocks in the Operating Man-
ual or to the section Periodic Maintenance
8000 SRM 1150.
NOTE: The belt tensioner is a nonadjustable, self-

tensioning device with two positions, tension applied
and tension relieved.
NOTE: The drive tool slot will accommodate the drive

end of either a 3/8-in. ratchet or breaker bar.
5. Using a drive tool, placed in the drive tool slot

located on the self-tensioning device, move the
self-tensioning device in a downward motion to
relieve tension on the serpentine belt. See Fig-
ure 76.
6. Remove the serpentine belt from the pulleys.
Inspect 1. CHECK TENSION HERE

2. DRIVE TOOL SLOT
Inspect the serpentine belt. If there are any cracks or 3. SELF-TENSIONING DEVICE
damage to the serpentine belt, replace the serpentine
belt. Figure 76. Serpentine Belt Check
42
600 SRM 1121 Cooling System Repair
minutes, do a touch test by touching the radi-

WARNING ator with your hand. If the radiator is still hot
During engine operation, be careful not to to the touch, wait another 30 minutes before
touch the fan, pulleys, or drive belts. Contact attempting any maintenance to the cooling
with these parts can cause serious injury. system.
5. Start the engine to make sure the serpentine belt
is operating correctly. CAUTION
Disposal of lubricants must meet local environ-
WATER PUMP mental regulations.
Remove 5. Remove the radiator cap.
1. Turn the ignition switch to the OFF position. 6. Loosen the lower radiator hose and drain the
coolant from the coolant system.
2. Disconnect the negative battery cable at the bat-
tery. 7. Remove the fan shroud. Refer to the section
Cooling System 700 SRM 1123.
3. Disconnect the air intake hoses from the air filter
assembly. 8. Place a piece of cardboard over the radiator sur-
face to prevent damage to the radiator.
NOTE: The ECM assembly must be disconnected
from the air filter assembly before removing the air 9. Remove the four bolts retaining the fan assembly.
filter assembly. For gasoline engines, refer to the
section Gasoline Fuel System, GM 2.4L Engine 10. Remove the fan assembly.
900 SRM 1126. For LPG fuel systems, refer to the
11. Remove the serpentine belt. See Serpentine Belt,
section LPG Fuel System, GM 2.4L Engine 900
Remove.
SRM 1124.
12. Remove the spacer and the pulley.
4. Remove the three bolts that attach the air filter
assembly mounting bracket to the frame and re- 13. Disconnect the electrical connections to the alter-
move air filter assembly with mounting bracket. nator.
14. Remove the alternator mounting bolts and re-

WARNING
move the alternator.
diator when the engine is hot. When the radia- 15. Remove the alternator bracket bolts, fan hub
tor cap is removed, pressure will release from bracket bolts, and fan hub bracket.
the coolant system. If the coolant system is hot,
the steam and boiling coolant can cause severe 16. Remove the timing belt and timing belt ten-
burns. sioner. See Timing Belt and Timing Belt Ten-
sioner, Remove.
WARNING NOTE: Before loosening the water pump bolts, make
The radiator or other parts of the cooling sys- alignment marks on the water pump and cylinder
tem may be hot or under pressure and can block to identify the correct alignment position of the
cause serious injury. Wait 30 minutes for the water pump. See Figure 77.
radiator and engine to cool before performing
maintenance to the cooling system. After 30 17. Remove the water pump bolts.
43
Figure 77. Water Pump Alignment
44

1. WATER PUMP 9. CRANKSHAFT TIMING BELT PULLEY
2. WATER PUMP TAB (11 O’CLOCK POSITION) 10. CRANKSHAFT TIMING PULLEY BOLT
3. WATER PUMP BOLT 11. CRANKSHAFT PULLEY HUB MARK
4. TENSIONER 12. OIL PUMP HOUSING TIMING MARK
5. TENSIONER BOLT 13. TIMING MARK (LOCATED ON PLASTIC TIMING
6. TENSIONER TAB (7 O’CLOCK POSITION) BELT HOUSING)
7. TIMING BELT TENSIONER POINTER 14. CAMSHAFT TIMING BELT MARK
8. USED AND NEW TIMING BELT MARKS
18. Remove the water pump O-ring. Discard O-ring. 2. Place the water pump into position and verify
See Figure 78. that the alignment marks are properly aligned.
Install the water pump bolts and tighten to 20 to
30 N•m (15 to 22 lbf ft).
3. Install the timing belt and timing belt tensioner.

See Timing Belt and Timing Belt Tensioner, In-
stall.
4. Install the timing belt front cover. See Timing

Belt Front Cover, Install.
NOTE: Before installing the crankshaft pulley and

crankshaft spacer, align these components with the
alignment marks made when disassembled.
5. Install the crankshaft spacer and crankshaft pul-

ley, ensuring that all alignment marks made dur-
ing removal are lined up properly. Tighten crank-
1. WATER PUMP BOLT shaft pulley bolts to 135 N•m (99 lbf ft).
2. WATER PUMP
3. O-RING 6. Install fan hub bracket and retaining bolts.
Figure 78. Water Pump Tighten bolts to 52 N•m (38 lbf ft).
7. Install alternator bracket and retaining bolts.

Inspect Tighten bolts to 38 N•m (28 lbf ft).
Inspect the water pump for the following:
8. Install the alternator. See the section Alternator
• Inspect the pulley for wear and damage.
Repair.
• Worn or damaged gasket sealing surfaces.
• Side-to-side play in the pulley shaft. 9. Install the fan spacer and the pulley.
• Leakage at the water inlet housing or rear cover
gasket areas. 10. Install the serpentine belt. See Serpentine Belt,
• Leakage at the water pump vent hole. A stain Install.
around the vent hole is acceptable. If leakage oc-
curs at the vent hole with the engine running and 11. Place the fan in position on the pulley and in-
the cooling system pressurized, replace the water stall the four retaining bolts. Tighten the bolts
pump. to 26 N•m (19 lbf ft).
12. Remove cardboard from the radiator surface.

Install
13. Install the fan shroud. Refer to the section Cool-
1. Install a new O-ring onto the water pump.
ing System 700 SRM 1123.
NOTE: Before installing a new water pump and tight-
ening the water pump bolts, make sure the water
pump tab is in the 11 o’clock position for proper align-
ment of the timing belt tensioner.
45
CAUTION WARNING
Additives may damage the cooling system. Be- The radiator or other parts of the cooling sys-
fore using additives, contact your local Hyster tem may be hot or under pressure and can
dealer. cause serious injury. Wait 30 minutes for the
14. Connect the bottom radiator hose. Fill cooling the radiator with your hand. If the radiator is
system with coolant. Refer to the section Peri- still hot to the touch, wait another 30 minutes
odic Maintenance 8000 SRM 1150 for correct before attempting to check or fix any part of
coolant amount and type. the cooling system.
15. Install radiator cap on radiator.
CAUTION
NOTE: The ECM assembly must be connected to the Additives may damage the cooling system. Be-
air filter assembly after installing the air filter as- fore using additives, contact your local Hyster
sembly. For gasoline engines, refer to the section dealer.
Gasoline Fuel System, GM 2.4L Engine 900 SRM
1126. For LPG fuel systems, refer to the section LPG 21. Stop engine. If coolant is hot, give engine time to
Fuel System, GM 2.4L Engine 900 SRM 1124. cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
16. Place the air filter assembly with mounting reservoir.
and tighten to 20 N•m (15 lbf ft). THERMOSTAT
17. Connect the air intake hoses to the air filter as-
Remove
sembly.
18. Connect the negative battery cable. WARNING

The radiator or other parts of the cooling sys-
WARNING tem may be hot or under pressure and can
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
the radiator with your hand. If the radiator is
before attempting to check or fix any part of
WARNING the cooling system.
CAUTION
DO NOT operate the engine without a ther-
19. Start engine and check cooling system for leaks. mostat. The engine and cooling system can be
damaged.
20. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the
alternator. When the air has been bled from the CAUTION
system, close the bleed screw. Disposal of lubricants and fluids must meet lo-
WARNING 1. Loosen the lower radiator hose and drain the
DO NOT remove the radiator cap from the ra- coolant from the coolant system.
ator cap is removed, the pressure is released 2. Remove the capscrew that holds the oxygen sen-
from the system. If the system is hot, the steam sor wire clamp to thermostat cover. See Fig-
and boiling coolant can cause burns. DO NOT ure 79.
remove the cover for the radiator when the en-
gine is running.
46
3. Remove the capscrews retaining the thermostat 4. Remove the thermostat and O-ring. See Fig-
cover to the thermostat housing. ure 79.
Check
WARNING
CAUTION
DO NOT operate the engine without a ther-
mostat. The engine and cooling system can be
damaged.
1. Inspect the thermostat and O-ring that connects

to the thermostat housing. If the O-ring is dam-
aged, replace the O-ring.
2. Inspect the two inner discs on the thermostat

that seal the water flow. Verify that they are
clean and in good condition. If damaged, replace
thermostat.
NOTE: While performing the test of the thermostat

in Step 3, make sure that the thermostat and ther-
mometer do not touch the sides or the bottom of the
container used for heating the water.
3. Hold thermostat with a wire and place in the

water. Slowly heat the water to 82°C (180°F).
At this temperature, the thermostat should be
starting to open. Continue to heat the water to
97°C (207°F). At this temperature, the thermo-
stat should be fully open. If not, replace the ther-
mostat.
4. Cool the water to 70°C (158°F). The thermostat

must close completely. If it does not, replace the
thermostat.
Install
1. Install a new O-ring and install the thermostat
into the thermostat housing.
1. CAPSCREW
2. OXYGEN SENSOR WIRE CLAMP
3. THERMOSTAT COVER 2. Install the thermostat cover and tighten the cap-
4. THERMOSTAT screws to 20 N•m (15 lbf ft).
5. THERMOSTAT AND THERMOSTAT COVER
(ONE-PIECE) 3. Connect the capscrew that holds the oxygen sen-
6. O-RING sor wire clamp to thermostat cover.
7. THERMOSTAT HOUSING
Figure 79. Thermostat Replacement
47
CAUTION CAUTION
Additives may damage the cooling system. Be- Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster fore using additives, contact your local Hyster
dealer. dealer.
4. Connect the bottom radiator hose. Fill cooling 8. Stop engine. If coolant is hot, give engine time to
system with coolant. Refer to the section Peri- cool. Check coolant level and fill as required be-
odic Maintenance 8000 SRM 1150 for correct tween the ADD and FULL marks on the coolant
coolant amount and type. reservoir.
5. Install radiator cap on radiator. THERMOSTAT HOUSING
WARNING Remove
During engine operation, be careful not to 1. Disconnect the negative battery cable at the bat-
touch the fan, pulleys, or drive belts. Contact tery.
2. Loosen the lower radiator hose and drain the
WARNING coolant.
The radiator or other parts of the cooling sys- 3. Disconnect the electrical connector from the en-
tem may be hot or under pressure and can gine coolant temperature sensor.
4. Disconnect the upper radiator hose to the ther-
6. Start the engine and check cooling system for mostat cover.
leaks.
7. Bleed air from the cooling system by opening the Belt Rear Cover, Remove.
bleed screw located on the left side behind the
alternator. When the air has been bled from the 6. Disconnect the coolant hoses, below the intake
system, close the bleed screw. manifold, from the thermostat housing to the
coolant manifold.
WARNING 7. Remove the bolts retaining the thermostat hous-
DO NOT remove the radiator cap from the ra- ing to the cylinder head. See Figure 80.
ator cap is removed, the pressure is released 8. Remove the thermostat housing.
from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT 9. Remove and discard the O-ring from the thermo-
remove the cover for the radiator when the en- stat housing.
gine is running.
Clean and Inspect
WARNING Remove all debris and residue from the thermostat
The radiator or other parts of the cooling sys- housing. Inspect the thermostat housing for cracks
tem may be hot or under pressure and can and other damage. Inspect the coolant hoses for wear
cause serious injury. Wait 30 minutes for the and damage. Repair or replace as needed.
the radiator with your hand. If the radiator is Install
1. Install a new O-ring in the thermostat housing.
the cooling system. 2. Place the thermostat housing in position.
48
10. Install the alternator. See the section Alternator

Repair.
11. Install the fan spacer and pulley.
12. Install the serpentine belt. See Serpentine Belt,

Install.
13. Connect the upper radiator hose to the thermo-

stat housing. Tighten the clamp to 4 to 5 N•m
(35 to 44 lbf in).
14. Connect the electrical connection to the engine

coolant temperature sensor.
15. Connect the negative battery cable to the battery.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
1. BOLT dealer.
2. ENGINE COOLANT TEMPERATURE SENSOR
(ECT) 16. Connect the lower radiator hose. Fill cooling
system with coolant. Refer to the section Peri-
Figure 80. Thermostat Housing odic Maintenance 8000 SRM 1150 for correct
coolant amount and type.
3. Install the bolts to retain the thermostat housing
and tighten to 11 N•m (97 lbf in). 17. Install radiator cap on radiator.
4. Connect the coolant hoses, below the intake man-

WARNING
ifold, to the thermostat housing. Tighten the
clamps to 4 to 5 N•m (35 to 44 lbf in). During engine operation, be careful not to
5. Install the timing belt rear cover. See Timing with these parts can cause serious injury.
6. Install the timing belt and timing belt tensioner.

WARNING
See Timing Belt and Timing Belt Tensioner, In- The radiator or other parts of the cooling sys-
stall. tem may be hot or under pressure and can
7. Install timing belt front cover. See Timing Belt
Front Cover, Install. 18. Start engine and check cooling system for leaks.
8. Install fan hub bracket and retaining bolts. 19. Bleed air from the cooling system by opening the
Tighten bolts to 52 N•m (38 lbf ft). bleed screw located on the left side behind the
alternator. When the air has been bled from the
9. Install alternator bracket and retaining bolts. system, close the bleed screw.
Tighten bolts to 38 N•m (28 lbf ft).
49
Sensors and Switches 600 SRM 1121

WARNING still hot to the touch, wait another 30 minutes
DO NOT remove the radiator cap from the ra- before attempting to check or fix any part of
diator when the engine is hot. When the radi- the cooling system.
ator cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT CAUTION
remove the cover for the radiator when the en- Additives may damage the cooling system. Be-
gine is running. fore using additives, contact your local Hyster
dealer.
WARNING 20. Stop engine. If coolant is hot, give engine time to
The radiator or other parts of the cooling sys- cool. Check coolant level and fill as required be-
tem may be hot or under pressure and can tween the ADD and FULL marks on the coolant
cause serious injury. Wait 30 minutes for the reservoir.
Sensors and Switches

CRANKSHAFT POSITION (CKP) SENSOR Install
Remove 1. Install new crankshaft sensor into the engine
block.
1. Raise the hood and disconnect the battery.
2. Install the capscrew to secure the crankshaft sen-
2. Disconnect the crankshaft sensor electrical har- sor. Tighten capscrew to 8 N•m (71 lbf in).
ness. See Figure 81.
3. Connect the crankshaft sensor electrical harness.
3. Remove the capscrew retaining the crankshaft See Figure 81.
sensor.
4. Connect the battery and lower the hood.
4. Remove the crankshaft sensor.
CAMSHAFT POSITION (CMP) SENSOR
Remove for Lift Trucks Built Before
January, 2010
Assembly
1. Open the hood. Disconnect the negative battery

cable.
2. Disconnect the CMP sensor electrical connector.

See Figure 82.
3. Remove harness clamp from CMP sensor support

plate.
4. Remove retaining screws, CMP sensor assembly,

and O-ring from engine block. See Figure 83.
1. CRANKSHAFT SENSOR
2. ELECTRICAL HARNESS
Figure 81. Crankshaft Sensor, GM 2.4L Engine
50
600 SRM 1121 Sensors and Switches
4. Remove screw, lockwasher, and CMP sensor from

CMP sensor plate. Remove and discard O-ring
from CMP sensor. See Figure 84.
1. CMP SENSOR
2. WIRE HARNESS CLAMP
Figure 82. CMP Sensor Electrical Connector

for Lift Trucks Built Before January, 2010
1. SCREW 4. O-RING
2. LOCKWASHER 5. CMP SENSOR
3. CMP SENSOR PLATE
Figure 84. CMP Sensor for Lift Trucks Built

Before January, 2010
Install for Lift Trucks Built Before January,

2010
Assembly
1. Lubricate new O-ring with clean engine oil. In-

stall O-ring into groove in CMP sensor plate. See
Figure 83.
1. RETAINING SCREW
2. CMP SENSOR ASSEMBLY 2. Install CMP sensor assembly onto engine block.
3. O-RING See Figure 83.
Figure 83. CMP Sensor Assembly for Lift NOTE: Before installing lockwasher and screw, verify
Trucks Built Before January, 2010 CMP sensor is fully seated.
Sensor Only 3. Install lockwasher and screw onto CMP sensor.
See Figure 83. Tighten to 10 N•m (88.5 lbf in).
1. Open the hood. Disconnect the negative battery
cable. 4. Connect the electrical connectors. Verify that the
connectors click/lock into place. See Figure 82.
See Figure 82. 5. Install harness clamp onto CMP sensor plate.
See Figure 82.
3. Remove harness clamp from CMP sensor support
plate. 6. Connect the negative battery cable. Close the
hood.
51
Sensor Only 3. Remove screw and CMP sensor assembly from

engine. See Figure 85.
1. Lubricate new O-ring with clean engine oil. In-
stall O-ring onto sensor. See Figure 84. Install for Lift Trucks Built After January,
2. Install CMP sensor, lockwasher, and screws onto 2010
CMP sensor plate. See Figure 84. Tighten screw 1. Install CMP sensor assembly and screw onto en-
to 6 N•m (53 lbf in). gine. See Figure 85.
3. Connect the electrical connectors. Verify that the 2. Connect CMP sensor electrical connector. See
connectors click/lock into place. See Figure 82. Figure 85.
4. Install harness clamp onto CMP sensor plate. 3. Connect negative battery cable. Close the hood.
See Figure 82.
5. Connect the negative battery cable. Close the OIL PRESSURE SENSOR
hood.
Remove
Remove for Lift Trucks Built After January, 1. Raise hood and disconnect the battery.
2010
2. Disconnect the electrical connector for the oil
1. Open the hood. Disconnect the negative battery pressure sensor. See Figure 86.
cable.
3. Remove the oil pressure sensor.
See Figure 85.
1. CMP SENSOR ELECTRICAL CONNECTOR 3. CMP SENSOR ASSEMBLY

2. SCREW
Figure 85. CMP Sensor Assembly for Lift Trucks Built After January, 2010
52
600 SRM 1121 Ignition System
Install
1. Install new oil pressure sensor onto engine.
Tighten sensor to 20 N•m (177 lbf in).
2. Connect the electrical connector for the oil pres-

sure sensor. See Figure 86.
3. Connect battery and lower the hood.
3. OIL FILTER
4. ADAPTER, O-RING, AND RETAINING RING
Figure 86. Oil Pressure Sensor, GM 2.4L Engine
Ignition System
SPARK PLUG WIRE INSPECTION If corrosion, carbon tracking, or arcing is indicated
on a spark plug wire boot or on a terminal, replace
Spark plug wire integrity is vital for proper engine the wire and the component connected to the wire.
operation. A thorough inspection will be necessary to
accurately identify conditions that may affect engine SPARK PLUG WIRE REPLACEMENT
operation. Inspect for the following conditions:
Remove
1. Correct routing of the spark plug wires. Incorrect
routing may cause cross-firing. 1. Disconnect the spark plug wire at each spark
plug. See Figure 87.
2. Any signs of cracks or splits in the wires.
a. Twist the boots 1/2 turn before removing the
3. Inspect each boot for the following conditions: boots.
• Tearing
• Piercing b. Pull only on the boot or use a tool designed
• Arcing for this purpose in order to remove the wire
• Carbon tracking from each spark plug.
• Corroded terminal
53
Ignition System 600 SRM 1121
a. Push sideways on each boot in order to in-

spect the seating.
b. Reinstall any loose boot. You should feel the

terminal snap onto the spark plug or coil
when installing the spark plug wire. Inspect
and replace component that is damaged.
c. Wire routings must be kept intact during ser-

vice and followed exactly when wires have
been disconnected or when replacement of
the wires is necessary. Failure to route the
wires properly can lead to radio ignition noise
and cross firing of the plugs or shorting of the
leads to the ground.
d. Any time the spark plug wires or boots are

1. ELECTRICAL CONNECTOR installed on the spark plugs, new dielectric
2. COIL PACK grease needs to be applied inside the boot.
3. NO. 1 CYLINDER SPARK PLUG WIRE
5. NO. 3 CYLINDER SPARK PLUG WIRE SPARK PLUG REPLACEMENT
Remove
Figure 87. Spark Plug Wire Removal/
Installation 1. Remove the spark plug wires. Refer to Spark
Plug Wire Replacement.
2. Disconnect the spark plug wire from the coil
pack. 2. Loosen each spark plug 1 or 2 turns.
a. Twist each spark plug boot 1/2 turn. 3. Brush or air blast away any dirt from around the
spark plugs.
b. Pull only on the boot or use a tool designed
for this purpose in order to remove the wires 4. Remove the spark plugs 1 at a time. Place each
from the coil pack. plug in a tray marked with the corresponding
cylinder number. See Figure 88.
Install
5. Inspect each spark plug. See Spark Plug Inspec-
NOTE: If the boot-to-wire movement has occurred, tion.
the boot will give a false visual impression of being
fully seated. Ensure that the boots have been prop- Install
erly assembled by pushing sideways on the installed
boots. Failure to properly seat the terminal onto the 1. Properly position each spark plug washer.
spark plug will lead to wire core erosion and result in
2. Inspect each spark plug gap. Adjust each plug as
an engine misfire or crossfire condition and possible
needed.
internal damage to the engine.
1. Install the spark plug wires at the coil pack. You Specification
should feel the terminal snap onto the coil. Spark plug gap: 0.8 to 0.9 mm (0.031 to
0.035 in.)
2. Install the spark plug wire to each spark plug.
You should feel the terminal snap onto the spark 3. Hand start the spark plugs in the corresponding
plug. See Figure 87. cylinders. See Figure 88.
3. Inspect the wires for proper installation:
54
Inspect
1. Inspect the terminal post for damage. See Fig-
ure 89.
a. Inspect for a bent or broken terminal post.
1. NO. 1 CYLINDER SPARK PLUG

Figure 88. Spark Plug Removal/Installation
CAUTION
Only use a spark plug socket or wrench to
tighten the spark plugs. Do not force the spark 1. TERMINAL POST 3. ELECTRODE
plug into the cylinder head. Any misalignment 2. INSULATOR 4. ELECTRODE
can damage the aluminum threads in the cylin- Figure 89. Spark Plug
der head and may require the replacement of
the cylinder head. b. Test for a loose terminal post by twisting and
pulling the post. The terminal post should
4. Tighten the spark plugs to 20 N•m (15 lbf ft). NOT move.
SPARK PLUG INSPECTION 2. Inspect the insulator for flashover or carbon
tracking soot. See Figure 90. This is caused
Usage by the electrical charge traveling across the in-
sulator between the terminal post and ground.
1. Ensure that the correct spark plug is installed.
Inspect for the following conditions:
An incorrect spark plug causes driveability con-
ditions. The correct spark plug type is NGK a. Inspect the spark plug boot for damage.
BPR5EY.
b. Inspect the spark plug recess area of the
2. Ensure that the spark plug has the correct heat cylinder head for moisture, such as oil,
range. An incorrect heat range causes the follow- coolant, or water. A spark plug boot that is
ing conditions: saturated causes arcing to ground.
• Spark plug fouling - Colder plug
• Pre-ignition causing spark plug and/or engine
damage - Hotter plug
55
1. TERMINAL POST 3. ELECTRODE 1. TERMINAL POST 3. ELECTRODE

2. INSULATOR 4. ELECTRODE 2. INSULATOR 4. ELECTRODE
Figure 90. Spark Plug With Flashover or Figure 91. Spark Plug Arcing Through a Crack
Carbon Tracking
3. Inspect the insulator for cracks. All or part of

the electrical charge may arc through the crack
instead of the electrodes. See Figure 91.
4. Inspect for evidence of improper arcing. See Fig-

ure 92.
a. Measure the gap between the center elec-

trode (4) and the side electrode (3) terminals.
An excessively wide electrode gap can pre-
vent correct spark plug operation. Refer to
Engine Specifications for the proper gap. Ad-
just as necessary.
b. Inspect for the correct spark plug torque.

The correct torque is 20 N•m (15 lbf ft).
Insufficient torque can prevent correct spark
plug operation. An over-torqued spark plug
causes the insulator to crack.
1. TERMINAL POST 3. ELECTRODE
c. Inspect for signs of tracking that occurred 2. INSULATOR 4. ELECTRODE
near the insulator tip instead of the center
electrode (4). Figure 92. Spark Plug Arcing Improperly
d. Inspect for a broken or worn side electrode

(3).
56
e. Inspect for a broken, worn, or loose center COIL PACK

electrode (4) by shaking the spark plug.
Remove
(1) A rattling sound indicates internal
damage. 1. Tag and disconnect the spark plug wires.
(2) A loose center electrode (4) reduces the 2. Disconnect the electrical connection to the coil
spark intensity. pack.
f. Inspect for bridged electrodes (3, 4). Deposits 3. Remove the capscrews retaining the coil pack to
on the electrodes (3, 4) reduce or eliminate the mounting bracket and remove coil pack. See
the gap. Figure 93.
g. Inspect for worn or missing platinum pads on 4. Remove the nuts retaining the mounting bracket
the electrodes (3, 4), if equipped. to the camshaft carrier assembly and remove
mounting bracket.
h. Inspect for excessive fouling.
Install
5. Inspect the spark plug recess area of the cylinder
head for debris. Dirty or damaged threads can 1. Place the coil pack mounting bracket in position
cause the spark plug not to seat correctly during on the camshaft carrier assembly. Install the two
installation. nuts to retain the mounting bracket. Tighten
nuts to 38 N•m (28 lbf ft).
Visual Inspection
2. Place the coil pack in position on the mounting
1. Normal operation - Brown to grayish-tan with bracket and install capscrews. Tighten cap-
small amounts of white powdery deposits are screws to 10 N•m (88.5 lbf in).
normal combustion by-products from fuels with
additives. 3. Connect the electrical connector to the coil pack.
2. Carbon fouled - Dry, fluffy, black carbon or soot 4. Connect the spark plug wires.
caused by the following conditions:
• Rich fuel mixtures.
– Leaking fuel injectors
– Excessive fuel pressure
– Restricted air filter element
– Incorrect combustion
• Reduced ignition system voltage output.
– Weak coil pack
– Worn ignition wires
– Incorrect spark plug gap
• Excessive idling or slow speeds under light
loads can keep spark plug temperatures so low
that normal combustion deposits may not burn
off.
3. Deposit fouling - Oil, coolant, or additives that

include substances such as silicone, very white 1. SPARK PLUG WIRES
coating, reduce the spark intensity. Most pow- 2. COIL PACK
3. CAPSCREW
dery deposits will not effect spark intensity un- 4. MOUNTING BRACKET
less they form into a glazing over the electrode. 5. NUTS
Figure 93. Coil Pack Removal/Installation
57
Alternator Repair 600 SRM 1121
Alternator Repair
ALTERNATOR 4. Tighten lower bolt to 20 N•m (15 lbf ft).
Remove 5. Tighten the bolts retaining the alternator mount-

ing bracket to the cylinder block to 38 N•m
(28 lbf ft).
WARNING
Always disconnect the battery ground cable be- 6. Connect electrical connectors to alternator.
fore making repairs to prevent possible dam-
age and injury. Install a tag on the battery ter- 7. Install the serpentine belt. See Serpentine Belt,
minal so that no one connects the cable on the Install.
terminal.
8. Connect battery cable at negative terminal.
1. Disconnect battery cable at negative terminal.
Install a tag on battery terminal to warn against ALTERNATOR FUSE, REPLACE
connecting cable.
1. Remove the cover from the fuse holder. See Fig-
2. Remove the serpentine belt. See Serpentine Belt, ure 95.
Remove.
2. Remove fuse from the fuse holder and discard the
3. Put labels on electrical connectors and wires fuse.
prior to disconnecting to aid in correct installa-
3. Install new fuse into fuse holder.
tion.
4. Install cover onto fuse holder.
4. Disconnect electrical connectors and wires from
alternator.
5. Remove the lower bolt and spacer from the alter-

nator. See Figure 94.
6. Remove the upper bolt from the alternator and

remove alternator.
Install
CAUTION
The bolts retaining the alternator mounting
bracket to the cylinder block must be loosened
to achieve proper alignment when the alterna-
tor is installed or damage may occur.
1. Loosen the bolts retaining the alternator mount-

ing bracket to the cylinder block.
2. Place alternator in position on the mounting

bracket and install the lower bolt and spacer
finger tight only. 1. UPPER BOLT 3. LOWER BOLT
2. ALTERNATOR 4. SPACER
3. Attach the upper alternator boss to the strap on
the fan mount bracket and tighten the upper bolt Figure 94. Alternator
58
600 SRM 1121 Starter Repair

1. FUSE HOLDER
2. FUSE
3. COVER
Figure 95. Alternator Fuse
Starter Repair
REMOVE 5. Hold starter so it won’t fall. Remove capscrews
that fasten the starter to the flywheel housing.
WARNING Remove starter from flywheel housing.
fore you make repairs to the engine. Discon-
INSTALL
nect the cable at the negative terminal first. In- 1. Place starter in position in flywheel housing. In-
stall a tag on the battery terminals so that no stall capscrews to fasten the starter to the fly-
one connects the cables on the terminals. wheel housing. Tighten capscrews to 38 N•m
(28 lbf ft).
1. Disconnect battery negative cable at negative
terminal. 2. Connect wires and cables as labeled in removal.
2. Disconnect the battery positive cable at positive 3. Connect the battery positive cable at positive ter-
terminal. minal.
3. Put labels on wires and cables prior to discon- 4. Connect battery negative cable at negative ter-
necting to aid in correct installation. minal.
4. Disconnect wires and cables from starter.
59
Engine Specifications 600 SRM 1121
Engine Specifications
ENGINE DATA
Number of Cylinders 4
Displacement 2405 cm 3 (146.46 in. 3 )
Bore 87.5 mm (3.445 in.)
Stroke 100 mm (3.937 in.)
Compression Ratio 9.53:1
Firing Order 1-3-4-2
Idle Speed 800 ±25
Governor Speed (No Load) 2700 ±25
Converter Stall Speed - LPG
New Engine 1950 ±100 rpm
Broken-in Engine 2053 ±100 rpm
Converter Stall Speed - Gasoline
New Engine 1914 ±100 rpm
Broken-in Engine 2015 ±100 rpm
Spark Plug Gap 0.8 to 0.9 mm (0.031 to 0.035 in.)
CYLINDER BORE
Bore Diameter 87.5 mm (3.44 in.)
Bore Out-of-Round Service Limit 0.127 mm (0.005 in.) Maximum
Bore Taper Thrust Side Service Limit 0.076 mm (0.003 in.) Maximum
Bore Taper Relief Side Service Limit 0.076 mm (0.003 in.) Maximum
PISTON
Piston-to-Bore Clearance
Production 0.010 to 0.030 mm (0.00040 to 0.0012 in.)
Service Limit 0.060 mm (0.0024 in.)
PISTON RINGS
Piston Compression Ring Groove
Clearance Production Top 0.030 to 0.050 mm (0.0012 to 0.0020 in.)
Clearance Production 2nd 0.020 to 0.040 mm (0.0008 to 0.0016 in.)
Piston Compression Ring Gap Top
*Measured in Cylinder Bore
60
600 SRM 1121 Engine Specifications
Production* 0.25 to 0.45 mm (0.010 to 0.018 in.)

Service Limit* 0.55 mm (0.022 in.) Maximum
Piston Compression Ring Gap 2nd
Piston Oil Ring Gap
*Measured in Cylinder Bore
WRIST PIN
Diameter 20.995 to 21.00 mm (0.8266 to 0.8268 in.)
Clearance in Piston
Service Limit 0.023 mm (0.0009 in.) Maximum
Fit in Piston Rod (Interference) 0.024 to 0.041 mm (0.00095 to 0.0016 in.)
Interference
CRANKSHAFT
Crankshaft Maximum Warping 0.03 mm (0.00118 in.)
Crankshaft Main Journal Diameter (All) 57.981 to 57.988 mm (2.2827 to 2.2830 in.)
Crankshaft Main Journal Taper 0.005 mm (0.00020 in.) Maximum
Crankshaft Main Journal Out-of-Round 0.004 mm (0.00016 in.) Maximum
Crankshaft Main Bearing Clearance
Service Limit 0.018 to 0.046 mm (0.0007 to 0.0018 in.)
Crankshaft Rod Journal Diameter 48.971 to 48.987 mm (1.9280 to 1.9286 in.)
Crankshaft Rod Journal Taper 0.020 mm (0.0008 in.)
Crankshaft End Play - Production 0.050 to 0.152 mm (0.002 to 0.006 in.)
PISTON ROD
Rod Bearing Clearance
Service 0.020 to 0.074 mm (0.0008 to 0.0029 in.)
Rod Side Clearance 0.070 to 0.242 mm (0.0028 to 0.010 in.)
61
CAMSHAFT AND CAMSHAFT CARRIER

Camshaft Carrier Bores
Number 1 Bore 42.500 to 42.525 mm (1.6732 to 1.6742 in.)
Camshaft Journal Diameter
Number 1 Journal 42.455 to 42.470 mm (1.6715 to 1.6720 in.)
Maximum Camshaft Warpage 0.04 mm (0.0016 in.)
Camshaft End Play 0.79 to 0.91 mm (0.031 to 0.036 in.)
Lobe Lift Intake 6.67 mm (0.263 in.)
Lobe Lift Exhaust 6.67 mm (0.263 in.)
VALVE SYSTEM
Valve Lash Intake Not applicable - engine utilizes hydraulic lash
adjusters to maintain zero lash.
Valve Lash Exhaust
Face Angle 46 degrees from vertical (stem centerline)
Seat Angle 45 degrees
Seat Runout 0.05 mm (0.002 in.) Maximum
Seat Width Intake 1.3 to 1.4 mm (0.051 to 0.055 in.)
Seat Width Exhaust 1.6 to 1.8 mm (0.063 to 0.070 in.)
Stem Clearance Intake
Stem Clearance Exhaust
Valve Spring Free Length Approximately 48 mm (1.89 in.)
Valve Spring Load - Closed 241 ±18 N (54 ±4 lbf) at 37.5 mm (1.48 in.)
Valve Spring Load - Open 615 ±29 N (138 ±7 lbf) at 26.5 mm (1.04 in.)
62
600 SRM 1121 Torque Specifications
Valve Spring Installed Height

Intake 37.5 mm (1.48 in.)
Exhaust 37.5 mm (1.48 in.)
Valve Lift
Intake 11.0 mm (0.433 in.)
Exhaust 11.0 mm (0.433 in.)
CYLINDER HEAD WARPAGE

Maximum Cylinder Head Warpage 0.015 mm (0.0006 in.) in 150 mm (5.9 in.) distance
LUBRICATION SYSTEM
Oil Pressure @ 80°C (176°F) 800 rpm: 186 ±34.5 kPa (27 ±5 psi) [oil temperature
approximately 60°C (140°F)]
NOTE: As engine oil temperature increases, oil pres- 2700 rpm: 345 ±69 kPa (50 ±10 psi) [oil temperature
sure will decrease. approximately 76.7 to 104.4°C (170 to 220°F)]
Oil Capacity (With Oil Filter Change) 5.0 liter (5.3 qt)
Oil Pump Type Internal Crescent Gear Pump
COOLING SYSTEM
Thermostat
Start to Open 82 ±1.5°C (179.6 ±34.7°F)
Fully Open 97 ±1.5°C (206.6 ±34.7°F)
Torque Specifications
Camshaft Carrier/Cylinder Head Bolts Crankshaft Timing Pulley Retaining Bolt
First Pass 25 N•m (18 lbf ft) First Pass 130 N•m (96 lbf ft)
Second Pass - Additional 180 degrees Final Final Pass - Additional 45 degrees
Pass - Additional 10 degrees
Crankshaft Pulley Bolts
Camshaft Timing Pulley Bolt 15 to 25 N•m (11 to 18 lbf ft)
40 to 50 N•m (30 to 37 lbf ft)
Crankshaft/RPM Sensor Capscrew
Camshaft Sensor Retaining Screws 8 N•m (71 lbf in)
10 N•m (88.5 lbf in)
Coil Mounting Capscrews
Camshaft Retainer Capscrews 10 N•m (88.5 lbf in)
8 N•m (71 lbf in)
Flywheel Capscrews
Crankshaft Main Bearing Cap Capscrews 52 N•m (38.35 lbf ft)
First Pass 50 N•m (37 lbf ft)
Second Pass - Additional 45 degrees Final Flywheel Housing Capscrews
Pass - Additional 15 degrees M10 Capscrews 38 N•m (28 lbf ft)
M12 Capscrews 66 N•m (48.7 lbf ft)
63
Torque Specifications 600 SRM 1121
Coil Mounting Bracket Attaching Nuts Reluctor Wheel Capscrews

38 N•m (28 lbf ft) First Pass 10 N•m (88.5 lbf in)
Final Pass - Additional 40 to 45 degrees
Exhaust Manifold to Head Nuts
18 to 22 N•m (13 to 16 lbf ft) Rocker Arm Cover Bolts
8 N•m (71 lbf in)
Exhaust Manifold Adapter to Exhaust Manifold
14 to 20 N•m (10 to 15 lbf ft) Spark Plugs
20 N•m (15 lbf ft)
Intake Manifold to Head Nuts
18 to 22 N•m (13 to 16 lbf ft) Starter mounting Bolts
38 N•m (28 lbf ft)
Lift Bracket Bolt
20 N•m (15 lbf ft) Timing Belt Front Cover Bolts
6 N•m (53 lbf in)
Lift Bracket Nut
20 N•m (15 lbf ft) Timing Belt Front Bracket Capscrews
25 N•m (18 lbf ft)
Oil Pump Safety Valve
37 N•m (27 lbf ft) Timing Belt Rear Cover Bolts
6 N•m (53 lbf in)
Oil Pan Capscrews
18 to 22 N•m (13 to 16 lbf ft) Timing Belt Tensioner Bolt
20 N•m (15 lbf ft)
Oil Pan Drain Plug
18 to 22 N•m (13 to 16 lbf ft) Thermostat Cover Capscrews
20 N•m (15 lbf ft)
Oil Pump Cover
6 N•m (53 lbf in) Thermostat Housing Capscrews
11 N•m (97 lbf in)
Oil Pump to Engine Block
8 N•m (71 lbf in) Water Pump Bolts
20 to 30 N•m (15 to 22 lbf ft)
Oil Pump Suction Tube Capscrews
6 to 10 N•m (53 to 89 lbf in) Cooling System Hose Clamps
4 to 5 N•m (35 to 44 lbf in)
Oil Pump Suction Tube Bracket Capscrew
18 to 22 N•m (13 to 16 lbf ft) Fan Hub Bracket Bolts
52 N•m (38 lbf ft)
Oil Pressure Sensor
20 N•m (15 lbf ft) Fan Retaining Bolts
26 N•m (19 lbf ft)
Baffle Plate Capscrews
First Pass 20 to 24 N•m (15 to 17.6 lbf ft) Alternator Bracket Bolts
Final Pass - Additional 45 degrees 38 N•m (28 lbf ft)
Bearing Bracket Capscrews Alternator Mounting Bolts

20 to 24 N•m (15 to 17.6 lbf ft) 20 N•m (15 lbf ft)
Piston Rod Bearing Cap Capscrews

First Pass 30 to 40 N•m (22 to 29.5 lbf ft)
Final Pass - Additional 40 to 45 degrees
64
600 SRM 1121 Special Tools
Special Tools
Valve Spring Compressor
Used to remove and install valve springs.
Valve Stem Oil Seal Tool

Used to remove and install valve stem oil seals.
Camshaft Seal Installer

Used to install the camshaft seal.
Wrench
Used to lock the crankshaft timing pulley.
65
Special Tools 600 SRM 1121
Piston Flange Universal Puller

Used to remove the crankshaft timing pulley.
Crankshaft Front and Rear Oil Seal Puller

Used with sliding mallet to remove oil seals.
Universal Sliding Mallet

Used with crankshaft front and rear oil seal puller
to remove oil seals.
66
Crankshaft Front Seal Installer

Used to install crankshaft front oil seal.
Crankshaft Rear Main Oil Seal Installer

Used to install the crankshaft rear main oil seal.
Rear Flange Alignment Tool

Used to align the oil pan with the cylinder block.
67
NOTES
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68
600 SRM 1121 12/12 (2/10)(11/08)(6/07)(1/07)(5/06) Printed in U.S.A.

COOLING SYSTEM
S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT,
S55FTS) [F187]; S50CT [A267]; H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274]; S4.0, 4.5, 5.50FT; 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]; S6.0FT, S7.0FT (S135FT,S155FT) [D024,
E024, F024]; H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006];
PART NO. 1580505 700 SRM 1123

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
Cooling System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Cooling System Checks...................................................................................................................................... 1
Exhaust Leaks Into Cooling System ............................................................................................................ 1
Water Flow Restrictions in Radiator ............................................................................................................ 1
Radiator Hoses............................................................................................................................................... 1
Water Pump ................................................................................................................................................... 1
Flushing the Cooling System ............................................................................................................................ 2
Cooling System, Clean................................................................................................................................... 2
Radiator Replacement ....................................................................................................................................... 3
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT,
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT
(A267); H2.0-3.5FT (H40-70FT) (L177); H2.0-2.5CT (H50CT) (A274); S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004) and H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)................................... 3
2.0FTS (H30FT, H35FT, H40FTS) (F001); S50CT (A267) and H2.0-2.5CT (H50CT) (A274)
Equipped with Oil Cooler .............................................................................................................................. 19
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024) ........... 21
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)................................... 30
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS
(H30FT, H35FT, H40FTS) (F001); S50CT (A267) and H2.0-2.5CT (H50CT) (A274) Equipped with
Oil Cooler ....................................................................................................................................................... 33
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024).............. 34
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
Fan Assembly Replacement............................................................................................................................... 47
Fan Removal .................................................................................................................................................. 47
Inspect ............................................................................................................................................................ 61
Fan Installation ............................................................................................................................................. 61
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S50CT [A267];
H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274];
S4.0, 4.5, 5.50FT; 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];
S6.0FT, S7.0FT (S135FT,S155FT) [D024, E024, F024];

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
700 SRM 1123 Cooling System Checks
General
This section contains the repair and replacement in- assembly (pusher type), fan shroud, coolant hoses,
structions for the radiator, coolant level sensor, fan coolant recovery bottle, and optional debris screen.
Cooling System Checks

EXHAUST LEAKS INTO COOLING SYSTEM RADIATOR HOSES
WARNING WARNING
with these parts can cause serious injury. cause serious injury. Wait 30 minutes for the
To check for exhaust leaks into the cooling system, the radiator with your hand. If the radiator is
use a Combustion Leak Test Kit for this purpose. Fol- still hot to the touch, wait another 30 minutes
low the manufacturer’s instructions when doing the before attempting to check or fix any part of
test. the cooling system.
WATER FLOW RESTRICTIONS IN Inspect all radiator hoses. If they feel spongy or have
RADIATOR visible cracks, replace hoses.
WARNING WATER PUMP

touch the fan, pulleys, or drive belts. Contact WARNING
with these parts can cause serious injury. During engine operation, be careful not to
To check for water flow restrictions in the radiator, with these parts can cause serious injury.
run engine until it is warm.
WARNING
WARNING The radiator or other parts of the cooling sys-
The radiator or other parts of the cooling system may be hot or under pressure and can
tem may be hot or under pressure and can cause serious injury.
radiator to cool. Do a touch test by touching Run engine until it is warm. Check the operation of
the radiator with your hand. If the radiator is water pump by holding the top radiator hose. If the
still hot to the touch, wait another 30 minutes pump is operating, there will be pressure surges in
before attempting to check or fix any part of the hose.
the cooling system.
Check for leaks around the timing belt cover near the
Shut engine OFF and feel the radiator. The temper- base of the oil pump.
ature must be even across the radiator. (The radiator
Check the weep hole where coolant that leaks past
will be hotter near the top radiator hose.) Cold spots
the water pump seal can be drained before reaching
on radiator indicate restrictions.
the water pump bearings. If there is a drip, check the
If radiator has leaks, either replace the radiator or pump shaft seal and water pump. Replacement of the
have it repaired by trained personnel. pump shaft seal or water pump may be necessary.
For repair procedures for the GM 2.4L water pump,

refer to the section GM Engine Repair, GM 2.4
Liter Engine 600 SRM 1121.
1
Flushing the Cooling System 700 SRM 1123
For repair procedures for the Mazda 2.0L and 2.2L For replacement procedures for the GM 5.7L water
water pump, refer to the section Mazda Engine, pump, refer to the section GM Engines, 5.7 Liter
2.0L and 2.2L 600 SRM 1122. V-8 LPG 600 SRM 1432.
For replacement procedures for the Yanmar 2.6L For replacement procedures for the Kubota water
and 3.3L water pump, refer to the section Yanmar pump, refer to the section
Diesel Engines, 2.6L, 3.0L and 3.3L 600 SRM • Kubota Diesel 3.8L Engines 600 SRM 1557
1205. • Kubota Diesel 3.6L Engine 600 SRM 1579
• Kubota Diesel 3.8L Engines , with Diesel Par-
For replacement procedures for the GM 4.3L water ticulate Filter (DPF) 600 SRM 1590
pump, refer to the section GM Engines, 4.3 Liter
V-6 600 SRM 1251. For replacement procedures for the Cummins 4.5L
and QSB 3.3L water pump, contact your local Hyster
Flushing the Cooling System

COOLING SYSTEM, CLEAN CAUTION
Disposal of lubricants and fluids must meet lo-
WARNING cal environmental regulations.
cause injury to the user or to other personnel. 2. Drain cooling system. Fill cooling system with
Make sure the path of the compressed air is clean water. See sections below for more infor-
away from all personnel. Wear protective gog- mation:
gles or a face shield to prevent injury to the • Radiator, Remove for Lift Trucks Models
eyes. S30FT, S35FT, S40FTS (E010); H1.6FT,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS)
WARNING (F187); S50CT (A267); H2.0-3.5FT (H40-70FT)
The radiator fins on the radiator are very (L177); H2.0-2.5CT (H50CT) (A274); S4.0,
sharp and can cause serious injury. Wear 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
gloves while checking the radiator fins. 100FTBCS; S120FTS; S120FTPRS) (G004,
H004) and H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
1. Check radiator fins. Clean exterior of radiator H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
with compressed air or water as needed. P005, R005)
• Radiator, Remove for Lift Truck Models
WARNING S6.0FT, S7.0FT (S135FT, S155FT) (D024,
DO NOT remove the radiator cap from the radi- E024, F024)
ator when the engine is hot. When the radiator • Radiator, Remove for Lift Truck Models
cap is removed, the pressure is released from H6.0FT, H7.0FT (H135FT, H155FT) (H006,
the system. If the system is hot, the steam and J006, K006) and H8.0FT, H8.0FT9, H9.0FT
boiling coolant can cause burns. (H170FT, H175FT36, H190FT) (A299, B299)
3. Install radiator cap. Run engine until top radia-

WARNING tor hose is hot. Stop engine and let engine cool.
tem may be hot or under pressure and can 4. Drain water from radiator. If water is dirty, fill
cause serious injury. Wait 30 minutes for the system with water and repeat procedure until
radiator to cool. Do a touch test by touching water is clean.
the cooling system.
2
700 SRM 1123 Radiator Replacement
CAUTION CAUTION
Follow the manufacturer’s instructions when Additives may damage the cooling system. Be-
using a chemical radiator cleaner. fore using additives, contact your local Hyster
dealer.
5. If water does not clean system, use a chemical
radiator cleaner. 7. Fill cooling system with ethylene glycol
boron-free antifreeze. Purchase a pre-diluted
CAUTION 50/50 solution; or mix 50 percent concentrate
with 50% distilled or deionized water. The 50/50
Follow the manufacturer’s instructions when
mixture will protect cooling system to 37°C
using special equipment to reverse clean the
( 35°F). Add coolant as necessary to keep level
radiator.
between the ADD and FULL marks on the reser-
6. If radiator or cooling system is very dirty or voir.
has a restriction, use reverse cleaning method.
This method uses water pressure to force water
through radiator in opposite direction of normal
flow.
Radiator Replacement
RADIATOR, REMOVE FOR LIFT TRUCKS See Frame 100 SRM 1120 for lift truck models
MODELS S30FT, S35FT, S40FTS (E010); • S30FT, S35FT, S40FTS (E010)
H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
H40FTS) (F001); S2.0-3.5FT (S40-70FT, • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
S55FTS) (F187); S50CT (A267); H2.0-3.5FT • H2.0-3.5FT (H40-70FT) (L177)
(H40-70FT) (L177); H2.0-2.5CT (H50CT)
See Frame 100 SRM 1243 for lift truck models
(A274); S4.0, 4.5, 5.5FT, S5.5FTS,
• S4.0, 4.5, 5.5FT; S5.5FTS (S80, 100, 120FT;
(S80, 100, 120FT; S80, 100FTBCS; S80, 100FTBCS; S120FTS, S120FTPRS)
S120FTS; S120FTPRS) (G004, H004) (G004, H004)
AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
(N005, P005, R005)
WARNING • S50CT (A267)
The radiator or other parts of the cooling sys- • H2.0-2.5CT (H50CT) (A274)
cause serious injury. Wait 30 minutes for the WARNING
radiator to cool. Do a touch test by touching Always disconnect the cable at the negative
the radiator with your hand. If the radiator is terminal first. Install a tag on the battery ter-
still hot to the touch, wait another 30 minutes minals so that no one connects the cables on
before attempting to check or fix any part of the terminals.
the cooling system.
3. Disconnect the negative battery cable.
1. Turn OFF truck.
4. Disconnect the positive battery cable.
2. Remove the hood and seat combination.
3
Radiator Replacement 700 SRM 1123
See Figure 2 or Figure 3 for lift truck models

WARNING • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
DO NOT remove the radiator cap from the radi- S80, 100FTBCS; S120FTS; S120FTPRS)
ator when the engine is hot. When the radiator (G004, H004)
cap is removed, the pressure is released from
the system. If the system is hot, the steam and See Figure 4 or Figure 5 for lift truck models
boiling coolant can cause burns. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
drain pan with a capacity greater than the capac- See Figure 6 for lift truck models below equipped
ity of the cooling system under radiator. Remove with a Cummins QSB 3.3L diesel engine
radiator cap. • H4.5FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
• S6.6FT, S7.0FT (S135FT, S155FT) (E024)
CAUTION
Disposal of lubricants and fluids must meet lo- See Figure 7 for lift truck models below equipped
cal environmental regulations. with Yanmar 2.6L diesel engine
• H2.0-2.5CT (H50CT) (A274)
6. Open the drain plug or loosen hose clamp and
disconnect the lower hose. See Figure 8 for lift truck models below equipped
with a Kubota 3.8L diesel engine
7. Lift trucks equipped with a Cummins QSB 3.3L • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
diesel engine: Loosen clamps and disconnect the 5.5FT (H80, 90, 100, 110, 120FT) (R005)
charge air cooler hoses from charge air cooler.
See Figure 6. 11. Remove battery and battery tray.
8. Lift trucks equipped with a Kubota 3.8L diesel 12. If equipped, disconnect electrical connector to the
engine: Loosen clamps and disconnect transmis- coolant level sensor.
sion cooler hoses from transmission cooler. See
Figure 8. NOTE: For Mazda LPG engine, the LPG converter
bracket needs to be moved for clearance of radiator.
9. Once coolant is drained from engine, loosen hose
clamps and disconnect coolant hoses from radia- 13. Remove screws and washers from the shroud and
tor. Cap radiator hoses. move shroud out of the way.
10. Loosen hose clamp and disconnect hose from 14. Place radiator guard shield between radiator and
reservoir and remove reservoir. fan so damage to radiator does not occur during
fan removal.
• S30FT, S35FT, S40FTS (E010) 15. Remove fan, fan spacer, and pulley.
16. Remove radiator guard shield.
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
4
17. Remove capscrews and upper radiator bracket. See Figure 6 for lift truck models below equipped
with a Cummins QSB 3.3L diesel engine
See Figure 1 for lift truck models • H4.5FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• S30FT, S35FT, S40FTS (E010) 5.5FT (H80, 90, 100, 110, 120FT) (P005)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, • S6.6FT, S7.0FT (S135FT, S155FT) (E024)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) See Figure 7 for lift truck models below equipped
• H2.0-3.5FT (H40-70FT) (L177) with Yanmar 2.6L diesel engine
• S50CT (A267) • H2.0-2.5CT (H50CT) (A274)
• H2.0-2.5CT (H50CT) (A274)
See Figure 8 for lift truck models below equipped
See Figure 2 or Figure 3 for lift truck models with a Kubota 3.8L diesel engine
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
S80, 100FTBCS; S120FTS; S120FTPRS) 5.5FT (H80, 90, 100, 110, 120FT) (R005)
(G004, H004)
18. Remove radiator from truck.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- 19. If necessary, remove the coolant level sensor.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
5
Figure 1. Cooling System for Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT,
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT (A267);
H2.0-3.5FT (H40-70FT) (L177) and H2.0-2.5CT (H50CT) (A274)
6
Legend for Figure 1

A. RADIATOR WITH EXTERNAL COOLER C. RESERVOIR BEFORE MAY ’06
B. RADIATOR WITH INTERNAL COOLER, MODINE D. RESERVOIR AFTER MAY ’06
SHOWN
1. RADIATOR 15. NUT-CLIP, S2.0-3.5FT (S40-70FT, S55FTS) [F187]
2. CAP AND S50CT (A267)
3. UPPER HOSE 16. ISOLATOR
4. LOWER HOSE 17. COOLANT LEVEL SENSOR
5. CLAMP 18. RESERVOIR
6. SHROUD 19. TUBE
7. CLIP 20. OUTLET ASSEMBLY
8. WASHER 21. HOSE
9. SCREW 22. RESERVOIR OUTLET
10. CLIP 23. CAP
11. UPPER RADIATOR BRACKET 24. BUSHING
12. CAPSCREW, S2.0-3.5FT (S40-70FT, S55FTS) 25. SCREEN ASSEMBLY (OPTIONAL)
[F187] AND S50CT (A267) 26. HEAT SHIELD
13. INSERT 27. RESERVOIR BRACKET
14. LOWER BRACKET, S2.0-3.5FT (S40-70FT, 28. HEAT SHIELD, H2.0-3.5FT (H40-70FT) [L177]
S55FTS) [F187] AND S50CT (A267) AND H2.0-2.5CT (H50CT) (A274)
7
Figure 2. Cooling System for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) Before 2011
8
Legend for Figure 2

A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER
1. RADIATOR 15. RESERVOIR BRACKET
2. SHROUD 16. OUTLET ASSEMBLY
3. WASHER 17. OUTLET
4. SCREW 18. CAP
5. CLIP NUT 19. BUSHING
6. CLIP 20. HOSE
7. UPPER HOSE 21. TUBE
8. LOWER HOSE 22. STRAP
9. CLAMP 23. NUT
10. UPPER RADIATOR BRACKET 24. SCREEN
11. INSERT 25. BAFFLE (RH AND LH)
12. CAPSCREW 26. RADIATOR CAP
13. ISOLATOR 27. COOLANT LEVEL SENSOR
14. RESERVOIR
9
100FTBCS; S120FTS; S120FTPRS) (G004, H004) After 2011
10
Legend for Figure 3

1. RADIATOR 14. RESERVOIR
4. SCREW 17. CAP
6. CLIP 19. HOSE
8. LOWER HOSE 21. NUT
9. CLAMP 22. SCREEN
10. UPPER RADIATOR BRACKET 23. BAFFLE (RH AND LH)
11. INSERT 24. RADIATOR CAP
12. CAPSCREW 25. COOLANT LEVEL SENSOR
13. ISOLATOR
11
Figure 4. Cooling System for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005, P005) Before 2011
12
Legend for Figure 4

A. RADIATOR WITH INTERNAL COOLER B. RADIATOR WITH EXTERNAL COOLER
1. CAPSCREW 14. WASHER
2. INSERT 15. SCREEN
3. UPPER RADIATOR BRACKET 16. STRAP
4. RADIATOR CAP 17. RESERVOIR BRACKET
5. ISOLATOR 18. RESERVOIR
6. CLIP NUT 19. OUTLET ASSEMBLY
7. COOLANT LEVEL SENSOR 20. OUTLET
8. RADIATOR 21. CAP
9. CLIP 22. BUSHING
10. RADIATOR SHROUD 23. TUBE
11. CLAMP 24. UPPER HOSE
12. LOWER HOSE 25. DRAIN PLUG
13. SCREW 26. OIL COOLER
13
90, 100, 110, 120FT) (N005, P005) After 2011
14
Legend for Figure 5

1. CAPSCREW 13. SCREW
2. INSERT 14. WASHER
4. RADIATOR CAP 16. RESERVOIR
5. ISOLATOR 17. OUTLET ASSEMBLY
6. CLIP NUT 18. OUTLET
7. COOLANT LEVEL SENSOR 19. CAP
8. RADIATOR 20. BUSHING
9. CLIP 21. TUBE
10. RADIATOR SHROUD 22. UPPER HOSE
11. CLAMP 23. DRAIN PLUG
12. LOWER HOSE 24. OIL COOLER
15
1. RADIATOR 16. CLAMP

2. RADIATOR CAP 17. CHARGE AIR COOLER HOSE
3. HARNESS CLIP 18. SCREW
4. UPPER RADIATOR BRACKET 19. WASHER
5. INSERT 20. CLIP
6. ISOLATOR 21. LOWER HOSE
7. CAPSCREW 22. RESERVOIR
8. CLAMP 23. BUSHING
9. TUBE 24. RESERVOIR CAP
10. UPPER HOSE 25. RESERVOIR OUTLET
11. CLAMP 26. HOSE
12. CHARGE AIR COOLER HOSE 27. TUBE
13. CLAMP 28. COOLANT LEVEL SENSOR
14. CHARGE AIR COOLER HOSE 29. SEAL
15. SHROUD
Figure 6. Cummins 3.3L Cooling System With Charge Air Cooler for H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)
16
1. LOWER HOSE 13. ISOLATOR

2. CLAMP 14. UPPER RADIATOR BRACKET
3. UPPER HOSE 15. RADIATOR
4. RESERVOIR 16. PLUG - COOLANT LEVEL SENSOR
5. OUTLET ASSEMBLY 17. HEAT SHIELD
6. BUSHING 18. CLIP NUT
7. CAP 19. WASHER
8. RESERVOIR OUTLET 20. SCREW
9. HOSE 21. DRAIN PLUG
10. CAPSCREW 22. SHROUD
11. INSERT 23. TUBE
12. RADIATOR CAP
Figure 7. Yanmar 2.6L Cooling System for Lift Truck Models H2.0-2.5CT (H50CT) (A274)
17
1. RADIATOR 11. TRANSMISSION COOLER RETURN LINE

2. RADIATOR CAP 12. TRANSMISSION COOLER SUPPLY LINE
3. UPPER RADIATOR BRACKET 13. SCREW
4. ISOLATOR 14. WASHER
6. INSERT 16. RESERVOIR
Figure 8. Kubota 3.8L Cooling System for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
18
RADIATOR, REMOVE FOR LIFT TRUCKS 5. Let coolant cool to ambient temperature. Place a
MODELS S30FT, S35FT, S40FTS (E010); drain pan with a capacity greater than the capac-
H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, ity of the cooling system under radiator. Remove
radiator cap.
H40FTS) (F001); S50CT (A267) AND
H2.0-2.5CT (H50CT) (A274) EQUIPPED
CAUTION
WITH OIL COOLER
WARNING
The radiator or other parts of the cooling sys- 6. Open the drain plug or loosen hose clamp and
tem may be hot or under pressure and can disconnect the lower hose.
radiator to cool. Do a touch test by touching 7. Loosen clamps and disconnect oil cooler hoses
the radiator with your hand. If the radiator is from oil cooler adapters. See Figure 9.
8. Remove oil cooler adapters and O-rings from ra-
diator. Discard O-rings. See Figure 9.
the cooling system.
1. Turn OFF truck.
clamps and disconnect coolant hoses from radia-
2. Remove the hood and seat combination. tor. Cap radiator hoses.
See section Frame 100 SRM 1120 for lift truck 10. Loosen hose clamp and disconnect hose from
models reservoir and remove reservoir. See Figure 9.
• S30FT, S35FT, S40FTS (E010)
11. Remove battery and battery tray.
H40FTS) (F001) 12. If equipped, disconnect electrical connector to the
coolant level sensor.
See section Frame 100 SRM 1423 for lift truck
models NOTE: For Mazda LPG engine, the LPG converter
• S50CT (A267) bracket needs to be moved for clearance of radiator.
• H2.0-2.5CT (H50CT) (A274)
13. Remove screws and washers from the shroud and
WARNING move shroud out of the way.
Always disconnect the cable at the negative 14. Place radiator guard shield between radiator and
terminal first. Install a tag on the battery ter- fan so damage to radiator does not occur during
minals so that no one connects the cables on fan removal.
the terminals.
15. Remove fan, fan spacer, and pulley.
17. Remove capscrews and upper radiator bracket.
See Figure 9.
WARNING
DO NOT remove the radiator cap from the radi- 18. Remove radiator from truck.
cap is removed, the pressure is released from 19. If necessary, remove the coolant level sensor.
the system. If the system is hot, the steam and
boiling coolant can cause burns.
19
1. RADIATOR 11. CAPSCREW

2. CAP 12. INSERT
4. LOWER HOSE 14. RESERVOIR
5. CLAMP 15. TUBE
7. O-RING 17. HOSE
8. OIL COOLER ADAPTER 18. RESERVOIR OUTLET
9. OIL COOLER HOSE 19. CAP
20
RADIATOR, REMOVE FOR LIFT TRUCK 11. Place a radiator guard shield between radiator
MODELS S6.0FT, S7.0FT (S135FT, S155FT) and fan so damage to radiator does not occur dur-
(D024, E024, F024) ing fan removal.
12. Remove fan. See Fan Removal procedures.

WARNING
radiator to cool. Do a touch test by touching DO NOT remove the radiator cap from the radi-
the radiator with your hand. If the radiator is ator when the engine is hot. When the radiator
still hot to the touch, wait another 30 minutes cap is removed, the pressure is released from
before attempting to check or fix any part of the system. If the system is hot, the steam and
the cooling system. boiling coolant can cause burns.
1. Turn off truck. 14. Let coolant cool to ambient temperature. Place
a drain pan with a capacity greater than the ca-
WARNING pacity of the cooling system under the radiator.
Always disconnect the cable at the negative Remove radiator cap.
terminal first. Install a tag on the battery ter-
minals so that no one connects the cables on CAUTION
the terminals. Disposal of lubricants and fluids must meet lo-
15. Open drain plug, loosen clamp and disconnect
the lower radiator hose from radiator to allow
4. Remove radiator cover. See Figure 10. coolant to drain into a suitable container. Install
caps on hose. See Figure 10.
5. Remove debris cover.
clamp and disconnect upper radiator hose from
CAUTION radiator. Install cap on hose. See Figure 10.
The counterweight cover is extremely heavy
185 kg (408 lb). Make sure that the eyebolts 17. Lift trucks equipped with a Cummins QSB 3.3L
and lifting device have sufficient capacity to diesel engine: Loosen clamps and disconnect the
lift the weight. charge air cooler hoses from charge air cooler.
See Figure 11.
6. Remove two bolts from counterweight cover.
18. Loosen clamp and disconnect remote refill hose
7. Install two eyebolts in the hole on each end of the from radiator. Install cap on hose.
counterweight cover. Connect a suitable lifting
device to the eyebolts and carefully remove the NOTE: Tag the transmission lines before disconnect-
counterweight cover from lift truck. ing from oil cooler.
8. Remove four capscrews from upper radiator 19. Disconnect transmission lines from oil cooler. In-
bracket. Remove bracket. See Figure 23. stall caps on transmission lines. Drain transmis-
sion oil from oil cooler into a suitable container.
9. If necessary, disconnect electrical connector from Install caps on the oil cooler ports.
the coolant level sensor.
NOTE: Removing the radiator from lift truck requires
10. Remove screws, washers, and clip nuts from the two people.
shroud and radiator and move shroud out of the
way. 20. Remove radiator from lift truck frame.
21. If necessary, remove the coolant level sensor from

radiator. See Figure 23.
21

1. DEBRIS COVER
2. COUNTERWEIGHT COVER
3. RADIATOR COVER
4. UPPER BRACKET
5. CAPSCREWS
6. REMOTE FILL HOSE
7. HOSE CLAMPS
8. OIL COOLER
9. TRANSMISSION OIL COOLER LINES
10. FITTINGS
11. UPPER HOSE
12. LOWER HOSE
13. REMOTE FILL
14. RADIATOR CAP
Figure 10. Radiator Removal for Lift Truck

Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
22

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
Figure 11. Cummins 3.3L Cooling System With Charge Air Cooler for S6.0FT, S7.0FT (S135FT,
S155FT) (E024)
23
RADIATOR, REMOVE FOR LIFT TRUCK See Figure 28 for lift truck models equipped with
MODELS H6.0FT, H7.0FT (H135FT, H155FT) Kubota 3.8L Diesel engine
(H006, J006, K006) AND H8.0FT, H8.0FT9, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299) 6. Lift trucks equipped with GM 4.3L (Gas/LPG) en-
gine, loosen clamp and disconnect inlet hose from
air filter and remove inlet hose. See Figure 25.
WARNING
The radiator or other parts of the cooling sys- NOTE: Perform Step 7 for lift truck models H6.0FT,
tem may be hot or under pressure and can H7.0FT (H135FT, H155FT) (H006, J006, K006).
radiator to cool. Do a touch test by touching 7. Lift trucks equipped with the Kubota 3.8L,
the radiator with your hand. If the radiator is Cummins 4.5L, or QSB 3.3L diesel engine loosen
still hot to the touch, wait another 30 minutes clamp and disconnect inlet hose from silencer.
before attempting to check or fix any part of Remove silencer. See Figure 25.
the cooling system.
NOTE: Before lifting the hood assembly from the lift
1. Turn off truck. truck frame, make sure to use a lifting device and lift-
ing straps as shown in Figure 12. The hood assembly
weighs approximately 45.6 kg (101 lb).
WARNING
Always disconnect the cable at the negative 8. Remove hood assembly. For hood assembly re-
terminal first. Install a tag on the battery ter- moval procedures, see
minals so that no one connects the cables on
the terminals. Frame 100 SRM 1321 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
2. Disconnect the negative battery cable. H175FT36, H190FT) (A299)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
3. Disconnect the positive battery cable. J006)
NOTE: Perform Step 4 for lift truck models H6.0FT, Frame 100 SRM 1581 for lift truck models
H7.0FT (H135FT, H155FT) (H006, J006, K006). • H6.0FT, H7.0FT (H135FT,H155FT) (K006)
4. Open hood and loosen clamp and disconnect in- • H8.0FT, H8.0FT9, H9.0FT (H170FT,
let hose that attaches to the hood support. See H175FT36, H190FT) (B299)
Figure 25. 9. Disconnect and cap auxiliary coolant reservoir
NOTE: Perform Step 5 for lift truck model H8.0FT, hose. See Figure 25.
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) 10. Remove capscrews from the auxiliary coolant
(A299, B299). reservoir bracket and upper bracket. Remove
5. Open hood, loosen clamp, and disconnect dirty auxiliary coolant reservoir assembly.
air hose attached to hood support. 11. Remove the four capscrews from the upper radi-
See Figure 26 for lift truck models below ator bracket. Remove bracket.
equipped with Cummins QSB 3.3L diesel en- 12. If necessary, disconnect electrical connector from
gine the coolant level sensor.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) 13. Remove screws, washers and clip nuts from the
shroud and move shroud out of the way.
See Figure 27 for lift truck models below
equipped with GM 5.7L LPG engine 14. Place a radiator guard shield between radiator
• H8.0FT, H8.0FT9, H9.0FT (H170FT, and fan so damage to radiator does not occur dur-
H175FT36, H190FT) (A299, B299) ing fan removal.
24
See Figure 15 for lift truck models equipped with

Kubota 3.8L Diesel engine
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
WARNING
18. Let coolant cool to ambient temperature. Place

a drain pan with a capacity equal to or greater
than the capacity of the cooling system under the
radiator. Remove radiator cap.
CAUTION
19. Open drain plug or loosen clamp and disconnect

lower radiator hose to allow coolant to drain.

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
1. PRE-CLEANER 2. STRAP CLAMP
Figure 12. Hood Assembly Removal
equipped with Cummins QSB 3.3L diesel en-
NOTE: Perform Step 15 for lift truck models H6.0FT, gine
H7.0FT (H135FT, H155FT) (H006, J006, K006). • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
15. Remove capscrews, washers, fan, fan spacer, and
shroud. See Figure 25. See Figure 14 for lift truck models below
equipped with GM 5.7L LPG engine
NOTE: Perform Step 16 for lift truck model H8.0FT, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) H175FT36, H190FT) (A299, B299)
(A299, B299).
16. Remove capscrews, washer, fan, fan spacers, and Kubota 3.8L Diesel engine
fan shroud. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
equipped with Cummins QSB 3.3L diesel en- 20. Lift trucks equipped with a Cummins QSB 3.3L
gine or Kubota 3.8L diesel engine, loosen clamps and
• H8.0FT, H8.0FT9, H9.0FT (H170FT, disconnect the charge air cooler hoses from radi-
H175FT36, H190FT) (A299, B299) ator. See Figure 13 or Figure 15.
See Figure 14 for lift truck models below 21. Once coolant is drained from engine, loosen hose
equipped with GM 5.7L LPG engine clamps and disconnect radiator hoses from radi-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, ator. Cap hoses.
H175FT36, H190FT) (A299, B299)
25
NOTE: Tag the transmission lines before disconnect- 23. For lift trucks equipped with GM 5.7L LPG
ing from oil cooler. engine, remove capscrews from baffles and re-
move baffles from radiator assembly. Remove
22. Disconnect and cap transmission lines from oil capscrews securing cooling baffle to radiator
cooler and allow transmission oil to drain from assembly. See Figure 14.
oil cooler into a suitable container, then cap the
oil cooler ports.
Figure 13. Cummins 3.3L Cooling System With Charge Air Cooler for H6.0FT, H7.0FT (H135FT,
H155FT) (J006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
26

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
27
1. BAFFLE 10. CAPSCREW

2. ISOLATOR 11. SHROUD
3. UPPER BRACKET 12. CLAMP
4. CAP 13. UPPER HOSE
5. RESERVOIR OUTLET 14. LOWER HOSE
6. BUSHING 15. SEAL
7. HOSE 16. COOLING BAFFLE
8. RESERVOIR 17. DRAIN HOSE
9. RADIATOR 18. PLASTIC TUBE
Figure 14. GM 5.7L Cooling System, Lift Truck Models H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

1. RADIATOR 12. CHARGE AIR COOLER HOSE
2. RADIATOR CAP 13. LOWER HOSE
3. UPPER RADIATOR BRACKET 14. SHROUD
5. ISOLATOR 16. BUSHING
6. CAPSCREW 17. RESERVOIR CAP
7. CLAMP 18. RESERVOIR OUTLET
8. TUBE 19. HOSE
9. UPPER HOSE 20. COOLANT LEVEL SENSOR
11. CHARGE AIR COOLER HOSE
28
Figure 15. Kubota 3.8L Cooling System, Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
29
NOTE: Removing the radiator from lift truck requires 11. Connect the reservoir hose from reservoir to the
two people. radiator. Tighten hose clamp.
24. Remove radiator from lift truck frame. 12. Lift trucks equipped with Cummins QSB 3.3L
engine, uncap the charge air cooler hoses and
25. If necessary, remove the coolant level sensor from connect the hoses to charge air cooler. See Fig-
radiator. ure 6.
RADIATOR, INSTALL FOR LIFT TRUCK 13. Lift trucks equipped with Kubota 3.8L diesel en-
MODELS S30FT, S35FT, S40FTS (E010); gine: Uncap transmission cooler hoses and con-
H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, nect hoses to transmission cooler. See Figure 8.
H40FTS) (F001); S2.0-3.5FT (S40-70FT, 14. Uncap the upper hose and connect the hose to
S55FTS) (F187); S50CT (A267); H2.0-3.5FT radiator. Tighten hose clamp.
(H40-70FT) (L177); H2.0-2.5CT (H50CT)
15. Close the drain plug or install lower hose.
(A274); S4.0, 4.5, 5.5FT, S5.5FTS, Tighten hose clamp.
(S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004, H004) WARNING
AND H4.0FT5/FT6; H4.5FTS5, H4.5FT6; DO NOT use an alcohol or methanol base an-
H5.0-5.5FT (H80, 90, 100, 110, 120FT) tifreeze. They are flammable and could cause
(N005, P005, R005) personal injury or damage to the lift truck.
1. If removed, install the coolant level sensor.

CAUTION
2. Install radiator into truck. Additives may damage the cooling system. Be-
3. Install upper radiator bracket, using capscrews dealer.
taken out during removal.
16. Fill cooling system with ethylene glycol boron-
4. Place a radiator guard shield between radiator free antifreeze. Purchase a pre-diluted 50/50 so-
and fan, so damage to radiator does not occur lution; or mix 50% concentrate with 50% distilled
during fan installation or deionized water. The 50/50 mixture will pro-
5. Place shroud in lift truck. DO NOT install on tect cooling system to 37°C ( 35°F).
radiator. 17. Use the same coolant mixture and fill the reser-
NOTE: Pull radiator shroud away from radiator while voir between the ADD and FULL marks.
installing fan, fan spacer, and pulley. See Figure 16 or Figure 17, for lift truck models
6. Install fan, fan spacer, and pulley. • S30FT, S35FT, S40FTS (E010)
7. Remove radiator guard shield. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
8. Install the radiator shroud on radiator using • H2.0-3.5FT (H40-70FT) (L177)
screws and washers taken out during removal.. • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
9. If equipped, connect the electrical connector to
the coolant level sensor. See Figure 18, for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
NOTE: For Mazda LPG engine, the LPG converter S80, 100FTBCS; S120FTS; S120FTPRS)
bracket and screws must be installed to hold the con- (G004, H004)
verter. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
10. Uncap radiator and reservoir ports and install 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
the reservoir.
30

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
1. RESERVOIR 3. FULL MARK

2. ADD MARK
Figure 17. Reservoir for Lift Truck Models

S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT,
2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT
(A267); H2.0-3.5FT (H40-70FT) (L177) and
H2.0-2.5CT (H50CT) (A274) After May ’06

2. ADD MARK

2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT
(A267); H2.0-3.5FT (H40-70FT) (L177) and
H2.0-2.5CT (H50CT) (A274) Before May ’06
31

1. AUXILIARY COOLANT RESERVOIR
2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
18. Install battery and battery tray.
19. Connect the positive battery cable.
20. Connect negative battery cable.
21. Install the hood and seat combination.

models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
2. FULL "HOT" MARK See section Frame 100 SRM 1243 for lift truck
3. FULL "COLD" MARK models
4. ADD "COLD" MARK • S4.0, 4.5, 5.5FT; S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS, S120FTPRS)
(G004, H004)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
R005)
(H80, 90, 100, 110, 120FT) (N005, P005)
models
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
WARNING
WARNING
22. Start and run engine until thermostat opens.

(The upper hose will be warm.)

(H80, 90, 100, 110, 120FT) (R005)
32
23. On lift trucks equipped with a GM 2.4L engine, 4. Place a radiator guard shield between radiator
bleed air from the cooling system by opening the and fan, so damage to radiator does not occur
bleed screw located on the left side behind the during fan installation
system close the bleed screw. See Figure 20. 5. Place shroud in lift truck. DO NOT install on
radiator.
NOTE: Pull radiator shroud away from radiator while

installing fan, fan spacer, and pulley.
6. Install fan, fan spacer, and pulley.
8. Install the radiator shroud on radiator using

screws and washers taken out during removal..

NOTE: For Mazda LPG engine, the LPG converter

bracket and screws must be installed to hold the con-
verter.
10. Uncap radiator and reservoir ports and install

the reservoir.
11. Connect the reservoir hose from reservoir to the

radiator. Tighten hose clamp. See Figure 9.
1. MANIFOLD 3. BLEED SCREW
2. COOLANT HOSES 4. RADIATOR HOSE
12. Install new O-rings on oil cooler connectors. See
Figure 20. Bleed Screw, GM 2.4L Engine Figure 9.
13. Install oil cooler adapters to radiator. Torque

CAUTION adapters to 14.7 to 17.6 N•m (130 to 156 lbf in).
Additives may damage the cooling system. Be- See Figure 9.
14. Uncap oil cooler hoses and connect hoses to oil
dealer.
cooler adapters. See Figure 9.
24. Check coolant level at the reservoir. Add coolant
15. Uncap the upper hose and connect the hose to
as necessary to keep level between the ADD and
FULL marks on the reservoir.
RADIATOR, INSTALL FOR LIFT TRUCK Tighten hose clamp.
MODELS S30FT, S35FT, S40FTS (E010);
H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, WARNING
H40FTS) (F001); S50CT (A267) AND DO NOT use an alcohol or methanol base an-
H2.0-2.5CT (H50CT) (A274) EQUIPPED tifreeze. They are flammable and could cause
WITH OIL COOLER personal injury or damage to the lift truck.

CAUTION
33

free antifreeze. Purchase a pre-diluted 50/50 so- WARNING
lution; or mix 50% concentrate with 50% distilled During engine operation, be careful not to
or deionized water. The 50/50 mixture will pro- touch the fan, pulleys, or drive belts. Contact
tect cooling system to 37°C ( 35°F). with these parts can cause serious injury.
18. Use the same coolant mixture and fill the reser-
WARNING
voir between the ADD and FULL marks. See Fig-
ure 21. The radiator or other parts of the cooling sys-

CAUTION
dealer.

RADIATOR, INSTALL FOR LIFT TRUCK

MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024)
1. If necessary, install coolant level sensor.
2. ADD MARK
NOTE: Installing the radiator into lift truck frame
Figure 21. Reservoir for Lift Truck Models requires two people.
2. Install radiator into lift truck frame.
2.0FTS (H30FT, H35FT, H40FTS) (F001); S50CT
(A267) and H2.0-2.5CT (H50CT) (A274) 3. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler. See Fig-
ure 10.
4. Uncap and connect remote refill hose onto radia-
21. Connect negative battery cable. tor and tighten hose clamp. See Figure 10.
22. Install the hood and seat combination. 5. Close drain plug and uncap the upper and lower
radiator hoses and connect hoses onto radiator
See section Frame 100 SRM 1120 for lift truck and tighten hose clamps. See Figure 10.
models
• S30FT, S35FT, S40FTS (E010) 6. Uncap the charge air cooler hoses and connect
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, the hoses to charge air cooler. See Figure 11.
H40FTS) (F001)
7. Install fan. See Fan Installation procedures.
8. Align shroud to radiator and install two cap-
models
screws, washers and clip nuts. See Figure 23.
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274) 9. If necessary, connect electrical connector onto the
34
10. Install upper radiator bracket and four cap-

screws. WARNING
tem may be hot or under pressure and cause
CAUTION
serious injury.
185 kg (408 lb). Make sure that the eyebolts 20. Start and run the engine until thermostat opens
and lifting device have sufficient capacity to (The upper radiator hose will be warm).
lift the weight.
11. If removed, install two eyebolts in the hole on CAUTION

each end of the counterweight cover. Connect a Additives may damage the cooling system. Be-
suitable lifting device to the eyebolts and care- fore using additives, contact you local Hyster
fully install the counterweight cover into the lift dealer.
truck frame. See Figure 10.
21. Check coolant level at the auxiliary coolant reser-
12. Install two bolts to counterweights cover. voir. Add coolant as necessary to keep level be-
Tighten to 38 N•m (28 lbf ft). tween the ADD and FULL marks on the reser-
voir.
13. Install debris cover.
22. Shut down the engine for one minute or longer
14. Install radiator cover. prior to checking the transmission oil level. If
the transmission oil is low, add transmission oil
15. Connect positive battery cable.
to the transmission at the dipstick tube to the cor-
16. Connect negative battery cable. rect level indicated on the dipstick. Oil is speci-
fied in Periodic Maintenance section for your
lift truck.
WARNING
DO NOT use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
CAUTION
fore using additives, contact you local Hyster
dealer.

free antifreeze. Purchase a pre-diluted 50/50 so-
lution; or mix 50% concentrate with 50% distilled
or deionized water. The 50/50 mixture will pro-
tect cooling system to 37°C ( 35°F).
18. Install radiator cap.
voir between the ADD and FULL marks. See
Figure 22.
2. FULL "HOT" MARK
WARNING 3. FULL "COLD" MARK
4. ADD "COLD" MARK
touch the fan, pulleys, or drive belts. contact Figure 22. Reservoir for Lift Truck Models
with these parts can cause serious injury. S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024,
F024)
35
Figure 23. Cooling System for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
F024)
36

A. LOWER HOSE (CUMMINS 4.5L/KUBOTA 3.8L C. UPPER HOSE (GAS AND LPG)
DIESEL) D. UPPER HOSE (CUMMINS 4.5L/KUBOTA 3.8L
B. LOWER HOSE (GAS AND LPG) DIESEL)
1. RADIATOR (WITH EXTERNAL OIL COOLER) 14. OUTLET ASSEMBLY
2. SHROUD 15. OUTLET
3. WASHER 16. CAP
4. SCREW 17. BUSHING
5. CLIP NUT 18. HOSE
6. CLIP SPRING 19. HOSE
7. CLAMP 20. REMOTE FILL HOSE
8. UPPER RADIATOR BRACKET 21. REMOTE FILL
12. RESERVOIR 25. DRAIN PLUG
13. BRACKET (COOLANT FILL)
RADIATOR, INSTALL FOR LIFT TRUCK See Figure 15 for lift truck models equipped with
H175FT36, H190FT) (B299)
H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299) 5. Install coolant reservoir bracket and coolant
reservoir assembly onto upper bracket and
1. If necessary, install coolant level sensor. tighten capscrews.
NOTE: Installing the radiator into lift truck frame See Figure 25 for lift truck models
requires two people. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
3. For lift trucks equipped with GM 5.7L LPG en-
gine, use capscrews and install baffles to radia-
gine
tor assembly. See Figure 14. Use capscrews and
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
attach radiator assembly to cooling baffle.
H175FT36, H190FT) (A299, B299)
screws.
See Figure 25 for lift truck models • H8.0FT, H8.0FT9, H9.0FT (H170FT,
J006, K006)
See Figure 13 for lift truck models below Kubota 3.8L Diesel engine
equipped with Cummins QSB 3.3L diesel en- • H8.0FT, H8.0FT9, H9.0FT (H170FT,
gine H175FT36, H190FT) (B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
6. Uncap and connect auxiliary coolant reservoir
H175FT36, H190FT) (A299, B299)
hose and tighten clamp.
7. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
37
8. Close drain plug and uncap the lower radiator • H8.0FT, H8.0FT9, H9.0FT (H170FT,
hose and connect hose onto radiator and tighten H175FT36, H190FT) (A299, B299)
clamp.
9. Uncap and connect upper radiator hose and equipped with GM 5.7L LPG engine
tighten clamp. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
10. Lift trucks equipped with Cummins QSB 3.3L or
Kubota 3.8L diesel engine, uncap the charge air See Figure 28 for lift truck models equipped with
cooler hoses and connect the hoses to the charge Kubota 3.8L Diesel engine
air cooler. See Figure 13 or Figure 15. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
17. Install hood assembly. For hood install proce-
12. Align shroud to radiator and install capscrews, dures, see section
washers and clip nuts.
Frame 100 SRM 1321 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, H175FT36, H190FT) (A299)
J006, K006) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
equipped with Cummins QSB 3.3L diesel en- Frame 100 SRM 1581 for lift truck models
gine • H6.0FT, H7.0FT (H135FT,H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) H175FT36, H190FT) (B299)
See Figure 14 for lift truck models below 18. Lift truck equipped GM 4.3L (Gas/LPG) engine,
equipped with GM 5.7L LPG engine open hood assembly and connect intake hose to
• H8.0FT, H8.0FT9, H9.0FT (H170FT, hood support and tighten clamp. See Figure 25.
H175FT36, H190FT) (A299, B299)
19. Lift trucks equipped with Kubota 3.8L, Cummins
See Figure 15 for lift truck models equipped with 4.5L, or QSB 3.3L diesel engine, open hood as-
Kubota 3.8L Diesel engine sembly and connect hose to hood support and
• H8.0FT, H8.0FT9, H9.0FT (H170FT, tighten clamp.
H175FT36, H190FT) (B299)
13. If necessary, connect electrical connector onto the • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
coolant level sensor. J006, K006)
14. Lift truck equipped GM 4.3L (Gas/LPG) engine, See Figure 26 for lift truck models below
install air intake hose to air filter and tighten equipped with Cummins QSB 3.3L diesel en-
clamp. gine
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
15. Lift trucks equipped with Cummins 4.5L or QSB
H175FT36, H190FT) (A299, B299)
3.3L diesel engine, install silencer and connect
hose from air filter side and tighten clamp. See See Figure 28 for lift truck models equipped with
Figure 25. Kubota 3.8L Diesel engine
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
16. Lift trucks equipped with Cummins QSB 3.3L,
H175FT36, H190FT) (B299)
Kubota 3.8L diesel engine or GM 5.7L LPG en-
gine, connect dirty air hose to hood support and 20. Connect positive battery cable.
install and tighten clamp.
gine
38

WARNING voir. Add coolant as necessary to keep level be-
DO NOT use an alcohol or methanol base an- tween the ADD and FULL marks on the reser-
tifreeze. They are flammable and could cause voir.
prior to checking the transmission oil level. If the
CAUTION transmission oil is low, add transmission oil at
Additives may damage the cooling system. Be- the dipstick tube at the correct level indicated on
fore using additives, contact you local Hyster the dipstick. Oil is specified in Periodic Main-
dealer. tenance section for your lift truck.
24. Use the same coolant mixture and fill the aux-
iliary coolant reservoir between the ADD and
FULL marks. See Figure 24.
WARNING
touch the fan, pulleys, or drive belts. contact
WARNING
tem may be hot or under pressure and cause 1. AUXILIARY COOLANT RESERVOIR
serious injury. 2. FULL "HOT" MARK
3. FULL "COLD" MARK
25. Start and run the engine until thermostat opens 4. ADD "COLD" MARK
(The upper radiator hose will be warm).
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
CAUTION K006) and H8.0FT, H8.0FT9, H9.0FT (H170FT,
Additives may damage the cooling system. Be- H175FT36, H190FT) (A299, B299)
dealer.
39
Figure 25. Cooling System for Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006) (Sheet 1 of 3)
40
H155FT) (H006, J006, K006) (Sheet 2 of 3)
41
H155FT) (H006, J006, K006) (Sheet 3 of 3)
42

A. GM 4.3L (GAS/LPG) C. KUBOTA (DIESEL)
B. CUMMINS 4.5L (DIESEL)
1. AIR INTAKE (WITHOUT PRE-CLEANER) 17. SCREW
2. PRE-CLEANER 18. SHROUD
3. HOOD ASSEMBLY 19. FAN
4. CLAMP 20. FAN SPACER
5. INLET HOSE 21. TRANSMISSION LINES
6. SILENCER (DIESEL) 22. AUXILIARY COOLANT RESERVOIR AND
7. AIR FILTER BRACKET ASSEMBLY
8. UPPER RADIATOR BRACKET 23. OUTLET
9. ISOLATOR 24. CAP
10. INSERT 25. BUSHING
11. CAPSCREW 26. HOSE
12. RADIATOR (WITH EXTERNAL OIL COOLER) 27. AUXILIARY COOLANT RESERVOIR HOSE
13. UPPER HOSE 28. DRAIN PLUG
14. LOWER HOSE 29. RADIATOR CAP
15. CLIP NUT 30. HOOD SUPPORT
16. WASHER
43
1. PRE-CLEANER 17. COOLANT LEVEL SENSOR

2. CLAMP 18. UPPER BRACKET
3. HOOD SUPPORT 19. RADIATOR ISOLATOR
4. HOOD ASSEMBLY 20. RADIATOR
5. DIRTY AIR HOSE 21. CAC HOSE
6. CLEAN AIR HOSE 22. CAC TUBE
7. AIR FILTER 23. INSULATED CLAMP
8. AIR CLEANER BRACKET 24. LOWER RADIATOR HOSE
9. CAPSCREW 25. UPPER RADIATOR HOSE
10. NUT 26. SHROUD AND BAFFLE
11. AUXILIARY COOLANT RESERVOIR HOSE 27. WASHER
12. RESERVOIR OUTLET 28. FAN
13. CAP 29. SPACER
14. BUSHING 30. AUXILIARY COOLANT RESERVOIR ASSEMBLY
15. COOLANT RECOVERY RESERVOIR 31. CLIP NUT
16. TUBE
Figure 26. Cooling System Cummins QSB 3.3L Diesel Engine for Lift Truck Model H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
44
1. PRE-CLEANER 13. RADIATOR

2. CLAMP 14. BAFFLE
3. HOOD SUPPORT 15. COOLANT RECOVERY RESERVOIR
4. HOOD 16. LOWER RADIATOR HOSE
5. DIRTY AIR HOSE 17. UPPER RADIATOR HOSE
6. CLEAN AIR HOSE 18. SEAL
7. AIR FILTER 19. BAFFLE
8. AIR CLEANER BRACKET 20. FAN SHROUD
9. CAPSCREW 21. FAN
10. NUT 22. SPACER
11. RADIATOR ISOLATOR 23. FAN MOUNTING SCREWS
12. UPPER BRACKET
Figure 27. Cooling System GM 5.7L LPG Engine for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
45
Figure 28. Cooling System Kubota 3.8L Diesel Engine for Lift Truck Model H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (B299)
46
700 SRM 1123 Fan Assembly Replacement

1. PRE-CLEANER 16. TUBE
3. HOOD SUPPORT 18. UPPER BRACKET
4. HOOD ASSEMBLY 19. RADIATOR ISOLATOR
5. DIRTY AIR HOSE 20. RADIATOR
6. CLEAN AIR HOSE 21. CAC HOSE
7. AIR FILTER 22. CAC TUBE
8. AIR CLEANER BRACKET 23. AIR FLOW SENSOR
9. CAPSCREW 24. LOWER RADIATOR HOSE
10. NUT 25. UPPER RADIATOR HOSE
11. AUXILIARY COOLANT RESERVOIR HOSE 26. SHROUD AND BAFFLE
12. RESERVOIR OUTLET 27. WASHER
13. CAP 28. FAN
14. BUSHING 29. SPACER
15. COOLANT RECOVERY RESERVOIR
Fan Assembly Replacement

FAN REMOVAL NOTE: Perform Step 4 through Step 6 for lift truck
models
WARNING • S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
WARNING 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
The radiator or other parts of the cooling sys- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
tem may be hot or under pressure and can (H80, 90, 100, 110, 120FT) (N005, P005, R005)
cause serious injury. Wait 30 minutes for the • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
radiator to cool. Do a touch test by touching F024)
the radiator with your hand. If the radiator is • S50CT (A267)
still hot to the touch, wait another 30 minutes • H2.0-2.5CT (H50CT) (A274)
the cooling system. 4. Release the steering tilt latch and move the steer-
ing wheel forward.
WARNING 5. Release the seat latch and move the seat forward.
The radiator fins on the radiator are very
sharp and can cause serious injury. Wear 6. Release hood latch and raise hood to open posi-
gloves while removing fan assembly. tion.
NOTE: The fan that is used is a pusher-type fan. Do NOTE: Perform Step 7 for lift truck models
not replace with a puller-type fan. • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006)
1. Turn OFF lift truck. • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
2. If equipped, turn the LPG tank valve to the OFF
position. 7. Release hood cover latch on hood cover and swing
hood cover up.
3. If equipped, release the LPG tank bracket and
swing tank away from the lift truck.
47
Fan Assembly Replacement 700 SRM 1123

WARNING equipped with Cummins 4.5L engine
To prevent a short circuit during fan belt re- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
moval, disconnect the battery negative cable at 5.5FT (H80, 90, 100, 110, 120FT) (N005)
the battery negative terminal. Install a lock or
tag on the connector to prevent connection. A See Figure 34 for lift truck models below
tool could cause a short circuit, the high cur- equipped with GM 4.3L, Cummins 4.5L, or
rent flow from the battery can cause an injury Kubota 3.8L engines
or parts damage. • S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
F024)
8. Disconnect the negative battery cable from the
negative battery terminal. See Figure 35 for lift truck models below
equipped with GM 4.3L, Cummins 4.5L, or
9. Remove screws and washers from the radiator Kubota engines
shroud. Lean radiator shroud toward the fan. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
K006)
equipped with GM 2.4L, Yanmar 2.6L, Yan- See Figure 36 for lift truck models below
mar 3.0L or Yanmar 3.3L engine equipped with Cummins QSB 3.3L diesel en-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) gines
• H2.0-3.5FT (H40-70FT) (L177) • S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • H6.0FT, H7.0FT (H135FT, H155FT) (J006)
H40FTS) (F001) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
equipped with Yanmar 2.6L engine. See Figure 37 for lift truck models below
• H2.0-2.5CT (H50CT) (A274) equipped with Cummins QSB 3.3L diesel en-
gines
See Figure 31 for lift truck models below • H8.0FT, H8.0FT9, H9.0FT (H170FT,
equipped with Mazda 2.0L and 2.2L engines H175FT36, H190FT) (A299, B299)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S50CT (A267) See Figure 38 for lift truck models below
• H2.0-2.5CT (H50CT) (A274) equipped with GM 5.7L LPG engine
• H2.0-3.5FT (H40-70FT) (L177) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
• S30FT, S35FT, S40FTS (E010) H175FT36, H190FT) (A299, B299)
H40FTS) (F001) See Figure 39 for lift truck models below
equipped with Kubota 3.8L diesel engine
See Figure 32 for lift truck models below • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
equipped with GM 4.3L engine 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) See Figure 40 for lift truck models below
(G004, H004) equipped with Kubota 3.8L diesel engine
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- • H8.0FT, H8.0FT9, H9.0FT (H170FT,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, H175FT36, H190FT) (B299)
R005)
48
1. FAN 5. SCREW
2. SPACER 6. RADIATOR SHROUD
3. WASHER 7. RADIATOR
4. CAPSCREW
Figure 29. Fan Removal for GM 2.4L, Yanmar 2.6L, Yanmar 3.0L and Yanmar 3.3L Engines, Lift
Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177), and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
49
1. SPACER 5. SHROUD
2. FAN 6. SCREW
4. CAPSCREW
Figure 30. Fan Removal for Yanmar 2.6L Engine, Lift Truck Models H2.0-2.5CT (H50CT) (A274)
50
NOTE: MODINE RADIATOR SHOWN, COPAR RADIATOR SIMILAR.

1. SPACER, H1.6FT, H1.8FT, H2.0FTS (H30FT, 4. WASHER
H35FT, H40FTS) (F001) AND H2.0-3.5FT 5. SCREW
(H40-70FT) (L177) LIFT TRUCKS ONLY 6. WASHER
2. FAN 7. RADIATOR SHROUD
3. CAPSCREW 8. RADIATOR
Figure 31. Fan Removal for Mazda 2.0L and 2.2L Engines, Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187), S50CT (A267), H2.0-2.5CT (H50CT) (A274), H2.0-3.5FT (H40-70FT) (L177), S30FT,
S35FT, S40FTS (E010), and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
51
1. FAN 5. SCREW
4. CAPSCREW
Figure 32. Fan Removal for GM 4.3L Engine, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
52
1. SPACER 6. SCREW
2. FAN 7. LOCKWASHER
3. WASHER 8. CLIP NUT
5. RADIATOR SHROUD
Figure 33. Fan Removal for Cummins 4.5L Engine, Lift truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
53
A. GM 4.3L AND KUBOTA 3.8L B. CUMMINS 4.5L (DIESEL)

1. FAN 5. SCREW
2. FAN SPACER 6. SHROUD
4. CAPSCREW
Figure 34. Fan Removal for GM 4.3L, Cummins 4.5L and Kubota 3.8L Engines, Lift truck Models
S6.0FT, S7.0FT, (S135FT,S155FT) (D024, F024)
54
A. GM 4.3L AND KUBOTA B. CUMMINS 4.5L (DIESEL)

1. FAN 5. SCREW
4. CAPSCREW
Figure 35. Fan Removal for GM 4.3L, Cummins 4.5L, and Kubota Engines, Lift Truck Models
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
55
1. SPACER 5. WASHER
2. FAN 6. CAPSCREW
3. SCREW 7. SHROUD
Figure 36. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005), S6.0FT, S7.0FT (S135FT, S155FT) (E024)
and H6.0FT, H7.0FT (H135FT, H155FT) (J006)
56
1. RADIATOR SHROUD 5. CAPSCREW

2. SCREW 6. FAN
4. SPACER
Figure 37. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
57
1. FAN SHROUD 5. CAPSCREW

2. SCREW 6. FAN
3. WASHER 7. RADIATOR ASSEMBLY
4. SPACER
Figure 38. Fan Removal for GM 5.7L LPG Engine, Lift Truck Models H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
58
1. FAN 5. SCREW
4. CAPSCREW
Figure 39. Fan Removal for Kubota 3.8L Diesel Engine for Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
59

2. SCREW 6. FAN
4. SPACER
Figure 40. Fan Removal for Kubota 3.8L Diesel Engine, Lift Truck Models H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (B299)
10. Remove capscrews, washers, and spacer from the • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
fan pulley. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
equipped with GM 2.4L, Yanmar 2.6L, Yan- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
mar 3.0L or Yanmar 3.3L engine R005)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) See Figure 33 for lift truck models below
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, equipped with Cummins 4.5L engine
5.5FT (H80, 90, 100, 110, 120FT) (N005)
equipped with Yanmar 2.6L engine See Figure 34. for lift truck models below
• H2.0-2.5CT (H50CT) (A274) equipped with GM 4.3L, Cummins 4.5L, or Kub-
ota 3.8L engines
See Figure 32 for lift truck models below • S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
equipped with GM 4.3L engine F024)
60
See Figure 35 for lift truck models below NOTE: Perform Step 13 for lift truck models
equipped with GM 4.3L, Cummins 4.5L, Kubota • S30FT, S35FT, S40FTS (E010)
engines • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • S50CT (A267)
J006, K006)
13. For lift trucks equipped with Mazda 2.0L or 2.2L
See Figure 39 for lift truck models below engines, remove the capscrews and washers re-
equipped with Kubota 3.8L diesel engine taining the fan.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005) See Figure 31 for lift truck models below
equipped with Mazda 2.0L and 2.2L engines
NOTE: Perform Step 11 for lift truck model H8.0FT, • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) • S50CT (A267)
(A299) and H8.0FT, H8.0FT9, H9.0FT (B299). • H2.0-2.5CT (H50CT) (A274)
• H2.0-3.5FT (H40-70FT) (L177)
11. For lift trucks equipped with Cummins QSB 3.3L • S30FT, S35FT, S40FTS (E010)
diesel engines, GM 5.7L LPG engines, or Kubota • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
3.8L diesel engines, remove capscrews, washers, H40FTS) (F001)
and spacers from fan.
14. Remove the fan.
equipped with Cummins QSB 3.3L diesel en- INSPECT
gines
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
WARNING
H175FT36, H190FT) (A299, B299)
DO NOT try to repair a damaged fan. If a fan
See Figure 38 for lift truck models below has a bent blade or is cracked, install a new fan.
equipped with GM 5.7L LPG engine A damaged fan can break during use and cause
• H8.0FT, H8.0FT9, H9.0FT (H170FT, damage or serious injury.
H175FT36, H190FT) (A299, B299)
1. Inspect the fan for any damage.
equipped with Kubota 3.8L diesel engine 2. If the fan is damaged, replace the entire fan.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) FAN INSTALLATION
NOTE: Perform Step 12 for lift truck models WARNING

• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, The radiator fins on the radiator are very
H40FTS) (F001) sharp and can cause serious injury. Wear
• H2.0-3.5FT (H40-70FT) (L177) gloves while installing fan assembly.
• H2.0-2.5CT (H50CT) (A274)
. 1. Install the lower portion of the shroud in the re-
taining clips and lean the shroud toward the en-
12. For lift trucks equipped with Mazda 2.0L and gine.
2.2L engines, remove capscrews, washers, and
spacer from the fan pulley. 2. Install the spacer, washers, and capscrews to the
fan. Tighten the capscrews to 52 N•m (38 lbf).
equipped with Mazda 2.0L and 2.2L engines See Figure 29 for lift truck models below
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) equipped with GM 2.4L, Yanmar 2.6L, Yan-
• S50CT (A267) mar3.0L or Yanmar 3.3L engine
• H2.0-2.5CT (H50CT) (A274) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
H40FTS) (F001)
61
equipped with Yanmar 2.6L engine. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• H2.0-2.5CT (H50CT) (A274) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 32 for lift truck models below • H2.0-2.5CT (H50CT) (A274)
equipped with GM 4.3L engine
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; 4. Install the spacer, washers, and capscrews to the
S80, 100FTBCS; S120FTS; S120FTPRS) fan. Tighten the capscrews to 27 N•m (20 lbf ft).
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- See Figure 31 for lift truck models below
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, equipped with Mazda 2.0L and 2.2L engines
R005) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
See Figure 33 for lift truck models below • H2.0-3.5FT (H40-70FT) (L177)
equipped with Cummins 4.5L engine • H2.0-2.5CT (H50CT) (A274)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005) NOTE: Perform Step 5 for lift truck models
• S30FT, S35FT, S40FTS (E010)
See Figure 34. for lift truck models below • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
equipped with GM 4.3L, Cummins 4.5L, or Kub- • S50CT (A267)
ota 3.8L engines
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024, 5. Place the fan in position of the pulley and install
F024) capscrews and washers. Tighten the capscrews
equipped with GM 4.3L, Cummins 4.5L, or See Figure 31 for lift truck models below
Kubota engines equipped with Mazda 2.0L or 2.2L engines
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • S30FT, S35FT, S40FTS (E010)
J006, K006) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S50CT (A267)
equipped with Kubota 3.8L diesel engine 6. Install the spacer, washers, and capscrews to the
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- fan. Tighten the capscrews to 27 N•m (20 lbf ft).
5.5FT (H80, 90, 100, 110, 120FT) (R005)
NOTE: Perform Step 3 for lift truck models H8.0FT, equipped with GM 4.3L engine
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
(A299, B299). S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
3. Install spacers, washers, and capscrews onto fan. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
See Figure 37 for lift truck models below R005)
gines See Figure 34 for lift truck models below
• H8.0FT, H8.0FT9, H9.0FT (H170FT, equipped with GM 4.3L, Cummins 4.5L, or
H175FT36, H190FT) (A299, B299) Kubota 3.8L engines
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
See Figure 38 for lift truck models below F024)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, See Figure 35 for lift truck models below
H175FT36, H190FT) (A299, B299) equipped with GM 4.3L, Cummins 4.5L, or
Kubota engines
See Figure 40 for lift truck models below • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
equipped with Kubota 3.8L diesel engine J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
62
7. Lean the radiator shroud back toward the radi- • H6.0FT, H7.0FT (H135FT, H155FT) (J006)
ator. Install the screws and washers and install • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
the radiator shroud cover. 5.5FT (H80, 90, 100, 110, 120FT) (P005)
See Figure 29 for lift truck models below See Figure 37 for lift truck models below
equipped with GM 2.4L, Yanmar 2.6L, Yan- equipped with Cummins QSB 3.3L diesel en-
mar 3.0L or Yanmar 3.3L engine gines
• 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)
equipped with Yanmar 2.6L engine H175FT36, H190FT) (A299, B299)
• H2.0-2.5CT (H50CT) (A274)
See Figure 31 for lift truck models below equipped with Kubota 3.8L diesel engine
equipped with Mazda 2.0L or 2.2L engines • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274) See Figure 40 for lift truck models below
• H2.0-3.5FT (H40-70FT) (L177) equipped with Kubota 3.8L diesel engine
• S30FT, S35FT, S40FTS (E010) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H175FT36, H190FT) (B299)
H40FTS) (F001)
8. Reconnect the negative battery cable to the neg-
See Figure 32 for lift truck models below ative terminal of the battery.
NOTE: Perform Step 9 through Step 11 for lift truck
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
models
S80, 100FTBCS; S120FTS; S120FTPRS)
• S30FT, S35FT, S40FTS (E010)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H40FTS) (F001)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
R005)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 33 for lift truck models below • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
equipped with Cummins 4.5L engine 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
5.5FT (H80, 90, 100, 110, 120FT) (N005) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
See Figure 34. for lift truck models below F024)
ota 3.8L engines • H2.0-2.5CT (H50CT) (A274)
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
F024) 9. Lower the hood and ensure that the hood latches.
See Figure 35 for lift truck models below 10. Move the seat back.
11. Release the steering wheel tilt latch and move
Kubota engines
the steering wheel back.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) NOTE: Perform Step 12 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
H190FT) (A299, B299)
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (E024)
63
12. Close hood cover. 14. If equipped, turn the LPG tank valve to the ON
position.
13. If equipped, swing the LPG tank bracket back
toward the truck and re-latch.
64
700 SRM 1123 11/12 (9/12)(7/12) (1/12)(8/11)(7/11)(8/10)(5/10)(4/09)(4/08) Printed in U.S.A.

LPG FUEL SYSTEM
GM 2.4L ENGINE
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580506 900 SRM 1124

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
LPG Fuel System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Hoses Replacement ............................................................................................................................................ 1
LPG Tank and Bracket Replacement ............................................................................................................... 1
Remove LPG Tank ......................................................................................................................................... 1
Install LPG Tank ........................................................................................................................................... 3
Remove LPG Bracket .................................................................................................................................... 4
Install LPG Bracket ...................................................................................................................................... 4
Remove LPG Tank Bracket Alignment Pin.................................................................................................. 6
Install LPG Tank Bracket Alignment Pin.................................................................................................... 6
Fuel Filter Unit Repair...................................................................................................................................... 8
Fuel Filter Element ....................................................................................................................................... 8
Remove....................................................................................................................................................... 8
Clean/Inspect ............................................................................................................................................. 8
Install ......................................................................................................................................................... 8
Fuel Filter Housing ....................................................................................................................................... 9
Remove....................................................................................................................................................... 9
Disassemble ............................................................................................................................................... 9
Assemble .................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Electronic Throttle Body Repair ....................................................................................................................... 10
Electronic Throttle Body ............................................................................................................................... 10
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Electronic Throttle Body Adapter Plate ....................................................................................................... 11
Remove....................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Fuel Injector Repair ........................................................................................................................................... 12
Fuel Rail......................................................................................................................................................... 12
Remove for Lift Trucks Built Before January, 2010................................................................................ 12
Install for Lift Trucks Built Before January, 2010 .................................................................................. 13
Remove for Lift Trucks Built After January, 2010 .................................................................................. 13
Install for Lift Trucks Built After January, 2010 .................................................................................... 14
Fuel Injector for Lift Trucks Built Before January, 2010............................................................................ 15
Remove....................................................................................................................................................... 15
Clean .......................................................................................................................................................... 15
Install ......................................................................................................................................................... 15
Fuel Injector Adapters for Lift Trucks Built Before January, 2010............................................................ 16
Remove....................................................................................................................................................... 16
Install ......................................................................................................................................................... 17
Fuel Injectors and Adapters for Lift Trucks Built After January, 2010 ..................................................... 18
Remove....................................................................................................................................................... 18
Clean .......................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
LPG Regulator Repair ....................................................................................................................................... 19
LPG Regulator ............................................................................................................................................... 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
LPG Regulator Fuel Filter ............................................................................................................................ 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 20
Lock-Off Solenoid and Cartridge .................................................................................................................. 21

Table of Contents LPG Fuel System

Remove....................................................................................................................................................... 21
Install ......................................................................................................................................................... 21
Control System................................................................................................................................................... 22
Electronic Control Unit (ECU)...................................................................................................................... 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Fuel Pump Relay ........................................................................................................................................... 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 24
Injector Driver Module .................................................................................................................................. 24
Remove....................................................................................................................................................... 24
Install ......................................................................................................................................................... 25
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor ......................................... 25
Remove....................................................................................................................................................... 25
Install ......................................................................................................................................................... 25
Engine Coolant Temperature (ECT) Sensor ................................................................................................ 26
Remove....................................................................................................................................................... 26
Install ......................................................................................................................................................... 26
Oxygen Sensor ............................................................................................................................................... 26
Remove....................................................................................................................................................... 26
Install ......................................................................................................................................................... 27
Low LPG Pressure Switch ............................................................................................................................ 27
Remove....................................................................................................................................................... 27
Install ......................................................................................................................................................... 27
Remove and Disassemble .............................................................................................................................. 28
Inspect ............................................................................................................................................................ 29
Assemble and Install ..................................................................................................................................... 30
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];

H2.0-3.5FT (H40-70FT) [L177]
ii
900 SRM 1124 LPG Tank and Bracket Replacement
General
This section has the repair procedures for the parts of the LPG fuel system used on the GM 2.4 liter engines.
Hoses Replacement
The hoses installed on LPG systems are special. When replacing the hose to the quick-disconnect
Hoses that are made for use with hydraulic oil are fitting, make sure it is the same length as the hose
damaged by LPG. When replacing the LPG hoses, it replaces. A longer hose permits the tank to be
make sure to use only Hyster Approved LPG installed in an incorrect position. If a fuel hose has
hoses. Make sure to use the correct size of hose. a restriction, it is coldest around the restriction.
LPG Tank and Bracket Replacement

REMOVE LPG TANK NOTE: The LPG tank bracket used on this line
of trucks to mount the LPG tank onto the coun-
WARNING terweight comes in two styles. One style of
bracket swings out to the side of the truck and
the other swings out to the side and drops down
(EZ-Xchange™). See Figure 1.
LPG system. LPG fuel systems can be discon-
nected indoors only if the lift truck is at least NOTE: Lift truck models H2.0-3.5FT (L177) may be
8 m (26 ft) from any open flame, motor vehicles, equipped with dual steel straps on the LPG tank
electrical equipment, or ignition source. bracket. See Figure 2.
LPG is heavier than air. LPG can stay in low 1. LPG tanks can be removed and replaced indoors
places and cause an explosion when a spark oc- only if the lift truck is at least 8 m (26 ft) from
curs. any flame or ignition source. Move the lift truck
to an the area where LPG tanks are changed.
DO NOT overfill the LPG tank. Liquid is ex-
pelled from the vent valve when the bottle has 2. Turn the shutoff valve clockwise until the valve
reached the 80 percent full point. At this point, is completely closed.
the bottle filling operation must be halted. Fill-
ing the bottle to 80 percent allows the appro- 3. Run the engine until it stops. If truck is equipped
priate expansion volume within the bottle. The with a key switch, turn the key switch to the
tank relief valve is installed in the tank to allow OFF position. If truck is equipped with a Power
for pressure relief if the bottle is overfilled or ON/OFF button, press the Power ON/OFF but-
if exposed to high temperatures. ton to turn power off.
Close the shutoff valve on the LPG tank before 4. Disconnect the quick-disconnect fitting on the
any part of the engine fuel system is discon- LPG tank. See Figure 1.
nected. Run the engine until the fuel in the sys-
tem is used and the engine stops. 5. Push in the bracket release pin, grab the bracket
handle, and swing the tank and bracket out
If the engine will not run, close the shutoff to the side of the lift truck. If your truck is
valve on the LPG tank. Loosen the fitting on equipped with a swing-out and drop-down LPG
the supply hose from the LPG tank where it en- tank bracket (EZ-Xchange™), drop the tank
ters the filter unit. Permit the pressure in the down to the side of the truck for ease of removal.
fuel system to decrease slowly. Fuel leaving See Figure 1.
the fitting removes heat. To avoid personal in-
jury, wear safety glasses and protective gloves. 6. Unlatch the tank strap and remove the LPG tank
Also use a cloth to further protect your hands from the bracket. See Figure 1 or Figure 2.
from the cold fitting.
1
LPG Tank and Bracket Replacement 900 SRM 1124
A. SWING-OUT LPG BRACKET

B. SWING-OUT AND DROP-DOWN LPG BRACKET (EZ-XCHANGE™)
1. LPG TANK 7. STOP PIN
2. TANK STRAP 8. BRACKET HANDLE
3. QUICK DISCONNECT FITTING 9. BRACKET PIVOT
4. HYDROSTATIC RELIEF VALVE 10. GAS SPRING (DROP-DOWN BRACKET ONLY)
5. MANIFOLD BLOCK 11. BRACKET RELEASE PIN (BUTTON)
6. ALIGNMENT PIN
Figure 1. LPG Tank and Bracket
2
A. SWING-OUT LPG BRACKET

B. SWING-OUT AND DROP-DOWN LPG BRACKET (EZXCHANGE BRACKET)
1. DUAL STEEL TANK STRAP 7. BRACKET RELEASE LEVER
2. MANIFOLD BLOCK 8. GAS SPRING
3. ALIGNMENT PIN 9. BRACKET DATA PLATE
4. STOP PIN 10. HYDROSTATIC RELIEF VALVE
5. BRACKET PIVOT 11. TANK FOOTREST PLATE
6. BRACKET HANDLE
Figure 2. LPG Tank Bracket With Dual Steel Straps, Lift Truck Models H2.0-3.5FT (L177)
INSTALL LPG TANK 1. Place the LPG tank into the bracket. Secure the
tank strap around the tank and close the strap.
NOTE: The LPG bracket must be in the swing-out
position to install the LPG tank. If your lift 2. Pull the stop pin (see Figure 1) and swing the
truck has the swing-out and drop-down bracket LPG tank bracket into the resting position on the
(EZ-Xchange™), position the bracket in the counterweight. Be sure that the bracket locks
drop-down position. into position.
3. Connect the hose to the LPG fuel lock-off connec-

WARNING tion on the LPG regulator. See Figure 1.
When closing the LPG tank strap, DO NOT
wrap your fingers around the strap handle. 4. Connect the quick-disconnect fitting on the LPG
The strap can close quickly and with enough tank. See Figure 1.
force to cause injury to the fingers and hand.
5. Turn the fuel valve counterclockwise to open the
fuel valve.
3
6. Inspect the fuel system for leaks when the fuel 4. Pull the bracket stop pin and swing the LPG
valve is open. There are four methods used to tank bracket back into the resting position on the
inspect the fuel system for leaks: counterweight. Be sure that the latch clicks shut
and locks.
a. Sound - Listen for sound of LPG escaping
from a tank fitting or hose connection. 5. Remove capscrews and LPG tank bracket from
counterweight. See Figure 5.
b. Smell - LPG has a very distinctive odor. If
you smell LPG, DO NOT start the engine. INSTALL LPG BRACKET
c. Soapy Water - This method is used in con- 1. Lift trucks built before 2010, equipped with
junction with Step b above. If the odor of LPG GM 2.4L engines - Place the LPG bracket onto
is present, but escaping fuel cannot be heard, the counterweight. Be sure to align the holes on
apply soapy water to the fittings and observe the counterweight with the holes on the bracket.
for bubbles. Insert hose assembly to LPG regulator/lock-off
through the hole in counterweight. See Figure 3
d. Frost - If the amount of LPG escaping is suf-
and Figure 5.
ficient, frost may appear on the fittings.
REMOVE LPG BRACKET

NOTE: The LPG tank must be removed from the lift
truck before removing the LPG tank bracket. See
section Remove LPG Tank.
1. Lift trucks built before 2010, equipped with

GM 2.4L engine - Disconnect the hose from the
LPG lock-off connection on the LPG regulator,
and remove hose through hole in counter weight.
See Figure 3.
2. Lift trucks built after January, 2010

equipped with GM 2.4L engines - Discon-
nect the hose from the LPG fuel filter and
remove hose through hole in counterweight. See
Figure 4.
WARNING
When removing the capscrews for the LPG 1. FITTING
tank bracket, only remove the capscrew (1, Fig- 2. HOSE ASSEMBLY
3. CAPSCREW
ure 5) with the LPG bracket in the swing-out 4. LPG TANK
or extended position. The LPG tank bracket 5. HOSE ASSEMBLY TO LPG
is heavy and difficult to handle if all the cap- REGULATOR/LOCK-OFF
screws are removed with the bracket in the 6. LPG REGULATOR CONNECTION
swing-out position. Personal injury and dam- 7. LPG REGULATOR
age to the lift truck can result if the bracket is
Figure 3. LPG Tank Hose Connections (Lift
removed and handled while in the swing-out
Trucks Built Before 2010, Equipped with GM
or extended position.
2.4L Engine)
3. Push in the bracket release pin, grab the bracket
handle, and swing the bracket out to the side of
the lift truck. Remove capscrew. See Figure 5.
4
to LPG fuel filter through the hole in counter-

weight. See Figure 4 and Figure 5.
3. Install three capscrews (2, Figure 5) onto LPG

bracket and counterweight. Tighten capscrews
4. Push bracket release pin (button) and pull

bracket handle to swing the bracket out to the
side of the lift truck. Install capscrew (1, Fig-
ure 5) onto bracket. Tighten capscrew to 38 N•m
(28 lbf ft).
5. Install LPG tank. See section Install LPG Tank.
1. HOSE ASSEMBLY TO LPG REGULATOR

2. BRACKET
3. LPG LOW LEVEL SENSOR
4. LPG FUEL FILTER
5. HOSE ASSEMBLY TO LPG FUEL FILTER
6. CAPSCREW
7. FITTING
8. LPG TANK
9. LPG FUEL FILTER CONNECTION
Figure 4. LPG Tank Hose Connections (Lift A. LPG BRACKET - SWING-OUT OPTION
Trucks Built After January, 2010 Equipped B. LPG BRACKET SWING-OUT AND DROP-DOWN
with GM 2.4L Engine) OPTION (EZ-XCHANGE™)
2. Lift trucks built after January, 2010 1. CAPSCREW - REMOVE WITH BRACKET IN
SWING-OUT (EXTENDED) POSITION
equipped with GM 2.4L engines - Place 2. CAPSCREW - REMOVE WITH BRACKET IN
the LPG bracket onto the counterweight. Be RESTING POSITION ON COUNTERWEIGHT
sure to align the holes on the counterweight with
the holes on the bracket. Insert hose assembly Figure 5. LPG Tank Bracket Remove/Install
5
REMOVE LPG TANK BRACKET Lift truck models H2.0-3.5FT (L177) may be
ALIGNMENT PIN equipped with dual steel straps on the LPG tank
bracket. See Figure 2.
The LPG tank alignment pin can be replaced if it
becomes damaged or worn. There are two types of 1. Remove the LPG tank from LPG tank bracket.
alignment pins used. If the LPG tank has fabric See Remove LPG Tank for procedures.
straps, the alignment pin will have a weldment off-
2. Remove the LPG tank bracket from lift truck.
set plate. If the LPG tank has a single steel strap or
See Remove LPG Bracket for procedures.
dual steel straps, the alignment pin will not have a
weldment offset plate. See Figure 6. 3. Remove alignment pin from LPG tank bracket.
a. If LPG tank is equipped with a fabric strap,

remove flange button head capscrew, hard-
ened washer, curved washer, spacer (if
equipped), hardened washer, and two pins
from alignment pin and weldment offset
plate. Remove alignment pin and weldment
offset plate from LPG tank bracket. See
Figure 7.
b. If LPG tank is equipped with a single steel

strap or dual steel straps, remove flange but-
ton head capscrew, hardened washer, curved
washer, spacer (if equipped), and hardened
washer from alignment pin. Remove align-
ment pin from LPG tank bracket. See Fig-
ure 7.
INSTALL LPG TANK BRACKET

ALIGNMENT PIN
1. Install new LPG tank alignment pin.
a. If LPG tank is equipped with a single steel

strap or dual steel straps, insert new align-
ment pin in slot on LPG tank bracket. Place
hardened washer, curved washer, spacer (if
equipped), and hardened washer on flanged
button head capscrew. Install flanged but-
ton head capscrew and hardware into bot-
tom of alignment pin. Tighten flanged but-
ton head capscrew to secure alignment pin to
A. ALIGNMENT PIN - LPG TANK WITH FABRIC LPG tank bracket. See Figure 7.
STRAP. SWING-OUT LPG BRACKET SHOWN
B. ALIGNMENT PIN - LPG TANK WITH SINGLE b. If LPG tank is equipped with fabric strap,
STEEL STRAP. SWING-OUT AND DROP-DOWN insert new alignment pin and weldment off-
LPG BRACKET (EZXCHANGE BRACKET) set plate in slot on LPG tank bracket. Place
SHOWN.
hardened washer, curved washer, spacer (if
1. ALIGNMENT PIN required), and hardened washer on flanged
2. PIN WELDMENT OFFSET PLATE button head capscrew. Install flanged but-
ton head capscrew and hardware into hole
Figure 6. LPG Tank Alignment Pin Types in weldment offset plate. Tighten flanged
button head capscrew to secure alignment
pin and weldment offset plate to LPG tank
bracket. See Figure 7.
6
2. After LPG tank alignment pin has been in-

stalled, measure the distance between the
hardened washers. The distance should not
exceed 2 ±1 mm (0.08 ±0.04 in.). Add or re-
move spacers between the hardened washer and
curved washer, as needed to achieve the correct
distance. See Figure 7 and Figure 8.
3. Install LPG tank bracket onto lift truck. See In-

stall LPG Bracket for procedures.
4. Install LPG tank onto LPG tank bracket. See

Install LPG Tank for procedures.
A. LPG TANK WITH FABRIC STRAP AND

WELDMENT OFFSET PLATE. SWING-OUT LPG 1. HARDENED WASHER
BRACKET SHOWN. 2. SPACER
B. LPG TANK WITH SINGLE STEEL STRAP. 3. CURVED WASHER
SWING-OUT AND DROP-DOWN LPG BRACKET 4. ALIGNMENT PIN
(EZXCHANGE BRACKET) SHOWN. DUAL
STEEL STRAPS SIMILAR. Figure 8. LPG Tank Alignment Pin
Measurement
1. FLANGE BUTTON HEAD CAPSCREW
2. HARDENED WASHER
3. CURVED WASHER
4. SPACER*
5. PIN
6. ALIGNMENT PIN
7. WELDMENT OFFSET PLATE
8. SLOT
*IF EQUIPPED.
Figure 7. LPG Tank Alignment Pin Removal
7
Fuel Filter Unit Repair 900 SRM 1124
Fuel Filter Unit Repair

FUEL FILTER ELEMENT 4. Install bolt and new seal washer. Tighten bolt to
13 N•m (115 lbf in).
Remove
NOTE: Opening the fuel valve too quickly can cause
the internal excess flow valve to close, restricting the
WARNING
flow of fuel. If this happens, close the fuel valve, wait
LPG can cause an explosion. DO NOT permit a few seconds, and then slowly open the fuel valve
any sparks or open flames in the work area. again. This will reset the excess flow valve.
1. Close fuel valve on tank. Run engine until it 5. Slowly open the fuel valve on tank.
stops.
6. Connect the negative battery cable.
2. Disconnect negative battery cable.
7. Turn the key to the ON position and back to
WARNING the OFF position to pressurize the fuel system.
Check for leaks.
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.
3. Remove the bolt and seal washer from the fuel

filter housing top section. Discard seal washer.
See Figure 9.
4. Remove fuel filter housing top section from fuel

filter housing bottom section.
5. Remove and discard housing O-ring.
6. Remove and discard fuel filter and fuel filter

O-ring.
Clean/Inspect
1. Clean and inspect the fuel filter housing top sec-
tion for contamination or damage. If damaged,
replace the housing.
2. Clean and inspect the fuel filter housing bottom

section for contamination or damage. If dam-
aged, replace the housing.
1. BOLT*
2. SEAL WASHER
Install 3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER
1. Install the new fuel filter and fuel filter O-ring. 5. FUEL FILTER O-RING
See Figure 9. 6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION*
2. Install new housing O-ring.
*NOT SERVICED SEPARATELY
3. Install fuel filter housing top section onto fuel
filter housing bottom section. Figure 9. Fuel Filter Removal/Installation
8
900 SRM 1124 Fuel Filter Unit Repair
8. Check for leaks at connections by using soapy 4. Disconnect low pressure switch from engine wire
solution or electron leak detector. If leaks are harness. See Figure 11.
detected, make proper repairs.
5. Remove the socket head capscrews and fuel filter
FUEL FILTER HOUSING housing from the mounting bracket. Remove fuel
filter assembly. See Figure 10.
Remove
Disassemble
WARNING 1. Remove the fuel filter. See Fuel Filter Element,
LPG can cause an explosion. DO NOT permit Remove.
any sparks or open flames in the work area.
2. Remove the low pressure switch from the low
1. Close fuel valve on tank. Run engine until it pressure switch fitting. See Figure 11.
stops.
3. Remove the inlet fitting from the fuel filter hous-
2. Disconnect negative battery cable. ing bottom section.
WARNING
closed.
3. Slowly loosen and disconnect inlet and outlet fit-

tings.
1. BOLT*
2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER
5. HOUSING O-RING
6. INLET FITTING*
7. LOW PRESSURE SWITCH
8. LOW PRESSURE SWITCH FITTING*
9. LOW PRESSURE SWITCH ADAPTER*
11. O-RING*
12. OUTLET ADAPTER FITTING*
13. OUTLET ELBOW FITTING*
1. FUEL FILTER ASSEMBLY 14. FUEL FILTER O-RING
2. MOUNTING BRACKET
3. SOCKET HEAD CAPSCREWS *NOT SERVICED SEPARATELY
Figure 10. Fuel Filter Assembly Removal/ Figure 11. Fuel Filter Assembly
Installation
9
Electronic Throttle Body Repair 900 SRM 1124
4. Remove the low pressure switch fitting from the Install

low pressure switch adapter.
1. Place the fuel filter assembly in position on the
5. Remove the outlet elbow fitting from the outlet mounting bracket.
adapter fitting.
2. Install the socket head capscrews to attach the
Assemble fuel filter housing to the mounting bracket.
Tighten socket head capscrews to 6 N•m
(53 lbf in).
CAUTION
DO NOT use Teflon tape on any fuel fitting. Use 3. Connect engine wire harness to the low pressure
a liquid pipe thread sealant when installing fit- switch.
tings.
4. Connect the inlet and outlet fuel lines.
1. Apply pipe thread sealant (Hyster P/N 0246108)
to the threads of the outlet elbow fitting and in- NOTE: Opening the fuel valve too quickly can cause
stall the outlet elbow fitting and O-ring. the internal excess flow valve to close, restricting the
2. Apply pipe thread sealant (Hyster P/N 0246108) a few seconds, and then slowly open the fuel valve
on the threads of the low pressure switch fitting. again. This will reset the excess flow valve.
Install the low pressure switch fitting onto the
low pressure switch adapter. 5. Slowly open the fuel valve on tank.
3. Apply pipe thread sealant (Hyster P/N 0246108) 6. Connect the negative battery cable.
on the threads of the low pressure switch. Install
the low pressure switch onto the low pressure
the OFF position to pressurize the fuel system.
switch fitting.
Check for leaks.
4. Apply pipe thread sealant (Hyster P/N 0246108)
8. Check for leaks at connections by using soapy
on the threads of the inlet fitting and install the
solution or electron leak detector. If leaks are
inlet fitting.
5. Install the fuel filter. See Fuel Filter Element,
Install.
Electronic Throttle Body Repair

ELECTRONIC THROTTLE BODY 5. Remove the throttle body and gasket. Discard
gasket.
Remove
Install
1. Clean the mating surfaces of the adapter plate
2. Remove the clean air tube from the throttle body and the throttle body.
to the air filter assembly.
2. Place the new gasket and throttle body in posi-
3. Disconnect the electrical connector from the tion on the adapter plate.
throttle body.
3. Install the lockwashers and socket head cap-
4. Remove the socket head capscrews and lock- screws. Tighten the socket head capscrews to
washers retaining the throttle body to the 10 N•m (88.5 lbf in).
adapter plate. See Figure 12.
10
900 SRM 1124 Electronic Throttle Body Repair
4. Install the clean air tube. ELECTRONIC THROTTLE BODY ADAPTER

PLATE
5. Connect the battery negative cable.
6. Key ON the vehicle and with the PC service tool Remove

send a "Restore ECU Defaults" command via the 1. Remove the throttle body. See Electronic Throt-
CAN communication bus. tle Body, Remove.
7. Key OFF the vehicle and wait 30 seconds. 2. Remove the socket head capscrews and lock-
8. Connect the electrical connector to the throttle washers retaining the adapter plate to the
body. Verify that the connector clicks/locks into intake manifold. See Figure 13.
place. 3. Remove the adapter plate and gasket.
WARNING Install
DO NOT insert fingers or foreign objects into
1. Clean the mating surfaces of the adapter plate
the throttle body.
and the intake manifold.
9. Start the vehicle and check for proper operation
2. Place the new gasket and adapter plate in posi-
of the throttle body and the ECU by exercising
tion on the intake manifold.
the accelerator pedal with the vehicle in neutral.
The engine should idle at 775 to 825 rpm with no 3. Install the lockwashers and socket head cap-
pedal to the governor speed of 2675 to 2725 rpm screws. Tighten the socket head capscrews to
at full pedal. 10 N•m (88.5 lbf in).
4. Install the throttle body. See Electronic Throttle

Body, Install.
1. ADAPTER PLATE 1. INTAKE MANIFOLD

2. GASKET 2. GASKET
3. ELECTRONIC THROTTLE BODY 3. ADAPTER PLATE
4. SOCKET HEAD CAPSCREWS 4. SOCKET HEAD CAPSCREWS
5. LOCKWASHER 5. LOCKWASHER
Figure 12. Electronic Throttle Body Figure 13. Electronic Throttle Body
11
Fuel Injector Repair 900 SRM 1124
Fuel Injector Repair

FUEL RAIL 6. Remove the two capscrews and lockwashers re-
taining the fuel rail to the mounting bracket. See
Remove for Lift Trucks Built Before Figure 15.
January, 2010
7. Move the fuel rail away from the injectors.
WARNING
CAUTION
LPG can cause an explosion. Do not permit any
sparks or open flames in the work area. When cutting the clamps, use caution not to cut
the hoses or the fuel rail barbs.
1. Close fuel valve on tank. Run engine until it
stops. 8. Carefully cut the clamps holding the hoses to the
fuel rail barbs. See Figure 16.
9. Disconnect each hose from the fuel rail by work-
3. Disconnect the fuel line from the fuel rail. ing each hose back and forth while pulling the
hose outward, away from the fuel rail.
4. Disconnect the four electrical connectors from
the fuel injectors. See Figure 14.
5. Disconnect the two hoses from the positive

crankcase ventilation (PCV) valve.
1. CAPSCREW
2. LOCKWASHER
3. FUEL RAIL
1. ELECTRICAL CONNECTORS Figure 15. Fuel Rail Capscrews for Lift Trucks
2. FUEL INJECTORS Built Before January, 2010
Figure 14. Fuel Injector Electrical Connectors

12
900 SRM 1124 Fuel Injector Repair

a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.
9. Slowly open the fuel valve on tank.

Check for leaks.

Remove for Lift Trucks Built After January,

2010
WARNING
LPG can cause an explosion. DO NOT permit
1. HOSE 3. FUEL RAIL any sparks or open flames in the work area.
2. CLAMP
Figure 16. Fuel Rail Hose Clamp for Lift stops.
Trucks Built Before January, 2010
Install for Lift Trucks Built Before January,
NOTE: Tag electrical connectors during removal to
2010
aid in installation.
1. Place the fuel rail in position on the mounting
3. Disconnect wire harness electrical connectors
bracket.
from fuel pressure sensor, if equipped.
2. Install two capscrews and washers to retain the
4. Disconnect wire harness electrical connectors
fuel rail to the mounting bracket. Tighten cap-
from fuel injectors.
screws to 10 N•m (88.5 lbf in).
5. If equipped, remove fuel pressure sensor from
3. Place new screw-type clamps over each of the
fuel rail. See Figure 17.
hoses. Push the hoses onto the fuel rail barbs.
6. Disconnect pcv valve from engine block and in-
4. Verify that all fuel hoses are in correct position
take manifold. See Figure 17.
and not kinked. Tighten each clamp screw to 2.45
to 2.77 N•m (22 to 25 lbf in). 7. Remove capscrews from bracket and fuel rail.
See Figure 17.
5. Connect the four electrical connectors to the fuel
injectors. Verify that the connectors click/lock NOTE: Fuel injectors may be removed with fuel rail
into place. and bracket.
6. Connect the two hoses to the PCV valve. 8. Remove capscrews, bracket, and fuel rail from
intake manifold. See Figure 17.
7. Connect the fuel line to the fuel rail.
13
1. ENGINE BLOCK 5. BRACKET

2. FUEL PRESSURE SENSOR 6. CAPSCREW
3. FUEL INJECTOR 7. INTAKE MANIFOLD
4. FUEL RAIL 8. PCV VALVE
Figure 17. Fuel Rail Remove/Install for LPG Lift Trucks Built After January, 2010
Install for Lift Trucks Built After January, 6. Connect negative battery cable.
2010
1. Install fuel rail, bracket, and capscrews onto in- the internal excess flow valve to close, restricting the
take manifold. See Figure 17. flow of fuel. If this happens, close the fuel valve, wait
2. Install capscrews onto bracket and fuel rail. See again. This will reset the excess flow valve.
Figure 17.
7. Slowly open the fuel valve on the tank.
3. Connect pcv valve to intake manifold and engine
block. See Figure 17. 8. Turn the key to the ON position and back to
4. Install fuel pressure sensor onto fuel rail. Con- Check for leaks.
nect fuel pressure sensor to wire harness as
tagged during removal. 9. Check for leaks at connections by using soapy
5. Connect wire harness electrical connectors to detected, make proper repairs.
fuel injectors as tagged during removal.
14
FUEL INJECTOR FOR LIFT TRUCKS BUILT

BEFORE JANUARY, 2010 CAUTION
When cutting the clamps, use caution not to cut
Remove the hoses or the fuel injector barbs.
2. Carefully cut the clamps holding the hoses to the

CAUTION fuel injector barbs.
The fuel injectors are held in place with an
internal "C" ring. When removing the fuel in- 3. Disconnect hoses from the fuel injectors by hold-
jectors, pull the injectors straight out. Do not ing hose and rotating fuel injector back and forth
pry the injectors with a screwdriver or prybar, while pulling the fuel injector outward, away
as this can damage the injectors or injector from the hose.
adapters.
Clean
NOTE: Do not cut the clamps for the hoses attaching
the fuel injectors to the fuel rail. Remove the fuel WARNING
injectors and fuel rail as an assembly. Compressed air can move particles so that they
1. Remove the fuel rail with the injectors attached cause injury to the user or to other personnel.
by pulling the injectors straight out of the Make sure that the path of the compressed air
adapters. See Fuel Rail, Remove for Lift Trucks is away from all personnel. Wear protective
Built Before January, 2010, Step 1 through goggles or a face shield to prevent injury to the
Step 6, and Figure 18. eyes.
CAUTION
DO NOT use any solvents or cleaners when
cleaning the fuel injectors.
Remove any debris on the open end (outlet toward

engine) of the fuel injector. Cleaning is only done by
carefully inserting a pick type tool into the passage
and scraping out debris. Only use compressed air for
blowing away any loose particles.
Install
CAUTION
When installing the fuel injectors, install using
hand pressure only. DO NOT use an object or
tool to hit the injectors to force them into the
adapters.
1. FUEL RAIL 1. Install the fuel injectors into the fuel injector
2. FUEL INJECTOR adapters. Push the injectors into the adapters
3. CLAMP using hand pressure only. See Figure 19.
4. HOSE
2. Place the fuel rail in position on the mounting
Figure 18. Fuel Injectors and Fuel Rail bracket.
15


Check for leaks.

FUEL INJECTOR ADAPTERS FOR LIFT

TRUCKS BUILT BEFORE JANUARY, 2010
Remove
CAUTION
1. ADAPTERS The fuel injectors are held in place with an
2. FUEL INJECTORS internal "C" ring. When removing the fuel in-
jectors, pull the injectors straight out. DO NOT
Figure 19. Fuel Injectors and Adapters
pry the injectors with a screwdriver or prybar,
3. Install two capscrews and washers to retain the as this can damage the injectors or injector
fuel rail to the mounting bracket. Tighten cap- adapters.
screws to 10 N•m (88.5 lbf in).
NOTE: DO NOT cut the clamps for the hoses attach-
4. Place new screw-type clamps over each of the ing the fuel injectors to the fuel rail. Remove the fuel
hoses. Insert the hoses onto the fuel injector injectors and fuel rail as an assembly.
barbs.
1. Remove the fuel rail with the injectors attached
5. Verify that all fuel hoses are in correct position by pulling the injectors straight out of the
and not kinked. Tighten each clamp screw to 2.45 adapters. See Fuel Rail, Remove for Lift Trucks
to 2.77 N•m (40 to 45 lbf in). Built Before January, 2010, Step 1 through
Step 6, and Figure 18.
6. Connect the four electrical connectors to the fuel
injectors. Verify that the connectors click/lock 2. Remove the two capscrews and lockwashers re-
into place. taining the fuel injector adapter retaining plate
and remove retaining plate. See Figure 20.
7. Connect the two PCV hoses.
3. Remove the fuel injector adapters by using a
8. Connect the fuel line to the fuel rail. slight twisting motion to pull the adapters out of
the intake manifold. See Figure 21.
4. Remove the O-rings from the adapters and dis-
NOTE: Opening the fuel valve too quickly can cause card O-rings. See Figure 22.
16
1. RETAINING PLATE 1. FUEL INJECTOR ADAPTERS

2. CAPSCREWS 2. INTAKE MANIFOLD
3. LOCKWASHERS
Figure 21. Fuel Injector Adapters
Figure 20. Fuel Injector Adapter Retaining
Plate
Install
1. Install new O-rings on adapters.
2. Lubricate the O-rings on the adapters with clean

engine oil and install the adapters into the intake
manifold. See Figure 21.
3. Place the fuel injector adapter retaining plate

in position on the intake manifold. Install the
two capscrews and lockwashers. Tighten the cap-
screws to 20 N•m (14.75 lbf ft).
4. Install the fuel injectors and fuel injector rail.

See Fuel Injector for Lift Trucks Built Before
January, 2010, Install.
1. FUEL INJECTOR ADAPTER

2. O-RING
Figure 22. Fuel Injector Adapter and O-ring
17
FUEL INJECTORS AND ADAPTERS FOR Install

LIFT TRUCKS BUILT AFTER JANUARY,
1. Install new O-ring onto adapter. See Figure 23.
2010
2. Install split sleeve onto injector body. See Fig-
Remove ure 23.
1. Remove fuel rail, with injectors attached, from 3. Install two new O-rings onto injector body. See
intake manifold. See Fuel Rail, Remove for Lift Figure 23.
Trucks Built After January, 2010 and Figure 17.
4. Install adapter onto injector body. See Figure 23.
2. Remove fuel injectors from fuel rail. See Fig-
ure 23. 5. Install fuel injector onto fuel rail. See Figure 23.
3. Remove adapter from injector body. See Fig- 6. Install fuel rail onto intake manifold. See Fuel
ure 23. Repeat for all injectors. Rail, Install for Lift Trucks Built After January,
2010 and Figure 17.
4. Remove two O-rings from injector body. See Fig-
ure 23.
5. Remove split sleeve from injector body. See Fig-

ure 23.
6. Remove O-ring from adapter. See Figure 23.
Clean
WARNING
eyes.
CAUTION
DO NOT insert pick type tool too deep into fuel
injector and cause damage to the diaphragm.
Remove any debris on the open end (outlet toward

1. FUEL RAIL
engine) of the fuel injector. Cleaning is only done by 2. O-RING
carefully inserting a pick type tool into the passage 3. SPLIT SLEEVE
and scraping out debris. Only use compressed air for 4. INJECTOR BODY
blowing away any loose particles. 5. ADAPTER
6. FUEL INJECTOR ASSEMBLY
Figure 23. Fuel Rail, Injectors, and Adapters
18
900 SRM 1124 LPG Regulator Repair
LPG Regulator Repair

LPG REGULATOR
Remove
WARNING

stops.
WARNING
boiling coolant can cause burns. 1. FUEL FILTER TO FUEL TANK FUEL LINE
2. FUEL FILTER ASSEMBLY
3. Put a drain pan under drain valve for radiator. 3. FUEL FILTER TO LPG REGULATOR FUEL LINE
Open drain valve so coolant drains into pan. Re- 4. LOCK-OFF SOLENOID
5. MOUNTING BRACKET
move radiator cap. 6. LPG REGULATOR
7. BALANCE LINE
WARNING 8. COOLANT HOSE
9. COOLANT HOSE
A small amount of fuel may still be present in 10. LPG REGULATOR TO FUEL RAIL FUEL LINE
wear eye protection. If liquid fuel continues Figure 24. LPG Regulator and Hose Assembly
check to make sure the manual valve is fully Install
closed.
1. Place the LPG Regulator in position on mount-
4. Slowly disconnect fuel line fitting from fuel filter ing bracket and install capscrew. See Figure 25.
assembly to LPG Regulator. See Figure 24. Tighten capscrew to 20 N•m (14.75 lbf ft).
5. Disconnect the fuel line from LPG Regulator to 2. Connect electrical connector to lock-off solenoid.
fuel rail. See Figure 24. See Figure 24.
6. Tag and disconnect coolant hoses from LPG Reg- 3. Connect balance line to LPG Regulator.
ulator. See Figure 24. Cap coolant hoses.
4. Remove caps from coolant hoses and connect
7. Disconnect balance line from LPG Regulator. See coolant hoses to LPG Regulator as tagged during
Figure 24. removal.
8. Disconnect electrical connector from lock-off so- 5. Connect the fuel line to LPG Regulator from fuel
lenoid. rail.
9. Remove capscrew and LPG Regulator from 6. Connect fuel line fitting from filter unit to LPG
mounting bracket. See Figure 25. Regulator.
19
LPG Regulator Repair 900 SRM 1124

stops.
WARNING
closed.
3. Disconnect the fuel inlet and outlet lines from the

LPG Regulator. See Figure 24.
4. Remove the fuel inlet fitting and O-ring. See Fig-

ure 26.
1. MOUNTING BRACKET 5. Remove the plastic body, foam filter, paper filter
2. CAPSCREW element, and filter gasket.
3. LPG REGULATOR
6. Remove the screws fuel outlet fitting O-ring, and
Figure 25. LPG Regulator Mounting Bracket filter. Discard O-ring and filter.
7. Fill the cooling system. Refer to Periodic Main- Install
tenance 8000 SRM 1150.
1. Install new filter in port for fuel outlet fitting.
8. Install radiator cap. See Figure 26.
9. Connect negative battery cable. 2. Install new O-ring and fuel outlet fitting.
NOTE: Opening the fuel valve too quickly can cause 3. Install retaining screws for fuel outlet fit-
the internal excess flow valve to close, restricting the ting. Tighten screws to 2 to 3 N•m (17.7 to
flow of fuel. If this happens, close the fuel valve, wait 26.55 lbf in).
again. This will reset the excess flow valve. 4. Install the filter gasket, new paper filter element,
new foam filter, and plastic body.
5. Install the O-ring and fuel inlet fitting. Tighten
11. Turn the key to the ON position and back to to 18 to 20 N•m (13.3 to 14.75 lbf ft).
Check for leaks. 6. Connect the fuel inlet line to the LPG Regulator.
See Figure 24.
solution or electron leak detector. If leaks are 7. Connect the negative battery cable.
LPG REGULATOR FUEL FILTER the internal excess flow valve to close, restricting the
Remove a few seconds, and then slowly open the fuel valve
WARNING 8. Slowly open the fuel valve on tank.
20
900 SRM 1124 LPG Regulator Repair
WARNING
closed.
4. Remove the nut and solenoid from the cartridge.

See Figure 27.
5. Remove the cartridge from the LPG Regulator.
Install
1. Install new cartridge into LPG Regulator.
Tighten cartridge to 16 to 24 N•m (11.8 to
1. LPG REGULATOR 17.7 lbf ft).
2. OUTLET FILTER
3. O-RING 2. Install solenoid and nut onto cartridge. Tighten
4. FUEL OUTLET FITTING nut to 7.85 N•m (69.5 lbf in).
5. SCREW
6. FILTER GASKET
7. PAPER FILTER ELEMENT
8. FOAM FILTER
9. PLASTIC BODY
10. O-RING
11. FUEL INLET FITTING
Figure 26. LPG Regulator Fuel Filter

Check for leaks.

LOCK-OFF SOLENOID AND CARTRIDGE

Remove
WARNING

stops. 1. LPG REGULATOR
2. CARTRIDGE
2. Disconnect the negative battery cable. 3. COIL
4. NUT
3. Disconnect the electrical connector from the lock-
off solenoid. Figure 27. Lock-Off Solenoid
21
Control System 900 SRM 1124
3. Connect electrical connector to solenoid. 5. Slowly open the fuel valve on tank.
4. Connect the negative battery cable. 6. Turn the key to the ON position and back to
NOTE: Opening the fuel valve too quickly can cause Check for leaks.
flow of fuel. If this happens, close the fuel valve, wait 7. Check for leaks at connections by using soapy
a few seconds, and then slowly open the fuel valve solution or electron leak detector. If leaks are
again. This will reset the excess flow valve. detected, make proper repairs.
Control System
ELECTRONIC CONTROL UNIT (ECU) 4. Lower the ECU and mounting bracket assembly
down toward the frame.
Remove
5. Disconnect the hoses from the air filter assembly.
2. Disconnect the throttle body electrical connector. assembly mounting bracket to the frame and re-
3. Remove the capscrews holding the air filter
mounting bracket to the ECU mounting bracket. 7. Remove capscrew retaining wire harness clamp
See Figure 28. to ECU mounting bracket.
8. Remove the capscrews and nuts holding the ECU

to the mounting bracket. See Figure 29.
1. CAPSCREW 1. MOUNTING BRACKET

2. AIR FILTER MOUNTING BRACKET 2. CAPSCREW
3. ECU MOUNTING BRACKET 3. NUTS
4. WIRE HARNESS CLAMP 4. ECU
Figure 28. Air Filter Mounting Bracket and Figure 29. ECU Mounting Bracket
ECU Mounting Bracket
22
900 SRM 1124 Control System
5. Connect the hoses to the air filter assembly.
6. Slide the ECU and mounting bracket assembly

into position on the air filter mounting bracket.
7. Install the capscrews to retain the ECU mount-

ing bracket to the air filter mounting bracket.
Tighten capscrews to 20 N•m (14.75 lbf ft).
9. Key ON the vehicle and with the PC service tool

send a "Restore ECU Defaults" command via the
CAN communication bus.
10. Key OFF the vehicle and wait 30 seconds.

1. MOUNTING BRACKET 11. Connect the throttle body electrical connector.
2. LOCKING TAB
3. ECU 12. Start the vehicle and check for proper operation
4. ELECTRICAL CONNECTORS
of the throttle body and the ECU by exercising
Figure 30. ECU and Electrical Connectors the accelerator pedal with the vehicle in neutral.
The engine should idle at 775 to 825 rpm with no
9. Disconnect the electrical connectors from the pedal to the governed speed of 2675 to 2725 rpm
ECU. Rotate the locking tabs on each connector at full pedal.
to unlock the electrical connectors. Disconnect
the connector closest to the fan assembly first. FUEL PUMP RELAY
Disconnect the center connector second. Dis-
connect the third connector. Remove ECU. See Remove
Figure 30.
Install 2. Remove the capscrews holding the air filter
1. Connect the electrical connectors to the ECU. mounting bracket to the ECU mounting bracket.
Connect the electrical connector furthest from See Figure 28.
the fan assembly first. Connect the center con-
3. Lower the ECU and mounting bracket assembly
nector second. Connect the connector closest to
the fan assembly last. Rotate the locking tabs to
lock the electrical connectors in position. 4. Disconnect the hoses from the air filter assembly.
2. Place the ECU in position on the mounting 5. Remove the three bolts that attach the air filter
bracket. Install the capscrews and nuts. Tighten assembly mounting bracket to the frame and re-
capscrews to 10 N•m (88.5 lbf in). move air filter assembly with mounting bracket.
3. Position the wire harness and wire harness 6. Remove the capscrews and nuts retaining the
clamp on the ECU mounting bracket. Install fuel pump relay to the ECU mounting bracket.
the capscrew to retain the wire harness clamp. See Figure 31.
Tighten capscrew to 10 N•m (88.5 lbf in).
7. Disconnect the electrical connector from the fuel
4. Place the air filter assembly with mounting pump relay.
and tighten to 20 N•m (14.75 lbf ft).
23
INJECTOR DRIVER MODULE

Remove

mounting bracket to the ECU mounting bracket.
See Figure 28.
3. Lower the ECU and mounting bracket assembly


assembly mounting bracket to the frame and re-
1. CAPSCREWS
2. FUEL PUMP RELAY 6. Remove the capscrew and nut retaining the injec-
3. ELECTRICAL CONNECTOR tor driver module to the mounting bracket. See
4. ECU MOUNTING BRACKET Figure 32.
5. NUTS
7. Disconnect the electrical connector from the in-
Figure 31. Fuel Pump Relay jector driver module. See Figure 33.
Install
1. Connect the electrical connector from the fuel
pump relay.
2. Place the fuel pump relay in position on the ECU

mounting bracket.
3. Install capscrews and nuts to retain the fuel

pump relay to the ECU mounting bracket.
Tighten capscrews to 10 N•m (88.5 lbf in).
4. Place the air filter assembly with mounting


1. CAPSCREW
6. Slide the ECU and mounting bracket assembly 2. NUT
into position on the air filter mounting bracket. 3. INJECTOR DRIVER MODULE
7. Install the capscrews to retain the ECU mount- Figure 32. Injector Driver Module
Tighten capscrews to 20 N•m (14.75 lbf ft).
24
MANIFOLD ABSOLUTE PRESSURE

(MAP)/MANIFOLD AIR TEMPERATURE
(MAT) SENSOR
Remove
1. Raise the hood. Disconnect the negative battery
cable.
2. Disconnect the electrical connector from the

MAP/MAT sensor. See Figure 34.
3. Remove the two screws retaining the MAP/MAT

sensor to the intake manifold. Remove MAP/
MAT sensor.
Install
1. Place the MAP/MAT sensor in position on the
intake manifold and install the two retaining
2. INJECTOR DRIVER MODULE screws. Tighten retaining screws to 6 N•m
(53 lbf in).
Figure 33. Injector Driver Module Electrical
Connector 2. Connect the electrical connector to the
MAP/MAT sensor. Verify that the connector
Install clicks/locks into place.
1. Connect the electrical connector to the injector 3. Connect the negative battery cable. Close the
driver module. hood.
2. Place the injector driver module in position on

the mounting bracket.
3. Install the capscrew and nut to retain the injector

driver module to the mounting bracket. Tighten
the capscrew to 10 N•m (88.5 lbf in).



ing bracket to the air filter mounting bracket. 1. MAP/MAT SENSOR
2. SCREW
Tighten capscrews to 20 N•m (14.75 lbf ft). 3. ELECTRICAL CONNECTOR
8. Connect the negative battery cable. Figure 34. MAP/MAT Sensor
25
ENGINE COOLANT TEMPERATURE (ECT) OXYGEN SENSOR

SENSOR
Remove
Remove
1. Raise the hood. Disconnect the negative battery cable.
cable.
2. Disconnect the oxygen sensor electrical connec-
2. Disconnect the electrical connector from the ECT tor. See Figure 36.
sensor. See Figure 35.
3. Remove nut and clip retaining the oxygen sensor
3. Remove the ECT sensor and washer. wiring harness and connector to the thermostat
housing.
Install
4. Using a special tool, oxygen sensor socket, re-
1. Install the new ECT sensor and washer. Tighten move the oxygen sensor. See Figure 37 and Fig-
the sensor to 20 N•m (14.75 lbf ft). ure 38.
2. Connect the electrical connector to the ECT sen-

sor.
3. Connect the negative battery cable. Close the

hood.
2. CLIP
3. NUT
Figure 36. Oxygen Sensor Electrical Connector

2. ECT SENSOR
3. WASHER
Figure 35. ECT Sensor
26
2. Install nut and clip to retain the oxygen sensor

wiring harness and connector to the thermostat
housing.
3. Connect the electrical connectors. Verify that the

connectors click/lock into place.
4. Verify that the wire is pulled up toward the ther-

mostat and away from any hot exhaust compo-
nents.

hood.
LOW LPG PRESSURE SWITCH

Figure 37. Oxygen Sensor Socket Remove
WARNING
Before disconnecting any part of the LPG fuel
system, close shutoff valve on fuel tank. Run
engine until fuel lines are empty and engine
stops. If engine will not run, close shutoff valve
on fuel tanks and release fuel slowly in a non-
hazardous area.

cable.
2. Disconnect the low LPG pressure switch electri-

cal connector from engine wire harness.
3. Remove switch from fitting in pipe that runs be-

tween the LPG vaporizer and LPG fuel tank. See
Figure 39.
1. EXHAUST MANIFOLD ADAPTER
2. OXYGEN SENSOR Install
Figure 38. Oxygen Sensor 1. Install new switch into fitting. See Figure 39.
2. Connect low LPG pressure switch electrical con-

Install nector to engine wire harness.
1. Before installing the sensor, coat sensor spar-
ingly with an antiseize compound, then install
hood.
oxygen sensor into exhaust manifold adapter.
Using a special tool, oxygen sensor socket,
tighten oxygen sensor to 40 to 60 N•m (30 to
44 lbf ft). See Figure 37 and Figure 38.
27
1. LOW LPG PRESSURE SWITCH ELECTRICAL 3. LPG FUEL FILTER

CONNECTOR 4. LPG VAPORIZER/REGULATOR
2. LOW LPG PRESSURE SWITCH 5. HARNESS CONNECTION
Figure 39. Low LPG Pressure Switch

REMOVE AND DISASSEMBLE 3. Disconnect exhaust pipes (11 and 15, Figure 40)
from catalytic converter. Remove and discard
NOTE: The muffler is installed inside the cavity of gaskets from catalytic converter. Remove cat-
the counterweight. A short exhaust pipe sends the alytic converter from lift truck.
exhaust gasses out of the lift truck through a grille
in the counterweight. 4. Remove exhaust pipe (15, Figure 40) from engine
exhaust adapter (18, ). Remove and discard gas-
1. Remove counterweight before removing muffler ket from exhaust pipe.
and other part of exhaust system. See Frame
100 SRM 1120 for counterweight removal proce- 5. Remove engine exhaust adapter from exhaust
dures. manifold. Remove and discard gasket from en-
gine exhaust adapter. See Figure 40.
WARNING 6. Remove clamps holding exhaust pipes (8 and 11,
Exhaust system components are hot to touch. Figure 40) onto muffler. Remove exhaust pipes
Be sure exhaust system components are cool from muffler.
may occur. 7. Remove plain flanged nuts and muffler from lift
truck frame.
2. Remove bracket attaching catalytic converter to
frame. See Figure 40. Disconnect oxygen sensor.
28
NOTE: EXHAUST WRAPS SHOWN ARE NOT ON ALL LIFT TRUCK MODELS.
1. CAPSCREW 12. LOCKWASHER
2. WASHER 13. GASKET
5. BRACKET 16. EXHAUST WRAP
6. FLANGE NUT 17. PLUG
7. NUT 18. ENGINE EXHAUST ADAPTER
8. EXHAUST PIPE 19. STUD
9. CLAMP 20. OXYGEN SENSOR
10. MUFFLER 21. EXHAUST MANIFOLD
11. EXHAUST PIPE 22. COPPER RING
Figure 40. Counterweight Exhaust System
INSPECT needed. If replacing an exhaust pipe section that

Inspect the following items in the exhaust system: wraps if they have been removed for a service
• Exhaust pipes for damage, corrosion, and rust. Re- operation.
place as needed. • Catalytic converter and muffler for damage, corro-
• If equipped, inspect all exhaust wraps for wear, sion, and rust. Replace as needed.
gaps in coverage, and failed fasteners. Replace as
29
ASSEMBLE AND INSTALL 5. Place catalytic converter onto lift truck frame.
Install new gaskets onto catalytic converter and
1. Place muffler onto frame of lift truck and install install exhaust pipes (11 and 15, Figure 40) onto
plain flanged nuts. Tighten nuts to 39 N•m catalytic converter.
(29 lbf ft).
6. Install bracket attaching catalytic converter to
2. Install exhaust pipes (8 and 11, Figure 40) onto lift truck frame. See Figure 40. Connect oxygen
muffler. Install clamps onto pipes to hold them sensor.
onto muffler.
7. Install counterweight. See Frame 100 SRM
3. Install new gasket onto engine exhaust adapter. 1120 for counterweight installation procedures.
Install engine exhaust adapter onto exhaust
manifold. See Figure 40.
4. Install new gasket onto exhaust pipe. Install ex-

haust pipe (15, Figure 40) onto engine exhaust
adapter (18, Figure 40).
30

GASOLINE FUEL
SYSTEM
GM 2.4L ENGINE
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580508 900 SRM 1126

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Gasoline Fuel System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Electronic Throttle Body ............................................................................................................................... 1
Remove....................................................................................................................................................... 1
Install ......................................................................................................................................................... 1
Fuel System Repair............................................................................................................................................ 2
Before Repair Procedure ............................................................................................................................... 2
After Repair Procedure.................................................................................................................................. 2
Fuel Leakage Check for Lift Trucks Built Before January, 2010 ........................................................... 2
Fuel Leakage Check for Lift Trucks Built After January, 2010 ............................................................. 3
Fuel Line Pressure Check ............................................................................................................................. 4
Fuel Injectors ................................................................................................................................................. 5
Remove....................................................................................................................................................... 5
Install ......................................................................................................................................................... 8
Pressure Regulator ........................................................................................................................................ 8
Remove....................................................................................................................................................... 8
Install ......................................................................................................................................................... 8
Control System................................................................................................................................................... 9
Electronic Control Unit (ECU)...................................................................................................................... 9
Remove....................................................................................................................................................... 9
Install ......................................................................................................................................................... 10
Power Latch Relay......................................................................................................................................... 10
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor ......................................... 11
Remove....................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Engine Coolant Temperature (ECT) Sensor................................................................................................. 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Oxygen Sensor ............................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 13
Inspect ............................................................................................................................................................ 15
S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
This section has the repair procedures for the parts of the gasoline fuel system used on the GM 2.4 liter engines.

ELECTRONIC THROTTLE BODY
Remove
2. Remove the clean air tube from the throttle body

to the air filter assembly.

throttle body.
4. Remove the socket head capscrews and lock-

washers retaining the throttle body to the
adapter plate. See Figure 1.
5. Remove the throttle body and gasket. Discard

gasket. 1. INTAKE MANIFOLD
2. GASKET
3. ADAPTER PLATE
4. SOCKET HEAD CAPSCREWS
5. LOCKWASHER
Figure 2. Electronic Throttle Body Adapter

Plate
7. Remove the adapter plate and gasket.
Install
1. Clean the mating surfaces of the intake manifold,
adapter plate, and the throttle body.
2. If removed, place the new gasket and adapter

plate in position on the intake manifold.
3. Install the lockwashers and socket head cap-

screws to retain the adapter plate. Tighten the
socket head capscrews to 10 N•m (88.5 lbf in).
1. ADAPTER PLATE 4. Place the new gasket and throttle body in posi-
2. GASKET tion on the adapter plate.
3. ELECTRONIC THROTTLE BODY
4. SOCKET HEAD CAPSCREWS 5. Install the lockwashers and socket head cap-
5. LOCKWASHER screws. Tighten the socket head capscrews to
Figure 1. Electronic Throttle Body 10 N•m (88.5 lbf in).
6. If necessary, remove the socket head capscrews 6. Install the clean air tube.
and lockwashers retaining the adapter plate to 7. Connect the battery negative cable.
1
Fuel System Repair 900 SRM 1126

send a "Restore ECU Defaults" command via the WARNING
CAN communication bus. Do not insert fingers or foreign objects into the
throttle body.
11. Start the vehicle and check for proper operation
10. Connect the electrical connector to the throttle of the throttle body and the ECU by exercising
body. Verify that the connector clicks/locks into the accelerator pedal with the vehicle in neutral.
place. The engine should idle at 775 to 825 rpm with no
pedal to the governor speed of 2675 to 2725 rpm
at full pedal.
Fuel System Repair

BEFORE REPAIR PROCEDURE death and damage. Always perform the follow-
ing procedure with the engine stopped.
WARNING 1. Disconnect the 29-pin electrical connector that
Fuel vapor is hazardous. It can easily ignite, is connecting the vehicle harness to the engine
causing serious injury and damage. Always harness. See Figure 3.
keep sparks and flames away from fuel.
2. Disconnect the electrical connector to the coil
Fuel line spills and leakage are dangerous. pack.
Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin
and eyes. To prevent this, always complete the CAUTION
following procedures: To prevent arcing, only use jumper wires with
a momentary switch located within the wire.
NOTE: Fuel in the fuel system is under high pres-
sure, even when the engine is not running. 3. Install a jumper wire from pin 6 of the 29-pin con-
nector, on the engine harness side, to the posi-
1. Remove the fuel-filler cap and release the pres- tive battery terminal. Then install a jumper wire
sure in the fuel tank. from pin 4 of the 29-pin connector, on the engine
harness side, to the negative battery terminal.
2. Disconnect the electrical connector from the fuel
See Figure 3.
pump.
4. Pressurize the system this way for at least 5 min-
3. Start the engine. After the engine stalls, crank
utes to be sure of no leakage. If there is fuel leak-
the engine several times.
age, inspect the fuel hoses and fuel pipe sealing
4. Turn the ignition to OFF position. surface for damage. Replace as needed.
5. Connect the electrical connector to the fuel pump. 5. After repair, assemble the system and repeat
Step 1 through Step 4.
AFTER REPAIR PROCEDURE
6. Disconnect jumper wires.
Fuel Leakage Check for Lift Trucks Built 7. Connect the electrical connector to the coil pack.
Before January, 2010
8. Connect the vehicle harness to the engine har-
ness.
WARNING
Fuel line spills and leakage are dangerous.
2
900 SRM 1126 Fuel System Repair
1. VEHICLE ELECTRICAL HARNESS AND 29-PIN CONNECTOR

2. ENGINE ELECTRICAL HARNESS AND 29-PIN CONNECTOR
3. BATTERY
Figure 3. 29-Pin Electrical Connector
Fuel Leakage Check for Lift Trucks Built 2. Disconnect coil wire from coil. See Figure 4.
After January, 2010
CAUTION
WARNING To prevent arcing, only use jumper wires with
Fuel line spills and leakage are dangerous. a momentary switch located within the wire.
death and damage. Always perform the follow- 3. Install a jumper wire from pin 2 of 8-pin connec-
ing procedure with the engine stopped. tor, on the engine harnnes side, to positive bat-
tery terminal. Then install a jumper wire from
1. Disconnect the 4-pin connector and 8-pin connec- pin 4 of 4-pin connector, on the engine harness
tor with 7 wires that are connecting the right- side, to negative battery terminal. See Figure 4.
hand chassis harness to the engine harness. See
Figure 4.
3
1. ENGINE HARNESS WITH CONNECTORS 5. COIL WIRE

2. 4-PIN CONNECTOR 6. BATTERY
3. 8-PIN CONNECTOR
4. RIGHT-HAND CHASSIS HARNESS WITH
CONNECTORS
Figure 4. Electrical Connectors
4. Pressurize system this way for at least 5 minutes FUEL LINE PRESSURE CHECK
to be sure of no leakage. If there is fuel leakage,
inspect fuel hoses and fuel pipe sealing surface WARNING
for damage. Replace as needed.
5. After repair, assembly the system and repeat Fuel can ignite and cause serious injuries or
Step 1 through Step 4. death. Fuel can also irritate skin and eyes.
Always perform the following procedure with
6. Disconnect jumper wires. the engine stopped.
7. Connect coil wire to coil. 1. Complete the Before Repair Procedure.
8. Connect right-hand chassis harness to engine 2. Disconnect the negative battery cable.
harness.
4
3. Connect a fuel pressure gauge to the schrader 7. Turn the key switch to OFF position to stop the
valve located on the outlet side of the fuel filter. fuel pump.
8. Measure the fuel hold pressure after 5 minutes.
If not within the specification, inspect the fuel
line for clogging or leakage.
Specification: More than 300 kPa (43.5 psi)
9. Disconnect the fuel pressure gauge.
10. Complete the After Repair Procedure.
1. SCHRADER VALVE 2. FUEL FILTER 1. SCHRADER VALVE 2. FUEL FILTER

Figure 5. Schrader Valve Location for Lift Figure 6. Schrader Valve Location for Lift
Trucks Built Before January, 2010 Trucks Built After January, 2010
FUEL INJECTORS
5. Turn the key switch to ON position to prime the
fuel pump. Remove
6. Measure the fuel line pressure. If less than the 1. Complete the Before Repair Procedure.
specification, inspect the fuel pump for fuel line
leakage. If fuel line pressure exceeds the spec-
ification, inspect the pressure regulator for fuel 3. Disconnect the positive crankcase ventilation
line clogging. (PCV) valve hose from the intake manifold. See
Specification: 379 to 448 kPa (55 to 65 psi) Figure 7 and Figure 8.
5
Legend for Figure 7

1. INTAKE MANIFOLD 5. FUEL INJECTORS
2. PRESSURE 6. ELECTRICAL
REGULATOR CONNECTOR
3. VACUUM HOSE 7. FUEL RAIL
4. PCV VALVE 8. ELECTRONIC
THROTTLE BODY
Figure 7. Gasoline Fuel System for Lift Trucks

Built Before January, 2010
1. INTAKE MANIFOLD 5. FUEL INJECTORS

2. PRESSURE REGULATOR 6. ELECTRICAL CONNECTOR
4. PCV VALVE 8. ELECTRONIC THROTTLE BODY
Figure 8. Gasoline Fuel System for Lift Trucks Built After January, 2010
6
4. Disconnect the vacuum hose from the pressure

regulator.
5. Disconnect the wire harness connector from each

fuel injector.
6. Disconnect the fuel inlet line and fuel return line.
7. Remove the two capscrews retaining the fuel rail

to the intake manifold. See Figure 9 and Fig-
ure 10.

2. FUEL RAIL 5. PRESSURE
3. ELECTRICAL REGULATOR
CONNECTOR 6. FUEL INJECTOR
Figure 10. Fuel Rail Assembly Remove/Install

for Lift Trucks Built After January, 2010
8. Remove the fuel rail and fuel injectors as an as-

sembly from the intake manifold.
2. FUEL RAIL 5. PRESSURE 9. Slide the fuel injector retaining clips off the fuel
3. ELECTRICAL REGULATOR injectors.
CONNECTOR 6. FUEL INJECTOR
10. Remove the fuel injectors from the fuel rail. See
Figure 9. Fuel Rail Assembly Remove/Install
Figure 11.
7
PRESSURE REGULATOR
Remove
1. Complete the Before Repair Procedure.
3. Disconnect vacuum hose from pressure regula-

tor.
4. Disconnect the fuel return line from pressure

regulator.
5. Remove capscrew retaining pressure regulator to

fuel rail. See Figure 12.
1. FUEL RAIL 3. RETAINING CLIP

2. FUEL INJECTORS
Figure 11. Fuel Rail and Fuel Injectors
11. Remove and discard the O-rings from the fuel

injectors.
Install
1. Install new O-rings onto the fuel injectors.
2. Apply a small amount of clean engine oil to the

O-rings and install fuel injectors into the fuel
rail.
3. Install the fuel rail and fuel injectors as an as-

sembly onto the intake manifold. Install the two 1. PRESSURE 3. CAPSCREW
retaining capscrews and tighten capscrews to REGULATOR
20 N•m (15 lbf ft). 2. FUEL RAIL
4. Connect the fuel inlet line and fuel return line. Figure 12. Pressure Regulator
5. Connect the wire harness connectors to each fuel 6. Remove pressure regulator from fuel rail.
injector. 7. Remove and discard O-ring from pressure regu-
6. Connect the vacuum hose to the pressure regula- lator.
tor.
Install
7. Connect the PCV valve hose to the intake mani-
1. Apply a light coat of clean engine oil to new
fold.
O-ring and install O-ring on pressure regulator.
2. Place the pressure regulator in position on the
9. Complete the After Repair Procedure. fuel rail and install capscrew to retain the pres-
sure regulator to the fuel rail. Tighten capscrew
to 9.4 N•m (83 lbf in).
8
3. Connect the fuel return line to pressure regula- 5. Connect the negative battery cable.
tor.
4. Connect vacuum hose to pressure regulator.
Control System
ELECTRONIC CONTROL UNIT (ECU) 5. Lower the ECU and mounting bracket assembly
Remove
2. Disconnect the electrical connector to the fuel assembly mounting bracket to the frame and re-
pump and fuel level sender. move air filter assembly with mounting bracket.
3. Disconnect the throttle body electrical connector. 8. Remove the capscrews and nuts holding the ECU
to the mounting bracket. See Figure 14.
See Figure 13.
1. MOUNTING BRACKET
2. CAPSCREW
3. NUTS
4. ECU
5. POWER LATCH RELAY
Figure 14. ECU Mounting Bracket
9. Disconnect the electrical connectors from the

ECU. Rotate the locking tabs on each connector
1. CAPSCREW to unlock the electrical connectors. Disconnect
2. AIR FILTER MOUNTING BRACKET the connector closest to the fan assembly first.
4. ECU MOUNTING BRACKET Disconnect the center connector second. Dis-
connect the third connector. Remove ECU. See
Figure 13. Air Filter Mounting Bracket and Figure 15.
ECU Mounting Bracket
9


Tighten capscrews to 20 N•m (15 lbf ft).

send a "Restore ECU Defaults" command via the
CAN communication bus.
10. Connect the throttle body electrical connector.
1. MOUNTING BRACKET 11. Start the vehicle and check for proper operation
2. ECU of the throttle body and the ECU by exercising
3. ELECTRICAL CONNECTORS the accelerator pedal with the vehicle in neutral.
The engine should idle at 775 to 825 rpm with no
Figure 15. ECU and Electrical Connectors pedal to the governed speed of 2675 to 2725 rpm
at full pedal.
Install
POWER LATCH RELAY
CAUTION Remove
The electrical connectors should connect to the
ECU without any resistance. Do not force the 1. Disconnect the negative battery cable.
connectors in position as this can damage the
connector and/or the ECU. 2. Remove the capscrews holding the air filter
1. Connect the electrical connectors to the ECU. See Figure 13.
Connect the electrical connector farthest from
the fan assembly first. Connect the center con- 3. Lower the ECU and mounting bracket assembly
nector second. Connect the connector closest to down toward the frame.
the fan assembly last. Rotate the locking tabs to 4. Disconnect the hoses from the air filter assembly.
lock the electrical connectors in position.
2. Place the ECU in position on the mounting assembly mounting bracket to the frame and re-
bracket. Install the capscrews and nuts. Tighten move air filter assembly with mounting bracket.
6. Remove the capscrews and nuts retaining the
3. Place the air filter assembly with mounting power latch relay to the ECU mounting bracket.
bracket in position on the frame. Install bolts See Figure 16.
and tighten to 20 N•m (15 lbf ft).
10
MANIFOLD ABSOLUTE PRESSURE

(MAP)/MANIFOLD AIR TEMPERATURE
(MAT) SENSOR
Remove
cable.

MAP/MAT sensor. See Figure 17.
3. Remove the two screws retaining the MAP/MAT

sensor to the intake manifold. Remove MAP/
MAT sensor.
1. CAPSCREWS
4. ECU MOUNTING BRACKET
5. NUTS
Figure 16. Power Latch Relay

power latch relay.
Install
1. Connect the electrical connector from the power
latch relay.
2. Place the power latch relay in position on the

ECU mounting bracket.
3. Install capscrews and nuts to retain the power 1. MAP/MAT SENSOR

2. SCREW
latch relay to the ECU mounting bracket. 3. ELECTRICAL CONNECTOR
Tighten capscrews to 10 N•m (89 lbf in).
Figure 17. MAP/MAT Sensor
bracket in position on the frame. Install bolts Install
1. Place the MAP/MAT sensor in position on the
5. Connect the hoses to the air filter assembly. intake manifold and install the two retaining
screws. Tighten retaining screws to 6 N•m
(53 lbf in).
2. Connect the electrical connector to the
MAP/MAT sensor. Verify that the connector
clicks/locks into place.
hood.
11
ENGINE COOLANT TEMPERATURE (ECT) 2. Disconnect the oxygen sensor electrical connec-
SENSOR tor. See Figure 19.
Remove
cable.
2. Disconnect the electrical connector from the ECT

3. Remove the ECT sensor and washer.
2. CLIP
3. NUT
Figure 19. Oxygen Sensor Electrical Connector
3. Remove nut and clip retaining the oxygen sensor

housing.
2. ECT SENSOR 4. Using a special tool, oxygen sensor socket, re-
3. WASHER move the oxygen sensor. See Figure 20 and Fig-
ure 21.
Figure 18. ECT Sensor
Install
1. Install the new ECT sensor and washer. Tighten
the sensor to 20 N•m (15 lbf ft).
2. Connect the electrical connector to the ECT sen-

sor.

hood.
OXYGEN SENSOR
Remove
1. Raise the hood. Disconnect the negative battery Figure 20. Oxygen Sensor Socket
cable.
12
Install
oxygen sensor into exhaust manifold adapter.
Using a special tool, oxygen sensor socket,
tighten oxygen sensor to 40 to 60 N•m (30 to
44 lbf ft). See Figure 20 and Figure 21.
2. Install nut and clip to retain the oxygen sensor

housing.
3. Connect the electrical connectors. Verify that the

4. Verify that the wire is pulled up toward the ther-

mostat and away from any hot exhaust compo-
1. EXHAUST MANIFOLD ADAPTER nents.
2. OXYGEN SENSOR
Figure 21. Oxygen Sensor hood.

REMOVE AND DISASSEMBLE 3. Disconnect exhaust pipes (11 and 15, Figure 22)
from catalytic converter. Remove and discard
NOTE: The muffler is installed inside the cavity of gaskets from catalytic converter. Remove cat-
the counterweight. A short exhaust pipe sends the alytic converter from lift truck.
exhaust gasses out of the lift truck through a grille
in the counterweight. 4. Remove exhaust pipe (15, Figure 22) from engine
exhaust adapter (18, ). Remove and discard gas-
1. Remove counterweight before removing muffler ket from exhaust pipe.
and other part of exhaust system. See the section
Frame 100 SRM 1120 for counterweight removal 5. Remove engine exhaust adapter from exhaust
procedures. manifold. Remove and discard gasket from en-
gine exhaust adapter. See Figure 22.
WARNING 6. Remove clamps holding exhaust pipes (8 and 11,
Exhaust system components are hot to touch. Figure 22) onto muffler. Remove exhaust pipes
Be sure exhaust system components are cool from muffler.
may occur. 7. Remove plain flanged nuts and muffler from lift
truck frame.
2. Remove bracket attaching catalytic converter to
frame. See Figure 22. Disconnect oxygen sensor.
13
NOTE: EXHAUST WRAPS SHOWN ARE NOT ON ALL LIFT TRUCK MODELS.
5. BRACKET 16. EXHAUST WRAP
6. FLANGE NUT 17. PLUG
7. NUT 18. ENGINE EXHAUST ADAPTER
8. EXHAUST PIPE 19. STUD
9. CLAMP 20. OXYGEN SENSOR
10. MUFFLER 21. EXHAUST MANIFOLD
11. EXHAUST PIPE 22. COPPER RING
14
INSPECT 3. Install new gasket onto engine exhaust adapter.

Install engine exhaust adapter onto exhaust
Inspect the following items in the exhaust system: manifold. See Figure 22.
• Exhaust pipes for damage, corrosion, and rust. Re-
place as needed. 4. Install new gasket onto exhaust pipe. Install ex-
• If equipped, inspect all exhaust wraps for wear, haust pipe (15, Figure 22) onto engine exhaust
proper fit, contamination with oil or antifreeze, adapter (18, Figure 22).
gaps in coverage, and failed fasteners. Replace as
needed. If replacing an exhaust pipe section that 5. Place catalytic converter onto lift truck frame.
has a wrap, also replace the wrap. DO NOT reuse Install new gaskets onto catalytic converter and
wraps if they have been removed for a service install exhaust pipes (11 and 15, Figure 22) onto
operation. catalytic converter.
• Catalytic converter and muffler for damage, corro-
6. Install bracket attaching catalytic converter to
sion, and rust. Replace as needed.
lift truck frame. See Figure 22. Connect oxygen
sensor.
ASSEMBLE AND INSTALL
7. Install counterweight. See the section Frame
1. Place muffler onto frame of lift truck and install
100 SRM 1120 for counterweight installation
plain flanged nuts. Tighten nuts to 39 N•m
procedures.
(29 lbf ft).
2. Install exhaust pipes (8 and 11, Figure 22) onto

muffler. Install clamps onto pipes to hold them
onto muffler.
15
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
16
900 SRM 1126 2/10 (5/05)(12/04) Printed in U.S.A.

FRAME
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580502 100 SRM 1120

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 8
Steering Column ................................................................................................................................................ 13
Description ..................................................................................................................................................... 13
Remove....................................................................................................................................................... 13
Disassemble ............................................................................................................................................... 15
Clean .......................................................................................................................................................... 15
Inspect........................................................................................................................................................ 15
Assemble .................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Remove ........................................................................................................................................................... 19
Install ............................................................................................................................................................. 22
Description ..................................................................................................................................................... 25
Remove ........................................................................................................................................................... 27
Install ............................................................................................................................................................. 32
Inspect ................................................................................................................................................... 49
Inspect ................................................................................................................................................... 51


Inspect ................................................................................................................................................... 53
Inspect ................................................................................................................................................... 57
Cooling System................................................................................................................................................... 58
Description ..................................................................................................................................................... 58
Remove ........................................................................................................................................................... 58
Install ............................................................................................................................................................. 58
Inspect ............................................................................................................................................................ 60
Clean .............................................................................................................................................................. 60
Safety Labels ...................................................................................................................................................... 62
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
ii
General
Description
See Figure 1.
H40FTS) (F001)
1

4. HOOD MOUNTS
Figure 1. Frame

umn. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S30FT, S35FT, S40FTS (E010)
• H2.0-3.5FT (H40-70FT) (L177)
2

9. GAS SPRING
3

S40FTS (E010)
4
from frame.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001) ure 2.
• S30FT, S35FT, S40FTS (E010)
CAUTION
• H2.0-3.5FT (H40-70FT) (L177)
move covers.
• H2.0-3.5FT (H40-70FT) (L177) Figure 2).

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
5
(L177)
6
Legend for Figure 4


7

(F187)
ure 2. • S30FT, S35FT, S40FTS (E010)
19.2 N•m (170 lbf in).
8
Legend for Figure 7

SUSPENSION SEAT
HOOD
(S40-70FT) (F187)

Suspension Seat
Without
E-Control
E-Control
9
Legend for Figure 8

SUSPENSION SEAT

10
Legend for Figure 9

A. LEFT SIDE
B. RIGHT SIDE

Suspension Seat
H40-70FT
(L177)
H2.0-3.5FT
(L177)
11
CAUTION
for latch.
to 18 N•m (159 lbf in).


ure 6.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)

• H2.0-3.5FT (H40-70FT) (L177)



• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S30FT, S35FT, S40FTS (E010)
• H2.0-3.5FT (H40-70FT) (L177)
12
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
Steering Column
Figure 11.

Remove
WARNING

FORWARD position.

horn wires. 3. COWL
13


gas or LPG engines.


diesel engines.


2. HEX NUT COLUMN
3. STEERING WHEEL

3. ISOLATOR
14
Disassemble Clean
WARNING
tions.
January, 2012.
WARNING
fore January, 2012.
Inspect
January, 2012.
damaged hardware.
fore January, 2012.

January, 2012.
15
16

8. FASTENER
1. BRACKET 9. PIN
4. NUT 12. BOLT
17
Assemble Install
truck models
4032542). • S30FT, S35FT, S40FTS (E010)
fore January 2012.
ure 13.
January 2012.
Covers Replacement.
fore January 2012.
fore January 2012.
January 2012.
18

• H2.0-3.5FT (H40-70FT) (L177)
• H2.0-3.5FT (H40-70FT) (L177)
• S3.0-3.5FT (S60-70FT, S55FTS) (F187)
• H3.0-3.5FT (H60-70FT) (L177)

H40FTS) (F001)
WARNING
19
• H2.0-3.5FT (H40-70FT) (L177)
1325.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
20

Model Kg Lb
S30FT 772 1702
S35FT 963 2123
S40FTS 1131 2493

(H30FT, H35FT, H40FTS) (F001)
Model Kg Lb
H1.6FT (H30FT) 812 1790
H1.8FT (H35FT) 887 1955
H2.0FTS (H40FTS) 1047 2308

Models H2.0-3.5FT (H40-70FT) (L177)
MOUNT 6. WASHERS

H3.0FTS (H60FTS) 1664 3668
Model Kg Lb
S2.0FT (S40FT) 1040 2293
S2.5FT (S50FT) 1395 3075
S55FTS 1643 3622
S3.0FT (S60FT) 1819 4010
S3.5FT (S70FT) 2153 4747
21
1325.

has been installed.

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

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• H2.0-3.5FT (H40-70FT) (L177)
22


pin.
Figure 18. Tow Pin


23

2. HANDLE
3. BOLTS 6. GROMMET
24

seat belt assembly.
the seat.
25

6. SEAT RAIL
26

Engine Replacement
REMOVE WARNING
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001)
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• H2.0-3.5FT (H40-70FT) (L177)
truck models
• S30FT, S35FT, S40FTS (E010)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
WARNING • H2.0-3.5FT (H40-70FT) (L177)
27


WARNING
the fuel system.
CAUTION





2. BATTERY TRAY
3. PDM
28

29
30

Figure 25.
WARNING
(428 lb).


B. GM ENGINE MOUNT
3. WASHER
5. CROSSMEMBER
31


is not damaged.
INSTALL Figure 25.

not damaged.
No smoking.
32
for the procedures.

CAUTION
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
33
WARNING

ual or

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)

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



3. LOAD SENSE LINE
34

HOUSING
sion.
WARNING





to gear pump.

ment pump (VDP).

See Figure 28.

35
ing lines.


pump
• S30FT, S35FT, S40FTS (E010)
mately 83.8 kg (184.7 lb).
36

ADAPTERS NOT SHOWN.
2. DRAIN FITTING
4. SUCTION HOSE
2. DRAIN FITTING
4. SUCTION HOSE

2011)
4. SUCTION HOSE

2011)

37

ADAPTERS NOT SHOWN.
38


pump.



pump.

inlet port.

pump
• S30FT, S35FT, S40FTS (E010)
4. DRAIN CASE LINE
10. PUMP INLET PORT
placement pump.
transaxle oil.
39


pump
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)


placement pump.

pump.


2. CAPSCREW
in installation.

Figure 37.
40


51 lbf ft).

port.
4. OIL SEAL pump
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
placement pump.
mately 83.8 kg (184.7 lb).
let port.
pump
See Figure 37.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
41
pump
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
wiring harness.
WARNING
mately 83.8 kg (184.7 lb).
H40FTS) (F001)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
42
model H2.0-3.5FT (H40-70FT) (L177).

43
44
45
ure 39.

Transmission
46




(71 to 133 lbf in).

See Figure 41.

(71 to 133 lbf in).

2. JAM NUT
ELECTRONIC THROTTLE
47
6. JAM NUT
48

Inspect
WARNING
may occur.
lift truck.

49
9. CLAMP
50

Inspect
procedures.
(195 lbf in).
51
52

2. WASHER 9. CLAMP
7. GASKET
pipe.
Inspect
53
54

2. WASHER 11. SOCK
9. CLAMP 18. COVER*

WARNING
may occur.
procedures.
sor.
55
56
3. SPACER 14. PLUG
operation.
57
Cooling System
components:
• Radiator
• Fan and belt
• Fan shroud

Figure 46.
the pump.
as necessary.
CAUTION
ure 46.
58


Hand tighten lid.
CAUTION
ter dealer.

indicated in

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

truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)

2. SPRING 7. BOWL
59

INSPECT WARNING
WARNING
mation:
electricity.
CAUTION
ter dealer.
WARNING
flammable vapors.

CLEAN drain plug.

60
WARNING 1999.

61
Safety Labels
read.

part numbers.
62
S2.0-3.5FT (S40-70FT, S55FTS) (F187)
63

16. JOYSTICK LABEL



64
65
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
66

OPERATOR’S CAB
H1.6FT, H1.8FT, 2.0FTS [F001];
H2.0-3.5FT (H40-70FT) [L177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005,
R005]; H6.0FT, H7.0FT (H135FT, H155FT) [H006,
J006, K006]; H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) [A299, B299]
PART NO. 1673866 100 SRM 1290

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Cab Replacement ............................................................................................................................................... 2
R005) .............................................................................................................................................................. 2
R005) .............................................................................................................................................................. 16
Door Assemblies ................................................................................................................................................. 25
120FT) (N005, P005, R005) ........................................................................................................................... 25
Remove....................................................................................................................................................... 25
Disassemble ............................................................................................................................................... 33
Heater Assembly ................................................................................................................................... 33
Windows ................................................................................................................................................ 39
Clean .......................................................................................................................................................... 39
Inspect........................................................................................................................................................ 39
Assemble .................................................................................................................................................... 39
Windows ................................................................................................................................................ 39
Heater Assembly ................................................................................................................................... 39
Install ......................................................................................................................................................... 40
120FT) (N005, P005, R005) ........................................................................................................................... 41
Remove....................................................................................................................................................... 41
Disassemble ............................................................................................................................................... 41
Door Cover............................................................................................................................................. 41
Windows ................................................................................................................................................ 41
Clean .......................................................................................................................................................... 41
Inspect........................................................................................................................................................ 41
Assemble .................................................................................................................................................... 41
Windows ................................................................................................................................................ 41
Door Cover............................................................................................................................................. 42
Install ......................................................................................................................................................... 42


Remove....................................................................................................................................................... 43
Disassemble ............................................................................................................................................... 44
Door Cover............................................................................................................................................. 44
Windows ................................................................................................................................................ 44
Clean .......................................................................................................................................................... 45
Inspect........................................................................................................................................................ 45
Assemble .................................................................................................................................................... 46
Windows ................................................................................................................................................ 46
Door Cover............................................................................................................................................. 46
Install ......................................................................................................................................................... 47
General ........................................................................................................................................................... 47
(L177) ......................................................................................................................................................... 47
110, 120FT) (N005, P005, R005)............................................................................................................... 59
120FT) (N005, P005, R005)....................................................................................................................... 59
General ........................................................................................................................................................... 63
120FT) (N005, P005, R005) ........................................................................................................................... 63
120FT) (N005, P005, R005) ........................................................................................................................... 64
ii

Remove....................................................................................................................................................... 70
Install ......................................................................................................................................................... 71
Remove....................................................................................................................................................... 72
Install ......................................................................................................................................................... 72
Remove....................................................................................................................................................... 74
Install ......................................................................................................................................................... 74
Strobe Light ................................................................................................................................................... 75
Remove....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Remove....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Remove....................................................................................................................................................... 77
Install ......................................................................................................................................................... 78
Remove....................................................................................................................................................... 81
Clean .......................................................................................................................................................... 81
Inspect........................................................................................................................................................ 81
Install ......................................................................................................................................................... 81
Fan.................................................................................................................................................................. 84
Remove....................................................................................................................................................... 84
Install ......................................................................................................................................................... 84
Mirror ............................................................................................................................................................. 84
Remove....................................................................................................................................................... 84
Install ......................................................................................................................................................... 84
H1.6FT, H1.8FT, 2.0FTS [F001];

H2.0-3.5FT (H40-70FT) [L177];
110, 120FT) [N005, P005, R005];
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
1
Cab Replacement



• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

WARNING

2
2. RELEASE LATCH
Legend for Figure 4
1. CAPSCREW
2. AIR FILTER HOSE
3
4
Legend for Figure 5

B. H2.0-3.5FT (H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
See Figure 11.
Figure 11.
people.
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005), open
See Figure 9.
5
P005)
3. RADIATOR COVER
6
7
Legend for Figure 9

1. GAS SPRING
3. LOCK NUT
8

HARNESS)

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
hoses.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)

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

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)

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

9
Engine
10
11
12


lift truck frame.
tached.
13
14

(H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
4. SEAL

6. CAPSCREWS
Cover Removal
15

H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177); AND H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005)
mounting holes.
16
ure 11.
ure 10.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
110, 120FT) (N005, P005).
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
Figure 10.
17
ure 22.
WARNING ure 23.
purged.

and drops down.

locked position.

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

See Figure 21.
left side door.
18

move dash assembly.

Figure 22.



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

Figure 27.
fluid reservoir.
to module.
and cowl panel.
19

5. REAR FLOOR MAT
20

3. SCREWS
4. KICK PANEL
7. LOCK NUT
8. FLANGE BOLT

Trucks
21

22

1. VSM
CHASSIS HARNESS)


ELS.
1. FLANGE BOLTS
6. MODULE
7. COWL PANEL
23

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




165 N•m (122 lbf ft).



24
J006, K006) frame.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
ure 22.
H190FT) (A299, B299)

Door Assemblies

25
26

B. H2.0-3.5FT (H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
quires two people.
See Figure 31.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80,
5.5FT (H80, 90, 100, 110, 120FT) (P005)
90, 100, 110, 120FT) (N005, P005, R005)
27
A. H1.6FT, H1.8FT, 2.0FTS (F001)
B. H2.0-3.5FT (H40-70FT) (L177)
3. RADIATOR COVER
28

HARNESS)

29
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)
30
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
31
2. MOUNTING BRACKET
32

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
Figure 37.
door frame.
door frame.
Heater Assembly
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
33
34

1. PLUG 9. WASHER
8. HANDLE PLATES

5. HANDLE 12. PLUG
35

36
switch.
Parts Manual.


7. CAPSCREW
37
and mounting plate.

38

Inspect screws.
Assemble
Windows

Door Lock Assembly


(170 lbf in).

39
See Figure 37.
Figure 39.
switch.
Install
ure 35.
See Figure 36.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
40
5.5FT (H80, 90, 100, 110, 120FT) (P005)
Clean
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
WARNING
5.5FT (H80, 90, 100, 110, 120FT) (R005)
eyes.
(F001); H2.0-3.5FT (H40-70FT) (L177);
Remove
Inspect
Door Cover Windows
to 19.2 N•m (170 lbf in).
Door Lock Assembly

41

3. COVER 7. HANDLE
42

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

Step 3.

2. WASHER
43

dle. See Figure 47.


2. SCREW 6. WASHER
44

WARNING
Inspect
window if damaged.

45

5.0 N•m (44 lbf in).
See Figure 46.

2. SEAL 4. GRIP
46
pin. See Figure 44.
ure 35.

(L177)
tor.
tor.
47

and H2.0-3.5FT (H40-70FT) (L177)
48
J006, K006), H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
from wiper arms.
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, J006)
R005)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
J006, K006)
J006, K006)
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) H155FT) (H006, J006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
5.5FT (H80, 90, 100, 110, 120FT) (R005)
H175FT36, H190FT) (A299, B299)
49
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
J006, K006)
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)

8. LOCK NUTS
50
51
52

53
2.0FTS (F001)
54

8. NUT 20. NUT
12. WIPER ARM
(F001)
55
(H40-70FT) (L177) (H40-70FT) (L177)
ure 52.
wire harness.
mounting bracket.
56

57

58
100, 110, 120FT) (N005, P005, R005) 100, 110, 120FT) (N005, P005, R005)
ure 52.
59
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
60

See Figure 55.
61

(A299, B299)
62
Window Replacement
bracket.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)

63
door frame.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005)

See Figure 57.



ing window.

dow. See Figure 57.


(H006, J006, K006) AND H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT)
2. SEAL
Door)
64

5. CAPSCREW
65
(H006, J006, K006) AND H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)

ment part numbers.



Heater Replacement
Figure 62.
66



1. SCREWS
67
68

14. HEATER BOX

H6.0FT, H7.0FT (H135FT, H155FT) (H006,
(H170FT, H175FT36, H190FT) (A299, B299)

heater.






3. CLIP NUTS
69

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)

70
Install

2. BUSHING
71
72


73
Light Replacement
J006, K006)
H175FT36, H190FT) (A299, B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
models
R005)
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
CAUTION
lamp failure.


and four capscrews.
3. NUT
74

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
both options.
Remove
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
models H175FT36, H190FT) (A299, B299)
• H2.0-3.5FT (H40-70FT) (L177) models
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, H40FTS) (F001)
R005) • H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-

Figure 69.
J006, K006)
H40FTS) (F001)
75
76

7. FLANGE NUT LIGHT
9. STROBE LIGHT
J006, K006)
models
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

Remove

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
3. FLANGE NUT
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, 8. LOCK NUT
R005)
77

models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
Display Switches
(F001)
78

79

80
Optional Equipment
els Clean
• H1.6FT, H1.8FT, 2.0FTS (F001)
• H2.0-3.5FT (H40-70FT) (L177)
WARNING
lift truck models
H190FT) (B299)
Install
head capscrews.
Figure 74.
81
82

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
H190FT) (A299, B299)
83

Remove
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
H175FT36, H190FT) (A299, B299) models
models • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H2.0-3.5FT (H40-70FT) (L177) R005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, MIRROR
R005)
Remove
ure 75.
84
1. MIRROR 6. WASHER
5. LOCKNUT
85
Label Replacement

86

MAZDA ENGINE
2.0L AND 2.2L
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]; S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
PART NO. 1580504 600 SRM 1122

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Mazda Engine Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Cylinder Head, Camshaft, and Valve Mechanism Repair ............................................................................... 2
Remove ........................................................................................................................................................... 2
Clean .............................................................................................................................................................. 4
Inspect and Repair......................................................................................................................................... 4
Cylinder Head............................................................................................................................................ 4
Rocker Shaft Assembly ............................................................................................................................. 4
Camshaft.................................................................................................................................................... 5
Valve Guides .............................................................................................................................................. 6
Valve Seats................................................................................................................................................. 6
Valves ......................................................................................................................................................... 6
Valve Springs............................................................................................................................................. 7
Install ............................................................................................................................................................. 8
Crankshaft and Main Bearings Repair ............................................................................................................ 12
Remove ........................................................................................................................................................... 12
Crankshaft ................................................................................................................................................. 12
Main Bearings ........................................................................................................................................... 13
Install ............................................................................................................................................................. 14
Pistons and Connecting Rods Repair................................................................................................................ 14
Clean .............................................................................................................................................................. 14
Pistons........................................................................................................................................................ 15
Piston Rings............................................................................................................................................... 15
Connecting Rods and Bearings................................................................................................................. 15
Cylinder Block Repair........................................................................................................................................ 17
Oil Pump Repair ................................................................................................................................................ 18
Remove ........................................................................................................................................................... 18
Disassemble ................................................................................................................................................... 19
Clean .............................................................................................................................................................. 19
Inspect ............................................................................................................................................................ 19
Assemble ........................................................................................................................................................ 20
Install ............................................................................................................................................................. 20
Thermostat..................................................................................................................................................... 22
Replace ....................................................................................................................................................... 22
Fan Assembly ................................................................................................................................................. 22
Remove and Disassemble.......................................................................................................................... 22
Assemble and Install................................................................................................................................. 22
Water Pump ................................................................................................................................................... 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 24
Flywheel and Ring Gear Repair........................................................................................................................ 24
Remove ........................................................................................................................................................... 24
Install ............................................................................................................................................................. 24
Valve Adjustment............................................................................................................................................... 25
Compression Pressure Check ............................................................................................................................ 26

Table of Contents Mazda Engine

Engine Timing Adjustment ............................................................................................................................... 26
Engine Data ................................................................................................................................................... 27
Engine Speeds................................................................................................................................................ 27
2007, and Later, Emission Compliant Engines ....................................................................................... 27
All Engines Except 2007, and Later, Emission Compliant Engines....................................................... 27
Thermostat..................................................................................................................................................... 28
Cylinder Head ................................................................................................................................................ 28
Valve Mechanism........................................................................................................................................... 28
Camshaft ........................................................................................................................................................ 29
Crankshaft ..................................................................................................................................................... 29
Connecting Rods ............................................................................................................................................ 30
Cylinder Block ............................................................................................................................................... 30
Pistons ............................................................................................................................................................ 30
Oil Pump ........................................................................................................................................................ 30
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
ii
General
This section has the instructions for removal, dis- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
assembly, repair, assembly, installation, checks, and • H2.0-3.5FT (H40-70FT) (L177)
adjustments for the Mazda 2.0L and 2.2L engines.
The engine specifications are given at the end of the See section LPG Fuel System, Mazda 2.0L and
section. 2.2L Engines 900 SRM 1125 for lift truck models
• S30FT, S35FT, S40FTS (E010)
Additional information on the Mazda 2.0L and 2.2L • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
2007 emissions compliant engine components and for (F001)
lift trucks built after January, 2010, can be found in • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
the following: • H2.0-3.5FT (H40-70FT) (L177)
See section Gasoline Fuel System, Mazda 2.0L See section Electrical System, Mazda 2.0L and
and 2.2LEmission Compliant Engines 900 SRM 2.2L 2200 SRM 1143 for lift truck models
1325 for lift truck models • S30FT, S35FT, S40FTS (E010)
• S30FT, S35FT, S40FTS (E010) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001)
(F001) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H2.0-3.5FT (H40-70FT) (L177)
• H2.0-3.5FT (H40-70FT) (L177)
SERIAL NUMBER
See section LPG Fuel System, Mazda 2.0L and
2.2L Emission Compliant Engines 900 SRM 1326 The engine serial number is located on the top left
for lift truck models hand side of the cylinder head cover. See Figure 1.
• S30FT, S35FT, S40FTS (E010)
(F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
See section Electrical System, Mazda 2.0L and

2.2L Emission Compliant Engines 2200 SRM
• S30FT, S35FT, S40FTS (E010)
(F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
Additional information on all other Mazda 2.0L and

2.2L engine components, for lift trucks built before
2007, can be found in the following:
See section Gasoline Fuel System, Mazda 2.0L

and 2.2L 900 SRM 1127 for lift truck models Figure 1. Engine Serial Number Location
• S30FT, S35FT, S40FTS (E010)
(F001)
1
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 1122

The removal and installation procedures for the en- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
gine are not included in this section. • H2.0-3.5FT (H40-70FT) (L177)
See section Frame 100 SRM 1120 for lift truck mod- See section Frame 100 SRM 1423 for lift truck mod-
els els
• S30FT, S35FT, S40FTS (E010) • S50CT (A267)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) • H2.0-2.5CT (H50CT) (A274)
(F001)
Cylinder Head, Camshaft, and Valve Mechanism Repair

REMOVE emissions compliant and lift trucks built after
January, 2010.
1. Disconnect connections at battery.
15. Remove camshaft pulley. Keep pulley from rotat-
2. Drain cooling system. ing and loosen capscrew. Remove capscrew and
pulley. See Figure 4.
3. Remove air cleaner, throttle cable (if equipped),
intake manifold, and exhaust manifold.
4. Remove coolant hoses.
5. Remove the V belt.
6. Remove the cooling fan.
7. Remove bracket for cooling fan.
8. Remove the six capscrews retaining the crank-

shaft pulley to the timing pulley and remove the
crankshaft pulley.
9. Remove the spark plugs from the cylinder head.
10. Remove upper and lower timing belt covers. See

Figure 2.
11. Loosen capscrews for timing belt tensioner and

remove spring. Remove capscrews and timing
belt tensioner.
12. Use chalk to mark direction of timing belt rota-

tion. See Figure 3. Remove timing belt.
13. If equipped with a distributor, remove the dis-

tributor. Refer to the section Electrical System,
Mazda 2.0L and 2.2L 2200 SRM 1143 for lift
trucks built before 2007.
1. LOWER TIMING BELT COVER
14. If equipped with a CAM angle sensor, remove the 2. UPPER TIMING BELT COVER
CAM angle sensor. Refer to the section Electri- 3. TIMING BELT TENSIONER
cal System, Mazda 2.0L and 2.2L Emission
Compliant Engines 2200 SRM 1327 for 2007 Figure 2. Timing Belt Covers
2
600 SRM 1122 Cylinder Head, Camshaft, and Valve Mechanism Repair
16. Remove nuts and capscrews for front housing.

Then remove housing. See Figure 5.
17. Remove valve cover.
18. Loosen capscrews for rocker shaft supports in

proper sequence. See Figure 6. Remove rocker
shaft assembly and camshaft.
19. Remove capscrews for cylinder head in proper se-

quence. See Figure 7.
20. Lift cylinder head from the block.
21. Use valve spring compressor to remove valve re-

tainers, springs, and valves from head. See Fig-
ure 8.
Figure 4. Camshaft Gear Removal

Figure 6. Rocker Assembly Removal Sequence
1. FRONT HOUSING
2. GASKET Figure 7. Cylinder Head Removal Sequence
3. OIL SEAL
Figure 5. Front Housing
3
Maximum amount of distortion is 0.15 mm

(0.0059 in.). If grinding of cylinder head is neces-
sary, maximum amount of correction is 0.2 mm
(0.008 in.).
Rocker Shaft Assembly

1. Disassemble rocker shaft assembly. Put marks
on rocker arms so they can be installed on correct
shafts.
2. Clean oil passages in rocker shafts and rocker

arms.
3. Check clearance between rocker arms and

rocker shafts. Maximum clearance is 0.10 mm
Figure 8. Valve Removal (0.004 in.).
Correct dimension for inside diameter of rocker

CLEAN
arm is 16.000 to 16.027 mm (0.6299 to 0.6311 in.).
Correct dimension for outside diameter of
WARNING rocker shaft is 15.966 to 15.984 mm (0.6286
Cleaning solvents can be flammable and toxic to 0.6293 in.). If components do not meet specifi-
and can cause skin irritation. When using cations, replace rocker arm(s) or rocker shaft(s)
cleaning solvents, always follow the solvent as necessary.
manufacturer’s recommended safety proce-
dures.
CAUTION
DO NOT damage machined surfaces when
cleaning.
Clean all parts in solvent. Make sure all oil passages

are clean and all machined surfaces are smooth.
INSPECT AND REPAIR

Cylinder Head
1. Use straight edge and thickness gauge to check
bottom surface of cylinder head for distortion. Do
the measurements at the positions shown in Fig-
ure 9.
Maximum amount of distortion is 0.15 mm

(0.0059 in.). If grinding of cylinder head is neces-
sary, maximum amount of correction is 0.2 mm
(0.008 in.). Figure 9. Cylinder Head Inspection
2. For the intake and exhaust manifold mounting
surfaces, use the same inspection procedures and
correct if there are any faults.
4
Camshaft c. Tighten capscrews for caps to 18 to 27 N•m

(13 to 20 lbf ft). See Figure 13.
1. Check camshaft for cracks or damage.
Correct clearance for journals No. 1 and 5
2. Use dial indicator on end of camshaft to check is 0.035 to 0.085 mm (0.0014 to 0.0033 in.).
movement of camshaft in cylinder head. See Correct clearance for journals No. 2, 3, and
Figure 10. Maximum movement is 0.20 mm 4 is 0.065 to 0.115 mm (0.0026 to 0.0045 in.).
(0.008 in.). If any clearances are greater than 0.15 mm
(0.0059 in.), replace cylinder head assembly.
7. Replace camshaft if there is any damage or if it

does not meet specifications.
Figure 10. Camshaft Check
3. Measure height of camshaft lobes. See Figure 11.

Minimum height of intake and exhaust lobes is
37.170 mm (1.4634 in.).
4. Measure camshaft journals at four points (A-D)

as shown in Figure 11. Minimum dimensions for
the journals are as follows:
Front and Rear Journals (Nos. 1 and 5) - 1. FRONT OIL SEAL SURFACE
31.940 to 31.965 mm (1.2575 to 1.2585 in.) 2. FRONT JOURNAL (NO. 1)
Center Journals (Nos. 2, 3 and 4) - 31.910 to 3. CENTER JOURNALS (NOS. 2, 3, AND 4)
4. REAR JOURNAL (NO. 5)
31.935 mm (1.2563 to 1.2573 in.)
Front Oil Seal Surface - 33.961 to 34.000 mm Figure 11. Camshaft Inspection
(1.3371 to 1.3386 in.)
5. Check camshaft for straightness. Put front and

rear journals in V blocks and rotate camshaft one
complete turn. See Figure 12. Maximum amount
that the dial indicator should indicate is 0.03 mm
(0.0012 in.).
6. Measure clearance between camshaft and bore in

cylinder head as follows:
a. Install camshaft in cylinder head.
b. Put plastic gauge material between each

camshaft journal and cap. Do not allow
camshaft to rotate. Figure 12. Camshaft Check
5
Valves
1. Measure length of each valve.
Minimum length for intake valve is 111.19 mm

(4.378 in.).
Minimum length for exhaust valve is 110.99 mm

(4.370 in.).
1. PLASTIC GAUGE 2. SCALE
Figure 13. Camshaft Clearance Measurement
Valve Guides
1. Measure clearance between valve stems and
valve guides.
Normal clearance for intake valve guides is 0.025

to 0.060 mm (0.001 to 0.002 in.). 1. CYLINDER HEAD 3. VALVE GUIDE
2. RETAINING RING
Normal clearance for exhaust valve guides is
0.030 to 0.065 mm (0.0012 to 0.0026 in.). Figure 14. Valve Guide Inspection
If clearance is more than 0.10 mm (0.004 in.),
replace valve or valve guide.
2. If replacement is necessary, remove seal from

valve guide(s). Then use tool to remove valve
guide(s) from the combustion chamber side.
3. To install valve guide, install retaining ring on

valve guide. Use valve guide installation tool to
install valve guide so that retaining ring contacts
cylinder head. See Figure 14.
Correct height of valve guide above valve spring

seat is 19.1 to 19.6 mm (0.75 to 0.77 in.).
A. EXHAUST B. INTAKE
Valve Seats 1. VALVE SEAT WIDTH
2. EXHAUST VALVE SEAT
1. Inspect condition of valve seats. If valve seats 3. INTAKE VALVE SEAT
have cracks, cylinder head must be replaced.
Figure 15. Valve Seat Specifications
2. If valve seats are in good condition, check contact
pattern of valve and valve seat. Use valve seat
grinder to make sure valve seats are within spec-
ifications shown in Figure 15. Use valve com-
pound to make sure valves fit seats.
6
2. Inspect stem of each valve for wear. Use microm-

eter to measure outside diameter of stem at dif-
ferent points (A - E). See Figure 16.
Minimum dimension for intake valve is

7.980 mm (0.3142 in.). Minimum dimension
for exhaust valve is 7.975 mm (0.3140 in.).
3. Inspect valves for cracks, burned faces, and dis-

tortion. Inspect seat face of valves for wear and
damage.
4. Measure thickness of valve head. Minimum

thickness for intake valve is 0.5 mm (0.020 in.).
Minimum thickness for exhaust valve is 1.0 mm
(0.040 in.).
If valves need grinding, correct surface angle is

30° for both intake and exhaust valves.
Valve Springs
1. Check valve springs for damage. 1. VALVE STEM
2. THICKNESS, VALVE HEAD
2. Measure free length of valve springs. See Fig-
ure 17. Figure 16. Valve Inspection
Minimum length of inner valve spring is 46.3 mm

(1.823 in.). Minimum length of outer valve spring
is 50.6 mm (1.992 in.).
3. Check valve springs for squareness. See Fig-

ure 17.
Correct squareness of inner valve spring is

1.66 mm (0.065 in.).
Correct squareness of outer valve spring is

1.82 mm (0.072 in.).
If measurement is more than specification, re-

place valve spring(s).
A. MEASURE HERE
Figure 17. Valve Springs Inspection
7
INSTALL 6. Apply gasket sealer to areas shown by arrows.

Lubricate camshaft with clean engine oil. Then
1. Clean surface of cylinder head and surface of en- install camshaft. Make sure dowel pin is at top
gine block. of camshaft. See Figure 21.
2. Using the appropriate seal installer tool, insert
valve seals into valve guides. See Figure 18.
1. TOOL
2. CYLINDER HEAD
3. VALVE GUIDE Figure 20. Cylinder Head Installation
4. VALVE SEAL
Figure 18. Valve Seal Installation
3. Use valve spring compressor to install valve re-

tainers, springs, and valves into head. See Fig-
ure 19.
Figure 19. Valve Installation
4. Install new gasket and cylinder head on engine

block.
5. Install capscrews and washers for cylinder

head. Tighten capscrews to 82 to 88 N•m (60 to 1. DOWEL PIN
65 lbf ft) in proper sequence. See Figure 20. 2. APPLY SEALANT HERE
Figure 21. Camshaft Installation
8
7. Assemble rocker shaft assembly. See Figure 22. 9. If necessary, install oil seal in front housing. See
Lubricate rocker arms and shafts with engine oil. Figure 24. Use new gasket and install front hous-
Put capscrews in rocker shaft supports. Then ing on cylinder head. Tighten capscrews for front
install assembly on cylinder head. housing to 19 to 26 N•m (168 to 230 lbf in).
10. With dowel pin at top of camshaft, install

camshaft pulley.
For 2.0L engines, check that number 1 on pul-

ley is aligned with timing mark on front housing.
See Figure 25.
For 2.2L engines, check that number 1 on pulley

is positioned approximately 2.5° in the retard di-
rection.
11. Install capscrew and washer for camshaft pulley.

See Figure 25. Keep pulley from turning and
tighten capscrew to 48 to 66 N•m (35 to 49 lbf ft).
A. NO. 1 AND NO. 3 ARE THE SAME

B. NO. 2 AND NO. 4 ARE THE SAME
Figure 22. Rocker Shaft Assembly
8. Tighten capscrews for rocker shaft supports to 18

to 27 N•m (13 to 20 lbf ft) in proper sequence. See
Figure 23.
1. FRONT HOUSING
2. GASKET
3. OIL SEAL
Figure 24. Front Housing
Figure 23. Rocker Shaft Assembly Installation
9
13. Install timing belt tensioner and spring. Move

tensioner fully toward intake side of engine and
temporarily tighten lock bolt.
14. Clean any oil or grease from pulleys. Install tim-

ing belt so that it goes in same direction as mark
made during removal.
15. Loosen lock bolt and apply spring tension on belt.

Rotate crankshaft pulley clockwise two complete
turns and check timing marks.
If timing marks are correct, tighten lock bolt for

tensioner to 20 to 35 N•m (15 to 26 lbf ft). Be
sure tensioner does not move together with lock
bolt rotation. Check movement on tension side of
timing belt. See Figure 27.
For both 2.0L and 2.2L engines, if tension is cor-

rect, belt will move 9 to 10 mm (0.36 to 0.39 in.)
with 10 kg (22 lb) of force.
1. TIMING MARKS
2. CAMSHAFT PULLEY
Figure 25. Camshaft Pulley Installation
12. Align timing marks for crankshaft timing pulley.

See Figure 26.
1. TENSIONER 3. LOCK BOLT

2. SPRING 4. TENSION SIDE
Figure 27. Timing Belt Installation
16. Install lower timing belt cover and new gasket.

Tighten capscrews to 7 to 8 N•m (5 to 6 lbf ft).
Install upper timing belt cover and new gasket.
Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft).
See Figure 28.
1. CRANKSHAFT TIMING PULLEY
2. TIMING MARK
Figure 26. Timing Belt Installation
10
21. If equipped with a distributor, install the distrib-

utor. Refer to the section Electrical System,
Mazda 2.0L and 2.2L 2200 SRM 1143 for lift
trucks built before 2007.
22. If equipped with a CAM angle sensor, install the

CAM angle sensor. Refer to the section Electri-
cal System, Mazda 2.0L and 2.2L Emission
Compliant Engines 2200 SRM 1327 for 2007
emissions compliant engines and lift trucks built
after January, 2010.
23. Install bracket for cooling fan.
24. Install coolant hoses.
25. Install air cleaner, throttle linkage (if equipped),

intake manifold, and exhaust manifold.
CAUTION
dealer.
26. Fill cooling system.
27. Connect connections at battery.

2. UPPER TIMING BELT COVER
3. TIMING BELT TENSIONER
Figure 28. Timing Belt Covers
17. Install crankshaft pulley and six capscrews to re-

tain pulley. Tighten pulley to 12 to 17 N•m (9 to
13 lbf ft).
18. Apply gasket sealer to the areas shown in Fig-

ure 29. Install new gasket and valve cover.
19. Install valve cover capscrews and tighten to 6 to Figure 29. Valve Cover Installation
8 N•m (52 to 70 lbf in).
20. Install spark plugs in cylinder head. Tighten

spark plugs to 15 to 23 N•m (11 to 16 lbf ft).
11
Crankshaft and Main Bearings Repair 600 SRM 1122
Crankshaft and Main Bearings Repair

REMOVE
4. Remove six capscrews that hold crankshaft pul-

ley to timing pulley.
5. Remove capscrew from crankshaft timing pulley.

Install special tool with spacer on crankshaft to
remove timing pulley. Rotate tool until it touches
front of crankshaft. Hit tool with hammer to
loosen timing pulley. Remove pulley, dowel pin,
tapered ring, and spacer. Remove tool. See Fig-
ure 30.
6. Remove oil pan and oil strainer.

1. CENTER MAIN BEARING
Figure 31. Crankshaft Clearance Measurement
10. Put identification marks on bearing caps. Loosen

capscrews for main bearing caps in steps. Then
remove capscrews, caps, and crankshaft.
INSPECT AND REPAIR

Crankshaft
1. Inspect crankshaft for wear, cracks, or other
damage. Replace crankshaft if it has cracks.
2. Use micrometer to measure diameter of journals

1. SPACER 2. TOOL for crankshaft. See Figure 32. Make measure-
ment at several locations for each journal. Cor-
Figure 30. Crankshaft Timing Pulley Removal rect dimensions for journals are as follows:
7. Remove rear cover. Remove front cover with oil Main Journal Diameter - 59.937 to 59.995 mm
pump. (2.3597 to 2.3620 in.)
8. Remove caps for connecting rods. Put identifica- Connecting Rod Journals - 50.940 to
tion mark on each cap so they will be installed in 50.955 mm (2.0055 to 2.0061 in.)
correct location. Rear Oil Seal Surface - 89.946 to 90.000 mm
(3.5412 to 3.5433 in.)
9. Before removing crankshaft, measure clearance Front Oil Seal Surface - 33.961 to 34.000 mm
between crankshaft and flange of center main (1.3371 to 1.3386 in.)
bearing. See Figure 31. Push crankshaft fully
forward before making measurement. If measurements are less than specifications,
grind crankshaft and install oversize bearings.
Maximum clearance is 0.30 mm (0.012 in.). If Refer to the Parts Manual for the different
clearance is greater than specification, replace bearing sizes.
center main bearing or grind crankshaft and in-
stall new main bearing.
12
600 SRM 1122 Crankshaft and Main Bearings Repair
3. Check crankshaft for straightness. See Fig- Main Bearings

ure 32. Put front and rear journals in V blocks
and rotate crankshaft one complete turn. Maxi- NOTE: Inspect main bearings for damage. If any
mum amount that dial indicator should indicate main bearing is damaged, all main bearings must be
is 0.03 mm (0.0012 in.). replaced.
4. Check oil passages crankshaft. Make sure pas- 1. To inspect main bearings for wear, measure
sages are clean and have no restrictions. clearance between main bearings and crank-
shaft using plastic gauge. See Figure 33.
a. Reinstall crankshaft in cylinder block.
b. Put plastic gauge material on journals and

install main bearing caps. Tighten cap-
screws for bearing caps to 84 to 90 N•m (62
to 66 lbf ft).
c. Remove bearing caps. Plastic gauge material

will adhere to journals or bearing caps.
d. Use graduations on scale to measure width

of plastic gauge material at its widest point.
Correct clearance for journals No. 1, 2,

4, and 5 is 0.025 to 0.043 mm (0.00099 to
0.00169 in.).
Correct clearance for journal No. 3 is 0.031

to 0.049 mm (0.00123 to 0.00192 in.).
If any clearance is greater than specification,

replace all main bearings.
1. REAR OIL SEAL SURFACE

2. CONNECTING ROD JOURNALS
3. MAIN BEARING JOURNALS
4. FRONT OIL SEAL SURFACE
Figure 32. Crankshaft Inspection
1. PLASTIC GAUGE MATERIAL

2. SCALE
Figure 33. Main Bearings Clearance Check
13
Pistons and Connecting Rods Repair 600 SRM 1122
INSTALL part of gasket that extends past bottom of cylin-

der block.
1. Clean areas of cylinder block around main bear-
ings. Carefully install bottom half of new main 8. Install oil strainer. Tighten capscrews to 8 to
bearings if necessary. Lubricate bearings with 12 N•m (70 to 106 lbf in).
clean engine oil.
9. Apply adhesive sealant to a new oil pan gasket
2. Install crankshaft. and install new gasket and oil pan. Tighten cap-
screws to 8 to 12 N•m (71 to 106 lbf in).
3. Install top half of main bearings in caps and
lubricate with oil. Use identification marks to
install main bearing caps in correct locations.
Tighten capscrews for main bearing caps to 84
to 90 N•m (62 to 66 lbf ft).
4. Install pistons and connecting rods as described

in Pistons and Connecting Rods Repair.
5. Make sure O-ring is in oil pump housing. Lubri-

cate oil seal with engine oil. Use adhesive sealant
to install housing to cylinder block. Make sure
there is no sealant in oil port. Tighten M10 cap-
screws to 38 to 53 N•m (28 to 39 lbf ft). Tighten
M8 capscrews to 19 to 26 N•m (14 to 19 lbf ft).
6. Lubricate surfaces of oil seal with engine oil. Use

press to install oil seal in rear cover. Install align- 1. REAR COVER
ment pin in cylinder block. 2. OIL SEAL
3. CRANKSHAFT
7. Install new gasket and rear cover. See Figure 34.
Make sure dowel pin is installed. Tighten cap- Figure 34. Rear Cover
screws to 8 to 12 N•m (70 to 106 lbf in). Cut off
Pistons and Connecting Rods Repair

REMOVE AND DISASSEMBLE NOTE: Measure and record the pin depth in the pis-
ton for correct reassembly.
1. Remove cylinder head as described in Cylinder
Head, Camshaft, and Valve Mechanism Repair. 6. Push connecting rod and piston from cylinder
block.
2. Remove oil pan and oil strainer.
7. Carefully remove piston rings from pistons. Use
tool to push piston pin from connecting rod.
CAUTION
DO NOT damage top of piston when placing CLEAN
identification mark. DO NOT place a deep
identification mark in top of piston.
WARNING
3. Put identification mark on top of each piston. Cleaning solvents can be flammable and toxic
4. Clean carbon from top of each cylinder bore. cleaning solvents, always follow solvent man-
ufacturer’s recommended safety procedures.
5. Remove caps and bearings from each connecting
rod. Keep caps and bearings with correct piston Clean all parts in solvent. Make sure all oil passages
assemblies. and grooves are clean. Make sure all machined sur-
faces are smooth.
14
600 SRM 1122 Pistons and Connecting Rods Repair
INSPECT AND REPAIR a. Put plastic gauge material on crankshaft

journals and install rod caps. Tighten cap-
Pistons screws for rod caps to 51 to 56 N•m (48 to
51 lbf ft). Do not rotate connecting rod.
1. Inspect pistons for wear and cracks. Replace any
piston that is damaged. b. Remove rod caps. Plastic gauge material will
adhere to journals or rod caps.
2. Measure outside diameter of piston. See
Figure 35. Correct dimension is 85.943 to c. Use graduations on scale to measure width
85.965 mm (3.3836 to 3.3844 in.). Maximum of plastic gauge material at its widest point.
clearance between piston and cylinder bore is
0.15 mm (0.0059 in.). Correct clearance is 0.027 to 0.067 mm
(0.0011 to 0.0026 in.). If any clearance is
Piston Rings greater than specification, replace all rod
bearings.
1. Install piston ring into cylinder bore where it will
be used. Use thickness gauge to measure amount
of end clearance of each piston ring. See Fig-
ure 36. Correct dimensions are as follows:
Top Piston Ring - 0.20 to 0.35 mm (0.008 to
0.014 in.)
2nd Piston Ring - 0.15 to 0.30 mm (0.006 to
0.012 in.)
Oil Ring - 0.20 to 0.70 mm (0.008 to 0.027 in.)
Maximum clearance is 1.0 mm (0.039 in.)
2. Measure clearance between piston ring and

groove in piston. See Figure 36. Correct dimen-
sions are as follows:
Top Piston Ring - 0.03 to 0.07 mm (0.0012 to Figure 35. Piston Measurement
0.0028 in.)
2nd Piston Ring - 0.03 to 0.07 mm (0.0012 to
0.0028 in.)
Maximum clearance is 0.15 mm (0.0059 in.)
Connecting Rods and Bearings

1. Use alignment tool to check connecting rods for
straightness. Contact your local machine shop.
Maximum amount of distortion per 50 mm

(1.97 in.) is 0.18 mm (0.007 in.).
Maximum amount of bending per 50 mm

(1.97 in.) is 0.075 mm (0.003 in.).
If amount of distortion is greater than specifica-

tion, install new connecting rod.
2. Clean rod bearings and crankshaft journals. To

check bearings for wear, measure clearance be-
tween rod bearings and journals. See Figure 37.
1. PISTON RING END CLEARANCE
2. PISTON RING GROOVE CLEARANCE
Figure 36. Piston Rings Measurement
15
Pistons and Connecting Rods Repair 600 SRM 1122
3. Install piston rings on pistons. During instal-

lation, writing on each piston ring must be to-
ward top of piston. Check that rings rotate freely.
Then put ends of rings in positions shown in Fig-
ure 39. Make sure ends of upper and lower oil
control rings are each 30° from piston pin. Also
make sure that top and second rings are each 30°
from piston pin. Lubricate rings with engine oil.
4. Apply clean engine oil to piston assembly. Install

bearings for connecting rods. Install piston into
correct cylinder, making sure F is toward front
(timing belt end) of engine. See Figure 40.
5. Apply clean engine oil to bearing. Then install

1. PLASTIC GAUGE 2. SCALE
each cap to correct connecting rod. During in-
Figure 37. Connecting Rod Bearings Clearance stallation of caps, make sure to align identifi-
Check cation marks that were made during disassem-
bly. Tighten nuts for caps to 51 to 56 N•m (38 to
ASSEMBLE AND INSTALL 41 lbf ft).
1. Align oil port on large end of connecting rod with

F mark on piston. See Figure 38. Lubricate pis-
ton pin and bore in piston with engine oil.
2. Use press to install piston pin. Amount of force

required to push pin into piston must be 500 to
1500 kg (1102 to 3306 lb). If force is not correct,
replace piston pin and/or connecting rod.
Make sure piston pin is installed to correct depth,

recorded earlier. After installation, check that
piston moves freely on piston pin.
Figure 39. Piston Rings

1. F MARK 2. OIL PORT
Figure 38. Connecting Rod and Piston
16
600 SRM 1122 Cylinder Block Repair

A. OIL CONTROL RING
B. TOP AND SECOND RINGS
1. EXPANDER RING
2. OIL RING (UPPER)
3. OIL RING (LOWER)
4. TOP RING
5. SECOND RING
1. F MARK
Figure 40. Piston Installation
Cylinder Block Repair

1. After cylinder block is cleaned, check surface for
distortion. See Figure 41.
If amount of distortion is greater than 0.15 mm

(0.0059 in.), grind surface of cylinder block. Max-
imum amount of correction permitted is 0.20 mm
(0.008 in.).
2. Check cylinder bores for wear and damage. Mea-

sure each bore. Correct dimension is 86.00 to
86.019 mm (3.3858 to 3.3866 in.). Wear limit
above this dimension is 0.15 mm (0.0059 in.).
Repair cylinder block or use bigger pistons as

necessary.
Refer to Parts Manual for available sizes.
Figure 41. Cylinder Block Inspection
17
Oil Pump Repair 600 SRM 1122
Oil Pump Repair

Before removing oil pump, replace sending unit with 7. Loosen capscrews for timing belt tensioner and
pressure gauge and check oil pressure. Minimum oil remove spring. Remove capscrews and timing
pressure at governed rpm is approximately 275 kPa belt tensioner.
(40 psi). If pressure is less than specification, oil
pump or engine bearings need repair. 8. Use chalk to mark direction of rotation of timing
belt. See Figure 43. Remove timing belt.
REMOVE
4. Remove six capscrews that hold crankshaft shaft

pulley to timing pulley.

Figure 42.
6. Align engine timing marks.
9. Remove capscrew from crankshaft timing pulley.

