Adjusting the electromagnetic brake on a pallet truck is a job you follow page by page in this 185-page Hyster P1.6 service manual PDF, OEM ID 4138678, which covers four pedestrian tiller operated pallet truck models from P1.6 to P2.2. Wiring diagrams lay out the electrical system, and the same chapter handles the tiller board and module replacement; hydraulic diagrams show the circuit through the pressure regulating valves, cartridge solenoid valves, pressure relief valve and lift pump. The mechanics section deals with the traction wheel, castor wheels, load wheels, tiller and traction motor, and routine maintenance lists oils, lubricants and scheduled service. Fit a 175 A power fuse. Torque the traction wheel retaining nuts to 120 Nm. When your truck throws a DTC code, combi controller alarm or tiller board alarm, the diagnostics chapter covers module connectors and the monitor menu for tracing it. Buy it once; the bookmarked, text-searchable PDF stays yours for this truck.
What's Inside This Hyster P1.6, P1.8, P2.0, P2.2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Information | 1 | Hyster Service Centres, Specialized Technicians, Hyster Service Network |
| Introduction | 2-3 | Service Manuals, Maintenance Guidelines, Safety Rules, Suspension Elements |
| General Safety Rules | 4-12 | Personal Protective Equipment, Workplace Safety, Battery Safety, Suspension Elements, Maintenance Tips |
| Presentation | 13-22 | Truck Presentation, Views of the Truck, Truck Identification Data and Load Capacities (Truck Identification Data Plate, Mast Serial Number Stamp), Location of Documentation |
| Installation and Settings | 23-32 | Truck Unloading, Oil Reservoir, Battery Installation, Battery Cable Connection, Truck Use Conditions |
| Diagnostics and Measurements | 33-60 | Module Connectors, Combi Module, Monitor Menu, DTC Codes, Combi Controller Alarms, Tiller Board Alarms |
| Electrical System | 61-110 | Wiring Diagrams, Electrical Components, Tiller Board, Battery Charge Level Indicator, Configuration Parameters, Module Replacement |
| Hydraulic System | 111-138 | Pressure Regulating Valves, Directional Valves, Hydraulic Diagrams, Pressure Relief Valve, Cartridge Solenoid Valves, Lift Pump |
| Mechanics | 139-165 | Traction Wheel, Castor Wheels Assembly, Load Wheels, Linkage, Tiller, Traction Motor |
| Reducer | 166-170 | Reduction Unit Components, Reduction Unit Removal, Reduction Gear Bearing |
| Routine Maintenance | 171-179 | Oils and Lubricants, Cleaning Products, Scheduled Maintenance |
| Braking System | 180-185 | Electromagnetic Brake Components, Braking System Operation, Electromagnetic Brake Dismantling, Electromagnetic Brake Adjustment |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| M3 Class 8 Torque | 4 Nm | p. 8 |
| M3 Class 10 Torque | 5.2 Nm | p. 8 |
| Traction wheel retaining nuts torque | 120 Nm | p. 141 |
| Valve installation torque | 15 Nm | p. 121 |
| Power fuse | 175 A | p. 68 |
| Voltage | 24V | p. 35 |
| Fuse rating | 4A | p. 103 |
| Power fuse rating | 175A | p. 103 |
| Valve pressure setting adjustment | approx. 35/40 bar for each screw turn | p. 122 |
| Traction wheel fastening nut torque | 120 Nm | p. 141 |
| P1.6, P1.8 | ||
| Unladen weight (P1.6, P1.8) | 545 kg | p. 19 |
| P2.0, P2.2 | ||
| Unladen weight (P2.0, P2.2) | 632 kg | p. 21 |
Hyster P1.6, P1.8, P2.0, P2.2 Common Problems This Manual Covers
Hyster P1.6 to P2.2 pallet truck pump contactor coil fault, Combi controller showing 30001 LiftCoil alarm
Inspect every connector tied to the code, restart, and see if 30001 returns. Following page 48, measure TS11 to B(-); outside 24 ± 2.5 V DC, check wire 239. Measure across the contactor coil contacts; if it is not 55 ± 5.25 ohms, replace the pump contactor, disconnecting the battery first as page 5 requires for electrical work. If nothing turns up, replace the controller.
