Hyster H6 0FT Series Operating instructions

Hyster L006 (H135FT, H155FT) Forklift Service
Repair Manual

ELECTRICAL SYSTEM
H6.0-7.0FT (H135-155FT) [L006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) [C299]
PART NO. 4139182 2200 SRM 1954

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

©2015 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Display Switch Cluster ........................................................................................................................................... 3
Remove ................................................................................................................................................................ 3
Install ...................................................................................................................................................................5
Direction Control and Turn Signal Levers ........................................................................................................5
Remove ............................................................................................................................................................5
Install ..............................................................................................................................................................7
Key Switch ...........................................................................................................................................................7
Remove ............................................................................................................................................................7
Install ..............................................................................................................................................................7
Display Switch Cluster Panel Bezel and Overlay .............................................................................................8
Remove ............................................................................................................................................................8
Install ..............................................................................................................................................................8
Steering Column Repair ......................................................................................................................................... 8
Remove ............................................................................................................................................................8
Disassemble .................................................................................................................................................. 11
Assemble ....................................................................................................................................................... 11
Install ............................................................................................................................................................11
Sensors and Switches ............................................................................................................................................11
General ..............................................................................................................................................................11
Dash and Kick Panel, Remove and Install ..................................................................................................11
Remove ......................................................................................................................................................12
Install ........................................................................................................................................................12
Accelerator Pedal Position Sensor ................................................................................................................... 13
Remove ..........................................................................................................................................................13
Install ............................................................................................................................................................15
Brake Fluid Level Switch .................................................................................................................................15
Remove ..........................................................................................................................................................15
Install ............................................................................................................................................................16
Service Brake Pedal Position Sensor ...............................................................................................................17
Remove ..........................................................................................................................................................17
Install ............................................................................................................................................................17
Parking Brake Position Sensor ........................................................................................................................17
Remove ..........................................................................................................................................................17
Install ............................................................................................................................................................18
Service Brake Pressure Sensor ........................................................................................................................18
Remove ..........................................................................................................................................................18
Install ............................................................................................................................................................18
Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299).............................................................................................................................18
Remove ..........................................................................................................................................................18
Install ............................................................................................................................................................19
Sensor Microswitch Monotrol®.........................................................................................................................19
Remove ..........................................................................................................................................................19
Install ............................................................................................................................................................21
Low Coolant Level Sensor ................................................................................................................................21
Remove ..........................................................................................................................................................21
Install ............................................................................................................................................................22
Fuel Level Sensor, Diesel Engines Only ..........................................................................................................23
Remove ..........................................................................................................................................................23
Table of Contents
i

Thanks very much for your reading,
Want to get more information,
Please click here, Then get the complete
manual
NOTE:
If there is no response to click on the link above,
please download the PDF document first, and then
click on it.
Have any questions please write to me:
[e-mail]

