ELECTRICAL SYSTEM

S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS

(H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT,
S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177]; S4.0,
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];
S6.0FT, S7.0FT (S135FT, S155FT) [D024]; H6.0FT,
H7.0FT (H135FT, H155FT) [H006]

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

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

PART NO. 1580520 2200 SRM 1142

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

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

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Electrical System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Display Switch Cluster ...................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install ............................................................................................................................................................. 4
Direction Control and Turn Signal Levers ................................................................................................... 4
Remove....................................................................................................................................................... 4
Install ......................................................................................................................................................... 4
Key Switch ..................................................................................................................................................... 6
Remove....................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Display Switch Cluster Panel Bezel and Overlay........................................................................................ 7
Remove....................................................................................................................................................... 7
Install ......................................................................................................................................................... 7
Steering Column Repair .................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Disassemble ................................................................................................................................................... 8
Assemble ........................................................................................................................................................ 8
Install ............................................................................................................................................................. 8
Sensors and Switches ........................................................................................................................................ 10
General ........................................................................................................................................................... 10
Dash and Kick Panel Remove and Install ............................................................................................... 10
Remove .................................................................................................................................................. 10
Install..................................................................................................................................................... 10
Accelerator Pedal Position Sensor ................................................................................................................ 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Brake Fluid Level Switch.............................................................................................................................. 15
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 15
Service Brake Pedal Position Sensor............................................................................................................ 16
Remove....................................................................................................................................................... 16
Install ......................................................................................................................................................... 16
Parking Brake Sensor ................................................................................................................................... 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 17
Service Brake Pressure Sensor ..................................................................................................................... 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
MONOTROL® Sensor Microswitch............................................................................................................... 18
Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 20
Low Coolant Level Sensor ............................................................................................................................. 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 22
Fuel Level Sensor, Gas and Diesel Engines Only ........................................................................................ 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 22
Armrest Switch .............................................................................................................................................. 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 23
Seat Sensor (Operator Presence System) ..................................................................................................... 25

©2007 HYSTER COMPANY i

Table of Contents Electrical System

TABLE OF CONTENTS (Continued)

Non-Suspension and Semi-Suspension Seats; All Lift truck Models Except H6.0FT, H7.0FT
(H135FT, H155FT) (H006) ........................................................................................................................ 25
Remove .................................................................................................................................................. 25
Install..................................................................................................................................................... 25
Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)...................... 26
Remove .................................................................................................................................................. 26
Install..................................................................................................................................................... 26
Full Suspension Seats; All Lift Truck Models ......................................................................................... 26
Remove .................................................................................................................................................. 26
Install..................................................................................................................................................... 27
Hood Shut Off Switch .................................................................................................................................... 27
Remove....................................................................................................................................................... 27
Install ......................................................................................................................................................... 27
Hydraulic Filter Pressure Switch ................................................................................................................. 31
Remove....................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
Transmission Speed Sensor .......................................................................................................................... 31
Remove....................................................................................................................................................... 31
Install ......................................................................................................................................................... 32
Transmission Pressure Sensors .................................................................................................................... 32
Remove....................................................................................................................................................... 32
Install ......................................................................................................................................................... 32
Transmission Temperature Sensor ............................................................................................................... 32
Remove....................................................................................................................................................... 32
Install ......................................................................................................................................................... 33
Engine Speed Sensor ..................................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Intermediate Speed Sensor ........................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Return to Set Tilt (Tilt Angle) Sensor .......................................................................................................... 34
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) ................. 34
Remove .................................................................................................................................................. 35
Install..................................................................................................................................................... 35
Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024); 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), and H6.0FT, H7.0FT (H135FT,
H155FT) (H006) ........................................................................................................................................ 35
Remove .................................................................................................................................................. 35
Install..................................................................................................................................................... 36
Rear Horn Button Switch.............................................................................................................................. 36
Remove....................................................................................................................................................... 36
Install ......................................................................................................................................................... 36
Impact Sensor ................................................................................................................................................ 37
All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H006)........................................... 37
Remove .................................................................................................................................................. 37
Install..................................................................................................................................................... 37
Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006) ............................................................. 39
Remove .................................................................................................................................................. 39

ii
Electrical System Table of Contents

TABLE OF CONTENTS (Continued)

Install..................................................................................................................................................... 40
Load Weight Sensor....................................................................................................................................... 40
Remove....................................................................................................................................................... 40
Install ......................................................................................................................................................... 40
Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engines (Except 2007 Emission
Compliant Engines) ....................................................................................................................................... 42
Oxygen Sensor ........................................................................................................................................... 42
Remove .................................................................................................................................................. 42
Install..................................................................................................................................................... 42
Intake Air Temperature (IAT) Sensor ...................................................................................................... 42
Remove .................................................................................................................................................. 42
Install..................................................................................................................................................... 42
Manifold Absolute Pressure (MAP)/Boost Sensor ................................................................................... 43
Remove .................................................................................................................................................. 43
Install..................................................................................................................................................... 43
Throttle Position (TPS) Sensor................................................................................................................. 43
Remove .................................................................................................................................................. 43
Install..................................................................................................................................................... 43
Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG Engines Only (Except 2007
Emission Compliant Engines)....................................................................................................................... 44
Oil Pressure Sensor................................................................................................................................... 44
Remove .................................................................................................................................................. 44
Install..................................................................................................................................................... 44
Low LPG Pressure Switch ........................................................................................................................ 44
Remove .................................................................................................................................................. 44
Install..................................................................................................................................................... 45
Air Filter Restriction Switch .................................................................................................................... 45
Remove .................................................................................................................................................. 45
Install..................................................................................................................................................... 45
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 45
Remove .................................................................................................................................................. 45
Install..................................................................................................................................................... 45
Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas Engines Only (Except 2007
Emission Compliant Engines)....................................................................................................................... 46
Oil Pressure Sensor................................................................................................................................... 46
Remove .................................................................................................................................................. 46
Install..................................................................................................................................................... 46
Mass Air Flow (MAF) Sensor.................................................................................................................... 46
Remove .................................................................................................................................................. 46
Install..................................................................................................................................................... 46
Air Filter Restriction Switch .................................................................................................................... 47
Remove .................................................................................................................................................. 47
Install..................................................................................................................................................... 47
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 47
Remove .................................................................................................................................................. 47
Install..................................................................................................................................................... 47
Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L Gas and LPG Engines (2007
Emission Compliant Engines Only) ............................................................................................................. 48
Oil Pressure Sensor................................................................................................................................... 48
Remove .................................................................................................................................................. 48
Install..................................................................................................................................................... 48

iii
Table of Contents Electrical System

TABLE OF CONTENTS (Continued)

Air Filter Restriction Switch .................................................................................................................... 48
Remove .................................................................................................................................................. 48
Install..................................................................................................................................................... 48
CAM Angle Sensor .................................................................................................................................... 49
Voltage Check ........................................................................................................................................ 49
Oxygen Sensor ........................................................................................................................................... 50
Remove .................................................................................................................................................. 50
Install..................................................................................................................................................... 50
Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG Engines Only (2007
Emission Compliant Engines Only) ............................................................................................................. 51
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 51
Remove .................................................................................................................................................. 51
Install..................................................................................................................................................... 51
Manifold Absolute Pressure (MAP) Sensor.............................................................................................. 52
Remove .................................................................................................................................................. 52
Install..................................................................................................................................................... 52
Intake Air Temperature (IAT) Sensor ...................................................................................................... 52
Remove .................................................................................................................................................. 52
Install..................................................................................................................................................... 53
Fuel Temperature Sensor ......................................................................................................................... 53
Remove .................................................................................................................................................. 53
Install..................................................................................................................................................... 54
Low LPG Pressure Switch ........................................................................................................................ 54
Remove .................................................................................................................................................. 54
Install..................................................................................................................................................... 54
Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas Engines Only (2007 Emission
Compliant Engines Only) .............................................................................................................................. 55
Intake Air Temperature (IAT) Sensor ...................................................................................................... 55
Remove .................................................................................................................................................. 55
Install..................................................................................................................................................... 55
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 56
Remove .................................................................................................................................................. 56
Install..................................................................................................................................................... 56
Manifold Absolute Pressure (MAP) Sensor.............................................................................................. 57
Remove .................................................................................................................................................. 57
Install..................................................................................................................................................... 57
Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and LPG Trucks ................................... 57
Crankshaft Sensor..................................................................................................................................... 57
Remove .................................................................................................................................................. 57
Install..................................................................................................................................................... 58
Camshaft Position (CMP) Sensor ............................................................................................................. 58
Remove .................................................................................................................................................. 58
Install..................................................................................................................................................... 59
Camshaft Position (CMP) Sensor Assembly ............................................................................................ 59
Remove .................................................................................................................................................. 59
Install..................................................................................................................................................... 59
Oil Pressure Sensor................................................................................................................................... 60
Remove .................................................................................................................................................. 60
Install..................................................................................................................................................... 60
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor ..................................... 61
Remove .................................................................................................................................................. 61

iv
Electrical System Table of Contents

TABLE OF CONTENTS (Continued)

Install..................................................................................................................................................... 61
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 62
Remove .................................................................................................................................................. 62
Install..................................................................................................................................................... 62
Air Flow Restriction Switch...................................................................................................................... 62
Remove .................................................................................................................................................. 62
Install..................................................................................................................................................... 63
Oxygen Sensor ........................................................................................................................................... 63
Remove .................................................................................................................................................. 63
Install..................................................................................................................................................... 66
Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only ....................................................... 67
Low LPG Pressure Switch ........................................................................................................................ 67
Remove .................................................................................................................................................. 67
Install..................................................................................................................................................... 67
LPG Pressure Sensor, GM 4.3L Engine Only .......................................................................................... 68
Remove .................................................................................................................................................. 68
Install..................................................................................................................................................... 68
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks................................................................. 68
Air Filter Restriction Switch .................................................................................................................... 68
Remove .................................................................................................................................................. 68
Install..................................................................................................................................................... 68
Oil Pressure Sensor................................................................................................................................... 68
Remove .................................................................................................................................................. 68
Install..................................................................................................................................................... 68
Engine Speed Sensor................................................................................................................................. 68
Remove .................................................................................................................................................. 68
Install..................................................................................................................................................... 68
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 68
Remove .................................................................................................................................................. 68
Install..................................................................................................................................................... 70
Throttle Position Sensor (TPS) ................................................................................................................. 70
Remove .................................................................................................................................................. 70
Install..................................................................................................................................................... 71
Fuel/Water Separator Sensor ................................................................................................................... 71
Remove .................................................................................................................................................. 71
Install..................................................................................................................................................... 71
Glow Plug Relay ........................................................................................................................................ 72
Remove .................................................................................................................................................. 72
Install..................................................................................................................................................... 72
Engine and Fuel Sensors and Switches, Cummins 4.5L Diesel Engine..................................................... 74
Air Filter Restriction Switch .................................................................................................................... 74
Remove .................................................................................................................................................. 74
Install..................................................................................................................................................... 74
Oil Pressure Sensor................................................................................................................................... 76
Remove .................................................................................................................................................. 76
Install..................................................................................................................................................... 76
Engine Speed Sensor................................................................................................................................. 76
Remove .................................................................................................................................................. 76
Install..................................................................................................................................................... 76
Engine Coolant Temperature (ECT) Sensor ............................................................................................ 76
Remove .................................................................................................................................................. 76

v
Table of Contents Electrical System

TABLE OF CONTENTS (Continued)

Install..................................................................................................................................................... 76
Throttle Position Sensor (TPS) ................................................................................................................. 77
Remove .................................................................................................................................................. 77
Install..................................................................................................................................................... 77
Fuel/Water Separator Sensor ................................................................................................................... 78
Remove .................................................................................................................................................. 78
Install..................................................................................................................................................... 78
Vehicle System Manager (VSM)........................................................................................................................ 78
General ........................................................................................................................................................... 78
VSM Replacement ......................................................................................................................................... 78
Remove....................................................................................................................................................... 78
Install ......................................................................................................................................................... 79
Programming a New VSM and/or Display Switch Cluster ......................................................................... 80
General....................................................................................................................................................... 80
PC Service Tool Software .......................................................................................................................... 80
Data Transferring...................................................................................................................................... 81
New or Used VSM ................................................................................................................................. 81
New (Blank) Display Switch Cluster ................................................................................................... 81
Used (Non-Blank) Display Switch Cluster .......................................................................................... 81
Power Distribution Module (PDM) and Component Parts .............................................................................. 82
Remove ........................................................................................................................................................... 82
PDM as a Unit ........................................................................................................................................... 82
Install ............................................................................................................................................................. 85
PDM as a Unit ........................................................................................................................................... 85
Remove and Install........................................................................................................................................ 85
PDM Component Parts ............................................................................................................................. 85
Transmission Control Unit ................................................................................................................................ 86
Remove S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006)............................................................................................................................................................. 86
Install S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT, H7.0FT (H135FT, H155FT)
(H006)............................................................................................................................................................. 86
Battery................................................................................................................................................................ 87
Remove ........................................................................................................................................................... 87
Install ............................................................................................................................................................. 87
Lights.................................................................................................................................................................. 87
Work Lights (Front and Rear)....................................................................................................................... 87
Remove....................................................................................................................................................... 87
Install ......................................................................................................................................................... 88
Strobe Light ................................................................................................................................................... 88
Remove....................................................................................................................................................... 88
Install ......................................................................................................................................................... 88
LED Tail, Backup, and Brake Lights ........................................................................................................... 88
Remove....................................................................................................................................................... 88
Install ......................................................................................................................................................... 89
Electronic-Hydraulic Controls........................................................................................................................... 90
General ........................................................................................................................................................... 90
Mini-Levers .................................................................................................................................................... 90
Remove....................................................................................................................................................... 90
Install ......................................................................................................................................................... 90
Joystick........................................................................................................................................................... 90
Remove and Disassemble.......................................................................................................................... 90

vi
Electrical System Table of Contents

TABLE OF CONTENTS (Continued)

Inspect........................................................................................................................................................ 90
Assemble and Install................................................................................................................................. 90

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 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];
S6.0FT, S7.0FT (S135FT, S155FT) [D024];
H6.0FT, H7.0FT (H135FT, H155FT) [H006]

vii
"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1142 General

General
The removal and replacement procedures for the • LPG Fuel System, GM 2.4L Engine 900 SRM
following electrical components are covered in this 1124
manual: • LPG Fuel System, GM 4.3L Engine 900 SRM
• Display Switch Cluster 1242
• Vehicle System Manager (VSM)
• Power Distribution Module (PDM)
• Joystick and mini-lever electronic-hydraulic con-
trols
• Lights
• Sensors and switches
• Transmission Control Unit (TCU) for lift truck
models S6.0FT, S7.0FT, (S135FT,S155FT) (D024)
and H6.0FT, H7.0FT (H135FT, H155FT) (H006)
• Battery

Some of the components used are made of plastic.

When using screws to replace and install plastic com-
ponents, the screws should be rotated counterclock-
wise until the screw thread turns over the last thread
in the plastic part. The screw can then be turned
clockwise to make a connection. This prevents "cut-
ting" new threads and damaging the existing thread
in the plastic part.

If any welding must be done, obtain proper autho-

rization from a Resident Service Engineer. If autho-
rization is given, be sure to follow the procedures in
the CAUTION below. NOTE: VIEW SHOWN IS FROM THE LEFT SIDE.
MAJOR COMPONENTS AND ELECTRICAL CON-
CAUTION NECTIONS NOT SHOWN FOR CLARITY.
When welding, always disconnect the negative 1. GROUND STUD
battery cable from battery and disconnect 2. TANK OPENING FOR HYDRAULIC FILTER
the ground wire from the ground stud on the 3. POWER DISTRIBUTION MODULE (PDM)
frame. See Figure 1. To prevent damage to the 4. BATTERY
Electronic Control Unit (ECU), remove it from Figure 1. Welding Preparation
the lift truck.
For more information on how to perform welding re-
See one of the following sections for the procedures pairs to lift truck and overhead guard, refer to one of
to remove the ECU from the lift truck: the following sections:
• Gasoline Fuel System, GM 2.4L Engine 900 • Periodic Maintenance 8000 SRM 1150 for lift
SRM 1126 truck models S2.0-3.5FT (S40-70FT, S55FTS)
• Gasoline Fuel System, Mazda 2.0L and 2.2L (F187) and H2.0-3.5FT (H40-70FT (L177)
900 SRM 1127 • Periodic Maintenance 8000 SRM 1207 for
• Gasoline Fuel System, Mazda 2.0L and 2.2L lift truck models S30FT, S35FT, S40FTS (E010)
2007 Emission Compliant Engines 900 SRM and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
1325 H40FTS) (F001)
• Gasoline Fuel System, GM 4.3L Engine 900 • Periodic Maintenance 8000 SRM 1248 for lift
SRM 1244 truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
• LPG Fuel System, Mazda 2.0L and 2.2L En- 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
gines 900 SRM 1125 (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
• LPG Fuel System, Mazda 2.0L and 2.2L 2007 H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
Emission Compliant Engines 900 SRM 1326

Confidential/Proprietary - Do Not Copy or Duplicate 1

Display Switch Cluster 2200 SRM 1142

• Periodic Maintenance 8000 SRM 1319 for lift • Periodic Maintenance 8000 SRM 1322 for lift
truck models S6.0FT, S7.0FT (S135FT, S155FT) truck models H6.0FT, H7.0FT (H135FT, H155FT)
(D024) (H006)

Display Switch Cluster

REMOVE latches (one on either side), and pulling cover
away from steering column. See Figure 2.
NOTE: The Display Switch Cluster is a nonrepairable
part. See the Parts Manual for replacement part 4. Remove the horn button and disconnect the horn
number. wires.

