Hyster J1.5.XNT, J1.6XNT, J1.8XNT, J2.0XNT (K160) Forkligt
J1.5.XNT, J1.6XNT, J1.8XNT,
J2.0XNT
(K160)
1674207 ©2013 HYSTER COMPANY
04/2013
04/2013
UNIT CODE K160
EUROPE
SECTIONS
1 FRAME
2 ELECTRICAL SYSTEM
3 DRIVE UNIT
4 STEERING SYSTEM
5 BRAKE/ACCELERATOR SYSTEM
6 HYDRAULIC SYSTEM
7 MAST-TWO STAGE LIMITED FREE-LIFT
8 MAST-THREE STAGE FULL FREE-LIFT
9 MAST-TWO STAGE FULL FREE-LIFT
10 OPTIONS
11 FIELD SERVICE KITS
12 NUMERICAL INDEX
This Parts Manual is divided into 12 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
04/2013
UNIT CODE K160
EUROPE
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCELERATOR PEDAL
MONOTROL ................................................................................................................................................ 5-10
STANDARD ................................................................................................................................................. 5-8
ARMREST SLIDER ASSEMBLY
→ 9/2010 .................................................................................................................................................... 1-102
9/2010 → .................................................................................................................................................... 1-104
AUDIBLE ALARMS ......................................................................................................................................... 10-2
AUXILIARY TUBE EXTENSION KITS ............................................................................................................ 11-4
AUXILIARY TUBE EXTENSIONS
TWO AND THREE STAGE FULL FREE-LIFT ............................................................................................ 10-42
TWO-STAGE LIMITED FREE-LIFT ............................................................................................................ 10-40
B
BATTERY CONNECTOR AND CABLE ASSEMBLY
WITH RAPID CHARGE OPTION ................................................................................................................ 2-18
WITHOUT RAPID CHARGE OPTION ........................................................................................................ 2-16
BATTERY RETENTION
→ S/N K160B03069J ................................................................................................................................. 1-60
S/N K160B03070J → ................................................................................................................................. 1-62
BATTERY TRAY OPTIONS
DROP-IN ..................................................................................................................................................... 1-54
SIDE REMOVAL (S/N K160B03070J →) ................................................................................................... 1-58
SIDE-REMOVAL (→ S/N K160B03069J) ................................................................................................... 1-56
BRAKE PEDAL LINKAGE ............................................................................................................................... 5-2
C
CAB
FRONT PANEL ASSEMBLY ....................................................................................................................... 1-20
FRONT WIPER ASSEMBLY ....................................................................................................................... 1-28
HEADLINER ASSEMBLY ........................................................................................................................... 1-30
HEATER ...................................................................................................................................................... 1-32
HEATER ASSEMBLY ................................................................................................................................. 1-34
HEATER ASSEMBLY - ALTERNATE HEATER ......................................................................................... 1-36
PVC DOORS ............................................................................................................................................... 1-6
REAR PANEL AND WIPER ATTACHMENT ............................................................................................... 1-24
REAR PANEL ASSEMBLY ......................................................................................................................... 1-26
STEEL DOOR ASSEMBLY - RIGHT HAND ............................................................................................... 1-12
STEEL DOOR ASSEMBLY - LEFT HAND .................................................................................................. 1-14
STEEL DOORS ........................................................................................................................................... 1-10
TOP PANEL ASSEMBLY ............................................................................................................................ 1-22
WINDOW - STEEL DOOR, RIGHT HAND .................................................................................................. 1-16
WINDOW - STEEL DOOR, LEFT HAND .................................................................................................... 1-18
CAB ASSEMBLY
FULL STEEL CAB ....................................................................................................................................... 1-8
WITH PVC DOORS ..................................................................................................................................... 1-4
CAB KITS
CARRIAGE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - STANDARD ............................................................................ 8-20
©2013 HYSTER COMPANY See Service Manual
for service procedures.