TABLE OF CONTENTS (Continued)
Install ............................................................................................................................................................23
Seat Sensor (Operator Presence System) ........................................................................................................24
Non-Suspension Seat ....................................................................................................................................24
Remove ......................................................................................................................................................24
Install ........................................................................................................................................................25
Full Suspension and Swivel Seats ...............................................................................................................25
Remove ......................................................................................................................................................25
Install ........................................................................................................................................................26
Hood Shut Off Switch .......................................................................................................................................26
Remove ..........................................................................................................................................................26
Install ............................................................................................................................................................26
Remote Key Switch ...........................................................................................................................................28
Remove ..........................................................................................................................................................28
Install ............................................................................................................................................................28
Hydraulic Filter Pressure Switch ....................................................................................................................28
Remove ..........................................................................................................................................................28
Install ............................................................................................................................................................28
Transmission Speed Sensor ..............................................................................................................................29
Remove ..........................................................................................................................................................29
Install ............................................................................................................................................................29
Transmission Pressure Sensors .......................................................................................................................30
Remove ..........................................................................................................................................................30
Install ............................................................................................................................................................30
Transmission Temperature Sensor ..................................................................................................................31
Remove ..........................................................................................................................................................31
Install ............................................................................................................................................................31
Engine Speed Sensor ........................................................................................................................................ 31
Remove ..........................................................................................................................................................31
Install ............................................................................................................................................................31
Intermediate Speed Sensor .............................................................................................................................. 31
Remove ..........................................................................................................................................................31
Install ............................................................................................................................................................31
Return To Set Tilt (Tilt Angle) Sensor .............................................................................................................31
Remove ..........................................................................................................................................................31
Install ............................................................................................................................................................32
Rear Horn Button Switch .................................................................................................................................32
Remove ..........................................................................................................................................................32
Install ............................................................................................................................................................33
Impact Sensor ....................................................................................................................................................33
Remove ..........................................................................................................................................................33
Install ............................................................................................................................................................33
Load Weight Sensor ..........................................................................................................................................34
Remove ..........................................................................................................................................................34
Install ............................................................................................................................................................34
Engine and Fuel Sensors and Switches, GM 4.3L and 5.7L LPG Engines ................................................... 35
Engine and Fuel Sensors and Switches, Cummins QSB 3.3L Diesel Engine ............................................... 36
Air Filter Restriction Switch ........................................................................................................................36
Remove ......................................................................................................................................................36
Install ........................................................................................................................................................36
Engine Oil Pressure Sensor .........................................................................................................................36
Table of Contents
ii

TABLE OF CONTENTS (Continued)
Remove ......................................................................................................................................................36
Install ........................................................................................................................................................38
Engine Speed Sensor ....................................................................................................................................38
Remove ......................................................................................................................................................38
Install ........................................................................................................................................................38
Engine Coolant Temperature (ECT) Sensor ...............................................................................................38
Remove ......................................................................................................................................................38
Install ........................................................................................................................................................38
Fuel/Water Separator Sensor .......................................................................................................................38
Remove ......................................................................................................................................................38
Install ........................................................................................................................................................38
Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Engine ............................................................39
Engine Coolant Temperature (ECT) Sensor ...............................................................................................39
Remove ......................................................................................................................................................39
Install ............................................................................................................................................................39
Throttle Position Sensor ...............................................................................................................................40
Engine Oil Pressure Sensor .........................................................................................................................40
Remove ......................................................................................................................................................40
Install ........................................................................................................................................................40
Fuel Shut Off Solenoid .................................................................................................................................40
Remove ......................................................................................................................................................40
Install ........................................................................................................................................................41
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine With Diesel
Particulate Filter (DPF) And Kubota 3.8L (Tier 4) 55kW Diesel Engine, With Diesel
Oxidation Catalyst (DOC) ................................................................................................................................ 41
Intake Air Temperature Sensor ...................................................................................................................42
Remove ......................................................................................................................................................42
Install ........................................................................................................................................................42
Boost Sensor ..................................................................................................................................................42
Remove ......................................................................................................................................................42
Install ........................................................................................................................................................42
Throttle Valve Assembly and Air Intake Heater ........................................................................................44
Remove ......................................................................................................................................................44
Install ........................................................................................................................................................44
Engine Coolant Temperature (ECT) Sensor ...............................................................................................44
Remove ......................................................................................................................................................44
Install ........................................................................................................................................................44
Engine Oil Pressure Sensor .........................................................................................................................44
Remove ......................................................................................................................................................44
Install ........................................................................................................................................................45
Crankshaft Position Sensor ......................................................................................................................... 45
Remove ......................................................................................................................................................45
Install ........................................................................................................................................................45
Adjust Shim Procedure ............................................................................................................................45
Camshaft Position Sensor ............................................................................................................................48
Remove ......................................................................................................................................................48
Install ........................................................................................................................................................48
Differential Pressure Sensor ........................................................................................................................48
Remove ......................................................................................................................................................48
Install ........................................................................................................................................................48
Table of Contents
iii