1. Disconnect ground wire. NOTE: A puller tool may be required to remove the
steering wheel.
2. Lift up on the steering wheel slightly and pull up
on the tilt lever. Fully lower the steering column. 5. Remove the lock nut securing the steering wheel
and remove steering wheel from steering column.
3. Remove upper steering column cover by pulling Take care to not damage the horn wires. See
up on upper steering column cover to release the Figure 3.

NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH
1. UPPER STEERING COLUMN COVER 3. LOWER STEERING COLUMN COVER
2. STEERING COLUMN TILT LEVER

Figure 2. Upper Steering Column Cover Removal

2 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Display Switch Cluster

6. Disconnect the Display Switch Cluster harness

from the Display Switch Cluster. Remove the
four bolts securing the Display Switch Cluster.
Slide the display panel off of the steering column.
See Figure 4.

1. HORN BUTTON 2. LOCK NUT

Figure 3. Steering Wheel Removal

NOTE: TOP DOWN VIEW SHOWN.

1. BOLTS 3. STEERING COLUMN
2. DISPLAY SWITCH CLUSTER HARNESS 4. HORN WIRES (CONTACT PADS)

Figure 4. Display Switch Cluster Removal

Confidential/Proprietary - Do Not Copy or Duplicate 3

Display Switch Cluster 2200 SRM 1142

INSTALL Display Switch Cluster. The direction control lever is

located on the left side of the Display Switch Cluster.
NOTE: When a new Display Switch Cluster is in-
stalled on a lift truck, the data that controls all the Remove
functions and features unique to that lift truck, needs
to be transferred to the new Display Switch Cluster. NOTE: There are no repairs for the direction control
See the section Vehicle System Manager (VSM), lo- lever and turn signal lever. If a lever malfunctions,
cated in the back of this manual, for the procedures replace with new lever. See the Parts Manual for
to transfer data to a new Display Switch Cluster. replacement part numbers.

1. Install Display Switch Cluster onto steering col- 1. Insert two small flat-blade or phillips screw-
umn. Install four bolts to secure panel to steering drivers, with a 3.175 mm (0.125 in.) or less, wide
column and tighten bolts to 19 N•m (168 lbf in). blade or die end, into the opening on the Display
See Figure 4. Switch Cluster on an outward angle enough to
compress the spring tab on the direction control
2. Connect the Display Switch Cluster to the dis- lever or turn signal lever. See A, Figure 5.
play harness.
2. Pry the spring tab toward the body of the direc-
3. Install steering wheel onto steering shaft and tion control lever or turn signal lever and, at the
tighten the lock nut until steering wheel is fully same time, pull on the handle of the lever enough
seated. The final torque for the lock nut is 40 to to free the tab of the interior lock of the Display
54 N•m (30 to 40 lbf ft). See Figure 3. Switch Cluster. See B, Figure 5.
4. Connect horn wires to horn button. Install horn 3. Repeat the previous steps on the opposite side of
lock nut and horn button into steering wheel. the direction control lever or turn signal lever.
Remove the direction control lever or turn signal
5. Install upper steering column cover by aligning
lever from the Display Switch Cluster.
the two latches and pushing down until latched.
See Figure 2. Install
DIRECTION CONTROL AND TURN SIGNAL Install the direction control lever or turn signal lever
LEVERS into the opening of the Display Switch Cluster until
the locking tabs are engaged in the Display Switch
The direction control lever and turn signal lever are Cluster.
similar in design, but perform different functions.
The turn signal lever is located on the right side of the

4 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Display Switch Cluster

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

Confidential/Proprietary - Do Not Copy or Duplicate 5

Display Switch Cluster 2200 SRM 1142

KEY SWITCH 2. Remove torx head capscrews. Slide key switch

assembly out of Display Switch Cluster. See Fig-
Remove ure 6.

NOTE: The lift truck models covered in this section Install

can be equipped with an optional key switch or Power
ON/OFF button. The Power ON/OFF button is a 1. Install new key switch assembly into Display
nonrepairable part. See the Parts Manual for re- Switch Cluster. Install torx head capscrews
placement parts. If truck is equipped with a key (T-15) to secure key switch to Display Switch
switch, follow the steps below to remove and replace Cluster. Tighten torx head capscrews to 1.1 N•m
the key switch. (9.7 lbf in). See Figure 6.

1. Fully lower the steering column and remove the 2. Install upper steering cover on steering column.
upper steering column cover by pushing in on Align latches on upper steering cover to holes on
both sides of the cover to release the latches (one steering column and push upper steering cover
on either side), and pulling cover away from into place on steering column.
steering column. See Figure 2.

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

6 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Steering Column Repair

DISPLAY SWITCH CLUSTER PANEL overlay when removing bezel. Lift bezel off of
BEZEL AND OVERLAY Display Switch Cluster. See Figure 6.

Remove 2. Remove overlay from Display Switch Cluster.

1. Insert a small, flat-bladed screwdriver into the Install

top slot on the inner edge of the bezel and pry
Place new overlay on display panel and install a new
outward. Repeat procedure at the lower slot on
bezel by inserting the outer edge in the display and
the bezel. Be careful to not damage bezel and
then pressing down the inner edge.

Steering Column Repair

REMOVE
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Remove the floor mat and floor plate (except

on lift truck models H6.0FT, H7.0FT (H135FT,
H155FT) [H006], where floor plate and mat are
removed in Step 1 to disconnect the battery),
kick panel, seal plate, and dash panel. See one
of the following sections for removal procedures:
• Frame 100 SRM 1120 for lift truck mod-
els 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)
• Frame 100 SRM 1243 for lift truck models
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)
• Frame 100 SRM 1316 for lift truck models
S6.0-7.0FT (S135-155FT) (D024)
• Frame 100 SRM 1321 for lift truck models
H6.0FT, H7.0FT (H135FT, H155FT) (H006)

3. Remove upper steering column cover by pulling

up on upper steering column cover to release
the latches (one on either side), and pulling
cover away from steering column. See Figure 2.
Remove steering wheel and instrument display
panel. See the section Display Switch Cluster
for the removal procedures.

4. Remove two screws and remove lower steering 1. SCREWS

2. LOWER STEERING COLUMN COVER
column cover. See Figure 7.
Figure 7. Lower Steering Column Cover
Removal

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Steering Column Repair 2200 SRM 1142

5. Disconnect Display Switch Cluster harness from 3. Connect Display Switch Cluster harness to
display panel. Remove harness from steering col- Display Switch Cluster panel. Install Display
umn. Switch Cluster harness on steering column.

6. Remove the four bolts (1, Figure 8) holding the 4. Install upper steering column cover by aligning
steering column to the cowl. the two latches and pushing down until latched.
See Figure 7.
7. Raise steering column to disengage steering
shaft from the steering control unit. 5. Install steering wheel and instrument display
panel. See the section Display Switch Cluster.
DISASSEMBLE Move steering column to its lowest position and
install the upper steering column cover. See
1. Remove steering shaft retention clip (4, Fig- Figure 2.
ure 8).
NOTE: For lift truck models H6.0FT, H7.0FT
2. Remove horn contact pads. (H135FT, H155FT) (H006). do not install floor
plate and mat. Floor plate and mat are installed in
3. Remove lower strut pivot pin from the gas cylin-
Step 7, after connecting the battery.
der.
6. Install the floor plate, kick panel, seal plate, and
4. Remove steering column pivot bolts and steering
dash panel. See one of the following sections for
shaft.
installation procedures:
ASSEMBLE • Frame 100 SRM 1120 for lift truck mod-
els S30FT, S35FT, S40FTS (E010), H1.6FT,
1. Install steering column pivot bolts and install H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
steering shaft. (F001), S2.0-3.5FT (S40-70FT, S55FTS)
(F187), and H2.0-3.5FT (H40-70FT) (L177)
2. Install lower strut pivot pin in the gas cylinder. • Frame 100 SRM 1243 for lift truck models
See Figure 8. S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
3. Install horn contact pads. (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
4. Install steering shaft retention clip. H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
• Frame 100 SRM 1316 for lift truck models
INSTALL S6.0-7.0FT (S135-155FT) (D024)
• Frame 100 SRM 1321 for lift truck models
1. Lubricate end of steering shaft with multipur- H6.0FT, H7.0FT (H135FT, H155FT) (H006)
pose grease. Install end of steering shaft into
steering control unit. 7. Connect the battery. For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
2. Install steering column to cowl using four bolts. and floor mat after connecting the battery. On all
Tighten bolts to 38 N•m (28 lbf ft). See Figure 8. other lift truck models, lower the hood.

8 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Steering Column Repair

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

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Sensors and Switches 2200 SRM 1142

Sensors and Switches

GENERAL
The dash and kick panel need to be removed and in-
CAUTION stalled on lift truck after a sensor or switch has been
replaced.
Before removing and replacing any sensors or
switches, ALWAYS disconnect the battery. Fail- Remove
ure to disconnect the battery can cause dam-
age to the sensor or switch and other electrical 1. Lower the steering column to its lowest posi-
components. Always cover or protect the sen- tion and remove upper steering column cover
sor or switch connector from contamination af- by pulling up on upper steering column cover
ter disconnecting the harness mating part. to release the latches (one on either side), and
pulling cover away from steering column. See
Do not use solvent based cleaners to clean area Figure 2.
around sensors or switches.
2. Remove the allen screws securing the dash to the
All sensors and switches used on these trucks are top of the cowl. Remove the dash from the clips,
nonrepairable parts. Replace with new sensors or located underneath dash, that attach the dash
switches whenever a sensor or switch malfunctions to the kick panel. Lift to remove the dash. See
and is not operating correctly. See the Parts Man- Figure 9.
ual for replacement part numbers. Before installing
new sensors or switches, use a clean cloth and make 3. Lift the kick panel from seal plate and remove
sure the area around the sensor or switch is clean from lift truck. See Figure 9.
and free 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 the dash into clips, located underneath

Dash and Kick Panel Remove and Install
dash, that attach the dash to kick panel. Install
Before removing and replacing the following sensors allen screws securing the dash to the top of the
and switches: cowl.

• Accelerator pedal position sensor 3. Install upper steering column cover by aligning
• Brake fluid level switch the two latches and pushing down until latched.
• Service brake pedal position sensor See Figure 2.
• Park brake sensor

10 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

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

Figure 9. Dash and Kick Panel Removal

Confidential/Proprietary - Do Not Copy or Duplicate 11

Sensors and Switches 2200 SRM 1142

ACCELERATOR PEDAL POSITION

SENSOR
Remove
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Remove upper steering column cover and the

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

3. If the lift truck is equipped with:

• Manual hydraulic control valve. Remove
lever bracket capscrews and move the hy-
draulic lever assembly toward the operator’s
seat. See Figure 10.
• Electronic hydraulic control valve. Dis-
connect valve harness from the Vehicle System
Manager (VSM). Remove two bolts and remove
valve harness bracket. See Figure 12.

4. Disconnect accelerator pedal position sensor.

5. Remove three bolts that hold the throttle base

plate and pedal assembly to the cowl and remove
throttle base plate and pedal assembly from cowl.
See Figure 11.

6. Remove two pan head screws and lockwashers

and remove accelerator pedal position sensor
from throttle base plate. See Figure 12. 1. LEVER BRACKET CAPSCREWS
2. COWL
Install
Figure 10. Manual Hydraulic Control Valve
1. Insert new accelerator pedal position sensor into Removal
opening on throttle base plate. See Figure 12.

2. Rotate sensor so that the D shaped throttle shaft

end slides into accelerator pedal position sensor.
Rotate sensor counterclockwise until locating
pin on sensor lines up with hole in throttle base
plate.

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2200 SRM 1142 Sensors and Switches

5. Connect accelerator pedal position sensor.

6. If the lift truck is equipped with:

• Manual hydraulic control valve. Install
lever bracket to cowl. Install clevis and reten-
tion 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 the VSM. See Figure 12.

7. Install kick panel and dash. Install upper steer-

ing column cover. See Dash and Kick Panel Re-
move and Install for procedures.

8. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

9. If throttle pedal needs to be adjusted, see one of

the following sections for the procedures:
• Frame 100 SRM 1120 for lift truck mod-
els S30FT, S35FT, S40FTS (E010), H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001), S2.0-3.5FT (S40-70FT, S55FTS)
1. BOLTS 3. COWL (F187), and H2.0-3.5FT (H40-70FT) (L177)
2. PEDAL ASSEMBLY • Frame 100 SRM 1243 for lift truck models
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
Figure 11. Accelerator Pedal and Throttle Base S80, 100FTBCS; S120FTS; S120FTPRS)
Plate Removal (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
3. Insert two pan head screws and lockwasher
• Frame 100 SRM 1316 for lift truck models
and install accelerator pedal position sensor to
S6.0FT, S7.0FT, (S135FT,S155FT) (D024)
throttle base plate. Tighten screws to 2.25 N•m
• Frame 100 SRM 1321 for lift truck models
(20 lbf in).
H6.0FT, H7.0FT (H135FT, H155FT) (H006)
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.

Confidential/Proprietary - Do Not Copy or Duplicate 13

Sensors and Switches 2200 SRM 1142

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

14 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

BRAKE FLUID LEVEL SWITCH • Periodic Maintenance 8000 SRM 1319 for
lift truck models S6.0FT, S7.0FT (S135FT,
Remove S155FT) (D024)
• Periodic Maintenance 8000 SRM 1322 for
NOTE: The brake fluid level switch is a component lift truck models H6.0FT, H7.0FT (H135FT,
of the master brake cylinder reservoir and is located H155FT) (H006)
inside the reservoir. When the switch is replaced, the
reservoir must be replaced as well.

1. To access the battery on H6.0FT, H7.0FT

(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Remove upper steering column cover and the

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

3. Disconnect the brake fluid level switch from cowl

harness.

CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.

4. Remove the reservoir from the bracket and drain

fluid from reservoir. Disconnect the master cylin-
der supply hose from reservoir. Make sure air
does not get into hose. See Figure 13 and Fig-
ure 14.

Install
1. Connect the master cylinder supply hose to a new
reservoir. See Figure 13 and Figure 14.

2. Install new reservoir onto bracket and fill with

new brake fluid. See one of the following sections
for brake fluid specifications:
• Periodic Maintenance 8000 SRM 1150
for lift truck models S2.0-3.5FT (S40-70FT,
S55FTS) (F187) and H2.0-3.5FT (H40-70FT) 1. RESERVOIR SUPPLY HOSE
(L177) 2. BRAKE FLUID RESERVOIR
• Periodic Maintenance 8000 SRM 1207 3. COWL
for lift truck models S30FT, S35FT, S40FTS 4. BRAKE FLUID LEVEL SWITCH (INSIDE
RESERVOIR)
(E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT, 5. BRAKE FLUID RESERVOIR MOUNTING
H35FT, H40FTS) (F001) BRACKET
• Periodic Maintenance 8000 SRM 1248
for lift truck models S4.0, 4.5, 5.5FT, Figure 13. Brake Fluid Level Switch, Lift Truck
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; Models S30FT, S35FT, S40FTS (E010); H1.6FT,
S120FTS; S120FTPRS) (G004), H4.0FT5/FT6; H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
100, 110, 120FT) (N005) and H2.0-3.5FT (H40-70FT) (L177)

Confidential/Proprietary - Do Not Copy or Duplicate 15

Sensors and Switches 2200 SRM 1142

and floor mat after connecting the battery. On all

other lift truck models, lower the hood.

SERVICE BRAKE PEDAL POSITION

SENSOR
Remove
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Remove upper steering column cover and the

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

3. Disconnect brake pedal position sensor from cowl

harness. See Figure 14 and Figure 15.

4. Remove the two screws securing sensor to

mounting bracket.

Install
1. SERVICE BRAKE PRESSURE SENSOR 1. Install new sensor to mounting bracket and con-
2. MASTER CYLINDER (BOOSTED) nect sensor to cowl harness. See Figure 15.
3. SERVICE BRAKE PEDAL POSITION SENSOR
4. BRAKE LEVEL SENSOR (INSIDE RESERVOIR) 2. After new service brake pedal position sensor has
5. BRAKE FLUID RESERVOIR MOUNTING been installed, check the gap between the sensor
BRACKET arm and tab. See the one of the following sections
6. COWL
7. BRAKE FLUID RESERVOIR for the procedures:
8. BRAKE FLUID SUPPLY HOSE • Brake System 1800 SRM 1135 for lift
truck models S30FT, S35FT, S40FTS (E010),
Figure 14. Brake Fluid Level Switch, Service H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
Brake Pedal Position Sensor, and Service H40FTS) (F001), S2.0-3.5FT (S40-70FT,
Brake Pressure Sensor For Lift Truck Models S55FTS) (F187), and H2.0-3.5FT (H40-70FT)
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, (L177)
100FTBCS; S120FTS; S120FTPRS) (G004); • Brake System 1800 SRM 1247 for lift truck
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
(H80, 90, 100, 110, 120FT) (N005); S6.0FT, 120FT; S80, 100FTBCS; S120FTS; S120FT-
S7.0FT (S135FT, S155FT) (D024); and H6.0FT, PRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H7.0FT (H135FT, H155FT) (H006) H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005), S6.0-7.0FT (S135-155FT)
3. Connect the brake fluid level switch to the cowl (D024), and H6.0FT, H7.0FT (H135FT,
harness. H155FT) (H006)
4. Install kick panel and dash. Install upper steer- 3. Install kick panel and dash. Install upper steer-
ing column cover. See Dash and Kick Panel Re- ing column cover. See Dash and Kick Panel Re-
move and Install for procedures. move and Install for procedures.
5. Connect the battery. For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate

16 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS)

(F187); H2.0-3.5FT (H40-70FT) (L177)

4. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

PARKING BRAKE SENSOR

Remove
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Remove upper steering column cover and the

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

3. Disconnect the parking brake sensor from cowl

harness. Remove the torx capscrews from sensor
and remove sensor from parking brake handle
assembly. See Figure 16.

