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.

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

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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

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

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