i
UNIT CODE K160
EUROPE 04/2013
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
THREE STAGE FULL FREE LIFT - A271 - INTEGRAL SIDE-SHIFT ........................................................ 10-24
THREE STAGE FULL FREE LIFT - C662 - STANDARD ........................................................................... 8-46
THREE STAGE FULL FREE LIFT - C662 - INTEGRAL SIDE-SHIFT ........................................................ 10-26
TWO STAGE FULL FREE- LIFT - STANDARD .......................................................................................... 9-16
TWO STAGE FULL FREE LIFT - C663 - INTEGRAL SIDE-SHIFT ............................................................ 10-30
TWO STAGE FULL FREE- LIFT-A272 - INTEGRAL SIDE-SHIFT ............................................................. 10-28
TWO STAGE FULL FREE- LIFT-STANDARD - A272 ................................................................................ 9-38
TWO STAGE LIMITED FREE LIFT - A270 - STANDARD .......................................................................... 7-12
TWO STAGE LIMITED FREE LIFT - A270 - INTEGRAL SIDE-SHIFT ....................................................... 10-20
TWO STAGE LIMITED FREE LIFT - C661 - STANDARD .......................................................................... 7-30
TWO STAGE LIMITED FREE LIFT - C661 - INTEGRAL SIDE-SHIFT ....................................................... 10-22
CONTACTOR .................................................................................................................................................. 2-24
CONTROL VALVE
ELECTRO-HYDRAULIC - 3 AND 4 FUNCTION ......................................................................................... 6-46
MANUAL - 3 AND 4 FUNCTION (→ S/N K160B04115K) .......................................................................... 6-28
CONTROLLER
HOIST AND FAN ASSEMBLY .................................................................................................................... 2-12
TRACTION AND FAN ASSEMBLY ............................................................................................................. 2-14
CONTROLLERS .............................................................................................................................................. 2-8
CONVERSION KIT
COUNTERWEIGHT ........................................................................................................................................ 1-64
COWL MOUNT
→ S/N K160B03069J ................................................................................................................................. 1-70
S/N K160B03070J → ................................................................................................................................. 1-72
D
DASH AND STEERING COLUMN COVERS
FIXED COLUMN ......................................................................................................................................... 1-76
TELESCOPIC COLUMN ............................................................................................................................. 1-78
DC/DC CONVERTER ...................................................................................................................................... 10-4
DISPLAY ......................................................................................................................................................... 2-20
DOME LIGHT .................................................................................................................................................. 10-16
DRIVE TIRE AND WHEEL ASSEMBLY .......................................................................................................... 3-6
DRIVE UNIT ASSEMBLY ................................................................................................................................ 3-4
E
ELECTRICAL ARRANGEMENT
→ S/N K160B02173H → S/N K160B02189H ............................................................................................ 2-2
S/N K160B02174H → S/N K160B02190H → ............................................................................................ 2-6
F
FLOOR PLATES ............................................................................................................................................. 1-74
FORKS ............................................................................................................................................................ 1-86
OPTIONAL .................................................................................................................................................. 1-87
FREE LIFT ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 (→ S/N A271B02146H) ........................................................... 8-8
THREE STAGE FULL FREE LIFT - A271 (S/N A271B02147H →) ........................................................... 8-12
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-38
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-8
ii
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
FREE LIFT CYLINDER ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-18
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-44
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-14
TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-36
FREE-LIFT ASSEMBLY
TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-34
FRONT WORK AND MARKER LIGHTS ......................................................................................................... 10-12
FUSE PANEL ASSEMBLY .............................................................................................................................. 2-22
H
HEADER HOSE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 (S/N A271B02147H →) (S/N K160B02118H →) .................... 8-26
THREE STAGE FULL FREE LIFT - A271 - 3 RD FUNCTION HOSES (→ S/N K160B02117H)
(→ S/N A271B02146H) .............................................................................................................................. 8-22
THREE STAGE FULL FREE LIFT - A271 - 4 TH FUNCTION HOSES (→ S/N A271B02146H)
(→ S/N K160B02117H) .............................................................................................................................. 8-24
THREE STAGE FULL FREE-LIFT - C662 .................................................................................................. 8-48
TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-40
TWO STAGE FULL FREE LIFT - C663 - 3 FUNCTION (→ S/N C663B01671H) (→ S/N K160B02117H)
.................................................................................................................................................................... 9-18
TWO STAGE FULL FREE LIFT - C663 - 4TH FUNCTION (→ S/N K160B02117H) (→ S/N C663B01671H)