Install
1. Install new sensor by using the torx capscrews to
secure sensor to parking brake handle assembly.

2. Visually inspect sensor to ensure sensor arm and

parking brake lever maintain continuous contact
throughout full range of lever operation.

3. Connect sensor to cowl harness. See Figure 16.

1. MOUNTING BRACKET BOLTS
2. BRAKE PEDAL POSITION SENSOR 4. Install kick panel and dash. Install upper steer-
3. MASTER CYLINDER ing column cover. See Dash and Kick Panel Re-
4. SERVICE BRAKE PRESSURE SENSOR move and Install for procedures.
5. PARKING BRAKE SENSOR CONNECTOR (TO
COWL HARNESS) 5. Connect the battery. For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
Figure 15. Service Brake Pedal Position Sensor and floor mat after connecting the battery. On all
and Service Brake Pressure Sensor For Lift other lift truck models, lower the hood.
Truck Models S30FT, S35FT, S40FTS (E010);
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,

Confidential/Proprietary - Do Not Copy or Duplicate 17

Sensors and Switches 2200 SRM 1142

2. Disconnect the sensor from the cowl harness and

remove it from the master cylinder. See Fig-
ure 14 and Figure 15.

Install
1. Install a new sensor on master cylinder. Tighten
sensor to 23 to 28 N•m (204 to 248 lbf in).

2. Connect new sensor to cowl harness. See Fig-

ure 14 or Figure 15.

3. Bleed the brake system as described in the sec-

tion
• Brake System 1800 SRM 1135 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)
• Brake System 1800 SRM 1247 for lift truck
models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005), S6.0-7.0FT (S135-155FT)
(D024), and H6.0FT, H7.0FT (H135FT,
H155FT) (H006)

4. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

MONOTROL® SENSOR MICROSWITCH

Remove
1. To access the battery on H6.0FT, H7.0FT
1. PARKING BRAKE SENSOR (H135FT, H155FT) (H006), remove the floor
2. PARKING BRAKE HANDLE ASSEMBLY
3. PARKING BRAKE SENSOR CONNECTOR (TO mat and floor plate. To access the battery on all
COWL HARNESS) other lift truck models, raise the hood. Discon-
4. TORX CAPSCREWS nect the battery.

Figure 16. Parking Brake Sensor 2. Remove the MONOTROL® pedal assembly from
throttle base plate and cowl. Follow the removal
SERVICE BRAKE PRESSURE SENSOR procedures in one of the following sections:
• Powershift Transmission, Repair 1300
Remove SRM 1129 for all lift truck models except
S6.0FT, S7.0FT (S135FT, S155FT) (D024) and
1. To access the battery on H6.0FT, H7.0FT H6.0FT, H7.0FT (H135FT, H155FT) (H006)
(H135FT, H155FT) (H006), remove the floor • Three-Speed Powershift Transmission
mat and floor plate. To access the battery on all Repair 1300 SRM 1317 for lift truck models
other lift truck models, raise the hood. Discon- S6.0FT, S7.0FT (S135FT, S155FT) (D024) and
nect the battery. H6.0FT, H7.0FT (H135FT, H155FT) (H006)

18 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

3. Remove u-clip, foam lock seal, and wiring har- and springs from the pedal frame. If any metal
ness from the pedal frame. Remove four pan inserts in the pedal pad are damaged, replace as
head screws, lockwashers, washers, pedal pad, necessary. See Figure 17.

1. WIRING HARNESS 7. STOP SCREW 13. HEX HEAD SCREW

2. FOAM LOCK SEAL 8. NUT 14. SPRING
3. U-CLIP 9. METAL INSERT 15. PEDAL PAD
4. PAN HEAD SCREW 10. NUT 16. PEDAL FRAME
5. LOCKWASHER 11. LOCKWASHER
6. WASHER 12. MICROSWITCH

Figure 17. Microswitch Removal

Confidential/Proprietary - Do Not Copy or Duplicate 19

Sensors and Switches 2200 SRM 1142

4. Remove two hex head screws 19 mm (3/4 in.),

lockwashers, nuts, and microswitch from the
pedal pad. Repeat for remaining microswitch
and remove the wiring harness from the pedal
frame.

Install
1. Install the microswitch and two hex head screws
in the pedal pad. Coat the exposed threads of
the hex head screws with Loctite™ 222 (Hyster
Part No. 0360387). Install the two lockwashers
and nuts on the hex head screws. Do not tighten
the nuts at this time. Repeat for the other mi-
croswitch.

2. Put the wires through the hole in the pedal

frame. The white banded wire is for the reverse
microswitch, and the blue banded wire is for the
forward microswitch. Adjust each microswitch
in its mount so that the measurement between
the edge of the mount and the base of the 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 18.

3. Install the wiring harness in the pedal frame.

Install the foam lock seal and u-clip. Install
pedal pad and springs in the pedal frame. Coat
the threads of four pan head screws with Loctite 1. MICROSWITCH MOUNT
2. MICROSWITCH BASE
222 (Hyster Part No. 0360387). Install pan
head screws, lockwashers, and washers in the Figure 18. Microswitch Adjustment
pedal pad. Tighten pan head screws to 2.25 to
2.50 N•m (19 to 22 lbf in). LOW COOLANT LEVEL SENSOR
4. Install the MONOTROL® pedal assembly onto NOTE: The low coolant level sensor is an optional fea-
the truck. Follow the installation procedures in ture on these lift trucks and is a part of the Electronic
one of the following sections: Monitoring package option. If the lift truck does not
• Powershift Transmission, Repair 1300 have a low coolant sensor, a plug will be in place of
SRM 1129 for all lift truck models except where the sensor goes. See Figure 19.
S6.0FT, S7.0FT (S135FT, S155FT) (D024) and
H6.0FT, H7.0FT (H135FT, H155FT) (H006) Remove
• Three-Speed Powershift Transmission
Repair 1300 SRM 1317 for lift truck models 1. To access the battery on H6.0FT, H7.0FT
S6.0FT, S7.0FT (S135FT, S155FT) (D024) and (H135FT, H155FT) (H006), remove the floor
H6.0FT, H7.0FT (H135FT, H155FT) (H006) mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
5. Connect the battery. For models H6.0FT, H7.0FT nect the battery.
(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

20 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Figure 19. Low Level Coolant Sensor

Confidential/Proprietary - Do Not Copy or Duplicate 21

Sensors and Switches 2200 SRM 1142

Legend for Figure 19

A. GM 2.4L ENGINES, RADIATOR WITH EXTERNAL COOLER SHOWN
B. MAZDA 2.0L AND 2.2L ENGINES EXCEPT 2007 EMISSION COMPLIANT ENGINES (MODINE SHOWN),
RADIATOR WITH INTERNAL COOLER SHOWN
C. CUMMINS 4.5L AND YANMAR DIESEL ENGINES AND GM 4.3L ENGINES WITH INTERNAL COOLER
SHOWN
D. CUMMINS 4.5L AND YANMAR DIESEL ENGINES AND GM 4.3L ENGINES WITH EXTERNAL COOLER
SHOWN
E. MAZDA 2007 EMISSION COMPLIANT 2.0L AND 2.2L ENGINES (MODINE SHOWN), RADIATOR WITH
INTERNAL COOLER SHOWN
1. RADIATOR 2. LOW LEVEL COOLANT SENSOR
FUEL LEVEL SENSOR, GAS AND DIESEL
CAUTION ENGINES ONLY
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. Remove
2. Drain coolant from radiator and disconnect the 1. To access the battery on H6.0FT, H7.0FT
electrical connector from the low coolant level (H135FT, H155FT) (H006), remove the floor
sensor. mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
3. Remove the low coolant level sensor from the ra-
nect the battery.
diator. See Figure 19.
2. Disconnect the electrical connector from the sen-
Install sor on the fuel pump cover.
1. Install new low coolant level sensor into radiator. 3. Unscrew the sensor and remove sensor and
See Figure 19. sender unit from fuel pump assembly. See Fig-
ure 20.
2. Connect the electrical connector to the low
coolant level sensor. Refill radiator with correct
Install
coolant of 50% water and 50% Ethylene Glycol
Boron-Free Antifreeze. 1. Install new fuel level sensor and sender unit
through hole in fuel pump cover. Be sure that
3. Seal threads with Loctite PST 567 (Hyster Part
the bracket in the fuel pump engages the plas-
No. 273338) thread sealant and torque to 7 N•m
tic piece on the bottom of the fuel sender unit.
(62 lbf in).
Tighten fuel level sensor and sender unit onto
4. Connect the battery. For models H6.0FT, H7.0FT fuel pump cover. See Figure 20.
(H135FT, H155FT) (H006), install the floor plate
2. Connect the fuel level sensor electrical connector.
and floor mat after connecting the battery. On all
other lift truck models, lower the hood. 3. Connect the battery. For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

22 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

ARMREST SWITCH
NOTE: Lift truck models H6.0FT, H7.0FT (H135FT,
H155FT) (H006) are not equipped with an armrest
switch.

Remove
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Unlatch and raise armrest.

3. Remove arm pad by removing four screws from

underside of armrest. Disconnect armrest
switch from seat harness. See Figure 21. Re-
move screws securing armrest switch to armrest
bracket and remove switch.

Install
1. Install new armrest switch on bracket. Connect
switch to seat harness. See Figure 21.

2. Install arm pad by inserting four screws into un-

derside of armrest.

3. Close and latch armrest.

4. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

NOTE: GAS FUEL PUMP SHOWN.

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

Figure 20. Fuel Pump and Sensor

Confidential/Proprietary - Do Not Copy or Duplicate 23

Sensors and Switches 2200 SRM 1142

Figure 21. Armrest Switch

24 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Legend for Figure 21

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

SEAT SENSOR (OPERATOR PRESENCE 3. Remove the four capscrews and washers holding
SYSTEM) the seat to the hood. Remove seat from the hood.

Non-Suspension and Semi-Suspension 4. Disconnect the seat sensor. See Figure 23.
Seats; All Lift truck Models Except H6.0FT, 5. Remove two capscrews and seat sensor from the
H7.0FT (H135FT, H155FT) (H006) seat.

Remove Install

1. Disconnect the battery. Raise the hood for access 1. Insert two capscrews and install sensor to seat.
to the battery. See Figure 23.

2. Disconnect seat harness from chassis harness.

Remove seat harness from brackets that are at-
tached to hood. See Figure 22.

NOTE: LIFT TRUCK MODELS H6.0FT, H7.0FT

(H135FT, H155FT) (H006) ARE NOT EQUIPPED
WITH SEMI-SUSPENSION SEATS.
NOTE: BOTTOM VIEW OF HOOD SHOWN.
1. CAPSCREWS 4. SEAT GROUND
1. CAPSCREWS 3. SEAT HARNESS 2. SEAT SENSOR WIRE
2. SEAT HARNESS 3. SEAT SENSOR 5. SEAT HARNESS
BRACKET ELECTRICAL
CONNECTOR
Figure 22. Seat Removal, Non-Suspension and
Semi-Suspension Seats, All Lift Truck Models Figure 23. Seat Sensor, Non-Suspension and
Except H6.0FT, H7.0FT (H135FT, H155FT) Semi-Suspension Seats
(H006)

Confidential/Proprietary - Do Not Copy or Duplicate 25

Sensors and Switches 2200 SRM 1142

2. Connect new seat sensor to seat harness. 6. Connect the battery and install the floor plate
and floor mat.
3. Install seat onto hood using four capscrews
and washers. Tighten capscrews to 18 N•m
(156 lbf in). See Figure 22.

4. Install seat harness to brackets on hood.

5. Connect seat harness to chassis harness.

6. Connect the battery and close hood.

Non-Suspension Seats; Lift Truck Models

H6.0FT, H7.0FT (H135FT, H155FT) (H006)
Remove

1. Disconnect the battery. For access to the battery,

remove the floor plate and floor mat.

2. Disconnect seat harness from chassis harness.

Remove the seat harness from the bracket that NOTE: BOTTOM VIEW SHOWN.
is attached to the seat surround plate. See Fig- 1. HARNESS BRACKET
ure 24. 2. SEAT HARNESS
3. SEAT SURROUND PLATE
3. Remove the four flange nuts holding the seat to 4. FLANGE NUTS
the seat plate. Remove seat from seat plate. 5. SEAT PLATE

4. Disconnect the seat sensor. See Figure 23. Figure 24. Seat Removal, Non-Suspension Seat,
Lift Truck Models H6.0FT, H7.0FT (H135FT,
5. Remove two capscrews and seat sensor from the H155FT) (H006)
seat.
Full Suspension Seats; All Lift Truck
Install
Models
1. Insert two capscrews and install new sensor to
Remove
seat. See Figure 23.
1. Remove two clips that secure the bottom seat
2. Connect new seat sensor to seat harness.
cushion to seat base. See Figure 25.
3. Install seat onto seat plate using four flange
2. Lift bottom seat cushion up and disconnect the
nuts. Tighten flange nuts to 18 N•m (156 lbf in)
seat sensor from harness.
See Figure 24.
3. Use a small, flat-bladed screwdriver and remove
4. Install seat harness to bracket on seat surround
the seat sensor from bottom seat cushion.
plate.

5. Connect seat harness to chassis harness.

26 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Install HOOD SHUT OFF SWITCH

1. Install new seat sensor into bottom seat cushion. NOTE: The hood shut off switch is found on lift trucks
manufactured for use in Europe only.
2. Connect seat sensor to seat harness. See Fig-
ure 25. Remove
3. Place bottom seat cushion onto seat base and se- 1. To access the battery on H6.0FT, H7.0FT
cure cushion to base with two clips. (H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Disconnect switch from rear harness to chassis

harness connector and remove capscrews to re-
move switch from bracket. See Figure 26 and
Figure 27.

Install
1. Install new switch on bracket using the cap-
screws and connect switch to rear harness to
chassis harness connector. See Figure 26 and
Figure 27.

2. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

1. SEAT SENSOR 4. CLIPS

2. SEAT HARNESS 5. BOTTOM SEAT
3. TO CHASSIS CUSHION
HARNESS 6. SEAT BASE

Figure 25. Seat Sensor, Full Suspension Seat

Confidential/Proprietary - Do Not Copy or Duplicate 27

Sensors and Switches 2200 SRM 1142

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 26. Hood Shut Off Switch, All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT)
(H006)

28 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

NOTE: BOTTOM VIEW OF HOOD SHOWN. KEY AND HOOD SWITCHES ARE OPTIONAL FEATURES.
1. HINGE BRACKET 4. REAR HARNESS TO CHASSIS HARNESS
2. ACTUATOR MAGNET CONNECTOR
3. HOOD SHUT OFF SWITCH 5. KEY SWITCH

Figure 27. Hood Shut Off Switch, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)

Confidential/Proprietary - Do Not Copy or Duplicate 29

Sensors and Switches 2200 SRM 1142

Figure 28. Hydraulic Filter Pressure Switch

30 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Legend for Figure 28

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 , H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), S6.0FT, S7.0FT (S135FT, S155FT) (D024), AND H6.0FT, H7.0FT
(H135FT, H155FT) (H006)
1. HYDRAULIC FILTER PRESSURE SWITCH 3. FILTER HEAD ASSEMBLY
2. O-RING (NOT SHOWN)

HYDRAULIC FILTER PRESSURE SWITCH 2. Disconnect sensor from transmission harness

and remove bolt securing sensor to transmission
NOTE: The hydraulic filter pressure switch is an op- housing. Discard the O-rings. See Figure 29 and
tional feature on these lift trucks and is a part of the Figure 30.
Electronic Monitoring package option.

Remove
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Disconnect the hydraulic filter pressure switch

from the chassis harness. Remove switch from
hydraulic filter head assembly and discard
switch and O-ring. See Figure 28.

Install
1. Insert new switch, with new O-ring, into hy-
draulic filter head assembly. Torque switch to
20 N•m (177 lbf in). Connect hydraulic filter
pressure switch to chassis harness. See Fig-
ure 28.

2. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.
NOTE: TWO-SPEED TRANSMISSION SHOWN FOR
TRANSMISSION SPEED SENSOR ALL LIFT TRUCK MODELS EXCEPT S6.0FT, S7.0FT
(S135FT, S155FT) (D024) AND H6.0FT, H7.0FT
Remove (H135FT, H155FT) (H006)
1. To access the battery on H6.0FT, H7.0FT 1. PRESSURE SENSORS
(H135FT, H155FT) (H006), remove the floor 2. PRESSURE SENSOR (TWO-SPEED ONLY)
mat and floor plate. To access the battery on all 3. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
other lift truck models, raise the hood. Discon- 4. TRANSMISSION INPUT SPEED SENSOR (TISS)
nect the battery. 5. BOLTS
6. TEMPERATURE SENSOR

Figure 29. Transmission Sensors

Confidential/Proprietary - Do Not Copy or Duplicate 31

Sensors and Switches 2200 SRM 1142

Install • Periodic Maintenance 8000 SRM 1150

for lift truck models S2.0-3.5FT (S40-70FT,
1. Install new O-rings on sensor and install sensor S55FTS) (F187) and H2.0-3.5FT (H40-70FT)
into transmission housing with the bolt. Tighten (L177)
bolt to 6.9 N•m (61 lbf in). Connect sensor to • Periodic Maintenance 8000 SRM 1207
transmission harness. See Figure 29 and Fig- for lift truck models S30FT, S35FT, S40FTS
ure 30. (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
2. Connect the battery. For models H6.0FT, H7.0FT
• Periodic Maintenance 8000 SRM 1248
(H135FT, H155FT) (H006), install the floor plate
for lift truck models S4.0, 4.5, 5.5FT,
and floor mat after connecting the battery. On all
S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
other lift truck models, lower the hood.
S120FTS; S120FTPRS) (G004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
TRANSMISSION PRESSURE SENSORS
100, 110, 120FT) (N005)
Remove • Periodic Maintenance 8000 SRM 1319 for
lift truck models S6.0FT, S7.0FT (S135FT,
1. To access the battery on H6.0FT, H7.0FT S155FT) (D024)
(H135FT, H155FT) (H006), remove the floor • Periodic Maintenance 8000 SRM 1322 for
mat and floor plate. To access the battery on all lift truck models H6.0FT, H7.0FT (H135FT,
other lift truck models, raise the hood. Discon- H155FT) (H006)
nect the battery.
WARNING
2. Disconnect the pressure sensors from the trans-
mission harness. Remove sensors from fitting on At operating temperature, the transmission oil
the control valve. See Figure 29 and Figure 30. is HOT. Do not permit the hot oil to touch the
skin and cause a burn. Make sure oil is cool
Install before draining.

