CAB HEATER/AIR

CONDITIONING
(BEFORE OCTOBER, 2017)

PART NO. 4023372 0100 SRM 1459

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

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
Description and Operation ......................................................................................................................................2
Heater System ..................................................................................................................................................... 2
General .............................................................................................................................................................2
Air Conditioning .................................................................................................................................................. 4
General .............................................................................................................................................................4
Dryer ................................................................................................................................................................ 4
Compressor Lubrication ..................................................................................................................................6
Control Systems, Sensors, and Switches ........................................................................................................6
Climate Control ................................................................................................................................................... 7
Description .......................................................................................................................................................7
Service Menu ................................................................................................................................................... 7
Set Up ...........................................................................................................................................................8
View 1 and View 2 ....................................................................................................................................... 8
Error List ..................................................................................................................................................... 8
Statistics .......................................................................................................................................................9
Exit ............................................................................................................................................................... 9
Temperature Sensors ...................................................................................................................................... 9
Troubleshooting ........................................................................................................................................... 9
Water Valve ................................................................................................................................................... 10
Troubleshooting ......................................................................................................................................... 10
Remove and Replace ..............................................................................................................................................11
Standard Heater Assembly ...............................................................................................................................12
Access ............................................................................................................................................................. 12
Remove ........................................................................................................................................................... 12
Install ............................................................................................................................................................. 13
Standard Heater Parts ......................................................................................................................................14
Heater Core ....................................................................................................................................................14
Remove ....................................................................................................................................................... 14
Install ......................................................................................................................................................... 15
Blower ............................................................................................................................................................ 15
Remove ....................................................................................................................................................... 15
Install ......................................................................................................................................................... 16
Water Valve ................................................................................................................................................... 17
Remove ....................................................................................................................................................... 17
Install ......................................................................................................................................................... 17
Push/Pull Cable ................................................................................................................................................. 18
Water Valve Cable .........................................................................................................................................18
Remove ....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Heater/Air Conditioner Assembly ................................................................................................................ 19
Remove ....................................................................................................................................................... 19
Install ......................................................................................................................................................... 20
Heater/Air Conditioner Parts ........................................................................................................................... 21
Vent Door ....................................................................................................................................................... 21
Remove ....................................................................................................................................................... 21
Install ......................................................................................................................................................... 21
Heater Core ....................................................................................................................................................22
Remove ....................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Evaporator Core .............................................................................................................................................23
Remove ....................................................................................................................................................... 23

©2017 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Install ......................................................................................................................................................... 24
Blower ............................................................................................................................................................ 25
Remove ....................................................................................................................................................... 25
Install ......................................................................................................................................................... 26
Thermostat .....................................................................................................................................................26
Remove ....................................................................................................................................................... 26
Install ......................................................................................................................................................... 27
Water Valve ................................................................................................................................................... 27
Remove ....................................................................................................................................................... 27
Install ......................................................................................................................................................... 28
Air Conditioning Technical Detail ....................................................................................................................29

This section is for the following models:

ii
0100 SRM 1459 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table

This section is for the following models:

Series Code European Model Americas Model

A236 H16.00-18.00XM/XMS-12 H400-450HD/HDS
A238 H16XM-9, H18XM-7.5, H16XM-12, H360-36HD, H360-48HD
H18XM-9
A917 H40.00-48.00XM-12, H36.00XMS-12 H800-1050HD/HDS
B214 H16.00-22.00XM-12EC H400-500HD/HDS-EC
B222 RS45-27CH, RS45-31CH, RS46-36CH, HR45-27, HR45-31, HR45-36, HR45-40,
RS46-40CH, RS46-41S CH, RS46-41L CH, HR45-41S, HR45-41L, HR45-41LS
RS46-41LS CH, RS45-24IH, RS45-28IH,
RS46-33IH, RS46-37IH, RS46-38S IH,
RS46-38L IH, RS46-38LS IH
B236 H16XM-12, H18XM-12, H20XM-12, H400HD, H450HD, H500HD, H550HD
H22XM-12
B238 H16XM-9, H16XM-12, H18XM-7.5, H360-36HD, H360-48HD
H18XM-9
B917 H36XMS-12, H40XM-12, H44XM-12, H800HD, H1050HD
H48XM-12
C214 H16XM-12EC, H18XM-12EC, H400HD-EC, H450HD-EC, H500HD-EC
H22XM-12EC
C222 RS45-27CH, RS45-31CH, RS46-36CH, RS45-27, RS45-31, RS46-36, RS46-41L,
RS46-41L CH, RS46-41S CH, RS46-41LS RS46-41S, RS46-41LS
CH, RS45-24IH, RS45-28IH, RS46-33IH,
RS46-38L IH, RS46-38S IH, RS46-38LS
IH
C227 N/A HR45-27, HR45-31, HR45-40S,
HR45-36L, HR45-40LS, HR45-45LSX
C236 H18-20XM-9, H18-20XMS-9 H400HD, H450HD, H400HDS, H450HDS
C917 H40XM-12, H44XM-12, H48XM-12, H800HDS, H900HDS, H970HDS,
H36XMS-12, H40XMS-12, H44XMS-12, H1050HDS
H48XMS-12
D214 H18XM-12EC, H22XM-12EC, H450HD-EC, H500HD-EC
H23XM-12EC
D222 RS45-27CH, RS45-31CH, RS46-36CH, RS45-27CH, RS45-31CH, RS46-36CH,
RS46-41L CH, RS46-41S CH, RS46-41LS RS46-41L CH, RS46-41S CH, RS46-41LS
CH, RS46-33IH, RS46-38L IH, RS46-38S CH
IH, RS46-38LS IH
E117 H40.00XM-16CH, H44.00XM-16CH, H880HD, H970HD, H1050HD-CH,
H48.00XM-16CH, H50.00XM-16CH, H1150HD-CH
H52.00XM-16CH

1
Description and Operation 0100 SRM 1459

Series Code European Model Americas Model

F008 H25-32XM-12, H28XM-16CH, H550-700HD, H550-700HDS
H32XM-16CH, H25-32XMS-9
F019, G019 H13.00-14.00XM, H16.00XM-6, H300-330HD, H360HD, H360HD-EC
H10.00-12.00XM-12EC
F117 H40.00-52.00XM-16CH H1050HD-CH, H1150HD-CH
G007, H007 H8.00-12.00XM H170-280HD
G008 H25-32XM-12, H25-30XMS-9 H550-700HD, H550-700HDS
G117 H40XM-16CH, H44XM-16CH, H48-16CH, H1050HD, H1150HD
G50-16CH, H52XM-16CH
H008 H25-32XM-12, H25-32XMS-9, H550-700HDS
H28-32XM-16CH H550-700HD,
H019 H13.0-16.0XM-6, H10.0-12.0XM-12EC H300-360HD2, H360HD2-EC
H117 H40.00-52.00XM-16CH H1050HD-16CH, H1150HD-16CH
J007 H8.0-12.0XM-6 H190-280HD2
J019 H13-16XM-6, H10-12XM-12EC H300-360HD2, H360HD2-EC
K007 H8-12XM-6, H10XMS-6 H190-280HD2, H230HDS
K019 H13-16XM-6 H210-250-48HD2, H300-360HD2
K019EC H6-7XM-12EC H360HD2-EC
L007 H8-12XM-6 H190-280HD2, H250HD2