.................................................................................................................................................................... 9-20
TWO STAGE LIMITED FREE LIFT - A270 (→ S/N A270B01595H) (→ S/N K160B02117H) .................. 7-14
TWO STAGE LIMITED FREE LIFT - A270 (S/N A270B01596H →) (S/N K160B02118H →) .................. 7-16
TWO STAGE LMITED FREE-LIFT - C661 .................................................................................................. 7-32
TWO-STAGE FULL FREE-LIFT - C663 (S/N K160B02118H →) (S/N C663B01672H →) ....................... 9-22
HEADER HOSE CONVERSION KITS
HOOD AND COUNTERWEIGHT COVER
LATE PRODUCTION .................................................................................................................................. 1-42
WITH RAPID CHARGE OPTION ................................................................................................................ 1-46
HOOD AND COVERS
EARLY PRODUCTION ............................................................................................................................... 1-38
HYDRAULIC CONTROL CONVERSION KITS ............................................................................................... 11-3
HYDRAULIC CONTROL VALVE
MANUAL - 3 AND 4 FUNCTION (S/N K160B04116K →) .......................................................................... 6-32
HYDRAULIC CONTROLS
ELECTRO-HYDRAULIC ............................................................................................................................. 6-44
MANUAL ..................................................................................................................................................... 6-20
HYDRAULIC FILTER HOUSING ..................................................................................................................... 6-12
HYDRAULIC HOSE CONVERSION KITS ...................................................................................................... 11-5
HYDRAULIC HOSES AND FITTINGS
AUXILIARY HOSES .................................................................................................................................... 6-18
STEERING .................................................................................................................................................. 6-16
SUPPLY AND RETURN .............................................................................................................................. 6-14
HYDRAULIC LEVERS - LINKAGE ASSEMBLY (MANUAL) ........................................................................... 6-24
HYDRAULIC MOTOR ..................................................................................................................................... 6-6
HYDRAULIC POWER UNIT INSTALLATION ................................................................................................. 6-2
HYDRAULIC PUMP ........................................................................................................................................ 6-8
©2013 HYSTER COMPANY See Service Manual
for service procedures.
iii
UNIT CODE K160
EUROPE 04/2013
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
HYDRAULIC PUMP AND MOTOR ASSEMBLY ............................................................................................. 6-4
HYDRAULIC TANK ASSEMBLY ..................................................................................................................... 6-10
I
IMPACT SENSOR ........................................................................................................................................... 10-44
INLET SECTION
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-48
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-36
INTEGRAL SIDE-SHIFT
FORK POSITIONER - TWO STAGE LIMITED FREE-LIFT ........................................................................ 10-32
FORK POSITIONER (907 MM) - 2 AND 3 FFL ........................................................................................... 10-34
FORK POSITIONER (977 MM) - 2 AND 3 FFL ........................................................................................... 10-36
INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 10-38
L
LABELS
EXTERIOR .................................................................................................................................................. 1-80
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-84
INTERIOR ................................................................................................................................................... 1-82
LIFT CYLINDER ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270 ................................................................................................. 7-10
TWO STAGE LIMITED FREE LIFT - C661 ................................................................................................. 7-26
LIFT/TILT SECTION
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-50
LIFT/TILT/AUXILIARY SECTION
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-38
LIGHT/ALARM ADD-ON OPTIONS KITS ....................................................................................................... 11-2
LOAD BACKREST EXTENSION ..................................................................................................................... 1-88
M
MAIN LIFT ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-6
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-34
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-6
TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-28
MAIN LIFT CYLINDER ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-16
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-40
MAIN LIFT CYLINDER LH
TWO STAGE FULL FREE LIFT - C662 ...................................................................................................... 9-10
TWO STAGE FULL FREE LIFT - A272 ...................................................................................................... 9-30
MAIN LIFT CYLINDER RH
TWO STAGE FULL FREE- LIFT - C662 ..................................................................................................... 9-12
TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-32
MAST ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - INNER, INTERMEDIATE AND OUTER (→ S/N A271B02146H)
.................................................................................................................................................................... 8-2
THREE STAGE FULL FREE LIFT - A271 - INNER, INTERMEDIATE AND OUTER (S/N A271B02147H →)
.................................................................................................................................................................... 8-4
iv
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