Install special tool with spacer on crankshaft to
remove timing pulley. Rotate tool until it touches
front of crankshaft. Hit tool with hammer to
loosen timing pulley. Remove pulley, dowel pin,
tapered ring, and spacer. Remove tool. See Fig-
ure 44.
1. SPACER 2. TOOL
2. UPPER TIMING BELT COVER Figure 44. Crankshaft Timing Pulley Removal
18
600 SRM 1122 Oil Pump Repair
10. Remove capscrews that hold oil pan to cylinder CLEAN

block. Remove oil pan.
11. Remove the capscrew retaining the oil strainer

WARNING
assembly and remove the oil strainer assembly. Cleaning solvents can be flammable and toxic
12. Remove capscrews that hold front cover (pump cleaning solvents, always follow the solvent
housing) to cylinder block. Remove front cover manufacturer’s recommended safety proce-
and oil pump assembly. dures.
DISASSEMBLE CAUTION
1. Remove screws and pump cover. See Figure 45. DO NOT damage machined surface when
cleaning.
Clean all parts in solvent. Make sure all machined

surfaces are smooth.
INSPECT
1. Check front cover (pump housing) and pump
cover for wear or damage. Check plunger spring
for damage.
2. Measure parts of oil pump. See Figure 46.
a. Measure clearance between inner rotor tip

and outer rotor. Maximum clearance is
0.18 mm (0.007 in.). If clearance is more
than 0.18 mm (0.007 in.), repair as neces-
sary.
1. SCREW
2. COVER b. Measure clearance between housing and
3. OUTER GEAR outer rotor. Correct clearance is 0.090 to
4. INNER GEAR 0.176 mm (0.0035 to 0.0069 in.). If clearance
5. FRONT COVER (HOUSING) is more than 0.20 mm (0.008 in.), repair as
6. OIL SEAL
7. PLUNGER necessary.
8. SNAP RING
c. Use straight edge to measure side clear-
Figure 45. Oil Pump ance of rotors. Correct clearance is 0.03 to
0.09 mm (0.0012 to 0.0035 in.). If clearance
2. Remove outer gear and inner gear from pump is more than 0.10 mm (0.004 in.), repair as
body. necessary.
3. Remove snap ring and plunger assembly from

housing.
19
Oil Pump Repair 600 SRM 1122
1. CLEARANCE BETWEEN INNER ROTOR TOOTH TIP AND OUTER ROTOR

2. CLEARANCE BETWEEN HOUSING AND OUTER ROTOR
3. SIDE CLEARANCE OF ROTORS IN HOUSING
Figure 46. Oil Pump Measurement
ASSEMBLE 3. Install new gasket for strainer and install

strainer assembly. Tighten capscrews to 8 to
1. Install oil seal in oil pump housing. Make sure 12 N•m (70 to 106 lbf in). See Figure 48.
front edge of oil seal is even with outer edge of
housing. See Figure 45. 4. Apply adhesive sealant to a new oil pan gasket
and install new gasket and oil pan. Tighten cap-
2. Lubricate gears with clean engine oil. Install screws to 8 to 12 N•m (70 to 106 lbf in). See Fig-
gears in housing. ure 48.
3. Install pump cover. Apply thread-locking com-
pound on screws for pump cover. Then install
screws.
4. Install plunger assembly and snap ring.
INSTALL
1. Install O-ring on oil pump housing. Use grease
to hold O-ring in position. Lubricate oil seal with
engine oil. See Figure 47.
2. Use adhesive sealant to install oil pump hous-

ing on cylinder block. Make sure there is no
sealant in oil port. Tighten M10 capscrews to 38
to 53 N•m (28 to 39 lbf ft). Tighten M8 capscrews 1. O-RING
to 19 to 26 N•m (14 to 19 lbf ft).
Figure 47. Oil Pump
20
600 SRM 1122 Oil Pump Repair
2. OIL STRAINER 6. CAPSCREW
4. OIL PAN 8. OIL PUMP
Figure 48. Oil Strainer and Oil Pan
21

THERMOSTAT FAN ASSEMBLY
Replace Remove and Disassemble
1. Drain cooling system to level of thermostat. 1. Loosen alternator and remove fan belt.
2. Disconnect hose and remove thermostat housing. 2. Remove capscrews for fan. Remove fan and pul-
Remove thermostat. See Figure 49. ley from hub.
3. Remove capscrews that hold fan bracket to en-

gine. Remove fan bracket.
4. Use press to remove fan hub from shaft. Remove

snap ring, push bearing, and shaft from bracket.
See Figure 50.
1. CYLINDER BLOCK 3. THERMOSTAT

2. GASKET 4. HOUSING
Figure 49. Thermostat
3. Test operation of thermostat. See the section

Thermostat must begin to open at 82 ±1.5°C (180

±3°F). Thermostat must be completely open at
1. FAN 4. SNAP RING
95°C (203°F). 2. PULLEY 5. SHAFT
3. HUB 6. BRACKET
4. Install thermostat and new gasket. Make sure
print side of gasket is toward thermostat. Figure 50. Fan Assembly
5. Install thermostat housing and tighten cap- Assemble and Install
screws to 19 to 26 N•m (14 to 19 lbf ft).
1. Use press to install shaft and bearing in bracket.
CAUTION See Figure 50. Push bearing in until it touches
bracket. Install snap ring. Install hub on shaft.
fore using additives, contact your local Hyster 2. Install bracket assembly on cylinder block.
dealer. Tighten M10 and M12 capscrews to 38 to 64 N•m
(28 to 47 lbf ft).
6. Connect hose and fill cooling system. Start en-
gine and check for leaks. 3. Install pulley and fan on hub. Tighten capscrews
22
4. Install fan belt. Adjust tension of the fan belt.

Check movement of fan belt between fan and al-
ternator.
NOTE: Tension for belt is correct when it moves 17 to

19 mm (0.67 to 0.75 in.) with 10 kg (22 lb) of force.
Tighten alternator when tension is correct.
WATER PUMP
Remove
1. Drain cooling system.
2. Loosen alternator and remove fan belt.
3. Remove capscrews for the fan. Remove fan and

pulley from the hub.
4. Remove capscrews that hold fan bracket to en-

gine. Remove fan bracket.
5. Remove six capscrews that hold crankshaft shaft

pulley to timing pulley.

Figure 51.
7. Align engine timing marks.
8. Loosen capscrews for timing belt tensioner and 1. LOWER TIMING BELT COVER
remove spring. Remove capscrews and timing 2. UPPER TIMING BELT COVER
belt tensioner.
CAUTION
DO NOT rotate the camshaft gear or the crank-
shaft gear while the timing belt is removed. If
either of the gears is moved, it will be neces-
sary to align the timing marks.
9. Use chalk to mark direction of rotation of timing

belt. See Figure 52. Then remove timing belt.
10. Disconnect hose at water pump. Remove cap-

screws for water pump. Then remove water
pump from cylinder block.
23
Flywheel and Ring Gear Repair 600 SRM 1122
Install 7. Start engine and check cooling system for leaks.
1. Install water pump with a new gasket. Tighten

capscrews to 19 to 26 N•m (14 to 19 lbf ft). WARNING
2. Clean any oil or grease from pulleys. Install tim- diator when the engine is hot. When the radi-
ing belt so that it goes in same direction as mark ator cap is removed, the pressure is released
made during removal. from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT
3. Loosen lock bolt and apply spring tension on belt. remove the cover for the radiator when the en-
Rotate crankshaft pulley clockwise two complete gine is running.
turns and check timing marks.
8. After engine has been operated, stop engine. If
If timing marks are correct, tighten lock bolt for coolant is hot, give engine time to cool. Check
tensioner to 38 to 53 N•m (28 to 39 lbf ft). Check coolant level and add coolant if necessary.
movement on tension side of timing belt. See
Figure 53.
For both 2.0L and 2.2L engines, if tension is cor-

rect, belt will move 9 to 10 mm (0.36 to 0.39 in.)
with 10 kg (22 lb) of force.
4. Install lower timing belt cover and gasket.

Tighten capscrews to 7 to 10 N•m (62 to
89 lbf in). Install upper timing belt cover and
gasket. Tighten capscrews to 7 to 10 N•m (62 to
89 lbf in). See Figure 51.
5. Install fan assembly as described in the proce-

dure for Fan Assembly, Assemble and Install.
CAUTION 1. TENSIONER 3. LOCK BOLT

Additives may damage the cooling system. Be- 2. SPRING 4. TENSION SIDE
dealer. Figure 53. Timing Belt Installation
6. Install coolant hoses. Fill cooling system with

coolant.
Flywheel and Ring Gear Repair

REMOVE (84 to 100 lbf ft). Tighten M10 capscrews to
38 N•m (28 lbf ft).
1. Remove capscrews for flywheel. Then remove fly-
wheel and adapter plate. See Figure 54. 2. Install adapter plate on crankshaft. Install the
flywheel.
2. If necessary, remove flywheel housing.
3. Apply Loctite® 222 or equivalent on threads of
INSTALL capscrews. Then install capscrews for flywheel.
Tighten capscrews to 96 to 103 N•m (71 to
1. If flywheel housing was removed, install it on en- 76 lbf ft) in proper sequence. See Figure 54.
gine. Tighten M14 capscrews to 114 to 136 N•m
24
600 SRM 1122 Valve Adjustment

A. TIGHTENING SEQUENCE
1. FLYWHEEL HOUSING
2. WASHER
3. CAPSCREW
4. ADAPTER PLATE
5. CAPSCREW
6. WASHER
7. FLYWHEEL
8. PIN
9. CAPSCREW
10. CAPSCREW
Figure 54. Flywheel Arrangement
Valve Adjustment
1. Rotate crankshaft until No. 1 piston is at TDC on
compression stroke (intake and exhaust valves
closed).
2. Adjust clearance of intake valves for No. 1 and

No. 2 cylinders and exhaust valves for the No. 1
and No. 3 cylinders. See Figure 55. Correct clear-
ance for intake valves when engine is cold is 0.15
±0.05 mm (0.0059 ±0.002 in.). Correct clearance
for exhaust valves when engine is cold is 0.35
±0.05 mm (0.0138 ±0.002 in.).
To adjust clearance, loosen lock nut and turn ad-

justment screw. Tighten lock nut to 16 to 21 N•m
(12 to 15 lbf ft).
NOTE: During adjustment of valves, check position

of balls in ends of rocker arms. Flat surface of ball
must be in contact with stem of valve.
3. Rotate crankshaft clockwise one complete turn.

Adjust remaining valves.

A. INTAKE VALVES
B. EXHAUST VALVES
C. INTAKE (ENGINE COLD): 0.15 mm (0.0059 in.),
EXHAUST (ENGINE COLD): 0.35 mm (0.0138 in.)
1. CAMSHAFT
2. ROCKER ARM
3. BALL
4. VALVE STEM Figure 55. Valve Adjustment
25
Engine Timing Adjustment 600 SRM 1122
Compression Pressure Check

• If pressure reading does not increase, low
CAUTION pressure was caused by worn valves, valve
When removing or installing the spark plugs seats, or valve guides.
from the aluminum cylinder head, it is impor- • If low pressure readings are in two cylin-
tant that you use care because of the dissimi- ders next to each other, cylinder head may
lar metals. Penetrating oil may need to be used be leaking.
when removing the spark plugs. Apply a cou-
ple of drops of engine oil to the spark plugs be- Table 1. Pressure Specifications
fore installation.
Pressure Gasoline LPG
1. Remove spark plugs from cylinder head. Discon-
nect high tension wire at ignition coil. Standard 1130 kPa 1130 kPa
Pressure (164 psi) @ (164 psi) @
2. Install compression gauge in No. 1 cylin- 270 rpm 270 rpm
der. Make sure gauge has minimum range Minimum 793 kPa 793 kPa
of 1725 kPa (250 psi). See Figure 56. Pressure (115 psi) @ (115 psi) @
3. Use starter to crank engine at least six revolu- 270 rpm 270 rpm
tions. Check pressure reading and release pres- Maximum
sure. Repeat test again and make note of highest Difference
196 kPa (28 psi)
pressure. Do this test for each cylinder. Between
Cylinders
The standard and minimum pressure specifica-
tions are shown in Table 1.
4. If the readings are lower than minimum reading,

there is a problem with the valves, piston rings,
or cylinder head gasket. Do the following tests to
find the problem:
a. Add approximately 30 ml (1.0 oz) of engine

oil to each cylinder at spark plug hole.
b. Crank engine approximately 10 revolutions

to distribute oil.
c. Install compression gauge and do same tests

as described in Step 3.
• If pressure reading increases to normal 1. ADAPTER
reading, low pressure was caused by worn
or damaged piston rings. Cylinder bore Figure 56. Compression Pressure Check
may also be damaged.
Engine Timing Adjustment

For Mazda 2.0L and 2.2L 2007 emission compliant The correct timing is as follows:
engines and for lift trucks built after January, 2010, • Gasoline Engine = 6° ±1° BTDC @ 800 ±25 rpm
see Ignition System in the section Electrical Sys- (orange mark)
tem, Mazda 2.0L and 2.2L Emission Compliant • LPG Engine = 6° ±1° BTDC @ 800 ±25 rpm (or-
Engines 2200 SRM 1327 for the adjustment proce- ange mark)
dure for engine timing.
26
For all other Mazda 2.0L and 2.2L engines, see The correct timing is as follows:
Ignition System in the section Electrical System, • Gasoline Engine = 6° ±1° BTDC @ 800 ±25 rpm
Mazda 2.0L and 2.2L 2200 SRM 1143 for the ad- (orange mark)
justment procedure for engine timing. • LPG Engine = 6° ±1° BTDC @ 800 ±25 rpm (or-
ange mark)
ENGINE DATA ENGINE SPEEDS
Engine Type ....................... In-line, Four Cylinders 2007, and Later, Emission Compliant
Bore × Stroke (2.0L)........... 86 mm (3.39 in.) × Engines
86 mm (3.39 in.)
Engine Speed, 1.5 to 2 Ton Lift Trucks, 2.0L and
Bore × Stroke (2.2L)........... 86 mm (3.39 in.) × 2.2L:
94 mm (3.70 in.)
– Idle Speed.................... 800 ±25 rpm
Displacement (2.0L) ........... 1998 cm 3 (121.9 in. 3 )
– Governed Speed .......... 2400 ±25 rpm
Displacement (2.2L) ........... 2184 cm 3 (133.2 in. 3 )
Engine Speed, 2.0 to 3.5 Ton Lift Trucks, 2.0L and
Firing Order ....................... 1 - 3 - 4 - 2 2.2L:
Valve Clearance (Exhaust, 0.35 ±0.05 mm (0.0138 – Idle Speed.................... 800 ±25 rpm
Engine Cold) ....................... ±0.002 in.)
– Governed Speed .......... 2700 ±25 rpm
Valve Clearance (Intake, 0.15 ±0.05 mm (0.0059
Engine Cold) ....................... ±0.002 in.) Stall Speed (New 2.0L Engine):
Compression Ratio – Gasoline....................... 1875 ±100 rpm

– Gasoline....................... 8.6:1 – LPG.............................. 1820 ±100 rpm
Compression Ratio Stall Speed (2.0L Engine With 30 Hours or More):
– LPG (2.0L)................... 9.3:1
– Gasoline....................... 1900 ±100 rpm
Compression Ratio
– LPG (2.2L)................... 10.1:1 – LPG.............................. 1865 ±100 rpm
Compression Pressure Stall Speed (New 2.2L Engine):

– Gasoline....................... 1130 kPa (164 psi) @ – Gasoline....................... 1990 ±100 rpm
270 rpm
– LPG.............................. 2010 ±100 rpm
Compression Pressure
– LPG.............................. 1130 kPa (164 psi) @ Stall Speed (2.2L Engine With 30 Hours or More):
270 rpm – Gasoline....................... 2010 ±100 rpm
Maximum Difference – LPG.............................. 2050 ±100 rpm
Between Cylinders ............. 196 kPa (28 psi)
Engine Timing (No. 1 Cylinder): All Engines Except 2007, and Later,
– Gasoline....................... 6° BTDC Emission Compliant Engines
(Orange Mark)
Engine Speed, 1.5 to 2 Ton Lift Trucks, 2.0L and
– LPG.............................. 6° BTDC 2.2L:
(Orange Mark)
– Idle Speed.................... 800 ±25 rpm
Oil Pressure @ 2400 rpm ... 226 to 362 kPa
(33 to 53 psi) – Governed Speed .......... 2400 ±25 rpm
27
Engine Speed, 2.0 to 3.5 Ton Lift Trucks, 2.0L and Valve Length (Intake) ........ 111.49 to 112.29 mm
2.2L: (4.390 to 4.420 in.)
– Idle Speed.................... 800 ±25 rpm – Service Limit............... 111.19 mm (4.378 in.)
– Governed Speed .......... 2700 ±25 rpm Valve Length (Exhaust) ..... 111.29 to 112.09 mm
(4.382 to 4.412 in.)
Stall Speed (New 2.0L Engine):
– Service Limit............... 110.99 mm (4.370 in.)
– Gasoline....................... 2000 ±100 rpm
Diameter of Valve Stem
– LPG.............................. 1875 ±100 rpm
(Intake) ............................... 8.03 to 8.045 mm
Stall Speed (2.0L Engine With 30 Hours or More): (0.3161 to 0.3167 in.)
– Gasoline....................... 2106 ±100 rpm – Service Limit............... 7.980 mm (0.3142 in.)
– LPG.............................. 1974 ±100 rpm Diameter of Valve Stem
(Exhaust) ............................ 8.025 to 8.045 mm
Stall Speed (New 2.2L Engine): (0.3159 to 0.3167 in.)
– Gasoline....................... 2073 ±100 rpm – Service Limit............... 7.975 mm (0.3140 in.)
– LPG.............................. 1995 ±100 rpm Valve Head Thickness
Stall Speed (2.2L Engine With 30 Hours or More): (Intake) ............................... 0.5 mm (0.020 in.)
– Gasoline....................... 2183 ±100 rpm Valve Head Thickness
(Exhaust) ............................ 1.0 mm (0.040 in.)
– LPG.............................. 2100 ±100 rpm
Valve Face Angle
(Intake and Exhaust) ......... 30°
THERMOSTAT
Spring Free Length
Starts to Open .................... 82 ±1.5°C (180 ±35°F) - Outer ................................ 52.2 mm (2.055 in.)
Fully Open.......................... 95 ±1.5°C (203 ±35°F) – Service Limit .............. 50.6 mm (1.992 in.)
Spring Free Length
CYLINDER HEAD - Inner ................................ 47.7 mm (1.878 in.)
Height ................................. 91.95 to 92.05 mm – Service Limit .............. 46.3 mm (1.823 in.)
(3.620 to 3.624 in.)
Spring Out of Square
Distortion Limit ................. 0.15 mm (0.006 in.) - Outer ................................ More than 1.82 mm
(0.072 in.)
Grinding Limit ................... 0.20 mm (0.008 in.)
Spring Out of Square
VALVE MECHANISM - Inner ................................ More than 1.66 mm
(0.065 in.)
Inside Diameter of Valve Rocker Arm Shaft
Guide................................... 8.07 to 8.09 mm Diameter............................. 15.966 to 15.984 mm
(0.3177 to 0.3185 in.) (0.6286 to 0.6293 in.)
Clearance in Guide Rocker Arm Bore
(Exhaust) ............................ 0.030 to 0.065 mm Diameter............................. 16.000 to 16.027 mm
(0.0012 to 0.0026 in.) (0.6299 to 0.6311 in.)
Clearance in Guide Clearance Between
(Intake) ............................... 0.025 to 0.060 mm Rocker Arm and
(0.001 to 0.0024 in.) Shaft ................................... 0.016 to 0.061 mm
– Service Limit (0.0006 to 0.0024 in.)
(Intake and Exhaust)..... 0.10 mm (0.004 in.) – Service Limit .............. 0.10 mm (0.004 in.)
28
CAMSHAFT 0.50 mm (0.02 in.)

Undersize (Nos. 1, 2,
Runout ................................ Less than 0.03 mm
4, and 5) .............................. 59.429 to 59.486 mm
(0.0012 in.) (2.3398 to 2.3419 in.)
Cam Lobes to 0.50 mm (0.02 in.)
Production Limit ................ 37.370 mm (1.4713 in.) Undersize (No. 3) ............... 59.423 to 59.480 mm
Cam Lobes to Service (2.3395 to 2.3417 in.)
Limit ................................... 37.170 mm (1.4634 in.) 0.75 mm (0.03 in.)
Bearing Journals Undersize (Nos. 1, 2,
(Nos. 1 and 5) ..................... 31.940 to 31.965 mm 4, and 5) .............................. 59.179 to 59.236 mm
(1.2575 to 1.2585 in.) (2.3299 to 2.3321 in.)
Bearing Journals 0.75 mm (0.03 in.)
(Nos. 2, 3, and 4) ................ 31.910 to 31.935 mm Undersize (No. 3) ............... 59.173 to 59.230 mm
(1.2563 to 1.2573 in.) (2.3297 to 2.3318 in.)
Bearing Journal Wear – Grinding Limit ............ 0.75 mm (0.030 in.)
Limit ................................... 0.03 mm (0.0012 in.) Clearance Between
Clearance Between Journals and Main
Journals and Bore Bearings
(Nos. 1 and 5) ..................... 0.035 to 0.085 mm (Nos. 1, 2, 4, and 5) ............
(0.0014 to 0.0033 in.) 0.025 to 0.043 mm
(0.000099 to 0.00169 in.)
Clearance Between
Journals and Bore Clearance Between
(Nos. 2, 3, and 4) ................ 0.065 to 0.115 mm Journals and Main
(0.0026 to 0.0045 in.) Bearings
(No. 3) .................................
– Service Limit .............. 0.15 mm (0.006 in.) 0.031 to 0.049 mm
End Clearance .................... 0.08 to 0.16 mm (0.0012 to 0.0019 in.)
(0.003 to 0.006 in.) – Service Limit............... 0.08 mm (0.003 in.)
– Service Limit............... 0.20 mm (0.008 in.) Connecting Rod Journal
Diameter, Standard............ 50.940 to 50.955 mm
CRANKSHAFT (2.0055 to 2.0061 in.)
Runout ................................ less than 0.03 mm 0.25 mm (0.01 in.)

(0.0012 in.) Undersize............................ 50.690 to 50.705 mm
(1.9957 to 1.9962 in.)
Main Bearing Journal
Diameter, Standard............ 59.937 to 59.955 mm 0.50 mm (0.02 in.)
(2.3597 to 2.3604 in.) Undersize............................ 50.440 to 50.455 mm
(1.9859 to 1.9864 in.)
0.75 mm (0.03 in.)
0.25 mm (0.01 in.) Undersize............................ 50.190 to 50.205 mm
Undersize (Nos. 1, 2, (1.9760 to 1.9765 in.)
4, and 5) .............................. 59.679 to 59.736 mm
(2.3496 to 2.3518 in.) – Service Limit............... 0.05 mm (0.002 in.)
0.25 mm (0.01 in.) – Grinding Limit ............ 0.75 mm (0.030 in.)

Undersize (No. 3) ............... 59.673 to 59.730 mm Thrust Bearing Thickness,
(2.3494 to 2.3515 in.) Standard ............................. 27.94 to 27.99 mm
(1.1000 to 1.1019 in.)
29
0.25 mm (0.01 in.) 0.50 mm (0.02 in.)

Undersize............................ 28.04 to 28.09 mm Oversize .............................. 86.443 to 86.465 mm
(1.1040 to 1.1060 in.) (3.4033 to 3.4041 in.)
0.50 mm (0.02 in.) Clearance Between
Undersize............................ 28.12 to 28.17 mm Piston and Bore .................. 0.035 to 0.076 mm
(1.1071 to 1.1090 in.) (0.0014 to 0.0030 in.)
0.75 mm (0.03 in.) – Service Limit............... 0.15 mm (0.0059 in.)
Undersize............................ 28.20 to 28.25 mm
Piston Pin Diameter .......... 21.988 to 21.998 mm
(1.1103 to 1.1122 in.)
(0.8657 to 0.8660 in.)
Thrust Bearing
Groove Width for Piston
Clearance............................ 0.08 to 0.18 mm
Rings Nos. 1 and 2 ............. 1.520 to 1.540 mm
(0.003 to 0.007 in.)
(0.0598 to 0.0606 in.)
Groove Width for
Oil Ring............................... 4.020 to 4.040 mm
CONNECTING RODS (0.1583 to 0.1591 in.)
Distortion Limit ................. 0.18 mm (0.007 in.) per Piston Ring Clearance in
50 mm (1.97 in.) Groove (Nos. 1 and 2) ........ 0.03 to 0.07 mm
(0.0012 to 0.0028 in.)
Bending Limit .................... 0.075 mm (0.003 in.) per
50 mm (1.97 in.) – Service Limit............... 0.15 mm (0.0059 in.)
Small End Bore .................. 21.943 to 21.961 mm Piston Ring End Clearance:
(0.8639 to 0.8646 in.) – Top Ring ...................... 0.20 to 0.35 mm
Interference Between (0.008 to 0.014 in.)
Piston Pin and – Second Ring................. 0.15 to 0.30 mm
Bore..................................... 0.037 to 0.013 mm (0.006 to 0.012 in.)
(0.0014 to 0.0006 in.)
– Oil Control Ring.......... 0.20 to 0.70 mm
Clearance Between (0.008 to 0.027 in.)
Crankshaft Journals
and Rod Bearings ............... 0.027 to 0.067 mm – Service Limit
(0.0011 to 0.0026 in.) (All Rings) ...................... 1.0 mm (0.039 in.)

OIL PUMP
CYLINDER BLOCK Clearance Between Inner Rotor Tip and Outer Rotor
Distortion at Top Surface .. 0.15 mm (0.0059 in.) – Service Limit............... 0.18 mm (0.007 in.)
Grinding Limit ................... 0.20 mm (0.008 in.) Clearance Between

Housing and Outer Rotor .. 0.090 to 0.176 mm
Bore Diameter .................... 86.00 to 86.019 mm (0.0036 to 0.0069 in.)
(3.3858 to 3.3866 in.)
– Wear Limit .................. 0.15 mm (0.0059 in.)
Side Clearance Between
Rotors and Housing ........... 0.03 to 0.09 mm
PISTONS (0.0012 to 0.0035 in.)
Diameter, Standard............ 85.945 to 85.965 mm – Service Limit............... 0.10 mm (0.004 in.)
(3.3836 to 3.3844 in.)
0.25 mm (0.01 in.)
Oversize .............................. 86.193 to 86.215 mm
(3.394 to 3.3943 in.)
30
Camshaft Pulley Lock Bolt Oil Pan
48 to 66 N•m (35 to 49 lbf ft) 8 to 12 N•m (71 to 106 lbf in)
Camshaft Cap Oil Pressure Switch

18 to 27 N•m (13 to 20 lbf ft) 12 to 17 N•m (9 to 13 lbf ft)
Cooling Fan Oil Pan Drain Plug

27 N•m (20 lbf ft) 30 to 41 N•m (22 to 30 lbf ft)
Connecting Rod Cap Oil Pump

66 to 70 N•m (49 to 52 lbf ft) M8 Capscrews 19 to 26 N•m (14 to 19 lbf ft)
M10 Capscrews 38 to 53 N•m (28 to 39 lbf ft)
Crankshaft Pulley
12 to 17 N•m (9 to 13 lbf ft) Oil Strainer
8 to 12 N•m (71 to 106 lbf in)
Cylinder Head
81 to 88 N•m (60 to 65 lbf ft) Rocker Cover
6 to 8 N•m (52 to 70 lbf in)
Engine Mount to Engine
55 N•m (41 lbf ft) Rear Cover
8 to 12 N•m (70 to 106 lbf in)
Engine Mount Capscrew
150 N•m (111 lbf ft) Rocker Shaft Assembly
18 to 27 N•m (13 to 20 lbf ft)
Exhaust Manifold
22 to 29 N•m (16 to 21 lbf ft) Spark Plugs
15 to 23 N•m (11 to 16 lbf ft)
Flywheel
96 to 103 N•m (71 to 76 lbf ft) Starter
38 N•m (28 lbf ft)
Flywheel Housing
M10 Capscrews 38 N•m (28 lbf ft) Thermostat Housing Capscrews
M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft) 19 to 26 N•m (14 to 19 lbf ft)
Front Housing Timing Belt Cover Capscrews

Heat Gauge Unit Timing Belt Tension Lock Bolt

11.8 to 17.6 N•m (105 to 156 lbf in) 38 to 53 N•m (28 to 39 lbf ft)
Intake Manifold Timing Pulley Lock Bolt

Main Bearing Cap Water Pump

31
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
32
600 SRM 1122 3/12 (7/11)(5/10)(12/09)(8/09)(12/06)(8/05)(5/05)(12/04) Printed in U.S.A.

COOLING SYSTEM
PART NO. 1580505 700 SRM 1123

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Radiator Hoses............................................................................................................................................... 1
Water Pump ................................................................................................................................................... 1
Oil Cooler ....................................................................................................................................................... 33
Fan Removal .................................................................................................................................................. 47
Inspect ............................................................................................................................................................ 61
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S50CT [A267];
H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274];
S120FTS; S120FTPRS) [G004, H004];
110, 120FT) [N005, P005, R005];

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General

WARNING WARNING
WARNING WATER PUMP

WARNING
the cooling system.

1

(F001); S2.0-3.5FT (S40-70FT, S55FTS)

the cooling system.
2
CAUTION CAUTION
dealer.
radiator.
flow.
H40FTS) (F001)
(H40-70FT) (L177); H2.0-2.5CT (H50CT)
(A274); S4.0, 4.5, 5.5FT, S5.5FTS,
• S4.0, 4.5, 5.5FT; S5.5FTS (S80, 100, 120FT;
S120FTS; S120FTPRS) (G004, H004) (G004, H004)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
(N005, P005, R005)
the cooling system.
1. Turn OFF truck.
3

5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
5.5FT (H80, 90, 100, 110, 120FT) (P005)
• S6.6FT, S7.0FT (S135FT, S155FT) (E024)
CAUTION
• H2.0-2.5CT (H50CT) (A274)
fan removal.
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
4
H40FTS) (F001)
• S50CT (A267) • H2.0-2.5CT (H50CT) (A274)
• H2.0-2.5CT (H50CT) (A274)
(G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
5
6
Legend for Figure 1

SHOWN
6. SHROUD 19. TUBE
8. WASHER 21. HOSE
10. CLIP 23. CAP
7
8
Legend for Figure 2

4. SCREW 18. CAP
6. CLIP 20. HOSE
9. CLAMP 23. NUT
14. RESERVOIR
9
10
Legend for Figure 3

4. SCREW 17. CAP
6. CLIP 19. HOSE
9. CLAMP 22. SCREEN
13. ISOLATOR
11
90, 100, 110, 120FT) (N005, P005) Before 2011
12
Legend for Figure 4

8. RADIATOR 21. CAP
9. CLIP 22. BUSHING
13
90, 100, 110, 120FT) (N005, P005) After 2011
14
Legend for Figure 5

9. CLIP 21. TUBE
15

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)
16

7. CAP 19. WASHER
11. INSERT 23. TUBE
12. RADIATOR CAP
17

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
18
radiator cap.
H40FTS) (F001); S50CT (A267) AND
CAUTION
WITH OIL COOLER
WARNING
the cooling system.
1. Turn OFF truck.
• S30FT, S35FT, S40FTS (E010)
• H2.0-2.5CT (H50CT) (A274)
the terminals.
See Figure 9.
WARNING
19

2. CAP 12. INSERT
5. CLAMP 15. TUBE
7. O-RING 17. HOSE
20

WARNING
See Figure 11.

21

1. DEBRIS COVER
3. RADIATOR COVER
4. UPPER BRACKET
5. CAPSCREWS
6. REMOTE FILL HOSE
7. HOSE CLAMPS
8. OIL COOLER
10. FITTINGS
11. UPPER HOSE
12. LOWER HOSE
13. REMOTE FILL
14. RADIATOR CAP

E024, F024)
22

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
S155FT) (E024)
23
H175FT36, H190FT) (B299)
H9.0FT (H170FT, H175FT36, H190FT)
WARNING
the cooling system.
WARNING
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
24

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

CAUTION


• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
H175FT36, H190FT) (A299, B299)
(A299, B299).
H175FT36, H190FT) (B299)
H175FT36, H190FT) (A299, B299)
25
oil cooler ports.
26

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
27

6. BUSHING 15. SEAL
H175FT36, H190FT) (A299, B299)

8. TUBE 19. HOSE
28
H175FT36, H190FT) (B299)
29
radiator. ure 6.
(H40-70FT) (L177); H2.0-2.5CT (H50CT)
(S80, 100, 120FT; S80, 100FTBCS;

CAUTION
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-2.5CT (H50CT) (A274)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
the reservoir.
30

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

2. ADD MARK

2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT
(A267); H2.0-3.5FT (H40-70FT) (L177) and

2. ADD MARK

2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT
(A267); H2.0-3.5FT (H40-70FT) (L177) and
31

2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK

models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
(G004, H004)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
(H80, 90, 100, 110, 120FT) (N005, P005)
models
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
WARNING
WARNING


(H80, 90, 100, 110, 120FT) (R005)
32
radiator.




verter.

the reservoir.


dealer.

CAUTION
33

WARNING

CAUTION
dealer.


(D024, E024, F024)
2. ADD MARK
ure 10.
models
H40FTS) (F001)
models
• S50CT (A267)
34

screws. WARNING
CAUTION
serious injury.
lift the weight.

voir.
lift truck.
WARNING
CAUTION
dealer.

Figure 22.
2. FULL "HOT" MARK
4. ADD "COLD" MARK
F024)
35
F024)
36

3. WASHER 16. CAP
H175FT36, H190FT) (B299)
H9.0FT (H170FT, H175FT36, H190FT)
J006, K006)
gine
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
screws.
J006, K006)
gine H175FT36, H190FT) (B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
37
clamp.
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (B299)
J006)
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (B299)
clamp. gine
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
gine
38

WARNING
WARNING
3. FULL "COLD" MARK
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
dealer.
39
H155FT) (H006, J006, K006) (Sheet 1 of 3)
40
H155FT) (H006, J006, K006) (Sheet 2 of 3)
41
H155FT) (H006, J006, K006) (Sheet 3 of 3)
42

9. ISOLATOR 24. CAP
16. WASHER
43

13. CAP 29. SPACER
16. TUBE
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
44

2. CLAMP 14. BAFFLE
9. CAPSCREW 21. FAN
10. NUT 22. SPACER
12. UPPER BRACKET
(H170FT, H175FT36, H190FT) (A299, B299)
45
H9.0FT (H170FT, H175FT36, H190FT) (B299)
46

13. CAP 28. FAN

models
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
ing wheel forward.
K006)
H190FT) (A299, B299)
hood cover up.
47

F024)
K006)
5.5FT (H80, 90, 100, 110, 120FT) (P005)
gines
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, H175FT36, H190FT) (B299)
R005)
48
1. FAN 5. SCREW
4. CAPSCREW
49
1. SPACER 5. SHROUD
2. FAN 6. SCREW
4. CAPSCREW
50

51
1. FAN 5. SCREW
4. CAPSCREW
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
52
1. SPACER 6. SCREW
5. RADIATOR SHROUD
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
53

1. FAN 5. SCREW
4. CAPSCREW
S6.0FT, S7.0FT, (S135FT,S155FT) (D024, F024)
54

1. FAN 5. SCREW
4. CAPSCREW
55
1. SPACER 5. WASHER
2. FAN 6. CAPSCREW
3. SCREW 7. SHROUD
56

2. SCREW 6. FAN
4. SPACER
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
57

2. SCREW 6. FAN
4. SPACER
(H170FT, H175FT36, H190FT) (A299, B299)
58
1. FAN 5. SCREW
4. CAPSCREW
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
59

2. SCREW 6. FAN
4. SPACER
(H170FT, H175FT36, H190FT) (B299)
(G004, H004)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
5.5FT (H80, 90, 100, 110, 120FT) (N005)
ota 3.8L engines
60
J006, K006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• H2.0-3.5FT (H40-70FT) (L177)
14. Remove the fan.
gines
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
WARNING
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,

• H2.0-2.5CT (H50CT) (A274)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001)
61
• H2.0-2.5CT (H50CT) (A274) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
(G004, H004)
H40FTS) (F001)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• S30FT, S35FT, S40FTS (E010)
ota 3.8L engines
J006, K006) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S50CT (A267)
5.5FT (H80, 90, 100, 110, 120FT) (R005)
(G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
Kubota engines
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
62
• H2.0-2.5CT (H50CT) (A274)
• S50CT (A267)
H40FTS) (F001)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
models
• S30FT, S35FT, S40FTS (E010)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H40FTS) (F001)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
R005)
• H2.0-3.5FT (H40-70FT) (L177)
5.5FT (H80, 90, 100, 110, 120FT) (N005) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
Kubota engines
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
H190FT) (A299, B299)
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (E024)
63
position.
64

LPG FUEL SYSTEM
MAZDA 2.0L AND 2.2L ENGINES
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580507 900 SRM 1125

SAFETY PRECAUTIONS
• 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.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Hoses Replacement ............................................................................................................................................ 1
LPG Tank Replacement..................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Install ............................................................................................................................................................. 1
Fuel Filter........................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 5
Relief Valve Replacement .................................................................................................................................. 6
Carburetor Repair.............................................................................................................................................. 6
Remove ........................................................................................................................................................... 6
Disassemble ................................................................................................................................................... 6
Clean .............................................................................................................................................................. 8
Assemble ........................................................................................................................................................ 8
Install ............................................................................................................................................................. 8
Fuel Injector Repair ........................................................................................................................................... 9
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................. 9
Governor Repair................................................................................................................................................. 9
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................. 9
Regulator Repair................................................................................................................................................ 10
Remove ........................................................................................................................................................... 10
Install ............................................................................................................................................................. 11
Control System................................................................................................................................................... 11
Engine Control Unit (ECU)........................................................................................................................... 11
Remove....................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Voltage Check ............................................................................................................................................ 12
Intake Air Temperature (IAT) Sensor .......................................................................................................... 13
Remove....................................................................................................................................................... 13
Install ......................................................................................................................................................... 13
Manifold Absolute Pressure (MAP) Sensor.................................................................................................. 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 14
Oxygen Sensor ............................................................................................................................................... 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 14
Throttle Position (TP) Sensor ....................................................................................................................... 15
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 15


S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
ii
900 SRM 1125 LPG Tank Replacement
General
This section has the repair procedures for the parts of the LPG fuel system used on the Mazda 2.0 liter and 2.2
liter engines.
Hoses Replacement
The hoses installed on LPG systems are specially When replacing the hose to the quick-disconnect fit-
made. Hoses that are made for use with hydraulic ting, make sure that it is the same length as the hose
oil will be damaged by LPG. When replacing the LPG it replaces. A hose that is the wrong length allows the
hoses, be sure to use only HYSTER APPROVED LPG tank to be installed in an incorrect position.
hoses.
LPG Tank Replacement

REMOVE 3. Run the engine until it stops. If truck is equipped
with a key switch, turn the key switch to the
WARNING OFF position. If truck is equipped with a Power
ON/OFF button, press the Power ON/OFF but-
LPG can cause an explosion. Do not cause
ton to turn engine off.
LPG system. LPG fuel systems can be discon- 4. Disconnect the quick-disconnect fitting on the
nected indoors only if the lift truck is at least LPG tank. See Figure 1.
8 m (26 ft) from any open flame, motor vehicles,
electrical equipment, or ignition source. 5. Push in the bracket release pin, grab the bracket
handle, and swing the tank and bracket out to
Close the shutoff valve on the LPG tank before the side of the lift truck. If your truck is equipped
any part of the engine fuel system is discon- with a EZXchange bracket, drop the tank down
nected. Run the engine until the fuel in the sys- to the side of the truck for ease of removal. See
tem is used and the engine stops. Figure 2.
If the engine will not run, close the shutoff 6. Unlatch the tank strap and remove the LPG tank
valve on the LPG tank. Loosen the fitting on from the bracket.
the supply hose from the LPG tank where it
enters the filter unit. Permit the pressure in INSTALL
the fuel system to decrease slowly. Fuel leav-
ing the fitting removes heat. Use a cloth to NOTE: The LPG bracket must be in the swing-out
protect your hands from the cold fitting. position to install the LPG tank. If your lift truck
has the EZXchange bracket, position the bracket in
NOTE: The LPG tank bracket used on this line of the drop-down position.
trucks to mount the LPG tank onto the counter-
weight comes in two styles. One style of bracket
swings out to the side of the truck and the other WARNING
swings out to the side and drops down (EZXchange™ When closing the LPG tank strap, do not wrap
bracket). See Figure 1. your fingers around the strap handle. The
strap can close quickly and with enough force
1. LPG tanks can be removed and replaced indoors to cause injury to the fingers and hand.
only if the lift truck is at least 8 m (26 ft) from
any flame or ignition source. Move the lift truck 1. Place the LPG tank into the bracket. Secure the
to an the area where LPG tanks are changed. tank strap around the tank and close the strap.
2. Turn the shutoff valve clockwise until the valve

is completely closed.
1
LPG Tank Replacement 900 SRM 1125
A. SWING-OUT LPG BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET

(EZXCHANGE)
6. ALIGNMENT PIN
2
900 SRM 1125 Fuel Filter
2. Pull the stop pin (see Figure 1) and swing the

LPG tank bracket into the resting position on the
counterweight. Be sure that the bracket locks
into position.
3. Connect the hose to the LPG fuel lock-off connec-

tion on the LPG regulator. See Figure 2.
4. Connect the quick-disconnect fitting on the LPG

tank. See Figure 1.

fuel valve.
6. Inspect the fuel system for leaks when the fuel

valve is open. There are four methods used to
inspect the fuel system for leaks:

from a tank fitting or hose connection.

you smell LPG, DO NOT start the engine.
c. Soapy Water - This method is used in con-

junction with Step b above. If the odor of LPG
1. QUICK-DISCONNECT CONNECTION is present, but escaping fuel cannot be heard,
2. HOSE ASSEMBLY apply soapy water to the fittings and observe
3. CAPSCREW for bubbles.
4. LPG TANK
5. HOSE ASSEMBLY TO LPG d. Frost - If the amount of LPG escaping is suf-
REGULATOR/LOCK-OFF ficient, frost may appear on the fittings.
6. LPG REGULATOR CONNECTION
7. LPG REGULATOR
Figure 2. LPG Tank Hose Connections
Fuel Filter
REMOVE wear protective eye protection. If liquid fuel
continues to flow from the connections when
WARNING loosened, check to make sure the manual valve
is fully closed.
sparks or open flames in the work area. 3. Remove the fuel hoses and clamps connected to
the fuel filter in two places. See Figure 3.
stops. 4. Remove the capscrews holding the fuel filter to
5. Remove the three screws from the top of the fuel
WARNING filter, then remove the cover, O-ring, filter (ele-
A small amount of fuel may still be present in ment), and spring. See Figure 4.
3
Fuel Filter 900 SRM 1125
CLEAN AND INSPECT
WARNING
Compressed air can move particles and cause
injury to the user or to other personnel. Make
sure compressed air path is away from all per-
sonnel. Wear eye protection.
CAUTION
Use caution that foreign material accumulated
in the fuel filter body does not enter the injec-
tor or slow-idle passages or damage may occur.
1. HOSE
2. CLAMP 1. Use commpressed air to clean out the fuel filter
3. FUEL FILTER body. See Figure 5.
4. INTAKE MANIFOLD
5. CAPSCREW
2. Check the fuel filter body for cracks and other
Figure 3. Fuel Filter damage.
Figure 5. Fuel Filter Body
1. SCREW 4. FILTER (ELEMENT)

2. COVER 5. SPRING
3. O-RING
Figure 4. Filter Removal
4
900 SRM 1125 Fuel Filter
INSTALL
CAUTION
Use caution that the spring is not installed at
an angle in the fuel filter body or damage may
occur.
Use caution not to install the fuel filter (ele-

ment) upside-down, or damage may occur.
1. Install a new spring and filter (element) inside

the fuel filter body. See Figure 6.
1. SCREW 3. O-RING
2. COVER
Figure 7. O-ring Installation
1. FILTER (ELEMENT) 2. SPRING
Figure 6. Spring and Filter (element)

Installation
CAUTION
Verify the O-ring is fully seated in the fuel filter
body groove, or damage may occur.
2. Install a new O-ring to the fuel filter body and

tighten the screws to 3.4 to 4.4 N•m (30 to
40 lbf in). See Figure 7.
3. Insert the fuel hoses until they are completely

seated against the base, and then firmly install A. WHITE PAINT
the clamps so that the fuel does not leak. See 1. INJECTOR HOSE
Figure 8. 2. CLAMP
Figure 8. Hose Installation
5
Carburetor Repair 900 SRM 1125
Relief Valve Replacement

REMOVE AND INSTALL 1. Close shutoff valve on tank.
2. Slowly loosen hose fitting for relief valve. Let fuel

WARNING drain from fitting before removing relief valve.
LPG can cause an explosion. Do not cause
sparks or permit flammable material near 3. The valve cannot be repaired. If the valve is dam-
LPG system. Close fuel valve on tank. Discon- aged, install new valve. After installation, open
nect negative battery cable to prevent sparks. shutoff valve slowly and inspect system for leaks.
Carburetor Repair
REMOVE 10. Disconnect both fuel inlet hoses (large hose to
carburetor and smaller hose to fuel injector).
WARNING 11. Disconnect regulator hose.
Before disconnecting any part of the LPG fuel
system, close shutoff valve on fuel tank. Run 12. Disconnect power valve hose.
engine until fuel lines are empty and engine
stops. If engine will not run, close shutoff valve 13. Disconnect throttle cable at carburetor.
on fuel tank and release fuel slowly in a non-
14. Remove two nuts retaining carburetor to the gov-
hazardous area.
ernor. Carefully slide the carburetor from the
1. Turn shutoff valve clockwise until valve is com- threaded studs and remove carburetor from gov-
pletely closed. ernor.
2. Run engine until it stops. Then turn key to OFF DISASSEMBLE

position.
NOTE: Note the position of the diaphragm prior to
3. Disconnect hose from air cleaner at bonnet. removal to aid in the installation. See Figure 9.
4. Disconnect positive crankcase ventilation (PCV) 1. Disassemble power valve actuator by removing
hose from air bonnet. three screws, cover, spring, and diaphragm from
carburetor. See Figure 9.
5. Disconnect hose from manifold absolute pressure
(MAP) sensor. 2. Remove nut, lockwasher, throttle cable link, and
lever from carburetor.
6. Disconnect MAP sensor electrical connection.
3. Remove capscrews retaining fuel injector to the
7. Disconnect fuel injector electrical connection. carburetor.
8. Disconnect throttle position sensor electrical con- 4. Remove fuel injector and seal.
nection.
9. Remove the two nuts retaining the air bonnet.

Remove air bonnet and MAP sensor together as
an assembly.
6
900 SRM 1125 Carburetor Repair
Figure 9. Carburetor Parts
7
Carburetor Repair 900 SRM 1125
Legend for Figure 9

1. NUT 12. INTAKE MANIFOLD
2. MAP SENSOR 13. ELECTRONIC GOVERNOR
3. BONNET 14. THREADED STUD
4. GASKET 15. SCREW
5. NUT 16. WASHER
6. NUT 17. ACTUATOR COVER
7. THROTTLE CABLE LINK 18. SPRING
8. CAPSCREW 19. DIAPHRAGM
9. FUEL INJECTOR 20. CAPSCREW
10. CARBURETOR 21. WASHER
11. GASKET 22. THROTTLE POSITION SENSOR
5. Remove capscrews retaining the throttle position INSTALL

sensor to the carburetor.
1. Install new gasket on governor.
6. Remove throttle position sensor.
2. Carefully slide the carburetor over the threaded
CLEAN studs onto the governor. Install the two retaining
nuts.
WARNING 3. Connect throttle cable at carburetor.
and can cause skin irritation. When using 4. Connect power valve hose.
cleaning solvents, always follow recommenda-
tions of manufacturer. 5. Connect regulator hose.
6. Connect both fuel inlet hoses (large hose to car-

CAUTION buretor and smaller hose to fuel injector).
Only use oxygen sensor safe carburetor clean-
ing solvent when cleaning the carburetor. 7. Install air bonnet and MAP sensor together as an
assembly. Install the two retaining nuts.
Make sure that all of carburetor parts are clean be-
fore assembly. Wash all parts (except diaphragm) in 8. Connect the throttle position sensor electrical
carburetor cleaning solvent. Make sure that air pas- connection.
sages in metering valve are clean. 9. Connect the fuel injector electrical connection.
ASSEMBLE 10. Connect MAP sensor electrical connection.
1. Install throttle position sensor and secure with 11. Connect positive crankcase ventilation (PCV)
two capscrews previously removed. hose to air bonnet.
2. Install seal, fuel injector, and two screws on car- 12. Connect hose from air cleaner to bonnet.
buretor.
13. Connect hose to MAP sensor.
3. Install lever, throttle cable link, lockwasher, and
nut on carburetor. Tighten nut to 9 to 12 N•m 14. Connect hose from air cleaner to bonnet.
(80 to 106 lbf in).
4. Install diaphragm (as noted during removal),

spring, cover, and three screws. Tighten screws
to 1.5 to 2.0 N•m (13 to 18 lbf in).
8
900 SRM 1125 Governor Repair
Fuel Injector Repair

REMOVE CAUTION
1. Turn shutoff valve clockwise until valve is com- Do not insert wire more than 2.0 mm (0.08 in.)
pletely closed. into fuel injector nozzle. Otherwise, internal
parts of fuel injector may be damaged.
2. Run engine until it stops, then turn key to OFF
position. 2. Use a 1.2 mm (0.05 in.) diameter piece of steel
wire to clean out inside of nozzle. Insert and pull
3. Disconnect hose from fuel injector. out wire approximately 10 times while adding
343 to 490 kPa (50 to 71 psi) of pressure through
4. Remove two mounting screws. Remove fuel in- fuel supply port.
jector and seal from carburetor.
3. Use an ohmmeter to check fuel injector coil for
CLEAN AND INSPECT continuity. The coil resistance should be 3.5 to
4.5 .
1. Use a clean cloth to remove any carbon deposits
around nozzle. 4. Apply 12 VDC to both connector terminals of fuel
injector. A clicking sound should be heard.
WARNING
Compressed air can move particles so that they INSTALL
cause injury to the user or to other personnel. 1. Insert seal and fuel injector into carburetor.
is away from all personnel. Wear protective 2. Install two mounting screws. Tighten screws to
goggles or a face shield to prevent injury to the 6.4 to 7.9 N•m (57 to 70 lbf in).
eyes.
3. Connect hose to fuel injector.
Governor Repair
REMOVE INSTALL
1. Remove the carburetor. See Carburetor Repair, 1. Verify that the mounting surface of the electronic
Remove. governor and the intake manifold are clean and
free of debris.
2. Disconnect the wiring harness connector from
the electronic governor sensor connector. 2. Install a new gasket.
3. Remove the two capscrews retaining the elec- 3. Slide the electronic governor over the threaded
tronic governor to the intake manifold. See Fig- studs onto the intake manifold.
ure 10.
4. Install the two capscrews to retain the electronic
4. Slide the electronic governor over the threaded governor.
studs away from the intake manifold and remove
electronic governor. 5. Install the carburetor. See Carburetor Repair,
Install.
9
Regulator Repair 900 SRM 1125

1. CAPSCREW
2. ELECTRONIC GOVERNOR
3. GASKET
4. THREADED STUD
5. INTAKE MANIFOLD
Figure 10. Electronic Governor
Regulator Repair
REMOVE
WARNING
sparks or flames in work area.
1. Close shutoff valve on tank. Run engine until it

stops.
2. Disconnect electrical connectors from main sole-

noid valve and fuel injector solenoid valve respec-
tively. See Figure 11.

1. FUEL INJECTOR SOLENOID VALVE
2. FUEL OUTLET
3. MAIN SOLENOID VALVE
4. CHAMBER A
5. COOLANT PORTS
6. RESONATOR PORT
7. CHAMBER C
8. CHAMBER B
9. FUEL FILTER CHAMBER
Figure 11. Regulator
10
3. Put drain pan under drain valve for radiator. 3. Connect liquid LPG hose to regulator.
Open drain valve so that coolant drains into pan.
4. Connect cooling system hoses to regulator.
4. Disconnect cooling system hoses from regulator.
5. Close drain valve and fill cooling system with
5. Disconnect liquid LPG hose from regulator. proper amount and mixture of coolant. See the
Periodic Maintenance manual for your lift
6. Disconnect both LPG vapor hoses from regulator. truck.
7. Disconnect balance line from regulator. Remove 6. Connect fitting from LPG tank to regulator as-
capscrews and regulator from mount. sembly. Connect electrical connectors from main
solenoid valve and fuel injector solenoid valve re-
INSTALL spectively.
1. Connect balance line to regulator. Install regula- 7. Connect hose to carburetor. Open shutoff valve
tor and capscrews on mount. on tank. Start engine.
2. Connect both LPG vapor hoses to regulator.
Control System
ENGINE CONTROL UNIT (ECU) 2. Connect the wiring harness to the ECU.
Remove 3. Connect the negative battery cable.
CAUTION
Never connect or disconnect the wiring har-
ness at the ECU when the key switch is ON.
Never connect jumper wires or test instru-
ments to the ECU when the key switch is
ON. The best procedure is to disconnect the
battery negative cable when removing or in-
stalling electrical components.
Do not touch the connector pins or the soldered

connections on the circuit board. The ECU can
be damaged with an electrostatic discharge.
1. Disconnect the battery negative cable.
2. Disconnect the wiring harness from the ECU lo-

cated on the frame on the right side of engine.
See Figure 12.
3. Remove the four capscrews retaining the ECU to 1. CAPSCREW

the mounting bracket and remove the ECU. 2. ECU
3. FRAME
4. WIRING HARNESS
Install 5. MOUNTING BRACKET
1. Position the ECU on the mounting bracket. In- Figure 12. Engine Control Unit
stall the four capscrews to retain the ECU to the
mounting bracket.
11
ENGINE COOLANT TEMPERATURE (ECT) 2. Connect the ECT sensor connector.

SENSOR
3. Refill the radiator with engine coolant after in-
Remove stalling the ECT sensor.
1. Drain the engine coolant from the radiator before CAMSHAFT POSITION (CMP) SENSOR
removing the ECT sensor. Refer to the section
Cooling System 700 SRM 1123. Voltage Check
2. Disconnect the ECT sensor connector.

WARNING
3. Remove the ECT sensor and packing from the Turning the ignition switch to the ON position
intake manifold. See Figure 13. with the fuel injector connector still connected
will actuate the fuel injector. Disconnect the
fuel injector connector.
WARNING
Turning the ignition switch to the ON position
with the high-tension lead still connected will
generate sparks, which can cause electrical
shock. Disconnect the high-tension lead and
avoid it from grounding to the vehicle body.
1. Verify that the ignition is OFF.
2. Remove the distributor.
3. Connect the distributor 4-pin connector.
4. Disconnect the high-tension lead from the dis-

tributor side.
5. Turn the ignition ON.
6. Measure the voltage between terminal 3 (signal)

and terminal 1 (signal ground). See Figure 14.
1. PACKING (COPPER WASHER)
2. ECT SENSOR 7. Rotate the distributor drive by hand and verify
3. WIRING CONNECTOR
4. INTAKE MANIFOLD the output signal. If not as specified, inspect the
related wiring harnesses for open or short. If
Figure 13. ECT Sensor wiring harnesses are okay, replace the distribu-
tor.
Install Specification: 4 pulse (5.0 V)/rev.
1. Install the ECT sensor and the new packing and

tighten the ECT sensor to 19 to 21 N•m (14 to
15.5 lbf ft).
12
1. DISTRIBUTOR
2. DISTRIBUTOR (CMP SENSOR) CONNECTOR (ON DISTRIBUTOR)
Figure 14. Camshaft Position (CMP) Sensor Voltage Check
INTAKE AIR TEMPERATURE (IAT)

SENSOR
Remove
the sensor connector.
2. Remove the sensor and aluminum seal washer.

See Figure 15.
Install
1. Install the IAT sensor and new aluminum seal
washer. Tighten the IAT sensor to 7.85 to
11.77 N•m ( 69 to 104 lbf in).
2. Connect the wiring harness connector to the sen-

sor connector.
1. IAT SENSOR
2. ALUMINUM SEAL WASHER
3. INTAKE MANIFOLD
Figure 15. IAT Sensor
13
MANIFOLD ABSOLUTE PRESSURE (MAP) 2. Connect the vacuum hose to the MAP sensor.
SENSOR
3. Connect the wiring connector to the MAP sensor.
Remove
OXYGEN SENSOR
1. Disconnect the electrical connection to the MAP
sensor. Remove
2. Disconnect the vacuum hose from the MAP sen- 1. Disconnect electrical connector from the oxygen
sor. sensor. See Figure 17.
3. Remove the two screws retaining the MAP sen- 2. Remove oxygen sensor from exhaust pipe.
sor to the air bonnet and remove MAP sensor.Fig-
ure 16. Install
1. Coat the oxygen sensor sparingly with an anti-
seize compound, then install sensor. Tighten sen-
sor to 39 N•m (29 lbf ft).
2. Connect the electrical connector to the oxygen

sensor.
1. MAP SENSOR 3. AIR BONNET

2. SCREWS
Figure 16. MAP Sensor 1. OXYGEN SENSOR

Install 3. EXHAUST PIPE
1. Place the MAP sensor in position on the air bon- Figure 17. Oxygen Sensor
net. Install the two screws to retain the MAP
sensor to the air bonnet.
14
THROTTLE POSITION (TP) SENSOR

Remove
1. Disconnect the electrical connector from the TP
sensor.
2. Remove the two capscrews retaining the TP sen-

sor to the carburetor and remove sensor. See Fig-
ure 18.
Install
1. Place the TP sensor in position on the carburetor.
Install the two capscrews to retain the sensor to
the carburetor.
2. Connect the electrical connector to the TP sensor.
1. TP SENSOR 2. CAPSCREW
Figure 18. TP Sensor
15
NOTES
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16
900 SRM 1125 5/05 (12/04) Printed in U.S.A.

GASOLINE FUEL
SYSTEM
MAZDA 2.0L AND 2.2L
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580509 900 SRM 1127

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Abbreviations ..................................................................................................................................................... 1
Engine Tune-up.................................................................................................................................................. 1
Engine Tune-Up Preparation........................................................................................................................ 1
Idle Speed Adjustment .................................................................................................................................. 1
Idle-Up Speed Check ..................................................................................................................................... 1
Intake-Air System.............................................................................................................................................. 3
Intake-Air System Manifold Vacuum Check................................................................................................ 3
Throttle Body ................................................................................................................................................. 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 4
Electronic Governor....................................................................................................................................... 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 4
Intake-Air Control (IAC) Valve ..................................................................................................................... 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 6
Intake Manifold ............................................................................................................................................. 6
Remove....................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Fuel System........................................................................................................................................................ 7
Fuel Line Safety Procedure ...................................................................................................................... 7
Fuel Hose, Install ...................................................................................................................................... 7
Fuel Leakage Check .................................................................................................................................. 8
Fuel Injector................................................................................................................................................... 9
Remove....................................................................................................................................................... 9
Install ......................................................................................................................................................... 9
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Exhaust System ................................................................................................................................................. 12
Exhaust System, Inspect............................................................................................................................... 12
Three-Way Catalytic (TWC) Converter ........................................................................................................ 12
Remove and Install ................................................................................................................................... 12
Exhaust Manifold .......................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Positive Crankcase Ventilation (PCV) Valve................................................................................................ 14
Remove....................................................................................................................................................... 14
Inspect........................................................................................................................................................ 14
Install ......................................................................................................................................................... 14
Control System................................................................................................................................................... 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 16
Intake Air Temperature (IAT) Sensor .......................................................................................................... 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 17

Table of Contents Gasoline Fuel System

Mass Air Flow (MAF) Sensor ........................................................................................................................ 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 17
Throttle Position (TP) Sensor ....................................................................................................................... 18
TP Sensor, Adjust ...................................................................................................................................... 18
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 20
Voltage Check ............................................................................................................................................ 20
Oxygen Sensor ............................................................................................................................................... 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 20
Manifold Absolute Pressure (MAP)/Boost Sensor........................................................................................ 21
Remove....................................................................................................................................................... 21
Install ......................................................................................................................................................... 21
Technical Data.................................................................................................................................................... 22
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]
ii
900 SRM 1127 Engine Tune-up
General
This section has the repair procedures for the engine and timing for the Mazda 2.0L and 2.2L gasoline en-
control unit (ECU) controlling the idle, fuel, spark, gines.
Abbreviations
AAS - air adjusting screw. IAT Sensor - intake air temperature sensor.
CMP Sensor - camshaft position sensor. MAF Sensor - mass air flow sensor.
ECT Sensor - engine coolant temperature sensor. MAP Sensor - manifold absolute pressure sensor.
ECU - engine control unit. PCV Valve - positive crankcase ventilation valve.
GCU - governor control unit. TP Sensor - throttle position sensor.
IAC Valve - idle air control valve. TWC Converter - three-way catalytic converter.
Engine Tune-up
ENGINE TUNE-UP PREPARATION 3. Verify that the idle speed is within the specifica-
tion. If not as specified, adjust the idle speed by
1. Warm up the engine to normal operating temper- turning the air adjustment screw (AAS) of throt-
ature. tle body. See Figure 2.
Specification: 775 to 825 (800 ±25) rpm
2. Turn off all electrical loads.
4. Remove the jumper wire from ECU test port con-
3. Verify that the steering wheel is at straight
nector.
ahead position.
4. Connect a tachometer. IDLE-UP SPEED CHECK

1. Perform Engine Tune-Up Preparation.
IDLE SPEED ADJUSTMENT
2. Verify that the idle speed is normal. See Idle
1. Perform Engine Tune-Up Preparation.
Speed Adjustment.
WARNING 3. Verify that the idle-up speed is within the specifi-

Fuel line spills and leakage are dangerous. cation. Load the engine at tilt relief, hoist relief,
Fuel can ignite and cause serious injuries or and steer relief while checking the engine speed
death and damage. Always perform the follow- at each condition. If not as specified with all load
ing procedure with the engine stopped. conditions, inspect the IAC valve. If not as spec-
ified with some load conditions, inspect the sen-
sors (MAP/Boost, TP sensor, CMP sensor), har-
CAUTION nesses, and connectors.
Only use a jumper wire with a momentary Specification: 900 to 1100 (1000 ±100) rpm
switch located within the wire to prevent arc-
ing.
2. Install a jumper wire across the engine control

unit (ECU) test port connector terminals. See
Figure 1.
1
Engine Tune-up 900 SRM 1127
1. FUEL PUMP TEST CONNECTOR 4. FUEL PUMP RELAY

2. ECU TEST PORT 5. GCU INTERFACE
3. 10 AMP FUSE, FUEL PUMP 6. ALTERNATOR RELAY
Figure 1. Relays and Test Connectors
2
900 SRM 1127 Intake-Air System
1. THROTTLE POSITION (TP) SENSOR 3. AIR ADJUSTING SCREW (AAS)

2. THROTTLE BODY
Figure 2. Throttle Body
Intake-Air System
NOTE: Always use new O-rings, seals, and gaskets c. Vacuum leaks (installation areas of throttle
when servicing the fuel and exhaust systems. body, electronic governor, fuel injector, IAC
valve, PCV valve, intake manifold).
INTAKE-AIR SYSTEM MANIFOLD VACUUM
CHECK 5. After measuring the intake manifold vacuum, in-
stall the intake manifold blind cap.
1. Verify that the intake-air system related parts
and hoses are securely installed.
2. Remove the intake manifold blind cap and install

the vacuum gauge. See Figure 3.
3. Warm up the engine.
4. Measure the intake manifold vacuum while

idling (no load) using the vacuum gauge. If not
within the specification, perform the following
inspection:
Specification: -60.0 kPa (-17.8 inHg) or more
a. Accelerator cable free play.
b. Compression pressure.
NOTE: If any vacuum leaks exist, the change in en- 1. VACUUM GAUGE
gine speed can be made apparent by spraying the
penetrant lubricating spray on the applicable part. Figure 3. Intake Manifold Vacuum Check
3
Intake-Air System 900 SRM 1127
THROTTLE BODY 9. Fill the radiator with coolant.
For the following procedures, refer to Figure 4. ELECTRONIC GOVERNOR

Remove Remove
1. Drain the coolant from the radiator. For the following procedures, refer to Figure 4.
2. Disconnect the air-intake hose from the throttle 1. Remove the throttle body. See Throttle Body, Re-
body. move.
3. Disconnect the wiring harness connector from 2. Disconnect the wiring harness connector from
the TP sensor connector. the electronic governor sensor connector.
4. Tag and disconnect the coolant hoses from the 3. Slide the electronic governor from the threaded
throttle body. studs and remove the electronic governor.
5. Disconnect the throttle cable. 4. Remove the gasket and discard.
6. Remove the two bolts from the bottom of the Install
throttle body.
For the following procedures, refer to Figure 4.
7. Remove the two nuts from the top of the throttle
body. 1. Verify that the mounting surface of the electronic
governor and the intake manifold are clean and
8. Slide the throttle body from the threaded studs free of debris.
and remove the throttle body.
2. Install a new gasket.
3. Slide the electronic governor onto the threaded
Install studs.
1. Verify that the mounting surface of the throttle 4. Install the throttle body. See Throttle Body, In-
body and the electronic governor are clean and stall.
free of debris.
INTAKE-AIR CONTROL (IAC) VALVE
2. Install a new gasket.
3. Slide the throttle body onto the threaded studs. Remove
4. Install the two nuts and two bolts and tighten. For the following procedures, refer to Figure 4.
Tighten the two nuts to 22 to 30 N•m (16 to 1. Drain the coolant from the radiator.
22 lbf ft). Tighten the two bolts to 19 to 25 N•m
(14 to 18 lbf ft). 2. Tag and disconnect the the coolant hoses.
5. Connect the throttle cable. 3. Disconnect the electrical connector from the IAC
valve connector.
6. Connect the coolant hoses.
4. Remove the two nuts and capscrew securing the
7. Connect the wiring harness connector to the TP IAC valve.
sensor connector.
5. Remove the IAC valve and gasket.
8. Connect the air-intake hose.
4
1. THROTTLE BODY 21. CAPSCREW

2. GASKET 22. COOLANT HOSE (TO ENGINE COOLANT HOSE
3. ELECTRONIC GOVERNOR ON RIGHT SIDE OF CYLINDER BLOCK)
4. GASKET 23. CLAMP
5. THROTTLE BRACKET 24. IDLE AIR CONTROL (IAC) VALVE
6. CAPSCREW 25. NUT
7. BRACKET 26. GASKET
8. CAPSCREWS 27. FUEL INJECTOR AND FUEL RAIL ASSEMBLY
9. MAP/BOOST SENSOR 28. PCV HOSE
10. NUT 29. CLAMP
11. FUEL PRESSURE REGULATOR 30. INTAKE MANIFOLD
12. BRACKET 31. THREADED STUD
13. CAPSCREWS 32. COOLANT HOSE (TO THERMOSTAT OUTLET
14. CAPSCREW HOUSING)
15. WASHER 33. CLAMP
16. CAPSCREW 34. COOLANT HOSE (TO ENGINE COOLANT HOSE
17. BRACKET ON RIGHT SIDE OF CLYINDER BLOCK)
18. GASKET 35. THROTTLE POSITION (TP) SENSOR
19. COOLANT HOSE 36. BOLT
20. CLAMP 37. NUT
Figure 4. Intake-Air System
5
Install 9. Remove the MAP/boost sensor. See Manifold Ab-

solute Pressure (MAP)/Boost Sensor, Remove.
10. Remove the capscrews retaining the rear bracket
1. Verify that the mounting surfaces of the intake (12) to the intake manifold and the cylinder head.
manifold and the IAC valve are clean and free Remove the bracket.
from dirt or debris.
11. Remove the capscrews retaining the lower sup-
2. Install a new gasket. port bracket (17) to the intake manifold and re-
move the bracket.
3. Place the IAC valve in position and secure with
the two nuts and capscrew. 12. Remove the nut and the capscrews retaining the
intake manifold to the cylinder head.
4. Torque the two nuts to 8.9 to 12.7 N•m (79
to 112 lbf in). Torque the capscrew to 7.9 to 13. Remove the intake manifold and gasket.
10.7 N•m (69.5 to 95.4 lbf in).
14. Remove the capscrew retaining the throttle
5. Connect the electrical connector to the IAC valve bracket to the intake manifold and remove
connector. bracket.
6. Connect the coolant hoses to the IAC valve. 15. Remove the fuel pressure regulator. See Pres-
sure Regulator, Remove.
7. Fill the radiator with coolant.
16. Remove the fuel injectors and the fuel rail. See
INTAKE MANIFOLD Fuel Injector, Remove.
Remove Install
For the following procedures, refer to Figure 4. For the following procedures, refer to Figure 4.
1. Drain the coolant from the radiator. 1. Verify that the mounting surfaces of the intake
manifold and the cylinder head are clean and free
2. Disconnect the fuel line from the fuel rail. See
from dirt or debris.
Fuel System, Before Repair Procedure.
2. Install the fuel injectors and the fuel rail. See
3. Remove the throttle body. See Throttle Body, Re-
Fuel Injector, Install.
move.
3. Install the fuel pressure regulator. See Pressure
4. Remove the electronic governor. See Electronic
Regulator, Install.
Governor, Remove.
4. Place the throttle bracket in position and install
5. Remove the capscrews retaining the front
capscrews. Tighten capscrews to 7.9 to 10.7 N•m
bracket (7) to the intake manifold and remove
(69.5 to 95.4 lbf in).
the bracket.
5. Place a new gasket in position on the cylinder
6. Remove the IAC valve. See Intake-Air Control
head.
(IAC) Valve, Remove.
6. Place the intake manifold in position on the cylin-
7. Tag and disconnect the vacuum hoses on the in-
der head.
take manifold.
7. Install the nut and capscrews to retain the intake
8. Remove the ECT sensors. See Engine Coolant
manifold to the cylinder head. Tighten the nut
Temperature (ECT) Sensor, Remove.
to 22 to 30 N•m (16 to 22 lbf ft). Tighten the
capscrews to 19 to 25 N•m (14 to 18 lbf ft).
6
900 SRM 1127 Fuel System
8. Place the lower support bracket (17) in position 13. Install the IAC valve. See Intake-Air Control
and install the capscrews. Tighten the capscrew (IAC) Valve, Install.
to the intake manifold to 19 to 25 N•m (14 to
18 lbf ft). Tighten the remaining capscrew to 38 14. Place the front bracket (7) in position and install
to 51 N•m (28 to 38 lbf ft). the capscrews. Tighten the capscrews to 19 to
25 N•m (14 to 18 lbf ft).
9. Place the rear bracket in position and install
the capscrews. Tighten the capscrews to 19 to 15. Install the electronic governor. See Electronic
25 N•m (14 to 18 lbf ft). Governor, Install.
10. Install the MAP/boost sensor. See Manifold Ab- 16. Install the throttle body. See Throttle Body, In-
solute Pressure (MAP)/Boost Sensor, Install. stall.
11. Install the ECT sensors. See Engine Coolant 17. Connect the fuel line to the fuel rail. See Fuel
Temperature (ECT) Sensor, Install. System, After Repair Procedure.
12. Connect the vacuum hoses to the intake mani- 18. Fill the radiator with coolant.
fold.
Fuel System
NOTE: Always use new O-rings, seals, and gaskets 3. Start the engine. After the engine stalls, crank
when servicing the fuel and exhaust systems. the engine several times.
BEFORE REPAIR PROCEDURE 4. Turn OFF ignition.
Fuel Line Safety Procedure 5. Connect the fuel pump relay.
AFTER REPAIR PROCEDURE

WARNING
Fuel vapor is hazardous. It can easily ignite, Fuel Hose, Install
causing serious injury and damage. Always
keep sparks and flames away from fuel. WARNING
Fuel line spills and leakage are dangerous. Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin death and damage. When installing the fuel
and eyes. To prevent this, always complete the hose, observe the following procedure and the
following procedure: Fuel Leakage Check procedure.
NOTE: Fuel in the fuel system is under high pressure 1. Replace damaged or deformed fuel hoses, fuel
also when the engine is not running. lines, and hose clamps.
1. Remove the fuel-filler cap and release the pres- 2. When installing the fuel hose on the fuel line,
sure in the fuel tank. fit the hose onto the line over 25 mm (0.98 in.).
When the line has a stopper, fit the hose until it
2. Disconnect the fuel pump relay. See Figure 1. contacts the stopper. See Figure 5.
7
Fuel System 900 SRM 1127
Fuel Leakage Check
WARNING
death and damage. Always perform the follow-
CAUTION
Only use a jumper wire with a momentary
ing.
1. Install a jumper wire across the fuel pump test

connector terminals. See Figure 1.
1. FUEL LINES 2. Turn the ignition ON to operate the fuel pump.

2. STOPPER
3. FUEL HOSE 3. Pressurize the system this way for at least 5 min-
Figure 5. Fuel Hose Installation age, inspect the fuel hoses and fuel pipe sealing
surface for damage. Replace as needed.
NOTE: Do not use a clamp larger than the recom-
mended size for the hose outside diameter. 4. After repair, assemble the system and repeat
3. Install a hose clamp over the fuel hose within the
clamp installation range as shown, avoiding the FUEL LINE PRESSURE CHECK
original clamp position. Tighten the clamp screw
to 2.45 to 2.77 N•m (22 to 25 lbf in). See Figure 6.
WARNING
Fuel line spills and leaks are dangerous. Fuel
can ignite and cause serious injuries or death.
Fuel can also irritate skin and eyes. Always
perform the following procedure with the en-
gine stopped.
3. Connect a fuel pressure gauge between the fuel

filter and the fuel rail. See Figure 7.
1. AVOID ORIGINAL CLAMP POSITION 5. Install a jumper wire across the fuel pump test
2. CLAMP INSTALLATION RANGE connector terminals. See Figure 1.
Figure 6. Clamp Installation
8
4. Disconnect the wiring harness from each fuel in-

jector.
5. Disconnect the fuel lines from the fuel rail.
6. Remove the two capscrews retaining the fuel rail

to the intake manifold.
7. Remove the fuel rail and fuel injectors.
8. Remove the fuel rail insulator.
9. Remove the fuel injector insulator.
10. Remove the fuel injectors.
11. Remove and discard O-rings.
Install
1. FUEL PRESSURE GAUGE 1. Apply a small amount of engine oil to the new
O-rings and install them into the fuel rail.
Figure 7. Fuel Pressure Gauge
2. Verify that the O-rings and the fuel injector seal-
6. Measure the fuel line pressure. If less than the ing surfaces are free of foreign material.
leakage. If it exceeds the specification, inspect 3. Install the fuel injectors in the fuel rail with light
the pressure regulator and fuel line for clogging. twisting motion so that the O-rings will not be
Specification: 260 to 310 kPa (38 to 45 psi) folded.
7. Turn the ignition OFF to stop the fuel pump. 4. Install the fuel injector insulator.
8. Measure the fuel hold pressure after 5 minutes. 5. Install the fuel rail insulator.
If not within the specification, inspect the fuel
6. Install the fuel rail and fuel injectors onto the
intake manifold. Install the two capscrews and
Specification: More than 140 kPa (20 psi)
tighten to 19 to 25 N•m (14 to 18 lbf ft).
9. Disconnect the jumper wire.
7. Connect the wiring harness for each fuel injector.
10. Disconnect the fuel pressure gauge.
8. Connect the vacuum hose to the pressure regula-
11. Complete the After Repair Procedure. tor.
9. Connect the fuel lines to the fuel rail.

FUEL INJECTOR
Remove

regulator. See Figure 8.
9
1. INTAKE MANIFOLD 6. FUEL INJECTOR INSULATOR

2. CAPSCREW 7. FUEL INJECTOR
3. PRESSURE REGULATOR 8. O-RING
5. FUEL RAIL INSULATOR
Figure 8. Fuel Injector Assembly
PRESSURE REGULATOR 4. Disconnect the fuel return line from the pressure
regulator.
Remove
5. Remove the two capscrews retaining the pres-
1. Complete the Before Repair Procedure. sure regulator.
2. Disconnect the negative battery cable. 6. Remove the pressure regulator.
3. Disconnect the vacuum hose from the pressure 7. Remove and discard the O-ring.
regulator. See Figure 9.
10
Install 4. Connect the vacuum hose to the pressure regula-

tor.
1. Apply a light coat of engine oil to the new O-ring
and install the O-ring. 5. Connect the negative battery cable.
2. Place the pressure regulator in position and in- 6. Complete the After Repair Procedure.
stall the two capscrews. Tighten the capscrews
to 7.9 to 10.7 N•m (70 to 95 lbf in).
3. Connect the fuel return line to the pressure reg-

ulator.
1. INTAKE MANIFOLD 4. CAPSCREW

2. O-RING 5. VACUUM HOSE
3. PRESSURE REGULATOR
Figure 9. Pressure Regulator Removal/Installation
11
Exhaust System 900 SRM 1127
Exhaust System
NOTE: Always use new O-rings, seals, and gaskets 2. Remove the three capscrews retaining the ex-
when servicing the fuel and exhaust systems. haust manifold insulator and remove the insu-
lator. See Figure 10.
EXHAUST SYSTEM, INSPECT
3. Remove the four nuts and washers retaining the
Start the engine and inspect the exhaust system com- exhaust pipe to the exhaust manifold.
ponent for exhaust gas leakage. If leakage is found,
repair or replace components as necessary. 4. Remove the six nuts and washers retaining the
exhaust manifold to the cylinder head.
THREE-WAY CATALYTIC (TWC)
5. Remove the exhaust manifold and gaskets.
CONVERTER
6. Discard all of the old gaskets.
Remove and Install
Install
WARNING
1. Place the new gaskets in position on the cylinder
When the engine and exhaust system are hot,
head and the exhaust manifold.
they can cause severe burns. Turn off the en-
gine and wait until they are cool before remov- 2. Place the exhaust manifold in position on the
ing the exhaust system. cylinder head and secure with the six nuts and
washers.
1. Refer to the section Frame 100 SRM 1120 for the
removal and installation of the TWC. 3. Tighten the six nuts evenly to 19 to 25 N•m (14
to 18 lbf ft).
EXHAUST MANIFOLD
4. Verify the position of the new exhaust manifold
Remove gasket to exhaust pipe is correct.
5. Connect the exhaust pipe to the exhaust mani-

WARNING
fold and secure with the four nuts and tighten
When the engine and exhaust system are hot, evenly.
they can cause severe burns. Turn OFF the en-
gine and wait until cool before removing the 6. Place the exhaust manifold insulator in position
exhaust system. and secure with the three capscrews. Tighten the
capscrews to 19 to 25 N•m (14 to 18 lbf ft).

1. VALVE COVER 13. CLAMP
2. CYLINDER HEAD 14. VACUUM HOSE
3. CAPSCREWS 15. NUT
4. EXHAUST MANIFOLD INSULATOR 16. LOCKWASHER
7. GASKET 19. THREE-WAY CATALYTIC (TWC) CONVERTER
8. EXHAUST MANIFOLD 20. NUT
9. GASKET 21. PLUG
10. GASKET 22. OXYGEN SENSOR
11. GROMMET 23. HEAT SHIELD
12. POSITIVE CRANKCASE VENTILATION (PCV) 24. EXHAUST PIPE
VALVE
12
900 SRM 1127 Exhaust System
Figure 10. Exhaust System
13
POSITIVE CRANKCASE VENTILATION Install

(PCV) VALVE
1. Install the PCV valve into the grommet in the
Remove valve cover.
1. Slide the clamp back on the vacuum hose con- 2. Connect the vacuum hose.
nected to the PCV valve. See Figure 10. 3. Slide the clamp into position.
2. Disconnect the vacuum hose.
3. Remove the PCV valve.
Inspect
1. Blow air through the PCV valve and verify that
air flows as specified. See Table 1 and Figure 11.
Table 1. PCV Valve Specifications
Condition Airflow
Air applied from port A Yes
Air applied from port B No
Figure 11. PCV Valve
2. If not as specified, replace the PCV valve.
Control System
NOTE: Always use new O-rings, seals, and gaskets the large portion of the mounting holes in the
when servicing the fuel and exhaust systems. mounting bracket and pull the ECU assembly
away from the mounting bracket.
ENGINE CONTROL UNIT (ECU)
6. Remove the socket head shoulder bolts.
Remove
7. Remove the capscrews retaining the ECU cover
1. Disconnect the negative battery cable. to the ECU box. See Figure 13.
2. Remove the capscrews retaining the drip shield 8. Remove the ECU cover.
to the ECU assembly mounting bracket and re-
move drip shield. See Figure 12. 9. Remove the capscrews retaining the ECU to the
ECU box.
3. Disconnect the wire harness connector from the
ECU assembly. 10. Disconnect the ECU connectors from the ECU.
4. Loosen the socket head shoulder bolt retaining 11. Remove the ECU.
the ECU assembly to the mounting bracket. 12. Remove all old sealant from the ECU cover and
5. Slide the ECU assembly up in the bracket until ECU box mating surfaces.
the socket head shoulder bolts are aligned with
14
1. DRIP SHIELD 5. SOCKET HEAD SHOULDER BOLT

2. CAPSCREWS 6. ECU ASSEMBLY
3. GCU 7. FRAME
4. MOUNTING BRACKET 8. WIRE HARNESS CONNECTOR
Figure 12. ECU Assembly Mounting
15
1. CAPSCREWS 4. ECU CONNECTORS

2. ECU COVER 5. ECU BOX
3. SILICONE BEAD 6. ECU
Figure 13. ECU Assembly
Install 6. Install the socket head shoulder bolts, but do not

tighten.
1. Place the ECU in position in the ECU box. See
Figure 13. 7. Align the ECU assembly and socket head shoul-
der bolts with the large openings of the mounting
2. Connect the ECU connectors to the ECU. holes of the mounting bracket. Slide the ECU
assembly down until the socket head shoulder
3. Install the capscrews to secure the ECU to
bolts seat at the bottom of the mounting holes.
the ECU box. Tighten the capscrews to 7.9 to
Tighten the socket head shoulder bolts to 20 N•m
10.7 N•m (69.5 to 95.4 lbf in).
(15 lbf ft).
4. Apply solventless RTV silicone sealant, Hyster
8. Connect the wire harness connector to the ECU
Part No. 1584621 or equivalent [thickness: 1 to
assembly.
2 mm (0.040 to 0.078 in.)], to the ECU cover along
the inside of the bolt holes, and overlap the ends. 9. Place the drip shield in position and install cap-
screws. Tighten capscrews to 10 N•m (89 lbf in).
5. Place the ECU cover in position on the ECU
box. Install the capscrews and tighten to 7.9 to 10. Connect the negative battery cable.
10.7 N•m (70 to 95 lbf in).
16
INTAKE AIR TEMPERATURE (IAT) MASS AIR FLOW (MAF) SENSOR

SENSOR
Remove
Remove
1. Disconnect the wiring harness connector from the sensor connector.
2. Loosen the hose clamps on both sides of the sen-
2. Remove the IAT sensor and aluminum seal sor. See Figure 15.
washer from the air intake manifold. See Fig-
3. Disconnect the intake-air hose from both sides of
ure 14.
the sensor.
Install 4. Remove the nuts retaining the sensor to the
1. Install the IAT sensor and new aluminum seal mounting bracket and remove sensor.
washer. Tighten sensor to 8 to 12 N•m (71 to 5. Remove isolators and spacers from sensor hous-
106 lbf in). ing.
sor connector.
Install
1. Install isolators and spacers.
2. Place the sensor in position on the mounting

bracket and install retaining nuts.
3. Connect the intake-air hose on both sides of the

sensor.
4. Tighten the hose clamps on both sides of the sen-

sor.

sor connector.
1. AIR INTAKE MANIFOLD

2. ALUMINUM SEAL WASHER
3. IAT SENSOR
Figure 14. Intake Air Temperature (IAT) Sensor
17
1. AIR FILTER ASSEMBLY 5. MAF SENSOR

2. CLAMP 6. AIR HOSE
3. AIR HOSE 7. SPACER
4. NUT 8. ISOLATOR
Figure 15. Mass Air Flow (MAF) Sensor
THROTTLE POSITION (TP) SENSOR Specification: 4.5 to 5.5 V (Closed Throttle)
TP Sensor, Adjust
CAUTION
Since the TP sensor is adjusted by the manufac-
turer, adjusting the TP sensor excessively can
adversely affect the engine. Do not adjust the
TP sensor excessively.
1. Verify that the throttle valve is at closed throttle Figure 16. TP Sensor Harness Connector (on
position. TPS)
2. Disconnect the TP sensor connector. 5. Reconnect the TP sensor connector.
3. Turn the ignition ON. 6. Loosen the TP sensor screws. See Figure 17.
4. Measure and record the voltage of the discon- 7. Use the voltmeter to adjust the TP sensor so the
nected harness side connector between terminals voltage of terminal B (signal) is within the spec-
C (reference voltage) and terminal A (ground) us- ification below when the throttle valve is at the
ing a voltmeter. See Figure 16. closed throttle position. See Table 2.
18
5. Connect the TP sensor connector.
6. Adjust the TP sensor. See TP Sensor, Adjust.
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
There are two ECT sensors located on the bottom of
the intake manifold. See Figure 18. The inboard
ECT sensor, closest to cylinder head, provides the in-
put to the engine control unit (ECU). The outboard
ECT sensor provides input to the governor control
unit (GCU). The removal and installation procedures
1. SCREWS 2. TP SENSOR
are the same.
Figure 17. TP Sensor
Remove
Table 2. Closed Throttle Position Specifications
1. Drain the engine coolant from the radiator before
TP Sensor Voltage (V) TP Sensor Voltage (V) removing the ECT sensor.
Between Terminal C Between Terminal B 2. Disconnect the ECT sensor connector.
and Terminal A and Terminal A
4.5 to 4.9 0.4 to 0.5 3. Remove the ECT sensor and packing from the
intake manifold. See Figure 18.
4.9 to 5.1 0.4 to 0.6
5.1 to 5.5 0.5 to 0.6
8. Tighten the TP sensor screws to 1.6 to 2.3 N•m

(14 to 20 lbf in).
9. Use the voltmeter to adjust the TP sensor so the

voltage of terminal B is within the specification
below when the throttle valve is at the wide open
throttle position. If not as specified, replace the
TP sensor.
Specification: 3.7 to 4.9 (Wide Open Throttle)
Remove
1. Disconnect the TP sensor connector.
2. Remove the TP sensor screws. See Figure 17.
3. Remove the TP sensor from the throttle body.
Install
1. Verify that the throttle valve is fully closed.
2. Install the TP sensor to the throttle body. 1. INTAKE MANIFOLD

2. COPPER WASHER
3. Tighten the TP sensor screws to 1.6 to 2.3 N•m 3. ECT SENSOR (INBOARD)
(14 to 20 lbf in). 4. ECT SENSOR (OUTBOARD)
4. Verify that the throttle valve moves smoothly. Figure 18. ECT Sensor Remove/Install
19
Install 3. Connect the distributor 4-pin connector.
1. Install the ECT sensor and the new packing. 4. Disconnect the high-tension lead from the dis-
Tighten the inboard ECT sensor to 24.5 to 29.4 tributor side.
N•m (18 to 22 lbf). Tighten the outboard ECT
sensor to 19 to 21 N•m (14 to 15.5 lbf). 5. Turn the ignition ON.
2. Connect the ECT sensor connector. 6. Measure the voltage between terminal 3 (signal)
stalling the ECT sensor. 7. Rotate the distributor drive by hand and verify
the output signal. If not as specified, inspect the
CAMSHAFT POSITION (CMP) SENSOR related wiring harnesses for open or short. If
wiring harnesses are okay, replace the distribu-
Voltage Check tor.
Specification: 4 pulse (5.0 V)/rev.
WARNING OXYGEN SENSOR
with the fuel injector connector still connected Remove
fuel injector connector. 1. Disconnect the oxygen sensor electrical connec-
tor. See Figure 20.
WARNING 2. Remove oxygen sensor from the exhaust pipe.
with the high-tension lead still connected will Install
shock. Disconnect the high-tension lead and 1. Coat the oxygen sensor sparingly with an anti-
avoid it from grounding to the vehicle body. seize compound. Install the oxygen sensor and
tighten to 39 N•m (29 lbf ft).
2. Connect the oxygen sensor electrical connector.
2. Remove the distributor.
1. DISTRIBUTOR
20
1. OXYGEN SENSOR
3. EXHAUST PIPE
Figure 20. Oxygen Sensor

1. RETAINING SCREWS
2. MAP/BOOST SENSOR
MANIFOLD ABSOLUTE PRESSURE 3. VACUUM HOSE
(MAP)/BOOST SENSOR 4. INTAKE MANIFOLD
Remove Figure 21. MAP/Boost Sensor
1. Disconnect the wiring harness connector from Install

the MAP/boost sensor connector.
1. Place the MAP/boost sensor in position and in-
2. Disconnect the vacuum hose from the MAP/boost stall the retaining screws.
2. Connect the vacuum hose to the MAP/boost sen-
3. Remove the retaining screws from the MAP/boost sor.
sensor and remove the MAP/boost sensor.
3. Connect the wiring harness connector to the
MAP/boost sensor connector.
21
Technical Data 900 SRM 1127
Technical Data
Table 3 shows the technical data specifications for
the Mazda 2.0L and 2.2L gasoline fuel systems.
Table 3. Gasoline Fuel Systems Technical Data
Engine
Item
2.0L 2.2L
Idle speed 775 to 825 (800 ±25) rpm
Idle-up speed* GCU load ON 1000 ±100 rpm
Fuel pressure Fuel line pressure 260 to 310 kPa (37 to 45 psi)
Fuel hold pressure More than 140 kPa (20 psi)
Fuel injector Resistance ( 23 C (73 F)) 14.2 to 14.8 Ohms
Fuel leakage Less than 1 drop/2 minutes
Injection volume 56 to 61 ml (1.9 to 2.0 oz)/15 seconds
(using a fuel injector tester).
Pressure regulator Fuel line pressure (At vacuum ON) 200 to 240 kPa (29 to 35 psi)
Fuel line pressure (At vacuum 260 to 310 kPa (37 to 45 psi)
OFF)
*Excludes temporary idle speed drop just after the electrical or hydraulic loads are turned on.
22

GASOLINE FUEL
SYSTEM
MAZDA 2.0L AND 2.2L
EMISSION COMPLIANT ENGINES
S30FT, S35FT, S40FTS [E010];
H30FT, H35FT, H40FTS [F001];
S40-70FT, S55FTS [F187];
H40-70FT [L177]
PART NO. 1653957 900 SRM 1325

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Abbreviations ..................................................................................................................................................... 1
Intake-Air System.............................................................................................................................................. 1
Intake-Air System Manifold Vacuum Check................................................................................................ 1
Throttle Body ................................................................................................................................................. 2
Remove....................................................................................................................................................... 2
Install ......................................................................................................................................................... 3
Intake Manifold ............................................................................................................................................. 3
Remove....................................................................................................................................................... 3
Install ......................................................................................................................................................... 3
Fuel System........................................................................................................................................................ 4
Fuel Line Safety Procedure ...................................................................................................................... 4
Fuel Hose, Install ...................................................................................................................................... 6
Fuel Leakage Check .................................................................................................................................. 7
Fuel Injectors ................................................................................................................................................. 9
Remove....................................................................................................................................................... 9
Install ......................................................................................................................................................... 10
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Exhaust System ................................................................................................................................................. 11
Counterweight Exhaust System ................................................................................................................... 11
Inspect........................................................................................................................................................ 11
Overhead Exhaust System............................................................................................................................ 13
Inspect........................................................................................................................................................ 13
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 17
Remove....................................................................................................................................................... 17
Inspect........................................................................................................................................................ 17
Install ......................................................................................................................................................... 17
Oxygen Sensor ............................................................................................................................................... 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Control System................................................................................................................................................... 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 21
Fuel Level Sensor .......................................................................................................................................... 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 22
Technical Data.................................................................................................................................................... 23

Table of Contents Gasoline Fuel System

S30FT, S35FT, S40FTS [E010];

H30FT, H35FT, H40FTS [F001];
S40-70FT, S55FTS [F187];
H40-70FT [L177]
ii
General
This section has the repair procedures for the parts of the gasoline fuel system used on the Mazda 2.0L and
2.2L 2007 emission compliant engines. Lift truck models S40-70FT (F187) and H40-70FT (L177) equipped with
a gas 2.2L engine and built after January, 2010 are covered in this service manual..
Abbreviations
CAM Angle Sensor - camshaft angle sensor. MAP Sensor - manifold absolute pressure sensor.
ECT Sensor - engine coolant temperature sensor. PCV Valve - positive crankcase ventilation valve.
ECU - engine control unit. TWC Converter - three-way catalytic converter.
IAT Sensor - intake air temperature sensor.
Intake-Air System
NOTE: Always use new O-rings, seals, and gaskets 5. After measuring the intake manifold vacuum, re-
when servicing the fuel and exhaust systems. move the vacuum gauge and install the intake
manifold blind cap.
INTAKE-AIR SYSTEM MANIFOLD VACUUM
CHECK
1. Verify that the intake-air system related parts
and hoses are securely installed.
2. Remove the intake manifold blind cap and install

the vacuum gauge. See Figure 1.
3. Warm up the engine.
4. Measure the intake manifold vacuum while

idling (no load) using the vacuum gauge. If not
within the specification, perform the following
inspection:
Specification: -60.0 kPa (-17.8 inHg) or more
a. Compression pressure. 1. VACUUM GAUGE

NOTE: If any vacuum leaks exist, the change in en- Figure 1. Intake Manifold Vacuum Check
gine speed can be made apparent by spraying the
penetrant lubricating spray on the applicable part.
b. Vacuum leaks (installation areas of throttle

body, fuel injector, IAT valve, PCV valve, in-
take manifold).
1
THROTTLE BODY 3. Disconnect the electrical connector from the

throttle body.
4. Remove the socket head screws and conical
Remove washers retaining the throttle body to the in-
take manifold and remove the throttle body and
1. Disconnect the negative battery cable. gasket. Discard the gasket and conical washers.
2. Disconnect the air-intake hose from the throttle
body.
1. SOCKET HEAD SCREW 8. CAPSCREW 15. COOLANT LINE

2. CONICAL WASHER 9. NUT 16. CAPSCREW
3. THROTTLE BODY ASSEMBLY 10. CAPSCREW 17. GASKET
4. GASKET 11. BRACKET 18. PCV VALVE
5. INTAKE MANIFOLD 12. CAPSCREW 19. CLAMP
6. BRACKET 13. CAPSCREW 20. PCV HOSE
7. CAPSCREW 14. BRACKET 21. CLAMP
Figure 2. Intake-Air System
2
Install 5. Remove the IAT sensor. See Electrical System,

Mazda 2.0L and 2.2L Emission Compliant
1. Verify that the mounting surface of the throttle Engines 2200 SRM 1327.
body and the intake manifold are clean and free
of debris. 6. Tag and disconnect the vacuum hoses on the in-
take manifold.
2. Install new conical washers on the socket head
screws as shown in Figure 3. 7. Tag and disconnect the coolant hoses from the
intake manifold.
3. Place the throttle body and a new gasket in
position on the intake manifold and install the 8. Remove the ECT sensor. See Electrical Sys-
socket-head screws and conical washers. Tighten tem, Mazda 2.0L and 2.2L Emission Compli-
the socket-head screws to 9.5 to 12 N•m (84 to ant Engines 2200 SRM 1327.
108 lbf in).
9. Remove the MAP sensor. See Electrical Sys-
4. Connect the electrical connector to the throttle tem, Mazda 2.0L and 2.2L Emission Compli-
body. ant Engines 2200 SRM 1327.
5. Connect the air-intake hose. 10. Remove the capscrews retaining the rear bracket
(11) to the intake manifold and the cylinder head.
6. Connect the negative battery cable. Remove the bracket.
11. Remove the capscrews retaining the lower sup-

port bracket (14) to the intake manifold and re-
move the bracket.
12. Remove the nuts and the capscrews retaining the

intake manifold to the cylinder head.
13. Remove the coolant line (15) from the intake

manifold.
14. Remove the intake manifold and gasket. Discard

the gasket.
1. SOCKET HEAD SCREW 15. Remove the fuel pressure regulator. See Pres-
2. CONICAL WASHER
sure Regulator, Remove.
Figure 3. Conical Washer Positioning
16. Remove the fuel injectors and the fuel rail. See
Fuel Injectors, Remove.
INTAKE MANIFOLD
Install
Remove
1. Verify that the mounting surfaces of the intake
1. Drain the coolant from the radiator.
manifold and the cylinder head are clean and free
2. Disconnect the fuel line from the fuel rail. See from dirt or debris.
Before Repair Procedure.
2. Install the fuel injectors and the fuel rail. See
3. Remove the throttle body. See Throttle Body, Re- Fuel Injectors, Install.
move.
3. Install the fuel pressure regulator. See Pressure
4. Remove the capscrews retaining the front Regulator, Install.
bracket (6) to the intake manifold and remove
4. Place a new gasket in position on the cylinder
the bracket.
head.
3
5. Place the intake manifold in position on the cylin- 11. Install the ECT sensor. See Electrical System,
der head. Mazda 2.0L and 2.2L Emission Compliant
Engines 2200 SRM 1327.
6. Place the coolant line (15) in position on the in-
take manifold. 12. Connect the coolant hoses to the intake manifold.
7. Install the nuts and capscrews to retain the in- 13. Connect the vacuum hoses to the intake mani-
take manifold to the cylinder head. Tighten the fold.
nuts to 22 to 30 N•m (16 to 22 lbf ft). Tighten the
capscrews to 19 to 25 N•m (14 to 18 lbf ft). 14. Install the IAT sensor. See Electrical System,
8. Place the lower support bracket (14) in position Engines 2200 SRM 1327.
and install the capscrews. Tighten the capscrew
to the intake manifold to 19 to 25 N•m (14 to 15. Place the front bracket (6) in position and install
18 lbf ft). Tighten the remaining capscrew to 38 the capscrews. Tighten the capscrews to 19 to
to 51 N•m (28 to 38 lbf ft). 25 N•m (14 to 18 lbf ft).
9. Place the rear bracket in position and install 16. Install the throttle body. See Throttle Body, In-
the capscrews. Tighten the capscrews to 19 to stall.
25 N•m (14 to 18 lbf ft).
17. Connect the fuel line to the fuel rail. See After
10. Install the MAP sensor. See Electrical System, Repair Procedure.
18. Fill the radiator with coolant.
Engines 2200 SRM 1327.
Fuel System
NOTE: Always use new O-rings, seals, and gaskets NOTE: Fuel in the fuel system is under high pressure
when servicing the fuel and exhaust systems. also when the engine is not running.
BEFORE REPAIR PROCEDURE 1. Remove the fuel-filler cap and release the pres-
sure in the fuel tank.
Fuel Line Safety Procedure
2. Remove cover from the fuse holder and remove
the 10 amp fuel pump fuse. See Figure 4 or Fig-
WARNING ure 5.
Fuel vapor is hazardous. It can easily ignite,
causing serious injury and damage. Always 3. Start the engine. After the engine stalls, crank
keep sparks and flames away from fuel. the engine several times.
Fuel line spills and leakage are dangerous. 4. Turn OFF ignition.
5. Install the fuel pump 10 amp fuse.
death and damage. Fuel can also irritate skin
and eyes. To prevent this, always complete the
following procedure:
4
1. FUEL PUMP TEST PORT CONNECTOR 4. ECU INTERFACE CONNECTOR

2. ECU TIMING TEST PORT CONNECTOR 5. 50-AMP FUSE, ALTERNATOR
3. FUSES (ECU 5 AMP FUSE AND 10 AMP FUEL
PUMP FUSE)
Figure 4. Relays and Test Connectors - 2007 Emission Compliant Engines
5
NOTE: MAZDA 2.2L GAS ENGINE FOR LIFT TRUCK MODELS S40-70FT (F187) AND H40-70FT (L177) SHOWN.
PUMP FUSE)
Figure 5. Gasoline Fuses and Test Connectors - Lift Trucks Built After January, 2010
AFTER REPAIR PROCEDURE hose, observe the following procedure and the
Fuel Leakage Check procedure.
Fuel Hose, Install
1. Replace damaged or deformed fuel hoses, fuel
lines, and hose clamps.
WARNING
Fuel line spills and leakage are dangerous. 2. When installing the fuel hose on the fuel line,
Fuel can ignite and cause serious injuries or fit the hose onto the line over 25 mm (0.98 in.).
death and damage. When installing the fuel When the line has a stopper, fit the hose until it
contacts the stopper. See Figure 6.
6
Fuel Leakage Check
WARNING
death and damage. Always perform the follow-
CAUTION
Only use a jumper wire with a momentary
ing.
NOTE: When the gasoline fuel pump test port is

jumped a diagnostic trouble code (DTC) will be set
due to the fuel pump diagnostics. Clear this fault
1. FUEL LINES after the following test is complete. Refer to the sec-
2. STOPPER tion Diagnostic Troubleshooting Manual 9000
3. FUEL HOSE
SRM 1112.
Figure 6. Fuel Hose Installation
1. Install a jumper wire across the fuel pump test
NOTE: Do not use a clamp larger than the recom- port connector terminals. See Figure 4 or Fig-
mended size for the hose outside diameter. ure 5.
3. Install a hose clamp over the fuel hose within the 2. Turn the ignition ON to operate the fuel pump.
clamp installation range as shown, avoiding the
3. Pressurize the system this way for at least 5 min-
original clamp position. Tighten the clamp screw
to 2.45 to 2.77 N•m (22 to 25 lbf in). See Figure 7.
age, inspect the fuel hoses and fuel pipe sealing
surface for damage. Replace as needed.
4. After repair, assemble the system and repeat

FUEL LINE PRESSURE CHECK
WARNING
Fuel line spills and leaks are dangerous. Fuel
can ignite and cause serious injuries or death.
Fuel can also irritate skin and eyes. Always
perform the following procedure with the en-
gine stopped.

1. AVOID ORIGINAL CLAMP POSITION
2. CLAMP INSTALLATION RANGE
Figure 7. Clamp Installation
3. Connect a fuel pressure gauge to the Schrader
valve on the fuel line between the fuel filter and
the fuel rail. See Figure 8.
7
1. SCHRADER VALVE 3. FUEL FILTER

2. FRAME 4. FUEL PUMP/SENDING UNIT
Figure 8. Schrader Valve
4. Connect the negative battery cable. leakage. If it exceeds the specification, inspect
the pressure regulator and fuel line for clogging.
NOTE: When the gasoline fuel pump test port is Specification: 260 to 310 kPa (38 to 45 psi)
jumped a diagnostic trouble code (DTC) will be set
due to the fuel pump diagnostics. Clear this fault 7. Turn the ignition OFF to stop the fuel pump.
after the following test is complete. Refer to the sec-
tion Diagnostic Troubleshooting Manual 9000 8. Measure the fuel hold pressure after 5 minutes.
SRM 1112. If not within the specification, inspect the fuel
5. Install a jumper wire across the fuel pump test Specification: More than 140 kPa (20 psi)
connector terminals. See Figure 4 or Figure 5.
9. Disconnect the jumper wire.
NOTE: Make sure the fuel shutoff valve is completely
open before measuring the fuel line pressure. 10. Disconnect the fuel pressure gauge.
6. Measure the fuel line pressure. If less than the 11. Complete the After Repair Procedure.
8
FUEL INJECTORS 6. Remove the two capscrews retaining the fuel rail
to the intake manifold.
Remove
7. Remove the fuel rail and fuel injectors.
8. Remove the fuel rail insulator.
9. Remove the fuel injector insulator.
regulator. See Figure 9. 10. Remove the fuel injectors.
4. Disconnect the wiring harness from each fuel in- 11. Remove and discard O-rings.
jector.
5. Disconnect the fuel lines from the fuel rail.
1. INTAKE MANIFOLD 6. FUEL INJECTOR INSULATOR

2. CAPSCREW 7. FUEL INJECTOR
3. PRESSURE REGULATOR 8. O-RING
5. FUEL RAIL INSULATOR
Figure 9. Fuel Injector Assembly
9
Install 8. Connect the vacuum hose to the pressure regula-

tor.
1. Apply a small amount of engine oil to the new
O-rings and install them into the fuel rail. 9. Connect the fuel lines to the fuel rail.
2. Verify that the O-rings and the fuel injector seal- 10. Connect the negative battery cable.
ing surfaces are free of foreign material.
3. Install the fuel injectors in the fuel rail with light
twisting motion so that the O-rings will not be PRESSURE REGULATOR
folded.
Remove
4. Install the fuel injector insulator.
5. Install the fuel rail insulator.
6. Install the fuel rail and fuel injectors onto the
intake manifold. Install the two capscrews and 3. Disconnect the vacuum hose from the pressure
tighten to 19 to 25 N•m (14 to 18 lbf ft). regulator. See Figure 10.
7. Connect the wiring harness for each fuel injector.
1. INTAKE MANIFOLD 4. CAPSCREW

2. O-RING 5. VACUUM HOSE
3. PRESSURE REGULATOR
Figure 10. Pressure Regulator Removal/Installation
10
4. Disconnect the fuel return line from the pressure 2. Place the pressure regulator in position and in-
regulator. stall the two capscrews. Tighten the capscrews
to 7.9 to 10.7 N•m (70 to 95 lbf in).
5. Remove the two capscrews retaining the pres-
sure regulator. 3. Connect the fuel return line to the pressure reg-
ulator.
6. Remove the pressure regulator.
4. Connect the vacuum hose to the pressure regula-
7. Remove and discard the O-ring. tor.
Install 5. Connect the negative battery cable.
1. Apply a light coat of engine oil to the new O-ring 6. Complete the After Repair Procedure.
and install the O-ring.
Exhaust System
NOTE: Always use new O-rings, seals, and gaskets 3. Remove the exhaust pipe (21 in Figure 11) from
when servicing the fuel and exhaust systems. the engine exhaust manifold.
COUNTERWEIGHT EXHAUST SYSTEM 4. Remove the clamp that holds the exhaust pipe (8,
Figure 11) to the muffler. Remove the exhaust
NOTE: Remove the counterweight before removing pipe.
the muffler and other parts of the exhaust system.
See section Frame 100 SRM 1120 for procedures. 5. Remove the flange nuts that hold the exhaust
pipe (14, Figure 11) to the muffler. Remove the
In a counterweight exhaust system, the muffler is exhaust pipe and gasket. Discard gasket.
installed inside the cavity of the counterweight. A
short exhaust pipe sends the exhaust gases out of the 6. Remove flanged nuts that attach the muffler to
lift truck through a grille in the counterweight. the frame of the lift truck. Remove the muffler
from the lift truck.
Inspect
Exhaust system components are hot to touch. • Exhaust pipes for damage, corrosion, and rust and
Be sure exhaust system components are cool replace as needed.
NOTE: Lift trucks equipped with Mazda 2007 emis- needed. If replacing an exhaust pipe section that
sions compliant engine and lift trucks built after has a wrap, also replace the wrap. Do not reuse
January, 2010 are equipped with two oxygen sensors; wraps if they have been removed for a service
a pre-catalytic oxygen sensor and a post-catalytic operation.
oxygen sensor. • Catalytic converter and muffler for damage, corro-
1. Remove bracket that attaches the catalytic con- sion, and rust. Replace as needed.
verter to frame. See Figure 11. Disconnect oxy- • Start the engine and inspect the exhaust system
gen sensors. component for exhaust gas leakage. If leakage is
found, repair or replace components as necessary.
2. Disconnect the exhaust pipes (21 in Figure 11)
from the catalytic converter and remove and dis-
card the gaskets from the catalytic converter. Re-
move the catalytic converter from the lift truck.
11
1. CAPSCREW 12. POST OXYGEN SENSOR

2. WASHER 13. FLANGE NUT
4. SPACER 15. NUT
5. BRACKET 16. LOCKWASHER
6. FLANGE NUT 17. CATALYTIC CONVERTER
7. NUT 18. GASKET
8. EXHAUST PIPE 19. FLANGE NUT
9. CLAMP 20. PRE-OXYGEN SENSOR
10. MUFFLER 21. EXHAUST PIPE
11. GASKET
12
Assemble and Install Remove clamp between overhead exhaust pipe

and exhaust pipe (13 in Figure 12) and remove
1. Place the muffler onto the frame of the truck and overhead exhaust pipe.
install flanged nuts. Tighten the nuts to 39 N•m
(29 lbf ft). 2. Remove clamp that attaches exhaust pipe to muf-
fler (13 in Figure 12). Remove exhaust pipe.
2. Install the exhaust pipe (8, Figure 11) onto the
muffler. Install the clamp on the pipe to hold it NOTE: Lift trucks equipped with Mazda 2007 emis-
onto the muffler. sions compliant engine and lift trucks built after
January, 2010 are equipped with two oxygen sensors;
3. Place a new gasket on the muffler and install a pre-catalytic oxygen sensor and a post-catalytic
the exhaust pipe (14, Figure 11) onto the muffler. oxygen sensor.
Install nuts and tighten to 39 N•m (29 lbf ft).
3. Remove bracket that attaches the catalytic con-
4. Install the exhaust pipe (21 in Figure 11) onto the verter to the frame. Disconnect the oxygen sen-
engine exhaust manifold. sors.
5. Place the catalytic converter on the lift truck 4. Disconnect upper and lower exhaust pipes from
frame. Make sure that the embossed F is fac- catalytic converter and remove and discard the
ing up. Install new gaskets onto the catalytic gaskets from catalytic converter. Remove cat-
converter and install the exhaust pipes onto the alytic converter from lift truck. See Figure 12.
catalytic converter.
6. Install the bracket that attaches the catalytic haust manifold.
converter to the frame. See Figure 11. Connect
oxygen sensors. 6. Remove the flange nuts that hold the exhaust
pipe (20, Figure 12) to the muffler. Remove the
7. Install the counterweight. See section Frame exhaust pipe and gasket. Discard gasket.
100 SRM 1120 for procedures.
OVERHEAD EXHAUST SYSTEM screws that fasten the muffler to the lift truck
NOTE: Remove the counterweight before removing
the muffler and other parts of the exhaust system. Inspect
See section Frame 100 SRM 1120 for procedures.
Inspect the following items in the exhaust system:
In an overhead exhaust system, the muffler is in- • Inspect all exhaust pipes for damage, corrosion,
stalled inside the cavity of counterweight. A long ex- and rust and replace as needed.
haust pipe, located above the overhead guard, sends • If equipped, inspect all exhaust wraps for wear,
exhaust gases out of lift truck. proper fit, contamination with oil or antifreeze,
Remove and Disassemble needed. If replacing an exhaust pipe section that
has a wrap, also replace the wrap. Do not reuse
WARNING wraps if they have been removed for a service
Exhaust system components are hot to touch. operation.
Be sure exhaust system components are cool • Inspect the catalytic converter and muffler for
before starting disassembly, or personal injury damage, corrosion, and rust. Replace as needed.
may occur. • Start the engine and inspect the exhaust system
component for exhaust gas leakage. If leakage is
1. Lift cover and remove three capscrews that at- found, repair or replace components as necessary.
tach the overhead exhaust pipe to counterweight.
13
Figure 12. Overhead Exhaust System
14

3. ISOLATOR 16. POST OXYGEN SENSOR
4. SPACER 17. FLANGE NUT
5. BRACKET 18. NUT
6. FLANGE NUT 19. LOCKWASHER
8. COVER 21. CATALYTIC CONVERTER
9. OVERHEAD EXHAUST PIPE 22. GASKET
10. CAPSCREW 23. FLANGE NUT
11. WASHER 24. PRE-OXYGEN SENSOR
12. CLAMP 25. EXHAUST PIPE
13. EXHAUST PIPE
Assemble and Install pipe and secure with clamp. Install and tighten
1. Install washers, isolators, spacer, and capscrews overhead exhaust pipe to counterweight. Cover
to secure muffler to lift truck frame. Tighten cap- capscrews with cover.
EXHAUST MANIFOLD
muffler. Install the clamp on the pipe to hold it Remove
onto the muffler.
3. Place a new gasket on the muffler and install WARNING

the exhaust pipe (20, Figure 12) onto the muffler. When the engine and exhaust system are hot,
Install nuts and tighten to 39 N•m (29 lbf ft). they can cause severe burns. Turn OFF the en-
gine and wait until cool before removing the
4. Install engine exhaust pipe to engine exhaust exhaust system.
manifold using four locknuts. Tighten locknuts
to 22 N•m (195 lbf in). See Figure 12. 1. Disconnect the negative battery cable.
NOTE: Make sure that the embossed F on catalytic 2. Remove the three capscrews retaining the ex-
converter is facing up. haust manifold insulator and remove the insu-
5. Use new gaskets and install catalytic converter
to upper and lower exhaust pipes. Tighten nuts 3. Remove the four nuts retaining the exhaust pipe
to 66 N•m (49 lbf ft). to the exhaust manifold.
6. Install bracket that attaches the catalytic con- 4. Remove the six nuts and washers retaining the
verter to frame. See Figure 12. Connect oxygen exhaust manifold to the cylinder head.
sensors.
7. Install the counterweight. See section Frame
100 SRM 1120 for procedures. 6. Discard all of the old gaskets.

15
A. TO INTAKE MANIFOLD
1. VALVE COVER 10. EXHAUST PIPE
2. CYLINDER HEAD 11. GASKET
3. CAPSCREWS 12. EXHAUST MANIFOLD
4. EXHAUST MANIFOLD INSULATOR 13. GASKET
5. CAPSCREW 14. GROMMET
6. WASHER 15. POSITIVE CRANKCASE VENTILATION (PCV)
7. NUT VALVE
8. OXYGEN SENSOR 16. CLAMP
9. NUT 17. VACUUM HOSE
Figure 13. Exhaust System
16
Install Inspect
1. Place the new gaskets in position on the cylinder 1. Blow air through the PCV valve and verify that
head and the exhaust manifold. air flows as specified. See Table 1 and Figure 14.
2. Place the exhaust manifold in position on the 2. If not as specified, replace the PCV valve.
cylinder head and secure with the six nuts and
washers. Install
3. Tighten the six nuts evenly to 19 to 25 N•m (14 1. Install the PCV valve into the grommet in the
to 18 lbf ft). valve cover.
4. Verify the position of the new exhaust manifold 2. Connect the vacuum hose.
gasket to exhaust pipe is correct.
3. Slide the clamp into position.
fold and secure with the four nuts and tighten Table 1. PCV Valve Specifications
evenly.
Condition Airflow
6. Place the exhaust manifold insulator in position
and secure with the three capscrews. Tighten the
capscrews to 19 to 25 N•m (14 to 18 lbf ft). Air applied from port B No
POSITIVE CRANKCASE VENTILATION

(PCV) VALVE
Remove
1. Slide the clamp back on the vacuum hose con-
nected to the PCV valve. See Figure 13.
3. Remove the PCV valve.
Figure 14. PCV Valve
17
OXYGEN SENSOR 3. Remove oxygen sensor from the exhaust pipe.

NOTE: If the lift truck is equipped with a catalytic
convertor, there will be two oxygen sensors. There Install
will be a pre-catalytic oxygen sensor and a post-cat-
alytic oxygen sensor. 1. Coat the oxygen sensor sparingly with an anti-
seize compound. Install the oxygen sensor and
Remove tighten to 39 N•m (29 lbf ft).
1. Disconnect the battery. 2. Connect the oxygen sensor electrical connector.
2. Disconnect the oxygen sensor electrical connec- 3. Connect the battery.

tor.

2. POST-CATALYTIC CONVERTER OXYGEN 5. EXHAUST PIPE
SENSOR 6. CATALYTIC CONVERTER
3. PRE-CATALYTIC CONVERTER OXYGEN
SENSOR
Figure 15. Oxygen Sensors - 2007 Emission Compliant Engines
18
NOTE: LIFT TRUCK MODELS S40-70FT (F187) AND H40-70FT (L177) EQUIPPED WITH 2.2L ENGINE AND
BUILT AFTER JANUARY, 2010 SHOWN.
1. MUFFLER 4. PRE-CATALYTIC CONVERTER OXYGEN
2. POST-CATALYTIC CONVERTER OXYGEN SENSOR
SENSOR 5. EXHAUST PIPE
3. CATALYTIC CONVERTER 6. EXHAUST SHIELD
Figure 16. Oxygen Sensors - Lift Trucks Built After January, 2010
19
Control System
NOTE: Always use new O-rings, seals, and gaskets 3. Remove the capscrews retaining the ECU to the
when servicing the fuel and exhaust systems. mounting bracket and remove the ECU. See Fig-
ure 18.
ENGINE CONTROL UNIT (ECU)
4. If necessary, remove the socket head screws re-
Remove taining the mounting bracket to the engine and
remove the mounting bracket.
2. Disconnect the wire harness connector from the

ECU. See Figure 17.
1. CAPSCREWS
2. ECU
3. WIRE HARNESS CONNECTOR
Figure 17. ECU and Wire Harness Connector
20
Install ECU to the mounting bracket. Tighten the cap-

screws to 9.5 to 12.2 N•m (84 to 108 lbf in).
1. If removed, place the ECU mounting bracket
in position on the side of the engine and install 3. Connect the wire harness connector to the ECU.
the socket head screws to secure the mounting See Figure 17.
bracket. Tighten the socket head screws to 47.5
to 54 N•m (35 to 40 lbf ft). See Figure 18. 4. Connect the negative battery cable.
2. Place the ECU in position on the mounting

bracket and install the capscrews to retain the
1. MOUNTING BRACKET 4. CAPSCREWS

2. SOCKET HEAD SCREWS 5. ENGINE
3. ECU
Figure 18. ECU Removal/Installation
21
FUEL LEVEL SENSOR

Remove
1. Raise hood and disconnect the battery.
2. Disconnect the electrical connector from the sen-

sor on the fuel pump cover.
3. Unscrew the sensor and remove sensor and

sender unit from fuel pump assembly. See Fig-
ure 19.
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 19.
2. Connect the fuel level sensor electrical connector.
3. Connect the battery and lower the hood.
1. BRACKET
2. FUEL SENDER UNIT
3. FUEL LEVEL SENSOR
4. FUEL PUMP COVER
Figure 19. Fuel Pump and Sensor
22
900 SRM 1325 Technical Data
Technical Data
Table 2 shows the technical data specifications for
the Mazda 2.0L and 2.2L gasoline fuel systems.
Table 2. Gasoline Fuel Systems Technical Data
Engine
Item
2.0L 2.2L
Idle speed 775 to 825 (800 ±25) rpm
Fuel pressure Fuel line pressure 260 to 310 kPa (37 to 45 psi)
Fuel hold pressure More than 140 kPa (20 psi)
Fuel injector Resistance ( 20 C (68 F)) 14.2 to 14.8 Ohms
Fuel leakage Less than 1 drop/2 minutes
Injection volume 56 to 61 ml (1.9 to 2.0 oz)/15 seconds
(using a fuel injector tester).
Pressure regulator Fuel line pressure (At vacuum ON) 200 to 240 kPa (29 to 35 psi)
Fuel line pressure (At vacuum OFF) 260 to 310 kPa (37 to 45 psi)
23
NOTES
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24

LPG FUEL SYSTEM
MAZDA 2.0L AND 2.2L
S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
PART NO. 1653958 900 SRM 1326

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
LPG Tank and Bracket Replacement ............................................................................................................... 1
Remove LPG Tank 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), and
H2.0-3.5FT (H40-70FT) (L177) ..................................................................................................................... 1
Install LPG Tank for Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
H2.0-3.5FT (H40-70FT) (L177) .................................................................................................................... 3
Remove LPG Tank for Lift Truck Models S50CT (A267) and H2.0-2.5CT (H50CT) (A274) ..................... 3
LPG Tank Install for Lift Truck Models S50CT (A267) and H2.0-2.5CT (H50CT) (A274) ....................... 5
Remove LPG Bracket for Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
H2.0-3.5FT (H40-70FT) (L177) ..................................................................................................................... 6
Install LPG Bracket for Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
H2.0-3.5FT (H40-70FT) (L177) .................................................................................................................... 8
Remove LPG Tank Bracket Alignment Pin, 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) ................................................................................................ 8
Install LPG Tank Bracket Alignment Pin, 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) ................................................................................................ 10
Remove LPG Bracket for Lift Truck Models S50CT (A267) and H2.0-2.5CT (H50CT) (A274)................. 10
Install LPG Bracket for Lift Truck Models S50CT (A267) and H2.0-2.5CT (H50CT) (A274) ................... 10
Fuel Filter Unit Repair...................................................................................................................................... 11
Fuel Filter Element ....................................................................................................................................... 11
Remove....................................................................................................................................................... 11
Clean/Inspect ............................................................................................................................................. 11
Install ......................................................................................................................................................... 12
Fuel Filter Housing ....................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Disassemble ............................................................................................................................................... 14
Assemble .................................................................................................................................................... 16
Install ......................................................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Install ............................................................................................................................................................. 18
Electronic Pressure Regulator (EPR) Repair ................................................................................................... 19
Remove ........................................................................................................................................................... 19
Disassemble ................................................................................................................................................... 23
Assemble ........................................................................................................................................................ 24
Install ............................................................................................................................................................. 25
LPG Shutoff Valve Assembly............................................................................................................................. 26
Remove ........................................................................................................................................................... 26
Install ............................................................................................................................................................. 29
Fuel Mixer Repair .............................................................................................................................................. 31
Remove ........................................................................................................................................................... 31
Install ............................................................................................................................................................. 33
Control System................................................................................................................................................... 34
Remove....................................................................................................................................................... 34


Install ......................................................................................................................................................... 34
Low LPG Pressure Switch ............................................................................................................................ 36
Remove....................................................................................................................................................... 36
Install ......................................................................................................................................................... 37
LPG Low Level Sensor .................................................................................................................................. 37
Remove....................................................................................................................................................... 37
Install ......................................................................................................................................................... 40
Exhaust System ................................................................................................................................................. 40
Counterweight Exhaust System ................................................................................................................... 40
Inspect........................................................................................................................................................ 42
Overhead Exhaust System............................................................................................................................ 42
Inspect........................................................................................................................................................ 44
Remove....................................................................................................................................................... 44
Install ......................................................................................................................................................... 46
Remove....................................................................................................................................................... 46
Inspect........................................................................................................................................................ 46
Install ......................................................................................................................................................... 46
Oxygen Sensor ............................................................................................................................................... 46
Remove....................................................................................................................................................... 46
Install ......................................................................................................................................................... 46
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
ii
General
This section has the repair procedures for the parts of the LPG fuel system used on the Mazda 2.0 liter and 2.2
liter 2007 emission compliant engines and lift trucks built after January, 2010 equipped with Mazda engines.
LPG Tank and Bracket Replacement

REMOVE LPG TANK FOR LIFT TRUCK If the engine will not run, close the shutoff
MODELS S30FT, S35FT, S40FTS (E010), valve on the LPG tank. Loosen the fitting on
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, the supply hose from the LPG tank where it
enters the filter unit. Permit the pressure in
H40FTS) (F001), S2.0-3.5FT (S40-70FT, the fuel system to decrease slowly. Fuel leav-
S55FTS) (F187), AND H2.0-3.5FT ing the fitting removes heat. Use a cloth to
(H40-70FT) (L177) protect your hands from the cold fitting.
NOTE: The LPG tank bracket used on this line of

WARNING trucks to mount the LPG tank onto the counter-
LPG can cause an explosion. DO NOT cause weight comes in two styles. One style of bracket
sparks or permit flammable material near the swings out to the side of the truck and the other
LPG system. LPG fuel systems can be discon- swings out to the side and drops down (EZXchange
nected indoors only if the lift truck is at least bracket). See Figure 1.
electrical equipment, or ignition source. 1. LPG tanks can be removed and replaced indoors
only if the lift truck is at least 8 m (26 ft) from
LPG is heavier than air. LPG can stay in low any flame or ignition source. Move the lift truck
places and cause an explosion when a spark oc- to an the area where LPG tanks are changed.
curs.
DO NOT overfill the LPG tank. Liquid is ex- is completely closed.
pelled from the vent valve when the bottle has
reached the 80 percent full point. At this point, 3. Run the engine until it stops. If truck is equipped
the bottle filling operation must be halted. Fill- with a key switch, turn the key switch to the
ing the bottle to 80 percent allows the appro- OFF position. If truck is equipped with a Power
priate expansion volume within the bottle. The ON/OFF button, press the Power ON/OFF but-
tank relief valve is installed in the tank to allow ton to turn engine off.
for pressure relief if the bottle is overfilled or
if exposed to high temperatures. 4. Disconnect the quick-disconnect fitting on the
LPG tank. See Figure 1.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is discon-
tem is used and the engine stops.
1
A. SWING-OUT LPG BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET

(EZXCHANGE)
6. ALIGNMENT PIN
2
5. Push in the bracket release pin, grab the bracket c. Soapy Water - This method is used in con-
handle, and swing the tank and bracket out to junction with Step b above. If the odor of LPG
the side of the lift truck. If your truck is equipped is present, but escaping fuel cannot be heard,
with a EZXchange bracket, drop the tank down apply soapy water to the fittings and observe
to the side of the truck for ease of removal. See for bubbles.
Figure 1.
6. Unlatch the tank strap and remove the LPG tank ficient, frost may appear on the fittings.
from the bracket. See Figure 1.
REMOVE LPG TANK FOR LIFT TRUCK
INSTALL LPG TANK FOR LIFT TRUCK MODELS S50CT (A267) AND H2.0-2.5CT
MODELS S30FT, S35FT, S40FTS (E010), (H50CT) (A274)
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001), S2.0-3.5FT (S40-70FT, WARNING
S55FTS) (F187), AND H2.0-3.5FT LPG can cause an explosion. DO NOT cause
(H40-70FT) (L177) sparks or permit flammable material near the
WARNING
When closing the LPG tank strap, DO NOT electrical equipment, or ignition source.
wrap your fingers around the strap handle.
The strap can close quickly and with enough LPG is heavier than air. LPG can stay in low
force to cause injury to the fingers and hand. places and cause an explosion when a spark oc-
curs.
NOTE: The LPG bracket must be in the swing-out
position to install the LPG tank. If your lift truck DO NOT overfill the LPG tank. Liquid is ex-
has the EZXchange bracket, position the bracket in pelled from the vent valve when the bottle has
the drop-down position. reached the 80 percent full point. At this point,
the bottle filling operation must be halted. Fill-
1. Place the LPG tank into the bracket. Secure the ing the bottle to 80 percent allows the appro-
tank strap around the tank and close the strap. priate expansion volume within the bottle. The
2. Pull the stop pin (see Figure 1) and swing the tank relief valve is installed in the tank to allow
LPG tank bracket into the resting position on the for pressure relief if the bottle is overfilled or
counterweight. Be sure that the bracket locks if exposed to high temperatures.
into position. Close the shutoff valve on the LPG tank before
3. Connect the hose to the LPG fuel filter. See Fig- any part of the engine fuel system is discon-
ure 1. nected. Run the engine until the fuel in the sys-
4. Connect the quick-disconnect fitting on the LPG
tank. See Figure 1. If the engine will not run, close the shutoff
valve on the LPG tank. Loosen the fitting on
5. Turn the fuel valve counterclockwise to open the the supply hose from the LPG tank where it
fuel valve. enters the filter unit. Permit the pressure in
6. Inspect the fuel system for leaks when the fuel ing the fitting removes heat. Use a cloth to
valve is open. There are four methods used to protect your hands from the cold fitting.
a. Sound - Listen for sound of LPG escaping is completely closed.
2. Run the engine until it stops.
you smell LPG, DO NOT start the engine. 3. Disconnect the quick disconnect fitting from the
LPG tank. See Figure 2 or Figure 3.
3
Figure 2. LPG Tank and Bracket With Fabric Tank Strap for Lift Truck Models S50CT (A267) and
H2.0-2.5CT (H50CT) (A274)
4
Legend for Figure 2

A. LPG TANK STRAP LATCH C. TANK BRACKET REMOVE/INSTALL
B. LPG TANK REMOVE/INSTALL
1. LPG TANK 5. TANK BRACKET
2. QUICK DISCONNECT FITTING 6. ALIGNMENT PIN
3. LATCH 7. CAPSCREW
4. FABRIC TANK STRAP 8. COUNTERWEIGHT
NOTE: Lift truck models S50CT (A267) and H50CT 6. Remove LPG tank from tank bracket. See Fig-
(A274) may be equipped with steel tank straps. See ure 2.
Figure 3.
LPG TANK INSTALL FOR LIFT TRUCK
4. If tank is equipped with fabric strap, squeeze MODELS S50CT (A267) AND H2.0-2.5CT
latch relieving tension on tank strap. See Fig-
ure 2. Loosen tank strap enough for LPG tank to (H50CT) (A274)
be removed. 1. Place LPG tank onto tank bracket. Be sure align-
5. If tank is equipped with steel strap, unlatch tank ment pin on tank bracket is properly aligned with
strap. See Figure 3. the hole on the tank. See Figure 2.
NOTE: Lift truck models S50CT (A267) and H50CT

(A274) may be equipped with steel tank straps. See
Figure 3.
2. If tank is equipped with fabric strap, tighten tank

strap around LPG tank by pulling on loose end
until latch ratchet is tight and tank is secure.
3. If tank is equipped with steel strap, secure the

tank strap around the tank and close the strap
latch. See Figure 3.
4. Connect quick disconnect fitting onto LPG tank.

See Figure 2.

fuel valve.
6. Inspect the fuel system for leaks when the fuel

valve is open. There are four methods used to


you smell LPG, DO NOT start the engine.
1. QUICK 4. STEEL TANK
DISCONNECT STRAP c. Soapy Water - This method is used in con-
FITTING 5. TANK BRACKET junction with Step b above. If the odor of LPG
2. ALIGNMENT PIN 6. COUNTERWEIGHT is present, but escaping fuel cannot be heard,
3. LATCH
apply soapy water to the fittings and observe
Figure 3. LPG Tank and Bracket With Steel for bubbles.
Tank Strap for Lift Truck Models S50CT (A267)
and H50CT (A274)
ficient, frost may appear on the fittings.
5
REMOVE LPG BRACKET FOR LIFT TRUCK 2. Lift trucks built after January, 2010
MODELS S30FT, S35FT, S40FTS (E010), equipped with Mazda engines - Disconnect
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, the hose from the LPG fuel filter and remove
hose through hole in counterweight. See Fig-
H40FTS) (F001), S2.0-3.5FT (S40-70FT, ure 5.
S55FTS) (F187), AND H2.0-3.5FT
(H40-70FT) (L177)
NOTE: The LPG tank must be removed from the lift
truck before removing the LPG bracket. See sec-
tion Remove LPG Tank 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), and H2.0-3.5FT (H40-70FT)
(L177).
1. Lift trucks equipped with 2007 Mazda emis-

sion compliant engines only - Disconnect the
hose from the LPG fuel filter and remove hose
through hole in counterweight. See Figure 4.

2. BRACKET
4. LPG FUEL FILTER
6. CAPSCREW
1. FITTING 7. FITTING
2. HOSE ASSEMBLY 8. LPG TANK
3. CAPSCREW 9. LPG FUEL FILTER CONNECTION
4. LPG TANK
5. HOSE ASSEMBLY TO LPG FUEL FILTER Figure 5. LPG Tank Hose Connections (Lift
6. LPG FUEL FILTER CONNECTION Trucks Built After January, 2010 Equipped
8. LPG FUEL FILTER with Mazda Engines)
Figure 4. LPG Tank Hose Connections (2007

Mazda Emission Compliant Engines Only)
6
3. Lift trucks built after November, 2012 removed and handled while in the swing-out
equipped with Mazda engines - Disconnect or extended position.
the hose from the LPG fuel filter and remove
hose through hole in counterweight. See Fig- 4. Push in the bracket release pin, grab the bracket
ure 6. handle, and swing the bracket out to the side of
the lift truck. Remove capscrew. See Figure 1.
5. Pull the bracket stop pin and swing the LPG

tank bracket back into the resting position on the
counterweight. Be sure that the latch clicks shut
and locks. See Figure 1.
6. Remove capscrews and LPG tank bracket from


2. BRACKET
4. LPG FUEL FILTER
6. CAPSCREW
7. FITTING
8. LPG TANK
9. LPG FUEL FILTER CONNECTION
Figure 6. LPG Tank Hose Connections (Lift

Trucks Built After November, 2012 Equipped
with Mazda Engines)
A. LPG BRACKET - SWING-OUT OPTION
B. LPG BRACKET SWING-OUT AND DROP-DOWN
WARNING OPTION (EZ-XCHANGE)
When removing the capscrews for the LPG
tank bracket, only remove the capscrew (1, Fig- 1. CAPSCREW - REMOVE WITH BRACKET IN
SWING-OUT (EXTENDED) POSITION
ure 1) with the LPG bracket in the swing-out 2. CAPSCREW - REMOVE WITH BRACKET IN
or extended position. The LPG tank bracket RESTING POSITION ON COUNTERWEIGHT
is heavy and difficult to handle if all the cap-
screws are removed with the bracket in the Figure 7. LPG Tank Bracket Remove/Install
swing-out position. Personal injury and dam-
age to the lift truck can result if the bracket is
7
INSTALL LPG BRACKET FOR LIFT TRUCK REMOVE LPG TANK BRACKET
MODELS S30FT, S35FT, S40FTS (E010), ALIGNMENT PIN, LIFT TRUCK MODELS
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, S30FT, S35FT, S40FTS (E010), H1.6FT,
H40FTS) (F001), S2.0-3.5FT (S40-70FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
S55FTS) (F187), AND H2.0-3.5FT (F001), S2.0-3.5FT (S40-70FT, S55FTS)
(H40-70FT) (L177) (F187), AND H2.0-3.5FT (H40-70FT) (L177)
1. Lift trucks equipped with 2007 Mazda emis- The LPG tank alignment pin can be replaced if it
sion compliant engines only - Place the LPG becomes damaged or worn. There are two types of
bracket onto the counterweight. Be sure to align alignment pins used. If the LPG tank has fabric
the holes on the counterweight with the holes on straps, the alignment pin will have a weldment offset
the bracket. Insert hose assembly to LPG fuel fil- plate. If the LPG tank has a steel strap, the align-
ter through hole in counterweight. See Figure 4 ment pin will not have a weldment offset plate. See
and Figure 7. Figure 8.
2. Lift trucks built after January, 2010 1. Remove the LPG tank from LPG tank bracket.
equipped with Mazda engines - Place the See Remove LPG Tank for Lift Truck Models
LPG bracket onto the counterweight. Be sure S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
to align the holes on the counterweight with the H2.0FTS (H30FT, H35FT, H40FTS) (F001),
hole on the bracket. Insert hose assembly to LPG S2.0-3.5FT (S40-70FT, S55FTS) (F187), and
fuel filter through the hole in counterweight. See H2.0-3.5FT (H40-70FT) (L177) for procedures.
2. Remove the LPG tank bracket from lift truck.
3. Lift trucks built after November, 2012 See Remove LPG Bracket for Lift Truck Models
equipped with Mazda engines - Place the S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
LPG bracket onto the counterweight. Be sure H2.0FTS (H30FT, H35FT, H40FTS) (F001),
to align the holes on the counterweight with the S2.0-3.5FT (S40-70FT, S55FTS) (F187), and
hole on the bracket. Insert hose assembly to LPG H2.0-3.5FT (H40-70FT) (L177) for procedures.
fuel filter through the hole in counterweight. See
Figure 6 and Figure 7. 3. Remove alignment pin from LPG tank bracket.
4. Install three capscrews (2, Figure 7) and LPG a. If LPG tank is equipped with a fabric strap,
bracket onto counterweight. Tighten capscrews remove flange button head capscrew, hard-
to 38 N•m (28 lbf ft). ened washer, curved washer, spacer (if
equipped), hardened washer, and two pins
5. Push bracket release pin (button) and pull from alignment pin and weldment offset
bracket handle to swing the bracket out to the plate. Remove alignment pin and weldment
side of the lift truck. Install capscrew (1, Fig- offset plate from LPG tank bracket. See
ure 7) onto bracket. Tighten capscrew to 38 N•m Figure 9.
(28 lbf ft).
b. If LPG tank is equipped with a steel strap,
6. Install LPG tank. See section Install LPG Tank remove flange button head capscrew, hard-
for Lift Truck Models S30FT, S35FT, S40FTS ened washer, curved washer, spacer (if
(E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, equipped), and hardened washer from align-
H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, ment pin. Remove alignment pin from LPG
S55FTS) (F187), and H2.0-3.5FT (H40-70FT) tank bracket. See Figure 9.
(L177) .
8
A. ALIGNMENT PIN - LPG TANK WITH FABRIC A. LPG TANK WITH FABRIC STRAP AND
STRAP. SWING-OUT LPG BRACKET SHOWN WELDMENT OFFSET PLATE. SWING-OUT LPG
B. ALIGNMENT PIN - LPG TANK WITH STEEL BRACKET SHOWN.
STRAP. SWING-OUT AND DROP-DOWN LPG B. LPG TANK WITH STEEL STRAP. SWING-OUT
BRACKET (EZXCHANGE BRACKET) SHOWN. AND DROP-DOWN LPG BRACKET
(EZXCHANGE BRACKET) SHOWN.
1. ALIGNMENT PIN
2. PIN WELDMENT OFFSET PLATE 1. FLANGE BUTTON HEAD CAPSCREW
2. HARDENED WASHER
Figure 8. LPG Tank Alignment Pin Types 3. CURVED WASHER
4. SPACER*
5. PIN
6. ALIGNMENT PIN
7. WELDMENT OFFSET PLATE
8. SLOT
*IF EQUIPPED.
Figure 9. LPG Tank Alignment Pin Removal
9
INSTALL LPG TANK BRACKET S2.0-3.5FT (S40-70FT, S55FTS) (F187), and

ALIGNMENT PIN, LIFT TRUCK MODELS H2.0-3.5FT (H40-70FT) (L177) for procedures.
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)
1. Install new LPG tank alignment pin.
a. If LPG tank is equipped with a steel strap, in-

sert new alignment pin in slot on LPG tank
bracket. Place hardened washer, curved
washer, spacer (if equipped), and hardened
washer on flanged button head capscrew.
Install flanged button head capscrew and
hardware into bottom of alignment pin.
Tighten flanged button head capscrew to
secure alignment pin to LPG tank bracket.
See Figure 9.
b. If LPG tank is equipped with fabric strap,

insert new alignment pin and weldment off- 1. HARDENED 3. CURVED WASHER
set plate in slot on LPG tank bracket. Place WASHER 4. ALIGNMENT PIN
hardened washer, curved washer, spacer (if 2. SPACER
required), and hardened washer on flanged
Figure 10. LPG Tank Alignment Pin
button head capscrew. Install flanged but-
Measurement
ton head capscrew and hardware into hole
in weldment offset plate. Tighten flanged REMOVE LPG BRACKET FOR LIFT TRUCK
button head capscrew to secure alignment
pin and weldment offset plate to LPG tank MODELS S50CT (A267) AND H2.0-2.5CT
bracket. See Figure 9. (H50CT) (A274)
2. After LPG tank alignment pin has been in- NOTE: The LPG tank must be removed from the lift
stalled, measure the distance between the truck before removing the LPG bracket. See Remove
hardened washers. The distance should not LPG Tank for Lift Truck Models S50CT (A267) and
exceed 2 ±1 mm (0.08 ±0.04 in.). Add or re- H2.0-2.5CT (H50CT) (A274).
move spacers between the hardened washer and
1. Remove three capscrews and tank bracket from
curved washer, as needed to achieve the correct
distance. See Figure 9 and Figure 10.
3. Install LPG tank bracket onto lift truck. See INSTALL LPG BRACKET FOR LIFT TRUCK
Install LPG Bracket for Lift Truck Models MODELS S50CT (A267) AND H2.0-2.5CT
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, (H50CT) (A274)
H2.0FTS (H30FT, H35FT, H40FTS) (F001),
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and 1. Install tank bracket and three capscrews onto
H2.0-3.5FT (H40-70FT) (L177) for procedures. counterweight. See Figure 2.
4. Install LPG tank onto LPG tank bracket. 2. Install LPG tank. See LPG Tank Install for Lift
See Install LPG Tank for Lift Truck Models Truck Models S50CT (A267) and H2.0-2.5CT
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, (H50CT) (A274).
10
Fuel Filter Unit Repair

FUEL FILTER ELEMENT 4. Remove fuel filter housing top section from fuel
filter housing bottom section. See Figure 11 or
Remove Figure 12.
5. Remove and discard housing O-ring. See Fig-

WARNING
ure 11 or Figure 12.
any sparks or open flames in the work area. 6. Remove and discard fuel filter and fuel filter
O-ring. See Figure 11 or Figure 12.
1. Close fuel valve on tank. Run engine until it runs
out of fuel and stops. Try to start engine 2 to 3 Clean/Inspect
times until it no longer starts.
1. Clean and inspect the fuel filter housing top sec-
2. Disconnect negative battery cable. tion for contamination or damage. If damaged,
replace the housing.
WARNING
2. Clean and inspect the fuel filter housing bottom
section for contamination or damage. If dam-
aged, replace the housing.
closed.
3. Remove the bolt and seal washer from the fuel

filter housing top section. Discard seal washer.
See Figure 11 or Figure 12.
1. BOLT*
2. SEAL WASHER
4. FUEL FILTER
5. FUEL FILTER O-RING
1. BOLT* 6. HOUSING O-RING
2. SEAL WASHER 7. FUEL FILTER HOUSING BOTTOM SECTION*
3. FUEL FILTER HOUSING TOP SECTION* 8. LOW PRESSURE SWITCH
4. FUEL FILTER
5. FUEL FILTER O-RING *NOT SERVICED SEPARATELY
6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION* Figure 12. Fuel Filter Removal/Installation for
8. LOW PRESSURE SWITCH Lift Trucks Built After November, 2012
Figure 11. Fuel Filter Removal/Installation
11
Install wear eye protection. If liquid fuel continues

1. Install the new fuel filter and fuel filter O-ring. check to make sure the manual valve is fully
See Figure 11 or Figure 12. closed.
2. Install new housing O-ring. See Figure 11 or Fig- 3. Slowly loosen and disconnect inlet and outlet fit-
ure 12. tings.
3. Install fuel filter housing top section onto fuel 4. Disconnect low pressure switch from engine wire
filter housing bottom section. See Figure 11 or harness. See Figure 18.
Figure 12.
5. Lift trucks built after January, 2010 - If lift
4. Install bolt and new seal washer. Tighten bolt to truck is equipped with optional LPG low level
13 N•m (115 lbf in). sensor instead of a low pressure switch, discon-
nect the LPG low level sensor from engine har-
ness. See Control System for procedures.
flow of fuel. If this happens, close the fuel valve, wait 6. Lift trucks built after November , 2012 - If
a few seconds, and then slowly open the fuel valve lift truck is equipped with optional LPG low level
again. This will reset the excess flow valve. sensor instead of a low pressure switch, discon-
nect the LPG low level sensor from engine har-
ness. See Control System for procedures.
NOTE: Perform Step 7 and Step 8 for lift truck mod-
7. Turn the key to the ON position and back to els:
the OFF position to pressurize the fuel system. • S30FT, S35FT, S40FTS (E010)
Check for leaks. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
8. Check for leaks at connections by using soapy • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
solution or electron leak detector. If leaks are • H2.0-3.5FT (H40-70FT) (L177)
7. Remove the capscrews and nuts holding the fuel
FUEL FILTER HOUSING filter assembly mounting bracket to the frame.
See Figure 13 or Figure 14.
Remove
8. Remove the socket head capscrews and fuel filter
housing from the mounting bracket. Remove fuel
WARNING filter assembly. See Figure 15 or Figure 16.
any sparks or open flames in the work area. NOTE: Perform Step 9 for lift truck models
• S50CT (A267)
1. Close fuel valve on tank. Run engine until it runs • H2.0-2.5CT (H50CT) (A274)
out of fuel and stops. Try to start engine 2 to 3
times until it no longer starts. 9. Remove two capscrews, two washers, and fuel fil-
ter assembly from frame. See Figure 17.
WARNING
12
1. FRAME
2. CAPSCREW
5. MOUNTING BRACKET
Figure 14. Fuel Filter Assembly Removal/

Installation for Lift Truck Models H1.6FT,
1. FRAME H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
2. CAPSCREW (F001) and H2.0-3.5FT (H40-70FT) (L177) Built
3. NUT After November, 2012
6. MOUNTING BRACKET
Figure 13. Fuel Filter Assembly Removal/

Installation for Lift Truck Models S30FT,
S35FT, S40FTS (E010), H30FT, H35FT, H40FTS
(F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
and H40-70FT (L177)
13

2. MOUNTING BRACKET
3. SOCKET HEAD CAPSCREWS

2. MOUNTING BRACKET
3. SOCKET HEAD CAPSCREWS 1. FRAME
2. CAPSCREW
Figure 15. Fuel Filter Assembly Removal From 3. WASHER
Mounting Bracket for Lift Truck Models S30FT, 4. FUEL FILTER ASSEMBLY
S35FT, S40FTS (E010), H30FT, H35FT, H40FTS 5. LOW LEVER SENSOR.
(F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
Figure 17. Fuel Filter Assembly Remove/Install
and H40-70FT (L177)
for Lift Truck Models S50CT (A267) and
H2.0-2.5CT (H50CT) (A274)
Disassemble
1. Remove the fuel filter. See Fuel Filter Element,
Remove.
2. Remove the low pressure switch from the low

pressure switch fitting. See Figure 18.
3. Lift trucks built after January, 2010 - If lift

truck is equipped with optional LPG low level
sensor, remove sensor from LPG low level sensor
and adapter fitting from fuel filter. See Control
System and Figure 19.
4. Lift trucks built after November, 2012 - If

lift truck is equipped with optional LPG low level
sensor, remove sensor from LPG low level sensor
and adapter fitting from fuel filter. See Control
System and Figure 20.
5. Remove the inlet fitting from the fuel filter hous-

Figure 16. Fuel Filter Assembly Removal ing bottom section. See Figure 18, Figure 19, or
From Mounting Bracket for Lift Truck Models Figure 20.
H40FTS) (F001) and H2.0-3.5FT (H40-70FT)
(L177) Built After November, 2012
14
6. Remove the low pressure switch fitting from the

low pressure switch adapter. See Figure 18.
7. Lift trucks built after January, 2010 - If truck

is equipped with optional LPG low level sensor,
remove LPG low level sensor adapter fitting and
O-ring from fuel filter housing bottom section.
See Figure 19.
1. BOLT*
2. SEAL WASHER
4. FUEL FILTER ELEMENT
5. HOUSING O-RING
8. INLET FITTING
9. LPG LOW LEVEL SENSOR ADAPTER FITTING
10. O-RING*
11. OUTLET ADAPTER FITTING**
12. OUTLET FITTING**
**NOT SERVICED SEPARATELY. ADAPTER AND FIT-

TING USED IF LIFT TRUCK IS EQUIPPED WITH LOW
PRESSURE SWITCH INSTEAD OF LPG LOW LEVEL
1. BOLT*
2. SEAL WASHER SENSOR.
4. FUEL FILTER ELEMENT Figure 19. Fuel Filter Assembly - Lift Trucks
5. HOUSING O-RING Built After January, 2010
7. INLET FITTING*
9. LOW PRESSURE SWITCH FITTING*
10. LOW PRESSURE SWITCH ADAPTER*
11. O-RING*
13. OUTLET ADAPTER FITTING*
14. OUTLET FITTING*
Figure 18. Fuel Filter Assembly
15
Assemble
CAUTION
DO NOT use Teflon tape on any fuel fitting. Use
a liquid pipe thread sealant when installing fit-
tings.
1. Apply pipe thread sealant (Hyster Part No.

0246108) to the threads of the outlet fitting and
install the outlet fitting and O-ring. See Fig-
ure 18, Figure 19, or Figure 20.

0246108) on the threads of the low pressure
switch fitting. Install the low pressure switch
fitting onto the low pressure switch adapter. See
Figure 18.

0246108) on the threads of the low pressure
switch. Install the low pressure switch onto the
low pressure switch fitting.
1. BOLT*
2. SEAL WASHER 4. For lift trucks built after January, 2010 - If
3. FUEL FILTER HOUSING TOP SECTION* lift truck is equipped with optional LPG low level
4. FUEL FILTER ELEMENT sensor, apply pipe thread sealant (Hyster Part
5. HOUSING O-RING No. 0246108) to the threads of the LPG low level
7. FUEL FILTER HOUSING BOTTOM SECTION* sensor adapter fitting and install LPG low level
8. INLET FITTING sensor adapter fitting and O-ring. See Figure 19.
10. O-RING* 5. For lift trucks built after November, 2012 - If
11. OUTLET ADAPTER FITTING** lift truck is equipped with optional LPG low level
12. LPG LOW LEVEL SENSOR sensor, apply pipe thread sealant (Hyster Part
No. 0246108) to the threads of the LPG low level
sensor adapter fitting and install LPG low level
**NOT SERVICED SEPARATELY. ADAPTER AND FIT- sensor adapter fitting and O-ring. See Figure 20.
TING USED IF LIFT TRUCK IS EQUIPPED WITH LOW
6. For lift trucks built after January, 2010 - If
PRESSURE SWITCH INSTEAD OF LPG LOW LEVEL
lift truck is equipped with optional LPG low level
SENSOR.
sensor, install LPG low level sensor to LPG low
Figure 20. Fuel Filter Assembly - Lift Trucks level sensor adapter fitting and fuel filter. See
Built After November, 2012 Figure 19 or Control System for installation pro-
cedures.
8. Lift trucks built after November, 2012 - If
truck is equipped with optional LPG low level 7. For lift trucks built after November, 2012 -
sensor, remove LPG low level sensor adapter fit- If lift truck is equipped with optional LPG low
ting and O-ring from fuel filter housing bottom level sensor, install LPG low level sensor to LPG
section. See Figure 20. low level sensor adapter fitting and fuel filter.
See Figure 20 or Control System for installation
9. Remove outlet fitting from outlet adapter fitting. procedures.
Remove O-ring from outlet adapter fitting. See
Figure 18, Figure 19, or Figure 20. 8. Apply pipe thread sealant (Hyster Part No.
0246108) on the threads of the inlet fitting and
install the inlet fitting.
16
9. Install the fuel filter. See Fuel Filter Element, 4. Place the fuel filter assembly mounting bracket
Install. in position on the frame and install the capscrews
and nuts to retain the bracket to the frame. See
Install Figure 13 or Figure 14.
NOTE: Perform Step 1 for lift truck models 5. Connect engine wire harness to the low pressure
• S50CT (A267) switch.
• H2.0-2.5CT (H50CT) (A274)
6. Connect the inlet and outlet fuel lines.
1. Install fuel filter assembly, two washers, and two
capscrews onto frame. See Figure 17. NOTE: Opening the fuel valve too quickly can cause
NOTE: Perform Step 2 through Step 4 for lift truck flow of fuel. If this happens, close the fuel valve, wait
models a few seconds, and then slowly open the fuel valve
• S30FT, S35FT, S40FTS (E010) again. This will reset the excess flow valve.
H40FTS) (F001) 7. Slowly open the fuel valve on tank.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
2. Place the fuel filter assembly in position on the
mounting bracket. See Figure 15 and Figure 16.
Check for leaks.
3. Install the socket head capscrews to attach the
fuel filter housing to the mounting bracket.
Tighten socket head capscrews to 5 N•m
(44 lbf in). See Figure 15 or Figure 16.

REMOVE 1. Turn the shutoff valve clockwise until the valve
WARNING 2. Run the engine until it stops. If truck is equipped
LPG can cause an explosion. DO NOT cause with a key switch, turn the key switch to the
sparks or permit flammable material near the OFF position. If truck is equipped with a Power
LPG system. LPG fuel systems can be discon- ON/OFF button, press the Power ON/OFF but-
nected indoors only if the lift truck is at least ton to turn engine off.
electrical equipment, or ignition source. 3. Disconnect the negative battery cable.
Close the shutoff valve on the LPG tank before 4. Remove the MAP sensor. See Electrical Sys-
any part of the engine fuel system is discon- tem, Mazda 2.0L and 2.2L Emission Compli-
nected. Run the engine until the fuel in the sys- ant Engines 2200 SRM 1327 for procedures.
5. Disconnect the electrical connector from the IAT
If the engine will not run, close the shutoff sensor.
the supply hose from the LPG tank where it 6. Disconnect the electrical connector from the elec-
enters the filter unit. Permit the pressure in tronic throttle body.
7. Remove the fuel mixer. See Fuel Mixer Repair,
ing the fitting removes heat. Use a cloth to
Remove.
protect your hands from the cold fitting.
17
Electronic Throttle Body Repair 900 SRM 1326
8. Remove the screws to the cover of the air box. See 12. Remove the electronic throttle body and gasket.
Figure 21. Discard old gasket.
9. Remove the cover of the air box and the O-ring. INSTALL
10. Remove the socket head screws retaining the air 1. Clean the mating surfaces of the intake manifold
box to the throttle body and the intake manifold. and the electronic throttle body.
Remove the air box.
2. Place a new gasket in position on the intake man-
11. Remove the O-ring and sleeve from the electronic ifold.
throttle body. See Figure 22.
3. Place the electronic throttle body in position on
the new gasket and intake manifold.
4. Place the sleeve and a new O-ring on the elec-

tronic throttle body.
1. SCREW
2. COVER 1. O-RING
3. AIR BOX 2. SLEEVE
4. ELECTRONIC THROTTLE BODY 3. ELECTRONIC THROTTLE BODY
5. INTAKE MANIFOLD 4. GASKET
6. SOCKET HEAD SCREW 5. INTAKE MANIFOLD
7. O-RING
Figure 22. Electronic Throttle Body
Figure 21. Air Box Removal/Installation Removal/Installation
18
900 SRM 1326 Electronic Pressure Regulator (EPR) Repair
5. Place the air box in position on the electronic 12. Install the MAP sensor. See Electrical System,
throttle body and the mounting bracket. Install Mazda 2.0L and 2.2L Emission Compliant
the socket head screws to retain the air box and Engines 2200 SRM 1327 for procedures.
electronic throttle body to the intake manifold
but do not tighten. 13. Connect the negative battery cable.
6. Install the fuel mixer. See Fuel Mixer Repair, 14. Slowly open the fuel valve on tank.
Install.
15. If truck is equipped with a key switch, turn the
7. Tighten the socket head screws that retain the key switch to the ON position and back to the
air box and electronic throttle body to the intake OFF position to pressurize the fuel system. If
manifold to 12 N•m (106 lbf in). truck is equipped with a Power ON/OFF button,
press the Power ON/OFF button to ON and back
8. Place a new O-ring in position on the air box. OFF again to pressurize the system. Check for
leaks.
9. Place the cover in position on the air box and
install the retaining screws. 16. Check for leaks at connections by using soapy
10. Connect the electrical connector to the electronic detected, make proper repairs.
throttle body.
11. Connect the electrical connector to the IAT sen-

sor.
Electronic Pressure Regulator (EPR) Repair

REMOVE 2. Run the engine until it stops. If truck is equipped
WARNING OFF position. If truck is equipped with a Power
LPG system. LPG fuel systems can be discon- 3. Disconnect the negative battery cable.
8 m (26 ft) from any open flame, motor vehicles, 4. Disconnect the electrical connector to the LPG
electrical equipment, or ignition source. shutoff valve.
Close the shutoff valve on the LPG tank before 5. Disconnect the electrical connector to the fuel
any part of the engine fuel system is discon- temperature sensor.
tem is used and the engine stops. 6. Disconnect the electrical connector from the ac-
tuator of the EPR assembly.
If the engine will not run, close the shutoff
valve on the LPG tank. Loosen the fitting on 7. Slowly disconnect the fuel inlet line from the
the supply hose from the LPG tank where it LPG shutoff valve.
8. Put drain pan under drain valve for radiator.
Open drain valve so that coolant drains into pan.
protect your hands from the cold fitting. 9. Tag and disconnect the inlet and outlet coolant
hoses from EPR. Cap coolant hoses. See Fig-
ure 23 or Figure 24.
19
Electronic Pressure Regulator (EPR) Repair 900 SRM 1326
10. Disconnect the fuel outlet line from the EPR as-
sembly. See Figure 25 or Figure 26.
11. Disconnect balance line from EPR assembly.
12. Remove the nuts holding the EPR assembly to

the mounting bracket and remove the EPR. See
Figure 27 or Figure 28.
1. FUEL OUTLET LINE

2. EPR ASSEMBLY
Figure 25. Fuel Outlet Line
1. COOLANT OUTLET HOSE

2. EPR ASSEMBLY
3. COOLANT INLET HOSE
Figure 23. EPR Coolant Hoses
1. FUEL OUTLET LINE

2. EPR ASSEMBLY
Figure 26. Fuel Outlet Line for Lift Trucks

Built After November, 2012
1. COOLANT OUTLET HOSE

2. EPR ASSEMBLY
3. COOLANT INLET HOSE
Figure 24. EPR Coolant Hoses for Lift Trucks

Built After November, 2012
20
Figure 27. EPR Assembly Removal/Installation
21

1. LPG SHUTOFF VALVE 9. VIBRATION MOUNTS
2. 90 DEGREE FITTING 10. NUTS
3. EPR ASSEMBLY 11. MOUNTING BRACKET
4. PLUG 12. RETAINING PINS
5. O-RINGS 13. FUEL OUTLET FITTING
6. O-RINGS 14. COOLANT OUTLET FITTING
7. COOLANT INLET FITTING 15. BALANCE LINE FITTING
8. FUEL TEMPERATURE SENSOR 16. 90 DEGREE FITTING
1. LPG SHUTOFF VALVE 9. VIBRATION MOUNTS

2. 90 DEGREE FITTING 10. NUTS
3. EPR ASSEMBLY 11. MOUNTING BRACKET
4. PLUG 12. RETAINING PINS
5. O-RINGS 13. FUEL OUTLET FITTING
6. O-RINGS 14. COOLANT OUTLET FITTING
7. COOLANT INLET FITTING 15. BALANCE LINE FITTING
8. FUEL TEMPERATURE SENSOR 16. 90 DEGREE FITTING
Figure 28. EPR Assembly Removal/Installation for Lift Trucks Built After November, 2012
22
DISASSEMBLE
CAUTION
1. Remove the vibration mounts from the bottom of Use care when removing the regulator from the
the EPR assembly. See Figure 27 or Figure 28. actuator to prevent damage to the secondary
lever of the regulator and the diaphragm of
2. Remove the retaining pins from the coolant inlet
the actuator. Neither part is serviceable and if
and outlet fittings and remove fittings. If neces-
damaged, the EPR assembly must be replaced.
sary, remove and discard O-rings.
NOTE: The lever from the primary valve slides into
3. Remove the retaining pin from the fuel tempera-
a slot of the secondary diaphragm, requiring the reg-
ture sensor and remove sensor. If necessary, re-
ulator to be moved sideways to free the tab from the
move and discard O-rings.
diaphragm.
4. Remove retaining pin from the fuel outlet fitting
8. Gently pull the regulator away from the actuator.
and remove fitting. If necessary, remove and dis-
If necessary, tap around the edge of the face plate
card O-rings.
with the handle of a plastic screwdriver to break
5. If necessary, remove balance line fitting from the regulator free. Remove and discard clamp
EPR assembly. plate seal.
6. Remove both 90 degree fittings and LPG shutoff 9. Place regulator face down and remove the retain-
valve as an assembly. See LPG Shutoff Valve ing screw holding the secondary lever.
Assembly, Remove.
10. Remove the secondary lever, fulcrum pin, and
NOTE: Be sure to identify the type of screw and its secondary spring. See Figure 30.
location during each stage of disassembly to ensure
11. Remove the secondary seat from the secondary
proper placement during reassembly.
lever.
7. Remove the six screws that retain the regulator
12. Remove the secondary valve jet from the regula-
to the actuator. See Figure 29.
tor body.
13. Inspect lever and fulcrum pin for excessive wear.

If the pin diameter is reduced at any point or
if the holes in the lever are irregular (oblong),
the EPR assembly is not repairable and must be
replaced.
14. Turn the regulator over and remove the screws

from the face cover of the regulator and remove
cover.
15. Remove the primary diaphragm.
16. Remove the secondary body cover plate.
17. Remove the retaining clip from the primary valve

pin.
18. Remove the primary valve pin and spring from

the secondary body cover plate.
19. Remove the secondary body gasket.

1. EPR REGULATOR (SERVICEABLE)
2. EPR ACTUATOR (NOT SERVICEABLE)
3. SCREW
Figure 29. EPR Assembly Disassemble/Assemble
23
2. Holding the valve pin in place, turn the body

CAUTION cover plate over. Place the valve pin spring over
Use only safety solvents for cleaning of the the valve pin and install retaining clip.
regulator and its components. Solvents such
as carburetor cleaners and brake cleaners may 3. Place a new secondary body gasket in position in
damage gaskets, seals, O-rings, diaphragms, or position on the secondary body cover plate, en-
other non-metal components. suring that the small hole in the gasket is aligned
with the small hole in the secondary body cover.
20. Inspect the regulator body and cover plates for
debris, deposits, heavy ends, and damage. Clean 4. Place the secondary body plate cover and gasket
components using a safety solvent. Inspect for in position on the front of the regulator body, en-
damaged or cracked components. If damaged or suring that the holes in the gasket are aligned
cracked components are found, replace the regu- with all screw holes.
lator.
ASSEMBLE
1. Place the new primary valve pin into the cover
plate orifice.
1. SCREW 10. REGULATOR BODY

2. FACE COVER 11. SECONDARY VALVE JET
3. PRIMARY DIAPHRAGM 12. SECONDARY SEAT
4. RETAINING CLIP 13. SECONDARY SPRING
5. PRIMARY SPRING 14. SECONDARY LEVER
6. PRIMARY VALVE PIN 15. SCREW
7. PRIMARY TEST PORT PLUG 16. FULCRUM PIN
8. SECONDARY BODY COVER PLATE 17. CLAMP PLATE SEAL
9. SECONDARY BODY GASKET
Figure 30. EPR Disassemble/Assemble
24
5. Position new primary diaphragm on the face of 16. Clean balance line fitting and apply pipe thread
the body cover using the screw holes for proper sealant (Hyster Part No. 0246108) to the threads
alignment. of the fitting and install the fitting on the EPR
assembly.
6. Place the regulator face over the diaphragm and
hand thread all seven screws through the face 17. Lubricate new O-rings using a lubricant compat-
plate and body cover into the regulator body. ible with LPG and install O-rings on the fuel out-
Tighten screws to 4.5 N•m (40 lbf in) in a criss- let fitting.
cross pattern.
18. Insert fuel outlet fitting into the EPR assembly
7. Install a new secondary seat on the secondary and install the retaining pin.
lever.
19. Lubricate new O-rings using a lubricant compat-
8. Install the secondary valve jet into the LPG reg- ible with LPG and install O-rings on the fuel tem-
ulator. perature sensor.
9. Place the secondary spring in position in the back 20. Insert fuel temperature sensor into the EPR as-
of the regulator body. sembly and install the retaining pin.
10. Position the secondary lever and fulcrum pin as- 21. Lubricate new O-rings using a lubricant compat-
sembly on top of the secondary spring. Push ible with LPG and install O-rings on the coolant
down, compressing the spring until the fulcrum inlet and outlet fittings.
pin can be slid into place.
22. Insert coolant inlet and outlet fittings into the
11. Install the screw to hold the lever and tighten EPR assembly and install the retaining pins.
screw to 4.5 N•m (40 lbf in).
23. Install the vibration mounts on the bottom of the
12. Verify the secondary lever height by placing a EPR assembly and tighten the vibration mounts
straight edge over the mating surface (rim) of until they are tight against the EPR assembly.
the regulator body. The distance between the
rim of the regulator (as determined by a straight INSTALL
edge) and lever should be 0.794 mm (0.031 in.).
If the measurement does not meet the specifica- 1. Place the EPR assembly in position on the
tion, the EPR cannot be repaired and must be re- mounting bracket.
placed.
2. Install the retaining nuts on the vibration
13. Place the regulator above the actuator, noting the mounts to secure the EPR assembly to the
position of the lever tab and slot on the secondary mounting bracket. Tighten the retaining nuts to
diaphragm. Carefully slide the lever tab into the 19 to 24 N•m (14 to 18 lbf ft).
slot of the secondary diaphragm and align the
3. Connect the balance line to the balance line fit-
regulator to the actuator. Place the regulator on
ting on the EPR assembly.
top the actuator, aligning the screw holes.
4. Connect the fuel outlet line to the EPR assembly.
14. Insert the six screws through the actuator and
into the regulator. Tighten screws to 4.5 N•m 5. Connect the coolant inlet and outlet hoses to the
(40 lbf in). coolant inlet and outlet fittings on the EPR as-
sembly.
WARNING
6. Connect the fuel inlet line to the LPG shutoff
DO NOT use Teflon tape to seal any LPG fit-
valve.
tings.
7. Connect the electrical connect to the actuator of
15. Clean shutoff valve fitting and apply pipe thread
the EPR assembly.
sealant (Hyster Part No. 0246108) to the threads
of the fitting and install the assembly on the EPR 8. Connect the electrical connector to the fuel tem-
assembly. See LPG Shutoff Valve Assembly, In- perature sensor.
stall.
25
LPG Shutoff Valve Assembly 900 SRM 1326
9. Connect the electrical connector to the LPG shut- 13. Slowly open the fuel valve on tank.
off valve.
10. Connect the negative battery cable. key switch to the ON position and back to the
OFF position to pressurize the fuel system. If
11. Fill the cooling system. Refer to the section Pe- truck is equipped with a Power ON/OFF button,
riodic Maintenance for your lift truck. press the Power ON/OFF button to ON and back
OFF again to pressurize the system. Check for
12. Bleed the air from the regulator by removing the
leaks.
radiator cap and disconnecting the coolant outlet
hose until coolant flows from the regulator. Con- 15. Check for leaks at connections by using soapy
nect the coolant outlet hose and check the coolant solution or electron leak detector. If leaks are
level. Refill the cooling system as needed as de- detected, make proper repairs.
scribed in the section Periodic Maintenance
for your lift truck. Install radiator cap.
LPG Shutoff Valve Assembly

REMOVE 5. Slowly disconnect the fuel inlet line from the
LPG shutoff valve.
WARNING 6. Remove the 90 degree fuel inlet fitting from the
LPG can cause an explosion. DO NOT cause LPG shutoff valve assembly. See Figure 31, Fig-
sparks or permit flammable material near the ure 32 and Figure 33.



2. Run the engine until it stops. If truck is equipped

OFF position. If truck is equipped with a Power
1. 90 DEGREE FUEL INLET FITTING
3. Disconnect the negative battery cable. 2. LPG SHUTOFF VALVE ASSEMBLY
3. EPR
4. Disconnect the electrical connector to the LPG
shutoff valve. Figure 31. 90 Degree Fuel Inlet Fitting Removal
- 2007 Emissions Compliant Engines
26
900 SRM 1326 LPG Shutoff Valve Assembly

2. LPG SHUTOFF VALVE ASSEMBLY
3. EPR
4. LPG SHUTOFF VALVE ELECTRICAL
CONNECTOR
7. Remove the LPG shutoff valve and the 90 degree

fitting connecting it to the EPR as an assembly.
See Figure 34, Figure 35 and Figure 36.

3. EPR
CONNECTOR
Figure 32. 90 Degree Fuel Inlet Fitting Removal

- Lift Trucks Built After January, 2010

2. EPR
3. 90 DEGREE FITTING
Figure 34. LPG Shutoff Valve Assembly

Figure 33. 90 Degree Fuel Inlet Fitting Removal
Removal/Installation - 2007 Emissions
- Lift Trucks Built After November, 2012
Compliant Engines
27

3. EPR

Removal/Installation - Lift Trucks Built After
November, 2012
3. EPR

Removal/Installation - Lift Trucks Built After
January, 2010
28
900 SRM 1326 LPG Shutoff Valve Assembly
8. Remove the 90 degree fitting that connects the Legend for Figure 38
LPG shutoff valve to the EPR from the LPG shut-
off valve. See Figure 37, Figure 38 or Figure 39. 1. LPG SHUTOFF VALVE
2. 90 DEGREE FITTING, LPG SHUTOFF VALVE TO
EPR
CONNECTOR
1. LPG SHUTOFF VALVE

EPR
Figure 37. LPG Shutoff Valve Disassembly/

Assembly - 2007 Emissions Compliant Engines

EPR
CONNECTOR
Figure 39. LPG Shutoff Valve Disassembly/

Assembly - Lift Trucks Built After November,
2012
9. Clean the threads of the 90 degree fittings.
INSTALL
0246108) to the threads of the LPG shutoff
valve.
2. Install the 90 degree fitting that connects the

LPG shutoff valve to the EPR into the LPG
shutoff valve and torque until tight, keeping the
Figure 38. LPG Shutoff Valve Disassembly/ alignment of the fitting as shown in Figure 40,
Assembly - Lift Trucks Built After January, Figure 41 and Figure 42.
2010
29

EPR

EPR
Figure 40. LPG Shutoff Valve to EPR Fitting EPR
Alignment - 2007 Emissions Compliant Engines 2. LPG SHUTOFF VALVE
Figure 42. LPG Shutoff Valve to EPR Fitting

Alignment - Lift Trucks Built After November,
2012

0246108) to the threads of the 90 degree that
connects the LPG shutoff valve to the EPR.
4. Install the LPG shutoff valve as an assembly on

the EPR and torque until tight.

0246108) to the threads of the 90 degree fuel
inlet fitting.
6. Install the 90 degree fitting into the LPG shutoff

valve and torque until tight, keeping the align-
ment of the fitting as shown in Figure 43.
Figure 41. LPG Shutoff Valve to EPR Fitting

Alignment - Lift Trucks Built After January,
2010
30
900 SRM 1326 Fuel Mixer Repair
7. Connect the electrical connector to the LPG shut-

off valve.
8. Connect the fuel inlet to the LPG shutoff valve.

key switch to the ON position and back to the
truck is equipped with a Power ON/OFF button,
leaks.

Figure 43. LPG Shutoff Valve Fuel Inlet Fitting
Alignment
Fuel Mixer Repair

REMOVE the fuel system to decrease slowly. Fuel leav-
WARNING protect your hands from the cold fitting.
LPG can cause an explosion. DO NOT cause 1. Turn the shutoff valve clockwise until the valve
sparks or permit flammable material near the is completely closed.
nected indoors only if the lift truck is at least 2. Run the engine until it stops. If truck is equipped
8 m (26 ft) from any open flame, motor vehicles, with a key switch, turn the key switch to the
electrical equipment, or ignition source. OFF position. If truck is equipped with a Power
Close the shutoff valve on the LPG tank before ton to turn engine off.
nected. Run the engine until the fuel in the sys- 3. Disconnect the negative battery cable.
4. Disconnect the air intake hose from the fuel
If the engine will not run, close the shutoff mixer.
the supply hose from the LPG tank where it 5. Disconnect the balance line from the fuel mixer.
enters the filter unit. Permit the pressure in See Figure 44 and Figure 45.
31
Fuel Mixer Repair 900 SRM 1326
6. Disconnect the fuel line from the fuel mixer.
7. Remove the four capscrews retaining the fuel

mixer to the air box and mounting bracket. See
Figure 46.
8. Remove the fuel mixer and gasket. Discard old

gasket. See Figure 47.
9. If necessary, remove the 90 degree balance line

fitting. See Figure 48.
10. Remove the fuel line fitting retaining pin and re-
move fuel line fitting.
11. Remove O-rings from fuel line fitting and dis-

card.
1. FUEL MIXER 3. FUEL LINE

2. BALANCE LINE
Figure 44. Balance Line and Fuel Line
1. FUEL MIXER 4. MOUNTING

2. AIR BOX BRACKET
3. CAPSCREWS
Figure 46. Fuel Mixer Mounting Capscrews
1. FUEL MIXER 3. FUEL LINE

2. BALANCE LINE
Figure 45. Balance Line and Fuel Line for Lift

Trucks Built After November, 2012
32
900 SRM 1326 Fuel Mixer Repair
INSTALL
1. Lubricate new O-rings using a lubricant compat-
ible with LPG and install O-rings on the fuel fit-
ting.
2. Insert fuel fitting into the fuel mixer and install

the retaining pin.
3. Clean balance line fitting and apply pipe thread

sealant (Hyster Part No. 0246108) to the threads
of the fitting and install the fitting on the fuel
mixer.
4. Clean the mating surfaces of the fuel mixer and

air box.
5. Place a new gasket in position on the air box.
6. Place the fuel mixer in position on the gasket and

air box. Install the four capscrews to retain the
fuel mixer to the air box and mounting bracket.
Tighten capscrews to 9 N•m (80 lbf in).
7. Connect the fuel line to the fuel mixer.
8. Connect the balance line to the fuel mixer.
9. Connect the air intake hose to the fuel mixer.

OFF position to pressurize the fuel system. If 1. FUEL MIXER 3. AIR BOX
truck is equipped with a Power ON/OFF button, 2. GASKET
OFF again to pressurize the system. Check for Figure 47. Fuel Mixer Mounting Capscrews
leaks.

33

1. FUEL MIXER
2. 90 DEGREE BALANCE LINE FITTING
3. RETAINING PIN
4. O-RINGS
5. FUEL INLET FITTING
Figure 48. Fuel Mixer
Control System
NOTE: Always use new O-rings, seals, and gaskets Install
when servicing the fuel and exhaust systems.
1. If removed, place the ECU mounting bracket
ENGINE CONTROL UNIT (ECU) in position on the side of the engine and install
the capscrews to secure the mounting bracket.
Remove Tighten the capscrews to 47.5 to 54 N•m (35 to
40 lbf ft). See Figure 50.
2. Place the ECU in position on the mounting
2. Disconnect the wire harness connector from the bracket and install the capscrews to retain the
ECU. See Figure 49. ECU to the mounting bracket. Tighten the cap-
3. Remove the capscrews retaining the ECU to the
mounting bracket and remove the ECU. See Fig- 3. Connect the wire harness connector to the ECU.
4. If necessary, remove the capscrews retaining the 4. Connect the negative battery cable.
mounting bracket to the engine and remove the
mounting bracket.
34
1. ECU 2. WIRE HARNESS CONNECTOR
Figure 49. ECU and Wire Harness Connector
35
1. MOUNTING BRACKET 4. CAPSCREWS

2. CAPSCREWS 5. ENGINE
3. ECU
Figure 50. ECU Removal/Installation
LOW LPG PRESSURE SWITCH WARNING

Remove
WARNING to flow from the connections when loosened,
LPG can cause an explosion. DO NOT permit check to make sure the manual valve is fully
any sparks or open flames in the work area. closed.
1. Close fuel valve on tank. Run engine until it runs 4. Slowly loosen and remove the low LPG pressure
out of fuel and stops. Try to start engine 2 to 3 switch from the low LPG pressure switch fitting.
times until it no longer starts. See Figure 51.
2. Disconnect the battery.
3. Disconnect engine wire harness from low LPG

pressure switch.
36
4. Connect the battery.

Check for leaks.

LPG LOW LEVEL SENSOR

NOTE: The procedures below are for lift trucks built
after January, 2010 and equipped with an optional
LPG low level sensor.
Remove
WARNING
1. LOW LPG PRESSURE SWITCH electrical equipment, or ignition source.
2. LOW LPG PRESSURE SWITCH FITTING
3. FUEL FILTER ASSEMBLY Close the shutoff valve on the LPG tank before
Figure 51. Low LPG Pressure Switch nected. Run the engine until the fuel in the sys-
Install
CAUTION
DO NOT use Teflon tape on any fuel fitting. Use enters the filter unit. Permit the pressure in
a liquid pipe thread sealant when installing fit- the fuel system to decrease slowly. Fuel leav-
tings. ing the fitting removes heat. Use a cloth to
1. Apply pipe thread sealant (Hyster Part No. protect your hands from the cold fitting.
0246108) on the threads of the low LPG pressure 1. Close shutoff valve on LPG tank. Run engine
switch fitting. Install the low LPG pressure until it runs out of fuel and stops. Try to start
switch fitting onto the low LPG pressure switch engine 2 to 3 times until it no longer starts.
adapter.
2. Raise hood.
2. Connect engine wire harness to the low LPG
pressure switch. 3. Disconnect the battery.
NOTE: Opening the fuel valve too quickly can cause 4. Disconnect engine wire harness from LPG low
the internal excess flow valve to close, restricting the level sensor connector.
a few seconds, and then slowly open the fuel valve 5. Disconnect outlet hose from outlet fitting. Re-
again. This will reset the excess flow valve. move outlet fitting from LPG low level sensor.
37

WARNING closed.
the fuel line. Use gloves to prevent burns and 6. Slowly loosen and remove the LPG low level sen-
wear eye protection. If liquid fuel continues sor from LPG low level sensor adapter fitting.
to flow from the connections when loosened, See Figure 52 and Figure 53.
NOTE: LPG LOW LEVEL SENSOR, FUEL FILTER AND MOUNTING BRACKET ARRANGEMENT FOR LIFT
TRUCK MODELS H2.0-3.5FT (H40-70FT) (L177) SHOWN. LPG LOW LEVEL SENSOR, FUEL FILTER AND
MOUNTING BRACKET ARRANGEMENT IS DIFFERENT ON TRUCKS COVERED IN THIS MANUAL, BUT
LOCATION ON ENGINE IS THE SAME.
1. LPG LOW LEVEL SENSOR 3. LPG FUEL FILTER
2. LPG LOW LEVEL SENSOR CONNECTOR 4. SENSOR FITTINGS
Figure 52. LPG Low Level Sensor Location for Lift Trucks Built After January, 2010
38
A. LPG LOW LEVEL SENSOR AND FUEL FILTER D. LPG LOW LEVEL SENSOR AND FUEL FILTER
ARRANGEMENT FOR LIFT TRUCKS S30FT, ARRANGEMENT FOR LIFT TRUCKS H2.0-3.5FT
S35FT, 40FTS (E010) (H40-70FT) (L177)
B. LPG LOW LEVEL SENSOR AND FUEL FILTER E. LPG LOW LEVEL SENSOR AND FUEL FILTER
ARRANGEMENT FOR LIFT TRUCKS H1.6FT, ARRANGEMENT FOR LIFT TRUCKS S50CT
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (A267) AND H2.0-2.5CT (H50CT) (A274)
(F001)
C. LPG LOW LEVEL SENSOR AND FUEL FILTER
ARRANGEMENT FOR LIFT TRUCKS S2.0-3.5FT
(S40-70FT, S55FTS) (F187)
1. FUEL FILTER 5. LPG LOW LEVEL SENSOR CONNECTOR
2. INLET FITTING 6. OUTLET FITTING
3. LPG LOW LEVEL SENSOR 7. MOUNTING BRACKET
Figure 53. LPG Low Level Sensor, Replace for Lift Trucks Built After January, 2010
39
Install NOTE: Opening the fuel valve too quickly can cause
CAUTION flow of fuel. If this happens, close the fuel valve, wait
DO NOT use Teflon tape on any fuel fittings.
Use a liquid pipe thread sealant when in-
stalling fittings. 4. Slowly open the fuel valve on tank.
NOTE: Install the LPG low level sensor with UP ar- 5. Connect the battery.
row pointing upwards. See Figure 52 and Figure 53.
6. Close hood.
1. Apply pipe thread sealant, Hyster Part No.
0246108, onto LPG low level sensor adapter 7. Turn the key to the ON position and back to
fitting. Install LPG low level sensor onto LPG the OFF position to pressurize the fuel system.
low level sensor adapter fitting See Figure 53. Check for leaks.
2. Apply pipe thread sealant, Hyster Part No. 8. Check for leaks at connections by using soap and
0246108, onto threads of outlet fitting. Install water solution or electron leak detector. If leaks
outlet fitting into LPG low level sensor. Connect are detected, make proper repairs.
outlet hose to outlet fitting.
3. Connect engine wire harness to LPG low level

sensor connector. See Figure 52 and Figure 53.
Exhaust System
NOTE: Always use new O-rings, seals, and gaskets Remove and Disassemble
when servicing the fuel and exhaust systems.
WARNING
COUNTERWEIGHT EXHAUST SYSTEM Exhaust system components are hot to touch.
NOTE: Remove the counterweight before removing Be sure exhaust system components are cool
the muffler and other parts of the exhaust system. before starting disassembly, or personal injury
may occur.
See section Frame 100 SRM 1120 for lift truck mod-
els NOTE: Lift trucks equipped with Mazda 2007 emis-
• S30FT, S35FT, S40FTS (E010) sions compliant engine and lift trucks built after
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, January, 2010 are equipped with two oxygen sensors;
H40FTS) (F001) a pre-catalytic oxygen sensor and a post-catalytic
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) oxygen sensor.
• H2.0-3.5FT (H40-70FT) (L177)
1. Remove bracket that attaches the catalytic con-
for procedures.
verter to frame. See Figure 54. Disconnect oxy-
See section Frame 100 SRM 1423 for lift truck mod- gen sensors.
els
2. Disconnect the exhaust pipes (21 in Figure 54)
• S50CT (A267)
from the catalytic converter and remove and dis-
• H2.0-2.5CT (H50CT) (A274)
card the gaskets from the catalytic converter. Re-
for procedures.
move the catalytic converter from the lift truck.
In a counterweight exhaust system, the muffler is
3. Remove the exhaust pipe (21 in Figure 54) from
installed inside the cavity of the counterweight. A
the engine exhaust manifold.
short exhaust pipe sends the exhaust gases out of the
lift truck through a grille in the counterweight. 4. Remove the clamp that holds the exhaust pipe (8,
Figure 54) to the muffler. Remove the exhaust
pipe.
40
5. Remove the flange nuts that hold the exhaust 6. Remove the flanged nuts that attach the muffler
pipe (14, Figure 54) to the muffler. Remove the to the frame of the lift truck. Remove the muffler
exhaust pipe and gasket. Discard gasket. from the lift truck.
1. CAPSCREW 8. EXHAUST PIPE 15. NUT

2. WASHER 9. CLAMP 16. LOCKWASHER
3. ISOLATOR 10. MUFFLER 17. CATALYTIC CONVERTER
4. SPACER 11. GASKET 18. GASKET
5. BRACKET 12. POST OXYGEN SENSOR 19. FLANGE NUT
6. FLANGE NUT 13. FLANGE NUT 20. PRE-OXYGEN SENSOR
7. NUT 14. EXHAUST PIPE 21. EXHAUST PIPE
41
Inspect See section Frame 100 SRM 1423 for lift truck
models
Inspect the following items in the exhaust system: • S50CT (A267)
• Exhaust pipes for damage, corrosion, and rust and • H2.0-2.5CT (H50CT) (A274)
replace as needed. for procedures.
proper fit, contamination with oil or antifreeze, OVERHEAD EXHAUST SYSTEM
needed. If replacing an exhaust pipe section that NOTE: Remove the counterweight before removing
has a wrap, also replace the wrap. Do not reuse the muffler and other parts of the exhaust system.
wraps if they have been removed for a service See section Frame 100 SRM 1120 for lift truck mod-
operation. els
• Catalytic converter and muffler for damage, corro- • S30FT, S35FT, S40FTS (E010)
sion, and rust. Replace as needed. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• Start the engine and inspect the exhaust system H40FTS) (F001)
component for exhaust gas leakage. If leakage is • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
found, repair or replace components as necessary. • H2.0-3.5FT (H40-70FT) (L177)
for procedures.
In an overhead exhaust system, the muffler is in-
1. Place the muffler onto the frame of the truck stalled inside the cavity of counterweight. A long ex-
and install the flanged nuts. Tighten the nuts haust pipe, located above the overhead guard, sends
to 39 N•m (29 lbf ft). exhaust gases out of lift truck.
2. Install the exhaust pipe (8, Figure 54) onto the Remove and Disassemble
muffler. Install the clamp on the pipe to hold it
onto the muffler.
WARNING
3. Place a new gasket on the muffler and install Exhaust system components are hot to touch.
the exhaust pipe (14, Figure 54) onto the muffler. Be sure exhaust system components are cool
Install nuts and tighten to 39 N•m (29 lbf ft). before starting disassembly, or personal injury
may occur.
4. Install the exhaust pipe (21 in Figure 54) onto the
engine exhaust manifold. 1. Lift cover and remove three capscrews that at-
tach the overhead exhaust pipe to counterweight.
5. Place the catalytic converter on the lift truck Remove clamp between overhead exhaust pipe
frame. Make sure that the embossed F is fac- and exhaust pipe (13 in Figure 55) and remove
ing up. Install new gaskets onto the catalytic overhead exhaust pipe.
converter and install the exhaust pipes onto the
catalytic converter. 2. Remove clamp that attaches exhaust pipe to muf-
fler (13 in Figure 55). Remove exhaust pipe.
6. Install the bracket that attaches the catalytic
converter to the frame. See Figure 54. Connect NOTE: The Mazda 2007 emission compliant en-
the oxygen sensors. gines and lift trucks built after January, 2010 are
equipped with two oxygen sensors, a pre-oxygen
7. Install the counterweight. sensor and post oxygen sensor.
See section Frame 100 SRM 1120 for lift truck 3. Remove bracket that attaches the catalytic con-
models verter to the frame. Disconnect the oxygen sen-
• S30FT, S35FT, S40FTS (E010) sors.
H40FTS) (F001) 4. Disconnect upper and lower exhaust pipes from
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) catalytic converter and remove and discard the
• H2.0-3.5FT (H40-70FT) (L177) gaskets from catalytic converter. Remove cat-
for procedures. alytic converter from lift truck. See Figure 55.
42
Figure 55. Overhead Exhaust System
43

1. CAPSCREW 10. CAPSCREW 19. LOCKWASHER
2. WASHER 11. WASHER 20. EXHAUST PIPE
3. ISOLATOR 12. CLAMP 21. CATALYTIC CONVERTER
4. SPACER 13. EXHAUST PIPE 22. GASKET
5. BRACKET 14. MUFFLER 23. FLANGE NUT
6. FLANGE NUT 15. GASKET 24. PRE-OXYGEN SENSOR
7. NUT 16. POST OXYGEN SENSOR 25. EXHAUST PIPE
8. COVER 17. FLANGE NUT
9. OVERHEAD EXHAUST PIPE 18. NUT
5. Remove engine exhaust pipe from engine ex- NOTE: Make sure that the embossed F on catalytic
haust manifold. converter is facing up.
6. Remove the flange nuts that hold the exhaust 5. Use new gaskets and install catalytic converter
pipe (20, Figure 55) to the muffler. Remove the to upper and lower exhaust pipes. Tighten nuts
exhaust pipe and gasket. Discard gasket. to 66 N•m (49 lbf ft).
7. Remove the washers, isolators, spacers, and cap- 6. Install bracket that attaches the catalytic con-
screws that fasten the muffler to the lift truck verter to frame. See Figure 55. Connect oxygen
frame and remove muffler from lift truck. sensors.
Inspect 7. Install the counterweight.
Inspect the following items in the exhaust system: See section Frame 100 SRM 1120 for procedures
• Inspect all exhaust pipes for damage, corrosion, for lift truck models
and rust and replace as needed. • S30FT, S35FT, S40FTS (E010)
• If equipped, inspect all exhaust wraps for wear, • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
proper fit, contamination with oil or antifreeze, H40FTS) (F001)
gaps in coverage, failed fasteners and replace as • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
needed. If replacing an exhaust pipe section that • H2.0-3.5FT (H40-70FT) (L177)
has a wrap, also replace the wrap. Do not reuse
operation.
• Start the engine and inspect the exhaust system
component for exhaust gas leakage. If leakage is
found, repair or replace components as necessary.
EXHAUST MANIFOLD
Remove
1. Install washers, isolators, spacer, and capscrews
to secure muffler to lift truck frame. Tighten cap- WARNING
screws to 39 N•m (29 lbf ft). When the engine and exhaust system are hot,
they can cause severe burns. Turn OFF the en-
gine and wait until cool before removing the
muffler. Install the clamp on the pipe to hold it
exhaust system.
onto the muffler.
3. Place a new gasket on the muffler and install
the exhaust pipe (20, Figure 55) onto the muffler. 2. Remove the three capscrews retaining the ex-
Install nuts and tighten to 39 N•m (29 lbf ft). haust manifold insulator and remove the insu-
manifold using four locknuts. Tighten locknuts 3. Remove the four nuts retaining the exhaust pipe
to 22 N•m (195 lbf in). See Figure 55. to the exhaust manifold.
44
4. Remove the six nuts and washers retaining the 6. Discard all of the old gaskets.
exhaust manifold to the cylinder head.
A. TO INTAKE MANIFOLD
1. VALVE COVER 7. NUT 14. GROMMET
2. CYLINDER HEAD 8. OXYGEN SENSOR 15. POSITIVE CRANKCASE
3. CAPSCREWS 9. NUT VENTILATION (PCV) VALVE
4. EXHAUST MANIFOLD 10. EXHAUST PIPE 16. CLAMP
INSULATOR 11. GASKET 17. VACUUM HOSE
5. CAPSCREW 12. EXHAUST MANIFOLD
Figure 56. Exhaust System Manifold
45
Install
1. Place the new gaskets in position on the cylinder
head and the exhaust manifold.
2. Place the exhaust manifold in position on the

cylinder head and secure with the six nuts and
washers.
3. Tighten the six nuts evenly to 19 to 25 N•m (14

to 18 lbf ft).
4. Verify the position of the new exhaust manifold

gasket to exhaust pipe is correct.
5. Connect the exhaust pipe to the exhaust mani- Figure 57. PCV Valve
fold and secure with the four nuts and tighten
evenly. 2. If not as specified, replace the PCV valve.
6. Place the exhaust manifold insulator in position Install

and secure with the three capscrews. Tighten the
capscrews to 19 to 25 N•m (14 to 18 lbf ft). 1. Install the PCV valve into the grommet in the
valve cover.
2. Connect the vacuum hose.
POSITIVE CRANKCASE VENTILATION 3. Slide the clamp into position.
(PCV) VALVE
OXYGEN SENSOR
Remove
NOTE: If the lift truck is equipped with a catalytic
1. Slide the clamp back on the vacuum hose con- convertor, there will be two oxygen sensors. There
nected to the PCV valve. See Figure 56. will be a pre-catalytic oxygen sensor and a post-cat-
alytic oxygen sensor.
3. Remove the PCV valve. Remove

Inspect
2. Disconnect the oxygen sensor electrical connec-
1. Blow air through the PCV valve and verify that
tor.
air flows as specified. See Table 1 and Figure 57.
3. Remove oxygen sensor from the exhaust pipe.
Table 1. PCV Valve Specifications
Condition Airflow
Install
1. Coat the oxygen sensor sparingly with an anti-
Air applied from port B No seize compound. Install the oxygen sensor and
tighten to 39 N•m (29 lbf ft).
2. Connect the oxygen sensor electrical connector.
46

2. POST-CATALYTIC CONVERTER OXYGEN 5. EXHAUST PIPE
SENSOR 6. CATALYTIC CONVERTER
3. PRE-CATALYTIC CONVERTER OXYGEN
SENSOR
Figure 58. Oxygen Sensors - 2007 Emission Compliant Engines
47
NOTE: LIFT TRUCK MODELS S2.0-3.5FT (S40-70FT) (F187) AND H2.0-3.5FT (H40-70FT) (L177) EQUIPPED
WITH 2.2L ENGINE AND BUILT AFTER JANUARY, 2010 SHOWN.
1. MUFFLER 4. PRE-CATALYTIC CONVERTER OXYGEN
2. POST-CATALYTIC CONVERTER OXYGEN SENSOR
SENSOR 5. EXHAUST PIPE
3. CATALYTIC CONVERTER 6. EXHAUST SHIELD
Figure 59. Oxygen Sensors - Lift Trucks Built After January, 2010
48

ELECTRICAL SYSTEM
MAZDA 2.0L AND 2.2L
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580521 2200 SRM 1143

SAFETY PRECAUTIONS

trucks.
nance section.
manual:
WARNING
CAUTION
Electrical System Table of Contents
TABLE OF CONTENTS
Ignition System .................................................................................................................................................. 1

General ........................................................................................................................................................... 1
Ignition Timing Adjustment, Gasoline and LPG ......................................................................................... 1
Spark Plugs Check ........................................................................................................................................ 1
Spark Plug Wires Check................................................................................................................................ 1
Distributor Repair.............................................................................................................................................. 4
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 5
Assemble ........................................................................................................................................................ 6
Install ............................................................................................................................................................. 6
Igniter............................................................................................................................................................. 7
Remove....................................................................................................................................................... 7
Test ............................................................................................................................................................. 7
Install ......................................................................................................................................................... 7
Voltage Check ............................................................................................................................................ 8
Ignition Coil Check ............................................................................................................................................ 9
Primary Coil Winding.................................................................................................................................... 9
Secondary Coil Winding ................................................................................................................................ 9
Starter Repair .................................................................................................................................................... 10
General ........................................................................................................................................................... 10
Remove ........................................................................................................................................................... 10
No-Load Test .................................................................................................................................................. 11
Magnetic Switch Test .................................................................................................................................... 11
Pull-Out Test ............................................................................................................................................. 11
Holding Coil Test ....................................................................................................................................... 12
Return Test ................................................................................................................................................ 12
Pinion Movement Inspection .................................................................................................................... 12
Install ............................................................................................................................................................. 12
General ........................................................................................................................................................... 13
Charging System Inspection ......................................................................................................................... 13
Output Current Check .................................................................................................................................. 14
No-Load Adjusted Voltage Check ................................................................................................................. 14
Remove ........................................................................................................................................................... 15
Inspect ............................................................................................................................................................ 15
Rectifier Check .......................................................................................................................................... 15
Install ............................................................................................................................................................. 16
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
Ignition System
GENERAL 8. If timing is correct, tighten the distributor
mounting bolt to 19 to 25 N•m (14 to 18 lbf ft).
An electronic ignition system HEI (high energy igni- See Figure 3.
tion) is employed. This system incorporates a con-
tactless distributor. Since the contactless distributor SPARK PLUGS CHECK
does not use contacting points, frequent maintenance
is eliminated. 1. Check condition of the spark plugs. Replace the
spark plugs if any of the following conditions ex-
IGNITION TIMING ADJUSTMENT, ist:
GASOLINE AND LPG • Abnormal burning of the insulator
• Damage to the insulator
1. Warm up the engine to normal operating temper- • Burning of the electrode
ature. • Carbon deposits
• Damage and weakening of the gasket
2. Make sure all accessories are OFF.
2. Using a spark plug gauge, measure the gap. The
3. Install a jumper wire across the engine control correct spark plug gap is 0.7 to 0.8 mm (0.028 to
unit (ECU) test port connector terminals. See 0.032 in.). If the gap is incorrect, bend the elec-
Figure 1 and Figure 2. trode slightly and measure again. Repeat until
the correct gap is obtained.
4. Connect the timing light to the high-tension lead
of No. 1 cylinder. 3. Install the spark plugs in the engine and tighten
to 14.7 to 22.5 N•m (130 to 199 lbf in).
NOTE: Do not use the BTDC timing marks on the
timing cover when timing the engine.
SPARK PLUG WIRES CHECK
5. Verify that the timing mark (orange mark) on
Using an ohmmeter, check the resistance of each
the crankshaft pulley aligns with the indicator
spark plug wire. See Table 1. If the spark plug wire
on the oil pump. See Figure 3. If not as specified,
resistance is not as specified, replace the wire.
loosen the distributor mounting bolt and turn the
distributor to adjust the ignition timing to 6 ±1 Table 1. Spark Plug Wire
BTDC. See Figure 3.
Spark Plug Wire No. 1 2.57 to 6.65
6. Remove the jumper wire from the ECU test port
connector. Spark Plug Wire No. 2 3.53 to 8.89
7. Verify that the timing varies within the range Spark Plug Wire No. 3 4.10 to 10.23
of 6 ATDC and 21 BTDC. If not as specified, Spark Plug Wire No. 4 5.26 to 12.92
inspect the following:
• CMP sensor Coil Wire 5.02 to 12.36
• TP sensor
• ECT sensor
If the devices are normal, replace the ECU.
1
1. FUEL PUMP TEST CONNECTOR 4. FUEL PUMP RELAY

2. ECU TEST PORT 5. GCU INTERFACE
3. 10-AMP FUSE, FUEL PUMP 6. 50-AMP FUSE, ALTERNATOR
Figure 1. Gasoline Relays and Test Connectors
2
1. ECU TEST PORT 3. 50-AMP FUSE, ALTERNATOR

2. ECU INTERFACE
Figure 2. LPG Relays and Test Connectors
3
Distributor Repair 2200 SRM 1143
Legend for Figure 3
NOTE: DO NOT USE THE BTDC TIMING MARKS ON

THE TIMING COVER WHEN TIMING THE ENGINE.
1. INDICATOR
2. TIMING MARK (ORANGE)
3. DISTRIBUTOR
Figure 3. Timing Mark Location
Distributor Repair
REMOVE 1. Disconnect the negative battery cable.
2. Rotate crankshaft until No. 1 piston is at TDC

WARNING on compression stroke. Make note of position of
Always disconnect the battery ground cable be- distributor rotor. See Figure 4.
age and injury. Install a tag on the battery ter- 3. Remove distributor cap and place in area near
minal so that no one connects the cable on the distributor. See Figure 5.
terminal.
4. Disconnect the electrical connector from the side
of the distributor. See Figure 5.
CAUTION
Do NOT move the engine crankshaft while the 5. Remove capscrew from flange of distributor shaft
distributor is removed. If the crankshaft is housing. Lift distributor assembly from engine.
moved, the distributor will not be installed
correctly. 6. Make alignment marks on the engine and the
distributor housing to aid in the correct instal-
NOTE: Do only the steps that are necessary to replace lation of the distributor. Mark position of rotor.
the part that has damage.
4
2200 SRM 1143 Distributor Repair
1. SPARK PLUG 4. DISTRIBUTOR

WIRES MOUNTING BOLT
2. COIL WIRE 5. DISTRIBUTOR
3. ELECTRICAL 6. O-RING
CONNECTOR 7. DRIVE GEAR
Figure 5. Distributor Removal
7. Remove and discard the O-ring from the engine.

See Figure 5.
DISASSEMBLE
1. Remove two screws and the distributor cap from
the distributor body. See Figure 6.
2. Remove the rotor from the distributor body. See

Figure 6.
NOTE: DO NOT USE THE BTDC TIMING MARKS ON 3. Remove the cover from the distributor body. See
THE TIMING COVER WHEN TIMING THE ENGINE. Figure 6.
1. INDICATOR
2. TIMING MARK (ORANGE) INSPECT
3. MATCHING MARKS
4. DISTRIBUTOR HOUSING Inspect the components of the distributor for cracks,
5. DISTRIBUTOR GEAR breaks, and wear. Replace if necessary. Inspect the
6. DISTRIBUTOR drive gear for excessive wear and broken, missing, or
worn teeth. If any of these conditions exist, replace
Figure 4. Distributor Replacement
the distributor.
5
1. SCREW 4. COVER
2. DISTRIBUTOR CAP 5. DISTRIBUTOR BODY
3. ROTOR
Figure 6. Distributor
ASSEMBLE 1. Install a new O-ring, coated with clean engine oil,

onto the distributor. See Figure 5.
1. Install the cover on the distributor body. See Fig-
ure 6.
CAUTION
2. Install the rotor onto the distributor. See Fig- If the engine crankshaft has been moved since
ure 6. the distributor was removed, see the repair
procedures for the engine to correctly install
3. Install the distributor cap on the distributor
the distributor. Do NOT do Step 2.
body. See Figure 6.
2. Make sure the alignment marks on the distribu-
4. Install two screws in the distributor cap. See
tor gear and the distributor housing are properly
Figure 6.
aligned. Install the distributor into the engine
without turning the distributor housing. Install
INSTALL the distributor mounting bolt and tighten to 19
NOTE: Coat the new O-ring and the gear on the dis- to 25 N•m (14 to 18 lbf ft). See Figure 4.
tributor with clean engine oil.
6
2200 SRM 1143 Distributor Repair
3. Connect the electrical connector to the side of the

distributor. See Figure 5.
4. Connect the spark plug wires to the distributor

cap, if removed. Check firing order. See Figure 5.
5. Re-time the engine. Refer to Ignition Timing Ad-

justment, Gasoline and LPG.
IGNITER
Remove
1. Disconnect the electrical connector from the ig-
niter. See Figure 7.
2. Remove the socket-head screws and nuts retain-

ing the igniter to the mounting plate. See Fig-
ure 8.
3. Remove the igniter.
Test
NOTE: For the igniter workbench test, the technician
will need a 270-ohm resistor, a 12-volt battery, an
ohmmeter, and a switch to assemble the test circuit.
1. Connect the igniter, resistor, battery, ohmmeter,

and switch as shown in Figure 9. Turn the switch
from OFF to ON. Check that the needle on the
ohmmeter wavers for a moment when the switch
is turned ON. If the needle does not waver, re-
place the igniter.
Install
1. Place the igniter in position on the mounting
2. Install the socket-head screws and nuts to retain

the igniter to the mounting plate. Tighten the 1. FRAME
socket-head screws to 1.5 N•m (13 lbf in). 2. IGNITER
3. COIL
3. Connect the electrical connector to the igniter. 4. ELECTRICAL CONNECTOR
See Figure 7. 5. CONDENSER
Figure 7. Igniter Location
7
CAMSHAFT POSITION (CMP) SENSOR

Voltage Check
WARNING
with the fuel injector connector still connected
fuel injector connector.
WARNING
with the high-tension lead still connected will
shock. Disconnect the high-tension lead and
avoid from grounding it to the vehicle body.
1. NUTS
2. MOUNTING PLATE 1. Verify that the ignition is OFF.
3. IGNITER
4. SOCKET-HEAD SCREWS 2. Remove the distributor.
5. COIL
6. CONDENSER 3. Connect the distributor 4-pin connector.
Figure 8. Igniter Removal/Installation 4. Disconnect the high-tension lead from the dis-
tributor side.
6. Measure the voltage between terminal 3 (signal)

7. Rotate the distributor drive by hand and verify

the output signal. If not as specified, inspect the
related wiring harnesses for open or short. If
wiring harnesses are okay, replace the distribu-
tor.
Specification: 4 pulse (5.0 V)/rev.
1. SWITCH 3. OHMMETER
2. IGNITER
Figure 9. Igniter Test Connections
8
2200 SRM 1143 Ignition Coil Check
1. DISTRIBUTOR
Ignition Coil Check

PRIMARY COIL WINDING SECONDARY COIL WINDING
Using an ohmmeter connected to the ignition coil as Using an ohmmeter connected to the ignition coil
shown in Figure 11, measure the resistance of the as shown in Figure 12, measure the resistance of
primary coil. The resistance should be 0.81 to 0.99 the secondary coil. The resistance should be 10.4 to
at 20 C (68 F). If the resistance is not within the spec- 15.6 at 20 C (68 F). If the resistance is not within
ifications, replace the ignition coil. the specifications, replace the ignition coil.
Figure 11. Primary Coil Check

Figure 12. Secondary Coil Check
9
Starter Repair 2200 SRM 1143
Starter Repair
GENERAL If the starter does not turn or turns unsatisfacto-
rily, inspect the following items before removing the
The starter solenoid is energized when 12 volts is ap- starter:
plied to the solenoid terminal. The solenoid magnet- • Battery discharging
ically pushes the clutch out to engage the engine fly- • Loose or corroded battery terminals
wheel teeth. The solenoid also closes contacts to en- • Loose or damaged wiring
ergize the starter motor. These operations occur at • Loose starter terminals
approximately the same time. The motor torque is • Ignition switch operation
applied just as the teeth engage. The starter con-
nections and circuitry are shown in Figure 13. The
specifications for the starter are given in Table 2.
Table 2. Starter Specifications
Model FFSN-18-400
Manufacturer Mitsubishi
Electric
Applied Engine Gasoline and
LPG
Nominal Output 12V - 0.9kW
Rated Time 30 Seconds
Rotation Direction Clockwise from
the pinion end 1. BATTERY POSITIVE POST
view 2. SOLENOID TERMINAL
3. STARTER
No Load Test Voltage 12 V
Figure 13. Starter
Current 90 A or less
RPM 2800 rpm or REMOVE
more
Lock Test Voltage 3.5 V WARNING
Always disconnect the battery ground cable be-
Current 550 A or less fore making repairs to prevent possible dam-
Torque 12.2 N•m age and injury. Install a tag on the battery ter-
(9.0 lbf ft) minal so that no one connects the cable on the
terminal.
Magnetic Switch Operating 8 V or less
Voltage 1. Disconnect battery cable at negative terminal.
4 Install a tag on battery terminal to warn against
Brushes Number
connecting cable.
Standard Size 16.5 mm 2. Put labels on wires and cables prior to discon-
(0.65 in.) necting to aid in correct installation.
Wear Limit 10 mm 3. Hold starter so it won’t fall. Remove two cap-
(0.39 in.) screws that fasten the starter to the flywheel
Commutator Groove Depth 0.5 to 0.8 mm housing. Remove starter from flywheel housing.
(0.02 to
0.03 in.)
10
NO-LOAD TEST
CAUTION
1. After the starter has been removed, perform the Do not apply current for more than 10 seconds.
no-load test. If the results are not as expected,
check Table 3 to find the cause of the problem. 2. Apply voltage between the S and M terminals of
Disassemble the starter only as required to re- the starter. Switch wires to see if the plunger is
pair the problem. actuated, moving the pinion out. See Figure 15.
Table 3. Problem Diagnosis Chart
Test Result Probable Cause

High indicated current Lack of lubrication/
and low rpm (low damaged bearings
rotation torque)
Armature coil or field
coil grounding
Armature coil short
circuit
High indicated current Magnetic switch
and no rotation grounding
coil grounding
Bearing seizure
No rotation without Armature coil or field
current coil open
Brush open
Commutator dirty
Poor brush contact due
to worn commutator A. BLOCK DIAGRAM
B. SCHEMATIC DIAGRAM
Low indicated current Improper field coil
and low rpm connection 1. STARTER 4. BATTERY
2. STARTER 5. VOLTMETER
High indicated current Field coil short circuit TERMINALS 6. AMMETER
and high rpm 3. SWITCH 7. SHUNT
Figure 14. No-Load Test Configuration

2. Connect a fully-charged 12 V battery with an am-
meter and a voltmeter to form the circuit shown
in Figure 14, and connect the starter switch ter-
minal to the positive (+) terminal of the battery.
If the ammeter indicates 90 A or below at 2,800
rpm, the starter is OK.
MAGNETIC SWITCH TEST

Pull-Out Test
Figure 15. Pull-Out Test
1. Disconnect the lead wire between the M terminal
and the starter.
11
Holding Coil Test Pinion Movement Inspection

1. Disconnect the lead wire between the M terminal 1. Disconnect the lead wire between the M terminal
and the starter. and the starter.
CAUTION CAUTION
Do not apply current for more than 10 seconds. Do not apply current for more than 20 seconds.
2. Apply voltage between the S terminal and the 2. Apply voltage between the S terminal and the
body of the magnetic switch, and manually pull body of the starter. This will cause the pinion to
the pinion out. See Figure 16. Make sure the extend out. With the pinion extended, measure
pinion does not return when released. the pinion gap. See Figure 18. If the pinion gap
is not within specification, repair or replace the
clutch shaft assembly.
Figure 16. Holding Coil Test
Return Test
and the starter. Figure 18. Pinion Gap
INSTALL
CAUTION
Do not apply current for more than 10 seconds. 1. Place starter in position in flywheel housing. In-
stall two capscrews to fasten the starter to the
2. Apply voltage between the M terminal and the flywheel housing. Tighten capscrews to 38 N•m
body of the magnetic switch, and pry the pinion (28 lbf ft).
out with a screwdriver. See Figure 17. Make sure
the pinion returns when released. 2. Connect wires and cables as labeled in removal.
3. Connect battery cable at negative terminal.
Figure 17. Return Test
12
2200 SRM 1143 Alternator Repair
Alternator Repair
GENERAL • Do not connect a load over 1 A on the L ter-
minal.
CAUTION • Do not ground the L terminal while engine is
operating.
• Connecting the battery in reverse polarity al-
lows high current to flow from the battery to NOTE: Always use a fully-charged battery.
the alternator, damaging the diodes and reg-
ulator. The alternator is connected as shown in Figure 19.
• Do not remove the battery terminal while en-
gine is operating. This procedure may some- CHARGING SYSTEM INSPECTION
times cause a surge in voltage, damaging the
diodes and regulator. 1. Connect a voltmeter between the alternator L
• Do not use a high-voltage tester such as a terminal and ground. See Figure 20.
Megger because it may damage the diodes
2. If voltage is present between the L terminal and
and regulator.
ground with the ignition switch turned to OFF,
• Always disconnect the battery terminal when
the alternator is faulty. Repair or replace the
charging the battery with a quick charger.
alternator.
If the terminals are not disconnected during
rapid charging, the diodes or regulator may 3. If the voltage is 0 volts with the ignition switch
be damaged. turned to ON, the alternator or the wiring is
• When steam cleaning, take care not to spray faulty. Perform wiring continuity and connection
steam directly on the alternator. checks. If no problems are found, repair or re-
• If the L and B terminals are short-circuited place the alternator.
during operation, the rectifier (diode trio)
may be damaged.
B. BATTERY TERMINAL POST R. REGULATOR TERMINAL

L. FIELD TERMINAL
1. STATOR COIL 3. IC REGULATOR
2. RECTIFIER 4. FIELD COIL
Figure 19. Alternator Schematic
13
Table 4. Specifications (Continued)
Pulley rotation direction Clockwise (from

the pulley side)
Output Voltage 13.5V
current
Current Hot 7A or 30A or
[ 20 C
more more
(68 F)]
Cold 12A or 37A or
more more
Rotation speed 1300 2500
rpm rpm
Regulator type IC regulator
1. ALTERNATOR 2. VOLTMETER Unloaded adjusted voltage 14.7 ±0.3V
Figure 20. Charging System Inspection
OUTPUT CURRENT CHECK

1. Verify that the alternator fuse is good. See Fig-
ure 1 and Figure 2.
CAUTION
When removing the wire from the alternator
B terminal, use care not to short the wire to a
ground.
2. Remove the wire from the alternator B terminal.
3. Connect an ammeter capable of measuring over

40 amperes between the alternator B terminal
and connector. See Figure 21.
1. ALTERNATOR 3. BATTERY
4. Install a tachometer to measure engine rpm. 2. AMMETER
5. Start the engine and rapidly increase the rpm Figure 21. Output Current Check
to 2,300. At this point, read the value on the
ammeter. NO-LOAD ADJUSTED VOLTAGE CHECK
At this time, set all the electric components to 1. Verify that the alternator fuse is good. See Fig-
ON to create a maximum load. ure 1 and Figure 2.
If the ammeter indicates more that 90% of nom-

inal output, the alternator is operating properly. CAUTION
Table 4. Specifications B terminal, use care not to short the wire to a
ground.
Applied engine Gasoline, LPG
Nominal output 12V-40A
Grounding polarity ( ) negative 3. Connect an ammeter capable of measuring over
40 amperes between the alternator B terminal
and connector. See Figure 22.
14
4. Connect a voltmeter between the alternator L INSPECT

terminal and ground. See Figure 22.
Rectifier Check
5. Start the engine and increase the rpm to 2,000.
1. Using an ohmmeter, check for continuity of the
At this time, set all unnecessary electric compo- diodes. See Table 5 and Figure 23. If continuity
nents to OFF. is not as specified, replace the rectifier.
6. When the current in Step 5 is 5 amperes or less, Table 5. Rectifier Check Table
read the L terminal voltage. The voltage should
be 14.7 ±0.3 V. This is the adjusted voltage. Negative Positive Continuity
E Yes
B P1, P2, P3 No
T No
E No
P1, P2, P3 B Yes
T Yes
1. ALTERNATOR 3. AMMETER
2. VOLTMETER 4. BATTERY
Figure 22. No-Load Adjusted Voltage Check
REMOVE
WARNING
age and injury. Install a tag on the battery ter-
minal so that no one connects the cable to the
terminal.
1. Disconnect battery cable at negative battery ter-

minal.
2. Put labels on wire connected to B terminal and

wire connected to ground terminal. Remove
wires from terminals and disconnect connector
plug from alternator.
3. Remove capscrews, washers, and nuts that fas-

ten alternator to engine. Remove alternator. Figure 23. Rectifier Inspection
15
INSTALL 3. Connect plug to alternator connector. Connect

other wires to B and ground terminals as indi-
1. Install alternator on engine using capscrews, cated on labels. Connect negative cable on bat-
washers, and nut. tery terminal.
2. Install belt on pulley. Adjust belt tension as de-
scribed in the Periodic Maintenance section.
16

ELECTRICAL SYSTEM
MAZDA 2.0L AND 2.2L
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]; S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1653959 2200 SRM 1327

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Ignition System .................................................................................................................................................. 1
General ........................................................................................................................................................... 1
Ignition Timing Adjustment, Gasoline and LPG ......................................................................................... 1
Spark Plugs Check ........................................................................................................................................ 6
Spark Plug Wires Check ............................................................................................................................... 6
Coil Replacement ............................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Inspect ............................................................................................................................................................ 8
Install ............................................................................................................................................................. 8
Starter Repair .................................................................................................................................................... 8
General ........................................................................................................................................................... 8
Remove ........................................................................................................................................................... 8
No-Load Test .................................................................................................................................................. 10
Magnetic Switch Test .................................................................................................................................... 10
Pull-Out Test ............................................................................................................................................. 10
Holding Coil Test ....................................................................................................................................... 11
Return Test ................................................................................................................................................ 11
Pinion Movement Inspection .................................................................................................................... 11
Install ............................................................................................................................................................. 11
General ........................................................................................................................................................... 12
Charging System Inspection ......................................................................................................................... 13
Output Current Check .................................................................................................................................. 14
No-Load Adjusted Voltage Check ................................................................................................................. 15
Remove ........................................................................................................................................................... 15
Inspect ............................................................................................................................................................ 16
Rectifier Check .......................................................................................................................................... 16
Install ............................................................................................................................................................. 17
Engine Sensors and Switches............................................................................................................................ 17
Oil Pressure Sensor, Gas and LPG Engines................................................................................................. 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 17
Air Filter Restriction Switch, Gas and LPG Engines .................................................................................. 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Cam Angle Sensor, Gas and LPG Engines ................................................................................................... 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Voltage Check ............................................................................................................................................ 20
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines ........................................................... 21
Remove....................................................................................................................................................... 21
Install ......................................................................................................................................................... 21
Intake Air Temperature (IAT) Sensor, LPG Engines .................................................................................. 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 22
Intake Air Temperature (IAT) Sensor, Gas Engines ................................................................................... 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 23
Fuel Temperature Sensor, LPG Engines ...................................................................................................... 24
Remove....................................................................................................................................................... 24

Table of Contents Electrical System

Install ......................................................................................................................................................... 25
Engine Coolant Temperature (ECT) Sensor ................................................................................................ 25
2007 Emissions Compliant Gas Engines ................................................................................................. 25
Remove .................................................................................................................................................. 25
Install..................................................................................................................................................... 25
2007 and 2010 Emissions Compliant LPG Engines ................................................................................ 26
Remove .................................................................................................................................................. 26
Install..................................................................................................................................................... 26
2010 Emissions Compliant Gas and LPG Engines ................................................................................. 27
Remove .................................................................................................................................................. 27
Install..................................................................................................................................................... 27
S50CT [A267];
H2.0-2.5CT (H50CT) [A274];
S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
ii
General
This service manual covers the repair and replace- engines and on lift trucks built after January, 2010
ment of electrical components used on the Mazda that are equipped with a Mazda 2.0L and 2.2L gas
2.0L and 2.2L gas and LPG 2007 emissions compliant and LPG engine.
Ignition System
GENERAL IGNITION TIMING ADJUSTMENT,
GASOLINE AND LPG
A CAM angle sensor is adopted for this ignition sys-
tem. See Figure 1. This sensor incorporates a crank The base ignition timing is adjustable by rotating the
position sensor that detects SGT signal (crank angle cam angle sensor housing. To check or set the timing,
signal) and SGC signal (cylinder discrimination sig- perform the following procedures:
nal).
1. Warm up the engine to normal operating temper-
ature.
2. Make sure all accessories are OFF.
3. Verify the engine speed is between 500 to 900

rpm.
4. Install a jumper wire across the engine control

unit (ECU) timing test port connector terminals.
For lift trucks equipped with a 2007 emissions

compliant gasoline engine, see Figure 2.
For lift trucks equipped with a 2007 emissions

compliant LPG engine, see Figure 3.
For lift trucks built after January, 2010 equipped

Figure 1. CAM Angle Sensor with a gasoline engine, see Figure 4.
For lift truck built after January, 2010 equipped

with an LPG engine, see Figure 5.
1

PUMP FUSE)
Figure 2. Gasoline Fuses and Test Connectors - 2007 Emissions Compliant Engines
2
1. ECU TIMING TEST PORT CONNECTOR 3. ECU INTERFACE CONNECTOR

2. FUSE HOLDER (ECU 5 AMP FUSE AND 10 AMP 4. 50-AMP FUSE, ALTERNATOR
EPR FUSE)
Figure 3. LPG Fuses and Test Connectors - 2007 Emissions Compliant Engines
3

PUMP FUSE)
Figure 4. Gasoline Fuses and Test Connectors - Lift Trucks Built After January, 2010
4
1. ECU TIMING TEST PORT CONNECTOR 3. ECU INTERFACE CONNECTOR

2. FUSE HOLDER (ECU 5 AMP FUSE AND 10 AMP 4. 60-AMP FUSE, ALTERNATOR
EPR FUSE)
Figure 5. LPG Fuses and Test Connectors - Lift Trucks Built After January, 2010
5
5. Connect the timing light to the spark plug wire Legend for Figure 7
of the No. 1 cylinder.
1. MOUNTING BOLT
NOTE: DO NOT use the BTDC timing marks on the 2. CAM ANGLE SENSOR
timing cover when timing the engine.
7. If timing is correct, tighten the CAM angle sensor
6. Verify that the timing mark (orange mark) on the mounting bolt to 19 to 25 N•m (14 to 18 lbf ft).
crankshaft pulley aligns with the indicator on the See Figure 7.
oil pump. See Figure 6. If not as specified, loosen
8. Repeat Step 6 to verify the CAM angle sen-
the CAM angle sensor housing mounting bolt and
sor housing did not move when tightening the
turn the CAM angle sensor housing to adjust the
mounting bolt.
ignition timing to 6 ±1° BTDC. See Figure 7.
9. Remove the jumper wire from the ECU timing
NOTE: When the orange timing mark aligns with the
test port connector.
indicator on the oil pump, the ignition timing is set
to 6 degrees BTDC. SPARK PLUGS CHECK
1. Check condition of the spark plugs. Replace the
spark plugs if any of the following conditions ex-
ist:
• Abnormal burning of the insulator
• Damage to the insulator
• Burning of the electrode
• Carbon deposits
• Damage and weakening of the gasket
2. Using a spark plug gauge, measure the gap. The

correct spark plug gap is 0.7 to 0.8 mm (0.028 to
0.032 in.). If the gap is incorrect, bend the elec-
trode slightly and measure again. Repeat until
NOTE: DO NOT USE THE BTDC TIMING MARKS ON the correct gap is obtained.
THE TIMING COVER WHEN TIMING THE ENGINE.
3. Install the spark plugs in the engine and tighten
1. TIMING MARK (ORANGE) to 14.7 to 22.5 N•m (130 to 199 lbf in).
2. INDICATOR
Figure 6. Timing Mark Location SPARK PLUG WIRES CHECK

Using an ohmmeter, check the resistance of each
spark plug wire. See Table 1. If the spark plug wire
resistance is not as specified, replace the wire.
Table 1. Spark Plug Wires
Spark Plug Wire No. 1 4.1 to 8.9 k

Figure 7. Timing Adjustment
6
2200 SRM 1327 Coil Replacement
Coil Replacement
REMOVE
2. Tag and number the spark plug wires, coils, and

coil electrical connectors as shown in Figure 8.
3. Disconnect the electrical connector to the coil

that is being removed. See Figure 9.
4. Disconnect the spark plug wire from the coil be-

ing removed. See Figure 9.
5. Remove the nut retaining the coil to the mount-

ing plate and remove the coil. See Figure 10.
6. If necessary, repeat Step 3 through Step 5 to re-

move the remaining coils.
1. SPARK PLUG WIRE

2. COIL
Figure 9. Coil Electrical Connector
Figure 8. Spark Plug Wire, Coil, and Coil

Electrical Connector Numbering
1. NUT 4. MOUNTING
2. COIL BRACKET
3. ALIGNMENT PINS
Figure 10. Coil Removal/Installation
7
INSPECT
Measure the resistance between each terminal on the
coil. See Figure 11. If the measurement corresponds
with the abnormal conditions in Table 2, replace the
coil.
INSTALL
1. Place the coil in position on the mounting plate
and install the retaining nut. Tighten the nut to
6.9 to 9.8 N•m (61 to 87 lbf in).
2. Connect the spark plug wire to the coil.
NOTE: Make sure the wiring for the electrical con-

nector is routed and pressed down as close to the coil
and away from the spark plug wire as possible.
3. Connect the electrical connector to the coil.
4. If more than one coil was removed, repeat Step 1 Figure 11. Coil Inspection
through Step 3.

Table 2. Coil Inspection
Tester Connection
Condition
Item Position
Positive Negative Abnormal Normal
A B Infinity (∞) or 0 Ohm 1 to 2 kilohm
Terminal B C 1 to 4 megaohm
C A 0 to several kilohm (continuity) Infinity (∞)
Starter Repair
GENERAL • Battery discharging
• Loose or corroded battery terminals
The starter solenoid is energized when 12 volts is ap- • Loose or damaged wiring
plied to the solenoid terminal. The solenoid magnet- • Loose starter terminals
ically pushes the clutch out to engage the engine fly- • Ignition switch operation
wheel teeth. The solenoid also closes contacts to en-
ergize the starter motor. These operations occur at REMOVE
approximately the same time. The motor torque is
applied just as the teeth engage. The starter con-
WARNING
nections and circuitry are shown in Figure 12. The
specifications for the starter are given in Table 3. Always disconnect the battery ground cable be-
If the starter does not turn or turns unsatisfacto- age and injury. Install a tag on the battery ter-
rily, inspect the following items before removing the minal so that no one connects the cable on the
starter: terminal.
8
1. Disconnect battery cable at negative terminal. Table 3. Starter Specifications

Install a tag on battery terminal to warn against
connecting cable. Model M000T92581
2. Put labels on wires and cables prior to discon- Manufacturer Mitsubishi

necting to aid in correct installation. Electric
Applied Engine Gasoline and LPG
3. Hold starter so it won’t fall. Remove two cap-
screws that fasten the starter to the flywheel Nominal Output 12V - 0.9kW
housing. Remove starter from flywheel housing.
Rated Time 30 Seconds
Rotation Direction Clockwise from
the pinion end
view
No Load Test Voltage 12 V
RPM 2800 rpm or more
Lock Test Voltage 3.5 V
Torque 12.2 N•m
(9.0 lbf ft)
Magnetic Switch Operating 8 V or more
Voltage
1. BATTERY POSITIVE POST
2. SOLENOID TERMINAL Brushes Number 4
3. STARTER
Figure 12. Starter Standard 16.5 mm (0.65 in.)

Size
Wear Limit 10 mm (0.39 in.)
Commutator Groove Depth 0.5 to 0.8 mm (0.02
to 0.03 in.)
9
NO-LOAD TEST Table 4. Problem Diagnosis Chart
1. After the starter has been removed, perform the Test Result Probable Cause
no-load test. If the results are not as expected,
check Table 4 to find the cause of the problem. High indicated current Lack of lubrication/
Disassemble the starter only as required to re- and low rpm (low damaged bearings
pair the problem. rotation torque)
coil grounding
2. Connect a fully-charged 12 V battery with an am-
meter and a voltmeter to form the circuit shown Armature coil short
in Figure 13, and connect the starter switch ter- circuit
minal to the positive (+) terminal of the battery.
High indicated current Magnetic switch
If the ammeter indicates 90 A or below at 2,800
and no rotation grounding
rpm, the starter is OK.
coil grounding
Bearing seizure
No rotation without Armature coil or field
current coil open
Brush open
Commutator dirty
Poor brush contact due
to worn commutator
Low indicated current Improper field coil
and low rpm connection
High indicated current Field coil short circuit
and high rpm
MAGNETIC SWITCH TEST

Pull-Out Test
and the starter.
A. BLOCK DIAGRAM B. SCHEMATIC CAUTION

DIAGRAM
DO NOT apply current for more than 10 sec-
1. STARTER 5. VOLTMETER onds.
2. STARTER 6. AMMETER
TERMINALS 7. SHUNT 2. Apply voltage between the S and M terminals of
3. SWITCH 8. TACHOMETER the starter. Switch wires to see if the plunger is
4. BATTERY (NOT SHOWN IN B) actuated, moving the pinion out. See Figure 14.
Figure 13. No-Load Test Configuration
10
Figure 14. Pull-Out Test Figure 16. Return Test
Holding Coil Test Pinion Movement Inspection

1. Disconnect the lead wire between the M terminal 1. Disconnect the lead wire between the M terminal
and the starter. and the starter.
CAUTION CAUTION
DO NOT apply current for more than 10 sec- DO NOT apply current for more than 20 sec-
onds. onds.
2. Apply voltage between the S terminal and the 2. Apply voltage between the S terminal and the
body of the magnetic switch, and manually pull body of the starter. This will cause the pinion to
the pinion out. See Figure 15. Make sure the extend out. With the pinion extended, measure
pinion does not return when released. the pinion gap. See Figure 17. If the pinion gap
is not within specification, repair or replace the
Return Test clutch shaft assembly.
1. Disconnect the lead wire between the M terminal INSTALL

and the starter.
1. Place starter in position in flywheel housing. In-
CAUTION stall two capscrews to fasten the starter to the
flywheel housing. Tighten capscrews to 38 N•m
DO NOT apply current for more than 10 sec-
(28 lbf ft).
onds.
2. Connect wires and cables as labeled in removal.
2. Apply voltage between the M terminal and the
body of the magnetic switch, and pry the pinion 3. Connect battery cable at negative terminal.
out with a screwdriver. See Figure 16. Make sure
the pinion returns when released.
Figure 15. Holding Coil Test Figure 17. Pinion Gap
11
Alternator Repair
GENERAL If the terminals are not disconnected during
rapid charging, the diodes or regulator may
CAUTION be damaged.
• When steam cleaning, take care not to spray
• Connecting the battery in reverse polarity al-
steam directly on the alternator.
lows high current to flow from the battery to
• If the L and B terminals are short-circuited
the alternator, damaging the diodes and reg-
during operation, the rectifier (diode trio)
ulator.
may be damaged.
• DO NOT remove the battery terminal while
• DO NOT connect a load over 1 A on the L ter-
engine is operating. This procedure may
minal.
sometimes cause a surge in voltage, damag-
• DO NOT ground the L terminal while engine
ing the diodes and regulator.
is operating.
• DO NOT use a high-voltage tester such as a
Megger because it may damage the diodes NOTE: Always use a fully-charged battery.
and regulator.
• Always disconnect the battery terminal when The alternator is connected as shown in Figure 18
charging the battery with a quick charger. and Figure 19.