Description and Operation

HEATER SYSTEM
General
The MCC heater system, used after October 2008,
can be identified by the absence of an air duct at the
rear window. The Aurora heater system, used up to
October 2008, does have this air duct. See Cab
Heater (Prior to Oct. 2008) 0100SRM1458 for
further information on the Aurora heater and air
conditioning systems.
Lift trucks with a closed cab are equipped with a
heater assembly which is installed on the underside
of the cab. The main components of the heater
assembly are the fan, heater core, vent door, and an
evaporator for the optional air conditioning system.
See Figure 1.
The vent door determines the percentage of fresh air
and recirculated air that the fan pulls through the
heater assembly. In heater assemblies without an
air conditioner, the vent door is in a fixed position
and allows for an air mixture of 85% fresh air and
15% recirculated air.
Cabs that are equipped with an air conditioner have
an electrically controlled vent door that can be used
to vary the percentage of recirculated air between 0
and 100 percent. The operator can select the
position of the vent door by turning a knob on the
dashboard. Cooling performance increases by
reducing the percentage of incoming fresh air.

2
0100 SRM 1459 Description and Operation

When the three vents are open, air flow is less

restricted, increased air volume passes through the
evaporator, and the majority of the air no longer
becomes warm in the air channels that lead to the
front window. See Figure 2.
The heater consists of a heater core and a water
valve. See Figure 1. The water valve controls the
flow of heated coolant to the heater core. By varying
the opening of the water valve, the desired amount
of heat is transferred by the heater core to the air
that enters the cab. The water valve opens
proportionally to the selected position of the heat
control knob. On standard units the knob and valve
are connected mechanically, on units with an Air
Conditioning system there is an electronic
connection.

A. RECIRCULATED AIR
B. FRESH AIR ENTRY
C. CAB AIR FLOW

1. VENT DOOR
2. VENT DOOR ACTUATOR
3. EVAPORATOR CORE
4. HEATER CORE
5. BLOWER
6. THERMOSTAT
7. WATER VALVE
8. EXPANSION VALVE

Figure 1. Heater/Airco Assembly Components

Recirculated air enters the heater assembly through

the openings in the side console at the fuse cover.
Fresh air enters the heater assembly through the
cab air filter, which is located at the left rear corner
of the cab. As the filter becomes restricted or
clogged, the percentage of recirculated air will
increase and the percentage of fresh air will
decrease.
When fresh air content and fan speed is increased,
positive air pressure is created in the cab,
preventing dust from entering the cab. The air
A. OPTIONAL AIR VENT
pressure escapes through the cab door posts and B. AIR TO FRONT WINDOW
through openings in the pedal area and sliding C. CAB AIR FLOW
window brush profiles. D. FRESH AIR ENTRY
When the fan is switched ON, air is pushed through
1. CAB AIR FILTER
channels in the cab floor to the air ducts at the front
window. Cabs that are equipped with an air Figure 2. Ventilation
conditioner have three additional vents at the foot
area that can be opened or closed. Cooling capacity
is increased by opening the three vents.

3
Description and Operation
AIR CONDITIONING
General
CAUTION
Replacement, installation, and repairs to air
conditioning units that require discharging and/or
refilling of the refrigeration fluid may only be
performed by a certified technician.
The air conditioning system consists of a compressor
with an electromagnetic clutch, condenser, dryer,
evaporator, and interconnected sensors and
switches. See Figure 3.
The engine drives the compressor when the clutch
at the compressor has been activated. Activation of
the clutch is determined by several sensors and
switches that are connected in series. The operator
must switch ON the button for the air conditioning
system and select one of the fan switch speeds.
Refer to the electrical schematic SRM pertaining to
each lift truck, for the schematic locations and
interconnections of the sensors and switches.
The compressor compresses the refrigerant and
continuously pumps the refrigerant through the air
conditioning system. As the refrigerant is being
compressed, the refrigerant temperature will rise.
The absorbed heat is dissipated in the condenser,
which is installed outside the cab. Fans at the
condenser accelerate heat dissipation.
After the refrigerant passes through the condenser,
the liquefied refrigerant passes through the dryer
4
0100 SRM 1459
that also serves as a reservoir for the refrigerant. At
the expansion valve, the refrigerant will expand in
the evaporator, causing the temperature of the
refrigerant to drop substantially. The expansion
valve regulates the flow of the refrigerant,
depending on the pressure difference between the
dryer and the compressor inlet. A minimum
pressure difference is necessary to open the valve.
After leaving the evaporator, the refrigerant will
reenter the compressor.
Dryer
The refrigerant functions as a coolant, and contains
lubricant for the compressor. Because humidity
affects the properties of the refrigerant and the
lubricant, a dryer is installed to absorb the trapped
humidity. The dryer also filters impurities in the
refrigerant.
Normal refrigerant leakage is approximately 10%
per year. To help prevent additional leakage
through the compressor seals, the air conditioning
system should be operated at least every two weeks
for 15 minutes. The air conditioning system cannot
be operated at temperatures below 0°C (32°F)
because the anti-ice switch will prevent the
compressor clutch from being activated.
The dryer, refrigerant, and lubricant must be
replaced every three years. Contact a certified
technician every three years to perform these
repairs.
0100 SRM 1459 Description and Operation

1. CONDENSER 6. EVAPORATOR
2. SERVICE CONNECTION, HIGH PRESSURE 7. EXPANSION VALVE
3. COMPRESSOR 8. RESERVOIR
4. SERVICE CONNECTION, LOW PRESSURE 9. DRYER
5. ANTI-ICE SENSOR 10. PRESSURE SWITCH

Figure 3. Refrigerant Cycle

5
Description and Operation 0100 SRM 1459

Compressor Lubrication
The oil specification for the compressor is indicated
on the nameplate of the compressor.
Most of the compressors used on Big Truck air
conditioning systems use SP-15 oil.
Only exception is for the compressor as installed on
the Cummins QSM-11 Tier-3 engines on series B/
C222, E/F117 and A/B917.
The compressor on QSM-11 engines requires ZXL
100PG oil.

