Hyster F160 Service & Repair Manual
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Hyster F160 Service & Repair Manual

Hyster F160 Service & Repair Manual

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Hyster F160 (J30XMT J35XMT J40XMT) Forklift

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Summary of Contents for Hyster F160

  • Page 1 Hyster F160 (J30XMT J35XMT J40XMT) Forklift...

  • Page 2: Instrument Panels

    INTRODUCTION GENERAL Some components that have inputs to the controller have installation adjustments. This section has the cor- This section has the checks, adjustments and repair pro- rect procedures for replacement, checks and adjustment cedures for the parts of the electrical system that are of these components.

  • Page 3: Standard Display

    show that the light is good. This instrument panel has the with a discharged battery can damage the battery, motors or the contactors. following components: 3.Warning light, parking brake indicator. The 1. Hourmeter. The hourmeter display shows red light is “ON” when the parking brake is applied the operating time of 0000 to 9999 hours.

  • Page 4: Premium Display

    will then be shown on the hourmeter for another 3. Warning Light, Brake Fluid Reservoir is Low. The red light is “ON” for approximately four seconds. The indicator lights for the hydraulic three seconds when the key switch is turned to the motor (6) and for the hourmeter (8) will also be “ON”...
  • Page 5 Thanks very much for your reading, Want to get 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 6: Printed Circuit Boards

    6. Indicator Light, Traction Motor. This light truck. The steering angle control board is located in the will illuminate with another warning light if a fault rear compartment and the lift pump control board, for occurs in the traction motor. Example: If the brush the hydraulic control circuit, is located above and be- wear sensor is activated in the motor, the warning hind the hydraulic control valve.
  • Page 7 signals from the lift pump control board. Outputs control board is used to monitor steering tire angle and from the steering angle board connect tothe lift supply inputs to the traction control. pump contactor coil. The lift pump contactor is With the single speed lift pump, one contactor is used to energized when the drivers (electronic relays) in the control the lift pump motor.

  • Page 8: Instrument Panel Components

    Seat switch is inside the seat and is open if the Brake fluid switch sends voltage to the indica- operator is not on the seat. The seat switch sends tor light in the instrument panel when the fluid a signal to the control card for operation of the in the brake master cylinder is low.
  • Page 9 1. PREMIUM INSTRUMENT PANEL 2. STANDARD INSTRUMENT PANEL 3. GAUGES 4. KEY SWITCH 5. HOUSING 6. INDICATOR LIGHT ASSEMBLY 7. O-RING SEAL FIGURE 5 – INSTRUMENT PANELS 4. Install the replacement panel assembly to the cover of the steering column and tighten the screws. Install the connectors and the key switch wires.
  • Page 10 Key Switch (See FIGURE 7) placed. Replace the instrument panel if the battery indi- cator is bad. See Instrument Panel Assembly of this sec- Replace the key switch as follows: tion. See the section BATTERY INDICATORS, 2200 1. Disconnect the battery and remove the key. SRM 138 to adjust these battery indicators.
  • Page 11 Lift Pump Control Board 2. Remove the two nuts and washers retaining the printed circuit board to the mounting bracket. Disconnect the battery. Raise the drive wheels, refer to the section PERIODIC MAINTENANCE, 8000 SRM 528. To gain access the lift pump control board, remove the hydraulic control valve lower cover.
  • Page 12 1. COWL 2. ACCELERATOR ASSEMBLY 3. LINKAGE 4. MONOTROL PEDAL OR ACCELERATOR PEDAL 5. FLOOR PLATE 6. MOUNT NUT 7. FORWARD/REVERSE SWITCH & CABLE ASSEMBLY 8. CLAMP SCREW 1377414 FIGURE 9 – MONOTROL PEDAL OR ACCELERATOR PEDAL POSITION, AND MONOTROL FWD./REV.
  • Page 13 4. Install the replacement switch in the same position. Do not bend or damage the actuator arm and roller of the switch during installation. Connect the wires as re- moved during removal. 5. Adjust the stop light switch as described in CHECKS AND ADJUSTMENTS.
  • Page 14 12. Connect the battery. NOTE: The direction switches used in the Monotrol pedal are made for Hyster Company with a special con- Direction Control Switches tact clearance and timing. Other switches made by the...
  • Page 15 of the two switches controls one direction. Both 1. Disconnect the battery and remove the key. switches must function correctly because both switches 2. Remove the screws retaining the lower front hy- are used to close the circuit. A bad switch must be re- draulic valve cover and remove the cover.
  • Page 16 to the control card of the instrument panel to illuminate CAUTION the indicator for low fluid level. The switch is part of the Make sure wire connectors do not touch other switch reservoir. or meter terminal wire connectors, metal brackets or the bracket mounting nuts.
  • Page 17 2. To replace the bulb for the tail light part of the light 4. To replace a bulb only, remove the lens from the assembly, remove the top screw and nut. Slide the stop base. Carefully remove the bulb. Use a cloth to install light portion of the lens off of the lens assembly.
  • Page 18 ROCKER SWITCHES LOCATED ON INSTRUMENT PANEL 1. STOP, TAIL & REVERSE ASSY 2. REAR WORK LIGHT 3. FLASHING LIGHT 4. REVERSE ALARM 5. ROCKER SWITCHES SEE THE SECTION DIAGRAMS, 8000 SRM 529 FOR CORRECT CONNECTIONS REAR LIGHTS SEE DETAIL “C” DETAIL “C”...
  • Page 19 3. To remove the driving light assembly, disconnect guard. the plug from the connector. Remove the nut that fastens 4. Align and install the spacers and replacement alarm the front or rear light assembly to the mounting bracket. on the bracket. Install the two screws, nuts and washers Remove the light assembly .
  • Page 20 8. Install the cowl cover. Connect the battery. 4. Pull the horn wires out of the contact set and remove the assembly. The Horn Switch and Cover (button) is in the center of WARNING the steering wheel. See FIGURE 18. Replace the horn If the steering wheel has been removed, make sure button assembly as follows: the steering wheel nut has been tightened.

  • Page 21: Checks And Adjustments

    CHECKS AND ADJUSTMENTS Replace all bad fuses. Check to see what caused the fuse WARNING to fail before replacing the rear compartment cover and Some checks and adjustments in this section must be connecting the battery. done with the battery connected and power applied to the controller.

This manual is also suitable for:

J30xmtJ35xmtJ40xmt

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