Hyster B160 (J25-35BS) Service Manual

Description

• Model List:
  • B160 (J25-35BS)

• 1. INTRODUCTION
• 2. GENERAL
• 3. LEAD-ACID BATTERIES
• 4. SPECIFIC GRAVITY
• 5. THE CHEMICAL REACTION IN A CELL
• 6. ELECTRICAL TERMS
• 7. HOW TO SELECT THE BATTERY
• 8. VOLTAGE OF A BATTERY
• 9. THE BATTERY AS A COUNTERWEIGHT
• 10. BATTERY RATINGS
• 11. Kilowatt-Hours
• 12. BATTERY MAINTENANCE
• 13. SAFETY PROCEDURES
• 14. MAINTENACE RECORDS
• 15. THE NEW BATTERY
• 16. HOW TO CLEAN THE BATTERY
• 17. HOW TO ADD WATER
• 18. THE HYDROMETER
• 19. BATTERY TEMPERATURE
• 20. CHARGING THE BATTERY
• 21. Types Of Battery Charges
• 22. Methods Of Charging
• 23. Troubleshooting The Charger
• 24. How To Know When The Battery Is Fully Charged
• 25. WHERE TO CHARGE THE BATTERIES
• 26. Equipment Needed
• 27. BATTERY CONNECTORS
• 28. BATTERY CARE
• 29. INTRODUCTION
• 30. General
• 31. Description
• 32. DISASSEMBLY AND ASSEMBLY
• 33. Overhead Guard
• 34. Hood and Seat Assembly
• 35. Counterweight
• 36. Hydraulic Tank Repairs
• 37. Decal Replacement
• 38. INTRODUCTION
• 39. GENERAL
• 40. DESCRIPTION
• 41. OPERATION
• 42. REPAIRS
• 43. STEERING WHEEL AND COLUMN ASSEMBLY
• 44. TYPE A STEERING COLUMN ASSEMBLY
• 45. Removal And Disassembly
• 46. Assembly And Installation
• 47. TYPE A STEERING COLUMN
• 48. TYPE A STEERING COLUMN
• 49. TYPE B STEERING COLUMN
• 50. Removal And Disassembly
• 51. Assembly And Installation
• 52. TYPE B STEERING COLUMN
• 53. Disassembly of Steering Control Unit
• 54. Cleaning of Steering Control Unit
• 55. Assembly of Steering Control Unit
• 56. CHECKS AND ADJUSTMENTS
• 57. REMOVE AIR FROM THE SYSTEM
• 58. TROUBLESHOOTING
• 59. INTRODUCTION
• 60. GENERAL
• 61. DESCRIPTION
• 62. REPAIRS
• 63. REMOVAL AND DISASSEMBLY
• 64. CLEANING
• 65. ASSEMBLY
• 66. CHECKS AND ADJUSTMENTS
• 67. DC Motor Maintenance
• 68. Safety Precautions Maintenance and Repair
• 69. General
• 70. Brush and Commutator Inspection
• 71. Hydraulic Pump Motor and Traction Motor
• 72. Steering Pump Motor
• 73. Normal Commutator Surface
• 74. Commutator Problems
• 75. Brush Replacement
• 76. Stoning the Commutator
• 77. Motors Repair
• 78. Disassemble
• 79. Traction Motor and Hydraulic Pump Motor
• 80. Steering Pump Motor
• 81. Assemble
• 82. Traction Motor and Hydraulic Pump Motor
• 83. Steering Pump Motor
• 84. Brush Alignment, Traction and Hydraulic Motors
• 85. Tests for Damaged Field and Armature
• 86. Test for an Open Circuit in Armature
• 87. Test for Short Circuit in One Armature Winding
• 88. Test for Short Circuit to Armature Shaft
• 89. Test for Open Circuit in Field Coil
• 90. Test for Short Circuit in Field Coil
• 91. Test for Short Circuit between Field and Motor Case
• 92. Brush Holder Test
• 93. Troubleshooting
• 94. Table 1. Normal Commutator Surfaces
• 95. Table 2. Commutator Problems
• 96. Table 3. Brush Wear Replacement Guide
