OPERATOR’S CAB

H25-32XM-12, H28XM-16CH, H32XM-16CH, H25-32XMS-9

(H550-700HD, H550-700HDS) [F008];
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236];
H16.00-22.00XM-12EC (H400-500HD/HDS-EC) [B214];
H8.00-12.00XM (H170-280HD) [H007]; H13.00-14.00XM (H300-330HD) [G019];
H16.00XM-6 (H360HD) [G019]; H10.00-12.00XM-12EC (H360HD-EC) [G019];
H8.00-12.00XM (H170-280HD) [F007]; H13.00-16.00XM (H300-360HD) [E019];
H10.00-12.00XM-12EC (H360HD-EC) [E019]; H8.00-12.00XM (H170-280HD) [G007];
H13.00-14.00XM (H300-330HD) [F019]; H16.00XM-6 (H360HD) [F019];
H10.00-12.00XM-12EC (H360HD-EC) [F019]; RS45-27CH, RS45-31CH, RS46-36CH,
RS46-40CH, RS46-41S CH, RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH,
RS46-33IH, RS46-37IH, RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27,
HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
H8.0-12.0XM-6 (H190-280HD 2) [J007]; H13.0-14.0XM-6 (H300-330HD 2) [H019];
H16.0XM-6 (H360HD 2) [H019]; H10.0-12.0XM-12EC (H360HD 2-EC) [H019]; H16XM-12EC,
H18XM-12EC, H22XM-12EC (H400HD-EC, H450HD-EC, H500HD-EC) [C214]; H16XM-12,
H18XM-12, H20XM-12, H22XM-12 (H400HD, H450HD, H500HD, H550HD) [B236]; H25-32XM-12,
H25-30XMS-9 (H550-700HD, H550-700HDS) [G008]; RS45-27CH, RS45-31CH, RS46-36CH,
RS46-41L CH, RS46-41S CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH,
RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222]

PART NO. 1703702 100 SRM 1390

 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
Description of Operation.................................................................................................................................... 2
Cab Structure................................................................................................................................................. 2
Cab Tilt System ............................................................................................................................................. 2
Cab Tilt System, Raise.............................................................................................................................. 3
Cab Tilt System, Lower............................................................................................................................. 3
Oil Filling for Cab Tilt System .......................................................................................................................... 5
Raising and Lowering Cab ................................................................................................................................ 6
Raise Cab ....................................................................................................................................................... 6
Lower Cab ...................................................................................................................................................... 7
Cab Door Assembly ............................................................................................................................................ 7
Cab Door......................................................................................................................................................... 7
Remove....................................................................................................................................................... 7
Install ......................................................................................................................................................... 8
Door Hinge ..................................................................................................................................................... 8
Remove....................................................................................................................................................... 8
Install ......................................................................................................................................................... 8
Door Striker Pin............................................................................................................................................. 9
Door Striker Pin Adjustment.................................................................................................................... 9
Door Latch...................................................................................................................................................... 9
Remove....................................................................................................................................................... 9
Install ......................................................................................................................................................... 9
Door Handle ................................................................................................................................................... 10
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Door Release .................................................................................................................................................. 10
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Door Push-button........................................................................................................................................... 11
Remove....................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Cab Tilt System.................................................................................................................................................. 12
Electric Tilt Pump ......................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Hand Pump .................................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 13
Cab Tilt Cylinder ........................................................................................................................................... 14
Remove....................................................................................................................................................... 14
Disassemble ............................................................................................................................................... 14
Clean .......................................................................................................................................................... 15
Inspect........................................................................................................................................................ 15
Assemble .................................................................................................................................................... 16
Install ......................................................................................................................................................... 16
Latch............................................................................................................................................................... 16
Remove....................................................................................................................................................... 16
Install ......................................................................................................................................................... 16
Brake and Inching Pedals ................................................................................................................................. 18
Remove ........................................................................................................................................................... 18
Install ............................................................................................................................................................. 18

©2011 HYSTER COMPANY i

Table of Contents Operator’s Cab

TABLE OF CONTENTS (Continued)

Brake Pedal Adjustment ............................................................................................................................... 18
Dry Brake .................................................................................................................................................. 18
Wet Brake .................................................................................................................................................. 18
Inching Pedal Adjustment............................................................................................................................. 19
Inching Pedal Sensor Adjustment Using Dana Dashboard Software......................................................... 19
Inching Pedal Sensor Calibration Procedure Using Dana Dashboard Software ....................................... 20
Inching Pedal Sensor Adjustment Using the APC200 Display................................................................... 20
Inching Pedal Sensor Calibration Procedure Using the APC200 Display.................................................. 21
Accelerator Pedal and Sensor............................................................................................................................ 22
Accelerator Pedal ........................................................................................................................................... 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 22
Accelerator Pedal Sensor............................................................................................................................... 22
Adjust ......................................................................................................................................................... 22
Seat Assembly .................................................................................................................................................... 23
Seat................................................................................................................................................................. 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 23
Seat Cushion .................................................................................................................................................. 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 24
Back Cushion ................................................................................................................................................. 24
Remove....................................................................................................................................................... 24
Install ......................................................................................................................................................... 24
Seat Suspension Replacement ...................................................................................................................... 24
Boot Replacement .......................................................................................................................................... 25
Suspension Scissor and Shock Absorber ...................................................................................................... 25
Remove....................................................................................................................................................... 25
Install ......................................................................................................................................................... 30
Compressor .................................................................................................................................................... 38
Remove....................................................................................................................................................... 38
Install ......................................................................................................................................................... 43
Power Assist Armrest ........................................................................................................................................ 49
Release Cable ................................................................................................................................................. 49
Remove....................................................................................................................................................... 49
Install ......................................................................................................................................................... 49
Gas Spring...................................................................................................................................................... 49
Remove....................................................................................................................................................... 49
Install ......................................................................................................................................................... 50
Joystick........................................................................................................................................................... 50
Remove....................................................................................................................................................... 50
Install ......................................................................................................................................................... 50
Electrical Levers ............................................................................................................................................ 50
Remove....................................................................................................................................................... 50
Install ......................................................................................................................................................... 51
Armrest Rocker Switches .............................................................................................................................. 51
Remove....................................................................................................................................................... 51
Install ......................................................................................................................................................... 51
Armrest Top Cover......................................................................................................................................... 51
Remove....................................................................................................................................................... 51
Install ......................................................................................................................................................... 51

ii
Operator’s Cab Table of Contents

TABLE OF CONTENTS (Continued)

Instrument Panel ............................................................................................................................................... 52
Key Switch ..................................................................................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 52
12V Power Socket .......................................................................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 52
Electric-Operated Heat Control and Air Recirculation Control (Airco Only) ............................................ 53
Remove....................................................................................................................................................... 53
Install ......................................................................................................................................................... 53
Cable-Operated Heater Control (Heater Only)............................................................................................ 54
Remove....................................................................................................................................................... 54
Install ......................................................................................................................................................... 54
Air Conditioning Switch Replacement ......................................................................................................... 54
Instrument Panel Rocker Switches Replacement........................................................................................ 54
Parking Brake Switch ................................................................................................................................... 55
Remove....................................................................................................................................................... 55
Install ......................................................................................................................................................... 55
Indicator Display Replacement..................................................................................................................... 55
Instrument Panel Top Console...................................................................................................................... 55
Remove....................................................................................................................................................... 55
Install ......................................................................................................................................................... 56
Steering Wheel and Column Assembly............................................................................................................. 56
Steering Wheel and Horn.............................................................................................................................. 56
Remove....................................................................................................................................................... 56
Install ......................................................................................................................................................... 56
Steering Column Assembly ........................................................................................................................... 58
Remove....................................................................................................................................................... 58
Install ......................................................................................................................................................... 58
Adjustment Handle ....................................................................................................................................... 59
Remove....................................................................................................................................................... 59
Install ......................................................................................................................................................... 59
Main Warning Lights .................................................................................................................................... 59
Remove....................................................................................................................................................... 59
Install ......................................................................................................................................................... 59
Shift Lever ..................................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
Turn Signal Lever.......................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Install ......................................................................................................................................................... 60
Window Wipers Replacement............................................................................................................................ 60
Window Wiper Assembly, Replace ................................................................................................................ 60
Remove....................................................................................................................................................... 60
Install ......................................................................................................................................................... 61
Window Wiper Motor Replacement .................................................................................................................. 61
Front Window Wiper Motor Assembly ......................................................................................................... 61
Remove....................................................................................................................................................... 61
Install ......................................................................................................................................................... 61
Rear Window Wiper Motor Assembly........................................................................................................... 62
Remove....................................................................................................................................................... 62

iii
Table of Contents Operator’s Cab

TABLE OF CONTENTS (Continued)

Install ......................................................................................................................................................... 62
Top Window Wiper Motor Assembly............................................................................................................. 62
Remove....................................................................................................................................................... 62
Install ......................................................................................................................................................... 62
Window Washer System .................................................................................................................................... 63
Window Washer Reservoir and Pumps ........................................................................................................ 63
Remove....................................................................................................................................................... 63
Install ......................................................................................................................................................... 63
Window Washer Hoses .................................................................................................................................. 64
Hoses for Top and Rear Window............................................................................................................... 64
Remove .................................................................................................................................................. 64
Install..................................................................................................................................................... 64
Hoses for Front Window............................................................................................................................ 65
Remove .................................................................................................................................................. 65
Install..................................................................................................................................................... 65
Window Washer Spray Nozzles..................................................................................................................... 66
Front........................................................................................................................................................... 66
Remove .................................................................................................................................................. 66
Install..................................................................................................................................................... 66
Rear ............................................................................................................................................................ 66
Remove .................................................................................................................................................. 66
Install..................................................................................................................................................... 66
Top.............................................................................................................................................................. 66
Remove .................................................................................................................................................. 66
Install..................................................................................................................................................... 66
Window Replacement ........................................................................................................................................ 67
Front Window ................................................................................................................................................ 68
Remove....................................................................................................................................................... 68
Install ......................................................................................................................................................... 68
Rear Window.................................................................................................................................................. 68
Remove....................................................................................................................................................... 68
Install ......................................................................................................................................................... 68
Top Window.................................................................................................................................................... 69
Remove....................................................................................................................................................... 69
Install ......................................................................................................................................................... 69
Door Window.................................................................................................................................................. 70
Upper/Lower Window................................................................................................................................ 70
Remove .................................................................................................................................................. 70
Install..................................................................................................................................................... 70
Sliding Window and Sliding Tracks ............................................................................................................. 70
Remove....................................................................................................................................................... 70
Install ......................................................................................................................................................... 70
Weather Strip Replacement...................................................................................................................... 72
Window Stopper Replacement .................................................................................................................. 72
Window Seal Replacement........................................................................................................................ 72
Sliding Window Frame.............................................................................................................................. 72
Remove .................................................................................................................................................. 72
Install..................................................................................................................................................... 72
Floor Mat ............................................................................................................................................................ 73
Front Floor Mat ............................................................................................................................................. 73
Remove....................................................................................................................................................... 73

iv
Operator’s Cab Table of Contents

TABLE OF CONTENTS (Continued)

Install ......................................................................................................................................................... 73
Rear Floor Mat............................................................................................................................................... 74
Remove....................................................................................................................................................... 74
Install ......................................................................................................................................................... 74
Radio Console ..................................................................................................................................................... 75
Remove ........................................................................................................................................................... 75
Install ............................................................................................................................................................. 75
Air Duct Replacement........................................................................................................................................ 76
Front............................................................................................................................................................... 76
Rear ................................................................................................................................................................ 76
Remove....................................................................................................................................................... 76
Install ......................................................................................................................................................... 77
Accessories.......................................................................................................................................................... 77
Mirror Replacement ...................................................................................................................................... 77
Sunshade Replacement ................................................................................................................................. 77
Top.............................................................................................................................................................. 77
Rear ............................................................................................................................................................ 78
Map Light Replacement ................................................................................................................................ 78
Interior Fan Replacement ............................................................................................................................. 78
Remove....................................................................................................................................................... 78
Training Seat ................................................................................................................................................. 78
Field Installation....................................................................................................................................... 78
Remove....................................................................................................................................................... 78
Label Replacement............................................................................................................................................. 79

v
Table of Contents Operator’s Cab

TABLE OF CONTENTS (Continued)

This section is for the following models:

H25-32XM-12, H28XM-16CH, H32XM-16CH, H25-32XMS-9

(H550-700HD, H550-700HDS) [F008];
H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117];
H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236];
H16.00-22.00XM-12EC (H400-500HD/HDS-EC) [B214];
H8.00-12.00XM (H170-280HD) [H007];
H13.00-14.00XM (H300-330HD) [G019];
H16.00XM-6 (H360HD) [G019];
H10.00-12.00XM-12EC (H360HD-EC) [G019];
H8.00-12.00XM (H170-280HD) [F007];
H13.00-16.00XM (H300-360HD) [E019];
H10.00-12.00XM-12EC (H360HD-EC) [E019];
H8.00-12.00XM (H170-280HD) [G007];
H13.00-14.00XM (H300-330HD) [F019];
H16.00XM-6 (H360HD) [F019];
H10.00-12.00XM-12EC (H360HD-EC) [F019];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
H8.0-12.0XM-6 (H190-280HD 2) [J007];
H13.0-14.0XM-6 (H300-330HD 2) [H019];
H16.0XM-6 (H360HD 2) [H019];
H10.0-12.0XM-12EC (H360HD 2-EC) [H019];
H16XM-12EC, H18XM-12EC, H22XM-12EC (H400HD-EC,
H450HD-EC, H500HD-EC) [C214];
H16XM-12, H18XM-12, H20XM-12, H22XM-12 (H400HD, H450HD,
H500HD, H550HD) [B236];
H25-32XM-12, H25-30XMS-9 (H550-700HD, H550-700HDS) [G008];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L
IH, RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36,
RS46-41L, RS46-41S, RS46-41LS) [C222]

vi
100 SRM 1390 General

General
This SRM describes the functions of the cab and the options that may not be present on each cab. The
replacement instructions for the cab components. operation of the various switches and controls can
See Figure 1. Some of the described components are be found in the Operating Manual.

