Hyster F160 Operating instructions

Hyster F160 (J30XMT J35XMT J40XMT) Forklift

1
INTRODUCTION
GENERAL
This section has the checks, adjustments and repair pro-
cedures for the parts of the electrical system that are
NOT part of the EV-100LX motor controller. This sec-
tion also does NOT include the electrical components
covered in other sections such as motors and battery in-
dicators. This section applies to the electric SitDrive
modelssuchastheJ30-40XM.Tocheck,adjustorrepair
the parts of the motor controller see the section,
EV-100LX MOTOR CONTROLLER, 2200 SRM
460.
See the section BATTERY INDICATORS, 2200
SRM138to adjust the battery indicator. See the section
INSTRUMENT PANEL INDICATORS AND
SENDERS, 2200 SRM 143 to check and replace the
other instrument panel indicators and the senders. See
thesectionTHEDCMOTORMAINTENANCE,620
SRM294formaintenanceofthemotors.Seethesection
THE INDUSTRIAL BATTERY, 2240 SRM 1 for in-
formation on the battery.
NOTE: This section does NOT include any compo-
nents of any of the motor controllers. Many of the com-
ponents in this section do have inputs to the EV-100LX
motor controllers, but are not part of the controller.
WARNING
Do not operate a lift truck that needs adjustment or
repairs. Report the need for adjustment or repairs
immediately. If adjustment or repair is necessary,
put a “DO NOT OPERATE” tag in the operator’s
area. Remove the key from the key switch.
Some of the checks and adjustments are done with
thebatteryconnected.Neverhaveanymetalonyour
fingers, arms or neck. These metal items can
accidentallymakeanelectricalconnectionandcause
an injury.
Some components that have inputs to the controller
have installation adjustments. This section has the cor-
rectproceduresforreplacement, checks and adjustment
ofthesecomponents.Thesecomponentsincludethefol-
lowing:
1. Key Switch
2. Accelerator Switch Assembly
3. Stop Light Switch
4. Seat Switch
5. Switch for Optional Seat Brake
6. Parking Brake Switch
7. Direction (FWD REV) Switches
Monotrol Pedal
Direction Control (on Steering Column)
8. Hydraulic Cut Off Switch
9. Brake Fluid Switch
10. Motor Temperature Switches
11. Rocker Switches for Lights
12. Lights and Reverse Alarm
13. Horn and Horn Button
14. Printed Circuit Boards

 !*+  *$)" )1 - ,-, ) %.,-( )-, +$,  -#
+$/  0# ', *!! -#  !'**+ ) '*& -#  '$!- -+.& 
        $) $2
-# + -#    *+ -#  
 
NOTE: Some checks and adjustments are difficult to
dounlessanotherpersoncanoperatethecontrols.When
working alone, put a weight in the seat to close the seat
switch.Ifyour lifttruckhasaseat brake,releasetheseat
brake when the operator in not in the seat. Put the volt-
meter in a position so that you can see it from the opera-
tor area. You can usually operate the controls with your
hand and also make the voltage measurements.
DESCRIPTION
INSTRUMENT PANELS
There are two instrument panel displays available on
these lift trucks:
•a standard display that gives the operator basic in-
formation about the operation of the lift truck and
•a premium display that also includes diagnostic
capabilities and performance settings.
Standard Display (See FIGURE 1)
Whenthe keyisfirstturnedtothe“ON”position,astart
program will cause each indicator light to illuminate to

2
showthatthelightisgood.Thisinstrumentpanelhasthe
following components:
1. Hourmeter. The hourmeter display shows
the operating time of 0000 to 9999 hours. The time
for the traction circuit is shown for four seconds
after the lift truck has been operating and the key is
turned to the “OFF” position.
2.Voltmeter. This battery indicator has a green,
yellow and red band to indicate the voltage of the
battery.Thebattery musthavea currentdraw(load)
to check the battery charge. Hold the tilt lever in the
tiltBACKWARDpositionand lookatthe indicator.
If the needle is in the red band, charge the battery.
Operating the lift truck with the needle in the red
band can decrease battery life. Continued operation
with a discharged battery can damage the battery,
motors or the contactors.
3.Warning light, parking brake indicator. The
red light is “ON”when the parking brake is applied
and the seat switch is closed. and goes “OFF’when
the parking brake is released.
4.Warning light, brake fluid reservoir is
low. The red light is ON for approximately three
seconds when the key switch is turned to the “ON”
position and must go “OFF” during operation. If
the warning light is “ON” during operation, the
brake fluid level in the reservoir is too low.
5.Warninglight,fastenseatbelt. Theredlightis
“ON”foreighttotensecondsafterthekeyswitchis
turned to the “ON” position.
FIGURE 1 – INSTRUMENT PANEL DISPLAY AND PLUG CONNECTOR
STANDARD DISPLAY
KEY SWITCH
LEADS
RED/BRN
“IGN”
TERMINAL
BRN
“BAT”
TERMINAL
STANDARD DISPLAY
18 PIN CONNECTOR
1-11 No Connection
12 Battery Negative ()
13 Hyd. Contactor Coil
14 Brake Fluid Switch
15 Parking Brake Switch
16 Seat Switch
17 Key Switch (Ign)
18 Battery Positive ()
PIN FUNCTION
2
15
3
1. HOURMETER
2. VOLTMETER
3. WARNING LIGHT,
PARKING BRAKE
4
4. WARNING LIGHT, BRAKE FLUID
INDICATOR RESERVOIR IS LOW
5. WARNING LIGHT, FASTEN SEAT BELT
Premium Display (See FIGURE 2)
Whenthekeyismovedtothe“ON”position,astartpro-
gramwillcauseeach warning andindicatorlight to illu-
minate to show that the indicator is operating. This
instrument panel has the following functions:
1. Status Code Indicator. This indicator is
blank when the lift truck is operating correctly. The
status codes and the hourmeter values are shown on
thisfour-digitLEDdisplay.Whenafaultoccurs,the
status code will be shown with a dash (–) in the left
digit position.
The hourmeter display shows the operating time of
0000to9999 hours.The timeforthe tractioncircuit
is shown for four seconds after the lift truck has
been operating and the key is turned to the “OFF”
position. The indicator lights for the traction motor
(5) and for the hourmeter (8) will also be
illuminated during this time. If there is an SCR
controlcard forthehydraulicpumpmotor,this time