• 97. INTRODUCTION
• 98. GENERAL
• 99. SERIAL NUMBER DATA
• 100. HOW TO MOVE A DISABLED LIFT TRUCK
• 101. How To Tow A Lift Truck
• 102. RELEASE THE SEAT BRAKE ON A DISABLED LIFT TRUCK
• 103. HOW TO PUT A LIFT TRUCK ON BLOCKS
• 104. HOW TO RAISE THE DRIVE TIRES
• 105. How to Raise the Steering Tires
• 106. MAINTENANCE SCHEDULE
• 107. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 108. CHECKS BEFORE OPERATION
• 109. HOW TO MAKE CHECKS WITH THE KEY OFF
• 110. Tires And Wheels
• 111. Fork Adjustment
• 112. Hook Fork, Removal
• 113. Hook Fork, Installation
• 114. Inspection Of Mast, Forks, And Lift Chains
• 115. Safety Labels
• 116. Operator Restraint System
• 117. Check The Operation
• 118. Battery Restraint System
• 119. Battery
• 120. Hydraulic System
• 121. HOW TO MAKE CHECKS WITH THE KEY ON
• 122. Gauges And Horn
• 123. Steering System
• 124. Service Brakes
• 125. Parking Brake
• 126. Control Levers And Pedals
• 127. Lift System Operation
• 128. EVERY 350 HOURS OR TWO MONTHS
• 129. HYDRAULIC TANK BREATHER
• 130. TRANSAXLE
• 131. WHEEL NUT TORQUE
• 132. LIFT CHAINS
• 133. Check for Wear
• 134. Lubrication
• 135. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 136. SEAT BRAKE
• 137. BRAKE FLUID
• 138. OTHER LUBRICATION
• 139. ELECTRICAL INSPECTION
• 140. CONTACTORS
• 141. MOTOR BRUSHES
• 142. HOURS OR YEARLY
• 143. HYDRAULIC SYSTEM
• 144. CHANGE THE OIL FILTER
• 145. CHANGE THE HYDRAULIC OIL
• 146. TRANSAXLE
• 147. STEERING SYSTEM
• 148. Manual Steering
• 149. Power Steering
• 150. CONTACTORS
• 151. LIFT CHAINS
• 152. GENERAL PROCEDURES
• 153. HOW TO CHARGE THE BATTERY
• 154. HOW TO CHANGE THE BATTERY
• 155. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 156. Check the Lift Cylinders for Leaks
• 157. Check the Tilt Cylinders for Leaks
• 158. WELDING REPAIRS
• 159. CHANGES TO THE OVERHEAD GUARD
• 160. LIFT CHAIN ADJUSTMENTS
• 161. HOW TO CHECK THE PMT CIRCUIT
• 162. WHEELS AND TIRES
• 163. How To Change A Solid Rubber (Press-on) Tire
• 164. How To Repair A Pneumatic Tire
• 165. How To Remove A Wheel From The Lift Truck
• 166. How To Remove Tire From The Wheel
• 167. How To Install The Tire On The Wheel
• 168. Add Air To The Tires
• 169. How To Install The Wheel
• 170. Solid Rubber Tires That Look Like Pneumatic Tires
• 171. Remove The Wheels From The Lift Truck
• 172. Remove The Tire From The Wheel
• 173. Install The Tire On The Wheel
• 174. REFERENCE TABLE
• 175.
• 175.1. INTRODUCTION
• 175.1.1. General
• 175.1.2. Description
• 175.2. REPAIRS
• 175.2.1. Removal
• 175.2.2. Disassembly
• 175.2.3. Assembly
• 175.2.4. Installation
• 175.3. WHEELS AND TIRES
• 175.3.1. Description
• 175.4. TROUBLESHOOTING
• 176.
• 176.1. STEERING CONTROL UNIT
• 176.1.1. GENERAL
• 176.1.2. DESCRIPTION
• 176.1.3. DISASSEMBLY AND INSPECTION
• 176.1.4. ASSEMBLY
• 176.2. TROUBLESHOOTING
• 177.
