Cabine Do Operador - h155

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CABINE DO OPERADOR
H1,6FT, H1,8FT, 2,0FTS [F001];
H2,0-3,5FT (H40-70FT) [L177, N177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) [N005, P005, R005,
S005];
H6,0FT, H7,0FT (H135FT, H155FT) [H006, J006,
K006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) [A299, B299]
PARTE NO. 1673866 0100 SRM 1290
PRECAUÇÕES DE
SEGURANÇA MANUTENÇÃO E
REPAROS
• Os Manuais de Serviço são atualizados regularmente, mas podem não refletir alterações recentes no
projeto do produto. Informações de serviço técnico atualizadas podem estar disponíveis em seu
®
revendedor autorizado Hyster local . Os Manuais de Serviço fornecem diretrizes gerais para
manutenção e serviço e devem ser usados por técnicos treinados e experientes. A falha em manter
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adequadamente o equipamento ou não seguir as instruções contidas no Manual de Serviço pode

resultar em danos aos produtos, ferimentos pessoais, danos materiais ou morte.
• Ao levantar peças ou conjuntos, certifique-se de que todas as eslingas, correntes ou cabos estejam
presos corretamente e que a carga que está sendo levantada esteja equilibrada. Certifique-se de que o
guindaste, cabos e correntes tenham capacidade para suportar o peso da carga.
• Não levante peças pesadas manualmente, use um mecanismo de elevação.
• Use óculos de segurança.
• DESCONECTE O CONECTOR DA BATERIA antes de fazer qualquer manutenção ou reparo em
empilhadeiras elétricas. Desconecte o cabo de aterramento da bateria em empilhadeiras de combustão
interna.
• Sempre use os blocos corretos para evitar que a unidade role ou caia. Veja COMO COLOCAR O

EMPILHADOR EM BLOCOS no Manual de Operação ou na seção Manutenção Periódica .
• Mantenha a unidade limpa e a área de trabalho limpa e organizada.
• Use as ferramentas corretas para o trabalho.
• Mantenha as ferramentas limpas e em boas condições.
• Sempre use peças HYSTER APPROVED ao fazer reparos. As peças de reposição devem atender ou

exceder as especificações do fabricante do equipamento original.
• Certifique-se de que todas as porcas, parafusos, anéis elásticos e outros dispositivos de fixação foram

removidos antes de usar força para remover as peças.
• Sempre prenda uma etiqueta NÃO OPERAR nos controles da unidade ao fazer reparos ou se a

unidade precisar de reparos.
• Certifique-se de seguir as notas de ADVERTÊNCIA e CUIDADO nas instruções.
• Gasolina, Gás Líquido de Petróleo (GLP), Gás Natural Comprimido (GNC) e óleo diesel são
inflamáveis. Certifique-se de seguir as precauções de segurança necessárias ao manusear esses
combustíveis e ao trabalhar nesses sistemas de combustível.
• As baterias geram gás inflamável quando estão sendo carregadas. Mantenha fogo e faíscas longe da

área. Certifique-se de que a área esteja bem ventilada.
NOTA: Os seguintes símbolos e palavras indicam informações de segurança

neste manual:
AVISO
Indica uma situação perigosa que, se não for evitada, pode resultar
em morte ou ferimentos graves.
CUIDADO
Indica uma situação perigosa que, se não for evitada, pode resultar
em ferimentos leves ou moderados e danos materiais.
Na empilhadeira, o símbolo de AVISO e a palavra estão em fundo
laranja. O símbolo de CUIDADO e a palavra estão em fundo
amarelo.
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"A
QUALIDADE
GUARDIÕES"
HISTER
APROVADO
© 2014
HYSTER COMPANY
PEÇAS ÍNDICE
Em geral
Substituição da cabine
Remova, para os modelos de empilhadeira H1.6FT, H1.8FT, 2.0FTS (F001);
H2,0-3,5FT (H40-70FT) (L177, N177); e H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Instale, para os modelos de empilhadeira H1.6FT, H1.8FT, 2.0FTS (F001);
H2,0-3,5FT (H40-70FT) (L177, N177); e H4.0FT5/FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Remova, para os modelos de empilhadeira H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006) e H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
ÍNDICE
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Instale, para os modelos de empilhadeira H6.0FT, H7.0FT (H135FT, H155FT)

(H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)
Conjuntos de portas
Conjunto da porta do lado direito, modelos de empilhadeira H1.6FT, H1.8FT,
2.0FTS (F001); H2,0-3,5FT (H40-70FT) (L177, N177); e H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005, S005)
Remover
Desmontar
Tampa da porta com unidade de aquecimento
Tampa da porta com unidade de ar condicionado/aquecedor
Conjunto do Aquecedor
Conjunto de Unidade de Ar Condicionado e Aquecedor
Conjunto da fechadura da porta
janelas
Limpar \ limpo
Inspecionar
Montar
janelas
Conjunto do Aquecedor
Conjunto de Unidade de Ar Condicionado e Aquecedor
Tampa da porta com unidade de aquecimento
Tampa da porta com ar condicionado e unidade de aquecimento
Instalar
Montagem da porta do lado esquerdo, modelos de empilhadeira H1.6FT,
H1.8FT, 2.0FTS (F001); H2,0-3,5FT (H40-70FT) (L177, N177); e H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005, S005)
Remover
Desmontar
Tampa da porta
janelas
Limpar \ limpo
Inspecionar
Montar
janelas
Tampa da porta
Instalar
Conjuntos de portas laterais direita e esquerda, modelos de empilhadeira
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299) , B299)
Remover
Desmontar
Tampa da porta
janelas
Limpar \ limpo
Inspecionar
Montar
ÍNDICE
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janelas
Tampa da porta
Instalar
Substituição de limpadores de janela
Em geral
Conjunto do limpador dianteiro e motor
Modelos de empilhadeira de remoção H1.6FT, H1.8FT, 2.0FTS (F001) e
H2.0-3.5FT (H40-70FT) (L177, N177)
Instalar, Modelos de empilhadeira H1.6FT, H1.8FT, 2.0FTS (F001) e H2.0-
3.5FT (H40-70FT) (L177, N177)
Remover, empilhar modelos H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005, S005), H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
Instalar, Modelos de empilhadeira H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005), H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006) e H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299, B299)
Conjunto e motor do limpador traseiro
Remover, empilhar modelos H1.6FT, H1.8FT, 2.0FTS (F001)
Instalar, Modelos de empilhadeira H1.6FT, H1.8FT, 2.0FTS (F001)
Remover, empilhar modelos H2.0-3.5FT (H40-70FT) (L177, N177)
Instalar, Modelos de empilhadeira H2.0-3.5FT (H40-70FT) (L177, N177)
Remover, empilhar modelos H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Instalar, Modelos de empilhadeira H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Remover, empilhar modelos H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299)
Instalar, Modelos de empilhadeira H6.0FT, H7.0FT (H135FT, H155FT)
H190FT) (A299, B299)
Substituição da janela
Em geral
Remova a janela da porta, modelos de empilhadeira H1.6FT, H1.8FT, 2.0FTS
(F001); H2,0-3,5FT (H40-70FT) (L177, N177); e H4.0FT5/FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Instale janelas de porta, modelos de empilhadeira H1.6FT, H1.8FT, 2.0FTS
(F001); H2,0-3,5FT (H40-70FT) (L177, N177); e H4.0FT5/FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
Remova a janela da porta, modelos de empilhadeira H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006) e H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Instale a janela da porta, modelos de empilhadeira H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006) e H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299)
Substituição do aquecedor
Remova, para os modelos de empilhadeira H6.0FT, H7.0FT (H135FT, H155FT)
H190FT) (A299, B299)
ÍNDICE
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Instale, para os modelos de empilhadeira H6.0FT, H7.0FT (H135FT, H155FT)

H190FT) (A299, B299)
Heater and Air Conditioner Assembly
Air Conditioner Condenser Unit
Remove
Install
Air Conditioner Receiver/Drier Unit
Remove
Install
Air Conditioner Compressor
Light Replacement
Work Lights (Front and Rear)
Remove
Install
Strobe Light
Remove
Install
Turn, Stop, Tail, and Backup Light
Remove
Install
Front Marker/Turn Signal Lights
Remove
Install
Display Switches
Electrical Schematics
Optional Equipment
Heavy Duty Pre-Cleaner
Remove
Clean
Inspect
Install
Fan
Remove
Install
Mirror
Remove
Install
Label Replacement
This section is for the following models:
H1.6FT, H1.8FT, 2.0FTS [F001];

H2.0-3.5FT (H40-70FT) [L177, N177];
H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005, P005,
R005, S005];
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299]
General
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The overhead guard is an integral part of operator cab. The operator cab is installed on a platform above main
frame members. Step plates on both sides of lift truck provide access to operator cab. The operator cab is a
separate unit and can be removed as a complete unit from module and frame of the lift truck. See Figure 1.
Figure 1. Operator Cab
Cab Replacement
REMOVE, FOR LIFT TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT (H40-70FT)
(L177, N177); AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
NOTE: The EZXchange bracket used on these trucks to mount LPG tank onto counterweight come in two
styles. One style of bracket swings out to side of truck and other swings out to side and drops down.
NOTE: On lift trucks equipped with LPG, make sure to release EZXchange bracket before opening hood.
1. For lift truck models H1.6FT, H1.8FT, 2.0FTS (F001), tilt steering column to UP position, slide seat

assembly forward, open rear door, and open hood to disconnect battery. See Figure 2.
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1. LATCH
2. HINGE
3. REAR DOOR
Figure 2. Rear Door and Latch for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)
2. Tilt steering column to UP position, slide seat assembly forward, open rear sliding window, and open

hood to disconnect battery.
See Figure 3 for lift truck models

• H2.0-3.5FT (H40-70FT) (L177, N177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005,

S005)
A.
LIFT TRUCKS MODELS H2.0-3.5FT (H40-70FT) (L177,N177) AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005) WITHOUT AIR CONDITIONING.
B.
LIFT TRUCKS MODELS H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005,
R005, S005) WITH AIR CONDITIONING.
1. REAR BOTTOM WINDOW 3. AC HOSE

2. RELEASE LATCH
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Figure 3. Rear Bottom Window for Lift Trucks Models H2.0-3.5FT (H40-70FT) (L177, N177)
and H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005,
R005, S005)
3. Disconnect air filter hose from rear left corner leg of cab frame. See Figure 4.
NOTE: AIR FILTER HOSE FOR H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005) SHOWN. AIR FILTER HOSE FOR OTHER LIFT TRUCK MODELS ARE
SIMILAR.
1. CAPSCREW
2. AIR FILTER HOSE
Figure 4. Air Filter Hose Removal
WARNING
DO NOT disconnect the heater hoses from the engine when the engine is hot or when the
cooling system is under pressure, to do so could cause serious injury.
WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator
is hot and the cap is removed, the pressure is released from the system and the steam and
boiling coolant can cause burns. Wait 30 minutes for the engine to cool. Do a touch test by
touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30
minutes before attempting to remove, check, or fix any part of the cooling system.
NOTE: Removing radiator cap will help depressurize cooling system.
4. Remove radiator cover to access radiator cap. Remove radiator cap. See Figure 5.
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A.
H1.6FT,
(F001)
H1.8FT, 2.0FTS C.
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005, R005)
B.
H2.0-3.5FT (H40-70FT)
(L177, N177)
D.
H4.0FT5/FT6;
120FT) (S005)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
1. RADIATOR COVER 2. RADIATOR CAP
Figure 5. Radiator Cover and Cap Location
CAUTION
DO NOT allow any fluid to drain when disconnecting the heater hose from the engine. The
method will help when purging the system during installation.
5. Disconnect and cap heater hoses from engine. See Figure 6.
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Figure 6. Heater Hose Connection

Legend for Figure 6
NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK.
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
A. LIFT TRUCK MODELS D.