THREE STAGE FULL FREE LIFT - C662 - INNER, INTERMEDIATE AND OUTER (→ S/N C662B02349H)
.................................................................................................................................................................... 8-30
THREE STAGE FULL FREE LIFT - C662 - INNER, INTERMEDIATE AND OUTER (S/N C662B02350H →)
.................................................................................................................................................................... 8-32
TWO STAGE FULL FREE LIFT - C663 (→ S/N C663B01671H) ............................................................... 9-2
TWO STAGE FULL FREE LIFT - C663 (S/N C663B01672H →) ............................................................... 9-4
TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-26
TWO STAGE LIMITED FREE LIFT - A270 (→ S/N A270B01595H) .......................................................... 7-2
TWO STAGE LIMITED FREE LIFT - A270 (S/N A270B01596H →) .......................................................... 7-6
TWO STAGE LIMITED FREE LIFT - C661 (→ S/N C661B01677H) ......................................................... 7-18
TWO STAGE LIMITED FREE LIFT - C661 (S/N C661B01678H →) ......................................................... 7-22
MAST/TILT CYLINDER INSTALLATION ........................................................................................................ 6-54
MASTER CYLINDER ...................................................................................................................................... 5-4
MINI-LEVER CONTROLS
3 FUNCTION ............................................................................................................................................... 2-28
4 FUNCTION ............................................................................................................................................... 2-30
MIRROR
CONVEX REAR VIEW ................................................................................................................................ 10-6
DUAL REAR VIEW ...................................................................................................................................... 10-8
MISCELLANEOUS OPTION KITS .................................................................................................................. 11-2
O
OUTLET SECTION
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-41
OVERHEAD GUARD
→ S/N K160B03069J ................................................................................................................................. 1-66
S/N K160B03070J → ................................................................................................................................. 1-68
P
PARKING BRAKE RELEASE .......................................................................................................................... 5-6
POSITIONER SENSOR
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-40
R
REAR REFLECTORS ..................................................................................................................................... 10-10
REVERSE HANDLE ........................................................................................................................................ 10-18
S
SEAT
FULL SUSPENSION - SHEET 1 0F 2 ......................................................................................................... 1-90
FULL SUSPENSION - SHEET 2 OF 2 ........................................................................................................ 1-94
FULL SUSPENSION, HIGH BACK - SHEET 1 0F 2 ................................................................................... 1-96
FULL SUSPENSION, HIGH BACK - SHEET 2 OF 2 .................................................................................. 1-100
SERVICE KITS
SIDE PANELS ................................................................................................................................................. 1-50
STATIC STRAP ............................................................................................................................................... 1-106
STEER AXLE ASSEMBLY .............................................................................................................................. 4-6
STEER AXLE MOUNTING .............................................................................................................................. 4-4
STEER COLUMN
FIXED .......................................................................................................................................................... 4-12
©2013 HYSTER COMPANY See Service Manual
for service procedures.
v
UNIT CODE K160
EUROPE 04/2013
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
TELESCOPIC .............................................................................................................................................. 4-14
STEER TIRE AND WHEEL ASSEMBLY ......................................................................................................... 4-2
STEERING ACCUMULATOR ......................................................................................................................... 4-16
STEERING HAND PUMP ASSEMBLY ........................................................................................................... 4-10
STROBE LIGHT ASSEMBLY AND REAR WORK LIGHT .............................................................................. 10-14
T
TIE RODS
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-52
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-42
TILT CYLINDER ASSEMBLY .......................................................................................................................... 6-56
TILT SENSOR GROUP ................................................................................................................................... 2-26
TRACTION MOTOR ASSEMBLY ................................................................................................................... 3-2
TRANSMISSION
COVER AND BRAKE DISCS ...................................................................................................................... 3-8
HOUSING .................................................................................................................................................... 3-10
W
WIRE HARNESS
CAB ACCESSORY ..................................................................................................................................... 2-80
CAB ACCESSORY - ALTERNATE PART .................................................................................................. 2-81
DC CONVERTER ........................................................................................................................................ 2-77
