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Hyster J160 Service Manual – PDF DOWNLOAD
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Hyster J160 Service Manual – PDF DOWNLOAD
PART NO. 1534737
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Hyster J160 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster J160 Service Manual – PDF DOWNLOAD
PART NO. 1534737
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies,make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit fromrolling or falling. See HOWTO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster J160 Service Manual – PDF DOWNLOAD
1534737-2200SRM1058-(09-2008)-US-EN............................................. 1 toc......................................................................... 1 Troubleshooting and Adjustments Using the AC Controls Program (E........ 1 Safety Precautions Maintenance and Repair............................... 2 General................................................................. 5 Computer Requirements............................................... 5 Software, Install................................................... 5 Language Selection.................................................. 5 Demo Mode........................................................... 6 Connect PC to Lift Truck............................................ 10 Starting AC Controls Program........................................ 12 Lift Truck Control Setup................................................ 16 Change Lift Truck Serial Number or Hourmeter........................ 16 Setting Factory Default Values or Changing Lift Truck Parameters.... 18 Create New Custom Lift Truck Configuration.......................... 24 Lift Truck Configuration Properties................................. 27 Import New Lift Truck Configuration From Disk....................... 30 Delete Custom Lift Truck Configuration or Password File............. 32 Dash Display............................................................ 35 Custom Display Languages............................................ 35 Download Display Language........................................... 37 Clear Operator Log.................................................. 37 Password Functions...................................................... 40 Enable/Disable Password and Lift Truck Inspection Functions......... 40 Truck Inspection Checklist...................................... 40 Password........................................................ 40 Password Properties................................................. 40 Create New Password File............................................ 45 Download Passwords.................................................. 47 Upload Passwords.................................................... 47 Reports Menu............................................................ 51 Devices Report...................................................... 51 Custom Report....................................................... 51 Password Report..................................................... 51 Operator Report..................................................... 58 Current Settings Report............................................. 61 Status Code Report.................................................. 64 Status Codes Log.................................................... 67 Troubleshooting......................................................... 69 Diagnostics......................................................... 69 Help Menu............................................................... 72 General............................................................. 72 Contents............................................................ 72 Technical Support................................................... 72 About Electric Truck AC Controls Program............................ 72 1554633-2200SRM1087-(08-2005)-US-EN............................................. 79 toc......................................................................... 79 AC Motor Controllers/ Display Panel..................................... 79 Safety Precautions Maintenance and Repair............................... 80 Description............................................................. 83 General............................................................. 83 Description......................................................... 83 AC Motors....................................................... 83 ZAPI™ AC Motor Controller....................................... 83 Principles of Operation......................................... 84 Controller Thermal Management................................... 85 Controller Area Network (CANbus)................................ 85 Discharging the Capacitors.......................................... 85 AC Motor Controller Repair.............................................. 86 General............................................................. 86 Special Precautions............................................. 86 Thermal Sensors..................................................... 87 Motor Controller, Replace........................................... 87 Controller Checks and Adjustments....................................... 87 Function Parameters..................................................... 88 General............................................................. 88 Function Parameter Descriptions......................................... 89 Parameters.......................................................... 89 Top Speed Forward............................................... 89 Top Speed Reverse............................................... 89 Acceleration.................................................... 89 Regen Braking................................................... 89 Auto Deceleration............................................... 89 Extended Shift.................................................. 89 Pump Acceleration............................................... 90 Tilt/Auxiliary Pump Acceleration................................ 90 Low Lift Speed.................................................. 90 Maximum Lift Speed.............................................. 90 Maximum Lowering Speed.......................................... 90 Tilt Speed...................................................... 90 3rd Function.................................................... 90 3rd Function Speed.............................................. 90 4th Function.................................................... 90 4th Function Speed.............................................. 91 Battery Voltage................................................. 91 Lift Interrupt.................................................. 91 BDI Adjustment (Early Models)................................... 91 BDI Adjustment (Later Models)................................... 91 BDI Decrement Time.............................................. 91 Service Reminder................................................ 92 Custom.......................................................... 92 Restore Defaults................................................ 92 Calibration Parameters.................................................. 92 Throttle Calibration................................................ 92 Steering Calibration................................................ 