Control Systems, Sensors, and Switches

The air conditioning system (A/C) is activated by
pushing the A/C switch on the dashboard and
selecting one of the fan speeds. A control light in the
A/C switch will illuminate, and the fans on the
condenser will turn. The anti-ice switch and the
pressure switches must be closed before the clutch
engages the compressor. If the anti-ice switch or one
of the pressure switches is open, the clutch will
disengage and the air conditioning system will not
1. CONDENSER COVER
activate. 2. CONDENSER COIL
Water in the air condensates on the evaporator. 3. SIGHT GLASS
4. DRYER
Normally, the condensed water drips on the bottom 5. PRESSURE SWITCH
plate of the heater assembly and escapes through 6. FAN
two hoses that open into the engine compartment. If
the condensed water becomes ice, the air flow Figure 4. Condenser
through the evaporator will be blocked, which will
block the entire cab ventilation system. The anti-ice High system pressure is a recurrent situation. The
switch protects the evaporator against ice buildup evaporator valve has a limited flow capacity. The
by opening at -1°C (30.2°F), causing the clutch to refrigerant flow generated by the compressor
disengage and allowing air to warm the evaporator. fluctuates with engine speed, and regularly exceeds
The anti-ice switch, which is inserted between the the flow capacity of the evaporator valve. When the
fins of the evaporator, will close when the flow capacity of the evaporator valve is exceeded,
temperature reaches 2.3°C (36.14°F). The anti-ice the compressor will have raised system pressure to
sensor is indicated by "T" on the electrical the maximum allowable level. The pressure switch
schematic. will send a signal to disengage the compressor
clutch, and the evaporator valve will continue to
The pressure switches are located at the dryer, and
regulate refrigerant flow. Pressure will drop until
protect the system against pressures that are too
the pressure switch is enabled, causing the clutch to
low or too high. See Figure 4. If the system pressure
reengage. System pressure will rise again until the
drops below 2 bar (29 psi), the refrigerant level is
maximum allowable level has been reached.
too low for proper functioning of the system and
proper lubrication of the compressor.

6
0100 SRM 1459 Description and Operation

Service Menu
CAUTION 1. Push the Power Button to turn the HVAC unit
NEVER bypass the electric clutch of the air ON. See Figure 5.
conditioning compressor. If the clutch does not
receive a signal, there is either an insufficient 2. Pressing the Set Button scrolls the screen
amount of refrigerant, or the condenser or the between:
evaporator is iced, and the pressure switch will not
• Climate Control Mode Settings
be enabled to protect the system against
excessive pressure. If the clutch does not receive • Air Circulation Settings
a signal, contact a certified and qualified air • Display Settings
conditioning specialist. Bypassing the compressor
will ALWAYS lead to system damage. 3. Press the set button to scroll to the Air
Circulation Settings.
The pressure switch, as installed on the dryer,
physically combines the high and low pressure 4. Push and hold the Power Button, and turn the
switches and their electrical interconnection. The Set Button three clicks clockwise to enter one of
pressure switch is indicated by "P1" on the electrical the service menu selections:
schematic.
• Set Up (Not an option for Hyster Lift trucks)
The pressure switch has an integrated third • View
function called the medium pressure switch. The
medium pressure switch changes the connection to • Error List
the fans on the condenser, causing them to turn at a • Statistics
higher speed when pressure in the system has • Exit
exceeded 16 bar (232 psi). At lower pressures, the
fans are connected in series, causing them to turn at To scroll to a next service screen, turn the Set
a lower speed. The medium pressure switch is Button one click clockwise. Push the Set Button
indicated by "P2" on the electrical schematic. to enter the selected service screen. Turning
the Set Button after the Exit screen further
CLIMATE CONTROL clockwise will bring you back to the Set Up
screen. To leave the Service Menu scroll to Exit
Description and push the Set Button.
Functionality of the individual components of the
normal air conditioning systems and the Climate
Control system is the same. The difference is that
for the Climate Control a controller sends the
signals to the components instead of the manually
operated knobs on the dashboard for the normal
system. This Controller is part of the control unit on
the dashboard that also has a display and a select
button. The display provides information on mode,
temperature, blower speed and fault conditions. An
explanation of the normally available information
and settings is in the Operating Manual.
1. POWER BUTTON
The explanation for how to read information and 2. SET BUTTON
apply settings for service purposes is described
under Service Menu. Figure 5. Climate Control

7
Description and Operation 0100 SRM 1459

Set Up • Valve - Indicates the percentage of maximum

The Set Up screen allows setting the date and the
blower speed for an additional interior heater. An
additional interior heater is not a standard option.
The date format is Month/Day/Year. To set the date,
go to Set Up screen and push the Set Button until it
flashes digital for "Month". Turn the Set Button
until the correct month number appears and push
the button to confirm. The digits for "Day" will now
flash. Repeat the procedure to set "Day" and "Year".
When finished, turn the knob to scroll to the Exit
screen and push the button to leave the service
menu.
heater valve opening that the controller sends
out as a signal.
Contrast - Indicates the contrast percentage
•
of the display.
• Brightness - Indicates the brightness
percentage of the display.
In case a temperature sensor is disconnected, the
display will show "open". Comparison of the
different values may provide an indication for a
possible defect.

View 1 and View 2

There are two View pages that show readings and
actual setting of the HVAC unit. After leaving the
previous service screen "Set Up", screen View 1 will
appear. Push the button to scroll between screen
View 1 and screen View 2 (see Figure 6).
Screen "View 1" displays below information: Figure 6. Climate Control View Display
• Scale - Selected temperature scale: Cel for
Celsius or Fah for Fahrenheit. Error List
• Setpoint - Selected (desired) interior The Main Display shows a warning sign in the left
temperature.
hand bottom corner of the Main Display if a fault
• Inside - Cab interior temperature as occurs. See Figure 7.
measured by the Inside Sensor.
• Outside - Cab exterior temperature as
measured by the Outside Sensor.
• Deice - Temperature of the refrigerant leaving
the evaporator coil.
• Coil - Temperature of the air at the blower.
• Heat - Flapper door position: Fresh or Recirc.
Screen "View 2" displays below information:
• AC - Indicates whether Air conditioning Mode
is switched ON or OFF.
• Heater - Indicates whether Heating Mode is
switched ON or OFF. 1. WARNING SIGN
• Blower - Indicates the selected percentage of
maximum blower speed. Figure 7. Climate Control Warning
• D Heat Fan - Indicates the selected blower
speed percentage for an additional interior
heater.

8
0100 SRM 1459 Description and Operation

The Error List page shows for each of the
temperature sensors and for the water valve the
number of occurrences that the connection was
shortened or open since the last reset date. For the
Water Valve there is an additional indication for the
number of times that the Water Valve was stuck.
See Figure 8.
Temperature Sensors
In addition to the normally present de-ice
temperature sensor in the evaporator, there are
three further temperature sensors that influence
the reaction of the controller:
• Outside Temperature Sensor, which is located
outside the cab under the condenser.
• Coil sensor, which is located behind the
evaporator and heater coil, in the suctioned
air flow of the blower fan.
• Inside Sensor, which is located in the side
console, measures the cab interior
temperature. Interior air flow past the sensor
is through a tube that connects between
suction side of the blower fan and inside
sensor.