DC/DC CONVERTER - ALTERNATE PART .............................................................................................. 2-78
DISPLAY, PREMIUM - FREEZER OPTION ............................................................................................... 2-34
DISPLAY, STANDARD ............................................................................................................................... 2-33
HEATER ...................................................................................................................................................... 2-68
HYDRAULIC FLUID LEVEL AND PRESSURE ........................................................................................... 2-83
LIGHTS WITH OVERHEAD GUARD .......................................................................................................... 2-84
MAIN-ELECTRO-HYDRAULIC - PAGE 1 OF 2 (→ S/N K160B02173H) ................................................... 2-36
MAIN-ELECTRO-HYDRAULIC - PAGE 1 OF 2 (S/N K160B02174H →) ................................................... 2-40
MAIN-ELECTRO-HYDRAULIC - PAGE 2 OF 2 (→ S/N K160B02173H) ................................................... 2-44
MAIN-ELECTRO-HYDRAULIC - PAGE 2 OF 2 (S/N K160B02174H →) ................................................... 2-48
MAIN-MANUAL-HYDRAULIC - PAGE 1 OF 2 (→ S/N K160B02189H) ..................................................... 2-52
MAIN-MANUAL-HYDRAULIC - PAGE 1 OF 2 (S/N K160B02190H →) ..................................................... 2-56
MAIN-MANUAL-HYDRAULIC - PAGE 2 OF 2 (→ S/N K160B02189H) ..................................................... 2-60
MAIN-MANUAL-HYDRAULIC - PAGE 2 OF 2 (S/N K160B02190H →) ..................................................... 2-64
MANUAL HYDRAULICS ............................................................................................................................. 2-73
MANUAL INTERLOCK ................................................................................................................................ 2-72
REAR WIPER .............................................................................................................................................. 2-79
STEER COLUMN ........................................................................................................................................ 2-76
STEER UNIT ............................................................................................................................................... 2-75
SYNCHRONOUS STEERING ..................................................................................................................... 2-74
TURN SIGNAL ............................................................................................................................................ 2-70
vi
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
ABBREVIATIONS QUICK REFERENCE SHEET
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION
TERM DEFINITION
Amp Amperes
AR As Required
BDI Battery Discharge Indicators
BWI Brush Wear Indicator
CE Communicator End
CRE Corrosive Environment
D/B Date Break
dbA Decibel "A" Scale
DE Drive End
ECH Empty Container Handler
ECH-3 Empty Container Handler - 3 High
Stacking
ECH-4 Empty Container Handler - 4 High
Stacking
ECH-5 Empty Container Handler - 5 High
Stacking
ECH-6 Empty Container Handler - 6 High
Stacking
ECH-7 Empty Container Handler - 7 High
Stacking
ECM Electronic Control Module
ECN Engineering Change Notice
EEPROM Electrically Erasable Programmable
Read Only Memory
EPA US Environmental Protection Agency
EPROM Electrically Programmable Read Only
Memory
FRE Freezer Environment
in. inches
LPG Liquefied Petroleum Gas
MAP Manifold Absolute Pressure
mm millimeters
MSTS Microprocessor Spark Timing System
NPT National Pipe Threads
O/S Oversize
PTO Power Take Off
RPM Revolutions per Minute
S/N Serial Number
TMM Truck Management Module
UL Type D Diesel-Powered Safety Rating
UL Type DS Diesel-Powered Safety Rating
UL Type E Battery-Powered Safety Rating
UL Type EE Battery-Powered Safety Rating
UL Type ES Battery-Powered Safety Rating
UL Type G Gasoline-Powered Safety Rating
UL Type GS Gasoline-Powered Safety Rating
UL Type LP Gas-Powered Safety Rating
UL Type LPS LP Gas-Powered Safety Rating
U/S Undersize
UL Underwriters Laboratory
V Volts
©2013 HYSTER COMPANY See Service Manual
for service procedures.
vii
UNIT CODE K160
EUROPE 04/2013
HOW TO USE THE ILLUSTRATED PARTS MANUAL
This parts manual describes and illustrates assemblies,
subassemblies, and detail parts needed for service
replacement.
The different constructions are indicated by keys and
footnotes. The callouts correspond to descriptions
found on the next page.
viii
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
HOW TO FIND THE DESIRED PART NUMBER
WHEN THE PART NUMBER AND THE NEXT
HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part
required. Turn to the Sections Page. Choose the
general area of reference most likely to include the
part.
2. Turn to the section you chose. Use the Section
Table of Contents to determine the assembly
which would normally contain the part required.
Then locate the part on the assembly breakdown
page.
WHEN THE PART NUMBER IS NOT KNOWN
AND THE NEXT HIGHER ASSEMBLY IS
KNOWN:
3. Determine the assembly the required part is used
on. Turn to the Table of Contents (Page i).
4. Locate the assembly the required part is used on
and turn to the page indicated for that assembly.
Then locate the part on the assembly breakdown
page.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 12-1) to find the
part number. Turn to the page listed and locate the
part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers,
descriptions, quantities required, keys and
footnotes to help in selecting correct parts.
6. Parts Supersession Information. Part numbers that
have this history will be displayed in the parts list
in the order that they were superseded (from oldest
to newest). The superseded part numbers will be
shown with a line through them.
Five periods in the PART NO. column (. . . . .)
indicate that the part is either Not Serviced
Separately or there is a reference to another figure.
A figure reference is denoted by a pointing hand
followed by a figure number in the DESCRIPTION
column (FFigure 10)
7. Keys are used to show two or more similar
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E"
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..)
indicate that the part is not used for that assembly.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and
subparts of assemblies. In the example on the
previous page, BEARING CAP (Item 2) is a
subpart of the major assembly CASE.
9. Quantities shown are for one assembly. The
quantities of the subpart BEARING CAP are
indicated as two and two. This means two per
CASE assembly.
