Cabine Operador

OPERATOR’S CAB
H1.6FT, H1.8FT, 2.0FTS [F001];

H2.0-3.5FT (H40-70FT) [L177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005]; H6.0FT,
H7.0FT (H135FT, H155FT) [H006, J006]; H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) [A299]
PART NO. 1673866 100 SRM 1290

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic 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.
Operator’s Cab Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Cab Replacement ............................................................................................................................................... 2
Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT (H40-70FT) (L177);
and H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005).............. 2
Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT (H40-70FT) (L177);
and H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005).............. 13
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299) .......................................................................... 14
Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and H8.0FT,
Door Assemblies ................................................................................................................................................. 20
Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177); and H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) ..................................................................................................................................... 20
Remove....................................................................................................................................................... 20
Disassemble ............................................................................................................................................... 24
Door Cover............................................................................................................................................. 24
Heater Assembly ................................................................................................................................... 26
Door Lock Assembly.............................................................................................................................. 27
Windows ................................................................................................................................................ 28
Clean .......................................................................................................................................................... 28
Inspect........................................................................................................................................................ 28
Assemble .................................................................................................................................................... 28
Windows ................................................................................................................................................ 28
Heater Assembly ................................................................................................................................... 28
Door Cover............................................................................................................................................. 29
Install ......................................................................................................................................................... 29
Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
120FT) (N005, P005) ..................................................................................................................................... 29
Remove....................................................................................................................................................... 29
Disassemble ............................................................................................................................................... 29
Door Cover............................................................................................................................................. 29
Windows ................................................................................................................................................ 29
Clean .......................................................................................................................................................... 30
Inspect........................................................................................................................................................ 31
Assemble .................................................................................................................................................... 31
Windows ................................................................................................................................................ 31
Door Cover............................................................................................................................................. 31
Install ......................................................................................................................................................... 31
Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299) .............................. 31
Remove....................................................................................................................................................... 31
Disassemble ............................................................................................................................................... 32
Door Cover............................................................................................................................................. 32
Windows ................................................................................................................................................ 32
Clean .......................................................................................................................................................... 34
©2009 HYSTER COMPANY i

Table of Contents Operator’s Cab
TABLE OF CONTENTS (Continued)

Inspect........................................................................................................................................................ 34
Assemble .................................................................................................................................................... 34
Windows ................................................................................................................................................ 34
Door Cover............................................................................................................................................. 35
Install ......................................................................................................................................................... 35
Window Wipers Replacement ............................................................................................................................ 35
General ........................................................................................................................................................... 35
Front Wiper Assembly and Motor................................................................................................................. 35
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0-3.5FT (H40-70FT)
(L177) ......................................................................................................................................................... 35
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0-3.5FT (H40-70FT) (L177) ........ 35
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006), and H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299) ...................................................................... 37
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006), and H8.0FT,
Rear Wiper Assembly and Motor .................................................................................................................. 41
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) ................................................................. 41
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) ................................................................... 41
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177) ................................................................... 43
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177) ..................................................................... 43
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005) ......................................................................................................................... 46
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005) ................................................................................................................................. 46
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and H8.0FT,
Install, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and H8.0FT,
Window Replacement......................................................................................................................................... 50
General ........................................................................................................................................................... 50
Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
120FT) (N005, P005) ..................................................................................................................................... 50
Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
120FT) (N005, P005) ..................................................................................................................................... 51
Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299)............................................................ 52
Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299)............................................................ 53
Heater Replacement .......................................................................................................................................... 54
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and H8.0FT,
Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and H8.0FT,
Light Replacement ............................................................................................................................................. 58
Work Lights (Front and Rear)....................................................................................................................... 58
Remove....................................................................................................................................................... 58
ii
Operator’s Cab Table of Contents
TABLE OF CONTENTS (Continued)

Install ......................................................................................................................................................... 58
Strobe Light ................................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
Turn, Stop, Tail, and Backup Light .............................................................................................................. 61
Remove....................................................................................................................................................... 61
Install ......................................................................................................................................................... 61
Front Marker/Turn Signal Lights................................................................................................................. 61
Remove....................................................................................................................................................... 61
Install ......................................................................................................................................................... 61
Display Switches ................................................................................................................................................ 62
Electrical Schematics......................................................................................................................................... 65
Optional Equipment .......................................................................................................................................... 65
Heavy Duty Pre-Cleaner ............................................................................................................................... 65
Remove....................................................................................................................................................... 65
Clean .......................................................................................................................................................... 65
Inspect........................................................................................................................................................ 65
Install ......................................................................................................................................................... 65
Fan.................................................................................................................................................................. 66
Remove....................................................................................................................................................... 66
Install ......................................................................................................................................................... 67
Mirror ............................................................................................................................................................. 68
Remove....................................................................................................................................................... 68
Install ......................................................................................................................................................... 68
Label Replacement............................................................................................................................................. 68
This section is for the following models:
H1.6FT, H1.8FT, 2.0FTS [F001];

H2.0-3.5FT (H40-70FT) [L177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) [N005, P005];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299]
iii
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
100 SRM 1290 General
General
The overhead guard is an integral part of the opera- cab. The operator cab is a separate unit and can
tor cab. The operator cab is installed on a platform be removed as a complete unit from the module and
above the main frame members. Step plates on both frame of the lift truck. See Figure 1.
sides of the lift truck provide access to the operator
Figure 1. Operator Cab
1
Cab Replacement 100 SRM 1290
Cab Replacement
REMOVE, FOR LIFT TRUCK MODELS
H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177); AND H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005)
NOTE: The EZXchange™ bracket used on these
trucks to mount the LPG tank onto the counter-
weight come in two styles. One style of bracket
swings out to the side of the truck and the other
swings out to the side and drops down.
NOTE: Lift trucks equipped with LPG, make sure to

release the EZXchange™ bracket before opening the
hood.
1. For lift truck models H1.6FT, H1.8FT, 2.0FTS

(F001), tilt the steering column to the UP posi-
tion, slide seat assembly forward, open rear door,
and open hood to disconnect battery. See Fig-
1. LATCH 3. REAR DOOR
ure 2. 2. HINGE
2. For lift trucks models H2.0-3.5FT (H40-70FT) Figure 2. Rear Door and Latch for Lift Truck
(L177) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; Models H1.6FT, H1.8FT, 2.0FTS (F001)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005), tilt the steering column to the UP po-
sition, slide seat assembly forward, open rear
sliding window and open the hood to disconnect
battery. See Figure 3.
3. Disconnect the air filter hose from the rear left

corner leg of the cab frame. See Figure 4.
WARNING
DO NOT disconnect the heater hoses from the
engine when the engine is hot or when the cool-
ing system is under pressure, to do so could
cause serious injury.
1. REAR BOTTOM WINDOW

2. RELEASE LATCH
Figure 3. Rear Bottom Window for Lift Trucks

Models H2.0-3.5FT (H40-70FT) (L177) and
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005)
2
100 SRM 1290 Cab Replacement
NOTE: Removing the door assemblies requires two

people.
6. Open left side door, remove lock nut, and discon-

nect gas spring from the cab mounting bracket.
See Figure 7.
7. Lift left side door up and over hinge pin and set
aside. See Figure 8.
WARNING
DO NOT disconnect the heater hoses from the
quick disconnect fittings (inside operator cab)
or engine when the engine is hot or under pres-
sure, to do so could cause serious injury.
CAUTION
Disconnecting the right-hand gas spring and
fully opening the door without disconnecting
the heater hoses may cause the hoses to pull
1. CAPSCREW 2. AIR FILTER HOSE loose from the quick disconnect fittings.
Figure 4. Air Filter Hose Removal 8. Disconnect heater hose quick disconnect fittings.
a. For Lift truck models H1.6FT, H1.8FT,

WARNING 2.0FTS (F001), open right side door and
DO NOT remove the radiator cap from the ra- push the buttons on quick disconnect fit-
diator when the engine is hot. When the radia- tings to disconnect the heater hoses from the
tor is hot and the cap is removed, the pressure heater assembly hoses (see Figure 6). Dis-
is released from the system and the steam and connect the heater wire harness connection.
boiling coolant can cause burns. Wait 30 min- See Figure 9.
utes for the engine to cool. Do a touch test by
touching the radiator with your hand. If the b. For lift truck models H2.0-3.5FT (H40-70FT)
radiator is still hot to the touch, wait another (L177), open right side door and remove radi-
30 minutes before attempting to remove, check, ator cover to access the quick disconnect fit-
or fix any part of the cooling system. tings. Push the buttons on the quick discon-
nect fittings to disconnect the heater hoses
NOTE: Removing the radiator cap will help depres- from heater assembly (see Figure 6). Discon-
surize the cooling system. nect the heater wire harness connection. See
Figure 9.
4. Remove radiator cover to access radiator cap. Re-
move radiator cap. See Figure 5. c. For lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
CAUTION 100, 110, 120FT) (N005, P005), open right
side door and located on inner rear cover
Do not allow any fluid to drain when discon-
there are two port holes (see Figure 6). Push
necting the heater hose from the engine. The
the buttons on the quick disconnect fittings
method will help when purging the system dur-
to disconnect the heater hoses from heater
ing installation.
assembly and disconnect the heater wire
5. Disconnect and cap the heater hoses from engine. harness connection. See Figure 9.
See Figure 6.
3
Figure 5. Radiator Cover and Cap Location
4
Legend for Figure 5

A. H1.6FT, H1.8FT, 2.0FTS (F001)
B. H2.0-3.5FT (H40-70FT) (L177)
C. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
1. RADIATOR COVER 2. RADIATOR CAP
5
Figure 6. Heater Hose Connection
6
Legend for Figure 6
NOTE: MAJOR COMPONENTS OF THE CAB HAVE BEEN REMOVED FOR CLARITY.
A. H1.6FT, H1.8FT, 2.0FTS (F001)
B. H2.0-3.5FT (H40-70FT) (L177)
1. QUICK DISCONNECT FITTING
2. INNER REAR COVER
3. RADIATOR COVER
4. RIGHT SIDE DOOR ASSEMBLY
5. HEATER HOSES
NOTE: RIGHT SIDE DOOR SHOWN. NOTE: RIGHT SIDE DOOR HINGE SHOWN.
1. GAS SPRING 1. HINGE PIN
2. CAB MOUNTING BRACKET 2. DOOR HINGE
3. LOCK NUT
Figure 8. Door Removal
Figure 7. Gas Spring Mounting Removal
7
NOTE: Wiper motor cover must be removed before

the dash assembly can be removed.
11. For lift truck models H1.6FT, H1.8FT, 2.0FTS

(F001) and H2.0-3.5FT (H40-70FT) (L177), un-
clip and remove front wiper motor cover. See Fig-
ure 10.
12. For lift truck models H4.0FT5/FT6; H4.5FTS5,

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005), remove two lock nuts from front
wiper motor cover. Remove front wiper motor
cover. See Figure 10.
13. Remove five capscrews from top of dash assembly

and cowl panel.
14. Remove two flange bolts securing the cowl panel

to the front operator cab legs.
15. Unclip the dash assembly from kick panel. Re-

move dash assembly.
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN
REMOVED FOR CLARITY. 16. Remove kick panel from seal plate assembly. See
Figure 11.
1. HEATER WIRE HARNESS CONNECTOR
2. REAR GRAB HANDLE HORN BUTTON
CONNECTOR (TO RIGHT-HAND CHASSIS 17. Remove floor mat and floor plates.
HARNESS)
18. Remove capscrews and seal plate assembly from
Figure 9. Heater Wire Harness and Rear Grab lift truck frame.
Handle Horn Button Connectors
19. Disconnect rear grab handle horn button connec-
tor from right-hand chassis harness, located in
CAUTION right rear corner leg of the cab frame. See Fig-
Disconnecting the right-hand gas spring and ure 9.
fully opening the door without disconnecting
the heater hoses may cause the hoses to pull 20. Disconnect the light harness connector from the
loose from the quick disconnect fittings. VSM (Vehicle Systems Manager) and right-hand
chassis harness connector. See Figure 12.
9. Remove lock nut and disconnect gas spring from
cab mounting bracket. See Figure 7.
10. Lift door up and over hinge pin and set aside. See
Figure 8.
Legend for Figure 10
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.