L. FIELD TERMINAL
Figure 18. Alternator Schematic - 2007 Emissions Compliant Engines
12

L. FIELD TERMINAL
Figure 19. Alternator Schematic - Lift Trucks Built After January, 2010
CHARGING SYSTEM INSPECTION

1. Connect a voltmeter between the alternator L
2. If voltage is present between the L terminal and

ground with the ignition switch turned to OFF,
the alternator is faulty. Replace the alternator.
3. If the voltage is 0 volts with the ignition switch

turned to ON, the alternator or the wiring is
faulty. Perform wiring continuity and connection
checks. If no problems are found, replace the al-
ternator.
1. ALTERNATOR 2. VOLTMETER
Figure 20. Charging System Inspection
13
OUTPUT CURRENT CHECK Table 5. Specifications - 2007 Emissions

Compliant Engines
1. Verify that the alternator fuse is good.
For lift trucks equipped with 2007 emissions
compliant gasoline engines, see Figure 2. Nominal output 12V-40A
For lift trucks equipped with 2007 emissions Grounding polarity ( ) negative
compliant LPG engines, see Figure 3. Pulley rotation direction Clockwise (from
the pulley side)
with gasoline engines, see Figure 4. Output Voltage 13.5V
current
For lift truck built after January, 2010 equipped Current Hot 7A or 30A or
[ 20°C
with LPG engines, see Figure 5. more more
(68°F)]
Cold 12A or 37A or
CAUTION more more
When removing the wire from the alternator Rotation speed 1300 2500
B terminal, use care not to short the wire to a rpm rpm
ground.
Regulator type IC regulator
2. Remove the wire from the alternator B terminal. Unloaded adjusted voltage 14.7 ±0.3V
40 amperes for engines that are 2007 emissions
Table 6. Specifications - Lift Trucks
compliant, or 50 amperes for lift trucks built af-
Built After January, 2010
ter January, 2010, between the alternator B ter-
minal and connector. See Figure 21.
4. Install a tachometer to measure engine rpm. Nominal output 12V-50A
5. Start the engine and rapidly increase the rpm Grounding polarity ( ) negative
to 2,300. At this point, read the value on the
Pulley rotation direction Clockwise (from the
ammeter.
pulley side)
At this time, set all the electric components to Output Voltage 13.5V
ON to create a maximum load. current
Current Hot 10A 35A 49A
[ 20°C
If the ammeter indicates more that 90% of nom- or or or
(68°F)]
inal output, the alternator is operating properly. more more more
For lift trucks equipped with 2007 emissions Cold N/A N/A N/A
compliant engines, see Table 5. Rotation speed 1300 2500 5000
rpm rpm rpm
For lift trucks built after January, 2010, see Ta-
ble 6. Regulator type IC regulator
Unloaded adjusted 14.7 ±0.3V
voltage
14
5. Start the engine and increase the rpm to 2,000.
At this time, set all unnecessary electric compo-

nents to OFF.
6. When the current in Step 5 is 5 amperes or less,

read the L terminal voltage. The voltage should
be 14.7 ±0.3 V. This is the adjusted voltage.
REMOVE
WARNING
age and injury. Install a tag on the battery ter-
1. ALTERNATOR 3. BATTERY minal so that no one connects the cable to the
2. AMMETER terminal.
Figure 21. Output Current Check 1. Disconnect battery cable at negative battery ter-
minal.
NO-LOAD ADJUSTED VOLTAGE CHECK
2. Put labels on wire connected to B terminal and
1. Verify that the alternator fuse is good.
wire connected to ground terminal. Remove
For lift trucks equipped with 2007 emissions wires from terminals and disconnect connector
compliant gasoline engines, see Figure 2. plug from alternator.
For lift trucks equipped with 2007 emissions 3. Remove capscrews, washers, and nuts that fas-
compliant LPG engines, see Figure 3. ten alternator to engine. Remove alternator.

with gasoline engines, see Figure 4.
For lift truck built after January, 2010 equipped

with LPG engines, see Figure 5.
CAUTION
B terminal, use care not to short the wire to a
ground.

40 amperes for engines that are 2007 emissions
compliant, or 50 amperes for lift trucks built af- 1. ALTERNATOR 3. AMMETER
ter January, 2010, between the alternator B ter- 2. VOLTMETER 4. BATTERY
minal and connector. See Figure 22. Figure 22. No-Load Adjusted Voltage Check
4. Connect a voltmeter between the alternator L
15
INSPECT
Rectifier Check
1. Using an ohmmeter, check for continuity of the
diodes. If continuity is not as specified, replace
the rectifier.
For lift trucks equipped with 2007 emissions

compliant engines, see Table 7 and Figure 23.
For lift trucks built after January, 2010, see Ta-

ble 8 and Figure 24
Table 7. Rectifier Check Table - 2007

Emissions Compliant Engines
Negative Positive Continuity

E Yes
B P1, P2, P3 No
T No
E No
P1, P2, P3 B Yes
T Yes
Figure 23. Rectifier Inspection - 2007 Emissions

Compliant Engines
Table 8. Rectifier Check Table - Lift Trucks

Negative Positive Continuity

E Yes
B P1, P2, P3, P4 No
T No
E No
P1, P2,
B Yes
P3, P4
T Yes
16
2200 SRM 1327 Engine Sensors and Switches
INSTALL
1. Install alternator on engine using capscrews,
washers, and nut.
2. Install belt on pulley. Adjust belt tension as de-

scribed in

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

truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)

truck models
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
3. Connect plug to alternator connector. Connect

other wires to B and ground terminals as indi-
cated on labels. Connect negative cable on bat-
tery terminal.
Figure 24. Rectifier Inspection - Lift Trucks

Engine Sensors and Switches

OIL PRESSURE SENSOR, GAS AND LPG Install
ENGINES
1. If removed, apply Loctite® 567 to the threads
Remove of the oil pressure sensor adaptor. Install the
oil pressure sensor adaptor and tighten to 7.9 to
1. Disconnect the battery. 11.7 N•m (69.6 to 103.2 lbf in).
2. Disconnect the electrical connector to the oil 2. Apply Loctite® 567 to the threads of the oil pres-
pressure sensor. sure sensor. Install the oil pressure sensor and
tighten to 7.9 to 11.7 N•m (69.6 to 103.2 lbf in).
3. Remove the oil pressure sensor. See Figure 25.
3. Connect the electrical connector to the oil pres-
4. If necessary, remove the oil pressure sensor adap- sure sensor.
tor.
17
Engine Sensors and Switches 2200 SRM 1327
Install
1. Install new air filter restriction switch onto air
filter restriction switch adapter. Tighten to 2 to
2.5 N•m (17.7 to 22.1 lbf in).
2. Connect air filter electrical connector.

2. OIL PRESSURE SENSOR ADAPTOR
Figure 25. Oil Pressure Sensor
AIR FILTER RESTRICTION SWITCH, GAS

AND LPG ENGINES
NOTE: The air filter restriction switch is an optional
feature on these lift trucks and is a part of the Elec-
tronic Monitoring package option.
NOTE: Lift truck models listed below are equipped

with an air filter restriction switch or Electronic
Monitoring package option.
• S30FT, S35FT, S40FTS (E010)
(F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
NOTE: Newer lift truck models have a metal insert

in the port where the air filter restriction switch
adapter is inserted. See Figure 26.
Remove
2. Disconnect air filter restriction switch from elec-

trical connector.
Figure 26. Air Filter Restriction Switch
3. Remove air filter restriction switch from air filter
restriction switch adapter. See Figure 26.
18
NOTE: ON NEWER LIFT TRUCK MODELS, THE

AIR FILTER RESTRICTION SWITCH ADAPTER AND
METAL INSERT DO NOT NEED TO BE REMOVED TO
REPLACE THE AIR FILTER RESTRICTION SWITCH.
A. OLDER LIFT TRUCK MODELS
B. NEWER LIFT TRUCK MODELS
1. AIR FILTER RESTRICTION SWITCH
2. AIR FILTER HOUSING
3. AIR FILTER RESTRICTION SWITCH ADAPTER
4. METAL INSERT
CAM ANGLE SENSOR, GAS AND LPG

ENGINES
Remove
WARNING
fore making repairs to prevent possible dam- A. LUBRICATE O-RING AND GEAR WITH CLEAN
age and injury. Install a tag on the battery ter- ENGINE OIL.
minal so that no one connects the cable on the
1. O-RING 4. ELECTRICAL
terminal. 2. MOUNTING BOLT CONNECTOR
3. CAM ANGLE
CAUTION SENSOR
DO NOT move the engine crankshaft while Figure 27. CAM Angle Sensor Removal
the distributor is removed. If the crankshaft
is moved, the distributor will not be installed Install
correctly.
NOTE: Coat the new O-ring and the gear on the dis-
1. Disconnect the negative battery cable. tributor with clean engine oil.
2. Rotate crankshaft until No. 1 piston is at TDC 1. Install a new O-ring onto the CAM angle sensor.
on compression stroke. See Figure 27.
3. Disconnect the electrical connector from the side
of the CAM angle sensor. See Figure 27. CAUTION
If the engine crankshaft has been moved since
4. Make alignment marks on the engine and the the CAM angle sensor was removed, see the re-
CAM angle sensor housing to aid in the correct pair procedures for the engine to correctly in-
installation of the CAM angle sensor. stall the CAM angle sensor. DO NOT do Step 2.
5. Remove the mounting bolt from the CAM angle 2. Verify that the CAM angle sensor matching
sensor housing. See Figure 27. marks on the CAM angle sensor housing and the
6. Remove the CAM angle sensor from the engine CAM angle sensor gear are properly aligned. See
without turning the CAM angle sensor housing. Figure 28. Install the CAM angle sensor into the
See Figure 27. engine without turning the CAM angle sensor
housing. Install the mounting bolt and tighten
7. Remove and discard the O-ring. to 19 to 25 N•m (14 to 18 lbf ft). See Figure 27.
3. Connect the electrical connector to the side of the

CAM angle sensor. See Figure 27.
19
4. Re-time the engine. Refer to Ignition System. ignition coil electrical connectors have been
disconnected from the ignition coils before
turning the ignition switch to the ON position
when performing the following voltage check.
2. Disconnect the fuel injector connector.
3. Remove the CAM angle sensor. See the section

Remove above.
4. Connect the CAM angle sensor 4-pin connector.
5. Tag and disconnect all the ignition coil electrical

1. MATCHING MARKS
2. CAM ANGLE SENSOR GEAR connectors.
3. CAM ANGLE SENSOR HOUSING
Figure 28. CAM Angle Sensor Matching Marks
7. Measure the voltage between terminal A and ter-
minal D. See Figure 29.
Voltage Check
8. Rotate the CAM angle sensor drive by hand and
WARNING verify the output signal. If not as specified, in-
Turning the ignition switch to the ON position spect the related wiring harnesses for open or
with the fuel injector connector still connected short. If wiring harnesses are okay, replace the
will actuate the fuel injector. Make sure that CAM angle sensor.
the fuel injector connector has been discon- Specification: 1 pulse (5 V)/rev.
nected.
9. Install the CAM angle sensor and set engine tim-
ing. See the section Install above.
WARNING
Turning the ignition switch to the ON position 10. Connect all the ignition coil electrical connectors
with the ignition coil electrical connectors as tagged.
still connected will generate sparks, which can
11. Connect the fuel injector connector.
cause electrical shock. Make sure that all the
1. CAM ANGLE SENSOR

2. CAM ANGLE SENSOR CONNECTOR (ON CAM ANGLE SENSOR)
3. 4-PIN ELECTRICAL CONNECTOR
Figure 29. CAM Angle Sensor Voltage Check
20
MANIFOLD ABSOLUTE PRESSURE (MAP) Install

SENSOR, GAS AND LPG ENGINES
1. Place the MAP sensor in position and install the
Remove retaining screws.
1. Disconnect the battery. For LPG lift trucks, see Figure 31.
2. Disconnect the wiring harness connector from For Gasoline lift trucks, see Figure 32.
the MAP sensor connector. See Figure 30. 2. Connect the vacuum hose to the MAP sensor.
3. Disconnect the vacuum hose from the MAP sen- 3. Connect the wiring harness connector to the
sor. MAP sensor connector.
For LPG lift trucks, see Figure 31. 4. Connect the battery.
For Gasoline lift trucks, see Figure 32.
4. Remove the retaining screws from the MAP sen-

sor and remove the MAP sensor.
For LPG lift trucks, see Figure 31.
For Gasoline lift trucks, see Figure 32.
1. RETAINING 2. MAP SENSOR

SCREWS 3. VACUUM HOSE
Figure 31. MAP Sensor Removal/Installation,

LPG Engine
1. MAP SENSOR
Figure 30. MAP Sensor Electrical Connector,

LPG Engine
21
Install
1. Install the IAT sensor and new aluminum
seal washer. Tighten the IAT sensor to 7.9 to
11.7 N•m (70 to 104 lbf in).

sor connector.
1. RETAINING 3. INTAKE MANIFOLD

SCREWS 4. VACUUM HOSE
2. MAP SENSOR
1. IAT SENSOR
Figure 32. MAP Sensor Removal/Installation, 2. ALUMINUM SEAL WASHER
3. AIR BOX
Gas Engine
Figure 33. IAT Sensor
INTAKE AIR TEMPERATURE (IAT)
SENSOR, LPG ENGINES
Remove

3. Remove the sensor and aluminum seal washer.

See Figure 33.
22
INTAKE AIR TEMPERATURE (IAT) Install

SENSOR, GAS ENGINES
1. If removed, verify the mating surface of the
Remove spacer/housing plate and the intake manifold
are clean. Place a new gasket in position on
1. Disconnect the battery. the intake manifold. Install the nuts and cap-
screw. Tighten the nuts to 8.9 to 12.7 N•m (79
2. Disconnect the wiring harness connector from to 112 lbf in). Tighten the capscrew to 7.9 to
the sensor connector. 10.7 N•m (69.5 to 95.4 lbf in). See Figure 35.
3. Remove the IAT sensor and aluminum seal 2. Install the IAT sensor and new aluminum seal
washer from the spacer/housing bracket. See washer. Tighten sensor to 8 to 12 N•m (71 to
Figure 34. 106 lbf in). See Figure 34.
4. If necessary, remove the nuts and capscrew re- 3. Connect the wiring harness connector to the sen-
taining the spacer/housing plate and remove the sor connector.
spacer/housing plate and gasket. See Figure 35.
Discard the old gasket. 4. Connect the battery.
1. IAT SENSOR 3. SPACER/HOUSING PLATE

2. ALUMINUM SEAL WASHER 4. INTAKE MANIFOLD
Figure 34. Intake Air Temperature (IAT) Sensor
23
1. NUTS 4. GASKET
2. CAPSCREW 5. INTAKE MANIFOLD
3. SPACER/HOUSING PLATE
Figure 35. Intake Air Temperature (IAT) Sensor Spacer/Housing Plate
FUEL TEMPERATURE SENSOR, LPG the supply hose from the LPG tank where it
ENGINES enters the filter unit. Permit the pressure in
Remove ing the fitting removes heat. Use a cloth to
WARNING 1. Turn the shutoff valve clockwise until the valve
LPG can cause an explosion. DO NOT cause is completely closed.
LPG system. LPG fuel systems can be discon- 2. Run the engine until it stops. If truck is equipped
nected indoors only if the lift truck is at least with a key switch, turn the key switch to the
8 m (26 ft) from any open flame, motor vehicles, OFF position. If truck is equipped with a Power
electrical equipment, or ignition source. ON/OFF button, press the Power ON/OFF but-
any part of the engine fuel system is discon- 3. Disconnect the battery.
tem is used and the engine stops. 4. Disconnect the electrical connector to the fuel
temperature sensor.
24
5. Remove the retaining pin from the fuel tempera- 2. Disconnect the ECT sensor connector.
ture sensor and remove sensor. See Figure 36.
3. Remove the ECT sensor and packing from the
Install intake manifold. See Figure 37.
1. Lubricate new O-rings using a lubricant compat- Install

ible with LPG and install O-rings on the new fuel
1. Apply Loctite® 567 to the threads of the ECT
temperature sensor.
sensor.
2. Insert fuel temperature sensor into the EPR as-
2. Install the ECT sensor and the new packing.
sembly and install the retaining pin.
Tighten the ECT sensor to 7.9 to 11.7 N•m (70
3. Connect the electrical connector to the fuel tem- to 104 lbf in).
perature sensor.
3. Connect the ECT sensor connector.

truck is equipped with a Power ON/OFF button,
leaks.

ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
2007 Emissions Compliant Gas Engines
NOTE: The procedures below are for lift truck mod-
els shown below, equipped with a 2007 gas compliant
engine only.
• S30FT, S35FT, S40FTS (E010)
• H30FT, H35FT, H40FTS (F001)
• S40-70FT (F187) 1. FUEL TEMPERATURE SENSOR
• H40-70FT (L177) 2. O-RINGS
3. RETAINING PIN
4. EPR ASSEMBLY
Remove
Figure 36. Fuel Temperature Sensor
1. Drain the engine coolant from the radiator before
Removal/Installation
Cooling System 700 SRM 1123 for procedures.
25
The procedures are also for lift truck models listed

below that are equipped with an LPG engine built
after January, 2010.
H40FTS) (F001)
• S2.0-3.5FT (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
Remove
2. Drain the engine coolant from radiator before

Cooling System 700 SRM 1123 for procedures.
3. Disconnect the ECT sensor connector.

1. INTAKE MANIFOLD 4. Remove the ECT sensor and packing from the
2. PACKING/COPPER WASHER intake manifold. See Figure 38.
3. ECT SENSOR
Install
Figure 37. ECT Sensor Removal/Installation -
2007 Gas Compliant Engines 1. Apply Loctite® 567 to the threads of the ECT
sensor.
stalling the ECT sensor. Refer to the section in- 2. Install the ECT sensor and the new packing.
dicated below for coolant specification and proce- Tighten the ECT sensor to 7.9 to 11.7 N•m (70
dures. to 104 lbf in).
Periodic Maintenance 8000 SRM 1150 for lift 3. Connect the ECT sensor connector.
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 4. Refill the radiator with engine coolant after in-
• H2.0-3.5FT (H40-70FT) (L177) stalling the ECT sensor. Refer to the section in-
dicated below for coolant specification and proce-
Periodic Maintenance 8000 SRM 1207 for lift dures.
truck models
• S30FT, S35FT, S40FTS (E010) Periodic Maintenance 8000 SRM 1150 for lift
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, truck models
H40FTS) (F001) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
2007 and 2010 Emissions Compliant LPG
Engines
truck models
NOTE: The procedures in this section are for lift truck • S30FT, S35FT, S40FTS (E010)
models listed below that are equipped with a 2007 • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
LPG compliant engine. H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
truck models
H40FTS) (F001)
• S50CT (A267)
• S2.0-3.5FT (S40-70FT (F187)
• H2.0-2.5CT (H50CT) (A274)
• H2.0-3.5FT (H40-70FT) (L177)
26
1. PACKING (COPPER WASHER) 3. WIRING CONNECTOR

2. ECT SENSOR 4. INTAKE MANIFOLD
Figure 38. ECT Sensor Removal/Installation - 2007 LPG Engine and LPG Engine Built After
January, 2010
2010 Emissions Compliant Gas and LPG 3. Disconnect the ECT sensor connector.
Engines
4. Remove the ECT sensor and packing from bottom
NOTE: The procedures below are for lift truck models of thermostat assembly. See Figure 39.
shown below, built after January, 2010 and equipped
Install
with gas and LPG engines.
• S30FT, S35FT, S40FTS (E010) 1. Apply Loctite® 567 to the threads of the ECT
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, sensor.
H40FTS) (F001)
• S40-70FT (F187) 2. Install the ECT sensor and the new packing.
• H2.0-3.5FT (H40-70FT) (L177) Tighten the ECT sensor to 7.9 to 11.7 N•m (70
to 104 lbf in).
Remove
2. Drain the engine coolant from radiator before stalling the ECT sensor. Refer to the section in-
removing the ECT sensor. Refer to the section dicated below for coolant specification and proce-
Cooling System 700 SRM 1123 for procedures. dures.
27
Periodic Maintenance 8000 SRM 1150 for lift Periodic Maintenance 8000 SRM 1207 for lift
truck models truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • S30FT, S35FT, S40FTS (E010)
• H2.0-3.5FT (H40-70FT) (L177) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
H40FTS) (F001)
NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY.

1. PACKING (COPPER WASHER) 3. WIRING CONNECTOR
2. ECT SENSOR 4. THERMOSTAT HOUSING
Figure 39. ECT Sensor Removal/Installation - Lift Trucks Built After January, 2010
28

FRAME
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580502 100 SRM 1120

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 8
Steering Column ................................................................................................................................................ 13
Description ..................................................................................................................................................... 13
Remove....................................................................................................................................................... 13
Disassemble ............................................................................................................................................... 15
Clean .......................................................................................................................................................... 15
Inspect........................................................................................................................................................ 15
Assemble .................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Remove ........................................................................................................................................................... 19
Install ............................................................................................................................................................. 22
Description ..................................................................................................................................................... 25
Remove ........................................................................................................................................................... 27
Install ............................................................................................................................................................. 32
Inspect ................................................................................................................................................... 49
Inspect ................................................................................................................................................... 51


Inspect ................................................................................................................................................... 53
Inspect ................................................................................................................................................... 57
Cooling System................................................................................................................................................... 58
Description ..................................................................................................................................................... 58
Remove ........................................................................................................................................................... 58
Install ............................................................................................................................................................. 58
Inspect ............................................................................................................................................................ 60
Clean .............................................................................................................................................................. 60
Safety Labels ...................................................................................................................................................... 62
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
ii
General
Description
See Figure 1.
H40FTS) (F001)
1

4. HOOD MOUNTS
Figure 1. Frame

umn. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S30FT, S35FT, S40FTS (E010)
• H2.0-3.5FT (H40-70FT) (L177)
2

9. GAS SPRING
3

S40FTS (E010)
4
from frame.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001) ure 2.
• S30FT, S35FT, S40FTS (E010)
CAUTION
• H2.0-3.5FT (H40-70FT) (L177)
move covers.
• H2.0-3.5FT (H40-70FT) (L177) Figure 2).

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
5
(L177)
6
Legend for Figure 4


7

(F187)
ure 2. • S30FT, S35FT, S40FTS (E010)
19.2 N•m (170 lbf in).
8
Legend for Figure 7

SUSPENSION SEAT
HOOD
(S40-70FT) (F187)

Suspension Seat
Without
E-Control
E-Control
9
Legend for Figure 8

SUSPENSION SEAT

10
Legend for Figure 9

A. LEFT SIDE
B. RIGHT SIDE

Suspension Seat
H40-70FT
(L177)
H2.0-3.5FT
(L177)
11
CAUTION
for latch.
to 18 N•m (159 lbf in).


ure 6.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)

• H2.0-3.5FT (H40-70FT) (L177)



• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S30FT, S35FT, S40FTS (E010)
• H2.0-3.5FT (H40-70FT) (L177)
12
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010)
Steering Column
Figure 11.

Remove
WARNING

FORWARD position.

horn wires. 3. COWL
13


gas or LPG engines.


diesel engines.


2. HEX NUT COLUMN
3. STEERING WHEEL

3. ISOLATOR
14
Disassemble Clean
WARNING
tions.
January, 2012.
WARNING
fore January, 2012.
Inspect
January, 2012.
damaged hardware.
fore January, 2012.

January, 2012.
15
16

8. FASTENER
1. BRACKET 9. PIN
4. NUT 12. BOLT
17
Assemble Install
truck models
4032542). • S30FT, S35FT, S40FTS (E010)
fore January 2012.
ure 13.
January 2012.
Covers Replacement.
fore January 2012.
fore January 2012.
January 2012.
18

• H2.0-3.5FT (H40-70FT) (L177)
• H2.0-3.5FT (H40-70FT) (L177)
• S3.0-3.5FT (S60-70FT, S55FTS) (F187)
• H3.0-3.5FT (H60-70FT) (L177)

H40FTS) (F001)
WARNING
19
• H2.0-3.5FT (H40-70FT) (L177)
1325.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
20

Model Kg Lb
S30FT 772 1702
S35FT 963 2123
S40FTS 1131 2493

(H30FT, H35FT, H40FTS) (F001)
Model Kg Lb
H1.6FT (H30FT) 812 1790
H1.8FT (H35FT) 887 1955
H2.0FTS (H40FTS) 1047 2308

Models H2.0-3.5FT (H40-70FT) (L177)
MOUNT 6. WASHERS

H3.0FTS (H60FTS) 1664 3668
Model Kg Lb
S2.0FT (S40FT) 1040 2293
S2.5FT (S50FT) 1395 3075
S55FTS 1643 3622
S3.0FT (S60FT) 1819 4010
S3.5FT (S70FT) 2153 4747
21
1325.

has been installed.

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

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• H2.0-3.5FT (H40-70FT) (L177)
22


pin.
Figure 18. Tow Pin


23

2. HANDLE
3. BOLTS 6. GROMMET
24

seat belt assembly.
the seat.
25

6. SEAT RAIL
26

Engine Replacement
REMOVE WARNING
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001)
truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• H2.0-3.5FT (H40-70FT) (L177)
truck models
• S30FT, S35FT, S40FTS (E010)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
WARNING • H2.0-3.5FT (H40-70FT) (L177)
27


WARNING
the fuel system.
CAUTION





2. BATTERY TRAY
3. PDM
28

29
30

Figure 25.
WARNING
(428 lb).


B. GM ENGINE MOUNT
3. WASHER
5. CROSSMEMBER
31


is not damaged.
INSTALL Figure 25.

not damaged.
No smoking.
32
for the procedures.

CAUTION
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
33
WARNING

ual or

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)

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



3. LOAD SENSE LINE
34

HOUSING
sion.
WARNING





to gear pump.

ment pump (VDP).

See Figure 28.

35
ing lines.


pump
• S30FT, S35FT, S40FTS (E010)
mately 83.8 kg (184.7 lb).
36

ADAPTERS NOT SHOWN.
2. DRAIN FITTING
4. SUCTION HOSE
2. DRAIN FITTING
4. SUCTION HOSE

2011)
4. SUCTION HOSE

2011)

37

ADAPTERS NOT SHOWN.
38


pump.



pump.

inlet port.

pump
• S30FT, S35FT, S40FTS (E010)
4. DRAIN CASE LINE
10. PUMP INLET PORT
placement pump.
transaxle oil.
39


pump
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)


placement pump.

pump.


2. CAPSCREW
in installation.

Figure 37.
40


51 lbf ft).

port.
4. OIL SEAL pump
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
placement pump.
mately 83.8 kg (184.7 lb).
let port.
pump
See Figure 37.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
41
pump
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
wiring harness.
WARNING
mately 83.8 kg (184.7 lb).
H40FTS) (F001)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
42
model H2.0-3.5FT (H40-70FT) (L177).

43
44
45
ure 39.

Transmission
46




(71 to 133 lbf in).

See Figure 41.

(71 to 133 lbf in).

2. JAM NUT
ELECTRONIC THROTTLE
47
6. JAM NUT
48

Inspect
WARNING
may occur.
lift truck.

49
9. CLAMP
50

Inspect
procedures.
(195 lbf in).
51
52

2. WASHER 9. CLAMP
7. GASKET
pipe.
Inspect
53
54

2. WASHER 11. SOCK
9. CLAMP 18. COVER*

WARNING
may occur.
procedures.
sor.
55
56
3. SPACER 14. PLUG
operation.
57
Cooling System
components:
• Radiator
• Fan and belt
• Fan shroud

Figure 46.
the pump.
as necessary.
CAUTION
ure 46.
58


Hand tighten lid.
CAUTION
ter dealer.

indicated in

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

truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)

2. SPRING 7. BOWL
59

INSPECT WARNING
WARNING
mation:
electricity.
CAUTION
ter dealer.
WARNING
flammable vapors.

CLEAN drain plug.

60
WARNING 1999.

61
Safety Labels
read.

part numbers.
62
S2.0-3.5FT (S40-70FT, S55FTS) (F187)
63

16. JOYSTICK LABEL



64
65
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
66

OPERATOR’S CAB
H1.6FT, H1.8FT, 2.0FTS [F001];
H2.0-3.5FT (H40-70FT) [L177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005,
R005]; H6.0FT, H7.0FT (H135FT, H155FT) [H006,
J006, K006]; H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) [A299, B299]
PART NO. 1673866 100 SRM 1290

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Cab Replacement ............................................................................................................................................... 2
R005) .............................................................................................................................................................. 2
R005) .............................................................................................................................................................. 16
Door Assemblies ................................................................................................................................................. 25
120FT) (N005, P005, R005) ........................................................................................................................... 25
Remove....................................................................................................................................................... 25
Disassemble ............................................................................................................................................... 33
Heater Assembly ................................................................................................................................... 33
Windows ................................................................................................................................................ 39
Clean .......................................................................................................................................................... 39
Inspect........................................................................................................................................................ 39
Assemble .................................................................................................................................................... 39
Windows ................................................................................................................................................ 39
Heater Assembly ................................................................................................................................... 39
Install ......................................................................................................................................................... 40
120FT) (N005, P005, R005) ........................................................................................................................... 41
Remove....................................................................................................................................................... 41
Disassemble ............................................................................................................................................... 41
Door Cover............................................................................................................................................. 41
Windows ................................................................................................................................................ 41
Clean .......................................................................................................................................................... 41
Inspect........................................................................................................................................................ 41
Assemble .................................................................................................................................................... 41
Windows ................................................................................................................................................ 41
Door Cover............................................................................................................................................. 42
Install ......................................................................................................................................................... 42


Remove....................................................................................................................................................... 43
Disassemble ............................................................................................................................................... 44
Door Cover............................................................................................................................................. 44
Windows ................................................................................................................................................ 44
Clean .......................................................................................................................................................... 45
Inspect........................................................................................................................................................ 45
Assemble .................................................................................................................................................... 46
Windows ................................................................................................................................................ 46
Door Cover............................................................................................................................................. 46
Install ......................................................................................................................................................... 47
General ........................................................................................................................................................... 47
(L177) ......................................................................................................................................................... 47
110, 120FT) (N005, P005, R005)............................................................................................................... 59
120FT) (N005, P005, R005)....................................................................................................................... 59
General ........................................................................................................................................................... 63
120FT) (N005, P005, R005) ........................................................................................................................... 63
120FT) (N005, P005, R005) ........................................................................................................................... 64
ii

Remove....................................................................................................................................................... 70
Install ......................................................................................................................................................... 71
Remove....................................................................................................................................................... 72
Install ......................................................................................................................................................... 72
Remove....................................................................................................................................................... 74
Install ......................................................................................................................................................... 74
Strobe Light ................................................................................................................................................... 75
Remove....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Remove....................................................................................................................................................... 75
Install ......................................................................................................................................................... 75
Remove....................................................................................................................................................... 77
Install ......................................................................................................................................................... 78
Remove....................................................................................................................................................... 81
Clean .......................................................................................................................................................... 81
Inspect........................................................................................................................................................ 81
Install ......................................................................................................................................................... 81
Fan.................................................................................................................................................................. 84
Remove....................................................................................................................................................... 84
Install ......................................................................................................................................................... 84
Mirror ............................................................................................................................................................. 84
Remove....................................................................................................................................................... 84
Install ......................................................................................................................................................... 84
H1.6FT, H1.8FT, 2.0FTS [F001];

H2.0-3.5FT (H40-70FT) [L177];
110, 120FT) [N005, P005, R005];
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
1
Cab Replacement



• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

WARNING

2
2. RELEASE LATCH
Legend for Figure 4
1. CAPSCREW
2. AIR FILTER HOSE
3
4
Legend for Figure 5

B. H2.0-3.5FT (H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
See Figure 11.
Figure 11.
people.
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005), open
See Figure 9.
5
P005)
3. RADIATOR COVER
6
7
Legend for Figure 9

1. GAS SPRING
3. LOCK NUT
8

HARNESS)

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
hoses.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)

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

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)

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

9
Engine
10
11
12


lift truck frame.
tached.
13
14

(H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
4. SEAL

6. CAPSCREWS
Cover Removal
15

H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177); AND H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005)
mounting holes.
16
ure 11.
ure 10.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
110, 120FT) (N005, P005).
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
Figure 10.
17
ure 22.
WARNING ure 23.
purged.

and drops down.

locked position.

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

See Figure 21.
left side door.
18

move dash assembly.

Figure 22.



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

Figure 27.
fluid reservoir.
to module.
and cowl panel.
19

5. REAR FLOOR MAT
20

3. SCREWS
4. KICK PANEL
7. LOCK NUT
8. FLANGE BOLT

Trucks
21

22

1. VSM
CHASSIS HARNESS)


ELS.
1. FLANGE BOLTS
6. MODULE
7. COWL PANEL
23

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




165 N•m (122 lbf ft).



24
J006, K006) frame.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
ure 22.
H190FT) (A299, B299)

Door Assemblies

25
26

B. H2.0-3.5FT (H40-70FT) (L177) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
quires two people.
See Figure 31.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80,
5.5FT (H80, 90, 100, 110, 120FT) (P005)
90, 100, 110, 120FT) (N005, P005, R005)
27
A. H1.6FT, H1.8FT, 2.0FTS (F001)
B. H2.0-3.5FT (H40-70FT) (L177)
3. RADIATOR COVER
28

HARNESS)

29
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)
30
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
31
2. MOUNTING BRACKET
32

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
Figure 37.
door frame.
door frame.
Heater Assembly
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
33
34

1. PLUG 9. WASHER
8. HANDLE PLATES

5. HANDLE 12. PLUG
35

36
switch.
Parts Manual.


7. CAPSCREW
37
and mounting plate.

38

Inspect screws.
Assemble
Windows

Door Lock Assembly


(170 lbf in).

39
See Figure 37.
Figure 39.
switch.
Install
ure 35.
See Figure 36.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
40
5.5FT (H80, 90, 100, 110, 120FT) (P005)
Clean
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
WARNING
5.5FT (H80, 90, 100, 110, 120FT) (R005)
eyes.
(F001); H2.0-3.5FT (H40-70FT) (L177);
Remove
Inspect
Door Cover Windows
to 19.2 N•m (170 lbf in).
Door Lock Assembly

41

3. COVER 7. HANDLE
42

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

Step 3.

2. WASHER
43

dle. See Figure 47.


2. SCREW 6. WASHER
44

WARNING
Inspect
window if damaged.

45

5.0 N•m (44 lbf in).
See Figure 46.

2. SEAL 4. GRIP
46
pin. See Figure 44.
ure 35.

(L177)
tor.
tor.
47

and H2.0-3.5FT (H40-70FT) (L177)
48
J006, K006), H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
from wiper arms.
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, J006)
R005)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
J006, K006)
J006, K006)
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) H155FT) (H006, J006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
5.5FT (H80, 90, 100, 110, 120FT) (R005)
H175FT36, H190FT) (A299, B299)
49
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
J006, K006)
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)

8. LOCK NUTS
50
51
52

53
2.0FTS (F001)
54

8. NUT 20. NUT
12. WIPER ARM
(F001)
55
(H40-70FT) (L177) (H40-70FT) (L177)
ure 52.
wire harness.
mounting bracket.
56

57

58
100, 110, 120FT) (N005, P005, R005) 100, 110, 120FT) (N005, P005, R005)
ure 52.
59
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
60

See Figure 55.
61

(A299, B299)
62
Window Replacement
bracket.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)

63
door frame.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005)

See Figure 57.



ing window.

dow. See Figure 57.


(H006, J006, K006) AND H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT)
2. SEAL
Door)
64

5. CAPSCREW
65
(H006, J006, K006) AND H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)

ment part numbers.



Heater Replacement
Figure 62.
66



1. SCREWS
67
68

14. HEATER BOX

H6.0FT, H7.0FT (H135FT, H155FT) (H006,
(H170FT, H175FT36, H190FT) (A299, B299)

heater.






3. CLIP NUTS
69

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)

70
Install

2. BUSHING
71
72


73
Light Replacement
J006, K006)
H175FT36, H190FT) (A299, B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
models
R005)
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
CAUTION
lamp failure.


and four capscrews.
3. NUT
74

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
both options.
Remove
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
models H175FT36, H190FT) (A299, B299)
• H2.0-3.5FT (H40-70FT) (L177) models
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, H40FTS) (F001)
R005) • H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-

Figure 69.
J006, K006)
H40FTS) (F001)
75
76

7. FLANGE NUT LIGHT
9. STROBE LIGHT
J006, K006)
models
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

Remove

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
3. FLANGE NUT
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, 8. LOCK NUT
R005)
77

models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
Display Switches
(F001)
78

79

80
Optional Equipment
els Clean
• H1.6FT, H1.8FT, 2.0FTS (F001)
• H2.0-3.5FT (H40-70FT) (L177)
WARNING
lift truck models
H190FT) (B299)
Install
head capscrews.
Figure 74.
81
82

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
H190FT) (A299, B299)
83

Remove
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
H175FT36, H190FT) (A299, B299) models
models • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H2.0-3.5FT (H40-70FT) (L177) R005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, MIRROR
R005)
Remove
ure 75.
84
1. MIRROR 6. WASHER
5. LOCKNUT
85
Label Replacement

86

YANMAR DIESEL
ENGINES
2.6L, 3.0L AND 3.3L
(H30FT, H35FT, H40FTS) [F001];
H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274]
PART NO. 1598588 600 SRM 1205

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
Yanmar Diesel Engines Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Engine Identification..................................................................................................................................... 1
Major Engine Component Identification.................................................................................................. 1
Location of Labels...................................................................................................................................... 1
Cylinder Head Assembly Repair ....................................................................................................................... 2
Glow Plugs ..................................................................................................................................................... 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 4
Valve Cover .................................................................................................................................................... 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 5
Rocker Arm Assembly ................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Disassemble ............................................................................................................................................... 6
Push Rods .............................................................................................................................................. 6
Rocker Arm Assembly........................................................................................................................... 6
Assemble .................................................................................................................................................... 7
Install ......................................................................................................................................................... 7
Valve Clearance Adjustments ....................................................................................................................... 7
Cylinder Head Assembly ............................................................................................................................... 9
Remove....................................................................................................................................................... 9
Disassemble ............................................................................................................................................... 12
Valves and Valve Springs, Remove ...................................................................................................... 12
Valve Guides, Remove........................................................................................................................... 13
Cylinder Head ....................................................................................................................................... 14
Valve Guides.......................................................................................................................................... 14
Valves..................................................................................................................................................... 14
Valve Sink.............................................................................................................................................. 14
Valve Seat .............................................................................................................................................. 15
Valve Springs......................................................................................................................................... 15
Assemble .................................................................................................................................................... 16
Valve Guides, Install............................................................................................................................. 16
Valves and Valve Springs, Install......................................................................................................... 16
Install ......................................................................................................................................................... 17
Timing Gear Case and Timing Gears Repair ................................................................................................... 19
Timing Gear Case Cover ............................................................................................................................... 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Timing Gears ................................................................................................................................................. 20
Crankshaft Gear........................................................................................................................................ 20
Remove .................................................................................................................................................. 20
Install..................................................................................................................................................... 21
Idler Gear................................................................................................................................................... 21
Remove .................................................................................................................................................. 21
Inspect ................................................................................................................................................... 21
Install..................................................................................................................................................... 22

Table of Contents Yanmar Diesel Engines

Camshaft Gear .......................................................................................................................................... 22
Remove .................................................................................................................................................. 22
Install..................................................................................................................................................... 22
Timing Gear Case .......................................................................................................................................... 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Drive Train, Camshaft, and Cylinder Block Repair......................................................................................... 24
Remove ........................................................................................................................................................... 24
Disassemble ................................................................................................................................................... 24
Pistons and Connecting Rods ................................................................................................................... 24
Crankshaft ................................................................................................................................................. 25
Camshaft.................................................................................................................................................... 27
Cylinder Block ........................................................................................................................................... 29
Honing and Boring................................................................................................................................ 31
Pistons........................................................................................................................................................ 32
Piston Pin................................................................................................................................................... 32
Connecting Rod.......................................................................................................................................... 32
Tappets....................................................................................................................................................... 33
Crankshaft ................................................................................................................................................. 33
Camshaft.................................................................................................................................................... 35
Camshaft Bushing..................................................................................................................................... 35
Assemble ........................................................................................................................................................ 35
Camshaft.................................................................................................................................................... 35
Crankshaft ................................................................................................................................................. 36
Pistons and Connecting Rods ................................................................................................................... 36
Install ............................................................................................................................................................. 37
Lubrication System Repair................................................................................................................................ 38
Engine Oil and Oil Filter Change................................................................................................................. 38
Oil Pan............................................................................................................................................................ 38
Remove....................................................................................................................................................... 38
Install ......................................................................................................................................................... 39
Oil Suction Tube ............................................................................................................................................ 39
Remove....................................................................................................................................................... 39
Clean .......................................................................................................................................................... 40
Install ......................................................................................................................................................... 40
Oil Pump ........................................................................................................................................................ 40
Remove....................................................................................................................................................... 40
Outer Rotor Outside Clearance............................................................................................................ 41
Outer Rotor to Inner Rotor Tip Clearance........................................................................................... 41
Outer Rotor Side Clearance.................................................................................................................. 41
Rotor Shaft Clearance........................................................................................................................... 42
Install ......................................................................................................................................................... 42
Fuel System Repair............................................................................................................................................ 43
Fuel Injectors ................................................................................................................................................. 43
Remove....................................................................................................................................................... 43
Inspect........................................................................................................................................................ 44
Clean .......................................................................................................................................................... 44
Test............................................................................................................................................................. 44
ii
Yanmar Diesel Engines Table of Contents

Install ......................................................................................................................................................... 47
Electronic Throttle System ........................................................................................................................... 47
Remove....................................................................................................................................................... 47
Install ......................................................................................................................................................... 50
Inspect........................................................................................................................................................ 51
Adjust ......................................................................................................................................................... 51
Fuel Injection Pump ...................................................................................................................................... 54
Remove....................................................................................................................................................... 54
Install ......................................................................................................................................................... 57
Check/Adjust Fuel Injection Timing ........................................................................................................ 58
V-Belt ............................................................................................................................................................. 59
Remove....................................................................................................................................................... 59
Inspect........................................................................................................................................................ 59
Install ......................................................................................................................................................... 59
Adjust ......................................................................................................................................................... 59
Water Pump ................................................................................................................................................... 60
4TNE92-NMHA and 4TNE92-NMHA/1688253 Engines ........................................................................ 60
Remove .................................................................................................................................................. 60
Install..................................................................................................................................................... 62
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/1688273, and 4TNE98-BNMH Engines..................... 63
Remove .................................................................................................................................................. 63
Install..................................................................................................................................................... 64
Thermostat..................................................................................................................................................... 65
Remove....................................................................................................................................................... 65
Inspect........................................................................................................................................................ 66
Install ......................................................................................................................................................... 66
Flywheel and Flywheel Housing ....................................................................................................................... 67
Flywheel ......................................................................................................................................................... 67
Remove....................................................................................................................................................... 67
Install ......................................................................................................................................................... 67
Flywheel Housing .......................................................................................................................................... 69
Remove....................................................................................................................................................... 69
Install ......................................................................................................................................................... 69
Electrical Equipment Repair............................................................................................................................. 70
Alternator....................................................................................................................................................... 70
Remove....................................................................................................................................................... 70
Bench Test ................................................................................................................................................. 72
Regulate Voltage Check ............................................................................................................................ 72
No Load Test.............................................................................................................................................. 74
Output Test................................................................................................................................................ 74
Install ......................................................................................................................................................... 74
Starter ............................................................................................................................................................ 75
Remove....................................................................................................................................................... 76
No Load Test.............................................................................................................................................. 76
Install ......................................................................................................................................................... 76
Engine Data ................................................................................................................................................... 77
Engine Tuning ............................................................................................................................................... 83
Cylinder Head ................................................................................................................................................ 84
iii
Table of Contents Yanmar Diesel Engines

Intake/Exhaust Valve and Guide.................................................................................................................. 84
Valve Spring................................................................................................................................................... 85
Rocker Arm and Shaft ................................................................................................................................... 85
Push Rod ........................................................................................................................................................ 85
Gear Train and Camshaft ............................................................................................................................. 85
Camshaft.................................................................................................................................................... 85
Idle Gear Shaft and Bushing .................................................................................................................... 86
Backlash of Each Gear .............................................................................................................................. 86
Cylinder Block ............................................................................................................................................... 87
Crankshaft ..................................................................................................................................................... 87
Thrust Bearing .............................................................................................................................................. 87
Piston.............................................................................................................................................................. 88
Piston Ring..................................................................................................................................................... 88
Connecting Rod .............................................................................................................................................. 89
Rod Small End........................................................................................................................................... 89
Tappet ........................................................................................................................................................ 89
Oil Pump ........................................................................................................................................................ 89
Engine Oil Pressure .................................................................................................................................. 89
Outer Rotor Outside Clearance ................................................................................................................ 89
Outer Rotor Side Clearance ...................................................................................................................... 89
Outer Rotor to Inner Rotor Tip Clearance ............................................................................................... 90
Rotor Shaft Clearance ............................................................................................................................... 90
Standard Torque Specifications ........................................................................................................................ 90
Standard Torque Chart ................................................................................................................................. 90
Special Torque Specifications ............................................................................................................................ 91
Special Tools ....................................................................................................................................................... 92

H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274]
iv
General
This section has the repair instructions for the fol- Legend for Figure 1
lowing Yanmar diesel engines:
• 4TNE92-NMH - 2.6L engine (Hyster Part No. 1. TOP FILLER PORT (ENGINE OIL)
2. STARTER MOTOR
1501687), used in lift truck H2.0-3.5FT (H40-70FT) 3. GLOW PLUG
(L177). 4. WATER PUMP
• 4TNE92-NMHA - 2.6L engine (Hyster Part No. 5. ALTERNATOR
1536725), used in lift truck H1.6FT, H1.8FT, 6. V-BELT
H2.0FTS (H30FT, H35FT, H40FTS) (F001) 7. CRANKSHAFT V-PULLEY
8. SIDE FILLER PORT (ENGINE OIL)
• 4TNE98-NMH - 3.3L engine (Hyster Part No. 9. DRAIN PLUG
1501690), used in lift truck H2.0-3.5FT (H40-70FT) 10. GOVERNOR LEVER
(L177) 11. ENGINE OIL FILTER
• 4TNE92-NMH/1688273 - 2.6L engine (Hyster 12. FUEL INJECTION PUMP
Part No. 1688273), used in lift truck H2.0-3.5FT 13. DIPSTICK (ENGINE OIL)
14. FUEL FILTER/WATER SEPARATOR
(H40-70FT) (L177). 15. FUEL PRIMING PUMP
• 4TNE98-BNMH - 3.3L engine (Hyster Part No.
1676883), used in lift truck H2.0-3.5FT (H40-70FT) Location of Labels
(L177).
• 4TNE92-NMHA/1688253 - 2.6L engine 2008 The typical location of the emission control informa-
(Hyster Part No. 1688253), used in lift truck mod- tion label is shown in Figure 2.
els H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) and H2.0-2.5CT (H50CT) (A274) The typical location of the engine nameplate is shown
• 4TNE94L-BSNMH - 3.0L engine (Hyster Part No. in Figure 2. The engine nameplate is shown in Fig-
4620796) used in lift truck H2.0-3.5FT (L177). ure 3.
ENGINE IDENTIFICATION
Major Engine Component Identification
Figure 1 shows where the major engine components
are located.
1. ENGINE NAMEPLATE
2. EMISSION CONTROL INFORMATION LABEL
Figure 2. Typical Location of Engine Labels
Figure 1. Major Engine Components
1
Cylinder Head Assembly Repair 600 SRM 1205
Figure 3. Engine Nameplate (Typical)

The procedures to remove and install the engine are See section Frame 100 SRM 1423 for lift truck mod-
not included in this section. els
• H2.0-2.5CT (H50CT) (A274)
See section Frame 100 SRM 1120 for lift truck mod-
els
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
Cylinder Head Assembly Repair

Refer to Figure 4 for the cylinder head components.
Legend for Figure 4

1. VALVE COVER NUT 16. EXHAUST VALVE
2. O-RING 17. CYLINDER HEAD GASKET
3. VALVE COVER 18. CYLINDER HEAD
4. VALVE COVER GASKET 19. GLOW PLUG
5. ROCKER ARM SHAFT 20. GLOW PLUG COVER
6. ROCKER ARM SHAFT RETAINING SCREW 21. PUSH ROD
7. CYLINDER HEAD BOLT 22. SUPPORT BRACKET BOLT
8. GLOW PLUG HARNESS 23. ROCKER ARM SHAFT SPRING
9. VALVE CAP 24. SUPPORT BRACKET STUD
10. VALVE KEEPERS 25. SUPPORT BRACKET
11. SPRING RETAINER 26. ROCKER ARM
12. VALVE SPRING 27. ROCKER ARM SHAFT RETAINING RING
13. VALVE STEM SEAL 28. VALVE ADJUSTING SCREW LOCK NUT
14. VALVE GUIDE 29. VALVE ADJUSTING SCREW
15. INTAKE VALVE 30. SUPPORT BRACKET NUT
2
600 SRM 1205 Cylinder Head Assembly Repair
Figure 4. Cylinder Head Components
3
GLOW PLUGS 2. Inspect the O-rings on each valve cover nut. Re-
place as needed.
Remove
3. Remove the valve cover.
tery. 4. Remove the valve cover gasket and discard.
2. Remove the glow plug cover from each of the glow

plugs. See Figure 5.
3. Disconnect the glow plug harness from the glow

plugs.
4. Remove the glow plugs from the cylinder head.
1. VALVE COVER NUT

2. O-RING
3. VALVE COVER
4. GASKET
Figure 6. Valve Cover
Clean and Inspect
WARNING
1. GLOW PLUG
2. COVER and can cause skin irritation. When using
3. WIRE HARNESS cleaning solvents, always follow the recom-
4. CYLINDER HEAD mendations of the manufacturer.
Figure 5. Glow Plugs

WARNING
Install Compressed air can move particles so that they
1. Install the glow plugs into the cylinder head. Make sure that the path of the compressed air
2. Connect the glow plug harness to the glow plugs. goggles or a face shield to prevent injury to the
eyes.
3. Install the glow plug covers on each glow plug.
4. Connect the negative battery cable. CAUTION

Use caution not to scratch the gasket mating
VALVE COVER surfaces when cleaning the valve cover and
cylinder head.
Remove
Carefully remove all gasket residue from the valve
1. Remove the valve cover nuts. See Figure 6.
cover and cylinder head.
4
Clean the valve cover in cleaning solvent. Dry the 4. Verify that the O-rings are installed on the valve
valve cover with compressed air. Inspect for wear, cover nuts.
cracks, and any other damage. If necessary, replace
valve cover. 5. Install and tighten the valve cover nuts. Refer to
Standard Torque Specifications.
Install
ROCKER ARM ASSEMBLY
1. Lightly grease the new valve cover gasket.
Remove
2. Place the new valve cover gasket in the groove of
the valve cover. 1. Remove the valve cover. See Valve Cover, Re-
move.
3. Place the valve cover in position on the cylinder
head. 2. Remove the bolt and locking nuts that retain
the rocker arm assembly support brackets to the
cylinder head. See Figure 7.
1. SUPPORT BRACKET NUT 7. SUPPORT BRACKET

2. VALVE ADJUSTING SCREW LOCK NUT 8. ROCKER ARM SHAFT SPRING
3. VALVE ADJUSTING SCREW 9. ROCKER ARM
4. ROCKER ARM SHAFT 10. SUPPORT BRACKET BOLT
5. ROCKER ARM SHAFT RETAINING RING 11. ROCKER ARM SHAFT RETAINING SCREW
6. SUPPORT BRACKET STUD 12. CYLINDER HEAD
Figure 7. Rocker Arm Assembly
5
3. Lift the rocker arm shaft assembly from the 2. Roll the push rods until a gap can be observed
cylinder head. between a portion of the push rod and the surface
of the inspection block.
NOTE: Mark the push rods so they can be reinstalled
in original location during reassembly. 3. Use a feeler gauge to measure the gap. Refer
to the Engine Specifications for the service limit.
4. Remove the push rods from the cylinder head. See Figure 8.
Disassemble
1. Remove the rocker arm shaft retaining screw
from the support bracket that secures the rocker
arm shaft. See Figure 7.
2. Remove the retaining rings from the ends of the

rocker arm shaft.
NOTE: Mark the rocker arms so they can be rein-

stalled in original location during reassembly.
NOTE: The rocker arm shaft fits tightly in the rocker

arm support brackets. Clamp the support bracket in
a padded vise and twist and pull the rocker arm shaft
to remove the shaft.
3. Slide the rocker arm shaft out of the rocker arm Figure 8. Push Rod Inspection
support brackets, springs, and rocker arms. Rocker Arm Assembly
4. If necessary, remove the valve adjusting screw Rocker Arm and Support Bracket Inside Diam-
and lock nut from the rocker arms. eter - Use a test indicator and micrometer to deter-
mine if the inside diameter of all the rocker arm sup-
Clean and Inspect port brackets and rocker arms are within limits. Re-
fer to the Engine Specifications for the service limit.
WARNING See Figure 9.
WARNING
eyes.
Clean all parts in cleaning solvent. Dry the parts

with compressed air. Inspect for wear, cracks, and Figure 9. Rocker Arm Inside Diameter
any other damage. Replace all parts as needed.
Shaft Outside Diameter - Use a micrometer to
Push Rods measure the rocker arm shaft outside diameter.
Refer to the Engine Specifications for the service
1. Place the push rods on a flat inspection block. limit. See Figure 10.
6
5. Tighten the rocker arm shaft retaining bolt and

nuts.
6. Tighten the rocker arm shaft alignment screw.
7. Adjust the valve lash. See Valve Clearance Ad-

justments.
8. Install the valve cover. See Valve Cover, Install.
VALVE CLEARANCE ADJUSTMENTS

NOTE: Make measurements and adjustments while
Figure 10. Rocker Arm Shaft Outside Diameter the engine is cold.
Assemble NOTE: The cylinder to be adjusted first does not have

to be the number one cylinder. Select and adjust the
NOTE: The rocker arm shaft fits tightly in the rocker cylinder where the piston is the nearest to top dead
arm support brackets. Clamp the rocker arm shaft in center (TDC) after rotating and make the adjustment
a padded vise and twist and push the support brack- for the other cylinders in the order of the ignition by
ets onto the rocker arm shaft. turning the crankshaft 180 degrees each time.
NOTE: To properly align the rocker arm shaft with 1. Remove the valve cover. See Valve Cover, Re-
the support brackets, first install the rocker arm move.
shaft support bracket with the hole for the shaft
alignment screw. Align the hole in the rocker arm NOTE: The number one piston position is on the fly-
shaft and the hole in the support bracket. Install the wheel end of the engine, opposite side of the radiator,
alignment screw. See Figure 7. and the ignition order is 1 - 3 - 4 - 2 at 180 degree
intervals.
1. Lubricate the rocker arm shaft. Slide the rocker
arm support brackets, springs, and rocker arms NOTE: Since the intake and exhaust valve rocker
onto the shaft. arms are operated the same and there is a clearance
between rocker arm and valve generally at top dead
2. Position the rocker arm assembly on a flat sur- center, the position can be checked by means of the
face. Install the retaining rings onto the ends of play when the arm head is held with a hand. Also,
the rocker arm shaft. See Figure 7. see that the crankshaft pulley top mark is positioned
at zero on the timing scale. If there is no valve clear-
3. If removed, install the valve adjusting screws
ance, inspection in the disassembled state is neces-
and lock nuts.
sary since the valve seat may be worn abnormally.
Install 2. Rotate the crankshaft clockwise, as seen from the
radiator side, to bring the number one piston to
1. Install the push rods.
top dead center (TDC) while watching the rocker
2. Place the rocker arm assembly in position on the arm motion, timing scale, and top mark position
cylinder head. of the crankshaft pulley. (Position where both the
intake and exhaust valves are closed.)
3. Install and hand tighten the rocker arm shaft
retaining bolt and nuts. 3. Insert a feeler gauge between the rocker arm and
valve cap. See Figure 11. Record the measured
4. Align the push rods with their respective rocker valve clearance. The valve clearance should be
arms. between 0.15 to 0.25 mm (0.006 to 0.010 in.).
7
A. NORMAL B. ABNORMAL
1. VALVE CAP
Figure 13. Valve Cap Check

1. FEELER GAUGE
NOTE: There is a tendency for the clearance to de-
Figure 11. Valve Clearance Measurement crease slightly when the lock nut is tightened. It is
suggested that you make the clearance adjustment
4. If adjustment is needed, loosen the valve adjust- slightly on the loose side before tightening the lock
ing screw lock nut and valve adjusting screw on nut.
the rocker arm (see Figure 12) and check the
valve for any inclination of valve cap, entrance 5. Insert a 0.2 mm (0.008 in.) feeler gauge between
of dirt, or wear. See Figure 13. the rocker arm and valve cap and adjust the
clearance so there is a slight drag on the feeler
gauge when sliding it between the rocker arm
and valve cap. Tighten the valve adjusting screw
lock nut and recheck the clearance. The valve
clearance should be between 0.15 to 0.25 mm
(0.006 to 0.010 in.).
6. Apply clean engine oil to the contact surface be-

tween the adjusting screw and push rod.
7. Turn the crankshaft 180 degrees and make the

measurement and adjustment for the number
three cylinder. Then turn the crankshaft 180
degrees and make the measurement and ad-
justment for the number four cylinder. Then
turn the crankshaft 180 degrees and make the
measurement and adjustment for the number 2
cylinder.
1. VALVE ADJUSTING SCREW 8. Install the valve cover. See Valve Cover, Install.
2. VALVE ADJUSTING SCREW LOCK NUT
Figure 12. Valve Clearance Adjustment
8
CYLINDER HEAD ASSEMBLY manifold and gasket. Discard gasket. See Fig-
ure 16.
Remove
14. Remove the valve cover. See Valve Cover, Re-
1. Disconnect the negative battery cable at the bat- move.
tery.
15. Remove the rocker arm assembly. See Rocker
2. Remove the alternator. See Electrical Equip- Arm Assembly, Remove.
ment Repair.
16. Loosen the cylinder head bolts following the se-
3. Remove the water pump. See Cooling System quence shown in Figure 17.
Repair.
4. Disconnect the air intake hose from the intake

manifold.
5. Remove the glow plugs. See Glow Plugs, Remove.
6. Remove the fuel injectors and high pressure

lines. See Fuel System Repair.
7. If equipped, remove the pull actuator and mount-

ing bracket. See Fuel System Repair.
8. Disconnect the electrical connector for the fuel

filter sensor.
9. Tag and disconnect the fuel hoses from the fuel

filter.
10. Remove the bolts retaining the fuel filter housing

assembly to the intake manifold and remove the
fuel filter housing assembly. See Figure 14.
11. Remove the bolts retaining the intake manifold

to the cylinder head and remove the intake man-
ifold and gasket. Discard gasket. See Figure 15. 1. BOLTS
2. INTAKE MANIFOLD
12. Remove the nuts retaining the exhaust pipe to 3. FUEL SENSOR ELECTRICAL CONNECTOR
the exhaust manifold and disconnect the exhaust 4. FUEL FILTER HOUSING ASSEMBLY
pipe from the exhaust manifold.
Figure 14. Fuel Filter Housing Assembly
13. Remove the bolts retaining the exhaust mani-
fold to the cylinder head and remove the exhaust
9
1. GASKET 3. BOLT
2. INTAKE MANIFOLD 4. CYLINDER HEAD
Figure 15. Intake Manifold
10
1. CYLINDER HEAD 3. EXHAUST MANIFOLD

2. BOLT 4. GASKET
Figure 16. Exhaust Manifold
11
Disassemble
Valves and Valve Springs, Remove
1. Using a valve spring compressor tool, compress

one of the valve springs. See Figure 19.
A. CAMSHAFT SIDE B. FAN SIDE
Figure 17. Cylinder Head Bolt Loosening

Sequence
17. Remove the cylinder head bolts. See Figure 18.
Figure 19. Valve Spring Compressor
2. Remove the valve keepers and the valve cap from

the end of the valve. See Figure 20.
1. BOLT 3. GASKET
2. CYLINDER HEAD 1. VALVE CAP 5. VALVE STEM SEAL
2. VALVE KEEPERS 6. VALVES
3. SPRING RETAINER 7. CYLINDER HEAD
Figure 18. Cylinder Head and Gasket 4. SPRING
18. Lift the cylinder head away from the cylinder Figure 20. Valves and Valve Springs
block. Place the cylinder head on a work bench
to prevent damage to the combustion chamber. 3. Slowly release the tension on the valve spring.
19. Remove the cylinder head gasket and discard.
12
4. Remove the spring retainer, valve spring, and

valve stem seal. CAUTION
Any part which is found defective as a result of
5. Repeat this procedure until all intake and ex- inspection or any part whose measured value
haust valve springs and valve stem seals are re- does not satisfy the standard or limit must be
moved. replaced.
NOTE: If existing valves are going to be reinstalled
in the cylinder head, mark the valves so they can be CAUTION
installed in their original location. Any part determined to not meet the service
standard or limit before the next service, as de-
6. Turn the cylinder head so the exhaust port side termined from the state of current rate of wear,
faces down. Remove the intake and exhaust should be replaced even though the part cur-
valves from the cylinder head. rently meets the service standard limit.
Valve Guides, Remove
CAUTION
Using a drift pin and hammer, drive the valve guides
out of the cylinder head. See Figure 21.
surfaces when cleaning the exhaust manifold
and cylinder head.
CAUTION
surfaces when cleaning the intake manifold
and cylinder head.
CAUTION
surfaces when cleaning the cylinder head and
cylinder block.
Carefully remove all gasket residue from the exhaust

manifold and cylinder head. Inspect the exhaust
1. VALVE GUIDE 2. CYLINDER HEAD manifold for scratches, cracks, or any other damage.
Repair or replace as needed.
Figure 21. Valve Guides
Carefully remove all gasket residue from the intake
Clean and Inspect manifold and cylinder head. Inspect the intake man-
ifold for scratches, cracks, or any other damage. Re-
WARNING pair or replace as needed.
Cleaning solvents can be flammable and toxic Carefully remove all gasket residue from the cylinder
and can cause skin irritation. When using head and cylinder block. Inspect the cylinder head
cleaning solvents, always follow the recom- for scratches, cracks, or any other damage. Repair or
mendations of the manufacturer. replace as needed.
WARNING Thoroughly clean all components using a non-metal-

lic brush and cleaning solvent. Dry the parts with
compressed air. Each part must be free of carbon,
metal filings, and other debris.
is away from all personnel. Wear protective Visually inspect the parts. Replace any parts that
goggles or a face shield to prevent injury to the are obviously discolored, heavily pitted, or otherwise
eyes. damaged. Replace parts that do not meet the speci-
fied limit.
13
Cylinder Head
1. Place the cylinder head flat and inverted (com-

bustion side up) on the work bench.
2. Use a straight edge and feeler gauge to measure

the amount of cylinder head distortion. Refer to
the Engine Specifications for the service limit.
See Figure 22.
A. MEASUREMENT POINTS
Figure 23. Valve Stem Diameter Measurement

Points
Valve Stem Straightness - Place the valve stem

on a flat surface. Roll the valve until a gap can be
observed between a portion of the valve stem and
the flat surface. Use a feeler gauge to measure the
gap. Refer to the Engine Specifications for the ser-
vice limit. See Figure 24.
Figure 22. Cylinder Head Distortion Check
3. Use the Magnaflux method and inspect the cylin-

der head for cracks. Replace the cylinder head if
evidence of fractures are found.
Valve Guides
Visually inspect the valve guides for distortions, scor-

ing, or other damage.
Use a test indicator and micrometer to measure the Figure 24. Valve Stem Straightness Check
inside diameter at each end of the valve guide. Refer
to the Engine Specifications for the service limit. Valve Sink
Valves Insert the valves into their proper places in the

cylinder head and press them down until they are
Valve Stem Diameter - Use a micrometer to mea- fully seated. Using a depth micrometer, measure the
sure the valve stem diameter. Measure the valve difference between the cylinder head surface and
stem near the combustion end and near the opposite the combustion surface of each exhaust and intake
end. Refer to the Engine Specifications for the ser- valve. Refer to the Engine Specifications for the
vice limit. See Figure 23. service limit. See Figure 25 and Figure 26.
14
Figure 25. Valve Sink Measurement
1. VALVE SEAT
Figure 27. Valve Seat
Roughness or burrs will cause poor seating of a valve.

Visually inspect the seating of each valve and deter-
mine if lapping or grinding is needed. Grinding is
needed if the cylinder head’s seat width exceeds stan-
dard limits. Refer to the Engine Specifications for the
service limit.
Lap the valve seat and the cylinder head with a mix-
ture of valve compound and engine oil.
If the valve requires grinding, lap the valve after

grinding. Be sure to thoroughly wash the parts to
remove all grinding powder or compound.
Figure 26. Valve Sink Valve Springs
Valve Seat Inspect the valve springs. If damage or corrosion is

seen, or if measurements exceed the specified limits,
Always check the clearance between the valve and replace the springs.
valve guide before correcting the valve seat. See Fig-
ure 27. If the clearance exceeds the limit, replace the Fractures - Check for fractures on the inside and
valve or valve guide to bring the clearance within the outside portions of the springs. If the valve spring is
limit. fractured, replace the spring.
15
Corrosion - Check for corrosion of spring material in a freezer for at least twenty minutes. This
caused by oxidation. will cause the valve guides to contract, making
it easier to install the valve guides into place.
Squareness - Use a flat surface and a square to
check each spring for squareness. Refer to the En- 2. Immediately after removing the valve guides
gine Specifications for the service limit. See Fig- from the freezer, insert the valve guides in their
ure 28. proper positions in the cylinder head.
3. Finish installing the valve guides into the cylin-

der head to the proper height using a special tool,
valve guide installation tool. See Figure 30.
Figure 28. Spring Squareness Check
Free Length - Use a caliper to measure the length

of the spring. Refer to the Engine Specifications for
the service limit. See Figure 29.
1. VALVE GUIDE INSTALLATION TOOL

2. CYLINDER HEAD
3. VALVE GUIDE
Figure 30. Valve Guide Installation
Valves and Valve Springs, Install
1. Place the cylinder head assembly on the exhaust

port side.
2. Place all the valves in their proper positions,

as marked when disassembled, in the cylinder
head.
Figure 29. Spring Free Length Check 3. Apply clean engine oil to the lip of the valve stem
seal. Using a special tool, valve stem seal instal-
Assemble lation tool, insert a new valve stem seal on each
of the valves. See Figure 31.
Valve Guides, Install
4. Measure the distance from the cylinder head to
1. The valve guides are installed into the cylinder the valve stem seal. Refer to the Engine Specifi-
head with an extremely tight press fit. Before cations for the clearance specifications. See Fig-
installing the valve guides, place the valve guides ure 32.
16
valve springs and valve spring retainers. See

Figure 20.
6. Using the valve compressor tool, compress the

valve spring.
7. Install the valve keepers and slowly release the

tension in the valve spring.
8. Install the valve cap.
9. Repeat these procedures until all the intake and

exhaust valves are installed.
Install
1. Carefully clean the combustion surface of the
cylinder head and the top surface of the cylinder
block.
1. VALVE STEM SEAL INSTALLATION TOOL
2. VALVE STEM SEAL 2. Place a new cylinder head gasket on the cylinder
3. VALVE GUIDE
4. CYLINDER HEAD block. See Figure 18.
Figure 31. Valve Stem Seal Installation 3. Position the cylinder head on the cylinder head
gasket and cylinder block.
4. Lightly oil the threads of the cylinder head bolts.
5. Install the cylinder head bolts and tighten the

cylinder head bolts to 49 to 59 N•m (36 to
43 lbf ft) in the sequence shown in Figure 33.
Then tighten the cylinder head bolts to 103 to
113 N•m (76 to 83 lbf ft) in the same sequence.
A. CAMSHAFT SIDE
B. FAN SIDE
Figure 33. Cylinder Head Torque Sequence

1. VALVE STEM SEAL
2. VALVE GUIDE 6. Install the push rods and rocker arm assembly.
3. VALVE GUIDE PROTECTION See Rocker Arm Assembly, Install.
4. VALVE STEM SEAL PROTECTION
5. CLEARANCE 7. Install the valve cover. See Valve Cover, Install.
Figure 32. Valve Stem Seal Clearance 8. Place a new gasket and the exhaust manifold in
position on the cylinder head and install the ex-
5. Place the cylinder head on the work bench with haust manifold retaining bolts.
the combustion chamber facing down. Install the
17

fold and install retaining nuts. WARNING
10. Place a new gasket and the intake manifold in tem may be hot or under pressure and can
position on the cylinder head and install the in- cause serious injury.
take manifold retaining bolts.
23. Start the engine and check for leaks.
11. Place the fuel filter housing assembly in posi-
tion on the intake manifold and install retaining 24. Change the engine oil and oil filter. See Lubri-
bolts. cation System Repair, Engine Oil and Oil Filter
Change.
12. Connect the fuel hoses to the fuel filter.
13. Connect the electrical connector for the fuel filter WARNING
sensor. DO NOT remove the radiator cap from the ra-
14. If equipped, install the pull actuator and mount- tor cap is removed, pressure will release from
ing bracket. See Fuel System Repair. the coolant system. If the coolant system is hot,
15. Install the fuel injectors and high pressure lines.
burns.
See Fuel System Repair.
16. Install the glow plugs. See Glow Plugs, Install. WARNING
17. Connect the air intake hose to the intake mani- tem may be hot or under pressure and can
fold. cause serious injury. Wait 30 minutes for the
18. Install the water pump. See Cooling System Re- radiator and engine to cool before performing
pair. maintenance to the cooling system. After 30
19. Install the alternator. See Electrical Equipment ator with your hand. If the radiator is still hot
Repair. to the touch, wait another 30 minutes before
attempting any maintenance to the cooling
system.
CAUTION
fore using additives, contact your local Hyster CAUTION
dealer. Additives may damage the cooling system. Be-
20. Fill the cooling system with coolant. Refer to dealer.
the Periodic Maintenance section for your lift
truck for the correct coolant amount and type. 25. Stop engine. If coolant is hot, allow engine time
to cool. Check coolant level and fill as required
21. Install the radiator cap. between the ADD and FULL marks on the
coolant reservoir.
WARNING
18
600 SRM 1205 Timing Gear Case and Timing Gears Repair
Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE COVER 7. If necessary, remove the front oil seal from the
timing gear case cover. See Figure 34.
Remove
Clean and Inspect
1. Remove the engine.
See section Frame 100 SRM 1120 for lift truck WARNING
models Cleaning solvents can be flammable and toxic
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, and can cause skin irritation. When using
H40FTS) (F001) cleaning solvents, always follow the recom-
• H2.0-3.5FT (H40-70FT) (L177) mendations of the manufacturer.
models WARNING
• H2.0-2.5CT (H50CT) (A274) Compressed air can move particles so that they
2. Remove the coolant fan, V-belt, and water pump. Make sure that the path of the compressed air
See Cooling System Repair. is away from all personnel. Wear protective
3. Remove the bolt and washer retaining the crank- eyes.
shaft pulley.
Clean all old sealant from the timing gear case cover
4. Using a gear puller, remove the crankshaft pul- and the timing gear case. Clean the timing gear case
ley. cover in cleaning solvent. Dry the timing gear case
cover with compressed air. Inspect for wear, cracks,
5. Remove the bolts retaining the timing gear case
and any other damage. If necessary, replace timing
gear case cover.
Install
1. Apply a continuous bead of ThreeBond Liquid
Gasket, Hyster Part Number 1599478, to the out-
side diameter of a new front oil seal.
2. Using a special tool, install the new front oil seal

into the timing gear case cover. Apply lithium
grease to the lip of the front oil seal. See Fig-
ure 35.
1. TIMING GEAR CASE

2. TIMING GEAR CASE COVER
3. BOLT
4. FRONT OIL SEAL
Figure 34. Timing Gear Case Cover
6. Remove the timing gear case cover.

Figure 35. Front Oil Seal Installation
19
Timing Gear Case and Timing Gears Repair 600 SRM 1205

Gasket, Hyster Part Number 1599478, to the
mating surface of the timing gear case cover.
4. Place the timing gear case cover in position on

the timing gear case and install retaining bolts.
5. Install the crankshaft pulley, washer, and bolt

to retain the crankshaft pulley. Tighten bolt to
117.6 N•m (86.7 lbf ft).
6. Install the water pump, V-belt, and coolant fan.

See Cooling System Repair.
7. Install the engine.

models
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 1. FUEL INJECTION PUMP DRIVE GEAR
2. CAMSHAFT GEAR
H40FTS) (F001) 3. CRANKSHAFT GEAR
• H2.0-3.5FT (H40-70FT) (L177) 4. DIRECTION OF ROTATION
5. OIL PUMP GEAR
See section Frame 100 SRM 1423 for lift truck 6. IDLER GEAR
models
• H2.0-2.5CT (H50CT) (A274) Figure 36. Timing Gear Alignment
8. Fill the engine oil to the correct level. Refer to Crankshaft Gear
the section Periodic Maintenance for your lift
truck, for correct oil amount and type. Remove
9. Start the engine and check for leaks. 1. Remove the timing gear case cover. See Timing
Gear Case Cover, Remove.
TIMING GEARS
2. Verify that the gears are properly aligned with
NOTE: For removal of the fuel injection pump drive the alignment marks. See Figure 36.
gear, refer to the section Fuel System Repair.
NOTE: If using a gear puller to remove the crank-
Before removing any of the timing gears, rotate the shaft gear, be careful not to damage the threads in
crankshaft to align the alignment marks on the gears the end of the crankshaft.
as follows (see Figure 36):
• Align mark "A" on the crankshaft gear with mark 3. Remove the crankshaft gear. See Figure 37.
"A" on the idler gear. 4. Remove the parallel pin and the key from the
• Align mark "B" on the fuel injection pump gear crankshaft.
with mark "B" on the idler gear.
• Align mark "C" on the camshaft gear with mark "C"
on the idler gear.
20
1. PARALLEL PIN
2. KEY
3. CRANKSHAFT GEAR
4. CRANKSHAFT 1. TIMING GEAR CASE
2. IDLER GEAR
3. BUSHING
Figure 37. Crankshaft Gear 4. IDLER GEAR SHAFT
5. BOLT
Install
Figure 38. Idler Gear
1. Install the parallel pin and the key into the
crankshaft. Inspect
2. Align the alignment mark "A" on the crankshaft 1. Measure the outside diameter of the idler gear
gear with the alignment mark "A" on the idler shaft. Refer to the Engine Specifications for the
gear and install the crankshaft gear onto the service limit. See Figure 39.
crankshaft.
2. Measure the inside diameter of the idler gear.
3. Verify that all alignment marks are properly Refer to the Engine Specifications for the service
aligned. Figure 36. limit. See Figure 39.
4. Install the timing gear case cover. See Timing
Gear Case Cover, Install.
Idler Gear
Remove
1. Remove the timing gear case cover. See Timing

2. Verify that the gears are properly aligned with

the alignment marks. See Figure 36.
3. Remove the bolts from the idler gear shaft. See

1. OUTSIDE DIAMETER
Figure 38. 2. IDLER GEAR SHAFT
3. INSIDE DIAMETER
4. Remove the idler gear shaft, idler gear, and bush- 4. IDLER GEAR
ing.
Figure 39. Idler Gear and Shaft Measurement
21
Timing Gear Case and Timing Gears Repair 600 SRM 1205
Install Legend for Figure 40
1. Lubricate the idler gear bushing and idler gear 1. TIMING GEAR CASE
shaft with clean engine oil. 2. CAMSHAFT
3. CAMSHAFT GEAR
NOTE: Make sure the oil hole in the bushing is facing
Install
toward the top of the engine.
1. Install the key into the camshaft.
2. Align the alignment mark "B" on the idler gear
with the alignment mark "B" on the fuel injec- 2. Align the alignment mark "C" on the camshaft
tion pump and the alignment mark "A" on the gear with the alignment mark "C" on the idler
idler gear with the alignment mark "A" on the gear and install the camshaft gear onto the
crankshaft gear. Install the idler gear, bushing, camshaft.
and idler gear shaft.
3. Align the alignment mark "A" on the crankshaft
3. Verify that all alignment marks are properly gear with the alignment mark "A" on the idler
aligned. See Figure 36 gear and install the crankshaft gear onto the
crankshaft.
4. Install the idler gear retaining bolts.
TIMING GEAR CASE
Camshaft Gear
Remove Remove
1. Remove the timing gear case cover. See Timing 1. Remove the engine.
2. Verify that the gears are properly aligned with models
the alignment marks. See Figure 36. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
3. Using a gear puller, remove the camshaft gear. • H2.0-3.5FT (H40-70FT) (L177)
See Figure 40.
4. Remove the key from the camshaft. models
• H2.0-2.5CT (H50CT) (A274)

3. Remove the fuel injection pump. See Fuel Sys-

tem Repair.
4. Remove the timing gears. See Timing Gears.
5. Remove the two bolts retaining the camshaft

thrust plate and remove thrust plate.
6. Remove the bolts retaining the gear case to the

cylinder block and remove the gear case. See Fig-
ure 41.
7. Remove the two O-rings from the cylinder block

Figure 40. Camshaft Gear
and discard.
22
cover and gear case in cleaning solvent. Dry the tim-

ing gear case cover and gear case with compressed
air. Inspect for wear, cracks, and any other damage.
Replace components as necessary.
Install
1. Install two new O-rings in the cylinder block.

mating surface of the timing gear case.
3. Position the gear case on the cylinder block and

install retaining bolts.
4. Install the timing gears. See Timing Gears.
1. TIMING GEAR CASE 5. Install the camshaft thrust plate and the retain-
2. BOLT ing bolts.
3. O-RINGS
4. CYLINDER BLOCK 6. Install the timing gear case cover. See Timing
Figure 41. Timing Gear Case
7. Install the fuel injection pump. See Fuel System
Clean and Inspect Repair.

WARNING
Cleaning solvents can be flammable and toxic See section Frame 100 SRM 1120 for lift truck
and can cause skin irritation. When using models
cleaning solvents, always follow the recom- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
mendations of the manufacturer. H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
WARNING See section Frame 100 SRM 1423 for lift truck
Compressed air can move particles so that they models
cause injury to the user or to other personnel. • H2.0-2.5CT (H50CT) (A274)
is away from all personnel. Wear protective 9. Change the engine oil and oil filter. See Lubri-
goggles or a face shield to prevent injury to the cation System Repair, Engine Oil and Oil Filter
eyes. Change.
Clean all old sealant from the timing gear case cover 10. Start the engine and check for leaks.
and the timing gear case. Clean the timing gear case
23
Drive Train, Camshaft, and Cylinder Block Repair 600 SRM 1205
Drive Train, Camshaft, and Cylinder Block Repair

REMOVE DISASSEMBLE
1. Remove the engine. Pistons and Connecting Rods
See section Frame 100 SRM 1120 for lift truck NOTE: It is necessary to rotate the crankshaft to ac-
models cess some of the connecting rod assemblies at the bot-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, tom dead center position.
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) 1. Using a feeler gauge, measure the connecting rod
thrust clearance. See Figure 42. Refer to Engine
See section Frame 100 SRM 1423 for lift truck Specifications for the standard limit. If the mea-
models surement is out of specification, either the crank-
• H2.0-2.5CT (H50CT) (A274) shaft or the connecting rod must be replaced.
2. Remove the starter. See Electrical Equipment 2. Remove the two bolts from one of the connecting
Repair. rod caps. See Figure 43.
3. Remove the flywheel and flywheel housing. See 3. Remove the connecting rod cap.
Flywheel and Flywheel Housing.
4. Remove the bearing halves.
4. Remove the alternator. See Electrical Equip-
ment Repair. 5. Tap the piston through the cylinder and remove
the piston assembly with the connecting rod.
5. Remove water pump. See Cooling System Re-
pair. 6. Mark the connecting rod cap and the connecting
rod and place the assembly on a bench.
6. Remove the fuel injection pump. See Fuel Sys-
tem Repair.
7. Remove the cylinder head. See Cylinder Head

Assembly Repair.
8. Remove the oil pan. See Lubrication System Re-

pair.
9. Remove the oil suction tube. See Lubrication

System Repair.

Gear Case and Timing Gears Repair.
11. Remove the oil pump. See Lubrication System

Repair.
NOTE: Do not remove the camshaft gear at this time.
12. Remove the crankshaft gear and idler gear. See

Timing Gear Case and Timing Gears Repair.
Figure 42. Connecting Rod Thrust Clearance
24
600 SRM 1205 Drive Train, Camshaft, and Cylinder Block Repair
11. Remove the piston from the connecting rod.
12. Remove the wrist pin bushing from the connect-

ing rod.
13. Repeat Step 2 through Step 12 for the remaining

pistons and piston rods.
Crankshaft
1. Remove the bolts retaining the rear oil seal as-
sembly and remove the rear oil seal assembly.
See Figure 44.
2. If necessary, remove the rear oil seal.
3. Measure the crankshaft side gap using on of the

following two methods:
a. Install a dial gauge on the cylinder block.

Move the crankshaft back and forth. Mea-
sure the side gap. See Figure 45.
1. COMPRESSION RINGS
2. OIL SEAL RING b. Using a shim gauge, measure the clearance
3. WRIST PIN between the thrust metal and crankshaft.
4. SNAP RING See Figure 46.
5. WRIST PIN BUSHING
6. BEARING HALVES NOTE: Be sure to note the markings on the main
7. CONNECTING ROD CAP
8. BOLT bearing caps, or mark them yourself, so they can
9. CONNECTING ROD be reinstalled in the same location as they were
10. PISTON removed.
Figure 43. Piston and Connecting Rod NOTE: The arrows on the main bearing caps point to
the flywheel end of the engine.
7. Remove the two compression rings from the pis-
ton. 4. Remove the bolts retaining the main bearing
caps and remove the main bearing caps.
8. Remove the oil seal ring from the piston.
5. Remove the bearing halves and thrust bearings.
9. Remove the snap rings retaining the wrist pin.
6. Remove the crankshaft from the cylinder block.
10. Remove the wrist pin.
25
1. CYLINDER BLOCK 7. THRUST BEARINGS

2. PARALLEL PIN 8. CRANKSHAFT
3. KEY 9. REAR OIL SEAL
4. BEARING HALVES 10. REAR OIL SEAL HOUSING
5. MAIN BEARING CAP 11. BOLT
6. BOLT
Figure 44. Crankshaft
26
Camshaft
1. Using a feeler gauge, measure the camshaft side
gap. Refer to Engine Specifications for the ser-
vice limit. See Figure 47.
Figure 45. Crankshaft Side Gap Measurement

With Dial Gauge
1. THRUST METAL 4. CAMSHAFT

2. CAMSHAFT PULLEY
3. SIDE GAP
Figure 47. Camshaft Side Gap
2. Using a gear puller, remove the camshaft gear.

See Figure 48.
3. Remove the key from the camshaft.
4. Remove the two bolts retaining the thrust plate

and remove thrust plate.
NOTE: If the engine is not installed on an engine

stand, position the engine with the mounting flange
(flywheel end) facing down. Rotate the camshaft a
few turns to bump the tappets out of the way to pre-
vent the tappets from interfering with the removal of
A. STANDARD WIDTH B. THRUST FACE the camshaft.
1. CYLINDER BLOCK 4. SHIM GAUGE 5. With the engine installed on an engine stand, ro-
2. CRANKSHAFT 5. CYLINDER BLOCK
tate the engine so the gravity causes the tappets
3. THRUST METAL
to drop away from the camshaft lobes.
Figure 46. Crankshaft Side Gap Measurement
6. Slowly pull the camshaft out of the cylinder
With Shim Gauge
block.
27
NOTE: Be sure to mark the tappets so they can be 8. Remove the timing gear case. See Timing Gear
installed in the same location as they were removed. Case and Timing Gears Repair.
7. Remove the tappets. 9. If damaged, remove the camshaft bushing.
1. CYLINDER BLOCK 7. KEY

2. CAMSHAFT BUSHING 8. THRUST PLATE
3. TIMING GEAR CASE 9. BOLT
4. BOLT 10. CAMSHAFT GEAR
5. TAPPETS 11. O-RINGS
6. CAMSHAFT
Figure 48. Camshaft
CLEAN AND INSPECT Make sure that the path of the compressed air
WARNING goggles or a face shield to prevent injury to the
eyes.
and can cause skin irritation. When using Clean all old sealant from all parts. Clean all parts in
cleaning solvents, always follow the recom- cleaning solvent. Dry the parts with compressed air.
mendations of the manufacturer. Each part must be free of carbon, metal filings, old
sealant, and other debris. Inspect for wear, cracks,
WARNING and any other damage. Replace components as nec-
Compressed air can move particles so that they essary.
28
Cylinder Block (c) and in the (d) direction. Record that

measurement as data j.
1. Verify that oil holes are clear and unobstructed.
Clear any oil holes as needed. f. Measure the inside diameter of cylinder
number one, near the bottom of the cylinder
2. Check for discoloration or evidence of cracks. (c) and in the (e) direction. Record that
If evidence of a fracture is found, use the color measurement as data k.
check method or the Magnaflux method to deter-
mine if the cylinder block is fractured. g. Roundness: Roundness for cylinder num-
ber one is calculated as follows:
3. Inspect the cylinder roundness and cylindricity f-g=X
for evidence of distortions. Collect and record the h-i=Y
measurements. See Figure 49 and Table 1. j-k=Z
X is the difference between the f and g mea-

surements at the top of the cylinder.
Y is the difference between the h and i mea-

surements at the center/middle of the cylin-
der.
Z is the difference between the j and k mea-

surements at the bottom of the cylinder.
Select the greatest of values X, Y and Z,

then record it as V. This value represents
the roundness of the cylinder.
Figure 49. Cylinder Measurement Points
h. Cylindricity - Cylindricity for cylinder
4. Perform the calculations as follows: number one is calculated as follows:
Select the least value of values X, Y and Z
a. Measure the inside diameter of cylinder record that value as S. Complete the cal-
number one, near the top of the cylinder (a) culation as follows:
and in the (d) direction. Record that mea- V - S =W
surement as data f.
W is the difference between the V and S mea-
b. Measure the inside diameter of cylinder surements. This value represents the cylin-
number one, near the top of the cylinder (a) dricity of the cylinder.
and in the (e) direction. Record that mea-
surement as data g. 5. Repeat the cylindricity and roundness measure-
ments and calculations for the remaining cylin-
c. Measure the inside diameter of cylinder ders.
number one, near the center of the cylinder
(b) and in the (d) direction. Record that 6. Compare the worksheet findings with the speci-
measurement as data h. fications listed in Engine Specifications.
d. Measure the inside diameter of cylinder 7. Consider honing, re-boring, or replacing the
number one, near the center of the cylinder cylinder block if the measurements fall outside
(b) and in the (e) direction. Record that the specifications.
measurement as data i.
e. Measure the inside diameter of cylinder

number one, near the bottom of the cylinder
29
Table 1. Cylinder Measurement Worksheet
Cylinder
Measurements Calculated Values
Number
Greatest of
Top Dimension (d) Dimension (e) f g=X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #1 Center Dimension (d) Dimension (e) h i=Y
X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
V S = W
Bottom Dimension (d) Dimension (e) j k=Z
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
V S = W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
V S = W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Cylinder #4 Least of
Center Dimension (d) Dimension (e) h i=Y
(As Needed) X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
V S = W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
30
Honing and Boring f. Maintain the up-and-down motion for thirty

to forty seconds.
Pistons must move freely in the cylinders while
maintaining adequate compression and oil sealing.
If the cylinder walls are scuffed, scored, out of round, WARNING
or have poor cylindricity, boring or boring and honing Compressed air can move particles so that they
might correct cylinder problems. Re-boring is nec- cause injury to the user or to other personnel.
essary if the bore dimensions fall outside specified Make sure that the path of the compressed air
limits. Honing must follow any re-boring operations. is away from all personnel. Wear protective
Slight imperfections can be corrected by honing goggles or a face shield to prevent injury to the
alone. eyes.
1. Boring - Significant cylinder damage might be g. When the honing is completed, wash the
corrected by re-boring. cylinder block with hot water and soap. Use
• Boring out a cylinder block can only be done in brushes to clean all passages and crevices.
a properly equipped machine shop. Rinse with hot water and blow dry with
• After re-boring, existing pistons must be re- compressed air. Apply clean engine oil to all
placed with oversized pistons. steel surfaces to prevent rusting.
• After re-boring a cylinder block, each cylinder
must be honed.
2. Honing - Slight cylinder imperfections might be

corrected by honing.
a. Insert the appropriate honing tool into the

chuck of an electric drill.
b. Saturate the cylinder wall with solvent using

a 50% diesel fuel and 50% engine oil mixture.
c. Rotate the honing tool at 300 to 1200 rpm.
CAUTION
DO NOT allow the honing tool to operate in one Figure 50. Cylinder Honing Angle
position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in con-
stant up-and-down motion.
NOTE: Tilt the honing tool at a 30 to 40 degree angle

during the honing operation, to leave a cross hatch
mark on the cylinder wall. See Figure 50.
d. Insert the rotating honing tool into the cylin-

der and move it down through the entire
length of the cylinder in a five-second mo-
tion. See Figure 51. Figure 51. Cylinder Honing
e. Without stopping the honing tool, pull it up
through the entire length of the cylinder in a
five-second motion.
31
Pistons c. Add the top compression ring groove width

and the top compression ring side clearance
1. Using a micrometer, measure the piston diame- together to determine the top ring groove
ter at the skirt. Refer to the Engine Specifica- width. Refer to the Engine Specifications for
tions for the service limit. See Figure 52. the service limit.
d. Replace the piston if the values fall outside

the specification.
e. Using a feeler gauge, measure the end gap

clearance of the top compression ring. Refer
to the Engine Specifications for the service
limit.
f. Measure the rings and ring grooves for the

second compression ring and oil ring using
the same method used to measure the top
compression ring and groove dimensions.
3. Repeat Step 2 for each of the pistons.

Figure 52. Piston Skirt Measurement Piston Pin
2. Measure the piston ring and the piston ring Measure the outside diameter of the piston pin
groove for cylinder number one. and the inside diameter of the wrist pin bushing.
a. Using a micrometer, measure the thickness Calculate the clearance between the piston pin and
of the top compression ring. Refer to the En- wrist pin bushing. Refer to the Engine Specifications
gine Specifications for the service limit. for the service limit. See Figure 54.
b. Place a properly-sized, top compression ring

in the groove as shown in Figure 53. Use
a feeler gauge to measure the gap between
the ring and the piston. Refer to the Engine
Specifications for the service limit.
NOTE: MEASURE AT POSITIONS A, B, AND C IN DI-

RECTIONS A AND B.
Figure 54. Piston Pin Outside Diameter
Connecting Rod
1. Measure the inside diameter of the connecting
rod small end. Refer to the Engine Specifications
A. WIDTH B. THICKNESS for the service limit. See Figure 55.
Figure 53. Piston and Piston Ring Side 2. Measure the crankpin and connecting rod bear-
Clearance ing halves. Place the connecting rod bearing
32
halves into the connecting rod and connecting

rod cap. Install the end of the connecting rod
to the connecting rod cap. Install the bolts and
Figure 57. Tappet Stem Measurement
Crankshaft
1. Measure the trueness of the crankshaft.
a. Place the crankshaft on V-blocks at the end

journals. See Figure 58.
b. Place a dial indicator on a main bearing sur-

face and zero the gauge.
1. CYLINDER GAUGE c. Rotate the crankshaft and observe the

2. CONNECTING ROD SMALL END runout. Refer to the Engine Specifications
for the service limit.
Figure 55. Connecting Rod Small End
d. Repeat this procedure for the remaining
3. Measure the inside diameter. Refer to the Engine
bearing surfaces.
Specifications for the service limit.
Tappets
1. Check the tappet contact surfaces with the
camshaft and push rods. Slight surface defects
can be corrected using an oilstone. See Figure 56.
1. ABNORMAL CONTACT SURFACE

2. NORMAL CONTACT SURFACE
A. BEND B. DEFLECTION
Figure 56. Tappet Contact Surface
1. DIAL GAUGE 3. V-BLOCK
2. Measure the outside diameter of the tappet stem. 2. CRANKSHAFT
Refer to the Engine Specifications for the service
limit. See Figure 57. Figure 58. Crankshaft Bend Measurement
33
2. Inspect the crankshaft for fractures.
a. Using the color check method, inspect the

crankshaft for cracks. Replace the crank-
shaft if evidence of fractures are found. See
Figure 59.
b. If the color check method is not available, use

the Magnaflux method. Inspect the crank-
shaft for cracks. Replace the crankshaft if ev-
idence of fractures are found.
3. Measure the outside diameter of each crankpin

and journal. See Figure 60.
a. If the crankpin clearance exceeds the service

limit, use an undersized bearing. Refer to the
Engine Specifications for the service limit.
b. If the journal clearance exceeds the service

limit, use an undersized bearing. Refer to the
1. CRANKSHAFT JOURNAL
2. CRANKPIN
Figure 60. Crankpin and Crankshaft Journal

Measurement
Figure 59. Crankshaft Fracture Check
34
Camshaft camshaft bushing inside diameter. Refer to the

1. Measure the trueness of the camshaft.
a. Place the camshaft on V-blocks positioned at

the end journals. See Figure 61.
b. Place a dial indicator on the gear side bearing

surface and zero the gauge.
c. Rotate the camshaft and observe the runout.

Refer to the Engine Specifications for the ser-
vice limit.
1. FLYWHEEL END BEARING SURFACE

2. INTERMEDIATE POSITION BEARING SURFACE
3. GEAR END BEARING SURFACE
Figure 63. Camshaft Bearing Surface

Measurements
Camshaft Bushing
If the camshaft bushing is damaged, replace the
bushing using the appropriate service tool.
Figure 61. Camshaft Runout Check ASSEMBLE
2. Measure the intake/exhaust cam height. Refer Camshaft

to the Engine Specifications for the service limit.
1. Verify that all parts are clean. Lightly lubricate
See Figure 62.
all parts with clean engine oil.
2. If removed, install new camshaft bushing.
3. Install the timing gear case. See Timing Gear

Case and Timing Gears Repair.
NOTE: Rotate the cylinder block into a position in

which it allows gravity to keep the tappets in place
and out of the way of the camshaft lobes for when the
camshaft is installed.
4. Install the tappets into the cylinder block in the

A. CAM HEIGHT same locations as they were removed.
Figure 62. Intake/Exhaust Cam Height 5. Slowly insert the camshaft through the front of
Measurement the engine.
3. Measure the gear end bearing surface, inter- 6. Place the camshaft thrust plate in position and
mediate position bearing surface, and flywheel install the retaining bolts. See Figure 48.
end bearing surface diameters. See Figure 63. 7. Install the key on the camshaft.
Determine the oil clearance. The oil clear-
ance is calculated by subtracting the measured 8. Install the camshaft gear.
camshaft bearing surface diameter from the
35
Crankshaft b. Install the top compression ring, second com-

pression ring, and oil ring. See Figure 66.
1. Place the crankshaft in position in the cylinder
block. c. Stagger the piston ring joints at 120 degree
intervals. DO NOT position the top compres-
NOTE: The numbers and arrows on the main bearing sion ring joint in line with the piston wrist
caps are for proper positioning. The caps are num- pin. The coil expander joint must be opposite
bered 1, 2, 3, and 4 with the number 1 cap at the the oil ring joint. See Figure 67.
flywheel end of the cylinder block. The arrows on the
bearing caps should point towards the flywheel end
of the cylinder block.
2. Position the bearing halves, thrust bearings, and

bearing caps on the crankshaft. See Figure 44.
3. Lubricate the bearing cap bolts and install the

bolts.
4. Install a new oil seal in the rear oil seal housing.

mating surface of the rear oil seal housing.
6. Align the rear oil seal housing with the two dowel
pins on the cylinder block and install the rear
oil seal housing. Install the retaining bolts and
Pistons and Connecting Rods

1. Select the parts needed to assemble the piston A. FUEL INJECTION PUMP SIDE
and connecting rod for the Number 1 cylinder. B. FLYWHEEL SIDE
C. CAMSHAFT SIDE
2. Lubricate and insert the wrist pin bushing into
the small end of the connecting rod. See Fig- 1. PISTON IDENTIFICATION MARK
ure 43. 2. CYLINDER SIZE MARK
3. EMBOSSED MARK (FLYWHEEL SIDE)
3. Install one snap ring into the piston. 4. PUNCHED MARK
4. Position the connecting rod into the piston under Figure 64. Piston and Connecting Rod
the skirt. The match marks on the connecting Identification Marks
rod must be opposite of the piston identification
mark on the top of the piston. See Figure 64.
5. Lubricate and install the piston wrist pin

through the piston and wrist pin bushing.
6. Install the second snap ring.
7. Using piston ring pliers, install the piston rings.
a. Install each piston ring on the piston with the

punched manufacture’s mark facing upward.
See Figure 65. Figure 65. Piston Ring Mark
36
8. Perform Step 1 through Step 7 for the assembly

of the remaining pistons.
9. Lubricate the Number 1 piston and piston rings

with clean engine oil.
10. Using special tool, piston ring compressor, com-

press the piston rings on the Number 1 piston.
11. Carefully install the piston into the Number 1

cylinder. Be sure the punched mark on the con-
necting rod is facing the fuel injector side and the
embossed mark is facing the flywheel. See Fig-
ure 64.
12. Install the connecting rod bearing halves and

connecting rod cap. Install the connecting rod
1. TOP COMPRESSION RING bolts and tighten to 54 to 59 N•m (40 to 43 lbf ft).
2. SECOND COMPRESSION RING
3. OIL RING 13. Perform Step 9 through Step 12 to install the re-
4. PISTON maining pistons in their respective cylinders.
Figure 66. Piston Rings INSTALL

1. Install the crankshaft gear and idler gear. See
Timing Gear Case and Timing Gears Repair.
2. Install the oil pump. See Lubrication System Re-

pair.

4. Install the oil suction tube. See Lubrication Sys-

tem Repair.
5. Install the oil pan. See Lubrication System Re-

pair.
6. Install the cylinder head. See Cylinder Head As-

sembly Repair.
7. Install the fuel injection pump. See Fuel System

Repair.
8. Install the water pump. See Cooling System Re-

pair.
9. Install the alternator. See Electrical Equipment

Repair.
10. Install the flywheel and flywheel housing. See

Flywheel and Flywheel Housing.
1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING 11. Install the starter. See Electrical Equipment Re-
3. OIL RING pair.
4. JOINTS
Figure 67. Piston Rings Staggering
37
See section Frame 100 SRM 1120 for lift truck filter. Install new filter. Turn filter until gasket
models touches, then tighten 1/2 to 3/4 turn with your
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, hand.
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) 14. Fill the engine oil to the correct level. Refer to
the section Periodic Maintenance for your lift
See section Frame 100 SRM 1423 for lift truck truck, for correct oil amount and type.
models
• H2.0-2.5CT (H50CT) (A274) 15. Start the engine and check for leaks.
13. If not previously removed, remove and discard

engine oil filter. Apply clean oil to gasket of new
Lubrication System Repair

ENGINE OIL AND OIL FILTER CHANGE OIL PAN
1. Remove the oil pan drain plug and drain the en- Remove
gine oil into a suitable container. See Figure 68.
WARNING
When putting the lift truck on blocks, make
sure the surface is solid, even, and level. Any
blocks used to support the lift truck must be
solid, one-piece units.
1. Put the lift truck on blocks so that you have ac-

cess under the lift truck. Refer to the Operating
Manual or the section Periodic Maintenance
2. Remove the crossmember and the flywheel ac-

cess cover.

1. OIL FILTER 3. DRAIN PLUG models
2. BOLT 4. OIL PAN • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
Figure 68. Oil Pan H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
2. Remove the engine oil filter.
3. Install the oil pan drain plug. Tighten the drain models
plug to 20 to 24 N•m (14.75 to 17.70 lbf ft). • H2.0-2.5CT (H50CT) (A274)
4. Apply clean oil to gasket of new filter. Install 3. Remove the oil pan drain plug and drain the en-
new filter. Turn filter until gasket touches, then gine oil into a suitable container. See Figure 68.
tighten 1/2 to 3/4 turn with your hand.
4. Remove the oil filter.
the section Periodic Maintenance for your lift 5. Remove the bolts retaining the oil pan to the en-
truck, for correct oil amount and type. gine block.
6. Start engine. Check area around oil filter for 6. Remove the oil pan.
leaks.
38
OIL SUCTION TUBE

CAUTION
Use care not to damage the mating sur- Remove
residues. 1. Remove the oil pan. See Oil Pan, Remove.
7. Carefully remove old sealant residue from the 2. Remove the two bolts retaining the oil suction
mating surfaces of the oil pan and cylinder block. tube. See Figure 69.
8. Thoroughly clean the outside and inside surfaces 3. Remove the oil suction tube.
of the oil pan.
4. Remove O-ring from the oil suction tube and dis-
card.
Install
Gasket, Hyster Part Number 1599478, around
the sealing surface of the oil pan.
2. Place the oil pan in position and install the re-

taining bolts. Refer to Standard Torque Specifi-
cations.
3. Apply clean oil to gasket of new filter. Install

new filter. Turn filter until gasket touches, then
tighten 1/2 to 3/4 turn with your hand.
4. Install the oil pan drain plug. Tighten the drain

plug to 20 to 24 N•m (14.75 to 17.70 lbf ft).
5. Install the crossmember and the flywheel access

cover.

models
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)

models
• H2.0-2.5CT (H50CT) (A274) 1. O-RING
2. BOLTS
6. Remove the lift truck from blocks. 3. OIL SUCTION TUBE
4. CYLINDER BLOCK
the section Periodic Maintenance for your lift Figure 69. Oil Suction Tube
truck, for correct oil amount and type.
8. Start the engine and check for leaks.
39
Clean See section Frame 100 SRM 1423 for lift truck
models
WARNING • H2.0-2.5CT (H50CT) (A274)
Cleaning solvents can be flammable and toxic 2. Remove the coolant fan, V-belt, and water pump.
and can cause skin irritation. When using See Cooling System Repair.
mendations of the manufacturer. 3. Remove the bolt and washer retaining the crank-
shaft pulley.
WARNING
4. Using a gear puller, remove the crankshaft pul-
Compressed air can move particles so that they ley.
Make sure that the path of the compressed air 5. Remove the timing gear case cover. See Timing
is away from all personnel. Wear protective Gear Case and Timing Gears Repair.
eyes. 6. Remove the bolts retaining the oil pump assem-
bly and remove the oil pump assembly from the
NOTE: The oil suction tube and screen are to be ser- timing gear case housing. See Figure 70.
viced as an assembly. DO NOT attempt to repair the
wire mesh portion of the tube and screen assembly. 7. Remove the outer rotor from the timing gear case
housing. See Figure 70.
Clean the oil suction tube in cleaning solvent. Dry
the oil suction tube with compressed air. Inspect for
wear and damage. If necessary, replace oil suction
tube.
Install
1. Install a new O-ring on the oil suction tube.
2. Position the oil suction tube in the cylinder block.
3. Install the two bolts to retain the oil suction tube.

Refer to Standard Torque Specifications.
4. Install the oil pan. See Oil Pan, Install.
OIL PUMP
1. GEAR CASE HOUSING
Remove 2. OUTER ROTOR
3. OIL PUMP ASSEMBLY
1. Remove the engine. 4. BOLT
See section Frame 100 SRM 1120 for lift truck Figure 70. Oil Pump Assembly
models
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
40
Clean and Inspect Outer Rotor to Inner Rotor Tip Clearance
Insert a feeler gauge between the top of an inner rotor

WARNING tooth and the top of an outer rotor tooth and measure
Cleaning solvents can be flammable and toxic the clearance. Refer to the section Engine Specifica-
and can cause skin irritation. When using tions for the clearance limits. See Figure 72.
WARNING
eyes.
CAUTION
If any oil pump component clearance exceeds
its limit, the oil pump must be replaced as
an assembly. Failure to replace the complete
pump assembly could result in pump failure 1. FEELER GAUGE 3. OUTER ROTOR
and damage to the engine. 2. INNER ROTOR
Clean all of the parts in cleaning solvent. Dry the Figure 72. Outer Rotor to Inner Rotor Tip
parts with compressed air. Inspect for wear and dam- Clearance Check
age. If necessary, replace oil pump assembly.
Outer Rotor Side Clearance
Outer Rotor Outside Clearance
Using a depth micrometer, measure the depression of
Insert a feeler gauge between the outer rotor and the the outer rotor across the pump cavity to determine
timing gear case oil pump cavity and measure the the side clearance. Refer to the section Engine Spec-
clearance. Refer to the section Engine Specifications ifications for the clearance limits. See Figure 73.
for the clearance limits. See Figure 71.
1. OUTER ROTOR
2. FEELER GAUGE
3. OIL PUMP CAVITY
Figure 73. Outer Rotor Side Clearance Check
Figure 71. Outer Rotor Outside Clearance
Check
41
Legend for Figure 73 See section Frame 100 SRM 1423 for lift truck
models
1. DEPTH MICROMETER • H2.0-2.5CT (H50CT) (A274)
2. PUMP CAVITY
3. OUTER ROTOR
8. Change the engine oil and oil filter. See Engine
Rotor Shaft Clearance Oil and Oil Filter Change.
Measure the outside diameter of the rotor shaft and 9. Start the engine and check for leaks.
the bore diameter in the gear case housing to deter-
mine the rotor shaft clearance. Refer to the section
Engine Specifications for the clearance limits. See
Figure 74.
Install
1. Lubricate the outer rotor and pump bore in the
gear case with clean engine oil.
NOTE: The punch mark end of the outer rotor must

face away from the gear case housing.
2. Install the outer rotor in the gear case housing.

Verify that the punch mark end of the outer ro- 1. ROTOR SHAFT
tor faces away from the gear case housing. See 2. GEAR CASE HOUSING
Figure 75.
Figure 74. Rotor Shaft Clearance Check
3. Position the oil pump assembly in the gear case
housing. Install the bolts to retain the oil pump.
Refer to Standard Torque Specifications. See
Figure 70.

5. Install the crankshaft pulley, washer, and bolt

to retain the crankshaft pulley. Tighten bolt to
117.6 N•m (86.7 lbf ft).
6. Install the water pump, V-belt, and coolant fan.

See Cooling System Repair.
7. Install the engine. 1. PUNCH MARK 3. TIMING GEAR

2. OUTER ROTOR CASE
models Figure 75. Outer Rotor
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
42
Fuel System Repair

b. Loosen the high pressure fuel line nuts on the
CAUTION fuel injection pump.
DO NOT attempt to remove or adjust the
tamper-proof devices from the full-load fuel
adjusting screw or the high-speed throttle CAUTION
limit screw on the fuel injection pump and DO NOT bend any of the fuel lines when remov-
governor assembly. These adjustments have ing them.
been made at the factory to meet all applicable
c. Finish loosening all of the high pressure fuel
emissions regulations and then sealed.
line nuts and remove the fuel lines as an as-
DO NOT attempt to make any adjustments to sembly.
these sealed adjustment screws. If adjustments
are required, they can be made only by a qual-
ified fuel injection shop that will ensure the
injection pump continues to meet all applica-
ble emissions regulations and then replace the
tamper-proof seals.
FUEL INJECTORS
Remove
1. Remove the bolt holding the oil dipstick tube
clamp. Rotate the dipstick tube to one side. This
is to allow removal of the high pressure fuel
lines. See Figure 76.
CAUTION
Remove the high pressure fuel lines as an as-
sembly whenever possible. Disassembling the
high pressure fuel lines from the retainers or
bending any of the fuel lines will make it diffi-
cult to reinstall the fuel lines.
2. Remove the high pressure fuel lines. See Fig-

ure 77.
CAUTION
When loosening or tightening the lines at the 1. OIL DIPSTICK
fuel injectors, you must hold the fuel injector 2. INTAKE MANIFOLD
3. DIPSTICK TUBE
with a second wrench to prevent the injector 4. BOLT
from turning and damaging the fuel return line
fitting. Figure 76. Oil Dipstick Tube
a. First loosen the high pressure fuel line nuts
at the fuel injectors.
43
2. Pull out the needle and clean carefully so as not

to damage it. Avoid use of hard, metallic tools.
3. Check for dents, damage, rusting, and wear. Pay

special attention to the stem and seat of the nee-
dle.
4. When setting the needle on the nozzle body after

thorough cleaning, check that it falls by its own
weight.
Test
1. Test the fuel injector using a special tool, fuel
injection nozzle tester. Use clean, filtered fuel for
the test.
WARNING
Never inject fuel toward you. Since the fuel
is injected at high pressure from the nozzle, it
may penetrate the skin, resulting in injury.
Never inject fuel toward a fire source. Atom-

ized fuel is highly flammable and may cause
1. HIGH PRESSURE LINE fire or skin burning.
2. RETURN LINE FITTING
3. RETURN LINE 2. Using the correct adapter, connect the fuel injec-
4. FUEL INJECTION PUMP tor to the high pressure pipe of the nozzle tester.
5. MAGNETIC VALVE (STOP SOLENOID)
ELECTRICAL CONNECTOR Aim the fuel injector nozzle into a suitable con-
tainer to catch the fuel spray. See Figure 78.
Figure 77. Fuel Injection Pump High Pressure
Lines
3. Remove the nuts retaining the fuel injector re-

turn line fittings and return lines.
4. Remove the fuel injector return lines and fittings

as an assembly.
5. Unscrew the fuel injectors from the cylinder

head. Also remove the two copper washers and
the nozzle protectors from the injector port in
the cylinder head.
Inspect
Visually inspect the fuel injectors and nozzle protec-
tors for deposits or damage. Clean and repair as nec- 1. INJECTION NOZZLE
essary. 2. NOZZLE TESTER
Figure 78. Fuel Injector Tester

Clean
1. Clean the exterior of the nozzle, taking care not
to damage the needle.
44
3. Pump the operating lever of the tester slowly, ob-

serving the pressure reading at the point where
the fuel injector begins spraying fuel. The fuel
injectors should begin spraying fuel at 11.8 to
13.2 MPa (1711 to 1914 psi). The operating pres-
sure may be adjusted by adding or subtracting
internal fuel injector shims. See Figure 79.
4. Adding or removing a 0.1 mm (0.0039 in.) shim

(shims are available in 0.4 mm (0.016 in.) incre-
ments) changes the pressure by 1.2 to 2.2 MPa
(174 to 319 psi).
5. Pump the operating lever more rapidly to repeat-

edly “pop” the injector and observe the spray pat-
tern. See Table 2 for examples of “good” and “bad”
spray patterns.
6. Pump the operating lever slowly to hold the pres-

sure steady at a point just below the “pop off ”
pressure point. Observe the injector to see that
it is sealing properly and is not “dripping.”
7. If the fuel injector fails any of these tests, it

should be repaired or replaced as necessary.
1. NUT
2. RETURN LINE FITTING
3. NOZZLE HOLDER
4. PRESSURE ADJUSTING SHIM
5. NOZZLE SPRING
6. NOZZLE SPRING SEAT
7. VALVE STOP SPACER
8. NOZZLE VALVE
9. NOZZLE BODY
10. NOZZLE CASE
Figure 79. Fuel Injector
45
Table 2. Fuel Injector Spray Patterns
A B C D E
Injection
Pattern
Pressure
Gauge
Reading
Pointer Same as A. Pointer stays Although the Pressure does not

fluctuate at a position pointer reaches increase even when
around the near the the valve opening the tester lever is
valve opening valve opening pressure, the operated.
pressure. pressure. pressure drop is
large.
Atomization Roughly Atomization Although Bar shape with Drops (bar shape).
Pattern uniform. is excessively atomized, the excessive after
one sided. needle does drops.
not pulsate
(burner like
shape).
Possible (Normal) 1. Normally 1. Caused by 1. Damage to the 1. Sticking of nee-
Cause caused by excessive seat. dle.
carbon con- carbon con- 2. Contamination 2. Excessively
tamination tamination of seat by fine damaged or
of the noz- of the noz- foreign parti- worn seat.
zle tip. zle tip. cles. 3. Contamination
2. Sometimes 2. Sometimes 3. Excessively of seat by for-
caused by caused by worn seat. eign matter.
flaws in or contami- 4. Damaged or
damage to nation. broken inter-
the needle nal parts of
tip. nozzle holder.
46
Install with a second wrench to prevent the injector

1. Install a new copper washer at the bottom of the fitting.
injector well.
c. Tighten the high pressure fuel line nuts on
2. Install the nozzle protector in the injector well. the fuel injectors. Refer to Standard Torque
Specifications.
3. Install the second new copper washer on top of
the nozzle protector. 9. Rotate the dipstick tube back to original position.
Install the retaining bolt to hold the oil dipstick
4. Install the fuel injectors. Tighten the fuel injec-
tube clamp to the intake manifold. See Figure 76.
tors to 39 N•m (29 lbf ft).
10. Prime the fuel system and check for leaks.
5. Install the fuel return lines and fittings as an
assembly using new copper washers.
ELECTRONIC THROTTLE SYSTEM
6. Install the fuel return line fitting retaining nuts
and tighten to 44 N•m (33 lbf ft). Remove
7. Connect the fuel injector return line to the fuel 1. Remove the capscrews and nuts to the linkage
pump. assembly and remove the linkage assembly. See
Figure 80.
8. Install the high pressure fuel lines.
2. Disconnect the electrical connector for the pull
actuator.
CAUTION
DO NOT bend any of the fuel lines when in- 3. Remove the capscrews and nuts retaining the
stalling them. pull actuator to the mounting bracket and re-
move the pull actuator. See Figure 81.
NOTE: Replace the high pressure fuel lines as an as-
sembly. 4. If necessary, remove the clevis with linkage as-
sembly, lockwasher, and nut from the pull actua-
a. Start all high pressure fuel line nuts by hand, tor. See Figure 82.
leaving the nuts on the fuel injection pump
and the fuel injectors untightened. 5. Disconnect the electrical connector from the
throttle position sensor (TPS).
b. Tighten the high pressure fuel line nuts on
the fuel injection pump. Refer to Standard 6. Remove the Torx-head screws retaining the TPS
Torque Specifications. and remove the TPS. See Figure 83.
7. Remove the Torx-head screws retaining the TPS

CAUTION bracket and remove bracket.
When loosening or tightening the lines at the
8. Remove the TPS rotor.
fuel injectors, you must hold the fuel injector
47
1. THROTTLE POSITION SENSOR 5. NUT

2. CAPSCREW 6. PULL ACTUATOR
3. NUT 7. CLEVIS
4. LINKAGE ASSEMBLY 8. CAPSCREW
Figure 80. Electronic Throttle System
48
1. MOUNTING BRACKET
2. INTAKE MANIFOLD
3. FUEL PUMP
4. CAPSCREW
5. PULL ACTUATOR
6. NUT
Figure 81. Pull Actuator Mounting
1. LOCKWASHER
2. TORX-HEAD SCREW
3. TPS BRACKET
4. WASHER
5. TORX-HEAD SCREW
6. THROTTLE POSITION SENSOR (TPS)
7. TPS ROTOR
8. THROTTLE LEVER
9. FUEL PUMP
Figure 83. Throttle Position Sensor (TPS)

1. PULL ACTUATOR Assembly
2. NUT
3. LOCKWASHER
4. CLEVIS WITH LINKAGE ASSEMBLY
Figure 82. Pull Actuator and Linkage Assembly
49
Install 7. Install the clevis with linkage assembly onto the

threaded end of the pull actuator rod and then
1. Install the TPS rotor. tighten the nut toward the clevis. Tighten the
nut to 6.8 N•m (60 lbf in).
NOTE: The TPS mounting screws are non-magnetic
stainless steel to avoid interference with the sensor 8. Place the pull actuator in position on the mount-
magnet and must be reused if the TPS is replaced. ing bracket and install capscrews and nuts hand
tight only to retain the pull actuator to the
2. Place the TPS bracket in position and install
mounting bracket. See Figure 81.
Torx-head screws. Tighten Torx-head screws to
10.5 N•m (93 lbf in). 9. Verify that the clevis is in the position shown in
Figure 80. Adjust as needed.
NOTE: When installing the TPS, rotate the sensor
rotor clockwise to match D-shape on the TPS rotor. 10. Verify that the rod ends of the linkage assembly
See Figure 84. are parallel to each other. Adjust as needed. See
Figure 85.
3. Place the TPS in position and install Torx-head
screws. Tighten Torx-head screws to 2.25 N•m
(20 lbf in).
1. PULL ACTUATOR
2. NUT
3. CLEVIS
4. NUT
5. TURNBUCKLE
6. ROD ENDS (MUST BE PARALLEL TO EACH
1. SENSOR ROTOR 3. TPS ROTOR OTHER)
2. TPS 4. D-SHAPE
Figure 85. Linkage Assembly
Figure 84. TPS and Rotor
NOTE: DO NOT force the lever or pull actuator rod
4. Connect the throttle position sensor (TPS) elec- when installing. The actuator component and the
trical connector. lever need to be at rest when installing.
5. Turn the lever clockwise to verify that the TPS NOTE: The outer hole of the throttle lever is used for
does not bind or stick. manual throttles only. The inner hole on the throttle
lever is used for electronic throttles only.
6. Install the nut and lockwasher onto the threaded
end of the pull actuator rod. See Figure 82. 11. Place the other rod end on the top side of the
throttle lever and align the rod end hole with the
NOTE: DO NOT tighten the clevis into the nut on the inner hole on the throttle lever. See Figure 86.
pull actuator rod. Always tighten the nut towards
the clevis.
50
Adjust
See Figure 87.
CAUTION
DO NOT attempt to adjust the low or high idle
speed limit screws. This may impair the safety
and performance of the lift truck and shorten
it’s engine life. If the idle speed limit screws re-
quire adjustment, see your authorized Yanmar
industrial engine dealer or distributor.
NOTE: If adjustment is required, disassemble the

link from the throttle pump lever and adjust the
length of the link.
1. Make sure the linkage length between rod ends

are 72.5 ±0.51 mm (2.85 ±0.02 in.). See Fig-
ure 88.
1. CLEVIS 3. OUTER HOLE
2. ROD END 4. THROTTLE LEVER 2. The link should be in line between the throttle ac-
tuator and the throttle pump lever. If necessary,
Figure 86. Rod End and Throttle Lever loosen the actuator mounting screws and adjust
Alignment the throttle actuator up or down to align the link
then tighten the mounting screws.
12. Slide the pull actuator forward in the mount-
ing bracket slots until the rod end hole is 2 to NOTE: DO NOT adjust the low speed or high speed
3 mm (0.0787 to 0.1181 in.) past the inner hole stop screws.
in the throttle lever. Tighten the pull actuator to
mounting bracket capscrews and nuts. 3. Check the prestroke on the actuator. Disassem-
ble the link from the throttle pump lever. Check
13. Push the actuator rod in toward the actuator un- the distance that the hole in the link end extends
til the rod end hole aligns with the inner throttle beyond the inner hole in the throttle pump lever.
lever hole and install the capscrew and nut to re- This distance should be 2-3 mm (0.08-0.11 in.). If
tain the rod end to the throttle lever. the distance is out of adjustment, loosen the cle-
vis jam nut. Rotate the clevis while holding the
14. Connect the electrical connector for the pull ac-
actuator rod to adjust then tighten the clevis jam
tuator.
nut. If additional adjustment is required, adjust
the length of the link. After proper adjustment
Inspect
is achieved, push the link toward the actuator to
1. Check the low idle stop position to see if the throt- align the hole in the link with the inner hole in
tle lever is in contact with the low idle stop. If the throttle pump lever and reassemble the link
adjustment is necessary, refer to the section Ad- hardware. Verify that the lever contacts both the
just. low and high idle stops when the lever is rotated
manually.
2. When the condition in Step 1 is met, check if the
actuator is fully extended by turning the actua- 4. Make sure the throttle position sensor is not
tor to the high idle position by hand to see if the binding. Bend or replace the TPS mounting
throttle lever will contact the high idle stop. Ver- bracket if necessary.
ify that the sensor rotates freely, without binding
or sticking.
51
NOTE: PROCEDURES ARE THE SAME FOR ALL DIESEL ENGINES. YANMAR ENGINE SHOWN.
1. THROTTLE POSITION SENSOR 5. NUT
2. CAPSCREW 6. PULL ACTUATOR
3. NUT 7. CLEVIS
4. LINKAGE ASSEMBLY 8. CAPSCREW
Figure 87. Throttle Actuator Assembly
52
sure the linkage is not binding or sticking. Make

sure the rod ends are parallel to each other and
all the hardware is installed properly.
NOTE: Dust on the actuator plunger can cause this

sticking.
9. Make sure the actuator is not sticking. With the

engine OFF and power ON, depress the throttle
pedal from idle to full throttle while watching the
Figure 88. Adjustment Rod Ends
actuator. The actuator should operate smoothly
5. With the engine OFF and power ON, navigate from the idle position to the full throttle position
display console menus to read throttle position without sticking or erratic movement. Replace
sensor "A” voltage under no-run data display the actuator if necessary.
menu. The PC Service Tool can also be used.
NOTE: DTC 51-7 may be set due to a change in the
With accelerator released and throttle pump
injection pump throttle lever force during an out-of-
lever against low idle stop, throttle sensor "A"
fuel condition.
voltage must be within 2.25 - 2.45 volts for the
Yanmar and within 0.90-2.48 volts for Cummins. 10. Check fuel level as necessary.
NOTE: Step 6 will immediately set a fault code since
the throttle position sensor exceeds the command.
The fault code must be cleared after performing
Step 6.
6. Manually rotate the throttle pump lever to full

throttle position. With the throttle pump lever
against high idle stop, throttle position sensor
"A" voltage must be within 3.15-4.70 volts for the
Yanmar and within 3.12-4.70 volts for Cummins.
See Figure 89.
7. If after adjustment, the TPS voltage does not fall

within the correct ranges, refer to Diagnostic
Troubleshooting Manual 9000 SRM 1112 for
the TPS diagnostic procedure. 1. LOW IDLE STOP SCREW
2. THROTTLE PUMP LEVER
NOTE: DO NOT lubricate the linkage or actuator 3. HIGH IDLE STOP SCREW
shaft with a wet lubricant. Figure 89. Throttle Lever Stop Screws
8. Clean any dust and debris from the linkage ends
and the return spring on the fuel pump. Make
53
FUEL INJECTION PUMP 2. Disconnect the fuel tank return line.
Remove 3. Disconnect the fuel injector return line from the

fuel pump. See Figure 90.
1. Disconnect the fuel supply line from the fuel in-
jection pump.
1. FUEL INJECTOR 7. L-SHAPED BRACKET

2. HIGH PRESSURE FUEL LINE 8. DIPSTICK TUBE
3. RETURN LINE FITTINGS 9. COLD START AID
4. RETURN LINE 10. MAGNETIC VALVE (STOP SOLENOID)
5. FUEL INJECTION PUMP ELECTRICAL CONNECTOR
6. BOLT 11. COLD START AID ELECTRICAL CONNECTOR
Figure 90. Fuel Injection Pump
54
4. Disconnect the electrical connection to the mag-

netic valve (stop solenoid). CAUTION
DO NOT bend any of the fuel lines when remov-
5. Disconnect the electrical connection to the cold ing them.
start aid.
c. Finish loosening all of the high pressure fuel
6. If equipped, remove the electronic throttle sys- line nuts and remove the fuel lines as an as-
tem. See Electronic Throttle System, Remove. sembly.
7. If equipped, disconnect the throttle cable. 10. Remove the bolts retaining the L-shaped brack-
ets and remove brackets. See Figure 90.
models 11. Remove the V-belt and fan assembly. See Cooling
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, System Repair.
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) 12. Remove the bolts from the fuel injection pump
cover on the front of the timing gear case cover.
See section Frame 100 SRM 1423 for lift truck Remove the fuel injection pump cover. See Fig-
models ure 91.
• H2.0-2.5CT (H50CT) (A274)
13. To aid in reassembly, mark one tooth on the idler
8. Remove the bolt holding the oil dipstick tube gear and two teeth on the fuel injection pump
clamp. Rotate the dipstick tube to one side. This drive gear with a dot of white paint. See Fig-
is to allow removal of the high pressure fuel ure 92.
lines. See Figure 76.
CAUTION
Remove the high pressure fuel lines as an as-
sembly whenever possible. Disassembling the
high pressure fuel lines from the retainers or
bending any of the fuel lines will make it diffi-
cult to reinstall the fuel lines.
9. Remove the high pressure fuel lines. See Fig-

ure 77.
CAUTION
When loosening or tightening the lines at the
with a second wrench to prevent the injector
fitting.
a. First loosen the high pressure fuel line nuts 1. TIMING GEAR CASE COVER
at the fuel injectors. 2. BOLT
3. FUEL INJECTION PUMP COVER
b. Loosen the high pressure fuel line nuts on the
Figure 91. Fuel Injection Pump Cover
fuel injection pump.
55
15. While holding the engine from turning with a

wrench on the crankshaft pulley bolt, remove the
fuel injection pump drive gear retaining nut and
lockwasher. See Figure 94.
1. FUEL INJECTION PUMP DRIVE GEAR

2. CAMSHAFT GEAR
3. CRANKSHAFT GEAR
4. DIRECTION OF ROTATION
5. OIL PUMP GEAR
6. IDLER GEAR
Figure 92. Timing Gear Alignment
14. Make matching marks on the rear of the timing

gear case housing and on the fuel injection pump
mounting flange before loosening the fuel injec-
tion pump mounting bolts. See Figure 93. 1. TIMING GEAR CASE
2. FUEL INJECTION PUMP DRIVE GEAR
3. LOCKWASHER
4. NUT
5. FUEL INJECTION PUMP
Figure 94. Fuel Injection Pump Drive Gear
NOTE: The fuel injection pump shaft is tapered with

a woodruff key. Once you have applied some pressure
with a puller, a slight tap with a hammer on the cen-
ter puller bolt will help pop the gear from the shaft.
16. Using a two-bolt gear puller, remove the fuel in-

jection pump drive gear from the fuel injection
pump shaft.
17. Remove the three nuts securing the fuel injection

pump to the rear of the timing gear case.
18. Remove the fuel injection pump.
19. If the fuel injection pump requires servicing, it

1. ALIGNMENT MARKS must be taken to an authorized ZEXEL fuel in-
jection shop or the fuel injection pump assembly
Figure 93. Fuel Injection Pump Alignment
must be replaced.
Marks
56
Clean and Inspect b. Tighten the high pressure fuel line nuts on
the fuel injection pump. Refer to Standard
Clean all old sealant from the timing gear case cover Torque Specifications.
and the fuel injection pump drive gear cover. Inspect
all parts for damage. Replace as needed.
CAUTION
Install When loosening or tightening the lines at the
1. Place the fuel injection pump in position and with a second wrench to prevent the injector
align the matching marks on the timing gear from turning and damaging the fuel return line
case housing and the fuel injection pump flange. fitting.
Install the retaining nuts. Refer to Standard
Torque Specifications. See Figure 93. c. Tighten the high pressure fuel line nuts on
the fuel injectors. Refer to Standard Torque
2. Install the fuel injection pump drive gear onto Specifications.
the fuel injection pump shaft while lining up the
two marks made on the pump drive gear with the 9. Rotate the dipstick tube back to original position.
mark made on the idler gear. Install the retaining bolt to hold the oil dipstick
tube clamp to the intake manifold. See Figure 76.
3. Install the drive gear retaining nut and washer.
While holding the engine from turning with a 10. If equipped, connect the throttle cable.
wrench on the crankshaft pulley bolt, tighten the
retaining nut to 59 to 69 N•m (44 to 51 lbf ft). See section Frame 100 SRM 1120 for lift truck
models
4. Apply a continuous bead of ThreeBond Liquid • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
Gasket, Hyster Part Number 1599478, to the H40FTS) (F001)
mating surface of the fuel injection pump cover. • H2.0-3.5FT (H40-70FT) (L177)
5. Place the fuel injection pump cover in position on See section Frame 100 SRM 1423 for lift truck
the timing gear case cover and install retaining models
bolts. Refer to Standard Torque Specifications. • H2.0-2.5CT (H50CT) (A274)
6. Install the fan assembly and V-belt. See Cooling 11. If equipped, install the electronic throttle sys-
System Repair. tem. See Electronic Throttle System, Install.
7. Install the L-shaped brackets and bolts to retain 12. Connect the electrical connection to the cold start
brackets. Refer to Standard Torque Specifica- aid.
tions. See Figure 90.
13. Connect the electrical connection to the magnetic
8. Install the high pressure fuel lines. valve (stop solenoid).
14. Connect the fuel injector return line to the fuel

CAUTION pump. See Figure 90.
DO NOT bend any of the fuel lines when in-
stalling them. 15. Connect the fuel tank return line.
NOTE: Replace the high pressure fuel lines as an as- 16. Connect the fuel supply line to the fuel injection
sembly. pump. Refer to Standard Torque Specifications.
a. Start all high pressure fuel line nuts by hand, 17. Prime the fuel system and check for leaks.
leaving the nuts on the fuel injection pump
and the fuel injectors untightened.
57
Check/Adjust Fuel Injection Timing Legend for Figure 96
1. Using a wrench on the front crankshaft pulley 1. TIMING TOOL

bolt, rotate the engine clockwise until the tim- 2. DIAL INDICATOR
ing mark on the crankshaft pulley is aligned with
NOTE: The dial indicator is not included with timing
the “O” or TDC (Top Dead Center) mark on the
tool. Collet size 8 mm (0.31 in.) and equivalent.
timing grid of the gear case cover.
4. Install the timing tool into the port where the
2. Remove the center bolt and sealing washer from
center bolt was removed. This will provide a
the rear of the fuel injection pump. See Fig-
reading of the fuel injection pump plunger lift.
ure 95.
See Figure 97.
5. Rotate the engine about 25 degrees in the coun-

terclockwise direction. The dial indicator should
move for approximately the first 10 degrees of en-
gine rotation and then stop. When you reach ap-
proximately the 25 degrees position, rotate the
engine slightly back and forth to make sure the
needle of the dial indicator does not move.
6. Set the dial indicator to “0.”
1. CENTER BOLT
Figure 95. Fuel Injection Pump Center Bolt
NOTE: The dial indicator is not included with timing

tool. Collet size 8 mm (0.31 in.) and equivalent.
3. Locate special timing tool. Install a dial indicator

into the timing tool. See Figure 96.
1. TIMING TOOL
Figure 97. Fuel Injection Pump Timing Tool

Installation
Figure 96. Fuel Injection Pump Timing Tool
58
NOTE: Timing for the 4TNE92 is 4 degrees ATDC. injection pump toward the engine retards the injec-
Timing for the 4TNE98 (Tier 2) is 6 degrees ATDC. tion timing.
Timing for the 4TNE98 (Tier 3) is 8.5 degrees ATDC
(After Top Dead Center). 9. If the injection timing is not correct, loosen the
three fuel Injection pump mounting nuts and the
7. Rotate the engine in the clockwise rotation un- bolts retaining the bottom / rear L-shaped injec-
til the timing mark on the crankshaft pulley is tion pump mounting brackets. Rotate the injec-
aligned with the mark at 4 degrees, 6 degrees, or tion pump to bring the dial indicator reading into
8.5 degrees ATDC (After Top Dead Center) on the the correct range.
timing grid on the gear case cover.
10. Retighten the pump mounting nuts and the
8. If the injection timing is correct, the dial in- mounting bracket bolts.
dicator should read 0.97 to 1.03 mm (0.038 to
0.041 in.). 11. Remove the timing tool and dial indicator. Re-
place and tighten the center bolt and sealing
NOTE: Rotating the injection pump away from the washer into the injection pump port.
engine advances the injection timing. Rotating the

V-BELT Inspect
Remove Inspect the V-belt for cracks, oil, wear, and damage.
If any of these conditions exist, replace the V-belt.
WARNING Install
touch the fan, pulleys, or drive belts. Contact 1. Place the V-belt over the pulleys.
2. Adjust the tension of the V-belt as shown in the
section Adjust.
WARNING
The radiator or other parts of the cooling sys- 3. Tighten the set bolt for the alternator to
tem may be hot or under pressure and can 25.5 N•m (18.8 lbf ft).
radiator to cool. Do a touch test by touching 4. Install the fan assembly. Refer to the section
the radiator with your hand. If the radiator is Cooling System 700 SRM 1123.
before attempting to check or fix any part of Adjust
the cooling system.
NOTE: The V-belt can be checked at any of the three
1. Turn the ignition switch to the OFF position. positions: A, B, or C shown in Figure 98. The correct
deflection for a used and new V-belt is shown in Ta-
2. Remove the fan assembly. Refer to the section ble 3.
1. Press the V-belt down with your thumb with a
3. Loosen the alternator set bolt and pivot the al- force of approximately 98 N•m (72 lbf ft) to check
ternator toward the engine. the deflection.
4. Remove the V-belt from the pulleys.
59
Table 3. V-Belt Deflection Table
Used V-Belt Tension New V-Belt Tension

A B C A B C
10-13 mm 7-10 mm 8-13 mm 8-11 mm (0.3125- 5-8 mm (0.1875- 7-11 mm
(0.375-0.5 in.) (0.250-0.375 in.) (0.3125-0.5 in.) 0.4375 in.) 0.3125 in.) (0.250-0.4375 in.)
1. SET BOLT 3. PRY BAR

2. ALTERNATOR
Figure 99. V-Belt Adjustment
WATER PUMP
4TNE92-NMHA and
4TNE92-NMHA/1688253 Engines
Figure 98. V-Belt Tension Check Points
Remove
2. If adjustment is necessary, loosen the alternator
set bolt and move the alternator with a pry bar 1. Turn the ignition switch to the OFF position.
to tighten the V-belt. See Figure 99.
3. When the tension is correct, tighten the set bolt tery.
to 25.5 N•m (18.8 lbf ft). Check the belt tension
again to verify the tension is still correct.
60
6. Remove the fan assembly. Refer to the section

WARNING Cooling System 700 SRM 1123.
diator when the engine is hot. When the radia- 7. Remove the V-belt. See V-Belt, Remove.
tor cap is removed, pressure will release from
the coolant system. If the coolant system is hot, 8. Remove the fan pulley.
the steam and boiling coolant can cause severe 9. Pivot the alternator away from the engine.
burns.
10. Disconnect the electrical connector for the
WARNING coolant temperature sensor. See Figure 101.
11. If necessary, remove the coolant temperature
sensor.
radiator and engine to cool before performing 12. Disconnect the coolant hoses from the water
maintenance to the cooling system. After 30 pump.
ator with your hand. If the radiator is still hot 13. Remove the water pump bolts and remove the
to the touch, wait another 30 minutes before water pump. See Figure 102.
system.
CAUTION
mental regulations.
3. Remove the radiator cap.
4. Loosen the lower radiator hose and drain the

coolant from the coolant system.
5. Remove the coolant drain plug and drain the

coolant from the engine block. See Figure 100.
2. COOLANT TEMPERATURE SENSOR
Figure 101. Coolant Temperature Sensor
1. COOLANT DRAIN PLUG
Figure 100. Engine Block Coolant Drain Plug
61
6. Connect the coolant hoses to the water pump.
7. If removed, install the coolant temperature sen-

sor and tighten to 24.5 to 34.3 N•m (18.1 to
25.3 lbf ft).
8. Connect the electrical connector for the coolant

temperature sensor.
9. Install the fan pulley.
10. Install the V-belt. See V-Belt, Install.
11. Install the fan assembly. Refer to the section

12. Connect the lower radiator hose.

1. GASKET 6. BOLT 13. Install the coolant drain plug in the engine block.
2. COVER 7. GASKET
3. GASKET 8. FLANGE See Figure 100.
4. WATER PUMP 9. O-RING
5. BOLT 10. BOLT
CAUTION
Figure 102. Water Pump Additives may damage the cooling system. Be-
14. Remove the bolt holding the cover on the water dealer.
pump.
14. Fill the cooling system with coolant. Refer to
15. Remove and discard cover gasket. the Periodic Maintenance section for your lift
truck for the correct coolant amount and type.
16. Remove the O-ring, flange, and mechanical seal.
15. Install the radiator cap.
17. Remove the thermostat cover, gasket, thermo-
stat, and O-ring. See Thermostat, Remove. 16. Connect the negative battery cable.
Install
WARNING
1. Install new O-ring, thermostat, new gasket, and During engine operation, be careful not to
thermostat cover. See Thermostat, Install. touch the fan, pulleys, or drive belts. Contact
2. Install new water pump cover gasket and water
pump cover. Install bolt to retain cover to water
pump. WARNING
3. Install the O-ring, flange, and mechanical seal. tem may be hot or under pressure and can
4. Position water pump with new gasket between
water pump and cylinder head on the engine. See 17. Start the engine and check cooling system for
Figure 102. leaks.
5. Install water pump retaining bolts.
62

WARNING the steam and boiling coolant can cause severe
DO NOT remove the radiator cap from the ra- burns.
WARNING
the steam and boiling coolant can cause severe The radiator or other parts of the cooling sys-
burns. tem may be hot or under pressure and can
WARNING maintenance to the cooling system. After 30
The radiator or other parts of the cooling sys- minutes, do a touch test by touching the radi-
tem may be hot or under pressure and can ator with your hand. If the radiator is still hot
cause serious injury. Wait 30 minutes for the to the touch, wait another 30 minutes before
radiator and engine to cool before performing attempting any maintenance to the cooling
maintenance to the cooling system. After 30 system.
ator with your hand. If the radiator is still hot
to the touch, wait another 30 minutes before CAUTION
attempting any maintenance to the cooling Disposal of lubricants must meet local environ-
system. mental regulations.
3. Remove the radiator cap.

CAUTION
Additives may damage the cooling system. Be- 4. Loosen the lower radiator hose and drain the
fore using additives, contact your local Hyster coolant from the coolant system.
dealer. 5. Remove the coolant drain plug and drain the
18. Stop engine. If coolant is hot, allow engine time coolant from the engine block. See Figure 100.
to cool. Check coolant level and fill as required 6. Remove the fan assembly. Refer to the section
between the ADD and FULL marks on the Cooling System 700 SRM 1123.
coolant reservoir.
7. Remove the V-belt. See V-Belt, Remove.
4TNE92-NMH, 4TNE98-NMH,
4TNE92-NMH/1688273, and 4TNE98-BNMH 8. Remove the fan pulley.
Engines 9. Pivot the alternator away from the engine.
Remove 10. Disconnect the electrical connector for the
coolant temperature sensor. See Figure 101.
1. Turn the ignition switch to the OFF position.
11. If necessary, remove the coolant temperature
sensor.
tery.
12. Disconnect the coolant hoses from the water
WARNING pump.
13. Remove the water pump bolts and remove the
water pump. See Figure 103.
63
5. Install water pump retaining bolts.
6. Connect the coolant hoses to the water pump.
7. If removed, install the coolant temperature sen-

sor and tighten to 24.5 to 34.3 N•m (18.1 to
25.3 lbf ft).
8. Connect the electrical connector for the coolant

temperature sensor.
9. Install the fan pulley.
10. Install the V-belt. See V-Belt, Install.
11. Install the fan assembly. Refer to the section

1. GASKET 5. BOLT 12. Connect the lower radiator hose.
2. COVER 6. O-RING
3. GASKET 7. PIPE 13. Install the coolant drain plug in the engine block.
4. WATER PUMP 8. BOLT See Figure 100.
Figure 103. Water Pump
CAUTION
14. Remove the water pump pipe. Remove and dis-
card O-rings.
15. Remove the bolts holding the cover on the water dealer.
pump.
14. Fill the cooling system with coolant. Refer to
16. Remove and discard cover gasket. the Periodic Maintenance section for your lift
truck for the correct coolant amount and type.
17. Remove the thermostat cover, gasket, thermo-
stat, and O-ring. See Thermostat, Remove. 15. Install the radiator cap.
Install 16. Connect the negative battery cable.
1. Install new O-ring, thermostat, new gasket, and

WARNING
thermostat cover. See Thermostat, Install.
2. Install new water pump cover gasket and water touch the fan, pulleys, or drive belts. Contact
pump cover. Install bolts to retain cover to water with these parts can cause serious injury.
pump.
3. Install new O-rings on coolant pipe and install

WARNING
coolant pipe to water pump. The radiator or other parts of the cooling sys-
4. Position water pump with new gasket between cause serious injury.
water pump and cylinder head on the engine.
Verify the coolant pipe is positioned properly in 17. Start the engine and check cooling system for
the engine and water pump. See Figure 102. leaks.
64
WARNING CAUTION
DO NOT remove the radiator cap from the ra- DO NOT operate the engine without a ther-
diator when the engine is hot. When the radia- mostat. The engine and cooling system can be
tor cap is removed, pressure will release from damaged.
burns.
CAUTION
mental regulations.
WARNING
The radiator or other parts of the cooling sys- 1. Drain the cooling system to the level of the ther-
tem may be hot or under pressure and can mostat.
radiator and engine to cool before performing 2. Disconnect the coolant hose from the thermostat
maintenance to the cooling system. After 30 cover.
3. Remove the bolts retaining the thermostat cover
and remove thermostat cover and gasket. Dis-
to the touch, wait another 30 minutes before
card gasket. See Figure 104 and Figure 105.
system.
CAUTION
dealer.
18. Stop engine. If coolant is hot, allow engine time

to cool. Check coolant level and fill as required
between the ADD and FULL marks on the
coolant reservoir.
THERMOSTAT
Remove
1. BOLT
WARNING 2. THERMOSTAT COVER
The radiator or other parts of the cooling sys- 3. GASKET
4. THERMOSTAT
tem may be hot or under pressure and can 5. O-RING
cause serious injury. Wait 30 minutes for the 6. WATER PUMP
maintenance to the cooling system. After 30 Figure 104. Thermostat - 4TNE92-NMHA and
minutes, do a touch test by touching the radi- 4TNE92-NMHA/1688253 Engines
system.
65
1. BOLT 1. THERMOMETER
2. THERMOSTAT COVER 2. THERMOSTAT
3. GASKET
4. THERMOSTAT Figure 106. Thermostat Check
5. O-RING
6. WATER PUMP Install
Figure 105. Thermostat - 4TNE92-NMH, 1. Install a new O-ring and the thermostat.
4TNE98-NMH, 4TNE92-NMH/1688273, and
4TNE98-BNMH Engines 2. Install the thermostat cover and a new gasket.
Install the bolts to retain the thermostat cover.
4. Remove the thermostat and O-ring. Tighten bolts to 23 to 28 N•m (17 to 21 lbf ft).
Inspect 3. Connect the coolant hose to the thermostat cover.
1. Place the thermostat and an accurate thermome- CAUTION

ter in warm water. See Figure 106.
2. Slowly increase the temperature of the water. fore using additives, contact your local Hyster
dealer.
3. The thermostat is operating correctly if it starts
to open at the temperature value stamped on the 4. Fill the cooling system with coolant. Refer to
flange of the thermostat and fully opens as the the Periodic Maintenance section for your lift
temperature of the water is increased. truck for the correct coolant amount and type.
66
WARNING WARNING
WARNING maintenance to the cooling system. After 30
5. Start the engine and check cooling system for system.
leaks.
CAUTION
WARNING Additives may damage the cooling system. Be-
DO NOT remove the radiator cap from the ra- fore using additives, contact your local Hyster
diator when the engine is hot. When the radia- dealer.
the coolant system. If the coolant system is hot, 6. Stop engine. If coolant is hot, allow engine time
the steam and boiling coolant can cause severe to cool. Check coolant level and fill as required
burns. between the ADD and FULL marks on the
coolant reservoir.
Flywheel and Flywheel Housing

FLYWHEEL Install
Remove 1. Place the flywheel in position on the crankshaft
flange and install retaining bolts. Tighten bolts
1. Remove the engine. See Engine Removal and to 155 N•m (114 lbf ft) in the torque sequence
Installation. shown in Figure 107.
2. Remove the bolts retaining the flex plate to the 2. Place the flex plate in position on the flywheel
flywheel and remove the flex plate. See Fig- and install retaining bolts. Tighten bolts to
ure 107. 52 N•m (38 lbf ft).
3. Remove the bolts retaining the flywheel to the 3. Install the engine. See Engine Removal and In-
crankshaft flange and remove the flywheel. stallation.
67
Flywheel and Flywheel Housing 600 SRM 1205
A. TORQUE SEQUENCE
1. FLYWHEEL HOUSING 5. FLEX PLATE
2. FLYWHEEL 6. WASHER
3. WASHER 7. BOLT
4. BOLT
Figure 107. Flywheel
68
FLYWHEEL HOUSING Install

Remove 1. Place the flywheel housing in position on the
cylinder block and install bolts. Tighten the
1. Remove the flywheel. See Flywheel, Remove. bolts to 44 to 54 N•m (32 to 40 lbf ft).
2. Remove the bolts retaining the flywheel housing 2. Install the flywheel. See Flywheel, Install.
to the cylinder block. See Figure 108.
3. Remove the flywheel housing.
1. CYLINDER BLOCK 3. WASHER

2. FLYWHEEL HOUSING 4. BOLT
Figure 108. Flywheel Housing
69
Electrical Equipment Repair 600 SRM 1205
Electrical Equipment Repair

ALTERNATOR Remove
The alternator specifications are listed in Table 4.
WARNING
Table 4. Alternator Specifications Always disconnect the cables at the battery be-
Rating Continuous nect the cable at the negative terminal first. In-
stall a tag on the battery terminals so that no
Battery Voltage 12 Volts one connects the cables on the terminals.
Nominal Output (12 60 Amps
Volts Heat) 1. Disconnect battery negative cable at negative
terminal.
1
No Load Test Maximum 1300 rpm (min )
rpm 2. Disconnect the battery positive cable at positive
terminal.
Output Test Minimum 13.5 V @ 5000 rpm
Current (Cool) (min 1) 3. Put labels on wires prior to disconnecting to aid
Grounding Negative ( ) Side in correct installation.
Characteristics of Circuit
4. Disconnect wires from alternator.
Direction of Revolution Clockwise
(Viewed from Pulley) 5. Loosen the set bolt on the alternator and tilt the
alternator towards the engine.
Rotor Coil Resistance 2.9 Ohms
6. Remove the V-belt from the alternator pulley.
Outside Diameter of 69.2 mm (2.7 in.)
Pulley 7. Remove the set bolt from the alternator. See Fig-
Standard 10.5 mm ure 109.
Brush Length (0.41 in.)
8. If necessary, remove the bolt retaining the alter-
Limit 8.4 mm (0.33 in.) nator adjustment bracket to the water pump and
remove the bracket.
9. Remove the nut and bolt retaining the alternator

to the gear case and remove the alternator.
70
600 SRM 1205 Electrical Equipment Repair
1. WATER PUMP 5. BOLT

2. SET BOLT 6. TIMING GEAR CASE
3. ALTERNATOR ADJUSTMENT BRACKET 7. NUT
4. ALTERNATOR 8. BOLT
Figure 109. Alternator
71
Bench Test 1. Turn battery switch S1 ON.
1. Verify that the test bench is set up and that the 2. Run the alternator. Turn the load switch S2 ON
charge light is on. when output current exceeds 0 amperes.
2. Place the alternator in position on the test bench.
3. Insert the main wiring harness inspection con-

nector into the alternator. See Figure 110.
4. Connect the main wiring harness and sub-wiring

harness C.
5. Connect the voltmeter and ammeter as shown in

Figure 110.
6. Turn SW1 ON and check that the main wiring

harness light (charge light) turns ON.
NOTE: If terminal S is disconnected during inspec-

tion, the charge light may remain ON continuously. 1. ALTERNATOR
In this case, use sub-wiring harness B instead of sub- 2. VOLTMETER POSITIVE SIDE (+)
wiring harness C. Connect terminal S of sub-wiring 3. VOLTMETER NEGATIVE SIDE ( )
harness B to terminal S on the alternator, turn SW1 4. TO BATTERY NEGATIVE ( ) TERMINAL
5. TO AMMETER POSITIVE (+) TERMINAL
ON, connect IG and L and check the light again.
6. MAIN WIRING HARNESS
7. SUB-WIRING HARNESS C
7. Turn the test bench motor ON, increase speed 8. CHARGE LIGHT
and check that the charge light turns OFF. 9. TERMINAL B
Regulate Voltage Check Figure 110. Alternator Bench Test
Refer to Figure 111 for the wiring diagrams for the

test wiring of the alternator.
72
A. WIRING DIAGRAM FOR ALTERNATORS WITH A D. WIRING DIAGRAM FOR ALTERNATORS WITH
M TYPE REGULATOR A GL TYPE REGULATOR, ALWAYS WIRE
B. WIRING DIAGRAM FOR ALTERNATORS WITH A THE CHARGE LIGHT FOR THE GL TYPE
GS TYPE REGULATOR REGULATOR
C. WIRING DIAGRAM FOR ALTERNATORS WITH
A D OR GA TYPE REGULATOR
Figure 111. Alternator Test Wiring Diagrams
73
3. Adjust the speed and load to the standard values. 1. Turn the battery switch S1 ON and load switch
S2 ON.
NOTE: Regulated voltage has the temperature char-
acteristics shown in Figure 112. Perform the mea- 2. Run the alternator.
surement quickly.
3. While adjusting the speed and load resistance,
4. Check that the voltage is within the standard set the speed and the voltage to the standard val-
values. ues.
4. Check that the current is within the standard

values.
Install
1. If removed, place the alternator adjustment
bracket in position and install the bolt to retain
the bracket to the water pump. Tighten the bolt
2. Position the alternator on the gear case. Install

the nut and bolt to retain the alternator to the
gear case, but do not tighten.
3. Install the set bolt for the alternator and adjust-

ment bracket but do not tighten.
4. Connect the electrical wires to the alternator.

Tighten the nut to 7.8 N•m (69.04 lbf in).
A. REGULATED VOLTAGE VALUES 5. Install the V-belt and adjust to the proper ten-
B. REGULATED VOLTAGE sion. See V-Belt, Adjust.
C. TEMPERATURE OF THE IC REGULATOR
6. Tighten the set bolt to 25.5 N•m (18.8 lbf ft).
Figure 112. Regulated Voltage Scale
7. Tighten the pivot bolt to 30 N•m (22 lbf ft).
No Load Test
8. Connect battery positive cable at positive termi-
Refer to Figure 111 for the wiring diagrams for the nal.
9. Connect battery negative cable at negative ter-
1. Turn battery switch S1 ON. minal.
2. Run the alternator. Turn S1 OFF when output 10. Start the engine and listen for any unusual
current exceeds 0 amperes. sounds from the alternator.
3. Adjust the speed and the voltage to the standard 11. Verify that the charge indicator is ON while the
values. engine is operating. If the charge indicator is
not ON, repair the problem before operating the
4. Check that the speed is within the standard val- engine.
ues.
Output Test
Refer to Figure 111 for the wiring diagrams for the
74
STARTER
The starter specifications are shown in Table 5.
Table 5. Starter Specifications
Hitachi Model Number S13-204

Nominal Output 2.3 kW (3.0 hp)
Weight 5.5 kg (12.1 lb)
Revolution Direction (As Viewed from Pinion) Clockwise
Engagement System Magnetic Shift
Terminal Voltage / Current 11 V / 140 A max
No-load
Revolution 4100 rpm min
Terminal Voltage / Current 2.5 V / 1050 A max
Loaded 24.5 N•m, 2.5 kgf•m
Torque
(18.1 lbf ft) min
Clutch System Overrunning
Pinion Projection Voltage at 100°C (212°F) 8.6 V max
Pinion DP or Module / Number of Teeth M3 / 9
Difference (O-ring, Oil Seal) Dry (none)
Application Standard
Spring Force 35 N, 3.6 kgf (7.868 lbf)
Brush Standard 15 mm (0.591 in.)
Height
Limit 9 mm (0.354 in.)
Series Coil Resistance 0.27 at 20°C (68°F)
Magnetic Switch
Shunt Coil Resistance 0.60 at 20°C (68°F)
Standard 36.5 mm (1.437 in.)
Outside Diameter
Limit 35 mm (1.398 in.)
Commutator Run-Out
Limit 0.2 mm (0.008 in.)
Standard 0.5 to 0.8 mm (0.020 to 0.031 in.)
Insulation Depth
Limit 0.2 mm (0.008 in.)
Armature Run-Out
Limit 0.2 mm (0.008 in.)
Armature Front 6903DDU
Armature Rear 608DDU
Bearing Type Nominal Number
Pinion Front 60004DDU
Pinion Rear 6904DDU
Pinion Projection Length (Length L) 0.3 to 1.5 mm (0.012 to 0.059 in.)
75
Remove 2. Connect an ammeter in series with the battery

positive terminal and the S terminal of the
WARNING starter solenoid. See Figure 114.
nect the cable at the negative terminal first. In-
one connects the cables on the terminals.
1. Disconnect battery negative cable at negative

terminal.
2. Disconnect the battery positive cable at positive

terminal.
3. Put labels on wires and cables prior to discon-

necting to aid in correct installation.
1. AMMETER
4. Disconnect wires and cables from starter. 2. BATTERY
3. VOLTMETER
5. Hold starter so it won’t fall. Remove the two M12 4. S TERMINAL
bolts that fasten the starter to the flywheel hous- 5. BATTERY POSITIVE TERMINAL
ing. Remove starter from flywheel housing. See
Figure 113. Figure 114. No Load Test
3. Connect a voltmeter between the solenoid M ter-

minal and the frame of the starter.
4. Attach a tachometer in the current line or hold a

vibration tachometer against the starter.
5. Attach a switch in the current line.
6. Turn the switch to the ON position. Observe the

starter rpm, amperage draw, and voltage read-
ings. The specifications are listed in Table 6.
Table 6. No Load Test Specifications
Terminal Voltage/ 11 Volts/140 Amps

Current maximum
1. FLYWHEEL HOUSING
2. BOLT Revolution 140 rpm minimum
3. STARTER
Figure 113. Starter

Install
1. Place starter in position in flywheel housing. In-
No Load Test stall the two M12 bolts to fasten the starter to
the flywheel housing.
CAUTION
2. Connect wires and cables as labeled in removal.
The starter motor can be damaged if operated
Tighten the M8 nut, B terminal, to 7.9 to 9.8 N•m
continuously for longer than 30 seconds while
(70 to 87 lbf in). Tighten the M4 screw, S termi-
performing the no load test.
nal, to 1.7 to 2.4 N•m (15 to 21 lbf in). Be sure
1. Secure the starter in a soft-jawed vise or other to place the cover over the M4 screw connection.
suitable fixture. See Figure 115.
76
3. Connect battery positive cable at positive termi-

nal.
4. Connect battery negative cable at negative ter-

minal.
1. M8 NUT 3. M4 SCREW
2. COVER 4. STARTER
Figure 115. Starter Connections
ENGINE DATA
Table 7. 4TNE92-NMH Engine
Engine Model 4TNE92-NMH (Hyster Part No. 1501687)

Version VM
Type Vertical Inline Diesel Engine
Combustion System Indirect Injection
Aspiration Natural
No. of Cylinders 4
Ignition Order 1 - 3 - 4 - 2
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
Displacement 2.659 liter (162.3 cu in.)
*Engine Specifications do not include height of lifting eyes nor dimensions or specifications for the Cooling
Fan, Radiator, Muffler, and Air Cleaner.
77
Table 7. 4TNE92-NMH Engine (Continued)
Max. Rated Output (Net) rpm 2450

(min -1)
hp SAE 45.1
kW 33.6
PS 45.7
High Idle Speed (Bare Engine) 2700 +50 rpm
Low Idle Speed (Bare Engine) 825 +50 rpm
Engine Weight (Dry)* 194 ±10 kg (427 ±22 lb)
Direction of Rotation Counterclockwise Viewed From Flywheel Side
Cooling System Liquid-Cooled With Radiator
Lubricating System Forced Lubrication With Trochoid Pump
At rated speeds, oil pressure is 0.29 to 0.39 MPa (42 to 57 psi)
At low idle, oil pressure is: No less than 0.06 MPa (8.5 psi)
Starting System Electric Starting - Starter Motor: DC12V, 2.3 kW (3.1 hp)
Alternator: DC12V, 60A
Recommended Battery Capacity: 12V, 622 CCA (Cold Cranking Amps)
Dimensions (L × W × H)* 632 × 498 × 711 mm (24.9 × 19.6 × 28.0 in.)
Engine Oil Pan Capacity 8.8 / 6.8 liter (9.3 / 7.2 qt)
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2 liter (1.11 gal) Engine Only
Table 8. 4TNE92-NMHA Engine
Engine Model 4TNE92-NMHA (Hyster Part No. 1536725)

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
*Engine Specifications Without Cooling Fan, Radiator, Muffler, and Air Cleaner.
78
Table 8. 4TNE92-NMHA Engine (Continued)

(min -1)
hp SAE 39.0
kW 29.1
PS 39.6
High Idle Speed (Bare Engine) 2450 ±25 rpm


Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 98 × 110 mm (3.86 × 4.33 in.)
79

(min -1)
hp SAE 63.6
kW 47.4
PS 64.4
Low Idle Speed (Bare Engine) 825 ±25 rpm
Engine Weight (Dry)* 194 kg (491.6 lb)

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
80

(min -1)
hp SAE 45.1
kW 33.6
PS 45.7
Table 11. 4TNE92-NMHA Engine
Engine Model 4TNE92-NMHA (Hyster Part No. 1688253)

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
81
Table 11. 4TNE92-NMHA Engine (Continued)

(min -1)
hp SAE 39.0
kW 29.1
PS 39.6

Table 12. 4TNE98-BNMH Engine

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 98 × 110 mm (3.86 × 4.33 in.)
82
Table 12. 4TNE98-BNMH Engine (Continued)

(min -1)
hp SAE 63.6
kW 43.0
PS 58.4
Engine Weight (Dry)* 194 ±10 kg (427.7 ±22 lb)
ENGINE TUNING
Inspection Item Standard Limit
Valve Gap Intake/Exhaust 0.15 to 0.25 mm -
(Engine Cold) (0.006 to 0.010 in.)
Fuel Injection Pressure 11.8 to 12.7 MPa -
(1711 to 1842 psi)
Fuel Injection Timing with Plunger Lifted 1 mm 6° ±1° ATDC -
(0.039 in.)
Compression Pressure at 250 rpm 2.84 to 3.04 MPa 2.35 MPa
(412 to 441 psi) (341 psi)
Lubricating Oil Pressure Max. (when cold) 0.59 MPa -
(86 psi)
At rated output 0.29 to 0.39 MPa -
(42 to 57 psi)
When idling 0.06 MPa or greater -
(8.7 psi)
83

Thermostat Valve Opening Temperature Full Opening Lift
Temperature
69 to 73°C 8 mm (0.32 in.) or
(156 to 163°F) Above 85°C (185°F)
Coolant Temperature Switch 107 to 113°C -
(225 to 235°F)
CYLINDER HEAD
Combustion Surface Distortion (Flatness) 0.05 mm 0.15 mm
(0.0020 in.) (0.0059 in.)
Valve Sink Intake 0.5 to 0.7 mm 1.0 mm
(0.020 to 0.028 in.) (0.039 in.)
Exhaust 0.6 to 0.8 mm 1.1 mm
(0.024 to 0.032 in.) (0.043 in.)
Valve Seat Angle Intake 120° -
Exhaust 90° -
INTAKE/EXHAUST VALVE AND GUIDE

Intake Valve Guide Inside Diameter 8.015 to 8.030 mm 8.10 mm
(0.3156 to 0.3161 in.) (0.3189 in.)
Valve Stem Outside 7.965 to 7.980 mm 7.90 mm
Diameter (0.3136 to 0.3142 in.) (0.3110 in.)
Oil Clearance 0.035 to 0.065 mm 0.18 mm
(0.0014 to 0.0026 in.) (0.0071 in.)
Exhaust Valve Guide Inside Diameter 8.015 to 8.030 mm 8.10 mm
(0.3156 to 0.3161 in.) (0.3189 in.)
Valve Stem Outside 7.965 to 7.970 mm 7.90 mm
Diameter (0.3136 to 0.3138 in.) (0.3110 in.)
Oil Clearance 0.045 to 0.075 mm 0.18 mm
(0.0018 to 0.0030 in.) (0.0071 in.)
Valve Guide Projection From Cylinder Head 14.7 to 15.0 mm -
(0.58 to 0.60 in.)
Valve Guide Driving-in Method Cold-fitted -
84
VALVE SPRING
Free Length 47.5 mm -
(1.87 in.)
Inclination - 1.2 mm
(0.05 in.)
ROCKER ARM AND SHAFT

Arm Shaft Hole Diameter 18.50 to 18.52 mm 18.57 mm
(0.7283 to 0.7291 in.) (0.7311 in.)
Shaft Outside Diameter 18.47 to 18.49 mm 18.42 mm
(0.7272 to 0.7280 in.) (0.7252 in.)
Clearance 0.01 to 0.05 mm 0.15 mm
(0.0004 to 0.0020 in.) (0.0059 in.)
PUSH ROD
Push Rod Bend - 0.03 mm
(0.0012 in.)
GEAR TRAIN AND CAMSHAFT

Camshaft
Side Gap 0.05 to 0.20 mm 0.30 mm
(0.0020 to 0.0079 in.) (0.0118 in.)
Bending (1/2 the dial gauge reading) 0 to 0.02 mm 0.05 mm
(0 to 0.0008 in.) (0.0020 in.)
Cam Height 42.435 to 42.565 mm 42.185 mm
(1.6707 to 1.6758 in.) (1.6608 in.)
85

Camshaft Oil Gear End Bushing Inside 49.990 to 50.055 mm 50.130 mm
Clearance Diameter (1.9681 to 1.9707 in.) (1.9736 in.)
Camshaft Outside 49.925 to 49.950 mm 49.890 mm
Diameter (1.9656 to 1.9665 in.) (1.9642 in.)
(0.0016 to 0.0051 in.) (0.0094 in.)
Intermediate Bushing Inside 50.000 to 50.025 mm 50.100 mm
Diameter (1.9685 to 1.9695 in.) (1.9724 in.)
Diameter (1.9650 to 1.9659 in.) (1.9636 in.)
(0.0026 to 0.0045 in.) (0.0089 in.)
Flywheel End Bushing Inside 50.000 to 50.025 mm 50.100 mm
Diameter (1.9685 to 1.9695 in.) (1.9724 in.)
Diameter (1.9656 to 1.9665 in.) (1.9642 in.)
(0.0020 to 0.0039 in.) (0.0083 in.)
Idle Gear Shaft and Bushing

Shaft Outside Diameter 45.950 to 49.975 mm 45.900 mm
(1.8091 to 1.9675 in.) (1.8071 in.)
Bushing Inside Diameter 46.000 to 46.025 mm 46.075 mm
(1.8110 to 1.8120 in.) (1.8140 in.)
(0.0010 to 0.0030 in.) (0.0069 in.)
Backlash of Each Gear

Crank Gear, Cam Gear, Idle Gear, Fuel Injection 0.08 to 0.14 mm 0.16 mm
Pump Gear, and PTO Gear (0.0031 to 0.0055 in.) (0.0063 in.)
Lubricating Oil Pump Gear 0.09 to 0.15 mm 0.17 mm
(0.0035 to 0.0059 in.) (0.0067 in.)
86
CYLINDER BLOCK
Cylinder Inside Diameter 4TNE92 92.000 to 92.030 mm 92.130 mm
(3.6220 to 3.6232 in.) (3.6272 in.)
4TNE98 98.000 to 98.030 mm 98.130 mm
(3.8583 to 3.8594 in.) (3.8634 in.)
Cylinder Bore Roundness 0.01 mm 0.03 mm
(0.0004 in.) or less (0.0012 in.)
Inclination
CRANKSHAFT
Bending (1/2 the dial gauge reading) - 0.02 mm
(0.0008 in.)
Connecting Rod Journals Pin Outside Diameter 57.952 to 57.962 mm 57.902 mm
(2.2816 to 2.2820 in.) (2.2796 in.)
Metal Inside Diameter 58.000 to 58.026 mm -
(2.2835 to 2.2845 in.)
Metal Thickness 1.492 to 1.500 mm -
(0.0587 to 0.0591 in.)
(0.0015 to 0.0029 in.) (0.0059 in.)
Crank Journal Selective Journal Outside 64.952 to 64.962 mm 64.902 mm
Pairing Diameter (2.5572 to 2.5576 in.) (2.5552 in.)
Metal Inside Diameter 65.000 to 65.020 mm -
(2.5591 to 2.5598 in.)
Metal Thickness 1.995 to 2.010 mm -
(0.0785 to 0.0791 in.)
(0.0015 to 0.0027 in.) (0.0059 in.)
THRUST BEARING
Crankshaft Side Gap 0.11 to 0.21 mm 0.28 mm
(0.0043 to 0.0083 in.) (0.0110 in.)
87
PISTON
Piston Outside Diameter 4TNE92 91.945 to 91.975 mm 91.900 mm
(Measure in the Direction (3.6199 to 3.6211 in.) (3.6181 in.)
Vertical to the Piston Pin.)
4TNE98 97.940 to 97.950 mm 97.900 mm
(3.8559 to 3.8563 in.) (3.8543 in.)
Piston Diameter Measure Position (Upward From the 22.000 mm
-
Bottom End of the Piston.) (0.8661 in.)
Piston Pin Hole Inside Diameter 30.000 to 30.009 mm 30.039 mm
(1.1811 to 1.1815 in.) (1.1826 in.)
Pin Outside 29.989 to 30.000 mm 29.959 mm
Diameter (1.1807 to 1.1811 in.) (1.1795 in.)
(0.0000 to 0.0008 in.) (0.0032 in.)
PISTON RING
Top Ring Ring Groove Width 2.040 to 2.060 mm -
(0.0803 to 0.0811 in.)
Ring Width 1.940 to 1.960 mm 1.920 mm
(0.0764 to 0.0772 in.) (0.0756 in.)
Side Clearance 0.080 to 0.120 mm -
(0.0032 to 0.0047 in.)
End Clearance 0.250 to 0.450 mm 0.540 mm
(0.0098 to 0.0177 in.) (0.0213 in.)
Second Ring Ring Groove Width 2.080 to 2.095 mm 2.195 mm
(0.0819 to 0.0825 in.) (0.0864 in.)
(0.0776 to 0.0783 in.) (0.0768 in.)
Side Clearance 0.090 to 0.125 mm 0.245 mm
(0.0035 to 0.0049 in.) (0.0096 in.)
(0.0177 to 0.0256 in.) (0.0287 in.)
Oil Ring Ring Groove Width 3.015 to 3.030 mm 3.130 mm
(0.1187 to 0.1193 in.) (0.1232 in.)
(0.1169 to 0.1177 in.) (0.1161 in.)
Side Clearance 0.025 to 0.060 mm 0.180 mm
(0.0010 to 0.0024 in.) (0.0071 in.)
(0.0100 to 0.0177 in.) (0.0217 in.)
88
CONNECTING ROD
Thrust Clearance 0.13 to 0.23 mm -
(0.0051 to 0.0091 in.)
Rod Small End

Bushing Outside Diameter 30.025 to 30.038 mm 30.068 mm
(1.1821 to 1.1826 in.) (1.1838 in.)
Pin Outside Diameter 29.987 to 30.000 mm 29.959 mm
(1.1806 to 1.1811 in.) (1.1795 in.)
(0.0010 to 0.0020 in.) (0.0043 in.)
Tappet
Tappet Hole (Block) Inside Diameter 12.000 to 12.018 mm 12.038 mm
(0.4724 to 0.4732 in.) (0.4739 in.)
Tappet Stem Outside Diameter 11.975 to 11.990 mm 11.955 mm
(0.4715 to 0.4720 in.) (0.4707 in.)
(0.0004 to 0.0017 in.) (0.0033 in.)
OIL PUMP
Engine Oil Pressure
Model Number at Rated Engine rpm at Low Idle Speed
All models 0.29 to 0.39 MPa (42.06 to 56.56 psi) 0.06 MPa (8.7 psi) or greater
Outer Rotor Outside Clearance

Model Standard Limit
All models 0.100 to 0.155 mm 0.25 mm
(0.0039 to 0.0061 in.) (0.0098 in.)
Outer Rotor Side Clearance

All models 0.05 to 0.10 mm 0.15 mm
(0.0020 to 0.0039 in.) (0.0059 in.)
89
Standard Torque Specifications 600 SRM 1205
Outer Rotor to Inner Rotor Tip Clearance

All models - 0.16 mm
(0.0063 in.)
Rotor Shaft Clearance

Model Inspection Item Standard Limit
All models Gearcase Bearing I.D. 12.980 to 13.020 mm 13.05 mm
(0.5110 to 0.5126 in.) (0.5138 in.)
Rotor Shaft O.D. 12.925 to 12.970 mm 12.915 mm
(0.5089 to 0.5106 in.) (0.5085 in.)
Rotor Clearance 0.010 to 0.065 mm 0.105 mm
(0.0004 to 0.0026 in.) (0.0041 in.)
Standard Torque Specifications

STANDARD TORQUE CHART
Nominal Thread
Item × Pitch Tightening Torque
Diameter
Hexagon Bolt (7T) and Nut M6 × 1.0 mm 9.8 to 11.8 N•m
(87 to 104 lbf in)
M8 × 1.25 mm 22.6 to 28.4 N•m
NOTE: Use 80% of the value of (17 to 21 lbf ft)
the Tightening Torque when the M10 × 1.5 mm 44.1 to 53.9 N•m
tightening part is aluminum. (33 to 40 lbf ft)
Use 60% of the value of the Tight-
ening Torque for 4T bolts and M12 × 1.75 mm 78.4 to 98.0 N•m
lock nuts. (58 to 72 lbf ft)
M14 × 1.5 mm 127.5 to 147.1 N•m
(94 to 108 lbf ft)
M16 × 1.5 mm 215.7 to 235.4 N•m
(159 to 174 lbf ft)
PT Plug 1/8 mm 9.8 N•m
(87 lbf in)
1/4 mm 19.6 N•m
(14 lbf ft)
3/8 mm 29.4 N•m
(22 lbf ft)
1/2 mm 58.8 N•m
(43 lbf ft)
90
600 SRM 1205 Special Torque Specifications
Nominal Thread
Item × Pitch Tightening Torque
Diameter
Pipe Joint Bolt M8 12.7 to 16.7 N•m
(112 to 148 lbf in)
M10 19.6 to 18.73 N•m
(14 to 19 lbf ft)
M12 24.5 to 34.3 N•m
(18 to 25 lbf ft)
M14 39.2 to 49.0 N•m
(29 to 36 lbf ft)
M16 49.0 to 58.8 N•m
(36 to 43 lbf ft)
NOTE: Lubricating oil is not applied to threaded portion and seat surface.
Special Torque Specifications

Alternator Adjuster/Set Bolt Flywheel Bolts
25.5 N•m (18.8 lbf ft) 155 N•m (114 lbf ft)
Alternator Pivot Bolt Flywheel Housing Bolts

30 N•m (22 lbf ft) 44 to 54 N•m (32 to 40 lbf ft)
Alternator Terminal Nut Fuel Injector

7.8 N•m (69 lbf in) 39 N•m (29 lbf ft)
Bearing Cap Set Bolt Fuel Pump Drive Gear Set Nut
108.1 to 117.9 N•m (79.7 to 87.0 lbf ft) 59 to 69 N•m (43 to 51 lbf ft)
Connecting Rod Bolt Fuel Return Line Retaining Nut

54 to 59 N•m (40 to 43 lbf ft) 44 N•m (33 lbf ft)
Coolant Temperature Sensor Starter Solenoid Nut (B Terminal)

24.5 to 34.3 N•m (18.1 to 25.3 lbf ft) 7.9 to 9.8 N•m (70 to 87 lbf in)
Crankshaft Pulley Bolt Starter Solenoid Screw (S Terminal)

117.6 N•m (86.7 lbf ft) 1.7 to 2.4 N•m (15 to 21 lbf in)
Cylinder Head Bolt Thermostat Cover Bolts

First Pass: 49 to 59 N•m (36 to 43 lbf ft) 23 to 28 N•m (17 to 21 lbf ft)
Second Pass: 103 to 113 N•m (76 to 83 lbf ft)
Engine Oil Drain Plug

20 to 24 N•m (14.75 to 17.7 lbf ft)
91
Special Tools
No. Tool Name Applicable Model and Tool Size Illustration
1 Valve Guide Tool
(for Extracting L1 L2 d1 d2
Valve Guide) 20 mm 75 mm 7.5 mm 11 mm
(0.787 in.) (2.953 in.) (0.295 in.) (0.433 in.)
Locally Manufactured
2 Valve Guide Tool

(for Inserting L1 L2 d1 d2
Valve Guide) 15 mm 65 mm 14 mm 20 mm
(0.591 in.) (2.559 in.) (0.551 in.) (0.787 in.)
3 Connecting
Rod Bushing L1 L2 d1 d2
Replacer (for 20 mm 100 mm 30 mm 33 mm
Removal/ (0.787 in.) (3.937 in.) (1.181 in.) (1.299 in.)
Installation of
Connecting Rod Locally Manufactured
Bushing)
4 Valve Spring
Compressor
(for Removal/
Hyster Part No. 1607211
Installation of
Valve Spring)
5 Stem Seal
Inserter (for d1 d2 d3 L1 L2 L3
Inserting Stem 16.2 mm 22 mm 13.5 mm 17.0 mm 65 mm 4 mm
Seal) (0.638 in.) (0.866 in.) (0.531 in.) (0.669 in.) (2.560 in.) (0.157 in.)
6 Filter Wrench
(for Removal/
Available Locally
Installation of
Engine Oil Filter)
92
No. Tool Name Applicable Model and Tool Size Illustration

7 Camshaft
Bushing Tool L1 L2 d1 d2
(for Extracting 18 mm 70 mm 50 mm 53 mm
Camshaft (0.709 in.) (2.756 in.) (1.969 in.) (2.087 in.)
Bushing)
Allowance d1: 03 to 0.6 mm (0.012 to 0.024 in.)
Allowance d2: 03 to 0.6 mm (0.012 to 0.024 in.)
8 Flex-Hone (for
Preparation of Model Part Number Cylinder Bore
Cylinder Walls) 4TNE92 83 to 95 mm
Hyster Part No.
1607212 ( in.)
Hyster Part No. 89 to 101 mm

4TNE98
1599906 ( in.)
9 Piston Ring Hyster Part No. 1607213

Compressor (for The Piston Insertion Tool is Applicable for
Inserting Piston) 60 to 125 mm (2.362 to 4.921 in.)
Diameter Pistons
10 Piston Ring Available Locally

Replacer (for
Removal/
Installation of
Piston Ring)
No. Instrument Name Application Illustration

1 Dial Indicator Measurements of shaft bending, and strain
and gap of surfaces.
2 Test Indicator Measurements of narrow or deep portions

that cannot be measured by dial Indicator.
3 Magnetic Stand For holding the dial gauge when measuring.
93

4 Micrometer For measuring the outside diameters of
crankshaft, pistons, piston pins, etc.
5 Cylinder Gauge For measuring the inside diameters of

cylinder liners, rod metal, etc.
6 Calipers For measuring outside diameters, depth,

thickness, and width.
7 Depth Micrometer For measuring of valve sink.
8 Square For measuring valve spring inclination and

straightness of parts.
9 V-Block For measuring shaft bend.
10 Torque Wrench For tightening nuts and bolts to the

specified torque.
11 Thickness Gauge ("Feeler" For measuring gaps between ring and ring
Gauge) groove and shaft joints during assembly.
94

12 Cooling System Tester For checking water leakage
13 Battery Coolant Tester For checking concentration of antifreeze

and the battery electrolyte charge status.
14 Fuel Injector Tester For measuring injection spray pattern of

fuel injection nozzle and injection pressure.
15 Fuel Injection Pump Timing Used to check and adjust fuel injection
Tool timing.
16 Digital Thermometer For measuring temperature.
17 Tachometer Contact Type For measuring revolution by contacting the

revolving shaft.
Photoelectric For measuring revolution by sensing the

Type reflecting mark on the outer periphery of
the revolving shaft.
Fuel High This measures the revolution regardless

Pressure Pipe of the center of periphery of the revolving
Clamp Type object.
95

18 Circuit Tester For measuring resistance, voltage, and
continuity of electrical circuits.
19 Compression Gauge Kit For measuring compression pressure.
New Compression Test Adapter Adapter for direct injection 2-valve cylinder
head.
96
600 SRM 1205 12/12 (7/11)(10/09)(3/07)(7/06)(3/06)(5/05) Printed in U.S.A.

COOLING SYSTEM
PART NO. 1580505 700 SRM 1123

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Radiator Hoses............................................................................................................................................... 1
Water Pump ................................................................................................................................................... 1
Oil Cooler ....................................................................................................................................................... 33
Fan Removal .................................................................................................................................................. 47
Inspect ............................................................................................................................................................ 61
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S50CT [A267];
H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274];
S120FTS; S120FTPRS) [G004, H004];
110, 120FT) [N005, P005, R005];

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General

WARNING WARNING
WARNING WATER PUMP

WARNING
the cooling system.

1

(F001); S2.0-3.5FT (S40-70FT, S55FTS)

the cooling system.
2
CAUTION CAUTION
dealer.
radiator.
flow.
H40FTS) (F001)
(H40-70FT) (L177); H2.0-2.5CT (H50CT)
(A274); S4.0, 4.5, 5.5FT, S5.5FTS,
• S4.0, 4.5, 5.5FT; S5.5FTS (S80, 100, 120FT;
S120FTS; S120FTPRS) (G004, H004) (G004, H004)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
(N005, P005, R005)
the cooling system.
1. Turn OFF truck.
3

5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
5.5FT (H80, 90, 100, 110, 120FT) (P005)
• S6.6FT, S7.0FT (S135FT, S155FT) (E024)
CAUTION
• H2.0-2.5CT (H50CT) (A274)
fan removal.
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
4
H40FTS) (F001)
• S50CT (A267) • H2.0-2.5CT (H50CT) (A274)
• H2.0-2.5CT (H50CT) (A274)
(G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
5
6
Legend for Figure 1

SHOWN
6. SHROUD 19. TUBE
8. WASHER 21. HOSE
10. CLIP 23. CAP
7
8
Legend for Figure 2

4. SCREW 18. CAP
6. CLIP 20. HOSE
9. CLAMP 23. NUT
14. RESERVOIR
9
10
Legend for Figure 3

4. SCREW 17. CAP
6. CLIP 19. HOSE
9. CLAMP 22. SCREEN
13. ISOLATOR
11
90, 100, 110, 120FT) (N005, P005) Before 2011
12
Legend for Figure 4

8. RADIATOR 21. CAP
9. CLIP 22. BUSHING
13
90, 100, 110, 120FT) (N005, P005) After 2011
14
Legend for Figure 5

9. CLIP 21. TUBE
15

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)
16

7. CAP 19. WASHER
11. INSERT 23. TUBE
12. RADIATOR CAP
17

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
18
radiator cap.
H40FTS) (F001); S50CT (A267) AND
CAUTION
WITH OIL COOLER
WARNING
the cooling system.
1. Turn OFF truck.
• S30FT, S35FT, S40FTS (E010)
• H2.0-2.5CT (H50CT) (A274)
the terminals.
See Figure 9.
WARNING
19

2. CAP 12. INSERT
5. CLAMP 15. TUBE
7. O-RING 17. HOSE
20

WARNING
See Figure 11.

21

1. DEBRIS COVER
3. RADIATOR COVER
4. UPPER BRACKET
5. CAPSCREWS
6. REMOTE FILL HOSE
7. HOSE CLAMPS
8. OIL COOLER
10. FITTINGS
11. UPPER HOSE
12. LOWER HOSE
13. REMOTE FILL
14. RADIATOR CAP

E024, F024)
22

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
S155FT) (E024)
23
H175FT36, H190FT) (B299)
H9.0FT (H170FT, H175FT36, H190FT)
WARNING
the cooling system.
WARNING
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
24

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

CAUTION


• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
H175FT36, H190FT) (A299, B299)
(A299, B299).
H175FT36, H190FT) (B299)
H175FT36, H190FT) (A299, B299)
25
oil cooler ports.
26

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
27

6. BUSHING 15. SEAL
H175FT36, H190FT) (A299, B299)

8. TUBE 19. HOSE
28
H175FT36, H190FT) (B299)
29
radiator. ure 6.
(H40-70FT) (L177); H2.0-2.5CT (H50CT)
(S80, 100, 120FT; S80, 100FTBCS;

CAUTION
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-2.5CT (H50CT) (A274)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
the reservoir.
30

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

2. ADD MARK

2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT
(A267); H2.0-3.5FT (H40-70FT) (L177) and

2. ADD MARK

2.0FTS (H30FT, H35FT, H40FTS) (F001);
S2.0-3.5FT (S40-70FT, S55FTS) (F187); S50CT
(A267); H2.0-3.5FT (H40-70FT) (L177) and
31

2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK

models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
(G004, H004)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
(H80, 90, 100, 110, 120FT) (N005, P005)
models
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
WARNING
WARNING


(H80, 90, 100, 110, 120FT) (R005)
32
radiator.




verter.

the reservoir.


dealer.

CAUTION
33

WARNING

CAUTION
dealer.


(D024, E024, F024)
2. ADD MARK
ure 10.
models
H40FTS) (F001)
models
• S50CT (A267)
34

screws. WARNING
CAUTION
serious injury.
lift the weight.

voir.
lift truck.
WARNING
CAUTION
dealer.

Figure 22.
2. FULL "HOT" MARK
4. ADD "COLD" MARK
F024)
35
F024)
36

3. WASHER 16. CAP
H175FT36, H190FT) (B299)
H9.0FT (H170FT, H175FT36, H190FT)
J006, K006)
gine
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
screws.
J006, K006)
gine H175FT36, H190FT) (B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
37
clamp.
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (B299)
J006)
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (B299)
clamp. gine
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
gine
38

WARNING
WARNING
3. FULL "COLD" MARK
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
dealer.
39
H155FT) (H006, J006, K006) (Sheet 1 of 3)
40
H155FT) (H006, J006, K006) (Sheet 2 of 3)
41
H155FT) (H006, J006, K006) (Sheet 3 of 3)
42

9. ISOLATOR 24. CAP
16. WASHER
43

13. CAP 29. SPACER
16. TUBE
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
44

2. CLAMP 14. BAFFLE
9. CAPSCREW 21. FAN
10. NUT 22. SPACER
12. UPPER BRACKET
(H170FT, H175FT36, H190FT) (A299, B299)
45
H9.0FT (H170FT, H175FT36, H190FT) (B299)
46

13. CAP 28. FAN

models
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
ing wheel forward.
K006)
H190FT) (A299, B299)
hood cover up.
47

F024)
K006)
5.5FT (H80, 90, 100, 110, 120FT) (P005)
gines
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, H175FT36, H190FT) (B299)
R005)
48
1. FAN 5. SCREW
4. CAPSCREW
49
1. SPACER 5. SHROUD
2. FAN 6. SCREW
4. CAPSCREW
50

51
1. FAN 5. SCREW
4. CAPSCREW
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
52
1. SPACER 6. SCREW
5. RADIATOR SHROUD
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
53

1. FAN 5. SCREW
4. CAPSCREW
S6.0FT, S7.0FT, (S135FT,S155FT) (D024, F024)
54

1. FAN 5. SCREW
4. CAPSCREW
55
1. SPACER 5. WASHER
2. FAN 6. CAPSCREW
3. SCREW 7. SHROUD
56

2. SCREW 6. FAN
4. SPACER
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
57

2. SCREW 6. FAN
4. SPACER
(H170FT, H175FT36, H190FT) (A299, B299)
58
1. FAN 5. SCREW
4. CAPSCREW
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
59

2. SCREW 6. FAN
4. SPACER
(H170FT, H175FT36, H190FT) (B299)
(G004, H004)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
5.5FT (H80, 90, 100, 110, 120FT) (N005)
ota 3.8L engines
60
J006, K006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• H2.0-3.5FT (H40-70FT) (L177)
14. Remove the fan.
gines
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
WARNING
H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (A299, B299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,

• H2.0-2.5CT (H50CT) (A274)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001)
61
• H2.0-2.5CT (H50CT) (A274) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
(G004, H004)
H40FTS) (F001)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• S30FT, S35FT, S40FTS (E010)
ota 3.8L engines
J006, K006) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S50CT (A267)
5.5FT (H80, 90, 100, 110, 120FT) (R005)
(G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
Kubota engines
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
62
• H2.0-2.5CT (H50CT) (A274)
• S50CT (A267)
H40FTS) (F001)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
models
• S30FT, S35FT, S40FTS (E010)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H40FTS) (F001)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
R005)
• H2.0-3.5FT (H40-70FT) (L177)
5.5FT (H80, 90, 100, 110, 120FT) (N005) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
Kubota engines
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
H190FT) (A299, B299)
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (E024)
63
position.
64

POWERSHIFT TRANSMISSION
REPAIR
S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 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]
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. 1580510 1300 SRM 1129

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Powershift Transmission Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Charge Pump Repair ......................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Inspect ............................................................................................................................................................ 2
Install ............................................................................................................................................................. 2
Torque Converter Replace ................................................................................................................................. 3
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 10
Front Cover Housing and Chain Drive Repair................................................................................................. 16
Remove ........................................................................................................................................................... 16
Clean .............................................................................................................................................................. 22
Inspect ............................................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Clutch Packs Repair .......................................................................................................................................... 29
Transmission, Remove and Disassemble ................................................................................................. 29
Clutch Assemblies, Remove and Disassemble ......................................................................................... 40
Clean .............................................................................................................................................................. 45
Inspect ............................................................................................................................................................ 45
Clutch Assemblies, Assemble and Install ................................................................................................ 46
Transmission, Assemble and Install ........................................................................................................ 53
Control Valve Repair.......................................................................................................................................... 59
Clean .............................................................................................................................................................. 62
Inspect ............................................................................................................................................................ 62
MONOTROL® Pedal Repair .............................................................................................................................. 64
Direction Control Lever ..................................................................................................................................... 68
Remove ........................................................................................................................................................... 68
Install ............................................................................................................................................................. 68
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S120FTS; S120FTPRS) [G004];
110, 120FT) [N005, P005]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
This section has the repair procedures for the transmission.
SERIAL NUMBER
The transmission serial number is located on the
right side of the transmission control valve directly
below the floor plate. See Figure 1.
A. EARLY LIFT TRUCK MODELS EXCEPT

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
Figure 1. Transmission Serial Number

Location
Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair 1300 SRM 1129
Charge Pump Repair

REMOVE INSPECT
NOTE: The charge pump can be removed from the Inspect the splines on the shaft of the transmission
transmission while it is still in the lift truck but, charge pump for damage or worn areas that could
for the sake of clarity, the following procedures are affect the operation of the pump. If the splines are
shown with the transmission removed from the lift damaged, replace the transmission charge pump.
truck.
INSTALL
Remove four mounting capscrews, washers, trans-
mission charge pump, and gasket from the torque Install new gasket, transmission charge pump, four
converter housing. Discard the gasket. See Figure 2. mounting capscrews, and washers in the torque
converter housing. Tighten capscrews to 19 N•m
(168 lbf in).
NOTE: THE TRANSMISSION IS SHOWN REMOVED

FROM THE LIFT TRUCK FOR CLARITY.
(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. CAPSCREW
2. CHARGE PUMP
3. GASKET
4. TORQUE CONVERTER HOUSING
Figure 2. Transmission Charge Pump
2 Confidential/Proprietary - Do Not Copy or Duplicate

1300 SRM 1129 Torque Converter Replace
Torque Converter Replace

REMOVE (N005, P005) lift trucks, and Frame 100 SRM
1120 for S30FT, S35FT, S40FTS (E010); H1.6FT,
WARNING H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
Make sure the engine and transmission are
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
held in position so that they will not fall and
cause an injury and damage to the equipment.
CAUTION
CAUTION Use care when disconnecting the wiring har-
ness connectors from electrical connectors on
Be careful that you do not damage parts of
the transmission and control valve. The con-
the torque converter or transmission when
nectors on the transmission and control valve
the transmission is separated from the engine.
are easily damaged.
Keep the transmission and engine in align-
ment until they are completely separated so NOTE: When disconnecting wiring harness connec-
parts of the transmission are not damaged. tors during disassembly, tag each connector to aid in
Use a crane or lifting device to separate the connecting the wiring harness during reassembly.
transmission from the engine.
2. Put the engine and transmission on solid blocks
1. Remove the engine and transmission as a unit on a work surface. Disconnect the connectors of
from the lift truck. See the section Frame 100 the transmission wiring harness from the control
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, valve and transmission. Remove the transmis-
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- sion wiring harness from the transmission. See
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, Figure 3.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)

Torque Converter Replace 1300 SRM 1129

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. GM 2.4L ENGINE 5. CAPSCREW
2. CAPSCREW 6. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 7. CONTROL VALVE
4. TRANSMISSION
Figure 3. Engine-Transmission Combination

use your fingers to check for alignment of the

WARNING bolts with the access hole.
Make sure that the engine/transmission assem-
bly is stable before attempting to rotate the en- 3. Move each bolt into view through the access hole
gine. of the flywheel housing by rotating the crank-
shaft. Remove the four capscrews that attach the
Use a flashlight to see the bolts as they are ro- flywheel to the torque converter. See Figure 4.
tated into view through the access hole. Do not


Legend for Figure 4

A. GM 2.4L ENGINE AND NEW FITTING DESIGN H4.5FT6; H5.0-5.5FT (H80, 90,
B. MAZDA ENGINE USED ON ENGINE AND 100, 110, 120FT) (N005, P005)
C. YANMAR ENGINE TRANSMISSIONS SHOWN IN LIFT TRUCK MODELS
D. GM 4.3L ENGINE ILLUSTRATIONS A THROUGH F. CUMMINS 4.5L DIESEL
E. ILLUSTRATES NEW DIPSTICK D, EXCEPT WHEN D IS USED ENGINE
AND BREATHER LOCATION ON H4.0FT5/FT6; H4.5FTS5,
1. ACCESS HOLE 2. FLYWHEEL HOUSING
4. Remove the access cover from the torque con- NOTE: The torque converter cannot be repaired and
verter housing. Install a lifting eye bolt into the must be replaced as a unit, if damaged.
rear access cover bolt hole, and connect a lifting
device to the eye bolt. Remove the 10 capscrews 5. Carefully remove the torque converter from the
that hold the torque converter housing to the fly- stator support. See Figure 5.
wheel housing on the engine. Carefully separate
the transmission from the engine.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TRANSMISSION OIL FILTER 10. PLUG
2. DIPSTICK 11. CAPSCREW
3. DIPSTICK TUBE 12. WASHER
4. TRANSMISSION HOUSING 13. SMALL ACCESS COVER
5. VENT TUBE ASSEMBLY 14. TORQUE CONVERTER
6. TORQUE CONVERTER HOUSING 15. TRANSMISSION CHARGE PUMP
7. TRANSMISSION OIL TEMPERATURE SENSOR 16. STATOR SUPPORT
8. SUCTION SCREEN 17. PILOT HUB
9. SUCTION SCREEN SPRING
Figure 5. Torque Converter Removal

6. Remove the plug, suction screen spring, and suc-

tion screen from the torque converter housing,
and drain the oil from the transmission.
7. Remove the transmission charge pump and

transmission oil filter from the torque converter
housing.
NOTE: Step 8, Step 9, and the NOTE below ap-

ply to early lift truck models except H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) models.
8. Remove the dipstick from the dipstick tube,

and disconnect the vent tube assembly from the
transmission housing.
NOTE: The dipstick tube must be removed before the

torque converter housing can be removed from the
front cover housing.
9. Remove the dipstick tube from the torque con-

verter housing.
10. If damaged, remove the small access cover from

the torque converter housing. A. EARLY LIFT TRUCK MODELS EXCEPT
NOTE: Perform Step 11 only if repair of the of the (H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
transmission chain drive is required. If the trans- B. NEWER LIFT TRUCK MODELS
mission clutch packs are in need of further repair,
see Clutch Packs Repair. 1. PRY POINTS
11. Remove 12 capscrews from the transmission 3. FRONT COVER HOUSING
housing and four mounting capscrews from the 4. TRANSMISSION HOUSING
front of the torque converter housing. Using
Figure 6. Pry Point Location
a small pry bar in the designated pry points,
remove the torque converter housing from the
front cover housing. Discard the O-rings and
gasket. See Figure 6 and Figure 7.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
2. WASHER 5. FRONT COVER HOUSING
Figure 7. Torque Converter Housing
INSTALL 2. If removed, install the small access cover on the

torque converter housing. Tighten capscrews to
1. Install new O-rings and gasket and using four 7.9 N•m (69 lbf in). See Figure 8.
capscrews, install the torque converter housing
on the front cover housing and 12 capscrews on
the transmission housing. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 7.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
5. VENT TUBE ASSEMBLY 14. TORQUE CONVERTER
6. TORQUE CONVERTER HOUSING 15. TRANSMISSION CHARGE PUMP
7. TRANSMISSION OIL TEMPERATURE SENSOR 16. STATOR SUPPORT
8. SUCTION SCREEN 17. PILOT HUB
9. SUCTION SCREEN SPRING
Figure 8. Torque Converter Installation

NOTE: The information in Step 3 and Step 4 applies

only to early lift truck models except for H4.0FT5/ CAUTION
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, Be careful that you do not damage parts of
110, 120FT) (N005, P005) models. the torque converter or transmission when
the transmission is joined to the engine. Keep
3. Clean the surface of the dipstick tube and dip- the transmission and engine in alignment un-
stick hole in the torque converter housing. Apply til they are completely joined so parts of the
adhesive (Hyster P/N 264159) to the entire sur- transmission are not damaged. Use a crane or
face of the hole in the housing. Insert the dipstick lifting device to join the transmission to the
tube until the collar bottoms on the housing and engine.
orient the tab against the housing flange.
11. Install the transmission to the engine. Install
4. Install the dipstick into the dipstick tube, and the capscrews that connect the torque converter
connect the vent tube assembly to the transmis- housing to the flywheel housing. Tighten the
sion housing. capscrews to 38 N•m (28 lbf ft). See Figure 9.
5. Install a new transmission oil filter on the torque
converter housing. CAUTION
Use care when connecting the wiring harness
6. Install the transmission charge pump on the connectors to electrical connectors on the
torque converter housing. Tighten capscrews to transmission and control valve. The connec-
19 N•m (168 lbf in). tors on the transmission and control valve are
7. Install the suction screen, suction screen spring, easily damaged.
and plug into the torque converter housing. 12. Install the transmission wiring harness on the
8. Install the torque converter onto the input shaft transmission. Connect the connectors of the
and stator support of the transmission. Make transmission wiring harness to the control valve
sure the splines are aligned and the converter and transmission. See Figure 9.
engages fully. 13. Rotate the engine crankshaft to position the
9. Lubricate the pilot hub on the torque converter flywheel mounting holes in line with the torque
with antiseize compound. See Figure 8. converter mounting holes. Install the capscrews
that hold the torque converter to the flywheel,
10. If removed, install a lifting eye bolt into the rear after coating the threads with Loctite™ 242,
access cover bolt hole, and connect a lifting de- through the access hole of the flywheel housing.
vice to the eye bolt. Align the torque converter See Figure 10. Tighten the capscrews to 56 N•m
housing with the flywheel housing. Make sure (41 lbf ft). Remove the lifting eye bolt, and install
the pilot hub on the torque converter engages the the access cover on the torque converter housing.
flywheel.


(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
4. TRANSMISSION



15. Fill the transmission to the correct level using
WARNING the correct transmission fluid and procedure
Make sure the engine and transmission are given in the section Periodic Maintenance
held in position so that they will not fall and 8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
cause an injury and damage to the equipment. S55FTS) (F187); H2.0-3.5FT (H40-70FT)
(L177) lift trucks, Periodic Maintenance
14. Install the engine and transmission as a unit into
8000 SRM 1207 for S30FT, S35FT, S40FTS
the lift truck. See the section Frame 100 SRM
(E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
H35FT, H40FTS) (F001) lift trucks, and Pe-
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
riodic Maintenance 8000 SRM 1248 for S4.0,
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
100FTBCS; S120FTS; S120FTPRS) (G004) and
P005) lift trucks, and Frame 100 SRM 1120 for
(H80, 90, 100, 110, 120FT) (N005, P005) lift
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-
trucks.
3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT
(H40-70FT) (L177) lift trucks.

Front Cover Housing and Chain Drive Repair 1300 SRM 1129
Front Cover Housing and Chain Drive Repair

REMOVE NOTE: When disconnecting wiring harness connec-
tors during disassembly, tag each connector to aid in
WARNING connecting the wiring harness during reassembly.
Make sure the engine and transmission are 2. Put the engine and transmission on solid blocks
held in position so that they will not fall and on a work surface. Disconnect the connectors of
cause an injury and damage to the equipment. the transmission wiring harness from the control
valve and transmission. Remove the transmis-
CAUTION sion wiring harness from the transmission. See
Keep the transmission and engine in alignment Figure 11.
until they are completely separated so parts of
the transmission are not damaged. Use a crane WARNING
or lifting device to separate the transmission Make sure that the engine/transmission assem-
from the engine. bly is stable before attempting to rotate the en-
gine.
1. Remove the engine and transmission as a unit
from the lift truck. See the section Frame 100 Use a flashlight to see the bolts as they are ro-
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, tated into view through the access hole. Do not
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- use your fingers to check for alignment of the
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, bolts with the access hole.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) lift trucks, and Frame 100 SRM 3. Move each bolt into view through the access hole
1120 for S30FT, S35FT, S40FTS (E010); H1.6FT, of the flywheel housing by rotating the crank-
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) shaft. Remove the four capscrews that attach the
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); flywheel to the torque converter. See Figure 12.
H2.0-3.5FT (H40-70FT) (L177) lift trucks.
4. Remove the access cover from the torque con-
verter housing. Install a lifting eye bolt into the
CAUTION rear access cover bolt hole, and connect a lifting
To prevent possible damage to the transmis- device to the eye bolt. Remove the 10 capscrews
sion assembly when placing the assembly on a that hold the torque converter housing to the fly-
work surface, place blocks under the back side wheel housing. Carefully separate the transmis-
of the transmission housing for additional sup- sion from the engine.
port.
5. Carefully remove the torque converter from the
stator support. See Figure 13.
CAUTION
Use care when disconnecting the wiring har-
are easily damaged.

1300 SRM 1129 Front Cover Housing and Chain Drive Repair

(H80, 90, 100, 110, 120FT) (N005,P005) MODELS
4. TRANSMISSION




(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TORQUE CONVERTER 5. SUCTION SCREEN SPRING
2. CAPSCREW 6. SUCTION SCREEN
3. WASHER 7. TORQUE CONVERTER HOUSING
4. PLUG 8. FRONT COVER HOUSING
Figure 13. Torque Converter Housing Removal

NOTE: The information in Step 6, Step 7, and the

NOTE below applies only to early lift truck mod-
els except H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) mod-
els.
6. Remove the dipstick from the dipstick tube, and

disconnect the tube assembly from the transmis-
sion housing.
NOTE: The dipstick tube must be removed before the

torque converter housing can be removed from the
7. Remove the dipstick tube from the torque con-

verter housing.
8. Remove the plug, suction screen spring, and suc-

tion screen from the torque converter housing
and drain the oil from the transmission.
9. Remove the transmission charge pump from the

torque converter housing.
10. Remove the four mounting capscrews from the

front of the torque converter housing. Loosen A. EARLY LIFT TRUCK MODELS EXCEPT
the remaining 12 capscrews on the transmission H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
housing and using a small pry bar, remove the MODELS
torque converter housing from the front cover B. NEWER LIFT TRUCK MODELS
housing. See Figure 14. Discard the O-rings on
the front cover housing and the gasket. 1. PRY POINTS
3. FRONT COVER HOUSING
NOTE: While performing Step 11, note the position

of the oil seal to aid in the proper installation of new
oil seal.
11. Remove and discard the oil seal from the rear of
the torque converter housing. See Figure 15.

A. EARLY LIFT TRUCK MODELS EXCEPT (H80, 90, 100, 110, 120FT) (N005, P005)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT MODELS
1. SNUBBER 8. O-RING 16. BAFFLE
2. PUMP DRIVE CHAIN 9. DRIVING SPROCKET 17. PLUG
3. BEARING 10. CAPSCREW 18. REGULATOR COMPRESSION
4. DRIVEN SPROCKET 11. LOCKWASHER SPRING
5. OIL SEAL 12. STATOR SUPPORT 19. REGULATOR SPOOL
6. ANGULAR CONTACT 13. SEALING RING 20. FRONT COVER HOUSING
BEARING 14. FRONT COVER HOUSING MOUNTING CAPSCREWS
7. BUSHING 15. TRANSMISSION HOUSING
Figure 15. Chain Drive

12. Remove the two snubbers from the front cover 1. Clean the snubbers with warm, soapy water and
housing. Carefully pull the driving and driven dry with compressed air.
sprockets, chain, and bearings from the front
cover housing as an assembly. Remove and dis- 2. Clean bearings, chain, stator support, and gears
card the O-ring from the driving sprocket. with solvent and dry with compressed air
13. Remove the stator support from the front cover INSPECT
housing. Remove and discard the sealing ring
and O-ring from the stator support. 1. Inspect the snubbers for cracks or wear. If dam-
aged or worn, replace both snubbers.
14. Remove the plug, regulator compression spring,
and regulator spool from the front cover housing. 2. Inspect the chain, gears, and stator support for
damage. If damage is present, replace the dam-
15. Remove the baffle from the front cover housing. aged component. Inspect the driving and driven
gears for damage or wear to the gear teeth. If
16. The front cover housing is held in alignment with the gear teeth are worn or damaged, replace the
the transmission housing with dowel pins. Re- gear. Inspect the splines on the input shaft for
move three mounting capscrews from the front of damage, and if damaged, replace the input clutch
the front cover housing. Remove the remaining pack. See Clutch Packs Repair.
12 capscrews from the transmission housing. To
separate the front cover housing from the trans- INSTALL
mission housing, use a small pry bar to loosen
the front cover housing. See Figure 14. Remove 1. Install new O-rings and gasket on the trans-
the front cover housing from the transmission mission housing. The front cover housing is
housing. Discard the O-rings on the transmis- held in alignment with the transmission hous-
sion housing and the gasket. ing with dowel pins. Install the front cover
housing on the transmission housing. Install
CLEAN 12 capscrews through the transmission housing
and front cover housing. Install the three front
WARNING cover housing capscrews and tighten to 38 N•m
(28 lbf ft) See Figure 16.
and can cause skin irritation. When using 2. Install the baffle in the front cover housing. See
cleaning solvents, always follow the solvent Figure 16.
dures. 3. Install the regulator spool, regulator compres-
sion spring, and plug into the front cover hous-
Compressed air can move particles so they ing.
Make sure the path of the compressed air is 4. Install the new sealing ring and O-ring on the
away from all personnel. Wear protective gog- stator support. Install the stator support on the
gles or a face shield to prevent injury to the front cover housing. See Figure 16. Tighten the
eyes. capscrews to 38 N•m (28 lbf ft).

A. EARLY LIFT TRUCK MODELS EXCEPT (H80, 90, 100, 110, 120FT) (N005, P005)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT MODELS
1. SNUBBER 8. O-RING 16. BAFFLE
2. PUMP DRIVE CHAIN 9. DRIVING SPROCKET 17. PLUG
3. BEARING 10. CAPSCREW 18. REGULATOR COMPRESSION
4. DRIVEN SPROCKET 11. LOCKWASHER SPRING
5. OIL SEAL 12. STATOR SUPPORT 19. REGULATOR SPOOL
6. ANGULAR CONTACT 13. SEALING RING 20. FRONT COVER HOUSING
BEARING 14. FRONT COVER HOUSING MOUNTING CAPSCREWS
7. BUSHING 15. TRANSMISSION HOUSING

5. On a lint-free cloth, place the driving sprocket 6. Install the new oil seal into rear of the torque
on the right side and the driven sprocket on the converter housing as noted during removal.
left side, and place the chain around both sprock-
ets (see Figure 16). Install the bearings on the 7. Install the new O-rings and gasket on the front
sprockets. The angular bearing should be in- cover housing. Using the front four mounting
stalled onto the driving sprocket with the thinner capscrews, install the torque converter housing
shoulder of the outer race towards the sprocket to the front cover housing. Install 12 capscrews
and the wider shoulder of the outer race (side from the back of the transmission housing.
marked with part number) towards the torque See Figure 17. Tighten 16 capscrews on the
converter housing. Carefully place the driving transmission housing and front cover housing to
and driven sprockets, chain, and bearings assem- 38 N•m (28 lbf ft).
bly on the front cover. Install two snubbers on the
A. EARLY LIFT TRUCK MODELS EXCEPT B. NEWER LIFT TRUCK MODELS

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TORQUE CONVERTER 5. SUCTION SCREEN SPRING
2. CAPSCREW 6. SUCTION SCREEN
3. WASHER 7. TORQUE CONVERTER HOUSING
4. PLUG 8. FRONT COVER HOUSING
Figure 17. Torque Converter Housing Installation

8. Install the suction screen, suction screen spring, housing with the flywheel housing. Make sure
and plug into the torque converter housing. the pilot hub on the torque converter engages the
flywheel.
NOTE: The information in Step 9 and Step 10 applies
only to early lift truck models except H4.0FT5/FT6; 15. Install the transmission to the engine. Install
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, the capscrews that connect the torque converter
120FT) (N005, P005) models. housing to the flywheel housing. Tighten the
capscrews to 38 N•m (28 lbf ft). See Figure 18.
9. Clean the surface of the dipstick tube and dip-
stick hole in the torque converter housing. Apply
adhesive (Hyster P/N 264159) to the entire sur- CAUTION
face of the hole in the housing. Insert the dipstick Use care when connecting the wiring harness
tube until the collar bottoms on the housing and connectors to electrical connectors on the
orient the tab against the housing flange. transmission and control valve. The connec-
tors on the transmission and control valve are
10. Install the dipstick into the dipstick tube, and easily damaged.
connect the tube assembly to the transmission
housing. 16. Install the transmission wiring harness on the
transmission. Connect the connectors of the
11. Install the torque converter onto the input shaft transmission wiring harness to the control valve
and stator support of the transmission. Make and transmission. See Figure 18.
sure the splines are aligned and the converter
engages fully. 17. Rotate the engine crankshaft to position the
flywheel mounting holes in line with the torque
12. Lubricate the pilot hub on the torque converter converter mounting holes. Install the capscrews
with antiseize compound. See Figure 17. that hold the torque converter to the flywheel,
after coating the threads with Loctite™ 242,
13. Install the transmission charge pump on the
through the access hole of the flywheel housing.
torque converter housing. Tighten the cap-
See Figure 19. Tighten the capscrews to 56 N•m
screws to 19 N•m (168 lbf in).
(41 lbf ft). Remove the lifting eye bolt, and install
14. If removed, install a lifting eye bolt into the rear the access cover on the torque converter housing.
access cover bolt hole, and connect a lifting de-
vice to the eye bolt. Align the torque converter

A. EARLY LIFT TRUCK MODELS EXCEPT B. NEWER LIFT TRUCK MODELS

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
4. TRANSMISSION

18. Install the engine and transmission as a unit into 19. Fill the transmission to the correct level using
the lift truck. See the section Frame 100 SRM the correct transmission fluid and procedure
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, given in the section Periodic Maintenance
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) 8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; S55FTS) (F187); H2.0-3.5FT (H40-70FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, (L177) lift trucks, Periodic Maintenance
P005) lift trucks, and Frame 100 SRM 1120 for 8000 SRM 1207 for S30FT, S35FT, S40FTS
S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0- H35FT, H40FTS) (F001) lift trucks, and Pe-
3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT riodic Maintenance 8000 SRM 1248 for S4.0,
(H40-70FT) (L177) lift trucks. 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) and
(H80, 90, 100, 110, 120FT) (N005, P005) lift
trucks.


1300 SRM 1129 Clutch Packs Repair

Clutch Packs Repair

REMOVE AND DISASSEMBLE CAUTION
Transmission, Remove and Disassemble To prevent possible damage to the transmis-
sion assembly when placing the assembly on a
work surface, place blocks under the back side
WARNING of the transmission housing for additional sup-
Make sure the engine and transmission are port.
CAUTION
CAUTION ness connectors from electrical connectors on
Be careful that you do not damage parts of the transmission and control valve. The con-
the torque converter or transmission when nectors on the transmission and control valve
the transmission is separated from the engine. are easily damaged.
ment until they are completely separated so NOTE: When disconnecting wiring harness connec-
parts of the transmission are not damaged. tors during disassembly, tag each connector to aid in
Use a crane or lifting device to separate the connecting the wiring harness during reassembly.
2. Put the engine and transmission on solid blocks
1. Remove the engine and transmission as a unit on a work surface. Disconnect the two connectors
from the lift truck. See the section Frame 100 of the chassis wiring harness from the transmis-
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, sion wiring harness. Disconnect the connectors
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- of the transmission wiring harness from the con-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5, trol valve and transmission. Remove the trans-
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) mission wiring harness from the transmission.
(N005, P005) lift trucks, and Frame 100 SRM See Figure 20.
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
and H2.0-3.5FT (H40-70FT) (L177) lift trucks.

Clutch Packs Repair 1300 SRM 1129

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
4. TRANSMISSION

use your fingers to check for alignment of the

WARNING bolts with the access hole.
bly is stable before attempting to rotate the en- 3. Move each bolt into view through the access hole
gine. of the flywheel housing by rotating the crank-
shaft. Remove the four capscrews that attach the
Use a flashlight to see the bolts as they are ro- flywheel to the torque converter. See Figure 21.
tated into view through the access hole. Do not

A. GM 2.4L ENGINE C. YANMAR ENGINE E. ILLUSTRATES NEW DIPSTICK

B. MAZDA ENGINE D. GM 4.3L ENGINE AND BREATHER LOCATION

AND NEW FITTING DESIGN H4.5FT6; H5.0-5.5FT (H80, 90,

USED ON ENGINE AND 100, 110, 120FT) (N005, P005)
TRANSMISSIONS SHOWN IN LIFT TRUCK MODELS
ILLUSTRATIONS A THROUGH F. CUMMINS 4.5L DIESEL
D, EXCEPT WHEN D IS USED ENGINE
ON H4.0FT5/FT6; H4.5FTS5,
4. Remove the access cover from the torque con- 5. Remove the torque converter housing and the
verter housing. Install a lifting eye bolt into the front cover housing from the transmission hous-
rear access cover bolt hole, and connect a lifting ing. See Front Cover Housing and Chain Drive
device to the eye bolt. Remove the 10 capscrews Repair, Remove, Step 4 through Step 16.
that hold the torque converter housing to the fly-
wheel housing. Carefully separate the transmis- 6. On the two-speed transmission, remove the idler
sion from the engine. gear and two bearings. See Figure 22.

Figure 22. Output Gear Removal


A. 1-SPEED TRANSMISSION B. 2-SPEED TRANSMISSION
1. BEARING 9. YOKE
2. IDLER GEAR 10. WASHER
3. SNAP RING 11. LOCKWASHER
4. SPECIAL NUT 12. BOLT
5. OUTPUT GEAR 13. REVERSE GEAR
6. TRANSMISSION HOUSING 14. FORWARD CLUTCH PACK
7. OIL SEAL 15. 2 SPEED HIGH FORWARD
8. SPACER CLUTCH PACK
NOTE: The procedure for removal of the output gear 9. Remove the oil seal from the back of the trans-
is the same for both transmissions. mission.
7. Remove the bolt, three washers, and yoke from 10. Remove the bearings, snap ring, special nut, and
the back of the transmission. See Figure 22. output gear from the transmission.
8. Remove the spacer from the yoke. 11. Disassembly of the clutch assemblies follows.
The procedures are the same for removal and
NOTE: Note the position of the oil seal during re- disassembly of the clutch pack assemblies for
moval to aid in installation. both the 1- and 2-speed transmissions. See Fig-
ure 23, Figure 24, and Figure 25.

Figure 23. 1- and 2-Speed Forward Clutch Packs


A. 1-SPEED TRANSMISSION FORWARD CLUTCH B. 2-SPEED TRANSMISSION FORWARD CLUTCH
1. SEAL 9. CONICAL PLATE
2. BEARING 10. FRICTION DISK
3. GEAR ASSEMBLY DRUM 11. SEPARATOR PLATE
4. PISTON SEAL 12. PRESSURE PLATE
5. PISTON 13. SPACER
6. SPRING 14. OUTPUT GEAR
7. SPRING GUIDE 15. BACK PLATE
8. SNAP RING

Figure 24. 1- and 2-Speed Reverse Clutch Packs


A. 1-SPEED TRANSMISSION REVERSE CLUTCH B. 2-SPEED TRANSMISSION REVERSE CLUTCH
8. SNAP RING
1. SEAL 6. SPRING 11. SEPARATOR PLATE

2. BEARING 7. SPRING GUIDE 12. PRESSURE PLATE
3. GEAR ASSEMBLY DRUM 8. SNAP RING 13. BACK PLATE
4. PISTON SEAL 9. CONICAL PLATE 14. SPACER
5. PISTON 10. FRICTION DISK 15. OUTPUT GEAR
Figure 25. 2-Speed High Clutch Pack

Clutch Assemblies, Remove and Disassemble

NOTE: The 1-speed forward clutch assembly is shown in the illustrations for the disassembly procedures.
STEP 1.
Pull the forward clutch assembly straight from the
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TRANSMISSION INPUT SPEED SENSOR (TISS)
4. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
STEP 2.
Remove the shaft seal and bearing from the input
shaft. Discard the shaft seal.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 3.
Remove the snap ring from the output gear. Remove
the output gear from the input shaft
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
NOTE: Before removing the seal bearing, note the position of the seal on the bearing.
STEP 4.
Remove seal from the output gear. Remove seal bear-
ing, snap ring, spacer, snap ring, and bearing from
the output gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING
NOTE: On 2-speed transmissions, there will be a back plate in front of the pressure plate.

STEP 5.
Remove the snap ring and pressure plate from the

gear assembly drum.
1. SNAP RING
2. PRESSURE PLATE
3. GEAR ASSEMBLY DRUM
STEP 6.
Remove the friction disks and separator plates alter-
nately until all have been removed from the gear as-
sembly drum
1. FRICTION DISK
2. SEPARATOR PLATE
STEP 7.
Remove the conical plate from the gear assembly
drum.
1. CONICAL PLATE

WARNING
The springs for the piston are compressed. Make sure the springs and spring retainer cannot cause
injury when the snap ring is removed.
NOTE: Remove the piston only if there is a problem with the piston or piston seals.
STEP 8.
Using the spring compression tool Hyster P/N 867890
and a press, place the spring compression tool on
the spring guide with the opening of the tool above
the opening of the snap ring, and compress the large
and small springs just enough to allow removal of
the snap ring from the spring guide. Slowly release
the press to decompress the springs.
1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

STEP 9.
Remove the snap ring, spring guide, large spring, and
small spring from the input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove the piston from the gear assembly drum and
the piston seal from the piston. Discard the piston
seal.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL

STEP 11.
Remove the shaft seals and bearing from the input
shaft. Discard shaft seals.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
CLEAN 4. The conical plate and separator plates must not

be bent, have damaged surfaces, or have large
WARNING blue areas from too much heat. If any of the
above conditions exist, replace the damaged com-
ponent.
cleaning solvents, always follow the solvent 5. Check the "H" dimension of the conical plate as
manufacturer’s recommended safety proce- shown in Figure 26. If the dimension is less than
dures. 3.2 mm (0.126 in.), replace the conical plate.
Clean all metal parts with cleaning solvent and place 6. Check the "t" dimension of the conical plate as
on a lint-free cloth to dry. Ensure that the cleaning shown in Figure 26. If the dimension is less than
and assembly environment is free of dust, dirt, and 2.4 mm (0.094 in.), replace the conical plate.
any other foreign matter that would affect the per-
formance of the parts.
INSPECT
1. Inspect the gear teeth on clutch assemblies and
all other gears for wear or damage. If the gear
teeth are worn or damaged, replace the damaged
component.
2. Check all parts that have splines for damage

to the splines. Check for notches worn in the
splines. Replace the clutch pack or gears that Figure 26. Conical Plate Inspection
have spline damage.
7. Inspect the bearings for wear or damage. If the
3. Inspect the friction discs for burned lining or bent bearings are damaged, replace them.
surfaces. Check for small holes in the lining. Re-
place the friction discs if one-half the depth of the 8. Inspect the piston for damage. Make sure that
oil grooves is worn away or the discs are dam- the sealing surfaces are good. Make sure the ori-
aged. Discard a friction disc that has a thickness fice is clean.
less than 2.2 mm (0.087 in.).
9. Check for grooves or other damage on the ma-
chined surfaces of the clutch pack shafts and

transmission housing. Check the mounting and alignment is not correct, damage to the trans-
sealing surfaces in the housing for damage. If mission assembly could occur.
there is evidence of any damage, replace the
housing or transmission. If the clutch pack shaft 11. Inspect dowel pins and dowel pin holes. If any
is damaged, replace the clutch pack. dowel pin is damaged at all, replace the dowel
pin. If a dowel pin hole is damaged, replace the
10. Inspect all hardware and mounting surfaces for housing.
the presence of rust, sealing compounds, and us-
able condition. If the hardware is to be reused, 12. Check the fit of bearings in the transmission
clean all rust and sealing compounds from the housings. If the bearings fit too loosely into the
threaded areas. If the hardware is not in usable housings, this could mean that the bores are
condition, replace the hardware. oversized. Replace housings as necessary.

CAUTION
The dowel pins are used to properly align the
housings for proper mating to each other. If the
Clutch Assemblies, Assemble and Install

NOTE: The 1-speed forward clutch assembly is shown in the illustrations for the assembly procedures.
STEP 1.
Install the bearing and new shaft seals on the input
shaft.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
NOTE: Perform STEP 2 through STEP 5 only if the piston was removed.

STEP 2.
Lubricate all parts with clean transmission oil. In-
stall the shaft seal on the shaft and the piston seal
on the piston.
1. PISTON SEAL
2. PISTON
STEP 3.
Install the piston into the gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
STEP 4.
Install the small spring, large spring, spring guide,
and snap ring on the input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT

STEP 5.
Using the spring compression tool Hyster P/N 867890
and a press, place the spring compression tool on
the spring guide with the opening of the tool above
the opening of the snap ring, and compress the large
and small springs just enough to allow installation
of the snap ring in the spring guide. Slowly release
the press.

2. SPRING GUIDE
NOTE: The conical plate is properly installed when the inner diameter is touching the piston, and the outer
diameter of the conical plate is touching the outer diameter of the friction disk.

STEP 6.
Install the conical plate into the gear assembly drum.
1. CONICAL PLATE
STEP 7.
Install the separator plates and friction disks alter-
nately until all have been installed in the gear assem-
bly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
NOTE: On 2-speed transmissions, install the back plate in front of the pressure plate.

STEP 8.
Install the pressure plate and snap ring in the gear

assembly drum. Using a dial indicator or feeler
gauge, check the clearance between the snap ring
and pressure plate. There must be 1.8±0.2 mm
(0.071±0.008 in.) of clearance for a single speed
transmission, and 2.7±0.2 mm (0.106±0.008 in.)of
clearance for a 2 speed trnasmission. If the clearance
is not correct, see the Parts Manual for the correct
pressure plate.
1. SNAP RING
2. PRESSURE PLATE
NOTE: Make sure the seal on seal bearing is in correct position as noted during removal.
STEP 9.
Install seal onto output gear. Install the bearing,
snap ring, spacer, snap ring, and seal bearing into
output gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING

STEP 10.
Install the output gear on the input shaft. Install
bearing and snap ring in the output gear.
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
STEP 11.
Install the bearing and shaft seal on the input shaft.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 12.
Install the reverse clutch assembly in the transmis-
sion housing. Do not damage the seal rings on the
end of the clutch shaft.
Check the gap between the TOSS and TISS sensors

and reverse gear. The allowable gap for the TOSS
sensor is 0.8 to 1.8 mm (0.031 to 0.071 in.). The al-
lowable gap for the TISS sensor is 0.8 to 2.0 mm
(0.031 to 0.080 in.).
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR
STEP 13.
Install the forward clutch assembly in the transmis-
sion housing. Do not damage the seal rings on the
end of the clutch shaft.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR

Transmission, Assemble and Install 1. Install the bearing, output gear, special nut, snap
ring, and bearing on the transmission. See Fig-
NOTE: The procedure for installation of the output ure 27.
gear is the same for both transmissions.

Figure 27. Output Gear Installation


A. 1 SPEED TRANSMISSION B. 2 SPEED TRANSMISSION
1. BEARING 7. OIL SEAL
2. IDLER GEAR 8. SPACER
3. SNAP RING 9. YOKE
4. SPECIAL NUT 10. WASHER
5. OUTPUT GEAR 11. LOCKWASHER
6. TRANSMISSION HOUSING 12. CAPSCREW
2. Install the oil seal into the back of the transmis-

sion as noted during removal.
CAUTION
3. Install the spacer in the yoke. connectors to electrical connectors on the
transmission and control valve. The connec-
4. Install the yoke, three washers, and bolt in the tors on the transmission and control valve are
back of the transmission. Tighten the bolt to easily damaged.
38 N•m (28 lbf ft). See Figure 27.
7. Install the transmission wiring harness on the
5. On the 2-speed transmission, install the two transmission. Connect the connectors of the
bearings and idler gear. See Figure 27. transmission wiring harness to the control valve
and transmission. Connect the two connectors of
6. Install the front cover housing and the torque
the chassis wiring harness to the transmission
converter housing on the transmission. See
wiring harness. See Figure 28.
Front Cover Housing and Chain Drive Repair,
Install, Step 1 through Step 15.

A. EARLY LIFT TRUCK MODELS EXCEPT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) MODELS
4. TRANSMISSION

8. Rotate the engine crankshaft to position the 3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT
flywheel mounting holes in line with the torque (H40-70FT) (L177) lift trucks.
converter mounting holes. Install the capscrews
that hold the torque converter to the flywheel 10. Fill the transmission to the correct level us-
through the access hole of the flywheel housing. ing the correct transmission fluid and proce-
See Figure 29. Tighten the capscrews to 56 N•m dure given in section Periodic Maintenance
(41 lbf ft). Remove the lifting eye bolt, and install 8000 SRM 1150 for S2.0-3.5FT (S40-70FT,
the access cover on the torque converter housing. S55FTS) (F187); H2.0-3.5FT (H40-70FT)
(L177) lift trucks, Periodic Maintenance
9. Install the engine and transmission as a unit into 8000 SRM 1207 for S30FT, S35FT, S40FTS
the lift truck. See the section Frame 100 SRM (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, H35FT, H40FTS) (F001) lift trucks, and Pe-
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) riodic Maintenance 8000 SRM 1248 for S4.0,
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, 100FTBCS; S120FTS; S120FTPRS) (G004) and
P005) lift trucks, and Frame 100 SRM 1120 for H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, (H80, 90, 100, 110, 120FT) (N005, P005) lift
2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0- trucks.