3
will then be shown on the hourmeter for another
four seconds. The indicator lights for the hydraulic
motor (6) and for the hourmeter (8) will also be
illuminated during this time.
2. Warning Light, Parking Brake
Indicator. The red light is “ON” when the
parking brake is applied and the seat switch is
closed, and goes “OFF” when the parking brake is
released.
If the parking brake is not applied and the operator
leaves the seat or turns the key to the “OFF”
position, a warning buzzer will make a noise for
approximately 10 seconds.
3. Warning Light, Brake Fluid Reservoir is
Low. The red light is “ON” for approximately
three seconds when the key switch is turned to the
“ON” position and must go “OFF” during
operation. If the warning light is “ON” during
operation,thebrakefluidlevelinthereservoiristoo
low.
4. Warning Light, Fasten Seat Belt. The red
light is “ON” for eight to ten seconds after the key
switch is turned to the “ON” position.
5. Warning Light, Motor Brushes are
Worn. When the sensor for brush wear closes,
this warning light and the indicator light for the
motor that has the problem will both illuminate.
FIGURE 2 – INSTRUMENT PANEL DISPLAY AND PLUG CONNECTOR
PREMIUM DISPLAY
KEY
SWITCH
LEADS
RED/BRN
“IGN”
TERMINAL
BRN
“BAT”
TERMINAL
PREMIUM DISPLAY
18 PIN CONNECTOR
PIN FUNCTION
2
1
3456789
10
11
1. STATUS CODE INDICATOR
2. WARNING LIGHT, PARKING BRAKE INDICATOR
3. WARNING LIGHT, BRAKE FLUID RESERVOIR IS LOW
4. WARNING LIGHT, FASTEN SEAT BELT
5. WARNING LIGHT, MOTOR BRUSHES ARE WORN
(TRACTION OR LIFT PUMP)
6. INDICATOR LIGHT, TRACTION MOTOR
7. INDICATOR LIGHT, LIFT PUMP MOTOR
8. WARNING LIGHT, MOTOR TEMPERATURE OVER LIMIT
(TRACTION OR HYDRAULIC)
9. INDICATOR LIGHT, HOURMETER
10. WARNING LIGHT, SERVICE INTERVAL
11. INDICATOR LIGHT, BATTERY
1 Traction Card PY 5
2 Pump Card PY 5
3 Traction Card PY 1
4 Traction Card PY 2
5 Traction Card PY 3
6 Pump Card PY 1
7 Pump Card PY 2
8 Pump Card PY 3
9 Traction Card PY 4
10 Pump Card PY 4
11 No Connection
12 Battery Negative
13 Park Brake Switch
14 Brake Fluid Switch
15 Lift Interrupt
16 Seat Switch Input
17 Key Switch (Ign)
18 BDI Positive

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:
[e-mail]

4
6. Indicator Light, Traction Motor. This light
will illuminate with another warning light if a fault
occurs in the traction motor. Example: If the brush
wear sensor is activated in the motor, the warning
light,brushwear(7)willgo“ON”andtheindicator
light for the traction motor will show which motor
has the problem.
7. Indicator Light, Hydraulic Motor. This
light will illuminate with another warning light if a
fault occurs in the hydraulic pump motor. Example:
If the temperature over limit switch closes in the
motor, the warning light, motor temperature over
limit (10) will go “ON” and the indicator light for
the hydraulic motor will show which motor has the
problem.
8. Warning Light, Motor Temperature Over
Limit. The traction motor and the hydraulic
pump motor have thermal switches inside the
motors.Whenthe temperature increasestothe limit
set by the manufacturer of the motor, the thermal
switch closes and the warning light on the
instrument panel display illuminates. The indicator
light for traction motor (8) or for the hydraulic
motor (9) will show which motor has the problem.
The travel speed will also be decreased.
9. Indicator Light, Hourmeter: When the
hourmeter indicator is illuminated, the status code
will display the operating time of the lift truck. The
hourmeter indicator lamp is illuminated for four
seconds after the key has been turned “OFF”. If
thereisanhourmeter for thehydraulicpumpmotor,
it will display for another four seconds.
10. Indicator Light, Fault: The fault indicator
light will flash if the control card senses a symptom
or a malfunction with the lift truck. A status code
number will appear on the digital display of the
status code indicator. The status number will be
preceded by a dash (–) in the left digit position.
11. Indicator Light, Battery Function: The
battery function indicator will flash when the status
code indicator reads 19 (battery is approximately
70% discharged). The lift pump circuit will be
disabled at a display of 10 (approximately 80%
discharged).
PRINTED CIRCUIT BOARDS
There are two printed circuit boards used to control
some of the electrical and hydraulic functions of the lift
truck. The steering angle control board is located in the
rear compartment and the lift pump control board, for
the hydraulic control circuit, is located above and be-
hind the hydraulic control valve.
The lift pump control board has been designed with test
pointstoprovide foreasychecking ofthedifferent elec-
trical circuits controlled by the printed circuit board.
Steering Angle Control Board
(See FIGURE 3)
The steering angle board is located in the rear compart-
ment. It is installed with the components facing down-
ward over the steering axle assembly. Optical switches
onthesteeringanglecontrolboardareusedtodetermine
steeringangle.Inaddition,separatefunctionsrelativeto
lift pump operation and lift interrupt (contactor con-
trolled lift pump motor only) are controlled. An internal
voltage regulator allows dual voltage operation (36 or
48 volts).
The steering angle board performs several functions:
1. Monitors steering angle and supplies input to
the SCR traction control for drive motor cutout and
reversal during turns. Signals are generated to
indicate left or right, and 60 or 90 turns.
Optical switches are mounted on the steering angle
board. and an interrupter (shade) is mounted to the
steering axle assembly to sense steering angle.
1
369
12
OPT1
OPT2
OPT3
OPT4 DS1
P1
BOTTOM VIEW AS INSTALLED
FIGURE 3 – STEERING ANGLE CONTROL
BOARD
2. Energizes the lift pump contactor, when
signaled by the lift pump control board.
(Contactor controlled lift pump motor only.)
The optical switches on the lift pump control board
supply an input to the steering angle board. A
portionofthesteeringangleboardisusedtoprocess