A. H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001) AND H2.0-3.5FT (H40-70FT) (L177)
B. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
1. CAPSCREWS 5. COWL PANEL
2. FRONT WIPER MOTOR COVER 6. FRONT OPERATOR CAB LEGS
3. DASH ASSEMBLY 7. LOCK NUT
4. KICK PANEL 8. FLANGE BOLT
8
Figure 10. Dash Installation
9
Figure 11. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
10
NOTE: CAB REMOVED FOR CLARITY.

A. H1.6FT, H1.8FT, 2.0FTS (F001) AND H2.0-3.5FT (H40-70FT) (L177)
B. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
1. CAPSCREWS 5. FLOOR PLATE (LEFT SIDE)
2. KICK PANEL 6. FLOOR PLATE (RIGHT SIDE)
3. SEAL PLATE ASSEMBLY 7. FLOOR PLATE
4. SEAL
23. Connect a lifting device to a spreader bar or lift
strap, that is through the door openings at the
top of the operator’s cab (under the overhead
guard structure). Place material that will be a
cushion at the top of the door opening to prevent
damage. Operate the lifting device just enough
to correctly position the spreader bar or lifting
strap on the operator’s cab. See Figure 15.
NOTE: KICK PANEL REMOVED FOR CLARITY.

1. VSM
2. LIGHT HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT-HAND
CHASSIS HARNESS)
Figure 12. Light Harness Connection to Vehicle

System Manager (VSM)
NOTE: LEFT SIDE DOOR REMOVED FOR CLARITY.
21. Remove rear panels, front panels, and fender cov-
1. REAR PANEL (LPG) 4. FENDER COVER
ers to access the cab mounting capscrews and 2. REAR PANEL (GAS 5. SCREWS
flange nuts. See Figure 13. AND DIESEL) 6. CAPSCREWS
3. FRONT PANEL
22. Remove front and rear cab capscrews and flange
nuts from lift truck frame. See Figure 14. Figure 13. Front and Rear Panels and Fender
Cover Removal
WARNING
Make sure that the lifting device has a mini-
mum capacity to lift 500 kg (1100 lb).
11
Figure 15. Lift Strap Connection
CAUTION
Lift the operator cab carefully. Check that all
electrical wires and attachments are discon-
nected and are not damaged.
24. Carefully lift the operator cab away from the lift
truck. Set the operator cab in a storage area
and place blocks under the operator cab to make
it stable and prevent damage to parts still at-
tached.
A. FRONT VIEW B. REAR VIEW
1. CAPCREWS 2. FLANGE NUTS
Figure 14. Front and Rear Cab Mounting
12
INSTALL, FOR LIFT TRUCK MODELS 13. For lift truck models H1.6FT, H1.8FT, 2.0FTS
H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT (F001) and H2.0-3.5FT (H40-70FT) (L177), in-
(H40-70FT) (L177); AND H4.0FT5/FT6, stall and clip front wiper motor cover.
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 14. For lift truck models H4.0FT5/FT6, H4.5FTS5,
100, 110, 120FT) (N005, P005) H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005), Install front wiper motor cover and
1. Connect a lifting device to a spreader bar or lift tighten two lock nuts.
top of the operator’s cab (under the overhead 15. Install right side door onto cab by lifting door
guard structure). Place material that will be a up and over the top and bottom hinge pins. See
cushion at the top of the door opening to prevent Figure 8.
to correctly position the spreader bar or lifting 16. Connect gas spring and lock nut to cab mounting
strap on the operator’s cab. See Figure 15. bracket. See Figure 7.
2. Carefully lift the operator cab onto the lift truck 17. Connect the heater hoses to the heater assembly
frame making sure that the front and rear leg and connect the heater wire harness connection.
mounting holes are aligned with the frame See Figure 6 and Figure 9.
mounting holes.
18. Install left side door onto cab by lifting door up
3. Install the capsrews and flange nuts to the rear and over the top and bottom hinge pins. See Fig-
operator cab legs. Tighten capscrews to 66 N•m ure 8.
(49 lbf ft). See Figure 14.
19. Connect gas spring and lock nut to cab mounting
4. Install the capscrews and lock nuts to the front bracket. See Figure 7.
operator’s cab legs. Tighten capscrews to 66 N•m
20. Uncap and connect heater hoses at the engine.
(49 lbf ft).
See Figure 6.
5. Install the fender covers, front panel, and rear
21. Check coolant level, fill if necessary.
panels to the frame. See Figure 13. Tighten cap-
screws to 10.8 N•m (7.96 lbf ft). 22. Install radiator cap and radiator cover. See Fig-
ure 5.
6. Connect light harness connector to the VSM (Ve-
hicle Systems Manager) and right-hand chassis 23. Connect the air filter hose onto the rear left cor-
harness. See Figure 12. ner leg of the cab frame. Tighten capscrews to
66 N•m (49 lbf ft). See Figure 4.
7. Connect the right-hand chassis harness to rear
grab handle horn button connector. See Figure 9. 24. Connect battery and close hood.
8. Install seal plate assembly to the lift truck frame 25. Start engine and turn on the heater to the ON po-
and tighten capscrews. See Figure 11. sition, run engine approximately 1 to 2 minutes
or until heater supply hose is fully purged.
9. Install floor plate and floor mat. Tighten cap-
screws to 10.8 N•m (7.96 lbf ft). NOTE: The EZXchange™ bracket used on these
trucks to mount the LPG tank onto the counter-
10. Install kick panel onto seal plate assembly.
weight comes in two styles. One style of bracket
11. Install two flange bolts securing the cowl to the swings out to the side of the truck and the other
front operator cab legs. See Figure 10. swings out to the side and drops down.
12. Install dash assembly onto kick panel and install 26. Lift trucks equipped with a LPG engine, swing
five capscrews to secure dash assembly to cowl EZXchange™ bracket back to its original and
panel. locked position.
13
REMOVE, FOR LIFT TRUCK MODELS

H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) AND H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299)
NOTE: Removing the door assemblies from opera-
tor’s cab requires two people.
1. Open right side door and remove hair pin from

rod pin. See Figure 16.
2. Remove rod pin and spacers from link.
3. Remove right side door from cab frame by lifting

door up and over the hinge pin and set door aside.
See Figure 17.
NOTE: RIGHT SIDE DOOR HINGE SHOWN

1. HINGE PIN
2. DOOR HINGE
4. Repeat Step 1 through Step 3 for the removal of

left side door.
5. Remove front floor mat and floor plate. See Fig-

ure 18.
6. Disconnect battery.
7. Remove two screws holding the right side rear

cover to the rear overhead guard leg. See Fig-
ure 19.
NOTE: RIGHT SIDE DOOR SHOWN
1. ROD PIN 5. GAS SPRING
2. SPACERS 6. LOCK NUT
3. HAIR PIN 7. WASHER
4. DOOR ASSEMBLY 8. LINK
Figure 16. Door Link Removal
14
1. DASH ASSEMBLY 6. FLANGE BOLT

2. KICK PANEL 7. REAR FLOOR PLATE
3. SEAL PLATE ASSEMBLY 8. FRONT FLOOR PLATE
4. FRONT FLOOR MAT 9. MODULE
5. REAR FLOOR MAT
Figure 18. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
15
NOTE: RIGHT SIDE VIEW SHOWN.

1. RIGHT SIDE REAR 4. REAR FLOOR
COVER PLATE
2. RIGHT SIDE 5. FRONT FLOOR
FRONT COVER PLATE 1. CAPSCREWS 6. FRONT
3. SCREWS 6. CLIP NUTS 2. FRONT WIPER OPERATORS CAB
MOTOR COVER LEGS
Figure 19. Side Cover Removal 3. DASH ASSEMBLY 7. LOCK NUT
8. Remove two screws holding the right side front 5. COWL PANEL
cover to frame. Remove right side rear cover.
Figure 20. Dash Removal, Early Model H6.0FT,
9. Remove two screws securing the right side front H7.0FT (H135FT, H155FT) (H006, J006) Lift
cover to the front overhead guard leg. Remove Trucks
right side front cover.
12. On later model H6.0FT, H7.0FT (H135FT,
10. Repeat Step 7 through Step 9 to remove the left H155FT) (H006, J006) and on H8.0FT, H8.0FT9,
side covers. H9.0FT (H170FT, H175FT36, H190FT) (A299)
lift truck models, remove three lock nuts from
11. On early model H6.0FT, H7.0FT (H135FT, front wiper motor cover. Remove front wiper
H155FT) (H006, J006) lift trucks, remove two motor cover. See Figure 21.
lock nuts from front wiper motor cover. Remove
front wiper motor cover. See Figure 20.
16
1. CAPSCREWS 5. COWL PANEL

2. FRONT WIPER MOTOR COVER 6. FRONT OPERATORS CAB LEGS
3. DASH ASSEMBLY 7. LOCK NUT
Figure 21. Dash Removal, Later Model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift Trucks
and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299) Lift Truck Models
13. Remove five capscrews from top of dash assembly 16. Remove two flange bolts securing cowl panel to
and cowl panel. front operator cab legs. See Figure 20 or Fig-
ure 21.
14. Unclip the dash assembly from kick panel. Re-
move dash assembly. 17. Disconnect three harness connectors from right
side front operator cab leg that are connected to
15. Remove kick panel from seal plate assembly. See the Vehicle Systems Manager (VSM) and right
Figure 18. hand chassis harness connectors. See Figure 22.
17
WARNING
Make sure that the lifting device has a mini-
mum capacity to lift 500 kg (1100 lb).

top of the operator’s cab (under the overhead
guard structure). Place material that will be a
cushion at the top of the door opening to prevent
to correctly position the spreader bar or lifting
NOTE: KICK PANEL REMOVED FOR CLARITY.