H1.6FT, H1.8FT, 2.0FTS LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
(F001) E.
B. LIFT TRUCK MODELS H2.0- LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-
5.5FT (H80, 90, 100, 110, 120FT) (R005, S005)
3.5FT (H40-70FT) (L177)
C. LIFT TRUCK MODELS H2.0-
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3.5FT (H40-70FT) (N177)
1. QUICK DISCONNECT FITTING 4. RIGHT SIDE DOOR ASSEMBLY

2. INNER REAR COVER 5. HEATER HOSES
3. RADIATOR COVER
WARNING
Replacement, installation and repairs to air conditioning units that require discharging
and/or refilling of the refrigeration fluid must be performed by a certified technician.
6. Contact a certified air conditioning specialist to have the refrigerant extracted from the air

conditioning system.
NOTE:
Step 7 is for lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (P005, R005, S005) with a Cummins QSB 3.3L or a Kubota diesel engine.
7. If lift truck cab is equipped with an air conditioner/heater unit, disconnect AC refrigerant hoses from

refrigerant compressor.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005)
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1. HOSE FITTING 3. AC/HEATER UNIT

2. REFRIGERANT COMPRESSOR 4. ENGINE
Figure 7. AC Refrigerant Hose Connections, Lift Truck Models H4.0FT5/FT6; H4.5FTS5,

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005) with Cummins QSB 3.3L Engine
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NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. KUBOTA 3.8L
DIESEL ENGINE SHOWN, 3.6L DIESEL ENGINE SIMILAR.
A. LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
B. LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005)
1. HOSE FITTING 3. AC/HEATER UNIT

2. REFRIGERANT COMPRESSOR 4. ENGINE
Figure 8. AC Refrigerant Hose Connection, Lift Truck Models H4.0FT5/FT6; H4.5FTS5,

H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005) with Kubota Diesel Engine
NOTE: Removing door assemblies requires two people.
8. Open left side door, remove lock nut, and disconnect gas spring from cab mounting bracket. See

Figure 9.
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NOTE: RIGHT SIDE DOOR SHOWN.

1. GAS SPRING
2. CAB MOUNTING BRACKET
3. LOCK NUT
Figure 9. Gas Spring Mounting Removal
9. Lift left side door up and over hinge pin and set aside. See Figure 10.
NOTE: RIGHT SIDE DOOR HINGE SHOWN.

1. HINGE PIN
2. DOOR HINGE
Figure 10. Door Removal
WARNING
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DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator
cab) or engine when the engine is hot or under pressure, to do so could cause serious
injury.
10. Disconnect heater hose quick disconnect fittings.
a. For lift truck models H1.6FT, H1.8FT, 2.0FTS (F001), open right side door and push buttons on
quick disconnect fittings to disconnect heater hoses from heater assembly hoses (see Figure 6).
Disconnect heater wire harness connection. See Figure 11.
b. For lift truck models H2.0-3.5FT (H40-70FT) (L177, N177), open right side door and remove
radiator cover to access quick disconnect fittings. Push buttons on quick disconnect fittings to

disconnect heater hoses from heater assembly (see Figure 6). Disconnect heater wire harness
connection. See Figure 11.
c. For lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005), open right side door and located on inner rear cover there are two port

holes (see Figure 6). Push buttons on quick disconnect fittings to disconnect heater hoses from
heater assembly and disconnect heater wire harness connection. See Figure 11.

1. HEATER WIRE HARNESS CONNECTOR
2. REAR GRAB HANDLE HORN BUTTON CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS)
Figure 11. Heater Wire Harness and Rear Grab Handle Horn Button Connectors
11. For lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(P005, R005, S005) with a Cummins QSB 3.3L or Kubota diesel engine, if lift truck cab is equipped
with an air conditioner/heater unit, disconnect AC hoses.
a. Remove six fasteners and remove rear cover.


• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
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• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005)
b. Disconnect air conditioner hoses at bulkhead bracket and at receiver/drier.



c. Disconnect air conditioner wire harness.



A. FRONT VIEW B. TOP VIEW
1. HOSE WRAP 5. BULKHEAD BRACKET

2. FASTENERS 6. RECEIVER/DRIER
3. REAR COVER 7. FITTINGS
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4. AIR CONDITIONER HOSES 8. AIR CONDITIONER WIRE HARNESS
Figure 12. AC System Arrangement and Hose Connections, Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005) With a Cummins QSB 3.3L
Diesel Engine

H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) With a Kubota Diesel
Engine
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H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005) With a Kubota Diesel Engine
12. Remove lock nut and disconnect gas spring from cab mounting bracket. See Figure 9.
13. Lift door up and over hinge pin and set aside. See Figure 10.
NOTE: Wiper motor cover must be removed before dash assembly can be removed.
14. Unclip and remove front wiper motor cover. See Figure 15 for lift truck models
• H1.6FT, H1.8FT, 2.0FTS (F001)

• H2.0-3.5FT (H40-70FT) (L177, N177)
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Figure 15. Dash Installation

Legend for Figure 15
A. H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001) AND H2.0-3.5FT (H40-70FT) (L177, N177)
B. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
1. CAPSCREWS 5. COWL PANEL

2. FRONT WIPER MOTOR COVER 6. FRONT OPERATOR CAB LEGS
3. DASH ASSEMBLY 7. LOCK NUT
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4. KICK PANEL 8. FLANGE BOLT
(N005, P005), remove two lock nuts from front wiper motor cover. Remove front wiper motor cover.
See Figure 15.

(R005, S005), remove three lock nuts from front wiper motor cover. Remove front wiper motor cover.
17. Remove five capscrews from top of dash assembly and cowl panel.
18. Remove two flange bolts securing cowl panel to front operator cab legs.
19. Unclip dash assembly from kick panel. Remove dash assembly.
20. Remove kick panel from seal plate assembly. See Figure 16.
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Figure 16. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
NOTE: CAB REMOVED FOR CLARITY.
A.
H1.6FT, H1.8FT, 2.0FTS (F001) AND
H2.0-3.5FT (H40-70FT) (L177, N177)
B.
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005, S005)
1. CAPSCREWS 5. FLOOR PLATE (LEFT SIDE)

2. KICK PANEL 6. FLOOR PLATE (RIGHT SIDE)
3. SEAL PLATE ASSEMBLY 7. FLOOR PLATE
4. SEAL
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21. Remove capscrews and seal plate assembly from lift truck frame.
22. Disconnect rear grab handle horn button connector from right-hand chassis harness, located in right

rear corner leg of cab frame. See Figure 11.
23. Disconnect light harness connector from Vehicle Systems Manager (VSM) and right-hand chassis

harness connector. See Figure 17.
NOTE: Perform Step 24 and Step 25 for lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (S005) equipped with Diesel Particulate Filter (DPF).
24. Disconnect light harness connector from Vehicle Systems Manager (VSM) and right-hand chassis

harness connector. See Figure 18.
25. Disconnect Diesel Particulate Filter (DPF) display harness connector from cowl harness. See

Figure 18.
NOTE: KICK PANEL REMOVED FOR CLARITY.

1. VSM
2. LIGHT HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS)
Figure 17. Light Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models
H1.6FT, H1.8FT, 2.0FTS (F001), H2.0-3.5FT (H40-70FT) (L177, N177), and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005)
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1. VSM
2. DPF DISPLAY HARNESS CONNECTOR (TO COWL HARNESS)
3. LIGHT HARNESS CONNECTOR (TO VSM)
4. HARNESS CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS)
Figure 18. Electrical Harness Connection to Vehicle System Manager (VSM) for Lift Truck
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005)
26. Remove rear panels, front panels, and fender covers to access cab mounting capscrews and flange

nuts. See Figure 19.
NOTE: LEFT SIDE DOOR REMOVED FOR CLARITY.

1. REAR PANEL (LPG)
2. REAR PANEL (GAS AND DIESEL)
3. FRONT PANEL
4. FENDER COVER
5. SCREWS
6. CAPSCREWS
Figure 19. Front and Rear Panels and Fender Cover Removal
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27. Remove front and rear cab capscrews and flange nuts from lift truck frame. See Figure 20.
NOTE: ILLUSTRATION FOR REFERENCE PURPOSES ONLY. ACTUAL LIFT TRUCK MAY BE
SLIGHTLY DIFFERENT.
A. FRONT VIEW
B. REAR VIEW
1. CAPSCREWS
2. FLANGE NUTS
Figure 20. Front and Rear Cab Mounting
WARNING
Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb).
28. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of
operator's cab (under overhead guard structure). Place material that will be a cushion at top of door
opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or
lifting strap on operator's cab. See Figure 21.
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Figure 21. Lift Strap Connection
CAUTION
Lift the operator cab carefully. Check that all electrical wires and attachments are
disconnected and are not damaged.
29. Carefully lift operator cab away from lift truck. Set operator cab in a storage area and place blocks

under operator cab to make it stable and prevent damage to parts still attached.
INSTALL, FOR LIFT TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT (H40-70FT)
(L177, N177); AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
1. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's
cab (under overhead guard structure). Place material that will be a cushion at top of door opening to

prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on
operator's cab. See Figure 21.
2. Carefully lift operator cab onto lift truck frame making sure that front and rear leg mounting holes are

aligned with frame mounting holes.
3. Install capscrews and flange nuts to rear operator cab legs. Tighten capscrews to 66 N•m (49 lbf ft).

See Figure 20.
4. Install capscrews and lock nuts to front operator's cab legs. Tighten capscrews to 66 N•m (49 lbf ft).
5. Install fender covers, front panel, and rear panels to frame. See Figure 19. Tighten capscrews to

10.8 N•m (7.96 lbf ft).
6. Connect light harness connector to Vehicle Systems Manager (VSM) and right-hand chassis harness.
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See Figure 17.
NOTE: Perform Step 7 and Step 8 for lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (S005) equipped with Diesel Particulate Filter (DPF).
7. Connect light harness connector to Vehicle Systems Manager (VSM) and right-hand chassis harness.

See Figure 18.
8. Connect Diesel Particulate Filter (DPF) harness connector to cowl harness. See Figure 18.
9. Connect right-hand chassis harness to rear grab handle horn button connector. See Figure 11.
10. Install seal plate assembly to lift truck frame and tighten capscrews. See Figure 16.
11. Install floor plate and floor mat. Tighten capscrews to 10.8 N•m (7.96 lbf ft).
12. Install kick panel onto seal plate assembly.
13. Install two flange bolts securing cowl to front operator cab legs. See Figure 15.
14. Install dash assembly onto kick panel and install five capscrews to secure dash assembly to cowl

panel.
15. Install and clip front wiper motor cover for lift truck models
• H1.6FT, H1.8FT, 2.0FTS (F001)

• H2.0-3.5FT (H40-70FT) (L177, N177)
16. Install front wiper motor cover and tighten two lock nuts for lift truck models H4.0FT5/FT6,

H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005).
17. Install front wiper motor cover and tighten three lock nuts for lift truck models H4.0FT5/FT6,

H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005).
18. Install right side door onto cab by lifting door up and over top and bottom hinge pins. See Figure 10.
19. Connect gas spring and lock nut to cab mounting bracket. See Figure 9.
20. Connect heater hoses to heater assembly and connect heater wire harness connection. See Figure 6

and Figure 11.
(P005) with a Cummins QSB 3.3L engine and equipped with an air conditioner/heater unit, connect

AC hoses. Tighten AC hose at bulkhead bracket to 29 to 37 N•m (21 to 27 lbf ft) and AC hose to
receiver/drier to 15 to 18 N•m (133 to 159 lbf in). See Figure 12.
(R005, S005) with a Kubota engine and equipped with an air conditioner/heater unit, connect AC

hoses. Tighten AC hose at bulkhead bracket to 29 to 37 N•m (21 to 27 lbf ft) and AC hose to
receiver/drier to 20 to 27 N•m (177 to 239 lbf in). See Figure 13.
23. Install left side door onto cab by lifting door up and over top and bottom hinge pins. See Figure 10.
24. Connect gas spring and lock nut to cab mounting bracket. See Figure 9.
25. Uncap and connect heater hoses at engine. See Figure 6.
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(P005, R005, S005) with a Cummins QSB 3.3L or a Kubota diesel engine and equipped with an air
conditioner/heater unit, connect AC refrigerant hoses to refrigerant compressor.