Figure 8. Climate Control Error Display Troubleshooting

Disconnect the sensor for which an error has been
To further establish the cause of failure, see
indicated. Use an Ohm meter to measure its
Temperature Sensors or Water Valve.
resistance. See Table 1 that provides an overview of
To reset the number of occurrences and the reset the resistance value for different temperatures. The
date, turn the Set Button one click in a counter electrical properties of the four sensors are the
clockwise direction and push the Set Button for a same. When the sensor itself shows no defects,
dialog box. When the dialog box is shown, press the check continuity of the wiring harness. See
Set Button once to reset all values. Figure 10. The sensors are connected to the
controller connector at the following pin numbers:
Statistics • Inside Sensor: Pin 14 and 32.
The Statistics page shows operating hours and cycle • Outside Sensor: Pin 4 and 33
times since the last reset date. To reset the
• De-Ice Sensor: Pin 13 and 24
Statistics Page, go to the Error Page, turn the Set
Button one click counter clockwise. A dialog box will • Coil Sensor: Pin 12 and 34
appear. When the dialog box is shown, press the Set
Button once to reset all values. See Figure 9. Table 1. Sensor Resistance Values
°C °F k?
0 32 32,649
5 41 25,394
10 50 19,903
15 59 15,713
20 68 12,493
25 77 10,000
30 86 8,056
Figure 9. Climate Control Statistics Display

Exit
To leave the Service menu scroll to Exit and push
the Set Button.

9
Description and Operation 0100 SRM 1459

Water Valve
Table 2. Water Valve Pin Outs
Fault indication "Valve Stuck" indicates a physical
obstruction that prevents the valve from moving. Water Controller Value
The physical obstruction may have its cause at the Valve
outside or inside of the water valve. The components Pin 8 Pin 31 ground
of the water valve are not serviced separately.
Replace the water valve if there is no obvious Pin 10 Pin 30 3.3 Volt
problem that can be rectified. Pin 9 Pin 5 0.6 Volt when valve
is closed. 2.2 Volt
Troubleshooting when valve is open.
When a fault for open or short circuit has been Pin 6 Pin 18 12 Volt when the
indicated, use a volt meter to measure the voltage valve is closing. 0
over the different connections. Measures can be Volt when opening
taken at either the connector of the water valve or or not moving.
at the controller connector. See Table 2. There are Pin 5 Pin 19 12 Volt when the
also two 15 amp fuses located in the wiring system valve is opening. 0
check these if a fault for open or short circuit has Volt when closing or
been indicated. For location of theses fuses see not moving.
Figure 11.

Figure 10. Climate Control Wiring Diagram

10
0100 SRM 1459 Description and Operation

1. 15A FUSES

Figure 11. Standard A/C Wiring Diagram

11
Remove and Replace 0100 SRM 1459

Remove and Replace

STANDARD HEATER ASSEMBLY
WARNING
Access
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
WARNING pressure cap is removed, pressure is released
from the system. If the system is hot, the steam
Make sure no one is under cab when raising or
and boiling coolant can cause burns.
lowering cab.
6. Remove the pressure cap to release the
pressure and place it back on the radiator
WARNING expansion tank.
Before placing any part of your body under cab,
always make sure the cab is fully tilted, or when 7. Tilt/raise the cab to the fully open position.
partially open, is locked using the tilt latch. Refer to the section Raising and Lowering Cab.

To access the heater assembly, raise the cab to the 8. Tag and disconnect the two heater hoses from
fully open position. Support the heater assembly, the heater inlet and outlet ports, and plug the
then remove the three screws holding the heater heater hoses and ports. See Figure 13.
assembly in place. Lower the heater assembly down,
remove screws and the cover plate. Individual
components are now accessible.

Remove

WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.

1. Remove the four screws that retain the fuse

panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure Fuse Panel and Cover Location.

2. Remove the heat control knob at the

instrument panel top console. See
Figure Switch Locations.

3. Remove the nut that retains the rotary control

to the instrument panel top console. See
Figure 12.

4. Remove the rotary control assembly for the

water valve from the underside of the 1. CABLE CLIP
instrument panel top console and place it with 2. EXTENDED CABLE (FULL HOT POSITION)
the cable on the heater assembly. 3. NUT
4. KNOB LOCATION
5. ROTARY CONTROL
5. Disconnect the wire harness from the fan speed
knob at the underside of the instrument panel Figure 12. Rotary Control
top console.

12
0100 SRM 1459
1. HEATER HINGE BRACKET
2. HEATER ASSEMBLY CAPSCREW LOCATION
3. HEATER OUTLET
4. HEATER INLET
Figure 13. Heater Assembly
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
9. Loosen the two nuts and capscrews at the hinge
bracket. Remove the three capscrews that
retain the heater assembly to the cab. Pull the
heater assembly downwards and push
simultaneously towards the hinge bracket to
provide sufficient clearance between heater
assembly and cab frame. See Figure 13 for the
location of the capscrews.
10. Make sure the wire harness and the cable
control are free and can be removed together
with the heater assembly.
11. Support the heater assembly and remove the
capscrews that retain the heater assembly to
the hinge brackets.
12. Remove the heater assembly from the
underside of the cab.
Install
1. Position the heater assembly to the underside
of the cab.
2. Route the cable harness and cable control
correctly to the inside of the instrument panel
box.
Remove and Replace
3. Support the heater assembly and install the
capscrews to retain the heater assembly to the
hinge brackets. Do not tighten capscrews at
this time.
4. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
the location of the capscrews.
5. Tighten the two capscrews at the hinge
bracket.
6. Remove the plugs and connect the heater hoses
to the inlet and outlet ports.
7. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
8. Connect the outer cable to the rotary control as
described in the section Push/Pull Cable,
Water Valve Cable, Install.
9. Connect the inner cable to the rotary control as
described in the section Push/Pull Cable,
Heater/Air Conditioner Assembly, Install.
10. Connect the wire harness for the fan speed
knob to the connector at the underside of the
instrument panel top console.
11. Install the rotary control assembly for the
water valve to the underside of the instrument
panel top console.
12. Install the nut to retain the rotary control to
the instrument panel top console. See
Figure 12.
13. Install the heat control knob at the instrument
panel top console. See Figure Switch Locations.
14. Position the fuse panel cover to the right side of
the instrument panel and install the four
screws. See
Figure Fuse Panel and Cover Location.
15. If required, fill the coolant to the correct level.
Depending on your lift truck see Periodic
Maintenance SRM .
16. Start the engine and warm the engine to
normal operating temperature.
13
Remove and Replace 0100 SRM 1459

17. Make sure the heater functions correctly. simultaneously towards the hinge bracket to
provide sufficient clearance between heater
STANDARD HEATER PARTS assembly and cab frame. See Figure 13 for the
location of the capscrews.
Heater Core
Remove 5. Remove the 10 screws that retain the top cover
to the heater assembly.