TABLE OF CONTENTS (Continued)
Oxygen Sensors (Inlet and Outlet) ..............................................................................................................49
Remove ......................................................................................................................................................49
Install ........................................................................................................................................................50
Inlet Temperature Sensor ............................................................................................................................51
Remove ......................................................................................................................................................51
Install ........................................................................................................................................................51
Mass Air Flow Sensor ...................................................................................................................................51
Remove ......................................................................................................................................................51
Install ........................................................................................................................................................51
Fuel/Water Separator ...................................................................................................................................51
Remove ......................................................................................................................................................51
Install ........................................................................................................................................................52
Air Filter Restriction Switch ........................................................................................................................52
Remove ......................................................................................................................................................52
Install ........................................................................................................................................................52
Vehicle System Manager (VSM) ...........................................................................................................................53
General ..............................................................................................................................................................53
VSM Replacement .............................................................................................................................................53
Remove ..........................................................................................................................................................53
Install ............................................................................................................................................................53
Programming A New VSM And/Or Display Switch Cluster .......................................................................... 54
Data Transferring .........................................................................................................................................55
New VSM ..................................................................................................................................................55
New (Blank) Display Switch Cluster ...................................................................................................... 55
Used (Non-Blank) Display Switch Cluster ............................................................................................. 55
PC Service Tool Software ................................................................................................................................. 56
Power Distribution Module (PDM) and Component Parts .................................................................................57
Remove .............................................................................................................................................................. 57
PDM as a Unit ..............................................................................................................................................57
Install .................................................................................................................................................................58
PDM as a Unit ..............................................................................................................................................58
Remove and Install ...........................................................................................................................................58
PDM Component Parts .................................................................................................................................58
Transmission Control Unit (TCU) ........................................................................................................................59
Remove .............................................................................................................................................................. 59
Install .................................................................................................................................................................59
Battery ...................................................................................................................................................................60
Remove .............................................................................................................................................................. 60
Install .................................................................................................................................................................60
Lights .....................................................................................................................................................................60
Work Lights (Front and Rear) ..........................................................................................................................60
Halogen Bulb Lights .....................................................................................................................................60
Remove ......................................................................................................................................................60
Install ........................................................................................................................................................61
LED Lights ....................................................................................................................................................61
Remove ......................................................................................................................................................61
Install ........................................................................................................................................................61
Strobe Light .......................................................................................................................................................62
Remove ..........................................................................................................................................................62
Install ............................................................................................................................................................62
Table of Contents
iv

TABLE OF CONTENTS (Continued)
LED Tail, Backup, and Brake Lights .............................................................................................................. 63
Remove ..........................................................................................................................................................63
Install ............................................................................................................................................................63
Front Marker/Turn Signal Lights ....................................................................................................................64
Replacing Whole Front Marker/Turn Signal Light Assembly ...................................................................64
Remove ......................................................................................................................................................64
Install ........................................................................................................................................................64
Replacing Just the Front Marker/Turn Signal Light LED Light Lens .....................................................65
Remove ......................................................................................................................................................65
Install ........................................................................................................................................................65
Electronic-Hydraulic Controls ..............................................................................................................................66
E-Hydraulic Controls - TEST ...........................................................................................................................66
Mini-Levers ...................................................................................................................................................66
Full Stroke Test ............................................................................................................................................66
Function Returns to Neutral Test ............................................................................................................... 66
Push Button Switch ......................................................................................................................................67
General ..............................................................................................................................................................67
Mini-levers, Remove and Install ......................................................................................................................67
Armrest Assembly .............................................................................................................................................68
Remove ..........................................................................................................................................................68
Install ............................................................................................................................................................71
Horn Button ...................................................................................................................................................... 72
Remove ..........................................................................................................................................................72
Install ............................................................................................................................................................72
Direction Control Switch ..................................................................................................................................72
Remove ..........................................................................................................................................................72
Install ............................................................................................................................................................72
Momentary Switches ........................................................................................................................................ 73
Remove ..........................................................................................................................................................73
Install ............................................................................................................................................................74
Diesel Particulate Filter (DPF) Display ...............................................................................................................75
Remove .............................................................................................................................................................. 75
Clean and Inspect ............................................................................................................................................. 75
Install .................................................................................................................................................................76
This section is for the following models:
H6.0-7.0FT (H135-155FT) [L006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [C299]
Table of Contents
v

