Hyster H50CT Page 5 Service & Repair Manual Download | Manualshive

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TABLE OF CONTENTS (Continued)

Install ............................................................................................................................................................ 20

Rear Horn Button Switch .................................................................................................................................20

Remove .......................................................................................................................................................... 20
Install ............................................................................................................................................................ 20

Engine and Fuel Sensors and Switches, PSI 2.4L Dual Fuel Trucks ............................................................ 21
Engine and Fuel Sensors, Yanmar 2.6L Diesel Trucks .................................................................................. 21

Engine Speed Sensor .................................................................................................................................... 21

Remove ......................................................................................................................................................21
Install ........................................................................................................................................................22

Oil Pressure Sensor ...................................................................................................................................... 22

Remove ......................................................................................................................................................22
Install ........................................................................................................................................................22

Engine Coolant Temperature (ECT) Sensor ............................................................................................... 22

Remove ......................................................................................................................................................22
Install ........................................................................................................................................................22

Fuel/Water Separator Sensor .......................................................................................................................22

Remove ......................................................................................................................................................22
Install ........................................................................................................................................................23

Glow Plug Relay ............................................................................................................................................23

Remove ......................................................................................................................................................23
Install ........................................................................................................................................................26

Power Distribution Module (PDM) and Component Parts ................................................................................. 26

Power Distribution Module (PDM) as a Unit .................................................................................................. 26

Remove .......................................................................................................................................................... 26
Install ............................................................................................................................................................ 27

Power Distribution Module (PDM) Components .............................................................................................28

Remove and Install .......................................................................................................................................28

Battery ................................................................................................................................................................... 28

Remove .............................................................................................................................................................. 28
Install .................................................................................................................................................................28

Lights ..................................................................................................................................................................... 29

Work Lights (Front and Rear) ..........................................................................................................................29

Remove .......................................................................................................................................................... 29
Install ............................................................................................................................................................ 29

Strobe Light .......................................................................................................................................................29

Remove .......................................................................................................................................................... 29
Install ............................................................................................................................................................ 30

LED Tail, Backup, and Brake Lights .............................................................................................................. 30

Remove .......................................................................................................................................................... 30
Install ............................................................................................................................................................ 31

Reflectors ...........................................................................................................................................................31

Remove .......................................................................................................................................................... 31
Install ............................................................................................................................................................ 31

This section is for the following models:

(S50CT) [B267];

H2.0-2.5CT (H50CT) [B274]

Table of Contents

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Summary of Contents for H50CT

Page 1: ...Hyster B274 H50CT Internal Combustion Engine Trucks Service Repair Manual ...

Page 2: ...ELECTRICAL SYSTEM S50CT B267 H2 0 2 5CT H50CT B274 PART NO 4120745 2200 SRM 1771 ...

Page 3: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when making repairs Replacement parts must meet or ex ceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using ...

Page 4: ...rs and Switches 10 General 10 Dash Panel Kick Panel and Seal Plate Remove and Install 10 Remove 10 Install 11 Accelerator Pedal Position Sensor 12 Remove 12 Install 13 Brake Fluid Level Switch 13 Remove 13 Install 14 Brake Pedal Position Sensor 14 Remove 14 Install 15 Parking Brake Position Sensor 16 Remove 16 Install 16 Seat Sensor Operator Presence System 16 Non Suspension Seat 16 Remove 16 Inst...

Page 5: ...tor Sensor 22 Remove 22 Install 23 Glow Plug Relay 23 Remove 23 Install 26 Power Distribution Module PDM and Component Parts 26 Power Distribution Module PDM as a Unit 26 Remove 26 Install 27 Power Distribution Module PDM Components 28 Remove and Install 28 Battery 28 Remove 28 Install 28 Lights 29 Work Lights Front and Rear 29 Remove 29 Install 29 Strobe Light 29 Remove 29 Install 30 LED Tail Bac...

Page 6: ...more information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions please write to me admin servicemanualperfect com ...

Page 7: ...s in the CAUTION below CAUTION When welding always disconnect the negative battery cable from battery and disconnect the ground wire from the ground stud on the frame See Figure 1 To prevent damage to the Electronic Control Unit ECU remove it from the lift truck For lift trucks equipped with LPG engine see Fuel System PSI 2 4L 0900SRM1757 for procedure to remove ECU from lift truck For lift trucks...