WARNING 6. Remove the top cover from the heater

Before removing the heater hoses, make sure the assembly.
heater hoses are cool. Hot coolant may cause
severe burns. 7. Loosen the hose clamp and disconnect the top
heater hose from the heater core, located
between the heater core and the water valve.
See Figure 14.
WARNING
When replacing the heater hoses, make sure the 8. Remove the two capscrews that retain the
replacement hoses meet correct specifications. heater core bracket to the inside of the heater
Failure to meet specifications may cause personal assembly. See Figure 15.
injury.
9. Remove the heater core bracket from the heater
assembly.
WARNING
DO NOT remove the pressure cap from the 10. Slide the heater core out of the heater
expansion tank when the engine is hot. When the assembly.
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.

1. Remove the pressure cap to release the

pressure and place it back on the radiator
expansion tank.

2. Tilt/raise the cab to the fully open position.

Refer to the section Raising and Lowering Cab.

3. Loosen the hose clamp and disconnect the

heater inlet hose from the heater core pipe
located at the underside of the heater assembly
and plug the heater hose.

NOTE: The heater assembly fits tightly underneath

the cab and will require a limited amount of force to 1. BOTTOM HEATER HOSE
swing the heater assembly down and away from the 2. WATER VALVE
cab. 3. TOP HEATER HOSE
4. HEATER CORE
4. Loosen the two nuts and capscrews at the hinge 5. HOSE CLAMP
bracket. Remove the three capscrews that
retain the heater assembly to the cab. Pull the Figure 14. Heater Water Valve
heater assembly downwards and push

14
0100 SRM 1459 Remove and Replace

8. Lower the cab to the fully lowered and latched

position. Refer to the section
Raising and Lowering Cab.

9. Add coolant as needed. Depending on your lift

truck see Periodic Maintenance SRM .

10. Start the engine and check for leaks. Add

coolant as needed.

11. Make sure the heater functions correctly.

Blower
Remove
1. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.

NOTE: The heater assembly fits tightly underneath

the cab and will require a limited amount of force to
1. HEATER CORE
2. BLOWER swing the heater assembly down and away from the
3. WATER VALVE cab.
4. HEATER CORE BRACKET 2. Remove the three capscrews that retain the
5. HEATER CORE BRACKET CAPSCREWS
heater assembly to the cab and swing the
Figure 15. Heater Assembly Components heater assembly down. See Figure 13 for the
location of the capscrews.
Install
3. Remove the 10 screws that retain the top cover
1. Slide the heater core into the heater assembly. to the heater assembly.

2. Position the heater core bracket to the inside of 4. Remove the top cover from the heater
the heater assembly and install the two assembly.
retaining capscrews.
5. Tag and disconnect the electrical connector
3. Connect the top heater hose to the heater core connected to the blower assembly. See
and tighten the hose clamp. Figure 16.

4. Position the top cover on the heater assembly.
5. Install the 10 screws to retain the top cover to
the heater assembly.
6. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
the location of the capscrews.
7. Connect the heater inlet hose to the heater core
pipe located at the underside of the heater
assembly and tighten the hose clamp.
6. Remove the four screws that retain the blower
to the heater assembly housing. See Figure 17.
7. Partially remove the blower assembly from the
heater assembly housing and tag and
disconnect the four electrical wires from the
blower assembly. See Figure 18.
8. Remove the blower assembly from the heater
assembly housing.

15
Remove and Replace
1. ELECTRICAL CONNECTOR
Figure 16. Blower Electrical Connector
1. BLOWER RETAINING CAPSCREWS
Figure 17. Blower Retaining Screws
16
0100 SRM 1459
1. ELECTRICAL WIRE CONNECTION
Figure 18. Blower Electrical Wire Connection
Install
1. Connect the electrical wires to the blower
assembly. See Figure 18.
2. Position the blower assembly into the heater
assembly housing.
3. Install the four screws to retain the blower to
the heater assembly housing. See Figure 17.
4. Connect the electrical connector to the blower
assembly. See Figure 16.
5. Position the top cover on the heater assembly.
6. Install the 10 screws to retain the top cover to
the heater assembly.
7. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
the location of the capscrews.
8. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
9. Make sure the blower functions correctly.
0100 SRM 1459
Water Valve
Remove
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
When replacing the heater hoses, make sure the
replacement hoses meet correct specifications.
Failure to meet specifications may cause personal
injury.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
1. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
2. Turn the heat control knob on the instrument
panel counterclockwise to the fully open
position or (full hot position). See
Figure Switch Locations.
3. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
4. Remove the three capscrews that retain the
heater assembly to the cab and swing the
heater assembly down. See Figure 13 for the
location of the capscrews.
5. Remove the 10 screws that retain the top cover
to the heater assembly.
6. Remove the top cover from the heater
assembly.
7. Remove the cable clip that retains the outer
cable to the water valve.
Remove and Replace
8. Remove the snap ring that retains the inner
cable to the water valve and disconnect the
inner cable from the water valve.
9. Loosen the two hose clamps that retain the
water valve between the heater hoses. See
Figure 14.
10. Disconnect the two heater hoses from the water
valve.
11. Remove the water valve from the heater
assembly.
Install
1. Make sure the heat control knob in the cab is in
the full hot position
2. Position the water valve between the two
heater hoses inside the heater assembly. See
Figure 14.
3. Connect the two heater hoses to the water
valve and tighten the hose clamps.
4. Connect the inner cable to the water valve and
install the snap ring to retain the inner cable to
the water valve.
5. Push the lever of the water valve towards the
heater core until it reaches its final position.
Hold the lever and push the outer cable
towards the water valve.
6. Install and tighten the cable clip to retain the
outer cable to the water valve.
7. Position the top cover on the heater assembly.
8. Install the 10 screws to retain the top cover to
the heater assembly.
9. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
the location of the capscrews.
10. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
11. Add coolant as needed. Depending on your lift
truck see Periodic Maintenance SRM .
17
Remove and Replace 0100 SRM 1459

12. Start the engine and check for leaks. Add 11. Remove the cable clip that retains the outer
coolant as needed. cable to the water valve.

