Hyster H2.0-2.5CT User manual

ELECTRICAL SYSTEM
S50CT, S50CT2 [B267];H2.0-2.5CT (H50CT) [B274]
PART NO. 4120745 2200 SRM 1771

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

©2018 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Engine Control Module (ECM), Yanmar Diesel Engine ....................................................................................... 2
Remove .................................................................................................................................................................2
Install ...................................................................................................................................................................2
Display Switch Cluster ........................................................................................................................................... 2
Remove .................................................................................................................................................................3
Install ...................................................................................................................................................................5
Direction Control Lever ...................................................................................................................................... 5
Remove .............................................................................................................................................................5
Install ............................................................................................................................................................... 6
Key Switch ........................................................................................................................................................... 6
Remove .............................................................................................................................................................6
Install ............................................................................................................................................................... 7
Display Switch Cluster Panel Bezel and Overlay ............................................................................................. 7
Remove .............................................................................................................................................................7
Install ............................................................................................................................................................... 7
Steering Column Repair ......................................................................................................................................... 7
Remove .................................................................................................................................................................8
Disassemble ......................................................................................................................................................... 9
Assemble .............................................................................................................................................................. 9
Install .................................................................................................................................................................10
Sensors and Switches ............................................................................................................................................10
General ...............................................................................................................................................................10
Dash Panel, Kick Panel, and Seal Plate, Remove and Install .................................................................... 10
Remove ....................................................................................................................................................... 10
Install ......................................................................................................................................................... 11
Accelerator Pedal Position Sensor ....................................................................................................................11
Remove ...........................................................................................................................................................11
Install ............................................................................................................................................................. 13
Brake Fluid Level Switch ................................................................................................................................. 14
Remove ...........................................................................................................................................................14
Install ............................................................................................................................................................. 14
Brake Pedal Position Sensor .............................................................................................................................15
Remove ...........................................................................................................................................................15
Install ............................................................................................................................................................. 16
Parking Brake Position Sensor .........................................................................................................................16
Remove ...........................................................................................................................................................16
Install ............................................................................................................................................................. 16
Seat Sensor (Operator Presence System) .........................................................................................................17
Non-Suspension Seat .....................................................................................................................................17
Remove ....................................................................................................................................................... 17
Install ......................................................................................................................................................... 18
Full Suspension Seats ................................................................................................................................... 18
Remove ....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Transmission Pressure Sensors (Transducers) ............................................................................................... 19
Remove ...........................................................................................................................................................19
Install ............................................................................................................................................................. 19
Transmission Temperature Sensor .................................................................................................................. 19
Remove ...........................................................................................................................................................19
Install ............................................................................................................................................................. 20
Rear Horn Button Switch ................................................................................................................................. 20
Table of Contents
i

TABLE OF CONTENTS (Continued)
Remove ...........................................................................................................................................................20
Install ............................................................................................................................................................. 20
Engine and Fuel Sensors and Switches, PSI 2.4L Dual Fuel Trucks ............................................................ 21
Engine and Fuel Sensors, Yanmar 2.6L Diesel Trucks .................................................................................. 21
Engine Speed Sensor .....................................................................................................................................21
Remove ....................................................................................................................................................... 21
Install ......................................................................................................................................................... 22
Oil Pressure Sensor .......................................................................................................................................22
Remove ....................................................................................................................................................... 22
Install ......................................................................................................................................................... 22
Engine Coolant Temperature (ECT) Sensor ................................................................................................ 23
Remove ....................................................................................................................................................... 23
Install ......................................................................................................................................................... 23
Fuel/Water Separator Sensor ....................................................................................................................... 23
Remove ....................................................................................................................................................... 23
Install ......................................................................................................................................................... 24
Glow Plug Relay ............................................................................................................................................ 24
Remove ....................................................................................................................................................... 24
Install ......................................................................................................................................................... 26
Power Distribution Module (PDM) and Component Parts ................................................................................. 26
Power Distribution Module (PDM) as a Unit .................................................................................................. 26
Remove ...........................................................................................................................................................26
Install ............................................................................................................................................................. 27
Power Distribution Module (PDM) Components ............................................................................................. 28
Remove and Install ........................................................................................................................................28
Battery ................................................................................................................................................................... 28
Remove ...............................................................................................................................................................28
Install .................................................................................................................................................................28
Lights ..................................................................................................................................................................... 28
Work Lights (Front and Rear) .......................................................................................................................... 29
Remove ...........................................................................................................................................................29
Install ............................................................................................................................................................. 29
Strobe Light ....................................................................................................................................................... 29
Remove ...........................................................................................................................................................30
Install ............................................................................................................................................................. 30
LED Tail, Backup, and Brake Lights ...............................................................................................................30
Remove ...........................................................................................................................................................30
Install ............................................................................................................................................................. 31
Reflectors ........................................................................................................................................................... 31
Remove ...........................................................................................................................................................31
Install ............................................................................................................................................................. 31
This section is for the following models:
(S50CT, S50CT2) [B267];
H2.0-2.5CT (H50CT) [B274]
Table of Contents
ii