Page 8: ...acket See Figure 2 5 Remove capscrew and bracket from frame See Figure 2 1 ECM 2 BRACKET 3 CAPSCREW 4 ECM CONNECTOR 5 CONDUIT CLIP 6 WIRE HARNESS 7 FRAME Figure 2 ECM Yanmar Diesel Engine INSTALL 1 Install bracket and capscrew on frame See Fig ure 2 2 Install ECM and four capscrews on bracket See Figure 2 3 Connect ECM connector to ECM See Figure 2 4 Install two conduit clips to wire harness and b...

Page 9: ...n either side and pulling cover away from steering column See Figure 3 NOTE TOP VIEW OF DASH SHOWN A INDICATES TO PULL UP TO UNLATCH 1 UPPER STEERING COLUMN COVER 2 STEERING COLUMN TILT LEVER 3 LOWER STEERING COLUMN COVER Figure 3 Upper Steering Column Cover Removal 4 Remove the horn button and disconnect the horn wires NOTE A puller tool may be required to remove the steering wheel 5 Remove the l...

Page 10: ... Display Switch Cluster Remove the four bolts securing the Display Switch Cluster Slide the display panel off of the steering col umn See Figure 5 NOTE TOP DOWN VIEW SHOWN 1 BOLTS 2 DISPLAY SWITCH CLUSTER HARNESS 3 STEERING COLUMN 4 HORN WIRES CONTACT PADS Figure 5 Display Switch Cluster Removal Display Switch Cluster 2200 SRM 1771 4 ...

Page 11: ... button into steering wheel 5 Install upper steering column cover by aligning the two latches and pushing down until latched See Figure 3 DIRECTION CONTROL LEVER Remove NOTE The direction control lever is located on left side of Display Switch Cluster The direction con trol lever is non repairable and must be replaced as an assembly See the Parts Manual for replace ment part number 1 Insert two sm...

Page 12: ...itch Cluster See B Figure 6 3 Repeat the previous steps on the opposite side of the direction control lever Remove the direc tion control lever from the Display Switch Clus ter Install Install the direction control lever into the opening of the Display Switch Cluster until the locking tabs are engaged in the Display Switch Cluster KEY SWITCH Remove 1 Fully lower the steering column and remove the ...

Page 13: ...ing column Align latches on upper steering cover to holes on steering column and push upper steering cover into place on steering column DISPLAY SWITCH CLUSTER PANEL BEZEL AND OVERLAY Remove 1 Insert a small flat bladed screwdriver into the top slot on the inner edge of the bezel and pry outward Repeat procedure at the lower slot on the bezel Be careful to not damage bezel and overlay when removin...

Page 14: ...est position 4 Remove upper steering column cover by pulling up on base of upper steering column cover to re lease latches one on either side and pulling cover away from steering column See Figure 3 5 Remove steering wheel and instrument display panel See section Display Switch Cluster for removal procedures 6 Remove two screws and remove lower steering column cover See Figure 8 1 SCREWS 2 LOWER S...

Page 15: ...p See Fig ure 9 2 Remove horn contact pads See Figure 9 1 BOLTS 2 PIVOT BOLTS 3 HORN WIRES 4 STEERING SHAFT RETENTION CLIP 5 HORN HARNESS 6 STEERING COLUMN 7 GAS CYLINDER 8 COWL 9 LOWER STRUT PIVOT PIN 10 HYDRAULIC CONTROL VALVE 11 STEERING CONTROL UNIT SCU 12 STEERING SHAFT 13 HORN CONTACT PADS Figure 9 Steering Column 3 Remove lower strut pivot pin from gas cylinder See Figure 9 4 Remove steerin...

Page 16: ...s and Switches GENERAL CAUTION Before removing and replacing any sensors or switches ALWAYS disconnect the battery Failure to disconnect the battery can cause damage to the sensor or switch and other electrical compo nents Always cover or protect the sensor or switch connector from contamination after dis connecting the harness mating part DO NOT use solvent based cleaners to clean area around sen...