13. Make sure the heat control knob functions 12. Remove the snap ring that retains the inner
correctly. cable to the water valve and disconnect the
inner cable from the water valve.
PUSH/PULL CABLE
13. Remove the water valve cable from the
Water Valve Cable instrument panel box and heater assembly.
Remove
Install
1. Turn the heat control knob on the instrument
panel counterclockwise to the fully open 1. Position the water valve cable inside the
position or the (full hot position). See instrument panel box and heater assembly.
Figure Switch Locations .
2. Connect the inner cable to the water valve and
2. Remove the four screws that retain the fuse install the snap ring to retain the inner cable to
panel cover to the right side of the instrument the water valve.
panel and remove the cover to gain access to
3. Push the lever of the water valve towards the
the underside of the instrument panel. See
heater core until it reaches its final position.
Figure Fuse Panel and Cover Location.
Position the outer cable until it extends a few
3. Remove the heat control knob at the mm out of the cable clip.
instrument panel top console. See
4. Install and tighten the cable clip to retain the
Figure Switch Locations.
outer cable to the water valve.
4. Remove the nut that retains the rotary control
5. Position the top cover on the heater assembly.
assembly to the instrument panel top console.
See Figure 12.
6. Install the 10 screws to retain the top cover to
the heater assembly.
5. Remove the cable clip that retains the outer
cable to the rotary control assembly.
7. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
6. Remove the snap ring that retains the inner
heater assembly to the cab. See Figure 13.
cable to the rotary control and remove the
inner cable from the rotary control.
8. Lower the cab to the fully lowered and latched
position. Refer to the section
7. Raise the cab to the fully open position. Refer to
Raising and Lowering Cab.
the section Raising and Lowering Cab.
9. Turn the rotary control into the (full hot
NOTE: The heater assembly fits tightly underneath
position). See Figure 12.
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
10. Connect the inner cable to the rotary control
cab.
and install the snap ring to retain the inner
8. Remove the three capscrews that retain the cable to the rotary control. See Figure 12.
heater assembly to the cab and swing the
heater assembly down. See Figure 13. 11. Hold the inner cable extended and pull the
outer cable away from the rotary control.
9. Remove the 10 screws that retain the top cover
to the heater assembly. 12. Install the cable clip to retain the outer cable to
the rotary control assembly.
10. Remove the top cover from the heater
assembly. 13. Make sure the heat control knob functions
correctly.

18
0100 SRM 1459 Remove and Replace

14. Install the rotary control assembly to the
underside of the instrument panel top console.
15. Install the nut to retain the rotary control
assembly to the instrument panel top console.
See Figure 12.
16. Install the heat control knob at the instrument
panel top console. See Figure Switch Locations.
17. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See
Figure Fuse Panel and Cover Location.
Heater/Air Conditioner Assembly
Remove
7. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
8. Tilt/raise the cab to the fully open position.
Refer to the section
Figure Fuse Panel and Cover Location.
9. Tag and disconnect the two heater hoses from
the heater inlet and outlet ports and plug the
heater hoses and ports. See Figure 19.
CAUTION
Repairs to the air conditioning system that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a certified air
conditioning specialist.

WARNING 10. Contact a certified air conditioning specialist to

Before removing the heater hoses, make sure the have the refrigerant extracted from the air
heater hoses are cool. Hot coolant may cause conditioning system.
severe burns.
11. Disconnect and plug the hose fittings leading to
1. Turn the key switch to the ON position. the evaporator.

2. Place the recirculation knob on the instrument

panel in position 1 or position 2.

3. Turn the key switch to the OFF position.

4. Remove the four screws that retain the fuse

panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure Fuse Panel and Cover Location.

5. Disconnect the wire harness for the fan speed

knob, heater knob, and recirculation knob from
the connectors at the underside of the
instrument panel top console.

6. Tag and disconnect the electrical wires for the

air conditioner switch at the underside of the 1. HEATER INLET
instrument panel top console. 2. HEATER OUTLET
3. HEATER ASSEMBLY CAPSCREW LOCATION
4. CONDENSATION DRAINS
5. AIR CONDITIONING OUTLET
WARNING 6. AIR CONDITIONING INLET
DO NOT remove the pressure cap from the 7. HEATER HINGE BRACKET
expansion tank when the engine is hot. When the
pressure cap is removed, pressure is released Figure 19. Heater/Air Conditioner Assembly
from the system. If the system is hot, the steam
and boiling coolant can cause burns.

19
Remove and Replace
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
12. Loosen the two nuts and capscrews at the hinge
bracket. Remove the three capscrews that
retain the heater assembly to the cab. Pull the
heater assembly downwards and push
simultaneously towards the hinge bracket to
provide sufficient clearance between heater
assembly and cab frame. See Figure 19 for the
location of the capscrews.
13. Make sure the wire harness is free and can be
removed together with the heater/air
conditioner assembly.
14. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position.
15. Support the heater/air conditioner assembly
and remove the capscrews that retain the
heater/air conditioner assembly to the hinge
brackets.
16. Remove the heater/air conditioner assembly
from the underside of the cab.
Install
1. Position the heater/air conditioner assembly to
the underside of the cab.
2. Support the heater/air conditioner assembly
and install the capscrews to retain the
heater/air conditioner assembly to the hinge
brackets. Do not tighten the capscrews at this
time.
3. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position.
4. Route the wire harness correctly to the side
instrument panel box.
5. Swing the heater/air conditioner assembly up
toward the cab and install the three screws to
retain the heater/air conditioner assembly to
the cab. See Figure 19 for the location of the
capscrews.
20
0100 SRM 1459
6. Tighten the two nuts and capscrews at the
hinge bracket.
7. Remove the plugs and connect the heater hose
to the inlet and outlet ports.
8. Connect the hose fittings leading to the
evaporator.
CAUTION
Repairs to the air conditioning system that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a certified air
conditioning specialist.
9. Contact a qualified and certified technician to
have the air conditioning system filled with
refrigerant. See
Air Conditioning Technical Detail, Table 3 for
the type and the amount of refrigerant required
to charge an evacuated A/C system.
10. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
11. Connect the electrical wires for the air
conditioning switch at the underside of the
instrument panel top console.
12. Connect the wire harness for the fan speed
knob, heater knob, and recirculation knob to
the connectors at the underside of the
instrument panel top console.
13. Add coolant as needed. Depending on your lift
truck see Periodic Maintenance SRM .
14. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See
Figure Fuse Panel and Cover Location.
15. Make sure the heater/air conditioner functions
correctly. Turn the recirculation knob a few
times to the fully open and fully closed
positions to be sure that the recirculation
functions correctly.
0100 SRM 1459
HEATER/AIR CONDITIONER PARTS
Vent Door
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
4. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
5. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19 for the location of the
capscrews.
6. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
7. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
8. Remove the top cover from the heater/air
conditioner assembly.
9. Remove the washer located on top of the nylon
bushing.
10. Remove the capscrew, two nuts, two washers,
and lock washer that retain the vent door to
the actuator that is located on the top cover.
11. Remove the vent door.
Install
1. Position the vent door and install the capscrew,
two nuts, two washers, and lock washer to
retain the vent door to the actuator on the top
cover.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
Remove and Replace
2. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.
3. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
4. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
5. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19 for the location of the
capscrews.
6. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
NOTE: The key switch much be turned to the ON
position before performing the following step.
7. Turn the recirculation knob a few times from
the fully open position to the fully closed
position to be sure that the recirculation
system functions correctly. See
Figure Switch Locations.
1. ELECTRICAL CONNECTOR
2. VENT DOOR ACTUATOR
3. TOP COVER
Figure 20. Electrical Connector Location of Vent
Door Actuator
21
Remove and Replace 0100 SRM 1459

Heater Core 9. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
Remove
1. Turn the key switch to the ON position. 10. Remove the top cover from the heater/air
conditioner assembly.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2. 11. Remove the washer that is positioned on top of
See Figure Switch Locations. the nylon bushing.