See Figure 8 for lift models

27. Check coolant level, fill if necessary.
28. Install radiator cap and radiator cover. See Figure 5.
29. Connect air filter hose onto rear left corner leg of cab frame. Tighten capscrews to 66 N•m (49 lbf ft).

See Figure 4.
30. Connect battery and close hood.
31. Start engine and turn on heater to ON position, run engine approximately 1 to 2 minutes or until

heater supply hose is fully purged.
WARNING
and/or refilling of the refrigeration fluid must be performed by a certified technician.
32. Contact a certified air conditioning specialist to have the refrigerant refilled into air conditioning

system.
33. On lift trucks equipped with an air conditioner/heater unit, start engine and turn on heater to ON

position, run engine approximately 1 to 2 minutes or until heater supply hose is fully purged.
NOTE: The EZXchange bracket used on these trucks to mount LPG tank onto counterweight comes in two
styles. One style of bracket swings out to side of truck and other swings out to side and drops down.
34. Lift trucks equipped with a LPG engine, swing EZXchange bracket back to its original and locked

position.
REMOVE, FOR LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
NOTE: Removing door assemblies from operators cab requires two people.
1. Open right side door and remove hair pin from rod pin. See Figure 22.
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NOTE: RIGHT SIDE DOOR SHOWN

1. ROD PIN
2. SPACERS
3. HAIR PIN
4. DOOR ASSEMBLY
Figure 22. Door Link Removal
2. Remove rod pin and spacers from link.
3. Remove right side door from cab frame by lifting door up and over hinge pin and set door aside. See

Figure 23.
NOTE: RIGHT SIDE DOOR HINGE SHOWN

1. HINGE PIN
2. DOOR HINGE

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4. Repeat Step 1 through Step 3 for removal of left side door.
5. Remove front floor mat and floor plate. See Figure 24.
1. DASH ASSEMBLY 6. FLANGE BOLT

2. KICK PANEL 7. REAR FLOOR PLATE
3. SEAL PLATE ASSEMBLY 8. FRONT FLOOR PLATE
4. FRONT FLOOR MAT 9. MODULE
5. REAR FLOOR MAT
Figure 24. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
6. Disconnect battery.
7. Remove two screws holding right side rear cover to rear overhead guard leg. See Figure 25.
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NOTE: RIGHT SIDE VIEW SHOWN.

1. RIGHT SIDE REAR COVER
2. RIGHT SIDE FRONT COVER
3. SCREWS
4. REAR FLOOR PLATE
5. FRONT FLOOR PLATE
6. CLIP NUTS
Figure 25. Side Cover Removal
8. Remove two screws holding right side front cover to frame. Remove right side rear cover.
9. Remove two screws securing right side front cover to front overhead guard leg. Remove right side

front cover.
10. Repeat Step 7 through Step 9 to remove left side covers.
NOTE: Perform Step 11 for early model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006).
11. Remove two lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 26.
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1. CAPSCREWS
2. FRONT WIPER MOTOR COVER
3. DASH ASSEMBLY
4. KICK PANEL
5. COWL PANEL
6. FRONT OPERATORS CAB LEGS
7. LOCK NUT
8. FLANGE BOLT
Figure 26. Dash Removal, Early Model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) Lift
Trucks
NOTE: Perform Step 12 on later model lift trucks

• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
12. Remove three lock nuts from front wiper motor cover. Remove front wiper motor cover. See

Figure 27.
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1. CAPSCREWS 5. COWL PANEL

2. FRONT WIPER MOTOR COVER 6. FRONT OPERATORS CAB LEGS
3. DASH ASSEMBLY 7. LOCK NUT
4. KICK PANEL 8. FLANGE BOLT
Figure 27. Dash Removal, Later Model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
Lift Trucks and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) Lift Truck
Models
13. Remove five capscrews from top of dash assembly and cowl panel.
14. Unclip dash assembly from kick panel. Remove dash assembly.
15. Remove kick panel from seal plate assembly. See Figure 24.
16. Remove two flange bolts securing cowl panel to front operator cab legs.
See Figure 26 for early model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) lift trucks.
See Figure 27 for later model lift trucks
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17. Disconnect three harness connectors from right side front operator cab leg that are connected to

Vehicle Systems Manager (VSM) and right hand chassis harness connectors. See Figure 28.
NOTE: PerformStep 18 and Step 19 for lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (K006) and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (B299) equipped with Diesel Particulate Filter
(DPF).
18. Disconnect three harness connectors from right side front operator cab leg that are connected to

Vehicle System Manager (VSM) and right-hand chassis harness connectors. See Figure 29.
19. Disconnect Diesel Particulate Filter (DPF) display harness connector from cowl harness. See

Figure 29.

1. VSM
2. HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT HAND CHASSIS HARNESS)
Figure 28. Light Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299)

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1. VSM
2. DPF DISPLAY HARNESS CONNECTOR (TO COWL)
3. HARNESS CONNECTOR (TO VSM)
4. HARNESS CONNECTOR (TO RIGHT HAND CHASSIS HARNESS)
Figure 29. Electrical Harness Connection to Vehicle System Manager (VSM) for Lift Truck
Models H6.0FT, H7.0FT (H135FT, H155FT) (K006) and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
20. Remove four flange bolts securing right and left side of front operator cab legs to module. See

Figure 30.
NOTE: RIGHT SIDE SHOWN. WIPER COVER AND ASSEMBLY FOR EARLY MODEL H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006) LIFT TRUCKS SHOWN. THE FRONT AND REAR CAB
MOUNTING IS SAME FOR LATER MODEL H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006) LIFT TRUCKS AND ON H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299,
B299) LIFT TRUCK MODELS.
A. REAR VIEW
B. FRONT VIEW
1. FLANGE BOLTS
2. REAR OPERATOR CAB LEG
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3. REAR LIGHT HARNESS
4. WASHER PUMP HARNESS CONNECTOR
5. WASHER FLUID RESERVOIR
6. MODULE
7. COWL PANEL
Figure 30. Front and Rear Cab Mounting
21. From inside cab, remove six flange bolts securing right and left side rear operator cab legs to module.
22. Open right side hood door and remove both wiper motor washer tubes from t-fitting and disconnect

washer pump harness connector from washer fluid reservoir.
23. Disconnect rear grab handle horn button connector from right hand chassis harness.
24. Remove bottom flange bolt securing right side rear operator cab leg to module.
25. Open left side hood door and remove bottom flange bolt securing rear left side operator cab leg to

module.
WARNING
Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb).
26. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of
operator's cab (under overhead guard structure). Place material that will be a cushion at top of door

opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or
lifting strap on operator's cab. See Figure 31.
Figure 31. Lift Strap Connection
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CAUTION
Lift the operator cab carefully. Check that all electrical wires and attachments are
disconnected correctly and are not damaged.
27. Carefully lift operator cab up and away from lift truck. Set operator cab in a storage area and place
blocks under operator cab to make it stable and prevent damage to wire harness and parts still
attached.
INSTALL, FOR LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006),
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
1. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's
cab (under overhead guard structure). Place material that will be a cushion at top of door opening to

prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on
operator's cab. See Figure 31.
2. Carefully lift operator cab onto lift truck frame making sure that front and rear leg mounting holes are

aligned with module mounting holes.
3. Open left side hood door and install bottom flange bolt to secure rear left side operator cab leg to

module. Tighten flange bolt to 165 N•m (122 lbf ft). See Figure 30.
4. Open right side hood door and install bottom flange bolt to secure rear right side operator cab leg to

module. Tighten flange bolt to 165 N•m (122 lbf ft).
5. Connect rear grab handle horn button harness connector to right hand chassis harness.
6. Connect both wiper motor washer tubes to t-fitting and connect washer pump harness connector to

washer fluid reservoir.
7. Install two flange bolts to secure right and left side front operator cab legs to module. Tighten flange

bolt to 165 N•m (122 lbf ft).
8. From inside cab, install four remaining flange bolts to right and left side rear operator cab legs to

module. Tighten flange bolt to 165 N•m (122 lbf ft).
9. Connect three harness connectors on front right side operator cab leg to Vehicle System Manager

(VSM) and right hand chassis harness. See Figure 28.
NOTE: Perform Step 10 and Step 11 for lift truck models H6.0FT, H7.0FT (H135FT, H155FT) (K006) and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (B299) equipped with Diesel Particulate Filter
(DPF).
10. Connect three harness connectors on front right side operator cab leg to Vehicle System Manager

(VSM) and right-hand chassis harness. See Figure 29.
11. Connect Diesel Particulate Filter (DPF) display harness connector from cowl harness. See Figure 29.
12. Install two flange bolts to secure cowl panel to front operator cab legs.
See Figure 26 for early model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) lift trucks.
See Figure 27 for later model lift trucks
13. Install kick panel to seal plate assembly. See Figure 24.

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14. Install and clip dash assembly onto kick panel. See Figure 26.
15. Install five capscrews to top of dash assembly to secure dash assembly onto cowl panel. Tighten

capscrew to 3.5 N•m (30 lbf in).
NOTE: Perform Step 16 on early model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) lift trucks.
16. Install front wiper motor cover using two lock nuts. See Figure 26.
NOTE: Perform Step 17 on later model lift trucks

17. Install front wiper motor cover using three lock nuts. See Figure 27.
18. Install right side front cover to front overhead guard leg using two screws. See Figure 25.
19. Install right side rear cover to right side front cover and install and tighten two screws to frame.
20. Align right side rear cover to rear overhead guard leg and install and tighten two screws to rear

overhead guard leg and install and tighten two screws to rear overhead guard leg.
21. Repeat Step 18 through Step 20 to install left side covers.
22. Connect battery.
23. Install front floor plate and floor mat. See Figure 24.
NOTE: Installing door assemblies onto operator cab requires two people.
24. Lift door up and over top and bottom hinge pins. See Figure 23.
25. Align link and spacers into guide and install rod pin. See Figure 22.
26. Install hair pin into rod pin.
27. Repeat steps Step 24 through Step 26 for installation of left side door.
Door Assemblies
RIGHT SIDE DOOR ASSEMBLY, LIFT TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-
3.5FT (H40-70FT) (L177, N177); AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005, R005, S005)
Remove
WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When radiator
cap is removed, the pressure is released from cooling system. If cooling system is hot, the
steam and boiling coolant can cause burns.
Wait 30 minutes for the engine to cool. Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to
remove the radiator cap.
NOTE: Removing radiator cap will help depressurize cooling system.
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1. Remove radiator cover to access radiator cap. Remove radiator cap. See Figure 32.
A.
H1.6FT,
(F001)
H1.8FT, 2.0FTS C.
120FT) (N005, P005, R005)
B.
H2.0-3.5FT (H40-70FT)
(L177, N177)
D.
H4.0FT5/FT6;
120FT) (S005)
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
Figure 32. Radiator Cover and Cap Location
WARNING
DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator
cab) or engine when the engine is hot or under pressure. Serious injury can occur.
NOTE: Removing right side door assembly requires two people.
2. Disconnect heater hose quick disconnect fittings. See Figure 33.

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NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK.