10. Serial number breaks identify the most current
parts information and are shown as follows:
→ S/N D001H2628
Indicates last serial number affected.
S/N D001H2629 →
Indicates the first serial number affected.
S/N D001H1553 ↔ S/N D001H3291
Indicates a range of serial numbers affected.
ECN numbers for pending serial numbers are
shown to allow for the inclusion of the most current
parts information and are identified as follows:
→ S/N Pending Per ECN 63243
Indicates a pending serial number for last unit
affected.
S/N Pending Per ECN 63243 →
Indicates a pending serial number for first unit
affected.
Date breaks are used to indicate when a change
occurred but a subsequent serial number break
was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
follows:
→ D/B 3/00
Indicates that a change occurred sometime
within that month for the item affected.
D/B 3/00 →
Indicates that a change occurred sometime
within that month for the item affected.
D/B 3/00 ↔ D/B 4/00
Indicates a range of production dates of the item
affected.
Contact your local dealer for Hyster lift trucks for
serial number information for items with a ECN or
a date break.
ORDERING PARTS:
When ordering replacement parts, give the unit serial
number, part number, name of part and quantity
required.
For any further information on parts, service, or
ordering, consult your local dealer for Hyster lift trucks.
©2013 HYSTER COMPANY See Service Manual
for service procedures.
ix
UNIT CODE K160
EUROPE 04/2013
IDENTIFICATION OF TRUCK SERIAL NUMBERS
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Hyster lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
x
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
UNIT CODE K160
04/2013
EUROPE
IDENTIFICATION OF MAST SERIAL NUMBERS
(1) and (2) The first letter and number indicates the mast unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
LIFT EQUIPMENT IDENTIFICATION
1. Fork part number, capacity rating, plant code letter,
and date of manufacture are stamped
approximately six inches below the top of most
forks.
2. The carriage group number is stamped on the right
hand side of the top crossmember (pin type) or on
the back of the right hand end of the bottom
crossmember (hook type). A date code has two
letters in line with or below the carriage group
number.
3. The mast identification number has a unit code, a
letter indicating the plant of manufacture, and a
serial number. Underneath the production
sequence number is a four digit number that
indicates the carriage travel in millimeters.
4. Tilt and lift cylinder group numbers are stamped on
the cylinder shell.
Always refer to the group, serial, or part number
when ordering service parts.
Modification of masts and carriages by SPED
(Special Products Engineering Department) are
identified by a model prefix code beginning with the
letter "S". contact your dealer for Hyster lift trucks
for information on these assemblies.
©2013 HYSTER COMPANY See Service Manual
for service procedures.
xi
UNIT CODE K160
EUROPE 04/2013
IDENTIFICATION OF ATTACHMENT AND SIDE-
SHIFT CARRIAGE SERIAL NUMBERS
(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify
the attachment.
Always refer to the group, serial, or part number when ordering service parts.
Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are
identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for information
on these assemblies.
xii
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
PUBLICATIONS
Every new lift truck is provided with an OPERATING
MANUAL. This manual has information that the
operator must know for inspection and operation of the
lift truck.
MANUALS with complete replacement part
identification, are available at a nominal fee from your
Hyster dealer to assist users in effectively maintaining
Hyster lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide
for this model lift truck.
service and overhaul procedures, and PARTS
PUBLICATION HYSTER PART NUMBER
Operating Manual........................................................................................................................ 1688715
Service Manual (Complete)......................................................................................................... 1689930
Parts Manual............................................................................................................................... 1674207
©2013 HYSTER COMPANY See Service Manual
for service procedures.