1. VSM
2. HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT HAND
CHASSIS HARNESS)
Figure 22. Light Harness Connection to Vehicle

System Manager (VSM)
18. Remove four flange bolts securing right and left

side of the front operator cab legs to module. See
Figure 23.
19. From inside the cab, remove the six flange bolts
securing right and left side rear operator cab legs
to module.
20. Open right side hood door and remove both wiper
motor washer tubes from t-fitting and disconnect
washer pump harness connector from washer
fluid reservoir.
21. Disconnect rear grab handle horn button connec-

tor from right hand chassis harness.
22. Remove the bottom flange bolt securing right

side rear operator cab leg to module.
23. Open left side hood door and remove the bottom
flange bolt securing rear left side operator cab leg
to module.
Figure 23. Front and Rear Cab Mounting
18
Legend for Figure 23 25. Carefully lift the operator cab up and away from
the lift truck. Set the operator cab in a storage
NOTE: RIGHT SIDE SHOWN. WIPER COVER AND area and place blocks under the operator cab to
ASSEMBLY FOR EARLY MODEL H6.0FT, H7.0FT make it stable and prevent damage to the wire
(H135FT, H155FT) (H006, J006) LIFT TRUCKS harness and parts still attached.
SHOWN. THE FRONT AND REAR CAB MOUNTING
IS THE SAME FOR LATER MODEL H6.0FT, H7.0FT INSTALL, FOR LIFT TRUCK MODELS
(H135FT, H155FT) (H006, J006) LIFT TRUCKS AND H6.0FT, H7.0FT (H135FT, H155FT) (H006,
ON H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299) LIFT TRUCK MODELS. J006) AND H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299)
A. REAR VIEW B. FRONT VIEW
1. FLANGE BOLTS strap, that is through the door openings at the
2. REAR OPERATOR CAB LEG
3. REAR LIGHT HARNESS top of the operator’s cab (under the overhead
4. WASHER PUMP HARNESS CONNECTOR guard structure). Place material that will be a
5. WASHER FLUID RESERVOIR cushion at the top of the door opening to prevent
6. MODULE damage. Operate the lifting device just enough
7. COWL PANEL to correctly position the spreader bar or lifting
2. Carefully lift the operator cab onto the lift truck

frame making sure that the front and rear leg
mounting holes are aligned with the module
mounting holes.
3. Open left side hood door and install the bottom

flange bolt to secure rear left side operator cab
leg to module. Tighten flange bolt to 165 N•m
(122 lbf ft). See Figure 23.
4. Open right side hood door and install bottom

flange bolt to secure rear right side operator cab
leg to module. Tighten flange bolt to 165 N•m
(122 lbf ft).
5. Connect rear grab handle horn button harness

connector to right hand chassis harness.
6. Connect both wiper motor washer tubes to t-fit-

ting and connect washer pump harness connector
to washer fluid reservoir.
7. Install two flange bolts to secure right and left

side front operator cab legs to module. Tighten
flange bolt to 165 N•m (122 lbf ft).
8. From inside the cab, install the four remaining

flange bolts to right and left side rear opera-
tor cab legs to module. Tighten flange bolt to
Figure 24. Lift Strap Connection 165 N•m (122 lbf ft).
9. Connect the three harness connectors on the

CAUTION front right side operator cab leg to Vehicle Sys-
Lift the operator cab carefully. Check that all tem Manager (VSM) and right hand chassis
electrical wires and attachments are discon- harness. See Figure 22.
nected correctly and are not damaged.
19
Door Assemblies 100 SRM 1290
10. Install two flange bolts to secure cowl panel to 17. Install right side rear cover to right side front
front operator cab legs. See Figure 20 or Fig- cover and install and tighten two screws to
ure 21. frame.
11. Install kick panel to seal plate assembly. See Fig- 18. Align right side rear cover to rear overhead guard
ure 18. leg and install and tighten two screws to rear
overhead guard leg and install and tighten two
12. Install and clip dash assembly onto kick panel. screws to rear overhead guard leg.
See Figure 20.
19. Repeat Step 16 through Step 18 to install left side
13. Install five capscrews to top of dash assembly covers.
to secure dash assembly onto the cowl panel.
Tighten capscrew to 3.5 N•m (30 lbf in). 20. Connect battery.
14. On early model H6.0FT, H7.0FT (H135FT, 21. Install front floor plate and floor mat. See Fig-
H155FT) (H006, J006) lift trucks, install front ure 18.
wiper motor cover using two lock nuts. See
Figure 20. NOTE: Installing the door assemblies onto operator
cab requires two people.
15. On later model H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) lift trucks, and on 22. Lift door up and over the top and bottom hinge
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, pins. See Figure 17.
H190FT) (A299) lift truck models, install front
23. Align link and spacers into guide and install rod
wiper motor cover using three lock nuts. See
pin. See Figure 16.
Figure 21.
24. Install hair pin into rod pin.
16. Install right side front cover to front overhead
guard leg using two screws. See Figure 19. 25. Repeat steps Step 22 through Step 24 for instal-
lation of left side door.
Door Assemblies
RIGHT SIDE DOOR ASSEMBLY, LIFT cooling system. If cooling system is hot, the
TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS steam and boiling coolant can cause burns.
(F001); H2.0-3.5FT (H40-70FT) (L177); Wait 30 minutes for the engine to cool. Do a
AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, touch test by touching the radiator with your
H5.0-5.5FT (H80, 90, 100, 110, 120FT) hand. If the radiator is still hot to the touch,
(N005, P005) wait another 30 minutes before attempting to
remove the radiator cap.
Remove
NOTE: Removing the radiator cap will help depres-
surize the cooling system.
WARNING
DO NOT remove the radiator cap from the ra- 1. Remove radiator cover to access radiator cap. Re-
diator when the engine is hot. When radiator move radiator cap. See Figure 25.
cap is removed, the pressure is released from

A. H1.6FT, H1.8FT, 2.0FTS (F001)
B. H2.0-3.5FT (H40-70FT) (L177)
1. RADIATOR COVER 2. RADIATOR CAP
20
100 SRM 1290 Door Assemblies
Figure 25. Radiator Cover and Cap Location
21
b. For lift truck models H2.0-3.5FT (H40-70FT)

WARNING (L177), open right side door and remove radi-
DO NOT disconnect the heater hoses from the ator cover to access the quick disconnect fit-
quick disconnect fittings (inside operator cab) tings. Push the buttons on the quick discon-
or engine when the engine is hot or under pres- nect fittings to disconnect the heater hoses
sure. Serious injury can occur. from the heater assembly hoses. See Fig-
ure 26. Disconnect the heater wire harness
CAUTION connection. See Figure 27.
Disconnecting the right-hand gas spring and c. For lift truck models H4.0FT5/FT6,
fully opening the door without disconnecting H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
the heater hoses may cause the hoses to pull 100, 110, 120FT) (N005, P005), open right
loose from the quick disconnect fittings. side door and locate the two port holes on
inner rear cover. Push the buttons on the
NOTE: Removing the right side door assembly re-
quick disconnect fittings to disconnect the
quires two people.
heater hoses from heater assembly. See Fig-
2. Disconnect heater hose quick disconnect fittings. ure 26. Disconnect the heater wire harness
See Figure 26. connection. See Figure 27.
a. For Lift truck models H1.6FT, H1.8FT,

CAUTION
2.0FTS (F001), open right side door and
push the buttons on quick disconnect fit- Disconnecting the right-hand gas spring and
tings to disconnect the heater hoses from the fully opening the door without disconnecting
heater assembly hoses. See Figure 26. Dis- the heater hoses may cause the hoses to pull
connect the heater wire harness connection. loose from the quick disconnect fittings.
See Figure 27.
3. Disconnect the gas spring. See Figure 28.
4. Remove right side door from cab frame by lifting

door up and over hinge pin. See Figure 29.
NOTE: MAJOR COMPONENTS OF THE CAB HAVE BEEN REMOVED FOR CLARITY.
A. H1.6FT, H1.8FT, 2.0FTS (F001)
B. H2.0-3.5FT (H40-70FT) (L177)
1. QUICK DISCONNECT FITTING 4. RIGHT SIDE DOOR ASSEMBLY
2. INNER REAR COVER 5. HEATER HOSES
3. RADIATOR COVER
22
Figure 26. Heater Hose Connection
23
NOTE: RIGHT SIDE DOOR SHOWN.

1. GAS SPRING
2. MOUNTING BRACKET
3. LOCK NUT
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN

REMOVED FOR CLARITY.
1. HEATER WIRE HARNESS CONNECTOR
2. REAR GRAB HANDLE HORN BUTTON
CONNECTOR (TO RIGHT-HAND CHASSIS
HARNESS)
Figure 27. Heater Wire Harness and Rear Grab

NOTE: RIGHT SIDE DOOR HINGE SHOWN.
Handle Horn Button Connectors
1. HINGE PIN
2. DOOR HINGE
Disassemble
Door Cover
1. Remove the four screws and washers that attach

the handle to the door cover. Remove the handle
and two handle plates. See Figure 30.
2. Remove the fan and heater knobs from knob

plate. Remove four screws that fasten the knob
plate to heater valve and switch plate. Remove
knob plate from door cover.
3. Remove the two fasteners from top of door cover.
4. Remove the five plugs along the sides and front

of the door cover. Remove the two capscrews and
washers from the bottom of door cover. Remove
Figure 28. Gas Spring Mounting Installation door cover from door frame.
24
Figure 30. Right Side Door Cover Removal
25

1. PLUG 9. WASHER
2. FASTENER 10. HEATER/FAN LOUVER
3. GAS SPRING 11. CAPSCREW
4. FAN AND HEATER KNOBS 12. DOOR COVER
5. SCREW 13. PRE-FILTER
6. KNOB PLATE 14. HEATER VALVE AND SWITCH PLATE
7. HANDLE 15. STAR NUT
8. HANDLE PLATES
5. Remove the prefilter, located on the bottom of 3. Remove two screws from heater valve and switch
door frame. plate and remove plate.
Heater Assembly 4. Disconnect supply hose at heater valve and dis-

connect return hose from the heater coil.
NOTE: The heater assembly is non-repairable, re-
place as a complete unit. 5. Remove two nuts and washers from heater as-
sembly bracket. Remove heater assembly and
1. Remove lock nut from heater valve and switch bracket from door frame.
plate. See Figure 31.
2. Disconnect heater switch connector from heater

switch.
1. LOCK NUT 7. HEATER VALVE AND SWITCH PLATE

2. NUT 8. HEATER VALVE
3. WASHER 9. HEATER SWITCH
4. HEATER ASSEMBLY BRACKET 10. RETURN HOSE
5. SUPPLY HOSE 11. SCREWS
6. HEATER ASSEMBLY 12. HEATER COIL
Figure 31. Heater Assembly Removal
26
Door Lock Assembly 5. Remove two nuts and capscrews from door lock
assembly. Remove door lock assembly from door
1. Remove inside lever handle cover. See Figure 32. frame.
2. Place the inside lever handle in the closed posi- 6. Remove the screw and washer from the release
tion. Remove the lock nut from the release bar at lever and release lever from outside door handle
the inside lever handle. Pull inside lever handle assembly. See Figure 32 and Figure 33.
to open position. Remove release bar from inside
lever handle. 7. Remove four capscrews that fasten the outside
door handle to door. Remove outside door handle
3. Remove two capscrews and inside lever handle from door.
and mounting plate.
8. Remove seal and grip from outside handle assem-
4. Remove lock nut from release bar and release bar bly. Discard seal. See Figure 33.
from door lock assembly.
A. LEVER IN CLOSED POSITION B. LEVER IN OPEN POSITION