NOTE: When new transmission pressure sensors 3. Drain the transmission oil. See one of the follow-
are installed, calibration is required. See the sec- ing sections for the procedures:
tion Calibration Procedures 8000 SRM 1134 for • Periodic Maintenance 8000 SRM 1150
calibration procedures. for lift truck models S2.0-3.5FT (S40-70FT,
S55FTS) (F187) and H2.0-3.5FT (H40-70FT)
1. Install new sensors on control valve. Connect (L177)
sensors to transmission harness. See Figure 29 • Periodic Maintenance 8000 SRM 1207
and Figure 30. for lift truck models S30FT, S35FT, S40FTS
(E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
2. Connect the battery. For models H6.0FT, H7.0FT H35FT, H40FTS) (F001)
(H135FT, H155FT) (H006), install the floor plate • Periodic Maintenance 8000 SRM 1248
and floor mat after connecting the battery. On all for lift truck models S4.0, 4.5, 5.5FT,
other lift truck models, lower the hood. S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), H4.0FT5/FT6;
TRANSMISSION TEMPERATURE SENSOR H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005)
Remove • Periodic Maintenance 8000 SRM 1319 for
lift truck models S6.0FT, S7.0FT (S135FT,
1. To access the battery on H6.0FT, H7.0FT
S155FT) (D024)
(H135FT, H155FT) (H006), remove the floor
• Periodic Maintenance 8000 SRM 1322 for
mat and floor plate. To access the battery on all
lift truck models H6.0FT, H7.0FT (H135FT,
other lift truck models, raise the hood. Discon-
H155FT) (H006)
nect the battery.
4. Disconnect temperature sensor from transmis-
2. Put the lift truck on blocks. See the Operating
sion harness and remove sensor from transmis-
Manual or one of the following sections for the
sion. See Figure 29 and Figure 30.
procedures:

32 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Install 3. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
1. Install new temperature sensor and connect sen- and floor mat after connecting the battery. On all
sor to transmission harness. See Figure 29 and other lift truck models, lower the hood.
Figure 30.

2. Remove lift truck from blocks.

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)
4. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)*

*TOSS SENSOR LOCATION, THREE-SPEED TRANSMISSION ONLY.

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

Figure 30. Transmission Sensors, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024)
and H6.0FT, H7.0FT (H135FT, H155FT) (H006)

Confidential/Proprietary - Do Not Copy or Duplicate 33

Sensors and Switches 2200 SRM 1142

4. Fill transmission with oil. Run the lift truck and models equipped with a three-speed transmission.
check oil level. See one of the following sections See Figure 30.
for transmission oil specifications and for the pro-
cedures to check the transmission oil level: Remove
• Periodic Maintenance 8000 SRM 1150
for lift truck models S2.0-3.5FT (S40-70FT, 1. For lift truck models S6.0FT, S7.0FT (S135FT,
S55FTS) (F187) and H2.0-3.5FT (H40-70FT) S155FT) (D024) raise the hood to disconnect the
(L177) battery. Remove the floor mat and floor plate
• Periodic Maintenance 8000 SRM 1207 from truck for access to the transmission.
for lift truck models S30FT, S35FT, S40FTS
For lift truck models H6.0FT, H7.0FT (H135FT,
(E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H155FT) (H006), remove the floor mat and floor
H35FT, H40FTS) (F001)
plate for access to the transmission and battery
• Periodic Maintenance 8000 SRM 1248 for
to disconnect it.
lift truck models, H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 2. Disconnect intermediate speed sensor from
120FT) (N005) transmission harness and remove bolt securing
• Periodic Maintenance 8000 SRM 1319 for sensor to transmission housing. Discard the
lift truck models S6.0FT, S7.0FT (S135FT, O-ring. See Figure 30.
S155FT) (D024)
• Periodic Maintenance 8000 SRM 1322 for Install
lift truck models H6.0FT, H7.0FT (H135FT,
H155FT) (H006) 1. Install new O-ring on intermediate speed sensor
and install intermediate speed sensor into trans-
ENGINE SPEED SENSOR mission housing with the bolt. Tighten bolt to
6.9 N•m (61 lbf in). Connect intermediate speed
NOTE: The engine speed sensor is used only on sensor to transmission harness. See Figure 30.
S6.0FT, S7.0FT (S135FT, S155FT) (D024) and
H6.0FT, H7.0FT (H135FT, H155FT) (H006) lift 2. Connect the battery. For lift truck models
truck models equipped with a three-speed transmis- S6.0FT, S7.0FT (S135FT, S155FT) (D024), close
sion. See Figure 30. the hood after connecting battery and install
floor plate and floor mat onto frame.
Remove
For lift truck models H6.0FT, H7.0FT (H135FT,
1. Remove the floor plate and mat from frame and H155FT) (H006) install floor plate and floor mat
disconnect the battery. after connecting battery.

2. Disconnect engine speed sensor from transmis- RETURN TO SET TILT (TILT ANGLE)
sion harness and remove bolt securing sensor to SENSOR
transmission housing. Discard the O-ring. See
Figure 30. Lift Truck Models S30FT, S35FT, S40FTS
Install (E010); H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001); S2.0-3.5FT
1. Install new O-ring on sensor and install sensor (S40-70FT, S55FTS) (F187); H2.0-3.5FT
into transmission housing with the bolt. Tighten
(H40-70FT) (L177)
bolt to 6.9 N•m (61 lbf in). Connect sensor to
transmission harness. See Figure 30. NOTE: Before working on or near the mast, see the
section Safety Procedures When Working Near Mast
2. Place floor plate and mat onto frame. Connect
in the section
the battery.
• Periodic Maintenance 8000 SRM 1150 for lift
truck models S2.0-3.5FT (S40-70FT, S55FTS)
INTERMEDIATE SPEED SENSOR
(F187) and H2.0-3.5FT (H40-70FT) (L177)
NOTE: The intermediate speed sensor is used only • Periodic Maintenance 8000 SRM 1207 for
on S6.0FT, S7.0FT (S135FT, S155FT) (D024) and lift truck models S30FT, S35FT, S40FTS (E010)
H6.0FT, H7.0FT (H135FT, H155FT) (H006) lift truck

34 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 2. Connect mast harness to cowl harness.
H40FTS) (F001)
3. Connect the battery and close the hood.
Remove
4. Tilt the mast completely forward and backward
1. Raise the hood and disconnect the battery. to ensure that the tilt sensor is correctly installed
and connected.
2. Disconnect the mast harness from the cowl har-
ness. Lift Truck Models S6.0FT, S7.0FT
3. Remove two torx capscrews and nuts holding the (S135FT, S155FT) (D024); S4.0, 4.5,
tilt sensor to the sensor bracket on the mast and 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
remove sensor and mast harness from sensor and 100FTBCS; S120FTS; S120FTPRS)
harness brackets. See Figure 31. (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), and H6.0FT, H7.0FT (H135FT,
H155FT) (H006)
NOTE: Before working on or near the mast, see the
section Safety Procedures When Working Near Mast
in the section
• Periodic Maintenance 8000 SRM 1248 for lift
truck models S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
• Periodic Maintenance 8000 SRM 1319 for lift
truck models S6.0FT, S7.0FT (S135FT, S155FT)
(D024)
• Periodic Maintenance 8000 SRM 1322 for lift
truck models H6.0FT, H7.0FT (H135FT, H155FT)
(H006)

Remove

1. To access the battery on H6.0FT, H7.0FT

(H135FT, H155FT) (H006), remove the floor
NOTE: MAST SHOWN MAY BE DIFFERENT, BUT LO- mat and floor plate. To access the battery on all
CATION OF TILT SENSOR IS THE SAME FOR ALL other lift truck models, raise the hood. Discon-
LIFT TRUCKS COVERED IN THIS SECTION. nect the battery.
1. TORX CAPSCREWS 2. Disconnect sensor harness from cowl harness.
2. RETURN TO SET TILT (TILT ANGLE) SENSOR
3. SENSOR BRACKET See Figure 32.
4. COWL
5. MAST HARNESS (TO COWL HARNESS) 3. Remove harness bracket from cowl and remove
6. HARNESS BRACKET harness from bracket.

Figure 31. Return to Set Tilt (Tilt Angle) Sensor 4. Remove capscrew that attaches tilt sensor
bracket to mast. See Figure 32.
Install
5. Remove sensor bracket and tilt sensor from mast.
1. Install new sensor onto sensor bracket and in-
sert two torx capscrews and nuts to secure sen- 6. Remove two torx capscrews and nuts holding the
sor to bracket. Secure mast harness to harness tilt sensor to the sensor bracket. Remove sensor
bracket. See Figure 31. from bracket.

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Sensors and Switches 2200 SRM 1142

5. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

6. Tilt the mast completely forward and backward

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

REAR HORN BUTTON SWITCH

Remove
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Disconnect rear horn button switch electrical

1. TILT SENSOR connector from chassis harness. See Figure 33.
2. TILT SENSOR BRACKET
3. CAPSCREW 3. Remove two capscrews and inserts that attach
4. SENSOR HARNESS BRACKET rear horn button switch and handle to the right
5. SENSOR CONNECTOR TO COWL HARNESS rear overhead guard leg.
6. COWL
7. TILT CYLINDERS 4. Remove switch and handle assembly from over-
head guard leg, pulling the wire and connector
Figure 32. Return to Set Tilt (Tilt Angle) Sensor,
through the holes in the overhead guard leg.
Lift Truck Models S6.0FT, S7.0FT (S135FT,
S155FT) (D024); S4.0, 4.5, 5.5FT, S5.5FTS
Install
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5, 1. Insert wire and connector in the hole in overhead
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) guard leg and thread wire until connector can
(N005), and H6.0FT, H7.0FT (H135FT, H155FT) be pulled through bottom hole in the overhead
(H006) guard leg.
Install 2. Attach handle and switch assembly to overhead
guard leg with two capscrews and inserts. See
1. Install new tilt sensor onto sensor bracket using
Figure 33.
two torx capscrews and nuts.
3. Connect rear horn switch electrical connector to
2. Secure sensor bracket and tilt sensor to mast us-
chassis harness.
ing capscrew. Tighten capscrew to 90 to 99 N•m
(66 to 73 lbf ft). See Figure 32. 4. Connect the battery. For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
3. Place sensor harness in harness bracket and
and floor mat after connecting the battery. On all
install bracket onto cowl. Tighten capscrew to
other lift truck models, lower the hood.
38 N•m (28 lbf ft).

4. Connect the sensor harness connector to the cowl

harness.

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2200 SRM 1142 Sensors and Switches

and right step plate. See one of the following

sections for the removal procedures:
• Frame 100 SRM 1120 for lift truck mod-
els 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)
• Frame 100 SRM 1243 for lift truck models
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)
• Frame 100 SRM 1316 for lift truck models
S6.0FT, S7.0FT, (S135FT,S155FT) (D024)

3. Disconnect the impact sensor from the right

chassis harness. See Figure 34.

4. Remove two capscrews that attach the impact

sensor to mounting bracket. Remove sensor from
lift truck.

Install

1. Install new impact sensor to mounting bracket.

Tighten capscrews to 26 N•m (19 lbf ft).
1. CAPSCREW
2. INSERT 2. Connect impact sensor to right chassis harness.
3. HANDLE AND SWITCH ASSEMBLY See Figure 34.
4. HOLE
5. HANDLE 3. Install the floor mat and floor plate. Install the
6. REAR HORN BUTTON SWITCH right rear panel, right panel, right fender cover,
7. ELECTRICAL CONNECTOR and right step plate. See one of the following
8. OVERHEAD GUARD LEG
sections for the installation procedures:
Figure 33. Rear Horn Button Switch • Frame 100 SRM 1120 for lift truck mod-
els S30FT, S35FT, S40FTS (E010), H1.6FT,
IMPACT SENSOR H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001), S2.0-3.5FT (S40-70FT, S55FTS)
The impact sensor is located under the right side step (F187), and H2.0-3.5FT (H40-70FT) (L177)
plate. • Frame 100 SRM 1243 for lift truck models
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
All Lift Truck Models Except H6.0FT, S80, 100FTBCS; S120FTS; S120FTPRS)
H7.0FT (H135FT, H155FT) (H006) (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
Remove • Frame 100 SRM 1316 for lift truck models
S6.0FT, S7.0FT, (S135FT,S155FT) (D024)
1. Raise the hood and disconnect the battery.
4. Connect the battery and close hood.
2. Remove the floor mat and floor plate. Remove the
right rear panel, right panel, right fender cover,

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Sensors and Switches 2200 SRM 1142

NOTE: THE FRAME SHOWN IN FIGURE 34 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 34. Impact Sensor Replacement, All Lift Truck Models Except H6.0FT, H7.0FT (H135FT,
H155FT) (H006)

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2200 SRM 1142 Sensors and Switches

Lift Truck Models H6.0FT, H7.0FT (H135FT, 2. Disconnect the impact sensor connector from the
H155FT) (H006) right chassis harness connector. See Figure 35.

Remove 3. Remove the two capscrews that secure impact

sensor to bracket and remove sensor from lift
1. Remove the floor mat and floor plate and discon- truck. See Figure 35.
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 35. Impact Sensor Replacement, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)

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Sensors and Switches 2200 SRM 1142

Install other lift truck models, raise the hood. Discon-

nect the battery.
1. Install new impact sensor to sensor bracket using
two capscrews. Tighten capscrews to 26 N•m 2. Disconnect the harness connector from the load
(230 lbf in). weight sensor. See Figure 36.

2. Insert the push-in fastener into the connector 3. Remove the load weight sensor from the special
clip, then connect the right chassis harness con- fitting on hydraulic control valve.
nector to the impact sensor connector. See Fig-
ure 35. Install
3. Connect the battery and install the floor plate 1. Insert new load weight sensor into special fitting.
and floor mat. Tighten sensor by hand, and then torque sensor
to 37 N•m (27 lbf ft).
LOAD WEIGHT SENSOR
2. Connect the harness connector to the load weight
Remove sensor. See Figure 36.

1. To access the battery on H6.0FT, H7.0FT 3. Connect the battery. For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor (H135FT, H155FT) (H006), install the floor plate
mat and floor plate. To access the battery on all and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

NOTE: THE POSITION OF THE VEHICLE SYSTEM MANAGER SHOWN IN FIGURE 36 MAY BE DIFFERENT,
BUT LOCATION OF LOAD WEIGHT SENSOR IS THE SAME FOR ALL LIFT TRUCKS COVERED IN THIS SRM.

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2200 SRM 1142 Sensors and Switches

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 36. Load Weight Sensor

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Sensors and Switches 2200 SRM 1142

ENGINE AND FUEL SENSORS - MAZDA Intake Air Temperature (IAT) Sensor
2.0L AND 2.2L GAS AND LPG ENGINES
Remove
(EXCEPT 2007 EMISSION COMPLIANT
ENGINES) 1. Disconnect the battery.

Oxygen Sensor 2. Disconnect the wiring harness connector from

the sensor connector.
Remove
3. Remove the sensor. See Figure 38.
1. Disconnect the battery.
Install
2. Disconnect electrical connector from oxygen sen-
sor. See Figure 37. 1. Install the IAT sensor and tighten the IAT sensor
to 7.85 to 11.77 N•m (69 to 104 lbf in).
3. Remove sensor from exhaust pipe.
2. Connect the wiring harness connector to the sen-
Install sor connector.

1. Coat the oxygen sensor sparingly with an an- 3. Connect the battery.
tiseize compound (Hyster Part No. 251979),
then install sensor. Tighten sensor to 39 N•m
(29 lbf ft).

2. Connect the electrical connector to the oxygen

sensor.

3. Connect the battery.

1. OXYGEN SENSOR 1. IAT SENSOR

2. ELECTRICAL CONNECTOR 2. ALUMINUM SEAL WASHER
3. EXHAUST PIPE 3. INTAKE MANIFOLD

Figure 37. Oxygen Sensor Figure 38. IAT Sensor

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2200 SRM 1142 Sensors and Switches

Manifold Absolute Pressure (MAP)/Boost Throttle Position (TPS) Sensor

Sensor
Remove
Remove
1. Disconnect the battery.
1. Disconnect the battery.
2. Disconnect the electrical connector from the TPS.
2. Disconnect the electrical connector from the
3. Remove the two capscrews retaining the TPS to
MAP/boost sensor.
the carburetor and remove sensor. See Figure 40.
3. Disconnect the vacuum hose from the MAP/boost
Install
sensor.
1. Verify that the throttle valve is fully closed.
4. Remove the retaining screws from the MAP/boost
sensor and remove MAP/boost sensor. See Fig- 2. Place the TPS in position on the carburetor. In-
ure 39. stall the two capscrews to secure the sensor to the
carburetor. Tighten capscrews to 1.6 to 2.3 N•m
Install
(14 to 20 lbf in).
1. Place the MAP/boost sensor in position and in-
3. Verify that the throttle valve moves smoothly.
stall the two retaining screws.
4. Connect the electrical connector to the TPS.
2. Connect the vacuum hose to the MAP/boost sen-
sor. 5. Connect the battery.
3. Connect the wiring connector to the MAP/boost
sensor connector.