5
signals from the lift pump control board. Outputs
from the steering angle board connect tothe lift
pump contactor coil. The lift pump contactor is
energizedwhenthedrivers(electronicrelays)inthe
steering angle board complete the circuit on the
negative side of the coil.
3. Provides protection against shorted pump
contactor coils.
(Contactor controlled lift pump motor only.)
If the current draw of a lift pump contactor coil is
excessive, the output driver will turn off to protect
the steering angle board. Normal operation is
automatically restored when the short is removed.
4. Provides lift interrupt when the signal from the
traction SCR card (PA2) is removed.
(Contactor controlled lift pump motor with lift
interrupt option only.)
Lift Pump Control Board (See FIGURE 4)
Theliftpumpcontrolboardislocatedabove thehydrau-
lic control valve. Optical switches on the lift pump con-
trol board are utilized to sense the position of the hy-
drauliccontrolvalvelevers.These opticalswitches take
the place of conventional mechanical switches. When a
hydraulic control lever is moved from the neutral posi-
tion, the corresponding optical switch is shaded (the
light path is interrupted) and the lift pump is activated.
Optical switches are shaded (the lift pump is activated)
during all functions except lower. An internal voltage
regulator allows dual voltage operation (36 or 48 volts).
The optical switches are used to control both lift pump
control options:
a. Single speed lift pump motor
(Contactor controlled)
b. SCR controlled lift pump motor
1. On the contactor controlled lift pump, the optical
switchesontheliftpump controlboardare connectedto
the steering angle control board. A portion of the steer-
ing angle control board is used to process signals from
the lift pump control board. The steering angle control
board is connected to the lift pump contactor coil. The
liftpumpcontactor isenergizedwhenthe steeringangle
control board completes the circuit on the negative side
of the coil. As a separate function, the steering angle
control board is used to monitor steering tire angle and
supply inputs to the traction control.
With the single speed lift pump, one contactor is used to
control the lift pump motor. Outputs from the logic cir-
cuit are used to energize the lift pump contactor.
FIGURE 4 – LIFT PUMP CONTROL BOARD
2. With the SCR controlled lift pump option, the opti-
cal switches on the lift pump control board are con-
nected to the TB terminals on the lift pump SCR card.
When a hydraulic lever is activated and an optical
switch is shaded, the voltage at the corresponding TB
terminalisdroppedto less than 2voltsandthe lift pump
starts. Four separate pump speeds are provided with the
SCR controlled lift pump:
a. Slow lift and fourth function (auxiliary # 2)
b. Fast lift
c. Tilt
d. Third function (auxiliary # 1)
OTHER CONTROL COMPONENTS
Following is a short description of the other control
components and their function:
Key switch is in the housing of the instrument
panel and connects battery voltage to all of the
control circuits except the horn.
Accelerator switch assembly is actuated by the
Monotrol pedal or accelerator pedal and is part
of the SRO circuit. If the accelerator switch as-
semblyisclosedbeforetheseatswitch,thecon-
troller will not permit the lift truck to move.
Stop light switch is actuated by the brake pedal
to energize the stop lights on the rear legs of the
overhead guard.

6
Seat switch is inside the seat and is open if the
operatorisnotontheseat.Theseatswitchsends
a signal to the control card for operation of the
SCR controller and the power steering.
If the lift truck has a seat brake, the seat switch
sends a signal to the seat brake solenoid, which
is mounted to the front of the cowl. The sole-
noidoperatesthe seat brakelinkageand applies
the parking brake if the operator leaves the lift
truck without applying the parking brake.
Parking brake switch operates if the parking
brake is applied. The parking brake switch is
fastened near the linkage for applying the park-
ing brake. The switch sends a signal to the con-
trol card of the instrument panel to illuminate
the parking brake indicator.
The parking brake switch and the control card
of the instrument panel are also used to operate
an alarm. The alarm sounds if the operator
leavestheseatofthelifttruckwhenthekeyisin
theONpositionandtheparkingbrakeisnot ap-
plied.
DirectioncontrolswitchesintheMonotrolped-
alorsteeringcolumnsendbatteryvoltageto the
controlcardtoclosetheforwardorreverse con-
tactors.
Brake fluid switch sends voltage to the indica-
tor light in the instrument panel when the fluid
in the brake master cylinder is low.
Optionalmotortemperatureswitchessendvolt-
agetotheindicatorlightintheinstrumentpanel
when either the lift pump or the traction motor
is too hot.
Optional brush wear indicators send voltage to
the indicator light in the instrument panel when
the brushes of either the lift pump or traction
motors are worn.
Rocker switches for lights control all the op-
tional lights on the lift truck.
The standard rear lights on the legs of the over-
headguardaresimilartoautomobilerearlights.
The stop lights come on when the brake pedal
is depressed. The reverse lights come on when
traveling in reverse. If there are also driving
lights installed, the tail lights come on with the
driving lights. A flashing light at the top of the
overhead guard and the reverse alarm are op-
tional.
•The horn switch at the center of the steering
wheel operates the horn located under the cowl
cover.
REPLACEMENT
WARNING
ALWAYSdisconnectthe batteryandremovethekey
before replacing components.
The capacitor in the SCR controller can hold an
electricalchargeafterthebatteryisdisconnected.To
prevent electrical shock and injury, discharge the
capacitor before inspecting or repairing any
component in the rear compartment. Wear safety
glasses. Make certain the battery has been
disconnected. Use a screwdriver or jumper wire to
discharge capacitors C1. Block the drive wheels.
NOTE: Noneoftheelectricalcomponentsofthissec-
tion can be repaired. All bad components must be re-
placed.
INSTRUMENT PANEL COMPONENTS
NOTE: The only replaceable parts of these instru-
mentpanelsaretheO-ringseal,keyswitchandthewires
to the switch.
Instrument Panel Assembly
Each of the two instrument panel assemblies, standard
and premium, can be replaced as a unit.
Follow this procedure to replace an instrument panel:
1. Disconnect the battery and remove the key.
2. Remove the front steering column cover with the
instrument panel assembly attached. Carefully discon-
nect the 18 pin connector, the key switch wires and, on
thestandardpanel,thetwopinconnectorfrominsidethe
column cover.
3. Remove the four screws that fasten the instrument
panel to the column cover.