92 Display Panel........................................................... 92 General............................................................. 92 Premium Display Panel........................................... 92 Standard Display Panel.......................................... 92 Display Functions and Features.......................................... 93 Key-On Initialization............................................... 93 Standard Display.................................................... 93 Premium Display..................................................... 95 Lift Truck Inspection Function...................................... 95 Access to Service Functions......................................... 96 Service Functions................................................... 96 Performance Modes................................................... 97 Battery Discharge Indication (BDI).................................. 98 Hourmeter........................................................... 98 Status Code List.................................................... 98 Dash Display Service Menu Navigation.................................... 99 General............................................................. 99 Moving Through Menu Selections...................................... 99 Editing and Adding Information...................................... 99 ETACC Test..............................................................100 Manual Hydraulics:..................................................100 Electro-Hydraulics:.................................................100 Troubleshooting.........................................................100 General.............................................................100 Status Codes........................................................101 Controller Connector Pin Outs.......................................192 Valve Driver Module (Electro-Hydraulic Valve Option)................193 Hydraulic Lever Console (Electro-Hydraulic Option Only).............194 Dash Display........................................................194 System Logic Diagrams...............................................195 tables...................................................................... 79 Table 1. Traction Parameters............................................ 88 Table 2. Transistor Lift With Manual Valve Parameters................... 88 Table 3. Transistor Lift With Electro-Hydraulic Valve Parameters........ 88 Table 4. List of Status Codes...........................................101 Table 5. Connector A....................................................192 Table 6. Connector C....................................................192 Table 7. Connector D - Standard Model...................................193 Table 8. Connector D - Premium Model....................................193 Table 9. Connector B....................................................193 Table 10. Connector C...................................................193 1554633-2200SRM1087-(10-2006)-US-EN.............................................201 toc.........................................................................201 AC Motor Controllers/Display Panel......................................201 Safety Precautions Maintenance and Repair...............................202 Description.............................................................205 General.............................................................205 Description.........................................................205 AC Motors.......................................................205 ZAPI™ AC Motor Controller.......................................205 Principles of Operation.........................................206 Controller Thermal Management...................................207 Controller Area Network (CANbus)................................207 Discharging the Capacitors..........................................207 AC Motor Controller Repair..............................................208 General.............................................................208 Special Precautions.............................................208 Thermal Sensors.....................................................209 Motor Controller, Replace...........................................209 Controller Checks and Adjustments.......................................209 Function Parameters.....................................................210 General.............................................................210 Function Parameter Descriptions.........................................211 Parameters..........................................................211 Top Speed Forward...............................................211 Top Speed Reverse...............................................211 Acceleration....................................................211 Regen Braking...................................................212 Auto Deceleration...............................................212 Extended Shift..................................................212 Pump Acceleration...............................................212 Tilt/Auxiliary Pump Acceleration................................212 Low Lift Speed..................................................212 Maximum Lift Speed..............................................212 Maximum Lowering Speed..........................................212 Tilt Speed......................................................213 3rd Function....................................................213 3rd Function Speed..............................................213 4th Function....................................................213 4th Function Speed..............................................213 Battery Voltage.................................................213 Lift Interrupt..................................................213 BDI Adjustment (Early Models)...................................213 BDI Adjustment (Later Models)...................................214 BDI Decrement Time..............................................214 Service Reminder................................................214 Custom..........................................................215 Restore Defaults................................................215 Calibration Parameters..................................................215 Throttle Calibration................................................215 Steering Calibration................................................215 Display Panel...........................................................216 General.............................................................216 Premium Display Panel...........................................216 Standard Display Panel..........................................216 Display Functions and Features..........................................217 Key-On Initialization...............................................217 Standard Display....................................................218 Premium Display.....................................................218 Lift Truck Inspection Function......................................218 Access to Service Functions.........................................219 Service Functions...................................................219 Performance Modes...................................................221 Battery Discharge Indication (BDI)..................................221 