1. INSIDE LEVER HANDLE 7. DOOR LOCK ASSEMBLY
2. CAPSCREWS 8. RELEASE LEVER
3. INSIDE LEVER HANDLE COVER 9. NUT
4. CAPSCREW (OUTSIDE HANDLE) 10. MOUNTING PLATE
5. LOCK NUT 11. SCREWS
6. RELEASE BAR 12. WASHER
Figure 32. Door Lock and Lever Disassembly
27
is no rust, grease, oil, or dirt on door lock and latch

assembly parts. Inspect windows for cracks or chips.
Replace windows if damaged.
Assemble
Windows
For procedures to remove and install door windows,

see the section Window Replacement.
Door Lock Assembly
1. Install new seal and grip to outside handle as-

sembly. See Figure 33.
2. Apply Loctite® 242 to the threads of the four cap-

screws and secure outside door handle to door
(see Figure 32). Tighten capscrews to 19.2 N•m
(170 lbf in).
3. Apply Loctite® 242 to capscrew and install re-

1. LATCH STRIKER ASSEMBLY lease lever to rear of outside door handle assem-
2. SEAL bly. Tighten capscrew to 5.0 N•m (44 lbf in).
3. OUTSIDE HANDLE ASSEMBLY
4. GRIP 4. Install door lock assembly onto door frame using
two capscrews and nuts. Tighten capscrews to
Figure 33. Outside Handle Disassembly 19.2 N•m (170 lbf in).
Windows 5. Install inside lever handle and mounting plate
For procedures to remove and install door windows, to door frame. Tighten capscrews to 19.2 N•m
see the section Window Replacement. (170 lbf in).
6. Place the inside lever handle in the closed posi-

Clean tion (see Figure 32). Insert release bar into door
lock assembly end and into the inside lever han-
WARNING dle. Secure release bar with lock nuts.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 7. Install cover onto inside lever assembly.
Make sure that the path of the compressed air
Heater Assembly
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the 1. Secure heater assembly to door frame with
eyes. mounting bracket. Insert washers and two lock
nuts onto mounting bracket, and tighten to
Check door assembly and parts for oil, grease, dirt,
19.2 N•m (170 lbf in). See Figure 31.
and other debris. Clean door assembly and parts
with a clean cloth, soap, and water. Compressed air 2. Connect supply and return hoses to heater valve.
can be used to dry door assembly and parts.
3. Install heater valve and switch plate using two
Inspect screws.
Inspect all hoses for cracks and wear. Replace dam- 4. Connect heater switch connector to heater
aged hoses. Inspect the seals around door window switch.
and door lock assembly and replace if damaged.
Check the door lock and latch assembly. Make sure 5. Secure heater valve and switch plate with lock
it opens, shuts, and locks door securely and there nut.
28
Door Cover 1. Open left side door and disconnect the gas spring.
See Figure 28.
1. Install the pre-filter on the bottom of door frame.
See Figure 30. 2. Remove left side door from cab frame by lifting
door over hinge pin. See Figure 29.
2. Align holes on door cover with holes that are on
door frame. Install the five plugs into holes that Disassemble
are along the sides and front of door cover. Secure
the bottom of door cover using two capscrews and Door Cover
washers.
1. Remove cover from rear of handle and remove
3. Install two fasteners into holes on top of door screw. Remove capscrew from door lock cover
cover. See Figure 30. and remove door lock cover from lock assembly.
See Figure 34.
4. Install the knob plate on heater valve and switch
plate with four screws. Install the fan and heater 2. Remove two capscrews that secure handle to door
knobs on knob plate. lock assembly. Remove handle from door.
5. Install handle and handle plates on door with 3. Remove two fasteners from top of door cover. Re-
four screws and washers. move five plugs along the edges of door cover and
remove door cover from door frame.
Install
Door Lock Assembly
1. Install right side door onto cab by lifting door
over the top and bottom hinge pins. See Fig- 1. Remove capscrew and washer from release lever.
ure 29. Remove release lever from door. See Figure 35.
2. Connect gas spring and lock nut to mounting 2. Remove four capscrews and two washers (right
bracket on operator cab frame. See Figure 28. side only) from rear of outside handle. Remove
outside door handle from door.
3. Connect the heater hoses to the heater assembly
and connect the heater wire harness connection. 3. Remove the grip and seal from outside handle.
See Figure 26 and Figure 27. Discard seal. See Figure 33.
4. Install radiator cover. See Figure 25. Windows

LEFT SIDE DOOR ASSEMBLY, LIFT
TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS
(F001); H2.0-3.5FT (H40-70FT) (L177);
AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
Remove
NOTE: Removing the left side door assembly requires
two people.
29
1. FASTENER 5. CAPSCREW
2. PLUG 6. DOOR LOCK COVER
3. COVER 7. HANDLE
4. SCREW 8. DOOR LOCK ASSEMBLY
Figure 34. Left Side Door Cover Removal

1. CAPSCREW
2. WASHER
3. RELEASE LEVER
Clean
WARNING
cause injury to the user or to other personnel.
goggles or a face shield to prevent injury to the
eyes.
Check door assembly and parts for oil, grease, dirt,

and other debris. Clean door assembly and parts
with a clean cloth and soap and water. Compressed
air can be used for drying door assembly and parts.
Figure 35. Release Lever Removal
30
Inspect RIGHT AND LEFT SIDE DOOR

ASSEMBLIES, LIFT TRUCK MODELS
Inspect the seals around the window, door, and door
lock assembly and replace if damaged. Check the H6.0FT, H7.0FT (H135FT, H155FT) (H006,
door lock and latch assembly. Make sure it opens, J006) AND H8.0FT, H8.0FT9, H9.0FT
shuts, and locks door securely and there is no rust, (H170FT, H175FT36, H190FT) (A299)
grease, oil, or dirt on door lock and latch assembly
parts. Inspect window for cracks or chips. Replace NOTE: On lift truck models H6.0FT, H7.0FT
window if damaged. (H135FT, H155FT) (H006, J006) and H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
Assemble (A299), the right and left doors are identical and are
repaired and serviced in the same manner.
Windows
Remove
see the section Window Replacement. NOTE: Removing the door assemblies from the oper-
ator’s cab requires two people.
Door Lock Assembly
1. Open right side door and remove hair pin from
1. Install seal and grip (see Figure 33) onto outside rod pin. See Figure 36.
door handle. Place outside door handle onto door
frame. Apply Loctite® 242 to threads of four cap- 2. Remove rod pin and spacers from link.
screws and secure outside handle to door frame
using capscrews and washers. The washers go on 3. Remove right side door from cab frame by lifting
right side from inside the cab. Tighten capscrews door up and over the hinge pin. See Figure 29.
to 19.2 N•m (170 lbf in).
2. Apply Loctite® 242 to capscrew and install

release lever to rear of outside door handle.
Tighten capscrew and washer to 5.0 N•m
(44 lbf in). See Figure 35.
Door Cover
1. Place door cover onto door frame. Install two fas-

teners onto top of door cover and install five plugs
along edges of door cover. See Figure 34.
2. Install handle to latch assembly with two

capscrews. Tighten capscrews to 19.2 N•m
(170 lbf in). Secure lock cover to door lock as-
sembly with capscrew.
3. Secure handle to rear of door cover with screw.

Tighten screw to 5.0 N•m (44 lbf in). Push cover
into place over screw.
Install
NOTE: RIGHT SIDE DOOR SHOWN
1. Install left side door onto cab by lifting door over
1. ROD PIN 5. GAS SPRING
the top and bottom hinge pins. See Figure 29. 2. SPACERS 6. LOCK NUT
3. HAIR PIN 7. WASHER
2. Connect gas spring to mounting bracket on oper- 4. DOOR ASSEMBLY 8. LINK
ator cab frame. See Figure 7.
Figure 36. Door Link Removal
31
4. To remove the left door, repeat Step 1 through Door Lock Assembly
Step 3.
1. Remove capscrew and washer from release lever.
Disassemble Remove release lever from rear of outside door
handle. See Figure 38.
Door Cover
2. Remove four screws from rear of outside door
1. Remove cover from rear of handle and remove handle. Remove outside door handle from door.
screw. Remove capscrew from door lock cover
and remove cover from lock assembly. Remove 3. Remove the grip and seal from outside door han-
two capscrews and washers that secure handle dle. See Figure 39.
to door lock assembly. Remove handle and door
Windows
lock assembly from door frame. See Figure 37.
2. Remove the five plugs that secure door cover to
door frame and remove cover from frame.

1. COVER 5. DOOR LOCK
2. SCREW 6. WASHER
3. CAPSCREW 7. HANDLE
4. LOCK COVER 8. PLUG
Figure 37. Door Cover Removal
32

1. SCREW 3. RELEASE LEVER
2. WASHER 4. CAPSCREW
Figure 38. Release Lever Removal
33

1. LATCH STRIKER ASSEMBLY 3. OUTSIDE DOOR HANDLE
2. SEAL 4. GRIP
Figure 39. Outside Handle Removal
Clean parts. Inspect window for cracks or chips. Replace

window if damaged.
WARNING
Assemble
cause injury to the user or to other personnel. Windows
is away from all personnel. Wear protective For procedures to remove and install door windows,
goggles or a face shield to prevent injury to the see the section Window Replacement.
eyes.
Door Lock Assembly
Check door assembly parts for oil, grease, dirt, and
other debris. Clean door assembly and parts with a 1. Install grip and seal to outside door handle as-
clean cloth, soap, and water. Compressed air can be sembly. See Figure 39.
used for drying door assembly and parts.
2. Apply Loctite® 242 to threads of four screws.
Use screws to install outside door handle to door
Inspect
frame. Tighten screws to 19.2 N•m (170 lbf in).
Inspect the seals around the window, door, and door See Figure 38.
lock assembly and replace if damaged. Check the
3. Apply Loctite® 242 to threads of capscrew for re-
door lock and latch assembly. Make sure it opens,
lease lever and install release lever to rear of out-
shuts, and locks door securely and there is no rust,
side door handle assembly. Tighten capscrew to
grease, oil, or dirt on door lock and latch assembly
5.0 N•m (44 lbf in).
34
100 SRM 1290 Window Wipers Replacement
Door Cover Install