Page 17: ...2 COWL 3 DASH PANEL 4 KICK PANEL 5 KICK PANEL NOTCHES 6 SEAL PLATE 7 CAPSCREWS 8 CLIPS Figure 10 Dash Panel Kick Panel and Seal Plate Removal Install 1 Using three capscrews install seal plate Tighten capscrews to 10 8 N m 95 6 lbf in See Figure 10 2 Place dash panel on cowl and secure dash to cowl using five Allen Head screws Tighten Al len Head screws to 3 5 N m 31 lbf in 3 Align notches on kick...

Page 18: ... seat See Figure 11 1 LEVER BRACKET CAPSCREWS 2 COWL Figure 11 Hydraulic Control Valve Removal NOTE Tag electrical connectors prior to disconnect to aid in correct reconnect 4 Disconnect throttle position sensor from wiring harness 5 Remove three bolts throttle base and pedal as sembly from cowl See Figure 12 1 BOLTS 2 PEDAL ASSEMBLY 3 COWL Figure 12 Accelerator Pedal and Throttle Base Removal 6 R...

Page 19: ...hree bolts onto cowl Tighten bolts to 19 to 25 N m 168 to 221 lbf in See Figure 12 6 Connect throttle position sensor connector to wiring harness as tagged during removal 7 Install lever bracket onto cowl Install clevis and retention pins and connect levers to con trol valve See Figure 11 8 Install kick panel and dash See Dash Panel Kick Panel and Seal Plate Remove and Install for installation pro...

Page 20: ...R 3 COWL 4 BRAKE FLUID LEVEL SWITCH INSIDE RESER VOIR 5 BRAKE FLUID RESERVOIR MOUNTING BRACKET Install 1 Connect reservoir supply hose to a new reser voir See Figure 14 2 Install new reservoir onto bracket and fill with new brake fluid See Periodic Maintenance 8000SRM1774 for brake fluid specifications 3 Connect brake fluid level switch to cowl har ness 4 Install kick panel and dash See Dash Panel...

Page 21: ...new brake pedal position sensor two torx screws and two nuts onto brake pedal po sition sensor mounting bracket See Figure 15 Tighten nuts to 2 25 N m 20 lbf in 2 Connect brake pedal position sensor connector to cowl harness as tagged during removal 3 After new service brake pedal position sensor has been installed check the gap between the sensor arm and tab See Brake System 1800SRM1743 for the p...

Page 22: ...rews and lockwashers onto parking brake assembly See Figure 15 and Figure 16 Tighten torx screws to 2 25 N m 20 lbf in 2 Visually inspect sensor to ensure sensor arm and parking brake lever maintain continuous contact throughout full range of lever opera tion 3 Connect parking brake position sensor connec tor to cowl harness as tagged during removal See Figure 15 and Figure 16 4 Install kick panel...

Page 23: ...ectly installing seat to hood See Figure 18 5 Remove the four capscrews and washers hold ing the seat to the hood Remove seat from the hood NOTE TOP VIEW OF HOOD SHOWN 1 MOUNTING HOLES NON SUSPENSION SEAT 2 HOOD LATCH HANDLE 3 HOOD 4 HOOD HINGE ASSEMBLY Figure 18 Seat Mounting Holes Non Suspension Seat NOTE Tag electrical connector prior to disconnect to aid in correct reconnect 6 Disconnect the s...

Page 24: ...er plate using two capscrews and washers See Figure 17 6 Connect the battery and close the hood Full Suspension Seats Remove 1 Disconnect the battery 2 Pull out two pins that secure bottom seat cush ion to seat base 3 Lift bottom seat cushion up and disconnect the seat harness from seat sensor See Figure 20 4 Use a small flat bladed screwdriver and re move the seat sensor from seat base 1 SEAT SEN...

Page 25: ...ess as tagged dur ing removal 3 Connect the battery and close the hood TRANSMISSION TEMPERATURE SENSOR Remove 1 Raise the hood Disconnect the battery 2 Put the lift truck on blocks See the Operating Manual or section Periodic Maintenance 8000SRM1774 for procedures WARNING At operating temperature the transmission oil is HOT DO NOT permit the hot oil to touch the skin and cause a burn Make sure oil...

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