Figure 1. Operator’s Cab

1
Description of Operation
Legend for Figure 1
1. HEATER SECTION
2. INCHING PEDAL
3. BRAKE PEDAL
4. ACCELERATOR PEDAL
5. STEERING COLUMN
6. FRONT, REAR, AND TOP WINDOWS
7. FRONT, REAR, AND TOP WIPER ASSEMBLIES
The description and repair instructions for the heater
assembly are in Cab Heater, (Prior to Oct. 2008)
100 SRM 1458 for lift trucks built prior to October,
2008, and in Cab Heater (after Oct. 2008) 100
SRM 1459 for lift trucks built after October, 2008.
The remove and replace instructions for the cab as
an assembly are in the frame SRM specific to each
model lift truck.
Information on systems that are related to the cab
are in SRM’s for the Electrical System, Hydraulic
Description of Operation
CAB STRUCTURE
The cab frame is a welded structure. The overhead
guard is an integral part of the cab frame. See Oper-
ator’s Cab. In order to maintain maximum overhead
protection, changes to the cab frame and integrated
overhead guard are not allowed. There are two cab
options: an open cab and a closed cab. The closed cab
features windows and wipers, doors, a heater, and op-
tional air conditioning. Both cab types feature inte-
rior components.
CAB TILT SYSTEM
On lift trucks with a cab tilt system, the cab can tilt
to the right-hand side, providing service access to the
engine compartment and components under the cab.
The cab tilt system consists of a cab support frame,
cab tilt cylinder, cab tilt hand pump assembly, cab
latches, and an optional electrical cab tilt pump. See
Figure 2.
The cab is attached to the lift truck in the lowered
position by the cab support pivots on the right-hand
frame channel, the two cab latches on the left-hand
frame channel, and the cab tilt cylinder.
Hydraulic pressure is required to unlock the cab
latches and extend the cab tilt cylinder. The cab
2
100 SRM 1390
8. INTEGRATED OVERHEAD GUARD
9. OPERATOR’S CONSOLE, CONTROLS, AND
ARMREST
10. AIR CONDITIONING CONDENSER, DRYER,
AND FAN ASSEMBLY (OPTIONAL)
11. SEAT
System, Brake System, Steering System and Dia-
grams specific to each model lift truck.
Before making any repairs to the lift truck, complete
the following procedures:
1. Place the lift truck on a solid, level surface.
2. Lower the mast completely and tilt forward.
3. Place the shift lever in NEUTRAL.
4. Apply the parking brake.
5. Shut down the engine.
can be raised by rotating the cab tilt hand pump
directional valve clockwise and operating the cab
tilt hand pump. See Figure 3. To lower the cab from
the raised position, rotate the cab tilt hand pump
directional valve counterclockwise and operating the
cab tilt hand pump. The cab tilt cylinder retracts to
lower the cab.
The optional electrical cab tilt pump is push-button
operated. See Raising and Lowering Cab, Raise Cab,
Figure 8.
NOTE: If the optional electrical cab tilt pump is inop-
erable, the cab can be raised or lowered by using the
manually operated cab tilt hand pump.
When the cab has been raised to the partially open
position, the safety latch will engage with a retainer
plate that is welded to the frame. To raise or lower
the cab after the safety latch has engaged, pull and
hold the tilt latch release and raise or lower the cab
until the safety latch has passed the retainer plate.
Just before the fully open position is reached, move-
ment becomes gravity-controlled by the weight of the
cab. The cab is in the fully open position when the cab
tilt cylinder is fully extended.
100 SRM 1390 Description of Operation

Cab Tilt System, Raise

When the directional valve is in the raise position,
the pump push port and pump pull port are con-
nected to each other. See Figure 4.

Hydraulic pressure is transferred to the cab latches

and both the piston and rod side of the cab tilt cylin-
der. Hydraulic oil extruded at the rod side enters
the piston side of the cylinder through the directional
valve in the hand pump. The end of stroke is deter-
mined by a retaining ring in the cab tilt cylinder.

Cab Tilt System, Lower

When the directional valve is in the lower position,
the pump push port is connected to the pump reser-
voir through a reservoir check valve. The reservoir
check valve retains enough pressure to keep the cab
locks open. The pump pull port is connected to the
hand pump. While the hand pump provides suffi-
A. PULL DIRECTION OF THE TILT LATCH cient pressure, the cylinder check valve will raise to
RELEASE allow the oil at the piston side of the cylinder to re-
turn to the reservoir. The cylinder cannot lower when
1. CAB SUPPORT FRAME
2. CAB TILT HAND PUMP there is insufficient pressure at the pull connection.
3. CAB LATCH
4. CAB TILT CYLINDER When the piston has reached the free fall area, the oil
at the piston side will escape to the rod side and the
Figure 2. Cab Tilt System cab will drop under the influence of its own weight.
When the cab drops, the oil in the cab lock cylinders is
pushed out through the reservoir check valve. After
the cab has dropped, the cab is locked into position
by the cab latches.

A. LOWER B. RAISE
1. PUMP LEVER CONNECTION
2. PUMP DIRECTIONAL VALVE

Figure 3. Cab Tilt Hand Pump

3
Description of Operation 100 SRM 1390

1. ROD AREA 9. CAB TILT HAND PUMP

2. CAB TILT CYLINDER 10. RESERVOIR CHECK VALVE
3. FREE FALL INTERCONNECTION 11. LOWER
4. CHECK VALVE 12. PUMP DIRECTIONAL VALVE
5. PULL 13. RAISE
6. ELECTRIC CAB TILT PUMP (OPTIONAL) 14. LATCH
7. RESERVOIR 15. PUSH
8. RELIEF VALVE

Figure 4. Cab Tilt System

4
100 SRM 1390 Oil Filling for Cab Tilt System

Oil Filling for Cab Tilt System

8. If necessary, repeat Step 1 through Step 7.
CAUTION
When oil is added to the cab tilt system, place 9. Lower the cab until it is in the fully lowered posi-
an oil absorbing material around the fill cap tion and completely latched. Refer to the section
before lowering the cab. Excess oil may bleed Raising and Lowering Cab.
out of the relief valve, which is located in the
fill cap.

NOTE: If the oil level is low, the cab will not tilt/raise
completely.

NOTE: If the cab is lowered, perform Step 1. If the

cab is raised, go to Step 2.

1. Tilt/Raise raise the cab until it locks in the par-

tially open position. Refer to the section Raising
and Lowering Cab.

2. Lower the cab until it locks in the partially open

position. Refer to the section Raising and Lower-
ing Cab.
1. FILL CAP
3. Place the pump lever connection in the fully 2. PUMP LEVER CONNECTION
down position to create easy access to the fill
cap. See Figure 5. Figure 5. Hand Pump

4. Remove the fill cap. See Figure 5.

5. Add hydraulic oil through the filler opening until

the level is within 30 to 35 mm (1.18 to 1.38 in.)
of the top of the reservoir. See Figure 6. Refer to
the manual Periodic Maintenance 8000 SRM
1400 for the correct hydraulic oil specification.

6. Install the fill cap. See Figure 5.

7. Tilt/raise the cab and make sure the maxi-

mum tilted/raised (fully opened) position can
be reached. Refer to the section Raising and
Lowering Cab. Figure 6. Cab Tilt Label

5
Raising and Lowering Cab 100 SRM 1390

Raising and Lowering Cab

RAISE CAB check the oil level. Refer to the section Oil Filling for
Cab Tilt System.
WARNING
Make sure no one is under the cab when tilting/
raising or lowering the cab, or serious personal
injury may occur.

WARNING
Before doing any work under the cab, always
make sure the cab is fully tilted/raised, or if
partially open, is locked with the tilt latch, or
serious personal injury may occur.

CAUTION
Cab damage may occur if the mast is not com-
pletely tilted forward.
A. LOWER B. RAISE
1. Tilt the mast fully forward.
1. PUMP LEVER CONNECTION
2. Remove all unsecured items from the cab. 2. PUMP DIRECTIONAL VALVE
3. Close and securely latch the left-hand and right- Figure 7. Pump and Direction Valve
hand cab doors.

4. Clear all obstacles from the right-hand side of

the lift truck. Provide a minimum of 2 m (7 ft)
clearance space.

5. Use the pump lever to turn the pump directional

valve clockwise to the "Tilt/Raise" position. See
Figure 7.

6. Operate the pump with the pump lever (or push-

button, if equipped with an electric pump), until
the cab locks in the partially open position. See
Figure 8.

NOTE: Just before the fully open position is reached,

movement becomes gravity-controlled by the weight
of the cab. 1. CAB
2. FRAME
7. Pull the tilt latch release and continue to tilt/ 3. TILT LATCH RELEASE KNOB
4. ELECTRIC CAB TILT PUSH-BUTTON
raise the cab to the fully open position. See Fig- (OPTIONAL)
ure 8. 5. PUMP LEVER
NOTE: If the cab will not fully tilt/raise, lower the cab Figure 8. Pump Lever and Tilt Latch Release
until the cab locks in the partially open position, and Knob

6
100 SRM 1390 Cab Door Assembly

LOWER CAB 1. Make sure all foreign items/tools are removed

WARNING
Make sure no one is under the cab when raising
or lowering the cab, or serious personal injury
may occur.
WARNING
Before doing any work under the cab, always
make sure the cab is fully tilted/raised, or if
partially open, is locked with the tilt latch, or
serious personal injury may occur.
from under the cab.
2. Use the pump lever to turn the pump directional
valve counterclockwise to the "Lower" position.
See Figure 7.
3. Operate the pump with the pump lever (or push-
button, if equipped), until the cab locks in the
partially open position. See Figure 8.
4. Pull the tilt latch release knob and continue to
lower the cab until the cab is in the fully lowered
and latched position.

CAUTION
Cab damage may occur if the mast is not com-
pletely tilted forward.

Cab Door Assembly

CAB DOOR
Remove
1. Open the sliding windows.

2. Attach a lift strap at the left-hand and right-hand

side of the sliding windows inside the sliding win-
dow frame. Place a cushion between the sliding
window frame and the lift straps (left-hand and
right-hand sides) to prevent damage.

3. Position the cab door at a 90° angle to the frame,

so the cab door can be lifted out the hinges.

CAUTION
Use caution when lifting the cab door to avoid
damage to the cab frame.

4. Lift the cab door out of the cab door hinges. See
Figure 9.

Legend for Figure 9

A. VIEW TURNED 90° COUNTERCLOCKWISE
1. DOOR HINGE
2. DOOR PUSH-BUTTON
3. DOOR RELEASE
4. DOOR LATCH Figure 9. Cab Door
5. DOOR HANDLE
5. Move the cab door away from the lift truck and
place it on the ground.

6. Close the sliding windows.

7
Cab Door Assembly 100 SRM 1390

Install 2. Install the cab door. Refer to the section Cab

1. Open the sliding windows.
2. Attach a lift strap to the left-hand and right-hand
side of the sliding windows inside the sliding win-
dow frame. Place a cushion between the sliding
window frame and the lift straps (left-hand and
right-hand sides) to prevent damage.
Door, Install.
3. Make sure the locking system functions properly.
NOTE: Adjust one hinge at a time.
4. If necessary, adjust the hinge location when the
door is closed.

3. Raise the cab door and place it in position above
the hinges.
4. Slowly lower the cab door until the cab door is
seated on the hinges.
5. Loosen the three capscrews and use a nylon
hammer to adjust the hinge. Retighten the cap-
screws.

5. Remove the lift strap.

6. Make sure the cab door is opening, closing, and

moving properly on the hinges.

7. Make sure the locking system functions properly.

NOTE: Adjust one hinge at a time.

8. If necessary, adjust the hinge location when the

door is closed. Door clearance must be evenly
divided around the door and door opening of the
cab.

9. Loosen the three capscrews and use a nylon

hammer to adjust the hinge. Retighten the cap-
screws.

10. If necessary, adjust the door striker pin. Refer to

the section Door Striker Pin Adjustment.

DOOR HINGE
Remove
1. Remove the cab door. See the section Cab Door,
Remove.

2. Mark the location of the two hinges on the cab

frame.

3. Remove the six capscrews retaining the two

hinges to the cab frame and remove the two
hinges. See Figure 10.

Install
1. Position the two hinges to the cab frame as 1. DOOR HINGE 3. CAB FRAME
marked and install the six capscrews to retain 2. CAPSCREW
the hinges to the cab frame.
Figure 10. Door Hinge

8
100 SRM 1390 Cab Door Assembly

DOOR STRIKER PIN DOOR LATCH

Door Striker Pin Adjustment
1. Make sure the door hinges are correctly installed.
2. Loosen the securing nut that retains the door
striker pin to the cab frame. See Figure 11.
3. Place the door striker pin in the expected latch-
ing position.
4. Push and hold the release button and close the
door with normal force so that the door is posi-
tioned correctly in the door opening of the cab.
5. Open the door with the release button still en-
gaged.
6. Carefully tighten the securing nut that retains
the door striker pin to the cab frame.
7. Close the door and make sure the door is correctly
seated against the door seals.
8. If necessary, repeat Step 1 through Step 7.
Remove
1. Remove the capscrew and washer that retain the
plastic cover to the door latch. See Figure 12.
2. Remove the two capscrews that retain the door
latch to the door frame.
3. Disconnect the connector rod from the door latch
attached to the door release.
Install
1. Connect the connector rod to the door latch at-
tached to the door release.
2. Install the two capscrews to retain the door latch
to the door frame.
3. Install the capscrew and washer that retain the
plastic cover to the door latch.
4. Make sure the locking system functions correctly.

1. CAPSCREW
2. WASHER
3. PLASTIC COVER
1. CAB FRAME 4. CAPSCREW
2. SECURING NUT 5. DOOR LATCH
3. DOOR STRIKER PIN 6. CAB DOOR
7. CONNECTOR ROD
Figure 11. Door Striker Pin
Figure 12. Door Latch

9
Cab Door Assembly 100 SRM 1390

DOOR HANDLE 3. Remove the connector rod and door release from
inside the bar.
Remove
4. Disconnect the connector rod from the door re-
1. Remove the door latch. Refer to the section Door lease.
Latch, Remove.
Install
2. Remove the plastic plug at the inside of the door
frame. See Figure 13. 1. Connect the connector rod to the door release.
See Figure 14.
3. Remove the capscrew and washer that retain the
door handle, through the hole from the plastic 2. Install the connector and door release inside the
plug. bar, located at the inside of the door frame.

4. Remove the large nut and washer that retain the
door handle on the release button side of the door
handle.
5. Remove the door handle and two rubber cush-
ions.
3. Install the capscrew that retains the door release
inside the bar.
4. Install the door latch. Refer to the section Door
Latch, Install.

Install
1. Position the door handle and two rubber cushions
on the door. See Figure 13.

2. Install the washer and large nut on the release

button side of the door handle.

3. Install the washer and capscrew through the hole

from the plastic plug.

4. Install the plastic plug at the inside of the door

frame.

5. Install the latch. Refer to the section Door Latch,

Install.

6. Make sure the locking system functions correctly.

1. WASHER
2. CAPSCREW
DOOR RELEASE 3. PLASTIC PLUG
4. CAB DOOR
Remove 5. RUBBER CUSHION (LARGE)
6. DOOR HANDLE
1. Remove the door latch. Refer to the section Door 7. RUBBER CUSHION (SMALL)
Latch, Remove.
Figure 13. Door Handle
2. Remove the capscrew that retains the door re-
lease inside the bar located at the inside of the
door frame. See Figure 15.

10
100 SRM 1390 Cab Door Assembly

Install
1. Install the three capscrews, washers, and
nuts that retain the door holder (push-but-
ton), washer, and seal to the door frame. Hand
tighten the nuts. See Figure 15.

2. Position the cab door in the locking system.

3. Tighten the three nuts.

4. Make sure the door holder is positioned properly

by placing the door in the lock system. Adjust the
door holder (push-button) as needed.

5. Install the three plastic caps to the nuts located

at the inside of the door frame.