1. Place door cover onto door frame. Install two fas- NOTE: The installation procedures outlined below
teners onto top of door cover. Install five plugs apply to both the left and right side doors.
along edges of door cover. See Figure 37.
1. Lift door over the top and bottom hinge. See Fig-
2. Install handle to lock assembly with two cap- ure 29.
screws and washers. Tighten capscrews to
19.2 N•m (170 lbf in). Install lock cover to lock 2. Align link and spacers into guide and install rod
assembly with capscrew. See Figure 37. pin. See Figure 36.
3. Secure handle to rear of door cover with screw. 3. Install hair pin into rod pin.
Tighten screw to 5.0 N•m (44 lbf in). Push cover
into place over screw.
Window Wipers Replacement

GENERAL that pass through two holes in window. Remove
wiper motor from front window.
Two window wiper motor assemblies are installed in
the operator cab. The front window motor assembly Install, Lift Truck Models H1.6FT, H1.8FT,
has two wiper arms connected to a single wiper blade. 2.0FTS (F001) and H2.0-3.5FT (H40-70FT)
The rear window has a wiper motor assembly that
has one wiper arm attached to a single wiper blade. (L177)
1. Install wiper motor to front window using one
FRONT WIPER ASSEMBLY AND MOTOR flange nut (right side) and two grommets onto
threaded shafts on wiper motor. Insert shafts
Remove, Lift Truck Models H1.6FT, H1.8FT, through two holes in the front window. See Fig-
2.0FTS (F001) and H2.0-3.5FT (H40-70FT) ure 40.
(L177)
2. Install cap and jam nut.
1. Remove wiper motor cover from wiper motor. See
Figure 40. NOTE: Inspect the wiper blade. If it is cracked, split,
or worn, replace with new blade before installing
2. Disconnect cab harness connector from wiper mo- wiper arms onto front window.
tor.
3. Install the wiper arms and blade to front window
3. Open hardware covers at base of wiper arms and using two lock nuts and lockwashers Close hard-
remove the two lock nuts and lockwashers from ware covers at base of wiper arms.
wiper arms. Remove wiper arms and blade from
wiper motor. 4. Connect the cab harness connector to wiper mo-
tor.
4. Remove cap and jam nut.
5. Install wiper motor cover to wiper motor.
5. Remove one flange nut (right side) and two grom-
mets from the threaded shafts on wiper motor
35
Window Wipers Replacement 100 SRM 1290
1. FRONT WINDOW 6. WIPER HOSE 11. WIPER MOTOR COVER

2. WIPER BLADE 7. JAM NUT 12. CAB HARNESS CONNECTOR
3. WIPER ARM 8. CAP (WIPER MOTOR)
4. LOCKWASHER 9. FLANGE NUT 13. WIPER MOTOR
5. LOCK NUT 10. GROMMET 14. HARDWARE COVERS
Figure 40. Front Wiper and Motor Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and
H2.0-3.5FT (H40-70FT) (L177)
36
Remove, Lift Truck Models H4.0FT5/FT6, Install, Lift Truck Models H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005), H6.0FT, 100, 110, 120FT) (N005, P005), H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006), H7.0FT (H135FT, H155FT) (H006, J006),
and H8.0FT, H8.0FT9, H9.0FT (H170FT, and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299) H175FT36, H190FT) (A299)
1. Open hardware covers at base of wiper arms and 1. Install wiper motor to wiper motor bracket using
remove two nuts and external tooth lockwashers three capscrews and external tooth lockwashers.
from wiper arms. See Figure 41 and Figure 42. See Figure 41 and Figure 42.
2. Remove wiper blade and wiper arm from wiper 2. Install wiper motor and bracket into wiper motor
motor threaded shafts. housing.
3. Remove the two hardware covers, nuts, washers, 3. Connect wiper motor harness to cab harness.
and lockwashers from two threaded shafts that
pass through two holes in the wiper motor hous- 4. On lift truck models H4.0FT5/FT6, H4.5FTS5,
ing. Remove wiper arms from front window. H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) and early model H6.0FT, H7.0FT
4. On lift trucks H4.0FT5/FT6, H4.5FTS5, (H135FT, H155FT) (H006, J006) lift trucks, at-
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) tach front wiper motor cover to wiper motor hous-
(N005, P005) and early model H6.0FT, H7.0FT ing with two lock nuts. See Figure 41.
(H135FT, H155FT) (H006, J006) lift trucks, re-
move the two lock nuts that secure front wiper 5. On later model H6.0FT, H7.0FT (H135FT,
motor cover to wiper motor housing. Remove H155FT) (H006, J006) lift trucks and on
cover. See Figure 41 H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299) lift trucks, attach front wiper
5. On later model H6.0FT, H7.0FT (H135FT, motor cover to wiper motor housing with three
H155FT) (H006, J006) lift trucks, and H8.0FT, lock nuts. See Figure 42.
H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299) lift truck models, remove the 6. Install two washers, nuts, and hardware covers
three lock nuts that secure front wiper motor onto threaded shafts.
cover to wiper motor housing. Remove cover.
NOTE: Inspect the wiper blade. If it is cracked, split,
See Figure 42.
or worn, replace with new blade before installing
6. Disconnect cab harness from wiper motor har- wiper arms onto front window.
ness.
7. Install wiper arms onto wiper motor threaded
7. Remove wiper motor and bracket from wiper mo- shafts, using two external tooth lockwashers
tor housing. and nuts. Close hardware cover at base of wiper
arms.
8. Remove three capscrews and external tooth lock-
washers and remove wiper motor from wiper mo-
tor bracket assembly. See Figure 41 and Fig-
ure 42.
37
Figure 41. Front Wiper and Motor Remove, H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005, P005) Lift Trucks and Early Model H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) Lift Trucks
38

A. OUTSIDE OF CAB B. INSIDE OF CAB
1. WIPER BLADE 9. FRONT WIPER MOTOR COVER
2. WIPER ARM 10. WIPER MOTOR
3. LOCKWASHERS 11. WIPER MOTOR BRACKET ASSEMBLY
4. WASHERS 12. CAPSCREWS
5. NUTS 13. THREADED SHAFTS
6. HARDWARE COVER 14. WIPER MOTOR HOUSING
7. EXTERNAL TOOTH LOCKWASHER 15. CAB HARNESS
8. LOCK NUTS
39
Figure 42. Front Wiper and Motor Remove, Later Model H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) Lift Trucks and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299) Lift Truck
Models
40

A. OUTSIDE OF CAB B. INSIDE OF CAB
1. WIPER BLADE 9. THREADED SHAFTS
2. WIPER ARM 10. WIPER MOTOR BRACKET ASSEMBLY
3. LOCKWASHER 11. WIPER MOTOR
4. WASHER 12. FRONT WIPER MOTOR COVER
5. NUTS 13. LOCKNUTS
6. HARDWARE COVER 14. CAPSCREW AND EXTERNAL TOOTH
7. EXTERNAL TOOTH LOCKWASHER LOCKWASHER
8. WIPER MOTOR HOUSING
REAR WIPER ASSEMBLY AND MOTOR pass through the window from the back side. Re-
move wiper motor from rear window.
Remove, Lift Truck Models H1.6FT, H1.8FT,
2.0FTS (F001) Install, Lift Truck Models H1.6FT, H1.8FT,
2.0FTS (F001)
1. To replace the rear wiper motor assembly, open
hardware covers at base of wiper arms and re- 1. Insert wiper motor mounting studs through holes
move the nut and lockwasher from wiper arm. in window. Place motor on mounting studs and
Remove the wiper arm and blade. See Figure 43. secure motor to mounting studs with two wash-
ers and nuts. See Figure 43.
2. Remove the hardware cover, nut, retainer,
washer, and grommet from the threaded shaft 2. Install washer reservoir onto reservoir mounting
that passes through the window of the operator bracket and connect the wiring harness connec-
cab. tor and the water tube.
3. Remove the wiper motor cover by pulling back- 3. Install the wiper motor cover. The cover snaps
ward. The cover is held in place by plastic tabs into place with plastic tabs.
on the inside of the cover.
4. Install the grommet, washer, retainer, nut, and
4. Disconnect the wiring harness connector and re- hardware cover on threaded shaft that passes
move the water tube. Remove washer reservoir through the window of the operator cab.
from reservoir mounting bracket.
NOTE: Inspect the wiper blade. If it is worn or
NOTE: The left mounting stud is also the spray noz- cracked, replace with new wiper blade.
zle for the window washer. See Figure 43.
5. Attach wiper arm to threaded shaft with lock-
5. From inside the cab, remove the nuts and wash- washer and nut. Install wiper blade onto wiper
ers from the wiper motor mounting studs that arm.
41
1. REAR WINDOW 10. WASHER 17. WATER TUBE

2. GROMMET 11. NUT 18. WIRE HARNESS CONNECTOR
3. WASHER 12. WIPER ARM 19. WIPER MOTOR COVER
4. MOUNTING STUD 13. WIPER BLADE 20. NUT
5. GROMMET 14. SPRAY NOZZLE MOUNTING 21. WASHER
6. WASHER STUD 22. WIPER MOTOR
7. RETAINER 15. WASHER RESERVOIR 23. THREADED SHAFT
8. NUT 16. RESERVOIR MOUNTING
9. HARDWARE COVER BRACKET
Figure 43. Rear Wiper and Reservoir Bottle Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS
(F001)
42
Remove, Lift Truck Models H2.0-3.5FT Install, Lift Truck Models H2.0-3.5FT
(H40-70FT) (L177) (H40-70FT) (L177)
1. Disconnect the washer tube connector. See Fig- 1. Place wiper motor mount stud through hole. In-
ure 44. stall rear wiper motor to lift truck using motor
mount grommet, flange nut, and cover. See Fig-
2. Open hardware cover at base of wiper arm and ure 44.
remove the nut and washer from the wiper arm.
Remove wiper arm and blade from window. Re- 2. Install reservoir onto mounting bracket with
move wiper blade from wiper arm. washer and nut. See Figure 45.
3. Remove the cap, nut, and wiper arm grommet 3. Connect the washer pump connectors to cab wire
from wiper motor shaft. harness.
4. Disconnect the wiper motor connector from cab 4. Insert washer tube through hole and secure tube
wire harness. See Figure 45. to window with nut and washer.
5. Remove the cover, flange nut, and motor mount 5. Connect the rear wiper motor connector to cab
grommet from the motor mount stud. See Fig- wire harness.
ure 44
6. Install the wiper arm grommet, nut, and cap onto
6. Disconnect the rear wiper motor connector, and rear wiper motor shaft.
remove rear wiper motor from the window. See
Figure 44 NOTE: Inspect wiper blade for cracks and wear. Re-
place with new blade if old blade is worn or damaged.
7. Remove the nut and washer and remove washer
tube from hole. See Figure 45. 7. Install wiper blade onto wiper arm. Install wiper
blade and arm to window using nut and washer.
8. Disconnect the washer pump connectors from cab See Figure 44. Close hardware cover.
wire harness
8. Connect the washer tube to wiper arm.
9. Remove the nut and washer from mounting
bracket and remove washer reservoir from
mounting bracket.
43
1. WIPER BLADE 8. NUT