1300 SRM 1129 Control Valve Repair

Control Valve Repair

REMOVE AND DISASSEMBLE
CAUTION
nesses from the connectors. The connectors
are easily damaged.
1. Clean the area around the control valve. Put

identification tags on the wire harness connec-
tors and the connectors on the transmission and
control valve. Disconnect the wiring harness con-
nectors from transmission and control valve con-
nectors, and remove the cable connector from the
standoff located on the torque converter housing.
See Figure 30.
2. Remove the capscrews that attach the control

valve to the transmission. Remove the control
valve assembly and discard the gasket. Put a
cover on top of the transmission to keep dirt out H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
of the transmission. See Figure 31. (H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
2. HARNESS STANDOFF
3. TRANSMISSION WIRING HARNESS
Figure 30. Transmission Assembly

Control Valve Repair 1300 SRM 1129
3. Remove two capscrews and the transmission

input speed sensor (TISS). Remove two cap-
screws and the transmission output speed sensor
(TOSS) from the transmission.
NOTE: Disassemble the control valve only to the ex-

tent to complete any repairs that are required.
NOTE: Disassemble the control valve in a clean, con-

tamination-free area.
4. Remove two pressure transducers, two fittings,

capscrew, lockwasher, and clip from the control
valve body. See Figure 32.

(H80, 90, 100, 110, 120FT) (N005, P005)
MODELS
1. TRANSMISSION ASSEMBLY
2. GASKET
3. CONTROL VALVE ASSEMBLY
4. LOCKWASHER
5. CAPSCREW
(TOSS)
Figure 31. Control Valve Removal

1. CONTROL VALVE BODY 9. PLUG
2. PRESSURE TRANSDUCER 10. FORWARD PROPORTIONAL VALVE
3. FITTING 11. SOCKET HEAD CAPSCREW
4. CLIP 12. TORQUE CONVERTER REGULATOR SPOOL
5. LOCKWASHER 13. REVERSE PROPORTIONAL VALVE
6. CAPSCREW 14. TRANSMISSION ENABLE VALVE
7. PROPORTIONAL SUPPLY REGULATOR SPOOL 15. SUPPLY SPOOL
8. SPRING

Figure 32. Control Valve Arrangement

INSPECT
WARNING
There are compressed springs under the plugs 1. Make sure there are no scratches or damage on
in the control valve. Carefully remove the the spools or in the bores of the control valve
plugs so that the compressed springs do not body. If the control valve body bores are dam-
cause injury. aged, replace the control valve.
5. Remove the plug for the proportional supply reg- 2. Inspect the control valve body for the presence of
ulator spool. Discard the O-ring. Remove the burrs. Burrs may be removed using a fine file,
spring and proportional supply regulator spool emery cloth, or crocus cloth.
from the control valve body.
3. Check that the springs are not bent or damaged.
6. Remove the plug for the torque converter reg- Make sure the spools move freely in their bores.
ulator spool. Discard the O-ring. Remove the
spring and torque converter regulator spool from 4. Inspect the connectors on the proportional and
the control valve body. solenoid valves and, if they are damaged, replace
the damaged proportional or solenoid valves.
7. Remove the plug for the supply spool. Discard
the O-ring. Remove the spring and supply spool ASSEMBLE AND INSTALL
from the control valve body.
NOTE: Lubricate the parts of the control valve with
8. Remove the socket head screws and forward pro- clean transmission oil during assembly.
portional valve from the control valve body. Re-
peat for the reverse proportional valve. 1. Install the transmission enable valve and socket
head screws into the control valve body. Tighten
9. Remove the socket head screws and transmission socket head screws to 3 to 4 N•m (27 to 35 lbf in).
enable valve from the control valve body. See Figure 32.
CLEAN 2. Install the reverse proportional valve, forward

proportional valve, and socket head capscrews
into the control valve body. Tighten socket head
WARNING screws to 3 to 4 N•m (27 to 35 lbf in).
and can cause skin irritation. When using 3. Install the supply spool and spring into the
cleaning solvents, always follow the solvent control valve body. Install the plug with a new
manufacturer’s recommended safety proce- O-ring.
dures.
4. Install the torque converter regulator spool and
Compressed air can move particles so they spring into the control valve body. Install the
cause injury to the user or to other personnel. plug and new O-ring.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog- 5. Install the proportional supply regulator spool
gles or a face shield to prevent injury to the and spring into the control valve body. Install
eyes. the plug and new O-ring.
6. Install the clip, lockwasher, capscrew, two fit-

CAUTION tings, and two pressure transducers into the con-
Do not allow cleaning solvent to come in control valve body.
tact with rubber or plastic components as it
7. Install the transmission input speed sensor (tiss)
can damage those components.
and two capscrews in the transmission. Install
Clean all metal components in solvent and dry with the transmission output speed sensor (toss) and
compressed air. two capscrews in the transmission. Tighten all
capscrews to 6.9 N•m (61 lbf in).

8. Install a new control valve gasket on the trans-

mission. Install the control valve on the trans- CAUTION
mission. See Figure 31. Install the capscrews Use care when connecting the wiring har-
that hold the control valve on the transmission. nesses to the connectors. The connectors are
Do not tighten at this time. easily damaged.
9. Tighten capscrews to 13.3 N•m (118 lbf in) in 10. Install the cable connector in the standoff and
the sequence shown in Figure 33. Retighten cap- connect the wiring harness connectors to the
screws to 19 N•m (168 lbf in) in the sequence transmission and control valve as tagged during
shown in Figure 33. removal. See Figure 30.
Figure 33. Control Valve Mounting Screw

Tightening Sequence

MONOTROL® Pedal Repair 1300 SRM 1129
MONOTROL® Pedal Repair

REMOVE AND DISASSEMBLE
1. Remove five screws, dash panel, and kick plate
from the lift truck. See the section Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) lift trucks, and Frame 100 SRM
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177) lift trucks. Re-
move three capscrews and swing the hydraulic
lever assembly toward the operator’s seat. Dis-
connect two cable assemblies from the pedal
assembly. See Figure 34.
1. CAPSCREWS
2. PEDAL ASSEMBLY
3. COWL
Figure 35. MONOTROL Pedal Removal
3. Remove two pan head screws, lockwashers, and

accelerator position sensor from throttle base.
See Figure 36.
CAUTION
Use care when removing the connector from its
holder as the connector can be easily damaged.
NOTE: Remove only those components necessary to

complete the repair of the MONOTROL pedal.
4. Remove the connector from the connector holder

on the throttle base. Remove the outer and inner
1. CAPSCREW springs from the throttle base and MONOTROL
2. HYDRAULIC LEVER ASSEMBLY pedal assembly.
Figure 34. Hydraulic Lever Relocation 5. Remove the e-clip and throttle base from the
throttle pedal shaft. Remove the roll pin and the
2. Remove three capscrews that hold the throttle
throttle pedal shaft from the MONOTROL pedal
base to the cowl, and remove the pedal assembly
assembly. Discard the roll pin.
from the lift truck. See Figure 35.

1300 SRM 1129 MONOTROL® Pedal Repair
1. PAN HEAD SCREW 6. THROTTLE PEDAL SHAFT

2. LOCKWASHER 7. E-CLIP
3. ACCELERATOR POSITION SENSOR (APS) 8. ROLL PIN
4. PEDAL FRAME 9. INNER AND OUTER SPRINGS
5. CONNECTOR 10. MONOTROL
Figure 36. MONOTROL Pedal Bracket Disassembly
NOTE: Tag wires prior to removing from mi- 7. Remove two hex head screws, lockwashers, nuts,
croswitches to aid in connecting. and microswitch from the pedal pad. Repeat for
remaining microswitch and remove the wiring
6. Remove u-clip, foam lock seal, and wiring har- harness from the pedal frame.
ness from the pedal frame. Remove four pan
head screws, lockwashers, washers, pedal pad, 8. If damaged, remove the stop screw and nut from
and springs from the pedal frame. If any metal the pedal frame.
inserts in the pedal pad are damaged, replace as
necessary. See Figure 37.

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 37. MONOTROL Pedal Disassembly

ASSEMBLE AND INSTALL 4. Install the wiring harness in the pedal frame. In-
stall the foam lock seal and u-clip. Install pedal
1. If removed, install the stop screw and nut on the pad and springs in the pedal frame. Coat the
pedal frame. See Figure 37. threads of four pan head screws with Loctite 222.
Install pan head screws, lockwashers, and wash-
2. Install the microswitch and two hex head screws
ers in the pedal pad. Tighten pan head screws to
in the pedal pad. Coat the exposed threads of
2.25 to 2.50 N•m (19 to 32 lbf in).
the hex head screws with Loctite™ 222. Install
the two lockwashers and nuts on the hex head 5. Using an ohmmeter, check for continuity be-
screws. Do not tighten the nuts at this time. Re- tween pins 3 and 4 of the MONOTROL wiring
peat for the other microswitch. harness connector with the MONOTROL pedal
in the reverse position, and between pins 1 and
3. Put the wires through the hole in the pedal
2 with the pedal in the forward position. See
frame. The white banded wire is for the reverse
Figure 39.
microswitch, and the blue banded wire is for the
forward microswitch. Adjust each microswitch
in its mount so that the measurement between
the edge of the mount and the base of the mi-
croswitch equals 0.0 to 0.5 mm (0.0 to 0.02 in.).
Tighten the mounting nuts of each microswitch
as adjustment is completed. See Figure 38.
1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
Figure 39. Microswitch Continuity Check
6. Install the throttle pedal shaft and new roll pin

in the MONOTROL pedal assembly. Install the
throttle base and e-clip on the throttle pedal
shaft. See Figure 36.
CAUTION
Use care when installing the connector in its
7. Install the inner and outer springs on the throt-

tle base and MONOTROL pedal assembly. In-
stall the connector in the connector holder on the
throttle base.
1. MICROSWITCH MOUNT 8. Install the actuator and magnet in the throttle
2. MICROSWITCH BASE base. Install the accelerator position sensor,
lockwashers, and two pan head screws in the
Figure 38. Microswitch Adjustment
throttle base. Tighten screws to 2.25 N•m
(19 lbf in).

Direction Control Lever 1300 SRM 1129
9. Apply adhesive compound to the three mounting 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
bolts. Using the three capscrews that hold the (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
throttle base to the cowl, install the pedal assem- H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
bly on the lift truck. Tighten the bolts to 19 to P005) lift trucks, and Frame 100 SRM 1120
25 N•m (168 to 221 lbf in). See Figure 35. for S30FT, S35FT, S40FTS (E010); H1.6FT,
10. Connect two cable assemblies to the pedal as- (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
sembly. Swing the hydraulic lever assembly H2.0-3.5FT (H40-70FT) (L177) lift trucks.
toward the cowl and install three capscrews.
See Figure 34. Install the dashboard on the 11. Depress the MONOTROL pedal until it stops.
lift truck. See the section Frame 100 SRM Unscrew stop screw until it contacts the metal
1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, floor plate. Tighten the nut to 10 N•m (89 lbf in).
Direction Control Lever

REMOVE the interior lock of the display panel. See B, Fig-
ure 40.
NOTE: There is no repair of the direction control
lever. 3. Repeat the above steps on the opposite side of
the direction control lever. Remove the direction
1. Insert a small, flat-blade screwdriver with a control lever from the display panel.
3.175 mm (0.125 in.) or less, wide blade into
the opening on the display panel on an outward INSTALL
angle enough to compress the spring tab on the
direction control lever. See A, Figure 40. Slide the direction control lever into the opening on
the left side of the display panel until the locking tabs
2. Pry the spring tab toward the body of the direc- are engaged in the display panel.
tion control lever and, at the same time, pull on
the handle of the lever enough to free the tab of

1300 SRM 1129 Direction Control Lever
NOTE: DISPLAY PANEL SHOWN OUTSIDE OF THE LIFT TRUCK FOR CLARITY.
A. STEP 1 B. STEP 2
1. DIRECTION CONTROL LEVER 3. DISPLAY PANEL
2. FLAT-BLADE SCREWDRIVER
Figure 40. Direction Control Lever Removal

NOTES
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____________________________________________________________
70

SINGLE SPEED
POWERSHIFT
ALUMINUM TRANSMISSION
S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT) [F187]; S50CT [A267];
H2.0-3.5FT (H40-70FT) [L177]; H50CT [A274]
PART NO. 4010440 1300 SRM 1421

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Single Speed PowerShift Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number ........................................................................................................................................... 1
Hydraulic Gear Pump........................................................................................................................................ 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 2
Remove ........................................................................................................................................................... 3
Disassemble ................................................................................................................................................... 4
Clean .............................................................................................................................................................. 4
Inspect ............................................................................................................................................................ 4
Assemble ........................................................................................................................................................ 4
Install ............................................................................................................................................................. 4
Torque Converter Replacement......................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 6
Stator Support Assembly Repair ...................................................................................................................... 6
Remove ........................................................................................................................................................... 6
Disassemble ................................................................................................................................................... 12
Clean .............................................................................................................................................................. 12
Inspect ............................................................................................................................................................ 13
Assemble ........................................................................................................................................................ 14
Install ............................................................................................................................................................. 14
Clutch Packs Repair........................................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Engine, Torque Converter, and Transmission Assembly ........................................................................ 15
Transmission Components........................................................................................................................ 16
Disassemble ................................................................................................................................................... 18
Transmission ............................................................................................................................................. 18
Housings ................................................................................................................................................ 18
Forward Clutch Pack ............................................................................................................................ 21
Reverse Clutch Pack ............................................................................................................................. 26
Clean .............................................................................................................................................................. 32
Inspect ............................................................................................................................................................ 32
Assemble ........................................................................................................................................................ 33
Transmission ............................................................................................................................................. 33
Housings ................................................................................................................................................ 47
Install ............................................................................................................................................................. 48
Transmission Components........................................................................................................................ 48
Engine, Torque Converter, and Transmission Assembly ........................................................................ 51
Inching Overlap Adjustment......................................................................................................................... 51
Proportional and Enable Solenoid Valves......................................................................................................... 52
Proportional Valves ....................................................................................................................................... 52
Remove....................................................................................................................................................... 52
Disassemble ............................................................................................................................................... 53
Assemble .................................................................................................................................................... 53
Install ......................................................................................................................................................... 53
Enable Solenoid Valve ................................................................................................................................... 53

Table of Contents Single Speed PowerShift

Remove....................................................................................................................................................... 53
Disassemble ............................................................................................................................................... 53
Assemble .................................................................................................................................................... 54
Install ......................................................................................................................................................... 54
MONOTROL® Pedal Repair ............................................................................................................................. 54
Remove and Disassembly.............................................................................................................................. 54
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT) [F187];
S50CT [A267];
H2.0-3.5FT (H40-70FT) [L177];
H50CT [A274]
ii
General
This section has repair procedures for the sin-
gle-speed powershift aluminum transmission.
Serial Number
The transmission serial number is located on the top
of the transmission housing. See Figure 1.
2. SERIAL NUMBER LOCATION
Figure 1. Serial Number
1
Hydraulic Gear Pump 1300 SRM 1421
Hydraulic Gear Pump

REMOVE INSTALL
NOTE: Remove liquid-proof covering from charge
CAUTION pump prior to operating lift truck.
Prior to removing hydraulic gear pump, cover
charge pump with liquid-proof covering to pre- 1. Apply 3 to 5 mm (0.12 to 0.20 in.) bead of sealant
vent damage. to either hydraulic gear pump or transmission
housing face at insertion point of flange head
1. Put a drain pan under hydraulic gear pump. Re- capscrews. Install hydraulic gear pump and two
move all hydraulic lines connected to pump. Re- flange head capscrews onto transmission hous-
move two flange head capscrews and hydraulic ing. See Figure 2. Tighten capscrews to 38 N•m
gear pump from transmission housing. See Fig- (28 lbf ft).
ure 2.
1. TRANSMISSION HOUSING 3. HYDRAULIC GEAR PUMP

Figure 2. Hydraulic Gear Pump
2
1300 SRM 1421 Charge Pump Repair
Charge Pump Repair

REMOVE See section Frame 100 SRM 1120 for lift truck
models listed below:
Make sure engine and transmission are held in
H40FTS) (F001)
position so that they will not fall and cause an
• S2.0-3.5FT (S40-70FT) (F187))
injury and damage to equipment.
• H2.0-3.5FT (H40-70FT) (L177)
The engine and transmission are heavy. Make models listed below:
sure that any lifting device has enough capac- • S50CT (A267)
ity to lift the engine and transmission. • H50CT (A274)
The engine can weigh approximately 162 kg 4. Remove capscrews, washers, charge pump, and
(357 lb). charge pump gasket from transmission housing.
See Figure 3. Discard charge pump gasket.
The transmission can weigh approximately
85 kg (187 lb). 5. Remove suction screen spring and suction screen
from transmission housing. See Figure 3.
NOTE: Charge pump can be removed from transmis-
sion while it is still in lift truck however, for the sake
of clarity, illustrations in following steps are shown
with transmission removed from lift truck.
NOTE: Perform Step 1 through Step 3 if engine and

transmission are removed from lift truck. Perform
ONLY Step 4 and Step 5 if transmission remains in
lift truck.
1. Using a lifting device, remove engine from lift

truck.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187))
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H50CT (A274)
1. TRANSMISSION 5. CHARGE PUMP
2. Remove torque converter from torque converter HOUSING GASKET
housing. See Torque Converter Replacement in 2. CAPSCREW 6. SUCTION SCREEN
this manual for procedure. 3. WASHER 7. SUCTION SCREEN
4. CHARGE PUMP SPRING
3. Using a lifting device, remove transmission from
lift truck. Figure 3. Charge Pump
3
DISASSEMBLE INSPECT
1. Remove capscrews, charge pump cover, and 1. Inspect splines on shaft of charge pump for dam-
O-ring from charge pump body. Discard O-ring. age or worn areas that could affect operation of
See Figure 4. pump. Replace charge pump if damaged.
2. Inspect capscrews for damaged threads. Replace

capscrews if damaged.
ASSEMBLE
1. Install new O-ring, charge pump cover, and cap-
screws onto charge pump body. See Figure 4.
INSTALL
1. Install suction screen and suction screen spring
into transmission housing. See Figure 3.
2. Using seven washers and seven capscrews, in-

stall charge pump gasket and charge pump onto
transmission housing. See Figure 3. Tighten
WARNING
1. CHARGE PUMP BODY Make sure engine and transmission are held in
2. O-RING position so that they will not fall and cause an
3. CHARGE PUMP COVER injury and damage to equipment.
4. SOCKET HEAD SCREW
Figure 4. Charge Pump Assembly WARNING

The engine and transmission are heavy. Make
CLEAN sure that any lifting device has enough capac-
ity to lift the engine and transmission.
WARNING
Cleaning solvents can be flammable and toxic The engine can weigh approximately 162 kg
and can cause skin irritation. When using (357 lb).
cleaning solvents, always follow the manufac- The transmission can weigh approximately
turer’s recommended safety procedures. 85 kg (187 lb).
Compressed air can move particles so they
cause injury to the user or to other personnel. CAUTION
Make sure the path of the compressed air is Be careful that you DO NOT damage parts of
away from all personnel. Wear protective gog- the torque converter or transmission when
gles or a face shield to prevent injury to the transmission is installed.
eyes.
1. Clean metal components with solvent and dry transmission were removed from lift truck.
with compressed air.
3. Using a lifting device, carefully install trans-
2. Clean rubber or plastic components with warm mission on lift truck frame. Place blocks under
soapy water and dry with a lint-free cloth. transmission for stability.
4
1300 SRM 1421 Torque Converter Replacement
See section Frame 100 SRM 1120 for lift truck • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
models listed below: H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010) • S2.0-3.5FT (S40-70FT) (F187)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187) See section Frame 100 SRM 1423 for lift truck
• H2.0-3.5FT (H40-70FT) (L177) models listed below:
• S50CT (A267)
See section Frame 100 SRM 1423 for lift truck • H50CT (A274)
• S50CT (A267) 6. Remove lifting device from eyebolt bracket.
• H50CT (A274)
CAUTION
4. Install torque converter in torque converter
housing. See Torque Converter Replacement in Disposal of lubricants and fluids must meet lo-
this manual for procedures. cal environmental regulations.
5. Using a lifting device, carefully install engine in 7. Dispose of drip pan contents.
lift truck.

• S30FT, S35FT, S40FTS (E010)
Torque Converter Replacement

REMOVE See section Frame 100 SRM 1120 for lift truck
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187))
• H2.0-3.5FT (H40-70FT) (L177)
The engine and transmission are heavy. Make models listed below:
sure that any lifting device has enough capac- • S50CT (A267)
ity to lift the engine and transmission. • H50CT (A274)
The engine can weigh approximately 162 kg NOTE: The torque converter cannot be repaired and
(357 lb). must be replaced as a unit, if damaged.
The transmission can weigh approximately 2. Carefully remove torque converter from stator
85 kg (187 lb). support. See Figure 5.
1. Using a lifting device, remove engine from lift 3. Remove and discard torque converter seal from
truck. Place blocks under transmission for sta- stator support. See Figure 5.
bility.
5
Stator Support Assembly Repair 1300 SRM 1421
2. Carefully install torque converter onto stator

support. See Figure 5.
WARNING
WARNING
sure that any lifting device has enough capac-

(357 lb).
NOTE: LIFT TRUCK FRAME NOT SHOWN FOR The transmission can weigh approximately
CLARITY. 85 kg (187 lb).
1. TORQUE CONVERTER 3. Using a lifting device, carefully install engine in

2. STATOR SUPPORT lift truck. Remove blocks under transmission.
3. TORQUE CONVERTER SEAL
Figure 5. Torque Converter models listed below:
• S30FT, S35FT, S40FTS (E010)
CLEAN AND INSPECT • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
1. Clean all components with a lint-free cloth. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187)
2. Inspect torque converter, replace as needed. • H2.0-3.5FT (H40-70FT) (L177)
INSTALL See section Frame 100 SRM 1423 for lift truck
1. Install new torque converter seal onto stator sup- • S50CT (A267)
port. See Figure 5. • H50CT (A274)
Stator Support Assembly Repair

REMOVE The transmission can weigh approximately
85 kg (187 lb).
WARNING 1. Using a lifting device, remove engine from lift
Make sure engine and transmission are held in truck.
injury and damage to equipment. See section Frame 100 SRM 1120 for lift truck
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187))
• H2.0-3.5FT (H40-70FT) (L177)
(357 lb).
6
1300 SRM 1421 Stator Support Assembly Repair
See section Frame 100 SRM 1423 for lift truck clutch assembly straight out of torque converter
models listed below: housing. See Figure 9.
• S50CT (A267)
• H50CT (A274) 10. Pull forward clutch assembly straight out of sta-
tor support. See Figure 10.
2. Remove torque converter from torque converter
housing. See Torque Converter Replacement in 11. Remove output gear from torque converter hous-
this manual for procedure. ing. See Figure 11.
3. Using a lifting device, remove transmission from 12. Remove snap ring, special nut, spacer, and two
lift truck. bearings from output gear. See Figure 11.
See section Frame 100 SRM 1120 for lift truck 13. Remove output gear cover from pins in torque
models listed below: converter housing. See Figure 11.
• S30FT, S35FT, S40FTS (E010)
14. Remove hex head capscrews, lockwashers, stator
support, and pto drive gear from torque con-
H40FTS) (F001)
verter housing. Remove and discard O-rings
• S2.0-3.5FT (S40-70FT) (F187))
from torque converter housing. See Figure 12.
• H2.0-3.5FT (H40-70FT) (L177)
15. Remove sealing ring, bearing, and angular con-
tact bearing from pto drive gear. Discard sealing
ring. See Figure 12.
• S50CT (A267)
• H50CT (A274)
4. Remove flange head capscrew and yoke from

back of transmission housing. Remove and dis-
card stato seal from yoke. See Figure 6.
NOTE: Note position of oil seal prior to removal to aid

in installation.

Figure 6.
6. Remove 26 flange bolts from transmission hous-

ing and torque converter housing. See Figure 8.
7. Using a small pry bar in the designated pry

points remove torque converter housing from
transmission housing. See Figure 7. 1. TRANSMISSION 4. STATO SEAL
HOUSING 5. FLANGE HEAD
8. Remove and discard gasket and O-rings from 2. OIL SEAL CAPSCREW
transmission housing. See Figure 8. 3. YOKE
9. Torque converter housing to be face down on a Figure 6. Drive Shaft Yoke

bench or work surface as shown. Pull reverse
7
A. LEFT SIDE AS VIEWED FROM DRIVERS SEAT B. RIGHT SIDE AS VIEWED FROM DRIVERS SEAT
1. TORQUE CONVERTER HOUSING 3. PRY POINT
Figure 7. Pry Points
8
1. TRANSMISSION HOUSING 4. GASKET

2. TORQUE CONVERTER HOUSING 5. O-RING
3. FLANGE BOLT
Figure 8. Transmission and Torque Converter Housings
9
1. REVERSE CLUTCH ASSEMBLY

Figure 9. Reverse Clutch
1. FORWARD CLUTCH ASSEMBLY

2. STATOR SUPPORT
Figure 10. Forward Clutch
10
1. TORQUE CONVERTER HOUSING 5. SPECIAL NUT

2. PIN 6. SPACER
3. OUTPUT GEAR COVER 7. BEARING
4. SNAP RING 8. OUTPUT GEAR
Figure 11. Output Gear
11
1. TORQUE CONVERTER HOUSING 6. STATOR SUPPORT

2. ANGULAR CONTACT BEARING 7. LOCKWASHER
3. PTO DRIVE GEAR 8. HEX HEAD CAPSCREW
4. BEARING 9. O-RING
5. SEALING RING
Figure 12. Stator Support and PTO Drive Gear
DISASSEMBLE cleaning solvents, always follow the solvent

1. Remove fitting with O-ring, pack regulator dures.
spring, and pack regulator spool from stator
support housing. Remove and discard O-ring Compressed air can move particles so they
from fitting. See Figure 13. cause injury to the user or to other personnel.
2. Remove fitting with O-ring, converter relief away from all personnel. Wear protective gog-
spring, and ball converter relief from stator gles or a face shield to prevent injury to the
support assembly housing. Remove and discard eyes.
O-ring from fitting. See Figure 13.
3. Remove bushing from stator support housing. CAUTION

See Figure 13. DO NOT allow cleaning solvent to come in con-
CLEAN can damage those components.
WARNING 1. Clean all metal components in solvent and dry

12
INSPECT
1. Make sure there are no scratches or damage on
the pack regulator spool. Make sure spool moves
freely in bore. Replace spool if damaged.
2. Make sure there are no scratches or damage to

ball converter relief assembly. Replace ball con-
verter relief assembly if damaged.
3. Make sure there are no scratches or damage in

the bores of the stator support housing. If bores
are damaged, replace stator support assembly.
4. Inspect bushing for damage. Replace if damaged.

Replace if damaged.
6. Measure pack regulator spring. Replace if speci-

fication shown below is not met.
7. Measure converter relief spring. Replace if spec-

ification shown below is not met.
1. FITTING WITH O-RING

2. PACK REGULATOR SPRING
3. PACK REGULATOR SPOOL
4. HYDRAULIC PLUG
5. BUSHING
6. BALL CONVERTER RELIEF Figure 14. Pack Regulator Spring - Free-Length
7. CONVERTER RELIEF SPRING
8. STATOR SUPPORT HOUSING Measurement
Figure 13. Stator Support Assembly
2. Clean rubber or plastic components with warm

soapy water and dry with a lint-free cloth.
13
7. Install forward clutch assembly straight into sta-

tor support. See Figure 10.
8. Install reverse clutch assembly straight into

torque converter housing. See Figure 9.
9. Install new O-rings and gasket onto transmis-

sion housing. See Figure 8.
10. Check pins for correct installation into torque

converter housing before installing onto trans-
mission housing. See Figure 16.
11. Using 26 flange bolts, install torque converter

housing onto transmission housing. See Fig-
ure 8. Tighten flange bolts to 38 N•m (28 lbf ft).
12. Install oil seal into back of transmission housing

as noted during removal. See Figure 6.
Figure 15. Converter Relief Spring -
Free-Length Measurement 13. Install new stato seal into yoke. Install yoke and
flange head capscrew onto back of transmission
ASSEMBLE housing. See Figure 6.
1. If necessary, install new bushing into stator sup-

port housing. See Figure 13.
2. Install new O-ring onto fitting. Install ball con-

verter relief, converter relief spring, and fitting
with O-ring into stator support housing. See Fig-
ure 13.
3. Install new O-ring onto fitting. Install pack reg-

ulator spool, pack regulator spring, and fitting
with O-ring into stator support housing. See Fig-
ure 13.
INSTALL
1. Install angular contact bearing, bearing, and
new sealing ring onto pto drive gear. See Fig-
ure 12.
2. Install new O-rings, pto drive gear, stator sup-

port, lockwashers, and hex head capscrews onto
NOTE: GEARS AND CLUTCH PACKS NOT SHOWN
3. Install output gear cover onto pins in torque con- FOR CLARITY.
verter housing. See Figure 11.
4. Install bearing, spacer, special nut, and snap ring 2. TRANSMISSION HOUSING
3. PIN
onto output gear. See Figure 11.
Figure 16. Alignment Pin Installation
5. Install gearing onto output gear. See Figure 11.
6. Install output gear onto torque converter hous-

ing. See Figure 11.
14
• S2.0-3.5FT (S40-70FT) (F187)

WARNING • H2.0-3.5FT (H40-70FT) (L177)
position so that they will not fall and cause an See section Frame 100 SRM 1423 for lift truck
injury and damage to equipment. models listed below:
• S50CT (A267)
• H50CT (A274)
WARNING
The engine and transmission are heavy. Make 15. Install torque converter in torque converter
sure that any lifting device has enough capac- housing. See Torque Converter Replacement in
ity to lift the engine and transmission. this manual for procedure.
The engine can weigh approximately 162 kg 16. Using a lifting device, carefully install engine in
(357 lb). lift truck.
The transmission can weigh approximately See section Frame 100 SRM 1120 for lift truck
85 kg (187 lb). models listed below:
• S30FT, S35FT, S40FTS (E010)
CAUTION
H40FTS) (F001)
Be careful that you DO NOT damage parts of • S2.0-3.5FT (S40-70FT) (F187)
the torque converter or transmission when • H2.0-3.5FT (H40-70FT) (L177)
transmission is installed.
14. Using a lifting device, carefully install trans- models listed below:
mission on lift truck frame. Place blocks under • S50CT (A267)
transmission for stability. • H50CT (A274)
See section Frame 100 SRM 1120 for lift truck 17. Remove lifting device from eyebolt bracket.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
Clutch Packs Repair

REMOVE The transmission can weigh approximately
85 kg (187 lb).
Engine, Torque Converter, and
Transmission Assembly 1. Using a lifting device, remove engine from lift
truck. Place blocks under transmission for sta-
bility.
WARNING
Make sure engine and transmission are held in See section Frame 100 SRM 1120 for lift truck
position so that they will not fall and cause an models listed below:
injury and damage to equipment. • S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
WARNING • S2.0-3.5FT (S40-70FT) (F187))
The engine and transmission are heavy. Make • H2.0-3.5FT (H40-70FT) (L177)
ity to lift the engine and transmission. See section Frame 100 SRM 1423 for lift truck
The engine can weigh approximately 162 kg • S50CT (A267)
(357 lb). • H50CT (A274)
15
2. Remove torque converter from torque converter 2. Remove temp sensor from torque converter hous-
housing. See Torque Converter Replacement in ing. See Figure 17.
this manual for procedure.
3. Remove capscrews, washers, TOSS speed sensor,
3. Using a lifting device, remove transmission from and TISS speed sensor from transmission hous-
lift truck. ing. See Figure 17
See section Frame 100 SRM 1120 for lift truck 4. Remove capscrews and enable solenoid valve
models listed below: from transmission housing. See Figure 17.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 5. Remove dipstick from torque converter housing.
H40FTS) (F001) See Figure 17.
• S2.0-3.5FT (S40-70FT) (F187))
6. Remove breather assembly from torque con-
• H2.0-3.5FT (H40-70FT) (L177)
NOTE: Prior to removing transmission oil filter, cover
charge pump with liquid proof covering to prevent
• S50CT (A267)
damage.
• H50CT (A274)
7. Remove and discard transmission oil filter from
Transmission Components transmission housing. See Figure 17.
1. If damaged, remove capscrews, washers, and bot- 8. Remove capscrews, washers, charge pump,
tom cover plate from torque converter housing. charge pump gasket, suction screen spring, and
See Figure 17. suction screen from transmission housing. See
Figure 18. Discard charge pump gasket.
NOTE: Perform Step 2 through Step 6 as needed.
9. Remove filter post fitting from transmission
See section Electrical System 2200 SRM 1142 for
repair procedures for lift truck models:
• S30FT, S35FT, S40FTS (E010) 10. Remove pressure transducers from transmission
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, housing. See Figure 19.
H40FTS) (F001)
• 2.0-3.5FT (S40-70FT, S55FTS) (F187) 11. Remove capscrews, reverse proportional valve,
• H2.0-3.5FT (H40-70FT) (L177) and forward proportional valve from transmis-
repair procedures for lift truck models 12. Remove fittings with O-ring from transmission
• S50CT (A267) housing. See Figure 19. Discard O-rings from
• H50CT (A274) fittings.
16
1. TORQUE CONVERTER HOUSING 8. BREATHER ASSEMBLY

2. TRANSMISSION HOUSING 9. ENABLE SOLENOID VALVE
3. BOTTOM COVER PLATE 10. TOSS SPEED SENSOR
4. CAPSCREW 11. TISS SPEED SENSOR
5. WASHER 12. TRANSMISSION OIL FILTER
6. TEMP SENSOR 13. PRESSURE TRANSDUCER
7. DIPSTICK
Figure 17. Sensors and Filters
17
NOTE: TRANSMISSION HOUSING ONLY SHOWN.

1. REVERSE PROPORTIONAL VALVE
2. CAPSCREW
3. PRESSURE TRANSDUCER
4. FILTER POST FITTING
6. REAR SIDE TRANSMISSION HOUSING
7. FORWARD PROPORTIONAL VALVE
DISASSEMBLE
Transmission
Housings
1. Remove 26 flange bolts from transmission hous-

ing and torque converter housing. See Figure 22.
2. Remove flange head capscrew and yoke from

back of transmission housing. Remove and dis-
card stator seal from yoke. See Figure 20.
NOTE: Note position of oil seal prior to removal to aid

1. TRANSMISSION HOUSING in installation.
2. CAPSCREW
3. WASHER 3. Remove and discard oil seal from back of trans-
4. CHARGE PUMP mission housing. See Figure 20.
5. CHARGE PUMP GASKET
6. SUCTION SCREEN 4. Using a small pry bar in the designated pry
7. SUCTION SCREEN SPRING points remove torque converter housing from
transmission housing. See Figure 21.
Figure 18. Charge Pump
2. OIL SEAL
3. YOKE
4. STATO SEAL
Figure 19. Transmission Housing, Fittings and
Valves Figure 20. Drive Shaft Yoke
18
1. TORQUE CONVERTER HOUSING 3. PRY POINT
19
5. Remove and discard gasket and O-rings from


3. FLANGE BOLT
20
Forward Clutch Pack
STEP 1.
Torque converter housing to be face down on a bench
or work surface as shown. Pull forward clutch assem-
bly straight out of torque converter housing.

2. STATOR SUPPORT
STEP 2.
Remove shaft seal and bearing from input shaft. Dis-
card shaft seal.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT
21
STEP 3.
Remove snap ring from output gear. Remove output
gear from input shaft.
1. SNAP RING
2. OUTPUT GEAR
3. BEARING
STEP 4.
Remove bearing and snap ring from output gear.
1. BEARING
2. SNAP RING
3. OUTPUT GEAR
22
STEP 5.
Remove snap ring and pressure plate from gear as-
sembly drum. Remove and discard O-ring from pres-
sure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 6.
Remove friction disks and separator plates al-
ternately until all have been removed from gear
assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
23
STEP 7.
Remove conical plate from gear assembly drum.
1. CONICAL PLATE
WARNING
NOTE: Remove piston only if there is a problem with the piston or piston seals.
STEP 8.
Using spring compression tool Hyster P/N 867890
and a press, place spring compression tool on spring
guide with opening of tool above opening of snap
ring, and compress large and small springs just
enough to allow removal of snap ring from spring
guide. Slowly release press to compress springs.

2. SNAP RING
3. SPRING GUIDE
24
STEP 9.
Remove snap ring, spring guide, large spring, and
small spring from input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove shaft seal and piston from gear assembly
drum. Remove piston seal from piston. Discard shaft
seal and piston seal.
1. SHAFT SEAL
2. PISTON
3. PISTON SEAL
25
STEP 11.
Remove shaft seals and bearing from input shaft.
Discard shaft seals.
1. INPUT SHAFT
2. SHAFT SEAL
3. BEARING
Reverse Clutch Pack
STEP 1.
or work surface as shown. Pull reverse clutch assem-
bly straight out of torque converter housing.

26
STEP 2.
Remove bearing from center shaft.
1. CENTER SHAFT
2. BEARING
STEP 3.
gear from center shaft.
1. OUTPUT GEAR
2. CENTER SHAFT
3. SNAP RING
27
STEP 4.
Remove bearing from output gear. Remove bearing,
snap ring, and bearing from output gear.
1. BEARING
2. OUTPUT GEAR
3. SNAP RING
STEP 5.
sure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
28
STEP 6.
assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
STEP 7.
1. CONICAL PLATE
29
WARNING
STEP 8.
guide with the opening of the tool above the opening
of snap ring, and compress large and small springs
just enough to allow removal of snap ring from
spring guide. Slowly release the press to decompress
springs.

2. SNAP RING
3. SPRING GUIDE
STEP 9.
small spring from center shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. CENTER SHAFT
30
STEP 10.
Remove piston from gear assembly drum. Remove
and discard piston seal from piston. Remove and dis-
card shaft seal from center shaft.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
5. CENTER SHAFT
STEP 11.
Remove shaft seals and bearing from center shaft.
1. SHAFT SEAL
2. BEARING
3. CENTER SHAFT
31
CLEAN
WARNING
cleaning solvents, always follow the solvent
dures.
Clean all metal parts with cleaning solvent and place

on a lint-free cloth to dry. Ensure that the cleaning
and assembly environment is free of dust, dirt, and Figure 23. Conical Plate Inspection
any other foreign matter that would affect the per- 7. Inspect bearings for wear or damage. Replace if
formance of the parts. damaged.
INSPECT 8. Inspect piston for damage. Make sure that seal-
ing surfaces are good. Make sure orifice is clean.
1. Inspect gear teeth on clutch assemblies and all
other gears for wear or damage. Replace gears if 9. Check for grooves or other damage on machined
damaged. surfaces of clutch pack shafts and transmission
housing. Check mounting and sealing surfaces
2. Check all parts that have splines for damage to
in housing for damage. Replace housing if dam-
splines. Check for notches worn in splines. Re-
aged. Replace clutch pack if clutch pack shaft is
place clutch pack or gears if damaged.
damaged.
3. Inspect friction disks for burned lining or bent
10. Inspect all hardware and mounting surfaces for
surfaces. Check for small holes in lining. Re-
presence of rust, sealing compounds, and usable
place friction disks if one-half the depth of the oil
condition. If hardware is to be reused, clean all
grooves is worn away or the disks are damaged.
rust and sealing compounds from threaded areas.
Discard a friction disk that has a thickness less
If hardware is not in usable condition, replace
than 2.2 mm (0.087 in.).
hardware.
4. The conical plate and separator plates must not
be bent, have damaged surfaces, or have large CAUTION
blue areas from too much hear. If any of the The dowel pins are used to properly align the
above conditions exist, replace the damaged com- housings for proper mating to each other. If the
ponent. alignment is not correct, damage to the trans-
mission assemble could occur.
5. Check the "H" dimensions of the conical plate as
shown in Figure 23. If dimension is less than 11. Inspect dowel pins and dowel pin holes. If any
3.2 mm (0.126 in.), replace conical plate. dowel pin is damaged at all, replace the dowel
pin. If a dowel pin hole is damaged, replace hous-
6. Check the "t" dimension of the conical plate as
ing.
shown in Figure 23. If dimension is less than
2.4 mm (0.094 in.), replace conical plate. 12. Check fit of bearings in transmission housings. If
bearings fit too loosely into housings, this could
mean that the bores are oversized. Replace hous-
ing as necessary.
32
ASSEMBLE
Transmission
Reverse Clutch Pack
1. SEAL 8. SNAP RING

2. BEARING 9. CONICAL PLATE
3. GEAR ASSEMBLY DRUM 10. FRICTION DISK
4. PISTON SEAL 11. SEPARATOR PLATE
5. PISTON 12. PRESSURE PLATE O-RING
6. SPRING 13. PRESSURE PLATE
7. SPRING GUIDE 14. OUTPUT GEAR
Figure 24. Reverse Clutch Pack Assembly
33
STEP 1.
Lubricate shaft seals with clean transmission oil. In-
stall bearing and new shaft seals onto center shaft.
1. SHAFT SEAL
2. BEARING
3. CENTER SHAFT
NOTE: Perform STEP 2 through STEP 4 only if piston was removed.
STEP 2.
stall new shaft seal onto center shaft. Install new
piston seal onto piston. Install piston into gear as-
sembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
5. CENTER SHAFT
34
STEP 3.
Install small spring, large spring, spring guide, and
snap ring onto center shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. CENTER SHAFT
STEP 4.
guide with the opening of tool above opening of snap
ring, and compress the large and small springs just
enough to allow installation of snap ring in spring
guide. Slowly release press.

2. SNAP RING
3. SPRING GUIDE
35
STEP 5.
Install conical plate into gear assembly drum.
1. CONICAL PLATE
STEP 6.
Install friction disks and separator plates alternately
until all have been installed into gear assembly
drum.
1. FRICTION DISK
2. SEPARATOR PLATE
36
STEP 7.
Lubricate O-ring and install into pressure plate. In-
stall pressure plate and snap ring into gear assembly
drum. Using a dial indicator or feeler gauge, check
the clearance between snap ring and pressure plate.
The must be 1.8 ±0.2 mm (0.071 ±0.008 in.) of clear-
ance. If clearance is not correct, see Parts Manual
for correct pressure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 8.
Install bearing, snap ring, and bearing into output
gear.
1. BEARING
2. OUTPUT GEAR
3. SNAP RING
37
STEP 9.
Install output gear and snap ring onto center shaft.
1. OUTPUT GEAR
2. CENTER SHAFT
3. SNAP RING
STEP 10.
Install bearing onto center shaft.
1. CENTER SHAFT
2. BEARING
38
STEP 11.
or work surface as shown. Install reverse clutch as-
sembly straight into torque converter housing.

39
Forward Clutch Pack

Figure 25. Forward Clutch Pack Assembly
40
STEP 1.
stall bearing and shaft seals onto input shaft.
1. INPUT SHAFT
2. SHAFT SEAL
3. BEARING
STEP 2.
stall new piston seal onto piston. Install piston and
new shaft seal into gear assembly drum.
1. SHAFT SEAL
2. PISTON
3. PISTON SEAL
41
STEP 3.
snap ring onto input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 4.
guide with the opening of the tool above opening of
snap ring, and compress the large and small springs
just enough to allow installation of snap ring in
spring guide. Slowly release press.

2. SNAP RING
3. SPRING GUIDE
42
STEP 5.
1. CONICAL PLATE
STEP 6.
until all have been installed into gear assembly
drum.
1. FRICTION DISK
2. SEPARATOR PLATE
43
STEP 7.
There must be 1.8 ±0.2 mm (0.071 ±0.008 in.) of clear-
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 8.
Install snap ring and bearing into output gear.
1. BEARING
2. SNAP RING
3. OUTPUT GEAR
44
STEP 9.
Install output gear and snap ring onto input shaft.
1. SNAP RING
2. OUTPUT GEAR
3. BEARING
STEP 10.
Lubricate new shaft seal with clean transmission oil.
Install bearing and shaft seal onto input shaft.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT
45
STEP 11.
or work surface as shown. Install forward clutch as-
sembly straight into stator support.

2. STATOR SUPPORT
46
Housings 3. Position transmission housing and torque con-

verter housing together and install 26 flange
1. Install new gasket and O-rings onto transmis- bolts. Tighten flange bolts to 38 N•m (28 lbf ft).
sion housing. See Figure 26. See Figure 26.
2. Check pins for correct installation into torque
converter housing before installing onto trans-

3. FLANGE BOLT
47
4. Install reverse proportional valve and capscrews

into transmission housing. Tighten capscrews to
5. Install transducers into transmission housing.

See Figure 28.
6. Install filter post fitting into transmission hous-

ing. See Figure 28.

3. PIN
INSTALL
Transmission Components NOTE: TRANSMISSION HOUSING ONLY SHOWN.
1. Lubricate new O-rings and install onto fittings. 1. REVERSE PROPORTIONAL VALVE
See Figure 28. 2. CAPSCREW
3. PRESSURE TRANSDUCER
2. Install fittings into transmission housing. See 4. FILTER POST FITTING
Figure 28. 6. TRANSMISSION HOUSING
7. FORWARD PROPORTIONAL VALVE
3. Install forward proportional valve and capscrews
into transmission housing. Tighten capscrews to Figure 28. Transmission Housing, Fittings and
3 to 4 N•m (27 to 35 lbf in). See Figure 28. Valves
48

into transmission housing. See Figure 29.
8. Install new charge pump gasket, charge pump,

washers, and capscrews onto transmission hous-
ing. See Figure 29. Tighten capscrews to 19 N•m
(168 lbf in).
9. Install breather assembly into torque converter

NOTE: Perform Step 10 and Step 11 if components

were removed.

lift truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• 2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

lift truck models
• S50CT (A267)
• H50CT (A274) 1. TRANSMISSION HOUSING
2. CAPSCREW
10. Install enable solenoid valve, capscrews, TISS 3. WASHER
4. CHARGE PUMP
speed sensor, washer, capscrew, TOSS speed 5. CHARGE PUMP GASKET
sensor, washer, and capscrew into transmission 6. SUCTION SCREEN
housing. See Figure 30 7. SUCTION SCREEN SPRING
11. Install temp sensor into torque convert housing. Figure 29. Charge Pump
See Figure 30.
12. If removed, install bottom cover plate and cap-

screws onto torque converter housing. See
Figure 30. Tighten capscrews to 7.9 N•m
(69.9 lbf in).
49
1. TORQUE CONVERTER HOUSING 7. DIPSTICK

2. TRANSMISSION HOUSING 8. BREATHER ASSEMBLY
3. BOTTOM COVER PLATE 9. ENABLE SOLENOID VALVE
4. CAPSCREW 10. TOSS SPEED SENSOR
5. WASHER 11. TISS SPEED SENSOR
6. TEMP SENSOR 12. TRANSMISSION OIL FILTER
Figure 30. Sensors and Filters
50
Engine, Torque Converter, and • H2.0-3.5FT (H40-70FT) (L177)

Transmission Assembly
Make sure engine and transmission are held in • H50CT (A274)
injury and damage to equipment. 4. Remove lifting device from eyebolt bracket.
INCHING OVERLAP ADJUSTMENT

WARNING
The engine and transmission are heavy. Make NOTE: Perform the following procedure for lift truck
sure that any lifting device has enough capac- models:
ity to lift the engine and transmission. • S50CT (A267)
• H50CT (A274)
(357 lb). NOTE: The amount of overlap is adjustable through a
ten-point range with 1 being minimum, 10 the max-
The transmission can weigh approximately imum, and 5 the default.
85 kg (187 lb).
1. Set inching overlap to default using the following
procedure.
CAUTION
Be careful that you DO NOT damage parts of a. Start engine and check inching overlap indi-
the torque converter or transmission when cator on display. Perform Step b or Step c to
transmission is installed. adjust overlap.
1. Using a lifting device, carefully install trans- b. To increase overlap, press Scroll Up button
mission on lift truck frame. Place blocks under on display switch cluster. See Figure 31.
transmission for stability.
c. To decrease overlap, press Scroll Down but-
See section Frame 100 SRM 1120 for lift truck ton on display switch cluster. See Figure 31.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H50CT (A274)
2. Install torque converter in torque converter

housing. See Torque Converter Replacement in
this manual for procedures.
3. Using a lifting device, carefully install engine in

lift truck.

models listed below: 1. SCROLL DOWN
• S30FT, S35FT, S40FTS (E010) 2. SCROLL UP
H40FTS) (F001) Figure 31. Display Switch Cluster
• S2.0-3.5FT (S40-70FT) (F187)
51
Proportional and Enable Solenoid Valves 1300 SRM 1421
Proportional and Enable Solenoid Valves

PROPORTIONAL VALVES NOTE: Tag wiring harness, valve, TOSS sensor, TISS
sensor, and transducer connectors prior to removal to
Remove aid in installation.
1. Remove hex head capscrew, washer, and shield 2. Disconnect transmission wiring harness connec-
from top of transmission housing. See Figure 32. tors from proportional valve, TOSS speed sen-
sor, TISS speed sensor, enable solenoid valve, and
transducer connectors. See Figure 32.
3. Remove transmission wiring harness from trans-

mission.
4. Remove two hex head capscrews and forward

proportional valve from transmission housing.
See Figure 33.
5. Remove two hex head capscrews and reverse pro-

portional valve from transmission housing. See
Figure 33.
2. TRANSMISSION WIRING HARNESS
4. WASHER
5. SHIELD
6. SPEED SENSOR
7. ENABLE SOLENOID VALVE
8. TRANSDUCER
9. PROPORTIONAL VALVE 1. REVERSE PROPORTIONAL VALVE
Figure 32. Transmission Wiring Harness and 4. TRANSMISSION HOUSING
Connectors 5. FORWARD PROPORTIONAL VALVE
CAUTION Figure 33. Proportional and Enable Solenoid

Valves
ness from the connectors. The connectors are
easily damaged.
52
1300 SRM 1421 Proportional and Enable Solenoid Valves
Disassemble 3. Install transmission wiring harness onto trans-

mission.
1. Remove and discard O-rings from proportional
valves. See Figure 34.
CAUTION
Clean and Inspect Use care when connecting the wiring harness
to the connectors. The connectors are easily
1. Clean proportional valves with lint-free cloth. damaged.
2. Inspect the connectors on the valves, if damaged, 4. Connect proportional valve, TISS sensor, TOSS
replace valve. sensor, enable solenoid valve, and transducer
connectors to transmission wiring harness con-
Assemble nectors as tagged during removal. See Figure 32.
1. Install new O-rings onto proportional valves as 5. Install shield, washer, and hex head capscrew
noted in disassembly. onto transmission housing. See Figure 32.
Install ENABLE SOLENOID VALVE

1. Install reverse proportional valve and two hex Remove
head capscrews into transmission housing. See
Figure 33. Tighten capscrews to 3 to 4 N•m (37 1. Remove hex head capscrew, washer, and shield
to 35 lbf in). from top of transmission housing. See Figure 32.
2. Install forward proportional valve and two hex

head capscrews into transmission housing. See CAUTION
Figure 33. Tighten capscrews to 3 to 4 N•m (37 Use care when disconnecting the wiring har-
to 35 lbf in). ness from the connectors. The connectors are
easily damaged.
NOTE: Tag wiring harness, valve, TOSS sensor, TISS

sensor, and transducer connectors prior to removal to
aid in installation.
2. Disconnect transmission wiring harness connec-

tors from proportional valve, TOSS speed sen-
sor, TISS speed sensor, enable solenoid valve, and
transducer connectors. See Figure 32.
3. Remove transmission wiring harness from trans-

mission.
4. Remove two hex head capscrews and enable so-

lenoid valve from transmission housing. See Fig-
ure 33.
Disassemble
1. Remove and discard O-rings from enable sole-
noid valve. See Figure 34.

2. PROPORTIONAL VALVE
3. O-RING
Figure 34. Valves and O-rings
53
Clean and Inspect 2. Install transmission wiring harness onto trans-

mission.
1. Clean enable solenoid valve with lint-free cloth.
2. Inspect the connector on the valve, if damaged, CAUTION

replace valve. Use care when connecting the wiring harness
Assemble damaged.
1. Install new O-rings onto enable solenoid valve. 3. Connect proportional valve, TISS speed sensor,
See Figure 34. TOSS speed sensor, enable solenoid valve, and
transducer connectors to transmission wiring
Install harness connectors as tagged during removal.
See Figure 32.
1. Install enable solenoid valve and two hex head
capscrews into transmission housing. See Fig- 4. Install shield, washer, and hex head capscrew
ure 33. Tighten capscrews to 3 to 4 N•m (37 to onto transmission housing. See Figure 32.
35 lbf in).

REMOVE AND DISASSEMBLY
1. Remove five screws, dash panel, and kick plate
from lift truck.

models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
2. Remove three capscrews (see Figure 35) and

swing hydraulic lever assembly toward opera-
tor’s seat.
3. Disconnect two cable assemblies from pedal as-

sembly.
4. Remove three capscrews and pedal assembly

from cowl. Remove pedal assembly from lift
truck. See Figure 36.
1. CAPSCREW
2. HYDRAULIC LEVER ASSEMBLY
Figure 35. Hydraulic Lever Relocation
54
9. Remove roll pin and throttle pedal shaft from

pedal assembly. Discard roll pin. See Figure 37.
NOTE: Tag wires prior to removing from mi-

croswitches to aid in connecting.
10. Remove u-clip, foam lock seal, and wiring har-

ness from pedal frame. See Figure 38.
11. Remove four pan head screws, lockwashers,

washers, pedal pad and springs from pedal
frame. If any metal inserts in pedal pad are
damaged, replace as necessary. See Figure 38.
12. Remove two hex head screws, lockwashers, nuts,

and microswitch from pedal pad. Repeat for re-
maining microswitch and remove wiring harness
from pedal frame. See Figure 38.
13. If damaged, remove stop screw and nut from

pedal frame. See Figure 38.
CLEAN AND INSPECT
WARNING
1. CAPSCREW 3. COWL cleaning solvents, always follow the solvent
2. PEDAL ASSEMBLY
Figure 36. MONOTROL Pedal Assembly and dures.
Cowl
Compressed air can move articles so they cause
5. Remove two pan head screws, lockwashers, and injury to the user or to other personnel. Make
accelerator position sensor from throttle base. sure the path of the compressed air is away
See Figure 37. from all personnel. Wear protective goggles or
a face shield to prevent injury to the eyes.
CAUTION
Use care when removing the connector from its CAUTION
holder as the connector can be easily damaged. DO NOT allow cleaning solvent to come in con-
NOTE: Remove only those components necessary to can damage those components.
complete repair of pedal.
1. Clean all metal components in solvent and dry
6. Remove connector from connector holder on with compressed air.
throttle base. See Figure 37.
2. Clean rubber or plastic components in warm
7. Remove outer and inner springs from throttle soapy water and dry with lint-free cloth.
base and pedal assembly. See Figure 37.
3. Inspect all components for damage. Replace if
8. Remove e-clip and throttle base from throttle damaged.
pedal shaft. See Figure 37.
55
1. PAN HEAD SCREW 7. E-CLIP

2. LOCKWASHER 8. ROLL PIN
3. ACCELERATOR POSITION SENSOR (APS) 9. INNER AND OUTER SPRINGS
4. THROTTLE BASE 10. MONOTROL PEDAL ASSEMBLY
5. CONNECTOR 11. CONNECTOR HOLDER
6. THROTTLE PEDAL SHAFT 12. THROTTLE PEDAL SHAFT
Figure 37. MONOTROL Pedal Bracket
56

Figure 38. MONOTROL Pedal
57
ASSEMBLE AND INSTALL 4. Install wiring harness in pedal frame. Install

foam lock seal and u-clip. Install pedal pad and
1. If removed, install stop screw and nut on pedal springs in pedal frame. Coat threads of four pan
frame. See Figure 38. head screws with Loctite™ 222. Install pan head
screws, lockwashers, and washers in pedal pad.
2. Install microswitch and two hex head screws in
See Figure 38. Tighten pan head screws to 2.25
pedal pad. Coat exposed threads of hex head
to 2.50 N•m (19 to 32 lbf in).
screws with Loctite™ 222. Install two lock-
washers and nuts on hex head screws. DO NOT 5. Using an ohmmeter, check for continuity be-
tighten nuts at this time. Repeat for other mi- tween pins 3 and 4 of wiring harness connector
croswitch. See Figure 38. with pedal in reverse position, and between pins
1 and 2 with pedal in forward position. See
3. Put wires through hole in pedal frame. The white
Figure 40.
banded wire is for the reverse microswitch, and
the blue banded wire is for the forward mi- 6. Install throttle pedal shaft and new roll pin in
croswitch. Adjust each microswitch in its mount pedal assembly. Install throttle base and e-clip
so that the measurement between the edge of the on throttle pedal shaft. See Figure 37.
mount and the base of the microswitch equals
0.0 to 0.5 mm (0.0 to 0.02 in.). Tighten mount-
ing nuts of each microswitch as adjustment is CAUTION
completed. See Figure 39. Use care when installing the connector in its
7. Install inner and outer springs on throttle base

and pedal assembly. Install connector in connec-
tor holder. on throttle base. See Figure 37.
8. Install actuator and magnet in throttle base.

Install accelerator position sensor, lockwash-
ers, and two pan head screws in throttle base.
Tighten screws to 2.25 N•m (19 lbf in).
1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
1. MICROSWITCH MOUNT Figure 40. Microswitch Continuity Check
2. MICROSWITCH BASE
58
9. Apply adhesive compound to three mounting • S2.0-3.5FT (S40-70FT, S55FTS) (F187)

bolts. Using three capscrews that hold throttle • H2.0-3.5FT (H40-70FT) (L177)
base to cowl, install pedal assembly on lift truck.
See Figure 36. Tighten bolts to 19 to 25 N•m 11. Depress pedal until it stops. Unscrew stop screw
(168 to 221 lbf in). until it contacts metal floor plate. Tighten nut to
10 N•m (89 lbf in).
10. Connect two cable assemblies to pedal assembly.
Swing hydraulic lever assembly toward cowl and
install three capscrews. See Figure 35. Install
kick panel and dashboard onto lift truck.

models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
59
NOTES
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60

SINGLE SPEED
POWERSHIFT
ALUMINUM CHAIN DRIVE
TRANSMISSION
(H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT) [F187];
S50CT [A267]; H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274]
PART NO. 4028968 1300 SRM 1447

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Single Speed Powershift Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Hydraulic Gear Pump........................................................................................................................................ 1
Remove ........................................................................................................................................................... 1
Install ............................................................................................................................................................. 1
Housing Fittings Replacement.......................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Disassemble ................................................................................................................................................... 2
Assemble ........................................................................................................................................................ 2
Install ............................................................................................................................................................. 2
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 5
Clean .............................................................................................................................................................. 5
Inspect ............................................................................................................................................................ 5
Assemble ........................................................................................................................................................ 5
Install ............................................................................................................................................................. 5
Torque Converter Replacement......................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Install ............................................................................................................................................................. 7
Stator Support Assembly Repair ...................................................................................................................... 9
Remove ........................................................................................................................................................... 9
Disassemble ................................................................................................................................................... 14
Clean .............................................................................................................................................................. 15
Inspect ............................................................................................................................................................ 15
Assemble ........................................................................................................................................................ 16
Install ............................................................................................................................................................. 16
Remove ........................................................................................................................................................... 19
Disassemble ................................................................................................................................................... 22
Housings .................................................................................................................................................... 22
Clutch Packs .............................................................................................................................................. 24
Clean .............................................................................................................................................................. 35
Inspect ............................................................................................................................................................ 35
Assemble ........................................................................................................................................................ 36
Clutch Packs .............................................................................................................................................. 36
Housings .................................................................................................................................................... 49
Install ............................................................................................................................................................. 51
Drive Chains and Sprockets .............................................................................................................................. 54
Remove ........................................................................................................................................................... 54
Clean .............................................................................................................................................................. 56
Inspect ............................................................................................................................................................ 56
Install ............................................................................................................................................................. 57
Proportional and Enable Solenoid Valves......................................................................................................... 57
Proportional Valves ....................................................................................................................................... 57
Remove....................................................................................................................................................... 57

Table of Contents Single Speed Powershift

Disassemble ............................................................................................................................................... 59
Assemble .................................................................................................................................................... 59
Install ......................................................................................................................................................... 59
Enable Solenoid Valve ................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Disassemble ............................................................................................................................................... 60
Assemble .................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT) [F187];
S50CT [A267];
H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274]
ii
1300 SRM 1447 Hydraulic Gear Pump
General
This section has repair procedures for the sin-
gle-speed powershift aluminum chain drive trans-
mission.
SERIAL NUMBER
The transmission serial number is located on the top
of the transmission housing. See Figure 1.

3. SERIAL NUMBER LOCATION
Figure 1. Serial Number
Hydraulic Gear Pump

REMOVE INSTALL
Lift truck models H2.0-3.5FT (L177) may be NOTE: Remove liquid-proof covering from charge
equipped with a variable displacement pump (VDP). pump prior to operating lift truck.
See service manual Hydraulic Gear Pump 1900
SRM 1136 for more information. NOTE: Apply a 3 to 5 mm (0.12 to 0.20 in.) bead
of sealant to either hydraulic gear pump or VDP or
transmission housing face at insertion point of flange
CAUTION head capscrews.
Prior to removing hydraulic gear pump or VDP,
cover charge pump with liquid-proof covering 1. Install hydraulic gear pump or VDP and two
to prevent damage. flange head capscrews on transmission housing.
See Figure 2. Tighten capscrews to 38 N•m
NOTE: Lift truck models H2.0-3.5FT (H40-70FT) (28 lbf ft).
(L177) may be equipped with an optional Quick-
Lok™ hydraulic hose and adapter. See service man-
ual Hydraulic Gear Pump 1900 SRM 1136 for CAUTION
more information. Disposal of lubricants and fluids must meet lo-
1. Put a drain pan under hydraulic gear pump or
VDP. Remove and plug all hydraulic lines con- 2. Dispose of drain pan contents.
nected to pump. Remove two flange head cap-
screws and hydraulic gear pump from transmis-
1
Housing Fittings Replacement 1300 SRM 1447
Legend for Figure 2
NOTE: HYDRAULIC GEAR PUMP SHOWN. THE RE-

MOVAL AND INSTALLATION OF THE VARIABLE DIS-
PLACEMENT PUMP IS THE SAME.
Figure 2. Hydraulic Gear Pump
Housing Fittings Replacement

REMOVE ASSEMBLE
1. Remove hole plug from top of converter housing. 1. Install new O-rings on fittings.
See Figure 3.
INSTALL
2. Remove fittings from converter housing and
transmission housing. See Figure 3. 1. Install hole plug on top of converter housing. See
Figure 3.
DISASSEMBLE
2. Install fittings on converter housing and trans-
1. Remove and discard O-rings from fittings. mission housing. See Figure 3.
2
1300 SRM 1447 Housing Fittings Replacement
A. TRANSMISSION HOUSING B. CONVERTER HOUSING

1. FITTING 2. HOLE PLUG
Figure 3. Housing Fittings and Hole Plug
3
Charge Pump Repair

REMOVE • H2.0-3.5FT (H40-70FT) (L177)
See section Frame 100 SRM 1423 for removal

WARNING procedures for lift truck models listed below:
Make sure engine and transmission are held in • S50CT (A267)
position so that they will not fall and cause an • H2.0-2.5CT (H50CT) (A274)
3. Remove torque converter from torque converter
WARNING housing. See Torque Converter Replacement in
this manual for procedure.
sure that any lifting device has enough capac- 4. Place transmission on torque converter housing
ity to lift the engine and transmission. face. See Figure 4.
The engine can weigh approximately 194 kg 5. Remove seven capscrews, seven washers, charge
(428 lb). pump, and charge pump gasket from transmis-
sion housing. See Figure 4. Discard charge pump
gasket.
84 kg (185 lb).
6. Remove suction screen spring and suction screen
NOTE: Charge pump can be removed from transmis-
from transmission housing. See Figure 4.
sion while it is still in lift truck. However, for the sake
of clarity, illustrations in following steps are shown
with transmission removed from lift truck.

transmission are removed from lift truck.

truck.

procedures for lift truck models listed below:
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)

lift truck.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
Figure 4. Charge Pump
• S2.0-3.5FT (S40-70FT) (F187)
4
Legend for Figure 4 Compressed air can move particles so they

1. TRANSMISSION HOUSING Make sure the path of the compressed air is
2. CAPSCREW
3. WASHER away from all personnel. Wear protective gog-
4. CHARGE PUMP gles or a face shield to prevent injury to the
5. CHARGE PUMP GASKET eyes.
6. SUCTION SCREEN
7. SUCTION SCREEN SPRING 1. Clean metal components with solvent and dry
8. TORQUE CONVERTER HOUSING with compressed air.
DISASSEMBLE 2. Clean rubber or plastic components with warm
1. Remove four socket head screws, charge pump
cover, and O-ring from charge pump body. Dis- INSPECT
card O-ring. See Figure 5.
1. Inspect splines on shaft of charge pump for dam-
age or worn areas that could affect operation of
pump. Replace charge pump if damaged.
2. Inspect capscrews for damaged threads. Replace

capscrews if damaged.
3. Inspect suction screen for foreign material.

Clean screen or replace if damaged,
ASSEMBLE
1. Install new O-ring, charge pump cover, and four
socket head screws on charge pump body. See
Figure 5.
INSTALL
in transmission housing. See Figure 4.
1. CHARGE PUMP BODY 2. Install charge pump gasket, charge pump, seven
2. O-RING washers, and seven capscrews on transmission
3. CHARGE PUMP COVER
4. SOCKET HEAD SCREW housing. See Figure 4. Tighten capscrews to
19 N•m (168 lbf in).
Figure 5. Charge Pump Assembly
NOTE: Perform Step 3 and Step 5 if engine and trans-
CLEAN mission were removed from lift truck.
3. Move transmission to upright position. Install

WARNING torque converter in torque converter housing.
Cleaning solvents can be flammable and toxic See Torque Converter Replacement in this man-
and can cause skin irritation. When using ual for procedures.
cleaning solvents, always follow the manufac-
turer’s recommended safety procedures.
5
WARNING WARNING
The engine and transmission are heavy. Make The engine and transmission are heavy. Make
sure that any lifting device has enough capac- sure that any lifting device has enough capac-
ity to lift the engine and transmission. ity to lift the engine and transmission.
The engine can weigh approximately 194 kg The engine can weigh approximately 194 kg
(428 lb). (428 lb).
The transmission can weigh approximately The transmission can weigh approximately
84 kg (185 lb). 84 kg (185 lb).
5. Using lifting device, install engine in lift truck.

CAUTION
Be careful that you DO NOT damage parts of See section Frame 100 SRM 1120 for install pro-
the torque converter or transmission when cedures for lift truck models listed below:
transmission is installed. • S30FT, S35FT, S40FTS (E010)
4. Using a lifting device, carefully install trans- H40FTS) (F001)
mission on lift truck frame. Place blocks under • S2.0-3.5FT (S40-70FT) (F187)
transmission for stability. • H2.0-3.5FT (H40-70FT) (L177)
See section Frame 100 SRM 1120 for install pro- See section Frame 100 SRM 1423 for install pro-
cedures for lift truck models listed below: cedures for lift truck models listed below:
• S30FT, S35FT, S40FTS (E010) • S50CT (A267)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • H2.0-2.5CT (H50CT) (A274)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187) 6. Remove lifting device from eyebolt bracket.
• H2.0-3.5FT (H40-70FT) (L177)
See section Frame 100 SRM 1423 for install pro- CAUTION
cedures for lift truck models listed below: Disposal of lubricants and fluids must meet lo-
• S50CT (A267) cal environmental regulations.
• H2.0-2.5CT (H50CT) (A274)
7. Dispose of drip pan contents.
WARNING
6
1300 SRM 1447 Torque Converter Replacement
Torque Converter Replacement

REMOVE section Hydraulic Gear Pump in this manual for
procedures.
WARNING NOTE: The torque converter cannot be repaired and
Make sure the engine and transmission are must be replaced as a unit, if damaged.
cause an injury and damage to equipment. 4. Place a drip pan under transmission and care-
fully remove torque converter from stator sup-
WARNING port. See Figure 6.
The engine and transmission are heavy. Make 5. Remove and discard oil seal from stator support.
sure that any lifting device has enough capac- See Figure 6.
CLEAN AND INSPECT
(428 lb). 1. Clean all components with a lint-free cloth.
The transmission can weigh approximately 2. Inspect torque converter, replace as needed.
84 kg (185 lb).
3. Inspect bolts and capscrews for damaged
1. Using a lifting device, remove engine from lift threads, replace if damaged.
truck.
INSTALL
procedures for lift truck models listed below: 1. Install new oil seal on stator support. See Fig-
• S30FT, S35FT, S40FTS (E010) ure 6.
H40FTS) (F001) 2. Carefully install torque converter on stator sup-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) port. See Figure 6. Ensure that torque converter
• H2.0-3.5FT (H40-70FT) (L177) is fully seated.
See section Frame 100 SRM 1423 for removal 3. If removed, connect a lifting device to eyebolt
procedures for lift truck models listed below: bracket.
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)

lift truck.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274) 1. TORQUE CONVERTER
2. STATOR SUPPORT
3. Remove hydraulic gear pump or variable dis- 3. OIL SEAL
placement pump from transmission housing. See
Figure 6. Torque Converter
7
Torque Converter Replacement 1300 SRM 1447
WARNING WARNING
Make sure engine and transmission are held in Make sure the engine and transmission are
position so that they will not fall and cause an held in position so that they will not fall and
injury and damage to equipment. cause an injury and damage to equipment.
WARNING WARNING
The engine and transmission are heavy. Make The engine and transmission are heavy. Make
sure that any lifting device has enough capac- sure that any lifting device has enough capac-
ity to lift the engine and transmission. ity to lift the engine and transmission.
The engine can weigh approximately 194 kg The engine can weigh approximately 194 kg
(428 lb). (428 lb).
The transmission can weigh approximately The transmission can weigh approximately
84 kg (185 lb). 84 kg (185 lb).
4. Using lifting device, carefully install transmis- 6. Using a lifting device, install engine in lift truck.
sion assembly on lift truck frame. Place blocks
under transmission for stability. See section Frame 100 SRM 1120 for install pro-
cedures for lift truck models listed below:
See section Frame 100 SRM 1120 for install pro- • S30FT, S35FT, S40FTS (E010)
cedures for lift truck models listed below: • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• S30FT, S35FT, S40FTS (E010) H40FTS) (F001)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001) • H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT) (F187)
• H2.0-3.5FT (H40-70FT) (L177) See section Frame 100 SRM 1423 for install pro-
See section Frame 100 SRM 1423 for install pro- • S50CT (A267)
cedures for lift truck models listed below: • H2.0-2.5CT (H50CT) (A274)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274) 7. Remove lifting device from eyebolt bracket.
5. Install hydraulic gear pump or variable displace-

CAUTION
ment pump on transmission housing. See section
Hydraulic Gear Pump in this manual for proce- Disposal of lubricants and fluids must meet lo-
dures. cal environmental regulations.
8. Dispose of drip pan contents.
8
Stator Support Assembly Repair

REMOVE NOTE: Place drip pan under transmission.
4. Remove torque converter from stator support.

WARNING See section Torque Converter Replacement for
Make sure the engine and transmission are procedures.
cause and injury and damage to equipment. 5. Remove charge pump from transmission hous-
ing. See section Charge Pump Repair for proce-
WARNING dures.
The engine and transmission are heavy. Make 6. Remove transmission filter and filter post fitting
sure that any lifting device has enough capac- from transmission housing. See Figure 7.
7. Remove four capscrews and two proportional
The engine can weigh approximately 194 kg valves from transmission housing.
(428 lb).
The transmission can weigh approximately • S30FT, S35FT, S40FTS (E010)
84 kg (185 lb). • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
truck.
• H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)

lift truck.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See section Frame 100 SRM 1423 for removal 1. TRANSMISSION HOUSING
procedures for lift truck models listed below: 2. TRANSMISSION FILTER
• S50CT (A267) 3. FILTER POST FITTING
• H2.0-2.5CT (H50CT) (A274)
Figure 7. Transmission Filter and Fitting
3. Remove hydraulic gear pump or variable dis-
placement pump. See section Hydraulic Gear
Pump for procedures.
9

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
8. Remove two capscrews and enable solenoid valve

from transmission housing.
See Figure 8. for lift truck models

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
9. Remove two pressure transducers from trans-

mission housing.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267) 1. TRANSMISSION HOUSING
• H2.0-2.5CT (H50CT) (A274) 2. PROPORTIONAL VALVE
3. TOSS SPEED SENSOR
10. If equipped, remove capscrew, lockwasher, and 4. TISS SPEED SENSOR
TOSS speed sensor from transmission housing. 5. PRESSURE TRANSDUCER
8. LOCKWASHER
11. If equipped, remove capscrew, lockwasher, and
TISS speed sensor from transmission housing. Figure 8. Transmission Housing Components
See Figure 8. for Lift Truck Models S30FT, S35FT, S40FTS
(E010), H1.6FT, H1.8FT, H2.0FTS (H30FT,
12. If equipped, remove two capscrews, two lock- H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT,
washers, and two transmission sensor plugs S55FTS) (F187), and H2.0-3.5FT (H40-70FT)
from transmission housing. Remove and discard (L177)
O-rings from plugs. See Figure 9.
13. Remove dipstick, breather assembly, and tem-

perature sensor from converter housing. See Fig-
ure 10.
10
3. CAPSCREW
4. TRANSDUCER 1. CONVERTER HOUSING
5. ENABLE SOLENOID VALVE 2. DIPSTICK
6. TRANSMISSION SENSOR PLUG 3. BREATHER ASSEMBLY
7. LOCKWASHER 4. TEMPERATURE SENSOR
8. O-RING
Figure 10. Converter Housing Components
Figure 9. Transmission Housing Components
H2.0-2.5CT (H50CT) (A274)
11
14. Remove two flange bolts and eyebolt bracket 17. Remove and discard gasket and O-rings from
from housings. See Figure 11. transmission housing. See Figure 11.
15. Remove twenty-four flange bolts from transmis- 18. Converter housing to be face down on a bench or
sion housing and converter housing. See Fig- work surface as shown. Pull forward clutch as-
ure 11. sembly straight out of stator support. See Fig-
ure 13.
16. Using a small pry bar in the designated pry
points remove converter housing from transmis-
1. TRANSMISSION HOUSING 4. O-RING

2. FLANGE BOLT 5. CONVERTER HOUSING
3. GASKET 6. EYEBOLT BRACKET
Figure 11. Transmission and Converter Housings
12
1. CONVERTER HOUSING 2. TRANSMISSION HOUSING 3. PRY POINT

2. STATOR SUPPORT ASSEMBLY
Figure 13. Forward Clutch
13
19. Pull reverse clutch assembly straight out of Legend for Figure 15
1. TRANSMISSION OUTPUT GEAR
2. OUTPUT GEAR COVER
3. PIN
4. CONVERTER HOUSING
21. Remove output gear cover from pins in converter

NOTE: Be careful when removing stator support, in-

put gear may hang up.
22. Remove four capscrews, four lockwashers, stator

support assembly, and sealing ring from input
gear. Remove and discard O-rings from converter
housing. Remove and discard sealing ring from
stator support assembly. See Figure 16.
DISASSEMBLE
1. Remove fitting with O-ring, pack regulator
spring, and pack regulator spool from stator
support housing. Remove and discard O-ring
from fitting. See Figure 17.
Figure 14. Reverse Clutch
20. Remove output gear from output gear cover. See

Figure 15.

2. CAPSCREW
3. LOCKWASHER
4. SEALING RING
5. O-RING
6. INPUT GEAR
Figure 16. Stator Support

Figure 15. Output Gear
14
2. Remove fitting with O-ring, converter relief CLEAN

spring, and ball converter relief from stator
support assembly housing. Remove and discard WARNING
O-ring from fitting. See Figure 17.
3. Remove bushing from stator support housing. and can cause skin irritation. When using
See Figure 17. cleaning solvents, always follow the solvent
dures.

away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
CAUTION
DO NOT allow cleaning solvent to come in con-

2. Clean rubber or plastic components with warm

INSPECT
the pack regulator spool. Make sure spool moves
freely in bore. Replace spool if damaged.
2. Make sure there are no scratches or damage to

ball converter relief assembly. Replace ball con-
verter relief assembly if damaged.
3. Make sure there are no scratches or damage in

the bores of the stator support housing. If bores
are damaged, replace stator support assembly.
4. Inspect bushing for damage. Replace if damaged.

1. FITTING WITH O-RING Replace if damaged.
2. PACK REGULATOR SPRING
3. PACK REGULATOR SPOOL 6. Measure pack regulator spring. Replace if speci-
4. HYDRAULIC PLUG fication shown below is not met. See Figure 18.
5. BUSHING
6. BALL CONVERTER RELIEF 7. Measure converter relief spring. Replace if spec-
7. CONVERTER RELIEF SPRING ification shown below is not met. See Figure 19.
8. STATOR SUPPORT HOUSING
Figure 17. Stator Support Assembly
15
ASSEMBLE 3. Install new O-ring on fitting. Install pack regula-

tor spool, pack regulator spring, and fitting with
1. If necessary, install new bushing in stator sup- O-ring in stator support housing. See Figure 17.
port housing. See Figure 17.
INSTALL
2. Install new O-ring on fitting. Install ball con-
verter relief, converter relief spring, and fitting 1. Install new O-rings on converter housing. See
with O-ring in stator support housing. See Fig- Figure 16.
ure 17.
2. Install new sealing ring on stator support assem-
bly. See Figure 16.
3. Install stator support assembly, four lockwash-

ers, and four capscrews on input gear. See Fig-
ure 16. Tighten capscrews to 38 N•m (28 lbf ft).
4. Install output gear cover on pins in converter

5. Install output gear on output gear cover. See Fig-

ure 15.
6. Push reverse clutch assembly straight into con-

7. Push forward clutch assembly straight into sta-

tor support assembly. See Figure 13.
8. Verify two pins in converter housing. Check for

correction installation, see Figure 20.
Figure 18. Pack Regulator Spring - Free-Length
Measurement 9. Install new O-rings and gasket on converter
10. Install transmission housing on converter hous-

ing. Install twenty-four flange bolts on trans-
mission housing and converter housing. See Fig-
ure 11. Tighten flange bolts to 38 N•m (28 lbf ft).
11. Install eyebolt bracket and two flange bolts on

transmission housing and converter housing.
See Figure 11. Tighten flange bolts to 38 N•m
(28 lbf ft).
12. Install temperature sensor on converter hous-

ing. See Figure 10. Tighten sensor to 20 N•m
(117 lbf in).
13. Install breather assembly and dipstick on con-

14. If equipped, install TISS speed sensor, lock-

Figure 19. Converter Relief Spring -
washer, and capscrew on transmission housing.
Free-Length Measurement
See Figure 8. Tighten capscrew to 6 to 9 N•m
(53 to 80 lbf in).
16

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
19. Install enable solenoid valve and two capscrews

on transmission housing. Tighten capscrews to 3
to 4 N•m (27 to 35 lbf in).

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
20. Install two proportional valves and four cap-

screws on transmission housing. Tighten cap-
NOTE: GEARS AND CLUTCH PACKS NOT SHOWN
FOR CLARITY. See Figure 8 for lift truck models
• S30FT, S35FT, S40FTS (E010)
1. CONVERTER HOUSING • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
3. PIN
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Figure 20. Alignment Pin Installation • H2.0-3.5FT (H40-70FT) (L177)
15. If equipped, install TOSS speed sensor, lock- See Figure 9 for lift truck models
washer, and capscrew on transmission housing. • S50CT (A267)
See Figure 8. Tighten capscrew to 6 to 9 N•m • H2.0-2.5CT (H50CT) (A274)
(53 to 80 lbf in).
21. Install filter post fitting and transmission filter
16. If equipped, install new O-rings on transmission on transmission housing. See Figure 7.
sensor plugs. See Figure 9.
22. Install charge pump on transmission housing.
17. If equipped, install transmission sensor plugs, See section Charge Pump Repair for installation
two lockwashers, and two capscrews on trans- procedures.
mission housing. See Figure 9. Tighten capscrew
23. Install torque converter on stator support. See
to 6 to 9 N•m (53 to 80 lbf in).
Torque Converter Replacement for procedures.
18. Install two pressure transducers on transmission
24. If removed, connect a lifting device to eyebolt
housing.
bracket.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
17
WARNING WARNING
Make sure the engine and transmission are The engine and transmission are heavy. Make
held in position so that they will not fall and sure that any lifting device has enough capac-
cause injury and damage to equipment. ity to lift the engine and transmission.

WARNING (428 lb).
sure that any lifting device has enough capac- The transmission can weigh approximately
ity to lift the engine and transmission. 84 kg (185 lb).
The engine can weigh approximately 194 kg 27. Using a lifting device, install engine into lift
(428 lb). truck.
The transmission can weigh approximately See section Frame 100 SRM 1120 for lift truck
84 kg (185 lb). models listed below:
• S30FT, S35FT, S40FTS (E010)
25. Using lifting device, carefully install transmis- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
sion in lift truck frame. Place blocks under trans- H40FTS) (F001)
mission for stability. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See section Frame 100 SRM 1120 for installa-
tion procedures for lift truck models listed below: See section Frame 100 SRM 1423 for lift truck
• S30FT, S35FT, S40FTS (E010) models listed below:
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • S50CT (A267)
H40FTS) (F001) • H2.0-2.5CT (H50CT) (A274)
• S2.0-3.5FT (S40-70FT) (F187)
• H2.0-3.5FT (H40-70FT) (L177) 28. Remove lifting device from eyebolt bracket and
engine eyebolts.
See section Frame 100 SRM 1423 for installa-
tion procedures for lift truck models listed below:
• S50CT (A267) CAUTION
• H2.0-2.5CT (H50CT) (A274) Disposal of lubricants and fluids must meet lo-
26. Install hydraulic gear pump or variable displace-
ment pump. See section Hydraulic Gear Pump 29. Dispose of drip pan contents.
for installation procedures.
WARNING
cause an injury and damage to equipment.
18
Clutch Packs Repair

REMOVE NOTE: Place drip pan under transmission.
4. Remove torque converter from stator support.

WARNING See section Torque Converter Replacement in
Make sure the engine and transmission are this manual for procedures.
cause an injury and damage to equipment. 5. Remove charge pump from transmission hous-
ing. See section Charge Pump Repair for removal
WARNING procedures.
The engine and transmission are heavy. Make 6. Remove transmission filter and filter post fitting
sure that any lifting device has enough capac- from transmission housing. See Figure 21.
The engine can weigh approximately 194 kg valves from transmission housing.
(428 lb).
The transmission can weigh approximately • S30FT, S35FT, S40FTS (E010)
84 kg (185 lb). • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
1. Using lifting device, remove engine from lift
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
truck.
• H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)

lift truck.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See section Frame 100 SRM 1423 for removal 1. TRANSMISSION HOUSING
procedures for lift truck models listed below: 2. TRANSMISSION FILTER
• S50CT (A267) 3. FILTER POST FITTING
• H2.0-2.5CT (H50CT) (A274)
3. Remove hydraulic gear pump or variable dis-
placement pump. See section Hydraulic Gear
Pump for procedures.
19

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
8. Remove two capscrews and enable solenoid valve


• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
9. Remove two pressure transducers from trans-

mission housing.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267) 1. TRANSMISSION HOUSING
• H2.0-2.5CT (H50CT) (A274) 2. PROPORTIONAL VALVE
3. TOSS SPEED SENSOR
10. If equipped, remove capscrew, lockwasher, and 4. TISS SPEED SENSOR
TOSS speed sensor from transmission housing. 5. PRESSURE TRANSDUCER
8. LOCKWASHER
11. If equipped, remove capscrew, lockwasher, and
TISS speed sensor from transmission housing. Figure 22. Transmission Housing Components
See Figure 22. for Lift Truck Models S30FT, S35FT, S40FTS
(E010), H1.6FT, H1.8FT, H2.0FTS (H30FT,
12. If equipped, remove two capscrews, two lock- H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT,
washers, and two transmission sensor plugs S55FTS) (F187), and H2.0-3.5FT (H40-70FT)
from transmission housing. Remove and discard (L177)
O-ring from plug. See Figure 23.
13. Remove dipstick, breather assembly, and tem-

perature sensor from converter housing. See Fig-
ure 24.
20
3. CAPSCREW
4. TRANSDUCER 1. CONVERTER HOUSING
5. ENABLE SOLENOID VALVE 2. DIPSTICK
6. TRANSMISSION SENSOR PLUG 3. BREATHER ASSEMBLY
7. LOCKWASHER 4. TEMPERATURE SENSOR
8. O-RING
Figure 23. Transmission Housing Components
H2.0-2.5CT (H50CT) (A274)
21
DISASSEMBLE 3. Using a small pry bar in the designated pry

points, remove converter housing from transmis-
Housings sion housing. See Figure 26.
1. Remove two flange bolts and eyebolt bracket 4. Remove and discard gasket and O-rings from
from housings. See Figure 25. transmission housing. See Figure 25.
2. Remove twenty-four flange bolts from transmis-

sion housing and converter housing. See Fig-
ure 25.

3. GASKET 6. EYEBOLT BRACKET
Figure 25. Transmission and Converter Housings
22
1. CONVERTER HOUSING 3. PRY POINT
23
Clutch Packs
Forward Clutch Pack
STEP 1.
Converter housing to be face down on a bench or
work surface as shown. Pull forward clutch assembly
straight out of stator support assembly.

STEP 2.
Remove shaft seal and bearing from input shaft. Dis-
card shaft seal.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT
24
STEP 3.
gear from input shaft.
1. SNAP RING
2. OUTPUT GEAR
3. BEARING
STEP 4.
Remove bearing, snap ring, and bearing from output
gear.
1. BEARING
2. SNAP RING
3. OUTPUT GEAR
25
STEP 5.
sure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 6.
assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
26
STEP 7.
1. CONICAL PLATE
WARNING
NOTE: Remove piston only if there is a problem with the piston or piston seals.
STEP 8.
guide with opening of tool above opening of snap
guide. Slowly release press to compress springs.

2. SNAP RING
3. SPRING GUIDE
27
STEP 9.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove shaft seal and piston from gear assembly
drum. Remove piston seal from piston. Discard shaft
seal and piston seal.
1. SHAFT SEAL
2. PISTON
3. PISTON SEAL
28
STEP 11.
1. INPUT SHAFT
2. SHAFT SEAL
3. BEARING
Reverse Clutch Pack
STEP 1.
Converter housing to be face down on a bench or
work surface as shown. Pull reverse clutch assembly
straight out of converter housing.

29
STEP 2.
Remove bearing from center shaft.
1. CENTER SHAFT
2. BEARING
STEP 3.
gear from center shaft.
1. OUTPUT GEAR
2. CENTER SHAFT
3. SNAP RING
30
STEP 4.
Remove bearing, snap ring, and bearing from output
gear.
1. BEARING
2. OUTPUT GEAR
3. SNAP RING
STEP 5.
sure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
31
STEP 6.
assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
STEP 7.
1. CONICAL PLATE
32
WARNING
STEP 8.
guide with the opening of the tool above the opening
of snap ring, and compress large and small springs
just enough to allow removal of snap ring from
spring guide. Slowly release the press to decompress
springs.

2. SNAP RING
3. SPRING GUIDE
STEP 9.
small spring from center shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. CENTER SHAFT
33
STEP 10.
Remove piston from gear assembly drum. Remove
and discard piston seal from piston. Remove and dis-
card shaft seal from center shaft.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
5. CENTER SHAFT
STEP 11.
Remove shaft seals and bearing from center shaft.
1. SHAFT SEAL
2. BEARING
3. CENTER SHAFT
34
CLEAN 8. Inspect piston for damage. Make sure that seal-

ing surfaces are good. Make sure orifice is clean.
WARNING 9. Check for grooves or other damage on machined
Cleaning solvents can be flammable and toxic surfaces of clutch pack shafts and transmission
and can cause skin irritation. When using housing. Check mounting and sealing surfaces
cleaning solvents, always follow the solvent in housing for damage. Replace housing if dam-
manufacturer’s recommended safety proce- aged. Replace clutch pack if clutch pack shaft is
dures. damaged.
Clean all metal parts with cleaning solvent and place 10. Inspect all hardware and mounting surfaces for
on a lint-free cloth to dry. Ensure that the cleaning presence of rust, sealing compounds, and usable
and assembly environment is free of dust, dirt, and condition. If hardware is to be reused, clean all
any other foreign matter that would affect the per- rust and sealing compounds from threaded areas.
formance of the parts. If hardware is not in usable condition, replace
hardware.
INSPECT
1. Inspect gear teeth on clutch assemblies and all CAUTION
other gears for wear or damage. Replace gears if The dowel pins are used to properly align the
damaged. housings for proper mating to each other. If the
alignment is not correct, damage to the trans-
2. Check all parts that have splines for damage to mission assembly could occur.
place clutch pack or gears if damaged. 11. Inspect dowel pins and dowel pin holes. If any
dowel pin is damaged at all, replace the dowel
3. Inspect friction disks for burned lining or bent pin. If a dowel pin hole is damaged, replace hous-
surfaces. Check for small holes in lining. Re- ing.
place friction disks if one-half the depth of the oil
grooves is worn away or the disks are damaged. 12. Check fit of bearings in transmission housings. If
Discard a friction disk that has a thickness less bearings fit too loosely into housings, this could
than 2.2 mm (0.087 in.). mean that the bores are oversized. Replace hous-
ing as necessary.
4. The conical plate and separator plates must not
be bent, have damaged surfaces, or have large
blue areas from too much heat. If any of the
above conditions exist, replace the damaged com-
ponent.
5. Check the "H" dimensions of the conical plate as

3.2 mm (0.126 in.), replace conical plate.
6. Check the "t" dimension of the conical plate as

2.4 mm (0.094 in.), replace conical plate.
Figure 27. Conical Plate Inspection
7. Inspect bearings for wear or damage. Replace if
damaged.
35
ASSEMBLE
Clutch Packs
Reverse Clutch Pack

Figure 28. Reverse Clutch Pack Assembly
36
STEP 1.
stall bearing and new shaft seals on center shaft.
1. SHAFT SEAL
2. BEARING
3. CENTER SHAFT
STEP 2.
stall new shaft seal on center shaft. Install new pis-
ton seal on piston. Install piston into gear assembly
drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
5. CENTER SHAFT
37
STEP 3.
snap ring on center shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. CENTER SHAFT
STEP 4.
guide with the opening of tool above opening of snap
ring, and compress the large and small springs just

2. SNAP RING
3. SPRING GUIDE
38
STEP 5.
Install conical plate in gear assembly drum.
1. CONICAL PLATE
STEP 6.
until all have been installed in gear assembly drum.
See Figure 28 for install order.
1. FRICTION DISK
2. SEPARATOR PLATE
39
STEP 7.
Lubricate O-ring and install in pressure plate. In-
stall pressure plate and snap ring in gear assembly
ance. If clearance is not correct, see the Parts Man-
ual for correct pressure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 8.
Install bearing, snap ring, and bearing in output gear.
1. BEARING
2. OUTPUT GEAR
3. SNAP RING
40
STEP 9.
Install output gear and snap ring on center shaft.
1. OUTPUT GEAR
2. CENTER SHAFT
3. SNAP RING
STEP 10.
Install bearing on center shaft.
1. CENTER SHAFT
2. BEARING
41
STEP 11.
or work surface as shown. Install reverse clutch as-
sembly straight into converter housing.

42
Forward Clutch Pack

Figure 29. Forward Clutch Pack Assembly
43
STEP 1.
stall bearing and shaft seals on input shaft.
1. INPUT SHAFT
2. SHAFT SEAL
3. BEARING
STEP 2.
stall new piston seal on piston. Install piston and
new shaft seal into gear assembly drum.
1. SHAFT SEAL
2. PISTON
3. PISTON SEAL
44
STEP 3.
snap ring on input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 4.
guide with the opening of the tool above opening of
snap ring, and compress the large and small springs
just enough to allow installation of snap ring in
spring guide. Slowly release press.

2. SNAP RING
3. SPRING GUIDE
45
STEP 5.
Install conical plate in gear assembly drum.
1. CONICAL PLATE
STEP 6.
until all have been installed in gear assembly drum.
See Figure 29 for install order.
1. FRICTION DISK
2. SEPARATOR PLATE
46
STEP 7.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 8.
Install bearing, snap ring,and bearing into output
gear.
1. BEARING
2. SNAP RING
3. OUTPUT GEAR
47
STEP 9.
Install output gear and snap ring on input shaft.
1. SNAP RING
2. OUTPUT GEAR
3. BEARING
STEP 10.
Lubricate new shaft seal with clean transmission oil.
Install bearing and shaft seal on input shaft.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT
48
STEP 11.
or work surface as shown. Install forward clutch as-
sembly straight into stator support assembly.

Housings
1. Install new gasket and O-rings on transmission
2. Verify two pins in converter housing. Check for

correct installation, see Figure 30.
3. Position transmission housing and converter

housing together and install twenty-four flange
bolts. Tighten flange bolts to 38 N•m (28 lbf ft).
See Figure 31.
4. Install eyebolt bracket and two flange bolts on

transmission housing and converter housing.
See Figure 31. Tighten flange bolts to 38 N•m
(28 lbf ft).

3. PIN
49

3. GASKET
50
INSTALL 9. Install two proportional valves and four cap-

1. Install temperature sensor on converter hous- screws to 3 to 4 N•m (27 to 35 lbf in).
ing. See Figure 32. Tighten sensor to 20 N•m
(117 lbf in). See Figure 33 for lift truck models
• S30FT, S35FT, S40FTS (E010)
2. Install breather assembly, and dipstick on con- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
verter housing. See Figure 32. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
3. If equipped, install TISS speed sensor, lock-
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 33. Tighten capscrew to 6 to 9 N•m See Figure 34 for lift truck models
(53 to 80 lbf in). • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
4. If equipped, install TOSS speed sensor, lock-
See Figure 33. Tighten capscrew to 6 to 9 N•m
(53 to 80 lbf in).
5. If equipped, install new O-ring on transmission

sensor plugs. See Figure 34.
6. If equipped, install two transmission sensor

plugs, two lockwashers, and two capscrews. See
Figure 34. Tighten capscrew to 6 to 9 N•m (53
to 80 lbf in).
7. Install two pressure transducers on transmission

housing.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
8. Install enable solenoid valve and two capscrews

on transmission housing. Tighten capscrews to 3
to 4 N•m (27 to 35 lbf in).

• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 1. CONVERTER HOUSING
2. DIPSTICK
H40FTS) (F001) 3. BREATHER ASSEMBLY
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 4. TEMPERATURE SENSOR
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
51

2. PROPORTIONAL VALVE 2. PROPORTIONAL VALVE
3. TOSS SPEED SENSOR 3. CAPSCREW
4. TISS SPEED SENSOR 4. TRANSDUCER
5. PRESSURE TRANSDUCER 5. ENABLE SOLENOID VALVE
6. ENABLE SOLENOID VALVE 6. TRANSMISSION SENSOR PLUG
8. LOCKWASHER 8. O-RING
Figure 33. Transmission Housing Components Figure 34. Transmission Housing Components
for Lift Truck Models S30FT, S35FT, S40FTS for Lift Truck Models S50CT (A267) and
(E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H2.0-2.5CT (H50CT) (A274)
H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT,
S55FTS) (F187), and H2.0-3.5FT (H40-70FT)
(L177)
52
10. Install filter post fitting and transmission filter Legend for Figure 35
on transmission housing. See Figure 35.
11. Install charge pump on transmission housing. 2. TRANSMISSION FILTER
3. FILTER POST FITTING
See section Charge Pump Repair for installation
procedures. 14. Using a lifting device, carefully install trans-
mission on lift truck frame. Place blocks under
12. Install torque converter on stator support. See
transmission for stability.
Torque Converter Replacement for procedures.
See section Frame 100 SRM 1120 for install pro-
13. If removed, connect a lifting device to eyebolt
bracket.
• S30FT, S35FT, S40FTS (E010)
WARNING H40FTS) (F001)
Make sure the engine and transmission are • S2.0-3.5FT (S40-70FT) (F187)
held in position so that they will not fall and • H2.0-3.5FT (H40-70FT) (L177)
cause injury and damage to equipment.
See section Frame 100 SRM 1423 for install pro-
The engine and transmission are heavy. Make • H2.0-2.5CT (H50CT) (A274)
ity to lift the engine and transmission. 15. Install hydraulic gear pump or variable displace-
ment pump. See section Hydraulic Gear Pump
The engine can weigh approximately 194 kg for installation procedures.
(428 lb).
The transmission can weigh approximately WARNING

84 kg (185 lb). Make sure the engine and transmission are
cause an injury and damage to equipment.
WARNING

(428 lb).

84 kg (185 lb).
16. Using a lifting device, install engine into lift

truck.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
53
Drive Chains and Sprockets 1300 SRM 1447

models listed below: CAUTION
• S50CT (A267) Disposal of lubricants and fluids must meet lo-
• H2.0-2.5CT (H50CT) (A274) cal environmental regulations.
17. Remove lifting device from eyebolt bracket and 18. Dispose of drip pan contents.
engine eyebolts.
Drive Chains and Sprockets

REMOVE
1. Remove clutch packs and stator support, follow
Remove procedures in section Stator Support
Assembly Repair of this manual.
NOTE: Note placement and orientation of compo-

nents during removal to aid in installation.
2. Remove small drive chain from upper and lower

driven sprocket assemblies. See Figure 36.
3. Remove large drive chain from upper driven

sprocket assembly and driving sprocket assem-
bly. See Figure 37.
4. Remove bearing, driven sprocket, and bearing

from converter housing. See Figure 38.
5. Remove bearing and two driven sprockets from

converter housing. See Figure 39.
1. SMALL DRIVE CHAIN
NOTE: Note orientation of angular bearing prior to 2. UPPER DRIVEN SPROCKET ASSEMBLY
removal to aid in installation. 3. LOWER DRIVEN SPROCKET ASSEMBLY
6. Remove bearing, driving sprocket, angular bear- Figure 36. Small Drive Chain
ing, and O-ring from converter housing. Discard
O-ring. See Figure 40.
7. If necessary, remove two capscrews, two lock-

washers, and baffle plate from converter housing.
See Figure 41.
54
1300 SRM 1447 Drive Chains and Sprockets
1. LARGE DRIVE CHAIN

2. UPPER DRIVEN SPROCKET ASSEMBLY
3. DRIVING SPROCKET ASSEMBLY
Figure 37. Large Drive Chain 1. BEARING

2. DRIVEN SPROCKET
3. DRIVEN SPROCKET
Figure 39. Upper Driven Sprocket Assembly
1. BEARING
2. DRIVEN SPROCKET
Figure 38. Lower Driven Sprocket Assembly
55
Drive Chains and Sprockets 1300 SRM 1447

1. CAPSCREW
2. LOCKWASHER
3. BAFFLE PLATE
CLEAN
WARNING
ceaning solvents, always follow the solvent
dures.

eyes.
CAUTION
1. BEARING
2. DRIVING SPROCKET can damage those components.
3. ANGULAR BEARING
4. O-RING 1. Clean all metal components in solvent and dry
5. CONVERTER HOUSING with compressed air.
Figure 40. Driving Sprocket Assembly 2. Clean rubber or plastic components with warm
soapy water and dry with lint-free cloth.
INSPECT
1. Inspect bearings for wear or damage. Replace if
damaged.
2. Inspect sprocket teeth for wear or breakage. Re-

place if worn or broken.
3. Check fit of bearings in converter housing. If

bearings fit too loosely, housing bores my be over-
sized. Replace housings as necessary.
Figure 41. Baffle Plate
56
INSTALL 4. Install bearing, driven sprocket, and bearing on

converter housing. See Figure 38.
1. If removed, install baffle plate, two lockwashers,
and two capscrews. See Figure 41. Tighten cap- 5. Install large drive chain on driving sprocket as-
screws to 3 to 4 N•m (27 to 35 lbf in). sembly and driven sprocket assembly. See Fig-
ure 37.
2. Install new O-ring on converter housing. Install
angular bearing, as noted during removal, on 6. Install small drive chain on both driven sprocket
converter housing. Install driving sprocket, and assemblies. See Figure 36.
bearing on converter housing. See Figure 40.
7. Install stator support and clutch packs, follow
3. Install two driven sprockets and bearing on con- Install procedures in section Stator Support As-
verter housing. See Figure 39. sembly Repair of this manual.
Proportional and Enable Solenoid Valves

PROPORTIONAL VALVES
Remove
CAUTION
ness from the connectors. The connectors are
easily damaged.
NOTE: Tag wiring harness and valve connectors prior

to removal to aid in installation.
1. Disconnect wiring harness connectors from pro-

portional valves and enable solenoid valve con-
nectors.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 1. WIRING HARNESS
• H2.0-3.5FT (H40-70FT) (L177) 2. PROPORTIONAL VALVE CONNECTOR
3. ENABLE SOLENOID VALVE CONNECTOR
• S50CT (A267) Figure 42. Wiring Harness and Valve
• H2.0-2.5CT (H50CT) (A274) Connectors for Lift Truck Models S30FT,
S35FT, S40FTS (E010), H1.6FT, H1.8FT,
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and
H2.0-3.5FT (H40-70FT) (L177)
57

valves from transmission housing.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
1. CAPSCREW
Figure 44. Proportional Valves for Lift Truck

Models S30FT, S35FT, S40FTS (E010), H1.6FT,
(F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
and H2.0-3.5FT (H40-70FT) (L177)
1. WIRING HARNESS
2. PROPORTIONAL VALVE CONNECTOR
3. ENABLE SOLENOID VALVE CONNECTOR
Figure 43. Wiring Harness and Valve

Connectors for Lift Truck Models S50CT (A267)
and H2.0-2.5CT (H50CT) (A274)
1. CAPSCREW
Figure 45. Proportional Valves for Lift Truck

Models S50CT (A267) and H2.0-2.5CT (H50CT)
(A274)
58

• S30FT, S35FT, S40FTS (E010)
1. Remove and discard O-rings from proportional • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
valves. See Figure 46. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Clean and Inspect • H2.0-3.5FT (H40-70FT) (L177)
1. Clean proportional valves with lint-free cloth. See Figure 43 for lift truck models
• S50CT (A267)
2. Inspect the connectors on the valves, if damaged,
• H2.0-2.5CT (H50CT) (A274)
replace valve.
Assemble
1. Install new O-rings onto proportional valves as
noted in disassembly. See Figure 46.
Install
1. Install two proportional valves and four cap-

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
CAUTION 1. ENABLE SOLENOID VALVE

Use care when connecting the wiring harness 2. PROPORTIONAL VALVE
3. O-RING
damaged. Figure 46. Valves and O-rings
2. Connect proportional valve and enable solenoid
valve to wiring harness connectors as tagged dur-
ing removal.
59
ENABLE SOLENOID VALVE Install

Remove 1. Install enable solenoid valve and capscrew on
transmission housing. Tighten capscrew to 3 to
4 N•m (37 to 35 lbf in).
CAUTION
Use care when disconnecting the wiring har- See Figure 47 for lift truck models
ness from the connectors. The connectors are • S30FT, S35FT, S40FTS (E010)
easily damaged. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
NOTE: Tag wiring harness and valve connectors prior • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
to removal to aid in installation. • H2.0-3.5FT (H40-70FT) (L177)
1. Disconnect wiring harness connectors from en- See Figure 48 for lift truck models
able solenoid valve connector. • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
2. Remove capscrews and enable solenoid valve


• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
Disassemble 1. CAPSCREW
1. Remove and discard O-rings from enable sole- 3. TRANSMISSION HOUSING
noid valve. See Figure 46.
Figure 47. Enable Solenoid Valve for Lift Truck
Clean and Inspect Models S30FT, S35FT, S40FTS (E010), H1.6FT,
1. Clean enable solenoid valve with lint-free cloth. (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
and H2.0-3.5FT (H40-70FT) (L177)
2. Inspect the connector on the valve, if damaged,
replace valve.
Assemble
1. Install new O-rings onto enable solenoid valve.
See Figure 46.
60
CAUTION
damaged.
2. Connect enable solenoid valve connector to

wiring harness connector as tagged during re-
moval.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
1. CAPSCREW
Figure 48. Enable Solenoid Valve for Lift Truck

Models S50CT (A267) and H2.0-2.5CT (H50CT)
(A274)

REMOVE AND DISASSEMBLE 2. Remove three capscrews from hydraulic lever as-
sembly. Swing hydraulic lever assembly toward
1. Remove five screws, dash panel, and kick plate operator’s seat. See Figure 49.
from lift truck.
3. Disconnect two cable assemblies from pedal as-
See section Frame 100 SRM 1120 for lift truck sembly.
• S30FT, S35FT, S40FTS (E010) 4. Remove three capscrews and pedal assembly
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, from cowl. Remove pedal assembly from lift
H40FTS) (F001) truck. See Figure 50.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) 5. Remove two pan head screws, lockwashers, and
See section Frame 100 SRM 1423 for lift truck See Figure 51.
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
61
1. CAPSCREW 3. COWL
1. CAPSCREW 2. PEDAL ASSEMBLY
Figure 50. MONOTROL Pedal Assembly and
Figure 49. Hydraulic Lever Relocation Cowl
62
8. Remove e-clip and throttle base from throttle

CAUTION pedal shaft. See Figure 51.
holder as the connector can be easily damaged. 9. Remove roll pin and throttle pedal shaft from
pedal assembly. Discard roll pin. See Figure 51.
NOTE: Remove only those components necessary to
complete repair of pedal. NOTE: Tag wires prior to removing from mi-
6. Remove connector from connector holder on
throttle base. See Figure 51. 10. Remove u-clip, foam lock seal, and wiring har-
ness from pedal frame. See Figure 52.
7. Remove outer and inner springs from throttle
base and pedal assembly. See Figure 51.
1. PAN HEAD SCREW 7. E-CLIP

2. LOCKWASHER 8. ROLL PIN
3. ACCELERATOR POSITION SENSOR (APS) 9. INNER AND OUTER SPRINGS
4. THROTTLE BASE 10. MONOTROL PEDAL ASSEMBLY
5. CONNECTOR 11. CONNECTOR HOLDER
6. THROTTLE PEDAL SHAFT 12. THROTTLE PEDAL SHAFT
Figure 51. MONOTROL Pedal Bracket
63
11. Remove four pan head screws, lockwashers, 12. Remove two hex head screws, lockwashers, nuts,
washers, pedal pad and springs from pedal and microswitch from pedal pad. Repeat for re-
frame. If any metal inserts in pedal pad are maining microswitch and remove wiring harness
damaged, replace as necessary. See Figure 52. from pedal frame. See Figure 52.
13. If damaged, remove stop screw and nut from

pedal frame. See Figure 52.

Figure 52. MONOTROL Pedal
64
CLEAN AND INSPECT 4. Install wiring harness in pedal frame. Install

foam lock seal and u-clip. Install pedal pad and
WARNING springs in pedal frame. Coat threads of four pan
head screws with Loctite™ 222. Install pan head
screws, lockwashers, and washers in pedal pad.
See Figure 52. Tighten pan head screws to 2.25
to 2.50 N•m (19 to 32 lbf in).
dures. 5. Using an ohmmeter, check for continuity be-
tween pins 3 and 4 of wiring harness connector
Compressed air can move articles so they cause
with pedal in reverse position, and between pins
injury to the user or to other personnel. Make
1 and 2 with pedal in forward position. See
sure the path of the compressed air is away
Figure 54.
from all personnel. Wear protective goggles or
a face shield to prevent injury to the eyes.
CAUTION

2. Clean rubber or plastic components in warm

soapy water and dry with lint-free cloth.
3. Inspect all components for damage. Replace if

damaged.

1. If removed, install stop screw and nut on pedal
frame. See Figure 52.

screws with Loctite™ 222. Install two lock-
washers and nuts on hex head screws. DO NOT
tighten nuts at this time. Repeat for other mi-
croswitch. See Figure 52.
3. Put wires through hole in pedal frame. The white

banded wire is for the reverse microswitch, and 1. MICROSWITCH MOUNT
the blue banded wire is for the forward mi- 2. MICROSWITCH BASE
croswitch. Adjust each microswitch in its mount
so that the measurement between the edge of the Figure 53. Microswitch Adjustment
mount and the base of the microswitch equals
0.0 to 0.5 mm (0.0 to 0.02 in.). Tighten mount-
ing nuts of each microswitch as adjustment is
completed. See Figure 53.
65
6. Install throttle pedal shaft and new roll pin in See section Frame 100 SRM 1423 for lift truck
pedal assembly. Install throttle base and e-clip models listed below:
on throttle pedal shaft. See Figure 51. • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
CAUTION 12. Depress pedal until it stops. Unscrew stop screw
Use care when installing the connector in its until it contacts metal floor plate. Tighten nut to
holder as the connector can be easily damaged. 10 N•m (89 lbf in).

and pedal assembly. Install connector in connec-
tor holder. on throttle base. See Figure 51.
8. Install actuator and magnet in throttle base.

Install accelerator position sensor, lockwash-
ers, and two pan head screws in throttle base.
9. Apply adhesive compound to three mounting

bolts. Using three capscrews that hold throttle
base to cowl, install pedal assembly on lift truck.
See Figure 50. Tighten bolts to 19 to 25 N•m
(168 to 221 lbf in).
10. Connect two cable assemblies to pedal assembly.

Swing hydraulic lever assembly toward cowl and
install three capscrews. See Figure 49. 1. WIRING HARNESS CONNECTOR
2. WIRING HARNESS
11. Install kick panel and dashboard on lift truck.
Figure 54. Microswitch Continuity Check
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
66
1300 SRM 1447 8/12 (7/11)(6/11)(11/10) Printed in U.S.A.

POWERSHIFT TRANSMISSION
REPAIR
S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S120FTS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [P005]

PART NO. 4043132 1300 SRM 1529

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Powershift Transmission Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Remove ........................................................................................................................................................... 1
Inspect ............................................................................................................................................................ 1
Install ............................................................................................................................................................. 1
Torque Converter Replace ................................................................................................................................. 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 7
Housings and Chain Drive Repair .................................................................................................................... 13
Remove ........................................................................................................................................................... 13
Clean .............................................................................................................................................................. 20
Inspect ............................................................................................................................................................ 20
Install ............................................................................................................................................................. 20
Transmission, Remove and Disassemble ................................................................................................. 25
Clutch Assemblies, Remove and Disassemble ......................................................................................... 33
Clean .............................................................................................................................................................. 39
Inspect ............................................................................................................................................................ 39
Clutch Assemblies, Assemble and Install ................................................................................................ 40
Transmission, Assemble and Install ........................................................................................................ 49
Control Valve Repair.......................................................................................................................................... 53
Clean .............................................................................................................................................................. 54
Inspect ............................................................................................................................................................ 54
Direction Control Lever ..................................................................................................................................... 61
Remove ........................................................................................................................................................... 61
Install ............................................................................................................................................................. 61
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S120FTS; S120FTPRS) [G004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) [P005]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
This section has the repair procedures for the transmission.
SERIAL NUMBER
The transmission serial number is located on the
right side of the transmission control valve directly
below the floor plate. See Figure 1.
1. TRANSMISSION SERIAL NUMBER
Figure 1. Transmission Serial Number

Location
Charge Pump Repair

REMOVE INSPECT
NOTE: The charge pump can be removed from the Inspect the splines on shaft of transmission charge
transmission while it is still in the lift truck but, pump for damage or worn areas that could affect op-
for the sake of clarity, the following procedures are eration of the pump. If the splines are damaged, re-
shown with the transmission removed from the lift place the transmission charge pump.
truck.
INSTALL
Remove four mounting capscrews, washers, trans-
mission charge pump, and gasket from torque con- Install new gasket, transmission charge pump,
verter housing. Discard gasket. See Figure 2. four washers, and mounting capscrews on torque
converter housing. Tighten capscrews to 19 N•m
(168 lbf in).

Legend for Figure 2
NOTE: THE TRANSMISSION IS SHOWN REMOVED

FROM LIFT TRUCK FOR CLARITY.
1. CAPSCREW
2. CHARGE PUMP
3. GASKET
Figure 2. Transmission Charge Pump
Torque Converter Replace

REMOVE See Frame 100 SRM 1120 for lift truck models:
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
CAUTION
CAUTION
Be careful that you DO NOT damage parts of
the torque converter or transmission when
the transmission is separated from the engine.
are easily damaged.
ment until they are completely separated so
parts of the transmission are not damaged. NOTE: When disconnecting wiring harness connec-
Use a crane or lifting device to separate the tors during disassembly, tag each connector to aid in
transmission from the engine. connecting the wiring harness during reassembly.
1. Remove engine and transmission as a unit from 2. Put engine and transmission on solid blocks on a
lift truck as described in one of the following sec- work surface.
tions:
Disconnect transmission wiring harness connec-
See Frame 100 SRM 1243 for lift truck models: tors from control valve and transmission.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) Remove transmission wiring harness from trans-
(G004) mission. See Figure 3.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)

1. GM 2.4L ENGINE 4. TRANSMISSION


8. Remove transmission oil filter from torque con-

WARNING verter housing. See Figure 5.
bly is stable before attempting to rotate the en- 9. If damaged, remove two cap screws and small
gine. access cover from the torque converter housing.
Use a flashlight to see the bolts as they are ro- 10. Remove dipstick and dipstick tube from torque
tated into view through the access hole. DO converter housing. See Figure 5.
NOT use your fingers to check for alignment of
the bolts with the access hole. 11. Remove transmission oil temperature sensor
from torque converter housing. See Figure 5.
3. Move each bolt into view through access hole
of flywheel housing by rotating crankshaft. Re- NOTE: Perform Step 12 through Step 16 only if repair
move four capscrews that attach flywheel to of the of the transmission chain drive is required. If
torque converter. See Figure 4. the transmission clutch packs are in need of further
repair, see Clutch Packs Repair.
4. Remove access cover from torque converter hous-
ing. Install a lifting eye bolt into rear access 12. Remove two long capscrews and washers from in-
cover bolt hole, and connect a lifting device to ner face of torque converter housing. See Fig-
eye bolt. Remove ten capscrews that hold torque ure 7.
converter housing to flywheel housing on engine. 13. Remove fifteen capscrews from transmission
Carefully separate transmission from engine. housing. See Figure 6.
NOTE: The torque converter cannot be repaired and 14. Remove two mounting capscrews and harness
must be replaced as a unit, if damaged. bracket from front of torque converter housing.
5. Carefully remove torque converter from stator See Figure 6.
support. See Figure 5. 15. Using a small pry bar in the designated pry
6. Remove plug, suction screen spring, and suction points, remove the torque converter housing
screen from torque converter housing, and drain from the transmission housing. See Figure 6.
oil from transmission. See Figure 5. 16. Remove and discard O-rings and gasket. See Fig-
7. Remove transmission charge pump. See Charge ure 7.
Pump Repair,Remove.
Legend for Figure 4

A. GM 2.4L ENGINE D. GM 4.3L ENGINE
B. MAZDA ENGINE E. CUMMINS 3.3L DIESEL ENGINE
C. YANMAR ENGINE


Figure 5. Torque Converter Removal

Legend for Figure 5

5. TORQUE CONVERTER HOUSING 13. TORQUE CONVERTER
6. TRANSMISSION OIL TEMPERATURE SENSOR 14. TRANSMISSION CHARGE PUMP
7. SUCTION SCREEN 15. STATOR SUPPORT
8. SUCTION SCREEN SPRING 16. PILOT HUB
INSTALL 10. Lubricate the pilot hub on the torque converter

with antiseize compound. See Figure 8.
NOTE: Perform Step 1 through Step 4 only if repair
of the transmission chain drive was performed. 11. Install transmission oil temperature sensor on
1. Install new O-rings and gasket to torque con-
verter housing and transmission housing. See
Figure 7.
2. Install harness bracket and two mounting cap-

screws to front of torque converter housing. See
Figure 6.
3. Using fifteen capscrews, install transmission

housing to torque converter housing. Tighten
capscrews to 38 N•m (28 lbf ft).
4. Install two washers and long capscrews into face

of torque converter housing. Tighten capscrews
5. If removed, install small access cover and two

capscrews on torque converter housing. Tighten
capscrews to 7.9 N•m (69 lbf in). See Figure 8.
6. Install a new transmission oil filter on torque

converter housing.
7. Install the transmission charge pump. See

Charge Pump Repair,Install. 1. PRY POINTS
8. Install suction screen, suction screen spring, and 3. TRANSMISSION HOUSING
plug into torque converter housing. See Figure 8. 4. HARNESS BRACKET
5. CAPSCREW
9. Install torque converter onto stator support.
Make sure splines are aligned and converter Figure 6. Pry Point Location
engages fully. See Figure 8.

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

2. WASHER 6. O-RING
3. TORQUE CONVERTER HOUSING 7. CAPSCREW
4. GASKET
Legend for Figure 8


Figure 8. Torque Converter Installation

NOTE: Apply adhesive to entire surface of hole, Remove lifting eye bolt, and install access cover
20.0 mm (0.79 in.) deep. Also apply adhesive to on torque converter housing.
lower 20.0 mm (0.79 in.) of dipstick tube.
12. Install dipstick tube and dipstick into torque con- WARNING
verter housing. See Figure 8. Make sure the engine and transmission are
13. If removed, install a lifting eye bolt into rear ac- cause an injury and damage to the equipment.
cess cover bolt hole, and connect a lifting device
to eye bolt. 17. Install engine and transmission as a unit into
lift truck as described in one of the following sec-
Align torque converter housing with flywheel tions:
housing. Make sure pilot hub on torque con-
verter engages flywheel. See Frame 100 SRM 1243 for lift truck models:
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
CAUTION (G004)
Be careful that you DO NOT damage parts of • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
the torque converter or transmission when 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
the transmission is joined to the engine. Keep
the transmission and engine in alignment un- See Frame 100 SRM 1120 for lift truck models:
til they are completely joined so parts of the • S30FT, S35FT, S40FTS (E010)
transmission are not damaged. Use a crane or • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
lifting device to join the transmission to the H40FTS) (F001)
engine. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
14. Install transmission on engine. Install ten cap-
screws that connect torque converter housing to 18. Fill transmission to correct level using transmis-
flywheel housing. Tighten capscrews to 38 N•m sion fluid and procedure indicated in following
(28 lbf ft). See Figure 9. sections:
See Periodic Maintenance 8000 SRM 1150 for

CAUTION lift truck models:
Use care when connecting the wiring harness • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
connectors to electrical connectors on the • H2.0-3.5FT (H40-70FT) (L177)
transmission and control valve. The connec-
tors on the transmission and control valve are See Periodic Maintenance 8000 SRM 1207 for
easily damaged. lift truck models:
• S30FT, S35FT, S40FTS (E010)
15. Install transmission wiring harness on transmis- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
sion. Connect transmission wiring harness con- H40FTS) (F001)
nectors to control valve and transmission. See
Figure 9. See Periodic Maintenance 8000 SRM 1248 for
lift truck models:
NOTE: Coat the bolt threads that hold the torque con- • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
verter to flywheel with Loctite™ 242. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
16. Rotate engine crankshaft to position the fly- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
wheel mounting holes in line with torque con- 5.5FT (H80, 90, 100, 110, 120FT) (P005)
verter mounting holes. Install capscrews that
hold torque converter to flywheel through access
hole of flywheel housing. See Figure 10. Tighten




1300 SRM 1529 Housings and Chain Drive Repair

C. YANMAR ENGINE
Housings and Chain Drive Repair

REMOVE work surface, place blocks under the back side
of the transmission housing for additional sup-
WARNING port.
held in position so that they will not fall and CAUTION
cause an injury and damage to the equipment. Use care when disconnecting the wiring har-
CAUTION the transmission and control valve. The con-
Keep the transmission and engine in alignment
are easily damaged.
until they are completely separated so parts of
the transmission are not damaged. Use a crane NOTE: When disconnecting wiring harness connec-
or lifting device to separate the transmission tors during disassembly, tag each connector to aid in
from the engine. connecting the wiring harness during reassembly.
1. Remove engine and transmission as a unit from 2. Put engine and transmission on solid blocks on
lift truck as described in one of the following sec- a work surface. Disconnect transmission wiring
tions: connectors from control valve and transmission.
Remove transmission wiring harness from trans-
See Frame 100 SRM 1243 for lift truck models:
mission. See Figure 11.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004) WARNING
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- Make sure that the engine/transmission assem-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) bly is stable before attempting to rotate the en-
gine.
• S30FT, S35FT, S40FTS (E010) Use a flashlight to see the bolts as they are ro-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, tated into view through the access hole. DO
H40FTS) (F001) NOT use your fingers to check for alignment of
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) the bolts with the access hole.
• H2.0-3.5FT (H40-70FT) (L177)
of flywheel housing by rotating crankshaft. Re-
CAUTION move four capscrews that attach flywheel to
To prevent possible damage to the transmis- torque converter. See Figure 12.
sion assembly when placing the assembly on a

Housings and Chain Drive Repair 1300 SRM 1529

4. TRANSMISSION



C. YANMAR ENGINE
4. Remove access cover from torque converter hous- 9. Remove fifteen capscrews from transmission
ing. Install a lifting eye bolt into rear access housing. See Figure 15.
cover bolt hole, and connect a lifting device to
eye bolt. Remove ten capscrews that hold torque 10. Remove two mounting capscrews and harness
converter housing to flywheel housing. Carefully bracket from front of torque converter housing.
separate transmission from the engine. See Figure 15.
5. Carefully remove torque converter from stator 11. Using a small pry bar in the designated pry
support. See Figure 13. points, remove the torque converter housing
from the transmission housing. See Figure 15.
6. Remove plug, suction screen spring, and suction
screen from torque converter housing and drain 12. Remove and discard O-rings and gasket. See Fig-
oil from the transmission. See Figure 13. ure 14.
7. Remove transmission charge pump. See Charge NOTE: While performing Step 13, note position of oil
Pump Repair,Remove. seal to aid in installation of new oil seal.
8. Remove two long capscrews and washers from in- 13. Remove and discard oil seal from rear of torque
ner face of torque converter housing. See Fig- converter housing. See Figure 16.
ure 14.




2. WASHER 6. O-RING
4. GASKET

1. PRY POINTS
4. HARNESS BRACKET
5. CAPSCREW

1. SNUBBER 9. DRIVING SPROCKET

2. PUMP DRIVE CHAIN 10. CAPSCREW
3. BEARING 11. LOCKWASHER
4. DRIVEN SPROCKET 12. STATOR SUPPORT
5. OIL SEAL 13. SEALING RING
6. ANGULAR CONTACT BEARING 14. TRANSMISSION HOUSING
7. BUSHING 15. BAFFLE
8. O-RING
14. Remove two snubbers from transmission hous- 18. Remove four capscrews, lockwashers, and stator
ing. See Figure 16. support from transmission housing. Remove and
discard sealing ring and O-ring from stator sup-
15. Carefully remove pump drive chain, driven port. See Figure 16.
sprocket, driving sprocket, and bearings from
transmission housing. See Figure 16. 19. Remove baffle from transmission housing. See
Figure 16.
16. Remove bearing from driven sprocket. See Fig-
ure 16. 20. Remove O-rings from transmission housing and
discard. See Figure 16.
17. Remove angular contact bearing, bushing, and
O-ring from driving sprocket. Discard O-ring.
See Figure 16.

CLEAN 4. Install stator support, lockwashers, and cap-

screws on transmission housing. See Figure 16.
WARNING Tighten capscrews to 38 N•m (28 lbf ft).
Cleaning solvents can be flammable and toxic 5. On a lint-free cloth, place driving sprocket on
and can cause skin irritation. When using right side, driven sprocket on left side, and place
cleaning solvents, always follow the solvent chain around both sprockets (see Figure 16).
manufacturer’s recommended safety proce- Install bearings on sprockets. The angular bear-
dures. ing should be installed onto driving sprocket
with thinner shoulder of outer race towards
the sprocket and wider shoulder of outer race
(side marked with part number) towards torque
converter housing. Carefully place driving and
driven sprockets, chain, and bearings assembly
on transmission. Install two snubbers on trans-
eyes.
1. Clean snubbers with warm, soapy water and dry
6. Install new oil seal into rear of torque converter
housing as noted during removal.
2. Clean bearings, chain, stator support, and gears
7. Install new O-rings and gasket on torque con-
with solvent and dry with compressed air
INSPECT 8. Using fifteen capscrews, install transmission
1. Inspect snubbers for cracks or wear. If damaged housing to torque converter housing. Tighten
or worn, replace both snubbers. capscrews to 38 N•m (28 lbf ft). See Figure 17.
2. Inspect chain, sprockets, and stator support for 9. Install two washers and long capscrews into face
damage. If damage is present, replace damaged of torque converter housing. Tighten capscrews
component. to 38 N•m (28 lbf ft). See Figure 17.
3. Inspect driving and driven gears for damage or 10. Install harness bracket and two mounting cap-
wear to gear teeth. If gear teeth are worn or screws to front of torque converter housing. See
damaged, replace gear. Figure 15.
4. Inspect splines on the input shaft for damage.If 11. Install suction screen, suction screen spring,
damaged, replace input clutch pack. See Clutch and plug into torque converter housing. See
Packs Repair. Figure 18.
12. Install torque converter onto input shaft and

INSTALL stator support of the transmission. Make sure
1. Install new O-rings on transmission housing. splines are aligned and converter engages fully.
See Figure 16. See Figure 18.
2. Install the baffle in transmission housing. See 13. Lubricate the pilot hub on the torque converter
Figure 16. with antiseize compound. See Figure 18.
3. Install new sealing ring and O-ring on the stator 14. Install the transmission charge pump. See
support. See Figure 16. Charge Pump Repair, Install.


2. WASHER 6. O-RING
4. GASKET
Figure 17. Torque Converter Housing Installation
15. If removed, install a lifting eye bolt into rear ac- 17. Install transmission wiring harness on transmis-
cess cover bolt hole, and connect a lifting device sion. Connect transmission wiring harness con-
to eye bolt. Align torque converter housing with nectors to control valve and transmission. See
flywheel housing. Make sure pilot hub on torque Figure 19.
converter engages flywheel.
NOTE: Coat the bolt threads that hold the torque con-
16. Install transmission to engine. Install ten cap- verter to flywheel with Loctite™ 242.
screws that connect torque converter housing to
flywheel housing. Tighten capscrews to 38 N•m 18. Rotate engine crankshaft to position the fly-
(28 lbf ft). See Figure 19. wheel mounting holes in line with torque con-
verter mounting holes. Install capscrews that
hold torque converter to flywheel through access
CAUTION hole of flywheel housing. See Figure 20. Tighten
Use care when connecting the wiring harness capscrews to 56 N•m (41 lbf ft).
connectors to electrical connectors on the
transmission and control valve. The connec- Remove lifting eye bolt, and install access cover
tors on the transmission and control valve are on torque converter housing.
easily damaged.

1. TRANSMISSION OIL FILTER 6. TRANSMISSION OIL 12. SMALL ACCESS COVER

2. DIPSTICK TEMPERATURE SENSOR 13. TORQUE CONVERTER
3. DIPSTICK TUBE 7. SUCTION SCREEN 14. TRANSMISSION CHARGE
4. TRANSMISSION HOUSING 8. SUCTION SCREEN SPRING PUMP
5. TORQUE CONVERTER 9. PLUG 15. STATOR SUPPORT
HOUSING 10. CAPSCREW 16. PILOT HUB
11. WASHER


4. TRANSMISSION



A. GM 2.4L ENGINE C. YANMAR ENGINE E. CUMMINS 3.3L DIESEL
B. MAZDA ENGINE D. GM 4.3L ENGINE ENGINE
19. Install engine and transmission as a unit into See Periodic Maintenance 8000 SRM 1150 for
lift truck as described in one of the following sec- lift truck models:
tions: • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; See Periodic Maintenance 8000 SRM 1207 for
S80, 100FTBCS; S120FTS; S120FTPRS) lift truck models:
(G004) • S30FT, S35FT, S40FTS (E010)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) H40FTS) (F001)
See Frame 100 SRM 1120 for lift truck models: See Periodic Maintenance 8000 SRM 1248 for
• S30FT, S35FT, S40FTS (E010) lift truck models:
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
H40FTS) (F001) S80, 100FTBCS; S120FTS; S120FTPRS)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (G004)
• H2.0-3.5FT (H40-70FT) (L177) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (P005)
20. Fill transmission to the correct level using trans-
mission fluid and procedure indicated in the fol-
lowing sections:
Clutch Packs Repair

REMOVE AND DISASSEMBLE 1. Remove engine and transmission as a unit from
lift truck as described in one of the following sec-
Transmission, Remove and Disassemble tions:

WARNING • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Make sure the engine and transmission are S80, 100FTBCS; S120FTS; S120FTPRS)
held in position so that they will not fall and (G004)
cause an injury and damage to the equipment. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
CAUTION See Frame 100 SRM 1120 for lift truck models:
Be careful that you do not damage parts of • S30FT, S35FT, S40FTS (E010)
the torque converter or transmission when • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
the transmission is separated from the engine. H40FTS) (F001)
Keep the transmission and engine in align- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
ment until they are completely separated so • H2.0-3.5FT (H40-70FT) (L177)
parts of the transmission are not damaged.
Use a crane or lifting device to separate the


CAUTION of flywheel housing by rotating crankshaft. Re-
To prevent possible damage to the transmis- move four capscrews that attach flywheel to
sion assembly when placing the assembly on a torque converter. See Figure 22.
work surface, place blocks under the back side
of the transmission housing for additional sup- 4. Remove access cover from torque converter hous-
port. ing. Install a lifting eye bolt into rear access
cover bolt hole, and connect a lifting device to
eye bolt. Remove ten capscrews that hold torque
CAUTION converter housing to flywheel housing. Carefully
Use care when disconnecting the wiring har- separate transmission from engine.
the transmission and control valve. The con- 5. Remove torque converter housing from transmis-
nectors on the transmission and control valve sion housing. See Housings and Chain Drive Re-
are easily damaged. pair, Remove.
NOTE: When disconnecting wiring harness connec- 6. Remove idler gear and two bearings. See Fig-
tors during disassembly, tag each connector to aid in ure 23.
connecting the wiring harness during reassembly.
7. Remove bolt, stato seal, and yoke from back of
2. Put engine and transmission on solid blocks on a transmission housing. See Figure 23.
work surface.
8. Remove spacer from yoke. See Figure 23.
Disconnect two connectors of chassis wiring har-
ness from transmission wiring harness. NOTE: Note the position of the oil seal during re-
moval to aid in installation.
Disconnect transmission wiring harness connec-
tors from control valve and transmission. Re- 9. Remove oil seal from back of transmission hous-
move transmission wiring harness from trans- ing. See Figure 23.
mission. See Figure 21. 10. Remove bearing, snap ring, special nut, output
gear, and bearing from transmission housing.
WARNING See Figure 23.
11. Removal and disassembly of clutch assemblies
bly is stable before attempting to rotate the en-
follows. The procedures are the same for for-
gine.
ward, reverse, and high clutch pack assemblies.
Use a flashlight to see the bolts as they are ro- See Figure 24, Figure 25, and Figure 26.
tated into view through the access hole. DO
NOT use your fingers to check for alignment of
the bolts with the access hole.





C. YANMAR ENGINE
1. BEARING 8. OIL SEAL

2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK
7. SPACER 14. HIGH FORWARD CLUTCH PACK
Figure 23. Output Gear Removal


8. SNAP RING
Figure 24. Forward Clutch Pack


5. PISTON 12. PRESSURE PLATE
Figure 25. Reverse Clutch Pack


5. PISTON 12. PRESSURE PLATE
6. SPRING 13. BACK PLATE
Figure 26. High Clutch Pack

Clutch Assemblies, Remove and Disassemble

STEP 1.
Pull forward clutch (low gear), reverse clutch and for-
ward clutch (high gear) assemblies straight out from
1. FORWARD CLUTCH (LOW GEAR)

2. REVERSE CLUTCH
3. FORWARD CLUTCH (HIGH GEAR)
(TOSS)
STEP 2.
Remove shaft seal and bearing from forward (low)
clutch pack input shaft. Discard shaft seal. Remove
bearing from forward (high) and reverse gear packs.

3. REVERSE CLUTCH
4. BEARING
5. SHAFT SEAL

STEP 3.
gear from input shaft

3. REVERSE CLUTCH
4. OUTPUT GEAR
5. SNAP RING
NOTE: Before removing seal bearing, note position of seal on bearing.
STEP 4.
Remove seal from output gear. Remove seal bearing,
snap ring, and bearing from output gear.
1. SEAL BEARING
2. SNAP RING
3. SEAL
4. OUTPUT GEAR
5. BEARING

STEP 5.
Remove snap ring, back plate and pressure plate

from gear assembly drum.
1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE

STEP 6.
Remove friction disks and separator plates alternately until all have been removed from gear assembly drum
1. FRICTION DISK 2. SEPARATOR PLATE 3. GEAR ASSEMBLY DRUM
STEP 7.
1. CONICAL PLATE

WARNING
NOTE: Remove piston only if there is a problem with piston or piston seals.
STEP 8.
Using spring compression tool, Hyster P/N 867890
guide with opening of the tool above opening of snap
guide. Slowly release press to decompress springs.

2. SPRING GUIDE

STEP 9.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove piston from gear assembly drum and piston
seal from piston. Discard piston seal.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL

STEP 11.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
CLEAN grooves is worn away or discs are damaged.

Discard a friction disc that has a thickness less
WARNING than 2.2 mm (0.087 in.).
Cleaning solvents can be flammable and toxic 4. The conical plate and separator plates must not
and can cause skin irritation. When using be bent, have damaged surfaces, or have large
cleaning solvents, always follow the solvent blue areas from too much heat. If any of the
manufacturer’s recommended safety proce- above conditions exist, replace damaged compo-
dures. nent.
Clean all metal parts with cleaning solvent and place 5. Check "H" dimension of conical plate as shown
on a lint-free cloth to dry. Ensure that the cleaning in Figure 27. If dimension is less than 3.2 mm
and assembly environment is free of dust, dirt, and (0.126 in.), replace conical plate.
any other foreign matter that would affect the per-
formance of the parts. 6. Check "t" dimension of conical plate as shown
in Figure 27. If dimension is less than 2.4 mm
INSPECT (0.094 in.), replace conical plate.
1. Inspect gear teeth on clutch assemblies and all
other gears for wear or damage. If the gear teeth
are worn or damaged, replace damaged compo-
nent.
2. Check all parts that have splines for damage to

place clutch pack or gears that have spline dam-
age.
3. Inspect friction discs for burned lining or bent

surfaces. Check for small holes in the lining.
Figure 27. Conical Plate Inspection
Replace friction discs if one-half depth of oil

7. Inspect bearings for wear or damage. If bearings

are damaged, replace them. CAUTION
The dowel pins are used to properly align the
8. Inspect piston for damage. Make sure that seal- housings for proper mating to each other. If the
ing surfaces are good. Make sure orifice is clean. alignment is not correct, damage to the trans-
mission assembly could occur.
9. Check for grooves or other damage on machined
surfaces of clutch pack shafts and transmission 11. Inspect dowel pins and dowel pin holes. If any
housing. Check mounting and sealing surfaces dowel pin is damaged at all, replace the dowel
in housing for damage. If there is evidence of pin. If a dowel pin hole is damaged, replace hous-
any damage, replace housing or transmission. ing.
If clutch pack shaft is damaged, replace clutch
pack. 12. Check fit of bearings in transmission housings.
If bearings fit too loosely into the housings, this
10. Inspect all hardware and mounting surfaces for could mean that bores are oversized. Replace
presence of rust, sealing compounds, and usable housings as necessary.
condition. If hardware is to be reused, clean all
rust and sealing compounds from threaded areas.
If hardware is not in usable condition, replace
hardware.
Clutch Assemblies, Assemble and Install

STEP 1.
Install bearing and new shaft seals on input shaft.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT

STEP 2.
stall shaft seal on shaft and piston seal on piston.
1. PISTON SEAL
2. PISTON
STEP 3.
Install piston into gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL

STEP 4.
snap ring on the input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT

STEP 5.
guide with opening of tool above opening of the snap

2. SPRING GUIDE

NOTE: The conical plate is properly installed when inner diameter is touching piston, and outer diameter of
conical plate is touching outer diameter of friction disk.
STEP 6.
1. CONICAL PLATE

STEP 7.
Install separator plates and friction disks alternately until all have been installed in gear assembly drum.
1. FRICTION DISK 2. SEPARATOR PLATE 3. GEAR ASSEMBLY DRUM

STEP 8.
Install pressure plate, back plate and snap ring

in gear assembly drum. Using a dial indicator or
feeler gauge, check clearance between snap ring
and pressure plate. There must be 2.7±0.2 mm
(0.106±0.008 in.) of clearance. If clearance is not
correct, see Parts Manual for correct pressure plate.
1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE
NOTE: Make sure seal on seal bearing is in correct position as noted during removal.
STEP 9.
Install seal onto output gear. Install bearing, snap
ring, and seal bearing into output gear.
1. SEAL BEARING
2. SNAP RING
3. SEAL
4. OUTPUT GEAR
5. BEARING

STEP 10.
Install output gear on input shaft. Install bearing
and snap ring in output gear.
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
STEP 11.
Install bearing and shaft seal on input shaft for
Forward (low) gear pack. Install bearing to Forward
(high) and Reverse gear packs.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 12.
Install reverse clutch assembly in transmission hous-
ing. DO NOT damage seal rings on end of clutch
shaft.
Check gap between TOSS and TISS sensors and re-

verse gear. The allowable gap for TOSS sensor is 0.8
to 1.8 mm (0.031 to 0.071 in.). The allowable gap for
TISS sensor is 0.8 to 2.0 mm
(0.031 to 0.080 in.).
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR
STEP 13.
Install forward clutch assemblies (high and low) in
transmission housing. DO NOT damage seal rings
on end of clutch shaft.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR

Transmission, Assemble and Install 4. Install yoke, stato seal, and bolt in back of trans-
mission. Tighten bolt to 38 N•m (28 lbf ft). See
1. Install bearing, output gear, special nut, snap Figure 28.
ring, and bearing on transmission. See Fig-
ure 28. 5. Install two bearings and idler gear. See Fig-
ure 28.
2. Install oil seal into back of transmission as noted
during removal. 6. Install torque converter housing on transmis-
sion. See Housings and Chain Drive Repair,
3. Install spacer in yoke. Install.
1. BEARING 8. SPACER
2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK (LOW)
7. OIL SEAL 14. FORWARD CLUTCH PACK (HIGH)
Figure 28. Output Gear Installation


CAUTION • S30FT, S35FT, S40FTS (E010)
Use care when connecting the wiring harness • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
connectors to electrical connectors on the H40FTS) (F001)
transmission and control valve. The connec- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
tors on the transmission and control valve are • H2.0-3.5FT (H40-70FT) (L177)
easily damaged.
10. Fill transmission to the correct level using trans-
7. Install transmission wiring harness on transmis- mission fluid and procedure indicated in the fol-
sion. Connect transmission wiring harness con- lowing sections:
nectors to control valve and transmission. Con-
nect two chassis wiring harness connectors to See Periodic Maintenance 8000 SRM 1150 for
transmission wiring harness. See Figure 29. lift truck models:
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
NOTE: Coat the bolt threads that hold the torque con- • H2.0-3.5FT (H40-70FT) (L177)
verter to flywheel with Loctite™ 242.
See Periodic Maintenance 8000 SRM 1207 for
8. Rotate engine crankshaft to position the fly- lift truck models:
wheel mounting holes in line with torque con- • S30FT, S35FT, S40FTS (E010)
verter mounting holes. Install capscrews that • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
hold torque converter to flywheel through access H40FTS) (F001)
hole of flywheel housing. See Figure 30. Tighten
capscrews to 56 N•m (41 lbf ft). See Periodic Maintenance 8000 SRM 1248 for
lift truck models:
Remove lifting eye bolt, and install access cover • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
on torque converter housing. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
9. Install engine and transmission as a unit into • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
lift truck as described in one of the following sec- 5.5FT (H80, 90, 100, 110, 120FT) (P005)
tions:

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)


4. TRANSMISSION



A. GM 2.4L ENGINE C. YANMAR ENGINE E. CUMMINS 3.3L DIESEL
B. MAZDA ENGINE D. GM 4.3L ENGINE ENGINE
Control Valve Repair

REMOVE AND DISASSEMBLE 2. Remove capscrews and lockwashers from control
valve and transmission. See Figure 32.
CAUTION
nesses from the connectors. The connectors
are easily damaged.
1. Clean area around control valve. Put identifica-

tion tags on wire harness connectors and connec-
tors on transmission and control valve. Discon-
nect wiring harness connectors from transmis-
sion and control valve connectors. Remove ca-
ble connector from standoff located on torque con-
2. GASKET
4. LOCKWASHER
2. HARNESS STANDOFF 6. TRANSMISSION INPUT SPEED SENSOR (TISS)
3. TRANSMISSION WIRING HARNESS 7. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
Figure 31. Transmission Assembly
Figure 32. Control Valve Removal

3. Remove control valve assembly and gasket from plugs so that the compressed springs do not
transmission. Discard gasket. Put a cover on cause injury.
top of the transmission to keep dirt out of the
transmission. See Figure 32. 7. Remove plug for proportional supply regulator
spool. Discard O-ring. See Figure 34.
4. Remove capscrew, lock washer and the transmis-
sion input speed sensor (TISS) from transmis- 8. Remove spring and proportional supply regula-
sion. See Figure 33. tor spool from control valve body. See Figure 34.
9. Remove plug for torque converter regulator

spool. Discard O-ring. See Figure 34.
10. Remove the spring and torque converter regula-

tor spool from control valve body. See Figure 34.
11. Remove plug for supply spool. Discard O-ring.

See Figure 34.
12. Remove the spring and supply spool from the con-
trol valve body. See Figure 34.
13. Remove socket head screws and forward propor-

tional valve from control valve body. Repeat for
reverse proportional valve. See Figure 34.
14. Remove socket head screws and transmission en-

able valve from control valve body. See Figure 34.
CLEAN
WARNING
1. TRANSMISSION ASSEMBLY and can cause skin irritation. When using
2. TRANSMISSION OUTPUT SPEED SENSOR cleaning solvents, always follow the solvent
(TOSS) manufacturer’s recommended safety proce-
4. LOCK WASHER dures.
5. CAPSCREW
Figure 33. Transmission Speed Sensor cause injury to the user or to other personnel.
5. Remove capscrew, lock washer and the transmis- away from all personnel. Wear protective gog-
sion output speed sensor (TOSS) from transmis- gles or a face shield to prevent injury to the
sion. See Figure 33. eyes.
NOTE: Disassemble control valve only to extent re-
quired for repairs. CAUTION
NOTE: Disassemble the control valve in a clean, contact with rubber or plastic components as it
tamination-free area. can damage those components.
6. Remove two pressure transducers and two fit- Clean all metal components in solvent and dry with
tings from control valve body. See Figure 34. compressed air.
WARNING INSPECT
There are compressed springs under the plugs
in the control valve. Carefully remove the
the spools or in the bores of the control valve body.

If the control valve body bores are damaged, re- 3. Check that the springs are not bent or damaged.
place the control valve. Make sure the spools move freely in their bores.
2. Inspect the control valve body for the presence of 4. Inspect the connectors on the proportional and
burrs. Burrs may be removed using a fine file, solenoid valves and, if they are damaged, replace
emery cloth, or crocus cloth. the damaged proportional or solenoid valves.
1. CONTROL VALVE BODY 7. FORWARD PROPORTIONAL VALVE

2. PRESSURE TRANSDUCER 8. SOCKET HEAD SCREW
3. FITTING 9. TORQUE CONVERTER REGULATOR SPOOL
4. PROPORTIONAL SUPPLY REGULATOR SPOOL 10. REVERSE PROPORTIONAL VALVE
5. SPRING 11. TRANSMISSION ENABLE VALVE
6. PLUG 12. SUPPLY SPOOL
Figure 34. Control Valve Arrangement

ASSEMBLE AND INSTALL Figure 32. Install capscrews that hold control
valve on transmission. DO NOT tighten at this
NOTE: Lubricate the parts of the control valve with time. See Figure 34.
clean transmission oil during assembly.
10. Tighten capscrews to 13.3 N•m (118 lbf in) in
1. Install transmission enable valve and socket the sequence shown in Figure 35. Retighten cap-
head screws onto control valve body. Tighten screws to 19 N•m (168 lbf in) in sequence shown
socket head screws to 3 to 4 N•m (27 to 35 lbf in). in Figure 35.
See Figure 34.
2. Install reverse proportional valve, forward pro- CAUTION

portional valve, and socket head screws onto con- Use care when connecting the wiring har-
trol valve body. Tighten socket head screws to 3 nesses to the connectors. The connectors are
to 4 N•m (27 to 35 lbf in). See Figure 34. easily damaged.
3. Install supply spool and spring into control valve 11. Install cable connector in standoff and connect
body. Install new O-ring on plug. Install plug wiring harness connectors to transmission and
into control valve body. See Figure 34. control valve as tagged during removal. See Fig-
ure 31.
4. Install torque converter regulator spool and
spring into control valve body. Install new
O-ring on plug. Install plug into control valve
body. See Figure 34.
5. Install proportional supply regulator spool and

spring into control valve body. Install new O-ring
on plug. Install plug into control valve body. See
Figure 34.
6. Install two fittings and two pressure transducers

into control valve body. See Figure 34.
7. Install transmission input speed sensor (tiss)

and capscrew in transmission. Tighten cap-
screws to 6.9 N•m (61 lbf in). See Figure 34.
8. Install the transmission output speed sensor

(toss) and capscrew in the transmission. Tighten
capscrews to 6.9 N•m (61 lbf in). See Figure 34.
Figure 35. Control Valve Mounting Screw
9. Install a new control valve gasket on transmis- Tightening Sequence
sion. Install control valve on transmission. See

REMOVE AND DISASSEMBLE See Frame 100 SRM 1120 for lift truck models:
• S30FT, S35FT, S40FTS (E010)
1. Remove five screws, dash panel, and kick plate • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
from lift truck. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) Remove three capscrews and swing hydraulic
(G004) lever assembly toward operator’s seat. Dis-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- connect two cable assemblies from the pedal
5.5FT (H80, 90, 100, 110, 120FT) (P005) assembly. See Figure 36.

from throttle base and MONOTROL pedal as-

sembly.
5. Remove e-clip and throttle base from throttle

pedal shaft. Remove roll pin and throttle pedal
shaft from MONOTROL pedal assembly. Dis-
card roll pin.
NOTE: Tag wires prior to removing from mi-

6. Remove u-clip, foam lock seal, and wiring har-

ness from pedal frame. Remove four pan head
screws, lockwashers, washers, pedal pad, and
springs from pedal frame. If any metal inserts
in pedal pad are damaged, replace as necessary.
See Figure 39.
1. CAPSCREW
Figure 36. Hydraulic Lever Relocation
2. Remove three capscrews that hold throttle base

to cowl, and remove pedal assembly from lift
3. Remove two pan head screws, lockwashers, and

See Figure 38.
CAUTION
NOTE: Remove only those components necessary to 1. CAPSCREWS

complete the repair of the MONOTROL pedal. 2. PEDAL ASSEMBLY
3. COWL
4. Remove connector from connector holder on
throttle base. Remove outer and inner springs Figure 37. MONOTROL Pedal Removal

1. PAN HEAD SCREW 6. THROTTLE PEDAL SHAFT

2. LOCKWASHER 7. E-CLIP
3. ACCELERATOR POSITION SENSOR (APS) 8. ROLL PIN
4. PEDAL FRAME 9. INNER AND OUTER SPRINGS
5. CONNECTOR 10. MONOTROL
Figure 38. MONOTROL Pedal Bracket Disassembly
7. Remove two hex head screws, lockwashers, nuts, screws with Loctite™ 222. Install two lockwash-
and microswitch from pedal pad. Repeat for re- ers and nuts on hex head screws. DO NOT
maining microswitch and remove wiring harness tighten nuts at this time. Repeat for the other
from pedal frame. microswitch.
8. If damaged, remove stop screw and nut from 3. Put wires through hole in pedal frame. The white
pedal frame. banded wire is for reverse microswitch, and the
blue banded wire is for forward microswitch.
ASSEMBLE AND INSTALL Adjust each microswitch in its mount so that the
measurement between the edge of the mount
1. If removed, install stop screw and nut on pedal and the base of the microswitch equals 0.0 to
frame. See Figure 39. 0.5 mm (0.0 to 0.02 in.). Tighten the mounting
nuts of each microswitch as adjustment is com-
pleted. See Figure 40.


Figure 39. MONOTROL Pedal Disassembly

6. Install throttle pedal shaft and new roll pin in

the MONOTROL pedal assembly. Install throt-
tle base and e-clip on throttle pedal shaft. See
Figure 38.
CAUTION
Use care when installing the connector in its

and MONOTROL pedal assembly. Install con-
nector in connector holder on throttle base.
8. Install actuator and magnet in the throttle base.

Install accelerator position sensor, lockwashers,
and two pan head screws in the throttle base.
9. Apply adhesive compound to three mounting

bolts. Using three capscrews that hold the throt-
tle base to the cowl, install the pedal assembly
on lift truck. Tighten the bolts to 19 to 25 N•m
(168 to 221 lbf in). See Figure 37.
1. MICROSWITCH MOUNT
2. MICROSWITCH BASE
4. Install wiring harness in the pedal frame. In-

stall foam lock seal and u-clip. Install pedal pad
and springs in the pedal frame. Coat threads of
four pan head screws with Loctite 222. Install
pan head screws, lockwashers, and washers in
the pedal pad. Tighten pan head screws to 2.25
to 2.50 N•m (19 to 32 lbf in).
5. Using an ohmmeter, check for continuity be- 1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
tween pins 3 and 4 of the MONOTROL wiring
harness connector with the MONOTROL pedal Figure 41. Microswitch Continuity Check
in the reverse position, and between pins 1 and
2 with the pedal in the forward position. See
Figure 41.

1300 SRM 1529 Direction Control Lever
10. Connect two cable assemblies to pedal assembly. See Frame 100 SRM 1120 for lift truck models:
Swing hydraulic lever assembly toward cowl and • S30FT, S35FT, S40FTS (E010)
install three capscrews. See Figure 36. Install • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
dashboard on the lift truck. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
SeeFrame 100 SRM 1243 for lift truck models: • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) 11. Depress the MONOTROL pedal until it stops.
(G004) Unscrew stop screw until it contacts metal floor
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- plate. Tighten nut to 10 N•m (89 lbf in).
5.5FT (H80, 90, 100, 110, 120FT) (P005)
Direction Control Lever

REMOVE of lever enough to free tab of interior lock of the
display panel. See B, Figure 42.
NOTE: There is no repair of the direction control
lever. 3. Repeat above steps on the opposite side of direc-
tion control lever. Remove direction control lever
1. Insert a small, flat-blade screwdriver with a from display panel.
3.175 mm (0.125 in.) or less, wide blade into
opening on display panel on an outward angle INSTALL
enough to compress spring tab on direction con-
trol lever. See A, Figure 42. Slide the direction control lever into opening on left
side of display panel until locking tabs are engaged
2. Pry spring tab toward body of direction control in display panel.
lever and, at the same time, pull on the handle

Direction Control Lever 1300 SRM 1529
NOTE: DISPLAY PANEL SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY.

A. STEP 1 B. STEP 2
1. DIRECTION CONTROL LEVER 3. DISPLAY PANEL
2. FLAT-BLADE SCREWDRIVER
Figure 42. Direction Control Lever Removal

1300 SRM 1529 10/11 Printed in U.S.A.

DRIVE AXLE AND
DIFFERENTIAL
ASSEMBLY REPAIR
(DRY BRAKE)
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1599963 1400 SRM 1214

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
Drive Axle and Differential Assembly Repair Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Drive Axle Repair............................................................................................................................................... 1
Differential Repair ............................................................................................................................................. 6
Remove ........................................................................................................................................................... 6
Differential Assembly From Center Section ............................................................................................ 6
Drive Pinion, Pinion Gear, and Bearings From Center Section ............................................................. 11
Disassemble ................................................................................................................................................... 16
Differential Assembly ............................................................................................................................... 16
Drop Box Housing ..................................................................................................................................... 19
Center Section ........................................................................................................................................... 20
Assemble ........................................................................................................................................................ 22
Center Section ........................................................................................................................................... 22
Drop Box Housing ..................................................................................................................................... 26
Install ............................................................................................................................................................. 31
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) .................................................................. 31
Drive Pinion, Pinion Gear, and Bearings Into Center Section ............................................................... 32
Differential Assembly Into Center Section .............................................................................................. 37
Ring Gear Backlash, Adjust...................................................................................................................... 43
Ring Gear, Runout Check ......................................................................................................................... 44
Gear Set, Tooth Contact Pattern Check................................................................................................... 44
H2.0-3.5FT (H40-70FT) [L177]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1400 SRM 1214 Drive Axle Repair
General
This section has the repair procedures for the drive axle and differential assembly.
Drive Axle Repair

REMOVE AND DISASSEMBLE WARNING
On lift trucks with pneumatic tires, completely
WARNING remove air from tires before removing them
When putting the lift truck on blocks, make from lift truck. Air pressure in tires can cause
sure the surface is solid, even, and level. Any tire and rim parts to explode, which can cause
blocks used to support the lift truck must be serious injury or death. Never loosen nuts that
solid, one-piece units. hold together inner and outer wheel halves
when there is air pressure in tire.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift 5. Remove the wheels.
truck.
6. Disconnect the brake line connecting the master
2. Raise the lift truck and put blocks under the cylinder to the brake manifold located on top of
frame so that the drive wheels do not touch the the assembly. See Figure 2.
floor. Put blocks under the counterweight for
stability. 7. Remove the parking brake cable. Refer to the
section Brake System 1800 SRM 1135.
3. Remove the mast assembly as described in the
section Mast Repairs, 2-, 3-, and 4-Stage 8. Place blocks under the axle assembly and connect
Masts 4000 SRM 1148. slings and lifting device.
4. Remove the drain plug and drain the oil from the 9. Place blocks under the transmission to support
drive axle into a suitable container. See Figure 1. the transmission while removing the drive axle.
10. Remove the capscrews retaining the drive shaft

and remove the drive shaft.
11. Remove the transmission isolator mounting bolt

located on top of the assembly.
12. Remove the four mounting capscrews from the

drive axle assembly. See Figure 2.
1. CENTER SECTION
2. DRAIN PLUG
Figure 1. Drain Plug
1
Drive Axle Repair 1400 SRM 1214
1. UNIVERSAL JOINT 9. ROLLER BEARING 17. ROLLER BEARING

2. INPUT SHAFT (YOKE) 10. WHEEL BEARING WASHER 18. OUTER SEAL
3. DUST COVER 11. LOCK PLATE 19. CAPSCREW
4. BRAKE MANIFOLD 12. LOCK NUT 20. BRAKE ASSEMBLY
5. CENTER SECTION HOUSING 13. AXLE SHAFT 21. BRAKE LINE
6. O-RING 14. CAPSCREW 22. HANGER ASSEMBLY
7. WASHER 15. HUB/BRAKE DRUM 23. WASHER
8. CAPSCREW ASSEMBLY 24. CAPSCREW
16. INNER SEAL
Figure 2. Drive Axle
2
13. Remove blocks and lower the drive axle assembly

and disengage the drive axle assembly from the
transmission.
14. Place blocks under the differential assembly.
15. Remove the axle shafts, hub/brake drum assem-

blies, and back plates. Refer to the section Brake
System 1800 SRM 1135.
16. Remove the capscrews that hold the hanger as-

sembly to the center section housing. Remove the
hanger assembly. Repeat this step on the oppo-
site side.
CLEAN AND INSPECT
WARNING
manufacturer’s recommended safety precau-
tions.
1. Clean all the parts of the drive axle with solvent.
2. Inspect the bearings and seals for damage. 1. O-RING

2. HANGER ASSEMBLY
3. Inspect the axle shafts for wear and cracks at the
Figure 3. Hanger Assembly
flange, shaft, and splines. If axle shafts show
signs of wear or damage, replace the axle shafts.
The splines for the axle shafts must not be dam-
aged.

1. Apply grease to new O-rings and install O-rings
on the hanger assemblies. See Figure 2 and Fig-
ure 3.
2. Place the hanger assembly in position on the cen-

ter section housing. Apply Loctite® 242 to the
capscrews and install capscrews to retain hanger
assembly. Tighten capscrews in sequence shown
in Figure 4 to 225 to 248 N•m (166 to 183 lbf ft).
Repeat this step on the opposite side.
Figure 4. Hanger Assembly Tightening
Sequence
3
Drive Axle Repair 1400 SRM 1214
NOTE: Apply Loctite® 515 or High Performance RTV

Silicone Gasket Maker on the axle shaft flange when WARNING
installing. Add air to the tires only in a safety cage. In-
spect safety cage for damage before use. When
3. Install the back plates, hub/brake drum assem- adding air, use a clip-on chuck with enough
blies, and axle shafts. Refer to the section Brake hose to let the operator stand clear of the cage.
NOTE: When tightening the wheel nuts, DO NOT use
4. Connect slings and lifting device to drive axle. any lubricant on the studs or nuts.
NOTE: When installing the drive axle, ensure the 12. Inflate the tires using a safety cage. Install the
drive axle is held with the upper surface of the drive wheels and nuts and tighten the nuts to 340 to
axle against the frame. This will prevent any gap be- 380 N•m (251 to 280 lbf ft).
tween the frame and the drive axle mount, and will
ensure even weight bearing distribution.
5. Position the drive axle in the lift truck.
NOTE: It is recommended to use a torque multiplier

to achieve the torque specification in Step 6.
6. Install the four mounting capscrews and wash-

ers. Tighten the capscrews to 820 to 902 N•m
(605 to 665 lbf ft).
7. Place the drive shaft in position and install the

retaining capscrews. Tighten the drive shaft cap-
NOTE: When installing the transmission isolator,

make sure to place one washer above and below the
isolators.
8. Install the transmission isolator mounting bolt

located on top of the assembly. Tighten the bolt to
225 to 250 N•m (166 to 184 lbf ft). See Figure 5.
9. Remove blocks from under the transmission.
10. Install the parking brake cable. Make sure the

1. TRANSMISSION
brake cable is routed properly and has no inter- 2. CENTER SECTION HOUSING
ference. Verify that the parking brake operates 3. ISOLATOR, TRANSMISSION
properly. Refer to the section Brake System 4. WASHER
1800 SRM 1135. 5. LOCKWASHER
6. MOUNTING BOLT
11. Connect the brake line connecting the master
cylinder to the brake manifold located on top of Figure 5. Transmission to Center Section
the assembly. Housing Mounting Bolt
4
13. Install the drain plug and tighten to 50 to

55 N•m (37 to 41 lbf ft). See Figure 1.
14. Remove the fill plug and fill the drive axle to the
proper level as shown in Figure 6, with 6.3 to
6.8 liter (6.6 to 7.1 qt) of SAE 80W-90 gear oil
through the fill hole. Install the fill plug.
15. Remove the air from the brake system as de-

scribed in the section Brake System 1800 SRM
1135.
16. Install the mast assembly as described in the sec-

tion Mast Repairs, 2-, 3-, and 4-Stage Masts
4000 SRM 1148.
17. Raise the lift truck and remove blocks from un- 1. OIL FILL PLUG
der the frame and from under the counterweight. 2. OIL FILL LEVEL
Lower the lift truck.
Figure 6. Oil Fill Level
18. Remove the blocks on each side (front and back)
of the steering tires.
19. Operate the lift truck and check for proper oper-
ation and leaks.
5
Differential Repair 1400 SRM 1214
Differential Repair
REMOVE
For the following repair procedures, the drive axle
must be removed and disassembled. Refer to the sec-
tion Drive Axle Repair.
Differential Assembly From Center Section

STEP 1.
Remove the capscrews retaining the center section
cover and remove cover.
1. CENTER SECTION COVER

2. CAPSCREW
3. CENTER SECTION
NOTE: Before working on the differential assembly, inspect the hypoid gear set for damage. If inspection shows
no damage, the same gear set can be used again. Using a dial indicator, measure the backlash of the gear
set and make a record of the dimension. See the procedure Gear Set, Tooth Contact Pattern Check. During
differential reassembly, adjust the backlash to the original recorded dimension when the gear set is installed
into the center section.
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced,
go to STEP 2. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced
in a lift truck manufactured prior to October 2006, go to STEP 3.
6
1400 SRM 1214 Differential Repair
STEP 2.
Remove differential assembly retainer ring cotter
pins. Using a retainer ring special tool, Hyster Part
No. 1581188, loosen the retainer rings. If neces-
sary, loosen the bearing cap capscrews to allow the
retainer rings to turn freely.
1. COTTER PIN
2. RETAINER RING
1. RETAINER RING SPECIAL TOOL
7
STEP 3.
Remove differential assembly retainer ring cotter
pins. Using a retainer ring special tool, Hyster Part
No. 1663599, loosen the retainer rings. If neces-
sary, loosen the bearing cap capscrews to allow the
retainer rings to turn freely.
1. COTTER PIN
2. RETAINER RING
8
STEP 4.
Mark one differential carrier leg and bearing cap to
correctly match the parts when assembling differen-
tial assembly. Mark the parts using a center punch
and hammer. Remove the capscrews and washers re-
taining the bearing caps. Remove the bearing caps.
1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. BEARING CAP
STEP 5.
Remove the retainer rings.
1. CENTER SECTION
2. RETAINER RING
9
STEP 6.
Loosen locknut, and remove thrust screw from center
section.
1. CENTER SECTION
2. THRUST SCREW
3. LOCKING NUT
STEP 7.
Remove the differential assembly.
1. CENTER SECTION
2. DIFFERENTIAL ASSEMBLY
3. TAPERED ROLLER BEARING AND CUP
10
Drive Pinion, Pinion Gear, and Bearings From Center Section

STEP 1.
Remove the snap ring from the pinion head.
1. CENTER SECTION
2. SNAP RING
3. PINION
STEP 2.
Remove the capscrews retaining the pinion support
bracket and remove bracket.
1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. PINION SUPPORT BRACKET
11
STEP 3.
Using a press, press the bearing out of the pinion sup-
port bracket.

2. BEARING
STEP 4.
Remove the capscrews and washers retaining the
pinion cover and remove cover.
1. CAPSCREW
2. WASHER
3. PINION NUT
4. CENTER SECTION
12
CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The
staked areas can cause damage to the pinion threads, making the pinion unserviceable.
NOTE: When removing the pinion, be sure to retain the shims.
STEP 5.
Using a small and flat chisel, unstake the pinion nut.
Remove the pinion nut, washer, bearing cone, and

shims.
1. CENTER SECTION
2. SHIMS
3. BEARING CONE
4. WASHER
5. PINION NUT
STEP 6.
Remove the capscrews and washers retaining the
drop box housing.
1. CENTER SECTION
2. DROP BOX
3. CAPSCREW
4. BRACKET
13
STEP 7.
Using two of the M8 × 1.25 × 50 capscrews removed
from the drop box housing, push the drop box hous-
ing from the center section. If the capscrews do not
have enough threaded length, use a pry bar to finish
removing the housing.
1. INSERT M8 × 1.25 × 50 CAPSCREWS
NOTE: When removing the pinion, be sure to retain the shims.
STEP 8.
Carefully remove pinion assembly from the center
section. Using a press and a bearing puller, remove
the shims and inner bearing from the pinion.
1. PINION
2. SHIMS
3. BEARING
4. CENTER SECTION
14
STEP 9.
Remove the driven gear.
1. DRIVEN GEAR
2. CENTER SECTION
STEP 10.
Using a suitable soft drift, remove the bearing cup.
1. DROP BOX
2. BEARING CUP
15
STEP 11.
Using a suitable soft drift, remove the pinion inner
bearing cup.
1. CENTER SECTION
2. INNER BEARING CUP
DISASSEMBLE
Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable bearing
puller, remove the bearings from the differential as-
sembly.
1. BEARING CUP
2. TAPERED ROLLER BEARING
16
STEP 2.
Remove the capscrews retaining the ring gear to the
differential assembly. Remove the ring gear.
1. RING GEAR
3. CAPSCREW
NOTE: Mark each side of the case halves before separating to ensure alignment at reassembly.
STEP 3.
Remove the capscrews retaining the case halves to-
gether and separate the case halves.
Inspect the case halves for wear or damage. If wear

or damage is present, the entire differential assem-
bly must be replaced.
1. CAPSCREW
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF
17
STEP 4.
Remove the side gears and thrust washers from the
differential halves.
1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF
STEP 5.
Remove the pinions and thrust washers from the spi-
der.
Inspect the spider for wear or damage. Replace as

needed.
1. THRUST WASHER
2. PINION
3. SPIDER
18
Drop Box Housing

STEP 1.
Remove the input shaft oil seal.
1. DROP BOX
2. OIL SEAL
STEP 2.
Remove the drive gear outer bearing.
1. BEARING
2. DROP BOX
19
Center Section
NOTE: Only remove the breather cap and elbow fitting if they are damaged.
STEP 1.
Remove the breather cap and elbow fitting.
1. BREATHER CAP
2. ELBOW FITTING
3. CENTER SECTION
NOTE: Only remove the brake manifold and bracket if they are damaged.
STEP 2.
Remove the capscrew and washer retaining the brake
manifold and bracket. Remove the brake manifold
and bracket.
1. CAPSCREW
2. WASHER
3. BRAKE MANIFOLD AND BRACKET
4. CENTER SECTION
20
STEP 3.
Remove the drive gear.
1. DRIVE GEAR
2. CENTER SECTION
STEP 4.
Remove the drive gear inner bearing.
1. BEARING
2. CENTER SECTION
21
CLEAN AND INSPECT Clean and inspect the following parts of the differen-
tial:
WARNING • Drive axle- Clean the parts of the axle with sol-
vent and dry with compressed air. Inspect all ma-
chined surfaces and bearings for wear and damage.
• Tapered roller bearings- Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
assembly. If bearings show signs of wear, cracks, or
damage, replace with new bearing.
WARNING • Pinions and gears- Inspect the pinions and gears
Compressed air can move particles so that they for wear or damage. Gears that are worn or dam-
cause injury to the user or to other personnel. aged must be replaced.
Make sure that the path of the compressed air • Main differential assembly- Inspect all parts of
is away from all personnel. Wear protective the main differential assembly for wear or damage.
goggles or a face shield to prevent injury to the Parts that are damaged must be replaced.
eyes.
ASSEMBLE
Center Section
NOTE: Only install a few threads of the thrust screw at this point. The thrust screw clearance between the
ring gear and the thrust screw will need to be set after installing the differential assembly.
STEP 1.
Partially install the thrust screw, but do not tighten
the locking nut.
1. LOCKING NUT
2. THRUST SCREW
3. CENTER SECTION
22
STEP 2.
Using a press on the outer race of the bearing, press
the drive gear inner bearing into the center section
until it is contacting the bottom of the bore.
1. BEARING
2. CENTER SECTION
23
STEP 3.
Install the drive gear. Check the orientation to make
sure the yoke will slip into the drive gear.
1. DRIVE GEAR
2. CENTER SECTION
A. TOWARD YOKE
B. TOWARD CENTER SECTION
24
STEP 4.
Place the brake manifold and bracket in position on
the differential assembly. Install the capscrew and
washer. Tighten the capscrew to 19 to 21 N•m (14 to
15.5 lbf ft)
1. CAPSCREW
2. WASHER
3. BRAKE MANIFOLD AND BRACKET
4. CENTER SECTION
STEP 5.
Wrap the breather cap and elbow fitting threads with
approximately 1.5 turns of Teflon tape. Install the
breather cap and elbow fitting.
1. BREATHER CAP
2. ELBOW FITTING
3. CENTER SECTION
25
Drop Box Housing

STEP 1.
Using a press on the outer race of the bearing, press
the drive gear outer bearing into the drop box until it
is contacting the bottom of the bore.
1. BEARING
2. DROP BOX
STEP 2.
Using a press on the outer diameter of the input shaft
oil seal, press the input shaft oil seal into the drop
box until the seal is flush with the housing.
After installing the seal, apply grease to the lip of the

seal.
1. DROP BOX
2. OIL SEAL
26
STEP 1.
Lubricate both sides of the thrust washers with 80W
- 90W gear lube. Install the pinions and thrust wash-
ers onto the spider.
1. THRUST WASHER
2. PINION
3. SPIDER
STEP 2.
Lubricate both sides of the thrust washers with 80W
- 90W gear lube. Install the side gears and thrust
washers into the differential halves.
1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF
27
STEP 3.
Place the spider assembly into the case halves and
assemble the case halves. Apply Loctite® 242 to the
threads of the capscrews and install the capscrews.
Tighten the capscrews in the sequence shown to 125
to 145 N•m (92 to 107 lbf ft).
1. CAPSCREW
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF
28
STEP 4.
Place the ring gear in position on the differential as-
sembly and install capscrews. Tighten the capscrews
in a cross/diagonal pattern to 152 to 167 N•m (112 to
123 lbf ft).
1. RING GEAR
3. CAPSCREW
29
CAUTION
Do not damage the bearing rollers or cage when pressing the bearing cones onto the differential
assembly. Press on the inner raceway of the cone.
STEP 5.
Press the bearing cones onto the onto the differential
assembly. Install the bearing cups onto the bearing
cones.
1. BEARING CUP
2. TAPERED ROLLER BEARING
30
INSTALL if the value is a plus (+) value. Subtract the num-

ber if the value is a minus ( ) value. The result
Pinion Inner Shim Set, Adjust Thickness is the correct thickness for the new shim set. See
(Depth of Pinion) the examples in Table 1.
NOTE: Use this procedure if a new ring gear and pin- NOTE: The value calculated in Step 3 is the thickness
ion set is installed, or if the depth of the pinion has of the new shim set that will be installed. See the
to be adjusted. examples shown in Table 1.
NOTE: If replacing the center section, use a new stan-

dard shim set with nominal thickness of 1 mm for ad-
justing the depth of the pinion and a new standard
shim set with nominal thickness of 1 mm for adjust-
ing the preload. Perform the following procedure un-
til the correct backlash and gear tooth contact pat-
tern is achieved.
The pinion is adjusted using shims. If the same bear-

ings, ring gear, and pinion are used, use the original
shim set. See Figure 7. If a new bearings, ring gear,
and pinion are used, adjust the pinion as described
below.
The correct shim set thickness can be found by us-

ing the original and new parts. Use the original shim
set thickness and the pinion variation number on the
original and new pinion. For the location and identi-
fication of the number, see Figure 8. 1. PINION NUT
2. WASHER
Find the correct thickness of the mounting distance 3. BEARING
(inner) shim set as follows: 4. OUTER SHIM SET (CONTROLS BEARING
PRELOAD)
1. Use a micrometer to measure the total thickness 5. GEAR
of the original shim set that was removed from 6. BEARING
7. INNER SHIM SET (CONTROLS DEPTH OF
under the pinion carrier. Make a note of the mea- PINION)
surement for later use.
Figure 7. Shim Set Location
2. Check the pinion variation number for the orig-
inal pinion. See Figure 8. If this number is a
plus (+) value, subtract the value from the value
in Step 1. If the pinion variation number is a mi-
nus ( ) value, add the number to the value in
Step 1. The number shown is in 0.00 × inch (+2 =
+0.002 in.). The result is the standard thickness
for a shim set.
NOTE: The value calculated in Step 2 is the thickness

of the standard shim set, without a variation. 1. PINION VARIATION NUMBER
3. Check the pinion variation number for the new Figure 8. Pinion Variation Number
pinion. Add or subtract this number to the stan-
dard thickness value of Step 2. Add the number
31
Table 1. Pinion Variation Numbers Examples
Examples in. mm
NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 8.
1. Original Shim Set Thickness 0.030 0.76
Original Pinion Variation Number = +2 in. (+0.05 mm) 0.002 0.05
Standard Shim Set Thickness 0.028 0.71
New Pinion Variation Number = +5 in. (+0.13 mm) +0.005 +0.13
New Shim Set Thickness = 0.033 0.84
Original Pinion Variation Number = 2 in. ( 0.05 mm) +0.002 +0.05
New Pinion Variation Number = +5 in. (+0.13 mm) +0.005 +0.13
Original Pinion Variation Number = +2 in. (+0.05 mm) 0.002 0.05
New Pinion Variation Number = 5 in. ( 0.13 mm) 0.005 0.13
Original Pinion Variation Number = 2 in. ( 0.05 mm) +0.002 +0.05
New Pinion Variation Number = 5 in. ( 0.13 mm) 0.005 0.13
Drive Pinion, Pinion Gear, and Bearings Into Center Section

STEP 1.
Press the pinion inner bearing cup into the center
section.
1. CENTER SECTION
2. INNER BEARING CUP
32
STEP 2.
Press the outer bearing cup into the drop box hous-
ing.
1. DROP BOX
2. BEARING CUP
NOTE: Install the thickest shim first, next to the pin-

ion head.
STEP 3.
Install mounting distance (inner) shims, determined
in Pinion Inner Shim Set, Adjust Thickness (Depth
of Pinion), and press pinion head bearing on pinion.
1. PINION
2. SHIMS
3. BEARING
33
STEP 4.
Install the pinion assembly into the center section
housing.
1. CENTER SECTION
2. PINION ASSEMBLY
STEP 5.
Install the driven gear onto the pinion.
1. DRIVEN GEAR
2. PINION
3. CENTER SECTION
34
STEP 6.
Apply sealant, Hyster Part No. 264159 or equivalent,
to the mating surface of the drop box housing.
Place the drop box housing in position on the cen-

ter section. Install the capscrews and washers and
1. CENTER SECTION
2. DROP BOX
3. CAPSCREW
4. BRACKET
NOTE: Install the thickest shim first, next to the

driven gear.
STEP 7.
Install the preload (outer) shims and outer bearing.
Install the washer and new pinion nut.
Tighten the pinion nut to 530 to 645 N•m (391 to

476 lbf ft) to seat the bearings. Rotate the pinion two
revolutions in both directions. Loosen the pinion nut
and retighten to 370 to 410 N•m (273 to 302 lbf ft)
for the pre-load. Rotate the pinion two revolutions in
both directions. Verify pinion shaft rotating torque is
4.0 to 6.0 N•m (35.4 to 53.1 lbf in). Add or remove
preload (outer) shims as necessary to obtain the cor-
rect rotating torque.
1. CENTER SECTION
2. SHIMS
3. BEARING
4. WASHER
5. PINION NUT
35
STEP 8.
Using a press, press on the outer race of the bear-
ing and press the bearing into the pinion support
bracket.

2. BEARING
STEP 9.
Place the pinion support bracket in position and in-
stall capscrews. Tighten capscrews to 90 to 108 N•m
(66 to 80 lbf ft).
1. CENTER SECTION
2. WASHER
3. CAPSCREW
36
STEP 10.
Install the snap ring on the pinion head.
1. CENTER SECTION
2. SNAP RING
3. PINION
Differential Assembly Into Center Section

STEP 1.
Place the differential assembly into the center sec-
tion.
1. CENTER SECTION
3. TAPERED ROLLER BEARING AND CUP
37
STEP 2.
Install the bearing caps in the same location as re-
moved. Install capscrews and washers. Tighten the
capscrews finger tight only.
1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. BEARING CAP
STEP 3.
Install the retainer rings.
1. CENTER SECTION
2. RETAINER RING
38
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced,
go to STEP 4. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced
in a lift truck manufactured prior to October 2006, go to STEP 5.
STEP 4.
Using a retainer ring special tool, Hyster Part No.
1581188, adjust the retainer rings in equal rotations
so the backlash of the ring gear is 0.20 to 0.28 mm
(0.008 to 0.011 in.). See Ring Gear Backlash, Adjust.
Tighten each retainer ring one to two notches past

the point where the retainer makes contact with the
bearing cup.
Tighten the bearing cap capscrews to 225 to 270 N•m

(166 to 199 lbf ft). Recheck the backlash.
Check the ring gear runout. See Ring Gear, Runout

Check.
Verify that the rotating torque at the pinion shaft has

increased 0.5 to 0.7 N•m (4.4 to 6.2 lbf in). Check the
pinion and ring gear tooth contact pattern. See Gear
Set, Tooth Contact Pattern Check.
1. PINION NUT
Install differential assembly retainer ring cotter pins. 2. CENTER SECTION
3. COTTER PIN
4. RETAINER RING
39
STEP 5.
Using a retainer ring special tool, Hyster Part No.
1663599, adjust the retainer rings in equal rotations
so the backlash of the ring gear is 0.20 to 0.28 mm
(0.008 to 0.011 in.). See Ring Gear Backlash, Adjust.
Tighten each retainer ring one to two notches past

the point where the retainer makes contact with the
bearing cup.
Tighten the bearing cap capscrews to 225 to 270 N•m

(166 to 199 lbf ft). Recheck the backlash.
Check the ring gear runout. See Ring Gear, Runout

Check.
Verify that the rotating torque at the pinion shaft has

increased 0.5 to 0.7 N•m (4.4 to 6.2 lbf in). Check the
pinion and ring gear tooth contact pattern. See Gear
Set, Tooth Contact Pattern Check.
Install differential assembly retainer ring cotter pins.

1. COTTER PIN
2. RETAINER RING
40
STEP 6.
Stake the pinion nut with 8 mm spherical punch un-
til a 1 to 2 mm (0.039 to 0.079 in.) gap is between
the nut and pinion shaft at two places. Retighten the
drop box capscrews to 19 to 23 N•m (14 to 17 lbf ft).

to the mating surface of the pinion cover.
Place the pinion cover in position on the drop box and

install the washers and capscrews. Tighten the cap-
1. CAPSCREW
2. WASHER
3. PINION NUT
4. CENTER SECTION
STEP 7.
Set the clearance between the thrust screw and the
ring gear to 0.25 to 0.38 mm (0.010 to 0.015 in.). This
can be done by setting the thrust screw so it just con-
tacts the ring gear and then backing the thrust screw
out 1/4 of a turn. After the clearance is set, tighten
the locking nut to 68 to 95 N•m (50 to 70 lbf ft). Verify
the clearance is still between 0.25 to 0.38 mm (0.010
to 0.015 in.).
1. CENTER SECTION
2. THRUST SCREW
3. LOCKING NUT
41
STEP 8.
to the mating surface of the center section for the cen-
ter section cover.
Place the center section cover in position and install

capscrews. Tighten capscrews to 19 to 23 N•m (14 to
17 lbf ft) in the torque sequence shown.
1. CENTER SECTION COVER

2. CAPSCREW
3. CENTER SECTION
42
Ring Gear Backlash, Adjust NOTE: To increase backlash, move ring gear away
from drive pinion. To decrease backlash, move ring
If the old gear set is installed, adjust the backlash to gear toward drive pinion.
the setting that was measured before the differential
assembly was disassembled. NOTE: When adjusting backlash, move the ring gear
only. Do not move the drive pinion.
If a new gear set will be installed, adjust the backlash
to 0.20 to 0.28 mm (0.008 to 0.011 in.). 9. Loosen one bearing adjusting ring one notch,
then tighten the opposite ring the same amount.
To adjust/check the backlash, follow the steps out- See Figure 10 and Figure 11.
lined below:
1. Install a dial indicator on the mounting flange of

the differential as shown in Figure 9.
2. Adjust the dial indicator so that the plunger or

pointer is against the tooth surface. See Figure 9.
1. TIGHTEN RETAINER RING THIS SIDE

2. INCREASE BACKLASH
3. LOOSEN RETAINER RING THIS SIDE
Figure 10. Backlash Increase
Figure 9. Gear Clearance Check
3. Adjust the indicator to zero.
4. Hold the drive pinion in position.
5. After reading the dial indicator, rotate the differ-

ential and ring gear a small amount in both di-
rections, against the drive pinion teeth.
6. If the backlash reading is within specifications,

0.20 to 0.28 mm (0.008 to 0.011 in.), continue
checking tooth contact patterns.
1. LOOSEN RETAINER RING THIS SIDE
7. If the backlash reading is not within specifica- 2. DECREASE BACKLASH
tions, adjust backlash as needed. Continue onto 3. TIGHTEN RETAINER RING THIS SIDE
Figure 11. Backlash Decrease
8. Verify that the bearing cap capscrews are only
finger tight.
43
10. Tighten the bearing cap capscrews to 225 to 2. Adjust the dial indicator so that the plunger or
270 N•m (166 to 199 lbf ft). Recheck the back- pointer is against the back surface of the ring
lash. gear.
11. Repeat Step 2 through Step 10 until backlash is 3. Set the indicator to zero.
within 0.20 to 0.28 mm (0.008 to 0.011 in.).
4. Rotate the ring gear and check the dial indicator
12. Check the tooth contact pattern. See Gear Set, for the maximum needle movement. The maxi-
Tooth Contact Pattern Check. mum movement permitted is 0.20 mm (0.008 in.).
13. Check the ring gear runout. See Ring Gear, 5. If the movement exceeds the maximum limit,
Runout Check. remove the differential and ring gear assembly
from the differential assembly and find the rea-
Ring Gear, Runout Check son for the movement.
1. Attach a dial indicator to the mounting flange of 6. Install the differential and ring gear into the dif-
the differential assembly as shown in Figure 12. ferential assembly after the parts are repaired or
replaced.
Gear Set, Tooth Contact Pattern Check

NOTE: The gear clearance can be changed within the
limits of 0.20 to 0.28 mm (0.008 to 0.011 in.).
NOTE: If the original gear set is installed, adjust the

clearance to the original value recorded in Differen-
tial Assembly From Center Section. If a new gear
set is installed, adjust the retainer rings for 0.20 to
0.28 mm (0.008 to 0.011 in.) clearance. Refer to Ring
and Pinion Tooth Contact Adjustment.
1. DIAL INDICATOR
Figure 12. Ring Gear Runout Check
Table 2. Ring and Pinion Tooth Contact Adjustment
1. Apply a colored dye or grease to approximately 12

of the ring gear teeth.
2. Rotate ring gear forward and backward so that
the 12 gear teeth go past the drive six times to
get to the contact patterns. Repeat if needed to
get a clearer pattern.
3. Check the tooth contact pattern on the ring gear.
See Table 3 and Table 4. Make sure that the pat-
tern is checked on the side of the tooth where the
pinion applies the force in the forward direction.
44
Table 3. Correct Tooth Contact
The contact area is the center between the top and

bottom of the tooth. The contact area is toward the NOTE: Normal pattern during adjustment shown.
inner circumference of the ring gear.
The contact area is the center between the top and

the bottom of the tooth. The contact area will be NOTE: Wear pattern from operation shown.
almost the full length of the tooth.
45
Table 4. Incorrect Tooth Contact
The pinion is too far away from the center of the

gear. Add shims to move pinion toward ring gear.
Check that the clearance is correct. Some movement
of ring gear away from pinion may be necessary.
The pinion is too close to the center of the ring gear.

Remove shims to move pinion away from the ring
gear. Check that the clearance is correct. Some
movement of the ring gear toward the pinion may
be necessary.
Assemble and install the drive axle. Refer to the section Drive Axle Repair.
46
Axle Shaft Capscrews Hanger Assembly to Frame
Bearing Cap Capscrews Pinion Cover Capscrews

Brake Assembly to Axle Mount Capscrews Pinion Nut, for Pre-Load

Brake Manifold to Center Section Pinion Nut, to Seat Bearings

Housing Capscrews 530 to 645 N•m (391 to 476 lbf ft)
19 to 21 N•m (14 to 15.5 lbf ft)
Pinion Support Bracket Capscrews
Differential Carrier Halves Capscrews 90 to 108 N•m (66 to 80 lbf ft)
125 to 145 N•m (92 to 107 lbf ft)
Ring Gear Capscrews
Differential Cover Capscrews 152 to 167 N•m (112 to 123 lbf ft)
19 to 23 N•m (14 to 17 lbf ft)
Thrust Screw Locking Nut
Drain Plug 68 to 95 N•m (50 to 70 lbf ft)
50 to 55 N•m (37 to 41 lbf ft)
Transmission Mount Bolt to Center
Drive Shaft Capscrews Section Housing
Drop Box Housing Capscrews Wheel Nuts

Hanger Assembly to Center Section Housing

225 to 248 N•m (166 to 183 lbf ft)
47
NOTES
____________________________________________________________
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____________________________________________________________
48

DRIVE AXLE REPAIR
(WET BRAKE)
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1599962 1400 SRM 1215

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Drive Axle Repair Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Identification Plate .......................................................................................................................................... 1
Drive Axle Removal ............................................................................................................................................. 1
Reduction Gear Assembly.................................................................................................................................... 7
Reduction Gear Assembly Repair ................................................................................................................... 7
Remove......................................................................................................................................................... 9
Install ......................................................................................................................................................... 17
Brake Repair ...................................................................................................................................................... 29
Wet Disc Brake .............................................................................................................................................. 29
Remove....................................................................................................................................................... 32
Install ......................................................................................................................................................... 39
Parking Brake Control Lever........................................................................................................................ 51
General....................................................................................................................................................... 51
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 54
Differential Repair ............................................................................................................................................. 57
Remove ........................................................................................................................................................... 57
Flange ........................................................................................................................................................ 57
Bevel Pinion............................................................................................................................................... 65
Disassemble ................................................................................................................................................... 70
Assemble ........................................................................................................................................................ 73
Install ............................................................................................................................................................. 78
Determine Bevel Pinion Shim Thickness ................................................................................................ 78
Bevel Pinion............................................................................................................................................... 80
Gear Set, Tooth Contact Pattern Check................................................................................................... 92
Flange ........................................................................................................................................................ 94
Drive Axle Installation ...................................................................................................................................... 95
Special Tools ..................................................................................................................................................... 100
Torque Specifications ....................................................................................................................................... 102
H2.0-3.5FT (H40-70FT) [L177]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1400 SRM 1215 Drive Axle Removal
General
This manual covers the repair of the drive axle, dif- IDENTIFICATION PLATE
ferential, and the wet disc brake.
See Figure 1.
1. CARRARO PART NUMBER 3. CARRARO SERIAL NUMBER

2. HYSTER PART NUMBER
Figure 1. Identification Plate
Drive Axle Removal

from lift truck. Air pressure in tires can cause
WARNING tire and rim parts to explode, which can cause
When putting the lift truck on blocks, make serious injury or death. Never loosen nuts that
sure the surface is solid, even, and level. Any hold together inner and outer wheel halves
blocks used to support the lift truck must be when there is air pressure in tire.
solid, one-piece units.
4. Remove the wheels.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift 5. Remove the oil fill/level plugs on both sides of the
truck. drive axle. See Figure 2.
2. Raise the lift truck and put blocks under the 6. Remove the oil drain plug (LH) from the drive
frame so that the drive wheels do not touch the axle to drain the oil from the left-hand side of the
floor. Put blocks under the counterweight for drive axle into a suitable container. See Figure 2.
stability.
7. Remove the oil drain plug (RH and center sec-
3. Remove the mast assembly as described in the tion) to drain the oil from the right-hand side
section Mast Repairs, 2-, 3-, and 4-Stage and center section of the drive axle into a suit-
Masts 4000 SRM 1148. able container. See Figure 2.
8. Remove the brake discs oil drain plug from the

WARNING drive axle to drain the brake oil into a suitable
On lift trucks with pneumatic tires, completely container. See Figure 2.
remove air from tires before removing them
1
Drive Axle Removal 1400 SRM 1215
1. OIL FILL/LEVEL PLUG (LH) 7. COOLING OIL INLET PORT

2. OIL DRAIN PLUG (LH) 8. COOLING OIL OUTLET PORT
3. OIL BREATHER (LH) 9. MASTER CYLINDER RELIEF PORT
4. OIL FILL/LEVEL PLUG (RH) 10. SERVICE BRAKE INLET PORT
5. OIL DRAIN PLUG (RH AND CENTER SECTION) 11. BRAKE DISCS OIL DRAIN PLUG
6. OIL BREATHER (RH) 12. BRAKE OIL BLEEDER VALVE
Figure 2. Oil Fill Plugs and Drain Plugs
9. Remove the parking brake cable. Refer to the 12. Disconnect the brake return hose from the drive
section Brake System 1800 SRM 1135. axle. See Figure 3.
10. Disconnect the cooling inlet hose from the mani- 13. Disconnect the cooling return hose from the man-
fold on top of the drive axle. See Figure 3. ifold on top of the drive axle. See Figure 3.
11. Disconnect the brake inlet hose from the drive

axle. See Figure 3.
2
A. DRIVE AXLE COOLING RETURN HOSE TO TRANSMISSION SUMP

1. HOSE CLAMP 4. BRAKE RETURN HOSE
2. BRAKE INLET HOSE 5. COOLING INLET HOSE
3. COOLING RETURN HOSE
Figure 3. Drive Axle Cooling Hoses and Brake Lines
3
14. Place blocks under the axle assembly and connect

slings and lifting device.
15. Place blocks under the transmission to support

the transmission while removing the drive axle.
16. Remove the capscrews retaining the drive shaft

and remove the drive shaft.
17. Remove the transmission isolator mounting bolt

located on top of the assembly. See Figure 4.
18. Remove the four mounting capscrews and wash-

ers from the drive axle. See Figure 5.
19. Remove blocks and lower the drive axle assembly.

Pull axle forward and away from frame.
20. Place blocks under the differential assembly.
21. Disconnect the cooling outlet crossover hose from

the manifold and the drive axle and remove the
hose. See Figure 6.
1. ISOLATORS
22. If necessary, remove the capscrews retaining the 2. WASHER
3. WASHER
manifold to the center section of the drive axle 4. CAPSCREW
and remove the manifold. See Figure 6. 5. TRANSMISSION
6. DRIVE AXLE
Figure 4. Transmission to Differential

Mounting Bolt
4
1. WASHER 3. TRUMPET ARM (LH)

2. CAPSCREW 4. TRUMPET ARM (RH)
Figure 5. Drive Axle Mounting Capscrews
5
1. HOSE CLAMP 4. CENTER SECTION

2. MANIFOLD 5. COOLING OUTLET CROSSOVER HOSE
3. CAPSCREWS
Figure 6. Manifold and Cooling Outlet Crossover Hose
6
1400 SRM 1215 Reduction Gear Assembly
Reduction Gear Assembly

REDUCTION GEAR ASSEMBLY REPAIR
1. PLUG 13. TAPERED ROLLER BEARING

2. RETAINING NUT 14. RING GEAR
3. LOCKWASHER 15. PLANETARY CARRIER
4. WASHER 16. WASHER
5. WHEEL HUB 17. PIN
6. STUD 18. NEEDLE BEARINGS
7. SEAL RING 19. SPACER
8. TAPERED ROLLER BEARING 20. REDUCTION GEAR
9. SPACER 21. NEEDLE BEARINGS
10. SUPPORT 22. WASHER
11. SOCKET-HEAD SCREW 23. SNAP RING
12. O-RING 24. DISK
Figure 7. Reduction Gear Assembly Left-Hand Side
7
Reduction Gear Assembly 1400 SRM 1215
1. PLUG 14. RING GEAR

2. RETAINING NUT 15. PLANETARY CARRIER
3. LOCKWASHER 16. WASHER
4. WASHER 17. PIN
5. WHEEL HUB 18. NEEDLE BEARINGS
6. STUD 19. SPACER
7. SEAL RING 20. REDUCTION GEAR
8. BEARING 21. NEEDLE BEARINGS
9. SPACER 22. WASHER
10. SUPPORT 23. SNAP RING
11. SOCKET-HEAD SCREW 24. DISK
12. O-RING 25. AXLE SHAFT
13. BEARING
Figure 8. Reduction Gear Assembly Right-Hand Side
8
Remove
STEP 1.
Remove the plug using a prybar.
1. PLUG
NOTE: Once the lockwasher has been flattened, a new lockwasher must be used.
STEP 2.
Flatten the lockwasher using a punch and hammer.
9
CAUTION
Install two nuts or suitable plastic pipes on the studs to prevent damage to the threads of the studs
from the support bar.
STEP 3.
Install a support bar on the studs to hold the wheel
hub in place as shown. Using a torque multiplier,
loosen the reduction gear assembly retaining nut.
STEP 4.
Remove the socket-head screws fastening the reduc-
tion gear assembly to the wheel hub support.
STEP 5.
Remove the reduction gear assembly from the wheel
hub support.
10
STEP 6.
Remove and discard the O-ring.
STEP 7.
Remove the ring gear.
1. AXLE SHAFT
2. RING GEAR
STEP 8.
Place the reduction gear assembly in a soft jawed vise
and lock the wheel hub. Remove the retaining nut.
1. RETAINING NUT
11
STEP 9.
Remove the lockwasher.
1. LOCKWASHER
STEP 10.
Remove the washer.
1. WASHER
STEP 11.
Remove the planetary carrier from the wheel hub.
1. PLANETARY CARRIER
12
STEP 12.
Remove the snap rings.
1. SNAP RING
STEP 13.
Remove the pins with a punch and hammer as shown.
STEP 14.
Remove the reduction gears.
Remove the needle bearings, spacer, and washers

from each reduction gear.
13
STEP 15.
Remove the disk from the planetary carrier.
2. DISK
STEP 16.
Remove the wheel hub from the support using a
suitable extractor and special tool driver (Hyster
Part Number 1641516). Refer to the section Special
Tools.
1. SUPPORT
2. WHEEL HUB
STEP 17.
Remove the bearing cone.
1. BEARING CONE
14
STEP 18.
Remove the spacer from the wheel hub.
1. WHEEL HUB
2. SPACER
STEP 19.
Using a prybar, remove and discard the seal ring.
1. WHEEL HUB
2. SEAL RING
STEP 20.
Place the wheel hub on a flat surface, then remove the
bearing cone using a suitable extractor and the spe-
cial tool driver (Hyster Part Number 1641515). Refer
to the section Special Tools.
1. WHEEL HUB
2. SPECIAL TOOL
3. BEARING CONE
15
NOTE: Place the wheel hub in a soft-jawed vise before removing the wheel fastening studs.
NOTE: If the wheel fastening studs are removed, they must be replaced.
STEP 21.
If necessary, remove the wheel fastening studs from
the wheel hub with a hammer.
STEP 22.
Remove the bearing cups from the wheel hub support
with a suitable drift and a hammer.
1. BEARING CUP
2. BEARING CUP
3. WHEEL HUB SUPPORT
Clean and Inspect WARNING

Cleaning solvents can be flammable and toxic Make sure that the path of the compressed air
and can cause skin irritation. When using is away from all personnel. Wear protective
cleaning solvents, always follow the recom- goggles or a face shield to prevent injury to the
mendations of the manufacturer. eyes.
16
Clean and inspect the following parts of the reduction

gear assembly:
damage, replace with new bearing.
• Ring gear- Inspect the ring gear for wear or dam-
age. If the gear is worn or damaged, it must be
replaced.
• Wheel hub and wheel hub support- Inspect
wheel hub and wheel hub support for wear or dam-
age. Parts that are damaged must be replaced.
• Planetary carrier and parts- Inspect all parts
of the planetary carrier for wear or damage. Parts
that are damaged must be replaced. If the gears
are replaced, new needle bearings must be used. Figure 9. Planetary Carrier and Parts
See Figure 9.
Install
STEP 1.
To support the wheel hub, it is recommended to use
a steel ring with dimensions as shown.
STEP 2.
Place the wheel hub under a press on a suitable sup-
port. See STEP 1. Install all of the studs with a suit-
able driver under the press or with a hammer.
1. STUD
2. WHEEL HUB
17
STEP 3.
Install the bearing cup into the wheel hub support us-
ing special tool driver (Hyster Part Number 1641507)
with a hammer or press.
1. BEARING CUP
1. BEARING CUP
3. BEARING CUP
18
STEP 4.
Turn the wheel hub support upside down and install
the other bearing cup into the wheel hub support
using the special tool driver (Hyster Part Number
1641507) with a hammer or a press.
1. BEARING CUP
1. BEARING CUP
3. BEARING CUP
19
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns.
STEP 5.
Place the wheel hub on a flat surface. Heat the bear-
ing cone to 80 to 90°C (176 to 194°F). Install the bear-
ing cone to the wheel hub with the special tool (Hys-
ter Part Number 1641518). Install the spacer into
the wheel hub.
1. SPACER
2. WHEEL HUB
3. BEARING CONE
20
CAUTION
Make sure the bearing cone has cooled before installing the seal ring.
STEP 6.
Position the seal ring as shown.
Install the seal ring into the wheel hub with the spe-
cial tool (Hyster Part Number 1641508) and a ham-
mer. Refer to the section Special Tools.
1. SEAL RING
2. WHEEL HUB
21
STEP 7.
Place the planetary carrier on a workbench with the
splined end down. Install the disk into the planetary
carrier.
2. DISK
STEP 8.
Grease the inner part of the reduction gears with
multipurpose grease with 2 to 4% molybdenum disul-
fide to help properly position the needle bearings.
1. REDUCTION GEAR
STEP 9.
Place the reduction gear onto a thrust washer.
1. REDUCTION GEAR
2. THRUST WASHER
22
STEP 10.
Insert the needle bearings into the reduction gears as
shown.
1. REDUCTION GEAR
2. NEEDLE BEARINGS
STEP 11.
Install the spacer into the gear as shown.
STEP 12.
Install the remaining needle bearings. Assemble the
thrust washer to the gear.
23
STEP 13.
Install the assembled reduction gears into the plan-
etary carrier. Install the pins into the planetary car-
rier and reduction gears using a hammer as shown.
STEP 14.
Install the snap rings into the planetary carrier with
suitable pliers.
1. SNAP RING
STEP 15.
Install the wheel hub support into the wheel hub.

2. WHEEL HUB
24
WARNING
STEP 16.
Heat the bearing cone to 80 to 90°C (176 to 194°F)
and install it into the wheel hub support.
1. BEARING CONE
STEP 17.
Install the planetary carrier.
STEP 18.
Install the washer.
1. WASHER
25
STEP 19.
Install the lockwasher.
1. LOCKWASHER
STEP 20.
Install the retaining nut.
1. RETAINING NUT
STEP 21.
Install the ring gear into the wheel hub support.
1. AXLE SHAFT
2. RING GEAR
26
STEP 22.
Lubricate a new O-ring with multipurpose grease
with 2 to 4% molybdenum disulfide and install
O-ring on the ring gear.
STEP 23.
Place the reduction gear assembly in position on
the wheel hub support. Apply Loctite® 270 to the
socket-head screws and install the socket-head
screws. Tighten the socket-head screws to 85 N•m
(62.7 lbf ft).
CAUTION
Install two nuts or suitable plastic pipes on the studs to prevent damage to the threads of the studs
from the support bar.
STEP 24.
Install a support bar on the studs to hold the wheel
hub in place as shown. Using a torque multiplier,
tighten the retaining nut to 400 N•m (295 lbf ft).
27
STEP 25.
Place the special tool ring (Hyster Part Number
1641521) around the retaining nut to prevent dam-
age to the plug seat.
Using a prybar, bend the lockwasher over two sides

of the nut.
1. LOCKWASHER
2. RETAINING NUT
3. SPECIAL TOOL RING
STEP 26.
Apply Loctite® 270 to the contact surface of the plug.
Using a soft hammer, install the plug.
1. PLUG
28
1400 SRM 1215 Brake Repair
Brake Repair
WET DISC BRAKE
Figure 10. Wet Disc Brake
29
Brake Repair 1400 SRM 1215

1. PIN 14. PIN
2. DRIVE PLATE 15. O-RING
3. PIN 16. O-RING
4. WET DISC BRAKE 17. O-RING
5. SNAP RING 18. CENTER SECTION
6. HUB/ACTUATOR 19. SEAL
7. SNAP RING 20. O-RING
8. SELF-ADJUST SCREW 21. TRUMPET ARM
9. BELLEVILLE SPRINGS 22. CAPSCREW
10. SPACER 23. OIL BREATHER
11. SPLIT PIN 24. AXLE SHAFT
12. WASHER 25. BRAKE OIL BLEEDER VALVE
13. PISTON

A. NEW FRICTION PLATE THICKNESS (QUANTITY 1) = 3.35 to 3.55 mm (0.13 to 0.14 in.)
WORN FRICTION PLATE MINIMUM THICKNESS = 2.9 mm (0.11 in.)
B. NEW FRICTION PLATE THICKNESS (QUANTITY 5) = 3.5 to 3.7 mm (0.138 to 0.146 in.)
C. ASSEMBLE WITH THE FRICTION SURFACE AS SHOWN
D. NEW FRICTION PLATE THICKNESS (QUANTITY 1) = 2.4 to 2.6 mm (0.094 to 0.102 in.)
E. NEW FRICTION PLATE THICKNESS (QUANTITY 1) = 3.9 to 4.1 mm (0.153 to 0.161 in.)
F. NEW FRICTION PLATES MINIMUM THICKNESS = 60.6 to 60.8 mm (2.386 to 2.394 in.)
WORN FRICTION PLATES MINIMUM THICKNESS = 56.3 mm (2.216 in.)
UNDER A LOAD OF 1600 N (360 lbf)
G. NEW FRICTION PLATE THICKNESS (QUANTITY 2) = 1.95 to 2.05 mm (0.077 to 0.081 in.)
30
Figure 11. Brake Disc Data
31
Remove
STEP 1.
Remove the left side reduction gear assembly and axle shaft. See Reduction Gear Assembly.
STEP 2.
Remove the capscrews retaining the trumpet arm to
the center section and remove the trumpet arm and
O-ring. Discard O-ring.
1. O-RING
STEP 3.
Remove the seal ring from the trumpet arm.
1. SEAL RING
32
NOTE: If the disc pack is not being replaced, note the positions and sequence of the discs.
STEP 4.
Remove the outer discs and counter discs from the
brake disc carrier.
1. COUNTER DISC
STEP 5.
Remove the brake disc carrier.
1. BRAKE DISC CARRIER
33
NOTE: If the disc pack is not being replaced, note the positions and sequence of the discs.
STEP 6.
Remove the inner discs and counter discs.
1. INNER DISCS AND COUNTER DISCS
STEP 7.
Check the wear of the inner and outer discs, and the
wear of the counter discs. See Figure 11.
1. OUTER DISCS
2. INNER DISCS
STEP 8.
Remove the pins with a suitable stud puller.
1. PIN
34
STEP 9.
Remove the snap ring retaining the inner hub/actu-
ator.
1. SNAP RING
STEP 10.
Remove the inner hub/actuator.
1. INNER HUB/ACTUATOR
STEP 11.
Remove the snap ring.
1. SNAP RING
35
STEP 12.
Remove the drive plate from the trumpet arm.
1. DRIVE PLATE
2. TRUMPET ARM
NOTE: The self-adjust screws must be replaced each time they are removed.
STEP 13.
Remove the self-adjust screws and belleville washers
retaining the piston.
1. SELF-ADJUST SCREW
2. BELLEVILLE WASHERS
STEP 14.
Remove the spacers and washers from the piston.
1. SPACER
2. WASHER
36
WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel.
Make sure that the path of the compressed air is away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
CAUTION
Hold onto the piston as it may be suddenly ejected and become damaged.
STEP 15.
Slowly apply compressed air [maximum 101 kPa
(14.7 psi)] through the oil breather port to extract
the piston.
1. PISTON
STEP 16.
Remove and discard the O-rings from the piston.
1. PISTON
2. O-RING
3. O-RING
37
NOTE: If the split pins are removed from the piston, they must be replaced with new split pins.
STEP 17.
If necessary, remove the split pins from the piston.
STEP 18.
Remove the pins from the holes inside the center sec-
tion.
Remove and discard the O-rings from the pins.
1. PIN
Clean and Inspect 1. Clean all the parts with solvent.
2. Inspect the all parts for wear and damage. Re-

WARNING place parts as needed.
and can cause skin irritation. When using 3. Inspect the brake disc(s). See Figure 11.
manufacturer’s recommended safety precau-
tions.
38
Install
STEP 1.
Install new O-rings on the pins and lubricate the
O-rings with Hyster Part Number 186061.
1. PIN
2. O-RING
CAUTION
Do not damage the O-rings when installing the pins.
STEP 2.
Install the pins into the holes in the center section
using a punch and a hammer.
1. PIN
39
STEP 3.
Lubricate new O-rings with Hyster Part Number
186061 and install new O-rings onto the piston.
1. PISTON
2. O-RING
3. O-RING
40
STEP 4.
Install new split pins into the piston using a hammer
and special tool (Hyster Part Number 1641498), until
the split pins contact the flat surface of the piston.
1. PISTON
2. SPLIT PIN
1. SPECIAL TOOL
2. SPLIT PIN
3. PISTON
41
STEP 5.
Lubricate the edge of the piston with lubricant (Hys-
ter Part Number 186061).
1. PISTON
STEP 6.
Loosen the brake bleeder valve.
Place the piston in position in the center section hous-

ing.
1. PISTON
STEP 7.
Seat the piston in the housing using special tool (Hys-
ter Part Number 1641517) and a hammer.
Tighten the bleeder valve to 10 N•m (88.5 lbf in).
1. PISTON
42
CAUTION
The belleville washers must assemble in opposition.
STEP 8.
Assemble the self-adjust groups.
Install the belleville washers onto the self-adjust

screw.
Install the spacer.
NOTE: Apply a small amount of multipurpose grease

with 2 to 4% molybdenum disulfide to the washer to
stick the washer in position on the self-adjust screw.
Install the washer.
1. WASHER
2. SPACER
3. BELLEVILLE WASHERS
4. SELF-ADJUST SCREW
WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel.
Make sure that the path of the compressed air is away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
STEP 9.
Verify that the threaded holes of the self-adjust
screws are clean. Blow excess oil out of the holes
Apply Loctite® 270 to the threads of the self-adjust

screws.
Install the self-adjust screw assemblies. Tighten the

self-adjust screws to 10 N•m (88.5 lbf in).
1. SELF-ADJUST SCREW ASSEMBLY

2. PISTON
43
STEP 10.
Install the snap ring.
1. SNAP RING
STEP 11.
Install the hub/actuator.
1. HUB/ACTUATOR
44
STEP 12.
Install the snap ring to retain the hub/actuator.
1. SNAP RING
STEP 13.
Install the pins.
1. PIN
45
WARNING
Assemble the friction surfaces as shown in Figure 11.
STEP 14.
Assemble the inner discs and counter discs onto the
disc carrier. Stagger the counter discs slots at 60 de-
gree intervals as shown in Figure 11 and in the two
illustrations on the right.
1. COUNTER DISC
2. DISC CARRIER
NOTE: Assemble counter discs shown at 60° inter-

vals.
1. COUNTER DISC
2. DISC CARRIER
46
STEP 15.
Insert the inner discs, counter discs, and disc carrier
into the carrier housing. Make sure the slots of the
counter discs are aligned with the pins.
STEP 16.
If removed, install the pins in the trumpet arm.
1. PIN
STEP 17.
Install the drive plate in the trumpet arm.
1. DRIVE PLATE
47
CAUTION
Do not lubricate the outer surface of the seal.
STEP 18.
Lubricate the lip of the seal with multipurpose grease
with 2 to 4% molybdenum disulfide.
Orientate the seal as shown.
Install the seal using special tool (Hyster Part Num-

ber 1641504).
1. SEAL
2. AXLE SHAFT
STEP 19.
Lubricate a new O-ring with multipurpose grease
with 2 to 4% molybdenum disulfide and install the
O-ring.
1. O-RING
48
STEP 20.
Install the outer discs and counter discs.
1. COUNTER DISC
NOTE: Make sure the oil circulation holes are aligned.
STEP 21.
Insert the false shaft (Hyster Part Number 1641519)
into the outer discs and counter discs.
CAUTION
Do not damage the seal during assembly.
STEP 22.
Assemble the trumpet arm to the center section.
49
CAUTION
Do not damage the seal during removal of the false shaft and installation of the axle shaft.
STEP 23.
Remove the false shaft (Hyster Part Number
1641519) and install the axle shaft.
STEP 24.
Verify the axle shaft is in the correct position for as-
sembly.
1. AXLE SHAFT
STEP 25.
Install the capscrews to retain the trumpet arm to
the center section. Tighten the capscrews to 85 N•m
(62.7 lbf ft).
STEP 26.
Install the left side reduction gear assembly. See Reduction Gear Assembly.
50
PARKING BRAKE CONTROL LEVER presses the pins in against the piston which com-
presses the brake discs to apply the brake. See Fig-
General ure 12.
The park brake is applied when the control lever ac-

tuates the actuation shaft. The actuation shaft then
1. SNAP RING 5. FLANGE

2. CONTROL LEVER 6. O-RING
3. O-RING 7. ACTUATION SHAFT
4. SOCKET-HEAD SCREW
Figure 12. Parking Brake Control Lever
51
Remove
STEP 1.
Remove the differential assembly. See Differential Repair.
STEP 2.
Make reference marks on the actuation shaft head
and the control lever to ensure proper alignment dur-
ing installation.
Remove the snap ring from the actuation shaft.
1. SNAP RING
2. ACTUATION SHAFT HEAD
3. CONTROL LEVER
STEP 3.
Remove the socket-head screws retaining the flange
to the center section.
52
STEP 4.
Remove the control lever and flange.
Remove and discard O-rings.
1. O-RING
2. FLANGE
3. O-RING
4. CONTROL LEVER
STEP 5.
Remove the actuation shaft from the center section.
1. ACTUATION SHAFT
Clean and Inspect manufacturer’s recommended safety precau-

tions.
WARNING 1. Clean all the parts with solvent.
and can cause skin irritation. When using 2. Inspect the all parts for wear and damage. Re-
cleaning solvents, always follow the solvent place parts as needed.
53
Install
STEP 1.
Verify the brake actuation pins are properly seated
in the center section housing.
1. BRAKE ACTUATION PIN
STEP 2.
Insert the actuation shaft into the center section
housing.
Verify the actuation shaft is correctly orientated.
1. ACTUATION SHAFT
54
STEP 3.
Install a new O-ring on the flange.
Lubricate the O-ring with Hyster Part Number

186061.
1. FLANGE
2. O-RING
STEP 4.
Install the flange into the center section housing.
Install the socket-head screws and tighten to 60 N•m

(44.25 lbf ft).
2. FLANGE
STEP 5.
Install a new O-ring on the actuation shaft.
Place the control lever in position on the actuation

shaft, aligning the marks made during removal.
1. O-RING
2. CONTROL LEVER
3. ACTUATION SHAFT
55
STEP 6.
Verify that the control lever is assembled with an an-
gle of 4 degrees as shown.
Correct as needed.
STEP 7.
Install the snap ring to retain the control lever.
1. SNAP RING
STEP 8.
Install the differential assembly. See Differential Repair.
56
Differential Repair
REMOVE
Flange
See Figure 13.
1. FLANGE 3. BEVEL PINION

2. SEAL RING 4. CENTER SECTION
Figure 13. Flange
57
STEP 1.
Remove the flange from the bevel pinion end.
1. BEVEL PINION
2. CENTER SECTION
3. FLANGE
STEP 2.
Using a prybar, remove and discard the seal.
1. SEAL
58
See Figure 14.
1. SEAL RING 10. BEARING SUPPORT FLANGE

2. CENTER SECTION 11. ALLEN-HEAD SCREW
3. CAPSCREW 12. O-RING
4. SPACER 13. ADJUSTER RING NUT
5. SHIM 14. ADJUSTER RING NUT RETAINER
6. BEARING 15. CAPSCREW
7. DIFFERENTIAL ASSEMBLY 16. TRUMPET ARM
8. BEARING 17. CAPSCREW
9. O-RING
Figure 14. Differential Assembly
59
STEP 1.
Remove the right side reduction gear assembly and axle shaft. See Reduction Gear Assembly.
STEP 2.
Remove the capscrews retaining the trumpet arm to
the center section and remove the trumpet arm.
1. CAPSCREW
2. TRUMPET ARM
3. CENTER SECTION
STEP 3.
Remove and discard the O-ring from the trumpet
arm.
1. O-RING
2. TRUMPET ARM
60
STEP 4.
Remove the capscrew and ring nut retainer from the
bearing support flange.
Remove the adjuster ring nut from the bearing

support using special tool (Hyster Part Number
1641514).
1. BEARING SUPPORT FLANGE

2. ADJUSTER RING NUT
3. RING NUT RETAINER
4. CAPSCREW
61
STEP 5.
Remove the socket-head screws and capscrew retain-
ing the bearing support flange to the center section.
Insert two capscrews into the flange extraction holes

and remove the flange.
1. CAPSCREW
4. CENTER SECTION

2. CAPSCREW
STEP 6.
Remove and discard the O-ring from the bearing sup-
port flange.
If necessary, remove the bearing cup.
1. BEARING CUP
2. O-RING
62
STEP 7.
Remove the brake disc assembly, hub/actuator, and snap rings. See Brake Repair.
STEP 8.
Hook the differential assembly with special tool (Hys-
ter Part Number 1641512) and remove the differen-
tial assembly.
STEP 9.
If necessary, remove the bearing cup with a slide
hammer.
STEP 10.
If necessary, remove the shims and spacer.
1. CENTER SECTION
2. SPACER
3. SHIMS
63
NOTE: It is recommended to replace the seal every time the differential is serviced.
STEP 11.
If necessary, remove the seal from the center section.
1. SEAL
2. CENTER SECTION
64
Bevel Pinion
See Figure 15.
1. BEVEL PINION 6. WASHER

2. SHIM 7. CENTER SECTION
3. BEARING 8. BEARING
4. WASHER 9. LOCKWASHER
5. SPACER 10. RING NUT
Figure 15. Bevel Pinion
65
NOTE: Once the lockwasher has been flattened, it must be replaced.
STEP 1.
Using a punch and hammer, flatten the lockwasher.
STEP 2.
Using special tools (Hyster Part Numbers 1641501
and 1644168), remove the ring nut.
STEP 3.
Remove the lockwasher.
1. LOCKWASHER
66
STEP 4.
Tap the end of the shaft with a rubber or plastic ham-
mer and remove the bevel pinion.
1. BEVEL PINION
STEP 5.
Remove the bearing cone.
1. BEARING CONE
67
NOTE: The spacer must be replaced with a new spacer during assembly.
STEP 6.
Remove the washers and spacer from the bevel pin-
ion.
1. WASHER
2. SPACER
3. WASHER
4. BEVEL PINION
STEP 7.
Check the condition of the bearing cups.
If the bearing cones are being replaced, the bearing

cups must also be replaced.
If necessary, remove the bearing cups using a suit-

able extractor.
1. BEARING CUP
2. CENTER SECTION
3. BEARING CUP
68
STEP 8.
Remove the bearing cone from the bevel pinion.
Remove the shim from the bevel pinion.
1. BEARING CONE
2. SHIM
3. BEVEL PINION
69
DISASSEMBLE
See Figure 16.
1. THRUST WASHER 7. BEARING CONE

2. PINION GEAR 8. DIFFERENTIAL CARRIER
3. SHAFT 9. BEVEL RING GEAR
4. THRUST WASHER 10. CAPSCREW
5. PINION GEAR 11. PIN
6. SPLIT DOWEL PIN 12. BEARING CONE
Figure 16. Differential Assembly
70
STEP 1.
Remove the bearing cones from the differential as-
sembly.
1. BEARING CONE
3. BEARING CONE
STEP 2.
Place the differential assembly in a soft jawed vise.
Remove the capscrews retaining the bevel ring gear

to the differential carrier.
If necessary, remove the dowel pin.
1. BEVEL RING GEAR

2. CAPSCREW
3. DOWEL PIN
71
NOTE: The split dowel must be removed on the indicated side shown.
STEP 3.
Extract the split dowel from the differential carrier
and pinion gear shaft as shown.
1. SPLIT DOWEL
STEP 4.
Remove the shaft, pinion gears, and thrust washers
from the differential carrier.
1. THRUST WASHER
2. PINION GEAR
3. SHAFT
4. PINION GEAR
5. THRUST WASHER
72
CLEAN AND INSPECT Clean and inspect the following parts of the differen-
tial:
WARNING • Center section- Clean the parts of the center sec-
tion with solvent and dry with compressed air. In-
spect all machined surfaces and bearings for wear
and damage.
WARNING damage, replace with new bearing.
Compressed air can move particles so that they • Bevel pinion and bevel ring gear- Inspect the
cause injury to the user or to other personnel. bevel pinion and bevel ring gear for wear or dam-
Make sure that the path of the compressed air age. The bevel pinion and bevel ring gear must be
is away from all personnel. Wear protective replaced as a set.
goggles or a face shield to prevent injury to the • Differential assembly- Inspect all parts of the
eyes. differential assembly for wear or damage. Parts
that are worn or damaged must be replaced.
ASSEMBLE
STEP 1.
Position a thrust washer in the differential carrier as
shown.
STEP 2.
Install a pinion gear into the differential carrier on
the thrust washer as shown.
73
STEP 3.
Assemble the opposite pinion gear and thrust washer
and place the assembly into position in the differen-
tial carrier.
STEP 4.
Lock the pinion gear in position with special tool
(Hyster Part Number 1641512) as shown.
STEP 5.
Assemble the remaining pinion gears and thrust
washers and place in position in the differential
carrier.
74
STEP 6.
Rotate all the pinion gears until properly aligned in
the differential carrier and insert the shaft into the
differential carrier through the pinion gears.
NOTE: The split dowel must be installed on the indicated side shown.
STEP 7.
Install the split dowel to retain the shaft in the dif-
ferential carrier.
STEP 8.
If removed, install the dowel pin into the differential
carrier.
75
STEP 9.
Place the bevel ring gear in position on the differen-
tial carrier.
STEP 10.
Apply Loctite® 270 to the threads of the capscrews
and install capscrews to retain bevel ring gear to
differential carrier. Tighten capscrews to 120 N•m
(88.5 lbf ft).
WARNING
STEP 11.
Heat the bearing cones to 80 to 90°C (176 to 194°F).
76
WARNING
STEP 12.
Install the bearing cone onto the differential carrier
on the bevel ring gear side.
If necessary, use special tool (Hyster Part Number

1641499) and a hammer to seat the bearing.
WARNING
STEP 13.
Install the bearing cone onto the differential carrier
opposite the bevel ring gear side.
If necessary, use special tool (Hyster Part Number

1641499) and a hammer to seat the bearing.
77
INSTALL
Determine Bevel Pinion Shim Thickness

STEP 1.
Measure the thickness of the old shim (S).
1. OLD SHIM
STEP 2.
Read the variation number (V) on the old pinion head
and the new pinion head.
78
STEP 3.
Calculate the value of the new shim.
If old value (V Old) is greater than new value (V New)

then:
S New = S Old + (V Old - V New)
If old value (V Old) is less than new value (V New) then:

S New = S Old - (V New - V Old)
1. OLD SHIM
2. OLD BEVEL PINION
3. NEW SHIM
4. NEW BEVEL PINION
STEP 4.
Choose the shim with thickness value (S New) from the
available shims.
Shim Range
Thick- 2.0 mm 2.1 mm 2.2 mm 2.3 mm 2.4 mm 2.5 mm 2.6 mm 2.7 mm 2.8 mm
ness (0.079 in.) (0.083 in.) (0.087 in.) (0.091 in.) (0.094 in.) (0.098 in.) (0.102 in.) (0.106 in.) (0.110 in.)
1. SHIMS
79
Bevel Pinion
STEP 1.
If removed, install new bearing cups into the center
section using special tool kit Hyster Part Number
1641509.
1. BEARING CUP
2. CENTER SECTION
3. BEARING CUP
NOTE: Always use a new collapsible spacer.
STEP 2.
Insert the chosen shim (S New) onto the bevel pinion
with the chamfer against the bevel pinion head.
Install the bearing onto the bevel pinion with spe-

cial tool (Hyster Part Number 1641500) and a press.
Press the bearing onto the bevel pinion until it is fully
seated against the shim and bevel pinion head.
Install the washer, new collapsible spacer, and re-

maining washer onto the bevel pinion.
1. BEVEL PINION
2. SHIM
3. BEARING
4. WASHER
5. COLLAPSIBLE SPACER
6. WASHER
80
WARNING
STEP 3.
Heat the outer bearing cone to 80 to 90°C (176 to
194°F).
Insert the bevel pinion into the center section and in-
stall the outer bearing cone onto the bevel pinion.
Force the bearing cone in position using special tool

(Hyster Part Number 1641500) and a hammer.
STEP 4.
Install a new lockwasher onto the bevel pinion end.
Screw the ring nut onto the bevel pinion end.
1. RING NUT
2. LOCKWASHER
81
CAUTION
The torque setting is given by the pre-loading measurement on the bearings. The ring nut must be
tightened gradually. If the ring nut is overtightened, the collapsible spacer must be replaced and
the procedure repeated.
NOTE: It is advised when checking the pre-loading to lightly tap on both ends of the bevel pinion to help seat
the bearings.
STEP 5.
Slowly tighten the ring nut in small increments with
special tools (Hyster Part Numbers 1641501 and
1644168). Measure the bearing preload in between
tightening increments. See STEP 6.
CAUTION
All preload measurements should be measured without the flange seal installed.
STEP 6.
Measure the preload torque (T P) of the bevel pinion
bearings using a torque wrench.
T P = 2 to 3 N•m (17.7 to 26.5 lbf in)
The adjustment is carried out by increasing the ring

nut torque in small, gradual increments.
82
CAUTION
STEP 7.
An alternative method for measuring the bearing
preload torque is done using a dynamometer whose
cord is wound on the special tool (Hyster Part Num-
ber 1641501) inserted on the end of the bevel pinion
shaft.
The effective preload torque (P m) of the bearings is

measured on the special tool (gauge diameter D m =
104 mm).
The measured value should be in the following range:

P m = 39 to 57 N•m (29 to 42 lbf ft)
1. BEVEL PINION
2. SPECIAL TOOL (HYSTER PART NUMBER
1641501)
STEP 8.
Once the correct preload has been achieved, remove
the special tools and bend the lockwasher against
two sides of the nut with a hammer and punch using
the special protection tool (Hyster Part Number
1641520).
83
STEP 1.
Choose the shims with a total thickness value of
1.2 mm (0.047 in.) from the following available
shims:
1. SHIMS
Shim Range
Thickness 0.05 mm 0.10 mm 0.30 mm 0.50 mm
(0.0020 in.) (0.0039 in.) (0.012 in.) (0.020 in.)
NOTE: If the spacer is damaged or worn, a new spacer must be installed.
STEP 2.
Assemble the spacer and shims with total thickness
of 1.2 mm (0.047 in.) and install into the center sec-
tion.
1. CENTER SECTION
2. SPACER
3. SHIMS (TOTAL THICKNESS OF 1.2 mm
(0.047 in.))
84
STEP 3.
Install the bearing cup into the center section using
special tool (Hyster Part Number 1641497).
1. CENTER SECTION
2. BEARING CUP
CAUTION
Do not damage the seal in the center section when installing the differential assembly.
STEP 4.
Lift the differential assembly with special tool (Hys-
ter Part Number 1641512) and install the differential
assembly into the center section.
Install the differential assembly with the bevel ring

gear on the right-hand side.
85
STEP 5.
Install the new bearing cup into the bearing sup-
port flange using special tool (Hyster Part Number
1641497).
1. BEARING CUP
STEP 6.
Verify that the dowel pin is in the correct position in
the center section.
Place the bearing support flange in position on the

center section. Install the capscrew and socket-head
screws.
Tighten the capscrew to 85 N•m (62.7 lbf ft).
Tighten the socket-head screws to 26 N•m

(19.2 lbf ft).
1. CAPSCREW
2. CENTER SECTION
5. DOWEL PIN
STEP 7.
Install the adjuster ring nut using special tool (Hys-
ter Part Number 1641514) and tighten the adjuster
ring nut until the backlash is eliminated and the dif-
ferential assembly bearings are slightly pre-loaded.
86
STEP 8.
Assemble the special tool (Hyster Part Number
1641513) on the differential assembly as shown.
87
STEP 9.
Position a comparator gauge with the feeler in con-
tact with and at a 90 degree respect to the surface of
the special tool bracket, in correspondence with the
edge of the center section housing.
Position the comparator gauge with the feeler at (R)

103 mm (4.055 in.) from the center.
NOTE: R = 103 mm (4.055 in.)
STEP 10.
Move the bracket of the special tool (Hyster Part
Number 1641513) installed on the differential as-
sembly back and forth by hand.
Measure the backlash between the bevel pinion and

the bevel ring gear.
Check if the measured backlash is within the pre-

scribed range.
0.13 to 0.16 mm (0.0051 to 0.0063 in.)
Set the backlash by turning the adjusting ring nut

with special tool (Hyster Part Number 1641514).
88
STEP 11.
If adjusting the ring nut does not bring the backlash
to the specified range, then one of the following must
be performed.
• If the measured backlash is less than the specified
range, increase the thickness of the shims under
the bearing cup.
• If the measured backlash is greater than the speci-
fied range, decrease the thickness of the shims un-
der the bearing cup.
CAUTION
STEP 12.
Once the backlash has been established, use a torque
wrench to measure the total pre-loading T T of the
bearings of the bevel pinion and bevel ring gear.
T T = T P + 0.5 N•m (4.4 lbf in) to T P + 0.7 N•m
(6.2 lbf in)
For the measurement of T P, see STEP 6 of Install,

Bevel Pinion.
CAUTION
STEP 13.
An alternative method for measuring the total
preload is done using a dynamometer whose cord
is wound on the special tool (Hyster Part Number
1641501) inserted on the end of the bevel pinion
shaft.
89
STEP 14.
The total preload T m of the bearings is measured on
the special tool (gauge diameter D m = 104 mm.
The measured value should be in the following range:

T m = P m + 9 N•m (80 lbf ft) to P m + 13 N•m
(115 lbf ft)
For the measurement of T P, see STEP 7 of Install,

Bevel Pinion.
NOTE: Only adjust the adjuster ring nut using special tool (Hyster Part Number 1641514).
STEP 15.
If the measurement is not within the specified range,
check the assembly of all components and adjust the
adjuster ring nut.
• If the total pre-loading is less than the specified
range, screw in the adjuster ring nut, keeping
the bevel pinion and bevel ring gear backlash
unchanged (A).
• If the total pre-loading is greater than the speci-
fied range, unscrew the adjuster ring nut, keeping
the bevel pinion and bevel ring gear backlash un-
changed (B).
90
NOTE: There are two holes for the adjuster ring nut retainer, us the hole near the slot and turn the adjuster
ring nut slightly in order to allow the retainer installation.
STEP 16.
Once all adjustments are completed, install the ad-
juster ring nut retainer and capscrew. Tighten the
capscrew to 13 N•m (115 lbf in).
NOTE: After the seal is installed, perform the Gear Set, Tooth Contact Pattern Check.
STEP 17.
Install a new seal into the center section using special
tool (Hyster Part Number 1641506) and a hammer.
1. SEAL
2. CENTER SECTION
STEP 18.
Install the brake disc assembly, hub/actuator, and snap rings. See Brake Repair.
STEP 19.
Install the right side reduction gear assembly and axle shaft. See Reduction Gear Assembly.
91
Gear Set, Tooth Contact Pattern Check

Table 1. Bevel Gear and Bevel Pinion Tooth Contact Adjustment
1. Apply a colored dye or grease to approximately 12

of the ring gear teeth.
2. Rotate bevel gear forward and backward so that
the 12 gear teeth go past the drive six times to get
to the contact patterns. Repeat if needed to get a
clearer pattern.
3. Check the tooth contact pattern on the bevel gear.
See Table 2 and Table 3. Make sure that the pat-
tern is checked on the side of the tooth where the
bevel pinion applies the force in the forward di-
rection.
Table 2. Correct Tooth Contact
The contact area is the center between the top and NOTE: Normal pattern during adjustment shown.
bottom of the tooth. The contact area is toward the
inner circumference of the bevel gear.
The contact area is the center between the top and NOTE: Wear pattern from operation shown.
the bottom of the tooth. The contact area will be
almost the full length of the tooth.
92
Table 3. Incorrect Tooth Contact
The bevel pinion is too far away from the center of

the bevel gear. Add shims to move pinion toward
bevel gear. Check that the clearance is correct. Some
movement of ring gear away from bevel pinion may
be necessary.
The bevel pinion is too close to the center of the

bevel gear. Remove shims to move pinion away from
the bevel gear. Check that the clearance is correct.
Some movement of the bevel gear toward the bevel
pinion may be necessary.
93
Flange
STEP 1.
Install the bevel pinion seal into the center section
using special tool (Hyster Part Number 1641503) and
a hammer.
STEP 2.
Lubricate the inner lip of the seal with multipurpose
grease with 2 to 4% molybdenum disulfide.
1. SEAL
STEP 3.
Install the flange on the bevel pinion end.
Push the flange onto the bevel pinion end until it is

fully seated.
1. BEVEL PINION
2. CENTER SECTION
3. FLANGE
94
1400 SRM 1215 Drive Axle Installation
Drive Axle Installation

1. If removed, position the manifold on the center axle against the frame. This will prevent any gap be-
section of the drive axle and install the capscrews tween the frame and the drive axle mount, and will
to retain the manifold. Tighten the capscrews to ensure even weight distribution.
4. Position the drive axle in the lift truck.
2. Connect the cooling outlet crossover hose to the
manifold and the drive axle. See Figure 17. NOTE: It is recommended to use a torque multiplier
to achieve the torque specification in Step 5.
3. Connect slings and lifting device to drive axle.
5. Install the four mounting capscrews and wash-
NOTE: When installing the drive axle, ensure the ers. Tighten the capscrews to 820 to 902 N•m
drive axle is held with the upper surface of the drive (605 to 665 lbf ft). See Figure 18.
1. HOSE CLAMP 4. CENTER SECTION

2. MANIFOLD 5. COOLING OUTLET CROSSOVER HOSE
3. CAPSCREWS
Figure 17. Manifold and Cooling Outlet Crossover Hose
95
Drive Axle Installation 1400 SRM 1215
1. WASHER 3. TRUMPET ARM (LH)

2. CAPSCREW 4. TRUMPET ARM (RH)
Figure 18. Drive Axle Mounting Capscrews
96
6. Place the drive shaft in position and install the

retaining capscrews. Tighten the drive shaft cap-
7. Install the transmission isolator mounting bolt

located on top of the assembly. Tighten the bolt to
8. Remove blocks from under the transmission.
9. Connect the cooling return hose to the manifold

on top of the drive axle. See Figure 20.
10. Connect the brake return hose to the drive axle.