1. CAPSCREW
2. DOOR RELEASE
3. CONNECTOR ROD
4. CAB DOOR

Figure 14. Door Release

DOOR PUSH-BUTTON
Remove
1. CAB DOOR
1. Remove the three plastic caps from the nuts lo- 2. WASHER
3. SEAL
cated at the inside of the door frame. See Fig- 4. DOOR HOLDER (PUSH-BUTTON)
ure 15. 5. WASHER
6. NUT
2. Remove the three nuts, washers, and cap- 7. CAPSCREW
screws that retain the door holder (push-button),
washer, and seal to the door frame. Figure 15. Door Push-button

11
Cab Tilt System
Cab Tilt System
ELECTRIC TILT PUMP
Remove
1. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.
2. Disconnect the electrical connector, located at the
left-hand panel, from the cab tilt push-button.
See Raising and Lowering Cab, Raise Cab, Fig-
ure 8.
3. Remove the two capscrews and washers that re-
tain the left-hand panel to the frame and remove
the left-hand panel.
4. Disconnect the electrical connector from the elec-
trical tilt pump.
5. Tag and disconnect the two hydraulic hoses from
the electrical tilt pump and place plugs on the
hose ends.
6. Remove the two nuts that retain the bracket with
the electrical tilt pump to the frame.
7. Remove the bracket with the electrical tilt pump
from the frame.
8. Remove the two capscrews that retain the elec-
trical tilt pump to the bracket.
9. Remove the electrical tilt pump from the bracket.
Install
1. Position the electrical tilt pump on the bracket.
2. Install the two capscrews that retain the electri-
cal tilt pump on the bracket.
3. Position the bracket with the electrical tilt pump
on the frame.
4. Install the two nuts that retain the bracket with
the electrical tilt pump to the frame.
5. Remove the plugs and connect the two hoses to
the electrical tilt pump.
6. Connect the electrical connector to the electrical
tilt pump.
12
100 SRM 1390
7. Position the left-hand panel on the frame and in-
stall the two capscrews and washers to retain the
panel to the frame.
8. Connect the electrical connector to the cab tilt
push-button. See Raising and Lowering Cab,
Raise Cab, Figure 8.
9. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and Lower-
ing Cab.
10. Operate the electric tilt pump to check for leaks
and to remove air from the cab tilt system.
11. Check the hydraulic oil level. Refer to the section
Oil Filling for Cab Tilt System.
12. Operate the cab tilt system to check for correct
operation.
HAND PUMP
Remove
1. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.
2. If equipped, disconnect the electrical connector
located at the left-hand panel, from the cab tilt
push-button. See Raising and Lowering Cab,
Raise Cab, Figure 8.
3. Remove the two capscrews and washers that re-
tain the left-hand panel to the frame and remove
the left-hand panel.
4. Remove the two capscrews and washers that re-
tain the hand pump to the frame. See Figure 16.
NOTE: Keep the hydraulic hose connection locations
from the hand pump facing upward to avoid spilling
hydraulic oil.
5. Tag and disconnect the three hydraulic hoses and
place plugs on the three hose ends. See Fig-
ure 16.
100 SRM 1390
Install
1. Remove the plugs from the three hose ends and
connect the three hydraulic hoses to the hand
pump. See Figure 16.
2. Position the hand pump on the frame and install
the two capscrews and washers that retain the
hand pump to the frame. See Figure 16.
3. Position the left-hand panel to the frame and in-
stall the two capscrews and washers to retain the
left-hand panel to the frame.
A. 180 DEGREES TURNED
1. FRAME
2. HAND PUMP
3. HYDRAULIC HOSE
Figure 16. Hand Pump
Cab Tilt System
4. If equipped, connect the electrical connector to
the cab tilt push-button. See Raising and Low-
ering Cab, Raise Cab, Figure 8.
5. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and Lower-
ing Cab.
6. Remove the fill cap of the hand pump and fill the
reservoir with hydraulic oil. Refer to the section
Oil Filling for Cab Tilt System.
7. Make sure the cab tilt system functions correctly.
4. WASHER
5. CAPSCREW
13
Cab Tilt System 100 SRM 1390

CAB TILT CYLINDER Legend for Figure 17

Remove 1. CAB TILT FRAME

2. SNAP RING
3. CAB TILT CYLINDER
1. Tilt/raise the cab until it locks in the partially 4. PIN
open position. Refer to the section Raising and 5. FRAME
Lowering Cab.
5. Remove the snap ring from the pin that retains
2. Place wooden blocks between the frame and the the cab tilt cylinder to the cab tilt frame.
cab to prevent the cab from suddenly lowering.
6. Remove the cab tilt cylinder from the pins and re-
3. Tag and disconnect the two hydraulic hoses from move the cab tilt cylinder from under the frame.
the cab tilt cylinder and install caps on the hy-
draulic fittings and plugs in the hydraulic hoses. Disassemble
See Figure 18.
1. Place the cab tilt cylinder in a horizontal posi-
4. Remove the snap ring from the pin that retains tion with the fittings pointing downward in a vise
the cab tilt cylinder to the frame. See Figure 17. with soft jaws.

2. Place a drain pan under the fittings.

3. Remove the caps from the fittings and drain the

hydraulic oil from the cab tilt cylinder.

4. Remove the wiper from the cylinder shell. See

Figure 18.

5. Press the gland inside the cylinder shell until the

gland retaining ring is free.

6. Remove the gland retaining ring.

CAUTION
Be careful not to damage the finished surface
of the piston rod when removing the piston rod
assembly from the cylinder shell in a horizon-
tal position.

7. Remove the piston rod assembly from the cylin-

der shell by pulling it out of the cylinder shell.

CAUTION
Be careful not to damage the grooves when re-
moving O-rings, sleeve, U-cup, and retaining
rings.

8. Remove the shaft retaining ring (10,Figure 18)

that retains the piston to the piston rod.

9. Remove the piston from the piston rod.

10. Remove the end of stroke ring (9,Figure 18) from

the piston rod.

11. Remove the gland from the piston rod.

Figure 17. Cab Tilt Cylinder

14
100 SRM 1390 Cab Tilt System

12. Remove and discard the O-ring from the piston Legend for Figure 18
rod.
1. FILTER
13. Remove and discard the O-ring and sleeve from 2. HYDRAULIC FITTINGS
3. SPACER
the piston. 4. WIPER
5. GLAND RETAINING RING
14. Remove and discard the O-ring and U-cup from 6. U-CUP
the gland. 7. O-RING
8. GLAND
15. Use a special tool to remove the check valve as- 9. END OF STROKE RING
sembly, located inside the cylinder shell. 10. SHAFT RETAINING RING
11. O-RING
16. Remove and discard the pilot piston assembly, 12. O-RING
located inside the cylinder shell. 13. SLEEVE
14. PISTON
15. WASHER
16. O-RING
17. CHECK VALVE ASSEMBLY
18. PILOT PISTON ASSEMBLY
19. O-RING

Clean

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.

Compressed air can move particles so they

cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to
the eyes.

Clean all parts in solvent and dry with compressed

air.

Inspect
Inspect the parts of the cab tilt cylinder for damage,
rust, or wear. Carefully inspect the rod surface for
dents and scratches. Make sure that the internal
stroke surface of the cylinder shell and grooves for
the seals do not show any nicks, scratches, or other
damage. Repair or replace parts as needed.

Figure 18. Cab Tilt Cylinder

15
Cab Tilt System
Assemble
NOTE: Make sure that all parts are clean before as-
sembly.
NOTE: Always use new O-rings, sleeve, and U-cup.
Lubricate all parts with clean hydraulic oil.
1. Install the new pilot piston assembly, located in-
side the cylinder shell.
2. Use a special tool to install the check valve as-
sembly into the cylinder shell and tighten to 40
to 45 N•m (30 to 33 lbf ft).
3. Install a new O-ring and U-cup to the gland.
4. Install a new O-ring and sleeve on the piston.
5. Install a new O-ring on the piston rod.
6. Assemble the gland on the piston rod.
7. Install the end of stroke ring (9,Figure 18) on the
piston rod.
8. Install the piston on the piston rod.
9. Install the shaft retaining ring (10,Figure 18)
that retains the piston to the piston rod.
CAUTION
Be careful not to damage the finished surface
of the piston rod when installing the piston rod
assembly into the cylinder shell in a horizontal
position.
10. Lubricate the cylinder shell bore with clean hy-
draulic oil. Place the piston rod assembly into the
cylinder shell.
11. Press the gland inside the cylinder shell until the
groove for the gland retaining ring is free.
12. Install the gland retaining ring.
13. Pressurize the push port until the extended rod
locks the gland into the gland retaining ring.
14. Install the wiper.
Install
1. Position the cab tilt cylinder inside the frame
with the hydraulic hose fittings positioned to the
underside.
16
100 SRM 1390
2. Install the cab tilt cylinder to the pin of the cab
tilt frame and the pin of the frame.
3. Install the snap ring to the pin that retains the
cab tilt cylinder to the cab tilt frame.
4. Install the snap ring to retain the cab tilt cylinder
to the frame.
5. Remove the caps and plugs from the cab tilt cylin-
der and hydraulic hoses and connect the two hy-
draulic hoses to the cab tilt cylinder.
NOTE: If the oil level is low, the cab will not tilt/raise
completely. Refer to the section Oil Filling for Cab
Tilt System.
6. Check the hydraulic oil level. Refer to the section
Oil Filling for Cab Tilt System.
7. Completely tilt/raise the cab. Refer to the section
Raising and Lowering Cab.
8. Remove the wooden blocks between the frame
and the cab.
9. Lower the cab until it is in the fully lowered and
latched position.
10. Operate the cab tilt system to check for leaks and
correct operation.
LATCH
Remove
1. Tilt/raise the cab until it locks in the partially
open position. Refer to the section Raising and
Lowering Cab.
2. Disconnect the hydraulic hose from the front
latch and plug the hose end. See Figure 19.
3. Remove the T-adapter from the rear latch and
place a cap at the T-adapter. See Figure 19.
4. Remove the eight capscrews and nuts, and 16
washers that retain the front and rear latches to
the frame. See Figure 19.
Install
1. Position the front and rear latches on the frame
and install the eight capscrews and nuts, and 16
washers to retain the front and rear latches to
the frame. See Figure 19.
100 SRM 1390 Cab Tilt System

A. 180 DEGREES TURNED

1. FRONT LATCH 5. CAPSCREW
2. REAR LATCH 6. WASHER
3. FRAME 7. NUT
4. HYDRAULIC HOSE 8. T-ADAPTER

Figure 19. Latch

2. Remove the cap at the T-adapter and install the
T-adapter to the rear latch. See Figure 19.
3. Remove the plug from the hose end and connect
the hydraulic hose to the front latch. See Fig-
ure 19.
5. Lower the cab until it is in the fully lowered and
latched position. Refer to the section Raising and
Lowering Cab. Check the latches for correct op-
eration.

4. If required, remove the fill cap of the hand pump

and fill the reservoir with hydraulic oil. Refer to
the section Oil Filling for Cab Tilt System.

17
Brake and Inching Pedals
Brake and Inching Pedals
REMOVE
1. Remove the split pin and washer from the rod,
located behind the inching pedal.
2. Disconnect the rod from the inching pedal.
3. Remove the two capscrews, washers, and nuts
that retain the inching pedal to the bracket at
the floor of the cab.
4. Remove the two capscrews, washers, and nuts
that retain the brake pedal to the bracket at the
floor of the cab.
5. Remove the inching and brake pedal assembly.
6. Separate the inching pedal from the brake pedal
and remove the three shims.
7. Remove the two bearings from the inching pedal.
INSTALL
1. Install the two bearings on the inching pedal.
NOTE: Make sure the three shims are positioned cor-
rectly.
2. Position the three shims and install the inching
pedal to the brake pedal.
3. Position the inching and brake pedal assembly
between the brackets at the floor of the cab.
4. Install the two capscrews, washers, and nuts that
retain the brake pedal to the bracket at the floor
of the cab.
5. Install the two capscrews, washers, and nuts that
retain the inching pedal to the bracket, at the
floor of the cab.
6. Connect the rod to the inching pedal.
7. Install the washer and split pin to the rod, lo-
cated behind the inching pedal.
18
100 SRM 1390
8. Check if adjustments to the inching and brake
pedals are required, and adjust as needed. Re-
fer to the sections Brake Pedal Adjustment and
Inching Pedal Adjustment.
BRAKE PEDAL ADJUSTMENT
Dry Brake
1. Adjust the capscrew (3,Figure 20) behind the
pedal on the brake pedal assembly so that there
is 5 to 10 mm (0.2 to 0.4 in.) travel until the
brake lights come ON.
Wet Brake
1. Adjust the capscrew (3,Figure 20) behind the
pedal on the brake pedal assembly so that the
roller has contact with the capscrew on the valve
and there is no free travel.
1. BRAKE PEDAL
2. INCHING PEDAL
3. ADJUSTMENT BOLT FOR BRAKE PEDAL
ASSEMBLY
4. ADJUSTMENT BOLT FOR INCHING/BRAKE
PEDAL COUPLING
5. ADJUSTMENT BOLT FOR INCHING PEDAL
ASSEMBLY
Figure 20. Brake Pedal System
100 SRM 1390
INCHING PEDAL ADJUSTMENT
NOTE: Inching pedal adjustment influences inching
sensor adjustment and inching sensor calibration.
After the inching pedal has been adjusted, always
correct inching sensor adjustment and inching sen-
sor calibration. Incorrect inching sensor calibration
triggers fault codes during operation.
1. Adjust the bolt (5,Figure 20) behind the inch-
ing pedal on the inching pedal assembly to the
same plane with the brake pedal adjustment bolt
(3,Figure 20).
2. Adjust the adjustment bolt for the inching/brake
pedal coupling (4,Figure 20) so that the inching
pedal has no free play. Both pedals should move
together when applying the inching pedal. An
additional spring installed under the inching
pedal allows for flexibility when adjusting the
brake/inching overlap. See Figure 20 and Fig-
ure 21.
Figure 21. Brake Inching Pedal Adjustment
Brake and Inching Pedals
INCHING PEDAL SENSOR ADJUSTMENT
USING DANA DASHBOARD SOFTWARE
NOTE: When the inching pedal is not activated (pedal
up position), the analog output of the inching pedal
sensor should be between 600 and 700 mV.
NOTE: A slight preload of the potentiometer arm is
required to achieve the output voltage for the inching
pedal up position. Use the Dana Dashboard software
to check the output voltage.
1. Connect a laptop computer to the diagnostic plug
in the side console.
2. Turn the key switch to the ON position.
3. Select "Inching Pedal Calibration Mode".
4. Make sure the analog input of the inching pedal
sensor is between 600 and 700 mV.
5. If the analog input is not within specifications,
proceed as follows:
a. Tilt/raise the cab until the latch locks in the
partial open position. Refer to the section
Raising and Lowering Cab.
b. Loosen the two inching pedal sensor mount-
ing capscrews. See Figure 22.
1. SENSOR MOUNTING CAPSCREW
2. INCHING PEDAL SENSOR
Figure 22. Sensor Adjustment
19
Brake and Inching Pedals 100 SRM 1390

c. Rotate the inching pedal sensor in the slotted INCHING PEDAL SENSOR ADJUSTMENT
holes underneath the inching pedal until the USING THE APC200 DISPLAY
output voltage of the released (up position)
inching pedal is between 600 and 700 mV. NOTE: This procedure does not require a laptop.

d. Tighten the two sensor-mounting capscrews
and make sure the output voltage of the inch-
ing pedal sensor is still between 600 and 700
mV, with the inching pedal in the up position.
e. Lower the cab to the fully lowered and
latched position. Refer to the section Raising
and Lowering Cab.
NOTE: Before calibrating the inching pedal sensor,
the inching pedal must be adjusted correctly. See the
section Brake Pedal Adjustment.
1. Press and hold the "S" button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show:

6. Turn the key switch to the OFF position.

7. Disconnect the laptop computer from the diag-

nostic plug.

INCHING PEDAL SENSOR CALIBRATION 2. Release the "S" button after 15 seconds when the
PROCEDURE USING DANA DASHBOARD display shows:
SOFTWARE
1. Make sure the pedals and inching sensor have
been correctly adjusted.

2. Connect a laptop computer to the diagnostic plug

in the side console.
3. Push the "M" button until the APC200 display
3. Turn the key switch to the ON position.
shows the analog input:
4. Use the "Automatic Calibration" mode of the
Dana Dashboard software.

5. Select the "Inching Pedal Calibration" mode of

the Dana Dashboard software and follow the in-
structions.