2. WIPER ARM 9. HARDWARE COVER
3. WASHER TUBE 10. WIPER ARM GROMMET
4. WASHER TUBE CONNECTOR 11. FLANGE NUT
5. NUT 12. MOTOR MOUNT GROMMET
6. WASHER 13. MOTOR MOUNT STUD
7. CAP 14. WIPER MOTOR SHAFT
Figure 44. Rear Wiper Removal, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)
44
1. WASHER TUBE 6. WIPER MOTOR CONNECTOR

2. NUT 7. REAR WIPER MOTOR
3. WASHER 8. CAB WIRE HARNESS
4. WASHER RESERVOIR 9. MOUNTING BRACKET
5. WASHER PUMP CONNECTORS
Figure 45. Washer Bottle and Wiper Motor Removal
45
Remove, Lift Truck Models H4.0FT5/FT6, Install, Lift Truck Models H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005) 100, 110, 120FT) (N005, P005)
1. Disconnect the washer tube connector. See Fig- 1. From inside of cab, install the washer reservoir
ure 46. and mounting bracket using four capscrews,
nuts, and washers. See Figure 46
2. Lift up hardware cover at base of wiper arm and
remove the nut and washer from the wiper arm. 2. Connect the washer reservoir pump connectors
Remove wiper arm and blade from rear window. and washer fluid hose. Install radiator cover. See
Remove wiper blade from wiper arm. See Fig- Figure 5.
ure 44.
3. Place wiper motor onto wiper motor mount and
3. Remove the cap, nut, and wiper arm grommet secure using nut and washer. Connect the wiper
from wiper motor shaft. motor to the cab harness.
4. Open both doors of cab. From inside of cab, re- 4. Install the inner cover using five screws.
move the five screws from inner cover and re-
move inner cover from cab. 5. Install the cap, nut, and wiper arm grommet onto
threaded wiper motor shaft that passes through
5. Disconnect the wiper motor from cab harness the window of the operator’s cab.
from inside the cab. From the outside of cab, re-
move nut and washer from wiper motor mount. NOTE: Inspect wiper blade for cracks and wear. Re-
Remove wiper motor from cab. place with new blade if old blade is worn or damaged.
6. Remove radiator cover (see Figure 5) and discon- 6. Install wiper blade to wiper arm. Install wiper
nect the washer reservoir pump connectors and arm and blade to window using nut and washer.
disconnect the washer fluid hose. Close hardware cover at base of wiper arm.
7. From inside the cab, remove four capscrews, 7. Connect the washer tube connector.
nuts, and washers from washer reservoir mount-
ing bracket. Remove washer reservoir and
mounting bracket from lift truck.

A. INNER REAR COVER C. WIPER ARM
B. WASHER RESERVOIR AND PUMP
1. SCREWS 9. WASHER RESERVOIR PUMP CONNECTOR
2. INNER REAR COVER 10. WASHER RESERVOIR PUMP
3. WASHER RESERVOIR 11. WASHER FLUID HOSE
4. WASHER 12. CAB HARNESS
5. WIPER MOTOR 13. WASHER TUBE CONNECTOR
6. NUT 14. WIPER ARM
7. CAPSCREW 15. WIPER MOTOR MOUNT
8. WASHER MOUNTING BRACKET
46
Figure 46. Washer Reservoir and Rear Wiper Removal, Lift Truck Models H4.0FT5/FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
47
Remove, Lift Truck Models H6.0FT, H7.0FT Install, Lift Truck Models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006) and H8.0FT, (H135FT, H155FT) (H006, J006) and H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299) H190FT) (A299)
1. Open hardware cover at base of wiper arm and 1. Install washer reservoir using four flange bolts.
remove nut and washer. Remove wiper arm and Connect the water tubes at T-fitting and cab har-
blade. See Figure 47. ness to washer reservoir. See Figure 47.
2. Disconnect water tube from water tube nozzle. 2. Install wiper motor to rear window using two
grommets, washers, and mounting studs. Con-
3. Remove hardware cover, nut, retainer, washer, nect cab harness to wiper motor.
and grommet from threaded shaft on wiper mo-
tor. 3. Install the wiper motor cover. The cover snaps
into place with plastic tabs.
4. Remove the wiper motor cover by pulling back-
ward. The cover is held in place by plastic tabs 4. Install grommet, washer, retainer, nut, and
on the inside of the cover. hardware cover onto threaded shaft of wiper
motor. See Figure 47.
5. Disconnect cab harness from wiper motor. Re-
move the two mounting studs, washers, and NOTE: Inspect wiper blade for cracks and wear. Re-
grommets that attached wiper motor to window. place with new blade if old blade is worn or damaged.
Remove wiper motor from window.
5. Install wiper arm and blade with washer and
6. Disconnect the water tubes at T-fitting and cab nut.
harness from the washer reservoir. Remove the
four flange bolts from washer reservoir and re- 6. Connect the water tube onto water tube nozzle.
move reservoir from lift truck.
48
1. COVER 11. CAB HARNESS

2. NUT 12. WATER TUBE NOZZLE
3. WASHER 13. WATER TUBE
4. WIPER MOTOR 14. FRONT WATER TUBE
5. REAR WINDOW 15. T-FITTING
6. GROMMET 16. FLANGE BOLTS
7. MOUNTING STUD 17. WASHER RESERVOIR
8. RETAINER 18. RESERVOIR PUMP
9. HARDWARE COVER 19. WIPER BLADE
10. WIPER MOTOR CONNECTOR 20. WIPER ARM
Figure 47. Rear Wiper, Motor, and Washer Reservoir Removal, Lift Truck Models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006) and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299)
49
Window Replacement 100 SRM 1290
Window Replacement
GENERAL To remove the lower window on the left side door,
perform Step 5 and Step 6.
See the Parts Manual for window replacement part
numbers for the front, back, and top windows. To 1. Slide window open half way. Grab window sides
replace the door windows, see the procedures below. and lift window off window guide. See Figure 48.
REMOVE DOOR WINDOW, LIFT TRUCK 2. Remove two setscrews from window mounting
MODELS H1.6FT, H1.8FT, 2.0FTS (F001); bracket and remove window from mounting
bracket.
H2.0-3.5FT (H40-70FT) (L177); AND
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, 3. Remove side seal from side of sliding window.
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
4. Remove two capscrews from window handle and
(N005, P005) remove handle from window.
NOTE: The procedures described below apply to the To remove the non-sliding window, repeat Step 1
sliding and non-sliding right side door windows. The through Step 4.
procedures to remove the sliding and non-sliding left
side door windows are the same as the right side.

1. SETSCREWS 5. WINDOW GUIDE
2. MOUNTING BRACKET 6. WINDOW HANDLE
3. SLIDING WINDOW 7. NON SLIDING WINDOW
4. SIDE SEAL 8. CAPSCREWS
Figure 48. Sliding Window Removal
50
100 SRM 1290 Window Replacement
NOTE: The lower window on the left side door is 5. Apply adhesive to side of new seal that goes
glued into place on the door frame. against window and install seal onto new win-
dow. See Figure 49.
5. On the outside of the door, cut the seal that holds
the window in place on the door frame. See Fig- 6. Apply adhesive to other side of seal and press
ure 49. seal and window into door frame.
6. Remove window and seal from door frame. Re-

move any excess seal material and adhesive from
door frame.
INSTALL DOOR WINDOWS, LIFT TRUCK

MODELS H1.6FT, H1.8FT, 2.0FTS (F001);
H2.0-3.5FT (H40-70FT) (L177); AND
H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005)
NOTE: The procedures described below apply to the
sliding and non-sliding right side door windows. The
procedures to install the sliding and non-sliding left
side door windows are the same as the right side. To
install the lower window on the left side door, per-
form Step 5 and Step 6.
NOTE: See the Parts Manual for window replace-

ment part numbers.
1. Attach window handle to window with two bolts.

See Figure 49.
2. Install side seal to side of sliding window.

1. DOOR FRAME
3. Place window in mounting bracket and secure 2. SEAL
window to mounting bracket with setscrews. 3. WINDOW
4. Place window onto window guide. Open and close Figure 49. Lower Window Removal (Left Side
window (sliding window only) to ensure it is prop- Door)
erly installed onto window guide.
Perform Step 1 through Step 4 to install the non-

sliding window.
51
Window Replacement 100 SRM 1290
REMOVE DOOR WINDOW, LIFT TRUCK 3. Remove side seal from side of sliding window.
MODELS H6.0FT, H7.0FT (H135FT, H155FT)
4. Remove two capscrews and washers from win-
(H006, J006) AND H8.0FT, H8.0FT9, H9.0FT dow slide/locking handle and remove handle
(H170FT, H175FT36, H190FT) (A299) from window.
NOTE: The procedures described below apply to the To remove the non-sliding window, repeat Step 1
sliding and non-sliding left side door windows. The through Step 4.
procedures to remove the sliding and non-sliding
right side door windows are the same as the left side. 5. To remove the lower window, remove seal from
To remove the lower windows, go to Step 5. window and remove window from door frame.
See Figure 51.
1. Slide window open half way. Grab window sides
and lift window off window guide. See Figure 50.
2. Remove two setscrews from window mounting

bracket and remove window from mounting
bracket. See Figure 50.
NOTE: LEFT SIDE DOOR SHOWN.

1. SETSCREW 6. WASHER
2. MOUNTING BRACKET 7. SLIDE/LOCKING HANDLE
3. SLIDING WINDOW 8. WINDOW GUIDE
4. SIDE SEAL 9. NON-SLIDING WINDOW
5. CAPSCREW
Figure 50. Sliding Window Removal
52
100 SRM 1290 Window Replacement
INSTALL DOOR WINDOW, LIFT TRUCK

MODELS H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) AND H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299)
NOTE: The procedures described below apply to the
sliding and non-sliding left side door windows. The
procedures to install the sliding and non-sliding right
side door windows are the same as the left side. To
install the lower windows, go to Step 1.
NOTE: See the Parts Manual for window replace-

ment part numbers.
1. Install seal around lower window. Install seal

and window into door frame. See Figure 51.
2. Attach handle to window with two capscrews and

washers. See Figure 50
3. Install side seal from side of sliding window.