xiii
UNIT CODE K160
EUROPE 04/2013
NOTES
xiv
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
1 FRAME
04/2013
UNIT CODE K160
EUROPE
SECTION 1
FRAME
DESCRIPTION PAGE
ARMREST SLIDER ASSEMBLY
→ 9/2010 .................................................................................................................................................... 1-102
9/2010 → .................................................................................................................................................... 1-104
BATTERY RETENTION
→ S/N K160B03069J ................................................................................................................................. 1-60
S/N K160B03070J → ................................................................................................................................. 1-62
BATTERY TRAY OPTIONS
DROP-IN ..................................................................................................................................................... 1-54
SIDE REMOVAL (S/N K160B03070J →) ................................................................................................... 1-58
SIDE-REMOVAL (→ S/N K160B03069J) ................................................................................................... 1-56
CAB
FRONT PANEL ASSEMBLY ....................................................................................................................... 1-20
FRONT WIPER ASSEMBLY ....................................................................................................................... 1-28
HEADLINER ASSEMBLY ........................................................................................................................... 1-30
HEATER ...................................................................................................................................................... 1-32
HEATER ASSEMBLY ................................................................................................................................. 1-34
HEATER ASSEMBLY - ALTERNATE HEATER ......................................................................................... 1-36
PVC DOORS ............................................................................................................................................... 1-6
REAR PANEL AND WIPER ATTACHMENT ............................................................................................... 1-24
REAR PANEL ASSEMBLY ......................................................................................................................... 1-26
STEEL DOOR ASSEMBLY - RIGHT HAND ............................................................................................... 1-12
STEEL DOOR ASSEMBLY - LEFT HAND .................................................................................................. 1-14
STEEL DOORS ........................................................................................................................................... 1-10
TOP PANEL ASSEMBLY ............................................................................................................................ 1-22
WINDOW - STEEL DOOR, RIGHT HAND .................................................................................................. 1-16
WINDOW - STEEL DOOR, LEFT HAND .................................................................................................... 1-18
CAB ASSEMBLY
FULL STEEL CAB ....................................................................................................................................... 1-8
WITH PVC DOORS ..................................................................................................................................... 1-4
COUNTERWEIGHT ........................................................................................................................................ 1-64
COWL MOUNT
→ S/N K160B03069J ................................................................................................................................. 1-70
S/N K160B03070J → ................................................................................................................................. 1-72
DASH AND STEERING COLUMN COVERS
FIXED COLUMN ......................................................................................................................................... 1-76
TELESCOPIC COLUMN ............................................................................................................................. 1-78
FLOOR PLATES ............................................................................................................................................. 1-74
FORKS ............................................................................................................................................................ 1-86
OPTIONAL .................................................................................................................................................. 1-87
HOOD AND COUNTERWEIGHT COVER
LATE PRODUCTION .................................................................................................................................. 1-42
WITH RAPID CHARGE OPTION ................................................................................................................ 1-46
HOOD AND COVERS
EARLY PRODUCTION ............................................................................................................................... 1-38
LABELS
EXTERIOR .................................................................................................................................................. 1-80
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-84
INTERIOR ................................................................................................................................................... 1-82
LOAD BACKREST EXTENSION ..................................................................................................................... 1-88
©2013 HYSTER COMPANY See Service Manual
for service procedures.
1-1
UNIT CODE K160
EUROPE 04/2013
SECTION 1
FRAME
DESCRIPTION PAGE
OVERHEAD GUARD
→ S/N K160B03069J ................................................................................................................................. 1-66
S/N K160B03070J → ................................................................................................................................. 1-68
SEAT
FULL SUSPENSION - SHEET 1 0F 2 ......................................................................................................... 1-90
FULL SUSPENSION - SHEET 2 OF 2 ........................................................................................................ 1-94
FULL SUSPENSION, HIGH BACK - SHEET 1 0F 2 ................................................................................... 1-96
FULL SUSPENSION, HIGH BACK - SHEET 2 OF 2 .................................................................................. 1-100
SIDE PANELS ................................................................................................................................................. 1-50
STATIC STRAP ............................................................................................................................................... 1-106
1-2
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
NOTES
©2013 HYSTER COMPANY See Service Manual
for service procedures.
1-3
UNIT CODE K160
EUROPE 04/2013
CAB ASSEMBLY (FIGURE 1-1)
WITH PVC DOORS
1-4
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
CAB ASSEMBLY
WITH PVC DOORS
KEY:
A: 546mm Battery Compartment
B: 642mm Battery Compartment
C: 750mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
1 1662391 Kit-Front Screen (Front Panel Assembly) (FFigure 1-9)..................
2 1661959 Cab (Top Panel Assembly) (FFigure 1-10)......................................
2 1661960 Cab (Top Panel Assembly) (FFigure 1-10)......................................
2 1661961 Cab (Top Panel Assembly) (FFigure 1-10)......................................
3 2107017 Cab (Door Assembly, PVC) (FFigure 1-2).......................................
3 2107018 Cab (Door Assembly, PVC) (FFigure 1-2).......................................
3 2107019 Cab (Door Assembly, PVC) (FFigure 1-2).......................................
4 1661962 Cab (Rear Panel Assembly) (Standard Hood) (FFigure 1-12).........
4 1661963 Kit-Rear Screen (Low Hood) (FFigure 1-12)....................................
5 2107023 Kit-Window Washer (FFigure 1-13)..................................................
6 2107020 Headliner (FFigure 1-14)..................................................................
6 2107021 Headliner (FFigure 1-14)..................................................................