6. The following two points must be calibrated 4. Push the "S" button three times. The display will
while the engine is running: show 0.11, 1.28, 2.29, and a value. Pushing the
• Fully released pedal (600- 700 mV) "S" button one more time changes the display to
• Fully depressed pedal (2500-4000 mV) 3.47. Releasing the "S" button shows the value in
Ohms for the inching pedal sensor (for instance,
7. Check the inching percentage of the transmis- "0.652"):
sion by using the Dana Dashboard software.
When the pedal is released, the inching per-
centage should be at 0%. If the value deviates
from 0%, the "Inching Pedal Calibration" process
must be repeated.

8. Turn the key switch to the OFF position.

9. Disconnect the laptop computer from the diag-

nostic plug.

20
100 SRM 1390 Brake and Inching Pedals

NOTE: The voltage reading of the inching pedal sen-

sor will be shown after a 1-2 second delay.

NOTE: The actual reading on the APC200 display

must be between 0.600 and 0.700, which represents
600 to 700mV.
4. Push the "S" button once to start the inching
5. Check the voltage reading of the inching pedal pedal sensor calibration. The APC200 display
sensor. The reading must be between 0.600 and will show:
0.700.

6. If the reading is not within range, adjust the

inching pedal sensor until the reading is within
specifications.

7. Turn the key switch to the OFF position to leave

the APC200 test function group. 5. Push the "S" button while in the pedal up posi-
tion. The APC200 display will show:
INCHING PEDAL SENSOR CALIBRATION
PROCEDURE USING THE APC200
DISPLAY
NOTE: This procedure does not require a laptop.

1. Press and hold the "S" button, and turn the key
switch to the ON position. During the first 15
seconds, the display will show:
6. Fully depress the inching pedal and push the "S"
button again.
7. When the calibration has been completed, the
APC200 display will show:

2. Release the "S" button after 15 seconds when the

display shows:
NOTE: Calibration procedure must be repeated if the
ignition is turned back ON too early.

8. Turn the key switch to the OFF position to save

the calibration settings.

Observe the APC200 display and wait until all

3. Push the "M" button several times until the
APC200 display shows:
segments no longer light up. When the display
remains OFF, new calibration has been entered
into the APC200 memory. The new calibration
settings will be lost if the key switch is turned
back ON too early.

21
Accelerator Pedal and Sensor 100 SRM 1390

Accelerator Pedal and Sensor

ACCELERATOR PEDAL
Remove
1. Remove the spring and capscrew on which the
pedal pivots. See Figure 23.
2. Turn the pedal 90 degrees and maneuver the
lower part of the pedal through the hole in the
floorplate into the cab.
Install
1. Maneuver the lower part of the pedal from the
cab interior through the hole in the floorplate.
2. Grease and install the bushing and pedal pivot
onto the capscrew. Position the end of the sen-
sor connecting rod into the pedal and fit the as-
sembly onto the mounting plate. Tighten the nut.
See Figure 23.

3. Fit the spring and check the adjustment of the

accelerator pedal sensor.

ACCELERATOR PEDAL SENSOR

Adjust
1. Start the engine and verify that idle speed will
raise after the pedal has been depressed between
6 and 10 mm (0.236 and 0.394 in.). See Dimen-
sion A in Figure 23.

2. If adjustment is incorrect, raise the cab until it

rests in the partially open position. Refer to the
section Raising and Lowering Cab.

3. Place a 5 mm (0.197 in.) spacer between the

pedal and the rubber pedal bumper.

4. Loosen the mounting screws of the pedal sensor

and turn the sensor until engine speed is about
1. DIMENSION A to increase from idle.
2. ACCELERATOR PEDAL
3. ACCELERATOR PEDAL ADJUSTMENT 5. Tighten the mounting screws and remove the
4. ACCELERATOR PEDAL SENSOR spacer between pedal and pedal bumper. Stop
5. MOUNTING SCREW the engine.
6. CONNECTING ROD
7. CAB FLOOR PLATE
8. ACCELERATOR PEDAL STOP
9. COUNTERCLOCKWISE
10. SLOTTED HOLE

Figure 23. Accelerator Arrangement

22
100 SRM 1390 Seat Assembly

Seat Assembly
SEAT 4. Connect the connector(s).

Remove NOTE: The ground cable is attached with the cap-

NOTE: Use a lifting device for the removal of the seat.
NOTE: The ground cable is attached with a capscrew
at the right rear corner of the suspension.
1. Disconnect the battery ground cable.
screw at the right rear corner of the suspension.
5. Connect the battery ground cable.
SEAT CUSHION
Refer to Figure 24 for the following procedures.

NOTE: There is one electrical connector on the me- Remove

chanical seat. There are two electrical connectors on
the air suspension seat. 1. Slide the seat forward.

2. Disconnect the electrical connector(s).
3. Turn the electrical plug counterclockwise and
disconnect the electrical plug located at the in-
strument panel side console.
2. Adjust the steering wheel upward to its maxi-
mum height position.
3. Remove and discard the screw from the front
right side.

NOTE: The seat must be positioned completely to the 4. Remove and discard the three clips from the
front to allow access to the two front capscrews in- cushion front.
side the sliding system. The seat must be positioned
completely to the rear to allow access to the two rear
capscrews inside the sliding system.

4. Remove the four capscrews, washers, and nuts

located above the sliding system that retain the
seat to the seat suspension.

5. Remove the seat. See Figure 24.

Install
NOTE: Use a lifting device to install the seat.

1. Position the seat onto the seat suspension.

NOTE: The seat must be positioned completely to the

front to allow access to the two front capscrews in-
side the sliding system. The seat must be positioned
completely to the rear to allow access to the two rear
capscrews inside the sliding system.

2. Install the four capscrews, washers, and nuts lo-

cated above the sliding system that retain the
seat to the seat suspension.

3. Connect the electrical plug located at the instru-

ment panel side console. 1. SEAT CUSHION
2. BACK CUSHION
NOTE: There is one electrical connector on the me- 3. BOOT
chanical seat. There are two electrical connectors on 4. SEAT SUSPENSION
the air suspension seat.
Figure 24. Seat

23
Seat Assembly
5. Slide the seat fully backward.
6. Grip the seat cushion on the front right corner.
7. Lift the seat cushion until the guide block be-
comes detached.
8. Rotate the seat cushion clockwise.
9. Lift the cushion upward to detach the front of the
seat cushion.
10. Grip the seat cushion at about the halfway point
toward the rear of the cushion.
NOTE: Increase the lifting force until the rear of the
cushion detaches.
11. Lift the seat cushion from right to left.
12. Cut the cable tie securing the connector block to
the seat cushion.
13. Disconnect the spade connectors from the con-
nector block.
14. Remove and discard the seat cushion.
Install
1. Feed the cables of the new cushion through the
hole in the armrest bracket.
2. Connect the spade connectors to the connector
block.
3. Use a cable tie to attach the connector block to
the seat cushion.
4. Locate the rear tab on the underside of the seat
cushion over the rectangular hole in the metal
pan.
5. Apply downward pressure over the tab.
6. Slide the cushion around until the tab is partially
located in the rectangular hole.
7. With the cushion angled at approximately 35° to
45°, apply a sharp blow to the front of the seat
cushion. The tab will enter the hole with an au-
dible click.
8. Pull the cushion upward to make sure the cush-
ion is correctly locked into position.
9. Install three new clips to the cushion front.
10. Install a new screw to the front right side.
24
100 SRM 1390
BACK CUSHION
Refer to Figure 24 for the following procedures.
Remove
1. Slide the seat assembly to the maximum forward
position.
2. If equipped, remove the headrest out of the two
guides.
3. Remove the two guides, located at the top side of
the back cushion, that retain the back cushion to
the back pan.
4. Remove the two screws that retain the back cush-
ion to the back pan.
5. Remove the back cushion.
Install
1. Position the back cushion.
2. Install the two screws that retain the back cush-
ion to the back pan.
3. Install the two guides, located at the top side of
the back cushion, that retain the back cushion to
the back pan.
4. If equipped, install the headrest in the two
guides.
5. Reposition the seat assembly to the correct oper-
ating position.
SEAT SUSPENSION REPLACEMENT
Refer to Figure 24 for the following procedures.
1. Remove the seat. Refer to the section Seat, Re-
move.
2. Remove the four capscrews that retain the seat
suspension to the cab floor.
3. Remove the seat suspension from the cab floor.
4. Position the new seat suspension onto the cab
floor.
5. Install the four capscrews that retain the seat
suspension to the cab floor.
6. Install the seat. Refer to the section Seat, Install.
100 SRM 1390 Seat Assembly

BOOT REPLACEMENT 3. Remove the boot.

Refer to Figure 24 for the following procedures. 4. Install the new boot.

1. Remove the seat. Refer to the section Seat, Re- 5. Install the 22 plastic plugs that retain the boot
move. to the seat suspension.

2. Use a small pry bar to remove the 22 plastic plugs 6. Install the seat. Refer to the section Seat, Install.
that retain the boot to the seat suspension.

SUSPENSION SCISSOR AND SHOCK ABSORBER

Remove
NOTE: Replacement instructions for the air seat and mechanical seat are similar.

STEP 1.
Remove the seat from the suspension. Refer to the section Seat, Remove.

STEP 2.
Remove the seat suspension from the cab. Refer to the section Seat Suspension Replacement.

STEP 3.
Remove the boot. Refer to the section Boot Replacement.

STEP 4.
Position the suspension on a workbench with the lower housing facing upward.

STEP 5.
For air seats remove the retaining screws for the air
bladder.

25
Seat Assembly 100 SRM 1390

STEP 6.
Using a 9/16” Allen wrench, remove the lower hous-
ing pivot shaft nut.

STEP 7.
Remove the pivot shaft.

STEP 8.
For mechanical seats: Lift the lower housing and
place the suspension scissor in the highest raised
position.

26
100 SRM 1390 Seat Assembly

STEP 9.
For mechanical seats: Lift the rear of the lower hous-
ing while sliding the lower housing forward to dis-
engage the height adjustment rollers from the roller
channels of the lower housing.

STEP 10.
Rotate the rear of the lower housing clockwise to dis-
engage the front suspension scissor rollers from the
roller channels of the lower housing.

STEP 11.
Remove the lower housing from the suspension.

STEP 12.
For mechanical seats: Remove the tether belts from
the suspension scissor lower pivot tubes.

27
Seat Assembly 100 SRM 1390

STEP 13.
Using a 9/16” Allen wrench, remove the upper hous-
ing pivot shaft nut.

STEP 14.
Remove the pivot shaft.

STEP 15.
Remove the weight indicator tension spring from the
suspension scissor to avoid damage to the weight in-
dicator tension spring.

STEP 16.
Lift the suspension scissor while sliding the suspen-
sion scissor forward to disengage the front suspen-
sion scissor rollers from the roller channels of the up-
per housing.

28
100 SRM 1390 Seat Assembly

STEP 17.
For both types: Remove the suspension scissor from
the upper housing and place the suspension scissor
on one side. For air seats: Remove the bladder.

STEP 18.
Remove the tether belts from the suspension scissor upper pivot tubes.

STEP 19.
Remove the rear bearing tubes from the suspension
scissor.

STEP 20.
Remove the front suspension scissor rollers from the
suspension scissor.

29
Seat Assembly 100 SRM 1390

STEP 21.
Remove the push-on PAL nut that retains the upper
shock absorber bearing to the suspension scissor.

STEP 22.
Slide the shock absorber and the shock absorber bear-
ings out of the suspension scissor.

Install
STEP 1.
Install a new upper shock absorber bearing onto the
suspension scissor and slide the shock absorber onto
the suspension scissor.

30
100 SRM 1390 Seat Assembly

STEP 2.
Install the new lower shock absorber bearing into the
shock absorber and onto the suspension scissor.

STEP 3.
Install a new push-on PAL nut to retain the shock
absorber to the suspension scissor.

STEP 4.
Use a hollow punch and a mallet to push the push-on
PAL nut until the push-on PAL nut contacts the up-
per shock absorber bearing.

31
Seat Assembly 100 SRM 1390

STEP 5.
Install the front suspension scissor rollers onto the
suspension scissor and apply MoS2 grease on the
rollers.

STEP 6.
Install the rear bearing tubes to the suspension scis-
sor.

STEP 7.
For mechanical seats: Place the tether belts over the
suspension scissor upper pivot tubes. For air seats:
Install the bladder.

32
100 SRM 1390 Seat Assembly

CAUTION
Make sure the front suspension scissor rollers are positioned completely within the roller channels
or damage may occur.

STEP 8.
Position the front suspension scissor rollers into the
roller channels of the upper housing and align the
bearing shaft tubes of the suspension scissor with the
upper housing holes.

STEP 9.
Install the weight indicator tension spring on the sus-
pension scissor.

33
Seat Assembly 100 SRM 1390

NOTE: The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the upper housing. This
alignment prevents the pivot shaft from rotating when the pivot shaft is installed.

STEP 10.
Apply a coat of MoS2 grease on the pivot shaft and
install the pivot shaft. Make sure the flat surface of
the pivot shaft head faces the upper housing.

STEP 11.
For mechanical seats: Install the pivot shaft nut and
tighten to 38 to 56 N•m (28 to 41 lbf ft).

STEP 12.
For mechanical seats: Position the height adjustment
mechanism so the suspension scissor is in the lowest
position.

34
100 SRM 1390 Seat Assembly

STEP 13.
For mechanical seats: Place the tether belts over the
suspension scissor lower pivot tubes.

STEP 14.
Lift the suspension scissor to the highest raised position.

STEP 15.
Use a wooden block [approximate length 110 mm
(4.33 in.)] to keep the suspension scissor in the
highest raised position.

35
Seat Assembly 100 SRM 1390

CAUTION
The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the upper housing.
This alignment prevents the pivot shaft from rotating when the pivot shaft is installed.

STEP 16.
Rotate the lower housing counterclockwise and posi-
tion the front suspension scissor rollers of the sus-
pension scissor into the roller channels of the lower
housing.

STEP 17.
Remove the wooden block and place the height ad-
justment rollers in the roller channels of the lower
housing. Place the wooden block back into position.

STEP 18.
Align the bearing shaft tubes of the suspension scissor with the lower housing holes.

36
100 SRM 1390 Seat Assembly

NOTE: The pivot shaft must be aligned so the flat surface of the pivot shaft head faces the lower housing. This
alignment prevents the pivot shaft from rotating when the pivot shaft is installed.

STEP 19.
Apply a coat of MoS2 grease on the pivot shaft and
install the pivot shaft. Make sure the flat surface of
the pivot shaft head faces the lower housing.

STEP 20.
Install the pivot shaft nut and tighten to 38 to
56 N•m (28 to 41 lbf ft).

STEP 21.
Remove the wooden block from the suspension.

STEP 22.
For air seats: Install the retaining screws for the air
bladder.

37
Seat Assembly 100 SRM 1390

STEP 23.
Install the boot. Refer to the section Boot Replacement.

STEP 24.
Install the seat suspension in the cab. Refer to the section Seat Suspension Replacement.

STEP 25.
Install the seat. Refer to the section Seat, Install.

COMPRESSOR

Remove
STEP 1.
Remove the seat from the suspension. Refer to the section Seat, Remove.

STEP 2.
Remove the seat suspension from the cab. Refer to the section Seat Suspension Replacement.

STEP 3.
Remove the boot. Refer to the section Boot Replacement.

STEP 4.
Using a 1/16" Allen wrench, remove the air control
knob.

38
100 SRM 1390 Seat Assembly

STEP 5.
Remove the nut and lockwasher that retain the air
valve to the upper housing and withdraw the air
valve into the suspension.

STEP 6.
Using a 9/16" Allen wrench, remove the upper hous-
ing pivot shaft nut.

STEP 7.
Remove the pivot shaft.

39
Seat Assembly 100 SRM 1390

STEP 8.
Lift the rear of the upper housing while sliding the
housing forward to disengage the front rollers from
the roller channels and remove the upper housing.