3. Turn the key switch to the OFF position. 12. Tag and disconnect the two electrical
connectors from the thermostat. See Figure 21.

13. Loosen the hose clamp that retains the top

WARNING
heater hose to the heater core inside the
Before removing the heater hoses, make sure the heater/air conditioner assembly and disconnect
heater hoses are cool. Hot coolant may cause the heater hose from the heater core.
severe burns.
14. Slide the heater core out of the heater/air
conditioner assembly.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.

4. Remove the pressure cap to release the

pressure and place it back on the radiator
expansion tank.

5. Tilt/raise the cab to the fully open position.

Refer to the section Raising and Lowering Cab.

6. Loosen the hose clamp and disconnect the inlet

heater hose from the heater core pipe located at
the underside of the heater/air conditioner
assembly. Plug the inlet heater hose. See
Figure 19.

NOTE: The heater assembly fits tightly underneath

1. THERMOSTAT
the cab and will require a limited amount of force to 2. ELECTRICAL CONNECTION POINTS
swing the heater assembly down and away from the 3. TOP HEATER HOSE
cab. 4. HOSE CLAMP
5. HEATER CORE
7. Remove the three capscrews that retain the 6. WATER VALVE
heater/air conditioner assembly to the cab and 7. BOTTOM HEATER HOSE
swing the heater/air conditioner assembly 8. BRACKET CAPSCREW (INNER)
down. See Figure 19 for the location of the 9. BRACKET CAPSCREW (OUTER)
capscrews. 10. WATER VALVE BRACKET

Figure 21. Thermostat, Water Valve, and Heater

8. Disconnect the electrical connector on top of the
Hoses
top cover from the actuator that controls the
vent door position. See Figure 20.

22
0100 SRM 1459
Install
1. Slide the heater core into the heater/air
conditioner assembly.
2. Connect the top heater hose between the water
valve and heater core to the heater core and
tighten the hose clamp. See Figure 21.
3. Connect the two electrical connectors to the
thermostat.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
4. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.
5. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
6. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
7. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19 for the correct location of
the capscrews.
8. Connect the inlet heater hose to the heater core
pipe located at the underside of the heater/air
conditioner assembly and tighten the hose
clamp.
9. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
10. Start the engine and check for leaks. Add
coolant as needed. Depending on your lift truck
see Periodic Maintenance SRM for the
correct coolant specifications.
NOTE: The key switch much be turned to the ON
position before performing the following step.
11. Turn the recirculation knob a few times from
the fully open position to the fully closed
position to be sure that the recirculation
system functions correctly. See
Figure Switch Locations.
Remove and Replace
Evaporator Core
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
4. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
5. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
CAUTION
Repairs to the evaporator core that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a trained and
certified air conditioning specialist.
6. Contact a certified technician to have the
refrigerant extracted from the air-conditioning
system. See Air Conditioning Technical Detail,
Table 3 for the type and amount of refrigerant
required to charge an evacuated A/C system.
7. Tag and disconnect the two evaporator hoses
that are connected to the expansion block at
the underside of the heater/air conditioner
assembly. See Figure 19.
23
Remove and Replace
8. Remove the two capscrews that retain the
expansion block bracket to the bottom plate of
the heater/air conditioner assembly. See
Figure 22.
1. EXPANSION BRACKET CAPSCREWS
Figure 22. Expansion Bracket Capscrews
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
9. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19 for the correct location of
the capscrews.
10. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
11. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
12. Remove the top cover from the heater/air
conditioner assembly.
13. Remove the washer that is positioned on top of
the nylon bushing.
14. Remove the blower. Refer to the section Blower,
Remove.
15. Remove the water valve. Refer to the section
Water Valve, Remove.
24
0100 SRM 1459
16. Remove the two clips that retain the evaporator
core inside the heater/air conditioner assembly.
See Figure 23.
17. Slide the evaporator core out of the heater/air
conditioner assembly.
18. Remove the expansion block from the
evaporator core pipes.
Install
1. Install the expansion block to the evaporator
core pipes.
2. Slide the evaporator core into the heater/air
conditioner assembly. Make sure the expansion
block is positioned correctly at the underside of
the heater/air conditioner assembly.
3. Install the two clips to retain the evaporator
core inside the heater/air conditioner assembly.
See Figure 23.
4. Install the two capscrews to retain the
expansion block bracket to the bottom plate of
the heater/air conditioner assembly. See
Figure 22.
5. Install the water valve. Refer to the section
Water Valve, Install.
6. Install the blower. Refer to the section Blower,
Install.
1. EVAPORATOR CORE CLIP
Figure 23. Evaporator Core Clips
0100 SRM 1459 Remove and Replace

NOTE: Make sure the nylon bushing and washer 2. Turn the recirculation knob located on the
are correctly positioned inside the heater/air instrument panel to position 1 or position 2.
conditioner assembly. See Figure Switch Locations.
7. Position the top cover on the heater/air
3. Turn the key switch to the OFF position.
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in 4. Tilt/raise the cab to the fully open position.
the washer and nylon bushing. Refer to the section Raising and Lowering Cab.
8. Install the 12 screws to retain the top cover to NOTE: The heater assembly fits tightly underneath
the heater/air conditioner assembly. the cab and will require a limited amount of force to
swing the heater assembly down and away from the
9. Connect the electrical connector on top of the
cab.
top cover to the actuator that controls the vent
door position. See Figure 20. 5. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
10. Swing the heater/air conditioner assembly up swing the heater/air conditioner assembly
toward the cab and install the three capscrews down. See Figure 19 for the correct location of
to retain the heater/air conditioner assembly to the capscrews.
the cab. See Figure 19 for the correct location of
the capscrews. 6. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
CAUTION
Repairs to the evaporator core that require 7. Remove the 12 screws that retain the top cover
discharging and/or refilling of the refrigeration to the heater/air conditioner assembly.
fluid must be performed only by a trained and
8. Remove the top cover from the heater/air
certified air conditioning specialist.
conditioner assembly.
11. Connect the two evaporator hoses to the
9. Remove the washer that is positioned on top of
expansion block at the underside of the
the nylon bushing.
heater/air conditioner assembly.
10. Tag and disconnect the electrical connector
12. Lower the cab to the fully lowered and latched
connected to the blower assembly. See
position. Refer to the section
Figure 16.
Raising and Lowering Cab.
11. Remove the four screws and nuts that retain
13. Start the engine and check for leaks. Add
the blower inside the heater/air conditioner
coolant as needed. Depending on your lift truck
assembly. See Figure 17.
see Periodic Maintenance SRM for the
correct coolant specifications.
12. Partially remove the blower assembly from the
heater/air conditioner assembly housing and
14. Turn the recirculation knob a few times from
tag and disconnect the four electrical wires
the fully open position to the fully closed
from the blower assembly. See Figure 18.
position to be sure that the recirculation
system functions properly. See
13. Remove the blower assembly from the
Figure Switch Locations.
heater/air conditioner assembly housing.
Blower
Remove
1. Turn the key switch to the ON position.