A.
H1.6FT,
(F001)
H1.8FT, 2.0FTS C.
120FT) (N005, P005)
B.
H2.0-3.5FT (H40-70FT)
(L177, N177)
D.
120FT) (R005, S005)
1. QUICK DISCONNECT FITTING 4. RIGHT SIDE DOOR ASSEMBLY

2. INNER REAR COVER 5. HEATER HOSES
3. RADIATOR COVER
Figure 33. Heater Hose Connection
a. For lift truck models H1.6FT, H1.8FT, 2.0FTS (F001), open right side door and push buttons on
quick disconnect fittings to disconnect heater hoses from heater assembly hoses. See Figure 33.
Disconnect heater wire harness connection. See Figure 34.
b. For lift truck models H2.0-3.5FT (H40-70FT) (L177, N177), open right side door and remove
radiator cover to access quick disconnect fittings. Push buttons on quick disconnect fittings to
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disconnect heater hoses from heater assembly hoses. See Figure 33. Disconnect heater wire harness
connection. See Figure 34.
c. For lift truck models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005) equipped with a heater unit, open right side door and locate two port

holes on inner rear cover. Push buttons on quick disconnect fittings to disconnect heater hoses from
heater assembly. See Figure 33. Disconnect heater wire harness connection. See Figure 34.

1. HEATER WIRE HARNESS CONNECTOR
2. REAR GRAB HANDLE HORN BUTTON CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS)
Figure 34. Heater Wire Harness and Rear Grab Handle Horn Button Connectors
WARNING
and/or refilling of the refrigerant fluid must be performed by a certified technician.
3. Contact a certified air conditioning specialist to have the refrigerant extracted from air conditioning

system.
(P005, R005, S005) with a Cummins QSB 3.3L or Kubota diesel engine, if lift truck cab is equipped
with an air conditioner/heater unit, disconnect AC hoses.
a. Remove six fasteners and remove rear cover.



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b. Disconnect air conditioner hoses at bulkhead bracket and at receiver/drier.



c. Disconnect air conditioner wire harness.




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H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005)

H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)
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H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005)
5. Disconnect gas spring. See Figure 38.
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1. GAS SPRING
2. MOUNTING BRACKET
3. LOCK NUT
Figure 38. Gas Spring Mounting Installation
6. Remove right side door from cab frame by lifting door up and over hinge pin. See Figure 39.
NOTE: RIGHT SIDE DOOR HINGE SHOWN.

1. HINGE PIN
2. DOOR HINGE
Disassemble
Door Cover With Heater Unit
1. Remove four screws and washers that attach handle to door cover. Remove handle and two handle

plates. See Figure 40.
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Figure 40. Right Side Door Cover Removal, Heater Unit

1. PLUG 9. WASHER
2. FASTENER 10. HEATER/FAN LOUVER
3. GAS SPRING 11. CAPSCREW
4. FAN AND HEATER KNOBS 12. DOOR COVER
5. SCREW 13. PRE-FILTER
6. KNOB PLATE 14. HEATER VALVE AND SWITCH PLATE
7. HANDLE 15. STAR NUT
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8. HANDLE PLATES
2. Remove fan and heater knobs from knob plate. Remove four screws that fasten knob plate to heater

valve and switch plate. Remove knob plate from door cover.
3. Remove two fasteners from top of door cover.
4. Remove five plugs along sides and front of door cover. Remove two capscrews and washers from

bottom of door cover. Remove door cover from door frame.
5. Remove prefilter, located on bottom of door frame.
Door Cover With Air Conditioner/Heater Unit

NOTE: Only lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(P005, R005, S005) with a Cummins QSB 3.3L or Kubota diesel engine may be equipped with an air
conditioner/heater unit.
NOTE: The procedures in this section remove air conditioner/heater unit assembly door cover from right
side door. For procedures to remove or replace other components of air conditioner/heater unit assembly, go
to Heater and Air Conditioner Assembly section.
1. Remove four screws and washers that attach handle to door cover. Remove handle. See Figure 41.
1. CAPSCREW 8. HEATER, FAN, AND AC LOUVER

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2. AC ROCKER SWITCH PLATE 9. PRE-FILTER
3. AC ROCKER SWITCH 10. DOOR COVER
4. HEATER/AC KNOBS 11. WASHER
5. HANDLE 12. PLUG
6. HEATER VALVE AND SWITCH PLATE 13. WASHER
7. FASTENER 14. STAR NUT
Figure 41. Right Side Door Cover Removal, Air Conditioner/Heater Unit
2. Remove hose wrap from AC hoses.



3. Remove fan and heater/AC knobs from knob plate. Remove four screws that fasten knob plate to

heater valve and switch plate. Remove knob plate and heater valve from door cover. See Figure 41.
4. Remove two fasteners from top of door cover.
5. Remove four capscrews that fasten AC rocker switch plate to door cover. Remove AC rocker switch

plate from door cover. See Figure 41.
6. Remove five plugs, washers, and star nuts along sides and front of door cover. Remove two capscrews

and washers from bottom of door cover. Remove door cover from door frame.
7. Remove prefilter, located on bottom of door frame. See Figure 41.
Heater Assembly
NOTE: The heater assembly is non-repairable, replace as a complete unit. See Parts Manual.
1. Remove lock nut from heater valve and switch plate. See Figure 42.
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1. LOCK NUT 7. HEATER VALVE AND SWITCH PLATE

2. NUT 8. HEATER VALVE
3. WASHER 9. HEATER SWITCH
4. HEATER ASSEMBLY BRACKET 10. RETURN HOSE
5. SUPPLY HOSE 11. SCREWS
6. HEATER ASSEMBLY 12. HEATER COIL
Figure 42. Heater Assembly Removal
2. Disconnect heater switch connector from heater switch.
3. Remove two screws from heater valve and switch plate and remove plate.
4. Disconnect supply hose at heater valve and disconnect return hose from heater coil.
5. Remove two nuts and washers from heater assembly bracket. Remove heater assembly and bracket

from door frame.
Air Conditioner and Heater Unit Assembly

NOTE: Only lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(P005, R005, S005) with a Cummins QSB 3.3L or Kubota diesel engine may be equipped with an air
NOTE: The procedures in this section remove air conditioner/heater unit assembly from right side door. For
procedures to remove or replace other components of air conditioner/heater unit assembly, go to Heater and
Air Conditioner Assembly section.
NOTE: The air conditioner and heater assembly is non-repairable, replace as a complete unit. See Parts
Manual.
1. Remove lock nut from heater valve and switch plate.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005, R005)
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1. HEATER RETURN HOSE 7. CAPSCREW

2. HEATER SUPPLY HOSE 8. AC/HEATER UNIT
3. AC HOSES 9. HEATER VALVE
4. HEATER VALVE AND SWITCH PLATE 10. AC ROCKER SWITCH
5. LOCKNUT 11. HEATER COIL
6. MOUNTING BRACKET 12. AC EXPANSION VALVE
Figure 43. Air Conditioner/Heater Unit Assembly Removal, Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005, R005)
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1. SCREW 7. AC HOSES
2. AC ROCKER SWITCH 8. HEATER SUPPLY HOSE
3. HEATER VALVE 9. HEATER RETURN HOSE
4. LOCKNUT 10. HEATER COIL
5. SWITCH PLATE 11. AC EXPANSION VALVE
6. AC/ HEATER UNIT 12. MOUNTING BRACKET
Figure 44. Air Conditioner/Heater Unit Assembly Removal, Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005)
2. Disconnect heater switch connector from heater switch plate.
3. Remove four screws from heater valve and switch plate and remove plate.
4. Disconnect AC rocker switch.


5. Disconnect supply hose at heater valve and disconnect return hose from heater coil.


6. Disconnect AC hoses from the AC expansion valve.

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7. Remove four screws from AC/heater assembly mounting bracket. Remove AC/heater assembly and

mounting bracket from door frame.


Door Lock Assembly
1. Remove inside lever handle cover. See Figure 45.
A. LEVER IN CLOSED POSITION B. LEVER IN OPEN POSITION
1. INSIDE LEVER HANDLE 7. DOOR LOCK ASSEMBLY

2. CAPSCREWS 8. RELEASE LEVER
3. INSIDE LEVER HANDLE COVER 9. NUT
4. CAPSCREW (OUTSIDE HANDLE) 10. MOUNTING PLATE
5. LOCK NUT 11. SCREWS
6. RELEASE BAR 12. WASHER
Figure 45. Door Lock and Lever Disassembly
2. Place inside lever handle in closed position. Remove lock nut from release bar at inside lever handle.

Pull inside lever handle to open position. Remove release bar from inside lever handle.
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3. Remove two capscrews and inside lever handle and mounting plate.
4. Remove lock nut from release bar and release bar from door lock assembly.
5. Remove two nuts and capscrews from door lock assembly. Remove door lock assembly from door

frame.
6. Remove screw and washer from release lever and release lever from outside door handle assembly.

See Figure 45 and Figure 46.
7. Remove four capscrews that fasten outside door handle to door. Remove outside door handle from

door.
8. Remove seal and grip from outside handle assembly. Discard seal. See Figure 46.
1. LATCH STRIKER ASSEMBLY

2. SEAL
3. OUTSIDE HANDLE ASSEMBLY
4. GRIP
Figure 46. Outside Handle Disassembly
Windows
For procedures to remove and install door windows, see section Window Replacement.
Clean
WARNING
Compressed air can move particles so that 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.
Check door assembly and parts for oil, grease, dirt, and other debris. Clean door assembly and parts with a
clean cloth, soap, and water. Compressed air can be used to dry door assembly and parts.
Inspect
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Inspect all hoses for cracks and wear. Replace damaged hoses. Inspect seals around door window and door
lock assembly and replace if damaged. Check door lock and latch assembly. Make sure it opens, shuts, and
locks door securely and there is no rust, grease, oil, or dirt on door lock and latch assembly parts. Inspect
windows for cracks or chips. Replace windows if damaged.
Assemble
Windows
Door Lock Assembly
1. Install new seal and grip to outside handle assembly. See Figure 46.
2. ®
Apply Loctite 242 to threads of four capscrews and secure outside door handle to door (see
Figure 45). Tighten capscrews to 19.2 N•m (170 lbf in).
3. Apply Loctite® 242 to capscrew and install release lever to rear of outside door handle assembly.

Tighten capscrew to 5.0 N•m (44 lbf in).
4. Install door lock assembly onto door frame using two capscrews and nuts. Tighten capscrews to

19.2 N•m (170 lbf in).
5. Install inside lever handle and mounting plate to door frame. Tighten capscrews to

19.2 N•m (170 lbf in).
6. Place inside lever handle in closed position (see Figure 45). Insert release bar into door lock assembly

end and into inside lever handle. Secure release bar with lock nuts.
7. Install cover onto inside lever assembly.
Heater Assembly
1. Secure heater assembly to door frame with mounting bracket. Insert washers and two lock nuts onto

mounting bracket, and tighten to 19.2 N•m (170 lbf in). See Figure 42.
2. Connect supply and return hoses to heater valve.
3. Install heater valve and switch plate using two screws.
4. Connect heater switch connector to heater switch.
5. Secure heater valve and switch plate with lock nut.
Air Conditioner and Heater Unit Assembly

NOTE: The procedures in this section install air conditioner/heater unit assembly to right side door. For
procedures to install or replace other components of air conditioner/heater unit assembly, go to Heater and Air
Conditioner Assembly section.
1. Insert four nuts and capscrews and secure air conditioner/heater unit assembly to door frame and

mounting bracket.
2. Connect AC hoses to AC expansion valve.

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3. Connect supply and return hoses to heater valve.
4. Connect AC rocker switch.
5. Install heater valve and switch plate using four screws.