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

General
The removal and replacement procedures for the
following electrical components are covered in this
manual:
• Display Switch Cluster
• Vehicle System Manager (VSM)
• Power Distribution Module (PDM)
• Mini-lever electronic-hydraulic controls
• Lights
• Sensors and switches
• Battery
• Transmission Control Unit (TCU)
Some of the components used are made of plastic.
When using screws to replace and install plastic
components, the screws should be rotated
counterclockwise until the screw thread turns over
the last thread in the plastic part. The screw can
then be turned clockwise to make a connection.
This prevents "cutting" new threads and damaging
the existing thread in the plastic part.
If any welding must be done, obtain proper
authorization from a Resident Service Engineer. If
authorization is given, be sure to follow the
procedures in the CAUTION below.
CAUTION
When welding, always disconnect the negative
battery cable from battery and disconnect the
ground wire from the ground stud on the frame.
See Figure 1. To prevent damage to the Electronic
Control Module (ECM), remove it from the lift
truck.
See one of the following sections for procedures to
remove ECM from your lift truck
LPG Fuel System, GM 4.3L Engine With PSI
0900SRM1556 for the following lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
LPG Fuel System, GM 5.7L Engine
0900SRM1433 for the following lift truck models
• H8.0FT, H8.0FT9, H9.0FT (C299)
NOTE: VIEW SHOWN IS FROM LEFT SIDE. MAJOR
COMPONENTS AND ELECTRICAL CONNECTIONS
NOT SHOWN FOR CLARITY.
1. GROUND STUD
2. TANK OPENING FOR HYDRAULIC FILTER
3. POWER DISTRIBUTION MODULE (PDM)
4. BATTERY
Figure 1. Welding Preparation
For more information on how to perform welding
repairs to lift truck and overhead guard, refer to
one of the following sections:
Periodic Maintenance 8000SRM1957 for the
following lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
Periodic Maintenance 8000SRM1959 for the
following lift truck models
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Additional information concerning the electrical
system may be included in other sections when the
information is closely related to other systems.
2200 SRM 1954 General
1

Sections may include:
Frame 0100SRM1948 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Wet Brakes - NMHG 1800SRM1597 for lift truck
models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Three-Speed Powershift Transmission Repair
1300SRM1317 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Two-Speed Powershift Transmission Repair
1300SRM1343 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
Calibration Procedures 8000SRM1134 for lift
truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Cooling System 0700SRM1950 for lift truck
models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Diagnostic Troubleshooting Manual
9000SRM1112 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
User Interface - Service Technician
2200SRM1131 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Kubota Diesel 3.6L Engine 0600SRM1579 for lift
truck models
• H6.0-7.0FT (H135-155FT) (L006)
Kubota Diesel 3.8L Engine (Tier 4 Final), 78/82
KW 0600SRM1962 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
Kubota 3.8L Diesel Engine (Tier 4), 55kW With
DOC 0600SRM1961 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
LPG Fuel System, GM 4.3L Engine With PSI
0900SRM1556 for the following lift truck models
equipped with a GM 4.3L LPG engine
• H6.0-7.0FT (H135-155FT) (L006)
LPG Fuel System, GM 5.7L Engine
0900SRM1433 for the following lift truck models
equipped with a GM 5.7L LPG engine
• H8.0FT, H8.0FT9, H9.0FT (C299)
High Voltage Switch (HVS) Ignition; GM4.3L
EPA Compliant Engines and GM5.7L LPG
EPA Compliant Engine 2200SRM1097 for the
following lift truck models equipped with a GM
4.3L and 5.7L LPG engine
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (C299)
Operator's Cab 0100SRM1892 for lift truck
models
• H6.0-7.0FT (H135-155FT) (L006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299)
If your lift truck is equipped with a Cummins QSB
3.3L diesel engine, contact your local Hyster
dealer, or see Hyster Hypass® Online for any
repair or service procedures.
General 2200 SRM 1954
2