See Figure 20.
11. Connect the brake inlet hose to the drive axle.

See Figure 20.
12. Connect the cooling inlet hose to the manifold on

top of the drive axle. See Figure 20.
13. Install the parking brake cable. Refer to the sec-

1. ISOLATORS
tion Brake System 1800 SRM 1135. 2. WASHER
3. WASHER
14. Install the brake discs oil drain plug and tighten 4. CAPSCREW
plug to 40 N•m (29.5 lbf ft). See Figure 21. 5. TRANSMISSION
6. DRIVE AXLE
Figure 19. Transmission to Differential

Mounting Bolt
97
Drive Axle Installation 1400 SRM 1215
A. DRIVE AXLE COOLING RETURN HOSE TO TRANSMISSION SUMP

1. HOSE CLAMP 4. BRAKE RETURN HOSE
2. BRAKE INLET HOSE 5. COOLING INLET HOSE
3. COOLING RETURN HOSE
Figure 20. Drive Axle Cooling Hoses and Brake Lines
15. Install the oil drain plug (RH and center sec- 17. Fill the sections of the drive axle with the proper
tion) for the right-hand side and center section fluid. Refer to the section Periodic Mainte-
of the drive axle and tighten plug to 40 N•m nance 8000 SRM 1150 for the correct fluid,
(29.5 lbf ft). See Figure 21. quantity, and fill procedure.
16. Install the oil drain plug (LH) for the left-hand 18. Install the oil fill/level plugs on both sides of
side of the drive axle and tighten plug to 40 N•m the drive axle and tighten plugs to 40 N•m
(29.5 lbf ft). See Figure 21. (29.5 lbf ft). See Figure 21.
98
1. OIL FILL/LEVEL PLUG (LH) 7. COOLING OIL INLET PORT

2. OIL DRAIN PLUG (LH) 8. COOLING OIL OUTLET PORT
3. OIL BREATHER (LH) 9. MASTER CYLINDER RELIEF PORT
4. OIL FILL/LEVEL PLUG (RH) 10. SERVICE BRAKE INLET PORT
5. OIL DRAIN PLUG (RH AND CENTER SECTION) 11. BRAKE DISCS OIL DRAIN PLUG
6. OIL BREATHER (RH) 12. BRAKE OIL BLEEDER VALVE
Figure 21. Oil Fill Plugs and Drain Plugs

21. Inflate the tires using a safety cage. Install the
CAUTION wheels and nuts and tighten the nuts to 450 to
If a new drive axle is being installed, perform 500 N•m (332 to 369 lbf ft).
Step 19. Failure to do so will cause damage to
the drive axle. 22. Install the mast assembly as described in the sec-
tion Mast Repairs, 2-, 3-, and 4-Stage Masts
19. Remove and discard plastic protective caps from 4000 SRM 1148.
the breather.
23. Raise the lift truck and remove blocks from under
20. Remove the air from the brake system as de- frame and from under the counterweight. Lower
scribed in the section Brake System 1800 SRM the lift truck.
1135.
24. Remove the blocks on each side (front and back)
of the steering tires.
WARNING
Add air to the tires only in a safety cage. In- 25. Operate the lift truck and check for proper oper-
spect safety cage for damage before use. When ation and leaks.
adding air, use a clip-on chuck with enough
hose to let the operator stand clear of the cage.
99
Special Tools
Special Tool Hyster Special Tool Hyster
Part Number Part Number
1641496 1644168
(Assembly)
1641497
1641503
1641498
1641504
1641499
1641505
1641506
1641500
1641501
1641507
100
Special Tool Hyster Special Tool Hyster

Part Number Part Number
1641508 1641514
1641509 1641515
(Assembly) (Assembly)
1641510 1641516
(This tool is
also part of
the assembly
1641515.)
1641517
1641511
1641518
1641512
(Assembly)
1641519
1641513
101
Special Tool Hyster

Part Number
1641520
1641521
Adjuster Ring Nut Retainer Capscrew Parking Brake Flange Socket-Head Screws
13 N•m (115 lbf in) 60 N•m (44.25 lbf ft)
Bevel Gear Capscrews Self-Adjust Screws

120 N•m (88.5 lbf ft) 10 N•m (88.5 lbf in)
Bleeder Valve Trumpet Arm Capscrews

10 N•m (88.5 lbf in) 85 N•m (62.7 lbf ft)
Drive Axle to Frame Mounting Capscrews Transmission Isolator Bolt

Drain Plugs Wheel Hub Retaining Nut

40 N•m (29.5 lbf ft) 400 N•m (295 lbf ft)
Drive Shaft Capscrews Wheel Hub Support Socket-Head Screws

30 to 37 N•m (22 to 27 lbf ft) 85 N•m (62.7 lbf ft)
Fill/Level Plugs Wheel Nuts

40 N•m (29.5 lbf ft) 450 to 500 N•m (332 to 369 lbf ft)
Manifold Retaining Capscrews

19 to 22 N•m (14 to 16 lbf ft)
102
Figure 22. Torque Specifications (Sheet 1 of 2)
103
Figure 22. Torque Specifications (Sheet 2 of 2)
104

BRAKE SYSTEM
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]; S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
PART NO. 1580513 1800 SRM 1135

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
Brake System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Dry Brake System ......................................................................................................................................... 1
Wet Brake System ......................................................................................................................................... 1
Service Brakes Repair (Dry Brake)................................................................................................................... 2
Clean .............................................................................................................................................................. 9
Inspect ............................................................................................................................................................ 10
Adjust ............................................................................................................................................................. 18
Inching Overlap Adjustment......................................................................................................................... 18
Parking Brake Repair ........................................................................................................................................ 19
Adjust ............................................................................................................................................................. 22
Master Cylinder Repair ..................................................................................................................................... 22
Remove (Dry Brake) ...................................................................................................................................... 22
Disassemble (Dry Brake) .............................................................................................................................. 22
Clean and Inspect (Dry Brake) ..................................................................................................................... 25
Assemble (Dry Brake) ................................................................................................................................... 25
Bench Bleed Master Cylinder (Dry Brake) .................................................................................................. 25
Install and Adjust (Dry Brake) ..................................................................................................................... 25
Remove (Wet Brake) ...................................................................................................................................... 26
Disassemble (Wet Brake) .............................................................................................................................. 27
Clean and Inspect (Wet Brake) ..................................................................................................................... 29
Assemble (Wet Brake) ................................................................................................................................... 29
Install and Adjust (Wet Brake) ..................................................................................................................... 29
Service Brakes Adjustment (Dry Brake) .......................................................................................................... 30
Brake System Air Removal ............................................................................................................................... 31
Using Pressure Bleed System ....................................................................................................................... 31
Using Brake Pedal Pressure ......................................................................................................................... 31
Brake Pedal Adjustment.................................................................................................................................... 32
Free Pedal Adjustment ...................................................................................................................................... 33
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
DRY BRAKE SYSTEM WET BRAKE SYSTEM
This section has service procedures for dry brake sys- Wet brake system in this section includes the follow-
tem. Dry brake system includes the following parts: ing parts: master cylinder and parking brake sys-
master cylinder, brake shoes, wheel cylinders, and tem. See Figure 2.
parking brake system. See Figure 1.
Wet disc brakes are a component of wet brake drive
axle. Brake discs are located inside planetary carrier
housing on left side of drive axle. See Drive Axle
Repair, (Wet Brake) 1400 SRM 1215 for Remove,
Assemble and Install procedures. See Figure 2.
1. PARK BRAKE HAND LEVER

2. INCH/BRAKE PEDAL
3. MASTER CYLINDER AND BOOSTER
4. PARK BRAKE LEVER
1. PARK BRAKE LEVER 5. WET DISC BRAKE HOUSING
2. ADJUSTMENT KNOB 6. PLANETARY CARRIER HOUSING (RIGHT SIDE
3. PARK BRAKE CABLES SHOWN)
4. INCHING/BRAKE PEDAL 7. BRAKE OIL SUPPLY HOSE
5. MASTER CYLINDER 8. ADJUSTMENT KNOB
6. BRAKE ASSEMBLY 9. BRAKE POSITION SENSOR
7. BRAKE POSITION SENSOR (RIGHT HAND 10. BRAKE POSITION SENSOR CONNECTOR
SIDE) 11. BRAKE OIL RESERVOIR
12. PARKING BRAKE CABLE BRACKET
13. PARKING BRAKE CABLE
Figure 1. Brake System
Figure 2. Wet Brake System for Lift Truck
Model H2.0-3.5FT (H40-70FT) (L177)
1
Service Brakes Repair (Dry Brake) 1800 SRM 1135
Service Brakes Repair (Dry Brake)

REMOVE AND DISASSEMBLE 3. Perform following steps for lift truck models
• S50CT (A267)
WARNING • H2.0-2.5CT (H50CT) (A274)
Brake linings can contain dangerous fibers. a. Bend bearing lockwasher tabs to release
Breathing the dust from these brake linings locknut.
is a cancer or lung disease hazard. DO NOT
create dust! DO NOT clean brake parts with b. Remove nut, lockwasher, locknut, and roller
compressed air or by brushing. Use vacuum bearing from hub/brake assembly. See Fig-
equipment approved for brake dust or follow ure 3.
the cleaning procedure in this section. When
the brake drums are removed, DO NOT create WARNING
dust.
When the brake shoes are removed, do not cre-
DO NOT sand, grind, chisel, hammer, or change ate dust in the air. See the Clean procedure in
linings in any way that will create dust. Any this section.
changes to brake linings must be done in a re-
c. Pull wheel assembly from lift truck. If wheel
stricted area with special ventilation. Protec-
assembly cannot be removed easily, use a
tive clothing and a respirator must be used.
small screwdriver to push adjuster actuator
1. Remove capscrews that hold axle shaft to the away from adjuster wheel. Use a brake ad-
hub. Remove axle shaft. justment tool or a screwdriver to turn ad-
juster wheel to loosen brake shoes. Remove
2. See procedure How to Put Lift Truck on Blocks hub and drum assembly. DO NOT damage
in Periodic Maintenance for your lift truck or grease seal when removing hub.
Operating Manual for your lift truck. Put lift
truck on blocks so drive wheels can be removed. d. Remove inner oil seal, inner bearing, and
Remove drive wheels. wear sleeve from hub. See Figure 3.
2
1800 SRM 1135 Service Brakes Repair (Dry Brake)
1. CAPSCREW 14. LEFT BRAKE LINE

2. DRIVE AXLE SHAFT 15. DRIVE AXLE MOUNTING CAPSCREW
3. LOCKNUT 16. DRIVE AXLE MOUNTING NUT
4. BEARING LOCKWASHER 17. DIFFERENTIAL COVER
5. WASHER 18. RIGHT BRAKE LINE
6. HUB/BRAKE ASSEMBLY 19. DRIVE AXLE CENTER SECTION UNIVERSAL
7. HUB BOLT JOINT
8. ROLLER BEARING 20. UNIVERSAL JOINT
9. OUTER SEAL 21. DUST COVER
10. INNER BEARING 22. INPUT SHAFT (YOKE)
11. INNER OIL SEAL 23. BRAKE MANIFOLD
12. WEAR SLEEVE 24. HANGER ASSEMBLY
13. BRAKE ASSEMBLY
Figure 3. Drive Axle Components, Lift Truck Models S50CT (A267) and H2.0-2.5CT (H50CT) (A274)
3
4. Perform following steps for lift truck models • S50CT [A267]

• S30FT, S35FT, S40FTS (E010) • H2.0-2.5CT (H50CT) (A274)
• H1.6FT, H1.8FT, H2.0FT (H30FT, H35FT,
H40FTS) (F001) 6. Remove retainers, springs, and anchor pins that
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) hold brake shoes to back plate.
• H2.0-3.5FT (H40-70FT) (L177)
7. Disengage link from adjuster wheel actuator. Re-
a. Bend lock plate and remove nut that holds move link, washer, and pivot plate. Remove an-
axle bearing. Remove washer and bearing chor guide.
cone.
8. Move brake shoes away from each other to dis-
engage brake shoes from wheel cylinder. Dis-
WARNING connect parking brake lever from parking brake
When the brake shoes are removed, DO NOT cable as brake assembly is removed from back
create dust in the air. See the Clean procedure plate. Parking brake lever has a hook that en-
in this section. gages parking brake cable.
b. Pull wheel assembly from lift truck. If wheel NOTE: Adjuster wheel for left brake is not same as
assembly cannot be removed easily, use a adjuster wheel for right brake. Adjuster wheel for
small screwdriver to push adjuster actuator left brake has left-hand threads.
away from adjuster wheel. Use a brake ad-
justment tool or a screwdriver to turn ad- 9. Remove parking brake link and spring if they are
juster wheel to loosen brake shoes. Remove still engaged with brake shoes. Parking brake
hub and drum assembly. DO NOT damage link and spring will often fall from brake assem-
grease seal when removing hub. bly when brake assembly is removed from back
plate. Adjuster wheel will also disengage from
NOTE: Note arrangement of brake parts during dis- brake shoes after brake assembly is removed.
assembly to aid in assembly.
10. Remove spring for adjuster wheel actuator. Re-
5. Remove return springs with spring pliers. move adjuster wheel actuator from brake shoe.
See Figure 4 and Figure 5 for lift truck models 11. Use a screwdriver or small pry bar to move apart
• S2.0-3.5FT (S40-70FT, S55FTS) [F187] ends of retainer. Remove spring washer and
• H2.0-3.5FT (H40-70FT) [L177] pivot pin to remove parking brake lever from
brake shoe.
• S30FT, S35FT, S40FTS (E010) 12. Disconnect brake line from wheel cylinder. Re-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, move capscrews that hold wheel cylinder to back
H40FTS) [F001] plate and remove wheel cylinder.
4
1. WHEEL CYLINDER 11. ADJUSTER WHEEL

2. RETURN SPRING 12. ADJUSTER ASSEMBLY
3. RETURN SPRING 13. PRIMARY BRAKE SHOE
4. ANCHOR 14. PARKING BRAKE LEVER
5. ANCHOR GUIDE 15. LINK, PARKING BRAKE
6. BACK PLATE 16. SPRING, PARKING BRAKE
7. SECONDARY BRAKE SHOE 17. PIVOT PIN, RETAINER, AND SPRING WASHER
8. LEVER 18. ADJUSTER ACTUATOR SPRING
9. PIVOT PLATE 19. SPRING
10. SPRING AND CABLE ASSEMBLY
Figure 4. Brake Assembly (Left-Hand Shown), S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT
(H40-70FT) [L177]
5
NOTE: RIGHT-HAND BRAKE ASSEMBLY SHOWN.

1. WHEEL CYLINDER 12. ADJUSTER ASSEMBLY
2. RETURN SPRING 13. PRIMARY BRAKE SHOE
3. RETURN SPRING 14. PARKING BRAKE LEVER
4. ANCHOR 15. PARKING BRAKE LINK
5. ANCHOR GUIDE 16. PARKING BRAKE SPRING
6. BACK PLATE 17. PIVOT PIN, RETAINER, AND SPRING WASHER
7. SECONDARY BRAKE SHOE 18. ADJUSTER ACTUATOR SPRING
8. LEVER 19. SPRING
9. PIVOT PLATE 20. RETAINING PIN
10. ADJUSTER ACTUATOR LINK 21. RETAINING WASHER
11. ADJUSTER WHEEL 22. PARKING BRAKE CABLE
Figure 5. Service Brake Parts, S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT (H40-70FT)
[L177]
6
1. BACKING PLATE 9. SPRING (ACTUATOR)

2. RETAINING RING 10. PAWL LEVER
3. LEVER PIN 11. SECONDARY BRAKE SHOE
4. GUIDE PLATE 12. ADJUSTER ASSEMBLY
5. WHEEL CYLINDER 13. ADJUSTER SPRING
6. PAWL LEVER STOPPER 14. PARK BRAKE LEVER
7. SPRING (ANTI-RATTLE) 15. PRIMARY BRAKE SHOE
8. RETURN SPRING 16. STRUT
Figure 6. Brake Assembly (Left Hand Side), S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001), S50CT (A267), and H2.0-2.5CT (H50CT) (A274)
7
1. BOLT 13. PAWL LEVER

2. WHEEL CYLINDER 14. PARK BRAKE CABLE
3. STRUT 15. ADJUSTER ASSEMBLY
4. SPRING 16. PLUG
5. SECONDARY BRAKE SHOE 17. SPRING (ADJUSTER)
6. PLATE 18. PRIMARY BRAKE SHOE
7. SPRING 19. PARK BRAKE LEVER
8. LEVER (STOP) 20. PIN
9. SPRING 21. PLUG
10. WASHER 22. BACKING PLATE
11. SPRING (SHOE HOLD DOWN) 23. PIN
12. WASHER
Figure 7. Service Brake Parts, S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001), S50CT (A267), and H2.0-2.5CT (H50CT) (A274)
8
NOTE: Back plate is not normally removed from axle cleaning solvents, always follow the safety
housing for brake repairs. Special capscrews are instructions of the solvent manufacturer.
used to fasten back plate to axle mount, and locking
function of capscrews is reduced if they are removed. 1. DO NOT release brake lining dust from brake
linings into the air when brake drum is removed.
13. Remove special capscrews if necessary.
2. Use a solvent approved for cleaning of brake
14. Remove push rods, dust covers, pistons, cups, parts to wet brake lining dust. Follow instruc-
and spring from wheel cylinder. See Figure 8. tions and cautions of manufacturer for use of
solvent. If a solvent spray is used, spray at a
CLEAN distance so that dust is not released into the air.
3. When brake lining dust is wet, clean parts. Put

WARNING
any cloth or towels in a plastic bag or an airtight
DO NOT use an oil solvent to clean the master container while they are still wet. Put a DAN-
cylinder, wheel cylinder, or brake linings. Use GEROUS FIBERS warning label on plastic bag
a solvent approved for cleaning of brake parts. or airtight container.
DO NOT permit oil or grease in the brake fluid
or on the brake linings. Oil and grease will
cause damage and leaks in the seals of a brake CAUTION
system. The brakes will not operate correctly DO NOT permit oil or grease on the brake lin-
if oil, grease, or brake fluid is on the brake linings. Use a brake cleaning fluid as necessary to
ings. clean linings that will not be replaced.
Cleaning solvents can be flammable and toxic 4. Any cleaning cloths that will be washed must be
and can cause skin irritation. When using cleaned so that fibers are not released into the
air.
1. PUSH ROD (2) 4. CUP (2) 7. INLET PORT

2. DUST COVER (2) 5. SPRING 8. PRESSURE BLEEDER
3. PISTON (2) 6. WHEEL CYLINDER BODY 9. DUST COVER
Figure 8. Wheel Cylinder
9
INSPECT 7. Check grease seals and surfaces of seals for wear

or damage.
1. Inspect the bore of wheel cylinder for holes or
scratches. Replace wheel cylinder assembly if ASSEMBLE AND INSTALL
there is any damage.
1. If removed, install back plate to drive axle.
2. Inspect return springs for wear and damage. Tighten special screws as indicated below:
Inspect back plate for wear where brake shoes
touch back plate. Remove any grooves or replace a. Eight special capscrews are tightened to 255
a worn or damaged back plate. to 306 N•m (188 to 226 lbf ft) for lift truck
models
• S2.0-3.5FT (S40-70FT, S55FTS) [F187]
WARNING
• H2.0-3.5FT (H40-70FT) [L177]
The brake shoes on both wheels must be re-
placed if any shoe is damaged. The brake per- b. Six special capscrews are tightened to 152
formance on both ends of an axle must be equal, to 167 N•m (112 to 123 lbf ft) for lift truck
or the lift truck can be difficult to steer when models
the brakes are applied. • S30FT, S35FT, S40FTS (E010)
3. Inspect brake shoes for cracks or damage. If H40FTS) [F001]
linings or shoes are worn or damaged, replace • S50CT (A267)
brake shoes. Maximum wear is to within 1 mm • H2.0-2.5CT (H50CT) (A274)
(0.039 in.) of contact with rivets, or metal shoe
on bonded linings. Brake shoes must be replaced 2. If wheel cylinder was disassembled for repair, as-
in complete sets. Inspect brake drums for cracks semble wheel cylinder. See Figure 8. Use only
or damage. Replace any damaged parts. HYSTER APPROVED parts.
4. Inspect brake drum for deep grooves or other 3. Install wheel cylinder on back plate and tighten
damage. two capscrews to 18 to 27 N•m (13 to 20 lbf ft).
Connect brake line to wheel cylinder.
NOTE: If grooves must be removed from brake
drums, DO NOT grind more than 1.5 mm (0.060 in.) 4. Install parking brake lever. Use pivot pin,
from internal diameter of brake drum. spring washer, and retainer to fasten parking
brake lever to brake shoe. Close ends of retainer
Maximum limit of internal diameter of the brake to fasten pivot pin in position.
drum is 312 mm (12.28 in.) for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) See Figure 5 for lift truck models
• H2.0-3.5FT (H40-70FT) (L177)
Maximum limit of internal diameter of brake drum
is 255.5 mm (10.06 in.) for lift truck models See Figure 7 for lift truck models
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
(F001) H40FTS) (F001)
• S50CT (A267) • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274) • H2.0-2.5CT (H50CT) (A274)
If internal diameter is larger than the limit, replace 5. Fasten adjuster actuator spring to adjuster
brake drum. wheel actuator and brake shoe.
5. The teeth of adjuster wheel must not be worn. 6. Put antiseize compound on threads of adjuster
Adjuster wheel must turn freely. Check adjuster wheel. Turn theadjuster wheel into adjuster nut
links for damage. so that adjuster assembly is in its shortest posi-
tion. This action permits brake drum to be easily
6. Make sure parking brake cables are in good con- installed over brake shoes.
dition.
10
the white return spring first and then the black

WARNING return spring. See Figure 10. Improper assem-
The threads of the adjuster wheel are not the bly can result in brake failure and/or compo-
same for each side. If the adjuster assemblies nent damage.
are installed on the wrong side, the brake shoe
clearance will increase each time the brakes NOTE: The shape of return springs permits them to
are applied. The adjuster wheel for the right be installed correctly in only one position. The ar-
brake has right-hand threads. The adjuster rangement of return springs on anchors is shown in
wheel for the left brake has left-hand threads. Figure 9 and Figure 10 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
7. Install adjuster wheel between two brake shoes. • H2.0-3.5FT (H40-70FT) (L177)
Make sure adjuster wheel will be toward rear of
lift truck. Move brake shoes apart so that ad- 15. Using correct tools, install return springs as fol-
juster wheel is held in position and adjuster ac- lows:
tuator spring is in tension.
a. Install white spring.
8. Lubricate back plate with a small amount of
lithium grease where brake shoes touch. Install b. Install black spring.
brake shoes on anchor and engage thepush rods c. Verify that return springs are properly in-
of wheel cylinder. Engage theparking brake stalled as shown in Figure 10.
lever in slot in parking brake cable as brake
shoes are installed on back plate. NOTE: The shape of return springs permits them to
be installed correctly in only one position. The ar-
9. Put an anchor pin, that holds brake shoes, rangement of return springs on anchors is shown in
through back plate. Put a spring seat, spring, Figure 11 for lift truck models
and retainer on anchor pin. Push retainer onto • S30FT, S35FT, S40FTS (E010)
anchor pin and rotate retainer 90 degrees. Make • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
sure retainer is in correct position. (F001)
10. Install link, parking brake, and spring between • S50CT (A267)
parking brake lever and brake shoe. • H2.0-2.5CT (H50CT) (A274)
11. Install other spring retainer, that holds brake 16. Using correct tools, install return springs as fol-
shoes. Make sure parking brake link and spring lows:
are correctly engaged after spring retainers are a. Install return spring.
installed.
b. Install washer.
12. Install anchor guide on anchor. Install pivot
plate on its anchor. c. Install return spring.
13. Lubricate adjuster cable where it slides in pivot d. Verify that return springs are properly in-
plate groove. stalled as shown in Figure 11.
14. Fasten link to adjuster wheel actuator and put NOTE: Seal and bearings are to be installed flush
cable around pivot plate. Raise adjuster wheel with hub. Seal is to be installed with no grease or
actuator against spring tension and connect link oil on outside surface.
to anchor.
17. Clean bearings and lubricate them with wheel
WARNING bearing grease. Install bearings and seals in
brake drum. Install assembly on axle housing.
For S2.0-3.5FT (S40-70FT, S55FTS) [F187] and
H2.0-3.5FT (H40-70FT) [L177]: Be sure to install
11
1. RETURN SPRING 4. ADJUSTER ACTUATOR LINK

2. ANCHOR GUIDE 5. PIVOT PLATE
3. RETURN SPRING
Figure 9. Return Springs, S2.0-3.5FT (S40-70FT, S55FTS) (F187) and H2.0-3.5FT (H40-70FT) (L177)
12
1. WHITE SPRING 2. BLACK SPRING
Figure 10. Proper Installation of Return Springs, S2.0-3.5FT (S40-70FT, S55FTS) (F187) and
H2.0-3.5FT (H40-70FT) (L177)
13
1. RETURN SPRING 3. RETURN SPRING

2. GUIDE PLATE 4. SPRING ACTUATOR
Figure 11. Return Springs, S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001), S50CT (A267), and H2.0-2.5CT (H50CT) (A274)
14
1. INNER SEAL 4. INNER BEARING

2. OUTER SEAL 5. OUTER BEARING
3. BRAKE DRUM
Figure 12. Grease Seals and Bearing Locations
15
NOTE: Perform steps Step a through Step f for all lift

truck models.
a. To align bearing rollers, tighten wheel

adjustment nut to 14 to 18 N•m (124 to
159 lbf in) and rotate hub 2 revolutions in
both directions.
b. To seat wheel bearings, tighten wheel adjust-

ment nut to 175 to 215 N•m (129 to 159 lbf ft)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
c. To seat wheel bearings, tighten wheel adjust-

Figure 13. Inner Oil Seal Installation ment nut to 120 to 145 N•m (89 to 107 lbf ft)
NOTE: To prevent damage to inner oil seal when in- • S30FT, S35FT, S40FTS (E010)
stalling hub, hub and drum assembly can be tem- • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
porarily fastened to the wheel. Align height of axle H40FTS) (F001)
housing with hub bearings. Put grease under wheel • S50CT (A267)
and slide wheel toward axle housing. • H2.0-2.5CT (H50CT) (A274)
18. Install outer bearing and nut, for lift truck mod- d. Back off wheel adjustment nut to zero end
els play.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, e. Preload wheel bearings by tightening wheel
H40FTS) (F001) adjustment nut to 14 to 18 N•m (124 to
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 159 lbf in). Rotate hub 3 complete revolu-
• H2.0-3.5FT (H40-70FT) (L177) tions in both directions.
Install wear sleeve, inner seal, inner bearing, f. Verify wheel adjustment nut torque is 14 to
outer seal, roller bearing and nut, for lift truck 18 N•m (124 to 159 lbf in) and that torque
models (see Figure 3) stabilizes at that specification.
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274) 20. Bend lock plate over lock nut. See Figure 14, for
lift truck models
19. Install washer, lock plate and wheel adjustment • S30FT, S35FT, S40FTS (E010)
nut for lift truck models • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) • H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) Bend bearing lockwasher over lock nut. See Fig-
ure 3 for lift truck models
Install lockwasher, locknut and wheel adjust- • S50CT (A267)
ment nut for lift truck models • H2.0-2.5CT (H50CT) (A274)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
16
capscrews. Tighten capscrews in cross pattern

to a torque specified below for your lift truck.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S50CT (A267)

• H2.0-3.5FT (H40-70FT) (L177)
• H2.0-2.5CT (H50CT) (A274)
a. Tighten between 90 to 99 N•m (66 to 73 lbf ft)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
b. Tighten between 90 to 108 N•m (66 to

80 lbf ft) for lift truck models
1. LOCK PLATE • H2.0-3.5FT (H40-70FT) (L177)
2. HUB/BRAKE DRUM ASSEMBLY
3. DOWEL PIN c. Tighten between 52 to 62 N•m (39 to 46 lbf ft)
Figure 14. Lock Plate
• S30FT, S35FT, S40FTS (E010)
CAUTION H40FTS) (F001)
If there is too much clearance, the automatic • S50CT (A267)
adjusters will not operate. If the clearance is • H2.0-2.5CT (H50CT) (A274)
too small, the automatic adjuster cannot turn
the adjuster wheel to increase the clearance,
and the adjuster wheel will not turn until
the brake shoes wear. If the adjuster wheel
does not move for a long operating period, the
adjuster link can wear a spot on the adjuster
wheel so that it will not turn correctly.
NOTE: If brake shoes were not replaced, loosen ad-

juster wheel approximately 20 teeth.
21. Adjust clearance of brake shoes. Put a brake ad-

justment tool or a screwdriver through slot in
back plate. Use tool to rotate adjuster wheel. Ac-
tuator for adjuster wheel will only permit rota-
tion in one direction. Turn adjuster wheel until
brake shoes have expanded against brake drum
and hub will not turn. Use a small screwdriver to
lift actuator away from adjuster wheel and turn
adjuster wheel approximately 20 teeth in the op-
posite direction. Brakes will adjust to correct Figure 15. Axle Shaft Tightening Sequence,
clearance when they are applied while lift truck S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
is traveling in reverse direction. H2.0FTS (H30FT, H35FT, H40FTS) (F001),
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and
22. Put liquid sealant, Hyster Part Number 264159, S50CT (A267)
on flange of axle shaft. Install axle shaft and
17
4. Service brakes must be adjusted before parking

brake can be adjusted. See Figure 18 and follow-
ing paragraphs in this section for correct adjust-
ment of parking brake.
INCHING OVERLAP ADJUSTMENT

NOTE: Perform following procedure for lift truck
models
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
NOTE: The amount of overlap is adjustable through a

ten-point range with 1 being minimum, 10 the max-
imum, and 5 the default.
1. Set inching overlap to default using the following

procedure.
Figure 16. Axle Shaft Torque Sequence,
a. Start engine and check inching overlap indi-
H2.0-3.5FT (H40-70FT) (L177) and H2.0-2.5CT
cator on display. Perform Step b or Step c to
(H50CT) (A274)
adjust overlap.
ADJUST b. To increase overlap, press Scroll Up button
on display switch cluster. See Figure 17.
1. Remove air from brake hydraulic system. See
Brake System Air Removal. c. To decrease overlap, press Scroll Down but-
ton on display switch cluster. See Figure 17.
2. Install wheel on hub. Tighten wheel nuts to
torque specified below for your lift truck.
a. Tighten between 340 to 380 N•m (251 to

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
b. Tighten between 450 to 500 N•m (332 to

• H2.0-3.5FT (H40-70FT) (L177)
c. Tighten between 155 to 175 N•m (115 to

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
3. Start engine and tilt mast backward to remove

blocks. Push on brake pedal. Pedal must not
touch floor plate. Move lift truck in REVERSE 1. SCROLL DOWN 2. SCROLL UP
and push on brake pedal to permit adjusting
Figure 17. Display Switch Cluster
mechanism to operate. Repeat this operation
several times.
18
1800 SRM 1135 Parking Brake Repair
Parking Brake Repair

REMOVE AND DISASSEMBLE If lever assembly for parking brake was removed
from cowl, use the following procedure for installa-
NOTE: For removal and disassembly procedures for tion:
a dry brake system use Step 1 through Step 5. For
a wet brake system use Step 1 through Step 4 and 1. Parking brake cables must be installed in back
Step 6. plate before service brake is installed. See Fig-
ure 18. A snap ring holds sheath of parking brake
If lever assembly for parking brake must be removed cable in back plate of service brake. Install park-
from cowl, use the following procedure. For dry brake ing brake cable in back plate and install snap
system see Figure 18 and for wet brake system see ring that holds sheath of parking brake cable in
Figure 19. back plate.
1. Block wheels front and rear side of the wheels to 2. For H2.0-3.5FT (H40-70FT) (L177) lift trucks
make sure lift truck cannot move. Release park- that are equipped with a wet brake system.
ing brake lever. Parking brake cable must be installed on park-
ing brake lever located on wet brake drive axle
2. Remove four capscrews that fasten bracket for
and cable loosely clamped to parking brake cable
parking brake to cowl. Remove bracket and
bracket in correct position before connecting
brake lever assembly.
parking brake cable to equalized link located on
3. Loosen jam nuts that fasten threaded ends of park brake assembly. See Figure 19.
brake cables to brake lever assembly.
3. Make sure parking brake lever is in released po-
4. Turn adjuster knob counterclockwise until brake sition. Turn adjustment knob until link is ad-
cables are loosened. Disconnect cables from link. justed to bottom of adjustment slot.
5. Service brake assembly must be removed before 4. Lift trucks equipped with a dry brake system.
parking brake cable can be removed from back Adjust jam nuts on ends of cable assemblies so
plate of service brake. A snap ring holds sheath that threads of cable sheaths extend 13 to 16 mm
of parking brake cable in back plate of service (0.51 to 0.63 in.) above their support plate in
brake. Remove snap ring and remove parking lever assembly. See Figure 18.
brake cable from back plate.
5. Lift trucks equipped with a dry brake system. In-
6. For H2.0-3.5FT (H40-70FT) (L177) lift trucks stall round ends of parking brake cables in their
equipped with a wet brake system. Remove cot- slots in link. Tighten upper jam nuts to hold
ter pin and clevis pin from parking brake lever, sheaths of parking brake cables in their support.
remove capscrew, insert and cable clamps from See Figure 18.
parking brake cable bracket before removing
6. For H2.0-3.5FT (H40-70FT) (L177) lift trucks
park brake cable from lift truck.
that are equipped with a wet brake system.
Install clevis end of parking brake cable in slot
in equalized link and install clevis pin and lock
NOTE: For Assemble and Install procedures for a dry ring cotter pin. Tighten lower parking brake
brake system use Step 1, Step 3 through Step 5 and cable bracket to 19 to 21 N•m (14 to 15.5 lbf ft)
Step 7. For a wet brake system use Step 2, Step 3, See Figure 19.
Step 6 and Step 7.
7. Use four capscrews, washers, and nuts and fas-
ten the bracket to inside of cowl.
19
Parking Brake Repair 1800 SRM 1135
1. PARKING BRAKE LEVER 6. BRAKE ASSEMBLY

2. ADJUSTMENT KNOB 7. BRAKE POSITION SENSOR
3. PARKING BRAKE CABLES 8. ADJUSTMENT SLOT
4. INCHING/BRAKE PEDAL 9. EQUALIZED LINK
5. MASTER CYLINDER 10. NUTS
Figure 18. Parking Brake Lever Adjustment With Dry Brake (Left Side Shown)
20
1800 SRM 1135 Parking Brake Repair
A. REAR VIEW SHOWN B. REAR RIGHT SIDE SHOWN

1. PARKING BRAKE LEVER HANDLE 11. PARK BRAKE LEVER
2. BRAKE POSITION SENSOR CONNECTOR 12. UPPER PARKING BRAKE CABLE BRACKET
3. BRAKE POSITION SENSOR 13. CABLE CLAMP
4. ADJUSTMENT KNOB 14. CAPSCREW
5. EQUALIZED LINK 15. INSERT
6. CLEVIS PIN 16. MASTER CYLINDER AND BOOSTER
7. LOCK RING COTTER PIN 17. INCHING/BRAKE PEDAL
8. BRAKE OIL SUPPLY HOSE 18. LOWER PARKING BRAKE CABLE BRACKET
9. DRIVE AXLE (WET BRAKE) 19. PARKING BRAKE CABLE
10. CLEVIS (PARKING BRAKE CABLE)
Figure 19. Parking Brake Lever Adjustment With Wet Brake for Lift Truck H2.0-3.5FT (H40-70FT)
(L177)
21
Master Cylinder Repair 1800 SRM 1135
ADJUST check the dash display to verify the transmis-

sion oil is at operating temperature, 49 to 66°C
Lift trucks equipped with a dry brake system. Make (120 to 150°F) before adjusting the parking
sure service brakes are adjusted and operation of au- brake adjustment knob.
tomatic adjuster mechanism is correct before parking
brake is adjusted. 1. To adjust the parking brake, Turn the adjust-
ment knob to raise the equalized link and tighten
Lift trucks equipped with a wet brake system. For the parking brake cables shown in Figure 18 and
lift truck models H2.0-3.5FT (H40-70FT) (L177) Figure 19. Do not tighten the adjustment so that
equipped with a wet brake system, make sure wet the brake is applied when the lever is released.
disc brakes are adjusted before parking brake is The lever for the parking brake has a lock. Use
adjusted. See Drive Axle Repair, (Wet Brake) your thumb or finger to release the lock on the
1400 SRM 1215. lever when the parking brake is released.
Lift trucks with a MONOTROL® pedal the 2. For new brakes, test operation of parking brake.
switch energizes the seat warning circuit when hand The lift truck with a capacity load must not move
lever is released. This switch puts the transmission when parking brake is applied on a 7.5 percent
in NEUTRAL by de-energizing direction solenoid. grade [a slope that increases .75 m in 10 m (9 in.
There is also a switch on the left side of bracket. in 10 ft)].
This switch prevents engine from starting unless
parking brake is applied. 3. For burnished brakes, test operation of parking
brake. The lift truck with a capacity load must
not move when parking brake is applied on a 15
CAUTION
percent grade [a slope that increases 1.5 m in
For Lift truck models H2.0-3.5FT (H40-70FT) 10 m (1.5 ft in 10 ft)].
(L177) equipped with the wet brake system,
Master Cylinder Repair

REMOVE (DRY BRAKE) DISASSEMBLE (DRY BRAKE)
1. Remove floor plate, kick plate, and seal plate
from lift truck for access to master cylinder. CAUTION
When the piston is removed or installed, make
2. For lift trucks equipped with a dry brake system. sure the cylinder bore and piston are not
Remove brake hydraulic line from master cylin- scratched or damaged.
der. Disconnect wire at brake pressure trans-
ducer, connected to the bottom of master cylinder 1. Remove clevis, push rod, nut, boot, fitting, and
and remove pressure transducer. See Figure 20. seal. See Figure 21.
3. Disconnect brake supply hose from master cylin- 2. Remove snap ring, piston seal, and piston.
der. Plug hose to prevent reservoir from drain-
ing. 3. Remove spacer, piston cup, retainer, spring,
check valve, and valve seat.
4. Remove brake fluid reservoir and supply hose
from lift truck. NOTE: Install new seals when the master cylinder is
disassembled for repair.
5. Remove cotter pin and clevis pin that is attached
to brake linkage lever arm.
6. Remove capscrews and nuts that hold master

cylinder to bracket assembly.
22
1800 SRM 1135 Master Cylinder Repair
1. RESERVOIR 9. PUSH ROD

2. RESERVE TANK HOLDER 10. NUT
3. BRAKE SUPPLY HOSE 11. CLEVIS
4. CAPSCREW 12. BRACKET
5. CAPSCREW 13. COTTER PIN
6. BRAKE HOSE 14. CLEVIS PIN
7. BRAKE PRESSURE TRANSDUCER 15. CAPSCREW
8. MASTER CYLINDER 16. CAPSCREW
Figure 20. Master Cylinder and Reservoir Assembly (Dry Brake)
23
1. CLEVIS 7. SEAL 13. RETAINER

2. NUT 8. FITTING 14. SPRING
3. PUSH ROD 9. PISTON SEAL 15. CHECK VALVE
4. BOOT 10. PISTON 16. VALVE SEAT
5. SNAP RING 11. SPACER
6. CYLINDER HOUSING 12. PISTON CUP
Figure 21. Master Cylinder (Dry Brake)
24
CLEAN AND INSPECT (DRY BRAKE) 2. Install brake hydraulic line on master cylinder.
3. Screw assembly of brake pressure transducer

CAUTION into master cylinder and tighten to 23 to 28 N•m
DO NOT use an oil solvent to clean the master (16.9 to 20.6 lbf ft).
cylinder, wheel cylinder, or brake linings. Use
a solvent approved for cleaning of brake parts. 4. Orient master cylinder side of brake hose assem-
Do not permit oil or grease in the brake fluid bly parallel with brake pressure transducer.
or on the linings.
5. Tighten fitting nuts at each end of brake hose
Inspect the bore of the master cylinder for holes or assembly to 13 to 18 N•m (84 to 117 lbf in).
scratches. Replace the master cylinder assembly, if
6. Apply a layer of multipurpose grease to the cle-
there is damage.
vis pin and, with twisting motion, insert through
ASSEMBLE (DRY BRAKE) clevis and the inching/brake pedal. Install cotter
pin into the clevis pin.
1. Install valve seat, check valve, spring, retainer,
piston cup, and spacer. 7. Adjust free pedal per the following procedure:
2. Install the piston, piston seal, and snap ring. a. Loosen nut and screw it away from clevis.
3. Install seal, fitting, boot, nut, push rod, and cle- b. Turn push rod counterclockwise, as viewed
vis. from top, until push rod can be moved from
side to side.
BENCH BLEED MASTER CYLINDER (DRY c. Turn push rod clockwise until it can no longer
BRAKE) be moved from side to side.
NOTE: Master cylinder must be bench bled before in- d. Turn push rod counterclockwise 1.5 to 1.75
stalling it on the lift truck. turns.
1. Place the master cylinder horizontally in a soft- e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft).
jawed vise.
f. Verify free pedal is 10 to 12 mm (0.39 to
2. Connect the brake fluid reservoir supply hose to 0.47 in.). See Figure 25.
the master cylinder.
8. Flush with brake fluid and air bleed system. See
3. Connect hoses to the pressure ports of the mas- Brake System Air Removal.
ter cylinder. Place other end of hoses in a clear
container of brake fluid. 9. Adjust fluid level until level is within 2.5 mm
(0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to
4. Fill the reservoir with brake SAE J-1703 (DOT 0.29 in.) above large rib on reservoir if MAX line
3) brake fluid. is not present.
5. Stroke the master cylinder until all air is purged 10. Verify all connections are leak-free.
from the master cylinder.
11. Install floor plate, kick plate, and seal plate on
INSTALL AND ADJUST (DRY BRAKE) lift truck.
1. Install brake fluid reservoir, supply hose, and 12. Check adjustment of brake pedal as described in
master cylinder on lift truck as an assembly. In- Brake Pedal Adjustment.
stall capscrews and nuts that hold master cylin-
der to bracket assembly. See Figure 20.
25
REMOVE (WET BRAKE)

NOTE: The removal procedure in this section is for
H2.0-3.5FT (H40-70FT) (L177) lift trucks equipped
with wet brake systems.
1. Remove the floor plate, kick plate, and seal plate

from the lift truck for access to the master cylin-
der and booster assembly.
2. Remove and tag the brake booster supply and re-

turn hoses from the master cylinder and booster
assembly. Plug hoses to prevent hoses from
draining. Disconnect the connector at the brake
pressure transducer, and remove brake pressure
transducer. See Figure 22.
3. Disconnect the upper brake oil supply hose from

the manifold. Plug hose to prevent brake oil
reservoir from draining.
4. Disconnect upper brake oil supply hose from

block. Plug hose to prevent brake oil reservoir
from draining.
5. Remove the brake oil reservoir and upper brake

oil supply hose from the lift truck.
6. Remove the lower brake oil supply hose from the

manifold and the master cylinder and booster as-
sembly.
7. Remove lower brake oil supply hose from block

and master cylinder and booster assembly.
8. Remove the manifold from the manifold mount.
9. Remove the cotter pin and rod end pin from the 1. CAPSCREW
clevis that is attached to the brake linkage lever 2. BRAKE OIL RESERVOIR
arm. 3. CLAMP
4. UPPER BRAKE OIL SUPPLY HOSE
10. Remove capscrews and nuts that hold master 5. MANIFOLD
6. MOUNT
cylinder and booster assembly to bracket assem- 7. LOWER BRAKE OIL SUPPLY HOSE
bly. 8. INSERT
9. BOOSTER RETURN HOSE
10. BRAKE HOSE
11. BRAKE PRESSURE TRANSDUCER
12. BOOSTER SUPPLY HOSE
13. MASTER CYLINDER AND BOOSTER ASSEMBLY
14. MOUNTING BOLT
15. MANIFOLD MOUNT
16. BRACKET
17. COTTER PIN
18. PIN
Figure 22. Master Cylinder and Reservoir

Assembly (Wet Brake), Lift Trucks
Manufactured Before January, 2013
26
DISASSEMBLE (WET BRAKE)
CAUTION
When the piston is removed or installed, make
sure the cylinder bore and piston are not
scratched or damaged.
1. Place master cylinder and booster into a soft

jawed vise.
2. Remove three mounting bolts and the master

cylinder from booster. See Figure 24.
WARNING
Piston is under extreme pressure. Use care
when removing snap ring to avoid possible
injury.
3. Remove the internal snap ring holding the pis-

ton.
1. CAPSCREW 4. Remove Piston.

2. BRAKE OIL RESERVOIR
3. CLAMP 5. Remove the spring and retainer from the bore.
4. UPPER BRAKE OIL SUPPLY HOSE
5. MOUNT 6. Remove and discard the pressure seal from the
6. LOWER BRAKE OIL SUPPLY HOSE spring end of the piston.
7. WET BRAKE COOLING HOSE
8. TRANSMISSION RETURN HOSE
9. TRANSMISSION HIGH TEMPERATURE HOSE 7. Remove the washer between the pressure seal
10. BRAKE BOOSTED RETURN HOSE and the piston.
11. BRAKE PRESSURE TRANSDUCER
12. BRAKE BOOSTED SUPPLY HOSE 8. Remove and discard the retaining seal from the
13. MANIFOLD piston. Note the position of the seal.
14. MASTER CYLINDER AND BOOSTER ASSEMBLY
15. COTTER PIN
16. PIN
17. BLOCK
18. CAPSCREW AND BLOCK MOUNTING
19. MASTER CYLINDER BRACKET ASSEMBLY
Figure 23. Master Cylinder and Reservoir

Assembly (Wet Brake), Lift Trucks
Manufactured After January, 2013
27
1. BOOSTER ASSEMBLY 6. PRESSURE SEAL

2. HOUSING (MASTER CYLINDER) 7. WASHER
3. SNAP RING 8. RETAINER
4. PISTON 9. SPRING
5. RETAINING SEAL 10. CAPSCREW
Figure 24. Master Cylinder and Booster With Wet Brake for Lift Truck Models H2.0-3.5FT
(H40-70FT) (L177)
28
CLEAN AND INSPECT (WET BRAKE) INSTALL AND ADJUST (WET BRAKE)
WARNING WARNING
Small amounts of water in the brake system Small amounts of water in the brake system
can cause reduced braking performance if can cause reduced braking performance if
the water reaches the wheel cylinders and is the water reaches the wheel cylinders and is
subject to high temperatures. DO NOT allow subject to high temperatures. DO NOT allow
water entry into the brake system. If water is water entry into the brake system. If water is
present, remove all water and refill the sys- present, remove all water and refill the sys-
tem with Dexron III from a sealed container. tem with Dexron III from a sealed container.
Unfiltered shop air can contain substantial Unfiltered shop air can contain substantial
amounts of water, therefore, DO NOT use un- amounts of water, therefore, DO NOT use un-
filtered shop air to blow out components. filtered shop air to blow out components.
NOTE: The master cylinder uses Dexron III oil. For

CAUTION the correct amount of oil used see the Maintenance
DO NOT permit brake cleaning fluid to con- Schedule.
tact master cylinder or wheel cylinders. Brake
cleaning fluid will cause damage and leaks in 1. For lift truck manufactured before January,
seals of the brake system. 2013, install brake oil reservoir, supply hose,
and master cylinder and booster assembly on
Inspect the bore of the master cylinder and the bore lift truck as an assembly. Install capscrews and
of the Booster Assembly for holes and scratches. Re- nuts that hold master cylinder and booster to
place the master cylinder and booster assembly if bracket assembly. See Figure 22.
there is damage. See Figure 24.
2. For lift trucks manufactured after January, 2013,
Inspect wheel and master cylinder parts for dirt or install brake oil reservoir to mounting bracket
water. Clean any dirt or water present in wheel and on cowl. Connect upper brake oil supply hose
master cylinder parts using a clean lint free cloth. to reservoir and block. Install master cylinder
bracket using four capscrews. See Figure 23.
ASSEMBLE (WET BRAKE)
3. Install brake supply and return lines to booster
NOTE: Install new seals when the master cylinder is assembly.
being assembled.
4. Install the brake pressure transducer into mas-
1. Install the new retaining seal on the piston, as ter cylinder and tighten to 23 to 28 N•m (16.9 to
noted during removal. 20.6 lbf ft). See Figure 22 and Figure 22.
2. Install the washer between the pressure seal and 5. Orient master cylinder side of brake supply and
the piston. return lines parallel with brake pressure trans-
ducer.
3. Install the new pressure seal and retainer over
the spring end of the plunger. 6. Tighten fitting nuts at each end of brake hose
assembly to 13 to 18 N•m (84 to 117 lbf in).
4. Install the retainer spring and piston into the
bore of the master cylinder. 7. Apply a layer of multipurpose grease to the
rod end pin and, with twisting motion, insert
5. Install the internal snap ring holding the piston. through yoke and the inching/brake pedal. In-
6. Install the master cylinder on the booster assem- stall cotter pin into the rod end pin.
bly with three bolts and tighten to 49 to 59 N•m
(36 to 43 lbf ft).
29
Service Brakes Adjustment (Dry Brake) 1800 SRM 1135
8. Adjust free pedal per the following procedure: 9. Flush with brake oil and air bleed system. See
Brake System Air Removal.
a. Loosen nut and screw it away from yoke.
10. Adjust oil level until level is within 2.5 mm
b. Turn push rod counterclockwise, as viewed (0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to
from top, until push rod can be moved from 0.29 in.) above large rib on reservoir if MAX line
side to side. is not present.
c. Turn push rod clockwise until it can no longer 11. Verify all connections are leak-free.
be moved from side to side.
12. Install floor plate, kick plate, and seal plate on
d. Turn push rod counterclockwise 1.5 to 1.75 lift truck.
turns.
13. Check adjustment of brake pedal as described in
e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft). Figure 25.
f. Verify free pedal is 10 to 12 mm (0.39 to
0.47 in.). See Figure 25.
Service Brakes Adjustment (Dry Brake)

The following procedure is for newly-installed brake NOTE: If the brake shoes were not replaced, loosen
shoes. If lift truck has been operated for more than adjuster wheel approximately 20 teeth.
25 hours and has correct pedal height, the brakes
normally will not need adjustment. 3. Push automatic adjuster lever away from ad-
juster wheel with a small screwdriver. Use
1. See the procedure How to Put Lift Truck on adjuster tool to loosen adjuster wheel approxi-
Blocks in Periodic Maintenance section for mately 20 teeth (new brake shoes).
your lift truck or Operating Manual for your
lift truck. Put lift truck on blocks so drive wheels 4. Install drive wheels. Remove lift truck from
can be removed. Remove drive wheels. blocks. Operate lift truck in FORWARD and
REVERSE directions. Stop lift truck 10 times
2. Use an adjuster tool to rotate adjuster wheel so in each direction. This procedure causes brake
that the teeth of the wheel move downward. This shoes to wear a small amount and fit brake drum
adjustment expands brake shoes. Adjust brake better.
shoes so that brake drum will not rotate.
30
1800 SRM 1135 Brake System Air Removal
Brake System Air Removal

There are two commonly used methods to remove air 6. Check level of brake fluid in reservoir for mas-
from brake system. The preferred method is using a ter cylinder. Fill brake fluid reservoir to correct
pressure bleed system. The other method is by ap- level.
plying pressure using brake pedal.
USING BRAKE PEDAL PRESSURE
NOTE: Two people are required for the two proce-
dures below to properly bleed brake system.
WARNING
USING PRESSURE BLEED SYSTEM On lift trucks with wet brake drive axles, only
use Dexron III oil in the master cylinder. On
lift trucks with dry brake drive axles, only use
WARNING SAE J-1703 (DOT 3) brake fluid in the master
On lift trucks with wet brake drive axles, only cylinder.
use Dexron III oil in the master cylinder. On
lift trucks with dry brake drive axles, only use NOTE: Adjust service brakes before the air is re-
SAE J-1703 (DOT 3) brake fluid in the master moved from brake system.
cylinder.
1. Fill brake fluid reservoir with brake fluid.
NOTE: Adjust service brakes before air is removed
from brake system. 2. Place one end of a rubber hose on bleeder screw
of wheel cylinder furthest from master cylinder.
1. Fill brake fluid reservoir with brake fluid. Place other end of the hose into a clear container
of brake fluid.
2. Place one end of a rubber hose on bleeder screw
of each wheel cylinder. Place other end of each NOTE: Check level of brake fluid in reservoir for mas-
hose into a clear container of brake fluid. ter cylinder during procedure. Make sure to main-
tain brake fluid at the correct level.
3. Connect a pressure bleeder to brake fluid reser-
voir. 3. Loosen bleeder screw at wheel cylinder one turn
so that air can be removed from brake system.
4. Loosen bleeder screws at wheel cylinders one Slowly push brake pedal and hold it at end of its
turn. stroke. Close bleeder screw.
NOTE: While applying air pressure to pressure 4. Repeat procedures in Step 1 through Step 3 until
bleeder, check level of the brake fluid in reservoir there are no air bubbles in container.
for master cylinder. Make sure to obtain brake fluid
at correct level to avoid forcing more air into brake 5. Repeat procedures in Step 1 through Step 4 for
system. remaining wheel cylinder.
5. Apply 34.5 kPa (5 psi) of air pressure to pres- 6. Check level of the brake fluid in reservoir for
sure bleeder, forcing fluid through the lines un- master cylinder. Fill brake fluid reservoir to cor-
til all air is removed from system. Close bleeder rect level.
screws.
31
Brake Pedal Adjustment 1800 SRM 1135
Brake Pedal Adjustment

NOTE: Measurements are made with floor mats re- Dual pedal assembly 29.0 ±1.0 mm (1.14
moved. ±0.04 in.).
1. Adjust height (dimension R) of inching/brake See Figure 25.

pedal to measurement below. Use upstop bolt to
change pedal height. Tighten nut while keeping 2. Depress arm V until it stops. Verify gap S be-
upstop bolt fixed. tween arm V and W is 3.5 to 4.5 mm (0.14 to
0.18 in.). If it is not, then loosen screw T and ad-
Single pedal assembly 26.6 ±1.0 mm (1.05 just sensor mount until proper gap S is achieved.
±0.04 in.). Retighten screw T. See Figure 25.
1. INCH/BRAKE PEDAL 5. NUT

2. PEDAL PAD 6. BUMPER
3. SENSOR MOUNT 7. UPSTOP BOLT
4. BRAKE POSITION SENSOR
Figure 25. Brake Pedal Adjustment
32
1800 SRM 1135 Free Pedal Adjustment
Free Pedal Adjustment

After brake pedal adjustment is completed, see
Brake Pedal Adjustment. Perform the following
procedure for free pedal adjustment.
1. Loosen nut and screw it away from clevis See Fig-

ure 26.
2. Turn push rod counterclockwise, as viewed from

top of push rod, until push rod can be moved from
side to side.
3. Turn push rod clockwise until it just begins to no

longer be moved from side to side.
4. Turn push rod counterclockwise 1.5 to 1.75 turns.
5. Tighten nut to 17 to 23 N•m (13 to 17 lbf ft).
6. Verify free pedal is 10 to 12 mm (0.39 to 0.47 in.).

See Brake Pedal Adjustment.
NOTE: DRY BRAKE SYSTEM SHOWN

1. COTTER PIN
2. WELDMENT
3. PIN
4. MASTER CYLINDER
5. PUSH ROD
6. NUT
7. CLEVIS
Figure 26. Free Pedal Adjustment
33
Back Plate to Axle Mount Capscrews Upper Parking Brake Cable Bracket
Capscrews (Wet Brake)
S2.0-3.5FT (S40-70FT, S55FTS) [F187] and H2.0-3.5FT (H40-70FT) [L177]
H2.0-3.5FT (H40-70FT) [L177] 38 to 42 N•m (28 to 31 lbf ft)
255 to 306 N•m (188 to 226 lbf ft)
Upper Parking Brake Cable Bracket
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, Capscrews (Wet Brake)
H2.0FTS (H30FT, H35FT, H40FTS) [F001], H2.0-3.5FT (H40-70FT) [L177]
S50CT (A267), and H2.0-2.5CT (H50CT) (A274) 38 to 42 N•m (28 to 31 lbf ft)
152 to 167 N•m (112 to 123 lbf ft)
Brake Pressure Transducer to Master
Wheel Cylinder Capscrews Cylinder (Wet Brake)
18 to 26 N•m (13 to 19 lbf ft) H2.0-3.5FT (H40-70FT) [L177]
23 to 28 N•m (16.9 to 20.6 lbf ft)
Axle Shaft Capscrews
S2.0-3.5FT (S40-70FT, S55FTS) [F187] Master Cylinder to Booster Capscrews
90 to 99 N•m (66 to 73 lbf ft) (Wet Brake)
H2.0-3.5FT (H40-70FT) [L177]
H2.0-3.5FT (H40-70FT) [L177] 49 to 59 N•m (36 to 43 lbf ft)
90 to 108 N•m (66 to 80 lbf ft)
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,

H2.0FTS (H30FT, H35FT, H40FTS) [F001],
S50CT (A267), and H2.0-2.5CT (H50CT) (A274)
52 to 62 N•m (39 to 46 lbf ft)
Wheel Nuts
S2.0-3.5FT (S40-70FT, S55FTS) [F187]
340 to 380 N•m (251 to 280 lbf ft)
H2.0-3.5FT (H40-70FT) [L177]

450 to 500 N•m (332 to 369 lbf ft)

H2.0FTS (H30FT, H35FT, H40FTS) [F001],
S50CT (A267), and H2.0-2.5CT (H50CT) (A274)
155 to 175 N•m (115 to 130 lbf ft)
34

STEERING AXLE
S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177]; S4.0, 4.5,
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];
S6.0FT, S7.0FT, (S135FT, S155FT) [D024, E024, F024]; H6.0FT,
H7.0FT (H135FT, H155FT) [H006, J006, K006]; H8.0FT, H8.0FT9,
H9.0FT (H170FT, H170FT36, H190FT) [A299, B299]
PART NO. 1580512 1600 SRM 1133

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Steering Axle Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Steering Axle Assembly Repair......................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Disassemble ................................................................................................................................................... 4
Clean .............................................................................................................................................................. 4
Inspect ............................................................................................................................................................ 4
Assemble ........................................................................................................................................................ 12
Install ............................................................................................................................................................. 17
Spindles, Bearings, and Tie Rods Repair.......................................................................................................... 18
Spindles and Bearings................................................................................................................................... 18
S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 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), S6.0FT, S7.0FT, (S135FT, S155FT)
(D024, E024, F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT,
Remove .................................................................................................................................................. 18
Disassemble........................................................................................................................................... 20
Clean...................................................................................................................................................... 20
Inspect ................................................................................................................................................... 20
Assemble................................................................................................................................................ 20
Install..................................................................................................................................................... 22
Spindles and Bearings................................................................................................................................... 25
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001),
and H2.0-3.5FT (H40-70FT) (L177) ......................................................................................................... 25
Tie Rods.......................................................................................................................................................... 26
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004, H004).................................................................................. 26
Remove .................................................................................................................................................. 26
Install..................................................................................................................................................... 27
Tie Rods.......................................................................................................................................................... 28
H2.0-3.5FT (H40-70FT) (L177), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005), S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, F024),
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), and H8.0FT, H8.0FT9, H9.0FT
(H170FT, H170FT36, H190FT) (A299, B299) .......................................................................................... 28
Remove .................................................................................................................................................. 28
Install..................................................................................................................................................... 31
Steering Cylinder Repair................................................................................................................................... 32

Table of Contents Steering Axle

S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S120FTS; S120FTPRS) [G004, H004];
110, 120FT) [N005, P005, R005];
S6.0FT, S7.0FT, (S135FT, S155FT) [D024, E024, F024];
ii
General
This section has the description and repair proce- pushes an equal amount of oil from the opposite side
dures for the steering axle. of the cylinder.
The steering axle assembly includes an axle frame, When the piston reaches the end of the stroke, a re-
steering cylinder, and two spindle and hub assem- lief valve in the steering circuit controls the oil pres-
blies. See Figure 1. The steering axle is articulated sure. The tie rods that connect the spindle arms to
and is connected to the frame by center pivot mounts. the cylinder are not adjustable.
The center pivot mounts permit the steering axle to
move in the frame mount when the lift truck travels Each spindle turns on two tapered roller bearings in
over rough surfaces. mounts in the axle frame. The preload on the bear-
ings is controlled by shims at the lower bearing cap.
The end caps of the steering cylinder are also the
mounts for the cylinder and are held to the shell by The wheels rotate on two tapered roller bearings and
the mount capscrews. There are O-rings, seals, and are held on the spindles by a castle nut. The bearing
wipers in the end caps to seal the caps to the shell preload of the wheels is adjusted by the castle nut.
and rod. The ends of the piston rod extend from both The grease seals protect the bearings from dirt and
ends of the cylinder. A single piston and the seal are water. Wear sleeves protect the hub from wear by the
at the center of the rod. Oil pressure on one side of seals.
the piston moves the piston in the bore. The piston
1
General 1600 SRM 1133
A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY

1. AXLE FRAME 5. TIE ROD
2. MOUNT 6. SPINDLE
3. BRACKET 7. MOUNT
4. STEERING CYLINDER 8. HUB ASSEMBLIES
Figure 1. Steering Axle
2
1600 SRM 1133 Steering Axle Assembly Repair
Steering Axle Assembly Repair

REMOVE 3. Slide floor jack or forks of another lift truck under
steering axle. Raise lifting device until it holds
WARNING the weight of the axle assembly.
PUTTING THE LIFT TRUCK ON BLOCKS a. To remove bracket type mounts, remove four
capscrews and nuts that fasten two brackets
under rubber mounts.
types of maintenance and repair. The removal
of the mast, drive axle, battery, or counter- See Figure 2 for lift truck model
weight assemblies will cause large changes • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the See Figure 3 for lift truck models
following positions: • H2.0-3.5FT (H40-70FT) (L177)
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift See Figure 5 for lift truck model
truck cannot fall backward. • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
• If the counterweight is removed, put blocks 120FT; S80, 100FTBCS; S120FTS;
under the mast so that the lift truck cannot S120FTPRS) (G004, H004)
fall forward.
Put the lift truck on blocks on a solid, even, and • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
level surface. Verify the blocks or stands have 5.5FT (H80, 90, 100, 110, 120FT) (N005,
enough capacity to hold the lift truck. Use ad- P005, R005)
ditional blocks next to the tires as necessary to
Remove brackets and slowly lower axle as-
prevent movement of the lift truck. Verify the
sembly onto wheels. Carefully roll steering
lifting devices used during repairs can lift the
axle assembly away from lift truck.
weight of the parts and assemblies.
b. To remove plate type mounts, remove four
See the Operating Manual or Periodic Mainte-
capscrews and washers from two plates.
nance section for your lift truck model, for the
procedures to put the lift truck on blocks. See Figure 4 for lift truck models
• S30FT, S35FT, S40FTS (E010)
The steering axle can be removed without removing
the counterweight.
H40FTS) (F001)
1. Verify wheels are set for straight travel. Put lift
truck on blocks so the steering axle will have
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
enough clearance to be removed. The top of the
E024, F024)
axle frame must have clearance under the bot-
tom of the frame at the rear of the lift truck. See Figure 8 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
2. Disconnect hydraulic lines at steering cylinder.
J006, K006)
Install plug fittings in cylinder and put caps on
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
hydraulic lines. Plug fittings will prevent spin-
H170FT36, H190FT) (A299, B299)
dles from turning as axle is removed from under
the lift truck. Remove plates and slowly lower steering axle
assembly onto wheels. Carefully roll steering
NOTE: Steering Axle Assembly may be mounted to
axle assembly away from lift truck.
the frame with brackets or plates.
3
Steering Axle Assembly Repair 1600 SRM 1133
DISASSEMBLE • H8.0FT, H8.0FT9, H9.0FT (H170FT,

H170FT36, H190FT) (A299, B299)
1. Remove ring seal, shims, flange, stub shaft and
bushing from steering axle assembly for lift truck NOTE: If the bearing is replaced, then the associated
models: bearing cup must be replaced also.
See Figure 8 for lift truck models 4. If the bearings must be replaced, use a brass drift
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, pin to remove the bearing cups and wear ring.
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 5. Repeat procedure for the other wheel.
H170FT36, H190FT) (A299, B299)
CLEAN
2. Put axle on blocks so the wheels just touch
the floor. Remove hub cap. Remove cotter pin, WARNING
washer, and castle nut. Remove bearing cone Cleaning solvents can be flammable and toxic
and discard cotter pin. and can cause skin irritation. When using
NOTE: Identify and tag the outer and inner bearing cleaning solvents, always follow the solvent
cones so they can be reassembled in their original manufacturer’s recommended safety proce-
locations. dures.
NOTE: The wear ring may not be present on all steer- WARNING
ing axles. Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
3. Slide wheel from spindle. Remove inner bearing
protective clothing (goggles/shield, gloves,
cone, wear ring, and oil seal from spindle.
etc.) to avoid injury to personnel.
See Figure 2 for lift truck model
1. Clean bearings by placing them in a wire basket
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
and immersing in a container of fresh solvent.
See Figure 3 for lift truck model Agitate the bearings in the solvent to remove all
• H2.0-3.5FT (H40-70FT) (L177) traces of old lubricant.
See Figure 4 for lift truck models 2. After cleaning the bearings, dry them with clean
• S30FT, S35FT, S40FTS (E010) compressed air. Take care to prevent spinning
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, the bearings when using a compressed air jet.
H40FTS) (F001)
3. Immediately wrap bearings in a lint-free cloth to
See Figure 5 for lift truck model protect them from dust and other foreign matter.
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) INSPECT
(G004, H004)
See Figure 6 for lift truck models damaged hardware.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
rust, corrosion or marred finish.
R005)
NOTE: If the spindle, bearings or tie rods need to be
repaired, go to Spindles, Bearings, and Tie Rods Re-
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
pair.
E024, F024)

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
4
1. MOUNT 10. COTTER PIN

2. STEER AXLE ASSEMBLY 11. OIL SEAL
3. MOUNT 12. WEAR RING
4. PLATE 13. BEARING CONE
5. WASHER 14. BEARING CUP
6. LOCK NUT 15. WASHER
7. CAPSCREW 16. CASTLE NUT
8. STEERING CYLINDER ROD 17. HUB CAP
9. LUBRICATION FITTING 18. STEERING CYLINDER
Figure 2. Spindle to Tie Rod Assembly for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)
5
1. MOUNT 12. WEAR RING

2. STEERING AXLE ASSEMBLY 13. BEARING CONE
3. MOUNT 14. BEARING CUP
4. BRACKET 15. HUB
5. NUT 16. BEARING CUP
6. WASHER 17. BEARING CONE
7. WASHER 18. CASTLE NUT
8. CAPSCREW 19. HUB CAP
9. STEERING CYLINDER ROD 20. COTTER PIN
10. LUBRICATION FITTING 21. STEERING CYLINDER
11. OIL SEAL
Figure 3. Spindle to Tie Rod Assembly for Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)
6
A. PNEUMATIC TRUCKS ONLY

1. MOUNT 9. BEARING
2. STEER AXLE ASSEMBLY 10. HUB
3. MOUNT 11. BEARING
4. PLATE 12. WASHER
5. CAPSCREW 13. CASTLE NUT
6. STEERING CYLINDER ROD 14. HUB CAP
7. LUBRICATION FITTING 15. COTTER PIN
8. OIL SEAL 16. STEERING CYLINDER
Figure 4. Spindle to Tie Rod Assembly for Lift Truck Models S30FT, S35FT, S40FTS (E010) and
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
7
1. HUB CAP 10. OIL SEAL

2. CASTLE NUT 11. STEERING CYLINDER ROD
3. COTTER PIN 12. STEERING CYLINDER
4. WASHER 13. PADS
5. BEARING CONE (OUTER) 14. MOUNT
6. BEARING CUP (OUTER) 15. CAPSCREW
7. BEARING CUP (INNER) 16. WASHER
8. BEARING CONE (INNER) 17. PLATE
9. WEAR RING 18. NUTS
Figure 5. Spindle to Tie Rod Assembly for Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
8
1. HUB CAP 11. MOUNT

2. CASTLE NUT 12. STEERING AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
5. BEARING CONE 15. WASHER
6. BEARING CUP 16. NUT
7. HUB 17. STEERING CYLINDER ROD
8. WEAR RING 18. SPINDLE (LEFT SIDE SHOWN)
9. OIL SEAL 19. TIE ROD
10. LUBE FITTING 20. STEERING CYLINDER
Figure 6. Spindle to Tie Rod Assembly for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
9
1. HUB CAP 10. WEAR RING

2. COTTER PIN 11. PAD
3. CASTLE NUT 12. MOUNT
4. WASHER 13. PLATE
5. BEARING CONE (OUTER) 14. CAPSCREW
6. BEARING CUP (OUTER) 15. LUBE FITTING
7. BEARING CONE (INNER) 16. STEERING CYLINDER ROD
8. BEARING CUP (INNER) 17. STEERING CYLINDER
9. SEAL
Figure 7. Spindle to Tie Rod Assembly for Lift Truck Models S6.0FT, S7.0FT, (S135FT, S155FT)
(D024, E024, F024)
10
1. STEER AXLE ASSEMBLY 15. GREASE FITTING

2. TIE ROD 16. COTTER PIN
3. BLOCK PLATE 17. HUB CAP
4. CAP PLATE 18. CASTLE NUT
6. CAPSCREW 20. HUB
7. RING SEAL 21. BEARING CUP (OUTER)
8. SHIM 22. BEARING CONE (OUTER)
9. FLANGE 23. BEARING CUP (INNER)
10. SHIM 24. BEARING CONE (INNER)
11. BUSHING 25. WEAR RING
12. STUB SHAFT 26. OIL SEAL
13. STEERING CYLINDER 27. SPINDLE
14. STEERING CYLINDER ROD 28. LUBE FITTING
Figure 8. Spindle to Tie Rod Assembly for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006) and H8.0FT, H8.0FT9, H9.0FT (H170FT, H170FT36, H190FT) (A299, B299)
11
ASSEMBLE Periodic Maintenance 8000 SRM 1598 for lift

truck model
NOTE: For specified lubricant to use, refer to one of • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
the following sections: 100FTBCS; S120FTS; S120FTPRS) (H004)
Periodic Maintenance 8000 SRM 1150 for lift 1. If necessary, use a press to install new bearing
truck models cups in wheel or hub.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) See Figure 9 for lift truck model
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
truck models See Figure 10 for lift truck model
• S30FT, S35FT, S40FTS (E010) • H2.0-3.5FT (H40-70FT) (L177)
H40FTS) (F001) See Figure 11 for lift truck model
Periodic Maintenance 8000 SRM 1248 for lift H40FTS) (F001)
truck models
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, See Figure 12 for lift truck model
100FTBCS; S120FTS; S120FTPRS) (G004) • S30FT, S35FT, S40FTS (E010)
See Figure 13 for lift truck model
(H80, 90, 100, 110, 120FT) (N005, P005)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Periodic Maintenance 8000 SRM 1558 for lift S80, 100FTBCS; S120FTS; S120FTPRS)
truck models (G004, H004)
(H80, 90, 100, 110, 120FT) (R005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
Periodic Maintenance 8000 SRM 1319 for lift 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
truck models R005)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024)
Periodic Maintenance 8000 SRM 1571 for lift • S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
truck models E024, F024)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
Periodic Maintenance 8000 SRM 1322 for lift • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
truck models J006, K006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H170FT36, H190FT) (A299, B299)
Periodic Maintenance 8000 SRM 1407
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H170FT36, Lubricate bearing cones with multipurpose
H190FT) (A299) grease. Verify bearings are filled with grease.
Install oil seal, wear ring (if removed) and inner
Periodic Maintenance 8000 SRM 1586 for lift bearing cone on spindle.
truck model
• H8.0FT, H8.0FT9, H9.0FT (B299)

truck model
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
12
Figure 10. Bearing Arrangement for Lift Truck

Models H2.0-3.5FT (H40-70FT) (L177)
1. WASHER
2. COTTER PIN
3. HUB CAP
4. CASTLE NUT
5. OUTER BEARING CUP AND CONE
6. INNER BEARING CUP AND CONE
7. WEAR RING
8. OIL SEAL


1. SPINDLE 6. BEARING CUP
2. HUB CAP 7. BEARING CONE
3. COTTER PIN 8. BEARING CUP
4. CASTLE NUT 9. OIL SEAL
5. BEARING CONE 10. WEAR RING
1. HUB 5. WASHER
2. OIL SEAL 6. CASTLE NUT
3. BEARING 7. COTTER PIN
4. BEARING 8. HUB CAP

Models H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
13

Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
(G004, H004)
1. BEARING 5. WASHER
2. BEARING 6. HUB CAP
3. CASTLE NUT 7. OIL SEAL
4. COTTER PIN


1. WEAR RING 6. HUB CAP
2. BEARING CONE 7. COTTER PIN
(INNER) 8. CASTLE NUT
3. BEARING CUP 9. WASHER
(INNER) 10. OIL SEAL
4. BEARING CONE
(OUTER) NOTE: RIGHT SIDE IS SHOWN
5. BEARING CUP
(OUTER) 1. OIL SLEEVE
2. OUTER BEARING CUP AND CONE
3. HUB
4. INNER BEARING CUP AND CONE
5. CASTLE NUT
6. COTTER PIN
7. HUB CAP
8. WASHER

Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005, R005)
14
NOTE: RIGHT SIDE IS SHOWN
1. BEARING CONE (OUTER) 1. HUB ASSEMBLY

2. BEARING CUP (OUTER) 2. HUB CAP
3. WASHER 3. COTTER PIN
4. HUB CAP 4. CASTLE NUT
5. COTTER PIN 5. WASHER
6. CASTLE NUT 6. OUTER BEARING CUP AND CONE
7. BEARING CONE (INNER) 7. INNER BEARING CUP AND CONE
8. BEARING CUP (INNER) 8. SEAL
9. WEAR RING
10. OIL SEAL Figure 16. Bearing Arrangement for Lift Truck
Models H6.0FT, H7.0FT (H135FT, H155FT)
Figure 15. Bearing Arrangement for Lift Truck (H006, J006, K006) and H8.0FT, H8.0FT9,
Models S6.0FT, S7.0FT, (S135FT, S155FT) H9.0FT (H170FT, H170FT36, H190FT) (A299,
(D024, E024, F024) B299)
15
f. H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

CAUTION H5.0-5.5FT (H80, 90, 100, 110, 120FT)
DO NOT damage the seals during installation. (N005, P005, R005) - Tighten castle nut to
200 to 220 N•m (148 to 162 lbf ft) while
2. Carefully slide wheel onto spindle. Install outer rotating the wheel in both directions to prop-
bearing cone and install washer. erly seat the bearings. Loosen the castle nut
until wheel turns freely with no end play.
NOTE: Ensure that the washer is seated properly
Tighten castle nut to 35 to 40 N•m (26 to
against the bearing cone and not against the shaft
30 lbf ft).
shoulder before tightening the castle nut.
g. H6.0FT, H7.0FT (H135FT, H155FT) (H006,
3. Install the castle nut and tighten as follows for
J006, K006) - Tighten castle nut to 203 N•m
your lift truck:
(150 lbf ft) while rotating the wheel in both
a. S2.0-3.5FT (S40-70FT, S55FTS) (F187) - directions to properly seat the bearings.
Tighten the castle nut to 68 N•m (50 lbf ft) Loosen the castle nut until wheel turns
while rotating the wheel in both directions freely with no end play. Tighten castle nut
to properly seat the bearings. Loosen the to 34 N•m (25 lbf ft).
castle nut 1/4 turn. Tighten nut to 3 N•m
h. H8.0FT, H8.0FT9, H9.0FT (H170FT,
(27 lbf in). Pull on the wheel axially to en-
H170FT36, H190FT) (A299, B299) - Tighten
sure that there is no end play. If there is
castle nut to 203 N•m (150 lbf ft) while rotat-
excessive end play, reassemble washer and
ing the wheel in both directions to properly
repeat Step 1 through Step 3.
seat the bearings. Loosen the castle nut
b. H2.0-3.5FT (H40-70FT) (L177) - Tighten the until wheel turns freely with no end play.
castle nut to 200 N•m (147.5 lbf ft) while ro- Tighten castle nut to 34 N•m (25 lbf ft).
tating the wheel in both directions to prop-
i. S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
erly seat the bearings. Loosen the castle nut
E024, F024) - Tighten castle nut to 203 N•m
(150 lbf ft) while rotating the wheel in both
Tighten nut to 15 N•m (133 lbf in).
directions to properly seat the bearings.
c. S30FT, S35FT, S40FTS (E010) - Tighten the Loosen the castle nut until wheel turns
castle nut to 200 N•m (147.5 lbf ft) while ro- freely with no end play. Tighten castle nut
tating the wheel in both directions to prop- to 34 N•m (25 lbf ft).
erly seat the bearings. Loosen the castle nut
4. Install new cotter pin in castle nut. If cotter pin
cannot be installed, tighten castle nut to the first
Tighten nut to 12 N•m (106 lbf in).
alignment position where the cotter pin can be
d. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, installed.
H40FTS) (F001) - Tighten the castle nut to
5. Install hub cap.
200 N•m (147.5 lbf ft) while rotating the
wheel in both directions to properly seat the 6. Repeat procedure for other wheel.
bearings. Loosen the castle nut until wheel
turns freely with no end play. Tighten nut to NOTE: Apply multipurpose grease to stub shaft prior
12 N•m (106 lbf in). to installing.
e. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; 7. Install stub shaft, bushing, shims, flange, and rig
S80, 100FTBCS; S120FTS; S120FTPRS) seal to steering axle assembly.
(G004, H004) - Tighten the castle nut to
203 N•m (150 lbf ft) while rotating the See Figure 8 for lift truck models
wheel in both directions to properly seat the • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
bearings. Loosen the castle nut until wheel J006, K006)
turns freely with no end play. Tighten nut to • H8.0FT, H8.0FT9, H9.0FT (H170FT,
34 N•m (25 lbf ft). H170FT36, H190FT) (A299, B299)
16
INSTALL See Figure 6 for lift truck models

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
1. Install rubber mounts and top mount(s) on axle. 5.5FT (H80, 90, 100, 110, 120FT) (N005,
Verify face of rubber mount with the part number P005, R005)
is away from the axle. Verify part number will be
right side up after axle assembly is installed. b. Install mount plates.
See Figure 2 for lift truck model See Figure 4 for lift truck models
See Figure 3 for lift truck model H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 4 for lift truck models • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
• S30FT, S35FT, S40FTS (E010) E024, F024)
H40FTS) (F001) See Figure 8 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
See Figure 5 for lift truck model J006, K006)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • H8.0FT, H8.0FT9, H9.0FT (H170FT,
S80, 100FTBCS; S120FTS; S120FTPRS) H170FT36, H190FT) (A299, B299)
(G004, H004)
4. Proceed as follows for your lift truck:
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- a. S2.0-3.5FT (S40-70FT, S55FTS) (F187)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, - tighten four bracket bolts and nuts to
R005) 90 N•m (66.4 lbf ft).
See Figure 7 for lift truck models b. H2.0-3.5FT (H40-70FT) (L177) - tighten four
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, bracket bolts and nuts to 88 N•m (65 lbf ft).
E024, F024)
c. S30FT, S35FT, S40FTS (E010) - tighten four
2. Apply lubricant that is approved for use with flange bolts to 41 to 49 N•m (30 to 36 lbf ft).
rubber to rubber mount. The lubricant is used to
ease assembly of the mount into frame and brack- d. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
ets. H40FTS) (F001) - tighten four flange bolts to
41 to 49 N•m (30 to 36 lbf ft).
3. Use floor jack or another lift truck to put steering
axle into position in frame. Verify rubber mounts e. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
fit inside frame brackets for mounts. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004) - tighten four flange bolts to
NOTE: Steering axle assembly may be attached to 215 N•m (159 lbf ft).
frame with brackets or plates.
f. H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
a. Install bottom brackets. H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005) - tighten four bracket
See Figure 2 for lift truck models bolts and nuts to 90 N•m (66 lbf ft).
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
g. S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
See Figure 3 for lift truck models E024, F024) - apply thread lock and wash-
• H2.0-3.5FT (H40-70FT) (L177) ers and tighten four capscrews to 250 to
275 N•m (184 to 203 lbf ft).
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
17
Spindles, Bearings, and Tie Rods Repair 1600 SRM 1133
h. H6.0FT, H7.0FT (H135FT, H155FT) (H006, 5. Remove plugs and caps and connect hydraulic
J006, K006) - apply thread lock and wash- lines to steering cylinder.
ers and tighten four capscrews to 270 N•m
(199 lbf ft). 6. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
i. H8.0FT, H8.0FT9, H9.0FT (H170FT, stop to the other. Check for hydraulic leaks.
H170FT36, H190FT) (A299, B299) - ap-
ply thread lock and washers and tighten four
Spindles, Bearings, and Tie Rods Repair

SPINDLES AND BEARINGS Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
S2.0-3.5FT (S40-70FT, S55FTS) (F187), enough capacity to hold the lift truck. Use ad-
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; ditional blocks next to the tires as necessary to
S80, 100FTBCS; S120FTS; S120FTPRS) prevent movement of the lift truck. Verify the
(G004, H004), H4.0FT5/FT6; H4.5FTS5, weight of the parts and assemblies.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005, R005), S6.0FT, S7.0FT, See the Operating Manual or Periodic Mainte-
(S135FT, S155FT) (D024, E024, F024), nance section for your lift truck model, for the
procedures to put the lift truck on blocks.
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006), H8.0FT, H8.0FT9, H9.0FT 1. Put the lift truck on blocks.
(H170FT, H170FT36, H190FT) (A299, B299)
2. Remove the wheel and bearings. See Steering
Remove Axle Assembly Repair, Disassemble.
NOTE: To remove the spindle from the steering rod,

WARNING the tie rod can be disconnected at the retaining pin
PUTTING THE LIFT TRUCK ON BLOCKS inside the dust cover.
The lift truck must be put on blocks for some 3. Loosen the clamps on the dust cover and slide the
types of maintenance and repair. The removal dust cover off the steering cylinder rod.
of the mast, drive axle, battery, or counter-
weight assemblies will cause large changes See Figure 17 for lift truck models
in the center of gravity. When the lift truck • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
is put on blocks, put additional blocks in the • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
following positions: S80, 100FTBCS; S120FTS; S120FTPRS)
• If the mast and drive axle are removed, put (G004, H004)
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
18
1600 SRM 1133 Spindles, Bearings, and Tie Rods Repair
4. Remove two snap rings from the pin holding the

tie rod to steering cylinder rod and remove pin. CAUTION
DO NOT hit the threads or the nut of the tie rod.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) NOTE: Rod end may be attached to spindle arm by
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; one of two methods, castle nut and cotter pin or by
S80, 100FTBCS; S120FTS; S120FTPRS) snap ring, washer and pin.
(G004, H004)
5. Remove the cotter pin and castle nut. Discard
See Figure 26 for lift truck models cotter pin. Use a puller to remove the tie rod end
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- from the spindle arm.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) See Figure 19 for lift truck model
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, See Figure 20 for lift truck model
E024, F024) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, S80, 100FTBCS; S120FTS; S120FTPRS)
J006, K006) (G004, H004)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
1. CLAMP 4. SNAP RING 7. TIE ROD

2. DUST COVER 5. STEERING CYLINDER ROD
3. CLAMP 6. PIN
Figure 17. Tie Rod for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187) and S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
19
6. Remove snap rings, washers and pin. Remove tie Clean

rod end from spindle arm.

WARNING
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- Cleaning solvents can be flammable and toxic
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, and can cause skin irritation. When using
R005) cleaning solvents, always follow the solvent
See Figure 22 or Figure 27 for lift truck models dures.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024) WARNING
See Figure 23 for lift truck models Compressed air is used for cleaning or drying
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, purposes, or for clearing restrictions. Wear
J006, K006) protective clothing (goggles/shield, gloves,
• H8.0FT, H8.0FT9, H9.0FT (H170FT, etc.) to avoid injury to personnel.
H170FT36, H190FT) (A299, B299) 1. Clean bearings by placing them in a wire basket
7. Remove the snap rings from the pin retaining the and immersing in a container of fresh solvent.
tie rod to the steering cylinder rod, then remove Agitate the bearings in the solvent to remove all
the pin. If necessary, use a hammer and brass traces of old lubricant.
drift to remove pin. Remove tie rod from steering 2. After cleaning the bearings, dry them with clean
cylinder rod. compressed air. Take care to prevent spinning
8. If necessary, repeat the procedure for the other the bearings when using a compressed air jet.
spindle and tie rod. 3. Immediately wrap bearings in a lint-free cloth to
Disassemble protect them from dust and other foreign matter.
1. Remove the grease cap from the spindle. Remove Inspect

the capscrews from the bearing cap. Remove the 1. Inspect for loose, missing, cracked, burned or
bearing cap and shims. If necessary, remove the damaged hardware.
bearing cup from the bearing cap as shown in
Figure 18, for the following lift truck models: 2. Inspect all parts for dents, holes, bends, burrs,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) rust, corrosion, or marred finish.
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) Assemble
(G004, H004)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 1. Install new seals on the spindle. Lubricate the
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, seals with grease. If necessary, press new bear-
E024, F024) ing cones on the spindle.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 2. Lubricate the bearings with wheel bearing
J006, K006) and H8.0FT, H8.0FT9, H9.0FT grease. Verify the bearings are filled with
(H170FT, H170FT36, H190FT) (A299, B299) grease. If necessary, press the new bearing cups
2. Tilt the spindle and lift the spindle from the axle. into the steering axle frame and bearing cap. In-
If necessary, remove the bearing and seals from stall the wear sleeve in the steering axle frame.
the spindle. If necessary, remove the wear sleeve 3. Install the spindle in the steering axle. Install
and bearing cup from the axle frame. the bearing cap without the O-rings.
3. If necessary, repeat the procedure for the other See Figure 19 for lift truck model
spindle and tie rod. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
20
See Figure 20 for lift truck models Measure the clearance between the bearing cap
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; and the axle. Remove the bearing cap and install
S80, 100FTBCS; S120FTS; S120FTPRS) enough shims to give a preload of 0.00 to 0.13 mm
(G004, H004) (0.000 to 0.005 in.).
See Figure 21 for lift truck models NOTE: The spindle bearings must have no clearance.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- Install shims 0.00 to 0.13 mm (0.000 to 0.005 in.) less
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, than the measured gap.
R005)
4. Install the O-ring on the bearing cap. Apply Loc-
See Figure 22 for lift truck models tite® 242 to threads of capscrews. Install the
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, bearing cap and capscrews.
E024, F024)
a. S2.0-3.5FT (S40-70FT, S55FTS) (F187) -
See Figure 23 for lift truck models tighten capscrews to 44 N•m (32 lbf ft).
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) b. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
• H8.0FT, H8.0FT9, H9.0FT (H170FT, S80, 100FTBCS; S120FTS; S120FTPRS)
H170FT36, H190FT) (A299, B299) (G004, H004) - tighten the capscrews to
52 N•m (38 lbf ft).
c. S6.0FT, S7.0FT, (S135FT, S155FT) (D024,

E024, F024) - tighten the capscrews to
52 N•m (38 lbf ft).
d. H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005) - tighten capscrews to 45
to 50 N•m (33 to 37 lbf ft).
e. H6.0FT, H7.0FT (H135FT, H155FT) (H006,

J006, K006) - tighten capscrews to 47 N•m
(35 lbf ft).
f. H8.0FT, H8.0FT9, H9.0FT (H170FT,

H170FT36, H190FT) (A299, B299) - tighten
5. If necessary, repeat the procedure for the other

spindle and tie rod.
1. PRY BAR 3. BEARING CAP

2. BEARING CUP 4. O-RING
Figure 18. Bearing Cup Removal
21
Install
NOTE: Tie rod end may be attached to spindle arm

by one of two methods, castle nut and cotter pin or
with snap rings, washers and pins.
1. Install the tie rod to the spindle arm and steering

cylinder.
If removed, tighten the castle nut to 163 N•m

(120 lbf ft) for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
If removed, tighten the castle nut to 175 N•m

(129 lbf ft) for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
2. Tighten the castle nut until the new cotter pin

can be installed.
3. Install tie rod end to spindle arm and steering

cylinder with pins, seals and snap rings.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
NOTE: THE LUBRICATION FITTING NEEDS TO BE
See Figure 27 for lift truck models ORIENTED TOWARDS THE CENTERLINE OF THE
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, LIFT TRUCK.
E024, F024)
1. GREASE CAP
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 2. BEARING ASSEMBLY
J006, K006) 3. WEAR SLEEVE
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 4. SEAL
H170FT36, H190FT) (A299, B299) 5. SPINDLE
6. OIL SEAL
4. Install the grease cap on the top of the steering 7. BEARING CONE
axle. 8. BEARING CUP
9. WASHER
10. CASTLE NUT
5. Install the bearings and wheel. See section 11. COTTER PIN
Steering Axle Assembly Repair, Assemble. 12. HUB CAP
13. O-RING
6. If necessary, repeat the procedure for the other 14. SHIMS (AS REQUIRED)
spindle and tie rod. 15. CAPSCREW AND LOCKWASHER ASSEMBLY
16. LUBRICATION FITTING
7. Remove the lift truck from blocks. 17. BEARING CAP
18. TIE ROD
19. CASTLE NUT
20. COTTER PIN
Figure 19. Spindle Assembly for Lift Truck

22

ORIENTED 45° TO CENTERLINE AND REAR OF LIFT
TRUCK.
1. HUB CAP
2. WASHER
3. BEARING CONE (OUTER)
4. BEARING CUP (OUTER) NOTE: LEFT SIDE SPINDLE ASSEMBLY SHOWN
5. BEARING CONE (INNER)
6. BEARING CUP (INNER) 1. HUB CAP
7. WEAR SLEEVE 2. CASTLE NUT
8. OIL SEAL 3. COTTER PIN
10. LUBE FITTING 5. BEARING CONE
11. CAP ASSEMBLY 6. BEARING CUP
12. SHIM 7. HUB
13. BEARING CUP 8. WEAR SLEEVE
14. BEARING CONE 9. OIL SEAL
15. SEAL 10. SPINDLE
16. O-RING 11. LUBE FITTING
17. CAP 12. CAP
18. CASTLE NUT 13. TIE ROD
19. COTTER PIN 14. SEAL
20. TIE ROD 15. O-RING
16. SHIM
Figure 20. Spindle Assembly for Lift Truck 17. CAP ASSEMBLY
18. LOCKWASHER
Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 19. CAPSCREW
(G004, H004) Figure 21. Spindle Assembly for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005, R005)
23

NOTE: THE LUBRICATION FITTING NEEDS TO BE TRUCK.
TRUCK. 1. SNAP RING
2. PIN
1. PLUG 3. SEAL
2. BEARING CONE (UPPER) 4. TIE ROD
3. BEARING CUP (UPPER) 5. SEAL
4. WEAR SLEEVE 6. BEARING CONE (LOWER)
5. OIL SEAL 7. O-RING
6. PIN 8. BEARING CUP (LOWER)
7. SNAP RING 9. SEAL
8. SPHERICAL BEARING 10. SHIM
9. TIE ROD 11. BEARING CAP
10. BEARING CONE (LOWER) 12. CAPSCREW
11. O-RING 13. LUBE FITTING
12. BEARING CUP (LOWER) 14. OIL SEAL
13. SHIM 15. WEAR SLEEVE
14. BEARING CAP 16. BEARING CONE (INNER)
15. CAPSCREW 17. BEARING CUP (INNER)
16. LUBE FITTING 18. BEARING CONE (OUTER)
17. HUB CAP 19. BEARING CUP (OUTER)
18. CASTLE NUT 20. HUB
19. COTTER PIN 21. COTTER PIN
21. BEARING CONE (OUTER) 23. CASTLE NUT
22. BEARING CUP (OUTER 24. HUB CAP
23. BEARING CONE (INNER) 25. SEAL
24. BEARING CUP (INNER) 26. WEAR SLEEVE
27. BEARING CUP (UPPER)
Figure 22. Spindle Assembly for Lift Truck 28. BEARING CONE (UPPER)
Models S6.0FT, S7.0FT, (S135FT, S155FT) 29. PLUG
(D024, E024, F024) Figure 23. Spindle Assembly for Lift Truck
Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006) and H8.0FT, H8.0FT9,
H9.0FT (H170FT, H170FT36, H190FT) (A299,
B299)
24
SPINDLES AND BEARINGS b. Remove the oil seal, sleeve, and bearing cone.
S30FT, S35FT, S40FTS (E010), H1.6FT, NOTE: If the bearing cone is being replaced, the bear-
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) ing cup must be replaced.
(F001), and H2.0-3.5FT (H40-70FT) (L177) c. If necessary, remove the bearing cup.
Remove and Disassemble 5. Disassemble the top half of the spindle as follows:
WARNING a. Remove pin and O-ring from kingpin.

PUTTING THE LIFT TRUCK ON BLOCKS b. Remove spacer, seal, and bearing cone.
The lift truck must be put on blocks for some NOTE: If the bearing cone is being replaced, the bear-
types of maintenance and repair. The removal ing cup must be replaced.
weight assemblies will cause large changes c. If necessary, remove the bearing cup.
is put on blocks, put additional blocks in the 6. Repeat the procedure for the other spindle and
following positions: tie rod.
truck cannot fall backward. 1. If new spindle bearings are installed, use a press
• If the counterweight is removed, put blocks to install new bearing cups into spindle. See Fig-
under the mast so that the lift truck cannot ure 24. Lubricate bearing cones and seal lips
fall forward. with grease.
Put the lift truck on blocks on a solid, even, and 2. Install bearings, seals, sleeves, and O-rings into
level surface. Verify the blocks or stands have spindle. If the groove pin was removed from the
enough capacity to hold the lift truck. Use ad- kingpin, install new groove pin. Apply grease
ditional blocks next to the tires as necessary to to kingpin. Position spindle in axle and install
prevent movement of the lift truck. Verify the kingpin.
weight of the parts and assemblies. 3. Install lock nut onto kingpin and tighten lock nut
to 90 N•m (66.4 lbf ft). Completely loosen lock
See the Operating Manual or Periodic Mainte- nut, then tighten to 34 N•m (25 lbf ft). Tighten
nance section for your lift truck model, for the castle nut until new cotter pin can be installed.
procedures to put the lift truck on blocks.
4. Install tie rod to spindle housing. Align holes and
1. Put the lift truck on blocks. place lubricated pin into the spindle and tie rod.
Install the two snap rings on top and bottom of
2. Remove the wheel and if necessary, the bearings.
pin.
See Steering Axle Assembly Repair, Disassem-
ble. 5. If removed, install the bearings and install the
wheel. See section Steering Axle Assembly Re-
3. If the tie rod is to be replaced, remove the two
pair, Assemble.
snap rings and pin. To loosen and remove the
pin, use a brass punch and hammer. 6. Repeat the procedure for the other spindle and
tie rod.
4. Disassemble the bottom half of the spindle as fol-
lows: 7. Remove the lift truck from blocks.
a. Remove and discard cotter pin from castle
nut and remove castle nut from kingpin. See
Figure 24.
25
TIE RODS
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
(G004, H004)
Remove
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS

weight assemblies will cause large changes
is put on blocks, put additional blocks in the
following positions:
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
Put the lift truck on blocks on a solid, even, and

1. PIN 12. WASHER level surface. Verify the blocks or stands have
2. O-RING 13. BEARING (OUTER) enough capacity to hold the lift truck. Use ad-
3. SPACER 14. BEARING (INNER) ditional blocks next to the tires as necessary to
4. SEAL 15. OIL SEAL prevent movement of the lift truck. Verify the
5. BEARING CONE 16. SPINDLE
6. BEARING CUP 17. KINGPIN lifting devices used during repairs can lift the
7. SLEEVE 18. SNAP RING weight of the parts and assemblies.
8. OIL SEAL 19. WASHER
9. CASTLE NUT 20. TIE ROD See the Operating Manual or Periodic Mainte-
10. COTTER PIN 21. PIN nance section for your lift truck model, for the
11. HUB CAP procedures to put the lift truck on blocks.
Figure 24. Spindle Assembly for Lift Truck 1. Put the lift truck on blocks.
Models S30FT, S35FT, S40FTS (E010), H1.6FT,
(F001), and H2.0-3.5FT (H40-70FT) (L177)
26
2. Remove the wheel and bearings. See Steering Install

Axle Assembly Repair, Disassemble.
1. Install the tie rod to the spindle arm. Install the
castle nut.
CAUTION
DO NOT hit the threads or the nut of the tie rod. a. S2.0-3.5FT (S40-70FT, S55FTS) (F187) -
tighten castle nut to 163 N•m (120 lbf ft).
3. Remove the cotter pin and castle nut. Discard
cotter pin. Use a puller to remove the tie rod end b. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
from the spindle arm. To loosen the tie rod end, S80, 100FTBCS; S120FTS; S120FTPRS)
place a hammer behind the arm to hold the arm. (G004, H004) - tighten castle nut to 175 N•m
Hit the spindle arm with another large hammer. (129 lbf ft)
See Figure 19 for lift truck models c. Tighten castle nut until new cotter pin can
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) be installed.
See Figure 20 for lift truck models 2. If removed, slide the clamps onto the dust cover.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
3. Slide the dust cover on the tie rod. See Figure 17.
(G004, H004) 4. Slide the tie rod into the steering cylinder rod.
4. Loosen the clamps on the dust cover and slide 5. Lubricate and install the pin to retain the tie rod
the dust cover off the steering cylinder rod. See and steering cylinder rod together.
Figure 17.
6. Install the snap rings.
5. Remove the snap rings from the pin retaining the
tie rod to the steering cylinder rod, then remove 7. Slide the dust cover on to the steering rod cylin-
the pin. der, against the rod-end shoulder.
6. Slide the tie rod from the cylinder rod. 8. Slide the clamps flush with the ends of the dust
cover and tighten clamps.
7. Remove the dust cover from the tie rod.
9. Install the bearings and wheel. See section
8. If necessary, remove the clamps from the dust Steering Axle Assembly Repair, Assemble.
cover.
10. Repeat the procedure for the other tie rod.
11. Remove the lift truck from blocks.
27
TIE RODS See the Operating Manual or Periodic Mainte-

nance section for your lift truck model, for the
S30FT, S35FT, S40FTS (E010), H1.6FT, procedures to put the lift truck on blocks.
1. Put the lift truck on blocks.
(F001), H2.0-3.5FT (H40-70FT) (L177),
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 2. Remove the wheel and if necessary, the bearings.
H5.0-5.5FT (H80, 90, 100, 110, 120FT) See Steering Axle Assembly Repair, Disassem-
ble.
(N005, P005, R005), S6.0FT, S7.0FT,
(S135FT, S155FT) (D024, E024, F024), 3. Remove the snap rings from the pin retaining
H6.0FT, H7.0FT (H135FT, H155FT) (H006, the tie rod to the spindle. Remove the pin. To
J006, K006), and H8.0FT, H8.0FT9, H9.0FT loosen and remove the pin, use a brass punch and
hammer.
(H170FT, H170FT36, H190FT) (A299, B299)
Remove
• S30FT, S35FT, S40FTS (E010)
WARNING H40FTS) (F001)
PUTTING THE LIFT TRUCK ON BLOCKS • H2.0-3.5FT (H40-70FT) (L177)
The lift truck must be put on blocks for some See Figure 26 for lift truck models
types of maintenance and repair. The removal • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
of the mast, drive axle, battery, or counter- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
weight assemblies will cause large changes R005)
is put on blocks, put additional blocks in the See Figure 27 for lift truck models
following positions: • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• If the mast and drive axle are removed, put E024, F024)
blocks under the counterweight so the lift • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
truck cannot fall backward. J006, K006)
• If the counterweight is removed, put blocks • H8.0FT, H8.0FT9, H9.0FT (H170FT,
under the mast so that the lift truck cannot H175FT36, H190FT) (A299, B299)
fall forward.
4. Remove the snap rings from the pin retaining the
Put the lift truck on blocks on a solid, even, and tie rod to the steering cylinder rod. Remove the
level surface. Verify the blocks or stands have pin.
enough capacity to hold the lift truck. Use ad-
5. Slide the tie rod and washers from the spindle
ditional blocks next to the tires as necessary to
housing and steering cylinder rod.
prevent movement of the lift truck. Verify the
weight of the parts and assemblies.

A. H2.0-3.5FT (H40-70FT) (L177)
B. S30FT, S35FT, S40FTS (E010) AND H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
1. SNAP RINGS 4. TIE ROD
2. STEERING CYLINDER ROD 5. PIN
3. WASHERS 6. SPINDLE
28
Figure 25. Tie Rod for Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001), and H2.0-3.5FT (H40-70FT) (L177)
29
1. SPINDLE (LEFT SIDE SHOWN) 4. TIE ROD ASSEMBLY

2. SNAP RING 5. PIN
3. SEAL 6. STEERING CYLINDER ROD
Figure 26. Tie Rod Assembly for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005)
30
Install See Figure 27 for lift truck models

• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
1. Place the tie rod and washers in position in the E024, F024)
spindle and steering cylinder rod. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• S30FT, S35FT, S40FTS (E010)
H175FT36, H190FT) (A299, B299)
H40FTS) (F001) 2. Align holes and place lubricated pin into the
• H2.0-3.5FT (H40-70FT) (L177) spindle and tie rod. Install the two snap rings
on top and bottom of pin.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- 3. Align holes and place lubricated pin into the
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, steering cylinder rod and tie rod. Install the two
R005) snap rings on top and bottom of pin.
1. SNAP RING 4. SEAL

2. PIN 5. TIE ROD ASSEMBLY
3. STEERING CYLINDER ROD 6. SPINDLE (LEFT SIDE SHOWN)
Figure 27. Tie Rod Assembly for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
F024); H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006); and H8.0FT, H8.0FT9, H9.0FT
(H170FT, H170FT36, H190FT) (A299, B299)
31
Steering Cylinder Repair 1600 SRM 1133
4. If removed, install the bearings and install the 5. Repeat the procedure for the other tie rod.
wheel. See Steering Axle Assembly Repair, As-
semble. 6. Remove the lift truck from blocks.
Steering Cylinder Repair

REMOVE AND DISASSEMBLE 1. Clean all metal parts in solvent.
NOTE: The end caps of the steering cylinder are held 2. Inspect piston rod for grooves or damage. Re-
in the shell by the installation of cylinder mount cap- move small scratches with fine emery cloth.
screws into the axle frame. To prevent oil leaks at the
caps, hold the caps on the shell during removal. 3. Inspect cylinder bore for damage
NOTE: Hydraulic oil is to be disposed of in accordance 4. Inspect mounts for cracks.

with local directives.
1. Disconnect and tag hydraulic lines at steering
cylinder. See Figure 28. Install caps in fittings CAUTION
on cylinder and put fittings on hydraulic lines.
Do not damage the O-rings, seals, or wipers
2. Remove the tie rods. See Spindles, Bearings, and during installation.
Tie Rods Repair, Tie Rods.
1. Put O-rings, seals, guide rings, and wipers in
3. Remove capscrews that fasten cylinder to axle warm hydraulic oil. Install O-rings, seals, guide
frame. Hold end caps on shell and remove steer- rings, and wipers as shown in Figure 28.
ing cylinder.
2. Lubricate O-rings, seals, and wipers with O-ring
4. Hold end of steering cylinder over a container. lubricant and carefully install one end cap on
Remove plug for hydraulic fitting from each end cylinder rod.
cap. Push rod toward end of shell that is over
3. Carefully slide cylinder rod into shell and end
container. Oil will drain from cylinder. Repeat
onto into shell. Keep cylinder rod aligned in cen-
procedure for other end.
ter of shell during installation so the parts are
5. Carefully remove one end cap from shell and not damaged. Install other end cap into shell.
slide off of rod. Carefully pull rod out of shell, Put caps on hydraulic fittings of end caps.
keeping rod centered in shell during removal.
4. Hold end caps and install cylinder on axle frame
Remove other end cap from shell. Remove all
using capscrews. Tighten capscrews to 225 N•m
seals, wipers, and O-rings. See Figure 28.
(166 lbf ft).
6. Remove piston seal. If present, remove two guide
5. Install tie rods. See section Spindles, Bearings,
rings.
and Tie Rods Repair, Tie Rods.
CLEAN AND INSPECT 6. Remove plugs and caps and connect hydraulic
lines as tagged during removal, to steering cylin-
WARNING der. Operate steering system to remove air from
Cleaning solvents can be flammable and toxic cylinders and system. Turn steering wheel sev-
and can cause skin irritation. When using eral times from one stop to the other. Check that
cleaning solvents, always follow the solvent the steer cylinder operates lock to lock.
dures.
32
1. ROD 7. PISTON SEAL

2. WIPER 8. ROD SEAL
3. END CAP 9. O-RING
4. O-RING 10. HYDRAULIC LINE PORT
5. BACKUP RING 11. GUIDE RING
6. SHELL
Figure 28. Steering Cylinder
Axle Mounting Bolts and Nuts Hub Nut (Initial)
S2.0-3.5FT (S40-70FT, S55FTS) (F187)
S2.0-3.5FT (S40-70FT, S55FTS) (F187) 68 N•m (50 lbf ft)
90 N•m (66.4 lbf ft)
S30FT, S35FT, S40FTS (E010) H1.6FT, H1.8FT,
H2.0-3.5FT (H40-70FT) (L177) H2.0FTS (H30FT, H35FT, H40FTS) (F001),
88 N•m (65 lbf ft) and H2.0-3.5FT (H40-70FT) (L177)
200 N•m (147.5 lbf ft)
S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
H40FTS) (F001) S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
41 to 49 N•m (30 to 36 lbf ft) H004) 203 N•m (150 lbf ft)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
S80, 100FTBCS; S120FTS; S120FTPRS) (G004, (H80, 90, 100, 110, 120FT) (N005, P005, R005)
H004) 215 N•m (159 lbf ft) 200 to 220 N•m (148 to 162 lbf ft)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT S6.0FT, S7.0FT, (S135FT, S155FT) (D024,

(H80, 90, 100, 110, 120FT) (N005, P005, E024, F024) 203 N•m (150 lbf ft)
R005) 90 N•m (66.4 lbf ft)
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, J006, K006) 203 N•m (150 lbf ft)
F024) 250 to 275 N•m (184 to 203 lbf ft)
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H6.0FT, H7.0FT (H135FT, H155FT) (H006, H190FT) (A299, B299) 203 N•m (150 lbf ft)
J006, K006) 270 N•m (199 lbf ft)
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,

H190FT) (A299, B299) 270 N•m (199 lbf ft)
33
Hub Nut (Final) Spindle Bearing Cap Capscrews

S2.0-3.5FT (S40-70FT, S55FTS) (F187) S2.0-3.5FT (S40-70FT, S55FTS) (F187)
3 N•m (27 lbf in) 44 N•m (32 lbf ft)
H2.0-3.5FT (H40-70FT) (L177) S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
15 N•m (133 lbf in) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004) 52 N•m (38 lbf ft)
S30FT, S35FT, S40FTS (E010) and H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
H40FTS) (F001) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
12 N•m (106 lbf in) 45 to 50 N•m (33 to 37 lbf ft)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
S80, 100FTBCS; S120FTS; S120FTPRS) E024, F024) 52 N•m (38 lbf ft)
(G004, H004) 34 N•m (25 lbf ft)
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT J006, K006) 47 N•m (35 lbf ft)
(H80, 90, 100, 110, 120FT) (N005, P005,
R005) 35 N•m (26 lbf ft) H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299) 47 N•m (35 lbf ft)
S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024) 35 N•m (26 lbf ft) Tie Rod Nut
S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H6.0FT, H7.0FT (H135FT, H155FT) (H006, 163 N•m (120 lbf ft)
J006, K006) 34 N•m (25 lbf ft)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
H190FT) (A299, B299) 34 N•m (25 lbf ft) H004) 175 N•m (129 lbf ft)
King Pin Lock Nut (Initial) Steer Cylinder Mounting Bolts

S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
H2.0FTS (H30FT, H35FT, H40FTS) (F001), E024, F024)
and H2.0-3.5FT (H40-70FT) (L177) 225 N•m (166 lbf ft)
90 N•m (66.4 lbf ft)
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
King Pin Lock Nut (Final) J006, K006) 225 N•m (166 lbf ft)
H2.0FTS (H30FT, H35FT, H40FTS) (F001), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
and H2.0-3.5FT (H40-70FT) (L177) H190FT) (A299, B299) 225 N•m (166 lbf ft)
34 N•m (25 lbf ft)
34

HYDRAULIC GEAR PUMP
H2.0-2.5CT (H50CT) [A274]; S4.0, 4.5, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005, R005];
S6.0FT, S7.0FT (S135FT,S155FT) [D024, E024, F024]; H6.0FT,
H7.0FT (H135FT, H155FT) [H006, J006, K006]; H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299]
PART NO. 1580514 1900 SRM 1136

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Hydraulic Gear Pump Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Hydraulic Gear Pump Assembly .............................................................................................................. 1
Variable Displacement Pump Assembly .................................................................................................. 1
Single Gear Pump Assembly Repair................................................................................................................. 2
Remove ........................................................................................................................................................... 2
Disassemble ................................................................................................................................................... 8
Clean .............................................................................................................................................................. 9
Inspect ............................................................................................................................................................ 9
Assemble ........................................................................................................................................................ 9
Install ............................................................................................................................................................. 9
Tandem Gear Pump Assembly .......................................................................................................................... 14
Remove ........................................................................................................................................................... 14
Disassemble ................................................................................................................................................... 14
Clean .............................................................................................................................................................. 16
Inspect ............................................................................................................................................................ 16
Assemble ........................................................................................................................................................ 16
Install ............................................................................................................................................................. 18
Gear Pump Specifications ................................................................................................................................. 19
Variable Displacement Pump Repair................................................................................................................ 24
Remove ........................................................................................................................................................... 24
Disassemble ................................................................................................................................................... 31
Clean .............................................................................................................................................................. 34
Inspect ............................................................................................................................................................ 34
Assemble ........................................................................................................................................................ 34
Install ............................................................................................................................................................. 34
Variable Displacement Pump Checks and Adjustments ................................................................................. 37
Margin Pressure Check ................................................................................................................................. 37
Flow Compensator Adjustment .................................................................................................................... 38
Pressure Compensator Adjustment.............................................................................................................. 38
Variable Displacement Pump Specifications .................................................................................................... 40
Hydraulic Gear Pump ................................................................................................................................... 41
Variable Displacement Pump........................................................................................................................ 42
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S50CT [A267];
H2.0-3.5FT (H40-70FT) [L177];
H2.0-2.5CT (H50CT) [A274];
S120FTS; S120FTPRS) [G004, H004];
110, 120FT) [N005, P005, R005];

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
This section includes a description and the repair Lift truck model listed below is equipped with a tan-
procedures for the hydraulic gear pump assembly dem gear pump: 63.3 cc/rev
and for the variable displacement pump (VDP) as- • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
sembly. H190FT) (A299, B299)
Hydraulic Gear Pump Assembly The repair procedures are similar for each type of
gear pump. When the repair has been completed, see
Lift truck models listed below can be equipped with the Gear Pump Specifications section in this manual.
one of three different gear pumps: 24 cc/rev, 25.7
cc/rev, or 29.4 cc/rev Variable Displacement Pump Assembly
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, Lift truck models listed below can be equipped with
H40FTS) (F001) one of three different variable displacement pumps:
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 24 cc/rev, 26 cc/rev, or 28 cc/rev
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (L177)
Lift truck models listed below can be equipped with Lift truck models listed below can be equipped with
the 24 cc/rev gear pump one of two different variable displacement pumps: 42
• S50CT (A267) cc/rev or 45 cc/rev
• H2.0-2.5CT (H50CT) (A274) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(P005, R005)
Lift truck models listed below can be equipped with
the 25.7 cc/rev gear pump The repair procedures are similar for each size of
• H2.0-2.5CT (H50CT) (A274) VDP. When the repair has been completed, see the
section Variable Displacement Pump Specifications.
Lift truck models listed below can be equipped with
a 32.5 cc/rev gear pump Repair information for other components of the
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT hydraulic system, equipped with either a hydraulic
(H80, 90, 100, 110, 120FT) (R005) gear pump or variable displacement pump, are found
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, in the following manuals
100FTBCS; S120FTS; S120FTPRS) (G004, H004)
See Steering Axle 1600 SRM 1133 for lift truck
Lift truck models listed below can be equipped with models
one of two different gear pumps: 41.3 cc/rev, or 51.6 • S30FT, S35FT, S40FTS (E010)
cc/rev • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, (F001)
100FTBCS; S120FTS; S120FTPRS) (G004, H004) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT • H2.0-3.5FT (H40-70FT) (L177)
(H80, 90, 100, 110, 120FT) (N005, P005, R005) • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
Lift truck model listed below can also be equipped • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
with a 46.5 cc/rev gear pump (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT • S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024,
(H80, 90, 100, 110, 120FT) (N005, P005, R005) F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
Lift truck models listed below can be equipped with K006)
one of two different tandem gear pumps: 63.3 cc/rev • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
or 68.5 cc/rev H190FT) (A299, B299)
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024,
F024) See Steering Axle 1600 SRM 1425 for lift truck
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, models
K006) • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
1
Single Gear Pump Assembly Repair 1900 SRM 1136
See Main Control Valve 2000 SRM 1137 for lift See Mast Repairs, 2-, 3-, and 4-Stage Masts 4000
truck models SRM 1148 for lift truck models
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274) See Mast Repairs, 2- and 3-Stage Masts 4000
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, SRM 1250 for lift truck models
100FTBCS; S120FTS; S120FTPRS) (G004, H004) • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
(H80, 90, 100, 110, 120FT) (N005, P005, R005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024, (H80, 90, 100, 110, 120FT) (N005, P005, R005)
F024) • S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, F024)
K006) • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, K006)
H190FT) (A299, B299)
See Mast Repair 4000 SRM 1406 for lift truck mod-
See Main Control Valve, (With Variable Dis- els
placement Pump) 2000 SRM 1457 for lift truck • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
• H2.0-3.5FT (L177)
See Mast Repair 4000 SRM 1431 for lift truck mod-
els
(P005, R005)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
Single Gear Pump Assembly Repair

REMOVE blocks used to support the lift truck are solid,
one-piece units.
WARNING NOTE: Worn or damaged seals are the most common
PUTTING THE LIFT TRUCK ON BLOCKS cause of pump damage. The pump bushings, gears,
and shafts also wear. They must be checked during
disassembly. DO NOT make any repairs to the parts.
To prevent more failures, always replace parts that
of the following assemblies will cause large
are worn or damaged. If several main parts need
changes in the center of gravity: mast, drive
replacing, replace the complete group.
axle, engine, transmission, and counterweight.
When the lift truck is put on blocks, put ad- 1. Put the lift truck on blocks. See the Operating
ditional blocks in the following positions to Manual or the Periodic Maintenance Man-
maintain stability: ual for your lift truck for the procedures to put
• Before removing the mast and drive axle, put the lift truck on blocks.
truck cannot fall backward. 2. Place a drain pan under the hydraulic tank, re-
• Before removing the counterweight, put move drain plug at the bottom of hydraulic oil
blocks under the mast assembly so the lift tank, and drain oil from tank.
a. Drain pan capacity approximately 30 liter
The surface must be solid, even, and level when (8 gal) for lift truck models
the lift truck is put on blocks. Make sure any • S30FT, S35FT, S40FTS (E010)
2
1900 SRM 1136 Single Gear Pump Assembly Repair
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, NOTE: Lift truck models H2.0-3.5FT (H40-70FT)
H40FTS) (F001) (L177), with a single speed transmission, electronic
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) or manual control valve, and manufactured after
• S50CT (A267) January, 2011, may be equipped with an optional
• H2.0-3.5FT (H40-70FT) (L177) Quick-Lok™ hydraulic hose and adapters.
• H2.0-2.5CT (H50CT) (A274)
6. On lift truck models not equipped with a Quick-
b. Drain pan capacity approximately 40 liter Lok hydraulic hose, disconnect all hydraulic lines
(11 gal) for lift truck model connected to the pump assembly. Remove pump
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, outlet fitting and suction adapter from hydraulic
120FT; S80, 100FTBCS; S120FTS; gear pump. Put caps on all hose fittings and hy-
S120FTPRS) (G004, H004) draulic gear pump ports.
c. Drain pan capacity approximately 51 liter See Figure 3 for lift truck models
(13.5 gal) for lift truck model • S30FT, S35FT, S40FTS (E010)
5.5FT (H80, 90, 100, 110, 120FT) (N005, H40FTS) (F001)
P005, R005) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
equipped with an iron transmission housing. See Figure 4 for lift truck models
• S30FT, S35FT, S40FTS (E010)
3. Put a drain pan under the pump assembly. Dis- • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
connect all hydraulic lines connected to the pump H40FTS) (F001)
assembly. Remove the pump outlet fitting and • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
suction adapter. Put caps on all the hose fittings • H2.0-3.5FT (H40-70FT) (L177)
and hydraulic pump ports. • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
• S30FT, S35FT, S40FTS (E010) 7. On lift truck models H2.0-3.5FT (H40-70FT)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, (L177) equipped with a Quick-Lok hydraulic
H40FTS) (F001) hose and single speed transmission, remove the
• (S40-70FT, S55FTS) (F187) adapter and hydraulic hose from gear pump
• H2.0-3.5FT (H40-70FT) (L177) assembly. Disconnect all other hydraulic hoses
connected to gear pump assembly. Remove
pump outlet fitting from hydraulic gear pump.
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
Put caps on all hose fittings and hydraulic gear
pump ports.
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- See Figure 4 for lift truck model
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • H2.0-3.5FT (H40-70FT) (L177)
R005)
4. Hold the pump assembly to keep it from falling. • H2.0-3.5FT (H40-70FT) (L177)
Remove the two socket head screws and the lock-
washers that fasten the pump to the transmis- 8. Hold the pump assembly to keep it from falling.
sion housing. Remove the pump assembly. Remove the two flange head capscrews that fas-
ten the pump to the transmission housing. Re-
NOTE: Perform Step 5 through Step 8 for lift trucks move the pump assembly.
equipped with an aluminum transmission housing.
5. Put a drain pan under the pump assembly. Cover • S30FT, S35FT, S40FTS (E010)
charge pump with liquid proof covering to pre- • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
vent damage. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
3
See Figure 4 for lift truck models • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, • S50CT (A267)
H40FTS) (F001) • H2.0-2.5CT (H50CT) (A274)
A. EARLY LIFT TRUCK MODELS B. NEWER LIFT TRUCK MODELS

1. SUCTION HOSE 5. HYDRAULIC PUMP
2. HYDRAULIC INLET HOSE 6. TRANSMISSION
3. SUCTION ADAPTER 7. PUMP OUTLET FITTING
4. SOCKET HEAD SCREW (2)
Figure 1. Hydraulic Pump for 1.5 to 3.5 Ton Lift Truck Models Equipped With an Iron Transmission
Housing
4
A. FOR EARLY MODEL S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) LIFT TRUCKS ONLY
B. FOR NEWER MODEL S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004) LIFT TRUCKS AND FOR ALL H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005) LIFT TRUCKS
1. TRANSMISSION 5. SUCTION ADAPTER
2. SOCKET HEAD SCREW 6. PUMP OUTLET FITTING
3. HYDRAULIC PUMP 7. HYDRAULIC INLET HOSE
4. SUCTION HOSE
Figure 2. Hydraulic Pump for 4 to 5.5 Ton Lift Truck Models
5
Legend for Figure 3

1. SUCTION HOSE
3. SUCTION ADAPTER
4. PUMP OUTLET FITTING
5. FLANGE HEAD CAPSCREW (2)
6. HYDRAULIC PUMP
7. TRANSMISSION
Figure 3. Hydraulic Pump for 1.5 to 3.5 Ton

Lift Truck Models, Equipped With Aluminum
Transmission Housing, Prior to January, 2011
Figure 4. Hydraulic Pump for 1.5 to 3.5 Ton Lift Truck Models, and Lift Trucks S50CT (A267) and
H2.0-2.5CT (H50CT) (A274) Equipped with Aluminum Transmission Housing, After January, 2011
6
Legend for Figure 4
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND ADAPTERS NOT SHOWN.

A. 1.5 TO 3.5 TON MODELS B. LIFT TRUCK MODELS S50CT (A267) AND
H2.0-2.5CT (H50CT) (A274)
1. SUCTION HOSE 5. SUCTION ADAPTER
2. HYDRAULIC INLET HOSE 6. HYDRAULIC PUMP
3. FLANGE HEAD CAPSCREW (2) 7. TRANSMISSION
4. PUMP OUTLET FITTING
NOTE: ELECTRO-HYDRAULIC MAIN CONTROL VALVE SHOWN.

1. STEERING CONTROL UNIT 3. QUICK-LOK HYDRAULIC HOSE
2. QUICK-LOK ADAPTER 4. HYDRAULIC GEAR PUMP
Figure 5. Quick-Lok Hydraulic Supply Hose System, Lift Truck Models H2.0-3.5FT (H40-70FT)
(L177) With Single Speed and Aluminum Transmission, After January, 2011
7
DISASSEMBLE 3. Make a note of the position of the plate seals

and pressure plates. Carefully remove the plate
1. Put the pump body in a vise. Put an alignment seals, pressure plates, and gears from the hous-
mark on each section of the pump body to aid in ings. Discard plate seals and backup seals. Re-
reassembly. move the snap ring and shaft seal from the flange
end housing.
2. Remove the capscrews that hold the pump to-
gether. Remove the flange end housing. Remove
the rear valve housing. DO NOT let the seals and
gears fall. See Figure 6.
1. SNAP RING 5. PRESSURE PLATE 9. REAR VALVE HOUSING

2. SHAFT SEAL 6. GEAR HOUSING 10. CAPSCREW
3. FLANGE END HOUSING 7. DRIVEN GEAR 11. BACKUP SEAL
4. PLATE SEAL 8. DRIVE GEAR
Figure 6. Hydraulic Pump Assembly
8
CLEAN INSTALL
1. Install pump outlet fitting and tighten to:
WARNING
Cleaning solvents can be flammable and toxic a. 88 to 98 N•m (65 to 72 lbf ft) for lift truck
and can cause skin irritation. When using models below
cleaning solvents, always follow the solvent • S30FT, S35FT, S40FTS (E010)
manufacturer’s recommended safety precau- • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
tions. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Compressed air can move particles so that they • H2.0-3.5FT (H40-70FT) (L177)
cause injury to the user or to other personnel. • H2.0-2.5CT (H50CT) (A274)
Make sure that the path of the compressed air • S6.0FT, S7.0FT, (S135FT,S155FT) (D024,
is away from all personnel. Wear protective E024, F024)
goggles or a face shield to prevent injury to the • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
eyes. J006, K006)
Clean all parts in solvent. Dry parts with compressed b. 98 to 118 N•m (72 to 87 lbf ft) for lift truck
air. DO NOT dry the parts with a cloth. Make sure models below
all surfaces are free of scratches and sharp edges. • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
INSPECT S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
Check parts for wear and damage. If any parts are 5.5FT (H80, 90, 100, 110, 120FT) (N005,
worn or damaged, replace the damaged parts. If the P005, R005)
pump housing is damaged, replace the pump.
2. On lift truck models not equipped with a Quick-
ASSEMBLE Lok™ hydraulic hose, install suction adapter and
1. Coat all pump components with hydraulic oil.
Use hydraulic oil meeting specification ISO VG NOTE: The information in Step 3 is used when the
46 hydraulic oil 15°C (5°F) and above. Quick-Lok hydraulic hose is installed for the first
time.
2. Use new plate and backup seals and install the
pressure plates and gears. Make sure to install 3. For lift truck models H2.0-3.5FT (H40-70FT)
the pressure plates as removed during disas- (L177) equipped with a Quick-Lok hydraulic
sembly. See the notes made during disassembly. hose:
Make sure all seals are complete and in the
a. Disconnect standard hydraulic hose from
correct positions. See Figure 6.
steering control unit (SCU) and remove fit-
3. Install a new shaft seal in the flange end hous- ting from SCU port.
ing. Carefully install the flange end housing. DO
b. Install Quick-Lok™ adapters into the SCU
NOT move the pressure plates. Make sure the
and gear pump ports. See Figure 5. Tighten
seals do not move out of the correct position. See
adapter at the gear pump to 59 to 69 N•m (44
Figure 6.
to 51 lbf ft). Tighten the adapter at the SCU
4. Carefully install the valve end housing on the port to 170 to 183 N•m (125 to 135 lbf ft).
pump body using the four capscrews and lock-
c. Install hydraulic gear pump to transmission.
washers. Make sure the pressure plates do not
Go to Step 6.
move and that the seals stay in the correct posi-
tion. Make sure the marks made during disas-
sembly are aligned. Tighten the capscrews to 88
to 98 N•m (65 to 72 lbf ft).
9
NOTE: Once the Quick-Lok hydraulic hose clicks into • H2.0-3.5FT (H40-70FT) (L177)
place on the adapters, the adapters are permanently
installed on the hose. To remove the Quick-Lok See Figure 8 for lift truck models
hydraulic hose again, remove the adapters from • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
the SCU and gear pump ports. When replacing the S80, 100FTBCS; S120FTS; S120FTPRS)
Quick-Lok hydraulic hose, replace both adapters (G004, H004)
and the hose at the same time. See Parts Manual. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
d. Push each end of Quick-Lok hydraulic hose R005)
into adapters on the SCU and gear pump, un-
til they click into place. Pull on the Quick-
Lok hydraulic hose to ensure that it is se-
curely in the adapters.
e. Position the Quick-Lok hydraulic hose (inlet

hose) as shown in Figure 10.

equipped with an iron transmission housing.
4. Clean the pump flange and transmission mount-

ing surfaces and put a 3 to 5 mm (0.118 to
0.197 in.) bead of Loctite™ 515 (Hyster Part
No. 264159) on the pump flange or transmis-
sion mounting surface. Hold the pump in the
correct position on the transmission. Install the
socket head screws and lockwashers that fasten
the pump to the transmission housing. Tighten
socket head screws to 38 N•m (28 lbf ft).

• S30FT, S35FT, S40FTS (E010)
A. Z = 60° ±5° FOR 1-SPEED TRANSMISSION,
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, LIFT TRUCK MODELS S30FT, S35FT, S40FTS
H40FTS) (F001) (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) H40FTS) (F001), AND S2.0-3.5FT (S40-70FT,
• H2.0-3.5FT (H40-70FT) (L177) S55FTS) (F187)
B. Z = 75° ±5° FOR 2-SPEED TRANSMISSION,
See Figure 2 for lift truck models LIFT TRUCK MODELS S2.0-3.5FT (S40-70FT,
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S55FTS) (F187)
C. Z = 50° ±5° FOR LIFT TRUCK MODELS
S80, 100FTBCS; S120FTS; S120FTPRS) H2.0-3.5FT (H40-70FT) (L177)
(G004, H004) D. X = 10° ±5° FOR LIFT TRUCK MODELS S30FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, (H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT
R005) (S40-70FT, S55FTS) (F187); H2.0-3.5FT
(H40-70FT) (L177)
5. Connect the hydraulic lines to the hydraulic 1. HYDRAULIC INLET HOSE
pump assembly. Position the hydraulic inlet 2. SUCTION HOSE
hose as shown in figures specified below:
Figure 7. Inlet Hose Orientation for Lift
See Figure 7 for lift trucks models Truck Models, With Iron Transmission
• S30FT, S35FT, S40FTS (E010) Housing,S30FT, S35FT, S40FTS (E010), H1.6FT,
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
H40FTS) (F001), (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
• S2.0-3.5FT (S40-70FT, S55FTS) (F187), and H2.0-3.5FT (H40-70FT) (L177)
10

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
7. On lift truck models not equipped with a

A. X = 32° ±5° FOR ALL LIFT TRUCK MODELS Quick-Lok™ hydraulic hose, connect hydraulic
EXCEPT S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, lines to hydraulic pump assembly. Position inlet
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) hydraulic line as shown in Figure 9.
(G004, H004) AND H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) NOTE: If the Quick-Lok hydraulic supply hose and
(N005, P005, R005) adapter is being installed for the first time, go to
B. X = 30° ±5° FOR LIFT TRUCK MODELS S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, Step 3 for procedures.
100FTBCS; S120FTS; S120FTPRS) (G004,
H004) AND H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 8. On lift truck models equipped with a Quick-Lok
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, hydraulic hose and adapter, connect hydraulic
P005, R005) lines, except for the Quick-Lok hydraulic hose,
to hydraulic gear pump assembly. Install the
2. SUCTION HOSE Quick-Lok hydraulic hose and adapter into gear
pump and position inlet hydraulic line as shown
Figure 8. Inlet Hose Orientation for Lift Truck in Figure 10. Tighten adapter at the gear pump
Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, to 59 to 69 N•m (44 to 51 lbf ft). Tighten the
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) adapter at the SCU port to 170 to 183 N•m (125
(G004, H004) and H4.0FT5/FT6; H4.5FTS5, to 135 lbf ft).
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005) 9. Remove the lift truck from the blocks. See the
Operating Manual or the Periodic Mainte-
NOTE: Perform Step 6, Step 7, and Step 8 for lift nance Manual for the procedures to remove lift
truck equipped with an aluminum transmission truck from blocks.
housing.
10. Fill the tank using the hydraulic oil shown in
6. Make sure pump flange and transmission the Maintenance Table located in the Operating
mounting surfaces are clean. Put a 3 to 5 mm Manual or the Periodic Maintenance Man-
(0.118 to 0.197 in.) bead of sealant on either ual for your lift truck model. When the oil level
pump or transmission housing face. Hold the is correct, operate the system and check for leaks.
pump in the correct position on the transmission Check the hydraulic oil level and add hydraulic
and install flange head capscrews into pump oil if necessary.
and transmission housing. Tighten capscrews to
38 N•m (28 lbf ft).
11
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND ADAPTERS NOT SHOWN.

1. HYDRAULIC INLET HOSE 2. SUCTION HOSE
Figure 9. Inlet Hose Orientation for Lift Truck Models, S30FT, S35FT, S40FTS (E010), H1.6FT,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
S50CT (A267), H2.0-3.5FT (H40-70FT) (L177), and H2.0-2.5CT (H50CT) (A274) With Aluminum
Transmission Housing Before January, 2011 and Equipped With Mazda Engine
12
NOTE: ELECTRO-HYDRAULIC CONTROL VALVE SHOWN. ORIENTATION IS THE SAME ON MANUAL CON-
TROL VALVE.
A. 40° ±5° B. 15° ±5°
1. INLET HOSE 2. SUCTION HOSE
Figure 10. Inlet Hose Orientation for All Lift Truck Models With Single Speed and Aluminum
Transmission After January, 2011 and Equipped With Quick-Lok™ Hydraulic Supply Hose and
Adapters
13
Tandem Gear Pump Assembly 1900 SRM 1136
Tandem Gear Pump Assembly

REMOVE a. Drain pan capacity approximately 64 liter
(16.9 gal) for lift truck models
WARNING • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
PUTTING THE LIFT TRUCK ON BLOCKS
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
The lift truck must be put on blocks for some J006, K006)
types of maintenance and repair. The removal • H8.0FT, H8.0FT9, H9.0FT (H170FT,
of the following assemblies will cause large H175FT36, H190FT) (A299, B299)
changes in the center of gravity: mast, drive
3. Put a drain pan under the tandem gear pump as-
axle, engine, transmission, and counterweight.
sembly. Remove hydraulic outlet hoses at the fit-
When the lift truck is put on blocks, put ad-
tings on the tandem gear pump assembly. Re-
ditional blocks in the following positions to
move the inlet hose clamps and inlet hoses from
maintain stability:
the tandem gear pump assembly. Put caps on all
the hose fittings and hydraulic pump ports. See
Figure 11.
• Before removing the counterweight, put 4. Support the tandem gear pump assembly to
blocks under the mast assembly so the lift keep it from falling. Remove the two socket head
truck cannot fall forward. screws and lock washers that fasten the tandem
gear pump assembly to the transmission charge
pump housing. Remove the tandem gear pump
the lift truck is put on blocks. Make sure any
assembly.
blocks used to support the lift truck are solid,
one-piece units.
DISASSEMBLE
NOTE: Worn or damaged seals are the most common
1. Secure the tandem gear pump assembly in a vise.
cause of pump damage. The pump bushings, gears,
Put an alignment mark on each section of the
and shafts also wear. They must be checked during
pump body to aid in reassembly.
disassembly. DO NOT make any repairs to the parts.
To prevent more failures, always replace parts that NOTE: The tandem gear pump assembly consists of
are worn or damaged. If several main parts need a driven pump attached to a drive pump. Each pump
replacing, replace the complete group. has an inlet adapter and outlet fitting.
1. Put the lift truck on blocks. See the Operating 2. Remove inlet adapters and outlet fittings from
Manual or the Periodic Maintenance Man- drive pump and driven pump of tandem gear
ual for your lift truck for the procedures to put pump assembly. See Figure 12.
the lift truck on blocks. The following lift trucks
are equipped with the tandem gear pump assem- 3. Remove two capscrews and washers attaching
bly: driven pump to drive pump. See Figure 13.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024) NOTE: Drive pump shaft and driven pump shaft are
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, connected by a coupling.
J006, K006)
4. Slowly remove driven pump from drive pump.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Note position of O-rings on coupling. Remove
H175FT36, H190FT) (A299, B299)
O-rings, and coupling. Discard O-rings.
2. Place a drain pan under the hydraulic tank, re-
5. Place driven pump on a clean work space and
move the drain plug at the bottom of hydraulic
continue with disassembly of the drive pump.
oil tank, and drain oil from tank.
14
1900 SRM 1136 Tandem Gear Pump Assembly
6. Remove snap ring and oil seal from drive pump 9. Secure the driven pump body in a vise.
flange end housing. Discard snap ring.
10. Remove the socket head flange screws that hold
7. Remove the socket head screws and washers that the pump together. Remove the mounting flange
hold the pump together, and remove from vise. cover. Remove the rear valve housing. DO NOT
Remove adapter plate, cover plate and housing let the seals and gears fall. See Figure 13.
from drive pump flange end housing. DO NOT
let the seals and gears fall. 11. Make a note of the position of the plate seals
and pressure plates. Carefully remove the plate
8. Make a note of the position of the plate seals seals, pressure plates, gear plate and gears from
and pressure plates. Carefully remove the plate the housings. Discard plate seals and backup
seals, back up seals, pressure plates, gear plate, seals. Remove the snap ring from the flange end
cover plate, oil seal and gears from the housings. housing. Discard snap ring.
Discard plate seals and backup seals.
1. OUTLET HOSES 5. HEX SOCKET CAPSCREW

2. OUTLET HOSE FITTINGS 6. LOCK WASHER
3. INLET HOSE CLAMPS 7. TRANSMISSION CHARGE PUMP
4. INLET HOSES 8. TANDEM GEAR PUMP
Figure 11. Hydraulic Pump Removal for Lift Truck Models S6.0FT, S7.0FT, (S135FT, S155FT)
(D024, E024, F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, and H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
15

eyes.
Clean all parts in solvent. Dry parts with compressed

air. DO NOT dry the parts with a cloth. Make sure
all surfaces are free of scratches and sharp edges.
INSPECT
Check parts for wear and damage. If any parts are
worn or damaged, replace the damaged parts. If the
pump housing is damaged, replace the pump.
ASSEMBLE
1. Coat all pump components with hydraulic oil.
Use hydraulic oil meeting specification ISO VG
46 hydraulic oil 15°C (5°F) and above.
2. Begin assembly of the driven pump. Use new

plate and backup seals and install the pressure
1. FITTING 3. ADAPTER plates, gear plate and gears. Make sure to in-
2. DRIVEN PUMP 4. DRIVE PUMP stall the pressure plates as removed during dis-
assembly. See the notes made during disassem-
Figure 12. Tandem Gear Pump Fittings bly. Make sure all seals are in the correct posi-
tions. See Figure 13.
CLEAN
3. Carefully install the mounting flange cover. DO
WARNING NOT move the pressure plates. Make sure the
seals do not move out of the correct position.
and can cause skin irritation. When using 4. Carefully install the flange end housing on the
cleaning solvents, always follow the solvent pump body using the four socket head flange
manufacturer’s recommended safety precau- screws. Make sure the pressure plates do not
tions. move and that the seals stay in the correct
position. Make sure the marks made during
WARNING disassembly are aligned. Tighten the capscrews
Compressed air can move particles so that they to 88 to 98 N•m (65 to 72 lbf ft). Install new
cause injury to the user or to other personnel. snap ring in flange end housing.

1. SOCKET HEAD FLANGE SCREW 11. FLANGE END HOUSING
2. MOUNTING FLANGE COVER 12. SNAP RING
3. PLATE SEAL 13. O-RING
4. BACKUP SEAL 14. COUPLING
5. PRESSURE PLATE 15. SOCKET HEAD SCREW
6. GEAR PLATE 16. ADAPTER PLATE
7. DOWEL PIN 17. COVER PLATE
8. GEARS 18. HOUSING
9. CAPSCREW 19. OIL SEAL
10. WASHER 20. DRIVE PUMP FLANGE END HOUSING
16
1900 SRM 1136 Tandem Gear Pump Assembly
Figure 13. Tandem Gear Pump Assembly
17
5. Begin assembly of the drive pump. Use new plate 10. Install two inlet adapters, tighten to 88 to
and backup seals and install the pressure plates 98 N•m (65 to 72 lbf ft). Remove tandem gear
and gears. Make sure to install the pressure pump from vise.
plates, cover plate, housing, oil seal and adapter
plate as removed during disassembly. See the INSTALL
notes made during disassembly. Make sure all
seals are in the correct positions. 1. Clean the tandem gear pump flange and trans-
mission charge pump mounting surfaces and
6. Install a new shaft seal in the drive pump flange put a 3-5 mm (0.118-0.197 in.) bead of Loctite™
end housing. Carefully install the flange end 515 (Hyster Part No. 264159) on the pump
housing. DO NOT move the pressure plates. flange or transmission charge pump mounting
Make sure the seals do not move out of the cor- surface. Hold the pump in the correct position
rect position. on the transmission. Install the socket head
screws and lockwashers that fasten the pump to
7. Carefully install the adapter plate on the drive the transmission housing. Tighten socket head
pump body using the four socket head screws and screws to 108 N•m (80 lbf ft). See Figure 11.
lock washers. Make sure the pressure plates do
not move and that the seals stay in the correct 2. Loosen inlet hose clamps and install inlet hoses
position. Make sure the marks made during dis- to inlet hose fittings. Tighten inlet hose clamps.
assembly are aligned. Tighten the capscrews to Install outlet hoses to outlet hose fittings.
123 to 132 N•m (91 to 97 lbf ft). Install new snap
ring in front of shaft seal. 3. Remove the lift truck from the blocks. See the
Operating Manual or the Periodic Mainte-
8. Assemble tandem gear pump. Place drive pump nance Manual for the procedures to remove lift
in vise and install oil seal, adapter, sleeve and truck from blocks.
O-ring to shaft of drive pump. Fit shaft of driven
pump into adapter and install two capscrews and 4. Fill the tank using the hydraulic oil shown in
washers securing the driven pump to the drive the Maintenance Table located in the Operating
pump. Tighten the capscrews to 42 to 46 N•m Manual or the Periodic Maintenance Man-
(31 to 34 lbf ft). ual for your lift truck model. When the oil level
is correct, operate the system and check for leaks.
9. Reposition tandem gear pump in the vise and Check the hydraulic oil level and add hydraulic
install two outlet hose fittings. See Figure 12. oil if necessary.
Tighten the fittings to 78 to 88 N•m (58 to
65 lbf ft).
18
1900 SRM 1136 Gear Pump Specifications
Gear Pump Specifications

Table 1. Hydraulic Gear Pumps for Lift Truck Models S30FT, S35FT, S40FTS (E010)
and H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001)
Model Engine Displacement Governed Speed Main Relief Pump Flow

Valve Rate - LPM
Pressure - (GPM)
Mpa (PSI)
S30FT, S35FT, Mazda 2.0L 24.0 cc/rev 2400 rpm 19.31 MPa 56.1 liter/min
S40FTS (E010) (2800 psi) (14.8 gal/min)
H1.6FT,
H1.8FT,
H2.0FTS
(H30FT,
H35FT,
H40FTS)
(F001)
S30FT, S35FT, Yanmar 2.6L 29.4 cc/rev 2400 rpm 19.31 MPa 68.7 liter/min
S40FTS (E010) (2800 psi) (18.1 gal/min)
H1.6FT,
H1.8FT,
H2.0FTS
(H30FT,
H35FT,
H40FTS)
(F001)
19
Gear Pump Specifications 1900 SRM 1136
Table 2. Hydraulic Gear Pumps for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187),
S50CT (A267) H2.0-3.5FT (H40-70FT) (L177), and H2.0-2.5CT (H50CT) (A274)
Model Engine Displacement Governed Speed Main Relief Pump Flow

Valve Rate - LPM
Pressure - (GPM)
Mpa (PSI)
S50CT (A267) 21.4 MPa 57.6 liter/min

Mazda 2.0L 24.0 cc/rev 2400 rpm
(3104 psi) (15.2 gal/min)
H2.0-2.5CT 23.4 MPa
(A274) (3394 psi) 57.6 liter/min
Mazda 2.0L 24.0 cc/rev 2400 rpm
H50CT (A274) 21.4 MPa (15.2 gal/min)
(3104 psi)
H2.0-2.5CT 23.4 MPa
(A274) (3394 psi) 61.7 liter/min
Yanmar 2.6L 25.7 cc/rev 2400 rpm
H50CT (A274) 21.4 MPa (16.3 gal/min)
(3104 psi)
S2.0-3.0FT Mazda 2.0L/ 24.0 cc/rev 63.1 liter/min
(S40-60FT, 2.2L (16.7 gal/min)
S55FTS)
GM 2.4L 25.7 cc/rev 67.5 liter/min
(F187) 2700 rpm
21.37 MPa (17.8 gal/min)
H2.0-3.0FT
(H40-60FT) Yanmar 2.6L (3100 psi) 77.3 liter/min
(L177) (20.4 gal/min)
29.4 cc/rev
Yanmar 3.3L 2600 rpm 74.4 liter/min
(19.7 gal/min)
S3.5FT Mazda 2.0L/ 24.0 cc/rev 63.1 liter/min
(S70FT) 2.2L (16.7 gal/min)
(F187) H3.5FT
GM 2.4L 25.7 cc/rev 67.5 liter/min
(H70FT) 2700 rpm
23.44 MPa (17.8 gal/min)
(L177)
Yanmar 2.6L (3400 psi) 77.3 liter/min
(20.4 gal/min)
29.4 cc/rev
Yanmar 3.3L 2600 rpm 74.4 liter/min
(19.7 gal/min)
20
Table 3. Hydraulic Gear Pumps for Lift Truck Model S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
Model Engine Displacement Governed Main Relief Pump Flow

Speed Valve Rate - LPM
Pressure - (GPM)
Mpa (PSI)
S4.0FT (S80FT, 32.5 cc/rev 75.9 liter/min
S80FTBCS) (20.1 gal/min)
(G004, H004)
96.5 liter/min
(25.5 gal/min)
41.3 cc/rev
S 4.5, 5.5FT, 22.06 MPa 96.5 liter/min
GM 4.3L 2400 rpm
S5.5FTS, (3200 psi) (25.5 gal/min)
(S100, 120FT;
51.6 cc/rev 120.5 liter/min
S100FTBCS;
(31.8 gal/min)
S120FTS;
S120FTPRS)
(G004, H004)
Table 4. Hydraulic Gear Pumps for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)

Pressure - (GPM)
Mpa (PSI)
GM 4.3L / 32.5 cc/rev 2400 rpm 22.06 MPa 75.9 liter/min
Kubota 3.8L (3200 psi) (20.1 gal/min)
(Paper Kit
Industry)
GM 4.3L 41.3 cc/rev 2400 rpm 22.06 MPa 96.5 liter/min
(3200 psi) (25.5 gal/min)
H4.0FT5/FT6 Kubota 41.3 cc/rev 2450 rpm 22.1 MPa 96.5 liter/min
(H80, 90FT) (3200 psi) (25.5 gal/min)
(N005, P005, Cummins 3.3L 41.3 cc/rev 2200 rpm 22.06 MPa 88.4 liter/min
R005) Turbo / Kubota (3200 psi) (23.4 gal/min)
3.8L (Paper Kit
Industry)
Cummins 3.3L 46.5 cc/rev 2200 rpm 22.06 MPa 99.6 liter/min
Turbo (3200 psi) (26.3 gal/min)
Kubota 3.8L 46.5 cc/rev 2450 rpm 22.06 MPa 96.5 liter/min
(3200 psi) (25.5 gal/min)
21
Gear Pump Specifications 1900 SRM 1136
Table 4. Hydraulic Gear Pumps for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005) (Continued)

Pressure - (GPM)
Mpa (PSI)
H4.5FTS5, GM 4.3L (Paper 41.3 cc/rev 2400 rpm 22.06 MPa 96.5 liter/min
H4.5FT6; Kit Industry) (3200 psi) (25.5 gal/min)
H5.0-5.5FT
Kubota 41.3 cc/rev 2450 rpm 22.1 MPa 96.5 liter/min
(H100, 110,
(3200 psi) (25.5 gal/min)
120FT) (N005,
P005, R005) GM 4.3L 51.6 cc/rev 2400 rpm 22.06 MPa 120.5 liter/min
(3200 psi) (31.8 gal/min)
Turbo (Paper (3200 psi) (29.2 gal/min)
Kit Industry)
Kubota 3.8L 51.6 cc/rev 2500 rpm 22.1 MPa 96.5 liter/min
(3200 psi) (25.5 gal/min)
Table 5. Hydraulic Gear Pumps for Lift Truck Models S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)

Pressure - (GPM)
Mpa (PSI)
S6.0FT GM 4.3L 41.3 cc/rev 2500 rpm 22.06 MPa 144.3 liter/min
(S135FT) (3200 psi) (38.1 gal/min)
(D024, E024,
F024); H6.0FT
(H135FT)
(H006, J006, Kubota 41.3 cc/rev 2500 rpm 22.1 MPa 96.5 liter/min
K006) (3200 psi) (25.5 gal/min)
22
Table 5. Hydraulic Gear Pumps for Lift Truck Models S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) (Continued)

Pressure - (GPM)
Mpa (PSI)
S7.0FT, GM 4.3L 63.3 cc/rev 2400 rpm 22.06 MPa 144.3 liter/min
(S155FT) (3200 psi) (38.1 gal/min)
(D024, E024,
Kubota 41.3 cc/rev 2500 rpm 22.1 MPa 96.5 liter/min
F024); H7.0FT
(3200 psi) (25.5 gal/min)
(H155FT)
(H006, J006,
K006)
Table 6. Hydraulic Gear Pumps for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)

Pressure - (GPM)
Mpa (PSI)
H8.0FT
(H170FT)
(A299, B299)
H8.0FT9
Cummins 3.3L 22.06 MPa 177.2 liter/min
(H175FT36) 46.5cc/rev 2500 rpm
(A299, B299)
H9.0FT
(H190FT)
(A299, B299)
H8.0FT
(H170FT)
(A299, B299)
H8.0FT9
22.06 MPa 177.2 liter/min
(H175FT36) GM 5.7L 46.5 cc/rev 2500 rpm
(3200 psi) (46.8 gal/min)
(A299, B299)
H9.0FT
(H190FT)
(A299, B299)
23
Variable Displacement Pump Repair 1900 SRM 1136
Variable Displacement Pump Repair

REMOVE 2. Place a drain pan under the hydraulic tank, re-
move drain plug at bottom of hydraulic oil tank,
WARNING and drain oil from tank. See Figure 14.
PUTTING THE LIFT TRUCK ON BLOCKS a. Drain pan capacity approximately 40 liter
(11 gal) for lift truck models
• H2.0-3.5FT (L177)
of the following assemblies will cause large b. Drain pan capacity approximately 62 liter
changes in the center of gravity: mast, drive (16.5 gal) for lift truck models
axle, engine, transmission, and counterweight. • H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
When the lift truck is put on blocks, put ad- 5.5FT (P005, R005) with short wheel base.
ditional blocks in the following positions to
maintain stability: c. Drain pan capacity approximately 78 liter
• Before removing the mast and drive axle, put (21 gal) for lift truck models
blocks under the counterweight so the lift • H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
truck cannot fall backward. 5.5FT (P005, R005) with long wheel base.
blocks under the mast assembly so the lift 3. Once hydraulic oil has finished draining from hy-
truck cannot fall forward. draulic tank, install drain plug.
The surface must be solid, even, and level when 4. Place drain pan under variable displacement
the lift truck is put on blocks. Make sure any pump (VDP).
blocks used to support the lift truck are solid,
5. Disconnect all hydraulic lines connected to vari-
one-piece units.
able displacement pump and steering control
NOTE: Worn or damaged seals and O-rings are the unit.
most common cause of pump damage. The pump
shaft, plugs, and plates also wear. They must be
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
checked during disassembly. DO NOT make any re-
5.5FT (P005, R005)
pairs to the parts. To prevent more failures, always
replace parts that are worn or damaged. If several See Figure 16 or Figure 17 for lift truck models
main parts need replacing, replace the with a new • H2.0-3.5FT (L177)
pump.
6. Remove the suction adapter from the VDP.
1. Put the lift truck on blocks. See the Operating
Manual or one of the following service manuals See Figure 15 for lift truck models
for the procedures to put the lift truck on blocks: • H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (P005, R005)
truck models See Figure 16 or Figure 17 for lift truck models
• H2.0-3.5FT (L177) • H2.0-3.5FT (L177)
Periodic Maintenance 8000 SRM 1248 for lift 7. Allow hydraulic oil to drain from VDP. Put caps
truck models on all hose fittings and VDP ports.
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (P005) 8. Support the VDP assembly to prevent it from
falling. Remove two flange head capscrews and
Periodic Maintenance 8000 SRM 1558 for lift VDP from transmission housing.
truck model
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
24
1900 SRM 1136 Variable Displacement Pump Repair
See Figure 15 for lift truck models See Figure 16 or Figure 17 for lift truck models
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0- • H2.0-3.5FT (L177)
5.5FT (P005, R005)
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 14. Drain Hydraulic Oil
25
Figure 15. Variable Displacement Pump Arrangement, Lift Truck Models H4.0FT5/FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT (P005, R005)
26

1. HYDRAULIC INLET HOSE 8. MAIN CONTROL VALVE
2. LOAD SENSE LINE 9. STEERING CONTROL UNIT
3. DRAIN CASE LINE 10. ACCUMULATOR
4. DRAIN CASE FILL PLUG 11. DRAIN CASE DRAIN PLUG
5. VARIABLE DISPLACEMENT PUMP 12. TRANSMISSION
6. FLANGE HEAD CAPSCREWS 13. SUCTION HOSE ADAPTER
7. SUCTION HOSE
27
Figure 16. Variable Displacement Pump Arrangement, Lift Truck Models H2.0-3.5FT (L177) With
1-Speed Transmission
28

2. LOAD SENSE LINE 8. ACCUMULATOR
3. DRAIN CASE LINE 9. STEERING CONTROL UNIT
4. VARIABLE DISPLACEMENT PUMP 10. DRAIN CASE DRAIN PLUG
5. FLANGE HEAD CAPSCREWS 11. TRANSMISSION
6. SUCTION HOSE 12. SUCTION HOSE ADAPTER
29
Figure 17. Variable Displacement Pump Arrangement, Lift Truck Models H2.0-3.5FT (L177) With
30

2. LOAD SENSE LINE 9. ACCUMULATOR
3. DRAIN CASE LINE 10. STEERING CONTROL UNIT
4. DRAIN CASE FILL PLUG 11. DRAIN CASE DRAIN PLUG
5. VARIABLE DISPLACEMENT PUMP 12. TRANSMISSION
6. FLANGE HEAD CAPSCREWS 13. SUCTION ADAPTER
7. SUCTION HOSE
DISASSEMBLE that has two rings to install the shaft seal. For lift
truck models H2.0-3.5FT (L177), use the end of the
1. Put the variable displacement pump in a vise. VDP shaft seal installation tool that has one ring to
install the shaft seal. See Figure 20.
CAUTION
e. Install new shaft seal onto drive shaft. Use
Protect the drive shaft from damage before re- special VDP shaft seal installation tool, Hys-
moving the retaining ring and shaft seal. ter Part Number 4035565, and seat shaft seal
down onto pump stop ring.
NOTE: Perform Step 2 ONLY if shaft seal is leaking.
f. Use rubber hammer and tap on VDP shaft
NOTE: Kits are available that include materials and
seal tool until VDP shaft seal tool shoulder
tools to remove and install shaft seal. See the Parts
stops against the face of VDP housing. See
Manual for kit part numbers.
Figure 20.
2. Remove retaining ring and shaft seal from drive
g. Install the retaining ring. Be sure retaining
shaft as described below:
ring correctly rests in the groove. See Fig-
a. Clean the shaft and shaft seal area. Wrap ure 18.
the pump drive shaft splines in tape or other
protective material to protect drive shaft be-
fore removing retaining ring and shaft seal.
See Figure 18.
b. Remove the retaining ring. See Figure 18.
c. Punch two holes into top surface of old shaft

seal being replaced. Make sure holes are
180° apart from each other. Insert two screws
into holes and into steel layer of the shaft
seal. Pull on screws and remove existing
shaft seal from drive shaft. See Figure 19.
d. Inspect and clean shaft and internal shaft

sealing area. Remove any metal shavings
created while inserting screws into old shaft
seal. See Figure 19.
NOTE: Be sure solid surface area of shaft seal is

pointing outwards from pump. 1. RETAINING RING 3. DRIVE SHAFT
2. SHAFT SEAL
NOTE: On lift truck models H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (P005, R005), Figure 18. Retaining Ring Removal
use the end of the VDP shaft seal installation tool
31
1. SCREWS 3. DRIVE SHAFT

2. SHAFT SEAL
Figure 19. Shaft Seal Removal
NOTE: SHAFT SEAL INSTALLATION FOR VDP USED

ON H2.0-3.5FT (L177) LIFT TRUCK MODELS SHOWN
(ONE RING SIDE OF VDP SHAFT SEAL TOOL PUSH-
ING DOWN ON SHAFT SEAL). TO INSTALL SHAFT
SEAL ON LIFT TRUCKS H4.0FT5/FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT (P005, R005), USE PART OF
VDP SHAFT SEAL TOOL WITH TWO RINGS.
1. VDP SHAFT SEAL TOOL
2. TWO RINGS
3. ONE RING
4. VDP SHAFT SEAL TOOL SHOULDER
5. STOP RING
6. BEARING
7. RETAINING RING
8. DRIVE SHAFT
Figure 20. Shaft Seal Installation
32
3. Remove four socket head screws from control

valve and VDP. Remove seal from control valve.

• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (P005, R005)

• H2.0-3.5FT (L177)
1. SOCKET HEAD SCREW

2. CONTROL VALVE
3. SEAL
4. VARIABLE DISPLACEMENT PUMP
5. DRIVE SHAFT
Figure 22. Variable Displacement Pump

1. SOCKET HEAD SCREW Dissembly, Lift Truck Models H2.0-3.5FT (L177)
2. CONTROL VALVE
3. SEAL
5. DRIVE SHAFT
Figure 21. Variable Displacement Pump

Dissembly, Lift Truck Models H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (P005, R005)
33
CLEAN INSTALL
1. Install the suction adapter and tighten flange
WARNING hardware 70 to 77 N•m (52 to 57 lbf ft). Posi-
Cleaning solvents can be flammable and toxic, tion suction adapter as shown in:
can cause skin irritation. When using cleaning
solvents, always follow the recommendations Figure 24 and Figure 25 for lift truck models
of the manufacturer. • H2.0-3.5FT (L177)

WARNING
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
Compressed air can move particles so that they 5.5FT (P005, R005)
Make sure that the path of the compressed air 2. Clean the VDP flange and transmission mount-
is away from all personnel. Wear protective ing surface and put a 3 to 5 mm (0.118 to
goggles or a face shield to prevent injury to the 0.197 in.) bead of Loctite™ 515 (Hyster P/N
eyes. 264159) on the VDP flange or transmission
mounting surface. Hold the pump in the correct
Clean all components in solvent. Dry components position on the transmission. Install two socket
with compressed air. DO NOT dry components with head screws on VDP and transmission housing.
a cloth. Make sure all surfaces are free of scratches Tighten socket head screws to 38 N•m (28 lbf ft).
and sharp edges.
3. Connect the hydraulic lines to the VDP and steer-
INSPECT ing control unit. Tighten the flange head cap-
screws at the VDP, using sequence shown in Fig-
Check the control valve seal, drive shaft seal, and re-
ure 23, to 70 to 77 N•m (52 to 57 lbf ft).
taining ring for wear or damage and replace if nec-
essary. Check the rest of the variable displacement
pump assembly. If any parts other than the control
valve seal, drive shaft seal, and retaining ring are
worn or damaged, replace with a new variable dis-
placement pump.
ASSEMBLE
1. Coat seal with clean hydraulic oil. Install seal,
control valve, and four socket head screws on
VDP.

• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (P005, R005)

• H2.0-3.5FT (L177)
2. Apply clean hydraulic oil to shaft seal and re-

taining ring. Install shaft seal and retaining ring Figure 23. Torque Tightening Sequence, Flange
onto drive shaft. Head Capscrews
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (P005, R005)

• H2.0-3.5FT (L177)
34
4. Position the hydraulic lines as shown in:
Figure 24, Figure 25, and Figure 27 for lift truck

models
• H2.0-3.5FT (L177)
Figure 26 and Figure 27 for lift truck models

• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (P005, R005)
A. X = 45° ±5° B. Y = 54° ±5°

2. SUCTION HOSE NOTE: HYDRAULIC INLET HOSE OMITTED FROM
3. LOAD SENSE LINE VIEW D FOR CLARITY.
4. DRAIN CASE LINE
5. VARIABLE DISPLACEMENT PUMP A. X = 74° ±5° D. FRONT VIEW
B. Y = 20° ±5° E. SIDE VIEW
Figure 24. Hydraulic Hose Orientation at C. Z = 35° ±5°
the Variable Displacement Pump, Lift Truck 1. LOAD SENSE LINE
Models H2.0-3.5FT (L177) Equipped With 2. SUCTION HOSE
1-Speed Transmission 3. DRAIN CASE LINE
Figure 25. Hydraulic Hose Orientation at

the Variable Displacement Pump, Lift Truck
Models H2.0-3.5FT (L177) Equipped With
35
A. X = 30° ±5° B. Y = 12° ±5°

1. LOAD SENSE LINE
2. SUCTION HOSE
4. DRAIN CASE LINE
Figure 26. Hydraulic Hose Orientation at

the Variable Displacement Pump, Lift Truck
Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (P005, R005)
A. X = 10° ±5° FOR LIFT TRUCK MODELS

H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(P005, R005) AND H2.0-3.5FT (L177), 1-SPEED
TRANSMISSION
B. X = 28° ±5° FOR LIFT TRUCK MODELS
H2.0-3.5FT (L177), 2-SPEED TRANSMISSION
C. Y = 65° ±5° FOR LIFT TRUCK MODELS
D. Y = 55° ±5° FOR LIFT TRUCK MODELS
E. 1-SPEED TRANSMISSION
F. 2-SPEED TRANSMISSION
1. STEERING CONTROL UNIT
2. MAIN CONTROL VALVE
4. LOAD SENSE LINE
Figure 27. Hydraulic Hose Orientation at the

Steering Control Unit
36
1900 SRM 1136 Variable Displacement Pump Checks and Adjustments
5. Remove the lift truck from the blocks. See the Periodic Maintenance 8000 SRM 1150 for lift
Operating Manual or one of the following ser- truck model
vice manuals for the procedures: • H2.0-3.5FT (L177)
• H2.0-3.5FT (L177) • H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (P005)
truck models Periodic Maintenance 8000 SRM 1558 for lift
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0- truck model
5.5FT (P005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
truck model 7. When the hydraulic oil level is correct, operate
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- the hydraulic system and check for leaks. Check
5.5FT (H80, 90, 100, 110, 120FT) (R005) the hydraulic oil level and add hydraulic oil if
necessary.
6. Fill the hydraulic tank using hydraulic oil speci-
fied in the Operating Manual or one of the fol-
lowing service manuals:
Variable Displacement Pump Checks and Adjustments

MARGIN PRESSURE CHECK
The margin pressure is the difference between the
pressure at the P-port and LS-port. If the margin
pressure is not within the range shown in Table 7, the
flow of hydraulic oil out of the variable displacement
pump (VDP) will be either too low or too high.
WARNING
DO NOT operate the hydraulic functions while
checking the margin pressure. Serious injury
to personnel and damage to the lift truck can
result if hydraulic functions are operated.
1. Install a 70 bar (1000 psi) gauge on the P-port

and a 35 bar (500 psi) gauge on the LS-port on
the main control valve. See Figure 28.
2. Start lift truck engine and keep truck at idle for

five minutes.
1. P-PORT 2. LS-PORT
3. Check the pressure on the gauges against those
listed in Table 7. Figure 28. Margin Pressure Check Ports
4. If the margin pressure is not within range spec-
ified in Table 7, go to Flow Compensator Adjust-
ment section.
37
Variable Displacement Pump Checks and Adjustments 1900 SRM 1136
Table 7. Margin Pressure 2. Using an allen wrench, hold the flow compen-
sator adjustment screw and turn the jam nut
Lift Truck Model Margin Pressure counterclockwise all the way.
H2.0-3.5FT (L177) 12.5 ±1 bar (180 ±15 psi) 3. Turn the flow compensator adjustment screw
H4.0FT5/FT6, 14.0 ±1 bar (203 ±15 psi) clockwise until it stops.
H4.5FTS5, H4.5FT6,
H5.0-5.5FT (P005, WARNING
R005) DO NOT operate the hydraulic functions while
adjusting the pressure compensator. Serious
FLOW COMPENSATOR ADJUSTMENT injury to personnel and damage to the lift truck
can result if hydraulic functions are operated.
WARNING 4. Start lift truck engine and let it idle. DO NOT op-
DO NOT operate the hydraulic functions while erate the hydraulic functions. Measure the pres-
adjusting the flow compensator. Serious injury sure at the P-port of the SCU. See Figure 28. If
to personnel and damage to the lift truck can pressure does not match what is shown in Ta-
result if hydraulic functions are operated. ble 8, adjust the pressure compensator as follows:
1. Insert an allen wrench into flow compensator ad- a. Turn pressure compensator adjustment
justment screw. Hold allen wrench in flow com- screw clockwise to increase pressure by
pensator screw and turn jam nut counter clock- 50 bar (725 psi) per turn.
wise all the way. See Figure 29.
b. Turn pressure compensator adjustment
2. Turn the flow compensator adjustment screw to screw counter clockwise to decrease pressure
adjust the P-port pressure: by 50 bar (725 psi) per turn.
• Clockwise to increase the P-port pressure by
16 bar (232 psi) per turn.
• Counter clockwise to decrease the P-port pres-
sure by 16 bar (232 psi) per turn.
3. Check the margin pressure as described in Mar-

gin Pressure Check. If margin pressure is not
correct, perform Step 1 and Step 2 until correct
margin pressure is reached.
4. Tighten the jam nut to 21 N•m (186 lbf in). See

Figure 29.
PRESSURE COMPENSATOR
ADJUSTMENT
WARNING
DO NOT operate the hydraulic functions while
adjusting the pressure compensator. Serious 1. FLOW COMPENSATOR
2. JAM NUT
injury to personnel and damage to the lift truck 3. FLOW COMPENSATOR ADJUSTMENT SCREW
can result if hydraulic functions are operated. 4. PRESSURE COMPENSATOR
5. PRESSURE COMPENSATOR ADJUSTMENT
1. Mark or measure the screw locations of the flow SCREW
and pressure compensators. See Figure 30.
Figure 29. Flow and Pressure Compensators
NOTE: Be sure to count and note the number of turns
on the jam nut.
38
1900 SRM 1136 Variable Displacement Pump Checks and Adjustments
5. Put the pressure compensator adjustment screw

back to its original position by turning the ad-
justment screw counter clockwise by the number
of turns noted earlier.
6. Tighten jam nut on pressure compensator adjust-

ment screw to 21 N•m (186 lbf in).
7. Put the flow compensator adjustment screw back

to its original position by turning the adjustment
screw counter clockwise by the number of turns
noted earlier.
8. Check the margin pressures as described in Mar-

gin Pressure Check.
9. If margin pressure is correct, tighten the flow

compensator jam nut to 21 N•m (186 lbf in). If
margin pressure is not correct, adjust margin
pressure as outlined in Margin Pressure Check.
Table 8. Pressure Compensator Adjustment

A. MEASURE AND NOTE THIS DISTANCE
Lift Truck Model Pressure
H2.0-3.5FT (L177) 239 ±3 bar 1. PRESSURE COMPENSATOR
2. FLOW COMPENSATOR
(3466 ±44 psi)
H4.0FT5/FT6, 226 ±3 bar Figure 30. Screw Location
H4.5FTS5, H4.5FT6, (3278 ±44 psi)
H5.0-5.5FT (P005,
R005)
39
Variable Displacement Pump Specifications 1900 SRM 1136
Variable Displacement Pump Specifications

Table 9. Variable Displacement Pump for Lift Truck Models H2.0-3.5FT (L177)
Displace- Governed Pump Speed Pressure Load Pump Pump

ment Speed Compen- Sense Flow Rate Flow Rate
sator Set- Margin @ ≤ 30 @ 210
ting - Bar Setting - Bar LPM Bar LPM
(PSI) Bar (PSI) (GPM) (GPM)
24.0 cc/rev 3200 rpm 2765 ±5 rpm 239 ±3 bar 12.5 ±1 bar 66.4 64.0
(3466 (180 ±3.1 liter/ ±3.0 liter/
±44 psi) ±15 psi) min (17.5 min (16.9
±0.82 gal/ ±0.80 gal/
min) min)
(3466 (180 ±3.1 liter/ ±3.0 liter/
±44 psi) ±15 psi) min (19.0 min (18.2
±0.82 gal/ ±0.80 gal/
min) min)
(3466 (180 ±3.1 liter/ ±3.0 liter/
±44 psi) ±15 psi) min (20.4 min (19.8
±0.82 gal/ ±0.80 gal/
min) min)
Table 10. Variable Displacement Pump for Lift Truck Models H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (P005, R005)
Displace- Governed Pump Speed Pressure Load Pump Pump

ment Speed Compen- Sense Flow Rate Flow Rate
sator Set- Margin @ ≤ 30 @ 210
ting - Bar Setting - Bar LPM Bar LPM
(PSI) Bar (PSI) (GPM) (GPM)
(3278 (203 ±4.4 liter/ ±4.3 liter/
±44 psi) ±15 psi) min (27.3 min (26.4
±1.20 gal/ ±1.10 gal/
min) min)
(3278 (203 ±4.4 liter/ ±4.3 liter/
±44 psi) ±15 psi) min (29.2 min (28.3
±1.20 gal/ ±1.10 gal/
min) min)
40
HYDRAULIC GEAR PUMP Pump Outlet Fitting - Lift Truck Models
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
Rear Valve End Housing to Gear Pump S80, 100FTBCS; S120FTS; S120FTPRS)
Body Capscrews - Lift Truck Models S30FT, (G004, H004) and H4.0FT5/FT6; H4.5FTS5,
S35FT, S40FTS (E010); H1.6FT, H1.8FT, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
H2.0FTS (H30FT, H35FT, H40FTS) (F001); 120FT) (N005, P005, R005)
H2.0-3.5FT (H40-70FT) (L177); H2.0-2.5CT 98 to 118 N•m (72 to 87 lbf ft)
(H50CT) (A274); S2.0-3.5FT (S40-70FT, S55FTS)
(F187); S50CT (A267); S4.0, 4.5, 5.5FT, S5.5FTS, Suction Adapter- All Lift Truck Models
(S80, 100, 120FT; S80, 100FTBCS; S120FTS; Not Equipped With Quick-Lok™ Hy-
S120FTPRS) (G004, H004); and H4.0FT5/FT6; draulic Supply Hose
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 78 to 88 N•m (58 to 65 lbf ft)
110, 120FT) (N005, P005, R005)
46 to 49 N•m (34 to 36 lbf ft) Outlet Adapter - Lift Truck Models H2.0-3.5FT
(H40-70FT) (L177) Equipped With Quick-Lok™
Driven Pump Rear Valve End Housing to Gear Hydraulic Supply Hose
Pump Body Capscrews - Lift Truck Models To Gear Pump 59 to 69 N•m (44 to 51 lbf ft)
S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, To SCU Port 170 to 183 N•m (125 to 135 lbf ft)
F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) and H8.0FT, H8.0FT9, H9.0FT Gear Pump to Transmission Socket Head
(H170FT, H175FT36, H190FT) (A299, B299) Screws - Lift Truck Models With Iron
88 to 98 N•m (65 to 72 lbf ft) Transmission Housing, S30FT, S35FT,
S40FTS (E010); H1.6FT, H1.8FT, H2.0FTS
Drive Pump Rear Valve End Housing to Gear (H30FT, H35FT, H40FTS) (F001); H2.0-3.5FT
Pump Body Capscrews - Lift Truck Models (H40-70FT) (L177); S2.0-3.5FT (S40-70FT,
S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, S55FTS) (F187); S4.0, 4.5, 5.5FT, S5.5FTS,
F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
J006, K006) and H8.0FT, H8.0FT9, H9.0FT S120FTPRS) (G004, H004); and H4.0FT5/FT6;
(H170FT, H175FT36, H190FT) (A299, B299) H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
123 to 132 N•m (91 to 97 lbf ft) 110, 120FT) (N005, P005, R005)
38 N•m (28 lbf ft)
Driven Pump to Drive Pump Capscrews -
Lift Truck Models S6.0FT, S7.0FT, (S135FT, Gear Pump to Transmission Flange Head
S155FT) (D024, E024, F024), H6.0FT, H7.0FT Capscrews - Lift Truck Models With Aluminum
(H135FT, H155FT) (H006, J006, K006) Transmission Housing, S30FT, S35FT, S40FTS
and H8.0FT, H8.0FT9, H9.0FT (H170FT, (E010); H1.6FT, H1.8FT, H2.0FTS (H30FT,
H175FT36, H190FT) (A299, B299) H35FT, H40FTS) (F001); H2.0-3.5FT (H40-70FT)
88 to 98 N•m (65 to 72 lbf ft) (L177); H2.0-2.5CT (H50CT) (A274); S2.0-3.5FT
(S40-70FT, S55FTS) (F187); S50CT (A267)
Pump Outlet Fitting - Lift Truck Models 38 N•m (28 lbf ft)
H2.0FTS (H30FT, H35FT, H40FTS) (F001); Tandem Gear Pump To Transmission Charge
H2.0-3.5FT (H40-70FT) (L177); H2.0-2.5CT Pump Socket Head Screws - Lift Truck Models
(H50CT) (A274); S2.0-3.5FT (S40-70FT, S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
S55FTS) (F187); S50CT (A267); S6.0FT, S7.0FT, F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006,
(S135FT, S155FT) (D024, E024, F024); H6.0FT, J006, K006), and H8.0FT, H8.0FT9, H9.0FT
H7.0FT (H135FT, H155FT) (H006, J006, K006) (H170FT, H175FT36, H190FT) (A299, B299)
and H8.0FT, H8.0FT9, H9.0FT (H170FT, 108 N•m (80 lbf ft)
H175FT36, H190FT) (A299, B299)
88 to 98 N•m (65 to 72 lbf ft)
41
VARIABLE DISPLACEMENT PUMP Pressure Compensator Jam Nut

21 N•m (186 lbf in)
Suction Hose Adapter
70 to 77 N•m (52 to 57 lbf ft) Variable Displacement Pump to Transmission
Socket Head Screws - All Transmissions
Flange Head Capscrews 38 N•m (28 lbf ft)
70 to 77 N•m (52 to 57 lbf ft)
Flow Compensator Jam Nut

21 N•m (186 lbf in)
42

MAIN CONTROL VALVE
S50CT [A267]; H2.0-2.5CT (H50CT) [A274];
S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 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];
S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024, F024];

PART NO. 1580515 2000 SRM 1137

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Main Control Valve Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Electro-Hydraulic Main Control Valve ............................................................................................................. 2
Description ..................................................................................................................................................... 2
Remove ........................................................................................................................................................... 8
Electro-Hydraulic Control Valve Sections .................................................................................................... 14
General....................................................................................................................................................... 14
Outlet Control Valve Section .................................................................................................................... 14
Remove .................................................................................................................................................. 14
Disassemble........................................................................................................................................... 14
Clean...................................................................................................................................................... 16
Inspect ................................................................................................................................................... 16
Assemble................................................................................................................................................ 16
Install..................................................................................................................................................... 17
Auxiliary Control Valve Sections.............................................................................................................. 17
Remove .................................................................................................................................................. 17
Disassemble........................................................................................................................................... 21
Clean...................................................................................................................................................... 23
Inspect ................................................................................................................................................... 23
Assemble................................................................................................................................................ 23
Install..................................................................................................................................................... 24
Tilt Control Valve Section ......................................................................................................................... 25
Remove .................................................................................................................................................. 25
Disassemble........................................................................................................................................... 25
Clean...................................................................................................................................................... 30
Inspect ................................................................................................................................................... 30
Assemble................................................................................................................................................ 30
Install..................................................................................................................................................... 31
Lift/Lower Control Valve Section ............................................................................................................. 31
Remove .................................................................................................................................................. 31
Disassemble........................................................................................................................................... 31
Clean...................................................................................................................................................... 38
Inspect ................................................................................................................................................... 38
Assemble................................................................................................................................................ 39
Install..................................................................................................................................................... 40
Mid-Inlet Section ....................................................................................................................................... 40
Remove .................................................................................................................................................. 40
Clean...................................................................................................................................................... 41
Inspect ................................................................................................................................................... 41
Install..................................................................................................................................................... 41
Install ............................................................................................................................................................. 41
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment .................................................................. 45
Lift Pilot Pin .............................................................................................................................................. 45
Lower Pilot Pin .......................................................................................................................................... 47
Abnormal/Erroneous EHPV Adjustment ................................................................................................. 49
Manual Main Control Valve .............................................................................................................................. 49
Description ..................................................................................................................................................... 49
Remove ........................................................................................................................................................... 53
OPS Solenoid Assembly................................................................................................................................. 60
General....................................................................................................................................................... 60
Remove....................................................................................................................................................... 60

Table of Contents Main Control Valve

Install ......................................................................................................................................................... 62
Manual Control Valve Sections..................................................................................................................... 63
General....................................................................................................................................................... 63
Outlet Control Valve Section .................................................................................................................... 63
Remove .................................................................................................................................................. 63
Disassemble........................................................................................................................................... 63
Clean...................................................................................................................................................... 66
Inspect ................................................................................................................................................... 66
Assemble................................................................................................................................................ 66
Install..................................................................................................................................................... 67
Auxiliary Control Valve Sections.............................................................................................................. 67
Remove .................................................................................................................................................. 67
Disassemble........................................................................................................................................... 67
Clean...................................................................................................................................................... 70
Inspect ................................................................................................................................................... 70
Assemble................................................................................................................................................ 70
Install..................................................................................................................................................... 70
Lift/Tilt Control Valve Section.................................................................................................................. 71
Remove .................................................................................................................................................. 71
Disassemble........................................................................................................................................... 71
Clean...................................................................................................................................................... 75
Inspect ................................................................................................................................................... 75
Assemble................................................................................................................................................ 77
Install..................................................................................................................................................... 78
Mid-Inlet Section ....................................................................................................................................... 78
Remove .................................................................................................................................................. 78
Clean...................................................................................................................................................... 79
Inspect ................................................................................................................................................... 79
Install..................................................................................................................................................... 79
Install ............................................................................................................................................................. 79
Pressure Relief Valve Check and Adjustment.................................................................................................. 85
Primary Relief Valve...................................................................................................................................... 85
Secondary Relief Valve .................................................................................................................................. 86
Steering Control Unit Repair ............................................................................................................................ 91
Steering Control Unit, Remove..................................................................................................................... 91
Steering Control Unit, Disassemble ............................................................................................................. 94
Steering Control Unit, Clean ........................................................................................................................ 94
Steering Control Unit, Inspect...................................................................................................................... 94
Steering Control Unit, Assemble .................................................................................................................. 94
Relief Valve, Disassemble.............................................................................................................................. 96
Relief Valve, Clean......................................................................................................................................... 96
Relief Valve, Inspect ...................................................................................................................................... 97
Relief Valve, Assemble................................................................................................................................... 97
Steering Control Unit, Install ....................................................................................................................... 97
ii
Main Control Valve Table of Contents

S50CT [A267];
H2.0-2.5CT (H50CT) [A274];
S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S120FTS; S120FTPRS ) [G004, H004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) [N005, P005, R005];
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
This section contains a description and repair pro-
cedures for both manual and electronic main control
valves used in the hydraulic system for this series of
lift trucks.
NOTE: Lift truck models S50CT (A267) and H2.0-

2.5CT (H50CT) (A274) are equipped only with a man-
ual main control valve.
There are two main control valves available for this

series of lift trucks. One is controlled manually (man-
ual main control valve) and the other is controlled
electronically (electro-hydraulic main control valve).
The main control valves are mounted to the cowl us-
ing three mounting bolts. See Figure 1.
NOTE: MAJOR COMPONENTS NOT SHOWN FOR

CLARITY. VIEW IS FROM THE FRONT OF LIFT
TRUCK.
1. COWL
2. INSERT
3. WASHER
4. MOUNTING CAPSCREW
5. MAIN CONTROL VALVE
6. FRAME
Figure 1. Main Control Valve Mounting,

Typical

Electro-Hydraulic Main Control Valve 2000 SRM 1137
Electro-Hydraulic Main Control Valve

DESCRIPTION • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
The E-Valve is an electronically-controlled, closed- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
center, load-sensing stack valve. It uses an un- • H2.0-3.5FT (H40-70FT) (L177)
loader valve (single functions only) and has parallel • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
hydraulic circuitry. Operating multiple functions 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
simultaneously will result in a non-proportionate • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
increase in pump flow to functions which receive (H80, 90, 100, 110, 120FT) (N005, P005, R005)
the lowest amount of pressurized fluid. A fixed
displacement pump is used in conjunction with the See Figure 7 for the following lift truck models
inlet compensator to achieve the required load-sense equipped with an E-Valve with an anti-stall solenoid
logic. Lift function is on main relief pressure setting. • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
Tilt and auxiliary functions are on secondary relief 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
pressure setting. Lift pressure is unaffected by • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
secondary relief operation. (H80, 90, 100, 110, 120FT) (N005, P005, R005)
The electronic main control valve incorporate an The electronic main control valve assembly with
emergency (manual) lowering valve. This valve fixed displacement pump is divided into the follow-
allows the operator or service technician to lower the ing sections
lift truck’s mast assembly if the electrical signal to • Steering Control Unit (SCU)
the electronic main control valve is disrupted. • Lift/Lower
• Tilt
See Figure 2 for the following lift truck models • Auxiliary
equipped with an E-Valve without an anti-stall port • Outlet
• S30FT, S35FT, S40FTS (E010) • Mid-Inlet* (Primary Pump Inlet)
H40FTS) (F001) See Figure 2 and Figure 6 for lift truck models
• H2.0-3.5FT (H40-70FT) (L177) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, H40FTS) (F001)
100FTBCS; S120FTS; S120FTPRS) (G004, H004) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT • H2.0-3.5FT (H40-70FT) (L177)
(H80, 90, 100, 110, 120FT) (N005, P005, R005) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
See Figure 3 for the following lift truck models with • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
an E-Valve without an anti-stall port (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
F024) See Figure 3 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, • S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
K006) F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
See Figure 4 for lift truck models below, equipped K006)
with anti-stall solenoid
• S6.0FT, S7.0FT (S135FT, S155FT) (E024) See Figure 4 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006) • S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
See Figure 5 for the following lift truck models
equipped with an E-Valve with an anti-stall plug See Figure 5 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299) H190FT) (A299, B299)

equipped with an E-Valve with an anti-stall plug
• S30FT, S35FT, S40FTS (E010)

2000 SRM 1137 Electro-Hydraulic Main Control Valve
See Figure 7 for lift truck models • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, H190FT) (A299, B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT See Figure 4 for lift truck models
(H80, 90, 100, 110, 120FT) (N005, P005, R005) • S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
*Mid-inlet (primary pump inlet) section is used only K006)
on the main control valve of lift truck models
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, See Figure 5 for lift truck models
F024) • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, H190FT) (A299, B299)
K006)
1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I SECTION

2. SCU MOUNTING CAPSCREW 8. AUXILIARY II SECTION
3. LIFT/LOWER SECTION 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
4. EMERGENCY LOWERING VALVE 10. OUTLET SECTION
5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 11. TILT SECTION
6. PROPORTIONAL PRESSURE REDUCING 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
VALVE (PPRV) 13. EF PORT
Figure 2. Electronic Control Valve Without Anti-Stall Port, 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, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004, H004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005)


3. MID-INLET SECTION (PRIMARY PUMP INLET) 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
4. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 10. OUTLET SECTION
(LIFT) 11. TILT SECTION
5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
(LOWER) 13. EMERGENCY LOWERING VALVE
6. PROPORTIONAL PRESSURE REDUCING 14. EF PORT
VALVE (PPRV) 15. LIFT/LOWER SECTION
Figure 3. Electronic Control Valve Without Anti-Stall Port, Lift Truck Models S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)

1. STEERING CONTROL UNIT (SCU) 7. TILT SECTION

2. SCU MOUNTING CAPSCREW 8. AUXILIARY I SECTION
(LIFT) 11. EF PORT
6. PROPORTIONAL PRESSURE REDUCING 14. ANTI-STALL SOLENOID
VALVE (PPRV)
Figure 4. Electronic Control Valve With Anti-Stall Solenoid, Lift Truck Models S6.0FT, S7.0FT
(S135FT, S155FT) (E024), and H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)


(LIFT) 12. EF PORT
6. PROPORTIONAL PRESSURE REDUCING 15. ANTI-STALL SOLENOID PORT
VALVE (PPRV) 16. ANTI-STALL PLUG
7. TILT SECTION 17. LIFT/LOWER SECTION
Figure 5. Electronic Control Valve With Anti-Stall Plug, Lift Truck Models H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)


3. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
(LIFT) 10. OUTLET SECTION
4. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 11. EF PORT
(LOWER) 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
5. PROPORTIONAL PRESSURE REDUCING 13. EMERGENCY LOWERING VALVE
VALVE (PPRV) 14. ANTI-STALL PLUG
6. TILT SECTION 15. ANTI-STALL SOLENOID PORT
Figure 6. Electronic Control Valve With Anti-Stall Plug, 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, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004, H004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005)

REMOVE NOTE: Most of the individual valve components can

be removed and replaced while the control valve is in-
WARNING stalled in the truck. Removal of the control valve for
repairs is normally only required to replace a valve
Lower carriage completely before working on
section, or to replace the O-rings between the sec-
control valve or hydraulic system. Do not work
tions.
under a raised carriage. Put mast in a verti-
cal position, with no forward or back tilt, and 1. Power wash the interior of the operator compart-
lower carriage completely before disconnect- ment to remove any dirt or debris.
ing any parts of hydraulic system. The mast
can lower suddenly and cause injury if the car- 2. Move truck to disassembly area and shut off en-
riage is not lowered. gine.

3. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
(LIFT) 10. OUTLET SECTION
4. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 11. EF PORT
(LOWER) 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
5. PROPORTIONAL PRESSURE REDUCING 13. EMERGENCY LOWERING VALVE
VALVE (PPRV) 14. ANTI-STALL SOLENOID
6. TILT SECTION
Figure 7. Electronic Control Valve With Anti-Stall Solenoid, Lift Truck Models S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)

the outside of the valve either by steam cleaning

WARNING or with cleaning solvent.
and cause skin irritation. When cleaning 5. To remove the accelerator pedal or
solvents are used, always follow the solvent MONOTROL® pedal assembly, disconnect
manufacturer’s recommended safety proce- the cowl wiring harness from the pedal assembly
dures. Wear protective goggles or a face shield wiring harness and remove three mounting
to prevent eye injuries. capscrews. See Figure 8.
NOTE: To aid in installation, tag all connectors prior

WARNING to disconnecting from the solenoids.
Be careful when cleaning with steam. Steam
can cause serious burns. Wear protective cloth- 6. Disconnect the cowl wiring harness connectors
ing, gloves, and eye protection. Never expose from the lift and lower Electro-Hydraulic Poppet
your skin to steam. Valve (EHPV) solenoids. Disconnect the cowl
wiring harness from the top auxiliary function
NOTE: Take all necessary steps to prevent debris, Proportional Pressure Reducing Valve (PPRV)
dust, or other contaminants from entering the valve solenoids. See Figure 9.
cavities, hydraulic lines, or replacement parts.
3. Remove the floor plate, kick panel, seal plate,

and dashboard. See one of the following service
manuals for your lift truck’s procedures.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)

• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299) NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
See Frame 100 SRM 1581 for lift truck models EVER, REMOVAL IS THE SAME.
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) 1. MOUNTING CAPSCREW
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 2. MONOTROL PEDAL ASSEMBLY
H175FT36, H190FT) (B299) 3. PEDAL ASSEMBLY WIRING HARNESS
4. Before disconnecting any hydraulic hoses or re- Figure 8. MONOTROL Pedal Removal
moving any parts from the control valve, clean

8. Remove the two SCU mounting capscrews and

CAUTION move the SCU approximately 1.3 cm (0.5 in.) to
To prevent any foreign matter from getting the left, and lower the SCU until the steering
into either the hydraulic hoses or the hy- shaft is disengaged. Remove the SCU from the
draulic control valve sections, all openings lift truck.
must have plugs or covers installed immedi-
ately after hoses are disconnected from the See Figure 2 and Figure 6 for lift truck models
control valve. This also applies if any other • S30FT, S35FT, S40FTS (E010)
items are removed from the control valve. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
NOTE: Lift truck models H2.0-3.5FT (H40-70FT) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(L177) may be equipped with an optional Quick- • H2.0-3.5FT (H40-70FT) (L177)
Lok™ hydraulic inlet hose and adapter between the • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
steering control unit and hydraulic gear pump. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
NOTE: To aid in correctly connecting hydraulic hoses • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
during installation, tag each hose prior to disconnect- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
ing from the control valve. R005)
7. Disconnect hydraulic hoses from the control See Figure 3 for lift truck models
valve. Install plugs or caps on all open hose ends • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
and control valve ports to prevent contamina- E024, F024)
tion. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, See Figure 4 for lift truck models
E024, F024) • S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H6.0FT, H7.0FT (H135FT, H155FT) (J006,
J006, K006) K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) See Figure 5 for the following lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
See Figure 10 for lift truck models H175FT36, H190FT) (A299, B299)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, See Figure 7 for the following lift truck models
H40FTS) (F001) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) S80, 100FTBCS; S120FTS; S120FTPRS)
• H2.0-3.5FT (H40-70FT) (L177) (G004, H004)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
S80, 100FTBCS; S120FTS; S120FTPRS) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
(G004, H004) R005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, 9. Remove and discard two O-rings located between
R005) the control valve and the SCU.

NOTE: HARNESS CONNECTORS FOR S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024), H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006), AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299,
B299) LIFT TRUCKS SHOWN. HARNESS CONNECTORS FOR ALL OTHER LIFT TRUCK MODELS COVERED
IN THIS SRM ARE SIMILAR.
1. LIFT ELECTRO-HYDRAULIC POPPET VALVE 6. MID INLET HOSE (MAIN PUMP HOSE)
(EHPV) HARNESS CONNECTOR 7. LIFT/LOWER HOSE
2. LOWER ELECTRO-HYDRAULIC POPPET VALVE 8. TILT HOSE
(EHPV) HARNESS CONNECTOR 9. AUXILIARY I HOSE
3. AUXILIARY FUNCTION PROPORTIONAL 10. AUXILIARY II HOSE
PRESSURE REDUCING VALVE (PPRV) 11. RETURN HOSE
HARNESS CONNECTOR 12. STEERING COLUMN
4. STEERING SYSTEM HOSES 13. STEERING CONTROL UNIT (SCU)
5. SECONDARY HYDRAULIC PUMP HOSE 14. SCU MOUNTING CAPSCREWS
Figure 9. Hydraulic Hose Removal and Harness Disconnection, Lift Truck Models S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024, F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)

NOTE: QUICK-LOK™ HYDRAULIC INLET HOSE AND ADAPTER NOT SHOWN.

1. STEERING SYSTEM HOSES 6. LIFT/LOWER HOSE
2. HYDRAULIC INLET HOSE 7. TILT HOSE
3. STEERING CONTROL UNIT (SCU) 8. AUXILIARY I HOSE
4. STEERING COLUMN 9. AUXILIARY II HOSE
5. SCU MOUNTING CAPSCREWS 10. RETURN HOSE
Figure 10. Hydraulic Hose Removal, 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, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005, R005)


WARNING • H8.0FT, H8.0FT9, H9.0FT (H170FT,
The main control valve weighs approximately H175FT36, H190FT) (A299, B299)
30.5 kg (67 lb). Use a lifting device capable of
lifting the main control valve to avoid the pos- See Figure 7 for the following lift truck models
sibility of injury to personnel. • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
10. Support the main control valve. Remove three (G004, H004)
mounting capscrews, washers, inserts, and the • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
main control valve from the lift truck. See Fig- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
ure 11. R005)
NOTE: To aid in installation, tag all connectors prior 12. Remove the main control valve from the lift
to disconnecting from the solenoids. truck.
11. Raise the main control valve approximately
25.4 cm (10 in.) to gain access to the lower tilt
and auxiliary function Proportional Pressure Re-
ducing Valve (PPRV) solenoids. Disconnect the
cowl harness from the lower tilt and auxiliary
function (PPRV) solenoids.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
1. COWL
See Figure 3 for lift truck models 2. INSERT
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 3. WASHER
E024, F024) 4. MOUNTING CAPSCREW
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 5. MAIN CONTROL VALVE
6. FRAME
J006, K006)
Figure 11. Main Control Valve Removal
• S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006,
K006)

ELECTRO-HYDRAULIC CONTROL VALVE NOTE: Note placement of backup rings and O-ring
SECTIONS prior to disassembly to aid in assembly.
General 2. Remove and discard two backup rings and one

O-ring from solenoid.
CAUTION 3. Remove the plug from the outlet control valve

While working on the electro-hydraulic control section and discard the O-ring. See Figure 13.
valve sections, place a cover over the remain-
4. If the secondary relief valve has been leaking,
ing sections of the control valve to prevent
remove it from the outlet control valve section.
the possibility of contaminants getting into
See Step 5 through Step 9 to disassemble the sec-
the control valve openings which could cause
ondary relief valve. See Figure 13.
damage to the control valve.
5. Remove the plug from the adjusting nut. Remove
CAUTION and discard the O-ring from the plug. Remove
If O-rings are to be replaced between two sec- and discard the backup rings and O-ring from the
tions that have a hydraulic oil leak, replace all adjusting nut. See Figure 13.
O-rings between all sections. This eliminates
the possibility of a subsequent oil leak or pos-
sible damage to another O-ring.
Disassemble the electro-hydraulic control valve only

as necessary for repairs. Most repairs to the control
valve will be for the replacement of O-rings to stop
leaks between sections.
Outlet Control Valve Section

Remove
1. Remove four nuts from the control valve tie rods.

See Figure 13.
2. Remove the outlet control valve section from the

four tie rods and discard 10 O-rings (item 13 in
Figure 15) from the auxiliary control valve sec-
tion.
Disassemble
NOTE: Perform Step 1 and Step 2 for lift truck models

listed below, equipped with anti-stall solenoid.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT 1. OUTLET CONTROL VALVE SECTION
(H80, 90, 100, 110, 120FT) (N005, P005, R005) 2. SOLENOID
3. ORIFICE DISK
• S6.0FT, S7.0FT (S135FT, S155FT) (E024) 4. CONNECTOR
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
Figure 12. Outlet Control Valve Section With
1. Remove solenoid and orifice disk from outlet con- Anti-Stall Solenoid
trol valve section. See Figure 12.

NOTE: SECONDARY RELIEF VALVE ASSEMBLY IS THE SAME FOR BOTH OUTLET SECTIONS COVERED IN
FIGURE 13.
A. OUTLET SECTION USED ON LIFT TRUCK MODEL COVERED IN THIS SERVICE MANUAL THAT ARE
EQUIPPED WITH AN ANTI-STALL PORT ON OUTLET SECTION.
B. OUTLET SECTION USED ON LIFT TRUCK MODELS, EXCEPT H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299), COVERED IN THIS SERVICE MANUAL THAT ARE NOT EQUIPPED
WITH AN ANTI-STALL PORT ON OUTLET SECTION.
1. O-RING 8. SPRING
2. PLUG 9. JAM NUT
3. OUTLET VALVE SECTION 10. ADJUSTING NUT
4. BACKUP RING 11. CONTROL VALVE TIE ROD
5. SECONDARY RELIEF VALVE PLUG 12. NUT
6. POPPET 13. ANTI-STALL PORT
7. WASHER 14. SECONDARY RELIEF VALVE ASSEMBLY
Figure 13. Outlet Control Valve Section

6. While holding the adjustment nut, loosen the jam NOTE: If the outlet control valve section is not to be
nut. reassembled immediately, coat surfaces with clean
hydraulic oil to prevent the possibility of rust. Cover
NOTE: While performing Step 7, count and note the the outlet control valve section with a clean, dry, lint-
number of turns used to remove the adjusting nut. free cloth to prevent the possibility of contaminants
entering the outlet control valve section.
7. Remove the adjusting nut and jam nut assembly
from the secondary relief valve plug and discard Assemble
the O-ring on the adjusting nut.
NOTE: Coat all backup rings and O-rings with a light
8. Remove the spring, washer, and poppet from the coat of clean hydraulic oil to make installation easier.
secondary relief valve plug.
NOTE: Perform Step 1 through Step 7 only if the sec-
9. Remove and discard the backup ring from the ondary relief valve was repaired.
1. Install a new backup ring on the secondary relief
Clean valve plug. See Figure 13.
WARNING 2. Install the poppet, washer, and spring into the

and can cause skin irritation. When using 3. Install a new O-ring on the adjusting nut, and in-
cleaning solvents, always follow the solvent stall the adjusting nut and jam nut assembly into
manufacturer’s recommended safety proce- the secondary relief valve plug using the same
dures. number of turns noted during disassembly.
WARNING 4. While holding the adjusting nut in place, tighten

Compressed air can move particles so they the jam nut to 24 ±3 N•m (18 ±2 lbf ft).
cause injury to the user or to other personnel. 5. Install a backup ring, O-ring, and backup ring
Make sure the path of the compressed air is into the adjusting nut.
gles or a face shield to prevent injury to the 6. Install a new O-ring onto the plug. Install the
eyes. plug into the adjusting nut.
1. If all components of the outlet control valve sec- 7. If removed, install secondary relief valve into
tion have been removed, clean the outlet control outlet control valve section. Tighten relief valve
valve section using cleaning solvent and dry us- plug to 45 N•m (33 lbf ft). See the section
ing compressed air. Pressure Relief Valve Check and Adjustment to
adjust the secondary relief valve and check the
2. If all components have not been removed, clean pressure.
the outlet control valve section using a lint-free
cloth. 8. Install new O-ring on plug and install in the out-
let valve section. See Figure 13.
Inspect
NOTE: Perform Step 9 and Step 10 for lift truck mod-
Inspect the outlet control valve section mating sur- els listed below, equipped with an anti-stall solenoid.
faces and the bore of the secondary relief valve, if re-
moved, for damage. If either the mating surface or • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
the secondary relief valve bore are damaged, replace (H80, 90, 100, 110, 120FT) (N005, P005, R005)
the outlet control valve section. • S6.0FT, S7.0FT, (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
If disassembled, inspect the components of the sec-
ondary relief valve. If any components other than 9. Install orifice disk into outlet control section as
O-rings, backup rings, and the spring are damaged, shown in Figure 14.
replace the secondary relief valve.

the tilt control valve will always have the anti-stall

valve installed as a part of that control valve section.
Remove
1. Remove the outlet control valve section. See Out-

let Control Valve Section, Remove.
NOTE: Step 2 and Step 3 are for a three-function con-

trol valve. If a four or five-function control valve is
being disassembled, go to Step 4.
NOTE: If lift truck is equipped with either an anti-

stall solenoid or plug in the anti-stall port on the out-
let section, there will not be an anti-stall valve in the
auxiliary control valve section that is next to the tilt
NOTE: CUTAWAY VIEW OF SOLENOID PORT control valve section.
SHOWN WITH ORIFICE DISK INSTALLED.
See Figure 4 for lift truck models below, equipped
1. ORIFICE DISK with anti-stall solenoid
Figure 14. Orifice Disk Placement • S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
NOTE: Make sure solenoid connector is oriented as
shown in Figure 12. See Figure 5 for the following lift truck models
10. Install new backup rings and O-ring onto sole- • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
noid as noted during disassembly. Install sole- H190FT) (A299, B299)
noid into outlet control valve section. See Fig-
ure 12. Tighten solenoid to 25.8 to 28.6 N•m (19 See Figure 6 for the following lift truck models
to 21 lbf ft). equipped with an E-Valve with an anti-stall plug
• S30FT, S35FT, S40FTS (E010)
Install • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
NOTE: Coat all O-rings with light coat of clean hy- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
draulic oil to make installation easier. • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
1. Install new O-rings (13, Figure 15) into the auxil- 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
iary valve section. Install the outlet control valve • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
section on the four tie rods. (H80, 90, 100, 110, 120FT) (N005, P005, R005)
2. Install the four nuts on the tie rods and tighten See Figure 7 for the following lift truck models
to 24 ±2 N•m (212 ±18 lbf in). equipped with an E-Valve with an anti-stall solenoid
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
Auxiliary Control Valve Sections 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
NOTE: There is the possibility of having two or three • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
auxiliary control valve sections depending upon how (H80, 90, 100, 110, 120FT) (N005, P005, R005)
many functions are on the lift truck. If the main con- 2. Remove the anti-stall valve from the auxiliary
trol valve is a four-function control valve, there will control valve section. See Figure 15. If the anti-
be two auxiliary control valve sections. If the main stall valve is to be repaired, go to Step 5 of the
control valve is a five-function control valve, there Disassemble procedure for the auxiliary control
will be three auxiliary control valve sections. valve section.
These sections are repaired the same way with one
exception. The auxiliary control valve section next to

Figure 15. Auxiliary I, II, and III Control Valve Sections, for All Lift Truck Models Except H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)

NOTE: IF LIFT TRUCK HAS AN E-HYDRAULIC CONTROL VALVE THAT IS NOT EQUIPPED WITH AN ANTI-STALL
PORT IN THE OUTLET SECTION, THEN THE AUXILIARY I CONTROL VALVE SECTION IS SHOWN IN ILLUS-
TRATION A AND THE OTHER AUXILIARY CONTROL VALVE SECTIONS SHOWN IN ILLUSTRATION B. IF LIFT
TRUCK IS EQUIPPED WITH AN E-HYDRAULIC CONTROL VALVE THAT DOES HAVE AN ANTI-STALL PORT IN
THE OUTLET SECTION, THEN THE AUXILIARY CONTROL VALVE SECTIONS ARE SHOWN IN ILLUSTRATION
B.
A. AUXILIARY I CONTROL VALVE SECTION (WITH ANTI-STALL VALVE)
B. AUXILIARY I, II AND III CONTROL VALVE SECTION (ANTI-STALL SOLENOID IN OUTLET SECTION)
1. PLUG 7. SPOOL
2. O-RING 8. POPPET
3. SPRING 9. AUXILIARY I CONTROL VALVE BODY
4. WASHER 10. BACKUP RING
5. SOCKET HEAD CAPSCREW 11. ANTI-STALL VALVE SLEEVE
6. PROPORTIONAL PRESSURE REDUCING 12. AUXILIARY II CONTROL VALVE BODY
VALVE (PPRV) 13. O-RING
3. Remove the auxiliary control valve section from NOTE: If lift truck is equipped with either an anti-
the four tie rods. Remove and discard O-rings stall solenoid or plug in the anti-stall port on the out-
from the side of tilt control valve section. let section, there will not be an anti-stall valve in the
auxiliary control valve section that is next to the tilt
See Figure 16 for lift truck models control valve section.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) See Figure 4 for lift truck models below, equipped
See Figure 18 for lift truck models • S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• S30FT, S35FT, S40FTS (E010) • H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
H40FTS) (F001) See Figure 5 for the following lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) equipped with an E-Valve with an anti-stall plug
• H2.0-3.5FT (H40-70FT) (L177) • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; H190FT) (A299, B299)
(G004, H004) See Figure 6 for the following lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- equipped with an E-Valve with an anti-stall plug
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
4. Remove the auxiliary III control valve section • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
from the four tie rods. Remove and discard • H2.0-3.5FT (H40-70FT) (L177)
O-rings (13, Figure 15, illustration B) from side • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
of the auxiliary II control valve section. Remove 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
the auxiliary II control valve section from the • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
four tie rods. Remove and discard O-rings (13, (H80, 90, 100, 110, 120FT) (N005, P005, R005)
Figure 15, illustration B) from side of the auxil-
iary I control valve section. See Figure 7 for the following lift truck models
equipped with an E-Valve with an anti-stall solenoid
NOTE: If working on lift truck model H8.0FT, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
(A299, B299) go to Step 6. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005)

Figure 16. Auxiliary Control Valve Sections, for Lift Truck Models H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299) With an E-Hydraulic Control Valve That is Equipped
With an Anti-Stall Port in the Outlet Section


A. AUXILIARY I CONTROL VALVE SECTION B. AUXILIARY II CONTROL VALVE SECTION
1. AUXILIARY I VALVE BODY 8. WASHER
2. AUXILIARY II VALVE BODY 9. CAPSCREW
3. PLUG 10. SOLENOID
4. POPPET - C.V. 11. SEALS
5. SPRING 12. O-RING
6. PLUG 13. SPOOL
7. SPRING
5. Remove the anti-stall valve from the auxiliary I • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
control valve section. If the anti-stall valve is • H2.0-3.5FT (H40-70FT) (L177)
to be repaired, go to Step 5 of the Disassemble • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
procedure for the auxiliary control valve section. 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
6. Remove the auxiliary I control valve section from (H80, 90, 100, 110, 120FT) (N005, P005, R005)
the four tie rods. Remove and discard O-rings • S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
from side of the tilt control valve section. F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 1. Remove four capscrews and two proportional
H40FTS) (F001) pressure reducing valves (PPRV) from the auxil-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) iary control valve section. Remove and discard
• H2.0-3.5FT (H40-70FT) (L177) the backup ring, two O-rings, backup ring, and
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; O-ring from each PPRV. See Figure 15.
(G004, H004) 2. Remove the plug, spring, washer, and spool from
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- the auxiliary control valve section. Discard the
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, O-ring on the plug. See Figure 15.
R005)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 3. Remove the plug, spring, and washer from the
E024, F024) auxiliary control valve section. Discard the
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, O-ring on the plug. See Figure 15.
J006, K006)
4. Remove two plugs, two springs, and two poppets
See Figure 16 for lift truck models from the auxiliary control valve. Discard one
• H8.0FT, H8.0FT9, H9.0FT (H170FT, O-ring from each plug. See Figure 15.
H175FT36, H190FT) (A299, B299)
Disassemble stall solenoid or plug in the anti-stall port on the out-
NOTE: Disassemble the auxiliary control valve auxiliary control valve section that is next to the tilt
section only as needed to accomplish the repairs re- control valve section.
quired. The disassemble procedures for the auxiliary
I, II, and III sections are the same. The auxiliary See Figure 4 for lift truck models below, equipped
I section is used in the procedures described below with anti-stall solenoid
because it contains the anti-stall valve. • S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
models See Figure 5 for the following lift truck models
• S30FT, S35FT, S40FTS (E010) equipped with an E-Valve with an anti-stall plug
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
(F001) H190FT) (A299, B299)

See Figure 6 for the following lift truck models NOTE: Note the orientation of the O-rings and
equipped with an E-Valve with an anti-stall plug backup rings for correct installation.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 7. Remove and discard two backup rings and two
H40FTS) (F001) O-rings from the anti-stall valve sleeve. See Fig-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) ure 17. To reassemble the anti-stall sleeve valve,
• H2.0-3.5FT (H40-70FT) (L177) see Step 5 of the assembly procedure.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
truck model H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
H175FT36, H190FT) (A299, B299).
(H80, 90, 100, 110, 120FT) (N005, P005, R005)
8. Remove four capscrews and two solenoids from
auxiliary II control valve section. See Figure 16.
equipped with an E-Valve with an anti-stall solenoid
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 9. Remove plug, spring, washer, and spool from aux-
100FTBCS; S120FTS; S120FTPRS) (G004, H004) iliary II control valve section. Remove and dis-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT card O-ring from plug. See Figure 16.
(H80, 90, 100, 110, 120FT) (N005, P005, R005)
10. Remove plug from top of auxiliary II control valve
5. Remove spring from the large end of the anti- section. Remove and discard O-ring from plug.
stall valve sleeve. See Figure 17. See Figure 16.
6. Remove the spool from the small end of the anti- 11. Remove plug, spring, and poppet-c.v. from bot-
stall valve sleeve. See Figure 17. tom of auxiliary II control valve section. Remove
and discard O-ring from plug. See Figure 16.

auxiliary I control valve section. See Figure 16.
NOTE: Note placement of seals during disassembly

to aid in assembly.
13. Remove and discard seals from solenoids, if

present. See Figure 16.
14. Remove plug, spring, washer, and spool from aux-

iliary I control valve section. Remove and discard
O-ring from plug. See Figure 16.
15. Remove plug from top of auxiliary I control valve

section. Remove and discard O-ring from plug.
1. SPOOL See Figure 16.
2. BACKUP RING
3. O-RING 16. Remove plug, spring, and poppet-c.v. from bot-
4. ANTI-STALL VALVE SLEEVE tom of auxiliary I control valve section. Remove
5. SPRING and discard O-ring from plug. See Figure 16.
Figure 17. Anti-Stall Valve

Clean Assemble

WARNING models
Cleaning solvents can be flammable and toxic • S30FT, S35FT, S40FTS (E010)
and can cause skin irritation. When using • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
cleaning solvents, always follow the solvent (F001)
manufacturer’s recommended safety proce- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
dures. • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
Compressed air can move particles so they • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
cause injury to the user or to other personnel. (H80, 90, 100, 110, 120FT) (N005, P005, R005)
Make sure the path of the compressed air is • S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
away from all personnel. Wear protective gog- F024)
gles or a face shield to prevent injury to the • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
eyes. K006)
1. If all components of the auxiliary control valve NOTE: Coat all backup rings and O-rings with a light
section have been removed, clean the auxiliary coat of clean hydraulic oil to make installation easier.
control valve section and components, except the
two PPRVs, using cleaning solvent and dry using NOTE: The assembly procedures for the auxiliary I,
compressed air. II, and III sections are the same. The auxiliary I
section is used in the procedures described below be-
2. If all components have not been removed, clean cause it contains the anti-stall valve.
the auxiliary control valve section using a lint-
free cloth. NOTE: If lift truck is equipped with either an anti-
3. If the anti-stall valve was disassembled, clean let section, there will not be an anti-stall valve in the
the spool, anti-stall valve sleeve, and spring with auxiliary control valve section that is next to the tilt
cleaning solvent. Dry with a lint-free cloth. control valve section.
Inspect See Figure 4 for lift truck models below, equipped

Inspect the auxiliary control valve section mating • S6.0FT, S7.0FT (S135FT, S155FT) (E024)
surfaces and any open bores for damage. If damage • H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
is found, replace the auxiliary control valve section.
If the spool has been removed, inspect the spool and See Figure 5 for the following lift truck models
the bore for damage. If damage to either the spool or equipped with an E-Valve with an anti-stall plug
the bore is found, replace the auxiliary control valve • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
section. H190FT) (A299, B299)
If the anti-stall valve was disassembled, inspect the See Figure 6 for the following lift truck models
spool, anti-stall valve sleeve, and spring for damage. equipped with an E-Valve with an anti-stall plug
If the spring is damaged, replace the spring. If the • S30FT, S35FT, S40FTS (E010)
spool or anti-stall valve sleeve is damaged, replace • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
the anti-stall valve assembly. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
NOTE: If the auxiliary control valve section is not to • H2.0-3.5FT (H40-70FT) (L177)
be reassembled immediately, coat surfaces with clean • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
hydraulic oil to prevent the possibility of rust. Cover 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
the auxiliary control valve section with a clean, dry, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
lint-free cloth to prevent the possibility of contami- (H80, 90, 100, 110, 120FT) (N005, P005, R005)
nants entering the auxiliary control valve section.

See Figure 7 for the following lift truck models See Figure 7 for the following lift truck models
equipped with an E-Valve with an anti-stall solenoid equipped with an E-Valve with an anti-stall solenoid
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004, H004) 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
1. Install the spool, washer, spring, and plug, with 5. Install two backup rings and two O-rings on the
new O-ring, into the bore of the auxiliary control anti-stall valve sleeve as noted during disassem-
valve section. Tighten the plug to 14 ±1 N•m bly. See Figure 17.
(120 ±12 lbf in). See Figure 15.
6. Install the spool in the small end of the anti-stall
2. Install the washer, spring, and plug, with new valve sleeve. See Figure 17.
O-ring, into the auxiliary control valve section.
See Figure 15. Tighten the plug to 14 ±1 N•m 7. Install the spring in the large end of the anti-stall
(120 ±12 lbf in). valve sleeve. See Figure 17.
3. Install two poppets, two springs, and two plugs, NOTE: Perform Step 8 through Step 12 for lift
with new O-rings installed, into the auxiliary truck model H8.0FT, H8.0FT9, H9.0FT (H170FT,
control valve section. See Figure 15. Tighten the H175FT36, H190FT) (A299, B299).
plugs to 81 ±8 N•m (60 ±6 lbf ft).
8. Install new O-ring onto plug. Install poppet-c.v.
4. Install the new O-ring, backup ring, two O-rings, spring, and plug into bottom of auxiliary control
and backup ring on each PPRV. Install two valve section. See Figure 16.
PPRVs and four capscrews into the auxiliary
9. Install new O-ring onto plug. Install plug into top
control valve section. See Figure 15. Tighten the
of auxiliary control valve section. See Figure 16.
capscrews to 3 ±0.3 N•m (24 ±2 lbf in).
10. Install new O-ring onto plug. Install spool,
washer, spring, and plug into auxiliary control
valve section. See Figure 16.
auxiliary control valve section that is next to the tilt 11. Install new seals onto solenoids as noted during
control valve section. disassembly. See Figure 16.
See Figure 4 for lift truck models below, equipped 12. Install two solenoids and four capscrews onto
with anti-stall solenoid auxiliary control valve section. See Figure 16.
• S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006) Install
See Figure 5 for the following lift truck models NOTE: Step 1 through Step 3 are for a three-function
equipped with an E-Valve with an anti-stall plug control valve. Step 4 through Step 7 are for a four
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, and five-function control valves.
H190FT) (A299, B299)
1. Install new O-rings into the side of tilt control
See Figure 6 for the following lift truck models valve section. Install the auxiliary I control valve
equipped with an E-Valve with an anti-stall plug section on the four tie rods. See Figure 18.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, NOTE: If lift truck is equipped with either an anti-
H40FTS) (F001) stall solenoid or plug in the anti-stall port on the out-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) let section, there will not be an anti-stall valve in the
• H2.0-3.5FT (H40-70FT) (L177) auxiliary control valve section that is next to the tilt
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, control valve section.
(H80, 90, 100, 110, 120FT) (N005, P005, R005)

See Figure 4 for lift truck models below, equipped Tilt Control Valve Section
• S6.0FT, S7.0FT (S135FT, S155FT) (E024) Remove
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
See Figure 5 for the following lift truck models let Control Valve Section, Remove.
2. Remove the auxiliary control valve section. See
Auxiliary Control Valve Sections, Remove.
H190FT) (A299, B299)
3. Remove the tilt control valve section from the lift/
lower control valve section.
• S30FT, S35FT, S40FTS (E010) 4. Remove and discard O-rings from the side of lift/
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, lower control valve section.
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • S30FT, S35FT, S40FTS (E010)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
100FTBCS; S120FTS; S120FTPRS) (G004, H004) H40FTS) (F001)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(H80, 90, 100, 110, 120FT) (N005, P005, R005) • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
See Figure 7 for the following lift truck models S80, 100FTBCS; S120FTS; S120FTPRS)
equipped with an E-Valve with an anti-stall solenoid (G004, H004)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004, H004) See Figure 22 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
(H80, 90, 100, 110, 120FT) (N005, P005, R005) E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
2. Install the anti-stall valve into the auxiliary I J006, K006)
control valve section. See Figure 15. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
3. Install the outlet control valve section. See Out-
R005)
let Control Valve Section, Install.
Disassemble
4. Install new O-rings into the side of tilt control
valve section. Install the auxiliary I control valve NOTE: Disassemble the tilt control valve section only
section on the four tie rods. See Figure 18. as needed to accomplish the repairs required.
5. Install the anti-stall valve into the auxiliary I NOTE: Perform Step 1 for lift truck models
control valve section. Install new O-rings into • S30FT, S35FT, S40FTS (E010)
the side of auxiliary I control valve section. See • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
Figure 15. (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
6. Install the auxiliary II control valve section on
• H2.0-3.5FT (H40-70FT) (L177)
the four tie rods. Install new O-rings into the side
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
of auxiliary II control valve section.
7. Install the outlet control valve section. See Out- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
let Control Valve Section, Install. (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006)

1. Remove four socket head capscrews and two pro- See Figure 20 for lift truck models
portional pressure-reducing valves (PPRV) from • H8.0FT, H8.0FT9, H9.0FT (H170FT,
the tilt control valve section. H175FT36, H190FT) (A299, B299)
See Figure 18 for lift truck models 5. Remove the socket head capscrew, spring and pis-
• S30FT, S35FT, S40FTS (E010) ton from the spool for lift truck models
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • S30FT, S35FT, S40FTS (E010)
H40FTS) (F001) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • H2.0-3.5FT (H40-70FT) (L177)
S80, 100FTBCS; S120FTS; S120FTPRS) • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
(G004, H004) S80, 100FTBCS; S120FTS; S120FTPRS)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- (G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
R005) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 6. Remove the plug, spring, and washer from the
E024, F024) tilt control valve section. Discard the O-ring on
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, the plug.
J006, K006)
2. Remove and discard the backup ring, two • S30FT, S35FT, S40FTS (E010)
O-rings, backup ring, and O-ring from each • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
PPRV. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
NOTE: Perform Step 3 for lift truck model • H2.0-3.5FT (H40-70FT) (L177)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
H190FT) (A299, B299) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
tilt control valve section. See Figure 20.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
4. Remove the plug, spring, washer, and spool from R005)
the tilt control valve section. Discard the O-ring
on the plug.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
See Figure 18 for lift truck models E024, F024)
• S30FT, S35FT, S40FTS (E010) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, J006, K006)
H40FTS) (F001)
• 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, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) 7. Remove two plugs, two springs, and two poppets
(G004, H004) from the tilt control valve section. Discard one
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- O-ring from each plug.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) See Figure 18 for lift truck models
• S30FT, S35FT, S40FTS (E010)
See Figure 19 for lift truck models • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, H40FTS) (F001)
E024, F024) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H2.0-3.5FT (H40-70FT) (L177)
J006, K006)

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
S80, 100FTBCS; S120FTS; S120FTPRS) J006, K006)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- See Figure 20 for lift truck models
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
R005) H175FT36, H190FT) (A299, B299)

• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
1. PLUG 8. TILT CONTROL VALVE BODY

2. O-RING 9. SETSCREW
3. SPRING 10. POPPET
5. SOCKET HEAD CAPSCREW 12. SPOOL
6. PISTON
7. PROPORTIONAL PRESSURE-REDUCING
VALVE (PPRV)
Figure 18. Tilt Control Valve Section, Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT,
120FT) (N005, P005, R005)

1. PLUG 7. TILT CONTROL VALVE BODY

2. O-RING 8. SETSCREW
3. SPRING 9. POPPET
5. SOCKET HEAD CAPSCREW 11. SPOOL
6. PROPORTIONAL PRESSURE-REDUCING
VALVE (PPRV)
Figure 19. Tilt Control Valve Section, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)

1. TILT CONTROL VALVE SECTION 7. SPRING

2. PLUG 8. WASHER
3. SPRING 9. CAPSCREW
4. POPPET-C.V. 10. SOLENOID
5. O-RING 11. SEAL
6. PLUG 12. SPOOL
Figure 20. Tilt Control Valve Section, Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

Clean • H2.0-3.5FT (H40-70FT) (L177)

• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
WARNING 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)
dures. 2. Install the spool, washer, spring, and plug, with
new O-ring, into the bore of the tilt control valve
WARNING section. Tighten the plug to 14 ±1 N•m (120
Compressed air can move particles so they ±12 lbf in).
Make sure the path of the compressed air is 3. Install the washer, spring, and plug, with new
away from all personnel. Wear protective gog- O-ring, into the tilt control valve section. Tighten
gles or a face shield to prevent injury to the the plug to 14 ±1 N•m (120 ±12 lbf in).
eyes. 4. Install two poppets, two springs, and two plugs,
1. If all components of the tilt control valve section with new O-rings installed, into the tilt control
have been removed, clean the tilt control valve valve section. Tighten the plugs to 81 ±8 N•m
section and components, except the two PPRVs, (60 ±6 lbf ft).
using cleaning solvent and dry using compressed See Figure 18 for lift truck models
air. • S30FT, S35FT, S40FTS (E010)
2. If not all components have been removed, clean • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
the tilt control valve section using a lint-free H40FTS) (F001)
cloth. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
Inspect • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Inspect the tilt control valve section mating surfaces (G004, H004)
and any open bores for damage. If damage is found, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
replace the tilt control valve section. If the spool has 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
been removed, inspect the spool and the bore for the R005)
spool for damage. If damage to either the spool or the
bore is found, replace the tilt control valve section. See Figure 19 for lift truck models
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
NOTE: If the tilt control valve section is not to be E024, F024)
reassembled immediately, coat surfaces with clean • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
hydraulic oil to prevent the possibility of rust. Cover J006, K006)
the tilt control valve section with a clean, dry, lint-
free cloth to prevent the possibility of contaminants See Figure 20 for lift truck models
entering the tilt control valve section. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Assemble
NOTE: Perform Step 5 for lift truck models.
NOTE: Coat all backup rings and O-rings with a light • S30FT, S35FT, S40FTS (E010)
coat of clean hydraulic oil to make installation easier. • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001)
1. Install the piston, spring, and socket head cap- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
screw in the spool for lift truck models listed be- • H2.0-3.5FT (H40-70FT) (L177)
low. See Figure 18. • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
• S30FT, S35FT, S40FTS (E010) 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
H40FTS) (F001) (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)

• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, 4. Install the outlet control valve section. See Out-
F024) let Control Valve Section, Install.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006) Lift/Lower Control Valve Section
5. Install the new O-ring, backup ring, two O-rings, Remove
and backup ring on each PPRV. Install two
PPRVs and four capscrews into the tilt con- 1. Remove the outlet control valve. See Outlet Con-
trol valve section. Tighten the capscrews to 3 trol Valve Section, Remove.
±0.3 N•m (24 ±2 lbf in).
2. Remove the auxiliary control valve section(s).
NOTE: Perform Step 6 for lift truck model H8.0FT, See Auxiliary Control Valve Sections Remove.
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
3. Remove the tilt control valve section. See Tilt
(A299, B299).
Control Valve Section, Remove.
6. Install two solenoids and four capscrews onto tilt
Disassemble
control valve section. See Figure 20.
NOTE: Disassemble the lift/lower control valve
Install
section only as needed to accomplish the repairs
1. Install new O-rings on the side of lift/lower con- required.
trol valve section.
1. Remove four tie rods from the lift/lower control
See Figure 21 for lift truck models valve section.
• S30FT, S35FT, S40FTS (E010)
2. Remove coil nut and coil from the lift electro-hy-
draulic poppet valve (EHPV).
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • S30FT, S35FT, S40FTS (E010)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
S80, 100FTBCS; S120FTS; S120FTPRS) H40FTS) (F001)
(G004, H004) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
(G004, H004)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) See Figure 22 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, E024, F024)
R005) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
2. Install the tilt control valve section on the lift/
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
3. Install the auxiliary control valve section. See R005)
Auxiliary Control Valve Sections, Install.