4. Connect the battery.

1. TPS 2. CAPSCREW

Figure 40. TPS Removal and Replacement

1. RETAINING SCREWS
2. MAP/BOOST SENSOR
3. VACUUM HOSE
4. INTAKE MANIFOLD

Figure 39. MAP/Boost Sensor

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Sensors and Switches 2200 SRM 1142

ENGINE AND FUEL SENSORS AND 2. Connect battery.

SWITCHES - MAZDA 2.0L AND 2.2L LPG
ENGINES ONLY (EXCEPT 2007 EMISSION Low LPG Pressure Switch
COMPLIANT ENGINES) Remove

Oil Pressure Sensor WARNING

Remove Before disconnecting any part of the LPG fuel
system, close shutoff valve on fuel tank. Run
1. Disconnect the battery. engine until fuel lines are empty and engine
stops. If engine will not run, close shutoff valve
2. Disconnect the electrical connector for the oil on fuel tank and release fuel slowly in a non-
pressure sensor. Remove the oil pressure sensor. hazardous area.
See Figure 41.
1. Disconnect the battery.
Install
2. Disconnect the low LPG switch electrical connec-
1. Install new oil pressure sensor. Tighten sensor tor. See Figure 41.
to 12 to 17 N•m (9 to 13 lbf ft). Connect the elec-
trical connector to the oil pressure sensor. See 3. Remove switch from fitting in pipe that runs be-
Figure 41. tween the LPG vaporizer and LPG fuel tank.

1. OIL PRESSURE SENSOR 3. LOW LPG PRESSURE SWITCH

2. AIR FILTER RESTRICTION SWITCH 4. AIR CLEANER

Figure 41. Oil Pressure Sensor and Air Filter and Low LPG Switch, Mazda LPG Engine

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2200 SRM 1142 Sensors and Switches

Install Install

1. Apply pipe thread sealant to threads on switch 1. Install new copper washer onto ECT sensor.
(Hyster Part No. 273338) and install new switch Install new ECT sensor and new packing and
into fitting. tighten the ECT sensor to 19 to 21 N•m (14 to
15.5 lbf ft).
2. Connect the low LPG switch electrical connector.
See Figure 41. 2. Connect the ECT sensor connector.

3. Connect the battery. 3. Refill the radiator with engine coolant after re-
placing the ECT sensor. See the section Peri-
Air Filter Restriction Switch odic Maintenance 8000 SRM 1150 for lift truck
models S2.0-3.5FT (S40-70FT, S55FTS) (F187)
NOTE: The air filter restriction switch is an optional and H2.0-3.5FT (H40-70FT) (L177) or the sec-
feature on these lift trucks and is a part of the Elec- tion Periodic Maintenance 8000 SRM 1207 for
tronic Monitoring package option. lift truck models S30FT, S35FT, S40FTS (E010)
and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
Remove
H40FTS) (F001) for coolant specification and pro-
1. Disconnect the battery. cedures.

2. Disconnect air filter restriction switch from elec- 4. Connect the battery.
trical connector.

3. Remove air filter restriction switch from air

cleaner. See Figure 41.

Install

1. Install new air filter restriction switch into air

cleaner.

2. Connect air filter electrical connector.

3. Connect the battery.

Engine Coolant Temperature (ECT) Sensor

Remove

1. Disconnect the battery.

2. Drain the engine coolant from radiator before

removing the ECT sensor. Refer to the section
Cooling System 700 SRM 1123.

3. Disconnect the ECT sensor connector. 1. PACKING (COPPER 3. WIRING

WASHER) CONNECTOR
2. ECT SENSOR 4. INTAKE MANIFOLD
4. Remove the ECT sensor and packing from the
intake manifold. Discard the copper washer. See Figure 42. ECT Sensor - Mazda LPG Engines
Figure 42.

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Sensors and Switches 2200 SRM 1142

ENGINE AND FUEL SENSORS AND Mass Air Flow (MAF) Sensor
SWITCHES- MAZDA 2.0L AND 2.2L GAS
Remove
ENGINES ONLY (EXCEPT 2007 EMISSION
COMPLIANT ENGINES) 1. Disconnect the battery.

Oil Pressure Sensor 2. Disconnect the wiring harness connector from

the sensor connector.
Remove
3. Loosen the hose clamps on both sides of the sen-
1. Disconnect the battery. sor and remove sensor. See Figure 43.

2. Disconnect the electrical connector for the oil 4. Disconnect the intake-air hose from both sides of
pressure sensor. Remove oil pressure sensor. the sensor and remove the sensor.
See Figure 43.
Install
Install
1. Connect the intake-air hose on both sides of the
1. Install new oil pressure sensor. Tighten sensor sensor and install the sensor.
to 12 to 17 N•m (9 to 13 lbf ft). Connect the elec-
trical connector to the oil pressure sensor. See 2. Tighten the hose clamps on both sides of the sen-
Figure 43. sor.

2. Connect battery. 3. Connect the wiring harness connector to the sen-

sor connector.

4. Connect the battery.

1. OIL PRESSURE SENSOR 3. AIR FILTER RESTRICTION SWITCH

2. MASS AIR FLOW SENSOR 4. INTAKE MANIFOLD

Figure 43. Oil Pressure and MAF Sensors and Air Filter Restriction Switch, Mazda Gas Engine

46 Confidential/Proprietary - Do Not Copy or Duplicate

2200 SRM 1142 Sensors and Switches

Air Filter Restriction Switch 29.4 N•m (18.1 to 21.6 lbf ft). Tighten the
outboard ECT sensor to 19 to 21 N•m (14 to
NOTE: The air filter restriction switch is an optional 15.5 lbf ft).
feature on these lift trucks and is a part of the Elec-
tronic Monitoring package option. 2. Connect the ECT sensor connector.

Remove 3. Refill the radiator with engine coolant after re-

placing the ECT sensor. See the section Peri-
1. Disconnect the battery. odic Maintenance 8000 SRM 1150 for lift truck
models S2.0-3.5FT (S40-70FT, S55FTS) (F187)
2. Disconnect air filter restriction switch from elec-
and H2.0-3.5FT (H40-70FT) (L177) or the sec-
trical connector.
tion Periodic Maintenance 8000 SRM 1207 for
3. Remove air filter restriction switch from air lift truck models S30FT, S35FT, S40FTS (E010)
cleaner. See Figure 43. and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) for coolant specification and pro-
Install cedures.

1. Install new air filter restriction switch into air 4. Connect the battery.
cleaner.

2. Connect air filter electrical connector.

3. Connect the battery.

Engine Coolant Temperature (ECT) Sensor

There are two ECT sensors located on the bottom of
the intake manifold. See Figure 44. The inboard
ECT sensor, closest to the cylinder head, provides
the input to the engine control unit (ECU). The out-
board ECT sensor provides input to the governor con-
trol unit (GCU). The removal and replacement proce-
dures are the same.

Remove

1. Disconnect the battery.

2. Drain the engine coolant from radiator before

removing the ECT sensor. Refer to the section
Cooling System 700 SRM 1123.

3. Disconnect the ECT sensor connector.

4. Remove the ECT sensor and packing from the 1. INTAKE MANIFOLD
intake manifold. See Figure 44. 2. COPPER WASHER
3. ECT SENSOR (INBOARD)
Install 4. ECT SENSOR (OUTBOARD)

1. Install new ECT sensor and new packing. Figure 44. ECT Sensor - Mazda Gas Engines
Tighten the inboard ECT sensor to 24.5 to

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Sensors and Switches 2200 SRM 1142

ENGINE AND FUEL SENSORS AND 3. Connect the electrical connector to the oil pres-
SWITCHES - MAZDA 2.0L AND 2.2L GAS sure sensor.
AND LPG ENGINES (2007 EMISSION 4. Connect the battery.
COMPLIANT ENGINES ONLY)
Air Filter Restriction Switch
Oil Pressure Sensor
NOTE: The air filter restriction switch is an optional
Remove feature on these lift trucks and is a part of the Elec-
tronic Monitoring package option.
1. Disconnect the battery.
Remove
2. Disconnect the electrical connector to the oil
pressure sensor. 1. Disconnect the battery.
3. Remove the oil pressure sensor. See Figure 45. 2. Disconnect air filter restriction switch from elec-
trical connector.
4. If necessary, remove the oil pressure sensor adap-
tor. 3. Remove air filter restriction switch from air
cleaner. See Figure 46.

Install

1. Install new air filter restriction switch into air

cleaner.

2. Connect air filter electrical connector.

3. Connect the battery.

1. OIL PRESSURE SENSOR

2. OIL PRESSURE SENSOR ADAPTOR

Figure 45. Oil Pressure Sensor

Install

1. If removed, apply Loctite® 567 to the threads of

the oil pressure sensor adaptor. Install the oil
pressure sensor adaptor and tighten to 7.9 to
11.7 N•m (69.6 to 103.2 lbf in).
1. AIR FILTER RESTRICTION SWITCH
2. Apply Loctite® 567 to the threads of the oil pres- 2. AIR FILTER HOUSING
sure sensor. Install the oil pressure sensor and
tighten to 7.9 to 11.7 N•m (69.6 to 103.2 lbf in). Figure 46. Air Filter Restriction Switch

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2200 SRM 1142 Sensors and Switches

CAM Angle Sensor 2007 Emission Compliant Engines 2200 SRM

1327.
Voltage Check
4. Connect the CAM angle sensor 4-pin connector.
WARNING 5. Tag and disconnect all the ignition coil electrical
Turning the ignition switch to the ON position connectors.
with the fuel injector connector still connected
will actuate the fuel injector. Make sure that 6. Turn the ignition ON.
the fuel injector connector has been discon-
nected. 7. Measure the voltage between terminal A and ter-
minal D. See Figure 47.
WARNING 8. Rotate the CAM angle sensor drive by hand and
Turning the ignition switch to the ON position verify the output signal. If not as specified, in-
with the ignition coil electrical connectors spect the related wiring harnesses for open or
still connected will generate sparks, which can short. If wiring harnesses are okay, replace the
cause electrical shock. Make sure that all the CAM angle sensor.
ignition coil electrical connectors have been Specification: 1 pulse (5 V)/rev.
disconnected from the ignition coils before
turning the ignition switch to the ON position 9. Install the CAM angle sensor and set engine tim-
when performing the following voltage check. ing. See the section Electrical System, Mazda
2.0L and 2.2L 2007 Emission Compliant En-
1. Verify that the ignition is OFF. gines 2200 SRM 1327.

2. Disconnect the fuel injector connector. 10. Connect all the ignition coil electrical connectors
as tagged.
3. Remove the CAM angle sensor. See the sec-
tion Electrical System, Mazda 2.0L and 2.2L 11. Connect the fuel injector connector.

1. CAM ANGLE SENSOR

2. CAM ANGLE SENSOR CONNECTOR (ON CAM ANGLE SENSOR)
3. 4-PIN ELECTRICAL CONNECTOR

Figure 47. CAM Angle Sensor Voltage Check

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Sensors and Switches 2200 SRM 1142

Oxygen Sensor 3. Remove oxygen sensor from the exhaust pipe.

See Figure 48.
If the lift truck is equipped with a catalytic convertor,
there will be two oxygen sensors. There will be a pre- Install
catalytic oxygen sensor and a post-catalytic 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.

1. MUFFLER 4. EXHAUST PIPE

2. POST-CATALYTIC CONVERTER OXYGEN 5. EXHAUST PIPE
SENSOR 6. CATALYTIC CONVERTER
3. PRE-CATALYTIC CONVERTER OXYGEN
SENSOR

Figure 48. Oxygen Sensors

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ENGINE AND FUEL SENSORS AND 3. Disconnect the ECT sensor connector.
SWITCHES - MAZDA 2.0L AND 2.2L
4. Remove the ECT sensor and packing from the
LPG ENGINES ONLY (2007 EMISSION intake manifold. See Figure 49.
COMPLIANT ENGINES ONLY)
Install
Engine Coolant Temperature (ECT) Sensor
1. Apply Loctite® 567 to the threads of the ECT sen-
Remove sor.

1. Disconnect the battery. 2. Install the ECT sensor and the new packing.
Tighten the ECT sensor to 7.9 to 11.7 N•m (70
2. Drain the engine coolant from the radiator before to 104 lbf in).
removing the ECT sensor. Refer to the section
Cooling System 700 SRM 1123. 3. Connect the ECT sensor connector.

1. PACKING (COPPER WASHER) 3. WIRING CONNECTOR

2. ECT SENSOR 4. INTAKE MANIFOLD

Figure 49. ECT Sensor

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Sensors and Switches 2200 SRM 1142

4. Refill the radiator with engine coolant after

installing the ECT sensor. Refer to the section
Periodic Maintenance 8000 SRM 1150 for lift
truck models S2.0-3.5FT (S40-70FT, S55FTS)
(F187) and H2.0-3.5FT (H40-70FT) (L177) or
the section Periodic Maintenance 8000 SRM
1207 for lift truck models S30FT, S35FT, S40FTS
(E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001) for coolant specification
and procedures.

5. Connect the battery.

Manifold Absolute Pressure (MAP) Sensor

Remove

1. Disconnect the battery.

2. Disconnect the wiring harness connector from

the MAP sensor connector. See Figure 50.

3. Disconnect the vacuum hose from the MAP sen- 1. RETAINING SCREWS
sor. See Figure 51. 2. MAP SENSOR
3. VACUUM HOSE
4. Remove the retaining screws from the MAP sen-
sor and remove the MAP sensor. See Figure 51. Figure 51. MAP Sensor Removal/Installation

Install

1. Place the MAP sensor in position and install the

retaining screws.

2. Connect the vacuum hose to the MAP sensor.

3. Connect the wiring harness connector to the

MAP sensor connector.

4. Connect the battery.

Intake Air Temperature (IAT) Sensor

Remove

1. Disconnect the battery.

2. Disconnect the wiring harness connector from

the sensor connector.

3. Remove the sensor and aluminum seal washer.

1. MAP SENSOR See Figure 52.
2. ELECTRICAL CONNECTOR

Figure 50. MAP Sensor Electrical Connector

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2200 SRM 1142 Sensors and Switches

enters the filter unit. Permit the pressure in

the fuel system to decrease slowly. Fuel leav-
ing the fitting removes heat. Use a cloth to
protect your hands from the cold fitting.

1. Turn the shutoff valve clockwise until the valve

is completely closed.

2. Run the engine until it stops. If truck is equipped

with a key switch, turn the key switch to the
OFF position. If truck is equipped with a Power
ON/OFF button, press the Power ON/OFF but-
ton to turn engine off.

3. Disconnect the battery.

4. Disconnect the electrical connector to the fuel

temperature sensor.
1. IAT SENSOR 5. Remove the retaining pin from the fuel tempera-
2. ALUMINUM SEAL WASHER ture sensor and remove sensor. See Figure 53.
3. AIR BOX

Figure 52. IAT Sensor

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).

2. Connect the wiring harness connector to the sen-

sor connector.

3. Connect the battery.

Fuel Temperature Sensor

Remove

WARNING
LPG can cause an explosion. Do not cause
sparks or permit flammable material near the
LPG system. LPG fuel systems can be discon-
nected indoors only if the lift truck is at least
8 m (26 ft) from any open flame, motor vehicles,
electrical equipment, or ignition source.

Close the shutoff valve on the LPG tank before 1. FUEL TEMPERATURE SENSOR
any part of the engine fuel system is discon- 2. O-RINGS
nected. Run the engine until the fuel in the sys- 3. RETAINING PIN
tem is used and the engine stops. 4. EPR ASSEMBLY

If the engine will not run, close the shutoff Figure 53. Fuel Temperature Sensor
valve on the LPG tank. Loosen the fitting on Removal/Installation
the supply hose from the LPG tank where it

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Sensors and Switches 2200 SRM 1142

Install

1. Lubricate new O-rings using a lubricant compat-

ible with LPG and install O-rings on the new fuel
temperature sensor.

2. Insert fuel temperature sensor into the EPR as-

sembly and install the retaining pin.

3. Connect the electrical connector to the fuel tem-

perature sensor.

4. Connect the battery.

5. Slowly open the fuel valve on tank.

6. If truck is equipped with a key switch, turn the

key switch to the ON position and back to the
OFF position to pressurize the fuel system. If
truck is equipped with a Power ON/OFF button,
press the Power ON/OFF button to ON and back
OFF again to pressurize the system. Check for
leaks.

7. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are
detected, make proper repairs.
1. LOW LPG PRESSURE SWITCH
Low LPG Pressure Switch 2. LOW LPG PRESSURE SWITCH FITTING
3. FUEL FILTER ASSEMBLY
Remove
Figure 54. Low LPG Pressure Switch
WARNING
Install
LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.
CAUTION
1. Close fuel valve on tank. Run engine until it runs Do not use Teflon tape on any fuel fitting. Use
out of fuel and stops. Try to start engine 2 to 3 a liquid pipe thread sealant when installing fit-
times until it no longer starts. tings.
2. Disconnect the battery. 1. Apply pipe thread sealant (Hyster Part No.
0246108) on the threads of the low LPG pressure
3. Disconnect engine wire harness from low LPG switch fitting. Install the low LPG pressure
pressure switch. switch fitting onto the low LPG pressure switch
adapter.
WARNING
2. Connect engine wire harness to the low LPG
A small amount of fuel may still be present in
pressure switch.
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues NOTE: Opening the fuel valve too quickly can cause
to flow from the connections when loosened, the internal excess flow valve to close, restricting the
check to make sure the manual valve is fully flow of fuel. If this happens, close the fuel valve, wait
closed. a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.
4. Slowly loosen and remove the low LPG pressure
switch from the low LPG pressure switch fitting. 3. Slowly open the fuel valve on tank.
See Figure 54.

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2200 SRM 1142 Sensors and Switches

4. Connect the battery. 2. Disconnect the wiring harness connector from

the sensor connector.
5. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system. 3. Remove the IAT sensor and aluminum seal
Check for leaks. washer from the spacer/housing bracket. See
Figure 55.
6. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are 4. If necessary, remove the nuts and capscrew re-
detected, make proper repairs. taining the spacer/housing plate and remove the
spacer/housing plate and gasket. See Figure 56.
ENGINE AND FUEL SENSORS AND Discard the old gasket.
SWITCHES- MAZDA 2.0L AND 2.2L
Install
GAS ENGINES ONLY (2007 EMISSION
COMPLIANT ENGINES ONLY) 1. If removed, verify the mating surface of the
spacer/housing plate and the intake manifold
Intake Air Temperature (IAT) Sensor are clean. Place a new gasket in position on
the intake manifold. Install the nuts and cap-
Remove screw. Tighten the nuts to 8.9 to 12.7 N•m (79
to 112 lbf in). Tighten the capscrew to 7.9 to
1. Disconnect the battery.
10.7 N•m (69.5 to 95.4 lbf in). See Figure 56.

1. IAT SENSOR 3. SPACER/HOUSING PLATE

2. ALUMINUM SEAL WASHER 4. INTAKE MANIFOLD

Figure 55. Intake Air Temperature (IAT) Sensor

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Sensors and Switches 2200 SRM 1142

1. NUTS 4. GASKET
2. CAPSCREW 5. INTAKE MANIFOLD
3. SPACER/HOUSING PLATE

Figure 56. Intake Air Temperature (IAT) Sensor Spacer/Housing Plate

2. Install the IAT sensor and new aluminum seal 3. Remove the ECT sensor and packing from the
washer. Tighten sensor to 8 to 12 N•m (71 to intake manifold. See Figure 57.
106 lbf in). See Figure 55.
Install
3. Connect the wiring harness connector to the sen-
sor connector. 1. Apply Loctite® 567 to the threads of the ECT sen-
sor.
4. Connect the battery.
2. Install the ECT sensor and the new packing.
Engine Coolant Temperature (ECT) Sensor Tighten the ECT sensor to 7.9 to 11.7 N•m (70
to 104 lbf in).
Remove
3. Connect the ECT sensor connector.
1. Drain the engine coolant from the radiator before
removing the ECT sensor. 4. Refill the radiator with engine coolant after in-
stalling the ECT sensor.
2. Disconnect the ECT sensor connector.

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1. INTAKE MANIFOLD
2. PACKING/COPPER WASHER
3. ECT SENSOR

Figure 57. ECT Sensor Remove/Install

Manifold Absolute Pressure (MAP) Sensor

Remove 1. RETAINING SCREWS
2. MAP SENSOR
1. Disconnect the battery. 3. INTAKE MANIFOLD
4. VACUUM HOSE
2. Disconnect the wiring harness connector from
Figure 58. MAP Sensor
the MAP sensor connector.

3. Disconnect the vacuum hose from the MAP sen- ENGINE AND FUEL SENSORS AND
sor. See Figure 58. SWITCHES, GM 2.4L AND 4.3L GAS AND
LPG TRUCKS
4. Remove the retaining screws from the MAP sen-
sor and remove the MAP sensor. Crankshaft Sensor
Install Remove
1. Place the MAP sensor in position and install the 1. To access the battery on H6.0FT, H7.0FT
retaining screws. (H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
2. Connect the vacuum hose to the MAP sensor.
other lift truck models, raise the hood. Discon-
3. Connect the wiring harness connector to the nect the battery.
MAP sensor connector.
2. Disconnect the crankshaft sensor electrical har-
4. Connect the battery. ness. See Figure 59 and Figure 60.

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2. Install the capscrew to secure the crankshaft sen-

sor. Tighten capscrew to 8 N•m (71 lbf in).

3. Connect the crankshaft sensor electrical har-

ness. See Figure 59 and Figure 60.

4. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

Camshaft Position (CMP) Sensor

NOTE: On the GM 4.3L engine, the camshaft position
sensor (see Figure 65) cannot be replaced separately
from the distributor. If the CMP sensor fails, the
whole distributor must be replaced. See the section
1. CRANKSHAFT SENSOR High Voltage Switch (HVS) Ignition, GM 4.3L
2. ELECTRICAL HARNESS EPA Compliant Engines 2200 SRM 1097 for pro-
cedures to replace the distributor. The procedures
Figure 59. Crankshaft Sensor, GM 2.4L Engine below apply only to the GM 2.4L engine.

Remove

1. Open hood and disconnect the battery.

2. Disconnect the CMP sensor electrical connector.

See Figure 61.

1. ELECTRICAL HARNESS
2. CAPSCREW
3. CRANKSHAFT SENSOR

Figure 60. Crankshaft Sensor, GM 4.3L Engine

1. CMP SENSOR
3. Remove the capscrew retaining the crankshaft 2. WIRE HARNESS CLAMP
sensor. 3. ELECTRICAL CONNECTORS

4. Remove the crankshaft sensor. Figure 61. CMP Sensor Electrical Connector,
GM 2.4L Engine
Install

1. Install new crankshaft sensor into the engine

block.

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3. Remove harness clamp from CMP sensor support 7. Connect the battery and close hood.
plate.
Camshaft Position (CMP) Sensor
4. Remove the screw and lockwasher retaining the Assembly
CMP sensor. See Figure 62.
NOTE: The procedures below apply to the GM 2.4L
engine only.

Remove

1. Raise the hood and disconnect the battery.

2. Disconnect the CMP sensor electrical connector.

See Figure 61.

3. Remove the retaining screws securing the CMP

sensor assembly to the engine. See Figure 63.

1. SCREW
2. LOCKWASHER
3. CMP SENSOR
4. O-RING
5. CMP SENSOR SUPPORT PLATE

Figure 62. CMP Sensor, GM 2.4L Engine

5. Remove the CMP sensor and O-ring. 1. RETAINING SCREWS

2. CMP SENSOR ASSEMBLY
6. Remove O-ring from CMP sensor and discard. 3. O-RING

Install Figure 63. CMP Sensor Assembly, GM 2.4L

Engine
1. Install new O-ring on CMP sensor.
4. Carefully remove the CMP sensor assembly from
2. Lubricate O-ring with clean engine oil. the camshaft carrier assembly.

3. Install the CMP sensor into the CMP sensor sup- 5. Remove the O-ring from the CMP sensor support
port plate. plate. Discard O-ring.

NOTE: Before installing retaining screw, verify the Install

CMP sensor is fully seated.
1. Install new O-ring into the groove on the support
4. Install retaining screw and lockwasher. Tighten plate.
retaining screw to 6 N•m (53 lbf in).
2. Place the CMP sensor assembly in position on the
5. Connect the electrical connectors. Verify that the camshaft carrier assembly.
connectors click/lock into place.
3. Install the retaining screws and tighten to
6. Install harness clamp to CMP sensor support 10 N•m (88.5 lbf in).
plate.

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Sensors and Switches 2200 SRM 1142

4. Connect the electrical connectors. Verify that the 3. Remove the oil pressure sensor.
connectors click/lock into place.
Install
5. Connect the battery and close hood.
1. Install new oil pressure sensor onto engine.
Oil Pressure Sensor Tighten sensor to 20 N•m (177 lbf in).

Remove 2. Connect the electrical connector for the oil pres-

sure sensor. See Figure 64 and Figure 65.
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor 3. Connect the battery. For models H6.0FT, H7.0FT
mat and floor plate. To access the battery on all (H135FT, H155FT) (H006), install the floor plate
other lift truck models, raise the hood. Discon- and floor mat after connecting the battery. On all
nect the battery. other lift truck models, lower the hood.

2. Disconnect the electrical connector for the oil

pressure sensor. See Figure 64 and Figure 65.

1. DISTRIBUTOR
2. CAMSHAFT POSITION SENSOR
3. OIL PRESSURE SENSOR
4. ELECTRICAL CONNECTOR, OIL PRESSURE
1. ELECTRICAL CONNECTOR SENSOR
2. OIL PRESSURE SENSOR
3. OIL FILTER Figure 65. Camshaft and Oil Pressure Sensors,
4. ADAPTER, O-RING, AND RETAINING RING GM 4.3L Engine
Figure 64. Oil Pressure Sensor, GM 2.4L Engine

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Manifold Absolute Pressure screws. Tighten retaining screws to 6 N•m

(MAP)/Manifold Air Temperature (53 lbf in).
(MAT) Sensor 2. Connect the electrical connector to the
Remove MAP/MAT sensor. Verify that the connector
clicks/locks into place.
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor 3. Connect the battery. For models H6.0FT, H7.0FT
mat and floor plate. To access the battery on all (H135FT, H155FT) (H006), install the floor plate
other lift truck models, raise the hood. Discon- and floor mat after connecting the battery. On all
nect the battery. other lift truck models, lower the hood.

2. Disconnect the electrical connector from the

MAP/MAT sensor. See Figure 66 and Figure 67.

3. For the GM 2.4L engine, remove the two screws

retaining the MAP/MAT sensor to the intake
manifold. On the GM 4.3L engine, remove the
screw retaining the MAP/MAT sensor to the
intake manifold. Remove MAP/MAT sensor.

NOTE: TOP VIEW OF ENGINE SHOWN.

1. ENGINE COOLANT TEMPERATURE SENSOR
1. MAP/MAT SENSOR 2. FUEL RAIL
2. SCREW 3. LPG PRESSURE SENSOR
3. ELECTRICAL CONNECTOR 4. MAP/MAT SENSOR

Figure 66. MAP/MAT Sensor, GM 2.4L Engine Figure 67. ECT, Low LPG, and MAP/MAT
Sensors, GM 4.3L Engine
Install

1. Place the MAP/MAT sensor in position on the

intake manifold and install the two retaining

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Engine Coolant Temperature (ECT) Sensor Air Flow Restriction Switch

Remove NOTE: The air flow restriction switch is an optional
feature on these lift trucks and is a part of the Elec-
1. To access the battery on H6.0FT, H7.0FT tronic Monitoring package option.
(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all Remove
other lift truck models, raise the hood. Discon-
nect the battery. 1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
2. Disconnect the electrical connector from the ECT mat and floor plate. To access the battery on all
sensor. See Figure 67 and Figure 68. other lift truck models, raise the hood. Discon-
nect the battery.
3. Remove the ECT sensor and packing.
2. Disconnect the air flow restriction switch electri-
cal connection. See Figure 69.

3. Remove air filter restriction switch from air

cleaner.

1. ELECTRICAL CONNECTOR
2. ECT SENSOR
3. WASHER
NOTE: AIR CLEANER HOSE NOT SHOWN FOR
Figure 68. ECT Sensor, GM 2.4L Engine CLARITY. SWITCH NOT SHOWN, BUT ITEM #4
POINTS TO ITS LOCATION.
Install
NOTE: GM 2.4L ENGINE SHOWN, BUT THE AIR
1. Install the new ECT sensor and packing. Tighten FLOW RESTRICTION IS IN SAME LOCATION ON
the sensor to 20 N•m (14.75 lbf ft). THE GM 4.3L ENGINE.

2. Connect the electrical connector to the ECT sen- 1. ECT SENSOR*

sor. 2. AIR FLOW RESTRICTION ELECTRICAL
CONNECTOR
3. AIR CLEANER
3. Connect the battery. For models H6.0FT, H7.0FT 4. AIR FLOW RESTRICTION SWITCH
(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all *SEE FIGURE 67 FOR LOCATION OF ECT SENSOR
other lift truck models, lower the hood. ON GM 4.3L ENGINE.

Figure 69. Air Flow Restriction Switch

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Install the GM 4.3L engine, remove the clip connector

retaining each wire harness to the oxygen sensor
1. Install new air flow restriction switch into air brackets. See Figure 67, Figure 73.
cleaner.

2. Connect the air flow restriction switch electrical

connection. See Figure 69.

3. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

Oxygen Sensor
Remove

1. To access the battery on H6.0FT, H7.0FT

(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

NOTE: The GM 4.3L engine has two oxygen sensors

and two electrical connectors.

2. Disconnect the oxygen sensor electrical connec- 1. ELECTRICAL CONNECTORS

tor. See Figure 70, Figure 71, Figure 72, or Fig- 2. CLIP
ure 73. 3. NUT
4. THERMOSTAT HOUSING
3. For the GM 2.4L engine, remove nut and clip
retaining the oxygen sensor wiring harness and Figure 70. Oxygen Sensor Electrical Connector,
connector to the thermostat housing. GM 2.4L Engine

4. For lift truck models S5.5FTS (S80, 100FTBCS;

S120FTS; S120FTPRS) (G004) equipped with

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Sensors and Switches 2200 SRM 1142

NOTE: EXHAUST SYSTEM FOR S4.0, 4.5, 5.5FT, (S80, 100, 120FT) (G004) LIFT TRUCK MODELS IS SIMILAR.

NOTE: SEE FIGURE 73 FOR OXYGEN SENSOR LOCATION ON LIFT TRUCK MODELS S5.5FTS (S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004)
1. OXYGEN SENSOR
2. ELECTRICAL CONNECTOR
3. EXHAUST PIPES TO EXHAUST MANIFOLD

Figure 71. 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)

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NOTE: OVERHEAD EXHAUST IS AN OPTIONAL FEATURE.

1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD
2. ELECTRICAL CONNECTOR

Figure 72. Oxygen Sensor, GM 4.3L Engine, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT)
(D024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006)

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Sensors and Switches 2200 SRM 1142

oxygen sensor into exhaust manifold adapter on

GM 2.4L engines or into the exhaust pipes to the
exhaust manifold for GM 4.3L engines. Using a
special tool, oxygen sensor socket, tighten oxy-
gen sensors to 40 to 60 N•m (30 to 44 lbf ft). See
Figure 71, Figure 72, Figure 73, Figure 74, and
Figure 75.

2. For the GM 2.4L engine, install nut and clip to

retain the oxygen sensor wiring harness and con-
nector to the thermostat housing.

3. For lift truck models S5.5FTS (S80, 100FTBCS;

S120FTS; S120FTPRS) (G004) equipped with
the GM 4.3L engine, install the clip connector to
attach oxygen sensor wiring harness to oxygen
sensor brackets.

4. Connect the electrical connectors. Verify that the

connectors click/lock into place.
1. OXYGEN SENSOR 4. SENSOR
(POST-CATALYTIC) ELECTRICAL
2. MUFFLER CONNECTORS 5. Verify that the wire is pulled up toward the ther-
3. OXYGEN SENSOR 5. CLIP CONNECTOR mostat and away from any hot exhaust compo-
(PRE-CATALYTIC) 6. BRACKET nents.

Figure 73. Oxygen Sensor, GM 4.3L Engine for 6. Connect the battery. For models H6.0FT, H7.0FT
Lift Truck Models (BCS/PRS Only)S5.5FTS (H135FT, H155FT) (H006), install the floor plate
(S80, 100FTBCS; S120FTS; S120FTPRS) (G004) and floor mat after connecting the battery. On all
other lift truck models, lower the hood.
5. Using a special tool, oxygen sensor socket (see
Figure 74), remove the oxygen sensor. See Fig-
ure 71, Figure 72, Figure 73, and Figure 75.

1. EXHAUST MANIFOLD ADAPTER

Figure 74. Oxygen Sensor Socket 2. OXYGEN SENSOR

Install Figure 75. Oxygen Sensor, GM 2.4L Engine

1. Before installing the sensor, coat sensor spar-

ingly with an antiseize compound, then install

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ENGINE AND FUEL SWITCHES, GM 2.4L 2. Disconnect the low LPG switch electrical connec-
AND GM 4.3L LPG TRUCKS ONLY tor from engine wire harness.

Low LPG Pressure Switch 3. Remove switch from fitting in pipe that runs be-
tween the LPG vaporizer and LPG fuel tank. See
Remove Figure 76.