Display Switch Cluster
REMOVE
NOTE: The Display Switch Cluster (DSC) is a non-
repairable part. See Parts Manual for replace-
ment parts.
1. Disconnect ground wire.
2. Lift up on steering wheel slightly and pull up
on tilt lever. Fully lower steering column.
3. Remove upper steering column cover by pulling
up on upper steering column cover to release
latches (one on either side), and pulling cover
away from steering column. See Figure 2.
4. Remove horn button and disconnect horn wires.
NOTE: A puller tool may be required to remove
steering wheel.
5. Remove lock nut securing steering wheel and
remove steering wheel from steering column.
Take care to not damage horn wires. See Fig-
ure 3.
6. Disconnect Display Switch Cluster harness
from Display Switch Cluster. Remove four bolts
securing Display Switch Cluster. Slide display
panel off of steering column. See Figure 4.
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 2. Upper Steering Column Cover Removal
2200 SRM 1954 Display Switch Cluster
3

Figure 3. Steering Wheel Removal
Legend for Figure 3
1. HORN BUTTON 2. LOCK NUT
NOTE: TOP DOWN VIEW SHOWN.
1. BOLTS
2. DISPLAY SWITCH CLUSTER HARNESS 3. STEERING COLUMN 4. HORN WIRES (CONTACT PADS)
Figure 4. Display Switch Cluster Removal
Display Switch Cluster 2200 SRM 1954
4

INSTALL
NOTE: When a new Display Switch Cluster is in-
stalled on a lift truck, the data that controls all
functions and features unique to that lift truck,
needs to be transferred to new Display Switch Clus-
ter. See section Vehicle System Manager (VSM),
located in the back of this manual, for procedures to
transfer data to a new Display Switch Cluster.
1. Install Display Switch Cluster onto steering
column. Install four bolts to secure panel to
steering column and tighten bolts to
19 N•m (168 lbf in). See Figure 4.
2. Connect Display Switch Cluster to display har-
ness.
3. Install steering wheel onto steering shaft and
tighten lock nut until steering wheel is fully
seated. Final torque for lock nut is 40 to
54 N•m (30 to 40 lbf ft). See Figure 3.
4. Connect horn wires to horn button. Install horn
lock nut and horn button into steering wheel.
5. Install upper steering column cover by aligning
two latches and pushing down until latched.
See Figure 2.
DIRECTION CONTROL AND TURN
SIGNAL LEVERS
Direction control lever and turn signal lever are
similar in design, but perform different functions.
The turn signal lever is located on right side of the
Display Switch Cluster. The direction control lever
is located on left side of Display Switch Cluster.
Remove
NOTE: The direction control lever and turn signal
lever are not repairable. If one of these levers mal-
functions, replace with new lever. See Parts Man-
ual for replacement part numbers.
1. Insert two small flat-blade or Phillips screw-
drivers, with a 3.175 mm (0.125 in.) or less,
wide blade or die end, into opening on Display
Switch Cluster on an outward angle enough to
compress spring tab on direction control lever
or turn signal lever. See A, Figure 5.
2. Pry spring tab toward body of direction control
lever or turn signal lever and, at the same time,
pull on handle of lever enough to free the tab of
interior lock of Display Switch Cluster. See B,
Figure 5.
3. Repeat previous steps on opposite side of direc-
tion control lever or turn signal lever. Remove
direction control lever or turn signal lever from
Display Switch Cluster.
2200 SRM 1954 Display Switch Cluster
5

NOTE: DISPLAY SWITCH CLUSTER SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY. FLAT-BLADE
SCREWDRIVERS SHOWN.
A. STEP 1 B. STEP 2
1. DIRECTION CONTROL AND TURN SIGNAL
LEVERS
2. FLAT-BLADE SCREWDRIVER
3. DISPLAY SWITCH CLUSTER
Figure 5. Direction Control and Turn Signal Levers, Remove
Display Switch Cluster 2200 SRM 1954
6