25
Remove and Replace
Install
1. Connect the four electrical wires to the blower
assembly. See Figure 18.
2. Position the blower assembly into the
heater/air conditioner assembly.
3. Install the four screws and nuts to retain the
blower inside the heater/air conditioner
assembly. See Figure 17.
4. Connect the electrical connector to the blower
assembly. See Figure 16.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
5. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.
6. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
7. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
8. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19.
9. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
10. Make sure the blower functions correctly.
Thermostat
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
26
0100 SRM 1459
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
4. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
5. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
6. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19.
7. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
8. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
9. Remove the top cover from the heater/air
conditioner assembly.
10. Remove the washer that is positioned on top of
the plastic bushing.
11. Tag and disconnect the two electrical
connectors from the thermostat. See Figure 21.
12. Loosen the hose clamp that retains the top
heater hose to the water valve inside the
heater/air conditioner assembly and disconnect
the heater hose.
0100 SRM 1459
13. Remove the temperature switch from the
evaporator core. See Figure 24.
1. TEMPERATURE SWITCH
Figure 24. Temperature Switch
14. Remove the nut and washer located outside the
heater/air conditioner assembly that retains
the thermostat inside the heater/air conditioner
assembly.
15. Remove the thermostat and temperature
switch from the heater/air conditioner
assembly.
Install
1. Position the thermostat and temperature
switch inside the heater/air conditioner
assembly and correctly route the temperature
switch.
2. Install the nut and washer located outside the
heater/air conditioner assembly to retain the
thermostat inside the heater/air conditioner
assembly.
3. Install the temperature switch to the
evaporator core. See Figure 24.
Remove and Replace
4. Connect the top heater hose between the water
valve and heater core to the water valve and
tighten the hose clamp.
5. Connect the two electrical connectors to the
thermostat. See Figure 21.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
6. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.
7. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
8. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
9. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19.
10. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
11. Start the engine and check for leaks. Add
coolant as needed. Depending on your lift truck
see Periodic Maintenance SRM for the
correct coolant specifications.
12. Turn the recirculation knob a few times from
the fully open position to the fully closed
position to be sure that the recirculation
system functions correctly. See
Figure Switch Locations.
Water Valve
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
27
Remove and Replace
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
4. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
5. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
6. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19.
7. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
8. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
9. Remove the top cover from the heater/air
conditioner assembly.
10. Remove the washer that is positioned on top of
the plastic bushing.
11. Tag and disconnect the two electrical
connectors from the thermostat. See Figure 21.
12. Loosen the two hose clamps that retain the top
heater hose between the water valve and
heater core.
13. Remove the top heater hose and the two hose
clamps between the water valve and heater
core.
28
0100 SRM 1459
14. Loosen the hose clamp that retains the bottom
heater hose to the water valve.
15. Remove the two capscrews located at the
outside of the heater/air conditioner assembly
that retain the water valve bracket to the
heater/air conditioner assembly.
16. Disconnect the electrical connector from the
water valve actuator.
17. Loosen the hose clamp and disconnect the
bottom heater hose from the water valve.
18. Remove the water valve bracket from the
heater/air conditioner assembly.
19. Remove the two screws that retain the water
valve to the water valve bracket.
Install
1. Position the water valve to the water valve
bracket and install the two retaining screws.
2. Position the water valve bracket inside the
heater/air conditioner assembly.
3. Connect the bottom heater hose to the water
valve and tighten the hose clamp.
4. Connect the electrical connector to the water
valve actuator.
5. Install the two capscrews located at the outside
of the heater/air conditioner assembly to retain
the water valve bracket inside the heater/air
conditioner assembly. See Figure 21.
6. Install the top heater hose and the two hose
clamps between the water valve and heater
core. Tighten the hose clamps.
7. Connect the two electrical connectors to the
thermostat.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
8. Position the top cover on the heater/air
conditioner assembly and make sure that the
pin at the underside of the vent door is
positioned in the washer and nylon bushing.
0100 SRM 1459 Remove and Replace

9. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
10. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
11. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
that retain the heater/air conditioner assembly
to the cab. See Figure 19.
12. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
13. Start the engine and check for leaks. Add
coolant as needed. Depending on your lift truck
see Periodic Maintenance SRM for the
correct coolant specifications.
14. Turn the heat control knob a few times from
the fully open position to the fully closed
position to be sure that the heating system
functions properly. See
Figure Switch Locations.

AIR CONDITIONING TECHNICAL DETAIL

NOTE: Table 3 provides technical details. It is
intended for use by a certified air conditioning
specialist.

Table 3. Air Conditioning Specifications

Compressor Values
Lubricant Type PAG See Compressor Nameplate
Lubricant Quantity 200 grams
Suction Port 7/8-14 UNF
Discharge Port 3/4-16 UNF
Refrigerant
Refrigerant R134a
Fill Capacity 1300 ± 25 grams
Pressure Switch
High pressure OFF 2.70 ±0.2 MPa (392 ±29 psi)
High pressure ON 2.10 ±0.2 MPa (305 ±29 psi)
Med pressure OFF 1.30 ±0.15 MPa (188 ±22 psi)
Med pressure ON 1.60 ±0.13 MPa (232 ±19 psi)
Low pressure OFF 0.20 ±0.02 MPa (29 ±2.9 psi)
Low pressure ON 0.21 ±0.03 MPa (30.5 ±4.4 psi)
Anti-Icing Switch
Opens -1°C (30.2°F)
Closes 2°C (35.6°F)
This chart is intended for use by a certified air conditioning specialist.

29
 NOTES

30
 TECHNICAL PUBLICATIONS

0100 SRM 1459 11/17 (12/15)(7/15)(7/14)(12/13)(6/13)