6. Connect heater switch connector to heater switch.
7. Secure heater valve and switch plate with lock nut.
Door Cover With Heater Unit
1. Install pre-filter on bottom of door frame. See Figure 40.
2. Align holes on door cover with holes that are on door frame. Install five plugs into holes that are along

sides and front of door cover. Secure bottom of door cover using two capscrews and washers.
3. Install two fasteners into holes on top of door cover. See Figure 40.
4. Install knob plate on heater valve and switch plate with four screws. Install fan and heater knobs on

knob plate.
5. Install handle and handle plates on door with four screws and washers.
Door Cover With Air Conditioner and Heater Unit

NOTE: The procedures in this section install air conditioner/heater unit assembly door cover onto right side
door. For procedures to install or replace other components of air conditioner/heater unit assembly, go to
Heater and Air Conditioner Assembly section.
1. Install pre-filter on bottom of door frame. See Figure 41.
2. Align holes on door cover with holes that are on door frame. Install five plugs into holes that are along

sides and front of door cover. Secure bottom of door cover using two capscrews and washers.
3. Install AC rocker switch plate to door cover using four capscrews.
4. Install two fasteners into holes on top of door cover. See Figure 41.
5. Install knob plate on heater valve and switch plate with four screws. Install fan and AC/heater knobs

on knob plate.
6. Install hose wrap around AC hoses.

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7. Install handle and handle plates on door with four screws and washers.
Install
1. Install right side door onto cab by lifting door over top and bottom hinge pins. See Figure 39.
2. Connect gas spring and lock nut to mounting bracket on operator cab frame. See Figure 38.
3. Connect heater hoses to heater assembly and connect heater wire harness connection. See Figure 33

and Figure 34.
4. On lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(P005, R005, S005) with a Cummins QSB 3.3L or Kubota diesel engine and equipped with an air
WARNING
and/or refilling of the refrigerant fluid must be performed by a certified technician.
5. Contact a certified air conditioning specialist to have the refrigerant refilled into the air conditioning

system.
a. Connect AC hoses at bulkhead bracket and to receiver/drier.



b. Install rear cover with six fasteners.



6. Install radiator cover. See Figure 32.
LEFT SIDE DOOR ASSEMBLY, LIFT TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-
3.5FT (H40-70FT) (L177, N177); AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90,
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100, 110, 120FT) (N005, P005, R005, S005)
Remove
NOTE: Removing left side door assembly requires two people.
1. Open left side door and disconnect gas spring. See Figure 38.
2. Remove left side door from cab frame by lifting door over hinge pin. See Figure 39.
Disassemble
Door Cover
1. Remove cover from rear of handle and remove screw. Remove capscrew from door lock cover and

remove door lock cover from lock assembly. See Figure 47.
1. FASTENER 5. CAPSCREW
2. PLUG 6. DOOR LOCK COVER
3. COVER 7. HANDLE
4. SCREW 8. DOOR LOCK ASSEMBLY
Figure 47. Left Side Door Cover Removal
2. Remove two capscrews that secure handle to door lock assembly. Remove handle from door.
3. Remove two fasteners from top of door cover. Remove five plugs along edges of door cover and

remove door cover from door frame.
Door Lock Assembly
1. Remove capscrew and washer from release lever. Remove release lever from door. See Figure 48.
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1. CAPSCREW
2. WASHER
3. RELEASE LEVER
Figure 48. Release Lever Removal
2. Remove four capscrews and two washers (right side only) from rear of outside handle. Remove

outside door handle from door.
3. Remove grip and seal from outside handle. Discard seal. See Figure 46.
Windows
Clean
WARNING
Check door assembly and parts for oil, grease, dirt, and other debris. Clean door assembly and parts with a
clean cloth and soap and water. Compressed air can be used for drying door assembly and parts.
Inspect
Inspect seals around window, door, and door lock assembly and replace if damaged. Check door lock and
latch assembly. Make sure it opens, shuts, and locks door securely and there is no rust, grease, oil, or dirt on
door lock and latch assembly parts. Inspect window for cracks or chips. Replace window if damaged.
Assemble
Windows
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Door Lock Assembly
1. Install seal and grip (see Figure 46) onto outside door handle. Place outside door handle onto door
®
frame. Apply Loctite 242 to threads of four capscrews and secure outside handle to door frame using
capscrews and washers. The washers go on right side from inside cab. Tighten capscrews to
19.2 N•m (170 lbf in).
2. ®
Apply Loctite 242 to capscrew and install release lever to rear of outside door handle. Tighten
capscrew and washer to 5.0 N•m (44 lbf in). See Figure 48.
Door Cover
1. Place door cover onto door frame. Install two fasteners onto top of door cover and install five plugs

along edges of door cover. See Figure 47.
2. Install handle to latch assembly with two capscrews. Tighten capscrews to 19.2 N•m (170 lbf in).

Secure lock cover to door lock assembly with capscrew.
3. Secure handle to rear of door cover with screw. Tighten screw to 5.0 N•m (44 lbf in). Push cover into

place over screw.
Install
1. Install left side door onto cab by lifting door over top and bottom hinge pins. See Figure 39.
2. Connect gas spring to mounting bracket on operator cab frame. See Figure 9.
RIGHT AND LEFT SIDE DOOR ASSEMBLIES, LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299,
B299)
NOTE: The right and left doors are identical and are repaired and serviced in same manner on lift truck
models
Remove
NOTE: Removing door assemblies from operators cab requires two people.
1. Open right side door and remove hair pin from rod pin. See Figure 49.
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NOTE: RIGHT SIDE DOOR SHOWN
1. ROD PIN 3. HAIR PIN

2. SPACERS 4. DOOR ASSEMBLY
Figure 49. Door Link Removal
2. Remove rod pin and spacers from link.
3. Remove right side door from cab frame by lifting door up and over hinge pin. See Figure 39.
4. To remove left door, repeat Step 1 through Step 3.
Disassemble
Door Cover
1. Remove cover from rear of handle and remove screw. Remove capscrew from door lock cover and
remove cover from lock assembly. Remove two capscrews and washers that secure handle to door
lock assembly. Remove handle and door lock assembly from door frame. See Figure 50.
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1. COVER 5. DOOR LOCK

2. SCREW 6. WASHER
3. CAPSCREW 7. HANDLE
4. LOCK COVER 8. PLUG
Figure 50. Door Cover Removal
2. Remove five plugs that secure door cover to door frame and remove cover from frame.
Door Lock Assembly
1. Remove capscrew and washer from release lever. Remove release lever from rear of outside door

handle. See Figure 51.
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1. SCREW 3. RELEASE LEVER

2. WASHER 4. CAPSCREW
Figure 51. Release Lever Removal
2. Remove four screws from rear of outside door handle. Remove outside door handle from door.
3. Remove grip and seal from outside door handle. See Figure 52.
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1. LATCH STRIKER ASSEMBLY 3. OUTSIDE DOOR HANDLE
2. SEAL 4. GRIP
Figure 52. Outside Handle Removal
Windows
Clean
WARNING
Check door assembly parts for oil, grease, dirt, and other debris. Clean door assembly and parts with a clean
cloth, soap, and water. Compressed air can be used for drying door assembly and parts.
Inspect
Inspect seals around window, door, and door lock assembly and replace if damaged. Check door lock and
latch assembly. Make sure it opens, shuts, and locks door securely and there is no rust, grease, oil, or dirt on
door lock and latch assembly parts. Inspect window for cracks or chips. Replace window if damaged.
Assemble
Windows
Door Lock Assembly
1. Install grip and seal to outside door handle assembly. See Figure 52.
2. Apply Loctite® 242 to threads of four screws. Use screws to install outside door handle to door frame.

Tighten screws to 19.2 N•m (170 lbf in). See Figure 51.
3. ®
Apply Loctite 242 to threads of capscrew for release lever and install release lever to rear of outside
door handle assembly. Tighten capscrew to 5.0 N•m (44 lbf in).
Door Cover
1. Place door cover onto door frame. Install two fasteners onto top of door cover. Install five plugs along

edges of door cover. See Figure 50.
2. Install handle to lock assembly with two capscrews and washers. Tighten capscrews to

19.2 N•m (170 lbf in). Install lock cover to lock assembly with capscrew. See Figure 50.
3. Secure handle to rear of door cover with screw. Tighten screw to 5.0 N•m (44 lbf in). Push cover into

place over screw.
Install
NOTE: The installation procedures outlined below apply to both left and right side doors.
1. Lift door over top and bottom hinge. See Figure 39.
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2. Align link and spacers into guide and install rod pin. See Figure 49.
3. Install hair pin into rod pin.
Window Wipers Replacement

GENERAL
Two window wiper motor assemblies are installed in operator cab. The front window motor assembly has two
wiper arms connected to a single wiper blade. The rear window has a wiper motor assembly that has one
wiper arm attached to a single wiper blade.
FRONT WIPER ASSEMBLY AND MOTOR
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0-3.5FT (H40-70FT) (L177, N177)
1. Remove wiper motor cover from wiper motor. See Figure 53.
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Figure 53. Front Wiper and Motor Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)
and H2.0-3.5FT (H40-70FT) (L177, N177)
1. FRONT WINDOW 8. CAP

2. WIPER BLADE 9. FLANGE NUT
3. WIPER ARM 10. GROMMET
4. LOCKWASHER 11. WIPER MOTOR COVER
5. LOCK NUT 12. CAB HARNESS CONNECTOR (WIPER MOTOR)
6. WIPER HOSE 13. WIPER MOTOR
7. JAM NUT 14. HARDWARE COVERS
2. Disconnect cab harness connector from wiper motor.

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3. Open hardware covers at base of wiper arms and remove two lock nuts and lockwashers from wiper

arms. Remove wiper arms and blade from wiper motor.
4. Remove cap and jam nut.
5. Remove one flange nut (right side) and two grommets from threaded shafts on wiper motor that pass

through two holes in window. Remove wiper motor from front window.
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0-3.5FT (H40-70FT) (L177, N177)
1. Install wiper motor to front window using one flange nut (right side) and two grommets onto threaded

shafts on wiper motor. Insert shafts through two holes in front window. See Figure 53.
2. Install cap and jam nut.
NOTE: Inspect wiper blade. If it is cracked, split, or worn, replace with new blade before installing wiper
arms onto front window.
3. Install wiper arms and blade to front window using two lock nuts and lockwashers. Close hardware

covers at base of wiper arms.
4. Connect cab harness connector to wiper motor.
5. Install wiper motor cover to wiper motor.
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
1. Open hardware covers at base of wiper arms and remove two nuts and external tooth lockwashers

from wiper arms.
See Figure 54 for early model lift trucks

• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
See Figure 55 for later lift truck models

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Figure 54. Front Wiper and Motor Remove, H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005) Lift Trucks and Early Model H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) Lift Trucks
A. OUTSIDE OF CAB B. INSIDE OF CAB
1. WIPER BLADE 9. FRONT WIPER MOTOR COVER

2. WIPER ARM 10. WIPER MOTOR
3. LOCKWASHERS 11. WIPER MOTOR BRACKET ASSEMBLY
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4. WASHERS 12. CAPSCREWS
5. NUTS 13. THREADED SHAFTS
6. HARDWARE COVER 14. WIPER MOTOR HOUSING
7. EXTERNAL TOOTH LOCKWASHER 15. CAB HARNESS
8. LOCK NUTS
Figure 55. Front Wiper and Motor Remove, Later Model H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006), H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299) Lift Truck
Models
A. OUTSIDE OF CAB B. INSIDE OF CAB
1. WIPER BLADE 8. WIPER MOTOR HOUSING
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2. WIPER ARM 9. THREADED SHAFTS
3. LOCKWASHER 10. WIPER MOTOR BRACKET ASSEMBLY
4. WASHER 11. WIPER MOTOR
5. NUTS 12. FRONT WIPER MOTOR COVER
6. HARDWARE COVER 13. LOCKNUTS
7. EXTERNAL TOOTH LOCKWASHER 14. CAPSCREW AND EXTERNAL TOOTH LOCKWASHER
2. Remove wiper blade and wiper arm from wiper motor threaded shafts.
3. Remove two hardware covers, nuts, washers, and lockwashers from two threaded shafts that pass

through two holes in wiper motor housing. Remove wiper arms from front window.
4. Remove two lock nuts that secure front wiper motor cover to wiper motor housing. Remove cover.

• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
5. Remove three lock nuts that secure front wiper motor cover to wiper motor housing. Remove cover.

• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005)
6. Disconnect cab harness from wiper motor harness.
7. Remove wiper motor and bracket from wiper motor housing.
8. Remove three capscrews and external tooth lockwashers and remove wiper motor from wiper motor

bracket assembly.
See Figure 54 for early lift truck models

• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)

• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005)
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), and H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
1. Install wiper motor to wiper motor bracket using three capscrews and external tooth lockwashers.

• Early model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
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H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005)
2. Install wiper motor and bracket into wiper motor housing.
3. Connect wiper motor harness to cab harness.
4. Attach front wiper motor cover to wiper motor housing with two lock nuts.

• Early model H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
5. Attach front wiper motor cover to wiper motor housing with three lock nuts.


H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005, S005)
6. Install two washers, nuts, and hardware covers onto threaded shafts.
NOTE: Inspect wiper blade. If it is cracked, split, or worn, replace with new blade before installing wiper
arms onto front window.
7. Install wiper arms onto wiper motor threaded shafts, using two external tooth lockwashers and nuts.

Close hardware cover at base of wiper arms.
REAR WIPER ASSEMBLY AND MOTOR
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)
1. To replace rear wiper motor assembly, open hardware covers at base of wiper arms and remove nut

and lockwasher from wiper arm. Remove wiper arm and blade. See Figure 56.
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Figure 56. Rear Wiper and Reservoir Bottle Remove, Lift Truck Models H1.6FT, H1.8FT,
2.0FTS (F001)
1. REAR WINDOW 13. WIPER BLADE

2. GROMMET 14. SPRAY NOZZLE MOUNTING STUD
3. WASHER 15. WASHER RESERVOIR
4. MOUNTING STUD 16. RESERVOIR MOUNTING BRACKET
5. GROMMET 17. WATER TUBE
6. WASHER 18. WIRE HARNESS CONNECTOR
7. RETAINER 19. WIPER MOTOR COVER
8. NUT 20. NUT
9. HARDWARE COVER 21. WASHER
10. WASHER 22. WIPER MOTOR
11. NUT 23. THREADED SHAFT
12. WIPER ARM
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2. Remove hardware cover, nut, retainer, washer, and grommet from threaded shaft that passes through

window of operator cab.
3. Remove wiper motor cover by pulling backward. The cover is held in place by plastic tabs on inside of

cover.
4. Disconnect wiring harness connector and remove water tube. Remove washer reservoir from reservoir

mounting bracket.
NOTE: The left mounting stud is also spray nozzle for window washer. See Figure 56.
5. From inside cab, remove nuts and washers from wiper motor mounting studs that pass through

window from back side. Remove wiper motor from rear window.
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)
1. Insert wiper motor mounting studs through holes in window. Place motor on mounting studs and

secure motor to mounting studs with two washers and nuts. See Figure 56.
2. Install washer reservoir onto reservoir mounting bracket and connect wiring harness connector and

water tube.
3. Install wiper motor cover. The cover snaps into place with plastic tabs.
4. Install grommet, washer, retainer, nut, and hardware cover on threaded shaft that passes through

window of operator cab.
NOTE: Inspect wiper blade. If it is worn or cracked, replace with new wiper blade.
5. Attach wiper arm to threaded shaft with lockwasher and nut. Install wiper blade onto wiper arm.
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177, N177)
1. Disconnect washer tube connector. See Figure 57.
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1. WIPER BLADE 8. NUT

2. WIPER ARM 9. HARDWARE COVER
3. WASHER TUBE 10. WIPER ARM GROMMET
4. WASHER TUBE CONNECTOR 11. FLANGE NUT
5. NUT 12. MOTOR MOUNT GROMMET
6. WASHER 13. MOTOR MOUNT STUD
7. CAP 14. WIPER MOTOR SHAFT
Figure 57. Rear Wiper Removal, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177, N177)
2. Open hardware cover at base of wiper arm and remove nut and washer from wiper arm. Remove wiper

arm and blade from window. Remove wiper blade from wiper arm.
3. Remove cap, nut, and wiper arm grommet from wiper motor shaft.
4. Disconnect wiper motor connector from cab wire harness. See Figure 58.
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1. WASHER TUBE 6. WIPER MOTOR CONNECTOR

2. NUT 7. REAR WIPER MOTOR
3. WASHER 8. CAB WIRE HARNESS
4. WASHER RESERVOIR 9. MOUNTING BRACKET
5. WASHER PUMP CONNECTORS
Figure 58. Washer Bottle and Wiper Motor Removal
5. Remove cover, flange nut, and motor mount grommet from motor mount stud. See Figure 57.
6. Disconnect rear wiper motor connector, and remove rear wiper motor from window. See Figure 57.
7. Remove nut and washer and remove washer tube from hole. See Figure 58.
8. Disconnect washer pump connectors from cab wire harness.
9. Remove nut and washer from mounting bracket and remove washer reservoir from mounting bracket.
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177, N177)
1. Place wiper motor mount stud through hole. Install rear wiper motor to lift truck using motor mount

grommet, flange nut, and cover. See Figure 57.
2. Install reservoir onto mounting bracket with washer and nut. See Figure 58.
3. Connect washer pump connectors to cab wire harness.

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4. Insert washer tube through hole and secure tube to window with nut and washer.
5. Connect rear wiper motor connector to cab wire harness.
6. Install wiper arm grommet, nut, and cap onto rear wiper motor shaft.
NOTE: Inspect wiper blade for cracks and wear. Replace with new blade if old blade is worn or damaged.
7. Install wiper blade onto wiper arm. Install wiper blade and arm to window using nut and washer. See

Figure 57. Close hardware cover.
8. Connect washer tube to wiper arm.
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
1. Disconnect washer tube connector. See Figure 59.
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Figure 59. Washer Reservoir and Rear Wiper Removal, Lift Truck Models H4.0FT5/FT6,
H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005)
A. INNER REAR COVER C. WIPER ARM

B. WASHER RESERVOIR AND PUMP
1. SCREWS 9. WASHER RESERVOIR PUMP CONNECTOR

2. INNER REAR COVER 10. WASHER RESERVOIR PUMP
3. WASHER RESERVOIR 11. WASHER FLUID HOSE
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4. WASHER 12. CAB HARNESS
5. WIPER MOTOR 13. WASHER TUBE CONNECTOR
6. NUT 14. WIPER ARM
7. CAPSCREW 15. WIPER MOTOR MOUNT
8. WASHER MOUNTING BRACKET
2. Lift up hardware cover at base of wiper arm and remove nut and washer from wiper arm. Remove

wiper arm and blade from rear window. Remove wiper blade from wiper arm. See Figure 57.
3. Remove cap, nut, and wiper arm grommet from wiper motor shaft.
4. Open both doors of cab. From inside of cab, remove five screws from inner cover and remove inner

cover from cab.
5. Disconnect wiper motor from cab harness from inside cab. From outside of cab, remove nut and

washer from wiper motor mount. Remove wiper motor from cab.
6. Remove radiator cover (see Figure 5) and disconnect washer reservoir pump connectors and

disconnect washer fluid hose.
7. From inside cab, remove four capscrews, nuts, and washers from washer reservoir mounting bracket.

Remove washer reservoir and mounting bracket from lift truck.
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
1. From inside of cab, install washer reservoir and mounting bracket using four capscrews, nuts, and

washers. See Figure 59.
2. Connect washer reservoir pump connectors and washer fluid hose. Install radiator cover. See Figure 5.
3. Place wiper motor onto wiper motor mount and secure using nut and washer. Connect wiper motor to

cab harness.
4. Install inner cover using five screws.
5. Install cap, nut, and wiper arm grommet onto threaded wiper motor shaft that passes through window

of operator's cab.
6. Install wiper blade to wiper arm. Install wiper arm and blade to window using nut and washer. Close

hardware cover at base of wiper arm.
7. Connect washer tube connector.
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
1. Open hardware cover at base of wiper arm and remove nut and washer. Remove wiper arm and blade.

See Figure 60.
2. Disconnect water tube from water tube nozzle.
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1. COVER 11. CAB HARNESS

2. NUT 12. WATER TUBE NOZZLE
3. WASHER 13. WATER TUBE
4. WIPER MOTOR 14. FRONT WATER TUBE
5. REAR WINDOW 15. T-FITTING
6. GROMMET 16. FLANGE BOLTS
7. MOUNTING STUD 17. WASHER RESERVOIR
8. RETAINER 18. RESERVOIR PUMP
9. HARDWARE COVER 19. WIPER BLADE
10. WIPER MOTOR CONNECTOR 20. WIPER ARM
Figure 60. Rear Wiper, Motor, and Washer Reservoir Removal, Lift Truck Models H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299)
3. Remove hardware cover, nut, retainer, washer, and grommet from threaded shaft on wiper motor.
4. Remove wiper motor cover by pulling backward. The cover is held in place by plastic tabs on the

inside of cover.
5. Disconnect cab harness from wiper motor. Remove two mounting studs, washers, and grommets that
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attached wiper motor to window. Remove wiper motor from window.
6. Disconnect water tubes at T-fitting and cab harness from washer reservoir. Remove four flange bolts

from washer reservoir and remove reservoir from lift truck.
Install, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006) and H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
1. Install washer reservoir using four flange bolts. Connect water tubes at T-fitting and cab harness to

washer reservoir. See Figure 60.
2. Install wiper motor to rear window using two grommets, washers, and mounting studs. Connect cab

harness to wiper motor.
3. Install wiper motor cover. The cover snaps into place with plastic tabs.
4. Install grommet, washer, retainer, nut, and hardware cover onto threaded shaft of wiper motor. See

Figure 60.
5. Install wiper arm and blade with washer and nut.
6. Connect water tube onto water tube nozzle.
Window Replacement
GENERAL
See the Parts Manual for window replacement part numbers for the front, back, and top windows. To replace
the door windows, see the procedures below.
REMOVE DOOR WINDOW, LIFT TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177, N177); AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005, S005)
NOTE: The procedures described below apply to sliding and non-sliding right side door windows. The
procedures to remove sliding and non-sliding left side door windows are same as right side. To remove lower
window on left side door, perform Step 5 and Step 6.
1. Slide window open half way. Grab window sides and lift window off window guide. See Figure 61.
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1. SETSCREWS 5. WINDOW GUIDE

2. MOUNTING BRACKET 6. WINDOW HANDLE
3. SLIDING WINDOW 7. NON SLIDING WINDOW
4. SIDE SEAL 8. CAPSCREWS
Figure 61. Sliding Window Removal
2. Remove two setscrews from window mounting bracket and remove window from mounting bracket.
3. Remove side seal from side of sliding window.
4. Remove two capscrews from window handle and remove handle from window.
To remove non-sliding window, repeat Step 1 through Step 4.
NOTE: The lower window on left side door is glued into place on door frame.
5. On outside of door, cut seal that holds window in place on door frame. See Figure 62.
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1. DOOR FRAME
2. SEAL
3. WINDOW
Figure 62. Lower Window Removal (Left Side Door)
6. Remove window and seal from door frame. Remove any excess seal material and adhesive from door

frame.
INSTALL DOOR WINDOWS, LIFT TRUCK MODELS H1.6FT, H1.8FT, 2.0FTS (F001); H2.0-3.5FT
(H40-70FT) (L177, N177); AND H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005, S005)
NOTE: The procedures described below apply to sliding and non-sliding right side door windows. The
procedures to install sliding and non-sliding left side door windows are same as right side. To install lower
window on left side door, perform Step 5 and Step 6.
NOTE: See Parts Manual for window replacement part numbers.
1. Attach window handle to window with two bolts. See Figure 62.
2. Install side seal to side of sliding window.
3. Place window in mounting bracket and secure window to mounting bracket with setscrews.
4. Place window onto window guide. Open and close window (sliding window only) to ensure it is

properly installed onto window guide.
Perform Step 1 through Step 4 to install non-sliding window.
5. Apply adhesive to side of new seal that goes against window and install seal onto new window. See

Figure 62.
6. Apply adhesive to other side of seal and press seal and window into door frame.
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REMOVE DOOR WINDOW, LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
NOTE: The procedures described below apply to sliding and non-sliding left side door windows. The
procedures to remove sliding and non-sliding right side door windows are same as left side. To remove lower
windows, go to Step 5.
1. Slide window open half way. Grab window sides and lift window off window guide. See Figure 63.
NOTE: LEFT SIDE DOOR SHOWN.
1. SETSCREW 6. WASHER
2. MOUNTING BRACKET 7. SLIDE/LOCKING HANDLE
3. SLIDING WINDOW 8. WINDOW GUIDE
4. SIDE SEAL 9. NON-SLIDING WINDOW
5. CAPSCREW
Figure 63. Sliding Window Removal
2. Remove two setscrews from window mounting bracket and remove window from mounting bracket.