STEP 9.
Use a wooden block (approximate dimensions of 45 x
25 x 100 mm (1.77 x 0.98 x 3.94 in.) to chock the front
roller bar of the suspension.

STEP 10.
Deflate the suspension to remove all air in the pneu-
matic system.

40
100 SRM 1390 Seat Assembly

STEP 11.
Remove the tie wrap that retains the air valve elec-
trical wire harness and tube to the suspension.

STEP 12.
Disconnect the orange electrical wire connector from
the air valve body.

STEP 13.
Disconnect the compressor black electrical wire con-
nector from the suspension harness at the rear of the
compressor assembly.

41
Seat Assembly 100 SRM 1390

STEP 14.
Unscrew (counterclockwise) the plastic tube retain-
ing nut from the output port of the compressor. Re-
move the nut and O-ring from the tube and discard.

STEP 15.
Remove and retain the two screws that retain the
compressor and bracket to the suspension scissor.
Remove the compressor and bracket from the sus-
pension.

STEP 16.
Note the orientation of the compressor in the bracket.
Remove the compressor from the bracket.

42
100 SRM 1390 Seat Assembly

Install
STEP 1.
Place the new compressor into the bracket as shown.

STEP 2.
Position the compressor and bracket into the suspen-
sion and make sure the black electrical wire is routed
toward the rear of the seat and the orange electrical
wire is routed forward toward the air valve.

43
Seat Assembly 100 SRM 1390

STEP 3.
Align the compressor bracket with the suspension
mounting holes and install the two retaining screws.
Remove the protective cap from the compressor.

STEP 4.
Trim the tube that enters the compressor port past
the grooved/necked area created by the old O-ring.
If the tube is damaged or kinked, replace the entire
length of the tube and use the original tube as a
guide.

44
100 SRM 1390 Seat Assembly

STEP 5.
Install a new plastic nut and O-ring on the tube as
shown.

CAUTION
DO NOT crossthread or overtighten the plastic nut, as damage can occur.

STEP 6.
Insert the tube into the compressor port and slide
the plastic nut and O-ring up to the compressor and
tighten (clockwise) the nut. Make sure while tight-
ening the nut that the tube remains fully inserted
into the compressor port. Tighten the plastic nut
until the face of the nut is flush with the body of the
compressor as shown.

STEP 7.
Connect the compressor black electrical wire connec-
tor to the black electrical wire connector of the sus-
pension harness.

45
Seat Assembly 100 SRM 1390

STEP 8.
Route the orange electrical wire to the air valve and
attach it to the air valve. Make sure the wires are
routed without knots or kinks.

STEP 9.
Install a new tie wrap to retain the electrical wire
harness and tube to the suspension.

STEP 10.
Power up the suspension and inflate the system
for approximately 45 seconds. Use a leak detection
spray or weak soapy water to check for leaks from
the air system. Remove the wooden chock block from
the suspension.

46
100 SRM 1390 Seat Assembly

STEP 11.
Position the front suspension scissor rollers into the
roller channels of the upper housing and lower the
upper housing onto the rear bearing shaft tubes of
the suspension scissor.

STEP 12.
Apply a coat of MoS2 grease on the pivot shaft and
install the pivot shaft.

STEP 13.
Install the pivot shaft nut and tighten to 38 to
56 N•m (28 to 41 lbf ft).

47
Seat Assembly 100 SRM 1390

STEP 14.
Insert the air valve through the upper housing. In-
stall the lockwasher and nut. Tighten the nut to 10
to 18 N•m (88 to 159 lbf in).

STEP 15.
Using a 1/16" Allen wrench, install the air control
knob.

STEP 16.
Install the boot. Refer to the section Boot Replacement.

STEP 17.
Install the seat suspension in the cab. Refer to the section Seat Suspension Replacement.

STEP 18.
Install the seat on the suspension. Refer to the section Seat, Install.

48
100 SRM 1390 Power Assist Armrest

Power Assist Armrest

RELEASE CABLE 3. Disconnect the cable from the armrest (1,Fig-
ure 25), and slide the cable out of the slot in the
Remove armrest.

1. Raise the power assist armrest.
2. Loosen the two adjustment nuts that retain the
cable to the armrest. See Figure 25.
4. Disconnect the cable at the rod end of the gas
spring and slide the cable out of the slot.
5. Remove the cable from the power assist armrest
through the front side of the power assist arm-
rest.

Install
1. Install the cable through the power assist arm-
rest from the front side of the power assist arm-
rest.

2. Connect the cable at the rod end of the gas spring.

3. Connect the cable to the armrest (1,Figure 25).

4. Adjust the cable length with the two nuts to ob-

tain a free lever movement of 1.5 to 2.0 mm before
the gas spring will unlock.

5. Tighten the two nuts that retain the cable to the

armrest (1,Figure 25).

6. Lower the power assist armrest.

GAS SPRING
Remove
1. Raise the power assist armrest, and make sure
the gas spring has reached its maximum ex-
tended length.

2. Disconnect the cable from the rod end of the gas

spring.

3. Support the power assist armrest and remove the

1. LEVER bottom-mounting capscrew and washer that re-
2. ROD END tain the gas spring rod to the armrest frame.
3. LOCK NUT
4. MOUNTING CAPSCREW 4. Manually lower the power assist armrest.
5. ARMREST
6. CABLE 5. Remove the top-mounting capscrew and washer
7. GAS SPRING
8. WASHER that retain the gas spring to the armrest frame.
9. ARMREST FRAME
10. NUT 6. Remove the gas spring.

Figure 25. Power Assist Armrest

49
Power Assist Armrest 100 SRM 1390

Install 6. Place the cover with the joystick label in posi-

1. Make sure that the gas spring has reached its
maximum extended length.
2. Position the gas spring.
3. Install the top-mounting capscrew and washer to
retain the gas spring to the armrest frame.
tion on the power assist armrest. Install the four
screws to retain the cover to the power assist
armrest.
7. Make sure the joystick functions properly.

4. Manually raise the power assist armrest.

5. Support the power assist armrest and install the

bottom-mounting capscrew and washer to retain
the gas spring to the armrest frame.

6. Connect and adjust the cable to the rod end of the

gas spring.

JOYSTICK
Remove
1. Remove the four screws that retain the cover
with the joystick label to the power assist arm- 1. COVER SCREWS
rest. See Figure 26. 2. COVER
3. JOYSTICK SCREWS
2. Remove the cover from the power assist armrest. 4. JOYSTICK
5. JOYSTICK ROTATION
3. Remove the four joystick screws that retain the
joystick to the power assist armrest. Figure 26. Joystick Removal

4. Partially raise the joystick until it is possible to ELECTRICAL LEVERS

turn the joystick 90° counterclockwise with the
electric cable inside the power assist armrest.
5. Completely remove the joystick from the power
assist armrest.
6. Tag and disconnect the four electrical connectors
from the joystick.
Install
NOTE: For lift trucks with hydraulic control levers,
the remove and replace instructions are shown in the
model specific Hydraulic System SRM.
Remove
1. Remove the four screws that retain the cover
with the levers to the power assist armrest. See
Figure 27.

1. Connect the four electrical connectors to the joy- NOTE: Most connectors are equipped with symbol la-
stick. bels for identification.

2. Position the joystick in the power assist armrest 2. If necessary, tag the electrical connector(s) for
with the electric cable pointing to the right. identification.

3. Turn the joystick 90° clockwise.
4. Reroute the electrical cables and electrical con-
nectors inside the power assist armrest.
5. Install the four joystick screws to retain the joy-
stick to the power assist armrest.
3. Disconnect the electrical connector(s) from the
lever(s).
4. Remove the two screws that retain the lever to
the cover.
5. Remove the lever from the underside of the cover.

50
100 SRM 1390 Power Assist Armrest

Install 2. Press the holding clips on the switches and push

1. Install the lever from the underside to the cover.
2. Install the two screws to retain the lever to the
cover.
3. Connect the electrical connector(s) to the lever(s).
4. Install the four screws that retain the cover with
the levers to the power assist armrest.
5. Calibrate the lever. See the model specific Hy-
draulic System SRM.
the rocker switch out of the armrest.
3. Disconnect the electrical connector.
Install
1. Connect the electrical connector to the rocker
switch.
2. Install the switch by pressing it into the opening
of the panel until the holding clips of switch are
seated.
3. Install the bottom plate using six retaining
screws.

ARMREST TOP COVER

Remove
1. Remove the joystick or lever cover. Refer to the
section Joystick, Remove or the section Electrical
Levers, Remove.

2. Remove all rocker switches. Refer to the section

Armrest Rocker Switches, Remove.

3. Remove the six screws at the underside of the

armrest frame that retain the armrest top cover
to the armrest frame.

4. Remove the eight screws that retain the armrest

top cover to the armrest plate.
1. COVER 5. Remove the armrest top cover from the armrest
2. COVER SCREWS
3. LEVER SCREWS plate.
4. LEVER
Install
Figure 27. Levers Removal
1. Position the armrest top cover on the armrest
ARMREST ROCKER SWITCHES plate.

2. Install the eight screws to retain the armrest top

Remove
cover to the armrest plate.
NOTE: If a failed switch is to be replaced by a new
3. Install the six screws at the underside of the arm-
one, use a screw driver to force the failed switch out
rest frame to retain the armrest top cover to the
of the panel. The switch may suffer additional dam-
armrest frame.
age beyond repair. Remove the electrical connector
from the failed switch and connect it to the replace- 4. Install the rocker switches. Refer to the section
ment switch. Install the switch by pressing it into Armrest Rocker Switches, Install.
the opening in the panel until the holding clips of the
switch are seated. 5. Install the joystick or lever cover. Refer to the
section Joystick, Install or the section Electrical
1. Remove six screws that retain the bottom plate Levers, Install.
and lower the plate.

51
Instrument Panel 100 SRM 1390

Instrument Panel
KEY SWITCH panel and remove the cover to gain access to
the underside of the instrument panel. See Fig-
Remove ure 28.

1. Switch the key to the OFF position.
2. Remove the key from the key switch.
3. Remove the nut that retains the key switch to the
instrument panel top console.
4. Remove the four screws that retain the fuse
panel cover at the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See Fig-
ure 30.
5. Remove the key switch by sliding the key switch
downward out of the hole to the inside of the in-
strument panel top console.
6. Disconnect the electrical connector from the key
switch.
Install
1. Connect the electrical connector to the key
switch.
2. Disconnect the electrical connector from the 12V
power socket.
3. Push the 12V power socket through the instru-
ment panel top console from the inside to the out-
side.
Install
1. Install the 12V power socket to the instrument
panel top console from the outside to the inside
until the 12V power socket is secured to the in-
strument panel top console. See Figure 29.
2. Connect the electrical connector to the 12V power
socket.
3. Position the fuse panel cover to the right side of
the instrument panel and install the four retain-
ing screws.

2. Install the key switch by sliding the key switch

upward into the hole to the outside of the instru-
ment panel top console.

3. Position the key switch correctly into the hole in

the instrument panel top console.

4. Install the nut to retain the key switch to the

instrument panel top console.

5. Make sure that the key switch functions cor-

rectly.

6. Position the fuse panel cover to the right side of

the instrument panel and install the four retain-
ing screws. See Figure 28.

12V POWER SOCKET

1. SCREWS 2. COVER
Remove
Figure 28. Fuse Panel and Cover Location
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument

52
100 SRM 1390 Instrument Panel

ELECTRIC-OPERATED HEAT CONTROL 5. Remove the potentiometer by sliding it down-

AND AIR RECIRCULATION CONTROL ward out of the hole to the inside of the instru-
(AIRCO ONLY) ment panel top console.

Remove Install

1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See Fig-
ure 28.
2. Disconnect the electrical connector from the po-
tentiometer at the inside of the instrument panel
box.
3. Remove the air recirculation knob at the instru-
ment panel top console. See Figure 29.
4. Remove the nut that retains the potentiometer to
the instrument panel top console.
1. Install the potentiometer by sliding it upward
into the hole to the inside of the instrument panel
top console.
2. Install the nut that retains the potentiometer to
the instrument panel top console.
3. Install the air recirculation knob at the instru-
ment panel top console. See Figure 29.
4. Connect the electrical connector to the poten-
tiometer at the inside of the instrument panel
box.
5. Position the fuse panel cover to the right side of
the instrument panel and install the four retain-
ing screws. See Figure 28.

1. KEY SWITCH 8. HEATER SWITCH COVER

2. POWER SOCKET 12V 9. ROCKER SWITCHES
3. KEY SWITCH COVER 10. PARKING BRAKE SWITCH COVER
4. FAN SPEED KNOB 11. PARKING BRAKE SWITCH
5. HEAT CONTROL KNOB 12. INSTRUMENT PANEL TOP CONSOLE
6. AIR RECIRCULATION KNOB (OPTIONAL) 13. INDICATOR DISPLAY
7. AIR CONDITIONING SWITCH (OPTIONAL)