7
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
5
12
3
4
6
7
4. Install the replacement panel assembly to the cover
ofthe steeringcolumnandtightenthescrews. Installthe
connectors and the key switch wires. On the standard
panel, set the DIP switches near the connector for the
panel to the voltage of the lift truck. See FIGURE 6.
Move the DIP switch for the correct voltage to the up
position and all others to the down position. Install the
column cover on the steering column.
FIGURE 6 – DIP SWITCHES
1. STEERING COLUMN
2. INSTRUMENT PANEL
3. ELECTRICAL
CONNECTOR
4. DIP SWITCHES
1340800 2/4
36V 48V 72V 80V
1
2
3
4
3

8
Key Switch (See FIGURE 7)
Replace the key switch as follows:
1. Disconnect the battery and remove the key.
2. Remove the eight screws from the bottom of the
housing that fasten the bezel of the instrument panel.
Thehourmeterisfastenedtothebezelwiththeelectrical
connector on the circuit board inside the housing. Care-
fully lift the bezel up off the housing without damaging
the O-ring seal. Disconnect the three wire connector for
the hourmeter.
3. Remove the nut that fastens the key switch. See
FIGURE 7. Remove the key switch from the housing.
Make a note of which wires are on which terminals and
disconnectthewires.Installthewiresonthesametermi-
nals of the replacement switch.
4. Align the notch in the shaft housing of the key
switchwiththe tabin thehousingof theinstrumentpan-
el. Install the replacement switch. Tighten the nut and
connect the wires.
5. If necessary, install a new O-ring. Make sure the O-
ring is in the groove of the bezel, connect the hourmeter
plug (standard only) and carefully install the bezel on
the housing.
6. Install and tighten the eight screws that fasten the
bezel using a cross pattern.
1. INSTRUMENT PANEL
(REFERENCE)
2. KEY SWITCH
3. NUT
FIGURE 7 – KEY SWITCH
2
13
Battery Indicators
There are two types of battery indicators for these
trucks. One type is a meter movement with colored
bands showing the battery charge (standard panel). The
other type is a light emitting diode (LED) display with
LEDs of different colors showing battery charge (per-
formance panel). The battery indicators cannot be re-
placed. Replace the instrument panel if the battery indi-
catorisbad. SeeInstrumentPanel Assemblyofthissec-
tion. See the section BATTERY INDICATORS, 2200
SRM 138 to adjust these battery indicators.
Hourmeter (Standard Panel Only)
This hourmeter is not replaced. Replace the instrument
panel if the hourmeter is bad. See Instrument Panel As-
sembly of this section.
Digital Display (Premium Panel Only)
NOTE: The only replaceable parts of the premium
instrument panel are the O-ring seal, key switch and the
wires to the switch. If the digital display is bad, replace
theinstrumentpanel.SeeInstrumentPanelAssemblyof
this section.
Indicator Lights
NOTE: The indicator lights of the standard instru-
ment panel and the LED indicators of the performance
panel are not replaced. If the indicator lights or LED in-
dicators are bad, replace the instrument panel. See
Instrument Panel Assembly of this section.
PRINTED CIRCUIT BOARDS
Steering Angle Control Board

ThecapacitorintheSCRcontrollercanholdanelec-
trical charge after the battery is disconnected. To
preventelectricalshockandinjury,dischargetheca-
pacitor before inspecting or repairing any compo-
nent in the rear compartment. Wear safety glasses.
Makecertainthebatteryhasbeendisconnected.Use
a screwdriver or jumper wire to discharge capaci-
tors C1. Raise the drive wheels.
Disconnect the battery. Remove the key from the key
switch. Raise the drive wheels off of the floor. Refer to
the section PERIODICMAINTENANCE8000 SRM
528. To gain access to the steering angle control board
remove the rear compartment cover. The rear compart-
ment cover is removed by loosening the two retaining
screws and lifting the cover off of the counterweight.
1. Remove the two wing nuts retaining the steering
angle control board cover and remove the cover. See
FIGURE 8.