Install
Install direction control lever or turn signal lever
into opening of Display Switch Cluster until locking
tabs are engaged in Display Switch Cluster.
KEY SWITCH
Remove
NOTE: The lift truck models covered in this man-
ual may be equipped with an optional remote key
switch in the engine compartment. See Sensors and
Switches section in this service manual for replace-
ment procedures.
NOTE: Lift truck models covered in this manual
can be equipped with an optional key switch or
Power ON/OFF button. The Power ON/OFF but-
ton is a nonrepairable part. See Parts Manual for
replacement parts. If truck is equipped with a key
switch, follow steps below to remove and replace
key switch.
1. Fully lower steering column and remove upper
steering column cover by pushing in on both
sides of cover to release latches (one on either
side), and pulling cover away from steering col-
umn. See Figure 2.
2. Remove torx head capscrews. Slide key switch
assembly out of Display Switch Cluster. See
Figure 6.
Install
1. Install new key switch assembly into Display
Switch Cluster. Install torx head capscrews
(T-15) to secure key switch to Display Switch
Cluster. Tighten torx head capscrews to
1.1 N•m (9.7 lbf in). See Figure 6.
2. Install upper steering cover on steering column.
Align latches on upper steering cover to holes
on steering column and push upper steering
cover into place on steering column. See Fig-
ure 2.
2200 SRM 1954 Display Switch Cluster
7

1. BEZEL
2. OVERLAY
3. KEY SWITCH
4. TORX HEAD SCREW
5. INSERT SCREWDRIVER IN SLOT AT THIS LO-
CATION
Figure 6. Display Switch Cluster Panel Bezel, Grid, and Key Switch Removal
DISPLAY SWITCH CLUSTER PANEL
BEZEL AND OVERLAY
Remove
1. Insert a small, flat-bladed screwdriver into top
slot on inner edge of bezel and pry outward. Re-
peat procedure at the lower slot on the bezel.
Be careful to not damage bezel and overlay when
removing bezel. Lift bezel off of Display Switch
Cluster. See Figure 6.
2. Remove overlay from Display Switch Cluster.
Install
Place new overlay on display panel and install a
new bezel by inserting outer edge in display and
then pressing down inner edge.
Steering Column Repair
Remove
1. Remove floor mat and floor plate for access to
battery.
2. Disconnect the battery. See Figure 7.
Display Switch Cluster 2200 SRM 1954
8

1. BATTERY POSITIVE CABLE
2. BATTERY NEGATIVE CABLE
3. BATTERY
Figure 7. Disconnect The Battery
3. Remove upper steering column cover by pulling
up on upper steering column cover to release
latches (one on either side), and pulling cover
away from steering column. See Figure 2.
4. Remove steering wheel and instrument display
panel. See Display Switch Cluster section for
procedures.
5. Remove two screws and remove lower steering
column cover. See Figure 8.
6. Disconnect Display Switch Cluster harness
from display panel. Remove harness from steer-
ing column.
7. Remove four bolts (1, Figure 9) holding steering
column to cowl.
8. Raise steering column to disengage steering
shaft from the steering control unit.
1. SCREWS
2. LOWER STEERING COLUMN COVER
Figure 8. Lower Steering Column Cover Removal
2200 SRM 1954 Steering Column Repair
9

NOTE: STEERING COLUMN ASSEMBLY FOR LIFT TRUCK MODELS H6.0-7.0FT (H135-155FT) (L006)
SHOWN. STEERING COLUMN ASSEMBLY FOR LIFT TRUCK MODELS H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT ) (C299) IS SIMILAR.
NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN. STEERING COLUMN ARRANGEMENT IS
THE SAME WITH MANUAL HYDRAULIC CONTROL VALVE.
1. BOLTS
2. PIVOT BOLTS
3. HORN WIRES
4. STEERING SHAFT RETENTION CLIP
5. HORN HARNESS
6. STEERING COLUMN
7. GAS CYLINDER
8. COWL
9. LOWER STRUT PIVOT PIN
10. HYDRAULIC CONTROL VALVE
11. STEERING CONTROL UNIT (SCU)
12. STEERING SHAFT
13. HORN CONTACT PADS
Figure 9. Steering Column Disassembly
Steering Column Repair 2200 SRM 1954
10