1. LOCK NUT 13. SETSCREW

2. ADJUSTING SCREW 14. SHUTTLE
3. O-RING 15. POPPET
4. SPRING 16. LIFT POPPET
5. PISTON 17. SOLENOID TUBE
6. PRIMARY RELIEF VALVE CARTRIDGE 18. COIL
7. BACKUP RING 19. COIL NUT
8. SPOOL 20. LOWER POPPET
9. LIFT/LOWER CONTROL VALVE SECTION 21. SLEEVE ASSEMBLY
10. SOCKET HEAD PLUG 22. LIFT POPPET VALVE ASSEMBLY
11. EMERGENCY LOWERING VALVE 23. LOWER POPPET VALVE ASSEMBLY
12. PLUG 24. PILOT PIN
Figure 21. Lift/Lower Control Valve Section, 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) and S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004, H004),


2. ADJUSTING SCREW 14. SHUTTLE
Figure 22. Lift/Lower Control Valve Section, For Lift Truck Models S6.0FT, S7.0FT (S135FT,
S155FT) (D024, E024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)


2. ADJUSTING NUT 14. SHUTTLE
Figure 23. Lift/Lower Control Valve Section, For Lift Truck Model H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)

3. Using special socket (Hyster P/N 1585481), re- NOTE: The lower poppet valve assembly is approx-
move the lift solenoid tube assembly from lift/ imately 7 mm (0.28 in.) longer than the lift poppet
lower control valve section. Take care to pull the valve assembly.
tube assembly straight out so that the pilot pin
does not get damaged. 5. Remove the lift poppet assembly from the lift/
• S30FT, S35FT, S40FTS (E010) See Figure 21 for lift truck models
H40FTS) (F001) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
S80, 100FTBCS; S120FTS; S120FTPRS) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
E024, F024) • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, E024, F024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- J006, K006)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
R005) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, See Figure 23 for lift truck models
H175FT36, H190FT) (A299, B299)
4. Remove the spring from the poppet assembly un-
less it came out with the solenoid tube assembly 6. Repeat Step 2 through Step 5 for the lower
in which case remove it from the solenoid tube EHPV. After completing Step 5, remove the
assembly. sleeve assembly from lower control valve sec-
tion.
• S30FT, S35FT, S40FTS (E010) See Figure 21 for lift truck models
(G004, H004)
E024, F024) • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- J006, K006)
R005) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

See Figure 23 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
H175FT36, H190FT) (A299, B299) R005)

CAUTION • H8.0FT, H8.0FT9, H9.0FT (H170FT,
Use care, when removing the emergency low- H175FT36, H190FT) (A299, B299)
ering valve, not to damage the tip of the emer-
gency lowering valve. 9. Remove the socket head plug from the lift/lower
control valve section. Remove and discard the
7. Remove the emergency lowering valve from the O-ring.
lift/lower control valve section. Remove and dis-
card the O-ring. See Figure 21 for lift truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001) • H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H2.0-3.5FT (H40-70FT) (L177) S80, 100FTBCS; S120FTS; S120FTPRS)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; (G004, H004)
(G004, H004) See Figure 22 for lift truck models
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
E024, F024) J006, K006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
J006, K006) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- R005)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) See Figure 23 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) 10. Remove the socket head plug, spring, and poppet
from the lift/lower control valve section. Remove
8. Remove the plug from the lift/lower control valve and discard the O-ring.
section. Remove and discard the O-ring.
See Figure 21 for lift truck models • S30FT, S35FT, S40FTS (E010)
• H2.0-3.5FT (H40-70FT) (L177) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
(G004, H004)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, F024)
E024, F024) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
J006, K006)

R005) H175FT36, H190FT) (A299, B299)
See Figure 23 for lift truck models NOTE: Step 13 through Step 16 are for the disassem-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, bly of the primary relief valve.
H175FT36, H190FT) (A299, B299)
13. While holding the adjustment screw in place,
11. Remove the shuttle and setscrew from the lift/ loosen the lock nut.
(G004, H004)
J006, K006) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (A299, B299)
NOTE: While performing Step 14, count and note the
12. Remove the primary relief valve, spring, and number of turns used to remove the adjusting screw.
spool from the lift/lower control valve section.
14. Remove the adjusting screw from the primary re-
See Figure 21 for lift truck models lief valve. Remove and discard the O-ring on the
• S30FT, S35FT, S40FTS (E010) adjusting screw.
H40FTS) (F001) See Figure 21 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; H40FTS) (F001)
S80, 100FTBCS; S120FTS; S120FTPRS) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(G004, H004) • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
See Figure 22 for lift truck models S80, 100FTBCS; S120FTS; S120FTPRS)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, (G004, H004)
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, See Figure 22 for lift truck models
J006, K006) • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- E024, F024)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
R005) J006, K006)

R005) H175FT36, H190FT) (A299, B299)
See Figure 23 for lift truck models Clean

• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) WARNING
15. Remove the spring and piston from the primary Cleaning solvents can be flammable and toxic
relief valve. and can cause skin irritation. When using
See Figure 21 for lift truck models manufacturer’s recommended safety proce-
• S30FT, S35FT, S40FTS (E010) dures.
H40FTS) (F001) WARNING
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) Compressed air can move particles so they
• H2.0-3.5FT (H40-70FT) (L177) cause injury to the user or to other personnel.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; Make sure the path of the compressed air is
S80, 100FTBCS; S120FTS; S120FTPRS) away from all personnel. Wear protective gog-
(G004, H004) gles or a face shield to prevent injury to the
See Figure 22 for lift truck models eyes.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 1. If all components of the lift/lower control valve
E024, F024) section have been removed, clean the lift/lower
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, control valve section and components, except the
J006, K006) two PPRVs, using cleaning solvent and dry using
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- compressed air.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) 2. If not all components have been removed, clean
the lift/lower control valve section using a lint-
See Figure 23 for lift truck models free cloth.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) Inspect
16. Remove and discard the small O-ring, backup Inspect the lift/lower control valve section mating
ring, and large O-ring from the primary relief surfaces and any open bores for damage. If damage
valve. is found, replace the lift/lower control valve section.
If the spool has been removed, inspect the spool and
See Figure 21 for lift truck models the bore for the spool for damage. If damage to either
• S30FT, S35FT, S40FTS (E010) the spool or the bore is found, replace the lift/lower
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, control valve section.
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) If disassembled, inspect the components of the pri-
• H2.0-3.5FT (H40-70FT) (L177) mary relief valve. If any components other than
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; O-rings, backup rings, and the spring are damaged,
S80, 100FTBCS; S120FTS; S120FTPRS) replace the primary relief valve.
(G004, H004)
NOTE: If the lift/lower control valve section is not to
See Figure 22 for lift truck models be reassembled immediately, coat surfaces with clean
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, hydraulic oil to prevent the possibility of rust. Cover
E024, F024) the lift/lower control valve section with a clean, dry,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, lint-free cloth to prevent the possibility of contami-
J006, K006) nants entering the lift/lower control valve section.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

Assemble • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-

5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
NOTE: Step 1 through Step 6 are for the assembly R005)
of the primary relief valve, if disassembled. If the
primary relief valve has not been disassembled, go See Figure 23 for lift truck models
to Step 6. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
coat of clean hydraulic oil to make installation easier. 3. Install a new O-ring on the adjusting screw, and
install the adjusting screw into the primary re-
1. Install the new large O-ring on the primary relief valve the number of turns noted during dis-
lief valve. Install the new backup ring and small assembly.
O-ring on the primary relief valve.
(G004, H004)
J006, K006) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
H175FT36, H190FT) (A299, B299)
4. Install the lock nut onto the adjusting screw
2. Install the piston and spring into the primary while holding the adjustment screw so that it
relief valve. will not turn. Tighten the lock nut to 9 ±1 N•m
(84 ±12 lbf in).
• S30FT, S35FT, S40FTS (E010) 5. Install the spool, spring, and primary relief
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, valve into the lift/lower control valve section.
H40FTS) (F001) Tighten the primary relief valve to 65 ±7 N•m
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (48 ±5 lbf ft).
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 6. Install the shuttle and setscrew into the body of
S80, 100FTBCS; S120FTS; S120FTPRS) the lift/lower control valve section. Tighten the
(G004, H004) setscrew to 4 ±0.6 N•m (36 ±6 lbf in). See the
section Pressure Relief Valve Check and Adjust-
See Figure 22 for lift truck models ment to adjust the primary relief valve and check
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, the pressure.
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 7. Install plug with new O-ring installed into the
J006, K006) lift/lower control valve section. Tighten the plug
to 45 ±5 N•m (33 ±4 lbf ft).

8. Install poppet, spring, and socket head plug with Mid-Inlet Section
new O-ring installed, into the lift/lower control
valve section. Tighten the plug to 65 ±7 N•m (48 Remove
±5 lbf ft).
NOTE: The mid-inlet section is used only on lift truck
9. Install the emergency lowering valve, with a new models
O-ring installed, into the lift/lower control valve • S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
section. Tighten to 14 ±1 N•m (120 ±12 lbf in). F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
NOTE: Ensure that the correct poppet is being in- K006)
stalled in the proper position. The lower poppet valve • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
assembly is approximately 7 mm (0.28 in.) longer H190FT) (A299, B299)
than the lift poppet valve assembly.
Remove the mid-inlet section only as necessary for
10. Install the lift poppet into the lift/lower control repair. Most repairs to the mid-inlet section will be
valve section until the poppet "bottoms out." for the replacement of O-rings to stop leaks. There
are no disassembly or assembly procedures for the
11. Install the spring onto the solenoid tube. mid-inlet section.
12. Install the solenoid tube into the lift/lower con- 1. Remove three socket head capscrews and wash-
trol valve section. Tighten to 100 ±11 N•m (74 ers that secure the mid-inlet section to the lift/
±8 lbf ft). lower section. See Figure 24.
13. Install the coil and coil nut on the solenoid tube. 2. Remove mid-inlet section from the lift/lower sec-
Tighten the coil nut to 2.3 N•m (20 lbf in). tion. Discard O-rings.
14. Repeat Step 10 through Step 13 for the lower 3. Remove socket head plug and discard O-ring.
EHPV. Before installing the lower poppet into
the lower control valve section in Step 10, in-
stall sleeve assembly into the lift/lower control
valve section first. Tighten sleeve assembly to
122 ±12 N•m (90 ±9 lbf ft).
Install
1. Install four tie rods into the lift/lower control

valve section. Tighten nuts to 24 ±2 N•m (212
±18 lbf in).
2. Install the tilt control valve section. See Tilt Con-

trol Valve Section, Install.
3. Install the auxiliary control valve section. See

4. Install the outlet control valve section. See Out- 1. MID-INLET SECTION
2. SOCKET HEAD PLUG
let Control Valve Section, Install. 3. O-RING
5. WASHER
Figure 24. Mid-Inlet Section

Clean INSTALL
WARNING WARNING
Cleaning solvents can be flammable and toxic The main control valve weighs approximately
and can cause skin irritation. When using 30.5 kg (67 lb). Use a lifting device capable of
cleaning solvents, always follow the solvent lifting the main control valve, to avoid the pos-
manufacturer’s recommended safety proce- sibility of injury to personnel.
dures.
1. Lower the control valve enough to allow the
cowl wiring harness to be connected to the lower
WARNING
PPRV solenoid connectors as noted during re-
Compressed air can move particles so they moval. See Figure 27.
Make sure the path of the compressed air is 2. Install three inserts into holes on cowl where
away from all personnel. Wear protective gog- the control valve will be mounted. While sup-
gles or a face shield to prevent injury to the porting the main control valve in place on the
eyes. cowl, install three mounting capscrews and
washers through the front of the cowl into the
Clean the mid-inlet control valve section using clean- control valve. Tighten the capscrews to 19 N•m
ing solvent and dry using compressed air. (14 lbf ft). See Figure 25.
Inspect 3. Coat new O-rings with clean hydraulic oil. In-
stall O-rings between control valve section and
Inspect the mid-inlet control valve section and mat-
SCU.
ing surfaces. If either the mating surfaces or mid-in-
let control valve section are damaged, replace the
mid-inlet control valve section.
Install
NOTE: If the mid-inlet control valve section is not to

be installed immediately, coat surfaces with clean hy-
draulic oil to prevent the possibility of rust. Cover
the mid-inlet control valve section with a clean, dry,
lint-free cloth to prevent the possibility of contami-
nants entering the mid-inlet control valve section.
NOTE: Coat all O-rings with a light coat of clean hy-

draulic oil to make installation easier.
1. Install new O-ring on socket head plug. Install

socket head plug into mid-inlet section. See Fig-
ure 24.
2. Install new O-rings on mating surfaces of mid-

inlet section. 1. COWL
2. INSERT
3. Install mid-inlet section to lift/lower section 3. WASHER
using three socket head capscrews and wash- 4. MOUNTING CAPSCREW
ers. Tighten capscrews to 45 to 55 N•m (33 to 5. MAIN CONTROL VALVE
41 lbf ft). 6. FRAME
Figure 25. Main Control Valve Installation

4. Position the SCU under the steering shaft and • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
raise the SCU to engage the steering shaft. 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
When the steering shaft is completely engaged, R005)
position the SCU against the main control valve,
and install two mounting capscrews and wash- See Figure 27 for lift truck models
ers. Tighten to 45 to 55 N•m (33 to 41 lbf ft). • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
See Figure 26 for lift truck models • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• S30FT, S35FT, S40FTS (E010) J006, K006)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H40FTS) (F001) H175FT36, H190FT) (A299, B299)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
Figure 26. Hydraulic Hose Installation, Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT,
120FT) (N005, P005, R005)


1. STEERING SYSTEM HOSES 4. STEERING COLUMN 7. TILT HOSE
2. HYDRAULIC INLET HOSE 5. SCU MOUNTING 8. AUXILIARY I HOSE
3. STEERING CONTROL UNIT CAPSCREWS 9. AUXILIARY II HOSE
(SCU) 6. LIFT/LOWER HOSE 10. RETURN HOSE
NOTE: HARNESS CONNECTORS FOR S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024), H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006), AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299,
B299) LIFT TRUCKS SHOWN. HARNESS CONNECTORS FOR ALL OTHER LIFT TRUCK MODELS COVERED
IN THIS SRM ARE SIMILAR.
1. LIFT ELECTRO-HYDRAULIC POPPET VALVE 6. MID INLET HOSE (MAIN PUMP HOSE)
(EHPV) HARNESS CONNECTOR 7. LIFT/LOWER HOSE
2. LOWER ELECTRO-HYDRAULIC POPPET VALVE 8. TILT HOSE
(EHPV) HARNESS CONNECTOR 9. AUXILIARY I HOSE
3. AUXILIARY FUNCTION PROPORTIONAL 10. AUXILIARY II HOSE
PRESSURE REDUCING VALVE (PPRV) 11. RETURN HOSE
HARNESS CONNECTOR 12. STEERING COLUMN
4. STEERING SYSTEM HOSES 13. STEERING CONTROL UNIT (SCU)
5. SECONDARY HYDRAULIC PUMP HOSE 14. SCU MOUNTING CAPSCREWS
Figure 27. Hydraulic Hose Installation and Harness Connection, Lift Truck Models S6.0FT, S7.0FT
(S135FT, S155FT) (D024, E024, F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)

NOTE: Lift truck models H2.0-3.5FT (H40-70FT) See Frame 100 SRM 1243 for lift truck models
(L177) may be equipped with an optional Quick- • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
Lok™ hydraulic inlet hose and adapter between the S80, 100FTBCS; S120FTS; S120FTPRS)
steering control unit and hydraulic gear pump. (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5. Remove all caps and plugs from the control valve 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
and hose fittings. Connect hydraulic hoses to the R005)
control valve as noted during removal.
• S30FT, S35FT, S40FTS (E010) E024, F024)
H40FTS) (F001) See Frame 100 SRM 1321 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H2.0-3.5FT (H40-70FT) (L177) J006)
S80, 100FTBCS; S120FTS; S120FTPRS) H175FT36, H190FT) (A299)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
6. Connect the cowl wiring harness to the top PPRV

solenoids and the lift/lower EHPV solenoids as
noted during removal.
7. Apply adhesive compound, (Hyster P/N 251099),

to the three mounting capscrews. Using the
three capscrews that hold the throttle base to
the cowl, install the pedal assembly on the lift
truck. Connect the cowl wiring harness to the
pedal assembly wiring harness. Tighten the
bolts to 19 to 25 N•m (168 to 221 lbf in). See
Figure 28.
8. Install the dashboard, seal plate, kick panel, and

floor plate.
See Frame 100 SRM 1120 for lift truck models NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
• S30FT, S35FT, S40FTS (E010) EVER, INSTALLATION IS THE SAME.
H40FTS) (F001) 1. MOUNTING CAPSCREW
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 2. MONOTROL PEDAL ASSEMBLY
3. PEDAL ASSEMBLY WIRING HARNESS
• H2.0-3.5FT (H40-70FT) (L177)
Figure 28. MONOTROL Pedal Installation

See Frame 100 SRM 1581 for lift truck models NOTE: The lift poppet should be bled prior to per-
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) forming this adjustment if the control valve has been
• H8.0FT, H8.0FT9, H9.0FT (H170FT, disassembled or hose has been disconnected by fol-
H175FT36, H190FT) (B299) lowing the procedure in Calibration Procedures
8000 SRM 1134.
9. Perform the calibration procedures in the section
Calibration Procedures 8000 SRM 1134. 1. Remove side covers, floor plates, seal plate and
dash.
ELECTRO HYDRAULIC POPPET VALVE
(EHPV) PILOT PIN ADJUSTMENT See Frame 100 SRM 1120 for lift truck models
• S30FT, S35FT, S40FTS (E010)
This section outlines the procedures for adjusting the • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
lift and lower EHPV pilot pin. This adjustment is H40FTS) (F001)
preset at the valve supplier and should not need to • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
be altered. However, minor adjustments may be re- • H2.0-3.5FT (H40-70FT) (L177)
quired if a new poppet assembly is installed.
These procedures assume the poppet assembly, tube • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
assembly, and coil have been replaced and installed S80, 100FTBCS; S120FTS; S120FTPRS)
correctly. These procedures also assume the forks are (G004, H004)
initially on the ground. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
The coil nut should be removed to access the adjust- R005)
ment screw and re-installed for proper operation.
See Figure 29. See Frame 100 SRM 1316 for lift truck models
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
Lift Pilot Pin E024, F024)

WARNING • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Hot hydraulic oil can cause serious burns to J006)
skin. Do not touch hydraulic components or oil • H8.0FT, H8.0FT9, H9.0FT (H170FT,
during test. Make sure hydraulic oil has cooled H175FT36, H190FT) (A299)
to safe temperature before installing or remov-
ing test equipment. See Frame 100 SRM 1581 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
WARNING
H175FT36, H190FT) (B299)
Hydraulic oil under pressure can be injected
into skin. Lower forks to ground and relieve all 2. To prevent truck from moving, block front and
circuit pressure before removing or installing rear wheels while the engine is operating.
test equipment.
3. Ensure hydraulic oil is at operating temperature,
which is 122° to 150°.
CAUTION
Do not permit dirt or other contaminants to en- 4. Monitor the EHPV coil current.
ter the hydraulic system. Disconnected hoses,
tubes, open valves, cylinder fittings, and ports a. Method 1: Connect a current probe to either
should be protected with clean caps or plugs. of the lift EHPV coil leads.
NOTE: Always attempt to re-calibrate the threshold b. Method 2: Monitor the current using the dis-
setting through the display switch cluster (DSC) to play switch cluster (DSC). See Diagnostic
eliminate the symptoms below before adjusting the Troubleshooting Manual 9000 SRM 1112
pilot pin. for the procedure.

5. Remove coil nut. See Figure 29. 11. If the forks have not started to move prior to
reaching 650 mA, turn the pilot adjustment
6. Loosen pilot pin adjustment screw lock nut. See screw approximately 15° counterclockwise to
Figure 29. reduce the value.
7. Start vehicle. 12. Repeat the adjustment until the forks begin to
move between 550 mA and 650 mA.
8. Slowly increase current to the lift function by
pulling back on the lever or joystick. 13. Tighten pilot pin adjustment screw lock nut
while holding the pilot pin adjustment screw
NOTE: A 1/4 turn will change the value approxi-
to prevent slipping. Slipping of the adjustment
mately 130 mA. Turn clockwise or IN to increase
screw will cause threshold to increase. See Fig-
value and counterclockwise or OUT to decrease
ure 29.
value.
14. Replace coil nut.
9. If the forks move before the current reaches 550
mA or appear to jump, turn pilot pin adjustment 15. Repeat test to verify that fork movement occurs
screw approximately 15° clockwise to increase between 550 mA and 650 mA.
the value.
10. Repeat the adjustment until the forks begin to

1. POPPET ASSEMBLY 5. COIL NUT

2. SOLENOID TUBE ASSEMBLY 6. PILOT PIN ADJUSTMENT SCREW LOCK NUT
3. COIL 7. O-RING
4. PILOT PIN ADJUSTMENT SCREW 8. BIAS SPRING
Figure 29. Hoist Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment

16. Install side covers, floor plates, seal plate and 1. Remove side covers, floor plates, seal plate and
dash. dash.
See Frame 100 SRM 1120 for lift truck models See Frame 100 SRM 1120 for lift truck models
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
H40FTS) (F001) H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) R005)
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024) E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) J006)
H175FT36, H190FT) (A299) H175FT36, H190FT) (A299)
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
H175FT36, H190FT) (B299) H175FT36, H190FT) (B299)
Lower Pilot Pin 2. To prevent truck from moving, block front and
rear wheels while the engine is operating.
WARNING 3. Ensure hydraulic oil is at operating temperature,
Hot hydraulic oil can cause serious burns to which is 122° to 150°.
skin. Do not touch hydraulic components or oil
during test. Make sure hydraulic oil has cooled NOTE: Always attempt to re-calibrate the threshold
to safe temperature before installing or remov- setting through the display switch cluster (DSC) to
ing test equipment. eliminate the symptoms below before adjusting the
pilot pin.
WARNING 4. Monitor the EHPV coil current.
into skin. Lower forks to ground and relieve all a. Method 1: Connect a current probe to either
circuit pressure before removing or installing of the lift EHPV coil leads.
test equipment.
b. Method 2: Monitor the current using the dis-
play switch cluster (DSC). See Diagnostic
CAUTION Troubleshooting Manual 9000 SRM 1112
Do not permit dirt or other contaminants to en- for the procedure.
ter the hydraulic system. Disconnected hoses,
tubes, open valves, cylinder fittings, and ports 5. Start vehicle and raise forks to approximately
should be protected with clean caps or plugs. 2 m (6.5 ft) above the ground.

6. Turn the engine off, and turn the display switch 12. If the forks have not started to move prior to
cluster (DSC) key back on. reaching 650 mA, turn the pilot adjustment
screw approximately 15° counterclockwise to
7. Remove coil nut. See Figure 30. reduce the value.
8. Loosen pilot pin adjustment screw lock nut. See 13. Repeat the adjustment until the forks begin to
Figure 30. move between 550 mA and 650 mA.
9. Slowly increase the current to the lower function 14. Tighten pilot pin adjustment screw lock nut
by pushing forward on the lever or joystick. while holding the pilot pin adjustment screw
to prevent slipping. Slipping of the adjustment
NOTE: A 1/4 turn will change the value approxi-
screw will cause threshold to increase. See Fig-
mately 130 mA. Turn clockwise or IN to increase
ure 30.
value and counterclockwise or OUT to decrease
value. 15. Replace coil nut.
10. If the forks move before the current reaches 550 16. Repeat test to verify that fork movement occurs
mA or appear to drop suddenly, turn the pilot pin between 550 mA and 650 mA.
adjustment screw approximately 15° clockwise to
increase the value.
11. Repeat the adjustment until the forks begin to

1. SOLENOID TUBE ASSEMBLY 6. COIL

2. O-RING 7. PILOT PIN AND BIAS SPRING
3. PILOT PIN ADJUSTMENT SCREW LOCK NUT 8. POPPET ASSEMBLY
4. COIL NUT 9. CAGE ASSEMBLY
5. PILOT PIN ADJUSTMENT SCREW
Figure 30. Lowering Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment

2000 SRM 1137 Manual Main Control Valve
17. Install side covers, floor plates, seal plate and See Frame 100 SRM 1581 for lift truck models
dash. • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
See Frame 100 SRM 1120 for lift truck models H175FT36, H190FT) (B299)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, Abnormal/Erroneous EHPV Adjustment
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) CAUTION
While only minor adjustments may be neces-
See Frame 100 SRM 1243 for lift truck models sary, the design of the EHPV is such that the
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; adjustment screw could erroneously be backed
S80, 100FTBCS; S120FTS; S120FTPRS) out to the point where the EHPV is normally
(G004, H004) open. This presents an extreme condition that
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- is not likely, but is possible.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) If this occurs on lift function and lower function si-
multaneously, the pump flow will bypass directly to
See Frame 100 SRM 1316 for lift truck models tank and there will be no hydraulic functionality. If
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, this occurs on the lift function only (with lower func-
E024, F024) tion calibrated correctly), the mast will raise as soon
as the engine is turned on. If this occurs on the lower
See Frame 100 SRM 1321 for lift truck models function only (with the lift function calibrated cor-
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, rectly, the auxiliary and tilt functions will be opera-
J006) tional, but the forks will not raise. See Figure 29 or
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Figure 30.
H175FT36, H190FT) (A299)
Manual Main Control Valve

DESCRIPTION • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
F024)
The manual control valve is an open-center valve • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
which utilizes parallel hydraulic circuitry. The valve K006)
is used with a fixed displacement pump. The hy-
draulic circuitry incorporates dual pressure logic. See Figure 31 for lift truck models
The lift function operates on the primary relief pres- • S30FT, S35FT, S40FTS (E010)
sure setting. The tilt and auxiliary functions operate • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
on the lower secondary relief pressure setting. If the H40FTS) (F001)
lift function is operated simultaneously with the tilt • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
and/or auxiliary function, the maximum lift pressure • H2.0-3.5FT (H40-70FT) (L177)
is limited to the secondary relief pressure setting. • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
The manual main control valve assembly without op- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
erator presence system (OPS) is divided in the follow- (H80, 90, 100, 110, 120FT) (N005, P005, R005)
ing sections:
• Steering Control Unit (SCU) See Figure 32 for lift truck models
• Monoblock (lift and tilt control) • S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
• Auxiliary F024)
• Outlet • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
• Mid-Inlet* (Primary Pump Inlet) K006)
*Mid-inlet (primary pump inlet) section is used only

on the main control valve of lift truck models

Manual Main Control Valve 2000 SRM 1137
NOTE: Lift truck models listed below may be • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
equipped with a manual main control valve with F024)
operator presence system (OPS). • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
• S30FT, S35FT, S40FTS (E010) K006)
• S50CT (A267) • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H190FT) (A299, B299)
H40FTS) (F001)
• H50CT (A274) The manual main control valve with OPS is divided
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) into the following sections. See Figure 33.
• H2.0-3.5FT (H40-70FT) (L177) • Steering Control Unit (SCU)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, • Monoblock (lift and tilt control)
100FTBCS; S120FTS; S120FTPRS) (G004, H004) • Auxiliary
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT • Outlet
(H80, 90, 100, 110, 120FT) (N005, P005, R005)
1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY II VALVE SECTION/SPOOL

2. SCU MOUNTING CAPSCREW 8. SECONDARY RELIEF VALVE
3. MONOBLOCK VALVE SECTION 9. OUTLET SECTION
4. LIFT/LOWER SPOOL 10. EF PORT
5. TILT SPOOL 11. PRIMARY RELIEF VALVE
6. AUXILIARY I VALVE SECTION/SPOOL
Figure 31. Manual Control Valve Without OPS, 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),
120FT) (N005, P005, R005)

1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I VALVE SECTION/SPOOL

2. SCU MOUNTING CAPSCREW 8. AUXILIARY II VALVE SECTION/SPOOL
3. MID-INLET SECTION 9. SECONDARY RELIEF VALVE
5. LIFT/LOWER SPOOL 11. PRIMARY RELIEF VALVE
6. TILT SPOOL 12. EF PORT
Figure 32. Manual Control Valve Without OPS, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)

NOTE: FOUR-FUNCTION MAIN CONTROL VALVE SHOWN.

1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY II VALVE SECTION/SPOOL
2. SCU MOUNTING CAPSCREW 8. SECONDARY RELIEF VALVE
4. LIFT/LOWER SPOOL 10. MANUAL LOWERING VALVE
5. TILT SPOOL 11. PRIMARY RELIEF VALVE
6. AUXILIARY I VALVE SECTION/SPOOL
Figure 33. Manual Main Control Valve With OPS

REMOVE • H2.0-3.5FT (H40-70FT) (L177)

Lower carriage completely before working on S80, 100FTBCS; S120FTS; S120FTPRS)
control valve or hydraulic system. Do not work (G004, H004)
under a raised carriage. Put mast in a verti- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
cal position, with no forward or back tilt, and 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
lower carriage completely before disconnect- R005)
ing any parts of hydraulic system. The mast
can lower suddenly and cause injury if the car- See Frame 100 SRM 1316 for lift truck models
riage is not lowered. • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
NOTE: Most of the individual valve components can
be removed and replaced while the control valve is in- See Frame 100 SRM 1321 for lift truck models
stalled in the truck. Removal of the control valve for • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
repairs is normally only required to replace a valve J006)
section, replace the O-rings between the sections, or • H8.0FT, H8.0FT9, H9.0FT (H170FT,
to remove a manual valve control spool. H175FT36, H190FT) (A299)
1. Power wash the interior of the operator compart- See Frame 100 SRM 1423 for lift truck models
ment to remove any dirt or debris. • S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
2. Move truck to disassembly area and shut off en-
gine. See Frame 100 SRM 1581 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
WARNING • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
and cause skin irritation. When cleaning Before disconnecting any hydraulic hoses or re-
solvents are used, always follow the solvent moving any parts from the control valve, clean
manufacturer’s recommended safety proce- the outside of the valve either by steam cleaning
dures. Wear protective goggles or a face shield or with cleaning solvent.
to prevent eye injuries.
4. Disconnect the hydraulic levers by removing the
NOTE: Take all necessary steps to prevent debris, locking ring cotter pins and rod end pins that con-
dust, or other contaminants from entering the valve nect the hydraulic lever linkages to the spools.
cavities, hydraulic lines, or replacement parts. Remove three capscrews and the hydraulic lever
assembly from the cowl.
and dashboard. See Figure 34
• For lift truck models without OPS
• S30FT, S35FT, S40FTS (E010) See Figure 35
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, • For lift truck models with OPS
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)

1. CAPSCREW
3. LOCKING RING COTTER PINS
4. MANUAL CONTROL VALVE
5. ROD END PINS 1. CAPSCREW
Figure 34. Hydraulic Lever Removal - Without 3. LOCKING RING COTTER PINS
OPS 4. MANUAL CONTROL VALVE
5. ROD END PINS
Figure 35. Hydraulic Lever Attachment - With

OPS

5. To remove the accelerator pedal or • H6.0FT, H7.0FT (H135FT, H155FT) (H006,

MONOTROL® pedal assembly, disconnect J006, K006)
the cowl wiring harness from the pedal assembly
wiring harness and remove three mounting See Figure 39
capscrews. See Figure 36. • For lift truck models equipped with manual
control valve with OPS.
CAUTION
To prevent any foreign matter from getting
into either the hydraulic hoses or the hy-
draulic control valve sections, all openings
ately after hoses are disconnected from the
control valve. This also applies if any other
items are removed from the control valve.
NOTE: Lift truck models H2.0-3.5FT (H40-70FT)

Lok™ hydraulic inlet hose and adapter between the
steering control unit and hydraulic gear pump.
NOTE: To aid in correctly connecting hydraulic hoses

during installation, tag each hose prior to disconnect-
ing from the control valve.
6. Disconnect hydraulic hoses from the control

valve. Install plugs or caps on all open hose ends
and control valve ports to prevent contamina-
tion.

without OPS
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
• H2.0-3.5FT (H40-70FT) (L177) EVER, REMOVAL IS THE SAME.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
1. MOUNTING CAPSCREW
S80, 100FTBCS; S120FTS; S120FTPRS) 2. MONOTROL PEDAL ASSEMBLY
(G004, H004) 3. PEDAL ASSEMBLY WIRING HARNESS
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, Figure 36. MONOTROL Pedal Removal
R005)

without OPS
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)


2. SCU MOUNTING CAPSCREWS 7. TILT HOSE
5. HYDRAULIC INLET HOSE 10. RETURN HOSE
Figure 37. Hydraulic Hose Removal, Manual Control Valve Without OPS, 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, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)

1. STEERING SYSTEM HOSES 6. TILT HOSE

2. SCU MOUNTING CAPSCREWS 7. AUXILIARY I HOSE
3. STEERING CONTROL UNIT (SCU) 8. AUXILIARY II HOSE
4. STEERING COLUMN 9. RETURN HOSE
5. MID INLET HYDRAULIC HOSE (MAIN PUMP 10. LIFT/LOWER HOSE
HOSE)
Figure 38. Hydraulic Hose Removal, Manual Control Valve Without OPS, Lift Truck Models S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006)


1. STEERING SYSTEM HOSES 6. AUXILIARY I HOSE
2. SCU MOUNTING CAPSCREW 7. AUXILIARY II HOSE
3. STEERING CONTROL UNIT (SCU) 8. RETURN HOSE
4. STEERING COLUMN 9. LIFT/LOWER HOSE
5. TILT HOSE 10. HYDRAULIC INLET HOSE
Figure 39. Hydraulic Hose Removal - Manual Control Valve With OPS

7. Remove the two SCU mounting capscrews, and

move the SCU approximately 1.3 cm (0.5 in.) to
the left. Lower the SCU until the steering shaft
is disengaged. Remove the SCU from the lift
truck.
See Figure 31 for lift truck models without OPS

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
See Figure 32 for lift truck models without OPS 1. COWL

• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 2. INSERT
E024, F024) 3. WASHER
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 4. CAPSCREW
J006, K006) 5. MAIN CONTROL VALVE
6. FRAME
See Figure 33
Figure 40. Manual Main Control Valve Without
• For lift truck models with OPS.
OPS Removal
8. Remove and discard two O-rings from the main
control valve. For lift truck models equipped with
manual control valve, with or without OPS, the
two O-rings are located between the SCU and
control valve.
9. For lift truck models equipped with manual con-

trol valve with OPS, disconnect solenoid assem-
blies from cowl wire harness.
WARNING
The main control valve weighs approximately
30.5 kg (67 lb). Use a lifting device capable of
lifting the main control valve to avoid the pos-
sibility of injury to personnel.
10. Support the main control valve. Remove three

mounting capscrews, washers, inserts and the
manual control valve from the lift truck.
See Figure 40 1. COWL

• For lift truck models without OPS. 2. INSERT
3. WASHER
See Figure 41 4. CAPSCREW
• For lift truck models with OPS. 5. MANUAL CONTROL VALVE WITH OPS
Figure 41. Manual Main Control Valve With

OPS Removal

OPS SOLENOID ASSEMBLY Remove

General 1. Remove two capscrews from solenoid lockout as-
sembly and seal plates at top of lift/tilt section.
There are two OPS solenoid assemblies. See Fig- See Figure 44.
ure 42 and Figure 44 for configurations.
2. Remove two capscrews from solenoid lockout as-
sembly and seal plates at top of auxiliary sec-
tion(s). See Figure 44.
3. Depress needle rollers and remove solenoid lock-

out assembly from seal plate and between valve
spools. See Figure 43 and Figure 44.
NOTE: NEEDLE ROLLERS SHOWN IN DEPRESSED

POSITION; LINK IS PUSHED UPWARD WHEN NEE-
DLE ROLLERS ARE DEPRESSED.
A. 3-FUNCTION MANUAL CONTROL VALVE 1. LINK
B. 4-FUNCTION MANUAL CONTROL VALVE 2. NEEDLE ROLLER
1. 1-FUNCTION SOLENOID LOCKOUT ASSEMBLY Figure 43. Needle Rollers, Depressed
2. 2-FUNCTION SOLENOID LOCKOUT ASSEMBLY
Figure 42. OPS Solenoid Assemblies

Figure 44. Solenoid Lockout and Manual Control Valve


A. 3-FUNCTION MANUAL CONTROL VALVE B. 4-FUNCTION MANUAL CONTROL VALVE
1. 1-FUNCTION SOLENOID LOCKOUT ASSEMBLY 4. SEAL PLATE
2. 2-FUNCTION SOLENOID LOCKOUT ASSEMBLY 5. LIFT/TILT SECTION
3. CAPSCREW 6. AUXILIARY SECTION
Clean and Inspect See Figure 44. Torque capscrews to 9.5 ±1.4 N•m
(84 ±12 lbf in).
WARNING
dures.
WARNING
eyes.
1. Clean metal components with cleaning solvents

and dry with compressed air.
2. Clean all other components with a lint-free cloth.
3. Inspect all components for damage; replace if

damaged.
Install
1. Install needle rollers into solenoid lockout assem-
bly. See Figure 45.
2. Install solenoid lockout assembly by depressing 1. 1-FUNCTION SOLENOID LOCKOUT ASSEMBLY

2. 2-FUNCTION SOLENOID LOCKOUT ASSEMBLY
needle rollers and placing solenoid between valve 3. NEEDLE ROLLER
spools. See Figure 43 and Figure 44.
Figure 45. Solenoid Assembly and Needle
3. Install two capscrews onto solenoid lockout as- Rollers - OPS II
sembly and seal plates at top of valve section(s).

MANUAL CONTROL VALVE SECTIONS See Figure 46

• For lift trucks without OPS.
General
See Figure 47
• For lift trucks with OPS.
CAUTION
While working on the manual control valve sec- NOTE: Perform Step 2 through Step 6 only if it is ab-
tions, place a cover over the remaining sections solutely necessary to disassemble the secondary re-
of the control valve to prevent the possibility lief valve.
of contaminants getting into the control valve
openings which could cause damage to the con- 2. Remove the plug from the adjusting nut. Remove
trol valve. and discard the O-ring from the plug. Remove
and discard the backup rings and O-ring from the
adjusting nut.
CAUTION
If O-rings are to be replaced between two sec- See Figure 46
tions that have a hydraulic oil leak, replace all • For lift trucks without OPS.
O-rings between all sections. This eliminates
the possibility of a subsequent oil leak or pos- See Figure 47
sible damage to another O-ring. • For lift trucks with OPS.
NOTE: Disassemble the manual control valve only 3. While holding the adjusting nut in place, loosen
as necessary for repairs. Most repairs to the control the jam nut.
valve will be for the replacement of O-rings to stop
See Figure 46
leaks between sections.
The manual control valve will be disassembled start-
See Figure 47
ing with the outlet control valve section.
Outlet Control Valve Section NOTE: While performing Step 4, count and note the
number of turns used to remove the adjusting nut.
Remove
1. Remove four nuts from the control valve tie rods.
from the relief valve plug and discard the O-ring
See Figure 46 on the adjusting nut.
See Figure 46
See Figure 47 • For lift trucks without OPS.
See Figure 47
2. Remove the outlet control valve section from the • For lift trucks with OPS.
four tie rods and discard three O-rings from the
5. Remove the spring, washer, and poppet from the
auxiliary control valve section.
relief valve plug.
See Figure 48
See Figure 46
See Figure 49
See Figure 47
Disassemble
1. Remove the secondary relief valve plug from

the outlet control valve section and discard the
O-ring.

6. Remove and discard the backup ring from the • For lift trucks without OPS.
relief valve plug.
See Figure 47
See Figure 46 • For lift trucks with OPS.
1. PLUG 7. WASHER
2. O-RING 8. SPRING
3. OUTLET VALVE SECTION 9. JAM NUT
4. BACKUP RING 10. ADJUSTING NUT
5. SECONDARY RELIEF VALVE PLUG 11. CONTROL VALVE TIE ROD
6. POPPET 12. NUT
Figure 46. Outlet Control Valve Section, Manual Main Control Valves Without OPS

1. PLUG 8. POPPET
2. O-RING 9. SECONDARY RELIEF VALVE PLUG
3. BACKUP RING 10. SECONDARY RELIEF VALVE ASSEMBLY
4. ADJUSTING NUT 11. OUTLET VALVE SECTION
5. JAM NUT 12. NUT
6. SPRING 13. CONTROL VALVE TIE ROD
7. WASHER
Figure 47. Outlet Control Valve Section, Manual Main Control Valve With OPS

Clean 1. Install a new backup ring on the relief valve plug.
See Figure 46
WARNING • For lift trucks without OPS.
and can cause skin irritation. When using See Figure 47
cleaning solvents, always follow the solvent • For lift trucks with OPS.
dures. 2. Install the poppet, washer, and spring into the
relief valve plug.
WARNING See Figure 46
Compressed air can move particles so they • For lift trucks without OPS.
Make sure the path of the compressed air is See Figure 47
away from all personnel. Wear protective gog- • For lift trucks with OPS.
eyes. 3. Install a new O-ring on the adjusting nut, and in-
stall the adjusting nut and jam nut assembly into
1. If all components of the outlet control valve sec- the relief valve plug the number of turns noted
tion have been removed, clean the outlet control during disassembly.
valve section using cleaning solvent and dry us-
ing compressed air. See Figure 46
2. If not all components have been removed, clean
the outlet control valve section using a lint-free See Figure 47
cloth. • For lift trucks with OPS.
Inspect 4. While holding the adjusting nut in place, tighten

the jam nut to 24 ±3 N•m (18 ±2 lbf ft).
Inspect the outlet control valve section mating sur-
faces and the bore of the secondary relief valve, if re- See Figure 46
moved, for damage. If either the mating surface or • For lift trucks without OPS.
the secondary relief valve bore are damaged, replace See Figure 47
the outlet control valve section. • For lift trucks with OPS.
If disassembled, inspect the components of the sec- 5. Install a backup ring, O-ring, and backup ring
ondary relief valve. If any components other than into the adjusting nut.
O-rings, backup rings, and the spring are damaged,
replace the secondary relief valve. See Figure 46
NOTE: If the outlet control valve section is not to be
reassembled immediately, coat surfaces with clean See Figure 47
hydraulic oil to prevent the possibility of rust. Cover • For lift trucks with OPS.
the outlet control valve section with a clean, dry, lint-
free cloth to prevent the possibility of contaminants 6. Install a new O-ring onto the plug. Install the
entering the outlet control valve section. plug into the adjusting nut.
Assemble See Figure 46

coat of clean hydraulic oil to make installation easier. See Figure 47
NOTE: Perform Step 1 through Step 7 only if the sec-
ondary relief valve was repaired.

7. If removed, install secondary relief valve into 2. Remove the auxiliary II control valve section
outlet control valve section. from the four tie rods. Remove and discard
three O-rings from the auxiliary I control valve
See Figure 46 section.
3. Remove the auxiliary I control valve section
See Figure 47 from the four tie rods. Remove and discard
• For lift trucks with OPS. three O-rings from the lift and tilt control valve
section.
Tighten relief valve plug to 45 N•m (33 lbf ft).
See the section Pressure Relief Valve Check and See Figure 50 for lift truck models listed below
Adjustment to adjust the secondary relief valve without OPS
and check the pressure. • S30FT, S35FT, S40FTS (E010)
8. Install new O-ring on plug and install in the out-
H40FTS) (F001)
let valve section.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
See Figure 46 • H2.0-3.5FT (H40-70FT) (L177)
• For lift trucks without OPS. • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
See Figure 47 (G004, H004)
• For lift trucks with OPS. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
Install R005)
1. Install three new O-rings into the auxiliary valve Figure 51 for lift trucks listed below without OPS
section. See Figure 48 and Figure 49. • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
See Figure 48
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
See Figure 49
See Figure 52
• For lift trucks equipped with OPS.
2. Install the outlet control valve section on the four
Disassemble
tie rods. Install the four nuts on the tie rods and
tighten to 24 ±2 N•m (212 ±18 lbf in). NOTE: On lift trucks equipped with a four-function
control valve, the disassembly procedures are the
See Figure 46
same for both auxiliary I and II control valve sec-
tions.
See Figure 47
1. Remove two socket head capscrews, end cap, and
seal plate from the auxiliary control valve sec-
tion.
Auxiliary Control Valve Sections
See Figure 48
Remove
1. Remove the outlet valve. See Outlet Control
Figure 49
Valve Section, Remove.
NOTE: Step 2 is used if a four-section control valve is
2. Remove the spool assembly and wiper from the
being disassembled. If a three-section control valve
auxiliary control valve section.
is being disassembled, go to Step 3.

1. SOCKET HEAD CAPSCREW 8. O-RING

2. END CAP 9. SPOOL
3. SPOOL END FASTENER 10. POPPET
4. SPRING SEAT 11. SPRING
5. SPRING 12. PLUG
6. SEAL PLATE 13. AUXILIARY CONTROL VALVE SECTION
7. WIPER
Figure 48. Auxiliary Control Valve I and II Sections, Manual Control Valve Without OPS

1. SOCKET HEAD CAPSCREW 7. WIPER

2. END CAP 8. O-RING
3. SPOOL END FASTENER 9. SPOOL
4. SPRING SEAT 10. POPPET
5. SPRING 11. PLUG
6. SEAL PLATE 12. AUXILIARY CONTROL VALVE SECTION
Figure 49. Auxiliary Control Valve I and II Sections, Manual Control Valve With OPS

3. Remove the spool end fastener, spring seat, hydraulic oil to prevent the possibility of rust. Cover
spring, spring seat, and O-ring from the spool the auxiliary control valve section with a clean, dry,
assembly. lint-free cloth to prevent the possibility of contami-
nants entering the auxiliary control valve section.
4. Remove two socket head capscrews, seal plate,
wiper, and O-ring from the auxiliary control Assemble
valve section.
5. Remove two plugs, springs, and poppets from the coat of clean hydraulic oil to make installation easier.
auxiliary control valve section. On manual main
control valves with OPS, there is only one spring 1. Install two poppets, springs, and plugs, with
and poppet. See Figure 49. Remove and discard new O-rings installed, into the auxiliary control
the O-rings from the plugs. valve section. On manual main control valves
with OPS, there is only one spring and poppet.
Clean Tighten the plugs to 45 ±5 N•m (33 ±4 lbf ft).
See Figure 48
WARNING • For lift trucks without OPS.
and can cause skin irritation. When using Figure 49
cleaning solvents, always follow the solvent • For lift trucks with OPS.
dures. 2. Install new O-ring, new wiper, seal plate, and two
socket head capscrews on the auxiliary control
valve section. Tighten the socket head screws to
WARNING
9.5 ±1 N•m (84 ±12 lbf in).
cause injury to the user or to other personnel. 3. Install the new O-ring, spring seat, spring,
Make sure the path of the compressed air is spring seat, and spool end fastener on the spool.
away from all personnel. Wear protective gog- Tighten the spool end fastener to 9.5 ±1 N•m
gles or a face shield to prevent injury to the (84 ±12 lbf in).
eyes.
4. Install the new wiper and spool assembly into the
1. If all components of the auxiliary control valve auxiliary control valve section.
section have been removed, clean the auxiliary
control valve section using cleaning solvent and 5. Install seal plate, end cap, and two socket head
dry using compressed air. capscrews into the auxiliary control valve sec-
tion. Tighten the socket head screws to 9.5
2. If not all components have been removed, clean ±1 N•m (84 ±12 lbf in).
the auxiliary control valve section using a lint-
free cloth. Install
Inspect NOTE: Step 1 and Step 2 are used if a four-section

control valve is being installed. If a three-section con-
Inspect the auxiliary control valve section mating trol valve is being installed, use Step 1, then go to
surfaces and the bore of the spool, if removed, for Step 3.
damage. If either the mating surfaces or the spool
bore are damaged, replace the auxiliary control 1. Install three new O-rings on the lift and tilt con-
valve section. trol valve section. Install the auxiliary I control
valve section on the four tie rods.
If disassembled, inspect the components of the spool.
If any components are damaged, replace the compo- 2. Install three new O-rings on the auxiliary I con-
nents. If the spool is damaged, replace the auxiliary trol valve section. Install the auxiliary II control
control valve section. valve section on the four tie rods.
NOTE: If the auxiliary control valve section is not to 3. Install the outlet valve. See Outlet Control Valve
be reassembled immediately, coat surfaces with clean Section, Install.

Lift/Tilt Control Valve Section • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,

H40FTS) (F001)
Remove • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
let Control Valve Section, Remove.
2. Remove the auxiliary control valve section(s). S120FTPRS) (G004, H004)
See Auxiliary Control Valve Sections, Remove. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005,
Disassemble P005, R005)
NOTE: Remove only those components required to re- b. On lift truck models listed below, equipped
pair the lift/tilt control valve section. with manual control valve without OPS, re-
move the spool end fastener, O-ring, spring
NOTE: Step 1 through Step 3 are for the disassembly seat, spring, and spring seat form the tilt
of the tilt side of the lift/tilt control valve section. spool. Discard the O-rings from the tilt spool.
See Figure 51.
1. Remove two socket head screws, end cap, seal
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
plate, and tilt spool assembly from the tilt side
E024, F024)
of the lift/tilt control valve section. Remove and
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
discard the wiper from the tilt bore of the lift/tilt
J006, K006)
control valve section.
c. On lift truck models equipped with manual
See Figure 50 for lift truck models listed below
control valve with OPS, remove the spool end
without OPS
fastener, O-ring, spring seat, spring, spring
• S30FT, S35FT, S40FTS (E010)
seat, spring, and piston from the tilt spool.
Discard the O-rings from the tilt spool. See
H40FTS) (F001)
Figure 52.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) 3. Remove two socket head screws and seal plate
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; from the tilt side of the lift/tilt control valve sec-
S80, 100FTBCS; S120FTS; S120FTPRS) tion. Remove and discard the wiper and O-ring
(G004, H004) from the tilt bore of the lift/tilt control valve sec-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- tion.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) NOTE: Step 4 through Step 6 are for the disassembly
of the lift side of the lift/tilt control valve section.
Figure 51 for lift trucks listed below without OPS
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 4. Remove two socket head screws, end cap, seal
E024, F024) plate, and lift spool assembly from the lift side
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, of the lift/tilt control valve section. Remove and
J006, K006) discard the wiper from the lift bore of the lift/tilt
control valve section.
See Figure 52
• For lift trucks equipped with OPS. See Figure 50 for lift truck models listed below
without OPS
2. Disassemble tilt spool as specified below • S30FT, S35FT, S40FTS (E010)
a. On lift truck models listed below, equipped
H40FTS) (F001)
with manual control valve without OPS, re-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
move the spool end fastener, O-ring, spring
• H2.0-3.5FT (H40-70FT) (L177)
seat, spring, spring seat, spring, and piston
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
from the tilt spool. Discard the O-rings from
the tilt spool. See Figure 50.
(G004, H004)
• S30FT, S35FT, S40FTS (E010)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • H6.0FT, H7.0FT (H135FT, H155FT) (H006,

5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, J006, K006)
R005)
See Figure 52
Figure 51 for lift trucks listed below without OPS • For lift trucks equipped with OPS.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
Figure 50. Lift/Tilt Control Valve Section, Manual Main Control Valve Without OPS, 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, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004), and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)


1. SOCKET HEAD CAPSCREW 13. POPPET
2. END CAP 14. SEAL PLATE
3. O-RING 15. LIFT/TILT CONTROL VALVE SECTION
4. SPOOL END FASTENER 16. BACKUP RING
5. SPRING 17. RELIEF VALVE PLUG
6. PISTON 18. POPPET
7. SPRING SEAT 19. WASHER
8. SEAL PLATE 20. LOCK NUT
9. WIPER 21. ADJUSTING NUT
10. O-RING 22. PLUG
11. TILT SPOOL 23. LIFT SPOOL
12. PLUG 24. SPOOL END FASTENER

1. SOCKET HEAD CAPSCREW 13. SEAL PLATE

2. END CAP 14. LIFT/TILT CONTROL VALVE SECTION
3. O-RING 15. BACKUP RING
4. SPOOL END FASTENER 16. RELIEF VALVE PLUG
5. SPRING 17. POPPET
6. SPRING SEAT 18. WASHER
7. SEAL PLATE 19. LOCK NUT
8. WIPER 20. ADJUSTING NUT
9. O-RING 21. PLUG
10. TILT SPOOL 22. LIFT SPOOL
11. PLUG 23. SPOOL END FASTENER
12. POPPET
Figure 51. Lift/Tilt Control Valve Section, Manual Main Control Valve Without OPS, Lift Truck
Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006)

5. Remove the spool end fastener, spring seat, cleaning solvents, always follow the solvent
spring, spring seat, and O-ring from the lift manufacturer’s recommended safety proce-
spool assembly. Discard the O-ring. dures.
6. Remove two socket head screws and seal plate

from the lift side of the lift/tilt control valve sec-
WARNING
tion. Remove and discard the wiper and O-ring Compressed air can move particles so they
from the lift bore of the lift/tilt control valve sec- cause injury to the user or to other personnel.
tion. Make sure the path of the compressed air is
7. Remove three plugs, springs, and poppets from gles or a face shield to prevent injury to the
the lift/tilt control valve section. Remove and dis- eyes.
card the O-rings from the plugs.
1. If all components of the lift/tilt control valve sec-
8. On lift trucks equipped with a manual main con- tion have been removed, clean the lift/tilt control
trol valve with OPS, remove the manual lowering valve section using cleaning solvent and dry us-
valve from the lift/tilt control valve section. Re- ing compressed air.
move and discard the O-ring. See Figure 52.
2. If not all components have been removed, clean
the lift/tilt control valve section using a lint-free
cloth.
NOTE: Perform Step 9 through Step 13 only if it is
necessary to disassemble the primary relief valve. Inspect
9. Remove the plug from the adjusting nut. Remove Inspect the lift/tilt control valve section mating sur-
and discard the O-ring from the plug. Remove faces. Inspect the bore of the primary relief valve, if
and discard the backup rings and O-ring from the removed, for damage. Inspect the bores of the lift and
adjusting nut. tilt spools, if removed. If the mating surface, the pri-
mary relief valve bore, or either the lift or tilt spool
10. While holding the adjusting nut in place, loosen bores are damaged, replace the lift/tilt control valve
the jam nut. section.
NOTE: While performing Step 11, count and note the If disassembled, inspect the components of the pri-
number of turns used to remove the adjusting nut. mary relief valve. If any components other than
O-rings, backup rings, and the spring are damaged,
replace the primary relief valve.
from the relief valve plug and discard the O-ring
on the adjusting nut. NOTE: If the lift/tilt control valve section is not to
be reassembled immediately, coat surfaces with clean
12. Remove the spring, washer, and poppet from the
hydraulic oil to prevent the possibility of rust. Cover
relief valve plug.
the lift/tilt control valve section with a clean, dry,
13. Remove and discard the backup ring from the lint-free cloth to prevent the possibility of contami-
relief valve plug. nants entering the lift/tilt control valve section.
Clean
WARNING

Figure 52. Lift/Tilt Control Valve Section, Manual Main Control Valve With OPS


1. END CAP 12. RELIEF VALVE ASSEMBLY
2. SOCKET HEAD CAPSCREW 13. MANUAL LOWERING VALVE
3. PLUG 14. SCREW
4. O-RING 15. SEAL PLATE
5. BACKUP RING 16. WIPER
6. ADJUSTING NUT 17. SPRING SEAT
7. LOCKNUT 18. SPOOL END FASTENER
8. SPRING 19. PISTON
9. WASHER 20. LIFT SPOOL
10. POPPET 21. TILT SPOOL
11. RELIEF VALVE PLUG
Assemble 5. Install a new backup ring, O-ring, and backup

ring into the adjusting nut.
coat of clean hydraulic oil to make installation easier. 6. Install a new O-ring onto the plug. Install the
plug into the adjusting nut.
NOTE: Perform Step 1 through Step 7 only if the pri-
mary relief valve was repaired. 7. Install primary relief valve into lift side of the
lift/tilt control valve section. Tighten primary re-
1. Install the new backup ring on the relief valve lief valve plug to 45 N•m (33 lbf ft).
plug.
See Figure 50 for lift truck models listed below
See Figure 50 for lift truck models listed below without OPS
without OPS • S30FT, S35FT, S40FTS (E010)
(G004, H004) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
R005)
See Figure 51 for lift trucks listed below without
See Figure 51 for lift trucks listed below without OPS
OPS • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
J006, K006)
See Figure 52
See Figure 52 • For lift trucks equipped with OPS.
See the section Pressure Relief Valve Check and
2. Install the poppet, washer, and spring into the Adjustment to adjust the primary relief valve
relief valve plug. and check the pressure.
3. Install a new O-ring on the adjusting nut. Install 8. On lift trucks equipped with a manual main con-
the adjusting nut and jam nut assembly in the re- trol valve with OPS, install the manual lowering
lief valve plug the number of turns noted during valve, with a new O-ring installed, into the lift/
removal. tilt control valve section. Tighten to 14 ±1 N•m
(120 ±12 lbf in).
4. While holding the adjusting nut in place, tighten
the jam nut to 24 ±3 N•m (18 ±2 lbf ft).

9. Install three poppets, springs, and plugs, with spool end fastener on the tilt spool assembly.
new O-rings installed, in the lift/tilt control valve Tighten the spool end fastener to 9.5 ±1 N•m
section. (84 ±12 lbf in).
10. Install the new O-ring and wiper in the lift bore of See Figure 51 for lift trucks without OPS
the lift/tilt control valve section. Install the seal • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
plate and two socket head screws on the lift side E024, F024)
of the lift/tilt control valve section. Tighten the • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
socket head screws to 9.5 ±1 N•m (84 ±12 lbf in). J006, K006)
11. Install a new O-ring on the lift spool. Install the c. On lift truck models, equipped with man-
spring seat, spring, spring seat, and spool end ual control valve with OPS, install a new
fastener on the lift spool assembly. Tighten the O-ring on the tilt spool. Install the piston,
spool end fastener to 9.5 ±1 N•m (84 ±12 lbf in). spring, spring seat, spring, spring seat, and
spool end fastener on the tilt spool assembly.
12. Install new the wiper into the lift bore of the Tighten the spool end fastener to 9.5 ±1 N•m
lift/tilt control valve section. Install the lift spool (84 ±12 lbf in). See Figure 52.
assembly, seal plate, end cap, and two socket
head screws into the lift side of the lift/tilt control 15. Install new the wiper into the tilt bore of the
valve section. Tighten the socket head screws to lift/tilt control valve section. Install the tilt spool
9.5 ±1 N•m (84 ±12 lbf in). assembly, seal plate, end cap, and two socket
head screws into the tilt side of the lift/tilt control
13. Install the new O-ring and wiper in the tilt valve section. Tighten the socket head screws to
bore of the lift/tilt control valve section. Install 9.5 ±1 N•m (84 ±12 lbf in).
the seal plate and two socket head screws on
the tilt side of the lift/tilt control valve section. Install
Tighten the socket head screws to 9.5 ±1 N•m
(84 ±12 lbf in). 1. Install the auxiliary control valve section(s). See
14. Assemble tilt spool as specified below
2. Install the outlet valve. See Outlet Control Valve
a. On lift truck models listed below, equipped Section, Install.
with manual control valve without OPS, in-
stall a new O-ring on the tilt spool. Install Mid-Inlet Section
the piston, spring, spring seat, spring, spring
seat, and spool end fastener on the tilt spool Remove
assembly. Tighten the spool end fastener to
NOTE: The mid-inlet section is used only on lift truck
9.5 ±1 N•m (84 ±12 lbf in).
models listed below equipped with manual control
See Figure 50 for lift trucks without OPS valve without OPS.
• S30FT, S35FT, S40FTS (E010) • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, F024)
H40FTS) (F001) • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) K006)
• H2.0-3.5FT (H40-70FT) (L177)
Remove the mid-inlet section only as necessary for
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
repair. Most repairs to the mid-inlet section will be
for the replacement of O-rings to stop leaks. There
S120FTPRS) (G004, H004)
are no disassembly or assembly procedures for the
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
mid-inlet section.
5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005, R005) 1. Remove three socket head capscrews and wash-
ers that secure the mid-inlet section to the lift/tilt
b. On lift truck models listed below, equipped
(monoblock) section. See Figure 53.
with manual control valve without OPS, in-
stall a new O-ring on the tilt spool. Install 2. Remove mid-inlet section from the lift/tilt sec-
the spring seat, spring, spring seat, and tion. Discard four O-rings.

3. Remove socket head plug and discard O-ring. Tighten capscrews to 45 to 55 N•m (33 to
41 lbf ft).
Clean
INSTALL
WARNING
Cleaning solvents can be flammable and toxic WARNING
and can cause skin irritation. When using The main control valve weighs approximately
cleaning solvents, always follow the solvent 30.5 kg (67 lb). Use a lifting device capable of
manufacturer’s recommended safety proce- lifting the main control valve, to avoid the pos-
dures. sibility of injury to personnel.
WARNING 1. While supporting the main control valve in place

on the cowl, install three mounting capscrews,
washers, and inserts through the front of the
cowl into the control valve. Tighten the cap-
gles or a face shield to prevent injury to the See Figure 54
eyes. • For lift trucks without OPS.
Clean the mid-inlet control valve section using clean- See Figure 55
ing solvent and dry using compressed air. • For lift trucks with OPS.
Inspect
Inspect the mid-inlet control valve section and mat-

ing surfaces. If either the mating surfaces or mid-in-
let control valve section are damaged, replace the
mid-inlet control valve section.
Install
NOTE: If the mid-inlet control valve section is not to

be installed immediately, coat surfaces with clean hy-
draulic oil to prevent the possibility of rust. Cover
the mid-inlet control valve section with a clean, dry,
lint-free cloth to prevent the possibility of contami-
nants entering the mid-inlet control valve section.
NOTE: Coat all O-rings with a light coat of clean hy-

1. MID-INLET SECTION
draulic oil to make installation easier. 2. SOCKET HEAD PLUG
3. O-RING
1. Install new O-ring on socket head plug. Install 4. SOCKET HEAD CAPSCREW
plug into mid-inlet section. See Figure 53. 5. WASHER
2. Install new O-rings on mating surfaces of mid- Figure 53. Mid-Inlet Section
inlet section.
3. Install mid-inlet section to lift/tilt section us-

ing three socket head capscrews and washers.

2. On lift trucks equipped with manual main con-

trol valve with OPS, connect solenoid assemblies
to cowl wire harness.
3. For lift truck models equipped with manual con-

trol valve, with or without OPS, coat two new
O-rings with hydraulic oil. Install the O-rings be-
tween control valve section and SCU.
4. Position the SCU under the steering shaft and

raise the SCU to engage the steering shaft.
When the steering shaft is completely engaged,
position the SCU against the main control valve,
and install two mounting capscrews and wash-
ers. Tighten to 45-55 N•m (33-41 lbf ft).

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
1. COWL
2. INSERT • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
3. WASHER • H2.0-3.5FT (H40-70FT) (L177)
4. CAPSCREW • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
5. MAIN CONTROL VALVE S80, 100FTBCS; S120FTS; S120FTPRS)
6. FRAME (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
Figure 54. Manual Main Control Valve Without
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
OPS Installation
R005)

• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
See Figure 33
• For lift truck models equipped with OPS.
NOTE: Lift truck models H2.0-3.5FT (H40-70FT)

5. Remove all caps and plugs from the control valve

and hose fittings. Connect hydraulic hoses to the
control valve as noted during removal.

• S30FT, S35FT, S40FTS (E010)
1. COWL • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
2. INSERT H40FTS) (F001)
3. WASHER
4. CAPSCREW • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
5. MANUAL CONTROL VALVE WITH OPS • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Figure 55. Manual Main Control Valve With S80, 100FTBCS; S120FTS; S120FTPRS)
OPS Installation (G004, H004)


5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, J006, K006)
R005)
See Figure 58
See Figure 57 for lift truck models without OPS • For lift trucks equipped with OPS.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
E024, F024)

2. SCU MOUNTING CAPSCREWS 7. TILT HOSE
5. HYDRAULIC INLET HOSE 10. RETURN HOSE
Figure 56. Hydraulic Hose Installation, Manual Control Valve Without OPS, Lift Truck Models
S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177), S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004), and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)

1. STEERING SYSTEM HOSES 6. TILT HOSE

2. SCU MOUNTING CAPSCREWS 7. AUXILIARY I HOSE
3. STEERING CONTROL UNIT (SCU) 8. AUXILIARY II HOSE
4. STEERING COLUMN 9. RETURN HOSE
5. MID INLET HYDRAULIC HOSE (MAIN PUMP 10. LIFT/LOWER HOSE
HOSE)
Figure 57. Hydraulic Hose Installation, Manual Control Valve Without OPS, Lift Truck Models
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)


1. STEERING SYSTEM HOSES 6. AUXILIARY I HOSE
2. SCU MOUNTING CAPSCREW 7. AUXILIARY II HOSE
3. STEERING CONTROL UNIT (SCU) 8. RETURN HOSE
4. STEERING COLUMN 9. LIFT/LOWER HOSE
5. TILT HOSE 10. HYDRAULIC INLET HOSE
Figure 58. Hydraulic Hose Installation - Manual Control Valve With OPS

6. Apply adhesive compound, Hyster P/N 251099, See Frame 100 SRM 1581 for lift truck models
to the three mounting capscrews. Using the • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
three capscrews that hold the throttle base to • H8.0FT, H8.0FT9, H9.0FT (H170FT,
the cowl, install the pedal assembly on the lift H175FT36, H190FT) (B299)
truck. Connect the cowl wiring harness to the
pedal assembly wiring harness. Tighten the
bolts to 19 to 25 N•m (168 to 221 lbf in). See
Figure 59.
7. Using three capscrews, mount the hydraulic

lever assembly to the cowl. Install the rods into
the valve section spool clevis. Install the rod end
pins and lock ring cotter pins. See Figure 34.
8. Install the dashboard, seal plate, kick panel, and

floor plate.

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)

• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
E024, F024) EVER, INSTALL IS THE SAME.
See Frame 100 SRM 1321 for lift truck models 1. MOUNTING CAPSCREWS
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 2. MONOTROL PEDAL ASSEMBLY
J006) 3. PEDAL ASSEMBLY WIRING HARNESS
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Figure 59. MONOTROL Pedal Install
H175FT36, H190FT) (A299)

• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)

2000 SRM 1137 Pressure Relief Valve Check and Adjustment
Pressure Relief Valve Check and Adjustment

NOTE: The main control valve has two relief valves: • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
a primary relief valve and a secondary relief valve. K006)
The primary relief valve is in the inlet section of the
control valve. The secondary relief valve is in the See Figure 33
outlet section of the control valve. For lift trucks • For lift truck models equipped with OPS.
equipped with a electro-hydraulic control valve,
PRIMARY RELIEF VALVE
• S30FT, S35FT, S40FTS (E010) WARNING
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, Never allow anyone under a raised carriage.
H40FTS) (F001) Do not put any part of your body in or through
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) the lift mechanism unless all parts of the mast
• H2.0-3.5FT (H40-70FT) (L177) are completely lowered and the key switch is
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, OFF.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT 1. Remove cap from EF port. If lift truck is
(H80, 90, 100, 110, 120FT) (N005, P005, R005) equipped with a electro-hydraulic control valve.
See Figure 3 for lift truck models See Figure 2 for lift truck models
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, • S30FT, S35FT, S40FTS (E010)
F024) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, H40FTS) (F001)
K006) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 4 for lift truck models listed below • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
equipped with anti-stall solenoid S80, 100FTBCS; S120FTS; S120FTPRS)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, (G004, H004)
100FTBCS; S120FTS; S120FTPRS) (G004, H004) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
(H80, 90, 100, 110, 120FT) (N005, P005, R005) R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (E024)
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006) See Figure 3 for lift truck models
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
See Figure 5 for lift truck models E024)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
H190FT) (A299, B299) J006, K006)
If lift truck is equipped with a manual control valve, If lift truck is equipped with a manual control
See Figure 31 for lift truck models without OPS valve,
• S30FT, S35FT, S40FTS (E010) See Figure 31 for lift truck models without OPS
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, • H2.0-3.5FT (H40-70FT) (L177)
100FTBCS; S120FTS; S120FTPRS) (G004, H004) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT S80, 100FTBCS; S120FTS; S120FTPRS)
(H80, 90, 100, 110, 120FT) (N005, P005, R005) (G004, H004)
See Figure 32 for lift truck models without OPS • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024, 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
F024) R005)

Pressure Relief Valve Check and Adjustment 2000 SRM 1137
See Figure 32 for lift truck models without OPS See Figure 52
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024, • For lift trucks equipped with OPS.
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 3. Operate the hydraulic system to warm the oil
J006, K006) temperature to 50 to 65°C (122 to 149°F).
See Figure 33
CAUTION
• For lift truck models with OPS.
During this test, the mast must be fully ex-
Install a 24 MPa (3500 psi) pressure gauge into tended. Make sure there is enough overhead
the EF port. clearance in the building, or do the test out-
doors.
2. Loosen lock nut. For lift truck equipped with an
electro-hydraulic control valve. 4. Raise the mast until it stops. Hold the lever and
check the reading of the gauge when the relief
See Figure 21 for lift truck models valve opens. Turn the adjustment screw, as nec-
• S30FT, S35FT, S40FTS (E010) essary, to change the setting. See Table 1 for
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, the correct relief valve setting for your lift truck
H40FTS) (F001) model. Tighten the jam nut when the adjustment
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) is correct.
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 5. Remove the gauge when the checks are complete.
(G004, H004) SECONDARY RELIEF VALVE
See Figure 22 for lift truck models 1. Remove cap from EF port. If lift truck is
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, equipped with a electro-hydraulic control valve,
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, See Figure 2 for lift truck models
J006, K006) • S30FT, S35FT, S40FTS (E010)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, H40FTS) (F001)
R005) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
For lift trucks equipped with a manual control • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
valve, S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
See Figure 50 for lift truck models without OPS • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• S30FT, S35FT, S40FTS (E010) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, R005)
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; E024, F024)
S80, 100FTBCS; S120FTS; S120FTPRS) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
(G004, H004) J006, K006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, If lift truck is equipped with a manual control
R005) valve,
See Figure 51 for lift truck models without OPS See Figure 31 for lift truck models without OPS
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, • S30FT, S35FT, S40FTS (E010)
E024, F024) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, H40FTS) (F001)
J006, K006) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; For lift trucks equipped with a manual control
S80, 100FTBCS; S120FTS; S120FTPRS) valve,
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- See Figure 61
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • For lift trucks without OPS.
R005)
See Figure 62
See Figure 32 for lift truck models without OPS • For lift trucks with OPS.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
3. Operate the hydraulic system to warm the oil
E024, F024)
temperature to 50 to 65°C (122 to 149°F).
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) 4. Tilt the mast until it stops. Hold the lever and
check the reading of the gauge when the relief
See Figure 33
valve opens. Turn the adjustment screw, as nec-
essary, to change the setting. See Table 1 for
Install a 24 MPa (3500 psi) pressure gauge into the correct relief valve setting for your lift truck
the EF port. model. Tighten the jam nut when the adjustment
is correct.
2. Loosen jam nut. For lift truck equipped with an
electro-hydraulic control valve, see Figure 60. 5. Remove the gauge when the checks are complete.
Table 1. Relief Valve Settings
Truck Model Primary Relief Valve Setting Secondary Relief Valve Setting
S30FT, S35FT, S40FTS (E010) 19.30 ±0.48 MPa (2800 ±70 psi) 15.90 ±0.48 MPa (2306 ±70 psi)
and H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001)
S2.0-3.5FT (S40-70FT, S55FTS) 21.37 ±0.48 MPa (3099 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
(F187), H2.0-3.5FT (H40-60FT)
(L177), S50CT (A267), and
H2.0-2.5CT (H50CT) (A274)
S2.0-3.5FT (S40-70FT, S55FTS) 23.44 ±0.48 MPa (3400 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
(F187) and H3.5FT (H70FT)
(L177)
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 22.10 ±0.48 MPa (3205 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004,
H004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT)
(N005, P005, R005)
S6.0FT, S7.0FT (S135FT, 22.10 ±0.48 MPa (3205 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
S155FT) (D024, E024, F024)
and H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006)
H8.0FT, H8.0FT9, H9.0FT 22.10 ±0.48 MPa (3205 ±70 psi) 17.2 ±0.50 MPa (2500 ±70 psi)
(H170FT, H175FT36, H190FT)
(A299, B299)

NOTE: SECONDARY RELIEF VALVE ASSEMBLY IS THE SAME FOR BOTH OUTLET SECTIONS COVERED IN
FIGURE 60.
A. OUTLET SECTION USED ON LIFT TRUCK MODEL COVERED IN THIS SERVICE MANUAL THAT ARE
EQUIPPED WITH AN ANTI-STALL PORT ON OUTLET SECTION.
B. OUTLET SECTION USED ON LIFT TRUCK MODELS, EXCEPT H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299), COVERED IN THIS SERVICE MANUAL THAT ARE NOT EQUIPPED
WITH AN ANTI-STALL PORT ON OUTLET SECTION.
1. O-RING 8. SPRING
2. PLUG 9. JAM NUT
3. OUTLET VALVE SECTION 10. ADJUSTING NUT
4. BACKUP RING 11. CONTROL VALVE TIE ROD
5. SECONDARY RELIEF VALVE PLUG 12. NUT
6. POPPET 13. ANTI-STALL PORT
7. WASHER 14. SECONDARY RELIEF VALVE ASSEMBLY
Figure 60. Secondary Relief Valve, Electro-Hydraulic Main Control Valve

1. O-RING 7. WASHER
2. PLUG 8. SPRING
3. OUTLET VALVE SECTION 9. JAM NUT
4. BACKUP RING 10. ADJUSTING NUT
5. SECONDARY RELIEF VALVE PLUG 11. CONTROL VALVE TIE ROD
6. POPPET 12. NUT
Figure 61. Secondary Relief Valve, Manual Hydraulic Main Control Valve Without OPS

1. PLUG 8. POPPET
2. O-RING 9. SECONDARY RELIEF VALVE PLUG
3. BACKUP RING 10. SECONDARY RELIEF VALVE ASSEMBLY
4. ADJUSTING NUT 11. OUTLET VALVE SECTION
5. JAM NUT 12. NUT
6. SPRING 13. CONTROL VALVE TIE ROD
7. WASHER
Figure 62. Secondary Relief Valve, Manual Hydraulic Main Control Valve With OPS

2000 SRM 1137 Steering Control Unit Repair
Steering Control Unit Repair

STEERING CONTROL UNIT, REMOVE See Frame 100 SRM 1321 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
WARNING
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Lower carriage completely before working on H175FT36, H190FT) (A299)
control valve or hydraulic system. Do not work
under a raised carriage. Put mast in a verti- See Frame 100 SRM 1423 for lift truck models
cal position and lower carriage completely be- • S50CT (A267)
fore disconnecting any parts of hydraulic sys- • H2.0-2.5CT (H50CT) (A274)
tem. The mast can lower suddenly and cause
injury if the carriage is not lowered. See Frame 100 SRM 1581 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
1. Power wash the interior of the operator compart- • H8.0FT, H8.0FT9, H9.0FT (H170FT,
ment to remove any dirt or debris. H175FT36, H190FT) (B299)
2. Move truck to disassembly area and shut off en-
gine. CAUTION
To prevent any foreign matter from getting
WARNING into either the hydraulic hoses or the hy-
draulic control valve sections, all openings
and cause skin irritation. When cleaning
ately after hoses are disconnected from the
solvents are used, always follow the solvent
control valve. This also applies if any other
items are removed from the control valve.
dures. Wear protective goggles or a face shield
to prevent eye injuries. NOTE: Lift truck models H2.0-3.5FT (H40-70FT)
NOTE: Take any necessary steps to prevent debris,
dust, or other contaminants from entering the valve
cavities, hydraulic lines, or replacement parts.
NOTE: To aid in the correct connection of hydraulic
hoses during installation, tag each hose prior to dis-
and dashboard.
connecting from the control valve.
4. Disconnect hydraulic hoses from the steering
• S30FT, S35FT, S40FTS (E010)
control unit. Install plugs or caps on all open
hose ends and control valve ports to prevent
H40FTS) (F001)
contamination.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) See Figure 63 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(G004, H004)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
(G004, H004)
See Frame 100 SRM 1316 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
E024, F024) R005)

Steering Control Unit Repair 2000 SRM 1137
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, H175FT36, H190FT) (A299, B299)
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
NOTE: ELECTRO-HYDRAULIC MAIN CONTROL VALVE SHOWN. LIFT TRUCK MODELS S50CT (A267) AND
H2.0-2.5CT (H50CT) (A274) EQUIPPED WITH MANUAL MAIN CONTROL VALVE ONLY, BUT REPAIR OF STEER-
ING CONTROL UNIT IS THE SAME.
1. "L" STEERING SYSTEM HOSE 4. SCU MOUNTING CAPSCREWS
2. "R" STEERING SYSTEM HOSE 5. STEERING CONTROL UNIT (SCU)
3. HYDRAULIC INLET HOSE 6. STEERING COLUMN
Figure 63. Steering Control Unit, Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT,
120FT) (N005, P005, R005)

5. Remove the two SCU mounting bolts and move See Figure 64 for lift truck models
the SCU approximately 1.3 cm (0.5 in.) to the • S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
left, and lower the SCU until the steering shaft is E024, F024)
disengaged. Remove the SCU from the lift truck. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
H40FTS) (F001) 6. Remove and discard two O-rings from between
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) the SCU and the main control valve.
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 7. Coat the machined surface of the main control
S80, 100FTBCS; S120FTS; S120FTPRS) valve with a light coat of hydraulic oil to prevent
(G004, H004) the possibility of rust. Cover the exposed ma-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- chined surface of the main control valve to pre-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, vent the possibility of foreign matter getting into
R005) the main control valve.
1. "R" STEERING SYSTEM HOSE 4. STEERING COLUMN

2. "L" STEERING SYSTEM HOSE 5. SCU MOUNTING CAPSCREWS
3. STEERING CONTROL UNIT (SCU) 6. HYDRAULIC INLET HOSE
Figure 64. Steering Control Unit, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), and H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)

STEERING CONTROL UNIT, needs to be repaired, go to Relief Valve, Disas-

DISASSEMBLE semble.
1. Place the steering pump into a soft-jaw vise with STEERING CONTROL UNIT, CLEAN
the splined end facing down.
NOTE: Note the position of the special screws when WARNING

removed, so that they will be installed in the same Cleaning solvents can be flammable and toxic
positions at assembly of the steering control unit. and can cause skin irritation. When using
2. Remove the capscrews, special screws, and wash- manufacturer’s recommended safety precau-
ers. Rotate the steering pump 90 degrees side- tions.
ways in the vise. See Figure 65.
3. Remove the end cover, O-ring, gear ring, O-ring, WARNING

gear, distributor plate, and O-ring from the steer- Compressed air can move particles so that they
ing control unit. Discard the O-rings. cause injury to the user or to other personnel.
4. Remove the cardan shaft from the spool assem- is away from all personnel. Wear protective
bly. goggles or a face shield to prevent injury to the
eyes.
5. Remove the spool assembly from the steering
control unit housing. Clean all the parts in solvent. Dry the parts with
compressed air. Do not dry the parts with a cloth.
6. Remove the thrust washer, thrust bearing, and Make sure all surfaces are free of scratches and sharp
thrust washer from the shaft end of the spool as- edges.
sembly.
STEERING CONTROL UNIT, INSPECT
7. Remove the retaining ring from the spool assem-
bly. Inspect all parts for damage, if any parts other
than those parts contained in parts kits Hyster P/N
8. Press the cross pin out of the spool assembly.
1579908 (seal kit) or Hyster P/N 1581858 (capscrew
9. Press the spool from the sleeve. Remove the kit) are damaged, replace the steering control unit.
springs from the spool. If the steering control unit is not going to be installed
on the main control valve immediately, coat the ma-
NOTE: To aid in installation of the emergency steer- chined mating surface with a light coat of hydraulic
ing seat and emergency steering check ball, note oil and install plugs in any open ports to prevent
the hole position of the emergency steering seat and the possibility of any foreign matter getting into the
emergency steering check ball during removal. steering control unit.
10. Remove the emergency steering seat and emer- STEERING CONTROL UNIT, ASSEMBLE
gency steering check ball from the steering con-
trol unit housing. NOTE: Apply a light coat of clean hydraulic oil to
O-rings and seals to assist in installation.
NOTE: To aid in installation of the load sense check
ball and seat, note the hole position of the load sense 1. Using a seal installer, install the shaft seals in
seat and load sense check ball during removal. the steering control unit housing.
11. Remove the load sense seat and load sense check 2. Install the spool into the sleeve with the key slots
ball from the steering control unit. opposite each other. See Figure 65.
12. Remove the shaft seals from the pump housing. 3. Insert the curved springs between the flat
Discard the seals. springs.
13. Remove the cap and system relief valve from the NOTE: The retaining ring must be able to rotate
steering control unit. If the system relief valve unimpeded by the springs.

4. Center the springs in the spool assembly, and in- 7. Place the pump housing in a soft-jawed vise in
stall the retaining ring over the springs. the horizontal position. Install the spool assem-
bly into the housing while holding the cross pin
5. Install the cross pin into the spool assembly. in a horizontal position.
6. Install the thrust washer, thrust bearing, and
thrust washer on the spool.
1. CAPSCREW 15. THRUST WASHER

2. SPECIAL SCREW 16. THRUST BEARING
3. WASHER 17. SEAL
4. END COVER 18. EMERGENCY STEER SEAT
5. O-RING 19. EMERGENCY STEER CHECK BALL
6. GEAR RING 20. STEERING CONTROL UNIT HOUSING
7. GEAR 21. SYSTEM RELIEF VALVE
8. DISTRIBUTOR PLATE 22. CAP
9. CARDAN SHAFT 23. MOUNTING BOLT
10. SPRING SET 24. LOCKWASHER
11. SLEEVE 25. LOAD SENSE PLUG
12. CROSS PIN 26. LOAD SENSE CHECK BALL
13. SPOOL 27. LOAD SENSE SEAT
14. RETAINING RING
Figure 65. Steering Control Unit

8. With the pump housing still in the horizontal po- 3. Remove and discard small O-ring, backup ring,
sition, install the spool so that the pin in the spool and large O-ring from the cartridge body.
is in the horizontal position. When the spool is
installed rotate the steering control unit to the RELIEF VALVE, CLEAN
vertical position.
9. Install the emergency steering check ball, and WARNING

emergency steering seat in the steering control Cleaning solvents can be flammable and toxic
unit housing as noted during removal. Tighten and can cause skin irritation. When using
the emergency steering seat to 1.5 ±0.3 N•m (13 cleaning solvents, always follow the solvent
±2.5 lbf in). manufacturer’s recommended safety precau-
tions.
10. Install the load sense check ball and load sense
seat in the steering control unit as noted dur- WARNING
ing removal. Tighten the load sense seat to 1.5
±0.3 N•m (13 ±2.5 lbf in).
11. Install a new O-ring on the steering control unit Make sure that the path of the compressed air
housing, and place the distributor plate on the is away from all personnel. Wear protective
steering control unit housing, with the holes goggles or a face shield to prevent injury to the
properly aligned with the steering control unit eyes.
housing.
Clean all the parts in solvent. Dry the parts with
12. Install the cardan shaft and rotate it until it is compressed air. Do not dry the parts with a cloth.
engaged with the pin in the spool assembly. Make sure all surfaces are free of scratches and sharp
edges.
13. Install the gear ring onto the cardan shaft.
14. Install new O-ring, gear, and new O-ring onto

the gear ring and install the gear ring onto the
distributor plate, making sure that the holes are
properly aligned.
15. Install a new O-ring onto the gear ring. Install

end cover, special capscrews, and washers as
noted during disassembly. Tighten all capscrews
to 30 ±6 N•m (265 ±53 lbf in).
16. If removed, install the system relief valve. Place

the torque tool in the notches on the cartridge
body (see Figure 66). Tighten to 18 ±6 N•m (160
±53 lbf in). Install the tamper proof cap into the
steering control unit housing.
1. SNAP RING
RELIEF VALVE, DISASSEMBLE 2. ANTI-TAMPER RING
3. PLUG
1. Remove the snap ring and anti-tamper ring from 4. SPRING
5. SEAT
the cartridge body. See Figure 66. 6. CARTRIDGE BODY
7. O-RING
NOTE: Note the number of turns to remove plug from 8. BACKUP RING
cartridge body to aid in installation.
Figure 66. System Relief Valve
2. Remove the plug, spring, and seat from the car-
tridge body.

RELIEF VALVE, INSPECT Lok™ hydraulic inlet hose and adapter between the
Inspect all parts for damage, if any parts other
than those parts contained in parts kits Hyster P/N 3. Remove all plugs and caps and install the hy-
1579908 (seal kit) are damaged, replace the relief draulic hoses as noted during removal.
valve. If the relief valve is not going to be installed
in the steering control housing immediately, coat the 4. Install dashboard, seal plate, kick panel, and
valve with a light coat of hydraulic oil. floor plate.

RELIEF VALVE, ASSEMBLE
• S30FT, S35FT, S40FTS (E010)
NOTE: Apply a light coat of clean hydraulic oil to • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
O-rings and seals to assist in installation. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
1. Install the large O-ring, backup ring, and small • H2.0-3.5FT (H40-70FT) (L177)
O-ring on the cartridge body. See Figure 66.
2. Install the seat and spring into the cartridge • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
body. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
3. Install plug the number of turns noted during • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
disassembly. 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
4. Install the anti-tamper ring and snap ring into
the cartridge body. See Frame 100 SRM 1316 for lift truck models
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024,
5. Install the system relief valve into steering con-
E024, F024)
trol unit housing. Place the torque tool in the
notches on the cartridge body (see Figure 66). See Frame 100 SRM 1321 for lift truck models
Tighten to 18 ±6 N•m (160 ±53 lbf in). Install • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
the cap onto system relief valve. See Figure 65. J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
STEERING CONTROL UNIT, INSTALL H175FT36, H190FT) (A299)
1. Coat the two O-rings to be installed on the main See Frame 100 SRM 1423 for lift truck models
control valve with clean hydraulic oil. Install the • S50CT (A267)
two O-rings between the main control valve and • H2.0-2.5CT (H50CT) (A274)
the SCU.
NOTE: During the performance of Step 2, use care • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
not to damage the O-rings on the main control valve. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
2. Position the SCU under the steering shaft and H175FT36, H190FT) (B299)
raise the SCU to completely engage the steering 5. Check the steering relief pressure. See Table 2.
shaft. When the steering shaft is completely en- If the steering relief pressure is not correct,
gaged, position the SCU against the main control adjust the pressure by turning the plug clock-
valve, and install two mounting capscrews and wise (increase pressure) or counterclockwise
washers. Tighten to 45 to 55 N•m (33 to 41 lbf ft). (decrease pressure) until the correct pressure is
NOTE: Lift truck models H2.0-3.5FT (H40-70FT) reached. See Figure 66.

Table 2. Steering Relief Pressures
Lift Truck Model Steering Relief Pressure @ 800 RPM

S30FT, S35FT, S40FTS (E010) and H1.6FT, H1.8FT, 7.25 ±0.3 MPa (1051 ±43.5 psi)
H2.0FTS (H30FT, H35FT, H40FTS) (F001)
S2.0-3.5FT (S40-70FT, S55FTS) (F187), 11.0 ±0.3 MPa (1595 ±43.5 psi)
H2.0-3.5FT (H40-70FT) (L177), S50CT (A267),
and H2.0-2.5CT (H50CT) (A274)
S2.0-3.5FT (S40-70FT, S55FTS) (F187) and 12.0 ±0.3 MPa (1740 ±43.5 psi)
H2.0-3.5FT (H40-70FT) (L177)
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 10.3 ±0.3 MPa (1494 ±43.5 psi)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT 12.4 ±0.3 MPa (1798 ±43.5 psi)
(H80, 90, 100, 110, 120FT) (N005, P005, R005)
S6.0FT, S7.0FT (S135FT, S155FT) (D024, 12.4 ±0.3 MPa (1798 ±43.5 psi)
E024, F024) and H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006)
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, 15.5 ±0.3 MPa (2250 ±43.5 psi)
H190FT) (A299, B299)

2000 SRM 1137 9/12 (7/12)(4/12)(3/12)(1/12)(8/11)(7/11)(6/11)(5/10)(4/09) Printed in U.S.A.

CYLINDER REPAIR
S30FT, S35FT, S40FTS [E010]; E1.50-2.00XM (E25-35Z,
E40ZS) [E114, F114]; H1.6FT, H1.8FT, H2.0FTS
S55FTS) [F187]; J1.60-2.00XMT (J30-40ZT) [J160];
H2.0-3.5FT (H40-70FT) [L177]; S4.0, 4.5, 5.5FT,
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [G004, H004]; J2.00-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]; H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005,
R005]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098];
S50CT [A267]; H2.0-2.5CT (H50CT) [A274]
PART NO. 1580516 2100 SRM 1139

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
Cylinder Repair Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 2
Tilt Cylinder Repair........................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 5
Clean .............................................................................................................................................................. 5
Assemble ........................................................................................................................................................ 8
Install ............................................................................................................................................................. 9
Tilt Cylinders, Adjust .................................................................................................................................... 10
Tilt Cylinder Leak Check .............................................................................................................................. 12
Torque Specifications..................................................................................................................................... 13
Piston Rod Nut .......................................................................................................................................... 13
Gland.......................................................................................................................................................... 13
Tilt Cylinder Mounting Capscrew ............................................................................................................ 13
Tilt Cylinder Rod End Nut........................................................................................................................ 13
Lift Cylinder Repair........................................................................................................................................... 14
Main Lift Cylinders ....................................................................................................................................... 14
Remove....................................................................................................................................................... 14
Disassemble ............................................................................................................................................... 15
Clean .......................................................................................................................................................... 16
Inspect........................................................................................................................................................ 16
Assemble .................................................................................................................................................... 16
Install ......................................................................................................................................................... 17
System Air Bleed Procedures ............................................................................................................... 18
Two-Stage FFL Left Side Main Lift Cylinder .............................................................................................. 19
Disassemble ............................................................................................................................................... 19
Clean .......................................................................................................................................................... 19
Inspect........................................................................................................................................................ 19
Assemble .................................................................................................................................................... 19
Install ......................................................................................................................................................... 21
Free-Lift Cylinder.......................................................................................................................................... 21
Remove....................................................................................................................................................... 21
Disassemble ............................................................................................................................................... 24
Clean .......................................................................................................................................................... 24
Inspect........................................................................................................................................................ 24
Assemble .................................................................................................................................................... 24
Install ......................................................................................................................................................... 25
Lift Cylinders Leak Check ............................................................................................................................ 27
Fork Positioner Cylinder Repair ....................................................................................................................... 27
Remove ........................................................................................................................................................... 27
Disassemble ................................................................................................................................................... 27
Clean .............................................................................................................................................................. 30
Inspect ............................................................................................................................................................ 30
Assemble ........................................................................................................................................................ 31
Install ............................................................................................................................................................. 31
Fork Positioner Cylinder Adjustment ...................................................................................................... 31
Seal Kit Installation .......................................................................................................................................... 32

Table of Contents Cylinder Repair

External Installation (Seal and Back-Up Ring)........................................................................................... 32
Internal Installation (Piston Rod Assembly) ............................................................................................... 32
S30FT, S35FT, S40FTS [E010];

E1.50-2.00XM (E25-35Z, E40ZS) [E114, F114];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
J1.60-2.00XMT (J30-40ZT) [J160];
H2.0-3.5FT (H40-70FT) [L177];
S120FTS; S120FTPRS) [G004, H004];
J2.00-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108];
110, 120FT) [N005, P005, R005];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
ii
General
This section has a description and the repair proce- number and the design of the parts can be different,
dures for several different types of cylinders. The but the operation of the cylinders is the same.
Description
This manual covers many different types of cylin- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
ders. Each cylinder will be described in detail. (H80, 90, 100, 110, 120FT) (N005, P005, R005)
• E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
Tilt cylinders are fastened between the frame of the (E098)
lift truck and the outer weldment of the mast to • S50CT (A267)
change the angle of the mast and forks.
On lift truck models listed below there is one free-lift
Two single-stage main lift cylinders and a free-lift chain and chain sheave.
cylinder are used to raise the carriage and extend the • S30FT, S35FT, S40FTS (E010)
mast weldments. • E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
The two main lift cylinders are installed at the back
of the outer mast. The base of each lift cylinder sits
H40FTS) (F001)
on a mount at the bottom crossmember of the outer
mast. The top of each main lift cylinder rod fits into a On lift truck models listed below, equipped with a
guide on the top crossmember of the inner mast. The three-stage full free-lift mast, there are two free lift
free-lift cylinder is installed in the inner mast. Each chains and chain sheaves. On lift truck models listed
of the lift cylinders has an internal lowering control below, equipped with a two-stage limited free-lift
valve. A single external lowering control valve is con- mast, there are no free lift chains or sheaves.
nected by tubing and hoses to all the lift cylinders. • H2.0-2.5CT (H50CT) (A274)
NOTE: On lift truck models listed below there are two On all lift trucks, the free-lift chains connect at one
free-lift chains and chain sheaves. end of the mid-crossmember of the inner mast. Two
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) chain sheaves are installed on a crosshead on the
• H2.0-3.5FT (H40-70FT) (L177) rod of the free-lift cylinder. The chains then go over
• E2.00-3.20XM (E45-65Z) (G108) sheaves on the crosshead and connect to the carriage.
• J2.00-3.20XM (J40-65Z) (B416)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
1
Safety Procedures When Working Near Mast 2100 SRM 1139
Safety Procedures When Working Near Mast

The following procedures MUST be used when in- OR
specting or working near the mast. Additional pre-
cautions and procedures can be required when re- • If parts of the mast must be in a raised po-
pairing or removing the mast. sition, install a safety chain to restrain the
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
WARNING these procedures:
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or 1. Put mast in vertical position.
death can result if part of the body is hit by
parts of the mast or the carriage. 2. Raise mast to align bottom crossmember of weld-
• Never put any part of the body into or under ment that moves in outer weldment with cross-
the mast or carriage unless all parts are com- member on outer weldment. On the two-stage
pletely lowered or a safety chain is installed. and free-lift mast, the moving part is the inner
Also make sure that the power is OFF and the weldment. On the three-stage mast, it is the in-
key is removed. Put a DO NOT OPERATE tag termediate weldment. On the four-stage mast, it
in the operator’s compartment. Disconnect is the first intermediate weldment. See Figure 1.
the battery and put a tag or lock on the bat- 3. Use a 3/8-inch minimum safety chain with a hook
tery connector. to fasten the crossmembers together so the mov-
• Be careful of the forks. When the mast is able member cannot lower. Put hook on back side
raised, the forks can be at a height to cause of mast. Make sure hook is completely engaged
an injury. with a link in the chain. Make sure safety chain
• DO NOT climb on the mast or lift truck at any does not touch lift chains or chain sheaves, tubes,
time. Use a ladder or personnel lift to work hoses, fittings, or other parts on the mast.
on the mast.
• DO NOT use blocks to support the mast weld- 4. Lower mast until there is tension in safety chain
ments nor to restrain their movement. and free-lift cylinder (two-stage full free-lift,
• Mast repairs require disassembly and re- three-stage, and four-stage) is completely re-
moval of parts and can require removal of tracted. If running, turn the power OFF. Apply
the mast or carriage. Follow the repair pro- the parking brake. Install a DO NOT REMOVE
cedures in this section. tag on the safety chain(s).
WHEN WORKING NEAR THE MAST ALWAYS: 5. Install another safety chain (3/8-in. minimum)
• Lower the mast and carriage completely. between the top or bottom crossmember of the
Push the lift/lower control lever forward and carriage bar and a crossmember on the outer
make sure there is no movement in the mast. weldment.
Make sure that all parts of the mast that
move are fully lowered. 6. After lowering or restraining the mast, shut off
the power, and remove key.
NOTE: Place a DO NOT OPERATE tag in the oper-

ator’s compartment.
7. Disconnect battery and put a tag or lock on bat-

tery connector.
2
2100 SRM 1139 Safety Procedures When Working Near Mast
A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST

B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER WELDMENT 5. FREE-LIFT CYLINDER
2. INNER WELDMENT 6. CARRIAGE BAR
3. INTERMEDIATE WELDMENT 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE WELDMENT
Figure 1. Two-Stage LFL, Two-Stage FFL, Three-Stage FFL, and Four-Stage FFL Masts
3
Tilt Cylinder Repair 2100 SRM 1139
Tilt Cylinder Repair

REMOVE 2. Stroke cylinder to the full back tilt position.
3. Disconnect the hydraulic lines at the tilt cylin-

WARNING der. Install caps on the hydraulic lines and in
Before removing the tilt cylinder(s), tilt the the cylinder ports.
mast forward. Use a chain to hold the mast to
the frame and prevent the mast from moving 4. Use a lifting device to move large tilt cylinders.
forward. Remove the capscrew and retainer from the an-
chor pin. Using a drift pin or similar tool, push
WARNING the anchor pin out of the frame.
DO NOT push the anchor pins out of the rod 5. Using a lifting device, remove the tilt cylinder
end with your fingers. DO NOT permit the tilt from the lift truck.
cylinders to drop and cause damage.
6. Repeat above steps for the remaining tilt cylin-
1. At the mast, remove the capscrew and retainer der.
from the anchor pin. Using a drift pin or similar
tool, push the anchor pin out of the rod end. See
Figure 2.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 4. ANCHOR PIN
2. RETAINER 5. TILT SPACER
3. LUBRICATION FITTING
Figure 2. Tilt Cylinder Removal
4
2100 SRM 1139 Tilt Cylinder Repair
DISASSEMBLE 5. Remove and discard the O-ring and piston seal

from the piston. See Figure 3.
NOTE: The following steps have detailed disassembly
instructions. Perform only those steps required to INSPECT
repair the tilt cylinder.
Inspect the gland for damage to the threads and the
NOTE: Note the position of the rod end and number seal surfaces. Replace the gland if damaged.
of turns used to remove the rod end.
Inspect the piston for any damage to the seal surfaces
1. Place the tilt cylinder in a soft jaw vise. Remove and replace if damaged.
the rod end and, if equipped, tilt spacer from the
rod. Inspect the rod for damage to the rod surface and
ensure that the rod is not bent. Replace the rod if
See Figure 3 for lift truck models found to be damaged.
• E2.00-3.20XM (E45-65Z) (G108)
• E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) Inspect the inner surface of the cylinder tube for
(E098) damage. If the tube is found to be damaged, replace
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, the cylinder.
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177) Inspect the bushings for damage. If damaged, re-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- place bushings.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) CLEAN
• H2.0-2.5CT (H50CT) (A274)
• J2.00-3.20XM (J40-65Z) (B416) WARNING
• S30FT, S35FT, S40FTS (E010) Cleaning solvents can be flammable and toxic
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) and can cause skin irritation. When using
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; cleaning solvents, always follow the solvent
S80, 100FTBCS; S120FTS; S120FTPRS) manufacturer’s recommended safety proce-
(G004, H004) dures.
• S50CT (A267)
See Figure 4 for lift truck models cause injury to the user or to other personnel.
• E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114) Make sure the path of the compressed air is
• J1.60-2.00XMT (J30-40ZT) (J160) away from all personnel. Wear protective gog-
2. Using a pin-type spanner wrench, remove the eyes.
gland from the tilt cylinder. Remove the rod and
piston assembly from the cylinder.
CAUTION
NOTE: To prevent damage to sealing surfaces, use DO NOT allow cleaning solvent to come in con-
brass tools when removing seals and O-rings. tact with rubber components, as it will damage
those components.
3. Remove and discard the O-ring, backup ring,
seal, and wiper from the gland. Clean all metal parts in solvent and dry with com-
pressed air.
NOTE: Perform Step 4 only if the piston or rod has
been damaged.
4. Place the rod in a soft-jaw vise and remove the

nut and piston from the rod.
5
Figure 3. Tilt Cylinder
6
Legend for Figure 3

A. S2.0-2.5FT (S40-S55FT, S55FTS) (F187), S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001), H2.0-2.5FT (H40-50FT) (L177), E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM
(J40-65Z) (B416), S50CT (A267), AND H2.0-2.5CT (H50CT) (A274)
B. S3.0-3.5FT (S60-S70FT) (F187) AND H3.0-3.5FT (H60-70FT) (L177)
C. S4.0, 4.5, 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) AND
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
1. SHELL 7. O-RING
2. GLAND 8. PISTON
3. ROD 9. PISTON SEAL
4. WIPER RING 10. NUT
5. SEAL 11. WEAR RING
6. BACKUP RING 12. BUSHING
1. CYLINDER SHELL 6. BACKUP RING

2. RETAINER 7. O-RING
3. ROD 8. NUT
4. WIPER RING 9. PISTON
5. SEAL 10. PISTON SEAL
Figure 4. Tilt Cylinder for Lift Truck Models E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114) and
J1.60-2.00XMT (J30-40ZT) (J160)
7
ASSEMBLE 4. Install the rod and piston assembly in the cylin-

der. Using a pin-type spanner, install the gland
NOTE: To prevent damage to sealing surfaces, use in the cylinder. Tighten the gland to:
brass tools when installing seals and O-rings.
a. 170 to 237 N•m (125 to 175 lbf ft) for lift
1. Install a new piston seal and O-ring on the pis- truck models
ton. See Figure 3. • S2.0-2.5FT (S40-S55FT, S55FTS) (F187)
• H2.0-2.5FT (H40-50FT) (L177
NOTE: Perform Step 2 only if the piston was removed
• S50CT (A267)
from the rod.
• H2.0-2.5CT (H50CT) (A274)
2. Place the rod in a soft-jaw vise and lube the
b. 163 to 190 N•m (120 to 140 lbf ft) for lift
threads of the nut with hydraulic oil. Install the
truck models
piston on the rod and tighten the nut to:
• S30FT, S35FT, S40FTS (E010)
a. 170 to 220 N•m (125 to 162 lbf ft) on lift truck • E1.50-2.00XM (E25-35Z, E40ZS)
models (E114,F114)
• S2.0-2.5FT (S40-S55FT, S55FTS) (F187) • J1.60-2.00XMT (J30-40ZT) (J160)
• S30FT, S35FT, S40FTS (E010) • H1.6FT, H1.8FT, H2.0FTS (H30FT,
• E1.50-2.00XM (E25-35Z, E40ZS) H35FT, H40FTS) (F001)
(E114,F114) • E2.00-3.20XM (E45-65Z) (G108)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • J2.00-3.20XM (J40-65Z) (B416)
H40FTS) (F001)
c. 400 to 500 N•m (295 to 370 lbf ft) for lift
• H2.0-2.5FT (H40-50FT) (L177)
truck models
• E2.00-3.20XM (E45-65Z) (G108)
• S3.0-3.5FT (S60-S70FT) (F187)
• J2.00-3.20XM (J40-65Z) (B416)
• H3.0-3.5FT (H60-70FT) (L177),
• S50CT (A267)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
• H2.0-2.5CT (H50CT) (A274)
b. 320 to 400 N•m (240 to 295 lbf ft) on lift truck S120FTPRS) (G004, H004)
models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• S3.0-3.5FT (S60-S70FT) (F187) 5.5FT (H80, 90, 100, 110, 120FT) (N005,
• H3.0-3.5FT (H60-70FT) (L177) P005, R005)
• E3.50-5.50XL, E4.50XLS (E70-120Z,
c. 163 to 190 N•m (120 to 140 lbf ft) on lift truck E100ZS) (E098)
model
• J1.60-2.00XMT (J30-40ZT) (J160) 5. Place cylinder in a soft-jaw vise and install tilt
spacer, if equipped, and rod end on rod as noted
d. 400-440 N•m (295 to 325 lbf ft) on lift truck during removal. Lubricate threads on capscrew
models with lubricant, Hyster P/N 186061. Install cap-
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, screw in rod end so that capscrew head is on the
120FT; S80, 100FTBCS; S120FTS; inboard side of rod end. Install washer and nut
S120FTPRS) (G004, H004) on capscrew. Washer and nut must be on the out-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- board side of rod end. See Figure 5. Tighten nut
5.5FT (H80, 90, 100, 110, 120FT) (N005, to 90 N•m (66 lbf ft).
P005, R005)
• E3.50-5.50XL, E4.50XLS (E70-120Z, 6. Repeat the above steps for the other tilt cylinder.
E100ZS) (E098)
3. Install a new wiper, seal, backup ring, and O-ring

on the gland.
8
INSTALL 5. Remove chain holding the mast to the frame.
1. Using a lifting device, place the cylinder in

mounting position on the lift truck frame. In- WARNING
stall the anchor pin. Install the retainer and DO NOT put hands between the cylinder rod
capscrew. See Figure 2. Lubricate the threads on end and the mast. Serious injury can occur.
the capscrew with lubricant, Hyster P/N 186061,
and tighten capscrew to: 6. Operate the tilt cylinders. Check for correct op-
eration and leakage. Adjust the tilt cylinders.
a. 38 N•m (28 lbf ft) for lift truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-S70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• E1.50-2.00XM (E25-35Z, E40ZS)
(E114,F114)
• E2.00-3.20XM (E45-65Z) (G108)
• J2.00-3.20XM (J40-65Z) (B416)
• J1.60-2.00XMT (J30-40ZT) (J160)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
b. 66 N•m (49 lbf ft) for lift truck models

• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
S120FTPRS) (G004, H004)
c. 66 to 73 N•m (49 to 54 lbf ft) for lift truck

models NOTE: LEFT TILT CYLINDER SHOWN. TILT CYLIN-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- DER AND MAST FOR LIFT TRUCK MODELS
5.5FT (H80, 90, 100, 110, 120FT) (N005, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
P005, R005) 90, 100, 110, 120FT) (N005, P005, R005) SHOWN,
ALL OTHERS SIMILAR. PARTS OF MAST OMITTED
d. 77 N•m (57 lbf ft) for lift truck model FOR CLARITY.
• E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098) A. OUTBOARD SIDE B. INBOARD SIDE
2. Connect the hydraulic lines to the tilt cylinder. 1. NUT 3. ROD END
Slowly stroke the cylinders until the rod holes
line up with the mast tilt anchor holes. Figure 5. Rod End Installation
3. Install anchor pin and retainer on tilt anchor.
4. Repeat above steps for remaining tilt cylinder.
9
TILT CYLINDERS, ADJUST • E1.50-2.00XM (E25-35Z, E40ZS)

(E114,F114)
• E2.00-3.20XM (E45-65Z) (G108)
WARNING
• J2.00-3.20XM (J40-65Z) (B416)
When the tilt cylinders have tilt limit spacers, • J1.60-2.00XMT (J30-40ZT) (J160)
make sure they are installed during installa- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
tion procedures. Without the tilt limit spacers, H5.0-5.5FT (H80, 90, 100, 110,
the mast can tilt too much and cause an acci- 120FT) (N005, P005, R005)
dent or serious injury. • E3.50-5.50XL, E4.50XLS (E70-120Z,
Check the tilt cylinder stroke by slowly tilting the E100ZS) (E098)
mast fully forward and backward several times. Both • S50CT (A267)
tilt cylinders must stop their stroke at the same time. • H2.0-2.5CT (H50CT) (A274)
Adjust the rod ends as shown in Figure 6. There must (2) 0.5 mm (0.02 in.) for lift truck model
be no twist in the mast weldments. • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
1. Adjust the stroke of the tilt cylinders WITHOUT 120FT; S80, 100FTBCS; S120FTS;
tilt limit spacers as follows: S120FTPRS) (G004, H004)
a. Adjust the rod ends to (3) After the adjustments are complete,
tighten the nuts on the rod ends to
(1) 15 mm (0.6 in.) for lift truck model 90 N•m (66 lbf ft).
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; c. Tilt the mast fully backward and measure
S120FTPRS) (G004, H004), See Fig- the tilt angle. See the Nameplate for tilt
ure 7. angles. If necessary, adjust both rod ends
equally for the correct angle.
(2) 20 mm (0.8 in.) for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 2. Adjust the stroke of the tilt cylinders WITH tilt
H5.0-5.5FT (H80, 90, 100, 110, limit spacers as follows:
120FT) (N005, P005, R005) See Fig- a. Adjust the rod ends to 15 mm (0.6 in.) for all
ure 7. tilt cylinders as shown in Figure 6.
(3) 32 mm (1.25 in.) for lift truck model b. Slowly tilt the mast forward until one cylin-
• J1.60-2.00XMT (J30-40ZT) (J160) der rod stops. On the opposite cylinder,
See Figure 7. loosen the capscrews on the rod end. Use
b. Slowly tilt the mast backward until one a wrench and turn the cylinder rod IN as
cylinder rod stops. On the opposite cylin- necessary. Repeat this procedure until both
der, loosen the capscrews on the rod end. cylinder rods stop at the same position
Measure the distance from the end of the within 1 mm (0.04 in.).
cylinder to the back end of the rod end. Use c. Slowly tilt the mast backward until one rod
a wrench and turn the cylinder rod IN until end just contacts the spacer. Add shims to
the dimension starts to decrease, then stop. fill the gap at the opposite rod end until both
Repeat this procedure until both cylinder rod ends contact the spacers within 0.5 mm
rods stop at the same position within: (0.02 in.).
(1) 1 mm (0.04 in.) for lift truck models d. After the adjustments are complete, tighten
• S30FT, S35FT, S40FTS (E010) the nuts on the rod ends to 90 N•m (66 lbf ft).
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001) e. Tilt the mast fully backward and measure
• S2.0-3.5FT (S40-S70FT, S55FTS) the tilt angle. See the nameplate for tilt an-
(F187) gles. If necessary, add an equal number of
• H2.0-3.5FT (H40-70FT) (L177) shims to both rods for the correct angle.
10
A. DIMENSION A = 15 mm (0.60 in.) A. 32 mm (1.25 in.) FOR J1.60-2.00XMT (J30-40ZT)

(J160) SHOWN.
1. MAST 4. TILT LIMIT SPACER
2. ROD END 5. TILT CYLINDER 1. MAST 3. TILT CYLINDER
3. SHIMS 2. ROD END
Figure 6. Tilt Cylinder Adjustments; for All Figure 7. Tilt Cylinder Adjustments for Lift
Models Except J1.60-2.00XMT (J30-40ZT) Truck Models J1.60-2.00XMT (J30-40ZT) (J160),
(J160), S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
(G004, H004), and H4.0FT5/FT6; H4.5FTS5, H004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
(N005, P005, R005) P005, R005) Only
11
TILT CYLINDER LEAK CHECK the rate in Table 1 by the time of the test and
compare the numbers.
WARNING 3. If the tilt rate is greater than the specifications,
Never allow anyone under a raised carriage. lower the mast and remove the load from the
DO NOT put any part of your body in or forks. Install a valve between the port at the
through the lift mechanism unless all parts front of the tilt cylinder and the hydraulic line.
of the mast are completely lowered and the The valve must be able to completely shut off the
engine is STOPPED. flow of hydraulic oil. Put the load on the forks
again. Close the valve. Tilt the mast forward just
DO NOT try to find hydraulic leaks by putting
past the vertical position. If the mast continues
your hand on hydraulic components under
to tilt SLOWLY forward, the seals on the piston
pressure. Hydraulic oil can be injected into
are leaking.
the body by the pressure.
4. If the mast does not move, open the valve and
1. Put a capacity load on the forks. Use a safety
check the movement again. If the mast moves
chain to hold the load to the carriage. Raise the
forward when the gate valve is open, check for
load approximately 2.5 m (8 ft). Put the mast in
leaks in the hydraulic lines and fittings. If no
a vertical position.
leaks are found, the main control valve can be
2. Measure the distance that the rod for tilt cylin- worn or damaged. Remove the load from the
der extends from the shell. Check the distance forks when the checks are complete.
the rod moves in five or ten minutes. Multiply
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Lift Truck Model Hydraulic Oil Temperature/Mast Tilt Rate

20°C (68°F) 60°C (140°F)
mm/min in./min mm/min in./min
S2.0-3.5FT 1.0 0.04 6.8 0.30
(S40-S70FT, S55FTS) (F187),
E2.00-3.20XM (E45-65Z) (G108)
J2.00-3.20XM (J40-65Z) (B416), and
S50CT (A267)
S30FT, S35FT, S40FTS (E010) 1.0 0.04 5.4 0.21
H1.6FT, H1.8FT, H2.0FTS (H30FT, 1.0 0.04 5.7 0.23
H35FT, H40FTS) (F001)
H2.0-3.5FT (H40-70FT) (L177) and 1.0 0.04 6.3 0.25
H2.0-2.5CT (H50CT) (A274)
E1.50-2.00XM (E25-35Z, E40ZS) (E114) 0.8 0.03 5.0 0.20
and J1.60-2.00XMT (J30-40ZT) (J160)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 1.1 0.04 7.3 0.30
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)
E1.50-2.00XM (E25-35Z, E40ZS) (F114) .63 0.25 4.3 0.16
E3.50-5.50XL, E4.50XLS (E70-120Z, .74 .029 4.94 1.94
E100ZS) (E098)
12
TORQUE SPECIFICATIONS S3.0-3.5FT (S60-S70FT) (F187), H3.0-3.5FT

(H60-70FT) (L177), S4.0, 4.5, 5.5FT, S5.5FTS,
Piston Rod Nut (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004), H4.0FT5/FT6;
S2.0-2.5FT (S40-S50FT, S55FTS) (F187), S30FT, H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z, 110, 120FT) (N005, P005, R005), E3.50-5.50XL,
E40ZS) (E114,F114), H1.6FT, H1.8FT, H2.0FTS E4.50XLS (E70-120Z, E100ZS) (E098)
(H30FT, H35FT, H40FTS) (F001), H2.0-2.5FT 400 to 500 N•m (295 to 370 lbf ft)
(H40-50FT) (L177), J2.00-3.20XM (J40-65Z)
(B416), E2.00-3.20XM (E45-65Z) (G108), S50CT S30FT, S35FT, S40FTS (E010), E1.50-2.00XM
(A267), and H2.0-2.5CT (H50CT) (A274) (E25-35Z, E40ZS) (E114), J1.60-2.00XMT
170 to 220 N•m (125 to 162 lbf ft) (J30-40ZT) (J160), and H1.6FT, H1.8FT,
S3.0-3.5FT (S60-S70FT) (F187), H3.0-3.5FT 163 to 190 N•m (120 to 140 lbf ft)
(H60-70FT) (L177)
320 to 400 N•m (240 to 295 lbf ft) Tilt Cylinder Mounting Capscrew
J1.60-2.00XMT (J30-40ZT) (J160) For lift truck models S2.0-2.5FT (S40-S50FT,
163 to 190 N•m (120 to 140 lbf ft) S55FTS) (F187), S30FT, S35FT, S40FTS (E010),
E1.50-2.00XM (E25-35Z, E40ZS) (E114), H1.6FT,
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
(F001), J1.60-2.00XMT (J30-40ZT) (J160),
H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H2.0-2.5FT (H40-50FT) (L177), S50CT (A267),
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
and H2.0-2.5CT (H50CT) (A274)
P005, R005), and E3.50-5.50XL, E4.50XLS
38 N•m (28 lbf ft)
(E70-120Z, E100ZS) (E098)
400 to 440 N•m (295 to 325 lbf ft) For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
Gland S120FTPRS) (G004, H004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
S2.0-2.5FT (S40-S50FT, S55FTS) (F187),
110, 120FT) (N005, P005, R005)
H2.0-2.5FT (H40-50FT) (L177), S50CT (A267),
68 N•m (50 lbf ft)
and H2.0-2.5CT (H50CT) (A274)
170 to 237 N•m (125 to 175 lbf ft) For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
77 N•m (57 lbf ft)
Tilt Cylinder Rod End Nut

90 N•m (66 lbf ft)
13
Lift Cylinder Repair 2100 SRM 1139
Lift Cylinder Repair

MAIN LIFT CYLINDERS mast section to the top crossmember of the
outer mast section.
Remove • On the three-stage mast, use safety chain to
connect the bottom crossmember of the inter-
WARNING mediate mast section to the top crossmember
Before working on or near the mast, see Safety of the outer mast section. Use another safety
Procedures When Working Near Mast and Fig- chain to connect the bottom crossmember to
ure 1. a crossmember on the intermediate or outer
mast section.
NOTE: The following procedures are for the removal Lower the mast so the safety chains hold the
of the lift cylinders with the mast installed on the lift weight of the mast sections.
truck.
3. Raise the mast until it is almost fully extended.
1. Remove the carriage as described in the carriage Use a safety chain to connect middle crossmem-
removal procedures located in the section ber of first intermediate mast section to top cross-
member on outer mast section. Lower mast so
Mast Repairs, 2-, 3-, and 4-Stage Masts 4000 safety chain holds weight of the mast sections.
SRM 1148 for lift truck models shown below:
• S30FT, S35FT, S40FTS (E010)
WARNING
H40FTS) (F001) Be careful when removing or installing snap
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) rings. These snap rings can come loose dur-
• H2.0-3.5FT (H40-70FT) (L177) ing removal or installation with enough force
• E1.50-2.00XM (E25-35Z, E40ZS) (E114, F114) to cause an injury. Always use the correct snap
• E2.00-3.20XM (E45-65Z) (G108) ring pliers and wear eye and face protection
• J2.00-3.20XM (J40-65Z) (B416) during removal or installation.
• J1.6-2.00XMT (J30-40ZT) (J160)
4. If working on a two- or three-stage mast, the
Mast Repairs, 2- and 3-Stage Masts 4000 snap ring and shims (washers) at the top of the
SRM 1250 for lift truck models shown below: cylinder are to be removed.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5. If working on a four-stage mast, on left-hand lift
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
cylinder, remove the snap ring from top of the
R005)
cylinder rod. On right-hand lift cylinder, remove
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
spacer and retainer from cylinder rod.
(G004, H004)
• E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) WARNING
(E098) Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
Mast Repair 4000 SRM 1431 for lift truck mod- draulic hoses until the oil in the system is cool.
els shown below:
• S50CT (A267) 6. Put a drain pan under the area of the hydraulic
• H2.0-2.5CT (H50CT) (A274) fittings. Disconnect and cap the hydraulic lines
at the cylinder. Retract the rod into the lift cylin-
NOTE: Perform Step 2 only if working on a lift truck der.
equipped with a two- or three-stage mast. Perform
Step 3 if working on a lift truck equipped with a four- 7. Remove the nut, washer, spacer, and capscrew
stage mast. at the mounting plate. On a two- or three-stage
mast, disconnect the main lift chain at the
2. Raise the mast until it is almost fully extended. mount. See Figure 10.
• On the two-stage mast, use safety chains to
connect the bottom crossmember of the inner 8. Use a lifting device, as necessary, to remove lift
cylinder from mast. Remove the lift cylinder
14
2100 SRM 1139 Lift Cylinder Repair
from the front of the mast. On a lift cylinder be-

ing removed from a four-stage mast, keep shims
from top of left-hand cylinder with cylinder.
Disassemble
CAUTION
Carefully disassemble the main lift cylinders
so the piston rods and sliding surfaces are not
damaged.
NOTE: To disassemble the left-hand main lift cylin-

der on trucks equipped with a two-stage FFL mast,
see the section Two-Stage FFL Left Side Main Lift
Cylinder.
NOTE: To prevent damage to sealing surfaces, use

brass tools when removing seals and O-rings. 1. SHELL 7. O-RING
2. ROD 8. SNAP RING
1. Loosen gland with spanner wrench. 3. GLAND 9. WIPER RING
4. ROD SEAL 10. SEAL
2. Remove gland from shell. 5. CHECK VALVE 11. BACKUP RING
6. WASHER 12. WEAR RING
3. Remove rod and piston assembly from shell.
Drain hydraulic oil into container. See Figure 8 Figure 8. Two-Stage LFL Main Lift Cylinder
and Figure 9.
4. Remove and discard O-rings, seals, backup rings,

wiper rings, and wear rings.
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection
during removal or installation.
NOTE: Step 5 does not apply for lift trucks shown

below or lift trucks equipped with a two-stage FFL
mast.
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
(H80, 90, 100, 110, 120FT) (N005, P005, R005) 1. SHELL 8. WIPER RING
2. ROD 9. SEAL
• E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) 3. GLAND 10. O-RING
(E098) 4. SPACER 11. BACKUP RING
5. CHECK VALVE 12. WEAR RING
5. Remove snap ring, washer, and check valve from 6. WASHER 13. ROD SEAL
base of piston. 7. SNAP RING 14. PISTON RING
6. Repeat disassembly procedure for the opposite Figure 9. Three-Stage FFL Main Lift Cylinder
cylinder.
15
Clean
WARNING
Be careful when removing or installing snap
WARNING
Cleaning solvents can be flammable and toxic ing removal or installation with enough force
and can cause skin irritation. When using to cause an injury. Always use the correct snap
cleaning solvents, always follow the solvent ring pliers and wear eye and face protection
manufacturer’s recommended safety proce- during removal or installation.
dures.
NOTE: Step 2 does not apply for lift trucks shown be-
Compressed air can move particles so they low or lift trucks equipped with two-stage FFL Mast.
cause injury to the user or to other personnel. • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
Make sure the path of the compressed air is 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
away from all personnel. Wear protective gog- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
gles or a face shield to prevent injury to the (H80, 90, 100, 110, 120FT) (N005, P005, R005)
eyes. • E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098)
CAUTION
2. Install check valve and O-ring in base of piston
of main lift cylinder and left-hand lift cylinder.
tact with rubber components, as it will damage
Make sure arrow on check valve is toward base
those components.
of piston. Install washer and snap ring for check
Clean all metal parts in solvent and dry with com- valve. See Figure 8 and Figure 9.
pressed air.
CAUTION
Inspect A difficult and important step in assembling
Inspect the gland for damage to the threads and the lift cylinders is the correct installation of the
seal surfaces. If damaged, replace gland. seals. Most lift cylinder maintenance is caused
by seal leaks. DO NOT damage any parts dur-
Inspect the piston for any damage to the seal suring assembly.
faces. If damaged, replace piston.
3. Install the wear ring, piston seal, and backup
Inspect the rod for damage to the rod surface and ring on to the piston assembly. On the main lift
ensure that the rod is not bent. If damaged, replace cylinders, install seal ring. Install spacer, if used.
rod.
4. Push the piston and rod assembly into the shell.
Inspect the inner surface of the cylinder tube for
damage. If damaged, replace cylinder assembly. 5. Install the rod seal ring and wiper into the gland.
Install the O-ring and backup ring on the outside
Assemble of the gland.
NOTE: The procedures in this section cover all cylin-

CAUTION
ders except for the left side main lift cylinders on two-
stage FFL masts. See the section Two-Stage FFL Additives may damage the hydraulic system.
Left Side Main Lift Cylinder for the procedures. Before using additives, contact your local Hys-
ter dealer.
brass tools when installing seals and O-rings. NOTE: To prevent possible damage to the piston rod,
use care while installing the gland.
1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil. Use new O-rings, seals, 6. Install the gland on the piston rod.
and wear rings. See Figure 8 and Figure 9. 7. Install gland into cylinder and tighten gland to
340 to 410 N•m (250 to 300 lbf ft).
16
8. Install the lowering control valve in port at base ring from the top of the cylinder rod. On the
of left-hand, main control cylinder. See Figure 9 right-hand lift cylinder, install spacer and re-
and Figure 8. tainer to the cylinder rod. Tighten nuts from
retainer to 33 N•m (24 lbf ft).
Install
4. Connect the hydraulic line at the base of the lift
1. Using a lifting device, install the lift cylinders in cylinders. Connect the hydraulic line at the top of
the mount at the bottom of the outer mast. the left-hand main lift cylinder on the two-stage
and four-stage full free-lift masts. Connect hy-
2. Install the nut, bolt, and spacer (11, Figure 10) draulic line at tube on right-hand lift cylinder.
at the mount for the lift cylinders.
5. For the four-stage full free-lift masts, install bal-
a. For lift truck models listed below, tighten nut ance line between main lift cylinders. See Fig-
to 53 N•m (39 lbf ft) ure 10.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, 6. Connect the main lift chains as necessary and
H40FTS) (F001) adjust as specified in the section
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) Mast Repairs, 2-, 3-, and 4-Stage Masts 4000
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, SRM 1148 for lift truck models shown below:
120FT; S80, 100FTBCS; S120FTS; • S30FT, S35FT, S40FTS (E010)
S120FTPRS) (G004, H004) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
• E1.50-2.00XM (E25-35Z, E40ZS (E114, H40FTS) (F001)
F114) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• E2.00-3.20XM (E45-65Z) (G108) • H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z) (B416) • E1.50-2.00XM (E25-35Z, E40ZS) (E114, F114)
• J1.60-2.00XMT (J30-40ZT) (J160) • E2.00-3.20XM (E45-65Z) (G108)
• S50CT (A267) • J2.00-3.20XM (J40-65Z) (B416)
• H2.0-2.5CT (H50CT) (A274) • J1.6-2.00XMT (J30-40ZT) (J160)
b. For lift truck models listed below, tighten nut Mast Repairs, 2- and 3-Stage Masts 4000
to 38 N•m (28 lbf ft) SRM 1250 for lift truck models shown below:
5.5FT (H80, 90, 100, 110, 120FT) (N005, 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
P005, R005) R005)
• E3.50-5.50XL, E4.50XLS (E70-120Z, • S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
E100ZS) (E098) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
3. Use a lifting device to lower the inner mast weld- • E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
ment (two-stage) or intermediate mast weldment (E098)
(three-stage) on to the lift cylinder. See Figure 10
for the correct adjustment of the lift cylinders. Mast Repair 4000 SRM 1431 for lift truck mod-
els shown below:
a. If working on the two- or three-stage mast, • S50CT (A267)
install the snap ring and shims (washers) at • H2.0-2.5CT (H50CT) (A274)
the top of the cylinders.
b. If working on the four-stage mast, on the left

hand cylinder, install the washers and snap
17
System Air Bleed Procedures b. With the forks unloaded and the engine
speed at idle, raise the carriage using the hy-
NOTE: To bleed the air from the cylinders, with a ca- draulic control. Raise the carriage 300 mm
pacity load properly secured to the forks, completely (12 in.) and then stop for 10 seconds to re-
cycle the mast 2 to 3 times. Repeat if necessary. duce the pressure in the cylinder. Repeat
this procedure until the oil flowing from
1. Remove the air from the cylinders on the two-
around the threads is free of air bubbles.
stage FFL as described below. See Figure 11.
c. Stop the carriage at the top of the cylinder
a. Loosen the screws two turns to permit oil to
stroke. Tighten the screws.
flow around the threads of the screw.
NOTE: BALANCE LINE IS USED ON FOUR-STAGE FFL MAST ONLY.

1. BALANCE LINE 8. HOSE
2. SNAP RING 9. LOWERING CONTROL VALVE
3. SHIM 10. RIGHT-HAND MAIN LIFT CYLINDER
4. FITTING AND O-RING 11. SPACER
5. LEFT-HAND MAIN LIFT CYLINDER 12. RETAINER
6. LOWERING CONTROL VALVE FITTING 13. NUT
7. HOUSING 14. BOLT
Figure 10. Main Lift Cylinders Installation
18
TWO-STAGE FFL LEFT SIDE MAIN LIFT Inspect the piston for any damage to the seal sur-
CYLINDER faces. If damaged, replace piston.
Disassemble Inspect the rod for damage to the rod surface and
ensure that the rod is not bent. If damaged, replace
NOTE: For disassembly procedures on the right side rod.
main lift cylinder, see the section Main Lift Cylinders
and Figure 11. Inspect the inner surface of the cylinder tube for
damage. If damaged, replace cylinder assembly.
1. Loosen the gland with a spanner wrench. See
Figure 11. Assemble
2. Remove gland, rod, and piston assembly from NOTE: To prevent damage to sealing surfaces, use
shell. Drain hydraulic oil into a container. brass tools when installing seals and O-rings.
3. Remove piston from rod. Remove gland from rod. 1. Install piston ring and wear ring onto piston.
4. Remove and discard rod wiper and rod seal from 2. Install rod wiper and rod seal in gland. Install
gland. Remove and discard O-ring, backup ring, O-ring, backup ring, and spacer outside of gland.
and spacer from gland.
3. Install gland onto rod and install the piston.
5. Remove and discard piston ring and wear ring Tighten piston to 170 to 200 N•m (125 to
from piston. 150. lbf ft).
Clean 4. Install gland, rod, and piston assembly into shell.
5. Tighten gland in shell until tight. Use the correct

WARNING spanner. Do NOT hit gland with a hammer and
Cleaning solvents can be flammable and toxic driver. Tighten gland to 340 to 410 N•m (250 to
and can cause skin irritation. When using 300 lbf ft).
manufacturer’s recommended safety proce- CAUTION
dures.
The correct screw and sealing washer must
Compressed air can move particles so they be used in this location. The wrong parts will
cause injury to the user or to other personnel. cause leaks or damage the cylinder. See your
Make sure the path of the compressed air is Hyster lift truck dealer for the correct parts.
gles or a face shield to prevent injury to the CAUTION
eyes.
CAUTION ter dealer.
6. Remove screw and sealing washer. Pour 150 cc
tact with rubber components, as it will damage
(5 oz) of hydraulic oil into the cylinder through
those components.
the hole. This oil provides a hydraulic cushion
Clean all metal parts in solvent and dry with com- when the cylinder reaches the top of its stroke.
pressed air. See Figure 10. Install the screw and sealing
washer and tighten to 6 N•m (53 lbf in).
Inspect
7. Install fitting at base of free-lift cylinder. This is
Inspect the gland for damage to the threads and the a special fitting that limits flow of the hydraulic
seal surfaces. If damaged, replace gland. oil.
19
A. RIGHT SIDE CYLINDER B. LEFT SIDE CYLINDER

1. SHELL 8. WEAR RING
2. ROD 9. ROD RING
3. GLAND 10. SCREW
4. SPACER 11. SEAL
5. WIPER RING 12. PISTON RING
6. BACKUP RING 13. PISTON
7. O-RING
Figure 11. Main Lift Cylinder, Right Side and Left Side Two-Stage FFL
20
Install
WARNING
For installation procedures, see Main Lift Cylinders, Hydraulic oil is hot after system operation and
Install. can cause burns. DO NOT disconnect any hy-
draulic hoses until the oil in the system is cool.
FREE-LIFT CYLINDER
2. Put a drain pan under the area of the hydraulic
Remove fittings. Disconnect the hydraulic line at the
cylinder.
1. Remove the carriage as described in the carriage
removal procedures located in the section 3. Remove chains from chain sheaves. Remove the
clamp and brackets for the free-lift cylinder. Re-
Mast Repairs, 2-, 3-, and 4-Stage Masts 4000 move the free-lift cylinder.
• S30FT, S35FT, S40FTS (E010) 4. Remove the crosshead from the cylinder rod. Dis-
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, assemble the crosshead as necessary.
H40FTS) (F001)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114, F114) • H2.0-3.5FT (H40-70FT) (L177)
• E2.00-3.20XM (E45-65Z) (G108) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• J2.00-3.20XM (J40-65Z) (B416) S80, 100FTBCS; S120FTS; S120FTPRS)
• J1.6-2.00XMT (J30-40ZT) (J160) (G004, H004)
• E2.00-3.20XM (E45-65Z) (G108)
Mast Repairs, 2- and 3-Stage Masts 4000 • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
SRM 1250 for lift truck models shown below: 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- R005)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
R005) (E098)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; • S50CT (A267)
S80, 100FTBCS; S120FTS; S120FTPRS) • H2.0-2.5CT (H50CT) (A274)
(G004, H004)
• E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) See Figure 13 for lift truck models
(E098) • S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114)
Mast Repair 4000 SRM 1431 for lift truck mod- • J1.60-2.00XMT (J30-40ZT) (J160)
els shown below: • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• S50CT (A267) H40FTS) (F001)
• H2.0-2.5CT (H50CT) (A274)
Lower the mast completely. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
21
1. LIFT CHAIN 7. PIN

2. CHAIN SHEAVE 8. FREE-LIFT
3. CHAIN GUARD CYLINDER
4. SNAP RING 9. WASHER
5. CROSSHEAD 10. LOCKWASHER 1. CHAIN 7. LOCKWASHER
6. BEARING 11. CAPSCREW 2. CHAIN SHEAVE 8. WASHER
3. BEARING 9. LOCK NUT
Figure 12. Crosshead Assembly, Two-Stage 4. CHAIN GUARD 10. CROSSHEAD PIN
and Three-Stage FFL, for Lift Truck Models 5. CROSSHEAD 11. PIN
S2.0-3.5FT (S40-70FT, S55FTS) (F187), 6. CAPSCREW
H2.0-3.5FT (H40-70FT) (L177), S4.0, 5.0, 5.50FT
([S80, 100, 120FT;] S80, 100, 120FTBCS; Figure 13. Crosshead Assembly, Two-Stage and
S120FTPRS) (G004, H004), E2.00-3.20XM Three-Stage FFL, for Lift Truck Models S30FT,
(E45-65Z) (G108), H4.0FT5/FT6; H4.5FTS5, S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) E40ZS) (E114,F114), J1.60-2.00XMT (J30-40ZT)
(N005, P005, R005), E3.50-5.50XL and E4.50XLS (J160), and H1.6FT, H1.8FT, H2.0FTS (H30FT,
(E70-120Z, E100ZS) (E098), S50CT (A267), and H35FT, H40FTS) (F001)
H2.0-2.5CT (H50CT) (A274)
NOTE: LIFT TRUCK MODELS H2.0-3.5FT (H40-70FT) (L177) DO NOT HAVE A FOUR-STAGE MAST, BUT THE
CROSSHEAD AND TWO- AND THREE-STAGE FREE-LIFT CYLINDER ASSEMBLY IS SIMILAR TO WHAT IS
SHOWN HERE.
1. HOSE 10. PIN
2. HOSE SHEAVE 11. CROSSHEAD
3. STUB SHAFT WELDMENT 12. ALIGNMENT PIN
4. WASHER 13. FREE-LIFT CYLINDER
5. CAPSCREW 14. STRAP
6. CHAIN GUARD 15. TUBE SPACER
7. SPACER 16. BRACKET
8. CHAIN SHEAVE 17. LOWERING CONTROL VALVE FITTING
9. SNAP RING 18. BEARING
22
Figure 14. Crosshead and Four-Stage Free-Lift Cylinder Assembly, for Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187)
23
Disassemble Clean
CAUTION WARNING
Carefully disassemble the free-lift cylinder so Cleaning solvents can be flammable and toxic
the piston rods and sliding surfaces are not and can cause skin irritation. When using
damaged. cleaning solvents, always follow the solvent
NOTE: To prevent damage to sealing surfaces, use dures.
brass tools when removing or installing seals and
O-rings. Compressed air can move particles so they
1. Loosen gland with a spanner wrench. Make sure the path of the compressed air is
2. Remove gland from shell.
3. Remove rod and piston assembly from shell. eyes.
Drain hydraulic oil into container. See Fig-
ure 15. CAUTION
4. Remove and discard O-rings, seals, and wear DO NOT allow cleaning solvent to come in con-
rings. tact with rubber components, as it will damage
those components.
WARNING Clean all metal parts in solvent and dry with com-
Be careful when removing or installing snap pressed air.
ing removal or installation with enough force Inspect
to cause an injury. Always use the correct snap
Inspect the gland for damage to the threads and the
ring pliers and wear eye and face protection
seal surfaces. If damaged, replace gland.
Inspect the piston for any damage to the seal sur-
5. Remove snap ring, washer, and check valve from
faces. If damaged, replace piston.
base of piston. Remove and discard O-ring from
check valve. Inspect the rod for damage to the rod surface and
ensure that the rod is not bent. If damaged, replace
rod.
Inspect the inner surface of the cylinder tube for

damage. If damaged, replace cylinder assembly.
Assemble
NOTE: The procedures in this section cover all masts.

brass tools when installing seals and O-rings.
1. Lubricate all internal parts of the free-lift cylin-

1. SHELL 7. SNAP RING der with clean hydraulic oil. Use new O-rings,
2. ROD 8. WIPER seals, and wear rings. See Figure 15.
3. GLAND 9. SEAL
4. SCREW 10. BACKUP RING
5. CHECK VALVE 11. O-RING
6. WASHER 12. WEAR RING
Figure 15. Free-Lift Cylinder, Two-Stage and

Three-Stage FFL
24
• E1.50-2.00XM (E25-35Z, E40ZS) (E114,

WARNING F114)
Be careful when removing or installing snap • E2.00-3.20XM (E45-65Z) (G108)
rings. These snap rings can come loose dur- • J2.00-3.20XM (J40-65Z) (B416)
ing removal or installation with enough force • J1.60-2.00XMT (J30-40ZT) (J160)
to cause an injury. Always use the correct snap • S50CT (A267)
ring pliers and wear eye and face protection • H2.0-2.5CT (H50CT) (A274)
b. 400 to 475 N•m (295 to 350 lbf ft)for lift truck
2. Install check valve and O-ring in base of piston of models listed below:
free-lift cylinder. Make sure arrow on check valve • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
is toward base of piston. Install washer and snap 5.5FT (H80, 90, 100, 110, 120FT) (N005,
ring for check valve. See Figure 15. P005, R005)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
CAUTION 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
A difficult and important step in assembling
• E3.50-5.50XL, E4.50XLS (E70-120Z,
free-lift cylinder is the correct installation
E100ZS) (E098)
of the seals. Most cylinders maintenance is
caused by seal leaks. DO NOT damage any
Install
parts during assembly.
1. Make sure alignment pin is in position, then in-
3. Install the wear ring, piston seal, and backup
stall the crosshead mount and crosshead assem-
ring on the piston assembly. On the free-lift
bly on the cylinder rod. Tighten the crosshead
cylinder, install seal ring. Install spacer, if used.
mount to 435 N•m (320 lbf ft). Tighten the
4. Carefully push the piston and rod assembly into chain guards to 66 N•m (49 lbf ft). Install chain
the shell. sheaves in mount. Install shaft through sheaves.
Install chain guard on mount, making sure the
5. Install the rod seal ring and wiper into the gland. shaft is in correct position.
Install the O-ring and backup ring on the outside
of the gland. See Figure 12 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
CAUTION • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Additives may damage the hydraulic system. S80, 100FTBCS; S120FTS; S120FTPRS)
Before using additives, contact your local Hys- (G004, H004)
ter dealer. • E2.00-3.20XM (E45-65Z) (G108)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
NOTE: Hydraulic oil is poured into the free-lift cylin- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
ders to act as a cushion during load lifting to prevent R005)
damage to the cylinder. • E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098)
6. Before installing gland, pour 150 cc (5 oz) of hy-
• S50CT (A267)
draulic oil into the cylinder shell.
• H2.0-2.5CT (H50CT) (A274)
7. Install the gland on the piston rod, and tighten
gland to
• S30FT, S35FT, S40FTS (E010)
a. 475 to 540 N•m (350 to 400 lbf ft) for lift truck • E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114)
models listed below: • J1.60-2.00XMT (J30-40ZT) (J160)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
25
2. Install the cylinder in the mounts. Install the Gland, Free-Lift Cylinders for Lift
brackets, nuts, and tighten the bolts to 53 N•m Truck Models
(39 lbf ft). On the three-stage FFL cylinder, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
the nuts are installed on the bracket side of the (H80, 90, 100, 110, 120FT) (N005, P005, R005)
free-lift cylinder. Tighten the nuts to 38 N•m • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(28 lbf ft). S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
H004)
3. Connect the hydraulic line at the cylinder. • E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098)
4. Install the carriage and load backrest as de-
400 to 475 N•m (295 to 350 lbf ft)
scribed in the procedures in the section
Piston, Main Lift Cylinders (Two-Stage
Mast Repairs, 2-, 3-, and 4-Stage Masts 4000
FFL Mast Only)
170 to 200 N•m (125 to 150 lbf ft)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, Main Lift Cylinder Mounting Nut To Outer
H40FTS) (F001) Mast, for Lift Truck Models
• H2.0-3.5FT (H40-70FT) (L177) • E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114, F114) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• E2.00-3.20XM (E45-65Z) (G108) H40FTS) (F001)
• J2.00-3.20XM (J40-65Z) (B416) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• J1.6-2.00XMT (J30-40ZT) (J160) • J1.60-2.00XMT (J30-40ZT) (J160)
• H2.0-3.5FT (H40-70FT) (L177)
Mast Repairs, 2- and 3-Stage Masts 4000
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• J2.00-3.20XM (J40-65Z) (B416)
R005)
• E2.00-3.20XM (E45-65Z) (G108)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
(G004, H004)
53 N•m (39 lbf ft)
• E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098) Main Lift Cylinder Mounting Nut To Outer
Mast, for Lift Truck Models
Mast Repair 4000 SRM 1431 for lift truck mod-
els shown below:
(H80, 90, 100, 110, 120FT) (N005, P005, R005)
• S50CT (A267)
• E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
• H2.0-2.5CT (H50CT) (A274)
(E098)
38 N•m (28 lbf ft)
TORQUE SPECIFICATIONS
Retainer Nuts
Gland, Main Lift Cylinders
33 N•m (24 lbf ft)
340 to 410 N•m (250 to 300 lbf ft)
Chain Guard Capscrew (Free-Lift Cylinder)
Gland, Free-Lift Cylinders for Lift
66 N•m (49 lbf ft)
Truck Models
• S30FT, S35FT, S40FTS (E010) Crosshead Mount Capscrew
• E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114) 435 N•m (320 lbf ft)
H40FTS) (F001) Free-Lift Cylinder Mounting Bolts (All
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) Mast Except Three-Stage FFL)
• H2.0-3.5FT (H40-70FT) (L177) 53 N•m (39 lbf ft)
• J2.00-3.20XM (J40-65Z) (B416)
• E2.00-3.20XM (E45-65Z) (G108)
475 to 540 N•m (350 to 400 lbf ft)
26
2100 SRM 1139 Fork Positioner Cylinder Repair
Free-Lift Cylinder Mounting Bolts 2. Raise carriage and load 1 m (3 ft). If carriage
(Three-Stage FFL) slowly lowers when control valve is in NEU-
38 N•m (28 lbf ft) TRAL position, there are leaks in hydraulic
system. The maximum speed the carriage is
LIFT CYLINDERS LEAK CHECK allowed to lower is 50 mm (2 in.) per 10 minutes
when hydraulic oil is 30°C (86°F). If oil tem-
WARNING perature is 70°C (158°F), the maximum speed
During the test procedures for the hydraulic the carriage can lower is 150 mm (6 in.) per 10
system, use chains to fasten the load to the car- minutes.
riage to prevent it from falling. Keep all people 3. Check lift cylinders for internal leaks. Remove
away from the lift truck during the tests. load from forks. Install valve in supply line be-
Do NOT try to find hydraulic leaks by putting tween main control valve and mast. Put capacity
your hand on hydraulic components under load on forks again. Raise carriage 1 m (3 ft).
pressure. Hydraulic oil can be injected into Close valve. If carriage or mast lower slowly,
the body by the pressure. seals in lift cylinders have leaks.
1. Operate hydraulic system. Put capacity load on 4. If carriage does not move, open valve and check
forks. Use safety chain to hold load to carriage. movement again. If carriage lowers when valve
Raise and lower load several times. Lower load is open, check for leaks in hydraulic lines and
and tilt mast forward and backward several fittings. If no leaks are found, main control valve
times. Check for leaks. can be worn or damaged. Remove load from
forks.
Fork Positioner Cylinder Repair

Lift truck models S50CT (A267), H2.0-2.5CT NOTE: Disassemble the fork positioner cylinders
(H50CT) (A274), and S4.0, 4.5, 5.5FT, S5.5FTS (S80, only as necessary for repairs. On the fork positioner
100, 120FT; S80, 100FTBCS; S120FTS; S120FT- covered in this manual, there are only three items
PRS) (G004, H004) are not equipped with a fork that can be replaced: the bronze bearings in the
positioner. outer fork carriers, the relief tube assemblies, and
hose guides. If any other component parts need
REMOVE to be replaced, the whole fork positioner assembly
will need to be replaced. See Parts Manual for
WARNING replacement kits and part numbers.
Before working on or near the mast, see Safety NOTE: Depending on the size and configuration of
Procedures When Working Near Mast. the forks installed on lift truck, there may be a spacer
1. Remove the fork positioner and cylinders from bar between the inner and outer fork carriers. See
the integral sideshift carriage. See Mast Re- Figure 16.
pairs, 2-, 3-, and 4-Stage Masts 4000 SRM 1. Remove cylinder rod anchor plug. See Figure 16.
1148 for procedures.
2. Move fork carriers towards manifold and fully re-
DISASSEMBLE tract fork positioner cylinder rods.
3. Disconnect hydraulic hoses from manifold. See

CAUTION
Figure 17.
Carefully disassemble the fork positioner so
the piston rods and sliding surfaces are not 4. Disconnect relief tube assembly. See Figure 17.
damaged.
27
Fork Positioner Cylinder Repair 2100 SRM 1139
5. Remove cylinder rod retainer and remove fork 8. Remove integral sideshift cylinder from carriage.
positioner cylinder from manifold. See Sideshift Cylinder Repair.
6. Remove fork carriers from cylinder shell. 9. Remove setscrews from hose guides and remove
hose guides from outer frame. See Figure 18.
7. Remove wiper shell and bronze bearings from
outer fork carrier. See Figure 16.
1. WIPER SHELL 5. CAPSCREW*

2. BRONZE BEARINGS 6. SPACER BAR*
3. OUTER FORK CARRIER 7. CYLINDER ROD ANCHOR PLUG
4. INNER FORK CARRIER
*PARTS USED ON 977 mm (38.5 in.) AND 1067 mm (42 in.) CLASS II CARRIAGES.
Figure 16. Fork Positioner, Disassemble
28
NOTE: FORK POSITIONER AND INTEGRAL SIDESHIFT CARRIAGE FOR LIFT TRUCKS S2.0-3.5FT (S40-70FT,
S55FTS) (F187) AND H2.0-3.5FT (H40-70FT, H55FTS) (L177) SHOWN. FORK POSITIONER AND INTEGRAL
SIDESHIFT CARRIAGE FOR OTHER LIFT TRUCKS COVERED IN THIS MANUAL ARE SIMILAR.
NOTE: BACK (DRIVER’S) VIEW SHOWN. THREE STAGE FFL INTEGRAL SIDESHIFT CARRIAGE SHOWN.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. FORK POSITIONER CYLINDER
2. FORK POSITIONER HYDRAULIC HOSE 6. OUTER FRAME
(CLOSE) 7. FORK CARRIER
3. INTEGRAL SIDESHIFT CARRIAGE HYDRAULIC 8. TUBE ASSEMBLY
HOSES 9. RELIEF TUBE ASSEMBLY
4. MANIFOLD 10. HOSE GUIDE
Figure 17. Hydraulic Connections, Fork Positioner Cylinder
29
Fork Positioner Cylinder Repair 2100 SRM 1139
NOTE: FORK POSITIONER AND INTEGRAL SIDESHIFT CARRIAGE FOR LIFT TRUCKS S2.0-3.5FT (S40-70FT,
S55FTS) (F187) AND H2.0-3.5FT (H40-70FT, H55FTS) (L177) SHOWN. FORK POSITIONER AND INTEGRAL
SIDESHIFT CARRIAGE FOR OTHER LIFT TRUCKS COVERED IN THIS MANUAL ARE SIMILAR.
1. SETSCREW 4. INTEGRAL SIDESHIFT CYLINDER
2. HOSE GUIDE 5. OUTER FRAME
3. HYDRAULIC HOSE
Figure 18. Fork Positioner Hose Guide
CLEAN CAUTION
WARNING tact with rubber components, as it will damage
Cleaning solvents can be flammable and toxic those components.
cleaning solvents, always follow the solvent 1. Clean all metal parts in solvent and dry with
manufacturer’s recommended safety proce- compressed air.
dures.
INSPECT
WARNING NOTE: The bronze bearings in the outer fork carri-
Compressed air can move particles so they ers, the relief tube assemblies, and hose guides are
cause injury to the user or to other personnel. the only components that can be replaced. If other
Make sure the path of the compressed air is components are worn or damaged, the whole fork po-
away from all personnel. Wear protective gog- sitioner assembly must be replaced. See the Parts
gles or a face shield to prevent injury to the Manual for replacement parts.
eyes.
30
1. Inspect rod, piston, and retainer for any damage INSTALL

to seal surfaces. Replace fork positioner if dam-
aged. WARNING
2. Inspect rod for damage to rod surface and ensure Before working on or near the mast, see Safety
rod is not bent. Replace fork positioner if dam- Procedures When Working Near Mast.
aged or bent.
1. Install fork positioner assembly to the integral
3. Inspect fork carrier bronze bearings for wear. sideshift carriage. See Mast Repairs, 2-, 3-,
Replace bronze bearings as necessary. See Fig- and 4-Stage Masts 4000 SRM 1148 for proce-
ure 16. dures.
4. Inspect relief tube assembly for wear or damage. Fork Positioner Cylinder Adjustment
Replace relief tube assembly if necessary. See
Figure 17. To adjust the flow restrictors for equal fork move-
ment, perform the following:
5. Inspect hose guides for wear or damage. Replace
hose guides if necessary. See Figure 18. NOTE: Procedures below apply to flow restrictors on
both fork positioner cylinders.
ASSEMBLE 1. Loosen jam nut on flow restrictor and screw flow
1. Install hose guides onto outer frame. Tighten restrictor in until it bottoms. Turn flow restrictor
setscrews to 17 N•m (150 lbf in). See Figure 18 counterclockwise approximately three turns. See
Figure 19.
2. Install integral sideshift cylinder to carriage. See
Sideshift Cylinder Repair for procedures. 2. Open forks all the way, then close the forks.
Watch for unequal fork movement.
NOTE: Lubricate all internal parts of the cylinder
with clean hydraulic oil during assembly. 3. To increase the speed of forks opening, turn flow
restrictor counterclockwise in 1/2 turn incre-
3. Lubricate new fork carrier bronze bearings with ments. To decrease the speed of forks closing,
clean hydraulic oil. Install new bronze bearings turn flow restrictor clockwise in 1/2 turn incre-
into outer fork carrier and install wiper shell. ments. See Figure 19.
See Figure 16.
4. Open and close the forks again. If fork movement
4. Connect relief tube assemblies. See Mast Re- is not equal, repeat Step 2 and Step 3.
pairs, 2-, 3-, and 4-Stage Masts 4000 SRM
1148 for procedures. 5. If fork movement is equal, tighten jam nut on
flow restrictor. See Figure 19.
5. Install fork carriers onto cylinder shell.
TORQUE SPECIFICATIONS
6. Install fork positioner cylinder assembly to man-
ifold. See Figure 16. Cylinder Rod Retainer
165 N•m (120 lbf ft)
7. Install rod retainer. Tighten rod retainer to
165 N•m (120 lbf ft). Fork Positioner Cylinder Mounting Capscrews
65 N•m (50 lbf ft)
8. Connect hydraulic hoses to manifold. See Fig-
ure 18. Cylinder Rod Anchor Plug
65 N•m (50 lbf ft)
9. Install cylinder rod anchor plug. Tighten cylin-
der rod anchor plug to 65 N•m (50 lbf ft). See Fork Carrier Capscrews
Figure 16. 35 N•m (25 lbf ft)
Hose Guide Capscrews

17 N•m (150 lbf in)
31
Seal Kit Installation 2100 SRM 1139
NOTE: BACK (DRIVER’S) VIEW SHOWN. LEFT

FLOW RESTRICTOR SHOWN.
1. JAM NUT
2. FLOW RESTRICTOR
Figure 19. Fork Positioner Cylinder Adjustment
Seal Kit Installation

EXTERNAL INSTALLATION (SEAL AND INTERNAL INSTALLATION (PISTON ROD
BACK-UP RING) ASSEMBLY)
NOTE: It is recommended that seal is heated in hy- 1. Insert internal installation sleeve into end of
draulic oil prior to installation to make it more flexi- cylinder tube. See Figure 20.
ble and pliable.
2. Install piston rod assembly into cylinder tube.
1. Lubricate seal, back-up ring, external installa- See Figure 20.
tion sleeve and piston rod groove with hydraulic
fluid. 3. Remove internal installation sleeve from cylin-
der tube and piston rod assembly. See Figure 20.
2. Install wear ring onto piston rod assembly. See
Figure 21.
3. Slide external installation sleeve over piston rod

assembly and wear ring. See Figure 21.
4. Install back-up ring into piston rod groove. See

Figure 21.
5. Slide seal over external installation sleeve and

into piston rod groove. See Figure 21.
6. Remove external installation sleeve.
32
2100 SRM 1139 Seal Kit Installation
1. PISTON ROD ASSEMBLY 1. PISTON ROD ASSEMBLY

2. BACK-UP RING 2. WEAR RING
3. SEAL 3. EXTERNAL INSTALLATION SLEEVE
4. INTERNAL INSTALLATION SLEEVE 4. BACK-UP RING
5. CYLINDER TUBE 5. SEAL
6. WEAR RING
Figure 21. Cylinder External Seal Installation
Figure 20. Cylinder Internal Installation
33
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
34

MAST REPAIRS
2-, 3-, AND 4-STAGE MASTS
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];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
J1.60-2.00XMT (J30-40ZT) [J160];
J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]
PART NO. 1580524 4000 SRM 1148

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
Mast Repairs Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Safety Procedures When Working Near Mast.................................................................................................... 1
Fork Replacement ................................................................................................................................................ 3
Remove ............................................................................................................................................................. 3
Install ............................................................................................................................................................... 5
Checks .............................................................................................................................................................. 5
Carriages Repair .................................................................................................................................................. 6
Standard Carriage ........................................................................................................................................... 6
Remove......................................................................................................................................................... 6
Repair........................................................................................................................................................... 6
Install ........................................................................................................................................................... 7
Integral Sideshift Carriage ............................................................................................................................. 7
Remove......................................................................................................................................................... 7
Repair......................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Fork Positioner............................................................................................................................................... 11
Remove....................................................................................................................................................... 12
Disassemble and Assemble ....................................................................................................................... 14
Install ......................................................................................................................................................... 15
Fork Positioner Hydraulic Hose Adjustment....................................................................................... 15
Disconnecting Attachment Hydraulic Quick Disconnect Hoses ................................................................. 17
Connecting Attachment Hydraulic Quick Disconnect Hoses ...................................................................... 17
Mast Repair........................................................................................................................................................ 18
Mast, Remove................................................................................................................................................. 18
Two-Stage LFL and Two-Stage FFL Masts ................................................................................................. 20
Disassemble ............................................................................................................................................... 20
Three-Stage FFL Mast .................................................................................................................................. 31
Disassemble ............................................................................................................................................... 31
Two-Stage LFL and Two-Stage FFL Mast ................................................................................................... 37
Assemble .................................................................................................................................................... 37
Three-Stage FFL Mast .................................................................................................................................. 38
Assemble .................................................................................................................................................... 38
Four-Stage FFL Mast - Manufactured Before July, 2009............................................................................ 39
Disassemble ............................................................................................................................................... 39
Assemble .................................................................................................................................................... 46
Four-Stage FFL Mast - Manufactured After July, 2009 .............................................................................. 47
Disassemble ............................................................................................................................................... 47
Assemble .................................................................................................................................................... 55
Mast, Install................................................................................................................................................... 57
Header Hose Arrangement................................................................................................................................ 60
Two-Stage LFL .............................................................................................................................................. 60
Two-Stage FFL .............................................................................................................................................. 67
Three-Stage FFL............................................................................................................................................ 82
Standard .................................................................................................................................................... 82
Four-Stage FFL Mast - Manufactured Before July, 2009............................................................................ 99

Table of Contents Mast Repairs

Four-Stage FFL Mast - Manufactured After July, 2009 ............................................................................ 107
Adjustment................................................................................................................................................... 111
Lift Chains Adjustment ................................................................................................................................... 115
Carriage Adjustments...................................................................................................................................... 117
Mast Adjustments............................................................................................................................................ 118
Load Roller Adjustment .............................................................................................................................. 118
Mast Side Kicking Adjustment ................................................................................................................... 120
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
J1.60-2.00XMT (J30-40ZT) [J160];
J2.0-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108]
ii
4000 SRM 1148 Safety Procedures When Working Near Mast
General
NOTE: For models J1.60-2.00XMT (J30-40ZT)
WARNING [J160], this section applies to only to Four-Stage
Before working on or near the mast, see Safety masts. Refer to Mast Repairs, 2- and 3-Stage
Procedures When Working Near Mast in this Masts 4000 SRM 522 for Two-Stage and Three-Stage
section. masts for these particular models.
This section has the repair procedures for the NOTE: Hoses have a service life that is determined
Two-Stage, Limited Free-Lift (LFL); Two-Stage, by application and time. Install a new hose if the
Full Free-Lift (FFL); Three-Stage, Full Free-Lift hose is worn, damaged, soft or hard, and no longer
(FFL); and Four-Stage, Full Free-Lift (FFL) masts flexible. If necessary, make a comparison to a new
and carriages. Procedures for Carriage Adjustments hose that is the correct replacement for the hose you
are located at the end of this section. are inspecting.
Safety Procedures When Working Near Mast

The following procedures MUST be used when in- push the lift/lower control lever forward un-
specting or working near the mast. Additional pre- til there is no movement in the mast. Make
cautions and procedures can be required when re- sure that all parts of the mast that move are
pairing or removing the mast. fully lowered.
OR
WARNING
Mast parts are heavy and can shift. Distances • If parts of the mast must be in a raised po-
between parts are small. Serious injury or sition, install a safety chain to restrain the
death can result if part of the body is hit by moving parts of the mast. Connect moving
parts of the mast or the carriage. parts to a part that does not move. Follow
• Never put any part of the body into or under these procedures:
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed. 1. Put mast in vertical position.
Also make sure that the power is OFF and the
2. Raise mast to align bottom crossmember of mast
key is removed. Put a DO NOT OPERATE tag
upright that moves in outer mast with crossmem-
in the operator’s compartment. Disconnect
ber on outer mast. On the two-stage mast, the
the battery and put a tag or lock on the bat-
moving part is the inner mast. On the three-
tery connector.
stage mast, it is the intermediate mast. On the
• Be careful of the forks. When the mast is
four-stage mast, it is the first intermediate mast.
raised, the forks can be at a height to cause
See Figure 1.
an injury.
• DO NOT climb on the mast or lift truck at any 3. Use a 3/8-inch minimum safety chain with a hook
time. Use a ladder or personnel lift to work to fasten the crossmembers together so the mov-
on the mast. able member cannot lower. Put hook on back side
• Mast repairs require disassembly and re- of mast. Make sure hook is completely engaged
moval of parts and can require removal of with a link in the chain. Make sure safety chain
the mast or carriage. Follow the repair pro- does not touch lift chains or chain sheaves, tubes,
cedures in this section. hoses, fittings, or other parts on the mast.
WHEN WORKING NEAR THE MAST ALWAYS: 4. Lower mast until there is tension in safety chain
• Lower the mast and carriage completely: and free-lift cylinder (full free-lift models) is com-
Turn the key switch to the ON position and pletely retracted.
1
Safety Procedures When Working Near Mast 4000 SRM 1148
A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST

B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST
Figure 1. Safety Chaining the Mast
2
4000 SRM 1148 Fork Replacement
NOTE: Apply the parking brake. After lowering or carriage (item 6, Figure 1) and a crossmember
restraining the mast, shut off the power, and remove on the outer mast as a secondary safety device.
key. Put a DO NOT OPERATE tag in the operator’s Install a DO NOT REMOVE tag on the safety
compartment. Disconnect battery and put a tag or chain(s).
lock on battery connector.
5. Install another safety chain (9.5 mm (3/8 in.)

minimum) between the top or bottom bar of the
Fork Replacement
Forks are held on the carriage by hooks and kept in NOTE: If lift truck is equipped with a fork positioner,
position by pins inserted through top fork hooks into see the section Carriages Repair for procedures to re-
slots in top carriage bar. If pin does not remain en- move the forks.
gaged in carriage slot, replace with new pin.
1. Slide fork to fork removal notch in bottom bar of
carriage. See Figure 3 and Figure 4.
CAUTION
Remove fork latch pins if adding a fork posi- 2. Lower fork onto blocks so bottom hook of fork
tioner attachment. Damage to forks and other moves through fork removal notch. See Figure 4.
carriage components can occur if fork latch
3. Lower carriage further so top hook of fork is dis-
pins are not removed prior to using attach-
engaged from top carriage bar.
ment.
4. Move carriage away from fork or use a lifting de-
The forks are held on the carriage by hooks. Forks on
vice to move fork away from carriage.
a standard carriage or an integral sideshift carriage
not equipped with a fork positioner attachment, are
held in position by pins that fit through the top fork
hooks and into slots in the top carriage bar. If pin
does not remain engaged in carriage slot, replace
with new pin. Always check that pins for forks keep
forks in position on carriage. Replace damaged fork
pin parts. Forks are removed from carriage by align-
ing forks with fork removal notch. Fork removal
notch is in bottom bar of carriage. See Figure 4.
Forks used on an integral sideshift carriage equipped

with a fork positioner attachment are held in posi-
tion with fork carriers (inner and outer) that slide
along the fork positioner cylinder. Depending on the 1. OUTER FORK CARRIER
size and configuration of forks installed on lift truck, 2. CAPSCREW
there may be a spacer bar between the inner and 3. SPACER BAR*
outer fork carriers. See Figure 2. The forks are re- 4. INNER FORK CARRIER
moved from the carriage by aligning the forks with
fork removal notch. Fork removal notch is in the bot- *SPACER BAR USED ON 977 mm (38.5 in.) AND
tom bar of carriage. See Figure 4. 1067 mm (42 in.) CLASS II CARRIAGES.
Figure 2. Fork Carrier Components

REMOVE
WARNING
DO NOT try to remove a fork without a lifting
device. Each hook fork for these lift trucks can
weigh 45 to 115 kg (99 to 254 lb).
3
Fork Replacement 4000 SRM 1148
Legend for Figure 3

1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Figure 3. Hook Fork Removal
1. LOAD BACKREST 6. WEDGE

2. CARRIAGE 7. WASHER
3. FORKS 8. SPRING
4. FORK 9. PIN
5. KNOB 10. FORK REMOVAL NOTCH
Figure 4. Carriage and Forks
4
4000 SRM 1148 Fork Replacement
INSTALL Table 1. Fork Tip Alignment (Continued)

NOTE: If lift truck is equipped with a fork positioner,
see Carriages Repair for procedures to remove the Fork Tip Alignment Specifications
forks. Standard Fork Maximum Fork Tip
Lengths Difference 1
WARNING mm mm
(in.) (in.)
device. Each hook fork for these lift trucks can 1372 (54) 41 (1.62)
weigh 45 to 115 kg (99 to 254 lb). 1524 (60) 46 (1.80)
1. Move fork and carriage so top hook of fork can 1829 (72) 55 (2.16)
engage upper carriage bar.
1Difference of alignment between fork tips must
2. Raise carriage to move bottom hook of fork be no more than 3% of the total fork length.
through fork removal notch.
3. Slide fork on carriage so both upper and lower

hooks engage carriage bars. See Figure 3.
4. Install latch pin in top hook and notch in upper

carriage bar. See Figure 4.
CHECKS
WARNING
Never repair damaged forks by heating or
welding. Forks are made of tempered steel
using special procedures. Always replace dam-
aged forks as a pair.
1. Inspect forks for cracks and wear.
2. Check alignment of fork tips. Difference in

height of fork tips must be less than three per- A. HEEL OF FORK (MUST BE 90% OF DIMENSION
cent of fork length. See Table 1 and Figure 5. B)
Some applications may require closer alignment. B. ORIGINAL FORK THICKNESS (DIMENSION B)
If forks DO NOT meet specification they both
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
must be replaced. FORK LENGTH)
2. CRACKS
Table 1. Fork Tip Alignment 3. MAXIMUM ANGLE 93°
4. FORK REMOVAL NOTCH
Fork Tip Alignment Specifications 5. CARRIAGE
Standard Fork Maximum Fork Tip Figure 5. Fork Check
Lengths Difference 1
3. Check that the bottom of each fork is not exces-
mm (in.) mm (in.) sively worn.
914 (36) 27 (1.08)
4. Check for smooth and proper operation of the
1067 (42) 32 (1.26) fork lock pins. Repair or replace any damaged
1219 (48) 37 (1.44) or broken fork lock pins or components and lu-
bricate, as necessary. See Figure 4.
5
Carriages Repair 4000 SRM 1148
Carriages Repair
STANDARD CARRIAGE Repair
Remove NOTE: The carriage can have four or six load rollers.
When the carriage has four load rollers, shims are
1. Remove the forks. See Fork Replacement. used behind all of the load rollers. When the carriage
has six load rollers, shims are installed on the bottom
2. Remove the four capscrews securing the load and middle rollers only.
backrest to the carriage. Remove the load back-
rest. 1. If any of the load rollers must be replaced, make
a note of the location and number of the shims.
3. Connect a lifting device to the carriage. Lift the Install the shims, load rollers, and snap rings.
carriage so that the lift chains become loose. See Carriage Adjustments for correct adjustment
of the load rollers.
WARNING
When disconnecting the lift chains, keep con-
trol of the ends. Use wire to temporarily
connect the ends of the lift chains to the mast.
This procedure will prevent the lift chains
from falling from the sheaves and causing an
injury or damage.
4. Remove the pin from each chain anchor at the

carriage. See Figure 6. Disconnect the lift chains
from the carriage. Use wire to connect the ends
of the lift chains to a part of the mast. Make sure
the chains can move freely when the inner mast
is raised.
WARNING
To help prevent possible injury, make sure the
carriage is stable when the inner mast is above
the load rollers of the carriage.
5. Use the lift cylinders to raise the inner or inter-

mediate mast. If the hydraulic system cannot be
used, disconnect the lift cylinders from the inner
or intermediate mast. See the section Cylinder NOTE: TWO-STAGE LFL CARRIAGE SHOWN.
Repair 2100 SRM 1139. 1. CARRIAGE 6. CHAIN PIN
2. SNAP RING 7. COTTER PIN
6. Connect a crane [the capacity of the crane must 3. SHIM 8. ANCHOR PIN
be at least 681 kg (1501 lb)] to the top of the in- 4. LOAD ROLLER 9. SPACER
ner mast. Carefully raise the inner mast until 5. CHAIN ANCHOR
it is above the load rollers of the carriage. In-
Figure 6. Standard Carriage
stall safety chains to secure the mast in its ex-
tended position and disconnect the crane. See
Safety Procedures When Working Near Mast.
7. Move the lift truck away from the carriage. Com-

pletely lower the inner mast so it cannot move.
6
4000 SRM 1148 Carriages Repair
INTEGRAL SIDESHIFT CARRIAGE

WARNING
Improper welding procedures can damage Remove
the structure of the mast or cause incorrect
function of the mast. Consult your Hyster® 1. Lower the carriage completely. Remove the forks
lift truck dealer for more information before and the load backrest extension. See section Fork
welding on the mast. Replacement.
2. If the carriage bars have any protruding welds See Figure 7 for lift truck models
or damaged notches, repair by grinding, filing, or • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
welding. • H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z) (B416)
Install • E2.00-3.20XM (E45-65Z) (G108)
1. Use the hydraulic system of the lift truck or a See Figure 8 for lift truck models
crane to raise the inner mast. Connect a crane • S30FT, S35FT, S40FTS (E010)
[the capacity of the crane must be at least 681 kg • E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
(1501 lb)] to the top of the inner mast. Carefully • J1.60-2.00XMT (J30-40ZT) (J160)
raise the inner mast until it is above the load • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
rollers of the carriage. Install safety chains to H40FTS) (F001)
secure the mast in its extended position and dis-
connect the crane. See Safety Procedures When WARNING
Working Near Mast.
Always wear the proper protective equipment
2. Move the lift truck toward the carriage until the including eye protection and petroleum-resis-
inner mast is aligned with the carriage rollers. tant gloves when handling hydraulic oil. Thor-
If the inner mast has been raised and secured oughly wash oil from exposed areas of skin as
using a crane and safety chains, connect the soon as possible.
crane, raise the inner mast, and remove the
The hydraulic oil is hot at normal operating
safety chains. Carefully lower the inner mast
temperatures. Be careful when draining the
until it engages all of the load rollers. Discon-
oil.
nect the crane, if attached, and reconnect the
lift cylinders. See the section Cylinder Repair Never check for leaks by putting hands on
2100 SRM 1139. hydraulic lines or components under pressure.
3. Check the clearance of the load rollers. See Car-
into the skin.
riage Adjustments in this section.
NOTE: Use new cotter pins each time the anchor pins CAUTION
are removed. Protect the hydraulic system from dirt and
contaminants when servicing the hydraulic
4. Connect the lift chains to the chain anchors at
system.
the carriage. Install the cotter pins in the anchor
pins. Adjust the lift chains as described in Car- NOTE: Tag hydraulic lines prior to disconnecting to
riage Adjustments in this section. insure correct connection during installation.
5. Install the backrest on the carriage. Tighten the NOTE: If lift truck is equipped with quick discon-
capscrews to 195 N•m (144 lbf ft). nect hoses, see section Disconnecting Attachment
Hydraulic Quick Disconnect Hoses.
6. Install the forks. See Fork Replacement.
7
NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 9. CLEVIS PIN 17. COTTER PIN
2. OUTER FRAME 10. HAIRPIN 18. LOAD ROLLER
3. SIDESHIFT CYLINDER 11. PIN 19. SHIMS
4. UPPER BEARING 12. LUBE FITTING 20. SPACER
5. LOWER BEARING 13. PIN 21. SNAP RING
6. LOWER HOOK 14. CHAIN ANCHOR 22. SPACER
7. CAPSCREW 15. SNAP RING 23. FORK REMOVAL NOTCH
8. WASHER 16. PIN
Figure 7. Integral Sideshift Carriage for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187);
H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (G108)
8
NOTE: TWO- AND THREE-STAGE FFL IS SHOWN.

1. INNER CARRIAGE 9. CLEVIS PIN 17. COTTER PIN
2. OUTER FRAME 10. HAIRPIN 18. LOAD ROLLER
3. SIDESHIFT CYLINDER 11. PIN 19. SHIMS
4. UPPER BEARING 12. LUBE FITTING 20. SPACER
5. LOWER BEARING 13. PIN 21. SNAP RING
6. LOWER HOOK 14. CHAIN ANCHOR 22. SPACER
7. CAPSCREW 15. SNAP RING 23. FORK REMOVAL NOTCH
8. WASHER 16. PIN
Figure 8. Integral Sideshift Carriage for Lift Truck Models S30FT, S35FT, S40FTS (E010);
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT, H1.8FT,
9
2. Disconnect the hydraulic lines at the sideshift 4. Inspect the sideshift cylinder. See Cylinder Re-
cylinder. Put caps on the open hydraulic lines. pair 2100 SRM 1139 for procedures.
3. Remove the lower mounting hooks by removing Repair

the four capscrews securing the hooks.
NOTE: Drain the oil from the cylinder before under-
4. Remove two hairpins, two pins, and sideshift taking any repairs.
cylinder from the carriage.
1. If any of the load rollers must be replaced, make a
See Figure 7 for lift truck models note of the location and number of the shims. In-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) stall the shims, load rollers, and snap rings. See
• H2.0-3.5FT (H40-70FT) (L177) Carriage Adjustments for correct adjustment.
• J2.00-3.20XM (J40-65Z) (B416)
• E2.00-3.20XM (E45-65Z) (G108)
WARNING
See Figure 8 for lift truck models Improper welding procedures can damage the
• S30FT, S35FT, S40FTS (E010) structure of the mast or cause incorrect func-
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) tion of the mast. Consult your Hyster lift truck
• J1.60-2.00XMT (J30-40ZT) (J160) dealer for more information before welding on
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, the mast.
H40FTS) (F001)
2. If carriage bars have any protruding welds or
5. Use a crane with a capacity of at least 450 kg damaged notches, repair by grinding, filing, or
(992 lb) to lift the outer frame away from the in- welding.
ner carriage. Lay the outer frame flat on a pallet
or workbench.
Clean and Inspect

1. Inspect the lower mounting hooks for wear. Re-
place the hooks if they are worn beyond the wear
limit. The wear limit clearance range is 0.76 mm
(0.03 in.) minimum and 1.52 mm (0.06 in.) max-
imum. See A in Figure 9.
2. Clean and inspect the carriage bars for damage

and smoothness. Ensure the bars are parallel
and the ends are flush.
3. Clean the bearing areas. Inspect the sideshift

bearings for wear as follows:
a. Remove the upper bearings from the upper

apron. If either upper bearing is worn to less
than 2.5 mm (0.1 in.) thickness, replace both
upper bearings by driving the upper bearings A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND
1.52 mm (0.06 in.) MAXIMUM.
from the upper apron. B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.
b. Remove the lower bearings from the lower
carriage bar. If either lower bearing is worn Figure 9. Lower Mounting Hooks Wear Limit
to less than 2.5 mm (0.1 in.) thickness, re- and Clearance Adjustment
place both lower bearings by prying the lower
bearings from the lower carriage bar.
10
Install clearance between bottom of hooks and outer

frame. See B in Figure 9.
NOTE: Use a wood block or a plastic hammer to fully
seat upper bearings onto upper carriage bar. Proper NOTE: If lift truck is equipped with quick disconnect
lower hook clearance requires upper bearings be fully hoses, see section Connecting Attachment Hydraulic
seated. Quick Disconnect Hoses.
1. If necessary, install lower sideshift bearings. 5. Connect hydraulic lines, as noted during re-
Then install upper sideshift bearings. Lubricate moval, to sideshift cylinder.
upper and lower sideshift bearings with chassis
grease. 6. Install backrest and capscrews on sideshift car-
riage. Tighten capscrews to 195 N•m (144 lbf ft).
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 7. Install forks. See Fork Replacement, in this ser-
• H2.0-3.5FT (H40-70FT) (L177) vice manual, for procedures.
• J2.00-3.20XM (J40-65Z) (B416)
• E2.00-3.20XM (E45-65Z) (G108) FORK POSITIONER
See Figure 8 for lift truck models NOTE: The fork positioner can be removed from in-
• S30FT, S35FT, S40FTS (E010) tegral sideshift carriage with integral sideshift car-
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) riage on or off the mast. In the steps below, the fork
• J1.60-2.00XMT (J30-40ZT) (J160) positioner is removed with integral sideshift carriage
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, on the mast. If integral sideshift carriage must be re-
H40FTS) (F001) moved from mast first, go to Integral Sideshift Car-
riage.
NOTE: The pin, located on the left top of the cylinder
looking from the front of the carriage, is for align- NOTE: Depending on the size and configuration of
ment purposes and to prevent the cylinder from forks installed on lift truck, there may be a spacer
rolling to the front or to the back. bar between the inner and outer fork carriers. See
Figure 10.
2. Install sideshift cylinder onto carriage with pin
in the up position. Install two pins and two hair-
pins.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z) (B416)
• E2.00-3.20XM (E45-65Z) (G108)

• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 1. OUTER FORK CARRIER
H40FTS) (F001) 2. CAPSCREW
3. SPACER BAR*
3. Use a crane with a capacity of at least 450 kg 4. INNER FORK CARRIER
(992 lb) to install outer frame on inner carriage.
*SPACER BAR USED ON 977 mm (38.5 in.) AND
4. Install lower mounting hooks and four cap- 1067 mm (42 in.) CLASS II CARRIAGES.
screws. Tighten capscrews to 165 ±15 N•m (120
Figure 10. Fork Carrier Spacer Bar
±12 lbf ft). For proper sideshift operation, make
sure there is 0.76 to 1.52 mm (0.03 to 0.06 in.)
11
Remove
WARNING
CAUTION device. Each hook fork for these lift trucks can
Remove fork latch pins if adding a fork posi- weigh 45 to 115 kg (99 to 254 lb)
tioner attachment. Damage to forks and other
carriage components can occur if fork latch 2. Slide fork to fork removal notch in bottom bar of
pins are not removed prior to using attach- carriage. See Figure 11. Lower fork onto blocks
ment. so the bottom hook of fork moves through fork re-
moval notch. Lower carriage further so top hook
1. Lower the carriage and remove four capscrews of fork is disengaged from top carriage bar. Move
from inner fork carriers. Slide inner fork carri- carriage away from fork or use a lifting device to
ers down cylinder shell to remove forks. See Fig- move fork away from carriage.
ure 11.
3. Remove four capscrews and load backrest from
carriage.
1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME
Figure 11. Fork Removal
12

WARNING into the skin.
Before disconnecting the hydraulic hoses, re-
lieve the pressure in the hydraulic system.
CAUTION
Serious injury can occur if pressure is not
relieved from hydraulic system prior to dis- Protect the hydraulic system from dirt and
connecting hydraulic hoses. contaminants when servicing the hydraulic
system.
WARNING
Always wear the proper protective equipment CAUTION
including eye protection and petroleum-resis- DO NOT bend tube assemblies during removal.
tant gloves when handling hydraulic oil. Thor-
NOTE: Note placement of fork positioner cylinders
oughly wash oil from exposed areas of skin as
and tag all hydraulic hoses, lines, and fittings prior
soon as possible.
to removal to aid in installation.
The hydraulic oil is hot at normal operating
4. Disconnect and cap tube assemblies (8, Fig-
temperatures. Be careful when draining the
ure 12) from header hoses.
oil.
Never check for leaks by putting hands on

hydraulic lines or components under pressure.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. FORK POSITIONER CYLINDER
2. FORK POSITIONER HYDRAULIC HOSE 6. OUTER FRAME
(CLOSE) 7. FORK CARRIER
3. INTEGRAL SIDESHIFT CARRIAGE HYDRAULIC 8. TUBE ASSEMBLY
HOSES 9. RELIEF TUBE ASSEMBLY
4. MANIFOLD 10. HOSE GUIDE
Figure 12. Hydraulic Connections, Fork Positioner Cylinder
13
5. Remove lower hooks and bracket weldments. See Clean and Inspect
See the section Cylinder Repair 2100 SRM 1139 for
6. Install lifting eye in hole (see Figure 13) on in- cleaning and inspection procedures.
tegral sideshift carriage and use lifting device to
lift outer frame up to disconnect relief tube as- Disassemble and Assemble
sembly and hydraulic hoses (open and close) from
fork positioner. See Figure 12. To disassemble and assemble the fork positioner
cylinders, see the section Cylinder Repair 2100
NOTE: Make note of shims used to aid in reassembly. SRM 1139 for procedures.
7. Remove capscrews, lock washers, and shims from

integral sideshift carriage. See Figure 13. Re-
move fork positioner from outer frame.
NOTE: RIGHT INTEGRAL SIDESHIFT CARRIAGE BAR REMOVED FOR CLARITY. THREE STAGE FFL INTE-
GRAL SIDESHIFT CARRIAGE SHOWN. HOSE GUIDE OMITTED FOR CLARITY.
NOTE: FRONT VIEW SHOWN.

1. CAPSCREW AND LOCK WASHER 5. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY
2. SHIM 6. LOWER HOOK
3. FORK POSITIONER CYLINDER 7. TAPPED HOLE FOR LIFT EYE
4. FORK CARRIER
Figure 13. Fork Positioner Cylinder Removal
14
Install Fork Positioner Hydraulic Hose Adjustment
1. Place fork positioner cylinders onto outer frame. 1. To adjust the fork positioner hydraulic hoses,
Hand tighten capscrew and lockwasher on one hold the large hex nut and rotate the small
side. See Figure 13. Add shims as follows: hex nut towards the load face of the carriage
(towards the forks). See Figure 16.
NOTE: Maximum number of shims per side is five.
The maximum difference in number of shims per side 2. The fork positioner hoses are correctly adjusted
is two. when the fork positioner hydraulic hoses stay en-
tirely within the integral sideshift carriage and
a. Measure gap at opposite side and determine do not contact the mast channels under all con-
the number of shims required. ditions.
NOTE: The maximum gap allowed before tightening 3. Move fork positioner and check to ensure fork
capscrews is 0.50 mm (.020 in.). carriers clear fork positioner relief tubes through
complete fork carrier cycle. See Figure 12.
b. Install equal amount of shims on both sides
of the fork positioner assembly. 4. Install backrest and capscrews on sideshift car-
riage. Tighten capscrews to 195 N•m (144 lbf ft).
2. Finish installing fork positioner assembly to
outer frame by tightening both capscrews and
lockwashers to 65 N•m (50 lbf ft). See Figure 13.
3. Thread fork positioner hydraulic hoses through

hose guides.
4. Assemble outer frame with fork positioner to in-

ner frame. Using a lifting device, position outer
frame at approximately the same height of the
inner frame and approximately 150 mm (6 in.)
away. From the rear of the outer frame, connect
fork positioner hydraulic tubes to header hoses
and hand tighten. See Figure 12.
5. Assemble outer frame onto inner frame. Position

fork positioner hydraulic tubes so they are in line
with inner frame retainer plates. See Figure 14.
6. Install bracket weldment to lower hook and hand

tighten. Assemble lower hook on retainer plate
and tighten capscrews to 165 N•m (122 lbf ft).
See Figure 15.
7. Position bracket weldment over fork positioner

hydraulic hoses (see Figure 12) and adjust so that
bracket weldment makes contract with fork po- 1. RETAINER PLATE
sitioner hoses and tighten capscrew to 8 N•m 2. INNER FRAME
(71 lbf in). See Figure 15.
Figure 14. Inner Frame Retainer Plates
8. Tighten fork positioner hydraulic tubes to header
hoses to 42 N•m (31 lbf ft).
15

1. BRACKET WELDMENT
2. RETAINER PLATE
3. WASHER
4. LOWER HOOK
5. CAPSCREW (LOWER HOOK)
6. CAPSCREW (BRACKET WELDMENT)
Figure 15. Bracket Weldment and Lower Hook

Assembly
Figure 16. Fork Positioner Hydraulic Hose Adjustment
16
HOSE BRACKET AND GUIDES OMITTED FOR CLARITY.
1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. LARGE HEX NUT
2. FORK POSITIONER HYDRAULIC HOSE 6. TUBE ASSEMBLY
(CLOSE) 7. RELIEF TUBE ASSEMBLY
3. MANIFOLD 8. INTEGRAL SIDESHIFT HYDRAULIC HOSES
4. SMALL HEX NUT
4. Disconnect the quick disconnect hose connectors.
WARNING
DO NOT try to install a fork without a lifting NOTE: Step 5 through Step 8 are to be used for lift
device. Each hook fork for these lift trucks can trucks equipped with manual hydraulics.
weigh 45 to 115 kg (99 to 254 lb)
5. Turn key switch or keyless switch to OFF posi-
tion.
CAUTION
Remove fork latch pins if adding a fork posi- 6. Disconnect negative terminal of the battery.
tioner attachment. Damage to forks and other
7. Move the manual hydraulic levers forward and
carriage components can occur if fork latch
backward to relieve the system hydraulic pres-
pins are not removed prior to using attach-
sure.
ment.
8. Disconnect the quick disconnect hose connectors.
5. Install forks to outer fork carriers. Secure inner
fork carriers to outer fork carriers using four cap-
CONNECTING ATTACHMENT HYDRAULIC
screws. Tighten capscrews to 35 N•m (25 lbf ft).
See Figure 11. QUICK DISCONNECT HOSES
6. To adjust the fork positioner cylinders, See the NOTE: The information in this section is for internal
section Cylinder Repair 2100 SRM 1139 for combustion engine (ICE) trucks only.
procedures. NOTE: Step 1 through Step 4 are to be used for lift
trucks equipped with manual hydraulics.
DISCONNECTING ATTACHMENT
HYDRAULIC QUICK DISCONNECT HOSES 1. Connect the quick disconnect hose connectors.
NOTE: The information in this section is for internal 2. Connect negative terminal of the battery.
combustion engine (ICE) trucks only.
NOTE: Step 1 through Step 4 are to be used for lift

trucks equipped with electro-hydraulics.
1. Turn key switch or keyless switch to OFF posi-

tion.
2. Disconnect negative terminal of the battery.
NOTE: If the Quick Disconnect hose connectors can-

not be disconnected, repeat Step 3 and Step 4. If the
hoses still cannot be disconnected, notify service per-
sonnel.
3. Press the plunger button, located on the top of

the pressure relief valve, and listen for the flow of 1. PRESSURE RELIEF VALVE
2. PLUNGER BUTTON
hydraulic fluid through the valve when the but-
ton is pressed. See Figure 17. Figure 17. Quick Disconnect Hoses
17
Mast Repair 4000 SRM 1148
3. Turn key switch or keyless switch to ON position 6. Connect negative terminal of the battery.
and start engine.
7. Turn key switch or keyless switch to ON position
4. Move manual hydraulic levers forward and back- and start engine.
ward, and check the hydraulic system for leaks.
8. Move the mini levers forward and backward, and
NOTE: Step 5 through Step 8 are to be used for lift check the hydraulic system for leaks.
trucks equipped with electro-hydraulics.
5. Connect the quick disconnect hose connectors.
Mast Repair
MAST, REMOVE 3. Remove the tilt and main lift cylinders. See
Cylinder Repair 2100 SRM 1139 for proce-
dures.
WARNING
The mast is heavy. The mast can weigh ap- 4. Remove the free-lift cylinder for lift trucks
proximately 907 kg (2000 lb). Make sure all lift- equipped with a two, three, or four-stage FFL
ing devices (hoists, cables, chains, slings, etc.) mast. See Cylinder Repair 2100 SRM 1139 for
are suitable and of adequate capacity to lift the procedures.
mast.
NOTE: Allow the mast to tilt forward enough to gain
access to the mast mount capscrews.
CAUTION
Make sure all the mast weldments are fastened 5. Disconnect the lower mast mounts from the lift
together. Make sure the safety chains will not truck:
damage the sheaves, tubing, or other parts of
the mast. a. Pivot Pin Connections - Remove the cap-
screws that hold the mast pivot pins to the
NOTE: If the mast needs to be disassembled, remove mounts on the drive axle.
the forks and carriage. If only the lift, tilt, or free-lift
cylinders need to be removed for repair, the mast does See Figure 18 for all lift truck models in this
not need to be removed from the lift truck. See the manual.
section Cylinder Repair 2100 SRM 1139.
NOTE: The length of the lift chains must be checked • S30FT, S35FT, S40FTS (E010)
before the mast is removed. See Lift Chains Adjust- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
ment. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
1. Fully lower all of the mast weldments. Tilt the • H2.0-3.5FT (H40-70FT) (L177)
mast fully forward. Connect a crane with a ca-
pacity of at least 907 kg (2000 lb) to the top of See Figure 20 for lift truck models
the mast using chains to support the mast in an • J2.00-3.20XM (J40-65Z) (B416)
upright position when the tilt cylinders are dis- • E2.00-3.20XM (E45-65Z) (G108)
connected.
b. Stub Shaft Connections - Remove the four
NOTE: Before disconnecting any hydraulic hoses, be capscrews securing the retainer cap over the
sure to tag each hose with a letter: A and B for three stub shafts on each side of the mast.
function mast and A, B, C, and D for four function
mast, to aid in reconnecting when installing the mast See Figure 21 for lift truck models
onto the lift truck. See section Header Hose Arrange- • J1.60-2.00XMT (J30-40ZT) (J160)
ment. • E1.50-2.00XM (E25-35Z, E40ZS) (E114/
F114)
2. Tag and disconnect hydraulic hoses from mast.
18
4000 SRM 1148 Mast Repair
1. HANGER MOUNTS 2. TRACTION MOTOR
Figure 20. Mast Mounting for Lift Truck

Models J2.00-3.20XM (J40-65Z) (B416) and
E2.00-3.20XM (E45-65Z) (G108)
1. MAST PIVOT PINS 2. BUSHING
Figure 18. Mast Mounts, Pivot Pin Connections
1. DRIVE AXLE 2. HANGER MOUNTS
Figure 19. Mast Mounts, Drive Axle, for Lift

Truck Models S30FT, S35FT, S40FTS (E010),
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 1. RETAINER CAP 6. NUT
H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) 2. LOCKWASHER 7. PIN
(F187), and H2.0-3.5FT (H40-70FT) (L177) 3. TILT CYLINDER 8. ROD END
4. OUTER MAST 9. WASHER
WELDMENT 10. CAPSCREW
5. BUSHING
Figure 21. Mast Mounting (Stub Shaft

Connections) for Lift Truck Models
J1.60-2.00XMT (J30-40ZT) (J160) and
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
19
TWO-STAGE LFL AND TWO-STAGE FFL

WARNING
MASTS
The mast is heavy. The mast can weigh ap-
proximately 907 kg (2000 lb). Make sure all lift- Disassemble
ing devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the 1. Slide the inner mast from the bottom of the outer
mast. mast approximately 30 cm (12 in.). Remove the
strip bearings (see Figure 23) and load rollers
6. Use the crane to lift the mast assembly from from the top of the outer mast. Remove the load
the lift truck. Position the mast across wooden rollers from the bottom of the inner mast. Make
beams on the floor with the carriage side up. a note of each shim arrangement and load roller
location. The shim arrangements will be approx-
7. Check the mast and mounting flanges for wear
imately the same during assembly.
or damage:
a. Pivot Pin Connections - Remove the mast
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
pivot pins from the outer mast (see Fig-
• H2.0-3.5FT (H40-70FT) (L177)
ure 18). Check that the pins fit snug in the
• J2.00-3.20XM (J40-65Z (B416)
outer mast. If pins can be moved up and
• E2.00-3.20XM (E45-65Z) (G108)
down a minimum of 4 mm (0.20 in.), replace
bushings in outer mast and/or mast pivot See Figure 25 for lift truck models
pins as required. See Figure 22. • S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
b. Stub Shaft Connections - Remove the bush-
• J1.60-2.00XMT (J30-40ZT) (J160)
ing from the stub shaft. Check that the bush-
ing fits snug over the stub shaft. Place the
H40FTS) (F001)
bushing into the drive unit mounts and place
the retainer cap into position. Check that the See Figure 26 for lift truck models
bushing is snug under the retainer cap. If • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
pins can be moved up and down a minimum • H2.0-3.5FT (H40-70FT) (L177)
of 4.0 mm (0.2 in.), replace bushings as re- • J2.00-3.20XM (J40-65Z) (B416)
quired. • E2.00-3.20XM (E45-65Z) (G108)
• J1.60-2.00XMT (J30-40ZT) (J160) • S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/ • E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
F114) • J1.60-2.00XMT (J30-40ZT) (J160)
H40FTS) (F001)
WARNING
proximately 907 kg (2000 lb). Make sure all lift-
are suitable and of adequate capacity to lift the
mast.
NOTE: When replacing the outer mast, copy the part

number and date code information from the old chan-
nel and stamp that information on the new channel
with a letter R at the end to indicate that it has been
replaced.
Figure 22. Mast Pivot Pin
20
2. Slide the inner mast halfway out of the top of the See Figure 27 for lift truck models
outer mast. Connect a crane [the capacity of the • S30FT, S35FT, S40FTS (E010)
crane must be at least 907 kg (2000 lb)] to the • E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
center of the inner mast. See Figure 28. Slide the • J1.60-2.00XMT (J30-40ZT) (J160)
inner mast out of the outer mast until the mast • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
stub shafts of the inner mast are in the notches of H40FTS) (F001)
the outer channels. Remove the inner mast from
the outer mast. 5. Remove and disassemble chain sheaves as neces-
sary for cleaning and repair.
3. Using a brass drift, remove tilt rod bushing from
outer mast. Discard tilt rod bushing. See Fig-
ure 29.
4. Remove lowering control valve from outer mast.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z (B416)
• E2.00-3.20XM (E45-65Z) (G108)

• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
H40FTS) (F001)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) 1. STRIP BEARING
• J2.00-3.20XM (J40-65Z) (B416) 2. SHIMS
• E2.00-3.20XM (E45-65Z) (G108) 3. TOP OF OUTER MAST
4. O-RINGS
Figure 23. Strip Bearings
21
Figure 24. Two-Stage, Limited Free-Lift (LFL) Mast for Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and E2.00-3.20XM
(E45-65Z) (G108)
22

1. OUTER MAST 12. VELOCITY FUSE
2. LOAD ROLLER 13. NUT
3. SHIM 14. CAPSCREW
4. SNAP RING 15. HOUSING
5. O-RING 16. LOWERING CONTROL VALVE
6. SHIM(S) 17. INNER MAST
7. STRIP BEARING 18. PIN (2)
8. WASHER 19. SPACER
9. MAIN LIFT CYLINDER 20. CHAIN SHEAVE
10. MAIN LIFT CHAIN 21. PIN
11. CHAIN ANCHOR
23
Figure 25. Two-Stage, Limited Free-Lift (LFL) Mast for Lift Truck Models S30FT, S35FT, S40FTS
(E010); E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT,
24

1. OUTER MAST 16. FITTING
2. STUBSHAFT 17. CAPSCREW
3. BEARING STRIP 18. HOUSING
4. SHIM(S) 19. HOSE
5. O-RING 20. NUT
6. LOAD ROLLER 21. LOWERING CONTROL VALVE
7. SHIM 22. LOCK NUT
8. CHAIN 23. SPACER
9. COTTER PIN 24. SNAP RING
10. PIN 25. INNER MAST
11. CHAIN ANCHOR 26. CHAIN SHEAVE ASSEMBLY
12. WASHER 27. CHAIN SHEAVE
13. NUT 28. BEARING
14. MAIN CYLINDERS 29. LOWER MAST MOUNT (J1.60-2.00XMT
15. SPRING (J30-40ZT) (J160) ONLY)
25
Figure 26. Two-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S2.0-3.5FT (S40-70FT,
(E45-65Z) (G108)
26

1. OUTER MAST 13. VELOCITY FUSE
2. LOAD ROLLER 14. HOUSING
3. SHIM 15. LOWERING CONTROL VALVE
4. SNAP RING 16. INNER MAST
5. O-RING 17. FREE-LIFT CHAIN
6. SHIM(S) 18. CHAIN ANCHOR
7. STRIP BEARING 19. FREE-LIFT CYLINDER
8. WASHER 20. CYLINDER BRACKET
9. MAIN LIFT CYLINDER (L) 21. CAPSCREW
10. MAIN LIFT CYLINDER (R) 22. CROSSHEAD
11. NUT 23. CHAIN GUARD
12. TUBE 24. SPACER
27
Figure 27. Two-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S30FT, S35FT, S40FTS
(E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT,
28

1. SNAP RING 14. FITTING
2. SHIM(S) 15. HOSE
3. LOAD ROLLER 16. LOWERING CONTROL VALVE HOUSING
4. INNER MAST 17. CAPSCREW
5. FREE-LIFT CYLINDER 18. SPACER
6. CROSSHEAD 19. BEARING STRIP
7. FREE-LIFT CHAIN 20. OUTER MAST
8. WASHER 21. STUBSHAFT
9. NUT 22. LOCKNUT
10. MAST MOUNTS 23. BRACKET
11. MAIN LIFT CYLINDER 24. LOWER MAST MOUNT (J1.60-2.00XMT
12. SPRING (J30-40ZT) (J160) ONLY
13. O-RING
Figure 28. Inner Mast
1. TILT ROD BUSHING
Figure 29. Tilt Rod Bushing Location
29
Clean and Inspect lift truck before they can be checked for correct
length. Lubricate the chains by soaking them in
SAE 30W engine oil for 30 minutes. Hang chains
CAUTION over a drip pan for one hour to remove excess oil.
DO NOT use steam to clean lift chains, sheaves,
or load rollers. The bearings in the sheaves and
load rollers are sealed and lubricated.
1. Inspect the chain sheaves and load rollers for

wear or damage.
WARNING
Never replace only the worn section of a chain.
Replace the complete chain. Never replace
only one chain of a chain pair. Replace both
chains.
NOTE: The chains must be inspected in the area of

chain that passes over the chain sheave during the
first portion of a lift. Those links will show maximum
wear.
2. Inspect the lift chains for wear or damage. A lift

chain becomes longer when it is worn. If a chain
is 3% longer than a new lift chain, the lift chain
must be replaced. If a chain scale is available, NOTE: THE INSTRUCTIONS FOR MEASURING
check the lift chain as shown in Figure 30. If a CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
chain scale is not available, measure 20 links of SCALE (HYSTER PART NO. 599737).
the lift chain. Compare the measurement with
the lengths given in Figure 30. 1. CHAIN WEAR SCALE
Pitch Wear Limit

WARNING Total length
The
of 20 links
Cleaning solvents may be flammable and toxic maximum
(pitch) of new
and can cause severe skin irritation. When length of 20
chain
using cleaning solvents, always follow the links
solvent manufacturer’s recommended safety
12.7 mm 254.0 mm 261.6 mm
precautions.
(0.5 in.) (10.0 in.) (10.3 in.)
Compressed air can move particles so that they 15.9 mm 317.5 mm 327.0 mm
cause injury to the user or to other personnel. (0.6 in.) (12.5 in.) (12.9 in.)
Make sure that the path of the compressed air 19.1 mm 381.0 mm 392.4 mm
is away from all personnel. Wear protective (0.8 in.) (15.0 in.) (15.5 in.)
goggles or a face shield to prevent injury to the 25.4 mm 508.0 mm 523.3 mm
eyes. (1.0 in.) (20.0 in.) (20.6 in.)
3. Clean the lift chains by soaking in solvent for 30 Figure 30. Lift Chains Check
minutes and remove all dirt and grease. Hang
lift chains up and remove solvent using com- 4. Inspect the chain anchors and pins. Replace any
pressed air. The lift chains must be installed in parts that are worn or damaged.
the mast and the mast must be installed on the
30
load rollers at the bottom of the inner mast. Re-

WARNING move the load rollers at the top of the intermedi-
Be careful when cleaning with steam. Steam ate mast. Make a note of each shim arrangement
can cause serious burns. Wear protective cloth- and load roller location. The shim arrangements
ing, gloves, and eye protection. Never expose will be approximately the same during assembly.
your skin to steam.
Cleaning solvents may be flammable and toxic • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
and can cause severe skin irritation. When • H2.0-3.5FT (H40-70FT) (L177)
using cleaning solvents, always follow the • J2.00-3.20XM (J40-65Z (B416)
solvent manufacturer’s recommended safety • E2.00-3.20XM (E45-65Z) (G108)
precautions.
5. Clean the mast weldments with steam or solvent. • S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
WARNING • J1.60-2.00XMT (J30-40ZT) (J160)
Improper welding procedures can damage the • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
structure of the mast or cause incorrect func- H40FTS) (F001)
tion of the mast. Consult your Hyster lift truck
dealer for more information before welding on WARNING
the mast. The mast is heavy. The mast can weigh ap-
6. Inspect sliding surfaces for wear or damage. In-
spect load roller contact surfaces for wear or dam-
age. Inspect all welds for cracks.
mast.
THREE-STAGE FFL MAST 3. Slide the inner mast halfway out of the top of the
intermediate mast. Connect a crane with a ca-
Disassemble pacity of at least 907 kg (2000 lb) to the center
1. Remove the pins for the lift chains at the chain of the inner mast. See Figure 28. Slide the in-
anchors on the inner mast. ner mast out of the intermediate mast until the
stub shafts are in the notches of the intermediate
mast. Remove the inner mast from the interme-
WARNING diate mast.
The weldments can slide when the mast is
moved. A weldment that slides can cause in- 4. Slide the intermediate mast from the bottom of
jury. Use a crane to turn the mast slowly and the outer mast approximately 30 cm (12 in.). Re-
carefully. move the strip bearings at the top of the outer
mast. Remove the snap rings and load rollers
2. Disconnect and remove lift chains between the from both weldments. Make a note of each shim
outer mast and inner mast. Slide inner mast arrangement and load roller location. The shim
from bottom of the intermediate mast approxi- arrangements will be approximately the same
mately 30 cm (12 in.). Remove the strip bearings during assembly.
at the top of the intermediate mast. Remove the
31
1. OUTER MAST 11. NUT 21. INNER MAST

2. LOAD ROLLER 12. HOSE 22. FREE-LIFT CYLINDER
3. SHIM 13. VELOCITY FUSE 23. BRACKET
4. SNAP RING 14. HOUSING 24. CAPSCREW
5. O-RING 15. LOWERING CONTROL VALVE 25. SPACER
6. SHIM(S) 16. CHAIN SHEAVE 26. FLOW CONTROL ASSEMBLY
7. STRIP BEARING 17. INTERMEDIATE MAST 27. CROSSHEAD
8. WASHER 18. HOSE 28. CHAIN GUARD
9. MAIN LIFT CYLINDER 19. HOSE SHEAVE 29. FREE-LIFT CHAIN
10. LIFT CHAIN 20. CHAIN ANCHOR
Figure 31. Three-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z ) (B416); and E2.00-3.20XM
(E45-65Z) (G108)
32
WARNING
WARNING Never replace only the worn section of a chain.
chains.
are suitable and of adequate capacity to lift the NOTE: The chains must be inspected in the area of
mast. chain that passes over the chain sheave during the
5. Slide the intermediate mast halfway out of the
wear.
top of the outer mast. Connect a crane with a
capacity of at least 907 kg (2000 lb) to the center 2. Inspect the lift chains for wear or damage. A lift
of the intermediate mast. See Figure 28. Slide chain becomes longer when it is worn. If a chain
the intermediate mast out of the outer mast until is 3% longer than a new lift chain, the lift chain
the stub shafts are in the notches of the outer must be replaced. If a chain scale is available,
mast. Remove the intermediate mast from the check the lift chain as shown in Figure 33. If a
outer mast. chain scale is not available, measure 20 links of
6. Using a brass drift, remove tilt rod bushing from
the lengths given in Figure 33.
outer mast. Discard tilt rod bushing. See Fig-
ure 29.
WARNING
7. Remove lowering control valve from outer mast. Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
precautions.
• J2.00-3.20XM (J40-65Z (B416)
• E2.00-3.20XM (E45-65Z) (G108) Compressed air can move particles so that they
• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
eyes.
H40FTS) (F001) 3. Clean the lift chains by soaking in solvent for 30
8. Disassemble the chain sheaves as necessary for
lift chains up and remove solvent using com-
repair and cleaning. Remove the hydraulic lines
pressed air. The lift chains must be installed in
and fittings from the weldments as necessary.
lift truck before they can be checked for correct
Clean and Inspect
SAE 30W engine oil for 30 minutes. Hang chains
or load rollers. The bearings in the sheaves and 4. Inspect the chain anchors and pins. Replace any
load rollers are sealed and lubricated. parts that are worn or damaged.

wear or damage.
33
Figure 32. Three-Stage, Full Free-Lift (FFL) Mast for Lift Truck Models S30FT, S35FT, S40FTS
(E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT,
34

1. OUTER MAST 19. HOSE
2. LOAD ROLLER 20. LOWERING CONTROL VALVE
3. SHIM 21. CAPSCREW
4. SNAP RING 22. CLAMP
5. STUBSHAFT 23. TUBE
6. O-RING 24. SPACER
7. SHIM 25. LOCK NUT
8. BEARING STRIP 26. INTERMEDIATE MAST
9. CHAIN 27. BEARING
10. COTTER PIN 28. CHAIN SHEAVE ASSEMBLY
11. PIN 29. CHAIN SHEAVE
12. CHAIN ANCHOR 30. INNER MAST
13. WASHER 31. CHAIN GUARD
14. NUT 32. CROSSHEAD
15. FREE-LIFT CYLINDER 33. BRACKET
16. MAIN LIFT CYLINDER 34. VALVE ASSEMBLY (FLOW LIMITING)
17. SPRING 35. LOWER MAST MOUNT (J1.60-2.00XMT
18. FITTING (J30-40ZT) (J160) ONLY)
35
WARNING
Cleaning solvents may be flammable and toxic
precautions.
Be careful when cleaning with steam. Steam

can cause serious burns. Wear protective cloth-
your skin to steam.
5. Clean the mast weldments with steam or solvent.
WARNING
Improper welding procedures can damage the
structure of the mast or cause incorrect func-
tion of the mast. Consult your Hyster lift truck
dealer for more information before welding on
the mast. Pitch Total length Wear Limit
6. Inspect the sliding surfaces for wear or damage. of 20 links The maximum
Inspect the load roller contact surfaces for wear (pitch) length of 20
or damage. Inspect all welds for cracks. of new chain links
12.7 mm 254.0 mm 261.6 mm
(0.5 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.6 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.8 in.) (15.0 in.) (15.4 in.)
25.4 mm 508.0 mm 523.3 mm
(1.0 in.) (20.0 in.) (20.6 in.)
NOTE: THE INSTRUCTIONS FOR MEASURING

CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE (HYSTER PART NO. 599737).
1. CHAIN WEAR SCALE
Figure 33. Lift Chains Check
36
TWO-STAGE LFL AND TWO-STAGE FFL • E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)

MAST • J1.60-2.00XMT (J30-40ZT) (J160)
Assemble H40FTS) (F001)
2. Install the strip bearings and the shims on the

WARNING outer mast. See Figure 34. Apply chassis lube to
The mast is heavy. The mast can weigh ap- the bearing surface. Check the clearance of the
proximately 907 kg (2000 lb). Make sure all lift- strip bearings as described in Carriage Adjust-
ing devices (hoists, cables, chains, slings, etc.) ments.
mast. 3. Install the load rollers and shims on both weld-
ments. Check the clearance of the load rollers as
NOTE: The shims for the load rollers keep the described in Carriage Adjustments.
mast weldments parallel and give correct clearance.
During assembly, the shim arrangement will be ap- 4. Install the housing for the lowering control valve
proximately the same as before disassembly. Check on the outer mast. Tighten the nuts for the low-
the clearance and adjust the shims for wear or for ering control valve to 18 N•m (13 lbf ft). Install
changes caused by repairs. The strip bearings are the lowering control valve in the housing. Con-
also adjusted by using shims. See Carriage Adjust- nect the hydraulic lines and fittings between the
ments in this section for the adjustment procedures. housing and the main lift cylinders.
NOTE: When the mast has header hoses, see the pro- 5. Install new tilt rod bushing into outer mast. See
cedures for Header Hose Arrangement. Figure 35.
1. Connect a crane with a capacity of at least 907 kg 6. On the lift truck listed below that are equipped
(2000 lb) to the center of the inner mast. Fit with the two-stage LFL mast, install the chain
the stub shafts through the notches in the outer sheaves at the inner mast. Be sure to install both
mast. Slide the inner mast into the outer mast pins that hold the shaft for the chain sheave in
so the stub shafts are seen at the top and bottom position.
of the weldments. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See Figure 24 for lift truck models • J2.00-3.20XM (J40-65Z) (B416)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • E2.00-3.20XM (E45-65Z) (G108)
• H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z (B416)
• E2.00-3.20XM (E45-65Z) (G108)

• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
H40FTS) (F001)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z) (B416)
• E2.00-3.20XM (E45-65Z) (G108)
See Figure 27 for lift truck models Figure 34. Strip Bearings
• S30FT, S35FT, S40FTS (E010
37
least 907 kg (2000 lb) to the center of the inter-

mediate mast. Fit the lower stub shafts of the
intermediate mast into the notches in the top of
the outer mast. Slide the intermediate mast into
the outer mast so the stub shafts are seen at the
top and bottom of both weldments.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z (B416)
• E2.00-3.20XM (E45-65Z) (G108)

• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
H40FTS) (F001)
1. TILT ROD BUSHING
NOTE: The load rollers must be in place before strip
bearing can be shimmed.
7. On the lift trucks listed below that are equipped
2. Install the strip bearings and the shims on the
with the two-stage LFL mast, install the chain
channels of the outer mast. See Figure 34. Apply
sheaves at the inner mast. Be sure to install the
chassis lube to the bearing surfaces. Check the
snap rings that hold the chain sheave to the shaft
clearance of the strip bearings as described in
for the correct position.
Carriage Adjustments.
• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) 3. Install the load rollers and the shims on the outer
• J1.60-2.00XMT (J30-40ZT) (J160) mast and at the bottom of the intermediate mast.
H40FTS) (F001) 4. Install the housing for the lowering control valve
on the outer mast. Tighten the nuts for the low-
8. Connect the lift chains to the chain anchors at the ering control valve to 18 N•m (13 lbf ft). Install
main lift cylinder mounts. Attach wires between the lowering control valve in the housing. Con-
the ends of the lift chains and the crossmember to nect the hydraulic lines and fittings between the
control the lift chains during mast installation. housing and the main lift cylinders.
THREE-STAGE FFL MAST 5. Install new tilt rod bushing into outer mast. See
Figure 35.
Assemble
6. On the lift truck models listed below, install the
NOTE: The shims for the load rollers keep the weld- chain sheaves at the intermediate mast. Be sure
ments parallel and give correct clearance. During as- to install both pins that hold the shaft for the
sembly, the shim arrangement will be approximately chain sheave in position.
the same as before disassembly. Check the clearance • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
and adjust the shims for wear or for changes caused • H2.0-3.5FT (H40-70FT) (L177)
by repairs. The strip bearings are also adjusted by • J2.00-3.20XM (J40-65Z) (B416)
using shims. See Carriage Adjustments in this sec- • E2.00-3.20XM (E45-65Z) (G108)
tion for the adjustment procedures.
1. Put the outer mast on the floor with the carriage

side up. Connect a crane with a capacity of at
38
7. On the lift truck models listed below, install hoses, see the procedures for the Header Hose Ar-
the chain sheaves at the intermediate mast. Be rangements.
sure to install the snap rings that hold the chain
sheave to the shaft for the correct position. 1. Disconnect lift chains at bottom of inner mast
• S30FT, S35FT, S40FTS (E010) and top of first intermediate mast. Remove lift
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) chains. Push inner mast toward bottom of mast
• J1.60-2.00XMT (J30-40ZT) (J160) assembly until bottom load rollers are seen. See
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, Figure 36 and Figure 37.
H40FTS) (F001)
2. Remove strip bearings at top of second interme-
8. Connect a crane with a capacity of at least 907 kg diate mast. Remove load rollers at bottom of in-
(2000 lb) to the center of the inner mast. Slide ner mast. Remove load rollers at top of second
the inner mast into the intermediate mast so the intermediate mast. Make a note of each shim ar-
stub shafts are seen at the top and bottom of both. rangement and load roller location. The shim ar-
rangements will be approximately the same dur-
NOTE: Use multipurpose grease #2 with 2 to 4% ing assembly.
Molybdenum Disulfide for normal operations.
3. Slide inner mast halfway out of top of second in-
NOTE: The load rollers must be in place before bear- termediate mast. Connect crane to center of in-
ing strips can be shimmed. ner mast. See Figure 38. Slide inner mast out
until stub shafts are in notches of second inter-
9. Install the strip bearings and the shims on the mediate mast. Remove inner mast from second
channels of the intermediate mast. Apply grease intermediate mast.
to the bearing surfaces. Install the load rollers
and the shims on the intermediate and inner 4. Disconnect lift chains at bottom of second inter-
masts. Before doing the next step, adjust the in- mediate mast and top of outer mast. Remove
ner mast as described in Carriage Adjustments. lift chains. Push second intermediate mast to-
ward bottom of mast assembly until bottom load
10. Connect the main lift chains to the chain anchors rollers are seen. See Figure 36 and Figure 37.
at the main lift cylinder mounts. Put the lift
chains over the chain sheaves and connect them 5. Remove strip bearings and spacers at top of first
to the anchors at the bottom of the inner mast. intermediate mast. Remove load rollers at bot-
tom of second intermediate mast. Remove load
11. Connect the free-lift chains to the chain anchors rollers at top of first intermediate mast. Make
at the crossmember. Attach a wire between the a note of each shim arrangement and load roller
end of the lift chain and the bottom of the mast location. The shim arrangements will be approx-
to control the lift chain during mast installation. imately the same during assembly. See Figure 36
and Figure 37.
FOUR-STAGE FFL MAST -
MANUFACTURED BEFORE JULY, 6. Slide second intermediate mast halfway out of
2009 top of first intermediate mast. Connect crane
to center of second intermediate mast. See Fig-
NOTE: The information in this section is for four- ure 38. Slide second intermediate mast out until
stage FFL mast manufactured BEFORE July, 2009. stub shafts are in notches of first intermediate
For four-stage FFL mast manufactured AFTER July, mast. Remove second intermediate mast.
2009, go to Four-Stage FFL Mast - Manufactured Af-
ter July, 2009. 7. Slide first intermediate mast from bottom of
outer mast approximately 30 cm (12 in.). Re-
Disassemble move strip bearings at top of outer mast. Remove
snap rings and load rollers from both mast up-
NOTE: If only the lift, tilt, or free-lift cylinders need rights. Make a note of each shim arrangement
to be removed and repaired, see the section Cylinder and load roller location. The shim arrangements
Repair 2100 SRM 1139. When the mast has header will be approximately the same during assembly.
39
Figure 36. Second Intermediate and Inner Mast (Four-Stage FFL)
40

1. SNAP RING 10. SHIMS
3. CHAIN SHEAVE 12. NUT
4. SECOND INTERMEDIATE MAST 13. WASHER
5. O-RING 14. CHAIN ANCHOR
6. SHIM(S) 15. ANCHOR PIN
7. STRIP BEARING 16. LIFT CHAIN
8. INNER MAST 17. FREE-LIFT CHAIN
9. LOAD ROLLER
41
Figure 37. Outer and First Intermediate Masts (Four-Stage FFL)
42

2. O-RING 11. NUT
3. SHIM(S) 12. FIRST INTERMEDIATE MAST
4. STRIP BEARING 13. SNAP RING
5. LIFT CHAIN 14. SHIMS
6. SPACER 15. LOAD ROLLER
7. ANCHOR PIN 16. BEARING
8. COTTER PIN 17. CHAIN SHEAVE
9. CHAIN ANCHOR
8. Slide intermediate mast halfway out of top of 9. Using a brass drift, remove tilt rod bushing from
outer mast. Connect crane to center of first in- outer mast. Discard tilt rod bushing. See Fig-
termediate mast. See Figure 38. Slide first inter- ure 35.
mediate mast out of outer mast until stub shafts
are in notches of outer mast. Remove first inter- 10. Remove lowering control valve from outer mast.
mediate mast from outer mast. See Figure 39.
11. Disassemble chain sheaves as necessary for re-

pair and cleaning. Remove hydraulic lines and
fittings from mast uprights as necessary.
Figure 38. Mast Disassembly
43
1. BALANCE LINE 7. HOUSING

2. SNAP RING 8. HOSE
4. FITTING AND O-RING 10. MAIN LIFT CYLINDER (RH)
5. MAIN LIFT CYLINDER (LH) 11. SPACER
6. VELOCITY FUSE 12. RETAINER
Figure 39. Main Lift Cylinders and Lowering Control Valve (Four-Stage FFL)
44
Clean and Inspect lift truck before they can be checked for correct
SAE 30 engine oil for 30 minutes. Hang chains
or load rollers. The bearings in the sheaves and
load rollers are sealed and lubricated.

wear or damage.
WARNING
Never replace only the worn section of a chain.
chains.
NOTE: The chains must be inspected in the area of

wear.
2. Inspect the lift chains for wear or damage. A lift

chain becomes longer when it is worn. If a chain
must be replaced. If a chain scale is available, NOTE: THE INSTRUCTIONS FOR MEASURING
check the lift chain as shown in Figure 40. If a CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
chain scale is not available, measure 20 links of SCALE (HYSTER PART NO. 599737).
the lengths given in Figure 40. 1. CHAIN WEAR SCALE
Pitch Wear Limit

WARNING Total length
The
of 20 links
Cleaning solvents may be flammable and toxic maximum
(pitch) of new
and can cause severe skin irritation. When length of 20
chain
using cleaning solvents, always follow the links
12.7 mm 254.0 mm 261.6 mm
precautions.
(0.5 in.) (10.0 in.) (10.3 in.)
Compressed air can move particles so that they 15.9 mm 317.5 mm 327.0 mm
cause injury to the user or to other personnel. (0.6 in.) (12.5 in.) (12.9 in.)
Make sure that the path of the compressed air 19.1 mm 381.0 mm 392.4 mm
is away from all personnel. Wear protective (0.8 in.) (15.0 in.) (15.5 in.)
goggles or a face shield to prevent injury to the 25.4 mm 508.0 mm 523.3 mm
eyes. (1.0 in.) (20.0 in.) (20.6 in.)
3. Clean the lift chains by soaking in solvent for 30 Figure 40. Lift Chains Check
lift chains up and remove solvent using com- 4. Inspect the chain anchors and pins. Replace any
pressed air. The lift chains must be installed in parts that are worn or damaged.
45
as described in Mast Adjustments. Install chain

WARNING sheaves, shims, and snap rings on first interme-
Be careful when cleaning with steam. Steam diate weldment.
can cause serious burns. Wear protective cloth-
ing, gloves, and eye protection. Never expose 4. Install housing for lowering control valve on
your skin to steam. outer mast. Tighten nuts for lowering control
valve to 18 N•m (13 lbf ft). Install lowering con-
Cleaning solvents may be flammable and toxic trol valve in housing. Connect hydraulic lines
and can cause severe skin irritation. When and fittings between lowering control valve and
using cleaning solvents, always follow the main lift cylinders. See Figure 39.
precautions. 5. Install chain sheaves and snap rings on second
intermediate mast.
6. Connect crane to center of second intermediate
WARNING mast. Slide mast into first intermediate mast so
stub shafts are seen at top and bottom of both
mast uprights.
structure of the mast or cause incorrect func-
tion of the mast. Consult your Hyster lift truck 7. Install strip bearings and shims on channels of
dealer for more information before welding on first intermediate mast. Apply grease to bearing
the mast. surfaces. Install load rollers and shims on first
and second intermediate mast. Before doing the
next step, adjust second intermediate mast as de-
scribed in Mast Adjustments.
8. Connect lift chains to chain anchors at outer
Assemble mast. Put lift chains over chain sheaves on first
intermediate mast and connect them to anchors
NOTE: The shims for the load rollers keep the mast
at bottom of second intermediate mast.
uprights parallel and provide correct clearance. Dur-
ing assembly, the shim arrangement will be approxi- 9. Connect crane to center of inner mast. Slide mast
mately the same as before disassembly. Check clear- into second intermediate mast so stub shafts are
ance and adjust shims for wear or for changes caused seen at top and bottom of both uprights.
by repairs. The strip bearings are also adjusted by
using shims. See Mast Adjustments in this section
for the adjustment procedures.
NOTE: When the mast has header hoses, see the pro-
cedures for the Header Hose Arrangements.
1. Put outer mast on floor with mast pivots toward

floor. See Figure 37. Connect crane to center
of first intermediate mast (see Figure 38.) Fit
lower stub shafts of first intermediate mast into
notches in top of outer mast. Slide first interme-
diate mast into outer mast so stub shafts are seen
at top and bottom of both mast uprights.
2. Install strip bearings and shims on channels of

outer mast. See Figure 41. Apply grease to bear-
ing surfaces. Figure 41. Strip Bearings
3. Install load rollers and shims on outer mast and

at bottom of first intermediate mast. Before do-
ing the next step, adjust first intermediate mast
46
10. Install strip bearings and shims on channels of 4. Disconnect lift chains at bottom of second inter-
second intermediate mast. Apply grease to bear- mediate mast and top of outer mast. Remove
ing surfaces. Install load rollers and shims on lift chains. Push second intermediate mast to-
second intermediate and inner mast. Before do- ward bottom of mast assembly until bottom load
ing the next step, adjust inner mast as described rollers are seen. See Figure 42 and Figure 43.
in Mast Adjustments.
5. Remove strip bearings and spacers at top of first
11. Connect lift chains to chain anchors at top of first intermediate mast. Remove load rollers at bot-
intermediate mast. Put lift chains over chain tom of second intermediate mast. Remove load
sheaves on second intermediate mast and con- rollers at top of first intermediate mast. Make
nect them to anchors at bottom of inner weld- a note of each shim arrangement and load roller
ment. location. The shim arrangements will be approx-
imately the same during assembly. See Figure 42
12. Connect free-lift chains to chain anchors at inner and Figure 43.
crossmember. Attach wire between other end of
lift chain and bottom of mast to control free-lift 6. Slide second intermediate mast halfway out of
chain during installation of mast. top of first intermediate mast. Connect crane
to center of second intermediate mast. See Fig-
FOUR-STAGE FFL MAST - ure 44. Slide second intermediate mast out until
MANUFACTURED AFTER JULY, 2009 stub shafts are in notches of first intermediate
mast. Remove second intermediate mast.
NOTE: The information in this section is for
four-stage FFL mast manufactured AFTER July, 7. Slide first intermediate mast from bottom of
2009. For four-stage FFL mast manufactured BE- outer mast approximately 30 cm (12 in.). Re-
FORE July, 2009, go to Four-Stage FFL Mast - move strip bearings at top of outer mast. Remove
Manufactured Before July, 2009. snap rings and load rollers from both mast up-
rights. Make a note of each shim arrangement
Disassemble and load roller location. The shim arrangements
will be approximately the same during assembly.
NOTE: If only the lift, tilt, or free-lift cylinders need
to be removed and repaired, see the section Cylinder 8. Slide intermediate mast halfway out of top of
Repair 2100 SRM 1139. When the mast has header outer mast. Connect crane to center of first in-
hoses, see the procedures for the Header Hose Ar- termediate mast. See Figure 44. Slide first inter-
rangements. mediate mast out of outer mast until stub shafts
are in notches of outer mast. Remove first inter-
1. Disconnect lift chains at bottom of inner mast mediate mast from outer mast.
and top of first intermediate mast. Remove lift
chains. Push inner mast toward bottom of mast 9. Remove nut, washer, and capscrew from outer
assembly until bottom load rollers are seen. See mast crossmember and bracket weldment and re-
Figure 42 and Figure 43. move hose channels from outer mast. See Fig-
ure 45.
2. Remove strip bearings at top of second interme-
diate mast. Remove load rollers at bottom of in- 10. Using a brass drift, remove tilt rod bushing from
ner mast. Remove load rollers at top of second outer mast. Discard tilt rod bushing. See Fig-
intermediate mast. Make a note of each shim ar- ure 46.
rangement and load roller location. The shim ar-
rangements will be approximately the same dur- 11. Remove lowering control valve from outer mast.
ing assembly. See Figure 47.
3. Slide inner mast halfway out of top of second in- 12. Disassemble chain sheaves as necessary for re-
termediate mast. Connect crane to center of in- pair and cleaning. Remove hydraulic lines and
ner mast. See Figure 44. Slide inner mast out fittings from mast uprights as necessary.
until stub shafts are in notches of second inter-
mediate mast. Remove inner mast from second
intermediate mast.
47
Figure 42. Second Intermediate and Inner Mast (Four-Stage FFL)
48
NOTE: SOME COMPONENTS OMITTED FOR CLARITY.

1. SNAP RING 10. SHIMS
3. CHAIN SHEAVE 12. NUT
4. SECOND INTERMEDIATE MAST 13. WASHER
5. O-RING 14. CHAIN ANCHOR
6. SHIM(S) 15. ANCHOR PIN
7. STRIP BEARING 16. LIFT CHAIN
8. INNER MAST 17. FREE-LIFT CHAIN
9. LOAD ROLLER
49
Figure 43. Outer and First Intermediate Masts (Four-Stage FFL)
50
NOTE: SOME COMPONENTS OMITTED FOR CLARITY.