9
2. Remove the two nuts and washers retaining the
printed circuit board to the mounting bracket.
1. NUT
2. COVER
3. P.C. BOARD
4. NUT
5. WASHER
6. WASHER
7. BOLT
8. WASHER
9. INTERRUPTER
10. CLIP
11. BRACKET
12. SCREW
13. WASHER
FIGURE 8 – STEERING ANGLE CONTROL
BOARD MOUNTING
12
3
4
5
6
7
8
9
10
11 12
13
3. Disconnect the plug to the printed circuit board and
remove the printed circuit board.
4. Visually check to see that the interrupter is posi-
tioned properly. The interrupter should be 90to the
center line of the steer tire. If necessary loosen the bolt
retaining the interrupter and adjust the interrupter.
Tighten the bolt to retain the interrupter. Align the
printed circuit board with the washer and bolt retaining
the interrupter to the steering axle and the bolts on the
mountingbracket.Installthetwowashersandnutstose-
cure the board to the bracket.
5. Connect the plug to the printed circuit board.
6. Install the cover and the wing nuts. Install the rear
compartmentcover.Lowerthe drivewheels tothe floor.
Connect the battery.
Lift Pump Control Board
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. See
FIGURE 14.
1. Toreplacetheprintedcircuitboard,removethecot-
terpins retainingthe lowerlinks tothe hydrauliccontrol
valve. Remove the clevis pins and swing the levers up
and out of the way.
2. Disconnect the connector to the lift pump control
board.
3. Remove the two capscrews, washers, lockwashers
andnutretainingtheboardtothevalvebracket.Remove
the printed circuit board.
4. Align the printed circuit board with the holes in the
mounting bracket and install the two capscrews, wash-
ers, lockwashers and nuts to retain the board to the
bracket.
5. Connect the plug from the main harness to the
printed circuit board.
6. Lower the levers and install the clevis pins to retain
the links to the hydraulic control valve. Install new cot-
ter pins to retain the clevis pins.
7. Install the lower cover for the hydraulic control
valve. Lower the drive wheels to the floor. Connect the
battery.
Whenever the printed circuit board is replaced the vane
settings must be checked for proper alignment. Refer to
section, MAIN CONTROL VALVE, 2000 SRM 576.
OTHER CONTROL COMPONENTS
Accelerator Switch Assembly (See FIGURE 9)
The accelerator switch assembly is a switch fastened to
the cowl. The accelerator switch assembly is linked to
the Monotrol pedal or accelerator pedal. This switch as-
sembly is in the normally open position when the pedal
is in the UP position. The switch assembly operates as
soon as the pedal starts to move, for an input to the con-
trolcardtoenergizethetraction motors. Replacetheac-
celerator switch assembly as follows:
1. Disconnect the battery and remove the key.

10
!      
         
FIGURE 9 – MONOTROL PEDAL OR ACCELERATOR PEDAL POSITION, AND MONOTROL
FWD./REV. SWITCHES REPLACEMENT AND ADJUSTMENT
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


2
3
1
4
5


2. Removethefloorplatesandthecowlcover.Theac-
celeratorswitchassemblyisunderthecowlcover onthe
front of the cowl. See FIGURE 9.
3. Disconnectthesixpinconnectorfromthemainhar-
ness. Remove the cotter pin retaining the lower clevis
pin to the accelerator or Monotrol pedal arm assembly.
Remove the two mount screws, lockwashers, washers
and nuts for the accelerator switch assembly. Remove
the accelerator assembly.
Stop Light Switch
The stop light switch is a small switch fastened to the
mount for the brake pedal assembly. This switch is nor-
mally open. The stop light switch is operated by the
brakepedaltoenergizethestop lights ontherear legs of
the overhead guard. These lights are standard on U.S.
units and optional on European units. Replace the stop
light switch as follows:
1. Disconnect the battery and remove the key.
2. Removethefloorplates.Thestoplightswitchisbe-
tween the pedal arm and the mount for the brake pedal.
See FIGURE 10.
1. BRAKE PEDAL
2. MOUNTING BRACKET
3. STOP LIGHT SWITCH
4. SWITCH MOUNTING BRACKET
FIGURE 10 – STOP LIGHT SWITCH
23
1
4
3. Install tags on the wires of the stop light switch for
correct connection during installation. Remove the
wires, mount screws, nut plate and insulator for the
switch.

11
4. Install the replacement switch in the same position.
Donotbendordamagetheactuatorarmandrollerofthe
switch during installation. Connect the wires as re-
moved during removal.
5. Adjust the stop light switch as described in
CHECKS AND ADJUSTMENTS. Install the floor
plates.
Seat Switch
The seat switch has no adjustments. The seat switch is
inside the cushion of the operator seat and must be re-
placedifitisdamaged.Theswitchisnormallyopen.Re-
place the seat switch as follows:
1. Disconnect the battery and remove the key.
2. Open the hood. Disconnect the connector for the
seat switch wires near the rear of the hood frame. Push
theconnectorthroughthegrommetinthehood.Itcanbe
necessary to remove the grommet from the hole in the
hood for enough clearance to get the connector through
the grommet.
3. Remove the screws that fasten the seat to the hood
and hood frame. Close and latch the hood and put the
seat on its side for access to the seat switch.
4. Use a flat blade screwdriver or other tool with a flat
blade to carefully lift the switch free of the seat pan.
Slide the switch out of the seat cushion.
5. Carefullyslidethereplacementswitch intothe cav-
ityoftheseatcushionuntiltheendoftheswitchwiththe
wires is aligned over the hole in the pan. Push on the
switch until the clips of the switch are fastened to the
seat.
6. Carefullyinstallthegrommetoverthewireconnec-
tor. Install the seat on the hood and tighten the nuts.
Install the grommet in the hole of the hood, connect the
wire connector and push the connector back inside the
hood frame.
Parking Brake Switch (See FIGURE 12)
Theparkingbrakeswitchisfastenednearthelinkagefor
applying the parking brake. This switch operates the in-
dicatorintheinstrumentpanelandthealarmthroughthe
control card for the instrument panel.
FIGURE 11 – SEAT SWITCH REPLACEMENT
1. SEAT PAN
2. SEAT SWITCH
3. WIRE CONNECTOR
1351472
1
2
3
1354140
2
SEAT CAN BE DIFFERENT
THAN SHOWN.
3
The park brake alarm will operate for 10 seconds when
the operator gets off the seat or the key is moved to the
“OFF” position and the parking brake is not applied.
The alarm is operated by the instrument panel from the
switch signal and is located within the instrument panel
housing. The alarm will not operate if the parking brake
switch is damaged or not adjusted correctly. An alarm
that does not operate cannot be repaired and must be re-
placed as part of the instrument panel. See Instrument
Panel Assembly. Replace the parking brake switch as
follows:
1. Disconnect the battery and remove the key.
2. Remove the cowl cover. Remove the nuts that fas-
tentheswitchtotheplateassembly.Donotlosethenuts.
4. Install the replacement switch in the same position.
Install the insulator, nut plate and mount screws. Do not
bendor damagethe actuatorarm androller ofthe switch
during installation. Connect the wires as removed dur-
ing removal.
3. Make a note of the wires fastened to the switch ter-
minals for correct connection during installation. Re-
move the wires from the switch terminals.
4. Connect the wires to the replacement switch as dis-
connected during removal. Install the replacement
switch using the same nuts. Do not damage the leaf of
the switch during installation.