NOTE: LEFT SIDE DOOR SHOWN. 4. Place window onto mounting bracket and secure
1. SEAL window to mounting bracket with setscrews.
2. WINDOW
3. DOOR FRAME 5. Place window onto window guide. Open and close
window (slide window only) to ensure it is prop-
Figure 51. Lower Window Removal erly installed onto window guide.
Perform Step 2 through Step 5 to install the non-

sliding window.
53
Heater Replacement 100 SRM 1290
Heater Replacement
REMOVE, FOR LIFT TRUCK MODELS 6. Remove flange bolts, clip nuts, and fresh air in-
H6.0FT, H7.0FT (H135FT, H155FT) (H006, take vent located outside on module. See Fig-
J006) AND H8.0FT, H8.0FT9, H9.0FT ure 55.
(H170FT, H175FT36, H190FT) (A299) 7. Disconnect heater control harness from heater
and cab harness and unclip heater control har-
1. Remove front and rear floor mat and front floor ness from seat support.
plate. See Figure 52.
8. Remove four screws from heater control at top of
2. Remove four flange bolts and rear floor plate. See seat surround. Remove Heater control.
Figure 52.
9. Loosen strap clamps and disconnect front and
3. Disconnect battery. rear duct heater hoses at top of surround cover.
4. Remove right side rear panel. See Figure 53. 10. Loosen strap clamp and disconnect floor vent
5. Loosen strap clamps and remove formed hose duct hose from rectangle adapter to heater vent.
from fresh air intake vent to heater box. See Fig- 11. Remove two capscrews securing heater vent and
ure 54. vent bracket to seat support.
1. FRONT FLOOR MAT 4. REAR FLOOR PLATE

2. REAR FLOOR MAT 5. FRONT FLOOR PLATE
3. FLANGE BOLT 6. MODULE
Figure 52. Floor Plate Removal
54
100 SRM 1290 Heater Replacement
NOTE: Drain supply and return hoses into a suitable INSTALL, FOR LIFT TRUCK MODELS
container. H6.0FT, H7.0FT (H135FT, H155FT) (H006,
12. Remove supply and return hoses from heater. J006) AND H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299)
13. Remove four capscrews from heater and seat sup-
port. Remove heater. 1. Install heater on seat support with four cap-
screws. See Figure 54.
2. Connect supply and return hoses from engine to

heater.
3. Pre-install heater vent to bracket and assemble

the bracket with two capscrews to seat support.
4. Install front and rear duct heater hoses and floor

vent hose to heater box.
5. Route front and rear ducts to the respective open-

ings at the top vent adapters.
6. Route floor vent hose to the bottom and connect

to heater vent through the rectangle adapter.
7. Install heater control on top of seat surround

with four screws and route the control cable and
harness firmly held by clips by the side of seat
support and connect middle connector to cab
harness and bottom connector heater.
8. Install air intake vent from outside on module

NOTE: RIGHT SIDE VIEW SHOWN. with flange bolts and clip nuts. See Figure 55.
1. SCREWS 9. Attach intake vent to heater box and air intake
2. RIGHT SIDE REAR
PANEL vent with formed hose. Tighten strap clamps.
Figure 53. Right Side Rear Panel Removal 10. Install right side rear panel. See Figure 53.
11. Connect battery.
12. Install rear floor plate with four flange bolts. See
Figure 52.
13. Install front floor plate and front and rear floor
mats.
55
Heater Replacement 100 SRM 1290
Figure 54. Heater and Hoses
56
100 SRM 1290 Heater Replacement

1. LOUVERS 15. HEATER CONTROL HARNESS
2. TOP VENT ADAPTERS 16. CONNECTOR TO CAB HARNESS
3. STRAP CLAMPS 17. CONNECTOR TO HEATER
4. REAR DUCT HEATER HOSE 18. FLOOR VENT DUCT HOSE
5. FRONT DUCT HEATER HOSE 19. NUT
6. SCREWS 20. FLOOR VENT
7. HEATER CONTROL 21. INSERT
8. CLIPS 22. BRACKET
9. RETURN HOSE 23. RECTANGLE ADAPTER
10. SUPPLY HOSE 24. FORMED HOSE
11. SWIVEL CLAMP 25. CLIP NUTS
12. CLAMP 26. FRESH AIR INTAKE VENT
13. CAPSCREWS 27. SURROUND COVER
14. HEATER BOX
1. FLANGE BOLTS
2. FRESH AIR INTAKE VENT
3. CLIP NUTS
Figure 55. Fresh Air Intake Vent
57
Light Replacement 100 SRM 1290
Light Replacement
WORK LIGHTS (FRONT AND REAR) 2. Connect the battery and close the hood on all lift
truck models except H6.0FT, H7.0FT (H135FT,
Remove H155FT) (H006, J006) and H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299).
1. Disconnect the battery. Raise the hood to For models H6.0FT, H7.0FT (H135FT, H155FT)
access the battery for all lift truck models (H006. J006) and H8.0FT, H8.0FT9, H9.0FT
except H6.0FT, H7.0FT (H135FT, H155FT) (H170FT, H175FT36, H190FT) (A299), install
(H006, J006) and H8.0FT, H8.0FT9, H9.0FT the front floor plate and floor mat after connect-
(H170FT, H175FT36, H190FT) (A299). For mod- ing the battery.
els H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299), remove the front
floor mat and floor plate to access the battery.
CAUTION
Clean any dirt or oil from the lamp surface with
alcohol and a lint-free cloth or tissue. Any for-
eign particles or materials on the bulb surface
can cause hot spots on the bulb and result in
lamp failure.
NOTE: The work light assembly does not need to be

removed from the lift truck to replace the bulb
2. Remove four capscrews, lens assembly, and bulb.

See Figure 56. Install the bulb, lens assembly,
and four capscrews.
3. Disconnect the work light wiring harness from

the cab wiring harness. Remove the lock nut, NOTE: REAR WORK LIGHT SHOWN, FRONT WORK
washer, and work light from the mounting LIGHT IS SIMILAR.
bracket located on the cab. See Figure 57.
1. CAPSCREWS (LENS ASSEMBLY)
Install 2. LENS ASSEMBLY
3. NUT
1. Using the washer and lock nut, install work light
Figure 56. Work Lights
on the cab mounting bracket. See Figure 57.
Connect work light to overhead guard harness.

A. FRONT VIEW B. REAR VIEW
1. CAB ASSEMBLY 10. MOUNTING BRACKET
2. RIGHT SIDE WORK LIGHT 11. STROBE LIGHT GUARD
3. RIGHT SIDE MARKER/TURN SIGNAL LIGHT 12. REAR WORK LIGHT
4. LEFT SIDE MARKER/TURN SIGNAL LIGHT 13. LOCKNUT
5. LEFT SIDE WORK LIGHT 14. WASHER
6. RIGHT SIDE TURN, STOP, TAIL, AND BACKUP 15. MOUNTING BRACKET
LIGHT 16. LEFT SIDE TURN, STOP, TAIL, AND BACKUP
7. FLANGE NUT LIGHT
8. CAPSCREW 17. FRONT MOUNTING BRACKET
9. STROBE LIGHT
58
100 SRM 1290 Light Replacement
Figure 57. Cab Light Assemblies
59
Light Replacement 100 SRM 1290
STROBE LIGHT For models H6.0FT, H7.0FT (H135FT, H155FT)

(H006. J006) and H8.0FT, H8.0FT9, H9.0FT
NOTE: The strobe light may either be mounted above (H170FT, H175FT36, H190FT) (A299), install
the top of the cab assembly (high-mounted) or below the front floor plate and floor mat after connect-
the top of the cab assembly (low-mounted). The re- ing the battery.
moval and installation procedures are the same for
both options.
Remove
1. Disconnect the battery. Raise the hood to
access the battery for all lift truck models
except H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) and H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299). For mod-
els H6.0FT, H7.0FT (H135FT, H155FT) (H006,
H175FT36, H190FT) (A299), remove the front
floor mat and floor plate to access the battery.
2. Disconnect the strobe light electrical connector

from the cab wiring harness. See Figure 58.
3. Remove the capscrews, washers, and flange nuts

securing the strobe light and light guard to strobe
light mounting bracket. Remove strobe light and
guard from lift truck. See Figure 57.
Install
1. Place strobe light assembly and strobe light
guard onto mounting bracket. Secure the as-
sembly to mounting bracket with capscrews, 1. STROBE LIGHT 6. MOUNTING
washers, and flange nuts. See Figure 58. GUARD BRACKET
2. STROBE LIGHT 7. CAPSCREW
2. Connect strobe light electrical connector to over- LENS 8. LOCK NUT
3. FLANGE NUT 9. ELECTRICAL
head guard wiring harness. 4. LOCKWASHER CONNECTOR
5. WASHER
3. Connect the battery and close the hood on all lift
truck models except H6.0FT, H7.0FT (H135FT, Figure 58. Strobe Light Assembly
H155FT) (H006, J006) and H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299).
60
100 SRM 1290 Light Replacement
TURN, STOP, TAIL, AND BACKUP LIGHT FRONT MARKER/TURN SIGNAL LIGHTS
NOTE: The turn, stop, tail, and backup light assem- NOTE: The front marker/turn signal light assembly
bly is non-repairable. See the Parts Manual for re- is non-repairable. See the Parts Manual for re-
placement turn, stop, tail, and backup lights. placement front marker/turn signal lights.
Remove Remove
1. Disconnect the battery. Raise the hood to 1. Disconnect the battery. Raise the hood to
access the battery for all lift truck models access the battery for all lift truck models
except H6.0FT, H7.0FT (H135FT, H155FT) except H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) and H8.0FT, H8.0FT9, H9.0FT (H006, J006) and H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299). For mod- (H170FT, H175FT36, H190FT) (A299). For mod-
els H6.0FT, H7.0FT (H135FT, H155FT) (H006, els H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006) and H8.0FT, H8.0FT9, H9.0FT (H170FT, J006) and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299), remove the front H175FT36, H190FT) (A299), remove the front
floor mat and floor plate to access the battery. floor mat and floor plate to access the battery.
2. Remove screw securing the turn, stop, tail, and NOTE: The following steps are used to remove either
backup light to mounting bracket. Pull Turn, the right or left side front marker/turn signal light
Stop, Tail, and Backup Light downward to re- assembly.
move it from the mounting bracket.
2. Remove two lock nuts, washers and front
3. Disconnect the turn, stop, tail, and backup light marker/turn signal light assembly from the
from the cab wiring harness. See Figure 57. front mounting bracket. See Figure 57
4. If the mounting bracket must be removed from 3. Disconnect the front marker/turn signal light
the cab, remove rear crossmember cover and re- wiring harness from the cab wiring harness.
move the mounting bracket from the cab. See
Figure 57. Install
Install NOTE: The following steps are used to install either