Figure 29. Switch Locations

53
Instrument Panel
CABLE-OPERATED HEATER CONTROL
(HEATER ONLY)
Remove
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See Fig-
ure 28.
2. Remove the heat control knob at the instrument
panel top console. See Figure 29.
3. Remove the nut that retains the heat rotary con-
trol assembly to the instrument panel top con-
sole.
4. Remove the heat rotary control assembly from
the underside of the instrument panel top con-
sole.
5. Remove the cable clip and unlatch the inner cable
from the rotary control.
Install
1. Pull the inner cable to make sure the water valve
has reached its end position.
2. Turn the rotary control to the extended (full hot)
position.
3. Position and latch the inner cable to the heat ro-
tary control and install the cable clip.
4. Install the heat rotary control assembly from the
underside of the instrument panel top console.
5. Install the nut to retain the heat rotary control
assembly to the instrument panel top console.
6. Install the heat control knob at the instrument
panel top console.
7. Position the fuse panel cover to the right side of
the instrument panel and install the four retain-
ing screws. See Figure 28.
AIR CONDITIONING SWITCH
REPLACEMENT
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
54
100 SRM 1390
panel and remove the cover to gain access to
the underside of the instrument panel. See Fig-
ure 28.
2. Tag and disconnect the three electrical wires
from the air conditioning switch.
3. Remove the air conditioning switch by pressing
the two clips together and pushing the air condi-
tioning switch from the inside to the outside. See
Figure 29.
4. Install the new air conditioning switch by push-
ing the air conditioning switch from the outside
to the inside until the two clips are latched. See
Figure 29.
5. Connect the three wires to the air conditioning
switch.
6. Position the fuse panel cover to the right side of
the instrument panel and install the four retain-
ing screws. See Figure 28.
INSTRUMENT PANEL ROCKER SWITCHES
REPLACEMENT
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See Fig-
ure 28.
NOTE: Most connectors are equipped with symbol la-
bels for identification.
2. If necessary, tag the connector for identification.
3. Disconnect the connector from the rocker switch
by pressing the clip at the connector.
4. Remove the rocker switch by pressing the two
clips together and pushing the rocker switch from
the inside to the outside. See Figure 29.
5. Install the new rocker switch by pushing the
rocker switch from the outside to the inside until
the two clips are latched. See Figure 29.
6. Connect the connector to the rocker switch.
7. Position the fuse panel cover to the right side of
the instrument panel and install the four retain-
ing screws. See Figure 28.
100 SRM 1390
PARKING BRAKE SWITCH
Remove
1. Remove the four screws that retain the parking
brake switch cover to the instrument panel top
console and remove the cover. See Figure 29.
2. Remove the tie wrap that connects the top and
bottom rubber boots to each other, which together
cover the electrical connector.
3. Remove the bottom rubber boot from the electri-
cal connector to gain access to the electrical con-
nector.
4. Disconnect the electrical connector by turning
the clip to one side.
5. Remove the nut that retains the parking brake
switch to the parking brake switch cover.
6. Remove the parking brake switch from the park-
ing brake switch cover.
Install
1. Position the parking brake switch in the parking
brake switch cover.
2. Install the nut to retain the parking brake switch
to the parking brake switch cover.
3. Connect the electrical connector to the parking
brake switch until the clip is securely latched.
4. Install the bottom rubber boot over the electrical
connector.
5. Place the top rubber boot over the bottom rubber
boot and tighten using a tie wrap.
6. Make sure the parking brake switch functions
correctly.
7. Position the parking brake switch cover to the
instrument panel top console and install the four
retaining screws.
INDICATOR DISPLAY REPLACEMENT
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See Fig-
ure 28.
Instrument Panel
2. Disconnect the electrical connector from the in-
dicator display at the inside of the instrument
panel box.
3. Remove the indicator display by pressing the two
clips together and pushing the indicator display
from the inside to the outside. See Figure 30.
4. Install the new indicator display by pushing the
indicator display from the outside to the inside
until the two clips are latched.
5. Connect the electrical connector to the indicator
display at the inside of the instrument panel box.
6. Position the fuse panel cover to the right side of
the instrument panel and install the four retain-
ing screws. See Figure 28.
INSTRUMENT PANEL TOP CONSOLE
Remove
1. Remove the key switch cover and key switch. Re-
fer to the section Key Switch, Remove.
2. Remove the heater switch cover and switches.
See Figure 29. Refer to the section Electric-Oper-
ated Heat Control and Air Recirculation Control
(Airco Only), Remove and the section Air Condi-
tioning Switch Replacement.
3. Remove the parking brake switch cover and
parking brake switch. Refer to the section Park-
ing Brake Switch, Remove.
4. Disconnect the electrical connector to the instru-
ment panel inside the instrument panel box.
1. INDICATOR DISPLAY CLIP
Figure 30. Indicator Display Removal
55
Steering Wheel and Column Assembly
5. Remove the five screws that retain the instru-
ment panel top console to the cab, and remove
the instrument panel top console.
Install
1. Position the instrument panel top console to the
cab and install the five retaining screws.
2. Connect the electrical connector to the instru-
ment panel inside the instrument panel box.
3. Install the parking brake switch and cover. Refer
to the section Parking Brake Switch, Install.
Steering Wheel and Column Assembly
STEERING WHEEL AND HORN
Remove
CAUTION
To prevent electrical arcs when removing the
cover, disconnect the battery ground cable.
1. Disconnect the battery ground cable.
2. Remove the horn button from the steering wheel.
See Figure 31.
3. Disconnect the electrical wire from the horn
switch to the horn button.
Legend for Figure 31
1. SCREW
2. WASHER
3. SCREW
4. WASHER
5. SOCKET
6. HORN BUTTON
7. SPINNER KNOB
8. STEERING WHEEL
9. WIRE HARNESS
10. TOP STEERING COLUMN COVER
11. UPPER LEFT-HAND STEERING COLUMN
COVER
12. UPPER RIGHT-HAND STEERING COLUMN
COVER
56
100 SRM 1390
4. Install the heater switch cover and switches. Re-
fer to the section Electric-Operated Heat Control
and Air Recirculation Control (Airco Only), In-
stall and the section Air Conditioning Switch Re-
placement.
5. Install the key switch and cover. Refer to the
section Key Switch, Install.
6. Make sure the switches function correctly.
4. Remove the large nut and remove the steering
wheel from the steering column.
Install
1. Install the steering wheel and the large nut onto
the steering column. See Figure 31. Tighten the
nut to 35 to 45 N•m (26 to 33 lbf ft).
2. Connect the electrical wire from the horn switch
to the horn button.
3. Install the horn button onto the steering wheel.
4. Connect the battery ground cable.
13. LOWER LEFT-HAND STEERING COLUMN
COVER
14. LOWER RIGHT-HAND STEERING COLUMN
COVER
15. STEERING COLUMN ASSEMBLY
16. BOOT
17. MAIN WARNING LIGHTS
18. STEERING CONTROL UNIT (UNDER CAB
FLOOR)
19. ADJUSTMENT HANDLE
20. CAPSCREW AND SPRING (LOCATION)
100 SRM 1390 Steering Wheel and Column Assembly

Figure 31. Steering Wheel and Steering Column Assembly

57
Steering Wheel and Column Assembly 100 SRM 1390

STEERING COLUMN ASSEMBLY
Remove
1. Turn the battery disconnect switch to the OFF
position.
2. Remove the screws that retain the lower left-
hand and right-hand steering column covers to
the steering column. See Figure 31.
3. Tilt/raise the cab until it locks in the partially
open position. Refer to the section Raising and
Lowering Cab.
4. Disconnect the steering column electrical connec-
tor located under the cab. See the Cab, Remove
section of the model specific Frame manual.
4. Install the two capscrews and nuts to retain the
steering column to the cab floor.
CAUTION
DO NOT force the steering control unit onto
the steering column shaft, as damage can oc-
cur.
5. Place the steering control unit in position under
the cab while aligning the steering column shaft
with the slot in the steering control unit.
6. Install the four capscrews and washers that re-
tain the steering control unit to the underside of
the operator’s cab.

CAUTION
Use caution when removing the steering con-
trol unit or damage may occur.

5. Remove the four capscrews that retain the steer-

ing control unit to the cab. See Figure 32.

6. Place the steering control unit with the hydraulic

hoses attached in the engine compartment.

7. Remove the two capscrews and nuts that retain

the steering column to the cab floor. See Fig-
ure 33.

8. Lower the cab until it is in the fully lowered and

latched position. Refer to the section Raising and
Lowering Cab.

9. Remove the two capscrews that retain the steer-

ing column to the bracket. See Figure 33.

10. Remove the steering column. Push the grommet

out of the hole and slide the connector through
the hole in the cab floor.

Install
1. Slide the connector through the hole in the cab
floor and push the grommet into the hole.
1. OPERATOR’S CAB
2. STEERING CONTROL UNIT
2. Position the steering column to the cab floor and 3. WASHER
Install the two capscrews to retain the steering 4. CAPSCREW
column to the bracket. See Figure 33.
Figure 32. Steering Control Unit, View Under
3. Tilt/raise the cab until it locks in the partially Operator’s Cab
open position. Refer to the section Raising and
Lowering Cab.

58
100 SRM 1390
1. CAPSCREW (STEERING COLUMN TO
BRACKET)
2. NUT (STEERING COLUMN TO CAB FLOOR)
Figure 33. Steering Column
7. Connect the steering column electrical connector
positioned under the cab. See the Cab, Remove
section of the model specific Frame manual.
8. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and Lower-
ing Cab.
9. Position the lower left-hand and right-hand
steering column covers and install the screws to
retain the covers. See Figure 31.
10. Turn the battery disconnect switch to the ON po-
sition.
11. Check for correct operation.
ADJUSTMENT HANDLE
Remove
1. Loosen the capscrew and spring that retain the
adjustment handle to the adjustment mecha-
nism. See Figure 31.
2. Turn the adjustment handle counterclockwise to
loosen and remove the adjustment mechanism
from the steering column.
3. Remove the capscrew and spring that retain the
adjustment handle to the adjustment mecha-
nism.
Steering Wheel and Column Assembly
Install
1. Position the adjustment handle and install the
capscrew and spring to retain the adjustment
handle to the adjustment mechanism. Hand
tighten the capscrew at this time.
2. Turn the adjustment handle clockwise to install
the adjustment mechanism to the steering col-
umn.
3. Tighten the capscrew and spring that retain the
adjustment handle to the adjustment mecha-
nism.
MAIN WARNING LIGHTS
Remove
NOTE: The main warning lights are part of the top
steering column cover. When the main warning
lights must be replaced, the complete top steering
column cover must be replaced.
1. Remove the steering wheel. Refer to the section
Steering Wheel and Horn, Remove.
2. Remove the six screws and washers that retain
the top steering column cover to the upper left-
hand and right-hand steering column covers. See
Figure 31.
3. Tag and disconnect the two wires from the main
warning lights inside the top steering column
cover by loosening the two screws.
4. Remove the top steering column cover from the
steering column.
Install
1. Position the top steering column cover on the
steering column.
2. Connect the two wires to the main warning lights
inside the top steering column cover and tighten
the two screws.
3. Position the top steering column cover to the
upper left-hand and right-hand steering column
covers and install the six retaining screws and
washers.
4. Install the steering wheel. Refer to the section
Steering Wheel and Horn, Install.
59
Window Wipers Replacement
SHIFT LEVER
Remove
1. Remove the steering wheel. Refer to the section
Steering Wheel and Horn, Remove.
2. Remove the six screws and washers that retain
the top steering column cover to the upper left-
hand and right-hand steering column covers. See
Figure 31.
3. Remove the upper steering column cover from
the steering column.
4. Remove the two screws that retain the shift lever
to the steering column and remove the shift lever.
5. Disconnect the electrical connector from the shift
lever.
Install
1. Connect the electrical connector to the shift lever.
2. Position the shift lever to the steering column
and install the two retaining screws.
3. Install the six screws and washers that retain the
top steering column cover to the upper left-hand
and right-hand steering column covers.
4. Install the steering wheel. Refer to the section
Steering Wheel and Horn, Install.
5. Make sure the shift lever functions correctly.
Window Wipers Replacement
NOTE: Three window wiper motor assemblies are in-
stalled in the cab. The front window has a single-
arm, parallelogram-type window wiper motor system
that creates a large wiping surface area. The op-
tional front window can be equipped with an H-wiper,
which creates a wider view capacity. The wiper motor
is mounted under the cab so it does not obstruct visi-
bility. The top window and rear window are equipped
with a window wiper motor assembly that has one
wiper arm with a wiper blade. A washer system is
directly connected to the front and top wipers. A
washer nozzle is installed to the rear cab frame to
provide window washer fluid to the rear window.
60
100 SRM 1390
TURN SIGNAL LEVER
Remove
1. Remove the steering wheel. Refer to the section
Steering Wheel and Horn, Remove.
2. Remove the top steering column cover from the
steering column. Refer to the section Steering
Column Assembly, Remove.
3. Remove the two screws and wire that retain the
turn signal lever to the steering column.
4. Remove the turn signal lever.
5. Tag and disconnect the three wires connected
to the turn signal lever by loosening the three
screws.
Install
1. Connect the three wires to the turn signal lever
and tighten the three screws.
2. Position the turn signal lever to the steering col-
umn.
3. Install the two screws and wire that retain the
turn signal lever to the steering column.
4. Install the top steering column cover to the steer-
ing column. Refer to the section Steering Column
Assembly, Install.
5. Install the steering wheel. Refer to the section
Steering Wheel and Horn, Install.
6. Make sure the turn signal lever functions cor-
rectly.
WINDOW WIPER ASSEMBLY, REPLACE
Remove
1. Mark the position of the window wiper assembly
on the window.
2. Disconnect the black washer hose from the con-
nection adapter, if applicable.
3. Lift the cover. See Figure 34.
4. Remove the nut and washer.
100 SRM 1390 Window Wiper Motor Replacement

5. Remove the window wiper assembly from the

shaft and window.

Install
NOTE: Make sure the window wiper assembly is
properly positioned to provide optimal coverage of
the window.

1. Position the window wiper assembly on the win-

dow and shaft.

2. Install and tighten the nut and washer.

3. Close the cover.

4. Connect the washer hose, if applicable. 1. COVER

2. COVER OPENED
3. NUT WITH WASHER

Figure 34. Wiper Assembly

Window Wiper Motor Replacement

FRONT WINDOW WIPER MOTOR 4. Connect the electrical connector to the wiper mo-
ASSEMBLY tor.

Remove 5. Lower the cab to the fully lowered and latched

position. Refer to the section Raising and Lower-
1. Mark the wiper position. ing Cab.

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

Refer to the section Raising and Lowering Cab.

3. Disconnect the electrical connector from the

wiper motor. See Figure 35.

4. Remove the capscrew on the wiper motor arm

and remove the wiper motor arm.

5. Remove the three capscrews that retain the

wiper motor to the underside of the cab.

6. Remove the wiper motor assembly.

Install
1. Position the wiper motor assembly to the under- 1. WIPER MOTOR ARM
side of the cab. 2. CAPSCREW
3. WIPER MOTOR ASSEMBLY
2. Install the three capscrews to retain the wiper 4. WIPER MOTOR ELECTRICAL CONNECTOR
motor to the underside of the cab.
Figure 35. Front Window Wiper Motor Assembly
3. Install the wiper motor arm and tighten the cap-
screw on the wiper motor arm.

61
Window Wiper Motor Replacement 100 SRM 1390

REAR WINDOW WIPER MOTOR 4. Disconnect the wiper motor electrical connector.
ASSEMBLY
5. Remove the two nuts and washers that retain the
Remove wiper motor assembly to the cab.

1. Disconnect battery ground cable. 6. Remove the wiper motor assembly.

2. Remove the wiper assembly. Refer to the section Install

Window Wipers Replacement.
1. Position the wiper motor assembly to the cab.
3. Remove the cover from the wiper motor assembly.
2. Install the two washers and nuts to retain the
4. Disconnect the wiper motor electrical connector. wiper motor assembly to the cab.
See Figure 36.
3. Connect the wiper motor electrical connector.
5. Remove the two nuts and washers that retain the
4. Install the wiper assembly. Refer to the section
wiper motor assembly to the cab.
Window Wipers Replacement.
6. Remove the wiper motor assembly.
5. Install the radio console. Refer to the section Ra-
Install dio Console.

1. Position the wiper motor assembly to the cab. 6. Connect battery ground cable.

2. Install the two washers and nuts to retain the

wiper motor assembly to the cab.

3. Connect the wiper motor electrical connector.

4. Install the cover on the wiper motor assembly.

5. Install the wiper assembly. Refer to the section

Window Wipers Replacement.

6. Connect battery ground cable.

TOP WINDOW WIPER MOTOR ASSEMBLY

Remove
1. Disconnect battery ground cable. 1. WIPER MOTOR CONNECTOR
2. NUTS AND WASHERS
2. Remove the radio console. Refer to the section
Radio Console. Figure 36. Rear Wiper Motor Assembly

3. Remove the wiper assembly. Refer to the section

Window Wipers Replacement.

62
100 SRM 1390 Window Washer System

Window Washer System

WINDOW WASHER RESERVOIR AND 5. Install the two capscrews to retain the two brack-
PUMPS ets to the reservoir at the left underside of the
cab.
Remove
6. Connect the electrical connectors to the washer
1. If installed, remove the training seat. motors and pumps.

2. Remove the four capscrews and washers that re- 7. Lower the cab to the fully lowered and latched
tain the cover to the right rear corner of the cab position. Refer to the section Raising and Lower-
and remove the cover. ing Cab.

3. Loosen the hose clamp that retains the fill hose 8. Connect the fill hose to the reservoir.
to the reservoir.
9. Tighten the hose clamp to retain the fill hose to
4. Disconnect the fill hose from the reservoir. the reservoir.

5. Tilt/raise the cab to the partially open position.
Refer to the section Raising and Lowering Cab.
6. Tag and disconnect the electrical connectors from
the washer motor and pumps.
10. Position the cover to the right rear corner of the
cab and install the four retaining capscrews and
washers.

NOTE: The reservoir must be drained prior to re-

moval of reservoir and pumps.

7. Drain the washer reservoir.

8. Remove the two capscrews that retain the two

brackets to the reservoir at the left underside of
the cab.

9. Remove the two brackets.

10. Remove the reservoir.

11. Tag and disconnect the three window washer

hoses from the washer motor and pumps.