Manual Section: Combi Controller Alarms (Node 30) p. 48Electromagnetic brake coil wiring or winding fault, Combi controller showing 30035 Brake alarm
Inspect the connectors paired with the code and restart to confirm 30035 is still active. Following page 49, compare the voltage at CPS01 pin 1 to B(-) with CRP04-A pin 1 to B(-); unequal readings point to wire 239. Measure across CRP04-A pins 1 and 2 and replace the brake coil if it is not 23 ± 2.3 ohms. Disconnect the battery before swapping the coil, per page 5.
Manual Section: Combi Controller Alarms (Node 30) p. 49Electromagnetic brake friction disc gap out of adjustment, truck showing weak braking action
Disconnect the battery first; page 4 forbids maintenance work with it connected. Measure the distance between the friction disc and the brake plate, then adjust the electromagnetic brake following page 185 until that distance is no greater than 0.35 mm. If the brake has to come apart, follow the dismantling steps in the Braking System section before resetting the gap.
Manual Section: Braking System p. 185Traction motor phase overcurrent or open circuit, Combi controller logging 30060 Mtr Curr or 30061 Mtr Open
Check battery condition and state of charge, inspect the paired connectors, and restart. Disconnect the battery before working on the phase connections (page 5), then verify the U, V and W phases are tight at the traction motor and Combi controller and test harness continuity as page 50 lays out. Test continuity across U-V, U-W and W-V; any pair without continuity means replace the traction motor. If all pass, replace the Combi controller.
Manual Section: Combi Controller Alarms (Node 30) p. 50Traction motor encoder wiring or encoder fault, Combi controller showing 30062 Encoder alarm
Disconnect encoder connector CPS03 and measure pin 1 to B(-), then pin 1 to pin 4, following page 51; each must read 5 ± 0.5 V DC, or check wires 250 and 102. With CPS01 unplugged, measure CPS01 pin 32 to CPS03 pin 3 and pin 31 to pin 2; above 1 ohm, check wires 578 and 577. Compare MotorSpeed A and B against Controller Frequency.
Manual Section: Combi Controller Alarms (Node 30) p. 51Main contactor jammed closed or contacts soldered, Combi controller showing 30067 MainCont alarm
Inspect the paired connectors and restart. With the key ON, measure TS07 to B(-); outside 24 ± 2.5 V DC, check wire 239, per page 51. With the key OFF, measure B(+) to B(-) at the Combi controller; a 24 ± 2.5 V DC reading means replace the main contactor. Discharge the capacitors before working in the electric compartment, and never file or lubricate contactor contacts (page 172).
Manual Section: Combi Controller Alarms (Node 30) p. 51Frequently Asked Questions
How to clear the error code on a Hyster P1.6/P1.8/P2.0/P2.2 pallet truck?
To clear a fault, first perform a visual inspection of the connectors paired with the error code. Restart the truck to check if the code persists. If the error is related to the fault history, you can reset it by navigating to the 'Faults' menu on the console and selecting 'Clear Fault History'. p. 86
What do the Hyster P1.6/P1.8/P2.0/P2.2 error codes mean?
Error codes are 5-digit numeric codes where the first two digits indicate the affected node (e.g., 30 for Traction Controller, 60 for Tiller Card, 12 for Battery Charger) and the last three digits indicate the specific alarm number. For example, code 30001 indicates a Lift Coil alarm on the Combi controller. p. 46
Why is a Hyster P1.6/P1.8/P2.0/P2.2 not moving or lifting?
If the truck is not moving or lifting, check for error codes on the LCD screen. For example, if the battery charge reaches 20%, fork lifting is inhibited. Additionally, if the traction motor temperature reaches 140°C, the motor lockout is tripped, preventing movement. p. 75
What is the torque specification for the traction wheel retaining nuts on a Hyster P1.6, P1.8, P2.0, P2.2?
The traction wheel retaining nuts must be tightened using a torque wrench to a torque of 120 Nm. p. 141
What is the required torque for the pressure relief valve assembly on the Hyster P1.6, P1.8, P2.0, P2.2?
When installing the pressure relief valve, it must be tightened with a torque wrench to 15 Nm. p. 121
Is this Hyster P1.6 manual a download or a disc?
You download the Service Manual yourself: 185 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Can I print pages of this Hyster P1.6 manual for my own shop?
Yes. Many buyers print one chapter at a time for their own shop and keep the rest on a tablet.
Reviews
There are no reviews yet.