12
5. Install the cowl cover. Connect the battery.
6. Adjust the switch as described in CHECKS AND
ADJUSTMENTS. Install the floor plates.
FIGURE 12 – PARKING BRAKE ASSEMBLY
1. COWL
2. RELEASE HANDLE
3. BRAKE ASSEMBLY
4. FLOOR PLATE
5. SWITCH
6. CAM
2
3
1
54
6
Direction Switches (Monotrol Pedal)
(See FIGURE 9)
There is a small direction switch under each pad of the
Monotrol pedal. See FIGURE 9. Each switch controls
one direction. If both sides of the Monotrol pedal are
pushed at the same time, the direction circuit is deener-
gized.Thecontactsofthetwodirectionswitchesareina
series and parallel arrangement so that both direction
contactors cannot be energized at the same time.
NOTE: The direction switches used in the Monotrol
pedal are made for Hyster Company with a special con-
tact clearance and timing. Other switches made by the
manufacturer look the same and will fit in the same
space in the Monotrol pedal. These other switches will
not operate the same and will often burn and not give
good service. The switches are also replaced as an as-
sembly that includes both switches and the wire cable
with connectors. Use only replacement switches with
the Hyster part number in the assembly.
Replace the direction switch assembly as follows:
1. Disconnect the battery and remove the key.
2. Removethecowlcover.Makeanoteofthelocation
of the wires for correct connection during installation.
Disconnect the plug for the Monotrol pedal from the
main harness.
3. Remove the two capscrews and washers retaining
the pedal to the Monotrol pedal arm assembly. Cut the
cable ties that fasten the switch harness wires to the arm
assembly. Remove the pedal assembly.
4. Turn the pedal assembly upside down and remove
the pedal pad by removing the four screws and lock-
washers.
5. Remove the nuts that fasten the switches. Remove
the screws and special washers that fasten the wires to
the pedal. Remove the switch assembly from the pedal.
6. Installthereplacementswitchassemblyontheped-
al. Make sure that the forward switch with wire 8 is on
therightofthebacksideofthepedal.Thereverseswitch
with wire 6 is on the left of the back side of the pedal.
7. Temporarilyinstallthenutsthatfastentheswitches,
but do not tighten the nuts.
8. Align the wires as noted during removal. Put Loc-
titeR222 on the screws for the special washers that fas-
ten the wires. Install the screws and washers and tighten
the screws to 0.8 – 1.0 NSm (7.0 – 8.8 lbf in) torque.
9. Install cable ties as removed during removal.
10. Beforeinstalling thepedalpadadjustthedirection
switches as described in CHECKS AND ADJUST-
MENTS. Tighten the nuts and install the pedal pad on
the pedal after adjustments are complete.
11. Connecttheswitchharnesstothemainwiringhar-
ness as disconnected. Install the cowl cover.
12. Connect the battery.
Direction Control Switches
(Steering Column) (See FIGURE 13)
The direction control switches send a signal to the trac-
tion control card to close the forward or reverse contac-
tors. This direction control has a pair of small switches
in the steering column. See FIGURE 13. Each position

13
of the two switches controls one direction. Both
switches must function correctly because both switches
are used to close the circuit. A bad switch must be re-
placed. Replace the switches as follows:
1. Disconnect the battery and remove the key.
2. Move the steering column to the forward position
andremovetherear coverofthesteering columnforac-
cess to the switches.
3. Make a note of the location of the wires for correct
connection during installation and disconnect the three
wires from the switch. Replace the switch and connect
the wires to the replacement switch.
4. There is no adjustment for these switches. Install
the cover for the steering column.
5. Connect the battery.
FIGURE 13 – DIRECTION CONTROL
(FORWARD AND REVERSE) SWITCHES
1. FORWARD AND
REVERSE LEVER
2. INDICATOR
3. REVERSE SWITCH
4. FORWARD SWITCH
5. MOUNT BRACKET
6. SHUTTLE
1
2
5
4
3
6
Hydraulic Cut Off Switch
Thisswitchprevents operationofthe hydrauliccontrols
if the hood is not closed and latched and the hydraulic
control valve cover is not closed. The switch prevents
thehydraulicprintedcircuitboardfromoperatingofany
of the hydraulic controls. The contacts are open in the
fault condition.
Replace the hydraulic cut off switch as follows:
1. Disconnect the battery and remove the key.
2. Remove the screws retaining the lower front hy-
draulic valve cover and remove the cover. Release and
raise the upper hydraulic valve covers and levers.
3. Remove the two nuts and washers retaining the
switch to the mounting bracket. Tag and disconnect the
wires to the switch.
1. LOWER COVER
2. UPPER COVERS AND LEVERS
3. SPRING
4. SWITCH
5. HYDRAULIC CONTROL VALVE
6. LIFT PUMP CONTROL BOARD
1
1
2
4
4
3
5
    