12. Remove the window washer pumps by pulling

them away from the rubber seal in the hole of the
reservoir. See Figure 37.

Install
1. Install the window washer pumps by pushing
them in the rubber seal in the hole of the reser-
voir. See Figure 37.

2. Connect the three window washer hoses to the

washer motors and pumps.
1. FRONT WINDOW WASHER MOTOR AND PUMP
3. Install the reservoir. 2. TOP WINDOW WASHER MOTOR AND PUMP
3. REAR WINDOW WASHER MOTOR AND PUMP
4. Position the two brackets.
Figure 37. Washer Motors and Pumps

63
Window Washer System 100 SRM 1390

11. If necessary, install the training seat.
12. Fill the window washer reservoir as needed.
WINDOW WASHER HOSES
7. Place the washer hoses inside the instrument
panel box.
8. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.

Hoses for Top and Rear Window
Remove
1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover. See Instrument
Panel, Install, Figure 28.
9. Remove the tie wraps that retain the washer
hose(s) to the underside of the cab.
10. Disconnect the washer hose(s) from the window
washer motor(s) and pump(s).
11. Disconnect the washer hose ends that are con-
nected to the valve(s) and remove the valve(s).

2. Remove the five screws and washers that retain
the cable cover located at the right rear corner of
the cab. See Figure 38.
12. Disconnect the washer hose(s) from the connec-
tion adapter located at the inside of the heater.
13. Remove the three capscrews that retain the
heater to the cab and swing the heater down.

14. Disconnect the washer hose(s) from the connec-

tion adapter located at the outside of the heater.

15. Remove the washer hose(s) from inside of the in-

strument panel box.

NOTE: Step 16, Step 17, and Step 18 are for the top
window washer hose only.

16. Disconnect the black washer hose from the con-

nection adapter, located at the top side of the cab
roof.

17. Disconnect the black washer hose from the win-

dow washer nozzle.

18. Remove the black washer hose from the top win-
dow washer wiper arm.

Install
1. CABLE COVER
2. PROTECTION SEAL NOTE: Step 1, Step 2, and Step 3 are for the top win-
3. SCREW dow washer hose only.
4. WASHER
1. Position the black washer hose to the top window
Figure 38. Cable Cover Removal washer wiper arm.
3. Remove the cable cover and protection seal. 2. Connect the black washer hose to the window
washer nozzle.
4. Remove the radio console to gain access to the
washer hose end. Refer to the section Radio Con- 3. Connect the black washer hose to the connection
sole, Remove. adapter at the top side of the cab roof.
5. Drain the washer reservoir. 4. Position the washer hose inside the instrument
panel box.
6. Disconnect the washer hoses at the connection
adapters located behind the radio console. 5. Connect the washer hose(s) to the connection
adapters located at the inside of the heater.

64
100 SRM 1390
6. Swing the heater up and install the three cap-
screws that retain the heater to the cab.
7. Connect the washer hose(s) to the connection
adapters located at the outside of the heater.
8. Connect the washer hose ends to the valve(s).
Make sure that the valve(s) are positioned cor-
rectly.
9. Connect the washer hose(s) to the window
washer motor(s) and pump(s) at the reservoir.
10. Install the tie wraps to retain the washer hose(s)
to the underside of the cab.
11. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and Lower-
ing Cab.
12. Position the washer hose(s), located inside the
instrument panel box, along the right rear corner
to the connection adapters.
13. Connect the washer hose(s) to the connection
adapters located behind the radio console.
14. Install the radio console. Refer to the section Ra-
dio Console, Install.
15. Install the cable cover and protection seal at the
right rear corner and install the five screws and
washers. See Figure 38.
16. Position the fuse panel cover to the right side of
the instrument panel and install the four retain-
ing screws. See Instrument Panel, Install, Fig-
ure 28.
17. Fill the reservoir with washer fluid.
18. Check for leaks.
Hoses for Front Window
Remove
1. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.
2. Remove the tie wraps that retain the washer
hose(s) to the underside of the cab.
3. Drain the washer fluid from the reservoir.
4. Disconnect the washer hose from the window
washer motor and pump at the reservoir.
Window Washer System
5. Disconnect the washer hose ends that are con-
nected to the valve and remove the valve.
6. Disconnect the washer hose from the connection
adapter, located at the outside of the heater.
7. Remove the washer hose.
8. Disconnect the washer hose from the connection
adapter, located to the outside of the cab floor.
9. Disconnect the washer hose from the connection
adapter, located to the front inside of the cab.
10. Remove the washer hose.
11. Remove the three capscrews that retain the
heater to the cab and swing the heater down.
12. Disconnect the washer hose from the connection
adapter, located to the inside of the heater.
13. Disconnect the washer hose from the connection
adapter, located to the inside of the cab floor.
14. Remove the washer hose from the instrument
panel box from the underside of the cab.
15. Disconnect the black washer hose from the con-
nection adapter, located at the front outside of
the cab under the window wiper.
16. Disconnect the black washer hose from the win-
dow washer nozzle.
17. Remove the black washer hose from the window
washer wiper arm.
Install
1. Position the black washer hose to the window
washer wiper arm.
2. Connect the black washer hose to the window
washer nozzle.
3. Connect the black washer hose to the connection
adapter, located at the front outside of the cab
under the window wiper.
4. Position the washer hose inside the instrument
panel box from the underside of the cab.
5. Connect the washer hose to the connection
adapter, located to the inside of the cab floor.
6. Connect the washer hose to the connection
adapter, located to the inside of the heater.
65
Window Washer System 100 SRM 1390

7. Swing the heater up and install the three cap- 4. Make sure the nozzle functions correctly.
screws to retain the heater to the cab.
Rear
8. Connect the washer hose to the connection
adapter, located to the front inside of the cab. Remove

9. Connect the washer hose to the connection 1. Remove the radio console inside the cab. Refer to
adapter, located to the outside of the cab floor. the section Radio Console, Remove.

10. Connect the washer hose to the connection 2. Disconnect the window washer hose from the
adapter, located at the outside of the heater. nozzle.

11. Connect the washer hose ends to the valve. Make 3. Remove the nut that retains the nozzle to the cab
sure that the valve is positioned correctly. rear frame.

12. Connect the washer hose to the window washer 4. Remove the nozzle and rubber boot to the outside
motor and pump at the reservoir. of the cab rear frame.

13. Install the tie wraps to retain the washer hose(s) Install
to the underside of the cab.
1. Install the nozzle and rubber boot from the out-
14. Lower the cab to the fully lowered and latched side to the cab rear frame.
position. Refer to the section Raising and Lower-
ing Cab. 2. Install the nut to retain the nozzle to the cab rear
frame.
15. Fill the reservoir with window washer fluid.
3. Connect the window washer hose to the nozzle.
16. Check for leaks.
4. Make sure the nozzle functions correctly.
WINDOW WASHER SPRAY NOZZLES
5. Install the radio console. Refer to the section Ra-
dio Console, Install.
Front
Remove Top

1. Remove the front window wiper assembly. Refer Remove

to the section Window Wipers Replacement.
1. Disconnect the window washer hose from the
2. Disconnect the window washer hose from the nozzle.
nozzle.
2. Remove the nozzle from the top window washer
3. Remove the two screws that retain the nozzle to wiper.
the front window wiper arm and remove the noz-
Install
zle.
1. Install the nozzle to the top window washer
Install
wiper.
1. Position the nozzle and install the two screws to
2. Connect the window washer hose to the nozzle.
retain the nozzle to the front window wiper arm.
3. Make sure the nozzle functions correctly.
2. Connect the window washer hose to the nozzle.

3. Install the front window wiper assembly. Refer

to the section Window Wipers Replacement.

66
100 SRM 1390 Window Replacement

Window Replacement
WARNING
All windows installed in the cab are made of
special glass. All replacement windows must
be made of the correct material and thickness.
Replacement windows that are not made of
the correct material or thickness may cause
the glass to break easily when struck and may
cause personal injury.
NOTE: Before replacing any window, remove all bro-
ken glass bits. Make sure replacement glass is dry,
clean, and free of grease.
The front, rear, and top windows are single units.
The front and rear windows are held in place by rub-
ber seals only. The top window is fastened by roof
clips. The door window and sliding window assem-
blies are glued in. See Figure 39.

1. SLIDING WINDOW 6. DOOR

2. SEAL 7. SEAL
3. WINDOW EDGE PROTECTION SEAL 8. GLUED SEAL
4. UPPER WINDOW 9. LOWER WINDOW
5. GLUED SEAL 10. WINDOW EDGE PROTECTION SEAL

Figure 39. Doors/Glass Assemblies

67
Window Replacement 100 SRM 1390

FRONT WINDOW 5. Press the window firmly into place.

Remove 6. Insert the string.

1. Remove the front window wiper assembly. Refer 7. Install the front window wiper assembly. Refer
to the section Window Wipers Replacement. to the section Window Wipers Replacement.

2. Remove the string from the window seal. See REAR WINDOW
Figure 40.
Remove
1. Remove the rear window wiper assembly. Refer
to the section Window Wipers Replacement.

2. Remove the rear window wiper motor assembly.

See the section Window Wiper Motor Replace-
ment, Rear Window Wiper Motor Assembly, Re-
move.

3. Remove the string from the window seal. See

Figure 40.

4. Remove the rear window from the window seal.

5. Remove the window seal from around the win-

dow at the operator’s compartment opening.
1. FRONT WINDOW
2. WINDOW SEAL Install
3. CAB SIDE SLOT
4. STRING NOTE: Replace the window seal if the seal is dam-
5. PLASTIC THREAD (INSTALLATION TOOL) aged.
6. CAB FRAME
1. Install the window seal around the window.
Figure 40. Front Window
2. Insert a plastic thread (insulated electric wire)
3. Remove the front window from the window seal.
approximately 3.0 mm (0.118 in.) in the slot of
4. Remove the window seal from around the win- the window seal (cab side slot).
dow at the operator’s compartment opening.
3. Position and press the window against the oper-
ator’s compartment opening.
Install
4. Pull the plastic thread out toward the inside of
NOTE: Replace the window seal if the seal is dam-
the cab. This will ensure that the slot of the win-
aged.
dow seal slides properly over the window frame.
1. Install the window seal around the window.
5. Press the window firmly into place.
2. Insert a plastic thread (insulated electric wire)
6. Insert the string.
approximately 3.0 mm (0.118 in.) in the slot of
the window seal (cab side slot). 7. Install the rear window wiper motor assembly.
See the section Window Wiper Motor Replace-
3. Position and press the window against the oper-
ment, Rear Window Wiper Motor Assembly, In-
ator’s compartment opening.
stall.
4. Pull out the plastic thread toward the inside of
8. Install the rear window wiper assembly. See the
the cab. This will ensure that the slot of the win-
section Window Wipers Replacement.
dow seal slides properly over the window frame.

68
100 SRM 1390 Window Replacement

TOP WINDOW Install

Remove 1. Clean the window opening and seal located under
the window clip.
1. Remove the top window wiper assembly. Refer to
the section Window Wipers Replacement. 2. Install a new adhesive seal to the top window.

2. Remove the five protecting caps, nuts, and wash- 3. Position the top window onto the operator’s com-
ers from the window clip. See Figure 41. partment opening. See Figure 41.

3. Remove the window clip and seal.
4. Remove the three protective caps, nuts, and plas-
tic washers that retain the roof clips to the cab.
5. Remove the three roof clips and roof clip covers.
6. Remove the top window from the operator’s com-
partment opening.
4. Position the window clip and seal over the thread
ends and install the five nuts and washers, hand
tighten.
5. Position the three roof clips and roof clip covers
and install the plastic washers and nuts, hand
tighten.

1. PROTECTIVE CAP 6. TOP WINDOW

2. NUT 7. PROTECTIVE CAP
3. PLASTIC WASHER 8. NUT
4. ROOF CLIP 9. WASHER
5. ROOF CLIP COVER 10. WINDOW CLIP AND SEAL

Figure 41. Top Window

69
Window Replacement
6. If necessary, carefully push the front side of the
top window until the seal touches the top window.
Tighten the three nuts of the three roof clips un-
til the top window is evenly held in the desired
position. Repeat the same procedure for the rear
side of the top window and the window clip.
7. Install the protective caps onto the nuts.
8. Install the top window wiper assembly. Refer to
the section Window Wipers Replacement.
DOOR WINDOW
Upper/Lower Window
Remove
1. Remove the window edge protection seal that re-
tains the window in the door frame. See Fig-
ure 39.
2. Remove the upper/lower window.
3. With a sharp knife, slice through the adhesive
line between the glued seal and the window open-
ing.
4. Remove the glued seal from the window opening.
5. Clean the window opening and the glued seal.
Install
1. Apply a bead of adhesive to the window opening.
NOTE: Replace the glued seal if the seal is damaged.
2. Install the glued seal to the window opening.
3. Install the upper/lower window.
4. Install the window edge protection seal.
5. Apply pressure to the window edge protection
seal and the window until the window is seated.
SLIDING WINDOW AND SLIDING TRACKS
Remove
1. Open the sliding window slightly to gain access
to the sliding tracks. See Figure 42.
2. Bend each end section of the window support pro-
file outward, to allow the sliding track to move
out of the window support profile. See Figure 43.
70
100 SRM 1390
CAUTION
Make sure the sliding window does not fall out
when the sliding tracks are removed. Take pre-
cautions to keep the sliding window in place.
3. Place a screwdriver behind the sliding track as
shown in Figure 43, and slide the sliding window
away to free the sliding track from underneath
the sliding window.
4. Remove the sliding track.
5. Place a screwdriver behind the second sliding
track as shown in Figure 43, and slide the sliding
window to the other side to free the second slid-
ing track from underneath the sliding window.
6. Remove the second sliding track.
7. Remove the sliding window, top side first, from
the window frame.
8. Remove the two capscrews that retain the win-
dow latch assembly and remove the assembly.
9. Slide the weather strip from the sliding window.
Install
1. Position and install the weather strip to the front
sliding window using a rubber mallet.
2. Position the window latch assembly and install
the two retaining capscrews.
3. Position the sliding window, bottom side first, in
the window frame.
4. Clamp the two sliding tracks on the sliding frame
at the left-hand and right-hand side of the sliding
window.
5. Place a screwdriver behind the sliding track as
show in Figure 43, and slide the sliding window
over the sliding track.
6. Bend the end section to the inside of the sliding
window until it locks the sliding track.
7. Place a screwdriver behind the second sliding
track as shown in Figure 43, and slide the sliding
window over the second sliding track.
8. Bend the end section to the inside of the sliding
window.
100 SRM 1390 Window Replacement

1. WINDOW SEAL 7. WINDOW SEAL

2. WINDOW STOPPER 8. WEATHER STRIP (PRE-ASSEMBLED)
3. WINDOW SEAL 9. FRONT SLIDING WINDOW (PRE-ASSEMBLED)
4. WINDOW STOPPER 10. SLIDING TRACKS
5. WINDOW SEAL 11. REAR SLIDING WINDOW (PRE-ASSEMBLED)
6. SLIDING WINDOW FRAME

Figure 42. Sliding Window Assembly

71
Window Replacement 100 SRM 1390

2. Remove the window seals. See Figure 42.

3. Apply instant glue to the sliding window frame.

4. Install the new window seals and apply pressure

until the seals are seated.

Sliding Window Frame

Remove

1. Separate the glued seal located at the upper win-

dow from the sliding window frame. See Fig-
ure 39.

NOTE: Do not completely remove the existing bead

of adhesive. Leave a remaining layer of adhesive on
the door frame.

2. Remove the sliding window frame by slicing

through the adhesive line one piece at a time
from the inside with a sharp knife.