General
The removal and replacement procedures for the
following electrical components are covered in this
manual:
•Display Switch Cluster
•Power Distribution Module (PDM)
•Lights
•Sensors and switches
•Battery
Some of the components used are made of plastic.
When using screws to replace and install plastic
components, the screws should be rotated
counterclockwise until the screw thread turns over
the last thread in the plastic part. The screw can
then be turned clockwise to make a connection. This
prevents "cutting" new threads and damaging the
existing thread in the plastic part.
If any welding must be done, obtain proper
authorization from a Resident Service Engineer. If
authorization is given, be sure to follow the
procedures in the CAUTION below.
CAUTION
When welding, always disconnect the negative
battery cable from battery and disconnect the
ground wire from the ground stud on the frame.
See Figure 1. To prevent damage to the Electronic
Control Unit (ECU), remove it from the lift truck.
For lift trucks equipped with LPG engine see Fuel
System PSI 2.4L 0900SRM1757 for procedure to
remove ECU from lift truck.
For lift trucks equipped with diesel engines see
section Engine Control Module (ECM), Yanmar
Diesel Engine in this manual for procedure to
remove ECM from lift truck.
NOTE: VIEW SHOWN IS FROM THE LEFT SIDE.
MAJOR COMPONENTS AND ELECTRICAL CON-
NECTIONS NOT SHOWN FOR CLARITY
.
1. GROUND STUD
2. TANK OPENING FOR HYDRAULIC FILTER
3. POWER DISTRIBUTION MODULE (PDM)
4. BATTERY
Figure 1. Welding Preparation
For more information on how to perform welding
repairs to lift truck and overhead guard, see
Periodic Maintenance 8000SRM1774.
2200 SRM 1771 General
1

Engine Control Module (ECM), Yanmar Diesel Engine
REMOVE
NOTE: ECM for Yanmar engine is located on left-
hand side of frame.
1. Disconnect negative battery cable.
2. Remove two conduit clips from wire harness
and bracket. See Figure 2.
3. Disconnect ECM connector from ECM. See
Figure 2.
4. Remove four capscrews and ECM from bracket.
See Figure 2.
5. Remove capscrew and bracket from frame. See
Figure 2.
1. ECM
2. BRACKET
3. CAPSCREW
4. ECM CONNECTOR
5. CONDUIT CLIP
6. WIRE HARNESS
7. FRAME
Figure 2. ECM, Yanmar Diesel Engine
INSTALL
1. Install bracket and capscrew on frame. See
Figure 2.
2. Install ECM and four capscrews on bracket.
See Figure 2.
3. Connect ECM connector to ECM. See Figure 2.
4. Install two conduit clips to wire harness and
bracket. See Figure 2.
5. Connect negative battery cable.
Engine Control Module (ECM), Yanmar Diesel Engine 2200 SRM 1771
2

Display Switch Cluster
REMOVE
NOTE: The Display Switch Cluster is a non-
repairable part. See Parts Manual for replacement
part number.
1. Disconnect ground wire.
2. Lift up on the steering wheel slightly and pull
up on the tilt lever. Fully lower the steering
column.
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 3.
NOTE: TOP VIEW OF DASH SHOWN.
A. INDICATES TO PULL UP TO UNLATCH
1. UPPER STEERING COLUMN COVER
2. STEERING COLUMN TILT LEVER
3. LOWER STEERING COLUMN COVER
Figure 3. Upper Steering Column Cover Removal
4. Remove the horn button and disconnect the
horn wires.
NOTE: A puller tool may be required to remove the
steering wheel.
5. Remove the lock nut securing the steering
wheel and remove steering wheel from steering
column. Take care to not damage the horn
wires. See Figure 4.
2200 SRM 1771 Display Switch Cluster
3