Hourmeter...........................................................222 Status Code List....................................................222 Dash Display Service Menu Navigation....................................222 General.............................................................222 Moving Through Menu Selections......................................222 Editing and Adding Information......................................223 ETACC Test..............................................................223 Manual Hydraulics...................................................223 Electro-Hydraulics..................................................223 Troubleshooting.........................................................224 General.............................................................224 Status Codes........................................................224 Controller Connector Pin Outs.......................................316 Valve Driver Module (Electro-Hydraulic Valve Option)................317 Hydraulic Lever Console (Electro-Hydraulic Option Only).............318 Dash Display........................................................318 System Logic Diagrams...............................................319 tables......................................................................201 Table 1. Traction Parameters............................................210 Table 2. Transistor Lift With Manual Valve Parameters...................210 Table 3. Transistor Lift With Electro-Hydraulic Valve Parameters........211 Table 4. List of Status Codes...........................................225 Table 5. Connector A....................................................316 Table 6. Connector C....................................................316 Table 7. Connector D - Standard Model...................................317 Table 8. Connector D - Premium Model....................................317 Table 9. Connector B....................................................317 Table 10. Connector C...................................................317 1554634-2200SRM1078-(07-2005)-US-EN.............................................325 toc.........................................................................325 Electrical System.......................................................325 Safety Precautions Maintenance and Repair...............................326 Introduction............................................................329 General.............................................................329 Discharging the Capacitors..........................................329 Emissions...........................................................331 Electromagnetic Interference....................................331 Motor Controllers.......................................................331 Controllers.........................................................331 Remove..........................................................331 Install.........................................................332 Hydraulics Contactor................................................333 Remove..........................................................333 Disassemble.....................................................333 Assemble........................................................333 Install.........................................................333 Contactor Panel.........................................................334 Main Contactor......................................................334 Remove..........................................................334 Disassemble.....................................................335 Assemble........................................................335 Install.........................................................335 Contactor Coil..................................................336 Contactor Tips..................................................336 Fuses...............................................................336 Display Units...........................................................337 Features............................................................337 Replace.............................................................338 Key Switch..............................................................339 Replace.............................................................339 Directional Controls....................................................340 Directional Control Switches........................................340 Accelerator Switches and Pedal Assembly.............................341 Install.............................................................341 Calibrate...........................................................344 MONOTROL™ Directional Control.......................................344 Brakes..................................................................346 Brake Switch........................................................346 Adjust or Replace...............................................346 Master Cylinder Indicator...........................................346 Parking Brake Disengage.............................................347 Override Mode...................................................347 Horn Components and Steering Encoder....................................348 Horn Components.....................................................348 Horn............................................................348 Horn Button and Contacts........................................349 Steering Encoder....................................................349 Hood and Seat Switches..................................................350 Hood Position Switches..............................................350 Seat Switch.........................................................350 Steer Angle Potentiometer...............................................350 General.............................................................350 Operation...........................................................350 Example.........................................................351 Position Steer Tire for Straight Travel.............................351 Install.............................................................352 Set Potentiometer to Midpoint...................................352 Install to Steer Axle...........................................352 Calibrate.......................................................353 Test................................................................353 Wiring Harness..........................................................354 tables......................................................................325 Table 1. Potentiometer Specifications...................................353 1554637-8000SRM1081-(04-2007)-US-EN.............................................361 toc.........................................................................361 Diagrams................................................................361 Safety Precautions Maintenance and Repair...............................362 1554637-8000SRM1081-(11-2004)-US-EN.............................................395 toc.........................................................................395 Diagrams................................................................395 Safety Precautions Maintenance and Repair...............................396
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