6
4. Installthereplacementswitchonthescrewslocated
on the mounting bracket. Install the nuts and washers.
.Do not bend or damage the actuator arm and roller of
the switch during installation. Connect the wires as re-
moved during removal.
5. Close the upper hydraulic valve covers and levers.
Make certain that the spring on the valve linkage con-
tacts the roller on the switch and that the switch closes
and opens as the covers and levers are moved.
6. Install the lower front hydraulic valve cover.
7. Connect the battery.
Brake Fluid Switch
This switch is a magnetic switch on the reservoir of the
master cylinder for the service brakes. It sends a signal

14
to the control card of the instrument panel to illuminate
theindicatorforlowfluidlevel.The switchis partofthe
reservoir.
Motor Temperature Switches
These switches are in the traction and lift pump motors.
The switches send signals to the pump SCR card or the
TMM card, then to the traction card and then to the
instrument panel. The signal will illuminate the indica-
tor to tell the operator that the motor is too hot.
The temperature switch is part of the motor and cannot
be replaced separately. However, they almost never go
bad.
Rocker Switches for Lights
(See FIGURE 15)
These switches are ON OFF switches that control the
optional front, rear and operator compartment lights.
Rocker switches for the optional lights are mounted to
the instrument panel to the right of the steering column.
Removethecover undertheinstrument panelforaccess
to the underside of the instrument panel or switch
mounting surface. Replace a switch as described in the
following paragraphs:
1. Disconnect the battery and remove the key.
2. Puttagsontheswitchwires,orwireharnessforcor-
rectidentification duringinstallation.Removethewires
from the switch terminals.
3. Use a flat blade screw driver or other similar tool
and press in on the retainer clips at each side of the
switch. Remove the switch from the face of the instru-
ment panel or switch mounting surface while holding
the retainer clips in the “released” position.
4. Remove the switch and install the replacement
switchinthepanel.Makesuretheswitchisinthecorrect
position for reading by the operator.
5. Connect the wires, or wire harness to the electrical
terminals on the switch as removed during removal.
CAUTION
Makesurewireconnectorsdonottouchotherswitch
or meter terminal wire connectors, metal brackets
or the bracket mounting nuts. Make sure there is no
tension or binding on the wires or connectors.
6. Install the cover under the instrument panel.
FIGURE 15 – ROCKER SWITCH
1. SWITCH ASSEMBLY
2. LENS AND FUNCTION
SYMBOL (NOT ON
ALL SWITCHES)
3. INSTRUMENT PANEL
4. RETAINER CLIP
5. SWITCH LIGHT &
OTHER TERMINALS
6. POWER TERMINALS
13284
1
23
4
5
56
6
Lights and Reverse Alarm (See FIGURE 16
and FIGURE 17)
The Lights are all fastened to the overhead guard. The
stop,tailandreverselightassembliesareontherearlegs
of the overhead guard and are standard in North Ameri-
ca and optional in Europe. These light sets operate on
thevoltageofthelifttruck.Theflashinglightisfastened
near the top of the overhead guard and is optional on all
units. This light also operates on the voltage of the lift
truckandis“ON”whenthekeyisinthe“ON”position.
Therear drivinglight (optional)is alsofastened nearthe
top of the overhead guard. The optional front driving
lights are fastened to the front legs of the overhead
guard.
NOTE: It is not necessary to replace the complete light
assemblies to replace a bulb. Do only the steps neces-
sary for your replacement needs.
Replace the Stop, Tail and Reverse Light Assembly.
1. Disconnect the battery and remove the key.

15
2. To replace the bulb for the tail light part of the light
assembly, remove the top screw and nut. Slide the stop
light portion of the lens off of the lens assembly. Push
and turn the bulb 1/4turn counterclockwise. Make sure
you are replacing the correct bulb of the set. Make sure
the replacement bulb is the correct voltage and has the
correct pin configuration. Install the replacement bulb
in the socket using the reverse procedure. Slide the tail
light portion of the lens on the lens assembly. Install the
screw and washer to retain the lens.
3. To replace the bulb for the reverse part of the light
assembly, remove the lower screw and nut. Slide the re-
verse (clear) portion of the lens off of the lens assembly.
Push and turn the bulb 1/4turn counterclockwise. Make
sure you are replacing the correct bulb of the set. Make
sure the replacement bulb is the correct voltage and has
the correct pin configuration. Install the replacement
bulb in the socket using the reverse procedure. Slide the
reverse portion of the lens on the lens assembly. Install
the screw and washer to retain the lens.
4. Ifthestoplight bulbmustbereplaced, removeboth
the upper and lower screws and nuts. Carefully remove
the lens assembly from the light base. Push and turn the
bulb 1/4turn counterclockwise. Make sure you are re-
placing the correct bulb of the set. Make sure the re-
placementbulbis thecorrectvoltage andhasthecorrect
pin configuration. Install the replacement bulb in the
socket using the reverse procedure. Align the lens as-
semblywiththe baseandinstall thetwoscrewsandnuts
to retain the lens assembly to the base.
5. Ifthe completelight assemblyisbeingreplaced,re-
move both screws and nuts and remove the light assem-
blywiththelensesfromthebracket.Disconnectthefour
pin connector.
6. Connect the plug of the new light assembly to the
connector. Align the new light assembly in the bracket
and install the two screws and nuts.
7. Connect the battery.
Replace the Flashing Light Assembly.
1. Disconnect the battery and remove the key.
2. Remove the two M4 screws, nuts and washers that
attach the flashing light.
3. Remove the wire guard.
4. To replace a bulb only, remove the lens from the
base. Carefully remove the bulb. Use a cloth to install
the replacement quartz bulb without touching the bulb
with your fingers. Go to Step 7 if the assembly will not
be replaced.
5. If the complete light assembly is being replaced,
disconnect the connector and remove the flashing light
basefromthemountingbracketbyremovingthemount-
ing nut.
6. Alignthenew flashing lightassemblyin bracketon
the lift truck and install the plug in the connector. Align
the flashing light assembly on the base.
7. Installthetwoscrews,nutsandwasherstoretainthe
flashing light and wire guard on the mounting bracket.
8. Connect the battery.
Replace the Front or Rear Driving Light Assemblies.
1. Disconnect the battery and remove the key.
2. Replace the bulb only by carefully moving the rub-
ber housing away from the edge of the lens to get the
light assembly out of the housing. Remove the socket
assembly from the back of the light assembly. Turn the
socket assembly 1/4turn counterclockwise. Push and
turn the bulb 1/4turn counterclockwise. Make sure the
replacement bulb is the correct voltage and has the cor-
rect pin configuration. Install the replacement bulb and
socket assembly using the reverse procedure. Install the
light assembly in the housing.
The Reverse Alarm is fastened to the right rear leg of
theoverheadguard. The alarmoperatesfrom signals re-
ceived from the traction control card to let people know
the lift truck is traveling in the reverse direction. See
FIGURE 16.
Replace the reverse alarm as follows:
1. Disconnect the battery and remove the key.
2. Remove the rear compartment cover for access to
the electrical plug of the alarm. Disconnect the square
six pin plug for the alarm from the main harness.
3. Removethetwoscrews,nutsandwashersretaining
the alarm to the mounting bracket. Remove the reverse
alarm. Make sure not to lose the two spacers that posi-
tion the alarm in the bracket.