See Figure 63.
3. Remove side seal from side of sliding window.
4. Remove two capscrews and washers from window slide/locking handle and remove handle from

window.
To remove non-sliding window, repeat Step 1 through Step 4.
5. To remove lower window, remove seal from window and remove window from door frame. See

Figure 64.
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NOTE: LEFT SIDE DOOR SHOWN.

1. SEAL
2. WINDOW
3. DOOR FRAME
Figure 64. Lower Window Removal
INSTALL DOOR WINDOW, LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) AND H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
NOTE: The procedures described below apply to sliding and non-sliding left side door windows. The
procedures to install sliding and non-sliding right side door windows are same as left side. To install lower
windows, go to Step 1.
NOTE: See Parts Manual for window replacement part numbers.
1. Install seal around lower window. Install seal and window into door frame. See Figure 64.
2. Attach handle to window with two capscrews and washers. See Figure 63.
3. Install side seal from side of sliding window.
4. Place window onto mounting bracket and secure window to mounting bracket with setscrews.
5. Place window onto window guide. Open and close window (slide window only) to ensure it is

properly installed onto window guide.
Perform Step 2 through Step 5 to install non-sliding window.
Heater Replacement
REMOVE, FOR LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
1. Remove front and rear floor mat and front floor plate. See Figure 65.
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1. FRONT FLOOR MAT 4. REAR FLOOR PLATE

2. REAR FLOOR MAT 5. FRONT FLOOR PLATE
3. FLANGE BOLT 6. MODULE
Figure 65. Floor Plate Removal
2. Remove four flange bolts and rear floor plate. See Figure 65.
4. Remove right side rear panel. See Figure 66.
NOTE: RIGHT SIDE VIEW SHOWN.
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1. SCREWS
2. RIGHT SIDE REAR PANEL
Figure 66. Right Side Rear Panel Removal
5. Loosen strap clamps and remove formed hose from fresh air intake vent to heater box. See Figure 67.
Figure 67. Heater and Hoses

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1. LOUVERS 15. HEATER CONTROL HARNESS

2. TOP VENT ADAPTERS 16. CONNECTOR TO CAB HARNESS
3. STRAP CLAMPS 17. CONNECTOR TO HEATER
4. REAR DUCT HEATER HOSE 18. FLOOR VENT DUCT HOSE
5. FRONT DUCT HEATER HOSE 19. NUT
6. SCREWS 20. FLOOR VENT
7. HEATER CONTROL 21. INSERT
8. CLIPS 22. BRACKET
9. RETURN HOSE 23. RECTANGLE ADAPTER
10. SUPPLY HOSE 24. FORMED HOSE
11. SWIVEL CLAMP 25. CLIP NUTS
12. CLAMP 26. FRESH AIR INTAKE VENT
13. CAPSCREWS 27. SURROUND COVER
14. HEATER BOX
6. Remove flange bolts, clip nuts, and fresh air intake vent located outside on module. See Figure 68.
1. FLANGE BOLTS
2. FRESH AIR INTAKE VENT
3. CLIP NUTS
Figure 68. Fresh Air Intake Vent
7. Disconnect heater control harness from heater and cab harness and unclip heater control harness from

seat support.
8. Remove four screws from heater control at top of seat surround. Remove Heater control.
9. Loosen strap clamps and disconnect front and rear duct heater hoses at top of surround cover.
10. Loosen strap clamp and disconnect floor vent duct hose from rectangle adapter to heater vent.
11. Remove two capscrews securing heater vent and vent bracket to seat support.
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NOTE: Drain supply and return hoses into a suitable container.
12. Remove supply and return hoses from heater.
13. Remove four capscrews from heater and seat support. Remove heater.
INSTALL, FOR LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
1. Install heater on seat support with four capscrews. See Figure 67.
2. Connect supply and return hoses from engine to heater.
3. Pre-install heater vent to bracket and assemble bracket with two capscrews to seat support.
4. Install front and rear duct heater hoses and floor vent hose to heater box.
5. Route front and rear ducts to respective openings at top vent adapters.
6. Route floor vent hose to bottom and connect to heater vent through rectangle adapter.
7. Install heater control on top of seat surround with four screws and route control cable and harness
firmly held by clips by side of seat support and connect middle connector to cab harness and bottom
connector heater.
8. Install air intake vent from outside on module with flange bolts and clip nuts. See Figure 68.
9. Attach intake vent to heater box and air intake vent with formed hose. Tighten strap clamps.
10. Install right side rear panel. See Figure 66.
11. Connect battery.
12. Install rear floor plate with four flange bolts. See Figure 65.
13. Install front floor plate and front and rear floor mats.
Heater and Air Conditioner Assembly

Lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005, R005,
S005) and H6.0FT, H7.0FT (H135FT,H155FT) (J006, K006) equipped with a Cummins QSB 3.3L or Kubota
diesel engine may be equipped with a cab that has an heater/air conditioner unit installed. In section Door
Assemblies, removal procedures for heater/air conditioner unit, control knobs, and AC rocker switch from
right side door are outlined.
The other component parts that make up this heating and air conditioning system are:
• Air conditioner condenser unit
• Air conditioner receiver/drier unit
• Air conditioner compressor unit.
AIR CONDITIONER CONDENSER UNIT

NOTE: The air conditioner condenser unit is a non-repairable part. Replace as a complete unit. See Parts
Manual.
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Remove
1. Open hood and disconnect battery.
2. Disconnect AC hose connections from AC condenser unit. See Figure 69.
1. FAN CONNECTION 3. LIGHT WIRE HARNESS

2. AC HOSE CONNECTION 4. AC CONDENSER UNIT
Figure 69. Air Conditioner Condenser Unit Wire/Hose Connections
3. Disconnect AC condenser unit fans wire harness from light harness. See Figure 69.
4. Remove four capscrews from front of AC condenser unit. See Figure 70.
5. Remove four capscrews and bushings from top of AC condenser unit. Remove AC condenser unit

from lift truck cab. See Figure 70.
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SLIGHTLY DIFFERENT.
1. CAPSCREW 3. AC CONDENSER UNIT

2. BUSHING
Figure 70. Air Conditioner Condenser Unit, Remove
Install
1. Install four bushings and capscrews in holes at top of AC condenser unit. See Figure 70.
2. Install four capscrews in front of AC condenser unit.
3. Connect AC condenser fan wire harness to lights wire harness. See Figure 69.
WARNING
Contact an authorized technician or company to charge the AC system. DO NOT charge the
AC system if you do not have the experience or authorization. To do so can result in serious
injury.
4. Connect AC hoses to AC condenser unit.
AIR CONDITIONER RECEIVER/DRIER UNIT

NOTE: The air conditioner receiver/drier unit is a non-repairable part. Replace as a complete unit. See Parts
Manual.
Remove
1. Raise hood and disconnect battery.
2. Remove radiator cover. See Figure 71.
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SLIGHTLY DIFFERENT.
Figure 71. Radiator Cover Removal
3. Disconnect air conditioner wire harness from air conditioner receiver/drier unit. See Figure 72.
4. Disconnect AC hoses from air conditioner receiver/drier unit.
5. Remove two strap clamps from air conditioner receiver/drier unit. Remove air conditioner

receiver/drier unit from mounting bracket. See Figure 72.
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1. STRAP CLAMP 4. MOUNTING BRACKET

2. AC HOSE CONNECTIONS 5. AC RECEIVER/DRIER UNIT
3. AC WIRE HARNESS 6. COUNTERWEIGHT
Figure 72. Air Conditioner Receiver/Drier Unit
Install
1. Attach air conditioner receiver/drier unit to mounting bracket using two strap clamps. See Figure 72.
2. Connect AC hoses to air conditioner receiver/drier unit. See Figure 72.
3. Connect air conditioner wire harness to air conditioner receiver/drier unit. See Figure 72.
4. Install radiator cover. See Figure 71.
AIR CONDITIONER COMPRESSOR
For removal and replacement instructions on air conditioner compressor, contact your local HYSTER dealer
or see Hyster Hypass Online.
Light Replacement
WORK LIGHTS (FRONT AND REAR)
Remove
To access battery, remove floor mat and floor plate on lift truck models
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To access battery, raise hood, on lift truck models

• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
CAUTION
Clean any dirt or oil from the lamp surface with alcohol and a lint-free cloth or tissue. Any
foreign particles or materials on the bulb surface can cause hot spots on the bulb and result
in lamp failure.
NOTE: The work light assembly does not need to be removed from lift truck to replace bulb
2. Remove four capscrews, lens assembly, and bulb. See Figure 73. Install bulb, lens assembly, and four

capscrews.
NOTE: REAR WORK LIGHT SHOWN, FRONT WORK LIGHT IS SIMILAR.

1. CAPSCREWS (LENS ASSEMBLY)
2. LENS ASSEMBLY
3. NUT
Figure 73. Work Lights
3. Disconnect work light wiring harness from cab wiring harness. Remove lock nut, washer, and work

light from mounting bracket located on cab. See Figure 74.
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Figure 74. Cab Light Assemblies

A. FRONT VIEW B. REAR VIEW
1. CAB ASSEMBLY 10. MOUNTING BRACKET

2. RIGHT SIDE WORK LIGHT 11. STROBE LIGHT GUARD
3. RIGHT SIDE MARKER/TURN SIGNAL LIGHT 12. REAR WORK LIGHT
4. LEFT SIDE MARKER/TURN SIGNAL LIGHT 13. LOCKNUT
5. LEFT SIDE WORK LIGHT 14. WASHER
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6. RIGHT SIDE TURN, STOP, TAIL, AND BACKUP 15. MOUNTING BRACKET
LIGHT
16.
7. FLANGE NUT LEFT
LIGHT
SIDE TURN, STOP, TAIL, AND BACKUP
8. CAPSCREW 17. FRONT MOUNTING BRACKET

9. STROBE LIGHT
Install
1. Using the washer and lock nut, install work light on cab mounting bracket. See Figure 74. Connect

work light to overhead guard harness.
2. Connect battery, install floor plate and floor mat on lift truck models

Connect battery, lower hood, on lift truck models

• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
STROBE LIGHT
NOTE: The strobe light may either be mounted above top of cab assembly (high-mounted) or below the top
of cab assembly (low-mounted). The removal and installation procedures are same for both options.
Remove

• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
2. Disconnect strobe light electrical connector from cab wiring harness. See Figure 75.
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1. STROBE LIGHT GUARD

2. STROBE LIGHT LENS
3. FLANGE NUT
4. LOCKWASHER
5. WASHER
6. MOUNTING BRACKET
7. CAPSCREW
8. LOCK NUT
9. ELECTRICAL CONNECTOR
Figure 75. Strobe Light Assembly
3. Remove capscrews, washers, and flange nuts securing strobe light and light guard to strobe light

mounting bracket. Remove strobe light and guard from lift truck. See Figure 74.
Install
1. Place strobe light assembly and strobe light guard onto mounting bracket. Secure assembly to

mounting bracket with capscrews, washers, and flange nuts. See Figure 75.
2. Connect strobe light electrical connector to overhead guard wiring harness.