2. O-RING 11. NUT
3. SHIM(S) 12. FIRST INTERMEDIATE MAST
4. STRIP BEARING 13. SNAP RING
5. LIFT CHAIN 14. SHIMS
6. SPACER 15. LOAD ROLLER
7. ANCHOR PIN 16. BEARING
8. COTTER PIN 17. CHAIN SHEAVE
9. CHAIN ANCHOR
Figure 44. Mast Disassembly
51
NOTE: FOUR FUNCTION MAST WITH FOUR HOSE CHANNELS SHOWN. THREE FUNCTION MAST WILL HAVE
TWO HOSE CHANNELS.
1. NUT 5. OUTER MAST CROSSMEMBER
2. WASHER 6. OUTER MAST
3. CAPSCREW 7. CLAMP
4. HOSE CHANNEL
Figure 45. Hose Channel Removal, Four-Stage FFL Mast
52

1. TILT ROD BUSHING
53
1. BALANCE LINE 7. HOUSING

2. SNAP RING 8. HOSE
4. FITTING AND O-RING 10. MAIN LIFT CYLINDER (RH)
5. MAIN LIFT CYLINDER (LH) 11. SPACER
6. VELOCITY FUSE 12. RETAINER
Figure 47. Main Lift Cylinders and Lowering Control Valve (Four-Stage FFL)
Clean and Inspect NOTE: The chains must be inspected in the area of
CAUTION wear.
or load rollers. The bearings in the sheaves and 2. Inspect the lift chains for wear or damage. A lift
load rollers are sealed and lubricated. chain becomes longer when it is worn. If a chain
1. Inspect the chain sheaves and load rollers for must be replaced. If a chain scale is available,
wear or damage. check the lift chain as shown in Figure 48. If a
chain scale is not available, measure 20 links of
WARNING the lift chain. Compare the measurement with
Never replace only the worn section of a chain. the lengths given in Figure 48.
chains.
54
WARNING
precautions.

eyes.
3. Clean the lift chains by soaking in solvent for 30

lift chains up and remove solvent using com-
pressed air. The lift chains must be installed in
lift truck before they can be checked for correct
length. Lubricate the chains by soaking them in NOTE: THE INSTRUCTIONS FOR MEASURING
SAE 30 engine oil for 30 minutes. Hang chains CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
over a drip pan for one hour to remove excess oil. SCALE (HYSTER PART NO. 599737).
4. Inspect the chain anchors and pins. Replace any 1. CHAIN WEAR SCALE
parts that are worn or damaged. Pitch Wear Limit
Total length
The
of 20 links
WARNING (pitch) of new
maximum
Be careful when cleaning with steam. Steam length of 20
chain
can cause serious burns. Wear protective cloth- links
ing, gloves, and eye protection. Never expose 12.7 mm 254.0 mm 261.6 mm
your skin to steam. (0.5 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.6 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.8 in.) (15.0 in.) (15.5 in.)
25.4 mm 508.0 mm 523.3 mm
precautions.
(1.0 in.) (20.0 in.) (20.6 in.)
Figure 48. Lift Chains Check
WARNING
Assemble
structure of the mast or cause incorrect func- NOTE: The shims for the load rollers keep the mast
tion of the mast. Consult your Hyster lift truck uprights parallel and provide correct clearance. Dur-
dealer for more information before welding on ing assembly, the shim arrangement will be approxi-
the mast. mately the same as before disassembly. Check clear-
ance and adjust shims for wear or for changes caused
by repairs. The strip bearings are also adjusted by
using shims. See Mast Adjustments in this section
for the adjustment procedures.
55
NOTE: When the mast has header hoses, see the pro- 9. Connect lift chains to chain anchors at outer
cedures in the section Header Hose Arrangements. mast. Put lift chains over chain sheaves on first
intermediate mast and connect them to anchors
1. Assemble and install chain sheaves onto mast at bottom of second intermediate mast.
weldments. See Figure 42 and Figure 43.
10. Connect crane to center of inner mast. Slide mast
2. Install housing for lowering control valve on into second intermediate mast so stub shafts are
outer mast. Tighten nuts for lowering control seen at top and bottom of both uprights.
valve to 18 N•m (13 lbf ft). Install lowering con-
trol valve in housing. Connect hydraulic lines 11. Install strip bearings and shims on channels of
and fittings between lowering control valve and second intermediate mast. Apply grease to bear-
main lift cylinders. See Figure 47. ing surfaces. Install load rollers and shims on
second intermediate and inner mast. Before do-
3. Install hose channels onto outer mast using nuts, ing the next step, adjust inner mast as described
washers, and capscrews. Tighten capscrews to in Mast Adjustments.
8 N•m (71 lbf in). See Figure 45.
12. Connect lift chains to chain anchors at top of first
4. Put outer mast on floor with mast pivots toward intermediate mast. Put lift chains over chain
floor. See Figure 43. Connect crane to center sheaves on second intermediate mast and con-
of first intermediate mast (see Figure 44.) Fit nect them to anchors at bottom of inner weld-
lower stub shafts of first intermediate mast into ment.
notches in top of outer mast. Slide first interme-
diate mast into outer mast so stub shafts are seen 13. Connect free-lift chains to chain anchors at inner
at top and bottom of both mast uprights. crossmember. Attach wire between other end of
lift chain and bottom of mast to control free-lift
5. Install strip bearings and shims on channels of chain during installation of mast.
outer mast. See Figure 49. Apply grease to bear-
ing surfaces.
6. Install load rollers and shims on outer mast and

at bottom of first intermediate mast. Before do-
ing the next step, adjust first intermediate mast
as described in Mast Adjustments. Install chain
sheaves, shims, and snap rings on first interme-
diate weldment.
7. Connect crane to center of second intermediate

mast. Slide mast into first intermediate mast so
stub shafts are seen at top and bottom of both
mast uprights.
8. Install strip bearings and shims on channels of

first intermediate mast. Apply grease to bearing
surfaces. Install load rollers and shims on first Figure 49. Strip Bearings
and second intermediate mast. Before doing the
next step, adjust second intermediate mast as de-
scribed in Mast Adjustments.
56
MAST, INSTALL 4. Install the tilt cylinders and main lift cylinders.
For two, three, and four-stage FFL mast, install
1. Lubricate the lower mast mounting surface to the free-lift cylinder. See service manual Cylin-
prepare for installation: der Repair 2100 SRM 1139 for procedures.
a. Pivot Pin Connections - Apply an even coat 5. Install carriage and forks as described in the pro-
of grease to the pivot pins and install them cedures for the Carriages Repair and Fork Re-
into mounts at bottom of outer mast. See placement.
Figure 50.
6. Connect hydraulic hoses as tagged during re-
b. Stub Shaft Connections - Coat the inside and moval. See Header Hose Arrangement for
outside of the stub shaft bushing and install procedures on installing and adjusting header
onto the stub shaft. hoses.
• J1.60-2.00XMT (J30-40ZT) (J160) WARNING
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/ Never check for leaks by putting hands on
F114) hydraulic lines or components under pressure.
2. Connect crane to top of mast using chains. Make into the skin.
sure all mast uprights are fastened together.
Make sure chains will not damage sheaves, tub- 7. Check tilt cylinder adjustment as described in
ing, or other parts of mast. Make sure crane has Cylinder Repair 2100 SRM 1139. Operate
a capacity of at least 1600 kg (3500 lb). mast and check for leaks and correct operation.
Check lift chains as described in Lift Chain Ad-
3. Use crane to position mast assembly onto its justments.
lower mounts:
a. Pivot Pin Connection - Position mast so pivot

pins seat into hanger mounts on drive axle.
Install capscrews that hold mast pivot pins
to drive axle hangers. Tighten capscrews to
270 N•m (199 lbf ft).

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• J2.00-3.20XM (J40-65Z) (B416)
• E2.00-3.20XM (E45-65Z) (G108)
b. Stub Shaft Connection - Position mast stub

shafts into the drive unit hangers. Install
retainer caps over stub shaft bushings. Ap-
ply Loctite® 290 or equivalent to capscrew
1. MAST PIVOT PINS
threads and install capscrews. Tighten to 2. BUSHING
35 N•m (26 lbf ft).
Figure 50. Mast Mounts, Pivot Pin Connections
• J1.60-2.00XMT (J30-40ZT) (J160)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/
F114)
57
1. DRIVE AXLE 2. HANGER MOUNTS
Figure 52. Mast Mounts, Drive Axle, for Lift

Truck Models S30FT, S35FT, S40FTS (E010),
H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS)
(F187), and H2.0-3.5FT (H40-70FT) (L177)
1. RETAINER CAP
2. LOCKWASHER
3. TILT CYLINDER
4. OUTER MAST WELDMENT
5. BUSHING
6. NUT
7. PIN
8. ROD END
9. WASHER
10. CAPSCREW
Figure 51. Mast Mounting (Stub Shaft

Connections) for Lift Truck Models
J1.60-2.00XMT (J30-40ZT) (J160) and
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
1. HANGER MOUNTS 2. TRACTION MOTOR
Figure 53. Mast Mounting for Lift Truck

Models J2.00-3.20XM (J40-65Z) (B416) and
E2.00-3.20XM (E45-65Z) (G108)
58
NOTE: Before checking for mast side kicking and ad- as it is being raised. If the mast is side kicking,
justing the chain anchors on the main lift cylinders see the Mast Adjustments section for procedures
for lift trucks equipped with either a three or four- to correct mast side kicking.
stage FFL mast, the mast must be fully assembled
to include the carriage, forks, load backrest and any NOTE: The load rollers and sheaves have sealed bear-
attachments if the lift truck is equipped with one. ings and do not need additional lubrication.
8. If lift truck is equipped with a three-stage FFL 11. Lubricate sliding surfaces and load roller sur-
mast, adjust chain anchors on the main lift cylin- faces along full length of channels as shown in
ders until the tops of the inner and outer mast Figure 54. Apply lubricant only to surfaces indi-
are at the same level within ±1.5 mm (0.06 in.). cated.

• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z (B416)
• E2.00-3.20XM (E45-65Z) (G108)

• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
H40FTS) (F001)
9. For lift trucks equipped with a four-stage FFL

mast, adjust chain anchors on the outer mast
until the tops of the second intermediate and
outer mast are at the same level within ±1.5 mm
(0.06 in.). See Figure 37 or Figure 43. Adjust
chain anchors on the first intermediate mast A. LOWER LOAD ROLLERS
until the tops of the inner and outer mast are at B. UPPER LOAD ROLLERS
the same level within ±1.5 mm (0.06 in.).
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
10. Raise the mast, without a load to its full height 3. LOAD ROLLER
and check for side kicking. Mast side kicking is
when the mast moves either to the right or left Figure 54. Lubricate Mast
59
Header Hose Arrangement 4000 SRM 1148
Header Hose Arrangement

2. Dimension E is determined by the height of the
WARNING outer mast channel from the ground and the
Always wear the proper protective equipment length of the outer mast channel. See dimen-
including eye protection and petroleum-resis- sions Y and Z in Figure 56. To determine E, use
tant gloves when handling hydraulic oil. Thor- the formula shown in the tables associated with
oughly wash oil from exposed areas of skin as Figure 56.
soon as possible.
3. Clamp the end of the hose (the smaller fitting)
Never check for leaks by putting hands on that attaches to the carriage in a vise (DO NOT
hydraulic lines or components under pressure. clamp on the threads), and pull on the other end
Hydraulic oil under pressure can be injected until the hose is straight. DO NOT apply enough
into the skin. force to stretch the hose. See Figure 56.
Before installing the header hoses, make sure you NOTE: This mark will be used to pretension the
know the lift height of the mast. The tension on the header hoses during installation.
header hoses is adjusted according to lift height. The
lift height is on the Nameplate of the lift truck and 4. Place a mark on all the hoses at dimension E (all
on the right-hand side of the outer mast. measurements are made from the carriage end of
the hose [the smaller fitting]).
Some lift trucks are equipped with auxiliary hy-
draulic functions that are fastened to the carriage. 5. Attach the hoses to the carriage brackets with
Examples of these auxiliary functions are sideshift the clamps. See Figure 57.
carriages or roll clamps. These auxiliary functions
require header hoses for their operation. 6. Place the hoses at the location of the hose sheave.
The sheave(s) and stub shafts must be assem-
TWO-STAGE LFL bled, and the hose(s) must be routed onto the
sheave(s) before the hose(s) are attached to the
mast. Refer to Figure 57. Tighten the hose clamp
WARNING hardware (12) to 8 N•m (71 lbf in) and the sheave
Before working on or near the mast, see Safety assembly capscrews (13) to 66 N•m (49 lbf ft).
Procedures When Working Near Mast in this
section. 7. Put the clamps (8) over the hoses and attach the
clamps to the upper brackets. DO NOT tighten
NOTE: This procedure is for the four-function option. the hardware.
The three-function option will have hoses A and B
only. NOTE: To make the alignment of dimension E eas-
ier, use a crane with a capacity of at least 907.2 kg
NOTE: The lift chains and carriage height must be (2000 lb) to raise the carriage high enough to install
correctly adjusted before the header hoses can be ad- a safety chain. See Figure 58.
justed. See the section Lift Chains Adjustment for
adjustment procedures. 8. Align mark E at the bottom of the clamps.
Tighten the hardware to 8 N•m (71 lbf in). Refer
1. Mark each hose with a single letter: A, B, C, and to Figure 57.
D. See Figure 55.

A. HOSE C. HOSE
B. HOSE D. HOSE
60
4000 SRM 1148 Header Hose Arrangement
Figure 55. Header Hose Alignment for Two-Stage Limited Free-Lift Mast
61
1. GROUND LEVEL 4. TOP OUTER CHANNEL

2. HOSE 5. BOTTOM OUTER CHANNEL
3. VISE
Figure 56. Header Hose Measurement for Two-Stage Limited Free-Lift Mast
62
Table 2. Pneumatic Tire Trucks
* Metric Formulas (All Dimensions are in Millimeters)

Dimension E = (Y + Z + 204) × 0.98
Example: Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98
Step 2. Dimension E = 2179 × 0.98
Step 3. Dimension E = 2135
* Inch Formulas (All Dimensions are in Inches)

Dimension E = (Y + Z + 8.0) × 0.98
Example: Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98
Step 2. Dimension E = 85.7 × 0.98
Step 3. Dimension E = 84.0
*All measurements are made with mast vertical and fully lowered.
Table 3. Cushion Tire Trucks

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 91+ 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 3.6 + 8.0) × 0.98
63
Figure 57. Header Hoses for Two-Stage Limited Free-Lift Mast
64

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP
1. HOSE 10. NUT
3. CLAMP 12. CAPSCREW
4. NUT 13. CAPSCREW
5. BRACKET 14. LOCKWASHER
6. CLAMP 15. STUB SHAFT
7. CLAMP 16. SHEAVE
8. CLAMP 17. SPACER
1. HOOK 2. SHACKLE
Figure 58. Chaining the Carriage
65
9. Connect the header hoses to the cowl hoses. full lift cycle two times. When properly adjusted,
the hoses will not be so tight that they compress
10. Use the rubber clamps and hose clamps to attach when they pass over the sheaves nor will they
the hoses to the main lift cylinders. DO NOT be so loose that they touch the load backrest or
allow the hoses to stretch or fold while tilting the any crossmember that is next to a sheave. If nec-
mast fully forward and backward. essary, repeat until hoses are properly adjusted.
See Table 4.
11. With no load on the forks, check the header hose
adjustment by operating the mast through the
Table 4. Standard Two-Stage Hose Dimensions
Channel
Dimension "G" Dimension "G"
Lift Height Length Dimension "E"
Third Function Fourth Function
(Reference)
mm in. mm mm in. mm in. mm in.
2043 80.8 1440 1780 70.1 X X X X
3060 120.5 2040 1363 53.7 3183 125.3 3054 120.2

3159 124.4 2090 2420 95.3 X X X X
3252 128.0 2040 2370 93.3 X X X X
3260 128.3 2140 1412 55.6 3380 133.1 3251 128.0
3262 128.4 2040 1397 55.0 3234 127.3 3106 122.3
"E" = (0.985 × channel length in mm) 358.2 "G" = (2.095 × channel length in mm) 291.0
66
TWO-STAGE FFL See Figure 60 for lift truck models

• S30FT, S35FT, S40FTS (E010)
WARNING • E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
Before working on or near the mast, see Safety
Procedures When Working Near Mast in this
H40FTS) (F001)
section.
NOTE: These marks will be used to pretension the
NOTE: This procedure is for the four-function option.
header hoses during installation.
only. 4. Place a mark on all the hoses at dimension E and
G (all measurements are made from the carriage
NOTE: The lift chains and carriage height must be
end of the hose [the smaller fitting]).
correctly adjusted before the header hoses can be ad-
justed. See the section Lift Chains Adjustment for 5. Attach the hoses to the carriage bracket with
adjustment procedures. clamps. Tighten hardware for clamps to 18 N•m
(159 lbf in).
1. Mark each hose with a single letter: A, B, C, and
D. 6. Put the header hoses over the free-lift chains.
2. Dimensions E and G are determined by the See Figure 62 and Figure 64 for lift truck models
height of the outer mast channel from the • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
ground and the length of the outer mast chan- • H2.0-3.5FT (H40-70FT) (L177)
nel. See dimensions Y and Z and to calculate E • J2.00-3.20XM (J40-65Z) (B416)
and G (see tables associated with figures). • E2.00-3.20XM (E45-65Z) (G108)
See Figure 59 for lift truck models 7. Route header hose A and C over the bottom right-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) and left-hand free-lift hose sheaves. Then route
• H2.0-3.5FT (H40-70FT) (L177) header hose B and D over the top right and left
• J2.00-3.20XM (J40-65Z (B416) free-lift hose sheaves.
• E2.00-3.20XM (E45-65Z) (G108)
• S30FT, S35FT, S40FTS (E010) • E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) • J1.60-2.00XMT (J30-40ZT) (J160)
• J1.60-2.00XMT (J30-40ZT) (J160) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
8. Put the clamps over the header hoses and attach
3. Clamp the end of the hose (the smaller fitting) the clamps to the free-lift bracket. (DO NOT
that attaches to the carriage in a vise (DO NOT tighten the hardware.)
clamp on the threads), and pull on the other end
until the hose is straight. DO NOT apply enough NOTE: To make the alignment of dimension E easier,
force to stretch the hose. use a crane with a capacity at least 907.2 kg (2000 lb)
to raise the carriage high enough to install a safety
See Figure 59 for lift truck models chain. See Figure 61.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) 9. Align mark E at the bottom of the clamp. Tighten
• J2.00-3.20XM (J40-65Z (B416) the hardware to 8 N•m (71 lbf in).
• E2.00-3.20XM (E45-65Z) (G108)
67
Figure 59. Header Hose Measurement for Two-Stage Full Free-Lift Mast, Lift Truck Models
S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-60Z)
(B416); and E2.00-3.20XM (E45-65Z) (G108)
68

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE
69
Figure 60. Header Hose Measurement for Two-Stage Full Free-Lift Mast, Lift Truck Models S30FT,
S35FT, S40FTS (E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT)
(J160); and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
70

2. BOTTOM OUTER CHANNEL 5. HOSE
3. VISE

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 91+ 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 3.6 + 8.0) × 0.98
71

Class II Mast Type (2.0 - 2.5 Ton Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 303
Step 1. Dimension E = (0.492 × 2482) + (0.985 × 2095) + 303
Step 2. Dimension E = 1221.1 + 2063.6 + 303
Step 3. Dimension E = 3284.7 + 303
Dimension G Calculations are Similar to Dimension E
Dimension G (3 Function) for Lift Heights of 2482 mm to 2982 mm:
(1.982 × Y) + (0.985 × Z) 801
(1.991 × Y) + (0.985 × Z) 917
Dimension G (4 Function) for Lift Heights of 2482 mm to 2982 mm
(1.982 × Y) + (0.985 × Z) 868
(1.991 × Y) + (0.985 × Z) 1046

Class II Mast Type (4000 - 5500 lb. Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Example: Dimension E = (0.492 × Y) + (0.985 × Z) + 11.938
Step 1. Dimension E = (0.492 × 97.7) + (0.985 × 82.5) + 11.938
Step 2. Dimension E = 48.1 + 81.3 + 11.938
Step 3. Dimension E = 129.4 + 11.938
Dimension G (3 Function) for Lift Heights of 97.7 to 117.4:
(1.982 × Y) + (0.985 × Z) 31.531
(1.991 × Y) + (0.985 × Z) 36.125
(1.982 × Y) + (0.985 × Z) 34.156
(1.991 × Y) + (0.985 × Z) 41.156
72

Class III Mast Type (3.0 - 3.5 Ton Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 269
The Calculation For Dimension E For Class III Mast Is The Same As Class II Mast. See Class
II Mast - Metric Formula.
Dimension G Calculations Are Similar to Dimension E
(1.981 × Y) + (0.985 × Z) 851
(1.991 × Y) + (0.985 × Z) 972
Dimension G (4 Function) for Lift Heights of 2360 mm to 2960 mm
(1.981 × Y) + (0.985 × Z) 919
(1.991 × Y) + (0.985 × Z) 1100

Class III Mast Type (6000 - 7000 lb. Capacity)
Dimension E = (0.492 × Y) + (0.985 × Z) + 10.594
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class II
Mast - Inch Formula.
(1.981 × Y) + (0.985 × Z) 33.500
(1.991 × Y) + (0.985 × Z) 38.281
(1.981 × Y) + (0.985 × Z) 36.156
(1.991 × Y) + (0.985 × Z) 41.156
73
1. HOOK 2. SHACKLE
74
10. Apply a spray lubricant on the hoses in the area 13. With no load on the forks, operate the mast
that will contact the channels. Make sure the through the full lift cycle two times. With the
hoses are properly aligned in the channels. Put mast at full lift height, attach clamp at the bot-
the clamps over the hoses and attach the clamps tom of the hose loop on the third and/or fourth
to the channels. Tighten the hardware to 8 N•m function hoses. This action allows the hoses to
(71 lbf in). fit properly in the hose channel.
11. Connect the header hoses (C and D) to the cowl 14. With no load on the forks, check the header hose
hoses. Connect the header hoses (A and B) to the adjustment by operating the mast through the
tubes. full lift cycle two times. When properly adjusted,
the hoses will not be so tight that they compress
See Figure 62 and Figure 64 for lift truck models when they pass over the sheaves nor will they be
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) so loose that they touch the load backrest or any
• H2.0-3.5FT (H40-70FT) (L177) crossmember that is next to a sheave.
• J2.00-3.20XM (J40-65Z (B416)
• E2.00-3.20XM (E45-65Z) (G108) See Figure 64 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
See Figure 63 and Figure 65 for lift truck models • H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010) • J2.00-3.20XM (J40-65Z (B416)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114) • E2.00-3.20XM (E45-65Z) (G108)
• J1.60-2.00XMT (J30-40ZT) (J160)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, See Figure 65 for lift truck models
H40FTS) (F001) • S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
12. Use the rubber clamps and strap clamps to at- • J1.60-2.00XMT (J30-40ZT) (J160)
tach the hoses to the main lift cylinders. DO • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
NOT allow the cowl hoses to stretch or fold while H40FTS) (F001)
tilting the mast fully forward and backward.
75
Figure 62. Header Hoses for Two-Stage Full Free-Lift Mast Lift Truck Models S2.0-3.5FT (S40-70FT,
(E45-65Z) (G108)
76
NOTE: THREE-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. ALIGN MARK G AT TOP OF THIS CLAMP.
1. CHANNEL 14. CARRIAGE BRACKET
2. COWL HOSES 15. LOWER CLAMP
3. HEADER HOSES 16. HOSE GUIDE
4. STRAP CLAMP 17. SNAP RING
5. CLAMP 18. CLIP
7. FITTING 20. HOSE GUARD
8. TUBE 21. STUB SHAFT
9. FITTING 22. FITTING
10. CLAMP 23. SPACER
11. BRACKET 24. WASHER
12. FREE-LIFT BRACKET 25. NUT
13. FREE-LIFT CHAIN
77
Figure 63. Header Hoses for Two-Stage Full Free-Lift Mast Lift Truck Models S30FT, S35FT,
S40FTS (E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
78
NOTE: FOUR-FUNCTION MAST SHOWN.

A. ALIGN MARK E AT BOTTOM OF THIS CLAMP. B. ALIGN MARK G AT TOP OF THIS CLAMP.
1. CLAMP 9. STUBSHAFT
2. TUBE 10. NUT
3. CLAMP 11. STRAP CLAMP
4. CAPSCREW 12. CHANNEL
5. BRACKET 13. HOSE
6. LOCKWASHER 14. CAP
7. WASHER 15. HOSE SHEAVE
8. SPACER
79
Figure 64. Header Hose Alignment for Two-Stage Full Free-Lift Mast, Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and
E2.00-3.20XM (E45-65Z) (G108)
80
Figure 65. Header Hose Alignment for Two-Stage Full Free-Lift Mast, Lift Truck Models S30FT,
81
THREE-STAGE FFL Use formulas shown in Table 7 and Table 8 to

calculate E and G.
Standard
3. Clamp the end of the hose (the smaller fitting)
that attaches to the carriage in a vise (DO NOT
WARNING
clamp on the threads), and pull on the other end
Before working on or near the mast, see Safety until the hose is straight. DO NOT apply enough
Procedures When Working Near Mast in this force to stretch the hose.
section.
NOTE: These marks will be used to pretension the
NOTE: This procedure is for the four-function option. header hose during installation.
only. 4. Place a mark on all the hoses at dimensions E
and G (all measurements are made from the car-
NOTE: The lift chains and carriage height must be riage end of the hose [the smaller fitting]).
justed. See the section Lift Chains Adjustment for See Figure 68 for lift truck models
adjustment procedures. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
1. Mark each hose with a single letter: A, B, C, or • J2.00-3.20XM (J40-65Z (B416)
D. • E2.00-3.20XM (E45-65Z) (G108)
• H2.0-3.5FT (H40-70FT) (L177) • E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
• J2.00-3.20XM (J40-65Z (B416) • J1.60-2.00XMT (J30-40ZT) (J160)
• E2.00-3.20XM (E45-65Z) (G108) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
See Figure 67 for lift truck models H40FTS) (F001)
• S30FT, S35FT, S40FTS (E010) See Table 9.
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160) 5. Attach the hoses to the carriage bracket with
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, clamps. Tighten hardware for clamps to 18 N•m
H40FTS) (F001) (159 lbf in). Apply spray lubricant to the surface
of the hose guide that contacts the hoses.
2. Dimensions E and G are determined by the
height of the outer mast channel from the ground 6. Place the hoses over the top of the free-lift chains
and the length of the outer mast channel. See and under the hose guides. Attach the hose
dimensions Y and Z in guides to the lower crossmember and tighten the
mounting hardware to 33 N•m (24 lbf ft) on the
Figure 68 for lift truck models following lift truck models
• H2.0-3.5FT (H40-70FT) (L177) • H2.0-3.5FT (H40-70FT) (L177)
• J2.00-3.20XM (J40-65Z (B416) • J2.00-3.20XM (J40-65Z) (B416)
• E2.00-3.20XM (E45-65Z) (G108) • E2.00-3.20XM (E45-65Z) (G108)
See Figure 69 for lift truck models Make sure the bracket is between the crossmem-
• S30FT, S35FT, S40FTS (E010) ber and the hose guide. Put the clamps over
• E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114) the hoses and attach the clamps to the free-lift
• J1.60-2.00XMT (J30-40ZT) (J160) bracket. (DO NOT tighten the hardware). See
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, Figure 66.
H40FTS) (F001)
82
Figure 66. Header Hose Alignment for Three-Stage Full Free-Lift Mast Lift Truck Models
S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM
(J40-65Z) (B416); and E2.00-3.20XM (E45-65Z) (G108) (Sheet 1 of 3)
83
84
A. HOSE A G. LEFT-HAND CYLINDER

B. HOSE B H. ALIGN MARK E AT BOTTOM OF THIS CLAMP.
C. HOSE C I. REAR VIEW
D. HOSE D J. RIGHT-HAND CYLINDER
E. FRONT VIEW K. FORKS
F. ALIGN G ON HOSES A AND D AT BOTTOM OF
THIS CLAMP. ALIGN G ON HOSES B AND C AT
BOTTOM OF THIS CLAMP.
1. HOSE GUIDE 4. FREE-LIFT CYLINDER
2. HOSE 5. CYLINDER GUARD
3. BOTTOM CROSSMEMBER, INNER CHANNEL
85
Figure 67. Header Hose Alignment for Three-Stage Full Free-Lift Mast Lift Truck Models S30FT,
(J160); and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) (Sheet 1 of 3)
86
87
A. HOSE A G. MAIN LIFT CYLINDER (LH)

B. HOSE B H. MAIN LIFT CYLINDER (RH)
C. HOSE C I. FREE-LIFT CYLINDER
D. HOSE D
E. FRONT VIEW
F. ALIGN G ON HOSES B AND C AT BOTTOM OF
THIS CLAMP. ALIGN G ON HOSES A AND D AT
BOTTOM OF THIS CLAMP.
1. HOSE GUIDE 4. NUT
2. CAPSCREW 5. HOSE CLAMP
3. WASHER
88
1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE
Figure 68. Header Hose Measurement for Three-Stage Full Free-Lift Mast Lift Truck Models
S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z)
(B416); and E2.00-3.20XM (E45-65Z) (G108)
89
1. GROUND LEVEL 4. HOSE

2. BOTTOM OUTER CHANNEL 5. TOP OUTER CHANNEL
3. VISE
Figure 69. Header Hose Measurement for Three-Stage Full Free-Lift Mast Lift Truck Models S30FT,
90

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 135 + 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 5.3 + 8.0) × 0.98

Dimension E = (Y + Z + 204) × 0.98
Step 1. Dimension E = (1840 + 91+ 204) × 0.98

Dimension E = (Y + Z + 8.0) × 0.98
Step 1. Dimension E = (72.4 + 3.6 + 8.0) × 0.98
91

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, use 842.
Dimension G Calculations are similar to Dimension E
Dimension G for Lift Heights of 3710 mm to 6110 mm:
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 To 240.6. For Lift Heights of 246.5 to 335.0, use 33.156.
Dimension G for Lift Heights of 146.1 to 240.6:
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
92

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65
** For Lift Heights of 3518 mm to 5918 mm. For Lift Heights of 6068 mm to 8318 mm, Use 842

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, use 33.156.
93
Table 9. Standard Three-Stage Hose Dimensions
Channel
Lift Height Length Dimension "E" Dimension "G"
(Reference)
mm in. mm mm in. mm in.
4310 169.7 1840 1594 62.8 3683 145.0
4568 179.8 2040 1811 71.3 4293 169.0

4718 185.7 2140 1910 75.2 4293 169.0
4760 187.4 1990 1741 68.5 4076 160.5
4910 193.3 2040 1791 70.5 4272 168.2
5060 199.2 2140 1889 74.4 4272 168.2
5318 209.4 2390 2156 84.9 4784 188.3
5510 216.9 2290 2037 80.2 4567 179.8
5768 227.1 2540 2304 90.7 5078 199.9
94
7. Route header hose B and C over the left- and See Figure 66, Sheet 3 for lift truck models
right-hand free-lift hose sheaves. Then route • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
headers A and D over the top left- and right-hand • H2.0-3.5FT (H40-70FT) (L177)
free-lift hose sheaves on the following lift truck • J2.00-3.20XM (J40-65Z (B416)
models • E2.00-3.20XM (E45-65Z) (G108)
• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) See Figure 67, Sheet 3 for lift truck models
• J1.60-2.00XMT (J30-40ZT) (J160) • S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
H40FTS) (F001) • J1.60-2.00XMT (J30-40ZT) (J160)
See Figure 67. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
NOTE: To make the alignment of dimension E eas-
ier, use a crane with a capacity of at least 907.2 kg 12. Install the clamps.
(2000 lb) to raise the carriage high enough to attach
a safety chain. See Figure 61.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
8. Align the mark for dimension E at the bottom • H2.0-3.5FT (H40-70FT) (L177)
of the clamp to create the proper hose tension. • J2.00-3.20XM (J40-65Z (B416)
Tighten the hardware to 8 N•m (71 lbf in). In- • E2.00-3.20XM (E45-65Z) (G108)
stall the hose guards. Tighten the capscrews that
mount the guards to 18 N•m (13 lbf ft).
• S30FT, S35FT, S40FTS (E010)
9. Position the hoses at the hose sheave. The hose • E1.50-2.00XM (E25-35Z, E40ZS)(E114/F114)
sheave and stub shaft must be installed on • J1.60-2.00XMT (J30-40ZT) (J160)
the hose before they are attached to the mast. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
Tighten the hardware to 66 N•m (49 lbf ft). H40FTS) (F001)
10. Put the clamps over the hoses and attach the 13. Connect the header hoses to the cowl hoses.
clamps to the upper brackets. (DO NOT tighten
14. Use the rubber clamps and strap clamps to at-
the hardware.)
tach the hoses to the main lift cylinders. Make
NOTE: To make the alignment of dimension G easier, sure the hoses do not stretch or fold while tilting
use a crane to raise the inner channel high enough to the mast fully forward and backward.
install a safety chain.
15. With no load on the forks, check the header hose
11. Align mark G on hoses A and D at the bottom adjustment by operating the mast through the
edge of clamp to create the proper tension. Align full lift cycle two times. When properly adjusted,
mark G on hoses B and C at the top edge of clamp the hoses will not be so tight that they compress
to create the proper tension. Tighten the hard- when they pass over the sheaves nor will they be
ware to 8 N•m (71 lbf in). so loose that they touch the load backrest or any
crossmember that is next to a sheave. If neces-
sary, repeat until hoses are properly adjusted.
95
Figure 70. Header Hoses for Three-Stage Full Free-Lift (FFL) Mast, Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177); J2.00-3.20XM (J40-65Z) (B416); and
E2.00-3.20XM (E45-65Z) (G108)
96

1. HOSE 17. CLAMP
2. NUT 18. CLAMP
3. CLAMP 19. SNAP RING
4. CAPSCREW 20. HOSE GUIDE
6. RESTRAINT 22. NUT
7. WASHER 23. STUB SHAFT
8. NUT 24. HOSE GUIDE AND SHEAVE
9. WASHER 25. SPACER
11. SHEAVE 27. CAPSCREW
12. CAPSCREW 28. BRACKET (RH)
13. TUBE 29. STUB SHAFT
14. CAPSCREW 30. SHEAVE
15. CLAMP 31. WASHER
16. PLATE 32. BRACKET (LH)
97
Figure 71. Header Hoses for Three-Stage Full Free-Lift (FFL) Mast, Lift Truck Models S30FT,
98

1. LOCK NUT 9. CLAMP
2. HOSE SHEAVE 10. HOSE
3. SPACER 11. NUT
4. WASHER 12. BRACKET
5. CAPSCREW 13. HOSE GUIDE
6. STUBSHAFT 14. CAP
7. BRACKETS 15. FREE-LIFT CYLINDER BRACKET
8. LOCKWASHER
FOUR-STAGE FFL MAST - inner channel so main-lift chains are not tight.
MANUFACTURED BEFORE JULY, Install chains to prevent inner channel and car-
2009 riage from moving. The chains must not be in the
path of the header hose. See Figure 61.
NOTE: The information in this section applies to
four-stage FFL mast manufactured BEFORE July, 2. Install all hose sheaves loosely. DO NOT tighten
2009. For header hose information on four-stage capscrews and nuts until header hoses are in-
FFL mast manufactured AFTER July, 2009, go to stalled.
Four-Stage FFL Mast - Manufactured After July, 3. Make sure replacement header hose is correct
2009. part number for your mast assembly. Make sure
header hoses are straight on a flat surface. Mark
WARNING header hose at points E and G (mm) as shown in
Before working on or near the mast, see Safety Table 10. Measure from end of hose with small
Procedures When Working Near Mast. fitting.
NOTE: This procedure is for the four-function option. 4. Loosely assemble hose sheaves as shown in Fig-
The three-function option will have hoses A and B ure 73:
only.
a. Put coating of multipurpose grease on stub
NOTE: The lift chains and carriage height must be shafts before assembly.
justed. See the section Lift Chains Adjustment for b. The nuts for the sheave capscrew (axle) must
adjustment procedures. be on the inside of each assembly.
NOTE: If the header hoses were removed, use this c. DO NOT tighten any nuts or capscrews.
procedure to install the header hoses. See Table 10. They must be loose to allow installation of
If the mast components have not been assembled, as- hoses on hose sheave.
semble the mast as described in the previous proce-
5. Install plate at middle hose clamp and tighten
dure.
1. Raise carriage so free-lift chains are not tight.
See Figure 72, Figure 73, and Figure 74. Raise
99
Table 10. Standard Four-Stage Hose Dimensions
Channel
Lift Height Length Dimension "E" Dimension "G"
(Reference)
mm in. mm mm in. mm in.
4839 190.5 1735 1351 53.2 4750 187.0
5143 202.5 1811 1426 56.1 4971 195.7
5450 214.6 1888 1501 59.1 5192 204.4
5754 226.5 1964 1576 62.1 5414 213.1
6058 238.5 2040 1651 65.0 5635 221.9
6364 250.6 2141 1751 68.9 5930 233.5
6670 262.6 2243 1851 72.9 6225 245.1
6977 274.7 2345 1951 76.8 6520 256.7
7274 286.4 2446 2051 80.8 6815 268.3
7583 298.5 2548 2151 84.7 7110 279.9
7886 310.5 2649 2251 88.6 7405 291.6
8192 322.5 2751 2351 92.6 7701 303.2
8496 334.5 2853 2452 96.5 7996 314.8
8799 346.4 2954 2552 100.5 8291 326.4
9108 358.6 3056 2652 104.4 8586 338.0
100

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 350
Step 1. Dimension E = (0.985 × 3710) + (0.985 × 2095) 350
Step 2. Dimension E = 3654.4 + 2063.6 350
Step 3. Dimension E = 5718 350
** For Lift Heights of 3710 mm to 6110 mm. For Lift Heights of 6260 mm to 8510 mm, use 842.
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
Example: Dimension E = (0.985 × Y) + (0.985 × Z) 8.781
Step 1. Dimension E = (0.985 × 146.1) + (0.985 × 82.5) 8.781
Step 2. Dimension E = 143.91 + 81.3 8.781
Step 3. Dimension E = 225.20 8.781
** For Lift Heights of 146.1 To 240.6. For Lift Heights of 246.5 to 335.0, use 33.156.
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
101

Dimension E = (0.985 × Y) + (0.985 × Z) 350**
The Calculation for Dimension E for Class III Mast is the Same as Class II Mast. See Class
(1.965 × Y) + (0.985 × Z) 65
(1.965 × Y) + (0.985 × Z) 65
** For Lift Heights of 3518 mm to 5918 mm. For Lift Heights of 6068 mm to 8318 mm, Use 842

Dimension E = (0.985 × Y) + (0.985 × Z) 8.781**
(1.965 × Y) + (0.985 × Z) 2.562
(1.965 × Y) + (0.985 × Z) 2.562
** For Lift Heights of 138.8 to 233.0. For Lift Heights of 238.9 to 327.5, use 33.156.
102
1. CARRIAGE 5. FRONT HOSE SHEAVES

2. MAST ASSEMBLY 6. MIDDLE HOSE SHEAVES
3. CHAIN AND HOSE SHEAVES AT FREE-LIFT 7. MIDDLE HOSE CLAMP
CYLINDER 8. CABLE MOUNT BLOCKS
4. REAR HOSE SHEAVES 9. BOTTOM HOSE CLAMP ASSEMBLIES
A B C D = HOSES
Figure 72. Hose Sheaves and Routing, Four-Stage Mast
103
Figure 73. Header Hoses, Four-Stage Mast
104

1. HOSE 18. ROLLER 35. WASHER
2. CLAMP 19. SPACER 36. NUT
3. CLAMP 20. IDLER 37. CLAMP
4. CAPSCREW 21. CABLE 38. STRAP CLAMP
5. CLAMP 22. WASHER 39. BRACKET
6. NUT 23. SPRING 40. CAPSCREW
7. LOCK NUT 24. NUT 41. PLATE
8. SPACER 25. COTTER PIN 42. SNAP RING
9. SHEAVE 26. PIN 43. WASHER
10. STUB SHAFT 27. BLOCK 44. STUB SHAFT
11. WASHER 28. CAPSCREW 45. GUARD
12. CAPSCREW 29. LOCKWASHER 46. WASHER
13. STUB SHAFT 30. CAPSCREW 47. CAPSCREW
14. CAPSCREW 31. WASHER 48. CAPSCREW
15. HOSE GUARD 32. HOSE GUARD (RH INNER) 49. CLAMP
16. HOSE GUARD 33. HOSE GUARD (RH OUTER)
17. STUB SHAFT 34. CAPSCREW
6. Install bottom hose clamps as shown in Fig- 11. Partially assemble floating sheaves as shown in
ure 72. Put some grease on bottom of brackets so Figure 72 and Figure 73. Install loops of hoses
hoses can slip to equalize the pressure. Ensure under sheaves. Then install roller guide assem-
that the inside hose goes through the rear of the blies over hoses and between hose guards. See
bracket and tracks to the inside. The outside Figure 72 and Figure 74. Tighten roller guide
hose goes through the front of the bracket and capscrews and nuts to 8 N•m (71 lbf in).
becomes the outside. Tighten capscrews and
nuts of bracket to 18 N•m (13 lbf ft). DO NOT 12. Fasten looped ends of cables of floating sheaves
tighten capscrews and nuts for strap clamps at to cable mount blocks. Use pins, washers, and
this time. cotter pins to fasten cable loops. See Figure 73.
If necessary, install mount blocks on bottom
7. If the crosshead of the free-lift cylinder does not crossmember of intermediate channel using
have hose guides, remove chain guard brackets, capscrews and washers. Tighten capscrews to
chains, and chain sheaves. Install hose guides 18 N•m (13 lbf ft).
(flare toward outside) and snap rings to chain
sheaves. Install free-lift sheaves, chains, and 13. Make sure cables are in grooves of idler wheels
chain guard brackets as shown in Figure 72 and and under formed feature of hose guards of float-
Figure 74. ing sheaves. Install ends of cables in brackets so
there is spring tension on cables. Make sure axle
8. Install hoses over free-lift cylinder with marks capscrews and nuts of sheaves are tightened to
E aligned with top edge of clamp of middle hose 53 N•m (39 lbf ft).
clamp assemblies. Tighten capscrews and nuts of
clamps to 8 N•m (71 lbf in). Refer to Figure 70, 14. Slowly operate hydraulic system so lift chains
Sheet 3 or Figure 67, Sheet 3. are tight. Remove chains that fasten carriage
and channel weldment. Slowly raise carriage us-
9. Pass hoses under lower hose clamps and install ing hydraulic system. Make sure hoses move
strap clamps on hoses. Align marks G to bot- through all sheaves correctly.
toms of lower hose clamps. Tighten capscrews
and nuts of strap clamps to 18 N•m (13 lbf ft). 15. Slowly operate mast through a few cycles to make
sure hoses track correctly. Tighten strap clamps
10. Install hoses on hose sheaves (Figure 72) with at bottom hose clamps to 18 N•m (13 lbf ft). Fas-
loops long enough to install on floating hose ten hose assemblies to main cylinders using hose
sheaves. Tighten axle capscrews and nuts of clamps and screw clamps as shown in Figure 72
sheaves to 53 N•m (39 lbf ft). and Figure 73.
105
A. BACK VIEW B. SIDE VIEW

1. HOSE SHEAVE NO. 1 4. A-B CLAMP 8. C-D CLAMP
2. HOSE SHEAVE NO. 2 5. CABLE MOUNT 9. A-B CLAMP
3. FLOATING SHEAVE 6. GUIDE BRACKET 10. FREE-LIFT CROSSHEAD
ASSEMBLY 7. C-D CLAMP
Figure 74. Header Hose Arrangement, Four-Stage Mast
106
FOUR-STAGE FFL MAST - NOTE: If the header hoses were removed, use this
MANUFACTURED AFTER JULY, 2009 procedure to install the header hoses. See Table 11.
If the mast components have not been assembled, as-
NOTE: The information in this section applies to semble the mast as described in the previous proce-
four-stage FFL mast manufactured AFTER July, dure.
2009. For header hose information on four-stage
FFL mast manufactured BEFORE July, 2009, go to 1. Raise carriage so free-lift chains are not tight.
Four-Stage FFL Mast - Manufactured Before July, Raise inner channel so main-lift chains are not
2009. tight. Install chains to prevent inner channel
and carriage from moving. The chains must not
be in the path of the header hose. See Figure 75.
WARNING
Before working on or near the mast, see Safety 2. Install all hose sheaves loosely. DO NOT tighten
Procedures When Working Near Mast. capscrews and nuts until header hoses are in-
stalled.
NOTE: This procedure is for the four-function option.
The three-function option will have hoses A and B 3. Make sure replacement header hose is correct
only. part number for your mast assembly. Make sure
header hoses are straight on a flat surface. Mark
NOTE: The lift chains and carriage height must be header hose at points E, G and H (mm) as shown
correctly adjusted before the header hoses can be ad- in Table 11. Measure from end of hose with small
justed. See the section Lift Chains Adjustment for fitting.
adjustment procedures.
1. HOOK 2. SHACKLE
107
Table 11. Standard Four-Stage Hose Dimensions
Channel Length
Lift Height Dimension "E" Dimension "G" Dimension "H"
(Reference)
mm in. mm in. mm in. mm in. mm in.
4839 190.5 1735 68.3 1473 58.0 4808 189.3 2935 115.6
5143 202.5 1811 71.3 1548 60.9 5105 201.0 3232 127.2
5450 214.6 1888 74.3 1623 63.9 5403 212.7 3530 139.0
5754 226.5 1964 77.2 1698 66.9 5701 224.4 3828 150.7
6058 238.5 2040 80.3 1773 69.8 5998 236.1 4125 162.4
6364 250.6 2141 84.3 1873 73.7 6394 251.7 4521 178.0
6670 262.6 2243 88.3 1973 77.7 6791 267.4 4918 193.6
6977 274.7 2345 92.3 2073 81.6 7188 283.0 5315 209.3
7274 286.4 2446 96.3 2173 85.6 7584 298.6 5711 224.8
7583 298.5 2548 100.3 2273 89.5 7981 314.2 6108 240.5
7886 310.5 2649 104.3 2373 93.4 8377 329.8 6504 256.1
8192 322.5 2751 108.3 2473 97.4 8775 345.5 6902 271.7
8496 334.5 2853 112.3 2574 101.3 9172 361.1 7299 287.4
8799 346.4 2954 116.3 2674 105.3 9568 376.7 7695 303.0
9108 358.6 3056 120.3 2774 109.2 9965 392.3 8092 318.6
108
4. Loosely assemble hose sheaves as shown in Fig- in Figure 77). Tighten capscrews and nuts of
ure 76: clamps to 8 N•m (71 lbf in).
a. Put coating of multipurpose grease on stub 9. Route hose assembly down and under hose guide
shafts before assembly. and install strap clamps over hoses. Tighten
capscrews and nuts of strap clamps to 18 N•m
b. The nuts for the sheave capscrew (axle) must (159 lbf in).
be on the inside of each assembly.
10. Route hoses over hose sheave 1 (see Figure 77).
c. DO NOT tighten any nuts or capscrews. Install clamps over hoses. Align mark H with
They must be loose to allow installation of bottom edge of clamp. Tighten clamp capscrews
hoses on hose sheave. to 8 N•m (71 lbf in).
5. Install plate at middle hose clamp and tighten 11. Route hoses through hose channels (load side)
capscrews to 18 N•m (159 lbf in). See Figure 76. and over hose channel brackets. See Figure 76.
Install clamps over hoses.
6. Install bottom hose guides as shown in Figure 76.
Put grease on bottom of hose guides so hoses can 12. Align mark G with bottom edge of clamp at top of
slip to equalize the pressure. Ensure that the outer mast. See Figure 77. Torque clamp hard-
inside hose goes through the rear of the bottom ware to 8 N•m (71 lbf in).
hose guide and tracks to the inside. The out-
side hose goes through the front of the bottom 13. Slowly operate hydraulic system so lift chains
hose guide and becomes the outside. Tighten cap- are tight. Remove chains that fasten carriage
screws and nuts of bottom hose guide to 18 N•m and channel weldment. Slowly raise carriage us-
(159 lbf in). DO NOT tighten capscrews and nuts ing hydraulic system. Make sure hoses move
for strap clamps at this time. through all sheaves correctly.
7. Install hose guides (flare toward outside) and 14. Slowly operate mast through a few cycles to make
snap rings to chain sheaves. Install free-lift sure hoses track correctly. Tighten strap clamps
sheaves, chains, and hose guards as shown in at bottom hose clamps to 18 N•m (159 lbf in).
Figure 76 and Figure 77. Tighten capscrews and nuts for hose sheaves to
53 N•m (39 lbf ft). Fasten hose assemblies to
8. Route hoses over hose sheave 2 (on free-lift cylin- main cylinders using hose clamps as shown in
der) with marks E aligned with either the top Figure 76 and Figure 77.
edge of clamp or bottom edge of clamp (1 or 2
109
Figure 76. Header Hose Sheaves, Guides, and Channels
110
NOTE: THREE FUNCTION FFL MAST SHOWN. A FOUR FUNCTION FFL MAST HAS TWO DRIVER SIDE HOSE
CHANNELS (15).
1. HOSE CHANNEL (LOAD SIDE) 11. HOSE SHEAVE
2. CAPSCREW 12. HEADER HOSES
3. WASHER 13. RIGHT HOSE GUARD
4. NUT 14. LEFT HOSE GUARD
5. HOSE CHANNEL BRACKET WELDMENT 15. HOSE CHANNEL (DRIVER SIDE)
6. HOSE CLAMP 16. PLATE
7. STRAP CLAMP 17. CAP
8. HOSE CHANNEL BRACKET 18. BOTTOM HOSE GUIDE
9. STUBSHAFT 19. SNAP RING
10. SPACER
ADJUSTMENT move 15.0 mm (0.6 in.) side to side. Tighten the

hardware to 8 N•m (71 lbf in).
When properly adjusted, the hoses will not be so tight
that they compress when they pass over the sheaves, NOTE: If the hose tension between the clamp at the
nor will they be so loose that they touch the load back- upper bracket and the clamp at the free-lift bracket
rest or any crossmember that is next to a sheave. is correct, go to Step 8.
1. Cap off hoses when attachments have been re- 7. If the tension of the hoses is incorrect, loosen the
moved. clamps and pull the hoses down (if too loose) or
push the hoses up (if too tight) so they can move
2. Check that hoses and cables are routed properly. 15.0 mm (0.6 in.) side to side. Retighten the
hardware to 8 N•m (71 lbf in).
3. Slowly raise the free-lift and main cylinders to
take up slack in the lift chains. 8. With no load on the forks, check the header hose
adjustment by operating the mast through the
4. Tighten strap clamps at the bracket weldment.
full lift cycle two times. If necessary, repeat until
5. Cycle the mast a few times to ensure proper the hoses are properly adjusted.
tracking of hoses.
9. On four-stage FFL masts, manufactured before
6. Secure hose assemblies to main lift cylinders July, 2009, adjust the floating sheave cable ten-
with hose clamp and screw clamp. sions to ensure that they are approximately the
same. Check that the sheaves are aligned prop-
NOTE: If the hose tension between the carriage and erly with the header hoses.
the clamp at the free-lift bracket is correct, go to
Step 7. 10. On four-stage FFL mast, manufactured after
July, 2009, loosen clamp at the top of mast near
If the hose tension between the carriage and the sheave 1. See Figure 77. Pull on hoses so that
clamp at the free-lift bracket is incorrect, loosen they move by clamp width of 30 mm (1.2 in.).
the clamps and pull (if the hoses are loose) or Tighten clamp hardware to 8 N•m (71 lbf in).
push (if the hoses are tight) on the hoses so they
111
Figure 77. Four-Stage FFL Mast Header Hose Arrangement (Sheet 1 of 3)
112
113
114
4000 SRM 1148 Lift Chains Adjustment
NOTE: SOME MAST COMPONENT PARTS OMITTED FOR CLARITY.

A. HEADER HOSE A F. CHAIN, HOSE SHEAVES AND HEADER HOSES
B. HEADER HOSE B AT FREE-LIFT CYLINDER
C. HEADER HOSE C G. SIDE VIEW
D. HEADER HOSE D H. FRONT VIEW
E. HEADER HOSE ARRANGEMENT THROUGH
HOSE CHANNELS
1. ALIGN MARK E AT BOTTOM EDGE OF CLAMP 10. HOSE SHEAVE 1
2. ALIGN MARK E AT TOP EDGE OF CLAMP 11. ALIGN HOSE MARK H AT BOTTOM OF CLAMP
3. HOSE GUIDE 12. CHAIN SHEAVE
4. HOSE CHANNEL BRACKET WELDMENT 13. FREE-LIFT CYLINDER
5. HOSE CLAMP 14. HOSE CHANNEL (LOAD SIDE)
6. HOSE CLAMP* 15. MAIN LIFT CYLINDER
7. HOSE CHANNEL (DRIVER SIDE) 16. HOSE SHEAVE 2
8. LOWERING CONTROL VALVE *Clamp used only on mast with lift heights of
9. ALIGN HOSE MARK G AT BOTTOM OF CLAMP 7886 mm (310 in.) or greater.
Lift Chains Adjustment

chain anchors are completely engaged. Inspect the
WARNING torque of the prevailing torque nut (locknut) used
When working on or near the mast, see Safety to adjust the chain anchor with every lift chain
Procedures When Working Near Mast in this adjustment. After carriage and or mast section(s)
section. are adjusted for proper ground clearance, prevent
the carriage and or mast section(s) from fully low-
During test procedures for the hydraulic sys-
ering (see Safety Procedures When Working Near
tem, fasten the load to the carriage with chains
Mast). With slack chain(s), check locknut torque. If
to prevent it from falling. Keep all personnel
2.5 N•m (22.1 lbf in) for 1/2-20, 4.5 N•m (39.8 lbf in)
away from the lift truck during the tests.
for 5/8-18 nuts, 6.0 N•m (53.1 lbf in) for 3/4-16 of
Never allow anyone under a raised carriage. torque cannot be reached; replace locknut. The chain
DO NOT put any part of your body in or anchors, after adjustment, must be able to move on
through the lift mechanism unless all parts their mountings.
of the mast are completely lowered and the
1. When adjusting the lift chains on forklift trucks
engine is STOPPED.
equipped with either pin or hook-type forks in-
Never check for leaks by putting hands on stalled, go to Step 2. If the forklift truck is nor-
hydraulic lines or components under pressure. mally equipped with a hook-type carriage and
Hydraulic oil under pressure can be injected has an attachment without forks, go to Step 3.
into the skin. If the forklift truck is normally equipped with a
pin-type carriage and has an attachment without
When the lift chains are correctly adjusted: forks, go to Step 4.
• The tension will be the same on each chain of the
chain set. Check tension by pushing on both chains NOTE: Prior to performing adjustment procedures,
at the same time. make sure the forklift truck is parked on a level sur-
• The chain length will be correct. face and the mast is in the vertical position.
• The chains must travel freely through the complete
2. Adjust the chain anchors that support the car-
cycle.
riage, until the bottom of the fork heel is 12.0
NOTE: When the lift chain adjustments are com- +3.0/ 6.0 mm (0.47 +0.12/ 0.24 in.) above the
plete, make sure the threads on the nuts of the floor level. See Figure 78.
115
Lift Chains Adjustment 4000 SRM 1148
3. See Figure 79. Adjust the chain anchors that

support the carriage, until the bottom of the
lower carriage bar is above the floor level as
shown in Table 12. Adjust the chain anchors
that support the carriage, until the bottom of
the lower carriage bar is 88.5 +3.0/ 6.0 mm
(3.50 +0.12/ 0.24 in.) above the floor level. See
Figure 79.
Table 12. Hook-Type Carriage Chain

Adjustment
Class II and III 88.5 +3.0/ 6.0 mm

(3.50 +0.12/ 0.24 in.)
Class IV 139.5 +3.0/ 6.0 mm
(5.50 +0.12/ 0.24 in.)
1. MAST
4. See Figure 80. Adjust the chain anchors, which 2. CARRIAGE
support the carriage, until the center line of the 3. FORK
fork pin is above the floor level as shown in Ta- 4. HEEL OF FORK IS 12.0 +3.0/ 6.0 mm (0.47
+0.12/ 0.24 in.) ABOVE FLOOR LEVEL
ble 13.
Figure 78. Lift Chain Adjustment, Hook- or
Table 13. Pin-Type Carriage Chain Adjustment
Pin-Type Forks
H70/80, 90XLS 551.0 +3.0/ 6.0 mm
(21.7 +0.12/ 0.24 in.)
H90-110XL 714.0 +3.0/ 6.0 mm
(28.12 +0.12/ 0.24 in.)
H135-155XL 913.0 +3.0/ 6.0 mm
(36.0 +3.0/ 6.0 in.)
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Figure 79. Lift Chain Adjustment, Hook-Type

Carriage
116
4000 SRM 1148 Carriage Adjustments

1. LOAD BACK REST
2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR
Figure 80. Lift Chain Adjustment, Pin-Type

Carriage
Carriage Adjustments
1. Install the load rollers on the carriage. Install 3. Remove carriage from mast. Adjust shim ar-
the shims for the load rollers onto the stubshaft rangement for each roller for clearance between
in the same sequence as when disassembled. On roller and inner channel. Repeat Step 1 and
carriages equipped with six load rollers, there are Step 2 until there is zero clearance at the point
no shims under the top load rollers. of tightest fit.
2. Use a lifting device to raise carriage. Find the 4. Keep shim arrangement on each side of carriage
point of tightest fit between the carriage load approximately equal. The carriage must be cen-
rollers and inner mast channels. tered within the inner mast within +1.50 mm
(0.06 in.).
117
Mast Adjustments 4000 SRM 1148
5. Check lateral movement of carriage: repeat Step a through Step d until correct
movement is achieved.
a. Fully lower carriage to ground.
b. Place hand or small pry bar between top of CAUTION

carriage side plate and the inner channel Too much grease will cause the rollers to slide
flange. See Figure 81. and wear flat areas on the rollers and intro-
duce contamination into and on mast channels.
c. Move carriage back and forth and check
movement. 6. After adjustment, lubricate channels with a thin
layer of grease. Adjust hydraulic hoses and make
d. Carriage lateral movement must not be sure connections are correct, if the carriage is
greater than 2.5 mm (0.10 in.). equipped with hydraulic attachments.
e. If carriage lateral movement is greater than
2.5 mm (0.10 in.), add or remove shims and
Mast Adjustments
LOAD ROLLER ADJUSTMENT 2. Perform the following steps to adjust the mast
load rollers:
NOTE: Shims are installed on both sides of the load
rollers. Do not add or remove shims from the stub a. Use a crowbar to move mast uprights from
shafts. To change the position of the roller on the side to side to measure movement. Measure
stub shaft, move the shims from one side of the load movement in a minimum of three different
roller to the other. positions of each mast upright.
During assembly, the shim arrangement will be ap- b. Separate mast uprights and change shim ar-
proximately the same as before disassembly. Check rangements as required. Assemble uprights.
the clearance and adjust shims after repairs have Slide upright all the way to the top and bot-
been completed. tom to find the tightest fit.
1. The load rollers control the alignment of the mast c. Repeat Step a and Step b until there is zero
uprights. See Figure 81. The alignment condi- clearance at the point of the tightest fit.
tions are given on a list below with the most im-
portant condition first. d. Measure distance between channels of mast
uprights on top and bottom. Change shims
a. The mast uprights must be parallel to each to keep distance equal between top and bot-
other. tom so mast uprights are parallel. Also make
sure the mast uprights are parallel within
b. Use shims to adjust load rollers so there is 1.5 mm (0.060 in.).
zero clearance between load roller and chan-
nel at point of tightest fit. 3. Adjust strip bearings. See Figure 82. Insert
shims under strip bearing. Adjust clearance un-
c. The number of shims under a load roller til there is less than 0.8 mm (0.030 in.) at the
must be approximately the same as the stub tightest fit. See Figure 81.
shaft in the opposite side of the upright. This
ensures the uprights will be approximately
in the center.
118
4000 SRM 1148 Mast Adjustments
NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST UPRIGHTS PARALLEL, TO PROVIDE APPROXIMATELY
EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND UPRIGHTS, AND TO PROVIDE ZERO CLEAR-
ANCE AT POINT OF TIGHTEST FIT.
A. TOP VIEW C. CARRIAGE FRONT VIEW
B. MAST FRONT VIEW
1. CHANNEL 9. PARALLEL TO CHANNEL ±1.5 mm (0.060 in.)
2. LOAD ROLLER 10. PUT SPACER ON OUTSIDE OF TOP LOAD
3. STUB SHAFT ROLLER, UNDER SNAP RING
4. SNAP RING 11. SHIM FOR ZERO CLEARANCE AT POINT OF
5. SHIMS TIGHTEST FIT
6. PARALLEL TO CHANNEL 12. CARRIAGE LATERAL MOVEMENT 2.5 mm
±1.5 mm (0.060 in.) (0.10 in.)
7. ZERO CLEARANCE AT POINT OF TIGHTEST FIT 13. CHECK CARRIAGE LATERAL MOVEMENT
8. EQUAL SPACE ±1.5 mm (0.060 in.) HERE
Figure 81. Mast Adjustments
119
Mast Adjustments 4000 SRM 1148
1. STRIP BEARING 4. SHIMS

2. LOAD ROLLER 5. O-RING
3. MAST UPRIGHT
Figure 82. Strip Bearings Arrangement
MAST SIDE KICKING ADJUSTMENT • J1.60-2.00XMT (J30-40ZT) (J160)

To adjust the mast for side kicking, do the following: H40FTS) (F001)
1. Place the lift truck on a level surface and apply See Figure 26, for shim location on the main lift
the parking brake. cylinders for the two-stage, full free-lift (FFL)
mast for lift truck models
2. Raise the mast and visually inspect it as it
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
reaches its full height.
• H2.0-3.5FT (H40-70FT) (L177)
3. If the mast is moving to the left, shims will need • J2.00-3.20XM (J40-65Z) (B416)
to either be added or removed from the top of • E2.00-3.20XM (E45-65Z) (G108)
the right main lift cylinder. If mast moves to the
See Figure 27, for shim location on the main lift
right, shims will need to either be added or re-
cylinders for the two-stage, full free-lift (FFL)
moved from the top of the left main lift cylinder.
mast for lift truck models
See Figure 24, for shim location on the main lift • S30FT, S35FT, S40FTS (E010)
cylinders for the two-stage, limited free-lift (LFL) • E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
mast for lift truck models • J1.60-2.00XMT (J30-40ZT) (J160)
• S2.0-3.5FT (S40-70FT,S55FTS) (F187) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• H2.0-3.5FT (H40-70FT) (L177) H40FTS) (F001)
• J2.00-3.20XM (J40-65Z) (B416)
See Figure 31, for shim location on the main lift
• E2.00-3.20XM (E45-65Z) (G108)
cylinders for the three-stage, full free-lift (FFL)
See Figure 25, for shim location on the main lift mast for lift truck models
cylinders for the two-stage, limited free-lift (LFL) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
mast for lift truck models • H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010) • J2.00-3.20XM (J40-65Z) (B416)
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) • E2.00-3.20XM (E45-65Z) (G108)
120
4000 SRM 1148 Mast Adjustments
See Figure 32, for shim location on the main lift 4. If shims are to be added, use the smallest shim
cylinders for the three-stage, full free-lift (FFL) size available on the cylinder being adjusted. See
mast for lift truck models the Parts Manual for shim sizes and part num-
• S30FT, S35FT, S40FTS (E010) bers.
• E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114)
• J1.60-2.00XMT (J30-40ZT) (J160) 5. Raise the mast again and visually inspect it to
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, ensure that it is no longer side kicking. If it is,
H40FTS) (F001) repeat Step 3 and Step 4.
121
NOTES
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____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
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122

WIRE HARNESS REPAIR
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) [A099];
A1.3-1.5XNT [D203];
S30FT, S35FT, S40FTS [E010];
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) [G004, H004];
H2.0-3.5FT (H40-70FT) [L177];
(H80, 90, 100, 110, 120FT) [N005, P005, R005];
E2.2-3.5XN (E45-70XN) [A268];
J2.2-3.5XN (J45-70XN) [A276];
J1.5-2.0XNT (J30-40XNT) [K160]; J1.6-2.0XN (J30-40XN) [A935];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299];
E30HSD 2, E35HSD 2, E40HSD 2 [B219];
S50CT [A267]; H2.0-2.5CT (H50CT) [A274];
E1.6-2.0XN (E30-40XN) [A269]; J4.0-5.0XN (J80-100XN) [A970]
PART NO. 1580517 2200 SRM 1128

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
Wire Harness Repair Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Deutsch Crimping Tool ........................................................................................................................................ 1
How to Strip a Wire for Use With Deutsch Crimping Tool ........................................................................... 1
How to Crimp With the Deutsch Crimping Tool............................................................................................ 2
Calibration Test for the Deutsch Crimping Tool............................................................................................ 4
Deutsch Connectors ............................................................................................................................................. 5
DT, DTM, and DTP Series Connectors ........................................................................................................... 5
Connector Receptacle Replacement.......................................................................................................... 14
Connector Plug Replacement.................................................................................................................... 22
Connector Receptacle Pin Replacement................................................................................................... 30
Connector Plug Socket Replacement........................................................................................................ 39
HD Series Connectors ................................................................................................................................... 48
Connector Receptacle Replacement.......................................................................................................... 50
Connector Plug Replacement.................................................................................................................... 54
Connector Receptacle Pin Replacement................................................................................................... 58
Connector Plug Socket Replacement........................................................................................................ 63
Sealing Plugs ................................................................................................................................................. 68
Metri-Pack Connectors ...................................................................................................................................... 70
Micro-Pack Connectors ...................................................................................................................................... 72
Weather-Pack Connectors.................................................................................................................................. 73
Weather-Pack Terminal Repair .................................................................................................................... 73
AMPSEAL Crimping Tools................................................................................................................................ 74
AMP Hand Crimping Tool With Certi-Crimp .............................................................................................. 74
Description................................................................................................................................................. 74
Stripping Wire for Use with AMP Hand Crimping Tool ......................................................................... 75
Insulation Crimp Adjustment................................................................................................................... 76
Maintenance and Inspection for AMP Hand Crimping Tool................................................................... 76
AMP Hand Crimping Tool .................................................................................................................... 76
Crimp Height Inspection ...................................................................................................................... 76
How to use AMP Hand Crimping Tool ......................................................................................................... 77
AMP Pro-Crimper II Tool .............................................................................................................................. 77
Description................................................................................................................................................. 77
Remove and Install Die Set and Locator Assembly ............................................................................ 78
Stripping Wire for Use With AMP PRO-CRIMPER II Tool .................................................................... 79
Contact Support Adjustment .................................................................................................................... 79
Crimp Height Adjustment ........................................................................................................................ 80
Maintenance and Inspection Procedures ................................................................................................. 80
PRO-CRIMPER II Tool ......................................................................................................................... 80
Crimp Height Inspection ...................................................................................................................... 80
How to Use AMP PRO-CRIMPER II Tool .................................................................................................... 81
AMPSEAL Connector Assemblies..................................................................................................................... 81
Description for Plug Connector Assembly.................................................................................................... 81
Seal Plug .................................................................................................................................................... 81
Contact Crimping ...................................................................................................................................... 81
Contact Removal ....................................................................................................................................... 83
Contact Insertion....................................................................................................................................... 85
Description for Plug Connector and Header Assembly ............................................................................... 87
Voltage Reading......................................................................................................................................... 90
Seal Plug .................................................................................................................................................... 90
Contact Crimping ...................................................................................................................................... 90

Table of Contents Wire Harness Repair

Contact Removal ....................................................................................................................................... 93
Contact Insertion....................................................................................................................................... 95
AMP Superseal 1.5 Crimping Tools .................................................................................................................. 97
Mini Mic Receptacle and Tab Contacts ........................................................................................................ 97
Description................................................................................................................................................. 97
Crimping Conditions and Measurements ................................................................................................ 97
Insertion of Rubber Seal on Cable............................................................................................................ 97
Correction or Replacement of Parts ....................................................................................................... 100
AMP Hand Application Tool ....................................................................................................................... 104
Description............................................................................................................................................... 104
Maintenance and Inspection................................................................................................................... 104
Crimp Height Inspection .................................................................................................................... 104
Crimp Height Adjustment ...................................................................................................................... 105
How to Use AMP Hand Application Tool ................................................................................................... 105
AMP Pro-Crimper II Tool ............................................................................................................................ 106
Description............................................................................................................................................... 106
Remove and Install Die Set and Locator Assembly .......................................................................... 107
Adjustments............................................................................................................................................. 108
Contact Support .................................................................................................................................. 108
Crimp Height....................................................................................................................................... 109
Inspections and Maintenance ................................................................................................................. 109
Crimp Height Inspection .................................................................................................................... 109
Visual Inspection................................................................................................................................. 110
Maintenance ........................................................................................................................................ 110
How to Use Pro-Crimper II Tool ................................................................................................................. 110
AMP Superseal 1.5 Connector Assemblies ..................................................................................................... 111
Description ................................................................................................................................................... 111
Harness Assembly ................................................................................................................................... 111
Positioning of Anti-Backout Device.................................................................................................... 112
Removal of Contacts ........................................................................................................................... 114
Repair and Maintenance ............................................................................................................................. 118
Panel Mount Option .................................................................................................................................... 118
AMP Fastin-Faston Hand Tools ...................................................................................................................... 118
Description - AMP Double Action Hand Tool............................................................................................. 118
Maintenance and Inspection Procedures ................................................................................................... 118
Daily Maintenance .................................................................................................................................. 118
Periodic Tool Inspection .......................................................................................................................... 118
Lubrication .......................................................................................................................................... 118
Visual Inspection................................................................................................................................. 118
Crimp Height Inspection......................................................................................................................... 120
Certi-Crimp Ratchet Inspection ............................................................................................................. 121
How to Use AMP Double Action Hand Tool ............................................................................................... 122
Description - AMP Extraction Tool............................................................................................................. 122
Maintenance and Inspection....................................................................................................................... 122
How to Use AMP Extraction Tool ............................................................................................................... 124
AMP Fastin-Faston Receptacles and Housings .............................................................................................. 125
Description ................................................................................................................................................... 125
Wire Repair ...................................................................................................................................................... 132
Wire Splicing Requirements ....................................................................................................................... 132
Deutsch Jiffy Splice ..................................................................................................................................... 133
Assemble .................................................................................................................................................. 133
ii
Wire Harness Repair Table of Contents

Disassemble ............................................................................................................................................. 135
Del-City Crimp-Solder-Shrink Splice ......................................................................................................... 137
Twisted/Shielded Cable and Leads Repair ..................................................................................................... 138
Twisted/Shielded Cable Repair................................................................................................................... 138
Twisted Leads Repair.................................................................................................................................. 140
Special Tools ..................................................................................................................................................... 140
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) [A099];

A1.3-1.5XNT [D203];
S30FT, S35FT, S40FTS [E010];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
S120FTS; S120FTPRS) [G004, H004];
H2.0-3.5FT (H40-70FT) [L177];
110, 120FT) [N005, P005, R005];
E2.2-3.5XN (E45-70XN) [A268];
J2.2-3.5XN (J45-70XN) [A276];
J1.5-2.0XNT (J30-40XNT) [K160];
J1.6-2.0XN (J30-40XN) [A935];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299];
E30HSD 2, E35HSD 2, E40HSD 2 [B219];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274];
E1.6-2.0XN (E30-40XN) [A269];
J4.0-5.0XN (J80-100XN) [A970]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
2200 SRM 1128 Deutsch Crimping Tool
General
This section covers the repair of the wire harness connectors, pins, sockets, and splicing of wires.
Deutsch Crimping Tool

HOW TO STRIP A WIRE FOR USE WITH
DEUTSCH CRIMPING TOOL
1. Choose the correct AWG for the contact being
used. See Table 1.
2. See Table 1 for recommended strip length for con-

tact size. Measure strip length from end of wire
as shown in Figure 1.
3. Strip the wire to the recommended strip length.

A small piece of insulation should come off the
wire after stripping. See Figure 2.
4. Check for any broken strands or for a nick in the

wire. If either exists, the wires are damaged and Figure 2. Stripped Wire
should be cut and stripped again.
5. Measure the exposed strands to verify strip

length is correct. See Figure 3.
Figure 3. Strip Length Measurement

Verification
Figure 1. Strip Length Measurement
1
Deutsch Crimping Tool 2200 SRM 1128
Table 1. Wire Strip Length Specifications
Contact Part Number Type Wire Gauge Range Recommended Strip Length
1463136 Pin 20 AWG (0.5 mm 2) 3.96 to 5.54 mm (0.156 to 0.218 in.)
2
1463137 Socket 20 AWG (0.5 mm ) 3.96 to 5.54 mm (0.156 to 0.218 in.)
1330433 Pin 16 to 20 AWG (1.0 to 6.35 to 7.92 mm (0.250 to 0.312 in.)
0.5 mm 2)
1330434 Socket 16 to 20 AWG (1.0 to 6.35 to 7.92 mm (0.250 to 0.312 in.)
0.5 mm 2)
0.5 mm 2)
0.5 mm 2)
2
2
2.0 mm 2)
2.0 mm 2)
HOW TO CRIMP WITH THE DEUTSCH in the contact barrel. The contact must be cen-
CRIMPING TOOL tered between indicators. See Figure 7.
1. Strip the insulation from the wire. See How to 7. Close handles until handles stop.
Strip a Wire for Use With Deutsch Crimping
8. Release handles and remove crimped contact.
Tool.
9. Visually check the crimped contact for the follow-
2. Raise the selector knob and rotate until arrow
ing:
is aligned with wire gauge to be crimped. See
Figure 4. a. The conductor is inserted to the proper depth
and is visible through the inspection hole.
3. Loosen lock nut and turn adjusting screw until it
See Figure 8.
stops. See Figure 5.
b. There is about 0.635 to 2.54 mm (0.025 to
4. Insert the contact into the crimping tool; for pin
0.100 in.) of conductor between the contact
contacts, insert short end into crimping tool; for
and the insulator.
socket contacts, insert long end into crimping
tool. See Figure 6. c. There are no damaged wire strands.
5. Turn the adjusting screw clockwise until the con- d. There are no frayed wires or wires not enter-
tact is flush or slightly above flush with the in- ing the contact barrel.
dentor cover (cover around insertion point). See
Figure 6. Tighten the lock nut. 10. If any of the conditions in Step 9 are not met,
discard the contact, re-cut and strip the wire, and
6. Insert the wire into the contact. There should be start the crimping process over.
no loose strands. All strands should be contained
2
2200 SRM 1128 Deutsch Crimping Tool
Figure 7. Wire Insertion
Figure 4. Selector Knob
1. INSPECTION HOLE
2. CRIMP
3. INSULATION GAP, 0.635 to 2.54 mm (0.025 to
0.100 in.)
Figure 8. Proper Crimp
1. LOCK NUT
2. ADJUSTING SCREW
Figure 5. Adjusting Screw and Lock Nut
1. INSERTION POINT 2. INDENTOR COVER
Figure 6. Insertion Point
3
Deutsch Crimping Tool 2200 SRM 1128
CALIBRATION TEST FOR THE DEUTSCH 2. Squeeze the handles of the crimp tool completely
CRIMPING TOOL together. See Figure 11.
The G454 testing tool is needed for the following pro-

cedures. The G454 testing tool is for use with the
Deutsch hand crimping tool only. See Figure 9.
Figure 11. Insertion Point
3. Insert the Go end (green) of the G454 testing tool

into the insertion point of the crimp tool while
1. GO END (GREEN) 2. NO-GO END (RED) the handles are completely closed. The Go end
(green) should insert easily. If it does not in-
Figure 9. G454 Testing Tool sert, the calibration is incorrect and the crimp
tool must be replaced. See Figure 12.
NOTE: Testing for all wire sizes should be #20 wire
size, selector number 4. This ensures proper calibra-
tion for all settings and further testing is not needed
for the other selections.
1. Set the Deutsch hand crimp tool to #20 wire size,

selector number 4. See Figure 10.
1. GO END (GREEN)
2. GO END COMPLETELY INSERTED
Figure 12. Go End Test
1. SELECTOR SET AT #20 WIRE SIZE, SELECTOR

NUMBER 4
Figure 10. Selector Test Setting
4
2200 SRM 1128 Deutsch Connectors
4. Insert the No-Go end (red) of the G454 testing

tool into the insertion point of the crimp tool
while the handles are still completely closed.
The No-Go end (red) should not insert. If it does
insert, the calibration is incorrect and the crimp
tool must be replaced. See Figure 13.
1. NO-GO END (RED)

2. NO-GO END SHOULD NOT INSERT ANY
FURTHER
Figure 13. No-Go End Test
Deutsch Connectors
DT, DTM, AND DTP SERIES CONNECTORS Figure 17 for the different connector plug secondary
locks.
All Deutsch DT, DTM, and DTP series pin- and
socket-type connectors are repaired in the same For examples of the DTM and DTP connectors, see
manner. Figure 18 for the different connector receptacles,
Figure 19 for the different connector receptacle sec-
For examples of the DT connectors, see Figure 14 ondary locks, Figure 20 for the different connector
for the different connector receptacles, Figure 15 for plugs, and Figure 21 for the different connector plug
the different connector receptacle secondary locks, secondary locks.
Figure 16 for the different connector plugs, and
5
Deutsch Connectors 2200 SRM 1128
NOTE: ALL CONNECTOR RECEPTACLES ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE AA G. CONNECTOR TYPE AB-A (SIMILAR TO TYPE
B. CONNECTOR TYPE AB AB)
C. CONNECTOR TYPE AC H. CONNECTOR TYPE AB-B (SIMILAR TO TYPE
D. CONNECTOR TYPE AD AB)
E. CONNECTOR TYPE AE I. CONNECTOR TYPE AB-C (SIMILAR TO TYPE
F. CONNECTOR TYPE AF AB)
Figure 14. DT Connector Receptacles
6
A. SECONDARY LOCK TYPE BA E. SECONDARY LOCK TYPE BE

B. SECONDARY LOCK TYPE BB F. SECONDARY LOCK TYPE BF
C. SECONDARY LOCK TYPE BC G. SECONDARY LOCK TYPE BG
D. SECONDARY LOCK TYPE BD H. SECONDARY LOCK TYPE BH
Figure 15. DT Connector Receptacle Secondary Locks
7
NOTE: ALL CONNECTOR PLUGS ARE SHOWN WITH THE SECONDARY LOCK INSTALLED.
A. CONNECTOR TYPE CA E. CONNECTOR TYPE CE
B. CONNECTOR TYPE CB F. CONNECTOR TYPE CF
C. CONNECTOR TYPE CC G. CONNECTOR TYPE CH (SIMILAR TO TYPE CB)
D. CONNECTOR TYPE CD H. CONNECTOR TYPE CG
Figure 16. DT Connector Plugs
8
A. SECONDARY LOCK TYPE DA E. SECONDARY LOCK TYPE DE

B. SECONDARY LOCK TYPE DB F. SECONDARY LOCK TYPE DF
C. SECONDARY LOCK TYPE DC G. SECONDARY LOCK TYPE DG
D. SECONDARY LOCK TYPE DD H. SECONDARY LOCK TYPE DH
Figure 17. DT Connector Plug Secondary Locks
9
Figure 18. DTM and DTP Connector Receptacles
10

A. DTP CONNECTOR TYPE EA D. DTP CONNECTOR TYPE ED
B. DTM CONNECTOR TYPE EB E. DTM CONNECTOR TYPE EE
C. DTM CONNECTOR TYPE EC F. DTM CONNECTOR TYPE EF
A. DTP SECONDARY LOCK TYPE FA D. DTP SECONDARY LOCK TYPE FD

B. DTM SECONDARY LOCK TYPE FB E. DTM SECONDARY LOCK TYPE FE
C. DTM SECONDARY LOCK TYPE FC F. DTM SECONDARY LOCK TYPE FF
Figure 19. DTM and DTP Connector Receptacle Secondary Locks
11
A. DTM CONNECTOR TYPE GA E. DTM CONNECTOR TYPE GF

B. DTM CONNECTOR TYPE GB F. DTM CONNECTOR TYPE GE
C. DTM CONNECTOR TYPE GC G. DTP CONNECTOR TYPE GG
D. DTP CONNECTOR TYPE GD H. DTM CONNECTOR TYPE GH
Figure 20. DTM and DTP Connector Plugs
12
A. DTM SECONDARY LOCK TYPE HA F. DTM SECONDARY LOCK TYPE HF

B. DTM SECONDARY LOCK TYPE HB G. DTM SECONDARY LOCK TYPE HG
C. DTM SECONDARY LOCK TYPE HC H. DTP SECONDARY LOCK TYPE HH
D. DTP SECONDARY LOCK TYPE HD I. DTM SECONDARY LOCK TYPE HJ
E. DTM SECONDARY LOCK TYPE HE
Figure 21. DTM and DTP Connector Plug Secondary Locks
13
Connector Receptacle Replacement

STEP 1.
Release the external locking clip(s) and separate the
connector plug from the connector receptacle.
14
STEP 2.
Using a small hook end tool (Hyster Part No.
866404), or needle nose pliers, remove the secondary
lock from the connector receptacle.
15
STEP 3.
Using a small, flat-blade screwdriver (Hyster P/N
866404), release the locking finger by moving it away
from the pin.
16
STEP 4.
Gently pull the wire backward while, at the same
time, releasing the locking finger with the small,
flat-blade screwdriver (Hyster P/N 866404).
17
STEP 5.
Tag the wire and mark it with the corresponding
number or letter on the back of the connector from
which the wire was removed.
STEP 6.
Repeat STEP 3 through STEP 5 for the removal of the remaining wires.
18
STEP 7.
Insert the wires into the new connector receptacle ac-
cording to the number or letter on the tag and connec-
tor receptacle. Push the wires straight into the back
of the receptacle until a click is felt. Slightly tug each
wire to verify the wire is properly locked in place. Re-
move tags.
19
NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.
STEP 8.
Install the secondary lock. Push the lock straight in
until the lock snaps into place.
20
STEP 9.
Push the connector plug into the connector receptacle
until the external locking mechanism(s) snap(s) into
place.
21
Connector Plug Replacement

STEP 1.
22
STEP 2.
866404), remove the secondary lock from the connec-
tor plug.
23
STEP 3.
from the socket.
24
STEP 4.
25
STEP 5.
STEP 6.
26
STEP 7.
Insert the wires into the back of the new connector
plug according to the number or letter on the tag and
connector plug. Push the wires straight into the back
of the plug until a click is felt. Slightly tug each wire
to verify the wire is properly locked in place. Remove
tags.
27
STEP 8.
until the lock snaps into place. On 3-way secondary
locks, the arrow on the lock must be oriented toward
the exterior locking mechanism.
1. SEAL
1. SEAL
28
STEP 9.
place.
29
Connector Receptacle Pin Replacement

STEP 1.
30
STEP 2.
Using a small hook end tool (Hyster P/N 866404), or
needle nose pliers, remove the secondary lock from
the connector receptacle.
31
STEP 3.
from the pin.
32
STEP 4.
33
STEP 5.
If more than one pin is being replaced, tag the wire
and mark it with the corresponding number or letter
on the back of the connector from which the wire was
removed.
STEP 6.
Using wire cutters, cut the wire behind the old pin
and discard old pin.
34
STEP 7.
Using wire strippers (Hyster P/N 866411), strip the
wire to the recommended length shown in Table 1.
STEP 8.
Using the Deutsch Crimping Tool (Hyster P/N
867888), crimp the new pin on the wire as shown in
How to Crimp With the Deutsch Crimping Tool.
35
STEP 9.
Insert the wire into the connector receptacle accord-
ing to the number or letter on the tag and connector
receptacle. Push the wire straight into the back of the
receptacle until a click is felt. Slightly tug the wire
tag.
36
STEP 10.
until the lock snaps into place.
37
STEP 11.
place.
38
Connector Plug Socket Replacement

STEP 1.
39
STEP 2.
866404), remove the secondary lock from the connec-
tor plug.
40
STEP 3.
from the socket.
41
STEP 4.
42
STEP 5.
If more than one socket is being removed, tag the wire
removed.
43
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
STEP 7.
Using wire strippers Hyster P/N 866411, strip the
STEP 8.
867888), crimp the new socket on the wire as shown
in How to Crimp With the Deutsch Crimping Tool.
44
STEP 9.
Insert the wire into the back of the new connector
connector plug. Push the wire straight into the back
of the plug until a click is felt. Slightly tug the wire
tag.
45
STEP 10.
until the lock snaps into place. On 3-way secondary
locks, the arrow on the lock must be oriented toward
the exterior locking mechanism.
1. SEAL
1. SEAL
46
STEP 11.
place.
47
HD SERIES CONNECTORS For examples of the HD connectors, see Figure 22 for

the different connector receptacles and Figure 23 for
All Deutsch HD series pin-type connectors are re- the different connector plugs.
paired in the same manner.
A. TYPE A B. TYPE B
Figure 22. HD Connector Receptacles
48
A. TYPE 1 B. TYPE 2
Figure 23. HD Connector Plugs
49
Connector Receptacle Replacement

STEP 1.
Separate the connector plug from the connector re-
ceptacle.
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
50
NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.
STEP 3.
Insert a Deutsch extraction tool over the wire being
removed.
NOTE: Do not twist the tool or insert the tool at an angle.
STEP 4.
Push the tool into the connector about 25 mm (1 in.)
until it bottoms on the contact flange.
51
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert
the tool into the connector.
STEP 5.
Hold the tool on the contact flange and pull the wire
and the connection pin out of the connector.
STEP 6.
52
STEP 7.
STEP 8.
Insert the wires into the back of the new connector re-
ceptacle according to the number or letter on the tag
and connector receptacle. Push the wire straight into
the back of the receptacle until a click is felt. Slightly
tug each wire to verify the wire is properly locked in
place. Remove tags.
STEP 9.
Install receptacle into mounting structure. Install
the lock nut and washer to retain the receptacle to
the mounting structure.
STEP 10.
Connect the connector plug to the connector recepta-
cle.
53
Connector Plug Replacement

STEP 1.
ceptacle.
STEP 2.
removed.
54
STEP 3.
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees, and reinsert
STEP 4.
and the connection socket out of the connector.
55
STEP 5.
56
STEP 6.
STEP 7.
of the plug until a click is felt. Slightly tug each wire
tags.
STEP 8.
cle.
57
Connector Receptacle Pin Replacement

STEP 1.
ceptacle.
STEP 2.
Remove the lock nut and washer retaining the recep-
tacle to the mounting structure. Remove receptacle
from mounting structure.
58
STEP 3.
removed.
STEP 4.
59
STEP 5.
and the connection pin out of the connector.
STEP 6.
If more than one wire is being removed, tag the wire
removed.
60
STEP 7.
Using wire cutters, cut the wire behind the old pin
and discard old pin.
STEP 8.
Using wire strippers, Hyster P/N 866411, strip the
STEP 9.
867888), crimp the new pin on the wire as shown in
How to Crimp With the Deutsch Crimping Tool.
61
NOTE: The rear seal/grommet must be seated properly before inserting wires.
STEP 10.
Insert the wires into the back of the new connector re-
ceptacle according to the number or letter on the tag
and connector receptacle. Push the wire straight into
the back of the receptacle until a click is felt. Slightly
tug each wire to verify the wire is properly locked in
place. Remove tags.
STEP 11.
Install receptacle into mounting structure. Install
the lock nut and washer to retain the receptacle to
the mounting structure.
STEP 12.
cle.
62
Connector Plug Socket Replacement

STEP 1.
ceptacle.
STEP 2.
removed.
63
STEP 3.
STEP 4.
and the connection socket out of the connector.
64
STEP 5.
If more than one wire is being removed, tag the wire
removed.
65
STEP 6.
Using wire cutters, cut the wire behind the old socket
and discard old socket.
STEP 7.
Using wire strippers, Hyster P/N 866411, strip the
STEP 8.
867888), crimp the new socket on the wire as shown
in How to Crimp With the Deutsch Crimping Tool.
66
NOTE: The rear seal/grommet must be seated properly before inserting wires.
STEP 9.
of the plug until a click is felt. Slightly tug wire to
verify the wire is properly locked in place. Remove
tags.
STEP 10.
cle.
67
SEALING PLUGS
All empty contact cavities must be filled with a sealing plug. See Figure 24.
A. 6 AWG (DARK RED) C. 12 TO 18 AWG (WHITE)

B. 8 AWG (CLEAR WHITE) D. 20 AWG (RED)
Figure 24. Sealing Plugs
STEP 1.
Hold the sealing plug with the large diameter end
away from the connector.
68
STEP 2.
Insert the sealing plug into the connector contact
cavity. Gently apply downward pressure to force the
sealing plug into the cavity.
STEP 3.
Apply pressure until sealing plug is forced to stop
by the connector rear grommet. Visually inspect
the sealing plug to ensure it is flush with the cavity
opening.
69
Metri-Pack Connectors 2200 SRM 1128
Metri-Pack Connectors
Some connectors use terminals called Metri-Pack Se- Push-to-Seat - Gently pull the wire to remove
ries 150. These may be used at the coolant sensor and the terminal from the back of the connector.
TBI units on ICE lift trucks.
Pull-to-Seat - Gently push the wire to remove
They are also called push-to-seat terminals because the terminal through the front of the connector.
to install a terminal on a wire, the wire is first in- See Figure 28.
serted through the seal and connector. The terminal
is then crimped on the wire and the terminal pulled
CAUTION
back into the connector to seat it in place.
Work carefully and do not use enough force to
NOTE: DO NOT cut contacts from reel, use loose con- damage the terminal or the connector.
tacts only.
5. Inspect the terminal and connector for damage.
REMOVE AND INSTALL See Figure 29.
1. Slide the seal back on the wire. NOTE: If reusing the terminal, reshape the locking
tab.
2. Hold the wire and use it to push the terminal to
its forward position in the connector body. Hold 6. If the terminal will be used again, make sure the
the terminal in this position. See Figure 25. lock tab is correctly bent so that the terminal will
be locked in the connector again.
3. Find the lock tab for the terminal in the connec-
tor channel. Push a removal tool (pick) (HYSTER 7. Push the terminal into the connector channel.
P/N 866420) of the correct size into the connector Make sure that the lock tab correctly locks the
channel. See Figure 26 and Figure 27. terminal in position.
4. Use the removal tool (HYSTER P/N 866420) to 8. Push the seals into their position and install any
move the lock tab to release the terminal from secondary locks.
its seat.
1. FEMALE TERMINAL 4. CONNECTOR BODY

2. LOCKING TAB 5. SEAL
3. TOOL KIT
Figure 25. Metri-Pack Terminal Removal
70
2200 SRM 1128 Metri-Pack Connectors
1. TOOL (PICK) 3. TERMINAL

2. LOCK TAB 4. CONNECTOR
BODY
Figure 26. Metri-Pack Push-to-Seat Connector
1. TERMINAL 4. CONNECTOR
2. LOCK TAB BODY
3. TOOL KIT 5. SEAL
Figure 28. Metri-Pack Pull-to-Seat Terminal

Removal
1. TOOL (PICK) 3. TERMINAL
2. LOCK TAB 4. CONNECTOR
BODY
Figure 27. Metri-Pack Pull-to-Seat Connector
71
Micro-Pack Connectors 2200 SRM 1128
NOTE: THE GREATER DISTANCE D, A FAULT CAN

OCCUR IN THE CONNECTION.
1. CONTACT TAB
Figure 29. Metri-Pack Terminal Inspection
Micro-Pack Connectors
The Micro-Pack connector is shown in Figure 30.
This connector is normally used to connect the
wire harness to the ECM. The repair procedures
for the Micro-Pack connectors are the same as
the Metri-Pack connectors. Refer to the section
Metri-Pack Connectors for the repair procedures.
1. CABLE
2. TERMINAL
3. LOCKING TAB
4. TOOL KIT (HYSTER P/N 866422
Figure 30. Micro-Pack Connector
72
2200 SRM 1128 Weather-Pack Connectors
Weather-Pack Connectors
A Weather-Pack connector can be identified by a rub- Make certain that the connectors are properly seated
ber seal at the rear of the connector. This connector, and all of the sealing rings are in place when connect-
which is used in the engine compartment, protects ing leads. The hinge-type flap provides a backup or
against moisture and dirt which could create oxida- secondary locking feature for the connector. They are
tion and deposits on the terminals. This protection used to improve the connector reliability by retaining
is important because of the very low voltage and cur- the terminals if the small terminal lock tabs are not
rent levels found in the electronic system. positioned properly.
Repair of a Weather-Pack terminal is shown in Weather-Pack connections cannot be replaced with

Weather-Pack Terminal Repair. Use the tool kit to standard connections. Instructions are provided
remove the pin and sleeve terminals. See Special with Weather-Pack connector and terminal pack-
Tools. ages.
If removal is attempted with an ordinary pick, there

is a good chance that the terminal will be bent or de-
formed. Unlike standard blade-type terminals, these
terminals cannot be straightened once they are bent.
WEATHER-PACK TERMINAL REPAIR

STEP 1.
Open secondary lock hinge on connector.
1. FEMALE CONNECTOR
2. MALE CONNECTOR
3. SECONDARY LOCK HINGE
STEP 2.
Remove terminal, using tool HYSTER P/N 866421.
1. TERMINAL 2. TOOL
73
AMPSEAL Crimping Tools 2200 SRM 1128
STEP 3.
Cut wire immediately behind cable seal.
1. WIRE 2. SEAL
STEP 4.
Replace terminal.
a. Slip new seal onto wire.
b. Strip 5 mm (0.2 in.) of insulation from wire.
c. Crimp terminal over wire and seal.
STEP 5.
Push terminal and connector onto wire and engage
locking tabs.
STEP 6.
Close secondary lock hinge.
1. SEAL
AMPSEAL Crimping Tools

AMP HAND CRIMPING TOOL WITH The contact support prevents the contact from bend-
CERTI-CRIMP ing during crimping.
Description The locator functions two ways:

• position the contact between the upper insert and
The tool, Hyster P/N 1698557, features two upper the anvil before crimping
inserts, two anvils, an insulation crimp adjustment • limits the insertion distance of the stripped wire
lever, a contact support, a locator, an ejector, and a into the contact.
CERTI-CRIMP ratchet. The contact is inserted into
the FRONT of the tool. The wire is inserted into the The ejector pulls the locator down, and ejects the
BACK of the tool. See Figure 31. crimped contact when the tool handles are fully
opened.
The insulation adjust lever regulates the crimp
height. See Insulation Crimp Adjustment.
74
2200 SRM 1128 AMPSEAL Crimping Tools

A. FRONT OF TOOL
B. BACK OF TOOL
1. UPPER INSERT
2. ANVIL
3. INSULATION CRIMP ADJUSTMENT LEVER
4. CONTACT SUPPORT
5. LOCATOR
6. CERTI-CRIMP RATCHET
7. STRIPPED WIRE
CAUTION
The crimping jaws bottom before the CERTI-
CRIMP ratchet releases. This is a design fea-
ture that ensures maximum electrical and ten-
sile performance of the crimp DO NOT readjust
the ratchet.
The CERTI-CRIMP ratchet assures full crimping of

the contact. Once engaged, the ratchet will not re-
lease until the handles have been fully closed.
Stripping Wire for Use with AMP Hand

Crimping Tool
1. Choose the correct AWG for the contact being
used.
2. See Table 2 for recommended strip length.
Figure 31. AMP Hand Crimping Tool
Table 2. Wire Size (AWG)
Wire Size Insulation Tool Contact Wire Strip Length

(AWG) Diameter Range Wire Size
Marking
16 1.7 to 2.7 mm (0.067 16 Hyster P/N 2035276 5.5 mm (0.215 in.)
to 0.106 in.)
20 - 18 20 - 18 4.7 mm (0.185 in.)
75
3. Crimp a contact on to the wire according to How

CAUTION to use AMP Hand Crimping Tool procedure.
DO NOT cut or nick the wire strands.
4. Using a modified micrometer, measure wire bar-
3. Strip wire to recommended strip length. A small rel crimp height as shown in Figure 33. If the
piece of insulation should come off the wire after crimp height conforms to measurement in Ta-
stripping. See Figure 32. ble 3 the tool is correct. If not, replace tool.
NOTE: SEE TABLE 2 FOR WIRE STRIP LENGTH.

1. STRIPPED WIRE 2. LOCATOR SLOT
Figure 32. Strip Length
Insulation Crimp Adjustment

The insulation barrel crimp height is regulated by
the insulation adjustment lever. To determine the
proper setting, test crimp a contact using the setting
which approximates the insulation size: 1) small, 2)
medium, or 3) large. If the crimped insulation barrel
is too tight or too loose, change the setting accord-
ingly. The crimp should hold the insulation firmly
without cutting into it.
Maintenance and Inspection for AMP Hand

Crimping Tool
A. CRIMP HEIGHT - SEE TABLE 3
AMP Hand Crimping Tool
1. TOOL CRIMP SECTION MARKING
1. Perform maintenance and inspections as speci- 2. WIRE SLOT IN LOCATOR
fied by AMP. 3. WIRE BARREL
4. LOCATOR SLOT IN CONTACT
Crimp Height Inspection 5. MODIFIED ANVIL ON MICROMETER
1. This inspection requires the use of a micrometer Figure 33. AMP Crimp Tool Inspection
with a modified anvil as shown in Figure 33.
2. Refer to Table 3 and select contact and wire (max-

imum size) for each crimp section listed.
76
Table 3. Crimp Height
Contact Part No Wire Size (AWG) Tool Crimp Section Crimp Height
Marking
20 20-18 1.22 ±0.05 mm (0.048
±0.002 in.)
18 20-18 1.22 ±0.05 mm (0.048
Hyster P/N 2035276
±0.002 in.)
16 16 1.40 ±0.05 mm (0.055
±0.002 in.)
HOW TO USE AMP HAND CRIMPING TOOL NOTE: Make sure wire barrel is not deformed during
crimping procedure.
1. Strip insulation from wire. See Stripping Wire
for Use with AMP Hand Crimping Tool. 5. Holding contact in this position, squeeze tool
handles together.
2. Hold tool so BACK side (wire side) faces you.
6. Insert properly stripped wire through locator and
3. Release tool ratchet by squeezing tool handles into wire barrel of contact.
then allowing them to open.
7. Crimp contact onto wire while holding wire in
4. Holding contact by its mating portion and look- place by squeezing tool handles together until
ing straight into crimp section, insert contact ratchet releases.
from the FRONT of tool into BACK of crimp
section. Position contact as shown in Figure 34. 8. Allow tool handles to open fully and remove
crimped contact from tool.
AMP PRO-CRIMPER II TOOL

Description
This tool has a tool frame with stationary jaw and
handle, a moving jaw and handle, and an adjustable
ratchet to ensure full contact crimping. The tool
frame contains a die assembly with two crimping
sections.
The die assembly contains a wire anvil, an insulation

anvil, a wire crimper and an insulation crimper. See
Figure 35.
The locator assembly, on the outside of the frame,

contains a locator, a spring retainer, and a contact
support.
The dies are secured to the frame with retaining pins

1. BACK OF TOOL 4. CONTACT and retaining screws. A nut on the upper retaining
2. STRIPPED WIRE 5. LOCATOR
3. WIRE BARREL screw holds the locator assembly in place.
Figure 34. Crimp Contact to Wire
77
7. Insert wire crimper and insulation crimper into

stationary jaw, with chamfered sides and marked
surfaces facing outward. See Figure 36.
8. Insert upper die retaining pins. See Figure 36.
9. Insert upper die retaining screw through sta-

tionary jaw and both crimpers. See Figure 36.
Tighten screw enough to hold crimpers in place,
but DO NOT tighten completely.
10. Carefully close tool handles. Make sure anvils

and crimpers align properly. Completely close
tool handles until ratchet is engaged enough to
hold anvils and crimpers in position. Tighten up-
per and lower die retaining screws.
11. Install locator assembly over the end of upper die

retaining screw and position against the side of
A. TOOL FRONT B. TOOL BACK the tool jaw. See Figure 36.
1. STATIONARY JAW 12. Install nut onto the end of upper die retaining
2. STATIONARY HANDLE screw and tighten enough to hold locator assem-
3. MOVING JAW bly in place while allowing the locator to slide up
4. MOVING HANDLE
5. DIE ASSEMBLY and down. See Figure 36.
6. LOCATOR ASSEMBLY
Figure 35. AMP PRO-CRIMPER II Tool
Remove and Install Die Set and Locator Assembly
NOTE: Perform Step 1 through Step 3 for removal of

die set and locator assembly. Follow Step 4 through
Step 12 for installation of die set and locator assem-
bly.
1. Close tool handles until ratchet releases.
2. Remove nut, locator assembly, upper and lower

die retaining screws, and upper and lower die
retaining pins. See Figure 36. 1. UPPER DIE RETAINING SCREW
2. LOWER DIE RETAINING SCREW
3. Slide wire anvil, insulation anvil, wire crimper, 3. WIRE ANVIL
4. INSULATION ANVIL
and insulation crimper out of tool frame. See Fig- 5. LOWER DIE RETAINING PIN
ure 36. 6. WIRE CRIMPER
7. INSULATION CRIMPER
4. Install wire anvil and insulation anvil into mov- 8. UPPER DIE RETAINING PIN
ing jaw of tool frame, with chamfered sides and 9. LOCATOR ASSEMBLY
marked surfaces facing outward. See Figure 36. 10. NUT
11. LOCATOR
5. Insert lower die retaining pins. See Figure 36. 12. TOOL FRAME
6. Insert lower die retaining screw through mov- Figure 36. Die Set and Locator Assembly
ing jaw and both anvils. Tighten screw enough
to hold the anvils in place, but DO NOT tighten
completely. See Figure 36.
78
Stripping Wire for Use With AMP Contact Support Adjustment

PRO-CRIMPER II Tool
1. Make a sample crimp. Determine if contact is
1. Choose the correct AWG for the contact being straight, bent upward or downward.
used.
2. If adjustment is required, loosen adjustment
2. See Table 4 for recommended strip length. screw, DO NOT remove screw. See Figure 38.
Table 4. Strip Length for PRO-CRIMPER II Tool 3. Insert contact and wire into tool as shown in
Figure 37. Close tool handles until the ratchet
Wire Wire Insulation Strip Length reaches the sixth clip or the contact support
Size Diameter touches the contact.
(AWG)
4. Loosen the nut, slightly, that holds the locator
16 1.7 to 2.7 mm 5.1 ±0.4 mm (0.20 assembly onto the tool frame. See Figure 38.
(0.07 to 0.11 in.) ±0.02 in.)
18-20 5. Move the contact support to eliminate bending
the contact.
CAUTION 6. Tighten the nut and squeeze handles until
DO NOT cut or nick the wire strands. ratchet releases.
3. Strip wire to recommended strip length. See Fig- 7. Remove and inspect the contact.
ure 37.
8. Make another sample crimp. If the contact is
straight, tighten the adjustment screw. If the
contact is bent, repeat Step 2 through Step 8.
1. CONTACT
2. LOCATOR (IN WIRE STOP SLOT)
3. WIRE (INSERTED TO STOP)
4. STRIP LENGTH
Figure 37. Contact and Wire Strip 1. ADJUSTMENT 3. LOCATOR

SCREW 4. WIRE
2. CONTACT 5. BACK OF TOOL
SUPPORT
Figure 38. Contact Support Adjustment
79
Crimp Height Adjustment 2. Inspect the crimping dies on a regular basis to

ensure they are not worn or damaged. If crimp
1. Remove lockscrew from ratchet adjustment sections are flattened, chipped, worn or broken
wheel. See Figure 39. replace tool.
2. Using screwdriver, adjust ratchet wheel as indi- Crimp Height Inspection
cated in Step 3 or Step 4.
1. This inspection requires the use of a micrometer
3. To tighten crimp, rotate ratchet adjustment with a modified anvil as shown in Figure 40.
wheel COUNTERCLOCKWISE. See Figure 39.
4. To loosen crimp, rotate ratchet adjustment wheel

CLOCKWISE. See Figure 39.
5. Replace lockscrew onto ratchet adjustment

wheel. See Figure 39.
6. Make a sample crimp and measure the crimp

height.
A. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM.
1. MODIFIED ANVIL ON MICROMETER
2. CRIMP HEIGHT, SEE TABLE 5
Figure 40. Crimp Height
2. Refer to Table 5 to select wire for each crimp sec-

tion listed.
Table 5. Crimp Measurement
Wire Size (AWG) Crimp Height

18 1.22 ±0.05 mm (0.048
±0.002 in.)
1. LOCKSCREW
2. RATCHET ADJUSTMENT WHEEL 16 1.41 ±0.05 mm (0.056
3. SCREWDRIVER ±0.002 in.)
Figure 39. Ratchet Adjustment Wheel
3. Crimp a contact onto the selected wire according
Maintenance and Inspection Procedures to How to Use AMP PRO-CRIMPER II Tool pro-
cedure.
PRO-CRIMPER II Tool
4. Using a modified micrometer, measure wire bar-
1. Make sure the tool and dies are clean by wip- rel height as shown in Figure 40. If the crimp
ing them with a clean, soft cloth. If debris is height matches measurement shown in Table 5
present, clear away with a soft brush. Keep han- the tool is correct. If not, follow Crimp Height
dles closed when not in use to prevent objects Adjustment procedure.
from becoming stuck in crimping dies. Store in
clean, dry area.
80
2200 SRM 1128 AMPSEAL Connector Assemblies
HOW TO USE AMP PRO-CRIMPER II TOOL slot in the contact. Butt the front end of the wire
barrel against locator.
1. Strip insulation from wire. See Stripping Wire
for Use With AMP PRO-CRIMPER II Tool proce- NOTE: Make sure neither wire barrel nor insulation
dure. barrel are damaged.
2. Hold PRO-CRIMPER II tool so BACK side (wire 6. Hold contact in position and squeeze tool handles
side) is facing you. until ratchet engages enough to hold contact.
3. Squeeze tool handles together, then allow to fully 7. Insert stripped wire into contact insulation and
open. wire barrels until butted against wire stop.
4. Holding contact by mating end, insulation barrel 8. Squeeze tool handles, while holding wire in posi-
first, insert contact through front of tool and into tion, until ratchet releases.
appropriate crimp section.
9. Allow tool handles to open and remove crimped
5. Mating end of contact should be on locator side contact from tool.
of tool; the open "U" of wire barrel and insulation
barrel should face the top of the tool. The contact 10. Check crimp height as described in Crimp Height
to be placed to that movable locator drips into Inspection.
AMPSEAL Connector Assemblies

DESCRIPTION FOR PLUG CONNECTOR Seal Plug
ASSEMBLY
All circuits are sealed by a diaphragm in the rubber
The plug assembly consists of a housing, a wedge wire seal. When assembling the connector, the di-
lock, a wire seal, and a mating seal. See Figure 41. aphragm is pierced as the contact passes through it.
Unused circuit cavities will remain sealed unless per-
For current ratings of special use connectors, forated by accidental insertion and removal of con-
AMPSEAL, refer to Table 6. tact in the wrong cavity. The seal plug is designed to
keep out contaminants if the diaphragm is pierced.
Table 6. Current Rating
1. Insert the seal plug, large end first, into the cir-
Single Wire Size Current Rating cuit cavity as far as it will go. No insertion tool
Circuit (AWG) (Max.) is usually required for this procedure. See Fig-
Plating ure 42.
Tin 16, 18, and 20 8A
Contact Crimping
Gold 16 14.5A
Information on contact crimping can be found in
18 13A AMPSEAL Crimping Tools.
20 11.5A
81
AMPSEAL Connector Assemblies 2200 SRM 1128
1. PLUG 3. CIRCUIT CAVITY

CONNECTOR
2. SEAL PLUG
Figure 42. Seal Plug
1. HOUSING 5. DIAPHRAGM
2. WEDGE LOCK 6. CONTACT
3. WIRE SEAL 7. RETENTION
4. MATING SEAL FINGERS
Figure 41. AMPSEAL Plug Connector
82
Contact Removal
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
STEP 1.
Insert a screwdriver blade between the mating seal
and one of the red wedge lock tabs. Pry open the
wedge lock to the OPEN position.
NOTE: SCREWDRIVER TO BE MOVED IN DIREC-

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
83
STEP 2.
While rotating the wire back and forth over a half
turn (1/4 turn each direction), gently pull the wire
until the contact is removed.
STEP 3.
Tag the wire and mark it with the corresponding number or letter on the back of the connector from which the
wire was removed.
STEP 4.
Repeat STEP 2 and STEP 3 to remove remaining wires.
84
Contact Insertion
NOTE: Check to be sure the wedge lock is in the OPEN position. Perform STEP 1 if wedge lock is closed
STEP 1.

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
85
STEP 2.
Insert contact by pushing it straight into the appro-
priate circuit cavity as far as it will go.
STEP 3.
Pull back on the contact wire with a force of 4 to 9 N
(1 to 2 lbf) to be sure the retention fingers are holding
the contact.
NOTE: PULL WIRE IN DIRECTION OF ARROW.

1. RETENTION FINGERS
STEP 4.
After all required contacts have been inserted, the
wedge lock must be closed to its LOCKED position.
Release the locking latches by squeezing them in-
ward.
1. LOCKING LATCHES
86
STEP 5.
Slide the wedge lock into the housing until it is flush
with the housing.
1. WEDGE LOCK
DESCRIPTION FOR PLUG CONNECTOR

AND HEADER ASSEMBLY
The plug assembly will accept multiple socket con-
tacts. See Figure 43. The head assembly is designed
to be fastened to the enclosure by four self-tapping
screws. The screw length will depend on panel thick-
ness.
Panel mounting cutout requirements shown in

Figure 44. Maximum panel thickness to be 2 mm
(0.08 in.) for proper clearance.
Use screwdriver slot to lift latch for unmating. To

mate the plug and head must be identical in color.
Securely fasten the locking latch when mating plug
and header. See Figure 45.
NOTE: PLUG AND HEADER ASSEMBLY COLORS
The wedge lock has slotted openings in the mating, ARE MECHANICALLY KEYED TO MATE ONLY WITH
forward, end. The slots are for circuit test tabs ap- IDENTICAL COLORS.
proximately 3.3 × 0.6 mm (0.13 × 0.02 in.), which pre- A. PLUG ASSEMBLY
vent damage to the receptacle. Circuit testing in the B. HEADER ASSEMBLY
field to be done by a flat probe, DO NOT use a sharp
point. 1. MATING SEAL
2. HOUSING
3. WEDGE LOCK
4. RETENTION LEG
Figure 43. AMPSEAL Plug and Header

Assembly
87
Figure 44. AMPSEAL Plug and Header Assembly Panel Mounting
88
A. WIRE STRANDS MUST BE VISIBLE IN THIS AREA

B. WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA
C. CUTOFF TAB MUST BE VISIBLE
1. SCREWDRIVER SLOT 3. PLUG AND HEADER
2. LOCKING LATCH
Figure 45. Contact, Plug, and Header
89
Voltage Reading
CAUTION
Cable far end to be sealed or isolated from the
CAUTION environment. DO NOT damage insulation.
DO NOT pierce wire insulation to take voltage
readings. NOTE: Wire stripping tools may leave indentations
on the surface of the wire insulation. If these inden-
When using AMPSEAL plug assembly DO NOT tations are present at the wire seal, leakage can oc-
pierce wire insulation with a sharp point. Pin holes cur. Insulation surface within 26 mm (1.02 in.) of
in the insulation allow moisture to invade the sealed contact tip must be smooth and free of indentations.
connector system nullifying effectiveness and result- Ensure wire insulation is not damaged during crimp-
ing in possible system failure. ing procedure. The insulation bars to be wrapped
around the wire insulation, leaving not sharp points
Seal Plug to damage rubber wire seal.
All circuits are sealed by a diaphragm in the rub- 3. The crimped contact to be a 2 mm (.08 in.) diam-
ber wire seal. This diaphragm is pierced when the eter cylinder. See Figure 48.
contact is pressed through it. Unused circuit cavities
will remain sealed unless perforated by accidental in-
sertion and removal of contact in the wrong cavity.
The seal plug is designed to keep out contaminants
if the diaphragm is accidentally pierced.
1. Insert the seal plug, large end first, into the cir-
cuit cavity as far as it will go. No insertion tool
is required for this procedure. See Figure 46.
Contact Crimping
1. Information on contact crimping can be found in
AMPSEAL Crimping Tools.
NOTE: DO NOT cut contacts from "reel", use loose

contacts only.
2. Crimped contacts to meet conditions shown in

Figure 47 and Table 7. 1. PLUG 3. CIRCUIT CAVITY
CONNECTOR
2. SEAL PLUG
Figure 46. Seal Plug
Table 7. Crimp Conditions
Wire Wire Barrel Insulation Barrel

Size Insulation Strip Crimp Crimp Width Crimp Crimp Width
(AWG) Diameter Length Height (Nom) Height ±0.1
Range Max
20 1.17 ±0.08
18 1.7 to 2.7 5.1 1.27 ±0.05 2.03 3.2 3.1
16 1.40 ±0.05
90
A. WIRE STRAND ENDS MUST BE VISIBLE IN THIS AREA

B. WIRE BARREL SHALL BE CLOSED AT SEAM WITH NO STRANDS PROTRUDING OR SHOWING
C. WIRE STRANDS AND INSULATION SHALL BOTH BE VISIBLE
D. FRONT BELLMOUTH SHALL BE 0.25 mm (0.01 in.)MAX; 0.13 mm (0.005 in.)MIN
E. REAR BELLMOUTH SHALL BE 0.13 to 0.75 mm (0.005 to 0.03 in.)
F. CUTOFF TAB SHALL BE 0.25 mm (0.01 in.)MAX
Figure 47. Crimp Conditions
91
A. CENTERLINE B. DIA 2 mm (0.08 in.)

1. CONTACT (PARTIALLY INSERTED) 4. DIAPHRAGM
2. WIRE SEAL 5. MATING SEAL
3. RETENTION FINGERS 6. WEDGE LOCK (OPEN POSITION)
Figure 48. Contact Concentricity
92
Contact Removal
STEP 1.

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
93
STEP 2.
While rotating the wire back and forth over a half
turn (1/4 turn each direction), gently pull the wire
until the contact is removed.
STEP 3.
Repeat STEP 2 to remove remaining wires.
94
Contact Insertion
NOTE: Check to be sure the wedge lock is in the OPEN position. Perform STEP 1 if wedge lock is closed.
STEP 1.
Insert a screw driver blade between the mating seal

TION OF ARROW.
A. CLOSED POSITION
B. OPEN POSITION
1. WEDGE LOCK TAB
95
STEP 2.
Insert contact straight into circuit cavity as far as it
will go.
STEP 3.
Pull back on contact wire with 4 to 9 N•m (1 to 2 lbf)
to be sure the retention fingers are holding the con-
tact.
1. RETENTION FINGERS
STEP 4.
After all required contacts have been inserted, the
wedge lock must be closed to the LOCKED position.
Release the locking latches by squeezing them in-
ward.
1. LOCKING LATCHES
STEP 5.
Slide the wedge lock into the housing until it is flush
with the housing.
1. WEDGE LOCK
96
2200 SRM 1128 AMP Superseal 1.5 Crimping Tools
AMP Superseal 1.5 Crimping Tools

MINI MIC RECEPTACLE AND TAB 5. Bend down = 5° max. See Figure 51.
CONTACTS
6. Bend right = 5° max. See Figure 50.
Description 7. Bend left = 5° max. See Figure 50.
Contacts are for 16-22 AWG wire, with single wire 8. Rolling = 5° max. See Figure 50.
seals. Each wire is inserted into a discrete wire seal
before crimping into contact. Insulation barrel is 9. Cable end protrusion = 0.2 to 0.7 mm (0.008 to
crimped so wire seal is gripped to avoid any move- 0.03 in.). See Figure 49.
ment of seal. Contacts are suitable for single wires
only. 10. Insulation stripping length = 3.0 to 3.5 mm (0.12
to 0.14 in.).
Crimping Conditions and Measurements
11. Wire barrel seam must be neatly closed. See Fig-
1. Cut-off tab length = 0.3 mm (0.01 in.) max. See ure 49.
Figure 49.
Insertion of Rubber Seal on Cable
2. Front bellmouth = 0.10 mm (0.004 in.) × 45° max.
See Figure 49. NOTE: Rubber seals are lubricated, lubrication must
not be removed.
3. Rear bellmouth = 0.25 mm (0.009 in.) × 45° max.
See Figure 49. The end of cable insulation to be positioned from edge
of rubber seal when rubber seal is installed on cable.
4. Bend up = 5° max. See Figure 51. See Figure 52.
97
AMP Superseal 1.5 Crimping Tools 2200 SRM 1128
A. TOP VIEW B. SIDE VIEW

1. WIRE BARREL SEAM 8. INSULATION BARREL
2. WIRE BARREL 9. FRONT BELLMOUTH
3. CABLE END PROTRUSION LENGTH 10. REAR BELLMOUTH
4. WIRE BARREL CRIMP WIDTH 11. INSULATION BARREL CRIMP HEIGHT
5. INSULATION BARREL CRIMP WIDTH 12. CUT-OFF TAB LENGTH
6. RUBBER SEAL 13. WIRE BARREL CRIMP HEIGHT
7. CABLE
Figure 49. Crimping Conditions
98
1. BEND RIGHT 3. ROLLING

2. BEND LEFT 4. DATUM LINE
Figure 50. Crimping Conditions Bend Right/Left
1. BEND UP 2. BEND DOWN 3. DATUM LINE
Figure 51. Crimping Conditions Bend Up/Down

A. 0.5 mm (0.02 in.)MAX
1. WIRE INSULATION
2. RUBBER SEAL
Figure 52. Rubber Seal Installed on Cable
99
Correction or Replacement of Parts

STEP 1.
When defects or improper applications are found on
parts to be installed, rework or replace with new
parts.
STEP 2.
Cut end of wire shall appear neat without any bend
or stranded conductor.
STEP 3.
Conductor shall be free from nick, cut or scrape.
100
STEP 4.
Wire insulation must have smooth surface in a round
form without damage, groove, or recessed surface.
STEP 5.
wire end shall be straight without bend or untidiness
after insertion of rubber seal.
STEP 6.
Flanges of rubber seal to be free of cuts or damage.
101
STEP 7.
Insertion of rubber seal to be done straight and even.
If flanges are tilted, plug must be corrected so flanges
are perpendicular to contact center line.
STEP 8.
After crimping, cable insulation inside rubber seal to
be in good condition and within requirements as spec-
ified in Crimping Conditions and Measurements in
this section.
A. 0.2 to 0.7 mm (0.008 to 0.03 in.)

B. 0.2 mm (0.008 in.)
STEP 9.
Rubber seal must protrude from insulation crimp
without damage. Check by visual inspection in the
transition area (between wire and insulation barrel)
as shown.
1. RUBBER SEAL
STEP 10.
No parts of insulation or rubber are allowed in the
wire crimp, after crimping.
STEP 11.
Part of rubber seal must stick out of transition hole.
1. RUBBER SEAL
102
STEP 12.
Tilt shape of rubber seal is unacceptable.
A. 8° MAX
STEP 13.
Crimped contacts should appear as shown.
103
AMP HAND APPLICATION TOOL

Description
This tool is designed for use with AMP Superseal 1.5
series contacts. The tool has two crimp sections, con-
tact locator, wire stop, and ratchet. See Figure 53.
A. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM.
1. MODIFIED ANVIL
2. CRIMP HEIGHT (SEE TABLE 8)
2. Use Table 8 to select wire for crimp height inspec-

tion.
Table 8. Wire Strip Lengths
Wire Size Strip Length Crimp Height

(AWG) ±0.05 mm
1. FRONT OF TOOL (LOCATOR SIDE) (0.002 in.)
2. BACK OF TOOL (WIRE SIDE)
3. DIE SET 3.0 to 3.5 mm 1.12 mm (0.044 in.)
4. MOVABLE LOCATOR 20 (0.12 to
5. RATCHET ADJUSTMENT WHEEL
6. PIVOT PIN 0.13 in.)
3.0 to 3.5 mm 1.30 mm (0.051 in.)
Figure 53. AMP Hand Application Tool for 18 (0.12 to
AMP Superseal 1.5 Contacts 0.13 in.)
Maintenance and Inspection 3.0 to 3.5 mm 1.45 mm (0.057 in.)
16 (0.12 to
1. Ensure tool and dies are clean by wiping with a 0.13 in.)
clean, soft cloth. Remove any debris with clean,
soft brush. DO NOT use objects that could dam- 3. Crimp a contact onto the selected wire according
age tool. When not in use, keep handles closed to How to use AMP Hand Application Tool proce-
to prevent debris from lodging in dies. Store in dure.
clean, dry area.
4. Using crimp height comparator, measure wire
2. Crimping dies to be inspected on a regular basis barrel crimp height as shown in Figure 54. If
for wear or damage. Inspect crimp sections for crimp height matches that shown in Table 8, the
flattened, chipped, worn, or broken areas. Re- tool is considered dimensionally correct. If not,
place tool if damaged. follow Crimp Height Adjustment procedure.
Crimp Height Inspection

with a modified anvil. See Figure 54.
104
Crimp Height Adjustment 4. Holding contact by insulation barrel, insert it

through back of tool into appropriate crimp sec-
1. Remove lockscrew from ratchet adjustment tion, receptacle/tab end first.
NOTE: Ensure both sides of insulation barrel are
started evenly into the crimper jaws. DO NOT
attempt to crimp improperly positioned contacts.
5. Align contact wire stop slot with the wire stop

in the crimping jaws. Contact insulation and
wire barrels must be position in crimp section as
shown in Figure 57.

2. LOCKSCREW
3. LOOSEN-TIGHTEN
4. BACK OF TOOL
5. FRONT OF TOOL
6. SCREWDRIVER
Figure 55. Ratchet Wheel Adjustment
2. Using a screwdriver, adjust ratchet wheel from

front of tool. See Figure 55.
3. To tighten crimp, rotate ratchet adjustment

wheel COUNTERCLOCKWISE. See Figure 55.
4. To loosen crimp, rotate ratchet adjustment wheel 1. WIRE STRIP LENGTH

CLOCKWISE. See Figure 55. 2. WIRE SEAL
3. INSULATION BARREL
5. Make a sample crimp and measure crimp height. 4. WIRE BARREL
If crimp height is acceptable, replace and tighten 5. WIRE STOP SLOT
lockscrew. If crimp height is unacceptable, follow 6. MATING END
Step 3 or Step 4 until acceptable crimp height is
Figure 56. Wire and Receptacle
achieved.
Table 9. Wire Strip Lengths
HOW TO USE AMP HAND APPLICATION
TOOL Wire Size Insulation Strip Length
(AWG) Diameter
1. Strip insulation from wire. See Figure 56 and
Table 9. 1.7 to 2.4 mm 3.0 to 3.5 mm
20-16 (0.07 to (0.12 to 0.13 in.)
2. Hold tool so BACK (wire side) faces you. 0.09 in.)
3. Release tool handles by squeezing them together 1.7 to 2.4 mm 3.0 to 3.5 mm
then allowing them to open fully. 22-20 (0.07 to (0.12 to 0.13 in.)
0.09 in.)
NOTE: Insert contact with open side of insulation and
wire barrel toward movable crimping jaw.
105
6. Squeeze handles together until ratchet engages

sufficiently to hold contact in position. DO NOT
deform insulation or wire barrel.
7. Insert stripped wire into contact insulation and

wire barrels until butted against wire stop. See
Figure 57.
8. Holding wire in position, squeeze tool handles to-

gether until ratchet releases. Allow tool handles
to open and remove crimped contact.
AMP PRO-CRIMPER II TOOL

Description
This tool has a tool frame with stationary jaw and
handle, a moving jaw and handle, and an adjustable
ratchet to endure full contact crimping. The tool
frame contains a die assembly with three crimping
sections.
The die assembly contains a wire anvil, an insulation

anvil, a wire crimper and an insulation crimper. See
Figure 58.
Die retaining pins and retaining screws are used to A. FRONT OF TOOL (LOCATOR SIDE)
position and secure the dies in the tool frame. A nut B. BACK OF TOOL (WIRE SIDE)
is used on upper retaining screw to hold locator as-
sembly in place. See Figure 58. 1. LOCATOR ASSEMBLY
2. STATIONARY JAW
3. DIE ASSEMBLY
4. MOVING JAW
6. PIVOT PIN
7. STATIONARY HANDLE
8. MOVING HANDLE
Figure 58. AMP PRO-CRIMPER II Tool and Die
1. WIRE INSERTED TO STOP

2. STRIP LENGTH (SEE TABLE 9)
Figure 57. Wire Stop Slot
106
Remove and Install Die Set and Locator Assembly 10. Install locator assembly over the end of upper
retaining screw and position against tool frame.
1. Close tool handles until ratchet releases, remove See Figure 59.
the nut, locator assembly, upper retaining screw,
lower retaining screw and four die retaining pins 11. Install nut onto end of upper retaining screw and
from tool frame. See Figure 59. tighten enough to hold locator assembly in posi-
tion while allowing locator to slide up and down.
2. Slide wire anvil, insulation anvil, wire crimper, See Figure 59.
and insulation crimper out of tool frame. See Fig-
ure 59.
3. Install wire anvil and insulation anvil, with

chamfered sides and marked surfaces facing
outward, into moving jaw. See Figure 59.
4. Insert two die retaining pins. See Figure 59.
5. Insert lower retaining screw through moving jaw,

insulation anvil, and wire anvil. Tighten lower
retaining screw just enough to hold anvils in po-
sition. DO NOT tighten lower retaining screw
completely. See Figure 59.
6. Install wire crimper and insulation crimper, with 1. TOOL FRAME

chamfered sides and marked surfaces facing out- 2. LOCATOR ASSEMBLY
3. NUT
ward, into stationary jaw. See Figure 59. 4. DIE RETAINING PIN
5. UPPER RETAINING SCREW
7. Insert two die retaining pins. See Figure 59. 6. LOWER RETAINING SCREW
7. WIRE CRIMPER
8. Install upper die retaining screw through 8. WIRE ANVIL
stationary jaw, insulation crimper, and wire 9. CHAMFER
crimper. Tighten upper retaining screw just 10. OFFSET
enough to hold crimpers in position. DO NOT 11. INSULATION CRIMPER
12. INSULATION ANVIL
tighten upper retaining screw completely. See 13. CHAMFER
Figure 59. 14. MOVING JAW
15. STATIONARY JAW
9. Carefully close tool handles making sure anvils
and crimpers align properly. Continue closing Figure 59. Die Set and Locator Assembly
tool handles until ratchet in tool frame engages
enough to hold anvils and crimpers in position.
Tighten upper and lower retaining screws.
107
Adjustments the sixth click, or until the contact support

touches the contact.
Contact Support
4. Slightly loosen the nut holding the locator assem-
NOTE: Contact support is preset prior to shipment bly onto the tool frame.
but minor adjustment may be necessary.
5. Move the contact support as needed to eliminate
1. Make a sample crimp and determine if the con- the bending of the contact.
tact is straight, bending upward, or bending
downward. 6. Tighten the nut and close the handles until the
ratchet releases.
2. If adjustment is required, loosen the adjustment
screw holding contact support onto locator as- 7. Remove and inspect the contact.
8. Make another sample crimp. If the contact is
NOTE: The ratchet has detents that create audible straight, tighten the adjustment screw. If the
clicks as the tool handles are closed. contact is still being bent during crimping, repeat
adjustment procedure.
3. Position contact with wire in the proper nest and
close the tool handles until the ratchet reaches
A. BACK OF TOOL B. STRIP LENGTH

1. LOCATOR 5. WIRE SEAL
2. CONTACT SUPPORT 6. CONTACT
3. ADJUSTMENT SCREW 7. LOCATOR IN WIRE STOP SLOT
4. WIRE 8. WIRE INSERTED TO STOP
Figure 60. Contact Support and Wire Strip
108
Crimp Height Inspections and Maintenance

1. Remove lockscrew from ratchet adjustment Crimp Height Inspection
2. Using a screwdriver, adjust the ratchet wheel with a modifier anvil as shown in Figure 62
from locator side of tool. See Figure 61. Observe
ratchet adjustment wheel.
3. If a tighter crimp is required, rotate ratchet ad-

justment wheel COUNTERCLOCKWISE to a
higher-numbered setting.
4. If a looser crimp is required, rotate ratchet ad-

justment wheel CLOCKWISE to a lower-num-
bered setting.
5. Replace lockscrew. See Figure 61.
6. Make a sample crimp and measure the crimp 1. POSITION POINT ON CENTER OF WIRE
height as specified in Crimp Height Inspection BARREL OPPOSITE SEAM
section. If the dimension is acceptable, secure 2. MODIFIED ANVIL
lockscrew. If the dimension is unacceptable, con- 3. CRIMP HEIGHT (SEE TABLE 10)
tinue to adjust the ratchet and measure a sample
crimp. Figure 62. Crimp Height
2. See Table 10 and select a wire (maximum size)

for each crimping chamber listed.
Table 10. Crimp Height - Dimension

"3" in Figure 62
Wire Crimping Crimp Height ±

Size Chamber 0.05 mm (0.002 in.)
AWG (Wire Size
Marking)
20 20 1.12 mm (0.044 in.)
18 18 1.30 mm (0.051 in.)
16 16 1.45 mm (0.057 in.)
3. See How to Use AMP Pro-Crimper II Tool section

and crimp contact accordingly.
1. LOCKSCREW
2. RATCHET ADJUSTMENT WHEEL 4. Using crimp height comparator, measure the
3. SCREWDRIVER wire barrel crimp height as shown in Figure 62.
If crimp height conforms to dimensions shown
Figure 61. Ratchet Adjustment Wheel in Table 10 the tool is considered dimensionally
correct. If not, the tool must be adjusted; see
Crimp Height section.
109
Visual Inspection 4. Holding contact by mating end, insert the con-

tact, insulation barrel first, through the front of
The crimping dies should be inspected on a regular the tool and into the appropriate crimping cham-
basis to ensure they have not become worn or dam- ber.
aged. Inspect the crimping chamfers for flattened,
chipped, worn or broken areas. If damage or abnor- 5. Position the contact tho that the mating end of
mal wear is present, replace tool. contact is on locator side of tool and the open "U"
of the wire and insulation barrels face the top of
Maintenance the tool. Fit the contact into the nest so the mov-
able locator drops into the slot in the contact. See
1. Wipe tool and dies with clean, soft cloth. Remove
Figure 60. Butt front end of wire barrel against
any debris with a clean, soft brush. DO NOT use
movable locator.
objects that could damage the tool. When not in
use, keep handles closed to prevent debris from NOTE: Make sure both sides of insulation barrel are
becoming lodged in the crimping dies, and store started evenly into the crimping chamber. DO NOT
in a clean, dry area. attempt to crimp and improperly positioned contact.
HOW TO USE PRO-CRIMPER II TOOL 6. Hold contact in position and squeeze the tool
handles together until ratchet engages enough
NOTE: This tool is provided with a crimp adjustment to hold contact in position. DO NOT deform
feature. Initially the crimp height should be veri- insulation barrel or wire barrel.
fied as stipulated in Crimp Height Inspection and
Crimp Height Adjustment sections to verify height 7. Insert stripped wire, with wire seal, into insula-
before using the tool to crimp desired contacts and tion and wire barrels until it is butted against
wire sizes. wire stop. See Figure 60.
1. Using Table 9 select wire of specified size and in- NOTE: The crimped contact may stick in the crimp-
sulation diameter. Assemble wire seal onto wire ing area, but the contact can be easily removed by
as specified in Mini Mic Receptacle and Tab Con- pushing downward on the top of the locator. See Fig-
tact section. ure 60.
2. Strip wire to the length indicated in Table 9 tak- 8. Holding wire in position, squeeze tool handles to-
ing care not to nick or cut wire strands. Select gether until ratchet releases. Allow tool handles
contact and identify appropriate crimping cham- to open and remove crimped contact.
ber according to the wire size markings on the
tool. 9. Check contact crimp height as described in
Crimp Height Inspection section. If necessary,
3. Hold tool so that the back (wire side) is facing adjust the crimp height as specified in Crimp
you. Squeeze tool handles together and allow Height section.
them to open fully.
110
2200 SRM 1128 AMP Superseal 1.5 Connector Assemblies
AMP Superseal 1.5 Connector Assemblies

DESCRIPTION
The AMP Superseal 1.5 connectors are designed to meet the performance requirements in the automotive field.
The following information is intended as a general guide for the best use of the connectors for wire harnesses
and their maintenance.
Harness Assembly
STEP 1.
Contacts can only be inserted into housing cavities
in one position. The correct placing is shown. After
insertion of a contact, pull back lightly on the wire to
check that the contact is securely locked in position.
STEP 2.
Cavity plug, Hyster P/N 2069381, must be used when
a cavity is not loaded with a contact. This prevents
the ingress of water. Insert cavity plug deeply into
the cavity by means of a pin as shown. If necessary,
the cavity plug can be removed by a pin point.
1. CAVITY PLUG
111
AMP Superseal 1.5 Connector Assemblies 2200 SRM 1128
Positioning of Anti-Backout Device
STEP 1.
These connectors are supplied with an anti-backout
device for both receptacle and tab housings. After
loading all of the crimped contacts, these devices
must be pushed into CLOSED position. If one con-
tact is not properly seated in the cavity, the plastic
locking lance remains deflected and the anti-backout
device cannot be closed. This serves as a warning for
the user. If the anti-backout device is not closed, the
mating with a counterpart cannot be completed.
A. CONTACT NOT PROPERLY SEATED

1. TAB HOUSING
2. PLUG HOUSING
3. ANTI-BACK OUT DEVICE
112
NOTE: Perform STEP 2 for manually operated, position 2 to 6 plugs.
STEP 2.
Rotate the anti-back out device to deflect the central
lances inward then push until the side arms lock.
NOTE: Perform STEP 3 for position 2 to 6 plugs inserted by a harness maker machine.
STEP 3.
Push the two lances for position 2 housing, the cen-
tral lance for positions 3 and 5 housing, and the two
central lances for positions 4 and 6 housing inward.
Then push until the side arms lock.
STEP 4.
For position 1, manually or machine operated, push
the anti-backout device until its upper end is the
same level as the housing mating face.
NOTE: Different jigs are needed for position 1 and 2 housings and position 3 to 6 housings.
113
STEP 5.
To close the anti-backout device for tab housings, ei-
ther manually or by machine, push the device in with
a jig until it meets the stop.
Removal of Contacts
Since the locking lance of contacts can be reached from the mating side of the housings, it is necessary to remove
the anti-backout device first.
NOTE: Perform STEP 1 and STEP 2 for removal of receptacle contact.
STEP 1.
Deflect the side arms of the anti-back out device and
pull it away.

2. EXTRACTION TOOL
114
CAUTION
Be careful not to insert the extraction tool in
the contacting area of the receptacle.
STEP 2.
Insert the contact extraction tool Hyster P/N 1698561
between contact and lance nose, then rotate slightly
as shown. Pull the wire.
1. CONTACT
2. CONTACT EXTRACTION TOOL
NOTE: Perform STEP 3 and STEP 4 for removal of tab contact.
115
STEP 3.
Insert the extraction tool Hyster P/N 1698560 in one
of the central holes of the anti-backout device and
pull it away.
NOTE: Pull extraction tool in direction of arrow.

1. EXTRACTION TOOL
116
CAUTION
When rotating the extraction tool, be careful
not to deform the tab.
STEP 4.
Insert the contact extraction tool Hyster P/N 1698561
between contact and lance note, then rotate slightly
as shown. Pull the wire up as shown.
1. CONTACT EXTRACTION TOOL
117
AMP Fastin-Faston Hand Tools 2200 SRM 1128
REPAIR AND MAINTENANCE panel mounting of the connector. The clip can be dif-
ferent shape according to the requirements. See ex-
During repair and maintenance operation for wiring, ample in Figure 63.
replacement of contacts may be required. Following
is the recommended procedure.
1. Cut the wire of the defective contact.
2. Strip the wire insulation to appropriate length.
3. Slide a new wire seal onto the wire.
4. Crimp the new contact on the wire using a hand

crimping tool.
PANEL MOUNT OPTION

The tab housings come with two "L" shaped guides NOTE: SLIDE CLIP IN DIRECTION OF ARROW.
for the insertion of a special elastic clip, allowing
Figure 63. Panel Mount Clip Example
AMP Fastin-Faston Hand Tools

DESCRIPTION - AMP DOUBLE ACTION Periodic Tool Inspection
HAND TOOL
Lubrication
Hand-crimping tools that accommodate full wire size
1. Coat all pins, pivot points, and bearing surfaces
range are designed for repair applications. This tool
with thin layer of SAE 20 motor oil per schedule
is designed for use with AMP micro and mini relay
below:
receptacles. The tool has two crimping jaws, each
1. Tool used daily: lubricate weekly
consisting of an anvil and a crimper. When jaws are
2. Tool used weekly: lubricate monthly
closed they form two crimping chambers, marked on
BACK of tool as "A" and "B". Crimping jaws "bottom" 2. Wipe excess oil from tool paying close attention to
before ratchet releases. This is a design feature to crimp area. Oil transferred from crimping area
assure maximum electrical and tensile performance onto terminations can affect electrical character-
of crimp; DO NOT readjust ratchet. See Figure 64. istics of application.
MAINTENANCE AND INSPECTION Visual Inspection
PROCEDURES
NOTE: Manufacturer’s replacement and repair pro-
Daily Maintenance cedures included in documentation received with
tool.
1. Immerse tool, with handles partially closed, in
reliable commercial de-greasing compound to re- 1. Close handles until ratchet releases and handles
move accumulated debris. If de-greasing com- open freely. If handles DO NOT open quickly
pound is not available, wipe tool with soft lint- and fully, the spring is defective and must be re-
free cloth. DO NOT use objects that could dam- placed. See Figure 65. If spring is defective, fol-
age tool. low manufacturers’ replacement and repair pro-
cedures.
2. Ensure retaining pins are in place and secured
with retaining rings. See Figure 65. 2. Inspect tool for worn, cracked, or broken jaws. If
jaws are damaged follow manufacturers’ replace-
3. When not in use, keep handles closed to prevent ment and repair procedures.
debris from lodging in jaws. Store in clean dry
area.
118
2200 SRM 1128 AMP Fastin-Faston Hand Tools
1. CRIMPER 5. INSULATION CRIMPING JAWS

2. ANVIL 6. BACK OF TOOL
3. CRIMPING CHAMBER MARKINGS 7. CERTI-CRIMP RATCHET
4. WIRE CRIMPING JAW 8. LINK
Figure 64. AMP Double Action Hand Tool
119
1. RETAINING RING 3. HANDLE SPRING

2. RETAINING PIN
Figure 65. Tool Inspection
Crimp Height Inspection

1. This inspections requires the use of a modified
micrometer with modified anvil and spindle.
Modified micrometer to be used when crimp
height is specified. See Figure 66.
2. Use Table 11 to select maximum size wire for

each crimping chamber.
3. Crimp receptacle onto selected wire according to

How to Use AMP Double Action Hand Tool pro-
cedure.
4. Using modified micrometer, measure wire barrel

crimp height as shown in Figure 67. If crimp
height matches measurement in Table 11, the
tool is considered dimensionally correct. If not,
follow manufacturers’ replacement and repair NOTE: SAMPLE READING SHOWN IN ILLUSTRA-
procedure. TION EQUALS 3.489 mm (0.1374 in.).
1. ANVIL
2. SPINDLE
3. STATIONARY HANDLE
4. MOVABLE HANDLE
5. TYPICAL CONTACT
Figure 66. Modified Micrometer
120
Table 11. Wire Size and Crimp Height 4. Check clearance between bottoming surfaces
of crimping jaws. If clearance is 0.025 mm
Crimp Wire Size Crimp Height (0.001 in.) or less, the ratchet is satisfactory. If
Chamber (AWG) clearance exceeds 0.025 mm (0.001 in.) follow
manufacturers’ replacement and repair proce-
1.27 ±0.076 mm
A 18-20 dure.
(0.05 ±0.003 in.)
1.65 ±0.076 mm
B 14-16
(0.065 ±0.003 in.)
1. POSITION POINT ON CENTER OF WIRE

BARREL OPPOSITE SEAM
2. MODIFIED ANVIL
3. CRIMP HEIGHT (SEE TABLE 11)
Certi-Crimp Ratchet Inspection

The ratchet on this tool should be checked to ensure
A. RECEPTACLE BARREL ALIGNMENT
it does not release prematurely, allowing jaws to open
before they have fully bottomed. Use a 0.025 mm 1. RECEPTACLE CRIMPING BARREL
(0.001 in.) shim suitable for checking clearance be- 2. STRIPPED WIRE
tween bottoming surfaces of crimping jaws. 3. WIRE CRIMPING JAW
4. INSULATION CRIMPING JAW
1. Select receptacle and maximum size wire for 5. BACK SIDE OF TOOL
tool.
Figure 68. Crimp Alignment
2. Position receptacle and wire between jaws as
shown in Figure 68.
3. While holding wire in position, squeeze tool han-

dles together until ratchet releases. Hold han-
dles in closed position.
121
HOW TO USE AMP DOUBLE ACTION 7. While holding wire position, squeeze tool handles
HAND TOOL together until ratchet releases. Open tool han-
dles and remove crimped receptacle.
NOTE: Wire size and insulation diameter must be
within specified range for receptacle. See Table 12.
1. Strip insulation from wire. See Table 12 and Fig-

ure 69.
2. Hold tool so BACK side is facing you.
3. Release tool handles by squeezing them together

until ratchet releases.
4. Insert receptacle barrel into crimping area as

shown in Figure 68.
5. Squeeze tool handles together just enough to hold

receptacle in place.
1. WIRE BARREL
NOTE: Make sure insulation DOES NOT enter wire 2. INSULATION BARREL
barrel. 3. LOCATOR SLOT
4. WIRE STRIP LENGTH (SEE TABLE 12)
6. Insert stripped wire into receptacle crimping bar-
rel from BACK of tool. Figure 69. Wire and Receptacle
Table 12. Wire Strip Length
Crimp Wire Size Strip Insulation

Chamber (AWG) Length Diameter
20-16 4.2 to 5.2 mm (0.16 to 0.20 in.)
B 2.2 to 3.1 mm (0.09 to 0.12 in.)
18-14 5.1 to 6.1 mm (0.20 to 0.24 in.)
DESCRIPTION - AMP EXTRACTION TOOL MAINTENANCE AND INSPECTION

Extraction tools are designed to release locking lance For proper operation, tool to conform to measure-
inside connector housing without damaging housing ments indicated in Figure 71. Inspections to be per-
or connectors. The extraction tip is used with the formed at regular intervals, refer to manufacturers
universal handle as shown in Figure 70. Extraction data for specifics.
tip, installed, is aligned with mating face of connector
housing to depress locking lance of receptacle holding Clean extraction tool with clean, soft, lint-free cloth
it in housing. and store in clean, dry place.
122
1. UNIVERSAL HANDLE 2. EXTRACTION TIP 3. DRIVE SCREW
Figure 70. AMP Extraction Tool With Tip
Figure 71. Tool Tip Inspection
123
HOW TO USE AMP EXTRACTION TOOL 3. Push wire from BACK of housing TOWARD tool
and depress locking lance. See view C of Fig-
It is necessary to depress locking lance of receptacle ure 72.
from its cavity inside connector housing. Procedure
below describes steps of extraction. 4. Pull BACK on wire and remove receptacle from
housing. See view D of Figure 72.
1. Orient extraction tool tip with mating face of con-
nector. See view A of Figure 72. 5. Remove extraction tool from housing.
2. Insert tip of extraction tool, aligned in center

of housing cavity where locking lance is located.
See view B of Figure 72.
A. EXTRACTION TOOL ORIENTATION C. WIRE DEPRESSIONS

B. TOOL TIP ALIGNMENT D. RECEPTACLE REMOVAL
1. EXTRACTION TOOL 3. RECEPTACLE
2. HOUSING 4. LOCKING LANCE
Figure 72. Contact Extraction
124
2200 SRM 1128 AMP Fastin-Faston Receptacles and Housings
AMP Fastin-Faston Receptacles and Housings

DESCRIPTION i. Wire barrel seam to be closed, no loose wire
strands visible.
This manual section covers FASTIN-FASTON recep-
tacle installation. These connectors are the multiple j. There shall be no twist, roll, deformation, or
circuit connectors use primarily as wire harness con- other damage to mating portion of crimped
nectors. receptacle that will prevent proper mating.
See Figure 77.
CAUTION k. Force applied during crimping can cause
DO NOT nick, scrape, or cut the wire conductor bending between the crimped wire barrel
during the striping operation. and mating portion of receptacle. Bending is
acceptable within limits shown in Figure 78.
1. Install receptacles as specified in How to Use
AMP Double Action Hand Tool. See Figure 73 3. Crimped receptacle should hold wire firmly and
for tool image. have a pull-test tensile value as specified in Ta-
ble 14.
2. Receptacle contact should appear as shown in
Figure 74. 4. Damaged crimped receptacles or housings must
be removed, discarded, and replaced with new
a. The most critical and compressed area is the
components. See Figure 79 and Figure 80 for
crimp applied to the wire portion of the con-
tools used during removal.
tact to ensure optimum electrical and me-
chanical performance of crimped receptacle. 5. For procedure to remove receptacles for connec-
See Figure 75 and Table 13. tor housings, see How to Use AMP Extraction
Tool section.
b. Crimp length must be within dimensions in-
dicated in Table 13.
c. Front and rear bellmouths to match images

and dimensions shown in Figure 76.
d. The cutoff tab to be cut as shown in Figure 76.
e. Max burr on cutoff tab shall not exceed di-

mensions indicated in enlarged view of Fig-
ure 76.
f. Acceptable dimensions for wire barrel flash

shown in section A-A, Figure 76.
g. After crimping, wire conductor and insula-

tion to be visible in areas shown in Figure 76.
h. Conductor may extend beyond wire barrel to Figure 73. AMP Double Action Hand Tool
maximum dimension shown in Figure 76.
125
AMP Fastin-Faston Receptacles and Housings 2200 SRM 1128
A. WIRE CONDUCTORS AND INSULATION BOTH B. CONDUCTOR VISIBLE

VISIBLE IN THIS AREA C. INSULATION BARREL CRIMP WIDTH
1. FRONT BELLMOUTH 5. WIRE BARREL CRIMP HEIGHT
2. CRIMP LENGTH 6. WIRE BARREL FLASH
3. REAR BELLMOUTH 7. CUTOFF TAB
4. WIRE BARREL CRIMP WIDTH 8. MAX BURR
Figure 74. Typical Crimped Receptacle

1. WIRE INSULATION
2. STRIP LENGTH (SEE TABLE 13)
Figure 75. Wire Strip Length
126
Table 13. Wire Strip Length and Crimp Measurements
Insulation
Wire Size Insulation Wire Barrel
Strip Length Barrel
(AWG) Diameter
Crimp Width Crimp Height Crimp Width
1.52 to 2.54 mm 2.49 to 2.59 mm
(0.06 to 0.10 in.) (0.98 to
5.82 to 6.48 mm 2.24 to 2.34 mm 1.07 to 1.32 mm 0.102 in.)
20 (0.229 to (0.088 to (0.042 to
2.16 to 3.18 mm 0.255 in.) 0.092 in.) 0.052 in.) 3.5 to 3.61 mm
(0.085 to (0.138 to
0.125 in.) 0.142 in.)
3.05 to 4.32 mm 6.23 to 6.48 mm
(0.120 to (0.245 to
0.170 in.) 0.255 in.)
3.05 to 4.06 mm 1.5 to 1.6 mm 4.01 to 4.11 mm
(0.120 to (0.059 to (0.158 to
0.160 in.) 0.063 in.) 0.162 in.)
3.5 to 3.68 mm 2.74 to 2.84 mm
(0.120 to (0.108 to
0.145 in.) 5.41 to 5.66 mm 0.112 in.)
(0.213 to
0.223 in.) 1.37 to 1.42 mm 4.52 to 4.62 mm
(0.054 to (0.178 to
2.54 to 4.42 mm 0.058 in.) 0.182 in.)
(0.100 to
0.170 in.) 1.47 to 1.57 mm 4.01 to 4.11 mm
(0.054 to (0.158 to
0.062 in.) 0.162 in.)
18
6.22 to 6.48 mm 1.35 to 1.45 mm
(0.245 to (0.053 to
2.16 to 3.18 mm 0.255 in.) 0.057 in.) 3.5 to 3.61 mm
(0.085 to (0.138 to
0.125 in.) 5.82 to 6.07 mm 1.17 to 1.27 mm 0.142 in.)
(0.229 to (0.046 to
0.239 in.) 2.24 to 2.34 mm 0.050 in.)
(0.088 to
6.22 to 6.48 mm 0.092 in.) 1.35 to 1.45 mm
(0.245 to (0.053 to
1.52 to 2.54 mm 0.255 in.) 0.057 in.) 2.49 to 2.59 mm
(0.060 to (0.098 to
0.100 in.) 5.82 to 6.07 mm 1.17 to 1.27 mm 0.102 in.)
(0.229 to (0.046 to
0.239 in.) 0.050 in.)
2.2 to 4.44 mm 5.1 to 6.1 mm 2.74 to 2.84 mm 1.42 to 1.52 mm 4.52 to 4.62 mm
(0.090 to (0.200 to (0.108 to (0.056 to (0.178 to
0.175 in.) 0.240 in.) 0.112 in.) 0.060 in.) 0.182 in.)
127
Table 13. Wire Strip Length and Crimp Measurements (Continued)
Insulation
Strip Length Barrel
(AWG) Diameter
4.06 to 5.33 mm 1.5 to 1.83 mm 6.3 to 6.4 mm
(0.160 to (0.059 to (0.248 to
0.210 in.) 0.072 in.) 0.252 in.)
3.81 to 4.83 mm 5.82 to 6.07 mm 3.0 to 3.11 mm 1.73 to 1.83 mm 5.28 to 5.38 mm
(0.150 to (0.229 to (0.118 to (0.068 to (0.208 to
0.190 in.) 0.239 in.) 0.122 in.) 0.072 in.) 0.212 in.)
3.3 mm 1.85 to 2.18 mm 6.3 to 6.4 mm
(0.130 in.)MAX (0.073 to (0.248 to
(2 Wires) 0.086 in.) 0.252 in.)
3.05 to 4.32 mm 6.22 to 6.48 mm
(0.120 to (0.245 to
0.170 in.) 0.255 in.)
3.05 to 4.06 mm 1.65 to 1.75 mm 4.01 to 4.11 mm
16 (0.120 to (0.065 to (0.158 to
0.160 in.) 0.069 in.) 0.162 in.)
3.05 to 3.68 mm
(0.120 to
0.145 in.) 5.41 to 5.66 mm 2.74 to 2.84 mm
(0.213 to (0.108 to
0.223 in.) 0.112 in.) 1.32 to 1.42 mm 4.52 to 4.62 mm
(0.052 to (0.178 to
2.54 to 4.32 mm 0.056 in.) 0.182 in.)
(0.100 to
0.170 in.) 1.6 to 1.7 mm 4.01 to 4.11 mm
(0.063 to (0.158 to
0.067 in.) 0.162 in.)
2.2 to 4.44 mm 5.1 to 6.1 mm 1.57 to 1.68 mm 4.52 to 4.62 mm
(0.090 to (0.200 to (0.062 to (0.178 to
0.175 in.) 0.240 in.) 0.066 in.) 0.182 in.)
128
Table 13. Wire Strip Length and Crimp Measurements (Continued)
Insulation
Strip Length Barrel
(AWG) Diameter
4.06 to 5.33 mm 1.7 to 2.03 mm 6.3 to 6.4 mm
(0.106 to (0.067 to (0.248 to
0.210 in.) 6.22 to 6.45 mm 3.0 to 3.1 mm 0.080 in.) 0.252 in.)
(0.245 to (0.118 to
3.81 to 4.83 mm 0.255 in.) 0.122 in.) 1.93 to 2.03 mm 5.28 to 5.38 mm
(0.150 to (0.076 to (0.208 to
0.190 in.) 0.080 in.) 0.212 in.)
(0.276 to (0.108 to (0.074 to (0.158 to
3.05 to 4.32 mm 0.286 in.) 0.112 in.) 0.078 in.) 0.162 in.)
(0.120 to
0.170 in.) 6.60 to 6.86 mm 3.25 to 3.35 mm 1.78 to 1.88 mm 4.52 to 4.62 mm
(0.260 to (0.128 to (0.070 to (0.178 to
0.270 in.) 0.132 in.) 0.074 in.) 0.182 in.)
3.05 to 4.06 mm 4.01 to 4.62 mm
14 (0.120 to (0.158 to
0.160 in.) 1.88 to 1.98 mm 0.182 in.)
(0.074 to
3.05 to 3.68 mm 0.078 in.) 4.01 to 4.11 mm
(0.120 to (0.158 to
0.145 in.) 5.82 to 6.07 mm 0.162 in.)
(0.229 to
0.239 in.) 2.74 to 2.84 mm 1.55 to 1.65 mm 4.52 to 4.62 mm
(0.108 to (0.061 to (0.178 to
2.54 to 4.32 mm 0.112 in.) 0.065 in.) 0.182 in.)
(0.100 to
0.170 in.) 1.83 to 1.93 mm 4.01 to 4.11 mm
(0.072 to (0.158 to
0.076 in.) 0.162 in.)
(0.090 to (0.201 to (0.071 to (0.178 to
0.175 in.) 0.240 in.) 0.075 in.) 0.182 in.)
129
A. WIRE CONDUCTORS AND INSULATION BOTH B. CONDUCTOR VISIBLE

VISIBLE IN THIS AREA C. INSULATION BARREL CRIMP WIDTH
1. FRONT BELLMOUTH 5. WIRE BARREL CRIMP HEIGHT (SEE TABLE 13)
2. CRIMP LENGTH (SEE TABLE 13) 6. WIRE BARREL FLASH
3. REAR BELLMOUTH 7. CUTOFF TAB
4. WIRE BARREL CRIMP WIDTH (SEE TABLE 13) 8. MAX BURR
Figure 76. Typical Crimp - Fastin-Faston Receptacle
130
Table 14. Crimp Pull-Out Test
Wire Size Minimum Force

(AWG) Newtons Pounds
20 57.8 13
18 89.0 20
16 133.4 30
14 222.4 50
1. FRONT OF RECEPTACLE
2. WIRE BARREL
Figure 77. Mating Portion
Figure 79. AMP Extraction Tool Universal

Handle
NOTE: ANGLES DRAWN FOR CLARIFICATION ONLY,

NOT TO SCALE. ANGLES ARE MAXIMUM DISTANCE
FROM DATUM LINE.
A. UP AND DOWN B. SIDE TO SIDE
1. DATUM LINE
Figure 78. Receptacle Bending Limits
Figure 80. AM Extraction Tool Tip
131
Wire Repair 2200 SRM 1128
Wire Repair
WIRE SPLICING REQUIREMENTS 3. 10 to 20 Gauge wire in area allowing use of a heat
gun - repair using Del-City crimp-solder-shrink
Refer to the following for determining which proce- splice.
dure to use for wire repairs.
4. 12 to 14 Gauge wire in area allowing 12.7 mm
1. 8 Gauge or heavier wire - no splicing, replace full (0.5 in.) diameter × 63.5 mm (2.5 in.) long splice
length of wire or replace harness. - use Deutsch jiffy splice.
2. Wires not meeting requirements of Step 3 5. 14 to 20 Gauge wire in area allowing 9.78 mm
through Step 5 - no splicing, replace full length (0.385 in.) diameter × 62.74 mm (2.47 in.) long
of wire or replace harness. splice - use Deutsch jiffy splice.
Table 15. Wire Strip Length Specifications
Contact Part Number Type Wire Gauge Range Recommended Strip Length
2
0.5 mm 2)
0.5 mm 2)
0.5 mm 2)
0.5 mm 2)
2
1653804 Socket 14 AWG (2.0 mm 2) 6.4 to 7.9 mm (0.252 to 0.311 in.)
2.0 mm 2)
2.0 mm 2)
132
2200 SRM 1128 Wire Repair
DEUTSCH JIFFY SPLICE

This splicing procedure adds 19.05 mm (0.75 in.) to
the length of the wire and may be used when slight
lengthening of the wire is desired.
Assemble
STEP 1.
Strip both wire ends to the specifications in Table 15.
STEP 2.
On one wire, crimp the appropriate pin onto the
wire using the Deutsch Crimping Tool (Hyster P/N
867888). See How to Crimp With the Deutsch
Crimping Tool.
STEP 3.
On second wire, crimp the appropriate socket onto
the wire using the Deutsch Crimping Tool (Hyster
P/N 867888). See How to Crimp With the Deutsch
Crimping Tool.
133
STEP 4.
Insert the wire with the socket contact into one end
of the jiffy splice.
STEP 5.
Push the contact into the jiffy splice until a positive
stop is felt. An audible snap will occur when correctly
installed. Slightly tug the wire to verify the wire is
properly locked in place.
STEP 6.
Insert the wire with the pin contact into opposite end
of the jiffy splice.
STEP 7.
Push the contact into the jiffy splice until a positive
stop is felt. An audible snap will occur when correctly
installed. Slightly tug the wire to verify the wire is
properly locked in place.
134
Disassemble
STEP 1.
Insert appropriate Deutsch extraction tool over the
wire being removed.
135
NOTE: Do not twist the tool or insert the tool at an

angle.
STEP 2.
Push the tool into the splice connector about 25 mm
(1 in.), until it bottoms on the contact flange.
NOTE: If pin is difficult to remove, remove the extraction tool, turn the extraction tool 90 degrees and reinsert
STEP 3.
and the connection socket or pin out of the connector.
STEP 4.
Repeat STEP 1 through STEP 3 on opposite end.
136
DEL-CITY CRIMP-SOLDER-SHRINK SPLICE

Refer to Table 16 for the correct splice part number for the wire gauge being repaired.
Table 16. Wire Splice Size
Part Number Wire Gauge Range

866417 10 to 12 AWG (5.0 to 3.0 mm 2)
866418 14 to 16 AWG (2.0 to 1.0 mm 2)
866419 18 to 20 AWG (0.8 to 0.5 mm 2)
STEP 1.
Strip approximately 9.525 mm (0.375 in.) from both
wire ends.
CAUTION
Do not crimp solder sleeve in the center of the
connector. This will make the connector unser-
viceable.
STEP 2.
Insert one wire into the connector. Make sure wire
is properly seated and crimp the connector using an
insulated connector crimping tool nest that matches
the color or gauge of the connector.
1. SOLDER SLEEVE 2. CRIMP POINT
CAUTION
Do not crimp solder sleeve in the center of the
connector. This will make the connector unser-
viceable.
STEP 3.
Insert the second wire into the opposite end of the
connector. Make sure wire is properly seated and 1. CRIMP POINT
crimp the connector using an insulated connector
crimping tool nest that matches the color or gauge of
the connector.
137
Twisted/Shielded Cable and Leads Repair 2200 SRM 1128
STEP 4.
Using a heat gun, apply heat evenly, to approx-
imately 135°C (275°F), around the length of the
tubing (including the crimp area) from the center
out to the ends until the tubing fully recovers and
adhesive flows.
Continue distributing the heat over the solder sleeve

until solder flows into the terminal barrel. Remove
from the heat and let cool for ultimate connection per-
formance.
1. EXPOSED NOTCHES AFTER SOLDER BAND

MELTS
Twisted/Shielded Cable and Leads Repair
TWISTED/SHIELDED CABLE REPAIR

STEP 1.
Remove outer jacket.
STEP 2.
Unwrap aluminum mylar tape. Do not remove mylar
tape.
1. DRAIN WIRE
2. OUTER JACKET
3. MYLAR
138
2200 SRM 1128 Twisted/Shielded Cable and Leads Repair
STEP 3.
Untwist conductors and strip insulation as necessary.
STEP 4.
Splice wires using splice clips and rosin core solder.
Wrap each splice to insulate.
1. SPLICE AND SOLDER
STEP 5.
Splice the drain (uninsulated) wire using splice clip
and rosin core solder.
STEP 6.
Wrap with mylar and drain (uninsulated) wire.
1. DRAIN WIRE
STEP 7.
Apply electrical tape over whole bundle to secure.
139
TWISTED LEADS REPAIR

STEP 1.
Locate damaged wire and remove insulation as re-
quired.
STEP 2.
Splice the two wires using splice clips and rosin core
solder.
1. SPLICE AND SOLDER
STEP 3.
Cover splice with electrical tape to insulate from
other wires.
STEP 4.
Twist and tape with electrical tape.
Special Tools
Illustration Tool Description
Not Illustrated Deutsch Connector Kit
Hyster P/N 866410
Not Illustrated Deutsch Connector/ Crimp/ Stripper Kit
Hyster P/N 867892
140

Wire Stripper
Hyster P/N 866411
Used for stripping wires.
Wire Stop for Wire Stripper

Hyster P/N 866412
Wire Crimping Pliers

Used for crimping connectors. (Except
Deutsch and AMP Connectors)
Deutsch Hand Crimping Tool

Hyster P/N 867888
Used for crimping pins and sockets for
Deutsch connectors.
Deutsch Wedge Removal Tool

Hyster P/N 866404
Used to remove secondary lock for
Deutsch connectors.
141

Yellow Extracting Tool
Hyster P/N 866402
Used to repair Deutsch HD 12 to 14
AWG connectors.
Orange Extracting Tool (E-Seal)

Hyster P/N 866413
Extra thin wall tool. Used to repair Deutsch
HD 12 to 14 AWG connectors.
Light Blue Extracting Tool

Hyster P/N 866400
AWG connectors.
Dark Blue Extracting Tool (E-Seal)

Hyster P/N 866414
Extra thin wall tool. Used to repair Deutsch
HD 16 to 18 AWG connectors.
Red Extracting Tool

Hyster P/N 866415
AWG connectors.
Deutsch G454 Testing Tool

Hyster P/N 866416
Used to check calibration of Deutsch
Hand Crimping Tool
142

Flat Blade Screwdriver
Used to open wedge lock for AMP plug connectors
AMP Hand Crimping Tool

Hyster P/N 1698557
(AMP P/N 58440-1)
Use for crimping AMPSEAL contacts
143

AMP Pro-Crimper II
Hyster P/N 1698558 with Die Set 1698559
Use for crimping AMPSEAL contacts
AMP Extracting Tool Hyster P/N 1698561

AMP Receptacle and Tab Contact Extraction
Tool for AMPSeal connectors
144

AMP Extracting Tool
Hyster P/N 1698560
AMP Tab Contact Extraction Tool for
AMPSeal connectors
AMP Hand Application Tool

Hyster P/N 1698562 with Die Set Hyster
P/N 1698563
Use for crimping AMP Superseal 1.5
Series Contacts
145

AMP Pro-Crimper II
Hyster P/N 1698565 with Die Set Hyster
P/N 1698566
Used for crimping AMP Superseal 1.5
Series Contacts
Heat Gun
Used to repair connector wires.
Tool Kit for Terminal Repair

Terminals cannot be removed from their
connectors or repaired without special tools.
This kit has the special removal and installation
tools and crimping tools required to make repairs
in Micro-Pack, Metri-Pack, and Weather-Pack
connectors. This repair kit does not have
the terminals or the connectors.
146

AMP Double Action Hand Tool
Hyster P/N 1701710
Use for crimping Fastin-Faston receptacle
connectors.
AMP Universal Handle Assembly with Strap

Hyster P/N 1701712
Use with Extraction Tool Tip for Fastin-Faston
receptacle connector extraction from
connector housings.
AMP Extraction Tool Tip

Hyster P/N 1701711
Use with Universal Handle Assembly for
Fastin-Faston receptacle connector extractions.
147
NOTES
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____________________________________________________________
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148
2200 SRM 1128 12/12 (9/12)(7/12)(1/12)(12/11)(7/11)(1/11)(5/10)(2/10)(9/09) Printed in U.S.A.

USER INTERFACE
SUPERVISOR
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS ([S80, 100, 120FT];
S80, 100FTBCS, S120FT; S120FTPRS) [G004, H004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) [N005, P005, R005]; S6.0FT,
S7.0FT (S135FT, S155FT) [D024, E024, F024]; H6.0FT,

PART NO. 1580518 2200 SRM 1130

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
User Interface Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
Dash Display Menu Access ........................................................................................................................... 1
Menu Navigation ............................................................................................................................................... 2
Standard Display ........................................................................................................................................... 2
Main Menu ......................................................................................................................................................... 3
Passwords Menu ................................................................................................................................................ 3
Password Administration .................................................................................................................................. 4
Add Password................................................................................................................................................. 4
Delete Password............................................................................................................................................. 5
Edit Password ................................................................................................................................................ 6
Other Password Functions ................................................................................................................................ 7
Operator Passwords - Enable/Disable .......................................................................................................... 7
Password Time-Out Delay............................................................................................................................. 8
Passwords - Number Wrong to Disable ........................................................................................................ 9
Lockout Reset Password................................................................................................................................ 10
View Password Log ........................................................................................................................................ 10
View Versions ..................................................................................................................................................... 11
VSM Versions................................................................................................................................................. 11
Dash Display Versions................................................................................................................................... 12
Engine Controller Version............................................................................................................................. 13
Transmission (Xmsn) Controller Version ..................................................................................................... 14
Truck Serial Number..................................................................................................................................... 15
Diagnostics ......................................................................................................................................................... 16
View Fault Log ............................................................................................................................................... 16
Set Travel and Braking ..................................................................................................................................... 17
Speed Limit .................................................................................................................................................... 17
Acceleration Rate........................................................................................................................................... 18
Auto-Deceleration Rate ................................................................................................................................. 19
Set Power Reversal Rate ............................................................................................................................... 20
Set Inching/Brake Overlap............................................................................................................................ 21
Setup Display Menu .......................................................................................................................................... 22
Set Operator Language ................................................................................................................................. 22
Set Units ........................................................................................................................................................ 23
Set Time Format (12/24 Hour) ...................................................................................................................... 24
Set Daylight Saving Time ............................................................................................................................. 25
Set Time ......................................................................................................................................................... 27
Set Date Format............................................................................................................................................. 28
Set Date.......................................................................................................................................................... 29
Setup Hydraulics ............................................................................................................................................... 30
Return to Set Tilt Delay/On/Off.................................................................................................................... 30
Setup General Items .......................................................................................................................................... 31
Light Shutdown Time-Out ............................................................................................................................ 31
Impact Sensor - Enable/Disable.................................................................................................................... 32
Impact Sensor - Soft Impact Settings........................................................................................................... 33
Impact Sensor - Hard Impact Settings......................................................................................................... 34
Adjust Impact Sensor Settings ..................................................................................................................... 35
Initial Adjustment of Soft and Hard Impact Settings............................................................................. 37
Readjustment of Soft and Hard Impact Settings .................................................................................... 37
Impact Sensor - Impact Alarm/Shutdown Reset.......................................................................................... 39
Impact Sensor - Alarm Time Duration and Deactivation ........................................................................... 40

Table of Contents User Interface

Impact Sensor - View Impact Event Log ...................................................................................................... 41
Economy Mode Indicator (ECO-eLo) ............................................................................................................ 42
Operator Checklist............................................................................................................................................. 43
Operator Checklist Off-On Mode .................................................................................................................. 43
Edit Operator Checklist ................................................................................................................................ 44
Set Operator Checklist Expiration ............................................................................................................... 45
View Checklist Log ........................................................................................................................................ 46
Clear Operator Checklist Log ....................................................................................................................... 47
Clear Operator Checklist Fault .................................................................................................................... 48
Calibrations........................................................................................................................................................ 49
Set Tilt Stop Point ......................................................................................................................................... 49
Calibrate Loaded Weight............................................................................................................................... 50
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS ([S80, 100, 120FT]; S80, 100FTBCS,
S120FT; S120FTPRS) [G004, H004];
110, 120FT) [N005, P005, R005];
ii
General
DESCRIPTION
NOTE: Initial setup of operator/supervisor pass-
words must be done by a qualified dealer technician
with service level menu access.
This section contains information to allow access to

the supervisor functions of the dash display. With a
proper supervisor password, the supervisor can ac-
cess menu items not visible to persons with operator
password level access. Menu items covering optional
equipment will only be displayed for those options in-
stalled on the lift truck. Access to display panel func-
tions is through the scroll keys #4 and #5 and the
(enter) key on the right-hand side of the dash dis-
play located on the steering column of the truck. See
Figure 1. After successfully entering your supervisor
password into the dash display, push the (enter) key
for access to the Main Menu.
DASH DISPLAY MENU ACCESS

NOTE: A qualified dealer technician with service
level access must install the initial supervisor
password. Once the initial supervisor password is 1. NUMERICAL PASSWORD ENTRY KEY #1
installed, that password may be used to access all 2. NUMERICAL PASSWORD ENTRY KEY #2
functions listed in this section and install additional 3. ENTER KEY
4. NUMERICAL PASSWORD ENTRY KEY #3
supervisor, operator, or password lockout passwords. 5. DOWN ARROW KEY
6. UP ARROW KEY
When the key is turned to the ON position or the 7. NUMERICAL PASSWORD ENTRY KEY #4
Power On button is pushed, the menu access keys are 8. NUMERICAL PASSWORD ENTRY KEY #5
activated.
Figure 1. Menu Access Keys

Menu Navigation 2200 SRM 1130
Upon initialization, the Password screen will be Table 1. Password Screen

shown on the dash display. See Table 1. Enter your
five-digit supervisor password using the five number
keys on the right-hand dash display input panel.
Press the (enter) key to enable all dash display Enter Password
menu options allowed for supervisor password ac- XXXXX
cess.
Menu Navigation
STANDARD DISPLAY Any time an optional value is changed within a
menu, pressing the key will take you to the Exit
Upon successful entry of your supervisor password, Options menu where you will have the opportunity
you will be directed to the Main Menu. Using the to return to the previous menu, exit the menu system
scroll keys #4 and #5, scroll through the menu choices without saving any changes, or save your changes
until you see the selection you want to access. Press and exit the menu system. See Table 2.
the (enter) key to access that selection. The Main
Menu will only include the menus that are accessible Some menus may contain several optional values
with a supervisor password. that can be adjusted. It is not necessary to exit the
menu after each adjustment and re-enter the menu
The (enter) key is used to make selections within a to make multiple changes within a menu. After
menu. The #4 and #5 scroll keys allow you to move making a change to an optional value, use the Back
from menu to menu. 1 Level option to re-enter the menu, scroll to the
next option to be adjusted, and make the change.
Each menu (except the Main Menu) will have a Back
After all adjustments have been made, press the *
One Level option within the menu options at that
key to access the Exit Menu and save your changes.
level. Use the scroll keys #4 and #5 to access this
option. Press the (enter) key to select this option
and return to the previous menu.
Table 2. Exit Options Menu
Main Menu Save All Changes and Press Key to Save

Save and Exit Press Key Exit Menu - Yes Changes and Return to
Menu
↑ ↑
SCROLL SCROLL
↓ ↓
Main Menu Cancel Save Press Key to Exit and
Exit Without Saving Return to Menu Return to Menu

2200 SRM 1130 Passwords Menu
Main Menu
NOTE: Depending upon how the lift truck is • Diagnostics
equipped, some of the functions described in this • Set Travel and Braking
section may not be included in the on-board menu • Setup Hydraulics
structure for a particular lift truck. • Setup Display
• Setup General Items
Upon entering the Main Menu from the password en- • Calibrations
try screen, the following menu functions are visible • Save and Exit
to the supervisor: • Exit Without Saving
• View Versions
• Passwords
Passwords Menu
NOTE: Personnel assigned with a supervisor level Password, Edit Password, Operator Passwords
password cannot add, change, or delete service level Enable/Disable, Password Time-Out Delay, and
passwords. Passwords – Number Wrong to Disable. These func-
tions are not available to anyone using an operator
Within the Passwords Menu, the supervisor has password.
access to the following additional dash display func-
tions: View Password Log, Add Password, Delete

Password Administration 2200 SRM 1130
Password Administration
ADD PASSWORD Supervisor - Same rights as the Service level
password except the Supervisor level cannot add,
NOTE: change, or delete Service level passwords.
• Personnel assigned with a supervisor level pass- Service Technician - Has all rights allowed for
word cannot add, change, or delete service level Operator, Lockout Reset and Supervisor pass-
passwords. words, plus the ability to add, delete, and edit
• The Vehicle System Manager can hold up to 250 Service passwords; view all diagnostic informa-
passwords. This can be in any combination of user, tion, and adjust all service access parameters
supervisor, or service passwords. within the pre-set limits. On trucks equipped
with the hood switch option, a Service password
After entering the Add Password menu, enter the
allows truck to be started with hood open.
new user’s five-digit password using the number keys
and press the * key to add the password. See Table 3. If the password is accepted, the display will return to
You will be asked to enter the password type. the Add Password menu. Scroll to the Exit Options
menu and choose the appropriate action.
Select:
Operator - Allows truck operation.
Lockout Reset - Allows supervisor to reset the
password function after password lockout has
been enabled.
Table 3. Add Password Menu
Enter 5-Digit Password Select 1

Main Menu Passwords Enter Password Type
Passwords Press * Key Add Password Press * Key Password and Press * Key Operator
Operator
Type
↑ ↑
SCROLL SCROLL
↓ ↓
Passwords Password Type

Back 1 Level Lockout Reset
↑
SCROLL
↓
Password Type
Supervisor

2200 SRM 1130 Password Administration
DELETE PASSWORD * key. See Table 4. You will be prompted to confirm

that you want to delete the password. If you want to
This function allows the supervisor to delete the
delete the password, choose Yes and press the * key.
password information of any user or supervisor.
If the delete is accepted, the display will return to the
After entering the Delete Password menu, enter the Delete Password menu. Scroll to the Exit Options
five-digit password you want to delete and press the menu and choose the appropriate action.
Table 4. Delete Password Menu
Enter 5-Digit Select Action

Main Menu Passwords Delete Password Delete Password? No
Press * Key Delete Password Press * Key Password and and
Passwords Enter Password
*
Press Key
Password XXXXX
*
Press Key
↑ ↑ ↑
SCROLL SCROLL SCROLL
↓ ↓ ↓
Passwords Passwords Delete Password? Yes

Back 1 Level Back 1 Level Password XXXXX

Password Administration 2200 SRM 1130
EDIT PASSWORD the password entered will now be displayed on the

dash display. You can edit the five-digit password
This function allows the supervisor to edit any exist- by entering the new password using the number
ing password information that has been stored in the keys. When finished, press the * key and edit the
dash display. password type. Use the scroll keys to select the
After entering the Edit Password menu, enter the new password type and press the * key to store the
password you want to edit and press the * key. selection.
If the password entered for editing has not been If you want to continue making edits, select the Save
stored in the dash display, the next higher stored and Return option to return to the Edit Password
password will be displayed. Use the scroll keys to menu. If you are finished making changes, scroll to
scroll through the stored passwords. Use the * the Exit Options menu and choose the appropriate
key to select a password for editing. See Table 5. action.
The password and password type information for
Table 5. Edit Password Menu
Enter 5-Digit Edit Password Select 1 Operator

Main Menu
Passwords Press * Key Passwords
Edit Password Press * Key Edit Password
Enter Password
Password and
Press * Key
Editing Password
Password XXXXX Type
and
Press * Key
Password Type
Operator
Type and
Press * Key
↑ ↑ ↑
↓ ↓ ↓
Passwords Passwords Password Type

Back 1 Level Back 1 Level Lockout Reset
↑
SCROLL
↓
Password Type
Supervisor
↑
SCROLL
↓
Password Type
Service

2200 SRM 1130 Other Password Functions
Other Password Functions

NOTE: Personnel assigned with a supervisor level OPERATOR PASSWORDS -
password cannot add, change, or delete service level ENABLE/DISABLE
passwords.
If your lift truck is configured for optional operator
passwords, this function can be used to enable or dis-
able the use of operator passwords.
Use the scroll keys to select Activated or Deactivated

and press the * key to access the Exit Options menu
and choose the appropriate action. See Table 6.
Table 6. Operator Passwords Menu
Main Menu Passwords Operator Password Select Action and

Passwords Press * Key Operator Password Press * Key Activated Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Passwords Operator Password
Back 1 Level Deactivated

Other Password Functions 2200 SRM 1130
PASSWORD TIME-OUT DELAY requiring re-entry of the operator password. See Ta-
ble 7. The delay must be entered in one-minute incre-
If your lift truck is configured for optional operator ments up to five minutes. For delay longer than five
passwords, this function can be used to select the minutes, the delay must be entered in five-minute in-
amount of time an operator can turn OFF the lift crements. The maximum delay that can be entered
truck and RESTART the lift truck without having is 30 minutes. After entering the delay, press the *
to re-enter operator’s password. key to access the Exit Options menu and choose the
After entering the Password Time-Out Delay menu, appropriate action.
enter the number of minutes you want to allow before
Table 7. Password Time-Out Delay Menu
Main Menu Passwords Time-Out Delay Select Delay from Available

Passwords Press * Key Time-Out Delay Press * Key 30 Minutes Selections and Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Passwords Time-Out Delay
Back 1 Level 0 Minutes

2200 SRM 1130 Other Password Functions
PASSWORDS - NUMBER WRONG TO and 10 attempts. See Table 8. You may also choose to
DISABLE deactivate this function and allow unrestricted log-in
attempts. After making your selection, press the *
This function is used to select the number of times key to access the Exit Options menu and choose the
an operator can enter an incorrect password before appropriate action.
disabling further access to the lift truck.
After entering the Passwords – Number Wrong to

Disable menu, use the scroll keys to select between 1
Table 8. Passwords - Number Wrong to Disable Menu
Select # of Wrong Entries

Main Menu Passwords # Wrong To Disable
Passwords Press * Key # Wrong To Disable Press * Key 10 Entries
from Available Selections and
Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Passwords # Wrong To Disable
Back 1 Level 1 Entries
↑
SCROLL
↓
# Wrong To Disable
Deactivated

Other Password Functions 2200 SRM 1130
LOCKOUT RESET PASSWORD VIEW PASSWORD LOG

If the operator continues to enter an incorrect pass- Entering this function allows the supervisor to view
word and activates the lockout feature above, the sys- the log-in information of all users who have entered
tem must be reset by someone with a lockout reset a password into the dash display. See Table 9. This
password, a supervisor password, or a service techni- provides the supervisor with the following informa-
cian password. The supervisor can assign a lockout tion – password, date, and the engine hourmeter
reset password to anyone using the Passwords menu. reading at the time of log-in each time a password
Enter the password using the Add Password menu has been entered into the dash display. If the truck
and select Lockout Reset for the password type. This has been accessed by a service technician, the log
allows the person assigned the lockout reset pass- will show a SERV entry.
word to unlock the lift truck without allowing access
to other dash display menu functions. The supervisor can scroll through the log entries us-
ing the scroll keys. Pressing the * key at any time
will return the display to the Passwords menu.
Table 9. View Password Log Menu
Main Menu Passwords Password Log XXXXX Press * Key to Return

Passwords Press * Key View Password Log Press * Key 06/12/04 998 to Main Menu
↑
SCROLL
↓
Passwords
Back 1 Level

2200 SRM 1130 View Versions
View Versions
Upon entering the View Versions Menu from the VSM VERSIONS
Main Menu, the following menu functions are visible
to the supervisor: This function allows the supervisor access to the
• Vehicle Systems Manager hardware, software, and configuration versions cur-
• Dash Display rently installed on the lift truck.
• Engine Controller (if equipped)
From the View Versions menu, select the Vehicle
• Transmission (Xmsn) Controller (if equipped)
System Manager menu and press the * key. Using
• Truck Serial Number
the scroll keys, you can view the hardware, software,
Use the scroll keys to move to the desired function and configuration versions of the vehicle system
and press the * key to select the function. manager. See Table 10. Select Back One Level, then
press the * key to return to the previous menu.
Table 10. View VSM Versions Menu
Main Menu View Versions Vehicle Syst Manager

View Versions Press * Key Vehicle Syst Manager Press * Key Hardware XXXXXXXX
↑
SCROLL
↓
Vehicle Syst Manager
Software XXXXXXXX
↑
SCROLL
↓
Config XXXXXXXX
↑
SCROLL
↓
Back One Level

View Versions 2200 SRM 1130
DASH DISPLAY VERSIONS you can view the hardware, software, and configura-
tion versions of the dash display. See Table 11. Select
This function allows the supervisor access to the Back One Level, then press the * key to return to the
hardware, software, and configuration versions of previous menu.
the dash display currently installed on the lift truck.
From the View Versions menu, select the Dash Dis-

play menu and press the * key. Using the scroll keys,
Table 11. View Dash Display Versions Menu
Main Menu View Versions

View Versions Press * Key Vehicle Syst Manager
↑
SCROLL
↓
View Versions Dash Display
Dash Display Press * Key Hardware XXXXXXXX
↑
SCROLL
↓
Dash Display
Software XXXXXXXX
↑
SCROLL
↓
Dash Display
Config XXXXXXXX
↑
SCROLL
↓
Dash Display
Back One Level

ENGINE CONTROLLER VERSION scroll keys, you can view the hardware and software
versions of the engine controller. See Table 12. Se-
If lift truck is equipped with Engine Controller Ver- lect Back One Level, then press the * key to return
sion, this function will allow the supervisor access to the previous menu.
to the hardware and software versions of the engine
controller currently installed on the lift truck.
From the View Versions menu, select the Engine

Controller menu and press the * key. Using the
Table 12. View Engine Controller Versions Menu
Main Menu Press * View Versions

View Versions Key Vehicle Syst Manager
↑
SCROLL
↓
View Versions Press * Engine Controller
Engine Controller Key Hardware XXXXXXXX
↑
SCROLL
↓
Engine Controller
Software XXXXXXXX
↑
SCROLL
↓
Engine Controller
Back One Level

TRANSMISSION (XMSN) CONTROLLER From the View Versions menu, select the Xmsn Con-
VERSION troller menu and press the * key. Using the scroll
keys, you can view the hardware and software ver-
If lift truck is equipped with Transmission Controller sions of the transmission controller. See Table 13.
Version, this function will allow the supervisor access Select Back One Level, then press the * key to re-
to the hardware and software versions of the optional turn to the previous menu.
transmission controller currently installed on the lift
truck.
Table 13. View Transmission Controller Versions Menu

↑
SCROLL
↓
View Versions Xmsn Controller
Xmsn Controller Press * Key Hardware XXXXXXXX
↑
SCROLL
↓
Xmsn Controller
Software XXXXXXXX
↑
SCROLL
↓
Xmsn Controller
Back One Level

TRUCK SERIAL NUMBER truck serial number. See Table 14. Select Back One
Level, then press the * key to return to the previous
This function allows the supervisor access to the menu.
truck serial number.
From the View Versions menu, select the Truck Se-

rial Number menu and press the * key to view the
Table 14. View Truck Serial Number Menu

↑
SCROLL
↓
View Versions Truck Serial Number
Truck Serial Number Press * Key XXXXXXXXXXXXXXX
↑
SCROLL
↓
Truck Serial Number
Back One Level

Diagnostics 2200 SRM 1130
Diagnostics
Upon entering the Diagnostics Menu from the Main Use the scroll keys to move to the desired function
Menu, the following menu function is visible to the and press the * key to select the function.
supervisor:
• View Fault Log VIEW FAULT LOG
For a complete description of the Diagnostic func- This function will allow the supervisor to view all
tions accessible through the Dash Display. See the faults stored in the VSM. All fault codes will be dis-
Diagnostic Troubleshooting Manual 9000 SRM played with the most recent fault listed first. See Ta-
1112. ble 15.
Table 15. View Fault Log
Main Menu Diagnostics

Diagnostics Press * Clear Fault
Key Log
↑
SCROLL
↓
Diagnostics 123456-12
VSM 9
View Fault Press * Key 1st
#
12 Press * Key
Log 9 Last
↑
SCROLL
↓
Hydr 123457- 2 # 1 Press * Key
1st 11 Last 11
↑
SCROLL
↓
ECU 111111- 3 # 12 Press * Key
1st 5 Last 9

2200 SRM 1130 Set Travel and Braking
Set Travel and Braking

Upon entering the Set Travel and Braking menu, the truck speed limit. Speed may be set from a minimum
following menu functions are visible to the supervi- of 6 km/h (4 mph) up to the maximum allowed for the
sor: lift truck model being adjusted. The speed may be set
• Speed Limit in 1 km/h (0.5 mph) increments up to a maximum
• Acceleration Rate speed of 24 km/h (15 mph). Setting the speed limit
• Auto-Deceleration Rate higher than the maximum allowed for the lift truck
• Set Power Reversal Rate model being adjusted will cause this function to be
• Set Inching/Brake Overlap deactivated.
Use the scroll keys to move to the desired function From the Set Travel and Braking menu, select Set
and press the * key to select the function. Speed Limit and press the * key. Enter the desired
limit for maximum truck speed or use the scroll keys
SPEED LIMIT to select Speed Limit Off. See Table 16. Press the *
key to save your selection and access the Exit Options
If the lift truck is configured for optional speed limit, menu.
this function can be used to adjust or deactivate the
Table 16. Speed Limit Menu
Select Maximum Speed from

Main Menu Set Travel & Braking Set Speed Limit
Set Travel & Braking Press * Key Set Speed Limit Press * Key Speed Limit Off
Menu or Turn the Speed Limit
Off and Press * Key to Exit
↑
SCROLL
↓
Set Speed Limit

Max Speed 15.0 mph
↑
SCROLL
↓
Set Speed Limit

Max Speed 4.0 mph

Set Travel and Braking 2200 SRM 1130
ACCELERATION RATE lower than 10 will result in a slower rate of accelera-

tion.
If the lift truck is configured for optional DuraMatch
Plus or DuraMatch Plus2 transmissions, this func- From the Travel and Braking menu, select Set Accel-
tion can be used to adjust the travel rate of accelera- eration and press the * key. See Table 17. Select a
tion. The rate of acceleration can be adjusted using number from 1 to 10 and press the * key to save your
a scale of 1 to 10. Using a setting of 10 will result selection and access the Exit Options menu.
in the fastest rate of acceleration. Using a number
Table 17. Acceleration Rate Menu
Main Menu Set Travel & Braking

Set Travel & Braking Press * Key Set Speed Limit
↑
SCROLL
↓
Set Travel & Braking Set Acceleration Rate from 1

Set Acceleration Press * Key Set Acceleration 10
*
to 10 and Press Key to Exit
↑
SCROLL
↓
Set Acceleration 1

AUTO-DECELERATION RATE of deceleration. Using a number lower than 10 will

result in a slower rate of deceleration.
Plus or DuraMatch Plus2 transmissions, this func- From the Travel and Braking menu, select Set Auto-
tion can be used to adjust the travel rate of decelera- Decel and press the * key. See Table 18. Select a
tion when the accelerator pedal is released. The rate number from 1 to 10 and press the * key to save your
of deceleration can be adjusted using a scale of 1 to selection and access the Exit Options menu.
10. Using a setting of 10 will result in the fastest rate
Table 18. Auto-Decel Menu

↑
SCROLL
↓
Set Travel & Braking Set Auto-Decel Rate from 1 to

Set Auto-Decel Press * Key Set Auto-Decel 10
*
10 and Press Key to Exit
↑
SCROLL
↓
Set Auto-Decel 1

SET POWER REVERSAL RATE will result in the fastest rate of deceleration. Using
a number lower than 10 will result in a slower rate
If the lift truck is configured for optional DuraMatch of deceleration.
Plus or DuraMatch Plus2 transmissions, this func-
tion can be used to adjust the travel rate of deceler- From the Travel and Braking menu, select Power Re-
ation when the truck is required to reverse direction versal and press the * key. See Table 19. Select a
while traveling. The rate of deceleration can be ad- number from 1 to 10 and press the * key to save your
justed using a scale of 1 to 10. Using a setting of 10 selection and access the Exit Options menu.
Table 19. Power Reversal Menu

↑
SCROLL
↓
Set Power Reversal Rate

Set Travel & Braking
Press * Key Set Power Reversal 10 from 1 to 10 and
Set Power Reversal
*
Press Key to Exit
↑
SCROLL
↓
Set Power Reversal 1

SET INCHING/BRAKE OVERLAP can be adjusted using a scale of 1 to 10. Using a set-
ting of 10 will result in the most overlap. Using a
This function is available on lift trucks equipped with setting of 1 will result in the transmission being de-
a two speed Basic Powershift transmission shown be- coupled before brake system pressure begins to rise
low (no overlap).
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, Typically, overlap will be set low if high rpm hy-
H40FTS) (F001) draulic operation is required at low travel speeds.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) High overlap is typically used to hold the lift truck
• H2.0-3.5FT (H40-70FT) (L177) in position at low travel speed when operating on
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, uneven or sloped terrain.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT From the Travel and Braking menu, select Set Inch/
(H80, 90, 100, 110, 120FT) (N005, P005, R005) Brk Overlap and press the * key. See Table 20. Select
Use this function to change the amount of overlap be- a number from 1 to 10 and press the * key to save
tween the brake and the transmission. The overlap your selection and access the Exit Options menu.
Table 20. Inch/Brake Overlap Menu

↑
SCROLL
↓
Set Inch/Brake Overlap

Press * Key Set Inch/Brk Overlap 10 from 1 to 10 and
Set Inch/Brk Overlap
*
Press Key to Exit
↑
SCROLL
↓
Set Inch/Brk Overlap 1

Setup Display Menu 2200 SRM 1130
Setup Display Menu

SET OPERATOR LANGUAGE Wait for the dash display to reset and display the new
operator language.
This function allows the supervisor to select the lan-
guage to be used to display information on the dash Select the language desired by using the scroll keys.
display. See Table 21. After making your selection, press the
NOTE: When changing languages, it may be neces-

* key to access the Exit Options menu and choose
the appropriate action.
sary for the dash display to reset to the new language.
This process may take several seconds to complete.
Table 21. Set Language Menu
Main Menu Select Language from

Setup Display Set Oper Language
Setup Press * Key Set Oper Language Press * Key English
Available Options and
Display Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Setup Display Set Oper Language
Back 1 Level Spanish
↑
SCROLL
↓
Set Oper Language
Italian
↑
SCROLL
↓
Set Oper Language
German
↑
SCROLL
↓
Set Oper Language
French
↑
SCROLL
↓
Set Oper Language
Optional

2200 SRM 1130 Setup Display Menu
SET UNITS Use the scroll keys to select between SI/Metric units
or Imperial/English units. See Table 22. After mak-
This function allows the supervisor to select the units ing your selection, press the * key to access the Exit
used to display information on the dash display. Options menu and choose the appropriate action.
Table 22. Set Units Menu
Main Menu Setup Display Set Units (SI/Imp) Select Units and
Setup Display Press * Key Set Units (SI/Imp) Press * Key Units - Imperial (Eng) Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Setup Display Set Units (SI/Imp)
Back 1 Level Units - SI (Metric)

SET TIME FORMAT (12/24 HOUR) your selection, press the * key to access the Exit Op-
tions menu and choose the appropriate action.
This function allows the supervisor to select the for-
mat used by the dash display.
Using the scroll keys, select between a 12-hour for-

mat or a 24-hour format. See Table 23. After making
Table 23. Set Time Format Menu
Main Menu Setup Display Set Time 12/24 Hr Select Time Format and
Setup Display Press * Key Set Time 12/24 Hr Press * Key Set Time 12 Hr Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Setup Display Set Time 12/24 Hr
Back 1 Level Set Time 24 Hr

SET DAYLIGHT SAVING TIME is to start. See Table 24. Press the * key again, select
the day of the month daylight saving time is to start
This function allows the supervisor to enable or dis-
and press the * key.
able the use of daylight saving time on the dash dis-
play. When daylight saving time is enabled, the su-
Scroll to Daylight Save End, press the * key and se-
pervisor can select the month and day daylight sav-
lect the number of the month daylight saving time is
ing time will start and the month and day daylight
saving time will end. to end. Press the * key again, select the day of the
month daylight saving time is to end and press the *
To enable daylight saving time, select Daylight Save key to access the exit menu selections.
On and press the * key.
NOTE: You have the option of specifying either the
Scroll to Daylight Save Start, press the * key, and date or the day of the week to start or stop daylight
select the number of the month daylight saving time saving time. See the menu options.
Table 24. Set Daylight Saving Time Menu
Set
Setup Daylight
Main Daylight Select On or
Menu
Press * Display
Set Press * Saving
Press * Save
On/Off Off and
Setup
Display
Key Daylight
Saving
Key
Daylight
Save
Key Daylight
Save On
Press * Key
On/Off
↑ ↑
SCROLL SCROLL
↓ ↓
Daylight
Setup
↑ Save
Display
SCROLL On/Off
Back One
↓ Daylight
Level
Save Off
Select Daylight
Set Select the Day
Saving Start
of the Month
Daylight
Saving Press * Daylight
Save Start
Month from
Available
Daylight
Save Start from Available
Selections and
Daylight Key Month 12 Day 31
Save Start
Selections and
Press * Key Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Daylight Daylight
Save Start Save Start
Month 01 Day 01
↑
SCROLL
↓
Daylight Daylight Save Select the Day of the Week

Save Start
Day Last
Press * Key Start
Last Su
from Available Selections
and Press * Key
↑
SCROLL
↓
Daylight Save
Start
Last Sa
↑ ↑
SCROLL SCROLL
↓ ↓

Table 24. Set Daylight Saving Time Menu (Continued)

Save Start
Day 1st
Press * Key Start
1st Su
and Press * Key
↑
SCROLL
↓
Daylight Save
Start
1st Sa
Select Daylight
Set Select the Day
Saving End
of the Month
Daylight
Saving Press * Daylight
Save End
Month from
Available
Daylight
Save End from Available
Selections and
Daylight Key Month 12 Day 31
Save End
Selections and
Press * Key Press * Key
↑ ↑ ↑
↓ ↓ ↓
Set
Daylight Daylight Daylight
Saving Save End Save End
Back One Month 01 Day 01
Level
↑
SCROLL
↓

Save End
Day Last
Press * Key End
Last Su
and Press * Key
↑
SCROLL
↓
Daylight Save
End
Last Sa
↑
SCROLL
↓

Save End
Day 1st
Press * Key End
1st Su
and Press * Key
↑
SCROLL
↓
Daylight Save
End
1st Sa

SET TIME changed. See Table 25. Move from segment to seg-
ment by pressing the * key. When finished, press the
This function allows the supervisor to set the time on
the on-board clock.
* key to access the Exit Options menu and choose the
appropriate action.
After entering the Set Time menu, a flashing cur-
sor will appear over the time segment that can be
Table 25. Set Time Menu
Main Menu Setup Display Set Time Change Hours Set Time Change Minutes Set Time Change am/pm
Setup Display Press * Key Set Time Press * Key *
Set Time XX:XX pm and Press Key Set Time XX:XX pm and Press * Key Set Time XX:XX pm and Press * Key

SET DATE FORMAT After entering the Set Date Format menu, use the
scroll keys to select from the three options. See Ta-
This function allows the supervisor to select the for- ble 26. When finished, press the * key to access the
mat for displaying the date on the dash display. Exit Options menu and choose the appropriate ac-
tion.
Table 26. Set Date Format Menu
Main Menu Setup Display Set Date Format Make Selection and
Setup Display Press * Key Set Date Format Press * Key Set Date mm/dd/yyyy Press * Key
↑ ↑
SCROLL SCROLL
↓ ↓
Setup Display Set Date Format
Back 1 Level Set Date dd/mm/yyyy
↑
SCROLL
↓
Set Date Format
Set Date yyyy/mm/dd

SET DATE changed. See Table 27. Move from segment to seg-
ment using the * key. When finished, press the *
This function is used to set the date used by the key to access the Exit Options menu and choose the
on-board clock in the dash display. appropriate action.
After entering the Set Date menu, a flashing cur-
sor will appear over the date segment that can be
Table 27. Set Date Menu
Main Menu Setup Display Set Date Set Month and Set Date Set Day and Set Date Set Year and
Setup Display Press * Key Set Date Press * Key Set Date 08/02/2004 Press * Key Set Date 08/02/2004 Press * Key *
Set Date 08/02/2004 Press Key
↑
SCROLL
↓
Setup Display
Back 1 Level

Setup Hydraulics 2200 SRM 1130
Setup Hydraulics
RETURN TO SET TILT DELAY/ON/OFF will cause tilt to stop and hold at the set point un-
til the function is returned to neutral or the override
If the lift truck is configured for optional return to button is pressed.
set tilt, this function can be used to set the time de-
lay before allowing tilt to resume. This function is From the Setup Hydraulics menu, select Tilt Set-
adjusted by selecting a time period from the menu Point Delay and press the * key. See Table 28. Us-
selection. The function can be set to delay from 0.1 ing the scroll keys, select the desired setting from
sec. to 3.0 sec. The function can also be deactivated the menu selections. When finished, press the * key
using the OFF setting. Using the continuous setting to save your selection and access the Exit Options
menu.
Table 28. Tilt Delay Menu
Main Menu Setup Hydraulics

Setup Hydraulics Press * Key Lift Max Speed
↑
SCROLL
↓
Set Tilt Set Point Delay

from 0.1 sec to 3.0
Setup Hydraulics Tilt Set Point Delay
Tilt Set Point Delay Press * Key Continuous
sec or Select OFF or
Continuous and Press
* Key to Exit
↑
SCROLL
↓
Tilt Set Point Delay 3.0 sec
↑
SCROLL
↓
↑
SCROLL
↓
Tilt Set Point Delay

Tilt Set Point Off

2200 SRM 1130 Setup General Items
Setup General Items

Upon entering the Setup General Items Menu from LIGHT SHUTDOWN TIME-OUT
the Main Menu, the following menu functions are vis-
ible to the supervisor: If the lift truck is equipped with optional work lights,
• Light Shutdown Time-Out this function can be used to time-delay or turn off the
• Impact Sensor - Enable/Disable work lights when system power has been turned off.
• Impact Sensor - Soft Impact Settings This function may be adjusted by entering a delay of
• Impact Sensor - Hard Impact Settings 1 to 10 minutes using the menu selections. The delay
• Adjust Impact Sensor Settings function may also be deactivated from the menu.
• Impact Sensor Alarm/Shutdown Reset
From the Setup General Items menu, select Light
• Impact Sensor - Alarm Time Duration and Deacti-
Shutdown Time and press the * key. Using the scroll
vation
keys, select the desired time delay or deactivate the
• Impact Sensor - View Impact Event Log
function. See Table 29. Press the * key to save your
• Economy Mode Indication (ECO-eLo)
selection and access the Exit Options menu.
Use the scroll keys to move to the desired function
and press the * key to select the function.
Table 29. Light Time-Out Menu
Main Menu Setup General Items

Setup General Items Press * Key Alarm Type
↑
SCROLL
↓
Select the Light

Shutdown Interval
from 1 to 10 min.
Setup General Items Light Shutdown Time
Light Shutdown Time Press * Key 10 Minutes
from the Menu
or Deactivate the
Function and Press *
Key to Exit
↑
SCROLL
↓
Light Shutdown Time

1 Minute
↑
SCROLL
↓
Light Shutdown Time

Item Deactivated

Setup General Items 2200 SRM 1130
IMPACT SENSOR - ENABLE/DISABLE

This function will allow the supervisor to enable or
disable the optional impact sensor. See Table 30.
Table 30. Impact Sensor Enable/Disable
Main Menu Press * Setup General Items

Setup General Items Key
↑
SCROLL
↓
Setup General Items Press * Impact Sensor Press * Enable/Disable Press *

Impact Sensor Key Enable/Disabled Key Activated Key
↑
SCROLL
↓
Enable/Disable
Deactivated

IMPACT SENSOR - SOFT IMPACT If your lift truck is configured for optional impact
SETTINGS sensor, this function allows the supervisor to set the
impact level and averaging time for soft (minor) im-
NOTE: The information in the following paragraphs pacts. See Table 34 for the recommended impact sen-
describe how to navigate through the Setup Menu sor settings by truck capacity and tire type.
and enter the data parameters for soft impacts. For
information on the recommended starting values for After entering the Impact Sensor Soft Impact Set-
the impact sensor settings based on truck capacity tings menu, select the Soft Threshold Set menu and
and tire type and for procedures on how to adjust press the * key. See Table 31. Select the impact level
these values, see Adjust Impact Sensor Settings. from the selections listed and press the * key.
Lift trucks equipped with the optional impact sensor, Scroll to the Soft Averaging Time menu and press the
leave the factory with the sensor deactivated and set * key. Select the averaging time for the selections
with default values (see Table 33). The impact sensor listed and press the * key. If you are finished making
is equipped with an accelerometer that measures the changes, scroll to the Exit Options menu and choose
rate and time of truck deceleration continuously and the appropriate action.
monitors how strong the deceleration is and how long
it lasts.
Table 31. Soft Impact Settings Menu
Main Menu
Setup General Items
Press * Setup General Items
Key
↑ Scroll ↓
Select Impact
Setup General Items Press * Impact Sensor Press * Soft Impact Settings Press * Soft Threshold Set Level and
Impact Sensor Key Soft Impact Settings Key Soft Threshold Set Key 2.5 g
Press * Key
↑ Scroll ↓
Soft Threshold Set

↑ Scroll ↓
0.2 g
↑ Scroll ↓
Select Time
Soft Impact Settings
Soft Averaging Time
Press * Soft Averaging Time
12 and Press *
Key Key
↑ Scroll ↓
Soft Averaging Time

1

IMPACT SENSOR - HARD IMPACT impact level and averaging time for soft (minor) im-
SETTINGS pacts. See Table 34 for the recommended impact sen-
sor settings by truck capacity and tire type.
NOTE: The information in the following paragraphs
describe how to navigate through the Setup Menu If your lift truck is configured for optional impact sen-
and enter the data parameters for hard impacts. For sor, this function allows the supervisor to set the im-
information on the recommended starting values for pact level and averaging time for hard (major) im-
the impact sensor settings based on truck capacity pacts.
and tire type and for procedures on how to adjust
After entering the Impact Sensor Hard Impact Set-
these values, see Adjust Impact Sensor Settings.
tings menu, select the Hard Threshold Set menu and
Lift trucks equipped with the optional impact sensor, press the * key. See Table 32. Select the impact level
leave the factory with the sensor deactivated and set from the selections listed and press the * key.
with default values (see Table 33). The impact sensor
is equipped with an accelerometer that measures the Scroll to the Hard Averaging time menu and press
rate and time of truck deceleration continuously and the * key. Select the averaging time for the selections
monitors how strong the deceleration is and how long listed and press the * key. If you are finished making
it lasts. changes, scroll to the Exit Options menu and choose
If your lift truck is configured for optional impact
sensor, this function allows the supervisor to set the
Table 32. Hard Impact Settings Menu
Main Menu
Setup General Items
Key
↑ Scroll ↓
Select
Impact
Setup General Items Press * Impact Sensor Press * Hard Impact Settings Press * Hard Threshold Set Level and
Impact Sensor Key Hard Impact Settings Key Hard Threshold Set Key 3.0 g
Press *
Key
↑ Scroll ↓
Hard Threshold Set

↑ Scroll ↓
0.5 g
↑ Scroll ↓
Select
Hard Impact Settings
Hard Averaging Time
Press * Hard Averaging Time
2
Time and
Press *
Key
Key
↑ Scroll ↓
Hard Averaging Time

1

ADJUST IMPACT SENSOR SETTINGS • Deceleration during impact at the rate of gravity
(g) = 32ft/sec 2 or 9.8m/sec 2
The supervisor can enable the impact sensor and set The figures in the Soft Averaging and Hard Av-
and adjust the impact levels and averaging times. eraging columns represent the amount of time the
selected deceleration rate of gravity (soft or hard
The information in Table 34 is the recommended
threshold) must be sustained in order for an impact
starting values for impact sensor settings based on
to be recorded.
lift truck capacity and tire type. In Table 33 and
Table 34, the figures in the Soft Threshold and
Hard Threshold columns represent: (see Figure 2)
Table 33. Impact Sensor Default Settings
Soft Threshold Soft Averaging Hard Threshold Hard Averaging

0.5 g 7 0.8 g 1

Figure 2. Soft and Hard Impact Graph

Legend for Figure 2

A. SOFT IMPACT C. POINT AT WHICH IMPACT IS RECORDED AND
B. HARD IMPACT ENGINE SHUTS DOWN
Initial Adjustment of Soft and Hard Impact • Was the operator picking up or setting down a load
Settings • Was the operator bulldozing a load
• Was the operator driving over rough or uneven ter-
NOTE: When adjusting the impact sensor settings, rain
be sure to: • Was the impact a soft or hard one
• Record the truck identification number, capacity,
and tire type If no impacts are recorded during normal operations,
• Record all changes in settings and record all results the adjustment is complete. If impacts are recorded
from changes made during normal operations, go to Readjustment of Soft
and Hard Impact Settings.
It is important to remember if there have been any
increases to the default value difference between the Readjustment of Soft and Hard Impact
soft and hard threshold adjustment. Settings
Enter the starting values shown Table 34 based If the majority of impacts recorded during the initial
on the capacity of the lift truck and the type of adjustment period are soft impacts, change the set-
tires used. Apply the brakes to bring the truck to tings as follows:
an abrupt stop. Read and record the value, from • New soft impact threshold = old soft impact thresh-
the dash display, that was triggered when abruptly old + 0.1 g
stopping the truck. Change the soft threshold to the • New hard impact threshold = new soft impact
next highest setting that is above the value that was threshold + 0.3 g
triggered when the truck was brought to an abrupt
stop. Record this value. If the majority of impacts recorded during the initial
adjustment period are hard impacts, change the set-
To adjust the hard threshold, take the soft threshold tings as follows:
value and add 0.3 g. Record the hard threshold value. • New hard impact threshold = old hard impact
threshold + 0.1 g
Clear the impact event log (see Impact Sensor - View
• New soft impact threshold = no change
Impact Event Log). Let the operator drive the truck
with the initial settings. Be sure to explain to the After making the necessary adjustments, have the
operator that the impact sensor settings are being operator again operate the lift truck under normal
adjusted and to drive the truck under normal con- conditions to ensure that the adjustments are cor-
ditions. If an impact event happens, the following rect.
information must be known:

Table 34. Recommended Starting Values for Impact Sensor Settings by Truck Capacity and Tire Type
Chassis Range Tire Type Soft Soft Hard Hard

Threshold Averaging Threshold Averaging
1-2T Cushion 0.6 g 7 0.9 g 1
1-2T Pneumatic 0.6 g 7 0.9 g 1
2-3T Cushion 0.6 g 7 0.9 g 1
3.5T Cushion 0.5 g 7 0.8 g 1
3.5T Pneumatic 0.5 g 7 0.8 g 1
4-5T Cushion 0.5 g 7 0.8 g 1
5.5T Cushion 0.4 g 7 0.8 g 1
6-7T Cushion 0.4 g 7 0.8 g 1
8T Pneumatic 0.4 g 7 0.8 g 1

IMPACT SENSOR - IMPACT

ALARM/SHUTDOWN RESET
If your lift truck is configured for optional impact sen-
sor, this function allows the supervisor to reset and
return the lift truck to normal operation after an im-
pact sensor shutdown. See Table 35.
Table 35. Shutdown Reset Menu

↑
SCROLL
↓
Setup General Items

Impact Sensor
Press * Impact Sensor
Impact Reset
Press * Impact Reset
Cleared
Press *
Key Key Key

IMPACT SENSOR - ALARM TIME After entering the Impact Sensor Alarm menu, enter
DURATION AND DEACTIVATION the amount of time to sound the alarm. See Table 36.
Enter the time in 15-second increments from zero up
If your lift truck is configured for optional impact to a maximum of 120 seconds. Scrolling down will
sensor, this function allows the supervisor to set the allow you to have the alarm operate continuously af-
amount of time the impact alarm will sound after deter detecting an impact. Press the * key to access
tecting an impact. The supervisor can also make the the Exit Options menu and choose the appropriate
alarm continuous using this function. action.
Table 36. Alarm Duration Menu
Main Menu
Setup General Items
Key
↑
SCROLL
↓
Setup General Items

Impact Sensor
Impact Enable/Disable
Press * Impact Alarm Time
0 Seconds
Press *
Key Key Key
↑ ↑
SCROLL SCROLL
↓ ↓
Impact Sensor
Impact Alarm Press * Impact Alarm Time
120 Seconds
Key
↑
SCROLL
↓
Impact Alarm Time

Continous

IMPACT SENSOR - VIEW IMPACT EVENT After entering the View Impact Event Log menu,
LOG press the * key to enter the log. See Table 37. The
system stores up to 20 log entries. These entries can
If your lift truck is configured for optional impact sen- be viewed by using the scroll keys to move through
sor, this function allows the supervisor to view the log each entry. When finished viewing the log, press the
of the operator password, impact severity, date, and * key, scroll to the Exit Options menu, and choose
time an impact event was recorded. the appropriate action.
Table 37. View Event Log Menu
Main Menu
Setup General Items
Key
↑
SCROLL
↓
XXXXX
(Operator
Impact Sensor
Setup General Items
Impact Sensor
Press * Impact Enable/ Press * Soft Impact
06/12/06
Password)
XXXXX PM Press *
Key Disable Key (Time Key
Impact
Occurred)
↑ ↑
SCROLL SCROLL
↓ ↓
Impact Sensor
Impact Log Press * Hard Impact
06/12/06
XXXXX
(Operator
Key Password)
XXXXX AM
(Time
Impact
Occurred)

ECONOMY MODE INDICATOR (ECO-ELO) When the ECO-eLo feature is turned ON, the max-
imum engine speed will be limited to a pre-defined
NOTE: Only lift truck models H2.0FT, H2.5FT, value (for example, 2100 rpm) that is specified in
H3.0FT, H3.5FT (L177) and H4.0FT5/FT6, the lift truck’s Configuration Data File (CDF). This
H4.5FTS5, H5.0-5.5FT (P005) can be equipped with pre-defined valve may be different for each engine
the optional ECO-eLo feature. type used by the lift truck models equipped with the
ECO-eLo feature.
If the lift truck is equipped with this feature, this
function can be used to turn the ECO-eLo feature ON From the Setup General Items menu, select ECO-eLo
or OFF. When lift truck power is turned ON, if the and press the * key. Using the scroll keys, select to
ECO-eLo feature has been enabled and activated, the turn the ECO-eLo feature ON or OFF. See Table 38.
dash display will show this feature as being turned Press the * key to save your selection and access the
on for up to five seconds after the engine starts, or Exit Options menu.
until the operator either presses a key or changes the
position of the key switch.
Table 38. ECO-eLo Settings Menu

Setup General Items Press * Key ECO-eLo
↑
SCROLL
↓
ECO-eLo Press * Key to Exit
ON
↑
SCROLL
↓
OFF

2200 SRM 1130 Operator Checklist
Operator Checklist
OPERATOR CHECKLIST OFF-ON MODE there is a negative response to any checklist item.
See Table 39. After making your selection, press the
If your lift truck is configured for optional operator * key to access the Exit Options menu and choose the
checklist, this function can be used to enable or dis- appropriate action.
able the checklist.
Use the scroll keys to select On, On-Stop,or Off. If

you select the On-Stop, the lift truck is disabled if
Table 39. Checklist Off-On Mode Menu
Main Menu
Press * Key
Setup Display
Press * Key
Checklist On/Off Press * Key
Setup Display Checklist On/Off Checklist Off
↑ ↑
SCROLL SCROLL
↓ ↓
Setup Display Checklist On/Off
Back 1 Level Checklist On
↑
SCROLL
↓
Checklist On/Off
Checklist On-Stop

Operator Checklist 2200 SRM 1130
EDIT OPERATOR CHECKLIST or Deactivate for the item you wish to change. See
Table 40. Press the * key again to save your selection
This function allows the supervisor to enable or dis- and return to the Setup Display menu. If finished,
able individual items included in the operator check- select the Exit Option you want and press the * key
list. again.
Use the scroll keys to select the checklist item and
press the * key. Use the scroll keys to select Activate
Table 40. Edit Checklist Menu
Make
Select Any Available
Main Menu Press * Setup Display Press * Edit Checklist
Checklist Item and
Operator Restraint Selection
Setup Display Key Edit Checklist Key Key-Off Checklist
*
Press Key
Item Deactivated and Press
* Key
↑ ↑ ↑
↓ ↓ ↓
Setup Display Edit Checklist Operator Restraint

Back 1 Level Forks & Carriage Item Activated

SET OPERATOR CHECKLIST EXPIRATION After entering the Set Operator Checklist Expiration
menu, enter the number of hours the truck can be
If your lift truck is configured for optional operator operated before requiring the operator to re-enter the
checklist, this function can be used to select how long checklist data. See Table 41. Press the * key and
a completed operator checklist remains in effect be- select between clock hours or engine hours. Press
fore the checklist must be entered again and whether the * key again to access the Exit Options menu and
it is to be measured using clock hours or engine op- choose the appropriate action.
erating hours.
Table 41. Checklist Expiration Menu
Set Hours for

Checklist to be Active
*
and Press Key Select if Hours are Clock
Main Menu Press * Setup Display Press * Checklist Expiration (Available Hour Checklist Expiration Hours or Engine Hours
Setup Display Key Checklist Expiration Key XX hr Clock Options are
between 0 to 60
XX hr Clock
and Press * Key
hours in 2 hour
increments)
↑ ↑ ↑
↓ ↓ ↓
Setup Display Checklist Expiration

Back 1 Level XX hr Engine

VIEW CHECKLIST LOG After entering the View Checklist Log menu, press
the * key to enter the log. See Table 42. The sys-
If your lift truck is configured for optional operator tem stores up to 20 checklist log entries. These en-
checklist, the supervisor can use this function to view tries can be viewed by using the scroll keys to move
the operator password, date, and engine hour read- through each checklist entry. When finished viewing
ing when a checklist was completed. the log, press the * key and return to the previous
menu. If you are finished making changes, scroll to
the Exit Options menu and choose the appropriate
action.
Table 42. View Checklist Log Menu
Scroll to View Log

Main Menu Press * Setup Display Press * Checklist Log XXXXX
Entries and Press *
Setup Display Key Checklist Log Key 06/12/04 engine hrs
Key When Finished
↑ ↑
SCROLL SCROLL
↓ ↓
Setup Display Checklist Log XXXXX
Back 1 Level 06/25/04 engine hrs

CLEAR OPERATOR CHECKLIST LOG See Table 43. Press the * key again to clear the log
and return to the previous menu. If you are finished
If your lift truck is configured for optional operator making changes, scroll to the Exit Options menu
checklist, the supervisor can use this function to clear and choose the appropriate action.
entries from the checklist failure log.
After entering the Clear Operator Checklist Log

menu, press the * key to select the Cleared option.
Table 43. Clear Checklist Log Menu
Main Menu Setup Display Clear Checklist Log Press * Key to

Setup Display Press * Key Clear Checklist Log Press * Key Cleared Clear Log
↑
SCROLL
↓
Setup Display
Back 1 Level

CLEAR OPERATOR CHECKLIST FAULT key again to clear the fault and return to the previ-
ous menu. If you are finished making changes, scroll
If your lift truck is configured for optional operator to the Exit Options menu and choose the appropriate
checklist, the supervisor can use this function to re- action.
turn a truck to service after the truck was disabled
by a negative response to an operator checklist item.
After entering the Clear Operator Checklist Fault

menu, press the * key. See Table 44. Press the *
Table 44. Clear Checklist Fault Menu
Main Menu Setup Display Clear Checklist Fail Press * Key to

Setup Display Press * Key Clear Checklist Fail Press * Key Cleared Clear Failure Log
↑
SCROLL
↓
Setup Display
Back 1 Level

2200 SRM 1130 Calibrations
Calibrations
This section contains the basic instructions and dash • Set Tilt Stop Point
display menu navigation steps for performing vari- • Calibrate Loaded Weight
ous truck system calibrations. For complete instruc-
tions for performing these calibrations, see Calibra- SET TILT STOP POINT
tion Procedures 8000 SRM 1134.
If the lift truck is equipped with optional return to set
NOTE: Unless otherwise specified, calibration values tilt, this function is used to calibrate that feature.
are not stored in memory until the Save All Changes
menu item has been selected by pressing the * key. From the Calibrations menu, select Set Tilt Stop
All calibrations must be performed after replacing a Point and press the * key. See Table 45. Refer
VSM. to Calibration Procedures 8000 SRM 1134 for
calibration procedures.
Upon entering the Calibrations Menu from the Main
Menu, the following menu functions are visible to the
supervisor:
Table 45. Tilt Stop Point Menu
Main Menu Calibrations

Calibrations Press * Key Lift Valve Output
↑ SCROLL ↓
Calibrations Press * Key With Mast at Press * Key to
Set Tilt Stop Point Press * Key
Desired Stop Point Exit

Calibrations 2200 SRM 1130
CALIBRATE LOADED WEIGHT If the lift truck is equipped with the optional load
weight feature, this function is used to calibrate the
During initial truck setup, a Weigh Point must be system to display the load weight on the dash display.
permanently marked on the mast. The Weight Point
becomes the reference point for weighing loads. The From the Calibrations menu, select the Load Wt Cal-
Weigh Point is to be marked on the mast where the ibration option. See Table 46. Press the * key. Refer
forks are somewhere between 305 to 610 mm (12 to Calibration Procedures 8000 SRM 1134 for cal-
to 24 in.) off the ground, but never more than the ibration procedures.
free-lift height of the forks.
Table 46. Calibrate Loaded Weight
Main Menu
Calibrations
Press * Calibrations
Lift Valve Output
Key
↑ Scroll ↓
Select Correct Load

Calibrations
Loaded Wt Calibration
Press * Load Weight-Set Zero
* With No Load Press * Lift Known Load to
Weighing Height
Press * Scroll to Correct
Weight #### Lbs
Weight from Menu
Selections and Press
Key Press Key Key
* Key to Exit


USER INTERFACE
(SERVICE TECHNICIAN)
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT,
S55FTS ) [F187]; H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS ([S80, 100, 120FT];
S80, 100FTBCS, S120FT; S120FTPRS) [G004, H004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) [N005, P005, R005]; S6.0FT,
S7.0FT (S135FT, S155FT) [D024, E024, F024]; H6.0FT,

PART NO. 1580519 2200 SRM 1131

SAFETY PRECAUTIONS
to remove parts.
unit needs repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ..................................................................................................................................................... 1
Dash Display Menu Access ........................................................................................................................... 1
Menu Navigation ............................................................................................................................................... 2
Main Menu ......................................................................................................................................................... 3
Passwords ........................................................................................................................................................... 3
Adding Passwords.......................................................................................................................................... 3
Hourmeters ........................................................................................................................................................ 5
View Versions ..................................................................................................................................................... 6
VSM Versions................................................................................................................................................. 6
Dash Display Versions................................................................................................................................... 7
Engine Controller Version............................................................................................................................. 8
Transmission (Xmsn) Controller Version ..................................................................................................... 9
Truck Serial Number..................................................................................................................................... 10
Truck Configuration ...................................................................................................................................... 11
Diagnostics ......................................................................................................................................................... 12
Clear Fault Log .............................................................................................................................................. 12
View Fault Log ............................................................................................................................................... 13
No-Run Data Display .................................................................................................................................... 14
Engine Accelerator and Throttle Data Display............................................................................................ 15
Engine Speeds and Governor Data Display ................................................................................................. 16
Engine Fuel and Emissions Data Display.................................................................................................... 17
Engine General Data Display ....................................................................................................................... 19
XMSN/Brake Data Display ........................................................................................................................... 20
Hydraulic Data Display................................................................................................................................. 22
General Truck Data Display ......................................................................................................................... 24
Set Travel and Braking ..................................................................................................................................... 26
Speed Limit .................................................................................................................................................... 26
Acceleration Rate........................................................................................................................................... 27
Auto-Deceleration Rate ................................................................................................................................. 28
Set Power Reversal Rate ............................................................................................................................... 29
Set Inching/Brake Overlap............................................................................................................................ 30
Setup Hydraulics ............................................................................................................................................... 31
Lift Maximum Speed ..................................................................................................................................... 31
Lower Maximum Speed................................................................................................................................. 32
Tilt Maximum Speed ..................................................................................................................................... 33
Auxiliary Function One, Direction A, Maximum Speed.............................................................................. 35
Auxiliary Function One, Direction B, Maximum Speed .............................................................................. 36
Auxiliary Function Two, Direction A, Maximum Speed.............................................................................. 37
Auxiliary Function Two, Direction B, Maximum Speed.............................................................................. 38
Auxiliary Function Three, Direction A, Maximum Speed........................................................................... 39
Auxiliary Function Three, Direction B, Maximum Speed ........................................................................... 40
Lift/Lower Ramp Rate ................................................................................................................................... 41
Hydraulic Auxiliary Ramp Rate ................................................................................................................... 42
Return to Set Tilt Delay/On/Off.................................................................................................................... 43
Hydraulic Input Device ................................................................................................................................. 44
Auxiliary Solenoid ......................................................................................................................................... 45
Dual Function ................................................................................................................................................ 46
Setup Display ..................................................................................................................................................... 47
Set Service Language .................................................................................................................................... 47
Setup General Items .......................................................................................................................................... 48

Table of Contents User Interface

Motion Alarm Activation Type...................................................................................................................... 48
Light Shutdown Time-Out ............................................................................................................................ 49
Restore Default Settings ............................................................................................................................... 50
Restore Engine Controller Default Calibration ........................................................................................... 51
Impact Sensor - Enable/Disable.................................................................................................................... 52
Impact Sensor - Soft Impact Settings........................................................................................................... 53
Impact Sensor - Hard Impact Settings......................................................................................................... 54
Adjust Impact Sensor Settings ..................................................................................................................... 55
Initial Adjustment of Soft and Hard Impact Settings............................................................................. 57
Readjustment of Soft and Hard Impact Settings .................................................................................... 57
Impact Sensor - Impact Alarm/Shutdown Reset.......................................................................................... 59
Impact Sensor - Alarm Time Duration and Deactivation ........................................................................... 60
Impact Sensor - View Impact Event Log ...................................................................................................... 61
Economy Mode Indicator (ECO-eLo) ............................................................................................................ 62
Diesel Particulate Filter (DPF) Display............................................................................................................ 63
General Description....................................................................................................................................... 63
Passive Regeneration Only ........................................................................................................................... 63
Regeneration Level 0................................................................................................................................. 63
Auto/Active Regeneration Inhibited ............................................................................................................. 64
Auto/Active Regeneration ............................................................................................................................. 64
Parked Regeneration Request....................................................................................................................... 64
Warning Level................................................................................................................................................ 65
Service Level .................................................................................................................................................. 65
Stop Level....................................................................................................................................................... 66
Operator Interface ......................................................................................................................................... 66
Refer to Operator Manual......................................................................................................................... 66
CAN Communication Lost ........................................................................................................................ 66
Calibrations........................................................................................................................................................ 67
Calibrate Transmission Valve....................................................................................................................... 69
Set Tilt Stop Point ......................................................................................................................................... 70
Calibrate Loaded Weight............................................................................................................................... 71
Calibrate Travel Speed Sensor ..................................................................................................................... 72
Calibrate Mazda LP and Gas Accelerator Pedal.......................................................................................... 73
ii

S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS ([S80, 100, 120FT];S80, 100FTBCS,
S120FT; S120FTPRS) [G004, H004];
110, 120FT) [N005, P005, R005];
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
DESCRIPTION Legend for Figure 1
This section contains information on accessing the 1. NUMERICAL PASSWORD ENTRY KEY #1
additional service technician functions of the dash 2. NUMERICAL PASSWORD ENTRY KEY #2
3. ENTER KEY
display. With a proper service technician password, 4. NUMERICAL PASSWORD ENTRY KEY #3
the service technician can access menu items not vis- 5. SCROLL DOWN KEY
ible to persons with operator or supervisor password 6. SCROLL UP KEY
level access. 7. NUMERICAL PASSWORD ENTRY KEY #4
8. NUMERICAL PASSWORD ENTRY KEY #5
9. POWER ON KEY (OPTIONAL)
DASH DISPLAY MENU ACCESS
If the operator passwords function is activated, the
When the key is turned to the ON position or the
password screen will be shown at startup. See Ta-
Power On button is pushed, the menu access keys will
ble 1. Enter your five-digit service technician pass-
be activated. See Figure 1.
word using the five number keys on the right-hand
dash display input panel. See Passwords in this sec-
tion. After input of your service password, the screen
will automatically revert to the Main Menu, Pass-
words screen. Use the scroll keys #4 and #5 to scroll
through the main menu. This will enable all dash
display menu options allowed for service technician
password access.
Table 1. Password Screen
Enter Password
XXXXX
If the operator passwords function is not activated or

a non-service technician password has been entered
at the initial passwords screen on the dash display,
the passwords entry screen may be accessed by press-
ing the * key to enter the Main Menu and selecting
Passwords.
Figure 1. Menu Access Keys

Menu Navigation 2200 SRM 1131
Menu Navigation
Upon successful entry of your service technician Any time an optional value is changed within a
password, you will be directed to the Main Menu. menu, pressing the * key will take you to the Exit
Using the scroll keys #4 and #5, scroll through the Menu where you will have the opportunity to return
menu selections until you see the menu selection to the previous menu, exit the menu system without
you want to access. Press the * key to access that saving any changes, or save your changes and exit
selection. the menu system. See Table 2.
The * key allows you to move within menus and is Some menus may contain several optional values
used to make selections within a menu. The #4 and that can be adjusted. It is not necessary to exit the
#5 scroll keys allow you to move up and down within menu after each adjustment and re-enter the menu
a menu. to make multiple changes within a menu. After
making a change to an optional value, use the Back
Each menu (except the Main Menu) will have a Back 1 Level option to re-enter the menu, scroll to the
1 Level option within the menu options at that level. next option to be adjusted, and make the change.
Use the scroll keys #4 and #5 to access this option. After all adjustments have been made, press the *
Press the * key to select this option and return to key to access the Exit Menu and save your changes.
the previous menu.
Table 2. Exit Menu
Main Menu Save All Changes Press * Key to Save

Save and Exit Press * Key and Exit Menu - Yes Changes
↑ ↑
SCROLL SCROLL
↓ ↓
Main Menu Cancel Save Press * Key to Exit and
Exit Without Saving Return to Menu Return to Menu

2200 SRM 1131 Passwords
Main Menu
NOTE: Depending upon how the lift truck is • Passwords
equipped, some of the functions described in this • Diagnostics
section may not be included in the on-board menu • Set Travel and Braking
structure for a particular lift truck. • Setup Hydraulics
• Setup Display
Upon entering the Main Menu from the password en- • Setup General Items
try screen, the following menu functions are visible • Calibrations
to the service technician: • Save and Exit
• Hourmeters • Exit Without Saving
• View Versions
Passwords
Service level password access is required to add, initial Supervisor password is installed, then that
delete, or edit Service Level Passwords and the first password access can add additional Supervisor
installation of a Supervisor level password. Anyone passwords to the dash display.
with Service Level access can add, delete, or edit • The Vehicle System Manager can hold up to 250
Operator or Supervisor passwords using the Dash passwords. This can be in any combination of user,
Display or PC Service tool. supervisor, or service passwords.
The default Service Level password installed at the ADDING PASSWORDS

factory is 55555. Use this password when installing
the lift truck at the customer location to set up cus- After entering the Add Password menu, enter the
tomer passwords in the display. When initial instal- new user’s five-digit password using the number keys
lation is complete, choose a new personal password and press the * key to add the password. See Table 3.
and enter it into the dash display. When you have You will be asked to enter the password type.
entered your personal service technician password in
the dash display, the default password can no longer Select:
be used to access the service technician function of Operator - Allows truck operation.
the dash display. If a Service Technician password is Lockout Reset - Allows person to reset the pass-
lost, the password can be reset using the PC Service word function after password lockout has been en-
Tool. abled.
Supervisor - Same rights as the Service level
Once activated, the service technician password will password except the Supervisor level cannot add,
remain active until the key is turned to the OFF change, or delete Service level passwords.
position and the Password Time-Out function cycles Service Technician - Has all rights allowed for
through the Time Delay setting. The service techni- Operator, Lockout Reset and Supervisor pass-
cian password can also be immediately disabled after words, plus the ability to add, delete, and edit
completing the lift truck service by turning the key Service passwords; view all diagnostic informa-
to the OFF position and then pressing the * key three tion, and adjust all service access parameters
times *,*,*. within the pre-set limits. On trucks equipped
with the hood switch option, a Service password
NOTE: allows truck to be started with hood open.
• The Service Technician must install the first Su-
pervisor password into the dash display. Once an

Passwords 2200 SRM 1131
Table 3. Add Password Menu
Passwords
Enter
Password
↑
Scroll
↓
Main Menu Passwords Enter Password Type Select One
Press * Key Press * Key Press * Key
Passwords Add Password Password Operator Password Type
↑
Scroll
↓
Password Type
Lockout Reset
↑
Scroll
↓
Password Type
Supervisor
↑
Scroll
↓
Password Type
Technician
See the section User Interface, Supervisor 2200

SRM 1130 for other Password Administration infor-
mation and instructions.