16
FIGURE 16 – REAR LIGHTS AND REVERSE ALARM
SEE THE SECTION DIAGRAMS,
8000 SRM 529 FOR CORRECT
CONNECTIONS
REAR LIGHTS
A
A
SEE DETAIL “C”
DETAIL “C”
VIEW A–A
REAR WORK LIGHT/STROBE LIGHT COMBINATION
VIEW B–B REAR WORK LIGHT OPTION STROBE LIGHT OPTION
B
B
1
23
1
4
1
23
1
423
1. STOP, TAIL & REVERSE ASSY
2. REAR WORK LIGHT
3. FLASHING LIGHT
4. REVERSE ALARM
5. ROCKER SWITCHES
ROCKER SWITCHES
LOCATED ON
INSTRUMENT PANEL
5

17
3. To remove the driving light assembly, disconnect
theplugfromtheconnector.Removethenutthatfastens
the front or rear light assembly to the mounting bracket.
Remove the light assembly .
4. Install the new driving light assembly on the lift
truckbracketusingthenut.Connectthe plugof thelight
assembly to the connector on the leg of the overhead
guard.
4. Alignand installthespacersandreplacementalarm
on the bracket. Install the two screws, nuts and washers
to retain the alarm to the bracket.
5. Connect the plug to the connector on the main har-
ness located in the rear compartment. Install the rear
compartment cover.
FRONT LIGHTS
A
A
B
B
VIEW A–A VIEW B–B
SEE THE SECTION DIAGRAMS,
8000 SRM 529 FOR CORRECT
CONNECTIONS
FIGURE 17 – OPTIONAL FRONT LIGHTS
Horn and Horn Button
(See FIGURE 18)
TheHornismountedonthecowl underthe cowlcover.
Replace the horn as follows:
1. Disconnect the battery and remove the key.
2. Remove the cowl cover by removing the four at-
taching screws.
3. Tag and disconnect the wires fastened to the horn
terminals.
4. Hold the horn and remove the capscrew, nut, and
washer that fasten the horn to the bracket welded to the
lift truck cowl. Do not lose the parts. Remove the horn.
5. Alignthehornassemblywiththeholeinthebracket
welded to the lift truck cowl. Install the capscrew in the
mounting hole and install lockwashers and the nut.
6. Align the horn in the same position as the old horn
and tighten the capscrew and nut.
7. Install the wires on the horn terminals.

18
8. Install the cowl cover. Connect the battery.
TheHornSwitchandCover(button)isin thecenterof
the steering wheel. See FIGURE 18. Replace the horn
button assembly as follows:
1. Disconnect the battery and remove the key.
2. Carefully lift the cover and horn button assembly
up off the steering wheel. Lift the assembly far enough
for access to the setscrews that fasten the horn wires.
There is some extra length of the horn wires, but the as-
sembly will not come up very far. If necessary for addi-
tional clearance, the cover, contact plate and spring can
be removed from the contact set.
3. Loosen the setscrews that fasten the contact set to
the horn wires.
4. Pullthehornwiresoutofthecontactsetandremove
the assembly.
WARNING
If the steering wheel has been removed, make sure
the steering wheel nut has been tightened. The
correct torque is 40 to 54 Nm (30 to 40 lbf ft).
5. Put the replacement assembly in position over the
steering wheel and install the wires in the contacts.
Tighten the setscrews to fasten the wires.
NOTE: If the contact set, spring, contact plate and
cover are separated, make sure they are installed and
aligned correctly.
6. Carefullypushthe wiresintothe shaftboreas faras
possible. Align the horn button assembly and press
downontheedgesofthecovertoinstallitinthesteering
wheel.
1. HORN
2. CAPSCREW
3. WASHER
4. NUT
5. LIFT TRUCK COWL
6. COVER
7. CONTACT PLATE
8. CONTACT SET & SETSCREW
9. SPRING
FIGURE 18 – HORN AND HORN BUTTON
1337111
5
7
8
9
6
1
2, 3, 4
1