Install
WARNING
Before disconnecting any part of the LPG fuel 1. Install new switch into fitting. See Figure 76.
system, close shutoff valve on fuel tank. Run
engine until fuel lines are empty and engine 2. Connect the low LPG switch electrical connector
stops. If engine will not run, close shutoff valve to engine wire harness.
on fuel tank and release fuel slowly in a non-
3. Connect the battery. For models H6.0FT, H7.0FT
hazardous area.
(H135FT, H155FT) (H006), install the floor plate
1. To access the battery on H6.0FT, H7.0FT and floor mat after connecting the battery. On all
(H135FT, H155FT) (H006), remove the floor other lift truck models, lower the hood.
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

1. LOW LPG PRESSURE SWITCH ELECTRICAL 3. LPG FUEL FILTER

CONNECTOR 4. LPG VAPORIZER/REGULATOR
2. LOW LPG PRESSURE SWITCH 5. HARNESS CONNECTION

Figure 76. Low LPG Pressure Switch

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LPG Pressure Sensor, GM 4.3L Engine Oil Pressure Sensor

Only
Remove
Remove
1. Raise hood and disconnect the battery.
1. To access the battery on H6.0FT, H7.0FT
2. Disconnect the electrical connector for the oil
(H135FT, H155FT) (H006), remove the floor
pressure sensor.
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon- 3. Remove the oil pressure sensor. See Figure 77.
nect the battery.
Install
2. Disconnect the sensor electrical connector.
1. Install new oil pressure sensor onto engine.
3. Remove sensor from fuel rail. See Figure 67. Tighten sensor to 9 N•m (80 lbf in).
Install 2. Connect the electrical connector for the oil pres-
sure sensor. See Figure 77.
1. Coat the threads of the sensor with thread
sealant (Hyster P/N 0246108) and install new 3. Connect the battery and close hood.
sensor into fuel rail. Tighten sensor to 28 to
32 N•m (21 to 24 lbf ft). See Figure 67. Engine Speed Sensor
2. Connect the sensor electrical connector. Remove
3. Connect the battery. For models H6.0FT, H7.0FT 1. Raise the hood and disconnect the battery.
(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all 2. Disconnect the electrical connection from engine
other lift truck models, lower the hood. speed sensor.

ENGINE AND FUEL SENSORS AND 3. Remove capscrew from engine speed sensor
SWITCHES, YANMAR DIESEL TRUCKS bracket and remove bracket and engine speed
sensor. See Figure 77.
Air Filter Restriction Switch Install
NOTE: The air filter restriction switch is an optional 1. Install engine speed sensor bracket and install
feature on these lift trucks and is a part of the Elec- new engine speed sensor.
tronic Monitoring package option.
2. Connect electrical connector to engine speed sen-
Remove sor.
1. Raise hood and disconnect the battery. 3. Connect the battery and close hood.
2. Disconnect the electrical connector from air filter
restriction switch. Engine Coolant Temperature (ECT) Sensor

3. Remove air filter restriction switch from air Remove

cleaner. See Figure 77. 1. Raise hood and disconnect the battery.
Install 2. Drain the engine coolant from radiator before
1. Install new air filter restriction switch into air removing the ECT sensor. Refer to the section
cleaner. Cooling System 700 SRM 1123.

2. Connect air filter electrical connector. 3. Disconnect the ECT sensor connector. See Fig-
ure 77.
3. Connect the battery and close hood.

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Figure 77. Yanmar Diesel Engine Sensors and Switches

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Sensors and Switches 2200 SRM 1142

Legend for Figure 77

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

4. Remove the ECT sensor and packing from the

intake manifold. Discard the copper washer. See
Figure 42.

Install

1. Install new copper washer onto ECT sensor.

Install new ECT sensor and new packing and
tighten the ECT sensor to 25 to 34 N•m (18 to
25 lbf ft).

2. Connect the ECT sensor connector.

3. Refill the radiator with engine coolant after re-

placing the ECT sensor. See one of the follow-
ing sections for coolant specifications and proce-
dures:
• Periodic Maintenance 8000 SRM 1150
for lift truck models S2.0-3.5FT (S40-70FT,
S55FTS) (F187) and H2.0-3.5FT (H40-70FT)
(L177)
• Periodic Maintenance 8000 SRM 1207
for lift truck models S30FT, S35FT, S40FTS
(E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• Periodic Maintenance 8000 SRM 1248
for lift truck models 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)

4. Connect the battery and close hood.

1. LOCKWASHER 6. THROTTLE
Throttle Position Sensor (TPS) 2. TORX-HEAD POSITION
SCREW SENSOR (TPS)
Remove (BRACKET) 7. TPS ROTOR
3. TPS BRACKET 8. THROTTLE LEVER
1. Open hood and disconnect the battery. 4. WASHER 9. FUEL PUMP
5. TORX-HEAD
2. Disconnect the electrical connector from the SCREW (SENSOR)
throttle position sensor (TPS).
Figure 78. Throttle Position Sensor (TPS)
3. Remove Torx-head screws securing the TPS to Assembly
TPS bracket. See Figure 78. Remove TPS sensor
from TPS bracket.

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Install 2. Connect sensor to harness.

NOTE: When installing the TPS, rotate the sensor 3. Install drain plug and O-ring into bottom of fuel/
rotor clockwise to match D-shape on the TPS rotor. water separator sensor.
See Figure 79.
4. Connect the battery and close hood.
1. Install new TPS sensor on TPS bracket and se-
cure with Torx-head screws. Tighten Torx-head
screws to 2.25 N•m (20 lbf in).

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

trical connector.

3. Connect the battery and close hood.

1. SENSOR ROTOR 3. TPS ROTOR

2. TPS 4. D-SHAPE

Figure 79. TPS and Rotor

Fuel/Water Separator Sensor

Remove

1. Open hood and disconnect the battery.

2. Remove drain plug from bottom of fuel/water sep-

arator sensor and drain water from fuel filter.
See Figure 80.

3. Disconnect sensor from harness.

1. DRAIN PLUG 4. FUEL FILTER
4. Remove sensor from bottom of fuel filter element 2. O-RING ELEMENT BODY
3. FUEL/WATER 5. FUEL FILTER
body. SEPARATOR 6. FUEL FILTER
SENSOR COVER
Install
Figure 80. Fuel/Water Separator Sensor
1. Install new sensor into bottom of fuel filter ele-
ment body. See Figure 80.

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Sensors and Switches 2200 SRM 1142

Glow Plug Relay 3. Install the protective boots over the terminals B
and M. See Figure 82.
Remove
4. Connect the electrical connectors at terminals E
WARNING and S. See Figure 81.
Always disconnect the cables at the battery be- 5. Connect the battery and close the hood.
fore you make repairs to the engine. Discon-
nect the cable at the negative terminal first. In-
stall a tag on the battery terminals so that no
one connects the cables on the terminals.

1. Open hood and disconnect the battery.

2. Tag and disconnect the wiring connectors at ter-

minals E and S. See Figure 81.

3. Slide the protective boots back on the wires for

terminals B and M. See Figure 81 and Figure 82.

4. Place tags on the wires for terminals B and M to

properly identify them for reinstallation.

5. Remove the nuts and washers retaining the

wires to terminals B and M. See Figure 82.

6. Remove the nuts retaining the glow plug relay to

the mounting bracket and remove the glow plug
relay. See Figure 83.

Install

1. Place the glow plug relay in position on the

mounting bracket and install retaining nuts. 1. M TERMINAL 3. B TERMINAL
Tighten retaining nuts to 2.50 to 2.75 N•m 2. E TERMINAL 4. S TERMINAL
(22.13 to 24.34 lbf in). See Figure 83. Figure 81. Glow Plug Relay Terminals
2. Connect the wiring connections to terminals B
and M. Install the nuts and washers. Tighten
the nuts to 2.9 to 4.0 N•m (25.67 to 35.40 lbf in).
See Figure 81 and Figure 82.

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2200 SRM 1142 Sensors and Switches

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

Figure 82. Glow Plug Relay and Wiring

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Sensors and Switches 2200 SRM 1142

ENGINE AND FUEL SENSORS AND

SWITCHES, CUMMINS 4.5L DIESEL
ENGINE
Air Filter Restriction Switch
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.

Remove

1. To access the battery on H6.0FT, H7.0FT

(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Disconnect the electrical connector from air filter

restriction switch.
NOTE: ENGINE NOT SHOWN FOR CLARITY.
3. Remove air filter restriction switch from air
1. MOUNTING BRACKET
2. GLOW PLUG RELAY cleaner. See Figure 84.
3. NUT
Install
Figure 83. Glow Plug Relay and Mounting
Bracket 1. Install new air filter restriction switch onto air
cleaner.

2. Connect air filter electrical connector.

3. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

Legend for Figure 84

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

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2200 SRM 1142 Sensors and Switches

Figure 84. Cummins 4.5L Diesel Engine Sensors and Switches

Confidential/Proprietary - Do Not Copy or Duplicate 75

Sensors and Switches 2200 SRM 1142

Oil Pressure Sensor 3. Connect the battery. For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
Remove and floor mat after connecting the battery. On all
other lift truck models, lower the hood.
1. To access the battery on H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove the floor
Engine Coolant Temperature (ECT) Sensor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon- Remove
nect the battery.
1. To access the battery on H6.0FT, H7.0FT
2. Disconnect the electrical connector from the oil (H135FT, H155FT) (H006), remove the floor
pressure sensor. mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
3. Unscrew and remove the oil pressure sensor (see
nect the battery.
Figure 84) from adapter. Adapter does not need
to be removed from engine. Discard O-ring. 2. Drain the engine coolant from radiator before
removing the ECT sensor. Refer to the section
Install
Cooling System 700 SRM 1123.
1. Apply 50 ml (1.7 oz) of Loctite 592™ thread
3. Disconnect the ECT sensor connector. See Fig-
sealant on O-ring. Install new oil pressure sen-
ure 85.
sor into adapter. Tighten sensor two to three
turns past finger tight. 4. Remove the ECT sensor and packing from the
intake manifold. Discard the O-ring.
2. Connect the electrical connector for the oil pres-
sure sensor. See Figure 84. Install
3. Connect the battery. For models H6.0FT, H7.0FT 1. Install new O-ring onto ECT sensor. Install new
(H135FT, H155FT) (H006), install the floor plate ECT sensor and new packing and tighten the
and floor mat after connecting the battery. On all ECT sensor to 20 N•m (177 lbf in).
other lift truck models, lower the hood.
2. Connect the ECT sensor connector. See Fig-
Engine Speed Sensor ure 85.

Remove 3. Refill the radiator with engine coolant after re-

placing the ECT sensor. See one of the following
1. To access the battery on H6.0FT, H7.0FT sections for coolant specification and procedures:
(H135FT, H155FT) (H006), remove the floor • Periodic Maintenance 8000 SRM 1248
mat and floor plate. To access the battery on all for lift truck models S4.0, 4.5, 5.5FT,
other lift truck models, raise the hood. Discon- S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
nect the battery. S120FTS; S120FTPRS) (G004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
2. Disconnect the electrical connection from engine
100, 110, 120FT) (N005)
speed sensor.
• Periodic Maintenance 8000 SRM 1319 for
3. Remove capscrew from engine speed sensor lift truck models S6.0FT, S7.0FT (S135FT,
bracket and remove bracket and engine speed S155FT) (D024)
sensor. See Figure 84. • Periodic Maintenance 8000 SRM 1322 for
lift truck models H6.0FT, H7.0FT (H135FT,
Install H155FT) (H006)

1. Install engine speed sensor bracket to engine. 4. Connect the battery. For models H6.0FT, H7.0FT
Tighten capscrew to 7 N•m (62 lbf in). Install (H135FT, H155FT) (H006), install the floor plate
new engine speed sensor onto bracket. and floor mat after connecting the battery. On all
other lift truck models, lower the hood.
2. Connect electrical connector to engine speed sen-
sor.

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2200 SRM 1142 Sensors and Switches

Install

1. Install new TPS sensor on TPS bracket and

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

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

trical connector. See Figure 86.

3. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery. On all
other lift truck models, lower the hood.

NOTE: TOP VIEW SHOWN.

1. ENGINE COOLANT TEMPERATURE SENSOR
(ECT)
2. ECT ELECTRICAL CONNECTOR

Figure 85. Engine Coolant Temperature Sensor,

Cummins 4.5L Diesel Engine

Throttle Position Sensor (TPS)

Remove

1. To access the battery on H6.0FT, H7.0FT

(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Disconnect the electrical connector from the

throttle position sensor (TPS).
1. TORX-HEAD 5. THROTTLE
3. Remove Torx-head screws and washers securing SCREW POSITION
2. WASHER SENSOR (TPS)
the TPS to TPS bracket. See Figure 86. Remove 3. TPS ELECTRICAL 6. TPS BRACKET
TPS sensor from TPS bracket. CONNECTOR 7. FUEL PUMP
4. TPS COVER

Figure 86. Throttle Position Sensor (TPS)

Assembly, Cummins 4.5L Diesel Engine

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Vehicle System Manager (VSM) 2200 SRM 1142

Fuel/Water Separator Sensor

Remove

1. To access the battery on H6.0FT, H7.0FT

(H135FT, H155FT) (H006), remove the floor
mat and floor plate. To access the battery on all
other lift truck models, raise the hood. Discon-
nect the battery.

2. Remove drain plug from bottom of fuel filter ele-

ment body and drain water from fuel filter. See
Figure 87.

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 87.

2. Connect sensor to harness.

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

fuel filter element body.

4. Connect the battery. For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate 1. FUEL FILTER 4. FUEL/WATER
and floor mat after connecting the battery. On all ELEMENT BODY SEPARATOR
other lift truck models, lower the hood. 2. DRAIN PLUG SENSOR
3. ELECTRICAL 5. FUEL FILTER
CONNECTOR

Figure 87. Fuel/Water Separator Sensor,

Cummins 4.5L Diesel Engine

Vehicle System Manager (VSM)

GENERAL Remove
The Vehicle System Manager (VSM) is a micropro- 1. To access the battery on H6.0FT, H7.0FT
cessor-powered controller which controls or moni- (H135FT, H155FT) (H006), remove the floor
tors, directly or indirectly, every electrical device on mat and floor plate. To access the battery on all
the lift truck, except for the Electronic Control Unit other lift truck models, raise the hood. Discon-
(ECU) and the Governor Control Unit (GCU). These nect the battery.
devices are controlled by the engine.
2. Fully lower the steering column and remove the
VSM REPLACEMENT upper steering column cover. See the section
Steering Column Repair for the removal proce-
NOTE: The VSM is not a serviceable part. If the dures.
VSM malfunctions, replace with a new VSM. See the
Parts Manual for replacement part number. 3. Remove the dash and kick panel. See the section
Dash and Kick Panel Remove and Install for re-
moval procedures.

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2200 SRM 1142 Vehicle System Manager (VSM)

4. Disconnect all electrical connections from the Install

VSM. These connections include the chassis
harness, cowl harness, transmission harness, 1. Install VSM and harness bracket onto lift truck
and electronic hydraulic (e-hydraulic) controls, cowl. Tighten bolts to 19.2 N•m (14 lbf ft).
if lift truck is equipped with this feature. See
2. Connect all electrical connections to the VSM.
Figure 88.
The connectors are color coded for easy connec-
5. Remove the three bolts securing the VSM and tion.
harness bracket to the cowl. Remove VSM from
3. Install the dash panel and kick panel. See the
lift truck cowl.
section Dash and Kick Panel Remove and Install
for installation procedures.

A. VSM ARRANGEMENT FOR ALL LIFT TRUCK MODELS EXCEPT FOR S6.0FT, S7.0FT (S135FT, S155FT)
(D024)
B. VSM ARRANGEMENT FOR LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024)
1. BOLTS 4. E-HYDRAULIC CONTROLS HARNESS
2. COWL HARNESS 5. COWL
3. VSM

Figure 88. Vehicle System Manager

4. Install the upper steering column cover. See the 5. Connect the battery. For models H6.0FT, H7.0FT
section Steering Column Repair for the installa- (H135FT, H155FT) (H006), install the floor plate
tion procedures.