2200 SRM 1131 Hourmeters
Hourmeters
This function allows the service technician access to Engine hours accumulate any time the engine is
the various hourmeter readings available on the lift running.
truck. When this menu is accessed, you can view System hours accumulate anytime system power
the engine hours, system hours, and starter hours. is on.
See Table 4. If the lift truck is equipped with op- Hydraulic hours accumulate anytime a powered
tional electro-hydraulics, hydraulic hours will also be hydraulic function is being used.
shown in the menu. The hourmeters are accessible Starter hours accumulate anytime the engine
with the engine running. starter solenoid is activated.
Table 4. Hourmeters Menu
Main Menu Hourmeters When Finished Viewing, Press *

Hourmeters Press * Key Engine Hours XXXXX Key to Return to the Main Menu
↑
SCROLL
↓
Hourmeters
System Hours XXXXX
↑
SCROLL
↓
Hourmeters
Hydraulic Hours XXXXX
↑
SCROLL
↓
Hourmeters
Starter Hours XXXXX
↑
SCROLL
↓
Hourmeters
Back One Level

View Versions
Upon entering the View Versions Menu from the VSM VERSIONS
Main Menu, the following menu functions are visible
to the service technician: This function allows the service technician access to
• Vehicle Systems Manager the hardware, software, and configuration versions
• Dash Display currently installed on the lift truck.
• Engine Controller (if equipped)
From the View Versions menu, select the Vehicle
• Transmission (Xmsn) Controller (if equipped)
System Manager menu and press the * key. Using
• Truck Serial Number
the scroll keys, you can view the hardware, software,
• Truck Configuration
and configuration versions of the vehicle system
Use the scroll keys to move to the desired function manager. See Table 5. Select Back One Level, then
and press the * key to select the function. press the * key to return to the previous menu.
Table 5. View VSM Versions Menu
Main Menu View Versions Vehicle Syst Manager

View Versions Press * Key Vehicle Syst Manager Press * Key Hardware XXXXXXXX
↑
SCROLL
↓
Software XXXXXXXX
↑
SCROLL
↓
Config XXXXXXXX
↑
SCROLL
↓
Back One Level

DASH DISPLAY VERSIONS you can view the hardware, software, and configura-
tion versions of the dash display. See Table 6. Select
This function allows the service technician access to Back One Level, then press the * key to return to the
the hardware, software, and configuration versions previous menu.
of the dash display currently installed on the lift
truck.
From the View Versions menu, select the Dash Dis-

play menu and press the * key. Using the scroll keys,
Table 6. View Dash Display Versions Menu

↑
SCROLL
↓
View Versions Dash Display
Dash Display Press * Key Hardware XXXXXXXX
↑
SCROLL
↓
Dash Display
Software XXXXXXXX
↑
SCROLL
↓
Dash Display
Config XXXXXXXX
↑
SCROLL
↓
Dash Display
Back One Level

ENGINE CONTROLLER VERSION From the View Versions menu, select the Engine
Controller menu and press the * key. Using the
If the lift truck is equipped with the Engine Con- scroll keys, you can view the hardware and software
troller Version, this function will allow the service versions of the engine controller. See Table 7. Select
technician access to the hardware and software ver- Back One Level, then press the * key to return to
sions of the engine controller currently installed on the previous menu.
the lift truck.
Table 7. View Engine Controller Versions Menu
Main Menu Press * View Versions

View Versions Key Vehicle Syst Manager
↑
SCROLL
↓
View Versions Press * Engine Controller
Engine Controller Key Hardware XXXXXXXX
↑
SCROLL
↓
Engine Controller
Software XXXXXXXX
↑
SCROLL
↓
Engine Controller
Back One Level

TRANSMISSION (XMSN) CONTROLLER From the View Versions menu, select the Xmsn Con-
VERSION troller menu and press the * key. Using the scroll
keys, you can view the hardware and software ver-
If the lift truck is equipped with the Transmission sions of the transmission controller. See Table 8. Se-
Controller Version, this function will allow the ser- lect Back One Level, then press the * key to return
vice technician access to the hardware and software to the previous menu.
versions of the optional transmission controller cur-
rently installed on the lift truck.
Table 8. View Transmission Controller Versions Menu

↑
SCROLL
↓
View Versions Xmsn Controller
Xmsn Controller Press * Key Hardware XXXXXXXX
↑
SCROLL
↓
Xmsn Controller
Software XXXXXXXX
↑
SCROLL
↓
Xmsn Controller
Back One Level

TRUCK SERIAL NUMBER truck serial number. See Table 9. Select Back One
Level, then press the * key to return to the previous
This function allows the service technician access to menu.
the truck serial number.
From the View Versions menu, select the Truck Se-

rial Number menu and press the * key to view the
Table 9. View Truck Serial Number Menu

↑
SCROLL
↓
View Versions Truck Serial Number
Truck Serial Number Press * Key XXXXXXXXXXXXXXX
↑
SCROLL
↓
Truck Serial Number
Back One Level

TRUCK CONFIGURATION to view the truck configuration codes. See Table 10.
Press the * key to return to the previous menu.
This function allows the service technician to view
the codes for the truck configuration.
From the View Versions menu, select the Truck Con-

fig menu and press the * key. Use the scroll keys
Table 10. View Truck Configuration Menu

↑
SCROLL
↓
View Versions Truck Config 0 When Finished
Truck Config XXXXXXXXXXXXXXXXX Viewing, Press *
Press * Key Key to Go Back
One Level
↑
SCROLL
↓
Truck Config 1
XXXXXXXXXXXXXXXXX
↑
SCROLL
↓
Truck Config 2
XXXXXXXXXXXXXXXXX

Diagnostics
Upon entering the Diagnostics Menu from the Main For a complete description of the Diagnostic func-
Menu, the following menu functions are visible to the tions accessible through the Dash Display. See the
service technician: Diagnostic Troubleshooting Manual 9000 SRM
• Clear Fault Log 1112.
• View Fault Log
• No-Run Data Display Use the scroll keys to move to the desired function
• Engine Accelerator and Throttle Data Display and press the * key to select the function.
• Engine Speeds and Governor Data Display
• Engine Fuel and Emission Data Display CLEAR FAULT LOG
• Engine General Data Display
This function will allow the service technician to
• XMSN/Brake Data Display
clear all fault log entries from the VSM. See Ta-
• Hydraulic Data Display
ble 11.
• General Truck Data Display
Table 11. Clear Fault Log
Main Menu
Press * Key
Diagnostics
Press * Key
Clear Fault Log Press * Key
Diagnostics Clear Fault Log No?
↑
SCROLL
↓
Clear Fault Log Press * Key
Yes?

2200 SRM 1131 Diagnostics
VIEW FAULT LOG

This function will allow the service technician to view
all faults stored in the VSM. All fault codes will be
displayed with the most recent fault listed first. See
Table 12.
Table 12. View Fault Log

Diagnostics Press * Clear Fault
Key Log
↑
SCROLL
↓
Diagnostics 123456-12
VSM 9
View Fault Press * Key 1st
#
12 Press * Key
Log 9 Last
↑
SCROLL
↓
Hydr 123457- 2 # 1 Press * Key
1st 11 Last 11
↑
SCROLL
↓
ECU 111111- 3 # 12 Press * Key
1st 5 Last 9

NO-RUN DATA DISPLAY or value, press the * key to return to the previous
menu.
inputs or values listed in the menu when the engine NOTE: Depending on how an individual lift truck is
is not running. Use the scroll keys to move to the de- equipped, some functions shown in the menu may not
sired function and press the * key to select the func- be available for viewing.
tion. See Table 13. When finished viewing an input
Table 13. No-Run Data Display

Diagnostics Press * Key Clear Fault Log
↑ Scroll ↓
Diagnostics No-Run Data Display Accelerator Pedal A

No-Run Data Display Press * Key Accelerator Pedal A Press * Key Volts Press * Key
↑ Scroll ↓
No-Run Data Display Accelerator Pedal B

Accelerator Pedal B Press * Key Volts Press * Key
↑ Scroll ↓
No-Run Data Display Throttle Position A

Throttle Position A Press * Key Volts Press * Key
↑ Scroll ↓
No-Run Data Display Throttle Position B

Throttle Position B Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
No-Run Data Display Hyd Lift/Lower Input

Hyd Lift/Lower Input Press * Key XX% Press * Key
↑ Scroll ↓
No-Run Data Display Hydraulic Tilt Input

Hydraulic Tilt Input Press * Key XX% Press * Key
↑ Scroll ↓
No-Run Data Display Hydraulic Aux 1 Input

Hydraulic Aux 1 Input Press * Key XX% Press * Key
↑ Scroll ↓
No-Run Data Display Hydraulic Aux 2 Input


ENGINE ACCELERATOR AND THROTTLE Table 14. When finished viewing an input or value,
DATA DISPLAY press the * key to return to the previous menu.
This function will allow the service technician to view NOTE: Depending on how an individual lift truck is
all inputs and other values associated with the accel- equipped, some functions shown in the menu may not
erator and throttle sensors while the engine is oper- be available for viewing.
ating. Use the scroll keys to move to the desired func-
tion and press the * key to select the function. See
Table 14. Engine Accelerator and Throttle Data Display

↑ Scroll ↓
Diagnostics Engine Accel & Throt Accelerator Pedal A

Engine Accel & Throt Press * Key Accelerator Pedal A Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
Engine Accel & Throt Accelerator Pedal B

Accelerator Pedal B Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
Engine Accel & Throt Accelerator Pedal %

Accelerator Pedal % Press * Key XX% Press * Key
↑ Scroll ↓
Engine Accel & Throt Throttle Position A

Throttle Position A Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
Engine Accel & Throt Throttle Position B

Throttle Position B Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
Engine Accel & Throt Accelerator Pedal %

Accelerator Pedal % Press * Key XX% Press * Key
↑ Scroll ↓
Engine Accel & Throt Cable-Actuated TPS

Cable-Actuated TPS Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
Engine Accel & Throt Gasoline ECU TPS

Gasoline ECU TPS Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
Engine Accel & Throt Throt Sens Supply A

Throt Sens Supply A Press * Key XXXXX Volts Press * Key
↑ Scroll ↓
Engine Accel & Throt Throt Sens Supply B

Throt Sens Supply B Press * Key XXXXX Volts Press * Key

ENGINE SPEEDS AND GOVERNOR DATA to select the function. See Table 15. When finished
DISPLAY viewing an input or value, press the * key to return
to the previous menu.
This function will allow the service technician to
view all inputs and other values associated with the NOTE: Depending on how an individual lift truck is
speeds and governing of the engine control system equipped, some functions shown in the menu may not
while the engine is operating. Use the scroll keys be available for viewing.
to move to the desired function and press the * key
Table 15. Engine Speeds and Governor Data Display
Main Menu
Diagnostics
Press * Diagnostics
Clear Fault Log
Key
↑ Scroll ↓
Diagnostics
Engine Speeds & Gov
Press * Engine Speeds & Gov
Engine Speed (RPM) Press * Key Engine Speed (RPM)
XXXX RPM Press * Key
Key
↑ Scroll ↓
Engine Speeds & Gov Gasoline ECU Speed

Gasoline ECU Speed Press * Key XXXX RPM Press * Key
↑ Scroll ↓
Engine Speeds & Gov Requested Speed

Requested Speed Press * Key XXXX RPM Press * Key
↑ Scroll ↓
Engine Speeds & Gov Target Idle Speed

Target Idle Speed Press * Key XXXX RPM Press * Key
↑ Scroll ↓
Engine Speeds & Gov Governed Speed

Governed Speed Press * Key XXXX RPM Press * Key
↑ Scroll ↓
Engine Speeds & Gov Governing Status

Governing Status Press * Key XX Press * Key
↑ Scroll ↓
Engine Speeds & Gov Torque Mode

Torque Mode Press * Key XX Press * Key
↑ Scroll ↓
Engine Speeds & Gov Actual Engine Torque

Actual Engine Torque Press * Key XX% Press * Key
↑ Scroll ↓
Engine Speeds & Gov Requested Torque

Requested Torque Press * Key XX% Press * Key

ENGINE FUEL AND EMISSIONS DATA or value, press the * key to return to the previous
DISPLAY menu.
This function will allow the service technician to view NOTE: Depending on how an individual lift truck is
inputs and other values associated with the engine equipped, some functions shown in the menu may not
fuel and emissions control system while the engine be available for viewing.
is operating. Use the scroll keys to move to the de-
sired function and press the * key to select the func-
tion. See Table 16. When finished viewing an input
Table 16. Engine Fuel and Emissions Data Display
Main Menu
Diagnostics Press * Diagnostics
Clear Fault Log
Key
↑ Scroll ↓
Diagnostics
Engine Fuel & Emissn Press * Engine Fuel & Emissn
Actual Ign Timing Press * Actual Ign Timing
XX Press * Key
Key Key
↑ Scroll ↓
Engine Fuel & Emissn

Desired Ign Timing Press * Desired Ign Timing
XX Press * Key
Key
↑ Scroll ↓

Inlet Air Temp Press * Inlet Air Temp
XXX F Press * Key
Key
↑ Scroll ↓

Manifold Abs Press Press * Manifold Abs Press
X PSI Press * Key
Key
↑ Scroll ↓

Fuel Pump Status Press * Fuel Pump Status
X Press * Key
Key
↑ Scroll ↓

Fuel Ctrl Status Sn1 Press * Fuel Ctrl Status Sn1
X Press * Key
Key
↑ Scroll ↓

Fuel Ctrl Status Sn2 Press * Fuel Ctrl Status Sn2
X Press * Key
Key
↑ Scroll ↓

Table 16. Engine Fuel and Emissions Data Display (Continued)

Short Term FuelTrim1 Press * Short Term FuelTrim1
XX% Press * Key
Key
↑ Scroll ↓

Short Term FuelTrim2 Press * Short Term FuelTrim2
XX% Press * Key
Key
↑ Scroll ↓

Long Term Fuel Trim Press * Long Term Fuel Trim
XX% Press * Key
Key
↑ Scroll ↓

Oxygen Sensor 1 Volt Press * Oxygen Sensor 1 Volt
XXXX Volts Press * Key
Key
↑ Scroll ↓

Oxygen Sensor 2 Volt Press * Oxygen Sensor 2 Volt
Key
↑ Scroll ↓

O2 Sensor1 Heat Duty Press * O2 Sensor1 Heat Duty
XX% Press * Key
Key
↑ Scroll ↓

O2 Sensor2 Heat Duty Press * O2 Sensor2 Heat Duty
XX% Press * Key
Key
↑ Scroll ↓

Idle Air Ctrl Valve Press * Idle Air Ctrl Valve
XX% Press * Key
Key
↑ Scroll ↓

Test Mode Status Press * Test Mode Status
X Press * Key
Key

ENGINE GENERAL DATA DISPLAY NOTE: Depending on how an individual lift truck is
equipped, some functions shown in the menu may not
This function allows the service technician to view be available for viewing.
inputs and other values associated with the general
engine control system while the engine is operating.
Use the scroll keys to move to the desired function
and press the * key to select the function. See Ta-
ble 17. When finished viewing an input or value,
press the * key to return to the previous menu.
Table 17. Engine General Data Display

↑ Scroll ↓
Diagnostics Engine General Data Engine Coolant Temp

Engine General Data Press * Key Engine Coolant Temp Press * Key XXX F Press * Key
↑ Scroll ↓
Engine General Data Coolant Temp - ECU

Coolant Temp - ECU Press * Key XXX F Press * Key
↑ Scroll ↓
Engine General Data Engine Oil Pressure

Engine Oil Pressure Press * Key XX PSI Press * Key
↑ Scroll ↓
Engine General Data XXXXXXXXXXXXXXX

Engine Starter Output Press * Key XXX Press * Key
↑ Scroll ↓
Engine General Data ECU Battery Voltage

ECU Battery Voltage Press * Key XXXX Volts Press * Key
↑ Scroll ↓
Engine General Data ECU Ignition Voltage

ECU Ignition Voltage Press * Key XXXX Volts Press * Key
↑ Scroll ↓
Engine General Data Malfunction Light

Malfunction Light Press * Key X Press * Key
↑ Scroll ↓
Engine General Data ECU Make

ECU Make Press * Key XXX Press * Key
↑ Scroll ↓
Engine General Data ECU Model

ECU Model Press * Key XXX Press * Key

XMSN/BRAKE DATA DISPLAY viewing an input or value, press the * key to return
to the previous menu.
inputs from the Transmission and Braking systems NOTE: Depending on how an individual lift truck is
while the engine is running. Use the scroll keys to equipped, some functions shown in the menu may not
move to the desired function and press the * key to be available for viewing.
select the function. See Table 18. When finished
Table 18. XMSN Brake Data Display
Main Menu
Diagnostics Press * Key Diagnostics
Fault Logs
↑ Scroll ↓
Diagnostics
XMSN/Brake Data Disp Press * Key XMSN/Brake Data Display
Forward Switch Press * Key Forward Switch
Switch XXXXXX Press * Key
↑ Scroll ↓
XMSN/Brake Data Display

Reverse Switch Press * Key Reverse Switch
Switch XXXXXX Press * Key
↑ Scroll ↓

Brake Pressure Press * Key Brake Pressure
XXX psi Press * Key
↑ Scroll ↓

Parking Brake Sensor Press * Key Parking Brake Sensor
↑ Scroll ↓

Inch/Brake Position Press * Key Inch/Brake Position
↑ Scroll ↓

Brake Fluid Level Press * Key Brake Fluid Level
Switch Open Press * Key
↑ Scroll ↓

Xmsn Input Speed Press * Key Xmsn Input Speed
↑ Scroll ↓

Xmsn Output Speed Press * Key Xmsn Output Speed
↑ Scroll ↓

Xmsn Forward 1 Pressure Press * Key Xmsn Forward 1 Pressure
XXX psi Press * Key
↑ Scroll ↓

Xmsn Forward 2 Pressure Press * Key Xmsn Forward 2 Pressure
XXX psi Press * Key
↑ Scroll ↓

Table 18. XMSN Brake Data Display (Continued)

Xmsn Reverse Pressure Press * Key Xmsn Reverse Pressure
XXX psi Press * Key
↑ Scroll ↓

Xmsn Oil Temp Press * Key Xmsn Oil Temp
XXX∞F Press * Key
↑ Scroll ↓

Xmsn Forward 1 Valve Press * Key Xmsn Forward 1 Valve
XXX Amps Press * Key
↑ Scroll ↓

Xmsn Forward 2 Valve Press * Key Xmsn Forward 2 Valve
↑ Scroll ↓

Xmsn Reverse Valve Press * Key Xmsn Reverse Valve
↑ Scroll ↓

Travel Speed Sensor Press * Key Travel Speed Sensor
Speed XX MPH Press * Key

HYDRAULIC DATA DISPLAY an input or value, press the * key to return to the
previous menu.
inputs and values from the hydraulic system while NOTE: Depending on how an individual lift truck is
the engine is running. Use the scroll keys to move equipped, some functions shown in the menu may not
to the desired function and press the * key to select be available for viewing.
the function. See Table 19. When finished viewing
Table 19. Hydraulic Data Display

Diagnostics Press * Key Fault Logs
↑ Scroll ↓
Diagnostics Hydraulic Data Display Lift Height Sensor

Hydraulic Data Display Press * Key Lift Height Sensor Press * Key XXXX Volts Press * Key
↑ Scroll ↓
Hydraulic Data Display Tilt Stop Sensor

Tilt Stop Sensor Press * Key XXXX Volts Press * Key
↑ Scroll ↓
Hydraulic Data Display Lift Valve Output

Lift Valve Output Press * Key XXXX Amps Press * Key
↑ Scroll ↓
Hydraulic Data Display Lower Valve Output

Lower Valve Output Press * Key XXXX Amps Press * Key
↑ Scroll ↓
Hydraulic Data Display Tilt Fw Valve Output

Tilt Fw Valve Output Press * Key XXXX Amps Press * Key
↑ Scroll ↓
Hydraulic Data Display Tilt Bk Valve Output

Tilt Bk Valve Output Press * Key XXXX Amps Press * Key
↑ Scroll ↓
Hydraulic Data Display Aux 1 Output Dir A

Aux 1 Output Dir A Press * Key XXXX Amps Press * Key
↑ Scroll ↓
Hydraulic Data Display Aux 1 Output Dir B

Aux 1 Output Dir B Press * Key XXXX Amps Press * Key
↑ Scroll ↓

↑ Scroll ↓

↑ Scroll ↓

↑ Scroll ↓

Table 19. Hydraulic Data Display (Continued)

↑ Scroll ↓
Hydraulic Data Display Manual Interlock Out

Manual Interlock Out Press * Key XXXXXXXXXX Press * Key
↑ Scroll ↓
Hydraulic Data Display Hyd Lift/Lower Input

Hyd Lift/Lower Input Press * Key XX% Press * Key
↑ Scroll ↓
Hydraulic Data Display Hydraulic Tilt Input

Hydraulic Tilt Input Press * Key XX% Press * Key
↑ Scroll ↓
Hydraulic Data Display Hydraulic Aux 1 Input

↑ Scroll ↓
Hydraulic Data Display Hydraulic Aux 2 Input

↑ Scroll ↓
Hydraulic Data Display Hydraulic Lift Pressure

Hydraulic Lift Pressure Press * Key XXXX psi Press * Key
↑ Scroll ↓
Hydraulic Data Display Hydraulic Filter

Hydraulic Filter Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓
Hydraulic Data Display Hyd Funct Switch 1

Hyd Funct Switch 1 Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓

↑ Scroll ↓

↑ Scroll ↓

↑ Scroll ↓
Hydraulic Data Display Armrest-Down Switch

Armrest-Down Switch Press * Key Switch XXXXXXX Press * Key

GENERAL TRUCK DATA DISPLAY finished viewing an input or value, press the * key
to return to the previous menu.
inputs and values associated with the general lift NOTE: Depending on how an individual lift truck is
truck operation while the engine is running. Use the equipped, some functions shown in the menu may not
scroll keys to move to the desired function and press be available for viewing.
the * key to select the function. See Table 20. When
Table 20. General Truck Data Display

Diagnostics Press * Key Fault Logs
↑ Scroll ↓
Diagnostics General Data Display Truck Voltage

General Data Display Press * Key Truck Voltage Press * Key XXXX Volts Press * Key
↑ Scroll ↓
General Data Display Engine Cover Switch

Engine Cover Switch Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓
General Data Display Seat Sensor

Seat Sensor Press * Key XXXX Volts Press * Key
↑ Scroll ↓
General Data Display Fuel Level Sensor

Fuel Level Sensor Press * Key XXXX Volts Press * Key
↑ Scroll ↓
General Data Display "1" Button

"1" Button Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓

↑ Scroll ↓

↑ Scroll ↓
General Data Display Front Wiper Button

Front Wiper Button Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓
General Data Display Rear Wiper Button

Rear Wiper Button Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓
General Data Display Washer Button

Washer Button Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓
General Data Display Left Turn Signal

Left Turn Signal Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓

Table 20. General Truck Data Display (Continued)
General Data Display Right Turn Signal

Right Turn Signal Press * Key Switch XXXXXX Press * Key
↑ Scroll ↓
General Data Display Accelerometer X-axis

Accelerometer X-axis Press * Key XXXX Volts Press * Key
↑ Scroll ↓
General Data Display Accelerometer Y-axis

Accelerometer Y-axis Press * Key XXXX Volts Press * Key
↑ Scroll ↓
General Data Display Steering Wheel Sensor

Steering Wheel Sensor Press * Key XX Volts Press * Key
↑ Scroll ↓
General Data Display Steer Tire < Sensor

Steer Tire < Sensor Press * Key XX Volts Press * Key

Set Travel and Braking

Upon entering the Set Travel and Braking menu, the truck speed limit. Speed may be set from a minimum
following menu functions are visible to the service of 6 km/h (4 mph) up to the maximum allowed for the
technician: lift truck model being adjusted. The speed may be set
• Speed Limit in 1 km/h (0.5 mph) increments up to a maximum
• Acceleration Rate speed of 24 km/h (15 mph). Setting the speed limit
• Auto-Deceleration Rate higher than the maximum allowed for the lift truck
• Set Power Reversal Rate model being adjusted will cause this function to be
• Set Inching/Brake Overlap deactivated.
Use the scroll keys to move to the desired function From the Set Travel and Braking menu, select Set
and press the * key to select the function. Speed Limit and press the * key. Enter the desired
limit for maximum truck speed or use the scroll keys
SPEED LIMIT to select Speed Limit Off. See Table 21. Press the *
If the lift truck is configured for optional speed limit, menu.
this function can be used to adjust or deactivate the
Table 21. Speed Limit Menu
Select Maximum Speed from

Main Menu Set Travel & Braking Set Speed Limit
Set Travel & Braking Press * Key Set Speed Limit Press * Key Speed Limit Off
Menu or Turn the Speed Limit
Off and Press * Key to Exit
↑
SCROLL
↓
Set Speed Limit

Max Speed 15.0 mph
↑
SCROLL
↓
Set Speed Limit

Max Speed 4.0 mph

ACCELERATION RATE lower than 10 will result in a slower rate of accelera-

tion.
Plus or DuraMatch Plus2 transmissions, this func- From the Travel and Braking menu, select Set Accel-
tion can be used to adjust the travel rate of accelera- eration and press the * key. See Table 22. Select a
tion. The rate of acceleration can be adjusted using number from 1 to 10 and press the * key to save your
a scale of 1 to 10. Using a setting of 10 will result selection and access the Exit Options menu.
in the fastest rate of acceleration. Using a number
Table 22. Acceleration Rate Menu

↑
SCROLL
↓
Set Travel & Braking Set Acceleration Rate from 1

Set Acceleration Press * Key Set Acceleration 10
*
to 10 and Press Key to Exit
↑
SCROLL
↓
Set Acceleration 1

AUTO-DECELERATION RATE of deceleration. Using a number lower than 10 will

result in a slower rate of deceleration.
Plus or DuraMatch Plus2 transmissions, this func- From the Travel and Braking menu, select Set Auto-
tion can be used to adjust the travel rate of decelera- Decel and press the * key. See Table 23. Select a
tion when the accelerator pedal is released. The rate number from 1 to 10 and press the * key to save your
of deceleration can be adjusted using a scale of 1 to selection and access the Exit Options menu.
10. Using a setting of 10 will result in the fastest rate
Table 23. Auto-Decel Menu

↑
SCROLL
↓
Set Travel & Braking Set Auto-Decel Rate from 1 to

Set Auto-Decel Press * Key Set Auto-Decel 10
*
10 and Press Key to Exit
↑
SCROLL
↓
Set Auto-Decel 1

SET POWER REVERSAL RATE will result in the fastest rate of deceleration. Using
a number lower than 10 will result in a slower rate
If the lift truck is configured for optional DuraMatch of deceleration.
Plus or DuraMatch Plus2 transmissions, this func-
tion can be used to adjust the travel rate of deceler- From the Travel and Braking menu, select Power Re-
ation when the truck is required to reverse direction versal and press the * key. See Table 24. Select a
while traveling. The rate of deceleration can be ad- number from 1 to 10 and press the * key to save your
justed using a scale of 1 to 10. Using a setting of 10 selection and access the Exit Options menu.
Table 24. Power Reversal Menu

↑
SCROLL
↓
Set Power Reversal Rate

Press * Key Set Power Reversal 10 from 1 to 10 and
Set Power Reversal
*
Press Key to Exit
↑
SCROLL
↓
Set Power Reversal 1

SET INCHING/BRAKE OVERLAP can be adjusted using a scale of 1 to 10. Using a set-
ting of 10 will result in the most overlap. Using a
This function is available for lift trucks equipped setting of 1 will result in the transmission being de-
with a two speed Basic Powershift transmission coupled before brake system pressure begins to rise
shown below (no overlap).
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, Typically, overlap will be set low if high rpm hy-
H40FTS) (F001) draulic operation is required at low travel speeds.
• High overlap is typically used to hold the lift truck
• H2.0-3.5FT (H40-70FT) (L177) in position at low travel speed when operating on
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, uneven or sloped terrain.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT From the Travel and Braking menu, select Set Inch/
(H80, 90, 100, 110, 120FT) (N005, P005, R005) Brk Overlap and press the * key. See Table 25. Select
a number from 1 to 10 and press the * key to save
Use this function to change the amount of overlap be- your selection and access the Exit Options menu.
tween the brake and the transmission. The overlap
Table 25. Inch/Brake Overlap Menu

↑
SCROLL
↓
Set Inch/Brake Overlap

Press * Key Set Inch/Brk Overlap 10 from 1 to 10 and
Set Inch/Brk Overlap
*
Press Key to Exit
↑
SCROLL
↓
Set Inch/Brk Overlap 1

2200 SRM 1131 Setup Hydraulics
Setup Hydraulics
Upon entering the Setup Hydraulics Menu from the NOTE: For all hydraulic settings, a setting of 10 will
Main Menu, the following menu functions are visible allow the function to operate at the maximum flow
to the service technician: rate of the lift truck.
• Lift Maximum Speed
• Lower Maximum Speed LIFT MAXIMUM SPEED
• Tilt Maximum Speed
• Aux. Function 1 Dir A Max Speed If the lift truck is equipped with optional electro-hy-
• Aux. Function 1 Dir B Max Speed draulics, this function can be used to set the maxi-
• Aux. Function 2 Dir A Max Speed mum mast lift speed. The lift speed can be adjusted
• Aux. Function 2 Dir B Max Speed using a scale of 1 to 10. Using a setting of 10 will
• Aux. Function 3 Dir A Max Speed result in maximum lift speed. Using a number less
• Aux. Function 3 Dir B Max Speed than 10 will result in a slower lift speed.
• Lift Lower Ramp Rate
From the Setup Hydraulics menu, select Lift Max
• Hyd. Aux. Ramp Rate
Speed and press the * key. See Table 26. Select a
• Return To Set Tilt Delay/On/Off
number from 1 to 10 and press the * key to save your
Use the scroll keys to move to the desired function selection and access the Exit Options menu.
and press the * key to select the function.
Table 26. Lift Speed Menu
Select Lift Maximum

Setup Hydraulics Press * Key Lift Max Speed Press * Key Lift Max Speed 10 Speed from 1 to 10 and
Press * Key to Exit
↑
SCROLL
↓
Lift Max Speed 1

LOWER MAXIMUM SPEED a number lower than 10 will result in a slower low-
ering speed.
If the lift truck is equipped with optional electro-hy-
draulics, this function can be used to set the maxi- From the Setup Hydraulics menu, select Lower Max
mum mast lowering speed. The lowering speed can Speed and press the * key. See Table 27. Select a
be adjusted using a scale of 1 to 10. Using a setting number from 1 to 10 and press the * key to save your
of 10 will result in maximum lowering speed. Using selection and access the Exit Options menu.
Table 27. Lower Speed Menu

↑
SCROLL
↓
Set Lower Maximum
Setup Hydraulics
Lower Max Speed Press * Key Lower Max Speed 10 Speed from 1 to 10 and
Press * Key to Exit
↑
SCROLL
↓
Lower Max Speed 1

TILT MAXIMUM SPEED From the Setup Hydraulics menu, select Tilt Max
Speed and press the * key. See Table 28. Select a
If the lift truck is equipped with optional electro-hy- number from 1 to 10 and press the * key to save your
draulics, this function can be used to set the maxi- selection and access the Exit Options menu.
mum mast tilt speed. The tilt speed can be adjusted
using a scale of 1 to 10. Using a setting of 10 will re-
sult in maximum tilt speed. Using a number lower
than 10 will result in a slower tilt speed.
Table 28. Tilt Speed Menu

↑
SCROLL
↓
Set Tilt Maximum
Setup Hydraulics
Tilt Max Speed Press * Key Tilt Max Speed 10 Speed from 1 to 10 and
Press * Key to Exit
↑
SCROLL
↓
Tilt Max Speed 1

For the setting of auxiliary functions and definitions

of Direction A and Direction B, see Figure 2.
A. E-HYD CONTROLS B. JOYSTICK CONTROLS

1. AUX 1 OR AUX 2 - DIRECTION A (↑) / DIRECTION 4. THIRD LEVER
B (↓) 5. AUX 1 - DIRECTION A (↑) / DIRECTION B (↓)
2. AUX 2 OR AUX 3 - DIRECTION A (↑) / DIRECTION 6. AUX 2 - DIRECTION A (↑) / DIRECTION B (↓)
B (↓) 7. SEAT ARMREST
3. FOURTH LEVER
Figure 2. Auxiliary Functions

AUXILIARY FUNCTION ONE, DIRECTION maximum auxiliary function speed. Using a num-
A, MAXIMUM SPEED ber lower than 10 will result in a slower auxiliary
function speed.
If the lift truck is equipped with optional elec-
tro-hydraulics, this function can be used to set the From the Setup Hydraulics menu, select Aux 1 Max
maximum auxiliary function speed in direction A. Spd Dir A and press the * key. See Table 29. Select
The auxiliary function speed can be adjusted using a number from 1 to 10 and press the * key to save
a scale of 1 to 10. Using a setting of 10 will result in your selection and access the Exit Options menu.
Table 29. Auxiliary Function Speed Menu

↑
SCROLL
↓
Set Aux 1 Maximum

Setup Hydraulics
Aux 1 Max Spd Dir A Press * Key Aux 1 Max Spd Dir A 10 Speed Dir A from 1 to 10
and Press * Key to Exit
↑
SCROLL
↓
Aux 1 Max Spd Dir A 1

AUXILIARY FUNCTION ONE, DIRECTION maximum auxiliary function speed. Using a num-
B, MAXIMUM SPEED ber lower than 10 will result in a slower auxiliary
function speed.
If the lift truck is equipped with optional elec-
tro-hydraulics, this function can be used to set the From the Setup Hydraulics menu, select Aux 1 Max
maximum auxiliary function speed in direction B. Spd Dir B and press the * key. See Table 30. Select
The auxiliary function speed can be adjusted using a number from 1 to 10 and press the * key to save
a scale of 1 to 10. Using a setting of 10 will result in your selection and access the Exit Options menu.

↑
SCROLL
↓
Set Aux 1 Maximum

Setup Hydraulics
Aux 1 Max Spd Dir B Press * Key Aux 1 Max Spd Dir B 10 Speed Dir B from 1 to 10
↑
SCROLL
↓
Aux 1 Max Spd Dir B 1

AUXILIARY FUNCTION TWO, DIRECTION a setting of 10 will result in maximum auxiliary

A, MAXIMUM SPEED function speed. Using a number lower than 10 will
result in a slower auxiliary function speed.
draulics and a four- or five-function valve, this From the Setup Hydraulics menu, select Aux 2 Max
function can be used to set the maximum auxiliary Spd Dir A and press the * key. See Table 31. Select
function speed in direction A. The auxiliary function a number from 1 to 10 and press the * key to save
speed can be adjusted using a scale of 1 to 10. Using your selection and access the Exit Options menu.

↑
SCROLL
↓
Set Aux 2 Maximum

Setup Hydraulics
↑
SCROLL
↓

AUXILIARY FUNCTION TWO, DIRECTION a setting of 10 will result in maximum auxiliary

B, MAXIMUM SPEED function speed. Using a number lower than 10 will
result in a slower auxiliary function speed.
draulics and a four- or five-function valve, this From the Setup Hydraulics menu, select Aux 2 Max
function can be used to set the maximum auxiliary Spd Dir B and press the * key. See Table 32. Select
function speed in direction B. The auxiliary function a number from 1 to 10 and press the * key to save
speed can be adjusted using a scale of 1 to 10. Using your selection and access the Exit Options menu.

↑
SCROLL
↓
Set Aux 2 Maximum

Setup Hydraulics
↑
SCROLL
↓

AUXILIARY FUNCTION THREE, 10 will result in maximum auxiliary function speed.

DIRECTION A, MAXIMUM SPEED Using a number lower than 10 will result in a slower
auxiliary function speed.
draulics and a five-function valve, this function can From the Setup Hydraulics menu, select Aux 3 Max
be used to set the maximum auxiliary function speed Spd Dir A and press the * key. See Table 33. Select
in direction A. The auxiliary function speed can be a number from 1 to 10 and press the * key to save
adjusted using a scale of 1 to 10. Using a setting of your selection and access the Exit Options menu.

↑
SCROLL
↓
Set Aux 3 Maximum

Setup Hydraulics
↑
SCROLL
↓

AUXILIARY FUNCTION THREE, 10 will result in maximum auxiliary function speed.

DIRECTION B, MAXIMUM SPEED Using a number lower than 10 will result in a slower
auxiliary function speed.
draulics and a five-function valve, this function can From the Setup Hydraulics menu, select Aux 3 Max
be used to set the maximum auxiliary function speed Spd Dir B and press the * key. See Table 34. Select
in direction B. The auxiliary function speed can be a number from 1 to 10 and press the * key to save
adjusted using a scale of 1 to 10. Using a setting of your selection and access the Exit Options menu.

↑
SCROLL
↓
Set Aux 3 Maximum

Setup Hydraulics
↑
SCROLL
↓

LIFT/LOWER RAMP RATE opening and closing rate of the valve. Changing this
function to a setting less than the factory default set-
If the lift truck is equipped with optional electro-hy- ting of 10 will result in additional travel after the
draulics, this function can be used to adjust the rate Lift/Lower lever is returned to the neutral position.
of valve opening and closing when requesting lift or
lower. This function is adjusted using only the num- From the Setup Hydraulics menu, select Lift/Lower
bers 1, 3, 5, 8, or 10. Using a setting of 10 will result Ramp and press the * key. See Table 35. Select a
in the fastest opening and closing rate of the valve. number (1, 3, 5, 8, or 10) and press the * key to save
Using a setting lower than 10 will result in a slower your selection and access the Exit Options menu.
Table 35. Lift/Lower Ramp Rate Menu

↑
SCROLL
↓
Set Lift/Lower Ramp
Setup Hydraulics
Lift/Lower Ramp Press * Key Lift/Lower Ramp 10 from 1 to 10 and
Press * Key to Exit
↑
SCROLL
↓
Lift/Lower Ramp 1

HYDRAULIC AUXILIARY RAMP RATE Changing this function to a setting less than the fac-
tory default setting of 10 will result in additional
If the lift truck is equipped with optional electro-hy- travel after the Hydraulic Auxiliary lever is returned
draulics, this function can be used to adjust the rate to the neutral position.
of valve opening and closing when requesting any
auxiliary function. This function is adjusted using From the Setup Hydraulics menu, select Hydraulic
only the numbers 1, 3, 5, 8, or 10. Using a setting of Aux Ramp and press the * key. See Table 36. Enter
10 will result in the fastest opening and closing rate a number (1, 3, 5, 8, or 10) and press the * key to save
of the valve. Using a setting lower than 10 will re- your selection and access the Exit Options menu.
sult in a slower opening and closing rate of the valve.
Table 36. Hydraulic Auxiliary Ramp Rate Menu

↑
SCROLL
↓
Set Hydraulic Aux Ramp

Setup Hydraulics
Press * Key Hydraulic Aux Ramp 10 from 1 to 10 and
Hydraulic Aux Ramp
*
Press Key to Exit
↑
SCROLL
↓
Hydraulic Aux Ramp 1

RETURN TO SET TILT DELAY/ON/OFF From the Setup Hydraulics menu, select Tilt Set-
Point Delay and press the * key. See Table 37. Us-
If the lift truck is configured for optional return to ing the scroll keys, select the desired setting from
set tilt, this function can be used to set the time de- the menu selections. When finished, press the * key
lay before allowing tilt to resume. This function is to save your selection and access the Exit Options
adjusted by selecting a time period from the menu menu.
selection. The function can be set to delay from 0.1
sec. to 3.0 sec. The function can also be deactivated
using the OFF setting. Using the continuous setting
will cause tilt to stop and hold at the set point un-
til the function is returned to neutral or the override
button is pressed.
Table 37. Tilt Delay Menu

↑
SCROLL
↓
Set Tilt Set Point Delay

from 0.1 sec to 3.0
Setup Hydraulics Tilt Set Point Delay
Tilt Set Point Delay Press * Key Continuous
sec or Select OFF or
Continuous and Press
* Key to Exit
↑
SCROLL
↓
↑
SCROLL
↓
↑
SCROLL
↓
Tilt Set Point Delay

Tilt Set Point Off

HYDRAULIC INPUT DEVICE table shows the menu items that are incompatible
and will not be displayed when specific e-hydraulic
If the lift truck is equipped with optional electro-hy- features are activated. In order to display any menu
draulics, this selection allows selection of the E-Hy- item not visible the user must deactivate the conflict-
draulic input device (1546087 – E hydraulic System ing feature(s).
Spec). Selection of a hydraulic input device enables
the appropriate diagnostics for that device. For ex- From the Setup Hydraulics menu, select Hydraulic
ample, selecting a MLM will enable the CAN com- Input Device and press the * key. See Table 38. Us-
munication failure diagnostic for the MLM and dis- ing the scroll keys, select the desired settings from
able the CAN communication failure diagnostic for the menu selections. When finished, press the * key
the Joystick. to save your selection and access the Exit Options
menu.
Menu items will appear only if all other hydraulic
settings will allow that combination. The following
Table 38. Hydraulic Input Device Menu

↑
SCROLL
↓
Setup Hydraulics Hydraulic Input Device 3 Lever Select Input Device and
Hydraulic Input Device Press * Key MLM Press * Key to Exit
↑
SCROLL
↓
Hydraulic Input Device 4 Lever

MLM
↑
SCROLL
↓
Hydraulic Input Device 1 Roller

Joystick
↑
SCROLL
↓
Hydraulic Input Device 2 Roller

Joystick

AUXILIARY SOLENOID auxiliary solenoid control button shall be assigned

to the 3rd MLM button.
If the lift truck is equipped with optional electro-hy- • If the user has selected a 4 lever MLM and the
draulics, this selection allows activation of the op- Clamp feature is not enabled in the CDF the Aux-
tional auxiliary solenoid (1546087 -E-Hydraulic Sys- iliary solenoid shall be assigned to the 4th MLM
tem Spec). This feature is mutually exclusive from button.
the dual function feature. The user shall not be able • If the user has selected any of the joystick config-
to scroll to “enabled” if any of the following conditions urations the auxiliary solenoid control shall be as-
are true: signed to the joystick button.
• The dual function feature is activated.
• The user has selected a joystick input device and From the Setup Hydraulics menu, select Auxiliary
the RTST or Clamp Interlock features are enabled. Solenoid and press the * key. See Table 39. Us-
• The truck is equipped with a 3 lever MLM and the ing the scroll keys, select the desired settings from
Clamp Interlock feature is enabled. the menu selections. When finished, press the * key
to save your selection and access the Exit Options
If the auxiliary solenoid feature is activated the aux- menu.
iliary solenoid control button shall be assigned as fol-
lows:
• If the CDF has enabled the Clamp Interlock fea-
ture or the user has selected a 3 lever MLM the
Table 39. Auxiliary Solenoid Menu

↑
SCROLL
↓
Setup Hydraulics
Auxiliary Solenoid Press * Key Auxiliary Solenoid
Activated Press * Key to Exit
↑
SCROLL
↓
Auxiliary Solenoid
Deactivated

DUAL FUNCTION • If the user has selected any of the joystick configu-
rations the dual function control shall be assigned
If the lift truck is equipped with optional electro-hy- to the joystick button.
draulics, this selection allows activation of the dual
function feature. Activating this feature enables the Auxiliary valve 1 diagnostics shall be enabled if any
user to control two hydraulic valves with a single of the following conditions exist:
analog input. The user shall not be able to scroll to • The dual function control is activated.
“enabled” if any of the following conditions are true: • The dual function control is deactivated and the
• The Auxiliary Solenoid feature is activated. user has selected a 4 lever MLM or a 2 roller joy-
• The user has selected a joystick input device and stick.
either the RTST or Clamp Interlock features are • Auxiliary valve 2 diagnostics shall be activated if
enabled. the dual function control is activated and the user
• The truck is equipped with a 3 lever MLM and the selects a 4 lever MLM or a 2 roller joystick as the
Clamp Interlock feature is enabled. input device.
If the dual function feature is activated the dual func- From the Setup Hydraulics menu, select Dual Func-
tion control button shall be assigned as follows: tion and press the * key. See Table 40. Using the
• If the user has activated the Clamp Interlock fea- scroll keys, select the desired settings from the menu
ture or selected a 3 lever MLM the dual function selections. When finished, press the * key to save
control shall be assigned to the 3rd MLM button. your selection and access the Exit Options menu.
• If the user has selected a 4 lever MLM and the
Clamp feature is not enabled the dual function con-
trol shall be assigned to the 4th MLM button.
Table 40. Dual Function Menu

↑
SCROLL
↓
Setup Hydraulics
Dual Function Press * Key Dual Function
Activated Press * Key to Exit
↑
SCROLL
↓
Dual Function
Deactivated

2200 SRM 1131 Setup Display
Setup Display
SET SERVICE LANGUAGE to select the desired language. See Table 41. Press
the * key to save your selection and access the Exit
This function allows the service technician to select Options menu.
the language used by the dash display. The dash dis-
play comes with English as the standard language. NOTE: After selecting the new language, it may take
A second language can be downloaded into the dash up to 15 seconds for the new language to become ac-
display and selected for use. tive.
From the Setup Display menu, select Set Service

Language and press the * key. Use the scroll keys
Table 41. Service Language Menu
Select the Service

Main Menu Setup Display Set Service Language Language from the
Setup Display Press * Key Set Service Language Press * Key English Options Provided and
Press * Key to Exit
↑
SCROLL
↓
Set Service Language
Spanish

Setup General Items

Upon entering the Setup General Items Menu from alarm will function. The alarm can be selected to op-
the Main Menu, the following menu functions are vis- erate as a backup alarm, which will operate any time
ible to the service technician: the reverse direction is selected with the travel direc-
• Motion Alarm Activation Type tion control; a forward or reverse travel alarm; any
• Light Shutdown Time-Out travel direction alarm; any hydraulic function alarm;
• Restore Default Settings any travel or hydraulic function alarm; or the alarm
• Restore Engine Controller Default Calibration can be set to operate any time the forward direction
• Impact Sensor - Enable/Disable is selected with the travel direction control.
• Economy Mode Indication (ECO-eLo)
From the Setup General Items menu, select Alarm
Use the scroll keys to move to the desired function Type and press the * key. Using the scroll keys, select
and press the * key to select the function. the desired alarm type. See Table 42. Press the *
MOTION ALARM ACTIVATION TYPE menu.
If the lift truck is equipped with an optional motion

alarm, this function can be used to select how the
Table 42. Alarm Type Menu
Select Alarm Type from

Main Menu Setup General Items Alarm Type
Press * Key Press * Key Menu Selections and
Setup General Items Alarm Type Backup
*
Press Key to Exit
↑
SCROLL
↓
Alarm Type
Forward
↑
SCROLL
↓
Alarm Type
Travel
↑
SCROLL
↓
Alarm Type
Lift/Lower
↑
SCROLL
↓
Alarm Type
Travel or Lift/Lower
↑
SCROLL
↓
Alarm Type
Forward Switch

LIGHT SHUTDOWN TIME-OUT From the Setup General Items menu, select Light
Shutdown Time and press the * key. Using the scroll
If the lift truck is equipped with optional work lights, keys, select the desired time delay or deactivate the
this function can be used to time-delay or turn off the function. See Table 43. Press the * key to save your
work lights when system power has been turned off. selection and access the Exit Options menu.
This function may be adjusted by entering a delay of
1 to 10 minutes using the menu selections. The delay
function may also be deactivated from the menu.
Table 43. Light Time-Out Menu

↑
SCROLL
↓
Select the Light

Shutdown Interval
from 1 to 10 min.
Setup General Items Light Shutdown Time
Light Shutdown Time Press * Key 10 Minutes
from the Menu
or Deactivate the
Function and Press *
Key to Exit
↑
SCROLL
↓
Light Shutdown Time

1 Minute
↑
SCROLL
↓
Light Shutdown Time

Item Deactivated

RESTORE DEFAULT SETTINGS From the Setup General Items menu, select Restore
Defaults. See Table 44. Press the * key and proceed
This function is used to restore all service technician to the Exit Options menu.
adjustable truck settings to the factory default set-
tings. This function will not change any calibration
settings.
Table 44. Restore Defaults Menu

↑
SCROLL
↓
Setup General Items Press * Key to Exit and
Restore Defaults Restore Defaults

RESTORE ENGINE CONTROLLER From the Setup General Items menu, select Restore
DEFAULT CALIBRATION ECU Defaults. Press the * key, scroll to the Exit
Options menu, and choose the Save and Exit menu
If the lift truck is equipped with a GM engine, this item. See Table 45. Press the * key to restore default
function can be used to restore the system to the fac- values.
tory default values.
Table 45. Restore Settings Menu

↑
SCROLL
↓
Setup General Items Press * Key to Exit and
Restore ECU Defaults Restore Defaults

IMPACT SENSOR - ENABLE/DISABLE

This function will allow the service technician to en-
able or disable the optional impact sensor.
Table 46. Impact Sensor Enable/Disable

↑
SCROLL
↓
Setup General Items Press * Impact Sensor Press * Enable/Disable Press *

Impact Sensor Key Enable/Disabled Key Activated Key
↑
SCROLL
↓
Enable/Disable
Deactivated

IMPACT SENSOR - SOFT IMPACT If your lift truck is configured for optional impact sen-
SETTINGS sor, this function allows the service technician to set
the impact level and averaging time for soft (minor)
NOTE: The information in the following paragraphs impacts. See Table 50 for the recommended impact
describe how to navigate through the Setup Menu sensor settings by truck capacity and tire type.
and enter the data parameters for soft impacts. For
information on the recommended starting values for After entering the Impact Sensor Soft Impact Set-
the impact sensor settings based on truck capacity tings menu, select the Soft Threshold Set menu and
and tire type and for procedures on how to adjust press the * key. See Table 47. Select the impact level
these values, see Adjust Impact Sensor Settings. from the selections listed and press the * key.
Lift trucks equipped with the optional impact sensor, Scroll to the Soft Averaging Time menu and press the
leave the factory with the sensor deactivated and set * key. Select the averaging time for the selections
with default values (see Table 49). The impact sensor listed and press the * key. If you are finished making
is equipped with an accelerometer that measures the changes, scroll to the Exit Options menu and choose
rate and time of truck deceleration continuously and the appropriate action.
monitors how strong the deceleration is and how long
it lasts.
Table 47. Soft Impact Settings Menu
Main Menu
Setup General Items
Key
↑ Scroll ↓
Select Impact
Setup General Items Press * Impact Sensor Press * Soft Impact Settings Press * Soft Threshold Set Level and
Impact Sensor Key Soft Impact Settings Key Soft Threshold Set Key 2.5 g
Press * Key
↑ Scroll ↓
Soft Threshold Set

↑ Scroll ↓
0.2 g
↑ Scroll ↓
Select Time
Soft Impact Settings
Soft Averaging Time
Press * Soft Averaging Time
12 and Press *
Key Key
↑ Scroll ↓
Soft Averaging Time

1

IMPACT SENSOR - HARD IMPACT the impact level and averaging time for soft (minor)
SETTINGS impacts. See Table 50 for the recommended impact
sensor settings by truck capacity and tire type.
NOTE: The information in the following paragraphs
describe how to navigate through the Setup Menu If your lift truck is configured for optional impact sen-
and enter the data parameters for hard impacts. For sor, this function allows the service technician to set
information on the recommended starting values for the impact level and averaging time for hard (major)
the impact sensor settings based on truck capacity impacts.
and tire type and for procedures on how to adjust
After entering the Impact Sensor Hard Impact Set-
these values, see Adjust Impact Sensor Settings.
tings menu, select the Hard Threshold Set menu and
Lift trucks equipped with the optional impact sensor, press the * key. See Table 48. Select the impact level
leave the factory with the sensor deactivated and set from the selections listed and press the * key.
with default values (see Table 49). The impact sensor
is equipped with an accelerometer that measures the Scroll to the Hard Averaging time menu and press
rate and time of truck deceleration continuously and the * key. Select the averaging time for the selections
monitors how strong the deceleration is and how long listed and press the * key. If you are finished making
it lasts. changes, scroll to the Exit Options menu and choose
sor, this function allows the service technician to set
Table 48. Hard Impact Settings Menu
Main Menu
Setup General Items
Key
↑ Scroll ↓
Select
Impact
Setup General Items Press * Impact Sensor Press * Hard Impact Settings Press * Hard Threshold Set Level and
Impact Sensor Key Hard Impact Settings Key Hard Threshold Set Key 3.0 g
Press *
Key
↑ Scroll ↓
Hard Threshold Set

↑ Scroll ↓
0.5 g
↑ Scroll ↓
Select
Hard Impact Settings
Hard Averaging Time
Press * Hard Averaging Time
2
Time and
Press *
Key
Key
↑ Scroll ↓
Hard Averaging Time

1

ADJUST IMPACT SENSOR SETTINGS • Deceleration during impact at the rate of gravity
(g) = 32ft/sec 2 or 9.8m/sec 2
The service technician can enable the impact sensor The figures in the Soft Averaging and Hard Av-
and set and adjust the impact levels and averaging eraging columns represent the amount of time the
times. selected deceleration rate of gravity (soft or hard
threshold) must be sustained in order for an impact
The information in Table 50 is the recommended
to be recorded.
starting values for impact sensor settings based on
lift truck capacity and tire type. In Table 49 and
Table 50, the figures in the Soft Threshold and
Hard Threshold columns represent: (see Figure 3)
Table 49. Impact Sensor Default Settings
Soft Threshold Soft Averaging Hard Threshold Hard Averaging

0.5 g 7 0.8 g 1

Figure 3. Soft and Hard Impact Graph

Legend for Figure 3

A. SOFT IMPACT C. POINT AT WHICH IMPACT IS RECORDED AND
B. HARD IMPACT ENGINE SHUTS DOWN
Initial Adjustment of Soft and Hard Impact • Was the operator picking up or setting down a load
Settings • Was the operator bulldozing a load
• Was the operator driving over rough or uneven ter-
NOTE: When adjusting the impact sensor settings, rain
be sure to: • Was the impact a soft or hard one
• Record the truck identification number, capacity,
and tire type If no impacts are recorded during normal operations,
• Record all changes in settings and record all results the adjustment is complete. If impacts are recorded
from changes made during normal operations, go to Readjustment of Soft
and Hard Impact Settings.
It is important to remember if there have been any
increases to the default value difference between the Readjustment of Soft and Hard Impact
soft and hard threshold adjustment. Settings
Enter the starting values shown Table 50 based If the majority of impacts recorded during the initial
on the capacity of the lift truck and the type of adjustment period are soft impacts, change the set-
tires used. Apply the brakes to bring the truck to tings as follows:
an abrupt stop. Read and record the value, from • New soft impact threshold = old soft impact thresh-
the dash display, that was triggered when abruptly old + 0.1 g
stopping the truck. Change the soft threshold to the • New hard impact threshold = new soft impact
next highest setting that is above the value that was threshold + 0.3 g
triggered when the truck was brought to an abrupt
stop. Record this value. If the majority of impacts recorded during the initial
adjustment period are hard impacts, change the set-
To adjust the hard threshold, take the soft threshold tings as follows:
value and add 0.3 g. Record the hard threshold value. • New hard impact threshold = old hard impact
threshold + 0.1 g
Clear the impact event log (see Impact Sensor - View
• New soft impact threshold = no change
Impact Event Log). Let the operator drive the truck
with the initial settings. Be sure to explain to the After making the necessary adjustments, have the
operator that the impact sensor settings are being operator again operate the lift truck under normal
adjusted and to drive the truck under normal con- conditions to ensure that the adjustments are cor-
ditions. If an impact event happens, the following rect.
information must be known:

Table 50. Recommended Starting Values for Impact Sensor Settings by Truck Capacity and Tire Type
Chassis Range Tire Type Soft Soft Hard Hard

Threshold Averaging Threshold Averaging
1-2T Cushion 0.6 g 7 0.9 g 1
2-3T Cushion 0.6 g 7 0.9 g 1
3.5T Cushion 0.5 g 7 0.8 g 1
4-5T Cushion 0.5 g 7 0.8 g 1
5.5T Cushion 0.4 g 7 0.8 g 1
6-7T Cushion 0.4 g 7 0.8 g 1

IMPACT SENSOR - IMPACT

ALARM/SHUTDOWN RESET
sor, this function allows the service technician to re-
set and return the lift truck to normal operation after
an impact sensor shutdown. See Table 51.
Table 51. Shutdown Reset Menu

↑
SCROLL
↓
Setup General Items

Impact Sensor
Impact Reset
Press * Impact Reset
Cleared
Press *
Key Key Key

IMPACT SENSOR - ALARM TIME After entering the Impact Sensor Alarm menu, enter
DURATION AND DEACTIVATION the amount of time to sound the alarm. See Table 45.
Enter the time in 15-second increments from zero up
If your lift truck is configured for optional impact sen- to a maximum of 120 seconds. Scrolling down will
sor, this function allows the service technician to set allow you to have the alarm operate continuously af-
the amount of time the impact alarm will sound after ter detecting an impact. Press the * key to access
detecting an impact. The supervisor can also make the Exit Options menu and choose the appropriate
the alarm continuous using this function. action.
Table 52. Alarm Duration Menu
Main Menu
Setup General Items
Key
↑
SCROLL
↓
Setup General Items

Impact Sensor
Impact Enable/Disable
Press * Impact Alarm Time
0 Seconds
Press *
Key Key Key
↑ ↑
SCROLL SCROLL
↓ ↓
Impact Sensor
Impact Alarm Press * Impact Alarm Time
120 Seconds
Key
↑
SCROLL
↓
Impact Alarm Time

Continous

IMPACT SENSOR - VIEW IMPACT EVENT After entering the View Impact Event Log menu,
LOG press the * key to enter the log. See Table 46. The
system stores up to 20 log entries. These entries can
If your lift truck is configured for optional impact be viewed by using the scroll keys to move through
sensor, this function allows the service technician to each entry. When finished viewing the log, press the
view the log of the operator password, impact sever- * key, scroll to the Exit Options menu, and choose
ity, date, and time an impact event was recorded. the appropriate action.
Table 53. View Event Log Menu
Main Menu
Setup General Items
Key
↑
SCROLL
↓
XXXXX
(Operator
Impact Sensor
Setup General Items
Impact Sensor
Press * Impact Enable/ Press * Soft Impact
06/12/06
Password)
XXXXX PM Press *
Key Disable Key (Time Key
Impact
Occurred)
↑ ↑
SCROLL SCROLL
↓ ↓
Impact Sensor
Impact Log Press * Hard Impact
06/12/06
XXXXX
(Operator
Key Password)
XXXXX AM
(Time
Impact
Occurred)

ECONOMY MODE INDICATOR (ECO-ELO) When the ECO-eLo feature is turned ON, the max-
imum engine speed will be limited to a pre-defined
NOTE: Only lift truck models H2.0FT, H2.5FT, value (for example, 2100 rpm) that is specified in
H3.0FT, H3.5FT (L177) and H4.0FT5/FT6, the lift truck’s Configuration Data File (CDF). This
H4.5FTS5, H5.0-5.5FT (P005) can be equipped with pre-defined valve may be different for each engine
the optional ECO-eLo feature. type used by the lift truck models equipped with the
ECO-eLo feature.
If the lift truck is equipped with this feature, this
function can be used to turn the ECO-eLo feature ON From the Setup General Items menu, select ECO-eLo
or OFF. When lift truck power is turned ON, if the and press the * key. Using the scroll keys, select to
ECO-eLo feature has been enabled and activated, the turn the ECO-eLo feature ON or OFF. See Table 54.
dash display will show this feature as being turned Press the * key to save your selection and access the
on for up to five seconds after the engine starts, or Exit Options menu.
until the operator either presses a key or changes the
position of the key switch.
Table 54. ECO-eLo Settings Menu

Setup General Items Press * Key ECO-eLo
↑
SCROLL
↓
ON
↑
SCROLL
↓
OFF

2200 SRM 1131 Diesel Particulate Filter (DPF) Display
Diesel Particulate Filter (DPF) Display

Lift truck models H6.0FT, H7.0FT (H135FT, PASSIVE REGENERATION ONLY
H155FT) (K006) and H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (B299) may be Regeneration Level 0
equipped with the Kubota 3.8L Diesel engines. If
lift truck has this engine, the lift truck may also 1. Soot Meter is blank to show DPF soot level is
be equipped with an operator’s display for the DPF empty. See Figure 5.
mounted to the overhead guard in the upper right
2. Empty Soot Meter will also flash if no soot level
hand corner. See Figure 4.
data is available from ECU. See Figure 5.
Figure 5. Empty Soot Meter
1. DPF DISPLAY 3. Soot Meter will show increasing soot level in

2. LED INDICATOR DPF. This is an estimate based on multiple ECU
3. AUTO/ACTIVE REGENERATION INHIBIT ICON parameters. See Figure 6.
4. PARKED REGENERATION AVAILABLE ICON
5. SOOT LEVEL METER 4. Soot Meter bars fill with increasing soot load.
6. AUTO/ACTIVE REGENERATION INHIBIT
ON/OFF BUTTON See Figure 6.
7. PARKED REGENERATION INITIATE BUTTON
Figure 4. DPF Display
GENERAL DESCRIPTION
The DPF Display will illuminate the appropriate
icon(s) according to regeneration level that the lift
truck is operating at:
• Passive Regeneration Only (Regeneration Level 0)
• Active Regeneration Inhibited (Regeneration Level
1)
• Auto/Active Regeneration (Regeneration Level 1)
• Parked Regeneration Request Level (Regeneration
Level 2)
• Warning Request Level (Regeneration Level 3)
• Service Request Level (Regeneration Level 4)
• Stop Request Level (Regeneration Level 5) Figure 6. Partial Soot Level

Diesel Particulate Filter (DPF) Display 2200 SRM 1131
AUTO/ACTIVE REGENERATION INHIBITED

Regeneration Level 1
1. Soot Meter shows 100% soot level in DPF. See
Figure 7.
NOTE: Auto/Active Regeneration can be inhibited at

any time by the operator pressing the Auto/Active
Regeneration Inhibit ON/OFF button.
2. Auto/Active Regeneration available but inhibited

by operator. See Figure 7.
Figure 8. Soot Percentage Display
1. AUTO/ACTIVE REGENERATION INHIBITED
Figure 7. Auto/Active Regeneration

Figure 9. Auto/Active Regeneration In Process
AUTO/ACTIVE REGENERATION Display
Regeneration Level 1 Lift truck operation can continue without any limi-
tations or loss of power during Auto/Active Regener-
Auto/Active Regeneration will be ready when one of ation. Higher engine speeds will lead to a more suc-
the following triggers is reached: cessful Auto/Active Regeneration.
• Soot percentage is 100%. See Figure 8.
• Total fuel consumption since last regen equals PARKED REGENERATION REQUEST
250 liter (66 gal)
• DPF Differential Pressure sensor has reached trig- Regeneration Level 2
ger level.
1. After thirty minutes of unsuccessful Auto/Active
Auto/Active Regeneration will begin when engine Regeneration, the ECU will request a Parked Re-
load and temperature meet appropriate conditions. generation.
See Figure 9.
2. Auto/Active Regeneration will continue to be at-
tempted by ECU even though Parked Regener-
ation is available. DPF icon and LED are on to
indicate Parked Regeneration is available. See
Figure 10.

2200 SRM 1131 Diesel Particulate Filter (DPF) Display
3. There is no effect on lift truck performance at this

point.
WARNING
Prior to initiating the Parked Regeneration
process, move the lift truck to a location suit-
able for elevated exhaust gas temperatures.
Make sure the suitable location is free of com-
bustible materials, liquids and gases. Failure
to do so could cause serious injury to operator
and/or serious damage to property!
4. To initiate the Parked Regeneration process, the

operator needs to push the Parked Regeneration
Initiate Button after all of the following condi-
tions have been met. See Figure 10.
Figure 11. Engine Warming Up Icon
• Engine running
• Park brake ON
WARNING LEVEL
• Transmission in Neutral
• Accelerator pedal NOT depressed
5. When Parked Regeneration is in process the
NOTE: Level 3 is the last opportunity for operator to
High Temperature Icon will be displayed. See
initiate the DPF regeneration process before a ser-
Figure 9.
vice technician will be required.
6. If Parked Regeneration process is initiated be-
1. DPF Icon is on and LED is flashing to indicate
fore lift truck has warmed up properly, the En-
Parked Regeneration is necessary. See Figure 10.
gine Warming Up Icon will be displayed. See Fig-
ure 11. 2. Auto/Active Regeneration is no longer enabled
by ECU. DPF regeneration must be performed
through Parked Regeneration process.
3. At this regeneration level there is a 50% torque

derate and 1600 RPM limit on the engine.
4. MIL on dash is on and diagnostic trouble code

(DTC) 3701-15 will be displayed. See Diagnos-
tic Troubleshooting Manual 9000 SRM 1112.
SERVICE LEVEL
NOTE: Level 4 is the last opportunity for service
technician to initiate parked regeneration process
for DPF before DPF assembly has to be replaced.
1. PARKED REGENERATION AVAILABLE ICON
2. LED INDICATOR 1. DPF Icon and LED both flash to indicate parked
3. PARKED REGENERATION INITIATE BUTTON regeneration must be completed by using PC Ser-
vice Tool. See Figure 10.
Figure 10. Parked Regeneration Request
2. Parked Regeneration and Auto/Active Regenera-
tion are not available.


Diesel Particulate Filter (DPF) Display 2200 SRM 1131
4. MIL on dash is on and diagnostic trouble code

(DTC) 3701-16 will be displayed. See Diagnos-
tic Troubleshooting Manual 9000 SRM 1112
for diagnostic procedures.
STOP LEVEL
1. DPF Icon and LED both flash. See Figure 10.
2. At this level the DPF is clogged to the point where

it needs to be removed for service or replacement.

4. MIL on dash is on and diagnostic trouble code Figure 12. Refer to Operator Manual Icon
(DTC) 3701-0 will be displayed. See Diagnostic
Troubleshooting Manual 9000 SRM 1112 for CAN Communication Lost
diagnostic procedures.
The Wrench Icon is shown when the DPF display
OPERATOR INTERFACE loses communication with ECU. See Figure 13.
Refer to Operator Manual

The Book Icon will be displayed at startup for approx-
imately 3 seconds.
The Book Icon will also be shown when operator at-

tempts to initiate a Parked Regeneration when truck
is not in the correct state (park brake on, transmis-
sion in neutral, etc...). This icon will also be displayed
for 30 seconds following an interrupted Parked Re-
generation while DPF cools off. See Figure 12.
Figure 13. CAN Communication Lost Icon

Calibrations
This section contains the basic instructions and dash menu item has been selected by pressing the * key.
display menu navigation steps for performing vari- All calibrations must be performed after replacing a
ous truck system calibrations. For complete instruc- VSM.
tions for performing these calibrations, see Calibra-
tion Procedures 8000 SRM 1134. If the lift truck is equipped with optional electro-hy-
draulics, the following functions can be used to cal-
Upon entering the Calibrations Menu from the Main ibrate the electro-hydraulic valve opening threshold
Menu, the following menu functions are visible to the values for the hydraulic functions contained in the
service technician: truck configuration data file.
• Calibrate Lift Valve Output
• Calibrate Lower Valve Output The functions that can be calibrated are:
• Calibrate Tilt Back Valve Output • Lift Valve Output
• Calibrate Tilt Forward Valve Output • Lower Valve Output
• Calibrate Auxiliary Valve #1 Direction A Output • Tilt Back Valve Output
• Calibrate Auxiliary Valve #1 Direction B Output • Tilt Forward Valve Output
• Calibrate Auxiliary Valve #2 Direction A Output • Auxiliary Valve #1 Direction A Output
• Calibrate Auxiliary Valve #2 Direction B Output • Auxiliary Valve #1 Direction B Output
• Calibrate Auxiliary Valve #3 Direction A Output • Auxiliary Valve #2 Direction A Output
• Calibrate Auxiliary Valve #3 Direction B Output • Auxiliary Valve #2 Direction B Output
• Calibrate Transmission Valve • Auxiliary Valve #3 Direction A Output
• Set Tilt Stop Point • Auxiliary Valve #3 Direction B Output
• Calibrate Loaded Weight
From the Calibrations Menu, select the desired
• Calibrate Travel Speed Sensor
electro-hydraulic function requiring calibration and
• Calibrate Accelerator Pedal
press the * key. See Table 55. Refer to Calibration
NOTE: Unless otherwise specified, calibration values Procedures 8000 SRM 1134 for calibration proce-
are not stored in memory until the Save All Changes dures.

Table 55. Calibrate Electro-Hydraulic Valve Menu
Main Menu Calibrations Lift Valve Output Press * Key to Proceed

Calibrations Press * Key Lift Valve Output Press * Key Press * At Creep With Next Function
↑ SCROLL ↓
Calibrations Press * Key Lower Valve Output Press * Key to Proceed
Lower Valve Output Press * At Creep With Next Function
↑ SCROLL ↓
Calibrations Press * Key Tilt Bk Valve Output Press * Key to Proceed
Tilt Bk Valve Output Press * At Creep With Next Function
↑ SCROLL ↓
Calibrations Press * Key Tilt Fw Valve Output Press * Key to Proceed
Tilt Fw Valve Output Press * At Creep With Next Function
↑ SCROLL ↓
Calibrations Press * Key Aux 1 Output Dir A Press * Key to Proceed
Aux 1 Output Dir A Press * At Creep With Next Function
↑ SCROLL ↓
Calibrations Press * Key Aux 1 Output Dir B Press * Key to Proceed
Aux 1 Output Dir B Press * At Creep With Next Function
↑ SCROLL ↓
↑ SCROLL ↓
↑ SCROLL ↓
↑ SCROLL ↓
If the calibration was successful, the program will calibration procedure until the hydraulic function
store the value and automatically move to the next has been successfully calibrated.
item in the calibration sequence.
At any time, use the scroll keys to access the Back
If the calibration was not successful, the display 1 Level option and press the * key to return to the
will read, Result Out of Range – Repeat Calibration. Main Menu.
Press the * key to repeat the calibration. Repeat the

CALIBRATE TRANSMISSION VALVE After successful calibration of the transmission

valve, the dash display automatically returns to the
This function allows the service technician to cali- Calibrate Xmsn Valve menu. This completes the
brate the transmission proportional valve after ser- calibration procedure. Scroll to the Exit Options
vicing or replacing the transmission valve. menu and choose the appropriate action.
NOTE: Always calibrate the transmission valve if the NOTE: After successful calibration, the values are
valve, VSM, or transmission has been replaced. automatically stored, so a Save and Exit step is not
necessary.
From the Calibrations menu, select Calibrate Xmsn
Valve and press the * key. See Table 56. Refer to
Calibration Procedures 8000 SRM 1134 for cali-
bration procedures.
Table 56. Calibrate Transmission Valve Menu
Main Menu
Calibrations Press * Key Calibrations
Lift Valve Output
↑ SCROLL ↓
When Calibration
Calibrate Xmsn Valve
Calibrations
Calibrate Xmsn Valve Press * Key Press * Key to Begin Press * Key Calibrate Xmsn Valve
Complete, Will Return
to Calibration/Calibrate
Xmsn Valve Menu

SET TILT STOP POINT Procedures 8000 SRM 1134 for calibration proce-
dures.
If the lift truck is equipped with optional return to set
tilt, this function is used to calibrate that feature.
From the Calibrations menu, select Set Tilt Stop

Point and press the * key. Refer to Calibration
Table 57. Tilt Stop Point Menu

↑ SCROLL ↓
Calibrations Press * Key With Mast at Press * Key to
Set Tilt Stop Point Press * Key
Desired Stop Point Exit

CALIBRATE LOADED WEIGHT If the lift truck is equipped with the optional load
weight feature, this function is used to calibrate the
During initial truck setup, a Weigh Point must be system to display the load weight on the dash display.
permanently marked on the mast. The Weight Point
becomes the reference point for weighing loads. The From the Calibrations menu, select the Load Wt Cal-
Weigh Point is to be marked on the mast where the ibration option. See Table 58. Press the * key. Refer
forks are somewhere between 305 to 610 mm (12 to Calibration Procedures 8000 SRM 1134 for cal-
to 24 in.) off the ground, but never more than the ibration procedures.
free-lift height of the forks.
Table 58. Calibrate Loaded Weight
Main Menu
Calibrations
Press * Calibrations
Lift Valve Output
Key
↑ Scroll ↓
Select Correct Load

Calibrations
Loaded Wt Calibration
Press * Load Weight-Set Zero
* With No Load Press * Lift Known Load to
Weighing Height
Press * Scroll to Correct
Weight #### Lbs
Weight from Menu
Selections and Press
Key Press Key Key
* Key to Exit

CALIBRATE TRAVEL SPEED SENSOR From the Calibrations menu, select the Travel Speed
Sensor option and press the * key. See Table 59. Re-
If the lift truck is equipped with the optional Dura- fer to Calibration Procedures 8000 SRM 1134 for
Match, DuraMatch Plus, or DuraMatch Plus2 trans- calibration procedures.
missions, this function is used to calibrate the travel
speed sensor. This calibration may be needed to fine If the calibration was not successful, a Result Out
tune the system to account for the use of non stan- of Range – Repeat Calibration message will be dis-
dard size tires on the lift truck. played. Press the * key to re-calibrate the travel
speed sensor.
Table 59. Travel Speed Menu

↑ SCROLL ↓
Calibrations
Travel Speed Sensor Press * Key
Travel Speed Sensor
Press * Key to Begin Press * Key
Travel Speed Sensor
Press * Key After 50 ft Press * Key to
Exit

CALIBRATE MAZDA LP AND GAS trucks equipped with the Mazda LP or Gas engines
ACCELERATOR PEDAL and electronic control transmission.
This function is used to calibrate the accelerator From the Calibrations menu select the Accelerator
pedal on trucks equipped with the Mazda LP or Gas Pedal option and press the * key. See Table 60. Re-
engine. Perform this calibration when adjusting or fer to Calibration Procedures 8000 SRM 1134 for
first installing an accelerator pedal assembly on fork calibration procedures.
Table 60. Travel Speed Menu

↑ SCROLL ↓
Calibrations Accelerator Pedal XX%

Accelerator Pedal Press * Key XXX RPM

NOTES
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74

ELECTRICAL SYSTEM
S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177]; S4.0, 4.5,
5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005, R005];
S6.0FT, S7.0FT (S135FT, S155FT) [D024, E024, F024]; H6.0FT,

PART NO. 1580520 2200 SRM 1142

SAFETY PRECAUTIONS
load.
repairs.
manual:
WARNING
CAUTION
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Display Switch Cluster ........................................................................................................................................ 3
Remove ............................................................................................................................................................. 3
Install ............................................................................................................................................................... 3
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 ...................................................................................................................................... 8
Remove ............................................................................................................................................................. 8
Disassemble ..................................................................................................................................................... 9
Assemble .......................................................................................................................................................... 9
Install ............................................................................................................................................................... 9
Sensors and Switches ........................................................................................................................................ 11
General ........................................................................................................................................................... 11
Dash and Kick Panel, Remove and Install............................................................................................... 11
Remove .................................................................................................................................................. 11
Install..................................................................................................................................................... 11
Accelerator Pedal Position Sensor ................................................................................................................ 13
Remove....................................................................................................................................................... 13
Install ......................................................................................................................................................... 14
Brake Fluid Level Switch.............................................................................................................................. 16
Remove....................................................................................................................................................... 16
Install ......................................................................................................................................................... 18
Service Brake Pedal Position Sensor ............................................................................................................ 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Parking Brake Sensor ................................................................................................................................... 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Service Brake Pressure Sensor ..................................................................................................................... 24
Remove....................................................................................................................................................... 24
Install ......................................................................................................................................................... 25
Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)............................................................................................................... 26
Remove....................................................................................................................................................... 26
Install ......................................................................................................................................................... 26
MONOTROL® Sensor Microswitch.............................................................................................................. 27
Remove....................................................................................................................................................... 27
Install ......................................................................................................................................................... 29
Low Coolant Level Sensor ............................................................................................................................. 30
Remove....................................................................................................................................................... 30
Install ......................................................................................................................................................... 31
Fuel Level Sensor, Gas and Diesel Engines Only ........................................................................................ 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34


Armrest Switch .............................................................................................................................................. 35
Remove....................................................................................................................................................... 35
Install ......................................................................................................................................................... 35
Seat Sensor (Operator Presence System) ..................................................................................................... 35
Non-Suspension and Semi-Suspension Seats; All Lift truck Models Except H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006) and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299) .............................................................................................................................. 35
Remove .................................................................................................................................................. 35
Install..................................................................................................................................................... 35
Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006) .......................................................................................................................................................... 35
Remove .................................................................................................................................................. 35
Install..................................................................................................................................................... 35
Full Suspension Seats; All Lift Truck Models ......................................................................................... 38
Remove .................................................................................................................................................. 38
Install..................................................................................................................................................... 38
Hood Shut Off Switch .................................................................................................................................... 38
Remove....................................................................................................................................................... 38
Install ......................................................................................................................................................... 40
Remote Key Switch........................................................................................................................................ 41
Remove....................................................................................................................................................... 41
Install ......................................................................................................................................................... 41
Hydraulic Filter Pressure Switch ................................................................................................................. 42
Remove....................................................................................................................................................... 42
Install ......................................................................................................................................................... 42
Transmission Speed Sensor .......................................................................................................................... 44
Remove....................................................................................................................................................... 44
Install ......................................................................................................................................................... 47
Transmission Pressure Sensors.................................................................................................................... 47
Remove....................................................................................................................................................... 47
Install ......................................................................................................................................................... 48
Transmission Temperature Sensor............................................................................................................... 49
Remove....................................................................................................................................................... 49
Install ......................................................................................................................................................... 51
Engine Speed Sensor ..................................................................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 52
Intermediate Speed Sensor ........................................................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 53
Return to Set Tilt (Tilt Angle) Sensor .......................................................................................................... 53
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) ................. 53
Remove .................................................................................................................................................. 53
Install..................................................................................................................................................... 53
Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024); S4.0, 4.5,
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), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299) .......................................................................................... 54
Remove .................................................................................................................................................. 54
ii

Install..................................................................................................................................................... 55
Rear Horn Button Switch.............................................................................................................................. 56
Remove....................................................................................................................................................... 56
Install ......................................................................................................................................................... 56
Impact Sensor ................................................................................................................................................ 57
All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006),
Remove .................................................................................................................................................. 57
Install..................................................................................................................................................... 57
Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) ............................................................................ 59
Remove .................................................................................................................................................. 59
Install..................................................................................................................................................... 60
Load Weight Sensor....................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda 2.0L and
2.2L Engines .................................................................................................................................................. 62
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines ................... 62
Crankshaft Position (CKP) Sensor .......................................................................................................... 62
Camshaft Position (CMP) Sensor ............................................................................................................. 62
Oil Pressure Sensor................................................................................................................................... 62
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor ..................................... 62
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 62
Air Flow Restriction Switch...................................................................................................................... 62
Remove for GM 2.4L Gas and LPG Trucks ......................................................................................... 63
Install for GM 2.4L Gas and LPG Trucks ........................................................................................... 63
Oxygen Sensor ........................................................................................................................................... 63
Remove .................................................................................................................................................. 63
Install..................................................................................................................................................... 66
Engine and Fuel Switches, GM 2.4L LPG Trucks Only .............................................................................. 67
Low LPG Pressure Switch ........................................................................................................................ 67
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks ................................................................ 67
Air Filter Restriction Switch .................................................................................................................... 67
Remove .................................................................................................................................................. 67
Install..................................................................................................................................................... 67
Oil Pressure Sensor................................................................................................................................... 67
Remove .................................................................................................................................................. 67
Install..................................................................................................................................................... 67
Engine Speed Sensor................................................................................................................................. 67
Remove .................................................................................................................................................. 67
Install..................................................................................................................................................... 67
Remove .................................................................................................................................................. 68
Install..................................................................................................................................................... 68
Throttle Position Sensor (TPS) ................................................................................................................. 70
Remove .................................................................................................................................................. 70
Install..................................................................................................................................................... 70
Fuel/Water Separator Sensor ................................................................................................................... 70
Remove .................................................................................................................................................. 70
Install..................................................................................................................................................... 71
iii

Glow Plug Relay ........................................................................................................................................ 71
Remove .................................................................................................................................................. 71
Install..................................................................................................................................................... 73
Engine and Fuel Sensors and Switches, Cummins Diesel Engines............................................................ 73
Air Filter Restriction Switch .................................................................................................................... 73
Remove .................................................................................................................................................. 73
Install..................................................................................................................................................... 73
Engine Oil Pressure Sensor ...................................................................................................................... 77
Remove .................................................................................................................................................. 77
Install..................................................................................................................................................... 77
Remove .................................................................................................................................................. 77
Install..................................................................................................................................................... 77
Remove .................................................................................................................................................. 78
Install..................................................................................................................................................... 78
Throttle Position Sensor (TPS) (Cummins 4.5L Only) ............................................................................ 79
Remove .................................................................................................................................................. 79
Install..................................................................................................................................................... 79
Fuel/Water Separator Sensor ................................................................................................................... 80
Remove .................................................................................................................................................. 80
Install..................................................................................................................................................... 80
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine Without DPF.................................. 81
Intake Air Temperature Sensor................................................................................................................ 82
Remove .................................................................................................................................................. 82
Install..................................................................................................................................................... 82
Intake Air Pressure Sensor....................................................................................................................... 82
Remove .................................................................................................................................................. 82
Install..................................................................................................................................................... 82
Air Inlet Heater ......................................................................................................................................... 82
Remove .................................................................................................................................................. 82
Install..................................................................................................................................................... 83
Remove .................................................................................................................................................. 83
Install..................................................................................................................................................... 83
Remove .................................................................................................................................................. 83
Install..................................................................................................................................................... 83
Crankshaft Position Sensor ...................................................................................................................... 84
Remove .................................................................................................................................................. 84
Install..................................................................................................................................................... 84
Adjust Shim Procedure ......................................................................................................................... 84
Camshaft Position Sensor ......................................................................................................................... 86
Remove .................................................................................................................................................. 86
Install..................................................................................................................................................... 86
Air Flow Restriction Sensor...................................................................................................................... 86
Remove .................................................................................................................................................. 86
Install..................................................................................................................................................... 86
Fuel/Water Separator................................................................................................................................ 87
Remove .................................................................................................................................................. 87
Install..................................................................................................................................................... 87
iv

Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine With DPF ....................................... 88
Intake Air Temperature Sensor................................................................................................................ 89
Remove .................................................................................................................................................. 89
Install..................................................................................................................................................... 89
Boost Sensor .............................................................................................................................................. 89
Remove .................................................................................................................................................. 89
Install..................................................................................................................................................... 89
Throttle Valve Assembly and Air Intake Heater..................................................................................... 90
Remove .................................................................................................................................................. 90
Install..................................................................................................................................................... 91
Remove .................................................................................................................................................. 91
Install..................................................................................................................................................... 91
Remove .................................................................................................................................................. 91
Install..................................................................................................................................................... 91
Crankshaft Position Sensor ...................................................................................................................... 92
Remove .................................................................................................................................................. 92
Install..................................................................................................................................................... 92
Adjust Shim Procedure ......................................................................................................................... 92
Camshaft Position Sensor ......................................................................................................................... 93
Remove .................................................................................................................................................. 93
Install..................................................................................................................................................... 93
Differential Pressure Sensor .................................................................................................................... 95
Remove .................................................................................................................................................. 95
Install..................................................................................................................................................... 95
Mass Air Flow Sensor ............................................................................................................................... 95
Remove .................................................................................................................................................. 95
Install..................................................................................................................................................... 95
Fuel/Water Separator................................................................................................................................ 96
Remove .................................................................................................................................................. 96
Install..................................................................................................................................................... 96
Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Engine......................................................... 97
Remove .................................................................................................................................................. 97
Install..................................................................................................................................................... 97
Remove .................................................................................................................................................. 98
Install..................................................................................................................................................... 98
Remove .................................................................................................................................................. 98
Install..................................................................................................................................................... 98
Fuel Shut Off Solenoid .............................................................................................................................. 98
Remove .................................................................................................................................................. 98
Install..................................................................................................................................................... 98
Vehicle System Manager (VSM)........................................................................................................................ 99
General ........................................................................................................................................................... 99
VSM Replacement ......................................................................................................................................... 99
Remove....................................................................................................................................................... 99
Install ....................................................................................................................................................... 101
Programming a New VSM and/or Display Switch Cluster ....................................................................... 101
v

General..................................................................................................................................................... 101
PC Service Tool Software ........................................................................................................................ 102
Data Transferring ................................................................................................................................... 102
New VSM............................................................................................................................................. 102
New (Blank) Display Switch Cluster ................................................................................................. 102
Used (Non-Blank) Display Switch Cluster ........................................................................................ 102
Power Distribution Module (PDM) and Component Parts ............................................................................ 104
Remove ......................................................................................................................................................... 104
PDM as a Unit ......................................................................................................................................... 104
Install ........................................................................................................................................................... 106
PDM as a Unit ......................................................................................................................................... 106
Remove and Install...................................................................................................................................... 107
PDM Component Parts ........................................................................................................................... 107
Transmission Control Unit.............................................................................................................................. 108
Remove ......................................................................................................................................................... 108
Install ........................................................................................................................................................... 108
Battery.............................................................................................................................................................. 108
Remove ......................................................................................................................................................... 108
Install ........................................................................................................................................................... 109
Lights................................................................................................................................................................ 110
Work Lights (Front and Rear)..................................................................................................................... 110
Remove..................................................................................................................................................... 110
Install ....................................................................................................................................................... 110
Strobe Light ................................................................................................................................................. 111
Remove..................................................................................................................................................... 111
Install ....................................................................................................................................................... 111
LED Tail, Backup, and Brake Lights ......................................................................................................... 112
Remove..................................................................................................................................................... 112
Install ....................................................................................................................................................... 112
Front Marker/Turn Signal Lights............................................................................................................... 114
Replacing Whole Front Marker/Turn Signal Light Assembly .............................................................. 114
Remove ................................................................................................................................................ 114
Install................................................................................................................................................... 114
Replacing Just the Front Marker/Turn Signal Light LED Light Lens ................................................ 114
Remove ................................................................................................................................................ 114
Install................................................................................................................................................... 114
Diesel Particulate Filter (DPF) Display.......................................................................................................... 115
Remove ......................................................................................................................................................... 115
Clean and Inspect ........................................................................................................................................ 115
Install ........................................................................................................................................................... 115
Electronic-Hydraulic Controls - Generation 1................................................................................................ 116
E-Hydraulic Controls - Test ........................................................................................................................ 116
Mini-Levers.............................................................................................................................................. 116
Full Stroke Test ....................................................................................................................................... 116
Function Returns to Neutral Test .......................................................................................................... 116
Push Button Switch ................................................................................................................................ 116
General ......................................................................................................................................................... 117
Mini-Lever Replacement ............................................................................................................................. 117
Remove..................................................................................................................................................... 117
Clean and Inspect.................................................................................................................................... 118
Install ....................................................................................................................................................... 118
vi

Push Button Switch Replacement .............................................................................................................. 119
Remove..................................................................................................................................................... 119
Install ....................................................................................................................................................... 120
Mini-Lever Module (MLM).......................................................................................................................... 121
Remove..................................................................................................................................................... 121
Install ....................................................................................................................................................... 121
Joystick......................................................................................................................................................... 122
Remove and Disassemble........................................................................................................................ 122
Inspect...................................................................................................................................................... 122
Assemble and Install............................................................................................................................... 122
Electronic-Hydraulic Controls - Generation 2................................................................................................ 122
General ......................................................................................................................................................... 122
Mini-levers, Remove and Install ................................................................................................................. 123
Armrest Assembly ....................................................................................................................................... 124
Remove..................................................................................................................................................... 124
Install ....................................................................................................................................................... 126
Horn Button ................................................................................................................................................. 126
Remove..................................................................................................................................................... 126
Install ....................................................................................................................................................... 126
Direction Control Switch............................................................................................................................. 127
Remove..................................................................................................................................................... 127
Install ....................................................................................................................................................... 127
Momentary Switches and Function Selection Button ............................................................................... 127
Remove..................................................................................................................................................... 128
Install ....................................................................................................................................................... 128
Joystick......................................................................................................................................................... 130
Remove and Disassemble........................................................................................................................ 130
Inspect...................................................................................................................................................... 130
Assemble and Install............................................................................................................................... 130
Joystick Armrest Slider Assembly.............................................................................................................. 130
Remove..................................................................................................................................................... 130
Install ....................................................................................................................................................... 130
S30FT, S35FT, S40FTS [E010];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S120FTS; S120FTPRS) [G004, H004];
110, 120FT) [N005, P005, R005];
vii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
NOTE: The joystick option identified in this manual See one of the following sections for procedures to
is not available for lift truck models remove ECU from your lift truck
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006) Gasoline Fuel System, GM 2.4L Engine 900 SRM
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, 1126 for lift truck models
H190FT) (A299, B299) • H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
The removal and replacement procedures for the
following electrical components are covered in this LPG Fuel System, GM 2.4L Engine 900 SRM 1124
manual: for lift truck models
• Display Switch Cluster • H2.0-3.5FT (H40-70FT) (L177)
• Vehicle System Manager (VSM) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• Power Distribution Module (PDM)
Gasoline Fuel System, GM 4.3L Engine With
• Joystick and mini-lever electronic-hydraulic con-
GFI 900 SRM 1244 for lift truck models
trols
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
• Lights
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
• Sensors and switches
100FTBCS; S120FTS; S120FTPRS) (G004)
• Battery
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
• Transmission Control Unit (TCU) for lift truck
models
(H80, 90, 100, 110, 120FT) (N005, P005)
• S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024,
F024) Gasoline Fuel System PSI GM 4.3L 900 SRM
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 1570 for lift truck models
J006, K006) • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
H190FT) (A299, B299) (H80, 90, 100, 110, 120FT) (R005)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
Some of the components used are made of plastic.
When using screws to replace and install plastic com-
• H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
ponents, the screws should be rotated counterclock-
wise until the screw thread turns over the last thread LPG Fuel System, GM 4.3L Engine With GFI 900
in the plastic part. The screw can then be turned SRM 1242 for lift trucks
clockwise to make a connection. This prevents "cut- • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
ting" new threads and damaging the existing thread • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
in the plastic part. 100FTBCS; S120FTS; S120FTPRS) (G004)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
If any welding must be done, obtain proper autho-
rization from a Resident Service Engineer. If autho-
(H80, 90, 100, 110, 120FT) (N005, P005)
rization is given, be sure to follow the procedures in
the CAUTION below.
H190FT) (A299)
CAUTION LPG Fuel System, GM 4.3L Engine With PSI 900

When welding, always disconnect the negative SRM 1556 for lift truck models
battery cable from battery and disconnect • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
the ground wire from the ground stud on the 100FTBCS; S120FTS; S120FTPRS) (G004, H004)
frame. See Figure 1. To prevent damage to the • H6.0FT, H7.0FT (H135FT, H155FT) (J006, K006)
Electronic Control Unit (ECU), remove it from • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
the lift truck. (H80, 90, 100, 110, 120FT) (P005, R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (E024, F024)

General 2200 SRM 1142
LPG Fuel System, GM 5.7L Engine 900 SRM 1433 • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
for lift truck models H40FTS) (F001)
H190FT) (A299, B299) Periodic Maintenance 8000 SRM 1248 for lift
truck models
Gasoline Fuel System, Mazda 2.0L and 2.2L 900 • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
SRM 1127 for lift truck models 100FTBCS; S120FTS; S120FTPRS) (G004)
• H2.0-3.5FT (H40-70FT) (L177) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (H80, 90, 100, 110, 120FT) (N005, P005)
LPG Fuel System, Mazda 2.0L and 2.2L Engines Periodic Maintenance 8000 SRM 1319 for lift
900 SRM 1125 for lift truck models truck models
• S30FT, S35FT, S40FTS (E010) • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
H40FTS) (F001) Periodic Maintenance 8000 SRM 1322 for lift
• H2.0-3.5FT (H40-70FT) (L177) • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
Gasoline Fuel System, Mazda 2.0L and 2.2LE- Periodic Maintenance 8000 SRM 1407 for lift
mission Compliant Engines 900 SRM 1325 for lift truck model
truck models • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
• H2.0-3.5FT (H40-70FT) (L177) H190FT) (A299)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
LPG Fuel System, Mazda 2.0L and 2.2L Emis- truck models
sion Compliant Engines 900 SRM 1326 for lift • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
truck models (H80, 90, 100, 110, 120FT) (R005)
• S30FT, S35FT, S40FTS (E010)
truck models
H40FTS) (F001)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) Periodic Maintenance 8000 SRM 1583 for lift
truck models
For more information on how to perform welding re-
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
pairs to lift truck and overhead guard, refer to one of
the following sections: Periodic Maintenance 8000 SRM 1586 for lift
truck models
truck models
H190FT) (B299)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
truck models
100FTBCS; S120FTS; S120FTPRS) (H004)
• S30FT, S35FT, S40FTS (E010)

2200 SRM 1142 Display Switch Cluster
Legend for Figure 1
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
Display Switch Cluster

REMOVE 6. Disconnect Display Switch Cluster harness from
Display Switch Cluster. Remove four bolts secur-
NOTE: The Display Switch Cluster is a nonrepairable ing Display Switch Cluster. Slide display panel
part. See Parts Manual for replacement part num- off of steering column. See Figure 4.
ber.
INSTALL
1. Disconnect ground wire.
NOTE: When a new Display Switch Cluster is in-
2. Lift up on steering wheel slightly and pull up on
stalled on a lift truck, the data that controls all func-
tilt lever. Fully lower steering column.
tions and features unique to that lift truck, needs to
3. Remove upper steering column cover by pulling be transferred to new Display Switch Cluster. See
up on upper steering column cover to release section Vehicle System Manager (VSM), located in
latches (one on either side), and pulling cover the back of this manual, for procedures to transfer
away from steering column. See Figure 2. data to a new Display Switch Cluster.
4. Remove horn button and disconnect horn wires. 1. Install Display Switch Cluster onto steering col-
umn. Install four bolts to secure panel to steering
NOTE: A puller tool may be required to remove steer- column and tighten bolts to 19 N•m (168 lbf in).
ing wheel. See Figure 4.
5. Remove lock nut securing steering wheel and re- 2. Connect Display Switch Cluster to display har-
move steering wheel from steering column. Take ness.
care to not damage horn wires. See Figure 3.

Display Switch Cluster 2200 SRM 1142

1. UPPER STEERING COLUMN COVER 3. LOWER STEERING COLUMN COVER
2. STEERING COLUMN TILT LEVER
Figure 2. Upper Steering Column Cover Removal

Legend for Figure 3
1. HORN BUTTON
2. LOCK NUT
Figure 3. Steering Wheel Removal

3. Install steering wheel onto steering shaft and 5. Install upper steering column cover by aligning
tighten lock nut until steering wheel is fully two latches and pushing down until latched. See
seated. Final torque for lock nut is 40 to 54 N•m Figure 2.
4. Connect horn wires to horn button. Install horn

lock nut and horn button into steering wheel.
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

Display Switch Cluster 2200 SRM 1142
DIRECTION CONTROL AND TURN SIGNAL with new lever. See Parts Manual for replacement
LEVERS part numbers.
Direction control lever and turn signal lever are sim- 1. Insert two small flat-blade or Phillips screw-
ilar in design, but perform different functions. Turn drivers, with a 3.175 mm (0.125 in.) or less,
signal lever is located on right side of the Display wide blade or die end, into opening on Display
Switch Cluster. Direction control lever is located on Switch Cluster on an outward angle enough to
left side of Display Switch Cluster. compress spring tab on direction control lever or
turn signal lever. See A, Figure 5.
Remove
NOTE: There are no repairs for direction control lever
and turn signal lever. If a lever malfunctions, replace
NOTE: DISPLAY SWITCH CLUSTER SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY. FLAT-BLADE SCREW-
DRIVERS SHOWN.
A. STEP 1 B. STEP 2
1. DIRECTION CONTROL AND TURN SIGNAL 2. FLAT-BLADE SCREWDRIVER
LEVERS 3. DISPLAY SWITCH CLUSTER
Figure 5. Direction Control and Turn Signal Removal

2. Pry spring tab toward body of direction control ON/OFF button. The Power ON/OFF button is a
lever or turn signal lever and, at the same time, nonrepairable part. See Parts Manual for replace-
pull on handle of lever enough to free the tab of ment parts. If truck is equipped with a key switch,
interior lock of Display Switch Cluster. See B, follow steps below to remove and replace key switch.
Figure 5.
NOTE: Lift truck models below may be equipped with
3. Repeat previous steps on opposite side of direc- an optional remote key switch in engine compart-
tion control lever or turn signal lever. Remove ment. See Sensors and Switches section in this ser-
direction control lever or turn signal lever from vice manual for replacement procedures.
Display Switch Cluster. • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006)
Install • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
Install direction control lever or turn signal lever into
opening of Display Switch Cluster until locking tabs 1. Fully lower steering column and remove upper
are engaged in Display Switch Cluster. steering column cover by pushing in on both sides
of cover to release latches (one on either side),
KEY SWITCH and pulling cover away from steering column.
See Figure 2.
Remove
2. Remove torx head capscrews. Slide key switch
NOTE: Lift truck models covered in this section can assembly out of Display Switch Cluster. See Fig-
be equipped with an optional key switch or Power ure 6.
1. BEZEL 4. TORX HEAD SCREW

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

Steering Column Repair 2200 SRM 1142
Install DISPLAY SWITCH CLUSTER PANEL

BEZEL AND OVERLAY
1. Install new key switch assembly into Display
Switch Cluster. Install torx head capscrews Remove
(T-15) to secure key switch to Display Switch
Cluster. Tighten torx head capscrews to 1.1 N•m 1. Insert a small, flat-bladed screwdriver into top
(9.7 lbf in). See Figure 6. slot on inner edge of bezel and pry outward. Re-
peat procedure at the lower slot on the bezel. Be
2. Install upper steering cover on steering column. careful to not damage bezel and overlay when
Align latches on upper steering cover to holes on removing bezel. Lift bezel off of Display Switch
steering column and push upper steering cover Cluster. See Figure 6.
into place on steering column.
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.
Steering Column Repair

REMOVE latches (one on either side), and pulling cover
away from steering column. See Figure 2.
1. On lift truck models below, to access battery, re-
move floor mat and floor plate. Disconnect bat- 3. Remove steering wheel and instrument display
tery. panel. See section Display Switch Cluster for re-
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, moval procedures.
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 4. Remove two screws and remove lower steering
H175FT36, H190FT) (A299, B299) column cover. See Figure 7.
On lift truck models below, to access battery, 5. Disconnect Display Switch Cluster harness from
raise the hood. Disconnect battery. display panel. Remove harness from steering col-
• S30FT, S35FT, S40FTS (E010) umn.
6. Remove four bolts (1, Figure 8) holding steering
H40FTS) (F001)
column to cowl.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) NOTE: This step only applies to lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S6.0FT, S7.0FT (S135FT, S155FT) (E024, F024).
(G004, H004) 7. Remove two washers from two lower bolts hold-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- ing steering column to cowl.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) 8. Raise steering column to disengage steering
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, shaft from the steering control unit.
E024, F024)
2. Remove upper steering column cover by pulling


2200 SRM 1142 Steering Column Repair
DISASSEMBLE 7. Move steering column to its lowest position and

install upper steering column cover. See Fig-
1. Remove steering shaft retention clip (4, Fig- ure 2.
ure 8).
2. Remove horn contact pads.
3. Remove lower strut pivot pin from the gas cylin-

der.
4. Remove steering column pivot bolts and steering

shaft.
ASSEMBLE
1. Install steering column pivot bolts and install
steering shaft.
2. Install lower strut pivot pin in the gas cylinder.

See Figure 8.
3. Install horn contact pads.
4. Install steering shaft retention clip.
INSTALL
1. Lubricate end of steering shaft with multipur-
pose grease. Install end of steering shaft into
steering control unit.
NOTE: This step only applies to lift truck models

S6.0FT, S7.0FT (S135FT, S155FT) (E024, F024).
2. Install two washers onto two lower bolts holding

steering column to cowl.
3. Install steering column to cowl using four bolts.

Tighten bolts to 38 N•m (28 lbf ft). See Figure 8.
4. Connect Display Switch Cluster harness to

Display Switch Cluster panel. Install Display
Switch Cluster harness on steering column.
5. Install upper steering column cover by aligning 1. SCREWS

2. LOWER STEERING COLUMN COVER
the two latches and pushing down until latched.
See Figure 7. Figure 7. Lower Steering Column Cover
Removal
6. Install steering wheel and instrument display
panel. See section Display Switch Cluster.

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

8. For lift truck models below, install floor plate, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
kick panel, seal plate, and dash panel. E024, F024)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, For lift truck models below, connect battery, in-
H40FTS) (F001) stall floor plate and floor mat.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H2.0-3.5FT (H40-70FT) (L177) J006, K006)
S80, 100FTBCS; S120FTS; S120FTPRS) H175FT36, H190FT) (A299, B299)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
Sensors and Switches

GENERAL • Service brake pedal position sensor
• Park brake sensor
CAUTION
The dash and kick panel need to be removed and in-
Before removing and replacing any sensors or
stalled on lift truck after a sensor or switch has been
switches, ALWAYS disconnect the battery. Fail-
replaced.
ure to disconnect the battery can cause dam-
age to the sensor or switch and other electrical Remove
components. Always cover or protect the sen-
sor or switch connector from contamination af- 1. Lower steering column to its lowest position and
ter disconnecting the harness mating part. remove upper steering column cover by pulling
DO NOT use solvent-based cleaners to clean latches (one on either side), and pulling cover
area around sensors or switches. away from steering column. See Figure 2.
All sensors and switches used on these trucks are 2. Remove Allen screws securing dash to top of
non-repairable parts. Replace with new sensors or cowl. Remove dash from clips, located under-
switches whenever a sensor or switch malfunctions neath dash, that attach dash to kick panel. Lift
and is not operating correctly. See Parts Manual to remove the dash. See Figure 9.
for replacement part numbers. Before installing new
sensors or switches, use a clean cloth and make sure 3. Lift kick panel from seal plate and remove from
the area around the sensor or switch is clean and free lift truck. See Figure 9.
of oils and contaminates.
Install
When removing and replacing sensors or switches, be
sure to tag connectors to aid in correct reconnecting. 1. Install kick panel onto seal plate.
2. Install dash into clips, located underneath dash,

Dash and Kick Panel, Remove and Install
that attach dash to kick panel. Install Allen
Before removing and replacing the following sensors screws securing dash to top of cowl.
and switches:
3. Install upper steering column cover by aligning
• Accelerator pedal position sensor two latches and pushing down until latched. See
• Brake fluid level switch Figure 2.

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

ACCELERATOR PEDAL POSITION

SENSOR
4. Disconnect accelerator pedal position sensor.
Remove
1. For lift truck models below, to access battery, re-
move floor mat and floor plate. Disconnect bat-
tery.
• 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)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
2. Remove upper steering column cover and dash

and kick panel See Dash and Kick Panel, Remove
NOTE: Lift truck model shown below is equipped only

with an electronic hydraulic control valve.
H190FT) (A299, B299)
3. If lift truck is equipped with:

NOTE: MANUAL HYDRAULIC CONTROL VALVE
Manual hydraulic control valve (with or WITHOUT OPS SHOWN. REMOVAL OF MANUAL
without Operator Presence System [OPS]). HYDRAULIC CONTROL VALVE WITH OPS IS THE
• Remove lever bracket capscrews and move hy- SAME.
draulic lever assembly toward operator’s seat.
1. LEVER BRACKET CAPSCREWS
See Figure 10. 2. COWL
Electronic hydraulic control valve. Figure 10. Manual Hydraulic Control Valve
• Disconnect valve harness from Vehicle System Removal
Manager (VSM). Remove two bolts and remove
valve harness bracket. See Figure 12.

5. Remove three bolts that hold throttle base plate • H8.0FT, H8.0FT9, H9.0FT (H170FT,
and pedal assembly to cowl and remove throttle H175FT36, H190FT) (A299, B299)
base plate and pedal assembly from cowl. See
Figure 11. Connect battery. For lift truck models below
lower hood.
6. Remove two pan head screws and lockwashers • S30FT, S35FT, S40FTS (E010)
and remove accelerator pedal position sensor • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
from throttle base plate. See Figure 12. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Install • H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
1. Insert new accelerator pedal position sensor into S80, 100FTBCS; S120FTS; S120FTPRS)
opening on throttle base plate. See Figure 12. (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
2. Rotate sensor so that the D shaped throttle shaft
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
end slides into accelerator pedal position sensor.
R005)
Rotate sensor counterclockwise until locating pin
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
on sensor lines up with hole in throttle base plate.
E024, F024)
3. Insert two pan head screws and lockwasher
and install accelerator pedal position sensor to
throttle base plate. Tighten screws to 2.25 N•m
(20 lbf in).
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.
H190FT) (A299, B299)
6. If lift truck is equipped with
Manual hydraulic control valve (with or

without Operator Presence System [OPS]).
• Install lever bracket to cowl. Install clevis and
retention pins and connect manual levers to
control valve. See Figure 10.
Electronic hydraulic control valve.

• Insert two bolts into valve harness bracket and
install valve harness bracket. Connect valve
harness to VSM. See Figure 12.
1. BOLTS
7. Install kick panel and dash. Install upper steer- 2. PEDAL ASSEMBLY
ing column cover. See Dash and Kick Panel, Re- 3. COWL
move and Install for procedures.
Figure 11. Accelerator Pedal and Throttle Base
8. Connect battery. For lift truck models below, in- Plate Removal
stall floor plate and floor mat.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)

NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN.

1. ACCELERATOR PEDAL POSITION SENSOR 5. THROTTLE BASE PLATE
2. BOLTS (THROTTLE BASE PLATE) 6. BOLTS (THROTTLE BASE PLATE)
3. VALVE HARNESS MOUNTING BRACKET 7. COWL
(ELECTRONIC VALVE) 8. VEHICLE SYSTEMS MANAGER (VSM)
4. BOLTS (VALVE HARNESS MOUNTING 9. CONTROL VALVE HARNESS
BRACKET) 10. SENSOR COVER
Figure 12. Accelerator Pedal Position Sensor

9. If throttle pedal needs to be adjusted, see one of For lift truck models below, to access battery,
the following sections for procedures: raise hood. Disconnect battery.
• S30FT, S35FT, S40FTS (E010)
Frame 100 SRM 1120 for lift truck models • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) • H2.0-3.5FT (H40-70FT) (L177)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H2.0-3.5FT (H40-70FT) (L177) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
(G004, H004)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
E024, F024)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) 2. Remove upper steering column cover and dash
and kick panel See Dash and Kick Panel, Remove
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024) 3. Disconnect brake fluid level switch from cowl
harness.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) CAUTION
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Disposal of lubricants and fluids must meet lo-
H175FT36, H190FT) (A299) cal environmental regulations.
Frame 100 SRM 1581 for lift ruck model 4. Remove reservoir from bracket and drain fluid
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) from reservoir. Disconnect master cylinder sup-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, ply hose from reservoir. Make sure air does not
H175FT36, H190FT) (B299) get into hose.
BRAKE FLUID LEVEL SWITCH See Figure 13 for lift truck models
• S30FT, S35FT, S40FTS (E010)
Remove • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
NOTE: Brake fluid level switch is a component of • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
master brake cylinder reservoir and is located inside • H2.0-3.5FT (H40-70FT) (L177)
reservoir. When switch is replaced, reservoir must
be replaced as well. See Figure 14 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
NOTE: Lift truck model shown below DOES NOT S80, 100FTBCS; S120FTS; S120FTPRS)
have a brake fluid level switch. (G004, H004)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
H190FT) (A299, B299) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
1. For lift truck models below, to access battery, re- • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
move floor mat and floor plate. Disconnect bat- E024, F024)
tery. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

1. SERVICE BRAKE PRESSURE SENSOR

2. MASTER CYLINDER (BOOSTED)
3. SERVICE BRAKE PEDAL POSITION SENSOR
4. BRAKE FLUID LEVEL SWITCH (INSIDE
RESERVOIR)
5. BRAKE FLUID RESERVOIR MOUNTING
BRACKET
6. COWL
7. BRAKE FLUID RESERVOIR
8. BRAKE FLUID SUPPLY HOSE
1. RESERVOIR SUPPLY HOSE Figure 14. Brake Fluid Level Switch, Service
2. BRAKE FLUID RESERVOIR Brake Pedal Position Sensor, and Service
3. COWL
4. BRAKE FLUID LEVEL SWITCH (INSIDE Brake Pressure Sensor For Lift Truck Models
RESERVOIR) S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
5. BRAKE FLUID RESERVOIR MOUNTING S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
BRACKET H004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
Figure 13. Brake Fluid Level Switch, Lift Truck P005, R005); S6.0FT, S7.0FT (S135FT, S155FT)
Models S30FT, S35FT, S40FTS (E010); H1.6FT, (D024, E024, F024); and H6.0FT, H7.0FT
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (H135FT, H155FT) (H006, J006, K006)
(F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
and H2.0-3.5FT (H40-70FT) (L177)

Install Periodic Maintenance 8000 SRM 1322 for lift

truck models
1. Connect the master cylinder supply hose to a new • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
reservoir. J006)
See Figure 13 for lift truck models Periodic Maintenance 8000 SRM 1558 for lift
• S30FT, S35FT, S40FTS (E010) truck models
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
H40FTS) (F001) 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
truck models
See Figure 14 for lift truck models • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) Periodic Maintenance 8000 SRM 1583 for lift
(G004, H004) truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) Periodic Maintenance 8000 SRM 1598 for lift
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, truck models
E024, F024) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, S80, 100FTBCS; S120FTS; S120FTPRS)
J006, K006) (H004)
2. Install new reservoir onto bracket and fill with 3. Connect brake fluid level switch to cowl harness.
new brake fluid. See one of the following sections
4. Install kick panel and dash. Install upper steer-
for brake fluid specifications:
ing column cover. See Dash and Kick Panel, Re-
Periodic Maintenance 8000 SRM 1150 for lift move and Install for procedures.
truck models
5. Connect battery. For lift truck models below, in-
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Periodic Maintenance 8000 SRM 1207 for lift J006, K006)
truck models • H8.0FT, H8.0FT9, H9.0FT (H170FT,
Connect battery. For lift truck models below
H40FTS) (F001)
lower hood.
Periodic Maintenance 8000 SRM 1248 for lift • S30FT, S35FT, S40FTS (E010)
truck models • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; H40FTS) (F001)
S80, 100FTBCS; S120FTS; S120FTPRS) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(G004) • H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
Periodic Maintenance 8000 SRM 1319 for lift • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
truck models 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, R005)
E024) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)

SERVICE BRAKE PEDAL POSITION • S2.0-3.5FT (S40-70FT, S55FTS) (F187)

SENSOR • H2.0-3.5FT (H40-70FT) (L177)
Remove See Figure 16 for lift truck models

• H8.0FT, H8.0FT9, H9.0FT (H170FT,
1. For lift truck models below, to access battery, re- H175FT36, H190FT) (A299, B299)
move floor mat and floor plate. Disconnect bat-
tery. See Figure 17 for lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
J006, K006) 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 4. Remove mounting bracket capscrew, mounting
H175FT36, H190FT) (A299, B299) bracket, and brake pedal position sensor from lift
For lift truck models below, to access battery, truck.
raise hood. Disconnect battery. For lift trucks built prior to December, 2009, see
• S30FT, S35FT, S40FTS (E010) Figure 16.
H40FTS) (F001) For lift trucks built after December, 2009, see
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) Figure 17.
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 5. Remove two capscrews, two nuts, and brake
S80, 100FTBCS; S120FTS; S120FTPRS) pedal position sensor from mounting bracket.
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- For lift trucks built prior to December, 2009, see
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, Figure 18.
R005) For lift trucks built after December, 2009, see
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, Figure 19.
E024, F024)
2. Remove upper steering column cover and dash

Install
and kick panel See Dash and Kick Panel, Remove 1. Install new service brake pedal position sensor to
and Install for procedures. mounting bracket using two capscrews and two
nuts.
3. Disconnect brake pedal position sensor from cowl
harness. For lift trucks built prior to December, 2009, see
Figure 18.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; For lift trucks built after December, 2009, see
S80, 100FTBCS; S120FTS; S120FTPRS) Figure 19.
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- 2. Install mounting bracket and service brake
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, pedal position sensor to lift truck using mount-
R005) ing bracket capscrew. Connect service brake
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, pedal position sensor to cowl harness.
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, For lift trucks built prior to December, 2009, see
J006, K006) Figure 16.
See Figure 15 for lift truck models For lift trucks built after December, 2009, see
• S30FT, S35FT, S40FTS (E010) Figure 17.
H40FTS) (F001)

NOTE: SERVICE BRAKE PEDAL POSITION SENSOR

FOR LIFT TRUCK MODELS H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299) SHOWN.
SERVICE BRAKE PEDAL POSITION SENSORS FOR
ALL LIFT TRUCKS COVERED IN THIS MANUAL ARE
MOUNTED THE SAME WAY.
1. MOUNTING BRACKET CAPSCREW
2. MOUNTING BRACKET
3. CAPSCREWS AND NUTS
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
COWL HARNESS) Figure 16. Service Brake Pedal Position Sensor
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);
H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS)
(F187); H2.0-3.5FT (H40-70FT) (L177)

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
1. NUTS
2. MOUNTING BRACKET
CONNECTOR
5. CAPSCREWS
Figure 19. Brake Pedal Position Sensor

Disassembly, After December, 2009

3. After new service brake pedal position sensor has • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
been installed, check the gap between the sensor • H2.0-3.5FT (H40-70FT) (L177)
arm and tab. See the one of the following sections • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
for the procedures: S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
Brake System 1800 SRM 1135 for lift truck • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
models 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S30FT, S35FT, S40FTS (E010) R005)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
H40FTS) (F001) E024, F024)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) PARKING BRAKE SENSOR
Brake System 1800 SRM 1247 for lift truck Remove
models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 1. For lift truck models below, to access battery, re-
E024, F024) move floor mat and floor plate. Disconnect bat-
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; tery.
S80, 100FTBCS; S120FTS; S120FTPRS) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
(G004) J006, K006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
J006, K006) H175FT36, H190FT) (A299, B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, For lift truck models below, to access battery,
R005) raise hood. Disconnect battery.
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S30FT, S35FT, S40FTS (E010)
H175FT36, H190FT) (A299, B299) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
Wet Brakes 1800 SRM 1597 for lift truck models • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
(H004) S80, 100FTBCS; S120FTS; S120FTPRS)
5.5FT (H80, 90, 100, 110, 120FT) (R005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
4. Install kick panel and dash. Install upper steer- R005)
ing column cover. See Dash and Kick Panel, Re- • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
move and Install for procedures. E024, F024)
5. Connect battery. For lift truck models below, in- 2. Remove upper steering column cover and dash
stall floor plate and floor mat. and kick panel See Dash and Kick Panel, Remove
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, and Install for procedures.
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 3. Disconnect parking brake sensor from cowl har-
H175FT36, H190FT) (A299, B299) ness. Remove torx capscrews from sensor and re-
move sensor from parking brake handle assem-
Connect battery. For lift truck models below bly. See Figure 20 or Figure 21.
lower hood.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)

Install 3. Connect sensor to cowl harness. See Figure 20 or

Figure 21.
1. Install new sensor by using torx capscrews to se-
cure sensor to parking brake handle assembly. 4. Install kick panel and dash. Install upper steer-
ing column cover. See Dash and Kick Panel, Re-
2. Visually inspect sensor to ensure sensor arm and move and Install for procedures.
parking brake lever maintain continuous contact
throughout full range of lever operation.
1. PARKING BRAKE SENSOR

2. PARKING BRAKE HANDLE ASSEMBLY
COWL HARNESS)
4. TORX CAPSCREWS
Figure 21. Parking Brake Sensor, Lift Truck

Model (Late Design)

2. PARKING BRAKE HANDLE ASSEMBLY
COWL HARNESS)
4. TORX CAPSCREWS
Figure 20. Parking Brake Sensor (Early

Design)

5. Connect battery. For lift truck models below, in- • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
stall floor plate and floor mat. E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) 2. Remove floor mat and floor plate to access service
• H8.0FT, H8.0FT9, H9.0FT (H170FT, brake pressure sensor for lift truck models
H175FT36, H190FT) (A299, B299) • S30FT, S35FT, S40FTS (E010)
Connect battery. For lift truck models below H40FTS) (F001)
lower hood. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (G004, H004)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
S80, 100FTBCS; S120FTS; S120FTPRS) R005)
(G004, H004) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- E024)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) 3. Disconnect the sensor from the cowl harness and
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, remove it from the master cylinder.
E024, F024)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
SERVICE BRAKE PRESSURE SENSOR
Remove (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
1. For lift truck models below, to access battery, re- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
move floor mat and floor plate. Disconnect bat- R005)
tery. • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• H8.0FT, H8.0FT9, H9.0FT (H170FT, J006, K006)
H175FT36, H190FT) (A299, B299)
For lift truck models below, to access battery, • S30FT, S35FT, S40FTS (E010)
raise hood. Disconnect battery. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) • H2.0-3.5FT (H40-70FT) (L177)
• 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,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
S80, 100FTBCS; S120FTS; S120FTPRS) (A299, B299).
(G004, H004) 4. Disconnect the sensor from the cowl harness and
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- remove it from the modulating brake valve. See
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, Figure 22.
R005)


2. ACCUMULATOR PRESSURE SWITCH
3. BRAKE PRESSURE SENSOR
4. MODULATING BRAKE VALVE
5. ACCUMULATOR
6. ACCUMULATOR CHARGE VALVE
7. PARKING BRAKE
8. BRAKE PEDAL
Install
1. Install a new sensor on master cylinder. Tighten
sensor to 23 to 28 N•m (204 to 248 lbf in) for lift
truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
NOTE: Perform Step 2 for lift truck models H8.0FT,

H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299).
2. Install a new sensor on modulating brake valve.

Tighten sensor to 23 to 28 N•m (204 to 248 lbf in).
3. Connect new sensor to cowl harness.

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Figure 22. Brake Pressure Sensor and
J006, K006)
Accumulator Pressure Switch, Lift Truck
Models H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
See Figure 16 for lift truck models R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
H175FT36, H190FT) (A299, B299) E024, F024)
4. Bleed the brake system as described in the sec-
ACCUMULATOR PRESSURE SWITCH FOR
tion:
LIFT TRUCK MODELS H8.0FT, H8.0FT9,
Brake System 1800 SRM 1135 for lift truck H9.0FT (H170FT, H175FT36, H190FT)
models (A299, B299)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001) WARNING
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) DO NOT continue to operate the lift truck if the
• H2.0-3.5FT (H40-70FT) (L177) light and audible alarm are on during opera-
tion. Low accumulator pressure will prevent
Brake System 1800 SRM 1247 for lift truck the service brakes from stopping the lift truck.
models Serious injury to personnel can result.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024) During operation of lift truck, if the red, low accu-
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; mulator pressure light illuminates and an audible
S80, 100FTBCS; S120FTS; S120FTPRS) alarm sounds (see Operating Manual), accumu-
(G004) lator pressure switch has detected that hydraulic
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, pressure is below 7240 kPa (1050 psi). Move lift
J006, K006) truck to level ground and/or apply the parking
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- brake. Turn lift truck power OFF immediately and
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, DO NOT restart engine until low pressure condition
R005) has been corrected.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) Remove
Wet Brakes 1800 SRM 1597 for lift truck models 1. Remove floor mat and floor plate and disconnect
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; battery.
(H004) 2. Disconnect ccumulator pressure switch from the
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- cowl harness and remove it from theaccumulator
5.5FT (H80, 90, 100, 110, 120FT) (R005) charge valve. See Figure 22.
5. Connect battery. For lift truck models below, in- Install

1. Install new accumulator pressure switch into ac-
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
cumulator charge valve. Connect cowl harness to
J006, K006)
accumulator pressure switch. See Figure 16.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) 2. Connect battery and install floor plate and floor
mat.
Connect battery. For lift truck models below
lower hood. 3. Bleed brake system as described in service man-
• S30FT, S35FT, S40FTS (E010) ual Brake System 1800 SRM 1247.
H40FTS) (F001)

MONOTROL® SENSOR MICROSWITCH • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Remove (H004)
1. For lift truck models below, to access battery, re- Three-Speed Powershift Transmission Re-
move floor mat and floor plate. Disconnect bat- pair 1300 SRM 1317 for lift truck models
tery. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• H8.0FT, H8.0FT9, H9.0FT (H170FT, E024, F024)
H175FT36, H190FT) (A299, B299)
For lift truck models below, to access battery,
raise hood. Disconnect battery. Single Speed PowerShift, Aluminum Trans-
• S30FT, S35FT, S40FTS (E010) mission 1300 SRM 1421 for lift truck models
(G004, H004) Single Speed Powershift, Aluminum Chain
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- Drive Transmission 1300 SRM 1447 for lift
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, truck models
R005) • S30FT, S35FT, S40FTS (E010)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
E024, F024) H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
2. Remove MONOTROL® pedal assembly from • H2.0-3.5FT (H40-70FT) (L177)
throttle base plate and cowl. Follow removal
procedures in one of the following sections: 3. Remove u-clip, foam lock seal, and wiring har-
ness from the pedal frame. Remove four pan
Powershift Transmission, Repair 1300 SRM head screws, lockwashers, washers, pedal pad,
1129 for lift truck models and springs from pedal frame. If any metal in-
• S30FT, S35FT, S40FTS (E010) serts in pedal pad are damaged, replace as nec-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, essary. See Figure 23.
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) 4. Remove two hex head screws 19 mm (3/4 in.),
• H2.0-3.5FT (H40-70FT) (L177) lockwashers, nuts, and microswitch from pedal
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; pad. Repeat for remaining microswitch and re-
S80, 100FTBCS; S120FTS; S120FTPRS) move wiring harness from pedal frame.
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
One and Two Speed Transmissions, Repair

1300 SRM 1569 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)


Figure 23. Microswitch Removal

Install • S6.0FT, S7.0FT (S135FT, S155FT) (D024,

E024, F024)
1. Install microswitch and two hex head screws in • H8.0FT, H8.0FT9, H9.0FT (H170FT,
pedal pad. Coat exposed threads of hex head H175FT36, H190FT) (A299, B299)
screws with Loctite™ 222 (Hyster P/N 0360387).
Install two lockwashers and nuts on hex head Single Speed PowerShift, Aluminum Trans-
screws. DO NOT tighten nuts at this time. Re- mission 1300 SRM 1421 for lift truck models
peat for the other microswitch. • S30FT, S35FT, S40FTS (E010)
2. Put wires through hole in pedal frame. The white H40FTS) (F001)
banded wire is for the reverse microswitch, and • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
the blue banded wire is for the forward mi- • H2.0-3.5FT (H40-70FT) (L177)
croswitch. Adjust each microswitch in its mount
so that the measurement between the edge of the Single Speed Powershift, Aluminum Chain
mount and the base of the microswitch equals Drive Transmission 1300 SRM 1447 for lift
0.0 to 0.5 mm (0.0 to 0.02 in.). Tighten mount- truck models
ing nuts of each microswitch as adjustment is • S30FT, S35FT, S40FTS (E010)
completed. See Figure 24. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
3. Install wiring harness in pedal frame. Install • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
foam lock seal and u-clip. Install pedal pad and • H2.0-3.5FT (H40-70FT) (L177)
springs in pedal frame. Coat threads of four
pan head screws with Loctite 222 (Hyster P/N
0360387). Install pan head screws, lockwashers,
and washers in pedal pad. Tighten pan head
4. Install MONOTROL® pedal assembly onto the

truck. Follow installation procedures in one of
the following sections:
Powershift Transmission, Repair 1300 SRM

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
One and Two Speed Transmissions, Repair

1300 SRM 1569 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(H004)
1. MICROSWITCH MOUNT
Three-Speed Powershift Transmission Re- 2. MICROSWITCH BASE
pair 1300 SRM 1317 for lift truck models Figure 24. Microswitch Adjustment
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)

5. Connect battery. For lift truck models below, in- • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
stall floor plate and floor mat. H40FTS) (F001)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
J006, K006) • H2.0-3.5FT (H40-70FT) (L177)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
H175FT36, H190FT) (A299, B299) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
Connect battery. For lift truck models below • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
lower hood. 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S30FT, S35FT, S40FTS (E010) R005)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
H40FTS) (F001) E024, F024)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; CAUTION
S80, 100FTBCS; S120FTS; S120FTPRS) Disposal of lubricants and fluids must meet lo-
(G004, H004) cal environmental regulations.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, 2. Drain coolant from radiator and disconnect elec-
R005) trical connector from low coolant level sensor.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 3. Remove low coolant level sensor from radiator.
E024, F024)
LOW COOLANT LEVEL SENSOR • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
NOTE: The low coolant level sensor is an optional fea-
• S30FT, S35FT, S40FTS (E010)
ture on these lift trucks and is a part of the Electronic
Monitoring package option. If the lift truck does not
H40FTS) (F001)
have a low coolant sensor, a plug will be in place of
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
where the sensor goes. See Figure 25.
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Remove
1. For lift truck models below, to access battery, re- (G004, H004)
move floor mat and floor plate. Disconnect bat- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
tery. 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, E024, F024)
H175FT36, H190FT) (A299, B299)
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)

Install 3. Seal threads with Loctite PST 567 (Hyster P/N

273338) thread sealant and torque to 7 N•m
1. Install new low coolant level sensor into radiator. (62 lbf in).
See Figure 25 for lift truck models 4. Connect battery. For lift truck models below, in-
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, stall floor plate and floor mat.
• S30FT, S35FT, S40FTS (E010) J006, K006)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H40FTS) (F001) H175FT36, H190FT) (A299, B299)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) Connect battery. For lift truck models below
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; lower hood.
S80, 100FTBCS; S120FTS; S120FTPRS) • S30FT, S35FT, S40FTS (E010)
(G004, H004) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- H40FTS) (F001)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
R005) • H2.0-3.5FT (H40-70FT) (L177)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
E024, F024) S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
See Figure 26 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
H175FT36, H190FT) (A299, B299) R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
2. Connect the electrical connector to the low
E024, F024)
coolant level sensor. Refill radiator with correct
coolant of 50% water and 50% Ethylene Glycol
Boron-Free Antifreeze.

Figure 25. Low Level Coolant Sensor


A. GM 2.4L ENGINES, RADIATOR WITH EXTERNAL AND KUBOTA 3.8L DIESEL ENGINES WITH
COOLER SHOWN EXTERNAL COOLER SHOWN
B. MAZDA 2.0L AND 2.2L ENGINES EXCEPT 2007 E. MAZDA 2007 EMISSION COMPLIANT 2.0L AND
EMISSION COMPLIANT ENGINES (MODINE 2.2L ENGINES (MODINE SHOWN), RADIATOR
SHOWN), RADIATOR WITH INTERNAL COOLER WITH INTERNAL COOLER SHOWN
SHOWN F. CUMMINS QSB 3.3L DIESEL ENGINE WITH
C. CUMMINS 4.5L AND YANMAR DIESEL ENGINES INTERNAL COOLER SHOWN, LIFT TRUCK
AND GM 4.3L ENGINES WITH INTERNAL MODELS H6.0FT, H7.0FT (H135FT, H155FT)
COOLER SHOWN (H006, J006)
D. CUMMINS 4.5L AND YANMAR DIESEL ENGINES
AND GM 4.3L ENGINES AND GM 5.7L ENGINES
1. RADIATOR 2. LOW LEVEL COOLANT SENSOR
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)

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 equipped
with Mazda gas engine, see the following service
manual to replace fuel level sensor.
• Gasoline Fuel System, Mazda 2.0L and 2.2LE-

mission Compliant Engines 900 SRM 1325
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 sen-

sor on the fuel pump cover.
3. Unscrew the sensor and remove sensor and

sender unit from fuel pump assembly. See Fig-
ure 27.
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 connector.
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)
NOTE: GAS FUEL PUMP SHOWN. FUEL LEVEL SEN-
SOR LOCATED IN SAME POSITION FOR DIESEL
FUEL PUMP.
1. BRACKET
2. FUEL SENDER UNIT
3. FUEL LEVEL SENSOR
4. FUEL PUMP COVER
Figure 27. Fuel Pump and Sensor

ARMREST SWITCH 5. Remove two capscrews and seat sensor from the
seat.
NOTE: Lift truck models shown below are NOT
equipped with an armrest switch Install
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006) 1. Insert two capscrews and install sensor to seat.
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, See Figure 30.
H190FT) (A299, B299)
2. Connect new seat sensor to seat harness.
Remove 3. Install seat onto hood using four capscrews
and washers. Tighten capscrews to 18 N•m
(156 lbf in). See Figure 29.
2. Unlatch and raise armrest.
4. Install seat harness to brackets on hood.
3. Remove arm pad by removing four screws from
5. Connect seat harness to chassis harness.
underside of armrest. Disconnect armrest
switch from seat harness. See Figure 28. Re- 6. Connect the battery and close hood.
move screws securing armrest switch to armrest
bracket and remove switch. Non-Suspension Seats; Lift Truck Models
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Install
J006, K006)
1. Install new armrest switch on bracket. Connect
switch to seat harness. See Figure 28. NOTE: Lift truck model shown below is NOT
equipped with a non-suspension seat.
2. Install arm pad by inserting four screws into un- • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
derside of armrest. H190FT) (A299, B299)
3. Close and latch armrest. Remove
4. Connect the battery and lower the hood. 1. For access to battery, remove floor plate and floor
mat. Disconnect battery.
SEAT SENSOR (OPERATOR PRESENCE
2. Disconnect seat harness from chassis harness.
SYSTEM)
Remove the seat harness from the bracket that
Non-Suspension and Semi-Suspension is attached to the seat surround plate. See Fig-
ure 31.
Seats; All Lift truck Models Except H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006, 3. Remove the four flange nuts holding the seat to
K006) and H8.0FT, H8.0FT9, H9.0FT the seat plate. Remove seat from seat plate.
(H170FT, H175FT36, H190FT) (A299, B299) 4. Disconnect the seat sensor. See Figure 30.
Remove 5. Remove two capscrews and seat sensor from the
seat.
1. Raise hood for access to battery and disconnect
battery. Install
2. Disconnect seat harness from chassis harness. 1. Insert two capscrews and install new sensor to
Remove seat harness from brackets that are at- seat. See Figure 30.
tached to hood. See Figure 29.
2. Connect new seat sensor to seat harness.
3. Remove the four capscrews and washers holding
the seat to the hood. Remove seat from the hood. 3. Install seat onto seat plate using four flange nuts.
Tighten flange nuts to 18 N•m (156 lbf in) See
4. Disconnect the seat sensor. See Figure 30. Figure 31.

Figure 28. Armrest Switch

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
4. Install seat harness to bracket on seat surround

plate.
5. Connect seat harness to chassis harness.
6. Connect the battery and install the floor plate

and floor mat.
1. CAPSCREWS
2. SEAT SENSOR
3. SEAT SENSOR ELECTRICAL CONNECTOR
4. SEAT GROUND WIRE
5. SEAT HARNESS
Figure 30. Seat Sensor, Non-Suspension and

NOTE: BOTTOM VIEW OF HOOD SHOWN. Semi-Suspension Seats
1. CAPSCREWS
2. SEAT HARNESS BRACKET
3. SEAT HARNESS
Figure 29. Seat Removal, Non-Suspension and

Semi-Suspension Seats

NOTE: BOTTOM VIEW SHOWN.

1. HARNESS BRACKET
2. SEAT HARNESS
3. SEAT SURROUND PLATE
4. FLANGE NUTS 1. SEAT SENSOR
5. SEAT PLATE 2. SEAT HARNESS
3. TO CHASSIS HARNESS
Figure 31. Seat Removal, Non-Suspension Seat, 4. CLIPS
Lift Truck Models H6.0FT, H7.0FT (H135FT, 5. BOTTOM SEAT CUSHION
H155FT) (H006, J006, K006) 6. SEAT BASE
Full Suspension Seats; All Lift Truck Figure 32. Seat Sensor, Full-Suspension Seat
Models HOOD SHUT OFF SWITCH
Remove NOTE: The hood shut off switch is found on certain
1. Remove two clips that secure the bottom seat lift truck models manufactured for use in Europe
cushion to seat base. See Figure 32. only.
2. Lift bottom seat cushion up and disconnect the Remove

seat sensor from harness.
1. To access the battery, remove the floor mat and
3. Use a small, flat-bladed screwdriver and remove floor plate, on lift truck models below. Disconnect
the seat sensor from bottom seat cushion. the battery.
• H6.0FT, H7.0FT (H006, J006, K006)
Install • H8.0FT, H8.0FT9, H9.0FT (A299, B299)
1. Install new seat sensor into bottom seat cushion. To access the battery, raise the hood, on lift truck
2. Connect seat sensor to seat harness. See Fig- • H1.6FT, H1.8FT, H2.0FTS (F001)
ure 32. • S2.0-3.5FT (F187)
3. Place bottom seat cushion onto seat base and se- • H2.0-3.5FT (L177)
cure cushion to base with two clips. • S4.0, 4.5, 5.5FT, S5.5FTS (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (N005, P005)
• S6.0FT, S7.0FT (D024, E024)

2. Raise the hood and disconnect switch from rear • S6.0FT, S7.0FT (D024, E024)
harness to chassis harness connector and remove • H1.6FT, H1.8FT, H2.0FTS (F001)
capscrews to remove switch from bracket. • S2.0-3.5FT (F187)
• H2.0-3.5FT (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (G004, H004) See Figure 34 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • H6.0FT, H7.0FT (H006, J006, K006)
5.5FT (N005, P005) • H8.0FT, H8.0FT9, H9.0FT (A299, B299)
NOTE: BOTTOM VIEW OF HOOD SHOWN.

1. REAR HARNESS TO CHASSIS HARNESS 3. BRACKET CAPSCREW
CONNECTOR 4. ACTUATOR MAGNET SWITCH
2. HOOD SHUT OFF SWITCH
Figure 33. Hood Shut Off Switch, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (G004, H004),
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (N005, P005), S6.0FT, S7.0FT (D024, E024), H1.6FT,
H1.8FT, H2.0FTS (F001), S2.0-3.5FT (F187), and H2.0-3.5FT (L177)

Install • S6.0FT, S7.0FT (D024, E024)

• H1.6FT, H1.8FT, H2.0FTS (F001)
1. Install new switch on bracket using the cap- • S2.0-3.5FT (F187)
screws and connect switch to rear harness to • H2.0-3.5FT (L177)
chassis harness connector.
See Figure 33 for lift truck models • H6.0FT, H7.0FT (H006, J006, K006)
• S4.0, 4.5, 5.5FT, S5.5FTS (G004, H004) • H8.0FT, H8.0FT9, H9.0FT (A299, B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (N005, P005)
NOTE: BOTTOM VIEW OF HOOD SHOWN. KEY AND HOOD SWITCHES ARE OPTIONAL FEATURES.
1. HINGE BRACKET 4. REAR HARNESS TO CHASSIS HARNESS
2. ACTUATOR MAGNET CONNECTOR
3. HOOD SHUT OFF SWITCH 5. KEY SWITCH
Figure 34. Hood Shut Off Switch, Lift Truck Models H6.0FT, H7.0FT (H006, J006, K006) and
H8.0FT, H8.0FT9, H9.0FT (A299, B299)

2. Connect the battery, install the floor plate and 2. Connect boot protector to remote key switch as-
floor mat, on lift truck models sembly. See Figure 35.
• H6.0FT, H7.0FT (H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (A299, B299) 3. Close the hood. Connect the battery and install
floor plate and floor mat.
Connect the battery and lower the hood, on lift
truck models
• H1.6FT, H1.8FT, H2.0FTS (F001)
• S2.0-3.5FT (F187)
• H2.0-3.5FT (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (N005, P005)
• S6.0FT, S7.0FT (D024, E024)
REMOTE KEY SWITCH

NOTE: Lift truck models shown below may be
equipped with an optional remote key switch on the
right side of the engine compartment.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006)
H190FT) (A299, B299)
Remove
1. Remove the floor mat and floor plate for access to 1. BOOT PROTECTOR
2. MOUNTING BRACKET
the battery. Disconnect the battery. 3. REMOTE KEY SWITCH ASSEMBLY
4. NUT
2. Raise the hood and pull back the boot protector 5. KEY
and disconnect boot protector from the remote
key switch assembly. See Figure 35. Figure 35. Remote Key Switch Replacement,
Lift Truck Models H6.0FT, H7.0FT (H135FT,
3. Loosen the nut and remove remote key switch H155FT) (H006, J006, K006) and H8.0FT,
assembly from mounting bracket. H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)
Install
1. Install new remote key switch assembly into
mounting bracket. Tighten nut to secure the
assembly to mounting bracket.

HYDRAULIC FILTER PRESSURE SWITCH hydraulic filter head assembly and discard
switch and O-ring. See Figure 36.
NOTE: The hydraulic filter pressure switch is an op-
tional feature on the lift trucks covered in this ser- Install
vice manual and is a part of the Electronic Monitor-
ing package option. 1. Insert new switch, with new O-ring, into hy-
draulic filter head assembly. Torque switch to
Remove 20 N•m (177 lbf in). Connect hydraulic filter
pressure switch to chassis harness. See Fig-
1. To access the battery, remove the floor mat and ure 36.
floor plate, on lift truck models below. Disconnect
the battery. 2. Connect the battery, install the floor plate and
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, floor mat, on lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT, J006, K006)
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood, on lift truck
models below. Disconnect the battery. Connect the battery and lower the hood, on lift
R005) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, R005)
E024, F024) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
2. Disconnect the hydraulic filter pressure switch
from the chassis harness. Remove switch from

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, 4.5, 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), S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024),
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
2. O-RING (NOT SHOWN)
3. FILTER HEAD ASSEMBLY

Figure 36. Hydraulic Filter Pressure Switch

TRANSMISSION SPEED SENSOR • H6.0FT, H7.0FT (H135FT, H155FT) (H006,

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

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)

an iron transmission housing.
2. Disconnect sensor from transmission harness NOTE: TWO-SPEED TRANSMISSION SHOWN FOR
and remove bolt securing sensor to transmission LIFT TRUCK MODELS
housing. Discard the O-rings. • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
See Figure 37 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; (H80, 90, 100, 110, 120FT) (N005, P005, R005)
(G004, H004) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- (F001)
R005) • H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 1. PRESSURE SENSORS
2. PRESSURE SENSOR (TWO-SPEED ONLY)
H40FTS) (F001) 3. TRANSMISSION OUTPUT SPEED SENSOR
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (TOSS)
• H2.0-3.5FT (H40-70FT) (L177) 4. TRANSMISSION INPUT SPEED SENSOR (TISS)
5. BOLTS
See Figure 38 for lift truck models 6. TEMPERATURE SENSOR
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024) Figure 37. Transmission Sensors - Iron Housing

NOTE: Perform Step 3 for lift trucks built prior to See Figure 39 for lift truck models
January, 2011 equipped with an aluminum transmis- • S30FT, S35FT, S40FTS (E010)
sion housing. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
3. Remove capscrew, washer, and shield from the • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
top of the transmission housing. See Figure 39. • H2.0-3.5FT (H40-70FT) (L177)
NOTE: Perform Step 4 and Step 5 for lift truck See Figure 40 for lift truck models
equipped with an aluminum housing. • S30FT, S35FT, S40FTS (E010)
4. Disconnect sensor from transmission harness.
H40FTS) (F001)
5. Remove capscrew, washer, and sensor from • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
transmission housing. Remove and discard • H2.0-3.5FT (H40-70FT) (L177)
O-ring from sensor.
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 7. TRANSMISSION INPUT SENSOR (TISS)
(THREE-SPEED TRANSMISSION ONLY)
(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), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

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), AND
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
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

Install 4. Install shield, washer, and capscrew onto top of

an iron transmission housing. 5. Connect the battery, install the floor plate and
floor mat, on lift truck models
1. Install new O-rings on sensor and install sensor • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
into transmission housing with the bolt. Tighten J006, K006)
bolt to 6.9 N•m (61 lbf in). Connect sensor to • H8.0FT, H8.0FT9, H9.0FT (H170FT,
transmission harness. H175FT36, H190FT) (A299, B299)
See Figure 37 for lift truck models Connect the battery and lower the hood, on lift
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; truck models
(G004, H004) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- H40FTS) (F001)
R005) • H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, S80, 100FTBCS; S120FTS; S120FTPRS)
H40FTS) (F001) (G004, H004)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• H2.0-3.5FT (H40-70FT) (L177) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
TRANSMISSION PRESSURE SENSORS
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Remove
H175FT36, H190FT) (A299, B299)
NOTE: Perform Step 2 and Step 3 for lift trucks floor plate, on lift truck models below. Disconnect
equipped with an aluminum transmission housing. the battery.
2. Install new O-ring on sensor. Install sensor, • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
washer, and capscrew on transmission housing. J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, To access the battery, raise the hood, on lift truck
H40FTS) (F001) models below. Disconnect the battery.
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
3. Connect sensor to transmission harness. R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
NOTE: Perform Step 4 for lift trucks built prior to E024, F024)
January, 2011 equipped with an aluminum transmis-
sion housing.

NOTE: Perform Step 2 for lift truck equipped with an • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
iron transmission housing. • H2.0-3.5FT (H40-70FT) (L177)
2. Disconnect the pressure sensors from the trans- See Figure 40 for lift truck models
mission harness. Remove sensors from fitting on • S30FT, S35FT, S40FTS (E010)
the control valve. • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
(G004, H004) Install
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, NOTE: When new transmission pressure sensors are
R005) installed, calibration is required for transmissions
• S30FT, S35FT, S40FTS (E010) with an iron housing. See the section Calibration
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, Procedures 8000 SRM 1134 for calibration proce-
H40FTS) (F001) dures.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) NOTE: Perform Step 1 for lift trucks equipped with
an iron transmission housing.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 1. Install new sensors on control valve. Connect
E024, F024) sensors to transmission harness.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
(G004, H004)
NOTE: Perform Step 3 for lift trucks shown below, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
built prior to January, 2011, equipped with an alu- 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
minum transmission housing. R005)
• S30FT, S35FT, S40FTS (E010)
3. Remove capscrew, washer, and shield from the • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
top of the transmission housing. H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
See Figure 39 for lift truck models • H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) E024, F024)
• H2.0-3.5FT (H40-70FT) (L177) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
NOTE: Perform Step 4 and Step 5 for lift trucks built • H8.0FT, H8.0FT9, H9.0FT (H170FT,
after January, 2011, equipped with an aluminum H175FT36, H190FT) (A299, B299)
NOTE: Perform Step 2 and Step 3 for lift trucks built
4. Disconnect pressure sensor from transmission after January, 2011, equipped with an aluminum
harness. transmission housing.
5. Remove pressure sensor from transmission hous- 2. Install pressure sensor on transmission housing.
ing.

• H2.0-3.5FT (H40-70FT) (L177) To access the battery, raise the hood, on lift truck
3. Connect pressure sensor to transmission har-
(G004, H004)
ness.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
NOTE: Perform Step 4 for lift trucks built prior to 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
January, 2011 equipped with an aluminum transmis- R005)
sion housing. • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
4. Install shield, washer, and capscrew onto top of
transmission housing. See Figure 39. 2. Put the lift truck on blocks. See the Operating
Manual or one of the following sections for the
5. Connect the battery, install the floor plate and procedures:
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, Periodic Maintenance 8000 SRM 1150 for lift
J006, K006) truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
Connect the battery and lower the hood, on lift Periodic Maintenance 8000 SRM 1207 for lift
H40FTS) (F001) H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, Periodic Maintenance 8000 SRM 1558 for lift
E024, F024) truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
TRANSMISSION TEMPERATURE SENSOR 5.5FT (H80, 90, 100, 110, 120FT) (R005)
Remove Periodic Maintenance 8000 SRM 1319 for lift
truck models
1. To access the battery, remove the floor mat and • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
floor plate, on lift truck models below. Disconnect E024)
the battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, Periodic Maintenance 8000 SRM 1571 for lift
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
H175FT36, H190FT) (A299, B299)

• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
J006) E024)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
H175FT36, H190FT) (A299)
Periodic Maintenance 8000 SRM 1586 for lift truck models
truck models • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• H8.0FT, H8.0FT9, H9.0FT (H170FT, J006)
H175FT36, H190FT) (B299)
Periodic Maintenance 8000 SRM 1583 for lift truck models
truck models • H8.0FT, H8.0FT9, H9.0FT (H170FT,
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) H175FT36, H190FT) (A299)
Periodic Maintenance 8000 SRM 1598 Periodic Maintenance 8000 SRM 1586 for lift
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; truck models
S80, 100FTBCS; S120FTS; S120FTPRS) • H8.0FT, H8.0FT9, H9.0FT (H170FT,
(H004) H175FT36, H190FT) (B299)

At operating temperature, the transmission oil • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
is HOT. DO NOT permit the hot oil to touch the
skin and cause a burn. Make sure oil is cool Periodic Maintenance 8000 SRM 1598
before draining. • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
3. Drain the transmission oil. See one of the follow- (H004)
ing sections for the procedures:
NOTE: Perform Step 4 for lift trucks built prior to
Periodic Maintenance 8000 SRM 1150 for lift January, 2011 equipped with an aluminum transmis-
truck models sion housing.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) 4. Remove capscrew, washer, and shield from the
top of the transmission housing. See Figure 39.
truck models 5. Disconnect temperature sensor from transmis-
• S30FT, S35FT, S40FTS (E010) sion harness and remove sensor from transmis-
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, sion.
H40FTS) (F001)
Periodic Maintenance 8000 SRM 1248 for lift • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
truck models S80, 100FTBCS; S120FTS; S120FTPRS)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; (G004, H004)
S80, 100FTBCS; S120FTS; S120FTPRS) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
(G004) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- R005)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) • S30FT, S35FT, S40FTS (E010)
Periodic Maintenance 8000 SRM 1558 for lift H40FTS) (F001)
truck models • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- • H2.0-3.5FT (H40-70FT) (L177)
5.5FT (H80, 90, 100, 110, 120FT) (R005)

• S6.0FT, S7.0FT (S135FT, S155FT) (D024, • S30FT, S35FT, S40FTS (E010)
E024, F024) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
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)
NOTE: Perform Step 2 for lift trucks built prior to
See Figure 39 for lift truck models January, 2011 equipped with an aluminum transmis-
• S30FT, S35FT, S40FTS (E010) sion housing.
H40FTS) (F001) 2. Install shield, washer, and capscrew onto top of
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) transmission housing. See Figure 39.
• H2.0-3.5FT (H40-70FT) (L177)
3. Remove lift truck from blocks.
• S30FT, S35FT, S40FTS (E010)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
H40FTS) (F001)
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)
Install Connect the battery and lower the hood, on lift
truck models
1. Install new temperature sensor and connect sen-
• S30FT, S35FT, S40FTS (E010)
sor to transmission harness.
See Figure 37 for lift truck models H40FTS) (F001)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
S80, 100FTBCS; S120FTS; S120FTPRS) • H2.0-3.5FT (H40-70FT) (L177)
(G004, H004) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- S80, 100FTBCS; S120FTS; S120FTPRS)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, (G004, H004)
R005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• S30FT, S35FT, S40FTS (E010) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, R005)
H40FTS) (F001) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) E024, F024)
• H2.0-3.5FT (H40-70FT) (L177)
5. Fill transmission with oil. Run the lift truck and
See Figure 38 for lift truck models check oil level. See one of the following sections
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, for transmission oil specifications and for the pro-
E024, F024) cedures to check the transmission oil level:
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H175FT36, H190FT) (A299, B299)
• H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010)
truck models
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)

Periodic Maintenance 8000 SRM 1248 for lift • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
truck models K006)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; • H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
S80, 100FTBCS; S120FTS; S120FTPRS) H190FT) (A299, B299)
(G004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- Remove
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
1. Remove the floor plate and mat from frame and
Periodic Maintenance 8000 SRM 1558 for lift disconnect the battery.
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- 2. Disconnect engine speed sensor from transmis-
5.5FT (H80, 90, 100, 110, 120FT) (R005) sion harness and remove bolt securing sensor to
transmission housing. Discard the O-ring. See
Periodic Maintenance 8000 SRM 1319 for lift Figure 38.
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, Install
E024)
1. Install new O-ring on sensor and install sensor
Periodic Maintenance 8000 SRM 1571 for lift into transmission housing with the bolt. Tighten
truck models bolt to 6.9 N•m (61 lbf in). Connect sensor to
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) transmission harness. See Figure 38.
Periodic Maintenance 8000 SRM 1322 for lift 2. Place floor plate and mat onto frame. Connect
truck models the battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) INTERMEDIATE SPEED SENSOR
Periodic Maintenance 8000 SRM 1407 for lift NOTE: The intermediate speed sensor is used only on
truck models lift truck models shown below, equipped with three-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, speed transmission.
H175FT36, H190FT) (A299)
Periodic Maintenance 8000 SRM 1586 for lift • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
truck models F024)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
H175FT36, H190FT) (B299) K006)
Periodic Maintenance 8000 SRM 1583 for lift H190FT) (A299, B299)
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) Remove
Periodic Maintenance 8000 SRM 1598 1. To access the battery, remove the floor mat and
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; floor plate, on lift truck models below. Disconnect
S80, 100FTBCS; S120FTS; S120FTPRS) the battery.
(H004) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
ENGINE SPEED SENSOR • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
NOTE: The engine speed sensor is used only on
lift truck models shown below, equipped with To access the battery, raise the hood, on lift truck
three-speed transmission. models below. Disconnect the battery.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
F024)

2. Disconnect intermediate speed sensor from 3. Remove two torx capscrews and nuts holding the
transmission harness and remove bolt securing tilt sensor to the sensor bracket on the mast and
sensor to transmission housing. Discard the remove sensor and mast harness from sensor and
O-ring. See Figure 38. harness brackets. See Figure 41.
Install Install
1. Install new O-ring on intermediate speed sensor 1. Install new sensor onto sensor bracket and in-
and install intermediate speed sensor into trans- sert two torx capscrews and nuts to secure sen-
mission housing with the bolt. Tighten bolt to sor to bracket. Secure mast harness to harness
6.9 N•m (61 lbf in). Connect intermediate speed bracket. See Figure 41.
sensor to transmission harness. See Figure 38.
2. Connect mast harness to cowl harness.
3. Connect the battery and close the hood.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 4. Tilt the mast completely forward and backward
J006, K006) to ensure that the tilt sensor is correctly installed
• H8.0FT, H8.0FT9, H9.0FT (H170FT, and connected.
H175FT36, H190FT) (A299, B299)

truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
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 Mast
in the section:

truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177) NOTE: MAST SHOWN MAY BE DIFFERENT, BUT LO-
CATION OF TILT SENSOR IS THE SAME FOR ALL
Periodic Maintenance 8000 SRM 1207 for lift LIFT TRUCKS COVERED IN THIS SECTION.
truck models
• S30FT, S35FT, S40FTS (E010) 1. TORX CAPSCREWS
2. RETURN TO SET TILT (TILT ANGLE) SENSOR
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 3. SENSOR BRACKET
H40FTS) (F001) 4. COWL
5. MAST HARNESS (TO COWL HARNESS)
Remove 6. HARNESS BRACKET
1. Raise the hood and disconnect the battery. Figure 41. Return to Set Tilt (Tilt Angle) Sensor
2. Disconnect the mast harness from the cowl har-
ness.

Lift Truck Models S6.0FT, S7.0FT (S135FT, Periodic Maintenance 8000 SRM 1583 for lift
S155FT) (D024, E024, F024); S4.0, 4.5, truck models
5.5FT, S5.5FTS (S80, 100, 120FT; S80, • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
100FTBCS; S120FTS; S120FTPRS) GDP135VX, GP/GLP/GDP155VX) (E878)
(G004, H004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, Periodic Maintenance 8000 SRM 1598
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
120FT) (N005, P005, R005), H6.0FT,
100FTBCS; S120FTS; S120FTPRS) (H004)
H7.0FT (H135FT, H155FT) (H006, J006,
K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, Remove
H175FT36, H190FT) (A299, B299) 1. To access the battery, remove the floor mat and
NOTE: Before working on or near the mast, see the floor plate, on lift truck models below. Disconnect
section Safety Procedures When Working Near Mast the battery.
in the section: • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
Periodic Maintenance 8000 SRM 1248 for lift • H8.0FT, H8.0FT9, H9.0FT (H170FT,
truck models H175FT36, H190FT) (A299, B299)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004) To access the battery, raise the hood, on lift truck
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT models below. Disconnect the battery.
(H80, 90, 100, 110, 120FT) (N005, P005) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Periodic Maintenance 8000 SRM 1558 for lift (G004, H004)
truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
(H80, 90, 100, 110, 120FT) (R005) R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
Periodic Maintenance 8000 SRM 1319 for lift E024, F024)
truck models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) 2. Disconnect sensor harness from cowl harness.
See Figure 42.
truck models 3. Remove harness bracket from cowl and remove
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) harness from bracket.
Periodic Maintenance 8000 SRM 1322 for lift 4. Remove capscrew that attaches tilt sensor
truck models bracket to mast. See Figure 42.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
5. Remove sensor bracket and tilt sensor from mast.
truck models 6. Remove two torx capscrews and nuts holding the
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, tilt sensor to the sensor bracket. Remove sensor
H190FT) (A299) from bracket.

truck models
H190FT) (B299)

Install
1. Install new tilt sensor onto sensor bracket using

two torx capscrews and nuts.
2. Secure sensor bracket and tilt sensor to mast us-

ing capscrew. Tighten capscrew to 90 to 99 N•m
3. Place sensor harness in harness bracket and

install bracket onto cowl. Tighten capscrew to
38 N•m (28 lbf ft).
4. Connect the sensor harness connector to the cowl

harness.

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

truck models NOTE: S6.0FT, S7.0FT (S135FT, S155FT) (F024)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; SHOWN.
S80, 100FTBCS; S120FTS; S120FTPRS) 1. TILT SENSOR
(G004, H004) 2. TILT SENSOR BRACKET
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- 3. CAPSCREW
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, 4. SENSOR HARNESS BRACKET
R005) 5. SENSOR CONNECTOR TO COWL HARNESS
6. COWL
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 7. TILT CYLINDERS
E024, F024)
Figure 42. Return to Set Tilt (Tilt Angle) Sensor
6. Tilt the mast completely forward and backward
to ensure that the tilt sensor is correctly installed
and connected.

REAR HORN BUTTON SWITCH 4. Connect the battery, install the floor plate and
J006, K006)
1. To access the battery, remove the floor mat and • H8.0FT, H8.0FT9, H9.0FT (H170FT,
floor plate, on lift truck models below. Disconnect H175FT36, H190FT) (A299, B299)
the battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, Connect the battery and lower the hood, on lift
• H8.0FT, H8.0FT9, H9.0FT (H170FT, • S30FT, S35FT, S40FTS (E010)
H175FT36, H190FT) (A299, B299) • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
To access the battery, raise the hood, on lift truck • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
models below. Disconnect the battery. • H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, S80, 100FTBCS; S120FTS; S120FTPRS)
H40FTS) (F001) (G004, H004)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
2. Disconnect rear horn button switch electrical

connector from chassis harness. See Figure 43.
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.
Install
1. Insert wire and connector in the hole in overhead
guard leg and thread wire until connector can
be pulled through bottom hole in the overhead
guard leg. 1. CAPSCREW
2. INSERT
2. Attach handle and switch assembly to overhead 3. HANDLE AND SWITCH ASSEMBLY
guard leg with two capscrews and inserts. See 4. HOLE
Figure 43. 5. HANDLE
6. REAR HORN BUTTON SWITCH
3. Connect rear horn switch electrical connector to 7. ELECTRICAL CONNECTOR
8. OVERHEAD GUARD LEG
chassis harness.
Figure 43. Rear Horn Button Switch

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- 3. Disconnect the impact sensor from the right
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, chassis harness. See Figure 44.
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 4. Remove two capscrews that attach the impact
E024, F024) sensor to mounting bracket. Remove sensor from
lift truck.
IMPACT SENSOR
Install
The impact sensor is located under the right side step
1. Install new impact sensor to mounting bracket.
plate.
All Lift Truck Models Except H6.0FT, 2. Connect impact sensor to right chassis harness.
H7.0FT (H135FT, H155FT) (H006, J006, See Figure 44.
K006), H8.0FT, H8.0FT9, H9.0FT (H170FT,
3. Install the floor mat and floor plate. Install the
H175FT36, H190FT) (A299, B299)
right rear panel, right panel, right fender cover,
Remove and right step plate. See one of the following
sections for the installation procedures:
2. Remove the floor mat and floor plate. Remove the • S30FT, S35FT, S40FTS (E010)
right rear panel, right panel, right fender cover, • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
and right step plate. See one of the following H40FTS) (F001)
sections for the removal procedures: • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S30FT, S35FT, S40FTS (E010) Frame 100 SRM 1243 for lift truck models
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (G004, H004)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
Frame 100 SRM 1243 for lift truck models R005)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) Frame 100 SRM 1316 for lift truck models
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) Frame 100 SRM 1321 for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Frame 100 SRM 1316 for lift truck models H175FT36, H190FT) (A299, B299)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024) 4. Connect the battery and close hood.

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

NOTE: THE FRAME SHOWN IN FIGURE 44 MAY BE DIFFERENT, BUT LOCATION OF IMPACT SENSOR IS THE
SAME.
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, All Lift Truck Models Except H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)

Lift Truck Models H6.0FT, H7.0FT (H135FT, 2. Disconnect the impact sensor connector from the
H155FT) (H006, J006, K006), H8.0FT, right chassis harness connector. See Figure 45.
H8.0FT9, H9.0FT (H170FT, H175FT36, 3. Remove the two capscrews that secure impact
H190FT) (A299, B299) sensor to bracket and remove sensor from lift
Remove
1. Remove the floor mat and floor plate and discon-

nect the battery.
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 2. Disconnect the harness connector from the load

weight sensor. See Figure 46.
1. Install new impact sensor to sensor bracket using
two capscrews. Tighten capscrews to 26 N•m 3. Remove the load weight sensor from the special
(230 lbf in). fitting on hydraulic control valve.
2. Insert the push-in fastener into the connector Install

clip, then connect the right chassis harness con-
nector to the impact sensor connector. See Fig- 1. Insert new load weight sensor into special fitting.
ure 45. Tighten sensor by hand, and then torque sensor
3. Connect the battery and install the floor plate
and floor mat. 2. Connect the harness connector to the load weight
LOAD WEIGHT SENSOR
Remove floor mat, on lift truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
1. To access the battery, remove the floor mat and J006, K006)
floor plate, on lift truck models below. Disconnect • H8.0FT, H8.0FT9, H9.0FT (H170FT,
the battery. H175FT36, H190FT) (A299, B299)
• H6.0FT, H7.0FT (H135FT, H155FT) (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 truck H40FTS) (F001)
models below. Disconnect the battery. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) (G004, H004)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
S80, 100FTBCS; S120FTS; S120FTPRS) R005)
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)

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 POSITION
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

ENGINE AND FUEL SENSORS AND NOTE: To replace the camshaft position sensor on the
SWITCHES, GAS AND LPG TRUCKS GM 2.4L engine, see section GM Engine Repair,
EQUIPPED WITH MAZDA 2.0L AND 2.2L GM 2.4 Liter Engine 600 SRM 1121.
ENGINES Oil Pressure Sensor
For lift trucks equipped with a Mazda engine, see the NOTE: To replace oil pressure sensor on GM 4.3L en-
following service manuals for procedures to replace gine, see section High Voltage Switch (HVS) Ig-
the engine and fuel sensors and switches. The list nition, GM 4.3L EPA Compliant Engines and
below is for Mazda engines built prior to 2007: GM 5.7L LPG EPA Compliant Engine 2200 SRM
• Electrical System, Mazda 2.0L and 2.2L 2200 1097.
SRM 1143
• Gasoline Fuel System, Mazda 2.0L and 2.2L NOTE: To replace oil pressure sensor on GM 2.4L en-
900 SRM 1127 gine, see section GM Engine Repair, GM 2.4 Liter
• LPG Fuel System, Mazda 2.0L and 2.2L En- Engine 600 SRM 1121.
gines 900 SRM 1125
Manifold Absolute Pressure
The list of service manuals below are for Mazda en-
(MAP)/Manifold Air Temperature
gines that are 2007 emissions compliant and for lift
trucks built after January, 2010: (MAT) Sensor
• Electrical System, Mazda 2.0L and 2.2L Emis-
NOTE: To replace manifold absolute pressure (MAP)/
sion Compliant Engines 2200 SRM 1327
manifold air temperature (MAT) sensor on GM 4.3L
• Gasoline Fuel System, Mazda 2.0L and 2.2LE-
engine, see section High Voltage Switch (HVS) Ig-
mission Compliant Engines 900 SRM 1325
nition, GM 4.3L EPA Compliant Engines and
• LPG Fuel System, Mazda 2.0L and 2.2L Emis-
GM 5.7L LPG EPA Compliant Engine 2200 SRM
sion Compliant Engines 900 SRM 1326
1097.
ENGINE AND FUEL SENSORS AND NOTE: To replace manifold absolute pressure (AMP)/
SWITCHES, GAS AND LPG TRUCKS manifold air temperature (MAT) sensor on GM 2.4L
EQUIPPED WITH GM ENGINES engine, see sections LPG Fuel System, GM 2.4L
Engine 900 SRM 1124 for LPG or Gasoline Fuel
Crankshaft Position (CKP) Sensor System, GM 2.4L Engine 900 SRM 1126 for gas.
NOTE: To replace crankshaft position sensor on Engine Coolant Temperature (ECT) Sensor
GM 4.3L engine, see section High Voltage Switch
(HVS) Ignition, GM 4.3L EPA Compliant En- NOTE: To replace engine coolant temperature (ECT)
gines and GM 5.7L LPG EPA Compliant Engine sensor on GM 4.3L engine, See section High Voltage
2200 SRM 1097. Switch (HVS) Ignition, GM 4.3L EPA Compliant
Engines and GM 5.7L LPG EPA Compliant En-
NOTE: To replace the crankshaft position sensor on gine 2200 SRM 1097.
GM 2.4L engine, see section GM Engine Repair,
GM 2.4 Liter Engine 600 SRM 1121. NOTE: To replace engine coolant temperature (ECT)
sensor on GM 2.4L engine, see sections LPG Fuel
Camshaft Position (CMP) Sensor System, GM 2.4L Engine 900 SRM 1124 for LPG
or Gasoline Fuel System, GM 2.4L Engine 900
NOTE: On the GM 4.3L engine, the camshaft position SRM 1126 for gas.
sensor cannot be replaced separately from the dis-
tributor. If the CMP sensor fails, the whole distribu- Air Flow Restriction Switch
tor must be replaced. See the section High Voltage
Switch (HVS) Ignition, GM 4.3L EPA Compliant NOTE: To replace engine air flow restriction switch
Engines and GM 5.7L LPG EPA Compliant En- on GM 4.3L or GM 5.7L engine, See section High
gine 2200 SRM 1097 for procedures to replace the Voltage Switch (HVS) Ignition, GM 4.3L EPA
distributor. Compliant Engines and GM 5.7L LPG EPA Com-
pliant Engine 2200 SRM 1097.

NOTE: The air flow restriction switch is an optional Oxygen Sensor

feature on these lift trucks and is a part of the Elec-
tronic Monitoring package option. NOTE: The procedures below cover GM 4.3L engine,
for lift trucks built before January, 2010. For pro-
Remove for GM 2.4L Gas and LPG Trucks cedures to replace oxygen sensor on GM 4.3L engine
on lift trucks built after January, 2010, see one of the
1. Raise hood and disconnect the battery. following service manuals:
• LPG Fuel System, GM 4.3L Engine With GFI
2. Disconnect the air flow restriction switch electri-
900 SRM 1242
cal connection. See Figure 47.
• LPG Fuel System, GM 4.3L Engine With PSI
3. Remove air filter restriction switch from air 900 SRM 1556
cleaner. • Gasoline Fuel System, GM 4.3L Engine With
GFI 900 SRM 1244
Install for GM 2.4L Gas and LPG Trucks • Gasoline Fuel System PSI GM 4.3L 900 SRM
1. Install new air flow restriction switch into air • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
cleaner. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (R005)
2. Connect the air flow restriction switch electrical
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
3. Connect the battery and lower the hood. 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, GM 2.4L Engine 900 SRM
1124
• Gasoline Fuel System, GM 2.4L Engine 900
SRM 1126
Remove

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

NOTE: AIR CLEANER HOSE NOT SHOWN FOR • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
CLARITY. SWITCH NOT SHOWN, BUT ITEM #4 S80, 100FTBCS; S120FTS; S120FTPRS)
POINTS TO ITS LOCATION. (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
1. ECT SENSOR 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
2. AIR FLOW RESTRICTION ELECTRICAL R005)
CONNECTOR • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
3. AIR CLEANER
4. AIR FLOW RESTRICTION SWITCH E024, F024)
Figure 47. Air Flow Restriction Switch

NOTE: The GM 4.3L engine has two oxygen sensors See Figure 49 for lift truck models
and two electrical connectors. • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
2. Disconnect the oxygen sensor electrical connec- • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
tor. J006, K006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, S80, 100FTBCS; S120FTS; S120FTPRS)
R005) (G004, H004)
NOTE: EXHAUST SYSTEM FOR LIFT TRUCK MODELS S4.0, 4.5, 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
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)

NOTE: OVERHEAD EXHAUST IS AN OPTIONAL FEATURE.

1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD
Figure 49. Oxygen Sensor, GM 4.3L Engine, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)

NOTE: Perform Step 3 for lift truck models S5.5FTS

(S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
H004), equipped with the GM 4.3L engine.
3. Remove the clip connector retaining each wire

harness to the oxygen sensor brackets. See Fig-
ure 50.
Figure 51. Oxygen Sensor Socket
Install

oxygen sensor into the exhaust pipes to the ex-
haust manifold for GM 4.3L engines. Using a
special tool, oxygen sensor socket (see Figure 51),
tighten oxygen sensors to 40 to 60 N•m (30 to
44 lbf ft).
1. OXYGEN SENSOR (POST-CATALYTIC) See Figure 48 for lift truck models
2. MUFFLER • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
3. OXYGEN SENSOR (PRE-CATALYTIC)
4. SENSOR ELECTRICAL CONNECTORS 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
5. CLIP CONNECTOR R005)
6. BRACKET
Figure 50. Oxygen Sensor, GM 4.3L Engine for • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
Lift Truck Models (BCS/PRS Only) S5.5FTS E024, F024)
(S80, 100FTBCS; S120FTS; S120FTPRS) (G004, • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
H004) J006, K006)
4. Using a special tool, oxygen sensor socket (see Figure 50 for lift truck models
Figure 51), remove the oxygen sensor. • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
See Figure 48 for lift truck models (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, NOTE: Perform Step 2 for lift truck models S5.5FTS
R005) (S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
H004) equiped with the GM 4.3L engine.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 2. Install the clip connector to attach oxygen sensor
E024, F024) wiring harness to oxygen sensor brackets.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) 3. Connect the electrical connectors. Verify that the
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 4. Verify that the wire is pulled up toward the ther-
S80, 100FTBCS; S120FTS; S120FTPRS) mostat and away from any hot exhaust compo-
(G004, H004) nents.

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

• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 1. Install new air filter restriction switch into air
J006, K006) cleaner.
Connect the battery and lower the hood, on lift 2. Connect air filter electrical connector.
truck models
3. Connect the battery and close hood.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Oil Pressure Sensor
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- Remove
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005) 1. Raise hood and disconnect the battery.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024) 2. Disconnect the electrical connector for the oil
pressure sensor.
6. Connect the battery; install the floor plate and
floor mat for lift truck model 3. Remove the oil pressure sensor. See Figure 52.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Install
J006, K006)
1. Install new oil pressure sensor onto engine.
ENGINE AND FUEL SWITCHES, GM 2.4L Tighten sensor to 9 N•m (80 lbf in).
LPG TRUCKS ONLY
Low LPG Pressure Switch sure sensor. See Figure 52.
NOTE: For procedures to replace Low LPG pressure 3. Connect the battery and close hood.
switch on GM 2.4L LPG engine, see section LPG
Fuel System, GM 2.4L Engine 900 SRM 1124. Engine Speed Sensor
ENGINE AND FUEL SENSORS AND Remove

SWITCHES, YANMAR DIESEL TRUCKS 1. Raise the hood and disconnect the battery.
Air Filter Restriction Switch 2. Disconnect the electrical connection from engine
speed sensor.
feature on these lift trucks and is a part of the Elec- 3. Remove capscrew from engine speed sensor
tronic Monitoring package option. bracket and remove bracket and engine speed
Remove
Install
1. Install engine speed sensor bracket and install
2. Disconnect the electrical connector from air filter new engine speed sensor.
restriction switch.
2. Connect electrical connector to engine speed sen-
3. Remove air filter restriction switch from air sor.
cleaner. See Figure 52.

Engine Coolant Temperature (ECT) Sensor Periodic Maintenance 8000 SRM 1150 for lift
truck models
Remove • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
truck models
• S30FT, S35FT, S40FTS (E010)
3. Disconnect the ECT sensor connector. See Fig- H40FTS) (F001)
ure 52.
4. Remove the ECT sensor and packing from the truck models
intake manifold. Discard the copper washer. See • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Figure 52. S80, 100FTBCS; S120FTS; S120FTPRS)
(G004)
Install • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
1. Install new copper washer onto ECT sensor.
Install new ECT sensor and new packing and Periodic Maintenance 8000 SRM 1598
tighten the ECT sensor to 25 to 34 N•m (18 to • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
25 lbf ft). S80, 100FTBCS; S120FTS; S120FTPRS)
(H004)
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:

A. FRONT VIEW B. SIDE VIEW
1. AIR FILTER RESTRICTION SWITCH 5. ENGINE SPEED SENSOR
ELECTRICAL CONNECTOR 6. ENGINE COOLANT TEMPERATURE SENSOR
2. AIR CLEANER 7. THROTTLE POSITION SENSOR
3. AIR FILTER RESTRICTION SWITCH 8. ENGINE OIL PRESSURE SENSOR
4. AIR CLEANER BRACKET 9. FUEL/WATER SEPARATOR SENSOR

Figure 52. Yanmar Diesel Engine Sensors and Switches

Throttle Position Sensor (TPS) Install
Remove NOTE: When installing the TPS, rotate the sensor

rotor clockwise to match D-shape on the TPS rotor.
1. Open hood and disconnect the battery. See Figure 54.
2. Disconnect the electrical connector from the 1. Install new TPS sensor on TPS bracket and se-
throttle position sensor (TPS). cure with Torx-head screws. Tighten Torx-head
screws to 2.25 N•m (20 lbf in).
3. Remove Torx-head screws securing the TPS to
TPS bracket. See Figure 53. Remove TPS sensor 2. Connect the throttle position sensor (TPS) elec-
from TPS bracket. trical connector.
1. SENSOR ROTOR 3. TPS ROTOR

2. TPS 4. D-SHAPE
Figure 54. TPS and Rotor
Fuel/Water Separator Sensor

Remove
2. Remove drain plug from bottom of fuel/water sep-

arator sensor and drain water from fuel filter.
See Figure 55.
1. LOCKWASHER
2. TORX-HEAD SCREW (BRACKET) 3. Disconnect sensor from harness.
3. TPS BRACKET
4. WASHER 4. Remove sensor from bottom of fuel filter element
5. TORX-HEAD SCREW (SENSOR) body.
7. TPS ROTOR
8. THROTTLE LEVER
9. FUEL PUMP

Assembly

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

water separator sensor.
1. Install new sensor into bottom of fuel filter ele-
ment body. See Figure 55. 4. Connect the battery and close hood.
2. Connect sensor to harness. Glow Plug Relay

Remove
WARNING
nect the cable at the negative terminal first. In-
one connects the cables on the terminals.
2. Tag and disconnect the wiring connectors at ter-

minals E and S. See Figure 56.
3. Slide the protective boots back on the wires for

terminals B and M. See Figure 56 and Figure 57.
1. DRAIN PLUG
2. O-RING 1. M TERMINAL 3. B TERMINAL
3. FUEL/WATER SEPARATOR SENSOR 2. E TERMINAL 4. S TERMINAL
4. FUEL FILTER ELEMENT BODY
5. FUEL FILTER Figure 56. Glow Plug Relay Terminals
6. FUEL FILTER COVER
Figure 55. Fuel/Water Separator Sensor

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 ENGINE AND FUEL SENSORS AND
properly identify them for reinstallation. SWITCHES, CUMMINS DIESEL ENGINES
5. Remove the nuts and washers retaining the Air Filter Restriction Switch
wires to terminals B and M. See Figure 57.
6. Remove the nuts retaining the glow plug relay to feature on these lift trucks and is a part of the Elec-
the mounting bracket and remove the glow plug tronic Monitoring package option.
relay. See Figure 58.
Remove
Install
1. Place the glow plug relay in position on the floor plate, on lift truck models below. Disconnect
mounting bracket and install retaining nuts. the battery.
Tighten retaining nuts to 2.50 to 2.75 N•m • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
(22.13 to 24.34 lbf in). See Figure 58. J006)
2. Connect the wiring connections to terminals B • H8.0FT, H8.0FT9, H9.0FT (H170FT,
and M. Install the nuts and washers. Tighten the H175FT36, H190FT) (A299, B299)
nuts to 2.9 to 4.0 N•m (25.67 to 35.40 lbf in). See To access the battery, raise the hood, on lift truck
Figure 56 and Figure 57. models below. Disconnect the battery.
3. Install the protective boots over the terminals B • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
and M. See Figure 57. 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
4. Connect the electrical connectors at terminals E E024)
and S. See Figure 56.
2. Disconnect the electrical connector from air filter
5. Connect the battery and close the hood. restriction switch.
3. Remove air filter restriction switch from air

cleaner. See Figure 59 (Cummins 4.5L) and
Figure 60 (Cummins QSB 3.3L).
Install
1. Install new air filter restriction switch onto air

cleaner.
2. Connect air filter electrical connector.

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

truck models
NOTE: ENGINE NOT SHOWN FOR CLARITY. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
1. MOUNTING BRACKET • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
2. GLOW PLUG RELAY E024)
3. NUT
Figure 58. Glow Plug Relay and Mounting

Bracket

Figure 59. Cummins 4.5L Diesel Engine Sensors and Switches


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

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


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 (H135FT,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) H155FT) (H006, J006), H8.0FT, H8.0FT9, H9.0FT
(N005, P005) (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
CONNECTOR AND SENSOR
Engine Oil Pressure Sensor Connect the battery and lower the hood, on lift
truck models
Remove • 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)
the battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Engine Speed Sensor
J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Remove
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood, on lift truck floor plate, on lift truck models below. Disconnect
models below. Disconnect the battery. the battery.
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) J006)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
E024) H175FT36, H190FT) (A299, B299)
2. Disconnect the electrical connector from the oil To access the battery, raise the hood, on lift truck
pressure sensor. models below. Disconnect the battery.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
3. Unscrew and remove the oil pressure sensor (see
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
Figure 59 (Cummins 4.5L) or Figure 60 (Cum-
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
mins QSB 3.3L)) from adapter. Adapter does not
E024)
need to be removed from engine. Discard O-ring.
2. Disconnect the electrical connection from engine
Install
speed sensor. See Figure 59 (Cummins 4.5L) and
1. Apply 50 ml (1.7 oz) of Loctite 592™ thread Figure 60 (Cummins QSB 3.3L).
sealant on O-ring. Install new oil pressure sen-
3. Remove capscrew from engine speed sensor
sor into adapter. Tighten sensor two to three
bracket and remove bracket and engine speed
turns past finger tight.
sensor.
Install
sure sensor. See Figure 59 (Cummins 4.5L) and
Figure 60 (Cummins QSB 3.3L). 1. Install engine speed sensor bracket to engine.
Tighten capscrew to 7 N•m (62 lbf in). Install
new engine speed sensor onto bracket.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 2. Connect electrical connector to engine speed sen-
J006) sor. See Figure 59 (Cummins 4.5L) and Figure 60
• H8.0FT, H8.0FT9, H9.0FT (H170FT, (Cummins QSB 3.3L).
H175FT36, H190FT) (A299, B299)

3. Connect the battery, install the floor plate and Periodic Maintenance 8000 SRM 1248 for lift
floor mat, on lift truck models truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
J006) S80, 100FTBCS; S120FTS; S120FTPRS)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, (G004)
H175FT36, H190FT) (A299, B299) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
truck models Periodic Maintenance 8000 SRM 1319 for lift
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- truck models
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
E024)
Engine Coolant Temperature (ECT) Sensor truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
Remove J006)
1. To access the battery, remove the floor mat and Periodic Maintenance 8000 SRM 1407 for lift
floor plate, on lift truck models below. Disconnect truck models
the battery. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

• 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)

3. Disconnect the ECT sensor connector. See Fig-

ure 60 (Cummins 4.5L) or Figure 61 (Cummins
QSB 3.3L).
4. Remove the ECT sensor and packing from the

intake manifold. Discard the O-ring.
Install
1. Install new O-ring onto ECT sensor. Install new

ECT sensor and new packing and tighten the
ECT sensor to 20 N•m (177 lbf in).
NOTE: TOP VIEW SHOWN.
2. Connect the ECT sensor connector. See Fig-
ure 60 (Cummins 4.5L) or Figure 61 (Cummins 1. ENGINE COOLANT TEMPERATURE SENSOR
QSB 3.3L). (ECT)
2. ECT ELECTRICAL CONNECTOR
3. Refill the radiator with engine coolant after re-
placing the ECT sensor. See one of the following Figure 61. Engine Coolant Temperature Sensor,
sections for coolant specification and procedures: Cummins 4.5L Diesel Engine

Periodic Maintenance 8000 SRM 1586 for lift 2. Connect the throttle position sensor (TPS) elec-
truck models trical connector. See Figure 62.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) 3. Connect the battery, install the floor plate and
4. Connect the battery, install the floor plate and • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
floor mat, on lift truck models J006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H8.0FT, H8.0FT9, H9.0FT (H170FT,
J006) H175FT36, H190FT) (A299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299) Connect the battery and lower the hood, on lift
truck models
Connect the battery and lower the hood, on lift • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
truck models 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) E024)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
Throttle Position Sensor (TPS) (Cummins

4.5L Only)
Remove

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

• 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)

throttle position sensor (TPS).
3. Remove Torx-head screws and washers securing

the TPS to TPS bracket. See Figure 62. Remove
TPS sensor from TPS bracket.
Install
NOTE: The TPS mounting screws are non-magnetic 1. TORX-HEAD SCREW

2. WASHER
stainless steel to avoid interference with the sensor 3. TPS ELECTRICAL CONNECTOR
magnet and must be reused if the TPS is replaced. 4. TPS COVER
1. Install new TPS sensor on TPS bracket and 6. TPS BRACKET
secure with Torx-head screws and washers. 7. FUEL PUMP
Tighten Torx-head screws to 2.25 N•m (20 lbf in).
Assembly, Cummins 4.5L Diesel Engine

Fuel/Water Separator Sensor Connect the battery and lower the hood, on lift
truck models
Remove • 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)
the battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)

• 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. Remove drain plug from bottom of fuel filter ele-

ment body and drain water from fuel filter. See
Figure 63.
3. Disconnect sensor from harness.
4. Remove sensor from bottom of fuel filter element

body.
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.
1. FUEL FILTER ELEMENT BODY
4. Connect the battery, install the floor plate and 2. DRAIN PLUG
floor mat, on lift truck models 3. ELECTRICAL CONNECTOR
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 4. FUEL/WATER SEPARATOR SENSOR
5. FUEL FILTER
J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Figure 63. Fuel/Water Separator Sensor
H175FT36, H190FT) (A299, B299)

ENGINE AND FUEL SENSORS AND SWITCHES, KUBOTA 3.8L DIESEL ENGINE WITHOUT
DPF
Refer to Figure 64 for location of engine sensors and switches.

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 Intake Air Pressure Sensor

Remove Remove
1. To access battery, raise hood, on lift truck models 1. To access battery, raise hood, on lift truck models
below. Disconnect the battery. below. Disconnect the battery.
5.5FT (H80, 90, 100, 110, 120FT) (R005) 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
2. Disconnect electrical connector from intake air 2. Disconnect electrical connector from intake pres-
temperature sensor. sure sensor.
3. Remove intake air temperature sensor from in- 3. Remove two capscrews and intake air pressure
take air inlet elbow. See Figure 65. sensor. See Figure 65.
Install Install
NOTE: If intake air temperature sensor has been NOTE: If intake air pressure sensor has been identi-
identified as faulty, replace sensor with new one. fied as faulty, replace sensor with new one.
1. Install intake air temperature sensor. Tighten to 1. Install two capscrews and intake air pressure
16 to 23 N•m (12 to 17 lbf ft). sensor. Tighten capscrews to 30 to 39 N•m (22
to 29 lbf ft).
2. Connect intake air temperature sensor electrical
sensor. 2. Connect intake air pressure sensor electrical con-
nector.
3. Connect battery and lower the hood on lift truck
models 3. Connect battery and lower the hood on lift truck
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- models
5.5FT (H80, 90, 100, 110, 120FT) (R005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
Air Inlet Heater

Remove
1. To access battery, raise 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) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
2. Disconnect electrical connections from air inlet

heater terminal nuts. See Figure 65.
3. Remove four capscrews from intake air inlet el-

bow.
4. Remove intake air inlet elbow and set aside for

1. AIR INLET ELBOW later installation.
2. INTAKE AIR TEMPERATURE SENSOR
3. AIR HEATER TERMINAL NUTS 5. Remove air intake heater from air intake mani-
4. AIR INLET HEATER fold.
5. INTAKE AIR PRESSURE SENSOR
Figure 65. Intake Air Inlet Elbow

Install 4. Connect battery and lower the hood on lift truck

models
NOTE: If intake air heater has been identified as • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
faulty, replace air intake heater with new one. 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
1. Install air inlet heater into air intake manifold.
2. Using four capscrews, install intake air inlet el- Engine Coolant Temperature (ECT) Sensor
bow to air intake manifold, cover the air intake
Remove
heater. See Figure 65.
3. Connect electrical connections for air intake
heater to terminal nuts.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
4. Tighten terminal nuts to 3.5 to 5.3 N•m (31 to 5.5FT (H80, 90, 100, 110, 120FT) (R005)
44 lbf in). See Figure 65. • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
5. Connect battery and lower the hood on lift truck 2. Drain engine coolant from radiator before remov-
models ing ECT sensor. Refer to the section Cooling
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- System 700 SRM 1123.
5.5FT (H80, 90, 100, 110, 120FT) (R005)
3. Disconnect the ECT sensor electrical connector
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
from the ECT sensor. See Figure 64.
Engine Oil Pressure Sensor 4. Remove the ECT sensor and O-ring. Discard
O-ring.
Remove
Install
below. Disconnect the battery. NOTE: If ECT sensor has been identified as faulty,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- replace ECT sensor with new one.
5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) 1. Install new O-ring onto ECT sensor.
2. Disconnect electrical connector from oil pressure 2. Install ECT sensor. Tighten sensor to 16 to
sensor. 23 N•m (12 to 17 lbf ft).
3. Unscrew and remove oil pressure sensor and 3. Connect ECT sensor connector. See Figure 64.
O-ring from adapter. See Figure 64.
4. Refill the radiator with engine coolant. See one
4. Discard O-ring. of the following sections for coolant specification
and procedures
Install • Periodic Maintenance 8000 SRM 1558 for
lift truck models
NOTE: If oil pressure sensor has been identified as
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
faulty, replace oil pressure sensor with new one.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
1. Lubricate new O-ring with multipurpose grease, (R005)
and install on oil pressure sensor. • Periodic Maintenance 8000 SRM 1571 for
lift truck models
2. Apply thread locker to threads of oil pressure • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
sensor. Install oil pressure sensor into adapter.
Tighten to 15 to 19 N•m (11 to 14 lbf ft).
3. Connect electrical connector for oil pressure sen-

sor. See Figure 64.

5. Connect battery and lower the hood on lift truck 6. Connect battery and lower the hood on lift truck
models models
5.5FT (H80, 90, 100, 110, 120FT) (R005) 5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
Crankshaft Position Sensor

Remove

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)
2. Disconnect crankshaft position sensor electrical

connector from the crankshaft position sensor.
See Figure 64.
3. Remove crankshaft position sensor mounting

1. PULSAR GEAR
capscrew. 2. AIR GAP
3. SHIM
4. Remove crankshaft position sensor and O-ring. 4. CRANKSHAFT POSITION SENSOR
Discard O-ring. 5. GEAR CASE
6. SHIM 0.25 mm (0.0098 in.)
Install 7. SHIM 0.50 mm (0.020 in.)
8. SHIM 1.00 mm (0.0394 in.)
NOTE: If crankshaft position sensor has been identi-
fied as faulty, replace crankshaft position sensor with Figure 66. Crankshaft Position Sensor Air Gap
new one.
Adjust Shim Procedure
1. Lubricate new O-ring with multipurpose grease.
1. Align TC mark of flywheel with flywheel housing
Install O-ring on crankshaft position sensor. See
timing window. See procedure in Engine Fuel
Figure 66.
System Repair section of Kubota Diesel 3.8L
NOTE: An air gap of 0.25 to 1.4 mm (0.0098 to Engines 600 SRM 1557.
0.055 in.) is needed between the crankshaft position
2. Install measurement jig 1 into sensor mounting
sensor and the pulsar gear. The air gap is achieved
position. See Figure 67.
by using shims shown in Figure 66 and procedure
outlined in Adjust Shim Procedure.
2. Add the appropriate amount of air gap by adding

shims to the crankshaft position sensor. See Fig-
ure 66.
3. Install crankshaft position sensor.
4. Install crankshaft position sensor mounting cap-

screw. Tighten to 4 to 5 N•m (35 to 45 lbf in).
5. Connect crankshaft position sensor electrical

connector to crankshaft position sensor.
1. MEASUREMENT JIG 1
Figure 67. Measurement JIG 1

3. Set dial gauge at measurement jig 2, then mea-

sure protrusion of jig 1. See Figure 68 and Fig-
ure 69.
4. Using the protrusion measurement, see Table 1

for the proper shim combination required to set
the air gap.
1. JIG 1
2. PROTRUSION
3. GEAR CASE
4. PULSE GEAR
Figure 69. Protrusion Measurement
1. MEASUREMENT JIG 2
2. DIAL GAUGE
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 (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 2. Disconnect air flow restriction sensor electrical

connector. See Figure 70.
Remove
3. Remove the air flow restriction sensor. See Fig-
1. To access battery, raise hood, on lift truck models ure 70.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- Install
5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) NOTE: If air flow restriction sensor has been identi-
fied as faulty, replace air flow restriction sensor with
2. Disconnect camshaft position sensor electrical new one.
connector from camshaft position sensor. See
Figure 64. 1. Install air flow restriction sensor. Tighten sensor
two to three turns past finger tight.
3. Remove camshaft position sensor mounting cap-
screw. 2. Connect electrical connector for air flow restric-
tion sensor. See Figure 70.
4. Remove camshaft position sensor and O-ring.
Discard O-ring. 3. Connect battery and lower the hood on lift truck
models
Install • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
NOTE: If camshaft position sensor has been identi- • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
fied as faulty, replace camshaft position sensor with
new one.

Install O-ring on camshaft position sensor. See
Figure 64.
2. Install camshaft position sensor.
3. Install camshaft position sensor mounting cap-

4. Connect camshaft position sensor electrical con-

nector to camshaft position sensor.

models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) 1. AIR FLOW RESTRICTION SENSOR
Air Flow Restriction Sensor
Figure 70. Air Flow Restriction Sensor
Remove

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (F024)

Fuel/Water Separator 1. Apply Loctite 567 or equivalent to threads on

fuel/water sensor assembly.
Remove
2. Install fuel/water sensor assembly into feul filter
1. To access battery, raise hood, on lift truck models element housing and tighten one half turn past
below. Disconnect the battery. hand tight.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005) 3. Apply Loctite 567 or equivalent to threads on fuel
• S6.0FT, S7.0FT (S135FT, S155FT) (F024) filter element housing.
NOTE: Disposal of lubricants and fluids must meet 4. Install fuel filter element housing to casting
local environmental regulations. mounted on engine. See Figure 71.
2. Attach a small hose to hose barb on drain valve at 5. Tighten housing one quarter turn past hand
bottom of fuel filter element and route hose into tight.
a suitable container to collect fuel and contami-
nants. See Figure 71. 6. Connect electrical connector. See Figure 71.
3. Open drain valve. See Figure 71. 7. Connect battery and lower the hood on lift truck
models
4. Disconnect electrical connector. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005)
5. Once all fuel and contaminants have been • S6.0FT, S7.0FT (S135FT, S155FT) (F024)
drained from fuel filter element housing, remove
drain hose.
6. Remove fuel filter element housing. See Fig-

ure 71.
CAUTION
DO NOT over tighten the vice. If over tighten-
ing of the vice occurs, the fuel filter element
housing will become misshapen and not seal
correctly.
7. Place fuel filter element housing in soft jawed

vice.
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 1. FUEL FILTER ELEMENT HOUSING
connection from fuel filter housing. 2. FUEL/WATER SENSOR ASSEMBLY
3. DRAIN
Install 4. ELECTRICAL CONNECTOR
5. CASTING
NOTE: If fuel/water sensor has been identified as
faulty, replace fuel/water sensor with new one. Figure 71. Fuel/Water Separator

ENGINE AND FUEL SENSORS AND SWITCHES, KUBOTA 3.8L DIESEL ENGINE WITH DPF
Refer to Figure 72 for location of engine sensors and switches.
Figure 72. Kubota 3.8L Diesel Engine with DPF Sensors and Switches

NOTE: H6.0FT, H7.0FT (H135FT, H155FT) (K006) ENGINE SHOWN, H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) SIMILAR.
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
Intake Air Temperature Sensor • H8.0FT, H8.0FT9, H9.0FT (H170FT,

H175FT36, H190FT) (B299)
Remove
2. Disconnect electrical connector from boost sen-
1. To access battery, raise hood, on lift truck models sor.
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) 3. Remove two hose clamps and hose from boost
• H8.0FT, H8.0FT9, H9.0FT (H170FT, sensor and air intake housing. See Figure 73.
H175FT36, H190FT) (B299)
4. Remove two capscrews from boost sensor. See
2. Disconnect electrical connector from intake air Figure 73.
temperature sensor.
5. Remove boost sensor from air intake housing.
3. Remove intake air temperature sensor and See Figure 73.
gasket from intake air intake housing. See Fig-
ure 73. Discard gasket. Install
Install NOTE: If boost sensor has been identified as faulty,

replace boost sensor with new one.
NOTE: If intake air temperature sensor has been
identified as faulty, replace sensor with new one. 1. Install boost sensor onto air intake housing. See
Figure 73.
1. Install new gasket and intake air temperature
sensor. Tighten to 16 to 23 N•m (12 to 17 lbf ft). 2. Install two capscrews to boost sensor. Torque to
2. Connect intake air temperature sensor electrical
sensor. 3. Install hose and two hose clamps to boost sensor
and air intake housing. See Figure 73.
models 4. Connect electrical connector to boost sensor.
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
models
H175FT36, H190FT) (B299)
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Boost Sensor
H175FT36, H190FT) (B299)
Remove

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

Throttle Valve Assembly and Air Intake 4. Remove two flange nuts and two flange bolts
Heater from air intake housing. See Figure 73.
Remove 5. Remove air intake housing and gasket from

throttle valve assembly. Discard gasket. See
1. To access battery, raise hood, on lift truck models Figure 73.
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) 6. Remove throttle valve assembly and gasket from
• H8.0FT, H8.0FT9, H9.0FT (H170FT, air intake heater. Discard gasket. See Figure 73.
H175FT36, H190FT) (B299)
7. Remove air intake heater and gasket from intake
2. Disconnect electrical connector from air intake manifold. Discard gasket. See Figure 73.
sensor and boost sensor.
8. Remove two studs from intake manifold. See Fig-
3. Disconnect electrical connections from air intake ure 73.
heater terminal nuts.
1. BOOST SENSOR 8. FLANGE NUTS

2. CAPSCREW 9. FLANGE BOLTS
3. CLAMP 10. THROTTLE VALVE ASSEMBLY
4. HOSE 11. STUD
5. INTAKE AIR TEMPERATURE SENSOR 12. AIR INTAKE HEATER
6. GASKET 13. INTAKE MANIFOLD
7. AIR INTAKE HOUSING 14. AIR HEATER TERMINAL NUTS
Figure 73. Air Intake Housing and Throttle Valve

Install Install
NOTE: If throttle valve assembly or air intake heater NOTE: If ECT sensor has been identified as faulty,
have been identified as faulty, replace with new one. replace ECT sensor with new one.
1. Install two studs into intake manifold. See Fig- 1. Install new O-ring onto ECT sensor.
ure 73.
2. Install ECT sensor. Tighten sensor to 16 to
2. Install new gasket and air intake heater onto 23 N•m (12 to 17 lbf ft).
studs and intake manifold. See Figure 73.
3. Connect ECT sensor connector. See Figure 72.
3. Install new gasket and throttle valve assembly
onto two studs and air intake heater. See Fig- 4. Refill the radiator with engine coolant. See one
ure 73. of the following sections for coolant specification
and procedures
4. Install new gasket and air intake housing onto
two studs and throttle valve assembly. See Fig- Periodic Maintenance 8000 SRM 1583 for lift
ure 73. truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
5. Install two flange bolts through air intake hous-
ing, throttle valve assembly and air intake heater Periodic Maintenance 8000 SRM 1586 for lift
into intake manifold. See Figure 73. truck model
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
6. Install two flange nuts onto two studs at air in- H175FT36, H190FT) (B299)
take housing. See Figure 73.
7. Connect electrical connectors to air intake heater models
terminal nuts. Torque nuts to 3.5 to 5.3 N•m • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
(30.9 to 46.9 lbf in). • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
8. Connect electrical connectors to boost sensor and
air temperature sensor. Engine Oil Pressure Sensor
9. Connect battery and lower the hood on lift truck Remove
models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) 1. To access battery, raise hood, on lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT, below. Disconnect the battery.
H175FT36, H190FT) (B299) • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
Engine Coolant Temperature (ECT) Sensor H175FT36, H190FT) (B299)
Remove 2. Disconnect electrical connector from oil pressure

sensor.
below. Disconnect the battery. 3. Unscrew and remove oil pressure sensor and
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) O-ring from adapter. See Figure 72.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) 4. Discard O-ring.
2. Drain engine coolant from radiator before remov- Install

ing ECT sensor. Refer to the section Cooling
1. Lubricate new O-ring with multipurpose grease,
and install on oil pressure sensor.
4. Remove the ECT sensor and O-ring. Discard
O-ring.

2. Apply thread locker to threads of oil pressure 5. Connect crankshaft position sensor electrical
sensor. Install oil pressure sensor into adapter. connector to crankshaft position sensor.
Tighten to 15 to 19 N•m (11 to 14 lbf ft).
3. Connect electrical connector for oil pressure sen- models
sor. See Figure 64. • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
4. Connect battery and lower the hood on lift truck H175FT36, H190FT) (B299)
models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
Crankshaft Position Sensor

Remove

• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
2. Disconnect crankshaft position sensor electrical

1. PULSAR GEAR
connector from the crankshaft position sensor. 2. AIR GAP
See Figure 72. 3. SHIM
4. CRANKSHAFT POSITION SENSOR
3. Remove crankshaft position sensor mounting 5. GEAR CASE
capscrew. 6. SHIM 0.25 mm (0.0098 in.)
7. SHIM 0.50 mm (0.020 in.)
4. Remove crankshaft position sensor and O-ring. 8. SHIM 1.00 mm (0.0394 in.)
Discard O-ring.
Figure 74. Crankshaft Position Sensor Air Gap
Install
Adjust Shim Procedure
NOTE: If crankshaft position sensor has been identi-
1. Align TC mark of flywheel with flywheel housing
fied as faulty, replace crankshaft position sensor with
timing window. See procedure in Engine Fuel
new one.
System Repair section of Kubota Diesel 3.8L
1. Lubricate new O-ring with multipurpose grease. Engines , with Diesel Particulate Filter
Install O-ring on crankshaft position sensor. See (DPF) 600 SRM 1590.
Figure 74.
2. Install measurement jig 1 into sensor mounting
NOTE: An air gap of 0.25 to 1.4 mm (0.0098 to position. See Figure 75.
0.055 in.) is needed between the crankshaft position
3. Set dial gauge at measurement jig 2, then mea-
sensor and the pulsar gear. The air gap is achieved
sure protrusion of jig 1. See Figure 76 and Fig-
by using shims shown in Figure 74 and procedure
ure 77.
outlined in Adjust Shim Procedure.
4. Using the protrusion measurement, see Table 2
2. Add the appropriate amount of air gap by adding
for the proper shim combination required to set
shims to the crankshaft position sensor. See Fig-
the air gap.
ure 74.
3. Install crankshaft position sensor.
4. Install crankshaft position sensor mounting cap-



1. JIG 1
2. PROTRUSION
3. GEAR CASE
4. PULSE GEAR
Camshaft Position Sensor

Remove

• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
1. MEASUREMENT JIG 1 H175FT36, H190FT) (B299)
Figure 75. Measurement JIG 1 2. Disconnect camshaft position sensor electrical

connector from camshaft position sensor. See
Figure 72.
3. Remove camshaft position sensor mounting cap-

screw.
4. Remove camshaft position sensor and O-ring.

Discard O-ring.
Install
NOTE: If camshaft position sensor has been identi-

fied as faulty, replace camshaft position sensor with
new one.

1. MEASUREMENT JIG 2 Install O-ring on camshaft position sensor. See
2. DIAL GAUGE
Figure 72.
2. Install camshaft position sensor.
3. Install camshaft position sensor mounting cap-

4. Connect camshaft position sensor electrical con-

nector to camshaft position sensor.

models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
Figure 77. Protrusion Measurement

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.)

Differential Pressure Sensor 4. Connect battery and lower the hood on lift truck
models
Remove • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
Mass Air Flow Sensor
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) Remove
2. Disconnect electrical connector from differential 1. To access battery, raise hood, on lift truck models
pressure sensor. below. Disconnect the battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
3. Remove two clamps and two hoses from bottom
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
of differential pressure sensor. See Figure 78.
H175FT36, H190FT) (B299)
4. Remove two capscrews and differential pressure
2. Disconnect mass air flow sensor electrical con-
sensor from bracket. See Figure 78.
nector. See Figure 79.
Install
3. Remove two capscrews and mass air flow sensor.
NOTE: If differential pressure sensor has been iden- See Figure 79.
tified as faulty, replace differential pressure sensor
Install
with new one.
NOTE: If mass air flow sensor has been identified as
1. Using two capscrews, install differential pres-
faulty, replace mass air flow sensor with new one.
sure sensor onto bracket. See Figure 78.
1. Install mass air flow restriction sensor and two
2. Connect electrical connector to differential pres-
capscrews.
sure sensor.
3. Install two hoses and two clamps onto bottom of

1. DIFFERENTIAL PRESSURE SENSOR

2. BRACKET
3. CAPSCREW 1. MASS AIR FLOW SENSOR
5. HOSE
Figure 79. Mass Air Flow Sensor
Figure 78. Differential Pressure Sensor

2. Connect electrical connector for mass air flow 8. Remove fuel/water sensor, drain, and electrical
sensor. See Figure 79. connection from fuel filter housing.
3. Connect battery and lower the hood on lift truck Install

models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) NOTE: If fuel/water sensor has been identified as
• H8.0FT, H8.0FT9, H9.0FT (H170FT, faulty, replace fuel/water sensor with new one.
H175FT36, H190FT) (B299)
1. Install fuel/water sensor assembly into fuel filter
element housing and tighten one half turn past
Fuel/Water Separator
hand tight.
Remove
2. Install fuel filter element housing to casting
1. To access battery, raise hood, on lift truck models mounted on engine. See Figure 80.
3. Tighten housing one quarter turn past hand
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
tight.
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299) 4. Connect electrical connector. See Figure 80.
NOTE: Disposal of lubricants and fluids must meet 5. Connect battery and lower the hood on lift truck
local environmental regulations. models
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
2. Attach a small hose to hose barb on drain valve at
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
bottom of fuel filter element and route hose into
H175FT36, H190FT) (B299)
a suitable container to collect fuel and contami-
nants. See Figure 80.
3. Open drain valve. See Figure 80.
4. Disconnect electrical connector.
5. Once all fuel and contaminants have been

drained from fuel filter element housing, remove
drain hose.
6. Remove fuel filter element housing. See Fig-

ure 80.
CAUTION
DO NOT over tighten the vice. If over tighten-
ing of the vice occurs, the fuel filter element
housing will become misshapen and not seal
correctly.
7. Place fuel filter element housing in soft jawed 1. FUEL FILTER ELEMENT HOUSING
2. FUEL/WATER SENSOR ASSEMBLY
vice. 3. DRAIN
NOTE: The fuel/water sensor, drain, and electrical 5. CASTING
connection are one piece and will be removed as an
assembly. Figure 80. Fuel/Water Separator

ENGINE AND FUEL SENSORS AND 4. Remove the ECT sensor and O-ring. Discard
SWITCHES, KUBOTA 3.6L DIESEL ENGINE O-ring.
Refer to Figure 81 for location of engine sensors and Install

switches.
NOTE: If ECT sensor has been identified as faulty,
Engine Coolant Temperature (ECT) Sensor replace ECT sensor with new one.
Remove 1. Install new O-ring onto ECT sensor.
1. Raise hood and disconnect the battery. 2. Install ECT sensor.
2. Drain engine coolant from radiator before remov- 3. Connect ECT sensor connector. See Figure 81.
ing ECT sensor. Refer to the section Cooling

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) SIMILAR.
A. RIGHT SIDE OF ENGINE B. LEFT SIDE OF ENGINE
1. COOLANT TEMPERATURE SENSOR
3. ENGINE SPEED SENSOR (H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005) ONLY)
4. FUEL SHUT OFF SOLENOID
Figure 81. Kubota 3.6L Diesel Engine Sensors and Switches

4. Refill the radiator with engine coolant. For 3. Remove engine speed sensor mounting capscrew.
coolant specification and procedure
4. Remove engine speed sensor and O-ring. Discard
See Periodic Maintenance 8000 SRM 1558 for O-ring.
lift truck model
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0- Install
5.5FT (H80, 90, 100, 110, 120FT) (R005)
NOTE: If engine speed sensor has been identified as
See Periodic Maintenance 8000 SRM 1583 for faulty, replace camshaft position sensor with new
lift truck model one.
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
5. Connect battery and lower the hood. Install O-ring on engine speed sensor.
2. Install engine speed sensor. See Figure 81.

Engine Oil Pressure Sensor
3. Install engine speed sensor mounting capscrew.
Remove
4. Connect engine speed sensor electrical connector.
5. Connect battery and lower hood on lift truck.
2. Disconnect electrical connector from oil pressure
sensor.
Fuel Shut Off Solenoid
3. Unscrew and remove oil pressure sensor and
Remove
O-ring from adapter. See Figure 81.
1. Raise hood and disconnect battery.
4. Discard O-ring.
2. Disconnect electrical connector from fuel shut off
Install
solenoid. See Figure 81.
3. Remove two socket head bolts from fuel shut off
solenoid.
1. Lubricate new O-ring with multipurpose grease,
4. Remove fuel shut off solenoid and O-ring. Dis-
and install on oil pressure sensor.
card O-ring.
2. Apply thread locker to threads of oil pressure
Install
sensor. Install oil pressure sensor into adapter.
Tighten two to three turns past finger tight. NOTE: If fuel shut off solenoid has been identified as
defective, replace fuel shut off solenoid with new one.
3. Connect electrical connector for oil pressure sen-
sor. See Figure 81. 1. Lubricate new O-ring with multipurpose grease
and install onto fuel shut off solenoid.
4. Connect battery and lower the hood.
2. Install fuel shut off solenoid. See Figure 81.
Engine Speed Sensor
3. Install two socket head bolts into fuel shut off
Remove solenoid.
1. Raise hood and disconnect the battery. 4. Connect battery and close hood.
2. Disconnect electrical connector from engine
speed sensor. See Figure 81.

2200 SRM 1142 Vehicle System Manager (VSM)
Vehicle System Manager (VSM)

GENERAL • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
The Vehicle System Manager (VSM) is a micropro- • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
cessor-powered controller which controls or moni- S80, 100FTBCS; S120FTS; S120FTPRS)
tors, directly or indirectly, every electrical device on (G004, H004)
the lift truck, except for the Electronic Control Unit • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
(ECU) and the Governor Control Unit (GCU). These 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
devices are controlled by the engine. R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
VSM REPLACEMENT E024, F024)
NOTE: The VSM is not a serviceable part. If the 2. Fully lower the steering column and remove the
VSM malfunctions, replace with a new VSM. See the upper steering column cover. See the section
Parts Manual for replacement part number. Steering Column Repair for the removal proce-
dures.
Remove
3. Remove the dash and kick panel. See the section
1. To access the battery, remove the floor mat and Dash and Kick Panel, Remove and Install for re-
floor plate, on lift truck models below. Disconnect moval procedures.
the battery.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 4. Disconnect all electrical connections from the
J006, K006) VSM. These connections include the chassis
• H8.0FT, H8.0FT9, H9.0FT (H170FT, harness, cowl harness, transmission harness,
H175FT36, H190FT) (A299, B299) and electronic hydraulic (e-hydraulic) controls,
if lift truck is equipped with this feature. See
To access the battery, raise the hood, on lift truck Figure 82.
• S30FT, S35FT, S40FTS (E010) 5. Remove the three bolts securing the VSM and
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, harness bracket to the cowl. Remove VSM from
H40FTS) (F001) lift truck cowl.

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) 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)
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 82. Vehicle System Manager

Install to remove and install the Display Switch Cluster) on

a lift truck, the data that controls all the functions
1. Install VSM and harness bracket onto lift truck and features unique to that lift truck needs to be
cowl. Tighten bolts to 19.2 N•m (14 lbf ft). transferred to the new VSM or Display Switch Clus-
ter.
2. Connect all electrical connections to the VSM.
The connectors are color coded for easy connec- There are two types of data files that may be required
tion. to be transferred when a new VSM or Display Switch
Cluster is installed:
3. Install the dash panel and kick panel. See the
• Configuration Data File (CDF). This data file
section Dash and Kick Panel, Remove and Install
has the configuration and optional details spe-
for installation procedures.
cific to a given truck. For example, configuration
4. Install the upper steering column cover. See the information may include data that shows the
section Steering Column Repair for the installa- truck’s lifting capacity and base type (e.g., 2-3
tion procedures. Ton Cushion tire truck). Optional information
may include data defining the type of engine the
5. Connect the battery, install the floor plate and truck has and whether any Software Enabled
floor mat, on lift truck models Options (SEO) have been installed (e.g., operator
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, passwords). Adding new SEO will require that
J006, K006) new CDF be downloaded and transferred into
• H8.0FT, H8.0FT9, H9.0FT (H170FT, the VSM and Display Switch Cluster. This data
H175FT36, H190FT) (A299, B299) information is directly linked to the truck’s serial
number. An example of a lift truck serial num-
Connect the battery and lower the hood, on lift ber is F187V12345A001. The first 11 characters
truck models (F187V12345A) represent the truck’s serial num-
• S30FT, S35FT, S40FTS (E010) ber and the last 3 digits (001) represent the CDF
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, revision loaded on the truck. The serial number of
H40FTS) (F001) a lift truck is stored in the Display Switch Cluster.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) See the section User Interface, (Service Tech-
• H2.0-3.5FT (H40-70FT) (L177) nician) 2200 SRM 1131 for the procedures to find
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; the serial number. A lift truck’s serial number
S80, 100FTBCS; S120FTS; S120FTPRS) can be found online at Hypass Online. The CDF
(G004, H004) revision will change every time a new version is
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0- loaded and transferred to either the VSM or Dis-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, play Switch Cluster.
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, The CDF for a particular truck cannot be modified
E024, F024) by a service technician. However, a replacement
file (with alternate options [SEO]) can be loaded
PROGRAMMING A NEW VSM AND/OR into a truck’s controller by a service technician.
DISPLAY SWITCH CLUSTER The operational copy of the CDF is stored in the
VSM and a backup copy is stored in the Display
NOTE: See the section Diagnostic Troubleshoot- Switch Cluster.
ing Manual 9000 SRM 1112 for information on how • Operating Data This includes periodically up-
delete and reset fault codes to the VSM, how to use dated and truck specific information such as
the PC Service Tool software, and for the procedures component serial numbers and hourmeters. It also
to troubleshoot the VSM, Display Switch Cluster, and includes the specific adjustments that can be made
other electrical components used on these trucks. by the service technician for various parameters
on a given lift truck. Examples are: auto-deceler-
General ation, which may be set on a scale from (1to10);
Whenever a new VSM or Display Switch Cluster is and certain features which can be activated or
installed (see Display Switch Cluster for procedures deactivated.

Vehicle System Manager (VSM) 2200 SRM 1142
PC Service Tool Software Depending on the part being replaced and the tools
available, different methods of transferring the
The PC Service Tool software (Hyster P/N 1582488) needed data exist. Refer to Table 3 for the best
is required to perform any CDF data file transfers method to use to transfer data based on the tools
from the Display Switch Cluster to a new VSM or available.
from the VSM to a nonblank Display Switch Cluster.
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 auto-
matically 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 in-
terface cable (Hyster P/N 1534010) to the PC service
tool diagnostic connector. See Figure 83. For mini-
mum PC requirements to run the software, refer to
the PC Service Tool Installation and Use Guide, Sys-
tems Requirements section.
Data Transferring
New VSM
NOTE: Data transfer to a used VSM is not possible.

Only a new VSM can be used.
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. De-
tailed instructions can be found in the PC Service
Tool (PCST) Truck Reprogramming Guide.
New (Blank) Display Switch Cluster
If the Display Switch Cluster is being replaced with

a new (blank) display, the VSM will automatically
upload the Operating Data and CDF to the Display
Switch Cluster. PC Service Tool software is not
needed. See Table 3.
1. STEERING COLUMN
2. PC SERVICE TOOL DIAGNOSTIC CONNECTOR
Used (Non-Blank) Display Switch Cluster
Figure 83. Connecting PC Service Tool
If the replacement Display Switch Cluster has been
used on another truck, the PC Service Tool software
must be used to perform the data copying sequence
discussed in New (Blank) Display Switch Cluster.
See Table 3.

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 Read back up Read back up
Original Display required CDF from Display, Display, download
Intact download into new into new VSM
VSM
VSM and Display Not allowed - Not allowed - Read back up
Replaced PC and Internet PC and Internet CDF from Hypass
required required Online, download
into new VSM,
new blank display
Field Repair auto updated after
installation
Display Replaced New blank display New blank display New blank display
With New Blank auto updated after auto updated after auto updated after
Display installation installation installation
Display Replaced Not allowed - PC PC Service Tool PC Service Tool
With Previously required enables over write enables over write
Used Display of old CDF in of old CDF in
display display

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

REMOVE • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
PDM as a Unit
2. Disconnect the chassis harness from the main
NOTE: The PDM as a unit, is not a serviceable part. power connection terminals on the PDM.
The component parts of the PDM (relays, fuses, and
resistors), can be replaced without replacing the 3. Remove bolts and PDM from battery tray for lift
PDM. If the PDM malfunctions, replace with a new truck models below.
PDM. See the Parts Manual for replacement part
number.
• S30FT, S35FT, S40FTS (E010)
1. To access the PDM and battery, remove the floor • H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
mat and floor plate, on lift truck models below. H40FTS) (F001)
Disconnect the battery. • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, • H2.0-3.5FT (H40-70FT) (L177)
J006, K006) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
• H8.0FT, H8.0FT9, H9.0FT (H170FT, S80, 100FTBCS; S120FTS; S120FTPRS)
H175FT36, H190FT) (A299, B299) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
To access the PDM and battery, raise the steering 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
column to its highest position, move the seat all R005)
the wary forward, and raise the hood on lift truck • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
models below. Disconnect the battery. E024, F024)
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 4. Remove bolts and PDM from PDM mounting
H40FTS) (F001) bracket, for lift truck models below.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
(G004, H004)
H175FT36, H190FT) (A299, B299)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
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

2200 SRM 1142 Power Distribution Module (PDM) and Component Parts
Figure 84. PDM Removal, 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, 4.5, 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), and S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024)

Power Distribution Module (PDM) and Component Parts 2200 SRM 1142
INSTALL • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-

5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
PDM as a Unit R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
1. For lift truck models below, install PDM and E024, F024)
bolts onto battery tray. Tighten bolts to 8 N•m
(71 lbf in). 2. For lift truck models below, install PDM and bolts
onto PDM mounting bracket. Tighten bolts to
See Figure 84 for lift truck models 8 N•m (71 lbf in).
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) J006, K006)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; H175FT36, H190FT) (A299, B299)
(G004, H004)
1. BATTERY 4. CHASSIS HARNESS

2. BATTERY CONNECTIONS 5. BOLTS
3. MAIN POWER TERMINALS 6. PDM
Figure 85. PDM Removal, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, k006)
and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)

2200 SRM 1142 Power Distribution Module (PDM) and Component Parts
3. Connect the chassis harness to the main power REMOVE AND INSTALL
connection terminals on the PDM.
PDM Component Parts
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, If lift truck is equipped with a key switch, turn key
J006, K006) to ON position. If lift truck is equipped with a Power
• H8.0FT, H8.0FT9, H9.0FT (H170FT, ON/OFF button, press button to turn system power
H175FT36, H190FT) (A299, B299) on. Check all indicator lights for correct operation as
described in the Operating Manual. Check the op-
See Figure 85 for lift truck models eration of the horn. Start the engine by turning the
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, key switch to the Start position, if truck is equipped
J006, K006) with a key switch, or press the Power ON/OFF but-
• H8.0FT, H8.0FT9, H9.0FT (H170FT, ton, if lift truck is equipped with this button. If any
H175FT36, H190FT) (A299, B299) indicator lights do not operate correctly, check the
fuses. The fuses are located in the Power Distribu-
4. Connect the lift truck battery.
tion Module (PDM) which is under the hood next to
5. Close the hood and move the seat and steering the battery on the right side. See Figure 86.
column into position, for lift truck models shown
below see section indicated for procedures:

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
1. RESISTOR (68 OHM)
Frame 100 SRM 1316 for lift truck models 2. START RELAY
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, 3. STARTER (30 AMP)
E024, F024) 4. IGNITION 3 RELAY
5. BACKUP RELAY
6. Install the floor plate and floor mat for lift truck 6. BACKUP (20 AMP)
7. IGNITION (30 AMP)
models shown below, see section indicated for 8. SPARE FUEL PUMP (20 AMP)
procedures: 9. SPARE FUEL PUMP RELAY
10. BATTERY (25 AMP)
Frame 100 SRM 1321 for lift truck models 11. FRONT WORK LIGHT (20 AMP)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 12. FRONT/REAR WORK LIGHT RELAYS
J006) 13. BATTERY (25 AMP)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 14. REAR WORK LIGHT (20 AMP)
15. IGNITION 1 (20 AMP)
H175FT36, H190FT) (A299) 16. IGNITION 1 RELAY
17. BATTERY (25 AMP)
Frame 100 SRM 1581 for lift ruck model
• H6.0FT, H7.0FT (H135FT, H155FT) (K006) Figure 86. PDM Component Parts
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)

Battery 2200 SRM 1142
Transmission Control Unit

NOTE: The transmission control unit (TCU) is used aid in connecting transmission harness connectors
only on lift truck models: during installation.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, E024,
F024) 2. Disconnect transmission harness connectors
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, from TCU. See Figure 87.
K006)
3. Remove four flange capscrews from bracket and
TCU.
H190FT) (A299, B299)
4. Remove TCU from bracket.
REMOVE
INSTALL
WARNING
1. Install TCU into bracket. See Figure 87.
Always disconnect the cables at the battery
before disconnecting the transmission control 2. Install four flange capscrews into bracket and
unit (TCU). Disconnect the cable at the nega- TCU.
tive terminal first.
3. Connect transmission harness connectors to
1. Open hood and disconnect battery, for lift truck TCU as tagged during removal.
models below.
• S6.0FT, S7.0FT, (S135FT, S155FT) (D024, 4. Connect battery and close hood, for lift truck
E024, F024) models
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
Remove front and rear floor mat and floor plates E024, F024)
and disconnect battery, for lift truck models be-
low. Connect battery and install front and rear floor
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, plate and floor mats, for lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT, J006, K006)
H175FT36, H190FT) (A299, B299)
NOTE: When disconnecting transmission harness
connectors during removal, tag each connector to
Battery
REMOVE • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
1. To access the battery, remove the floor mat and (G004, H004)
floor plate, on lift truck models below. Disconnect • H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
the battery. 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, R005)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, E024, F024)
H175FT36, H190FT) (A299, B299)
2. Remove the battery lockdown bar securing bat-
To access the battery, raise the hood, on lift truck tery to battery tray. Remove battery from lift
models below. Disconnect the battery. truck.
• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001) • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) J006)
• H2.0-3.5FT (H40-70FT) (L177)

2200 SRM 1142 Battery
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Connect the battery and lower the hood, on lift
H175FT36, H190FT) (A299, B299) truck models:
• S30FT, S35FT, S40FTS (E010)
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) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
INSTALL (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
1. Install new battery onto battery tray. Secure bat-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
tery to battery tray with battery lockdown bar.
R005)
2. Connect the battery, install the floor plate and • S6.0FT, S7.0FT (S135FT, S155FT) (D024,
floor mat, on lift truck models: E024, F024)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
A. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
B. S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024)
1. FLANGE CAPSCREW 4. TRANSMISSION HARNESS CONNECTOR
2. TRANSMISSION CONTROL UNIT (TCU) (CRP128)
3. TRANSMISSION HARNESS CONNECTOR 5. BRACKET
(CRP129)
Figure 87. Transmission Control Unit Location

Lights 2200 SRM 1142
Lights
WORK LIGHTS (FRONT AND REAR) Install
Remove 1. Install work light to overhead guard using the
capscrew, washer, and nut. See Figure 88. Con-
1. To access the battery, remove the floor mat and nect work light to overhead guard harness.
floor plate on lift truck models below. Disconnect
• H8.0FT, H8.0FT9, H9.0FT (H170FT, J006, K006)
H175FT36, H190FT) (A299, B299)
To access the battery, raise the hood on lift truck
R005) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, R005)
E024, F024)
CAUTION
DO NOT touch the Halogen bulb surface or in-
side reflectors with your bare hands. Oils from
skin can lead to breakage or shorten the life of
the lamp. Use clean gloves or lint free cloth for
installation and removal.
Clean any dirt or oil, from the lamp surface

with alcohol and a lint free cloth or tissue. Any
foreign particles or materials on the bulb sur-
face can cause hot spots on the bulb and result
in lamp failure.
2. To replace the bulb, remove the lens assembly

by removing the four capscrews. See Figure 88.
Replace the bulb and reinstall the lens assembly.
3. To replace the work light assembly, disconnect

the light from the overhead guard harness and
remove the capscrew, washer, and nut attaching
the work light to the overhead guard. Figure 88. Work Lights

2200 SRM 1142 Lights
Legend for Figure 88 strobe light mounting bracket. Remove strobe

light and guard from lift truck.
LIGHT IS SIMILAR. 4. If the strobe light bulb needs to be replaced, re-
move the strobe light lens from base and remove
1. CAPSCREWS (LENS ASSEMBLY) bulb.
2. LENS ASSEMBLY
3. NUT (ATTACHES LIGHT TO OVERHEAD GUARD)
Install
STROBE LIGHT
1. If bulb is being replaced, install new bulb into
NOTE: The strobe light may either be mounted above strobe light base. Install strobe light lens onto
the top of the overhead guard (high-mounted) or be- base.
low the top of the overhead guard (low-mounted).
The removal and installation procedures are the
guard onto mounting bracket. Secure the as-
same for both options.
sembly to mounting bracket with capscrews,
washers, lockwasher, and nuts. See Figure 89.
Remove
head guard harness.
floor plate on lift truck models below. Disconnect
• H8.0FT, H8.0FT9, H9.0FT (H170FT, J006, K006)
H175FT36, H190FT) (A299, B299)
R005) 5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, R005)
E024, F024)
2. Disconnect the strobe light electrical connector
from the overhead guard harness. See Figure 89.
3. Remove the capscrews, washers, lockwasher, and

nuts securing the strobe light and light guard to

Lights 2200 SRM 1142

• S30FT, S35FT, S40FTS (E010)
H40FTS) (F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024, F024)
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 down-
ward to remove it from the mounting bracket.

Hyster - h40ft, h50ft, h60ft, h70ft - M. Service

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FRAME

S30FT, S35FT, S40FTS [E010];

PART NO. 1580502 100 SRM 1120

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2012 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

1. COWL PLATE 5. COUNTERWEIGHT MOUNTS

Hood, Seat, and Side Covers Replacement

NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.

Figure 2. Hood and Seat Arrangement

1. LOWER STEERING COLUMN COVER 14. LEFT HAND FRONT PANEL

12. Lift the kick panel to remove from truck.

See Figure 3 for lift truck models

Legend for Figure 4

NOTE: TOP VIEW OF DASH SHOWN.

Figure 5. Remove Dash From Cowl

INSTALL See Figure 7 and Table 1 for lift truck models

1. CAPSCREWS 2. SEAL PLATE

Figure 6. Remove Seal Plate From Dash

Legend for Figure 7

NOTE: LEFT SIDE SHOWN

Full or Semi Non-Suspension Seat

Legend for Figure 8

NOTE: LEFT SIDE SHOWN.

Figure 8. Gas Spring Installation, Lift Truck

Legend for Figure 9

Full or Semi Non-Suspension Seat

9. If truck is equipped with a non-swivel seat, tie ca-

10. Install seal plate using three capscrews. See Fig-

11. Install kick panel onto truck.

See Figure 3 for lift truck models

See Figure 4 for lift truck models

12. Install dash to top of cowl. See Figure 5. Install

13. Install upper steering column cover to dash.

14. Using four capscrews, install left and right front

See Figure 3 for lift truck models

STEERING COLUMN REPAIR

2. Attach a tag on the battery connector or nega-

CAUTION NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

Figure 11. Steering Column and Cowl

4. Remove steering column covers. Remove floor

NOTE: Perform Step 5 for lift trucks equipped with

5. Remove four capscrews, four bushings and steer-

NOTE: Perform Step 6 for lift trucks equipped with

6. Remove four capscrews, four bushings, four iso-

1. HORN BUTTON 4. STEERING

Figure 12. Steering Wheel Remove/Install

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

Figure 13. Steering Column Remove/Install

See Figure 15, for lift trucks manufactured after

Legend for Figure 14

LPG Tank and Bracket Assembly

WARNING One M24 × 3 x 90 capscrew holds the counterweight