6 2107022 Headliner (FFigure 1-14)..................................................................
1 1 1
1 .. ..
.. 1 ..
.. .. 1
1 .. ..
.. 1 ..
.. .. 1
1 1 1
1 1 1
1 1 1
1 .. ..
.. 1 ..
.. .. 1
©2013 HYSTER COMPANY See Service Manual
for service procedures.
1-5
UNIT CODE K160
EUROPE 04/2013
CAB (FIGURE 1-2)
PVC DOORS
1-6
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
CAB
PVC DOORS
KEY:
A: 546mm Battery Compartment
B: 642mm Battery Compartment
C: 750mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
2107017 Cab (Door Assembly, PVC) ............................................................... 1 .. ..
2107018 Cab (Door Assembly, PVC) ............................................................... .. 1 ..
2107019 Cab (Door Assembly, PVC) ............................................................... .. .. 1
1 4001966 Door Pvc (LH) ............................................................................... 1 .. ..
1 4001978 Door Pvc (LH) ............................................................................... .. 1 ..
1 4001983 Door Pvc (LH) ............................................................................... .. .. 1
2 4001967 Door Pvc (RH) ............................................................................... 1 .. ..
2 4001979 Door Pvc (RH) ............................................................................... .. 1 ..
2 4001984 Door Pvc (RH) ............................................................................... .. .. 1
3 4001971 Channel ......................................................................................... 1 1 1
4 4001970 Channel ......................................................................................... 1 .. ..
4 4001980 Channel ......................................................................................... .. 1 ..
4 4001985 Channel ......................................................................................... .. .. 1
5 4001969 Channel ......................................................................................... 1 1 1
6 4001975 Channel ......................................................................................... 1 1 1
7 4001974 Channel ......................................................................................... 1 .. ..
7 4001982 Channel ......................................................................................... .. 1 ..
7 4001987 Channel ......................................................................................... .. .. 1
8 4001973 Channel ......................................................................................... 1 .. ..
8 4001981 Channel ......................................................................................... .. 1 ..
8 4001986 Channel ......................................................................................... .. .. 1
9 4001972 Channel ......................................................................................... 1 1 1
10 4001968 Plate .............................................................................................. 1 1 1
11 2109965 Capscrew .......................................................................................... 19 19 19
a 4001977 Tape .................................................................................................. AR AR AR
4000295 Kit (Door Mounting) ........................................................................... 1 1 1
FOOTNOTES:
a Not Illustrated
©2013 HYSTER COMPANY See Service Manual
for service procedures.
1-7
UNIT CODE K160
EUROPE 04/2013
CAB ASSEMBLY (FIGURE 1-3)
FULL STEEL CAB
1-8
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
04/2013
UNIT CODE K160
EUROPE
CAB ASSEMBLY
FULL STEEL CAB
KEY:
A: 546 mm Battery Compartment
B: 642 mm Battery Compartment
C: 750 mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
1 1662391 Kit-Front Screen (Front Panel Assembly) (FFigure 1-9)..................
2 1661959 Cab (Top Panel Assembly) (FFigure 1-10)......................................
2 1661960 Cab (Top Panel Assembly) (FFigure 1-10)......................................
2 1661961 Cab (Top Panel Assembly) (FFigure 1-10)......................................
3 1661964 Cab (Door Assembly) (FFigure 1-4).................................................
3 1661965 Cab (Door Assembly) (FFigure 1-4).................................................
3 1661967 Cab (Door Assembly) (FFigure 1-4).................................................
4 1661962 Cab (Rear Panel Assembly) (Standard Hood) (FFigure 1-12,
FFigure 1-11)....................................................................................
4 1661963 Kit-Rear Screen (Low Hood) (FFigure 1-12, FFigure 1-11)............
5 2107023 Kit-Window Washer (FFigure 1-13)..................................................
6 2107020 Headliner (FFigure 1-14)..................................................................
6 2107021 Headliner (FFigure 1-14)..................................................................
6 2107022 Headliner (FFigure 1-14)..................................................................
1 1 1
1 .. ..
.. 1 ..
.. .. 1
2 .. ..
.. 2 ..
.. .. 2
1 1 1
1 1 1
1 1 1
1 .. ..
.. 1 ..
.. .. 1
©2013 HYSTER COMPANY See Service Manual
for service procedures.
1-9
UNIT CODE K160
EUROPE 04/2013
CAB (FIGURE 1-4)
STEEL DOORS
1-10
See Service Manual
for service procedures.
©2013 HYSTER COMPANY
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