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Vehicle System Manager (VSM) 2200 SRM 1142

and floor mat after connecting the battery. On all revision will change every time a new version
other lift truck models, lower the hood. is loaded and transferred to either the VSM or
Display Switch Cluster.
PROGRAMMING A NEW VSM AND/OR The CDF for a particular truck cannot be modified
DISPLAY SWITCH CLUSTER by a service technician. However, a replacement
file (with alternate options [SEF]) can be loaded
NOTE: See the section Diagnostic Troubleshoot- into a truck’s controller by a service technician.
ing Manual 9000 SRM 1112 for information on The operational copy of the CDF is stored in the
how delete and reset fault codes to the VSM, how VSM and a backup copy is stored in the Display
to use the PC Service Tool software, and for the Switch Cluster.
procedures to troubleshoot the VSM, Display Switch • Truck Operations Data File (TODF). This data
Cluster, and other electrical components used on file includes periodically updated and truck spe-
these trucks. cific information such as component serial num-
bers and hourmeters. This data must be backed
General up and replaced during controller replacements.
Truck Operations Data Files can be saved to a data
Whenever a new VSM or Display Switch Cluster is file through the PC Service Tool software. When
installed (see Display Switch Cluster for procedures using backup copies of the TODF, the latest ver-
to remove and install the Display Switch Cluster) on sion will be copied into the Display Switch Cluster
a lift truck, the data that controls all the functions at every system power down cycle.
and features unique to that lift truck needs to be • Truck Settings File (TSF). This data file in-
transferred to the new VSM or Display Switch Clus- cludes information on the specific adjustments
ter. done to the various parameters on a given lift
There are three types of data files that may be re- truck. The parameters on a given truck are those
quired to be transferred when a new VSM or Display items that can be adjusted by a service technician.
Switch Cluster is installed: For example, auto-deceleration, which may be
• Configuration Data File (CDF). This data file set on a scale from 1 to 10. Each parameter will
has the configuration and optional details spe- also have a default value. Truck Setting Files
cific to a given truck. For example, configuration also include the ability to activate and deactivate
information may include data that shows the features. For example, a truck which has a CDF
truck’s lifting capacity and base type (e.g., 2-3 that enables the operator password feature, would
Ton Cushion tire truck). Optional information have a selection in the TSF indicating whether
may include data defining the type of engine the the option has been activated or deactivated. A
truck has and whether any Software Enabled backup copy of TSF is stored in the Display Switch
Features (SEF) have been installed (e.g., operator Cluster. Truck Settings Files can be copied across
passwords). Adding new SEF will require that trucks within a fleet.
new CDF be downloaded and transferred into
the VSM and Display Switch Cluster. This data PC Service Tool Software
information is directly linked to the truck’s serial The PC Service Tool software (Hyster Part No.
number. An example of a lift truck serial num- 1582488) is required to perform any CDF data file
ber is F187V12345A001. The first 11 characters transfers from the Display Switch Cluster to a new
(F187V12345A) represent the truck’s serial num- VSM or from the VSM to a nonblank Display Switch
ber and the last 3 digits (001) represent the CDF Cluster. A nonblank Display Switch Cluster is one
revision loaded on the truck. The serial number of that has been used on several trucks. If the Display
a lift truck is stored in the Display Switch Cluster. Switch Cluster is brand new (blank display), the PC
See the section User Interface, (Service Tech- Service Tool software is not used. The CDF data will
nician) 2200 SRM 1131 for the procedures to find automatically be transferred to the new display from
the serial number. A lift truck’s serial number can the VSM (see Table 1).
be found online at Hypass Online®. The CDF

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2200 SRM 1142 Vehicle System Manager (VSM)

To connect the PC Service Tool, remove the plug that discussed in New (Blank) Display Switch Cluster.
covers the PC service tool diagnostic connector on the See Table 1.
right side of the steering column and connect the in-
terface cable (Hyster Part No. 1534010) to the PC Depending on the part being replaced and the tools
service tool diagnostic connector. See Figure 89. All available, different methods of transferring the
transfers will create a transfer log on the PC’s hard needed data exists. Refer to Table 1 for the best
drive and can be accessed by service personnel. The method to use to transfer data based on the tools
file transfer log will include all serial number trans- available.
fers and other configuration information related to
a specific truck. The minimum PC requirements to
run the software are as follows:
• Pentium III or compatible, running at 700 MHz
• 128MB of RAM
• 20GB of hard drive space
• CD-ROM drive
• Modem with 56Kbps
• USB port
• Compatible vehicle adapter
• Microsoft Windows® 2000, SP3, IE 5.5 or Microsoft
Windows® XP, SP1, IE 6.0

Data Transferring
New or Used VSM

If the VSM is being replaced, the lift truck’s CDF,

TODF, and TSF data backup files can be retrieved
from the Display Switch Cluster using the PC Service
Tool software. The serial number of the new VSM
will be written into the TODF, the revised TODF
loaded to the Display Switch Cluster, and the combi-
nation of CDF, TSF, and revised TODF written to the
new VSM. This sequence of data transferring can be
performed on both a new or used VSM. See Table 1.

New (Blank) Display Switch Cluster

If the Display Switch Cluster is being replaced with

a new (blank) display, the VSM will revise its TODF
to include the new serial number of the Display
Switch Cluster, then upload the CDF, TSF, and
revised TODF to the Display Switch Cluster via
the use of the Controller Area Network (CAN). PC
Service Tool software is not needed. See Table 1.

Used (Non-Blank) Display Switch Cluster

1. STEERING COLUMN
If the replacement Display Switch Cluster has been 2. PC SERVICE TOOL DIAGNOSTIC CONNECTOR
used on another truck, the PC Service Tool software
Figure 89. Connecting PC Service Tool
must be used to perform the data copying sequence

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

Table 1. 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, CDF from Hypass
Intact download into new Online or display,
VSM download into new
VSM
VSM and Display Not allowed - Not allowed - Read back up
Replaced PC and Internet PC and Internet CDF from Hypass
Field Repair
required required Online, download
into new VSM,
new blank display
auto updated after
installation
Display Replaced New blank display New blank display New blank display
With New Blank auto updated after auto updated after auto updated after
Display installation installation installation
Display Replaced Not allowed - PC PC Service Tool PC Service Tool
With Previously required enables over write enables over write
Used Display of old CDF in of old CDF in
display display

Power Distribution Module (PDM) and Component Parts

REMOVE 2. For lift truck models H6.0FT, H7.0FT (H135FT,
H155FT) (H006), remove the floor mat and floor
PDM as a Unit plate for access to the PDM and battery. Discon-
nect the battery.
NOTE: The PDM as a unit, is not a serviceable part.
The component parts of the PDM (relays, fuses, and 3. Disconnect the chassis harness from the main
resistors), can be replaced without replacing the power connection terminals on the PDM.
PDM. If the PDM malfunctions, replace with a new
PDM. See the Parts Manual for replacement part 4. For all lift truck models except H6.0FT, H7.0FT
number. (H135FT, H155FT) (H006), remove bolts secur-
ing the PDM to the battery tray. See Figure 90.
1. For all lift truck models except H6.0FT, H7.0FT Remove PDM from lift truck.
(H135FT, H155FT) (H006), raise the steering col-
umn to it highest position, move the seat all the 5. For lift truck models H6.0FT, H7.0FT (H135FT,
way forward and raise the hood for access to the H155FT) (H006), remove bolts securing the PDM
PDM and battery. Disconnect the battery. to the PDM mounting bracket. See Figure 91.

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

Figure 90. PDM Removal, All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H006)

Confidential/Proprietary - Do Not Copy or Duplicate 83

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

Legend for Figure 90

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

1. BATTERY 3. MAIN POWER TERMINALS 5. BOLTS

2. BATTERY CONNECTIONS 4. CHASSIS HARNESS 6. PDM

Figure 91. PDM Removal, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)

84 Confidential/Proprietary - Do Not Copy or Duplicate

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

INSTALL ON/OFF button, press button to turn system power

on. Check all indicator lights for correct operation as
PDM as a Unit described in the Operating Manual. Check the op-
eration of the horn. Start the engine by turning the
1. For all lift truck models except H6.0FT, H7.0FT key switch to the Start position, if truck is equipped
(H135FT, H155FT) (H006), fasten PDM to bat- with a key switch, or press the engine start button,
tery tray with bolts. Tighten bolts to 8 N•m if lift truck is equipped with this button. If any indi-
(71 lbf in). cator lights do not operate correctly, check the fuses.
The fuses are located in the Power Distribution Mod-
2. For lift truck models H6.0FT, H7.0FT (H135FT,
ule (PDM) which is under the hood next to the battery
H155FT) (H006), fasten the PDM to the PDM
on the right side. See Figure 92.
mounting bracket using the bolts. See Figure 91.
Tighten bolts to 8 N•m (71 lbf in).

3. Connect the chassis harness to the main power

connection terminals on the PDM. See Figure 90
and Figure 91.

4. Connect the lift truck battery.

5. For all lift truck models except H6.0FT, H7.0FT

(H135FT, H155FT) (H006), close the hood and
move the seat and steering column into position.
See the section:
• Frame 100 SRM 1120 for lift truck mod-
els 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)
• Frame 100 SRM 1243 for lift truck models 1. RESISTOR (68 OHM)
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; 2. START RELAY
S80, 100FTBCS; S120FTS; S120FTPRS) 3. STARTER (30 AMP)
(G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 4. IGNITION 3 RELAY
5. BACKUP RELAY
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) 6. BACKUP (20 AMP)
• Frame 100 SRM 1316 for lift truck models 7. IGNITION (30 AMP)
S6.0FT, S7.0FT (S135FT, S155FT) (D024) 8. SPARE FUEL PUMP (20 AMP)
for the procedures. 9. SPARE FUEL PUMP RELAY
10. BATTERY (25 AMP)
6. For lift truck models H6.0FT, H7.0FT (H135FT, 11. FRONT WORK LIGHT (20 AMP)
12. FRONT/REAR WORK LIGHT RELAYS
H155FT) (H006), install the floor plate and floor
13. BATTERY (25 AMP)
mat. See the section Frame 100 SRM 1321 for 14. REAR WORK LIGHT (20 AMP)
the procedures. 15. IGNITION 1 (20 AMP)
16. IGNITION 1 RELAY
REMOVE AND INSTALL 17. BATTERY (25 AMP)

PDM Component Parts Figure 92. PDM Component Parts

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

to ON position. If lift truck is equipped with a Power

Confidential/Proprietary - Do Not Copy or Duplicate 85

Transmission Control Unit 2200 SRM 1142

Transmission Control Unit

REMOVE S6.0FT, S7.0FT, (S135FT,S155FT) aid in connecting transmission harness connectors
(D024) AND H6.0FT, H7.0FT (H135FT, during installation.
H155FT) (H006) 2. Disconnect transmission harness connectors
from TCU. See Figure 93.
WARNING
3. Remove four flange capscrews from bracket and
Always disconnect the cables at the battery
TCU.
before disconnecting the transmission control
unit (TCU). Disconnect the cable at the nega- 4. Remove TCU from bracket.
tive terminal first.
INSTALL S6.0FT, S7.0FT, (S135FT,S155FT)
1. Disconnect battery.
• For lift truck models S6.0FT, S7.0FT, (D024) AND H6.0FT, H7.0FT (H135FT,
(S135FT,S155FT) (D024), open hood and H155FT) (H006)
disconnect battery.
1. Install TCU into bracket. See Figure 93.
• For lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), remove front and 2. Install four flange capscrews into bracket and
rear floor mat and floor plates and disconnect TCU.
battery.
3. Connect transmission harness connectors to
NOTE: When disconnecting transmission harness TCU as tagged during removal.
connectors during removal, tag each connector to

A. H6.0FT, H7.0FT (H135FT, H155FT) (H006) B. S6.0FT, S7.0FT, (S135FT,S155FT) (D024)

1. FLANGE CAPSCREW 4. TRANSMISSION HARNESS CONNECTOR
2. TRANSMISSION CONTROL UNIT (TCU) (CRP128)
3. TRANSMISSION HARNESS CONNECTOR 5. BRACKET
(CRP129)

Figure 93. Transmission Control Unit Location

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2200 SRM 1142 Lights

4. Connect battery. • For lift truck models H6.0FT, H7.0FT

• For lift truck models S6.0FT, S7.0FT, (H135FT, H155FT) (H006), connect battery
(S135FT,S155FT) (D024), connect battery and install front and rear floor plate and floor
and close hood. mats.

Battery
REMOVE INSTALL
1. Disconnect the battery. Raise the hood to ac- 1. Install new battery onto battery tray. Secure bat-
cess the battery for all lift truck models except tery to battery tray with battery lockdown bar.
H6.0FT, H7.0FT (H135FT, H155FT) (H006).
For models H6.0FT, H7.0FT (H135FT, H155FT) 2. Connect the battery and close the hood on all lift
(H006), remove the floor mat floor plate for ac- truck models except H6.0FT, H7.0FT (H135FT,
cess to the battery. H155FT) (H006). For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
2. Remove the battery lockdown bar securing bat- and floor mat after connecting the battery.
tery to battery tray. Remove battery from lift
truck. See Figure 90 and Figure 91.

Lights
WORK LIGHTS (FRONT AND REAR) remove the capscrew, washer, and nut attaching
the work light to the overhead guard.
Remove
1. Disconnect the battery. Raise the hood to ac-
cess the battery for all lift truck models except
H6.0FT, H7.0FT (H135FT, H155FT) (H006).
For models H6.0FT, H7.0FT (H135FT, H155FT)
(H006), remove the floor mat floor plate for ac-
cess to the battery.

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. NOTE: REAR WORK LIGHT SHOWN, FRONT WORK
LIGHT IS SIMILAR.
2. To replace the bulb, remove the lens assembly
1. CAPSCREWS (LENS ASSEMBLY)
by removing the four capscrews. See Figure 94. 2. LENS ASSEMBLY
Replace the bulb and reinstall the lens assembly. 3. NUT (ATTACHES LIGHT TO OVERHEAD GUARD)
3. To replace the work light assembly, disconnect Figure 94. Work Lights
the light from the overhead guard harness and

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Lights 2200 SRM 1142

Install H155FT) (H006). For models H6.0FT, H7.0FT

(H135FT, H155FT) (H006), install the floor plate
1. Install work light to overhead guard using the and floor mat after connecting the battery.
capscrew, washer, and nut. See Figure 94. Con-
nect work light to overhead guard harness.

2. Connect the battery and close the hood on all lift

truck models except H6.0FT, H7.0FT (H135FT,
H155FT) (H006). For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery.

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

Remove
1. Disconnect the battery. Raise the hood to ac-
cess the battery for all lift truck models except
H6.0FT, H7.0FT (H135FT, H155FT) (H006).
For models H6.0FT, H7.0FT (H135FT, H155FT)
(H006), remove the floor mat floor plate for ac-
cess to the battery.

2. Disconnect the strobe light electrical connector

from the overhead guard harness. See Figure 95. 1. STROBE LIGHT GUARD
2. STROBE LIGHT LENS
3. Remove the capscrews, washers, lockwasher, 3. STROBE LIGHT BULB
and nuts securing the strobe light and light 4. LIGHT BASE
5. NUT
guard to strobe light mounting bracket. Remove 6. LOCKWASHER
strobe light and guard from lift truck. 7. WASHER
8. MOUNTING BRACKET
4. If the strobe light bulb needs to be replaced, re- 9. CAPSCREW
move the strobe light lens from base and remove 10. LOCK NUT
bulb. 11. ELECTRICAL CONNECTOR

Figure 95. Strobe Light Assembly

Install
1. If bulb is being replaced, install new bulb into LED TAIL, BACKUP, AND BRAKE LIGHTS
strobe light base. Install strobe light lens onto
NOTE: These light assemblies are nonrepairable and
base.
must be replaced as an assembly. See the Parts
2. Place strobe light assembly and strobe light Manual for replacement LED lights.
guard onto mounting bracket. Secure the as-
sembly to mounting bracket with capscrews, Remove
washers, lockwasher, and nuts. See Figure 95.
1. Disconnect the battery. Raise the hood to ac-
3. Connect strobe light electrical connector to over- cess the battery for all lift truck models except
head guard harness. H6.0FT, H7.0FT (H135FT, H155FT) (H006).
For models H6.0FT, H7.0FT (H135FT, H155FT)
4. Connect the battery and close the hood on all lift (H006), remove the floor mat floor plate for ac-
truck models except H6.0FT, H7.0FT (H135FT, cess to the battery.

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2200 SRM 1142 Lights

2. If lift truck is equipped with an optional key Install

switch, remove the key.
1. If the mounting bracket was removed, install
3. Remove screw and clip nut securing the LED the rear crossmember cover. Install mounting
light to mounting bracket. Pull LED light down- bracket to overhead guard leg.
ward to remove it from the mounting bracket.
2. Connect the LED light to the chassis light har-
4. Disconnect the LED light from the chassis light ness. See Figure 96.
harness. See Figure 96.
3. Insert the screw and install the LED light to the
5. If the mounting bracket must be removed from mounting bracket. See Figure 96.
the overhead guard leg, remove rear crossmem-
ber cover and remove the mounting bracket from 4. Connect the battery and close the hood on all lift
the overhead guard leg. See Figure 96. truck models except H6.0FT, H7.0FT (H135FT,
H155FT) (H006). For models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), install the floor plate
and floor mat after connecting the battery.

1. CHASSIS LIGHT HARNESS 6. SCREW

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

Figure 96. LED Tail, Backup, and Brake Lights Replacement

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Electronic-Hydraulic Controls 2200 SRM 1142

Electronic-Hydraulic Controls
GENERAL Install
NOTE: The mini-levers and joystick do not need to be 1. Install new mini-lever assembly onto armrest
calibrated. and secure with four flange nuts.

The line of trucks covered in this manual come NOTE: When closing the armrest cover, be sure the
standard with manual hydraulic levers, but have wires for the electrical connection are inside the arm-
the option of using electronic-hydraulic controls. rest. If they are hanging out, they can be cut when
Electronic-hydraulic controls are not serviceable closing the armrest cover.
parts. If the joystick or mini-levers malfunction,
replace with new part. See the Parts Manual for 2. Connect the electrical connection and put arm-
replacement parts. rest cover in the down position.

MINI-LEVERS JOYSTICK

Remove Remove and Disassemble

1. Pull up on armrest lever and put armrest cover 1. Remove four nuts that attach joystick to mount-
in the up position (see Figure 21). Disconnect the ing bracket.
electrical connector. See Figure 97.
2. Disconnect the joystick connector. See Figure 98.

3. Remove four screws that secure the bottom cover

to the bracket.

4. Remove four nuts, lockwashers, washers, screws,

and upper housing from the bracket.

Inspect
Inspect the components of the joystick to ensure that
there is no damage. If any component is damaged,
other than the wiring harness, replace that compo-
nent. Inspect the pins of the wiring harness. If any
are damaged, see the section Wire Harness Repair
2200 SRM 1128 for the proper repair procedures.

Assemble and Install

1. Install upper housing, four screws, washers,
lockwashers, and nuts to the bracket. See Fig-
ure 98.
1. MINI-LEVER 3. ELECTRICAL
ASSEMBLY CONNECTOR 2. Install the bottom cover to the bracket using four
2. FLANGE NUTS 4. MINI-LEVER screws.
Figure 97. Mini-Levers, Removal 3. Connect the joystick connector.
2. Remove four flange nuts that secure mini-lever 4. Using four nuts, attach joystick to mounting
assembly to armrest and remove mini-lever as- bracket.
sembly from armrest.

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2200 SRM 1142 Electronic-Hydraulic Controls

Legend for Figure 98

1. BOTTOM COVER
2. SCREW
3. ELECTRICAL CONNECTOR
4. MOUNTING BRACKET
5. WASHER
6. LOCKWASHER
7. NUT
8. SCREW
9. JOYSTICK
10. LOCK NUT
11. TOP COVER
12. BRACKET

Figure 98. Joystick

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2200 SRM 1142 3/07 (6/06)(3/06)(6/05)(5/05)(12/04) Printed in U.S.A.