the right or left side front marker/turn signal light
1. If the mounting bracket was removed, install assembly.
the rear crossmember cover. Install mounting
bracket on the cab. 1. Connect the front marker/turn signal light
wiring harness to the cab wiring harness.
2. Connect the turn, stop, tail, and backup light to
the cab wiring harness. See Figure 57. 2. Using two lock nuts, and washers, install the
front marker/turn signal light assembly on the
3. Install the screw to attach the turn, stop, tail, front mounting bracket.
and backup light to the mounting bracket. See
Figure 57. 3. Connect the battery and close the hood on all lift
4. Connect the battery and close the hood on all lift H155FT) (H006, J006) and H8.0FT, H8.0FT9,
truck models except H6.0FT, H7.0FT (H135FT, H9.0FT (H170FT, H175FT36, H190FT) (A299).
H155FT) (H006, J006) and H8.0FT, H8.0FT9, For models H6.0FT, H7.0FT (H135FT, H155FT)
H9.0FT (H170FT, H175FT36, H190FT) (A299). (H006. J006) and H8.0FT, H8.0FT9, H9.0FT
For models H6.0FT, H7.0FT (H135FT, H155FT) (H170FT, H175FT36, H190FT) (A299), install
(H006. J006) and H8.0FT, H8.0FT9, H9.0FT the front floor plate and floor mat after connect-
(H170FT, H175FT36, H190FT) (A299), install ing the battery.
the front floor plate and floor mat after connect-
ing the battery.
61
Display Switches 100 SRM 1290
Display Switches
The lift trucks covered in this manual can have sev- Power Distribution Module (PDM), which is under
eral different options and configurations. Depending the hood next to the battery on the right side. See
on the equipment on the lift truck, warnings and in- Figure 61.
dicator lights on the right side of the Display Switch
Cluster will vary and the truck may not contain all For lift truck models H6.0FT, H7.0FT (H135FT,
the warnings and indicator lights shown in Figure 59 H155FT) (H006, J006) and H8.0FT, H8.0FT9,
and Figure 60. H9.0FT (H170FT, H175FT36, H190FT) (A299), the
fuses are located in the Power Distribution Mod-
For lift truck models H1.6FT, H1.8FT, 2.0FTS, ule (PDM), which is located under the floor plates
H2.0-3.5FT (H40-70FT) (L177), and H4.0FT5/FT6, mounted on the right side of lift truck frame. See
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, Figure 61.
120FT) (N005, P005), the fuses are located in the
A. LEFT SIDE B. RIGHT SIDE

1. HOURMETER 10. POWER (ON/OFF)
2. #1 BUTTON (ADMINISTERING PASSWORDS) 11. ENGINE START (KEYLESS REMOTE)
3. #2 BUTTON (ADMINISTERING PASSWORDS) 12. 1ST GEAR LOCKING
4. ENTER BUTTON 13. FRONT WORK LIGHTS
5. #3 BUTTON (ADMINISTERING PASSWORDS) 14. REAR WORK LIGHTS
6. SCROLL DOWN 15. REAR WIPER
7. SCROLL UP 16. FRONT WIPER
8. #4 BUTTON (ADMINISTERING PASSWORDS) 17. FRONT WASHER
9. #5 BUTTON (ADMINISTERING PASSWORDS)
Figure 59. Right and Left Side Display Switch Cluster
62
100 SRM 1290 Display Switches
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator Malfunction Indicator
14 Indicator Light, 1st Gear Locking
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 60. Warning and Indicator Lights
63
Display Switches 100 SRM 1290
Figure 61. PDM Showing Fuses and Relays
64
100 SRM 1290 Optional Equipment

A. H1.6FT, H1.8FT, 2.0FTS (F001), H2.0-3.5FT (H40-70FT) (L177), AND H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
B. H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299)
1. BATTERY 11. SPARE FUEL PUMP RELAY
2. PDM 12. BATTERY (25-AMP FUSE)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20-AMP FUSE)
4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30-AMP FUSE) 15. BATTERY (25-AMP FUSE)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20-AMP FUSE)
7. BACKUP RELAY 17. IGNITION 1 (20-AMP FUSE)
8. BACKUP (20-AMP FUSE) 18. IGNITION RELAY
9. IGNITION (30-AMP FUSE) 19. BATTERY (25-AMP FUSE)
10. SPARE FUEL PUMP (20-AMP FUSE)
Electrical Schematics
Refer to Diagrams and Schematics 8000 SRM 1409 for complete lift truck electrical schematics.
Optional Equipment
HEAVY DUTY PRE-CLEANER Clean
The procedure below only pertains to lift truck
models H1.6FT, H1.8FT, 2.0FTS (F001), H2.0-3.5FT
WARNING
(H40-70FT) (L177), and H4.0FT5/FT6; H4.5FTS5, Compressed air can move particles so that they
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) cause injury to the user or to other personnel.
(N005, P005). Make sure that the path of the compressed air
The heavy-duty pre-cleaner removal and installation goggles or a face shield to prevent injury to the
procedures for lift truck models H6.0FT, H7.0FT eyes.
(H135FT, H155FT) (H006, J006) and H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) Clean the heavy-duty pre-cleaner and air duct with
(A299), can be found in the Frame 100 SRM 1321 compressed air as necessary.
service manual.
Inspect
In environments with very dirty conditions, the lift
truck may be equipped with a heavy-duty air cleaner Inspect the air duct and pre-cleaner for excessive
which pre-cleans the air before it enters the standard wear, cracks, or damage. If damaged, replace.
air filter. The pre-cleaner is mounted on the rear of
the cab in place of the air vent. See Figure 62. Install
NOTE: Orient ejection port away from operator.
Remove
1. Install pre-cleaner and hose clamp onto air duct.
1. Remove two socket head capscrews and washers Tighten hose clamp.
securing the air duct to left side rear operator
cab leg. Remove air duct and pre-cleaner. See 2. Install air duct and pre-cleaner onto left side rear
Figure 62. operator cab leg with two washers and socket
head capscrews.
2. Remove hose clamp securing pre-cleaner to air
duct. Remove pre-cleaner.
65
Optional Equipment 100 SRM 1290
1. PRE-CLEANER 5. INSERT
2. AIR DUCT 6. HOSE CLAMP
3. WASHER 7. INJECTION PORT
4. SOCKET HEAD CAPSCREW
Figure 62. Heavy Duty Pre-Cleaner
FAN H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,

H190FT) (A299), remove the front floor mat and
Remove floor plate to access the battery.
1. Disconnect the battery. Raise the hood to ac- 2. Disconnect the fan assembly wiring harness con-
cess the battery for all lift truck models except nector from the cab wiring harness connector.
H6.0FT, H7.0FT (H135FT, H155FT) (H006, See Figure 63.
H175FT36, H190FT) (A299) For models H6.0FT, 3. Remove four nuts, lockwashers, capscrews, and
H7.0FT (H135FT, H155FT) (H006, J006) and fan assembly from the mounting bracket
66
100 SRM 1290 Optional Equipment
Install H155FT) (H006, J006) and H8.0FT, H8.0FT9,

H9.0FT (H170FT, H175FT36, H190FT) (A299)..
1. Using four nuts, lockwashers, and capscrews, in- For models H6.0FT, H7.0FT (H135FT, H155FT)
stall the fan assembly on the mounting bracket. (H006, J006) and H8.0FT, H8.0FT9, H9.0FT
See Figure 63. (H170FT, H175FT36, H190FT) (A299), install
the front floor plate and floor mat after connect-
2. Connect the fan assembly wiring harness connec-
ing the battery.
tor to the cab wiring harness connector.
3. Connect the battery and close the hood on all lift

1. MIRROR 6. WASHER
2. MOUNTING BRACKET 7. WIRING HARNESS CONNECTOR
3. NUT 8. MOUNTING BRACKET
4. SCREW 9. FAN ASSEMBLY
5. LOCKNUT
Figure 63. Fan and Mirror Replacement
67
Label Replacement 100 SRM 1290
MIRROR Install
Remove Using nut, install mirror on the mounting bracket.
See Figure 63.
Remove nut and mirror from the mounting bracket.
See Figure 63.
Label Replacement
2. Remove paper from back of label. Do not touch
WARNING adhesive surface.
Labels that have WARNINGS or CAUTIONS
must be replaced if they are damaged. If a mast 3. Carefully hold label in correct position above sur-
of a different size or an accessory carriage is face. Label cannot be moved after it touches sur-
installed, the capacity rating can change. face. Put label on surface. Make sure all air is
Changes in the kind of drive tires can change removed from under label and corners and edges
the capacity rating. See a dealer for Hyster are tight.
lift trucks for a replacement nameplate. The
nameplate information is a safety item and See Parts Manual for correct location and part num-
must be correct for the equipment and config- ber.
uration of the lift truck.
1. Make sure surface is dry and free of oil or grease.

Do not use solvent on new paint. Clean the sur-
face of old paint using cleaning solvent.
68
TECHNICAL PUBLICATIONS
100 SRM 1290 4/09 (7/08)(7/07) Printed in United Kingdom

Cabine Operador

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OPERATOR’S CAB

H1.6FT, H1.8FT, 2.0FTS [F001];

PART NO. 1673866 100 SRM 1290

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2009 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

H1.6FT, H1.8FT, 2.0FTS [F001];

Figure 1. Operator Cab

NOTE: Lift trucks equipped with LPG, make sure to

1. For lift truck models H1.6FT, H1.8FT, 2.0FTS

3. Disconnect the air filter hose from the rear left

1. REAR BOTTOM WINDOW

Figure 3. Rear Bottom Window for Lift Trucks

NOTE: Removing the door assemblies requires two

6. Open left side door, remove lock nut, and discon-

a. For Lift truck models H1.6FT, H1.8FT,

Figure 5. Radiator Cover and Cap Location

Legend for Figure 5

Figure 6. Heater Hose Connection

Legend for Figure 6

NOTE: Wiper motor cover must be removed before

11. For lift truck models H1.6FT, H1.8FT, 2.0FTS

12. For lift truck models H4.0FT5/FT6; H4.5FTS5,

13. Remove five capscrews from top of dash assembly

14. Remove two flange bolts securing the cowl panel

15. Unclip the dash assembly from kick panel. Re-

Legend for Figure 10

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.

Figure 10. Dash Installation

Legend for Figure 11

NOTE: CAB REMOVED FOR CLARITY.

NOTE: KICK PANEL REMOVED FOR CLARITY.

Figure 12. Light Harness Connection to Vehicle

Figure 15. Lift Strap Connection

Figure 14. Front and Rear Cab Mounting

REMOVE, FOR LIFT TRUCK MODELS

1. Open right side door and remove hair pin from

2. Remove rod pin and spacers from link.

3. Remove right side door from cab frame by lifting

NOTE: RIGHT SIDE DOOR HINGE SHOWN

Figure 17. Door Removal

4. Repeat Step 1 through Step 3 for the removal of

5. Remove front floor mat and floor plate. See Fig-

7. Remove two screws holding the right side rear

Figure 16. Door Link Removal

1. DASH ASSEMBLY 6. FLANGE BOLT

NOTE: RIGHT SIDE VIEW SHOWN.

1. CAPSCREWS 5. COWL PANEL

24. Connect a lifting device to a spreader bar or lift

NOTE: KICK PANEL REMOVED FOR CLARITY.

Figure 22. Light Harness Connection to Vehicle

18. Remove four flange bolts securing right and left

21. Disconnect rear grab handle horn button connec-

22. Remove the bottom flange bolt securing right

2. Carefully lift the operator cab onto the lift truck

3. Open left side hood door and install the bottom

4. Open right side hood door and install bottom