3. Trim the existing bead of adhesive down to ap-

proximately 1 to 2 mm (0.039 to 0.078 in.) at the
1. SLOT door frame.
2. SLIDING WINDOW
3. WINDOW SUPPORT PROFILE Install
4. SCREWDRIVER LOCATION (REMOVAL)
5. INNER SLOT BEND LOCATION NOTE: The installation of the sliding window frame
6. SLIDING TRACK requires the use of a glue kit, Hyster P/N 1674109.
7. END SECTION The glue kit consists of the following:
8. SCREWDRIVER LOCATION (INSTALLATION)
• Sika Coating Activator
Figure 43. Slot Location • Sika Remover 208
• Sikaflex 260
Weather Strip Replacement
1. Clean the bond area of the sliding window frame
1. Slide the clamped weather strip from the sliding with a clean lint-free cloth and Sika Coating Ac-
window. See Figure 42. tivator. The waiting time after cleaning is a min-
imum of 10 minutes to a maximum of 2 hours.
2. Position and install the new weather strip to the
front sliding window using a rubber mallet. 2. Clean the bead at the door frame with a clean
lint-free cloth and Sika Coating Activator. The
Window Stopper Replacement waiting time after cleaning is a minimum of 10
minutes to a maximum of 2 hours.
1. Remove the window stopper. See Figure 42.
3. Apply Sikaflex 260 in the shape of a triangular
2. Apply instant glue to the window frame. bead on the remaining bead of adhesive at the
door frame. Make sure the height of the trian-
3. Install the window stopper and apply pressure gular bead is 4 to 5 mm (0.157 to 0.197 in.). See
until the stopper is seated. Figure 44.
Window Seal Replacement
1. Remove the front and rear sliding windows. Re-
fer to the section Sliding Window and Sliding
Tracks.

72
100 SRM 1390
1. ADHESIVE
2. REMAINDER OF ORIGINAL BEAD
Figure 44. Silicon Bead
Floor Mat
FRONT FLOOR MAT
Remove
1. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.
2. Remove the foam from around the throttle pedal.
3. If the lift truck is equipped with a
MONOTROL® pedal, disconnect the elec-
trical connector.
4. Remove the capscrew, spring washer, and
nut that retain the accelerator pedal or
MONOTROL® pedal to the cab frame.
5. Separate the coupling from the accelerator pedal
or MONOTROL® pedal.
6. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and Lower-
ing Cab.
7. Remove the accelerator pedal or MONOTROL®
pedal.
8. Remove the steering column. Refer to the section
Steering Column Assembly, Remove.
9. Remove the split pin and washer from the rod
located behind the inching pedal.
10. Disconnect the rod from the inching pedal.
Floor Mat
NOTE: The clamps that hold the sliding window
frame to the door frame should remain in place for a
minimum of 12 hours.
4. Use clamps for correct positioning, and install
the sliding window frame to the door frame.
Make sure there is a gap between the sliding
window frame and the door frame to allow water
to drain.
5. Remove excess (uncured) adhesive with Sika Re-
mover 208 immediately. Do not use solvents.
6. Use a roller to position the removed glued seal lo-
cated at the upper window to the sliding window
frame and upper window.
7. Make sure the sliding window frame is firmly
mounted in the door frame.
11. Remove the two capscrews, washers, and nuts
that retain the inching pedal to the bracket at
the cab floor.
12. Remove the two capscrews, washers, and nuts
that retain the brake pedal to the bracket at the
cab floor.
13. Remove the inching and brake pedal assembly.
14. Remove the front floor mat.
Install
1. Install the front floor mat.
2. Position the inching and brake pedal assembly
between the brackets on the floor of the cab.
3. Install the two capscrews, washers, and nuts to
retain the brake pedal to the bracket, at the cab
floor.
4. Install the two capscrews to retain the inching
pedal to the bracket, at the cab floor.
5. Connect the rod to the inching pedal.
6. Install the washer and split pin to the rod located
behind the inching pedal.
7. Install the steering column. Refer to the section
Steering Column Assembly, Install.
73
Floor Mat
8. Position the accelerator pedal or MONOTROL®
pedal, if the lift truck is equipped with a
MONOTROL® pedal.
9. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.
10. Attach the coupling to the accelerator pedal or
MONOTROL® pedal.
11. Install the capscrew, spring washer, and nut to
retain the accelerator pedal or MONOTROL®
pedal to the cab frame.
12. If the lift truck is equipped with a
MONOTROL® pedal, connect the electri-
cal connector to the MONOTROL® pedal.
13. Install the foam around the throttle pedal.
14. Lower the cab until it is in the fully lowered and
latched position. Refer to the section Raising and
Lowering Cab.
15. Check if any inching and brake pedal adjustment
is required and adjust as needed. Refer to the
section Brake and Inching Pedals.
16. Check and adjust the accelerator pedal. Refer to
the section Accelerator Pedal and Sensor.
REAR FLOOR MAT
Remove
1. Open the left-hand and right-hand cab doors un-
til the doors are securely latched.
2. If equipped with a storage box, remove the two
screws located at the left side of the seat that
retain the storage box to the cab floor.
3. If equipped, remove the training seat, located at
the left rear corner of the cab. Refer to the section
Training Seat.
4. Remove the four capscrews located at the left
rear corner that retain the cover to the cab.
74
100 SRM 1390
5. Remove the seat suspension. Refer to the section
Seat Suspension Replacement.
NOTE: If equipped with a storage box, the capscrews
are located inside the storage box behind the opera-
tor’s seat.
6. Remove the four capscrews that retain the stor-
age box behind the operator’s seat to the cab floor.
7. Remove the four screws located at the right side
of the rear floor mat that retain the strip to the
cab floor.
8. If equipped, remove the three air nozzles.
9. Remove the rear floor mat.
Install
1. Install the rear floor mat.
2. If equipped, install the three air nozzles.
3. Install the four screws located at the right side
of the rear floor mat to retain the strip to the cab
floor.
NOTE: If equipped with a storage box, the capscrews
are located inside the storage box behind the opera-
tor’s seat.
4. Install the four capscrews that retain the storage
box behind the operator’s seat to the cab floor.
5. Install the seat suspension. Refer to the section
Seat Suspension Replacement.
6. Install the four capscrews located at the left rear
corner to retain the cover to the cab.
7. If equipped, install the training seat located at
the left rear corner of the cab. Refer to the section
Training Seat.
8. If equipped with a storage box, install the two
screws located at the left side of the seat that
retain the storage box to the cab floor.
100 SRM 1390 Radio Console

Radio Console
REMOVE
1. Remove the top sunshade. Refer to the section ,
Sunshade Replacement, Top.
2. Remove the rear sunshade. Refer to the section
Accessories, Sunshade Replacement, Rear.
3. Remove the cover from the rear window wiper
motor.
5. Position the bracket between the radio console
and the rear window wiper motor.
6. Install the capscrew to retain the bracket to the
radio console.
7. Install the capscrew to retain the bracket to the
rear window wiper motor.
8. Install the cover to the rear window wiper motor.

4. Remove the capscrew that retains the bracket to 9. Install the rear sunshade. Refer to the section
the rear window wiper motor. Accessories, Sunshade Replacement, Rear.

5. Remove the capscrew that retains the bracket to 10. Install the top sunshade. Refer to the section ,
the radio console and remove the bracket. Sunshade Replacement, Top.

6. Remove the six capscrews and washers at the

front side of the radio console. See Figure 45.

7. Remove the four capscrews and washers at the

underside of the radio console.

8. Disconnect the two electrical connectors of the in-

terior lights at the left-hand and right-hand side
of the radio console.

9. Remove the radio console from the rear side of

the interior cab roof.

INSTALL
1. Position the radio console to rear side of the inte-
rior cab roof.

2. Connect the two electrical connectors of the inte- 1. RADIO CONSOLE

2. CAPSCREW
rior lights at the left-hand and right-hand side of 3. WASHER
the radio console.
Figure 45. Radio Console
3. Install the four capscrews and washers at the un-
derside of the radio console. See Figure 45.

4. Install the six capscrews and washers at the front

side of the radio console.

75
Air Duct Replacement 100 SRM 1390

Air Duct Replacement

FRONT
1. Remove the six capscrews located at the
left-hand and right-hand underside of the air
duct.

CAUTION
Use caution when removing and installing the
air duct to avoid damage to the steering col-
umn and the front window.

2. Remove the air duct from the front side of the cab.

3. Position the new air duct to the front side of the

cab.

4. Install the six capscrews located at the left-hand

and right-hand underside of the air duct.

REAR
Remove
1. Open the left- and right cab door completely.
2. Remove the rear floor mat. See the section Rear
Floor Mat, Remove.
3. Remove the five screws that retain the cable
cover at the right rear corner of the operator’s
cab.
4. Remove the four screws that retain the fuse
panel cover at the right side of the instrument
panel. See Figure 46.
5. Remove the six screws retaining the cover for the
key switch at the instrument panel top console.
6. Remove the key switch, see the section Key
Switch, Remove.
7. Remove the six screws that retain the cover to the
instrument panel top console and lift the cover
partially out the instrument panel top console.
8. Remove the four screws that retain the cover
with the heater switches to the instrument panel
top console and lift the cover partially out the
instrument panel top console.
1. RETAINING SCREWS
2. FUSE PANEL COVER
Figure 46. Fuse Panel and Cover Location
9. Remove the four screws that retain the cover
with the parking brake to the instrument panel
top console and lift the cover partially out the
instrument panel top console.
10. Remove the five screws that retain the instru-
ment panel top console to the instrument panel.
CAUTION
Use caution not to damage the electrical wires
of the instrument panel switches.
11. Partially remove the instrument panel top con-
sole to gain access to the heater hose clamp and
the screw at the underside of the air duct.
12. Remove the three screws located at the underside
that retain the instrument panel side console to
the cab.
13. Remove the instrument panel side console.
14. Remove the heater hose clamp from the under-
side of the air duct.

76
100 SRM 1390
NOTE: Screws can be partially hidden by the foam
cover underneath the air duct.
15. Remove the four screws located at the underside
of the air duct.
16. Remove the four screws located at the topside of
the air duct.
17. Remove the air duct.
Install
1. Position the air duct.
2. Install the four screws located at the topside of
the air duct.
NOTE: The screw locations can be partially hidden
by the foam cover underneath the air duct.
3. Install the four screws located at the underside
of the air duct.
4. Install the heater hose clamp to the underside of
the air duct.
5. Position the instrument panel side console.
6. Install the three screws located at the underside
that retain the instrument panel side console to
the cab.
NOTE: Make sure the wires of the instrument panel
clear of any restrictions.
Accessories
MIRROR REPLACEMENT
NOTE: Mirrors are located at the top left-hand and
right-hand front corner inside the cab.
1. Remove the nut behind the mirror that retains
the mirror to the cab frame.
2. Remove the mirror from the cab frame.
3. Position the new mirror to the cab frame.
4. Install the nut behind the mirror to retain the
mirror to the cab frame.
Accessories
7. Carefully position the instrument panel top con-
sole.
8. Install the five screws that retain the instrument
panel top console to the instrument panel.
9. Position the cover with the parking brake and
install the four screws that retain the cover to
the instrument panel top console.
10. Position the cover with the heater switches and
install the four screws that retain the cover to the
instrument panel top console.
11. Position the cover to the instrument panel top
console and install the six screws that retain the
cover to the instrument panel top console.
12. Position the cover for the key switch and install
the six screws that retain the cover for the key
switch to the instrument panel top console.
13. Install the key switch, see the section Key
Switch, Install.
14. Install the four screws that retain the fuse panel
cover at the right side of the instrument panel.
15. Install the five screws that retain the cable cover
at the right rear corner of the operator’s cab.
16. Install the floor mat rear. See the section Rear
Floor Mat, Install.
SUNSHADE REPLACEMENT
Top
NOTE: The top sunshade is located under the cab roof
and attached to the radio console.
1. Remove the two capscrews that retain the handle
with a bracket to the sliding bar at the roof.
2. Remove the handle.
3. Remove the two capscrews at the left-hand and
right-hand side of the sunshade that retain the
sunshade to the radio console.
77
Accessories
4. Remove the sunshade.
5. Position the new sunshade.
6. Install the two capscrews at the left-hand and
right-hand side of the sunshade to retain the sun-
shade to the radio console.
7. Position the handle to the sliding bar at the roof.
8. Install the two capscrews to retain the handle
with a bracket to the sliding bar.
Rear
NOTE: The rear sun shade is located at the rear win-
dow inside the cab and is attached to the radio con-
sole.
1. Remove the two capscrews that retain the han-
dle with a bracket to the sliding bar at the rear
window.
2. Remove the handle.
3. Remove the two capscrews at the left-hand and
right-hand side of the sunshade that retain the
sunshade to the radio console.
4. Remove the sunshade.
5. Position the new sunshade.
6. Install the two capscrews at the left-hand and
right-hand side of the sunshade to retain the sun-
shade to the radio console.
7. Position the handle to the sliding bar at the rear
window.
8. Install the two capscrews to retain the handle
with a bracket to the sliding bar.
MAP LIGHT REPLACEMENT
NOTE: The map light is attached to the frame in the
right rear corner of the cab.
1. Disconnect the wire connector located inside the
fuse panel.
2. Remove the two capscrews that retain the map
light to the cab frame.
3. Remove the map light from the cab frame.
4. Position the new map light to the cab frame.
78
100 SRM 1390
5. Install the two capscrews to retain the map light
to the cab frame.
6. Connect the wire connector located inside the
fuse panel.
INTERIOR FAN REPLACEMENT
Remove
NOTE: The interior fan is located at the right rear
corner inside the cab, and is attached to the frame.
1. Disconnect the wire connector from the fan.
2. Remove the four capscrews that retain the inte-
rior fan to the cab frame.
3. Remove the interior fan from the cab frame.
4. Position the new interior fan to the cab frame.
5. Install the four capscrews to retain the interior
fan to the cab frame.
6. Connect the wire connector to the fan.
TRAINING SEAT
Field Installation
NOTE: The training seat is located at the left rear
corner of the cab and is attached to the cab floor and
the side frame of the cab.
NOTE: Two threaded holes in the cab floor are cov-
ered by a rubber mat. Holes are partially punched in
the rubber mat to show the location of the threaded
holes and to create access to the threaded holes in the
cab floor.
1. Remove the rubber from the two partially
punched holes in the rubber mat to create access
to the threaded holes in the cab floor.
2. Position the training seat and install two cap-
screws at the cab floor side and one capscrew at
the cab frame side.
Remove
1. Remove the two capscrews at the cab floor side
and one capscrew at the cab frame side.
2. Remove the training seat.
100 SRM 1390
Label Replacement
WARNING
Labels that have WARNINGS or CAUTIONS
must be replaced if they are damaged. If a
mast of a different size or an accessory car-
riage is installed, the capacity rating may
change. Installing different drive tires can
change the capacity rating. See a dealer for
Hyster lift trucks for a replacement name-
plate. The nameplate information is a safety
item and must be correct for the equipment
and configuration of the lift truck.
1. Make sure the surface is dry and free of oil or
grease. DO NOT use solvent on new paint.
Label Replacement
Clean the surface of old paint using cleaning
solvent.
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
3. Carefully position the label in the correct position
above the surface. The label cannot be moved
after it touches the surface. Place the label on
the surface. Make sure all of the air is removed
from under the label and the corners and edges
are tightly affixed.
See the Parts Manual for correct location and part
numbers of the labels.
79
 NOTES

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

80
 TECHNICAL PUBLICATIONS

100 SRM 1390 7/11 (3/11)(1/11)(3/10) Printed in U.S.A.