• H2.0-3.5FT (H40-70FT) (L177, N177)
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S005)
TURN, STOP, TAIL, AND BACKUP LIGHT

NOTE: The turn, stop, tail, and backup light assembly is non-repairable. See Parts Manual for replacement
turn, stop, tail, and backup lights.
Remove

• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
2. Remove screw securing turn, stop, tail, and backup light to mounting bracket. Pull Turn, Stop, Tail,

and Backup Light downward to remove it from mounting bracket.
3. Disconnect turn, stop, tail, and backup light from cab wiring harness. See Figure 74.
4. If mounting bracket must be removed from cab, remove rear crossmember cover and remove

mounting bracket from cab. See Figure 74.
Install
1. If mounting bracket was removed, install rear crossmember cover. Install mounting bracket on cab.
2. Connect turn, stop, tail, and backup light to cab wiring harness. See Figure 74.
3. Install screw to attach turn, stop, tail, and backup light to mounting bracket. See Figure 74.


• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
FRONT MARKER/TURN SIGNAL LIGHTS

NOTE: The front marker/turn signal light assembly is non-repairable. See Parts Manual for replacement
front marker/turn signal lights.
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Remove

• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
NOTE: The following steps are used to remove either right or left side front marker/turn signal light
assembly.
2. Remove two lock nuts, washers and front marker/turn signal light assembly from front mounting

bracket. See Figure 74.
3. Disconnect front marker/turn signal light wiring harness from cab wiring harness.
Install
NOTE: The following steps are used to install either right or left side front marker/turn signal light
assembly.
1. Connect front marker/turn signal light wiring harness to cab wiring harness.
2. Using two lock nuts, and washers, install front marker/turn signal light assembly on front mounting

bracket.


• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
Display Switches
The lift trucks covered in this manual can have several different options and configurations. Depending on
equipment on lift truck, warnings and indicator lights on right side of Display Switch Cluster will vary and
truck may not contain all warnings and indicator lights shown in Figure 76 and Figure 77.
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A. LEFT SIDE B. RIGHT SIDE
1. HOURMETER 10. POWER (ON/OFF)

2. #1 BUTTON (ADMINISTERING PASSWORDS) 11. ENGINE START (KEYLESS REMOTE)
3. #2 BUTTON (ADMINISTERING PASSWORDS) 12. 1ST GEAR LOCKING
4. ENTER BUTTON 13. FRONT WORK LIGHTS
5. #3 BUTTON (ADMINISTERING PASSWORDS) 14. REAR WORK LIGHTS
6. SCROLL DOWN 15. REAR WIPER
7. SCROLL UP 16. FRONT WIPER
8. #4 BUTTON (ADMINISTERING PASSWORDS) 17. FRONT WASHER
9. #5 BUTTON (ADMINISTERING PASSWORDS)
Figure 76. Right and Left Side Display Switch Cluster
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Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator Malfunction Indicator
14 Indicator Light, 1st Gear Locking
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 77. Warning and Indicator Lights
The fuses are located in Power Distribution Module (PDM), which is under hood next to battery on right side.
• H1.6FT, H1.8FT, 2.0FTS, H2.0-3.5FT (H40-70FT) (L177, N177)
• H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005,

S005)
The fuses are located in Power Distribution Module (PDM), which is under floor plates mounted on right
side. See Figure 78 for lift truck models
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Figure 78. PDM Showing Fuses and Relays

A. H1.6FT, H1.8FT, 2.0FTS (F001), H2.0-3.5FT (H40- B. H6.0FT, H7.0FT (H135FT, H155FT)
70FT) (L177, N177), AND H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(H006, J006, K006) AND H8.0FT,
H8.0FT9, H9.0FT (H170FT, H175FT36,
(N005, P005, R005, S005) H190FT) (A299, B299)
1. BATTERY 11. SPARE FUEL PUMP RELAY

2. PDM 12. BATTERY (25-AMP FUSE)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20-AMP FUSE)
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4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30-AMP FUSE) 15. BATTERY (25-AMP FUSE)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20-AMP FUSE)
7. BACKUP RELAY 17. IGNITION 1 (20-AMP FUSE)
8. BACKUP (20-AMP FUSE) 18. IGNITION RELAY
9. IGNITION (30-AMP FUSE) 19. BATTERY (25-AMP FUSE)
10. SPARE FUEL PUMP (20-AMP FUSE)
Electrical Schematics
Refer to Diagrams and Schematics 8000SRM1409 or Diagrams and Schematics 8000SRM1585 for
complete lift truck electrical schematics.
Optional Equipment
HEAVY DUTY PRE-CLEANER
The procedure below only pertains to lift truck models

• H1.6FT, H1.8FT, 2.0FTS (F001)
• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
See section Frame 0100SRM1321 for the heavy-duty pre-cleaner removal and installation procedures for lift
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299)
See section Frame 0100SRM1581 for the heavy-duty pre-cleaner removal and installation procedures for lift
truck models
• H6.0FT, H7.0FT (H135FT,H155FT) (K006)
• H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (B299)
In environments with very dirty conditions, the lift truck may be equipped with a heavy-duty air cleaner
which pre-cleans the air before it enters the standard air filter. The pre-cleaner is mounted on the rear of the
cab in place of the air vent. See Figure 79.
Remove
1. Remove two socket head capscrews and washers securing the air duct to left side rear operator cab leg.

Remove air duct and pre-cleaner. See Figure 79.
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1. PRE-CLEANER 5. INSERT
2. AIR DUCT 6. HOSE CLAMP
3. WASHER 7. INJECTION PORT
4. SOCKET HEAD CAPSCREW
Figure 79. Heavy Duty Pre-Cleaner
2. Remove hose clamp securing pre-cleaner to air duct. Remove pre-cleaner.
Clean
WARNING
Clean the heavy-duty pre-cleaner and air duct with compressed air as necessary.
Inspect
Inspect the air duct and pre-cleaner for excessive wear, cracks, or damage. If damaged, replace.
Install
NOTE: Orient ejection port away from operator.
1. Install pre-cleaner and hose clamp onto air duct. Tighten hose clamp.
2. Install air duct and pre-cleaner onto left side rear operator cab leg with two washers and socket head

capscrews.
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FAN
Remove
To access battery, remove the floor mat and floor plate on lift truck models
To access battery, raise the hood, on lift truck models

• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
2. Disconnect fan assembly wiring harness connector from cab wiring harness connector. See Figure 80.
1. MIRROR 6. WASHER
2. MOUNTING BRACKET 7. WIRING HARNESS CONNECTOR
3. NUT 8. MOUNTING BRACKET
4. SCREW 9. FAN ASSEMBLY
5. LOCKNUT
Figure 80. Fan and Mirror Replacement

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3. Remove four nuts, lockwashers, capscrews, and fan assembly from mounting bracket.
Install
1. Using four nuts, lockwashers, and capscrews, install fan assembly on mounting bracket. See

Figure 80.
2. Connect fan assembly wiring harness connector to cab wiring harness connector.
3. Connect battery, install the floor plate and floor mat on lift truck models

Connect battery, lower the hood, on lift truck models

• H2.0-3.5FT (H40-70FT) (L177, N177)

S005)
MIRROR
Remove
Remove nut and mirror from the mounting bracket. See Figure 80.
Install
Using nut, install mirror on the mounting bracket. See Figure 80.
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 carriage is installed, the capacity rating can change.
Changes in the kind of drive tires can change the capacity rating. See a dealer for Hyster lift
trucks for a replacement nameplate. The nameplate information is a safety item and must be
correct for the equipment and configuration of the lift truck.
1. Make sure surface is dry and free of oil or grease. DO NOT use solvent on new paint. Clean the

surface of old paint using cleaning solvent.
2. Remove paper from back of label. Do not touch adhesive surface.
3. Carefully hold label in correct position above surface. Label cannot be moved after it touches surface.

Put label on surface. Make sure all air is removed from under label and corners and edges are tight.
See Parts Manual for correct location and part number.

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PARTE NO. 1673866 0100 SRM 1290

adequadamente o equipamento ou não seguir as instruções contidas no Manual de Serviço pode

NOTA: Os seguintes símbolos e palavras indicam informações de segurança

Instale, para os modelos de empilhadeira H6.0FT, H7.0FT (H135FT, H155FT)

Instale, para os modelos de empilhadeira H6.0FT, H7.0FT (H135FT, H155FT)

This section is for the following models:

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

Figure 1. Operator Cab

See Figure 3 for lift truck models

1. REAR BOTTOM WINDOW 3. AC HOSE

Figure 4. Air Filter Hose Removal

1. RADIATOR COVER 2. RADIATOR CAP

Figure 5. Radiator Cover and Cap Location

Figure 6. Heater Hose Connection

A. LIFT TRUCK MODELS D.

1. QUICK DISCONNECT FITTING 4. RIGHT SIDE DOOR ASSEMBLY

See Figure 7 for lift truck models

See Figure 8 for lift truck models

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

1. HOSE FITTING 3. AC/HEATER UNIT

Figure 7. AC Refrigerant Hose Connections, Lift Truck Models H4.0FT5/FT6; H4.5FTS5,

1. HOSE FITTING 3. AC/HEATER UNIT

Figure 8. AC Refrigerant Hose Connection, Lift Truck Models H4.0FT5/FT6; H4.5FTS5,

NOTE: Removing door assemblies requires two people.

NOTE: RIGHT SIDE DOOR SHOWN.

Figure 9. Gas Spring Mounting Removal

NOTE: RIGHT SIDE DOOR HINGE SHOWN.

Figure 10. Door Removal

10. Disconnect heater hose quick disconnect fittings.

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

a. Remove six fasteners and remove rear cover.

See Figure 12 for lift truck models

See Figure 13 for lift truck models

See Figure 14 for lift truck models

b. Disconnect air conditioner hoses at bulkhead bracket and at receiver/drier.

See Figure 12 for lift truck models

See Figure 13 for lift truck models

See Figure 14 for lift truck models

c. Disconnect air conditioner wire harness.

See Figure 12 for lift truck models

See Figure 13 for lift truck models

See Figure 14 for lift truck models

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

A. FRONT VIEW B. TOP VIEW

1. HOSE WRAP 5. BULKHEAD BRACKET

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

A. FRONT VIEW B. TOP VIEW

1. HOSE WRAP 5. BULKHEAD BRACKET

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

A. FRONT VIEW B. TOP VIEW

1. HOSE WRAP 5. BULKHEAD BRACKET

• H1.6FT, H1.8FT, 2.0FTS (F001)

Figure 15. Dash Installation

1. CAPSCREWS 5. COWL PANEL

1. CAPSCREWS 5. FLOOR PLATE (LEFT SIDE)

NOTE: KICK PANEL REMOVED FOR CLARITY.

NOTE: KICK PANEL REMOVED FOR CLARITY.

NOTE: LEFT SIDE DOOR REMOVED FOR CLARITY.

Figure 19. Front and Rear Panels and Fender Cover Removal

Figure 20. Front and Rear Cab Mounting

Figure 21. Lift Strap Connection

12. Install kick panel onto seal plate assembly.