• 177.1. INTRODUCTION
• 177.1.1. GENERAL
• 177.1.2. DESCRIPTION
• 177.2. STEERING WHEEL AND COLUMN ASSEMBLY
• 177.2.1. STEERING WHEEL AND HORN
• 177.2.2. STEERING CONTROL UNIT
• 177.3. POWER STEERING MOTOR AND PUMP
• 177.3.1. DESCRIPTION
• 177.3.2. REMOVAL AND DISASSEMBLY
• 177.3.3. ASSEMBLY AND INSTALLATION
• 177.3.4. REPAIRS, POWER STEERING PUMP
• 177.4. HYDRAULIC STEERING MOTOR
• 177.4.1. DESCRIPTION
• 177.4.2. REPAIRS, HYDRAULIC STEERING MOTOR
• 177.5. STEERING TRUNNION ASSEMBLY
• 177.5.1. TRUNNION AND WHEEL ASSEMBLY
• 177.6. CHECKS AND ADJUSTMENTS
• 177.6.1. Air In The Steering System
• 177.7. TROUBLESHOOTING
• 178.
• 178.1. INTRODUCTION
• 178.1.1. General
• 178.1.2. Description
• 178.2. REPAIRS
• 178.2.1. Service Brakes
• 178.2.2. Parking Brake
• 178.2.3. Seat Brake
• 178.3. CHECKS AND ADJUSTMENTS
• 178.3.1. Removing Air From The Service Brakes
• 178.3.2. Brake Pedal Adjustment
• 178.3.3. Adjustment Of The Parking Brake Linkage
• 178.3.4. Adjustment Of The Seat Brake
• 178.3.5. Adjustment Of The Friction Pads
• 178.4. TROUBLESHOOTING
• 179.
• 179.1. INTRODUCTION
• 179.1.1. General
• 179.2. HYDRAULIC SYSTEM
• 179.2.1. Hydraulic System (Early Production Lift Trucks)
• 179.2.2. Hydraulic System (Later Production Lift Trucks)
• 179.3. MAIN CONTROL VALVE
• 179.3.1. Main Control Valve (Early Production Lift Trucks)
• 179.3.2. Repairs
• 179.3.3. Main Control Valve (Later Production Lift Trucks)
• 179.3.4. Repairs
• 179.3.5. Checks and Adjustments
• 179.4. HYDRAULIC PUMP
• 179.4.1. Description
• 179.4.2. Repairs
• 179.5. TROUBLESHOOTING (HYDRAULIC PUMP)
• 179.6. TROUBLESHOOTING (MAIN CONTROL VALVE)
• 179.7. SPECIFICATIONS
• 180.
• 181.
• 182.
• 182.1. INTRODUCTION
• 182.1.1. General
• 182.2. CONTROL SWITCHES
• 182.2.1. Steering Switches
• 182.2.2. MONOTROL and Accelerator Pedal Adjustments
• 182.2.3. Later Production MONTROL
• 182.2.4. FORWARD and REVERSE Switch (Steering Column)
• 182.2.5. Brake Switch
• 182.2.6. Seat Switch
• 182.2.7. Hydraulic Pump Switches
• 182.3. EV-100 DUAL MOTOR CONTROLLER
• 182.3.1. Control Card
• 182.3.2. Checking An SCR
• 182.3.3. The OFF Circuit For SCR 1
• 182.3.4. Diodes D3 and D4
• 182.3.5. Motor Current Sensor
• 182.3.6. The Electronic Driver Module
• 182.3.7. Contactors
• 182.3.8. Contactor Repair
• 182.3.9. Control Card Adjustments
• 183.
• 183.1. INTRODUCTION
• 183.1.1. General
• 183.2. SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)
• 183.2.1. Static Return To Off (SRO) Circuit
• 183.2.2. Pulse Monitor Trip (PMT)
• 183.2.3. Sequence of Operation
• 183.2.4. Checking For Correct Operation
• 183.3. TROUBLESHOOTING
• 183.3.1. General Procedures
• 183.3.2. Fault Guide
• 184.
• 185.
• 186.
• 186.1. INTRODUCTION
• 186.1.1. GENERAL
• 186.1.2. INDICATORS WITH METER MOVEMENT
• 186.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
• 186.2. CHECKS AND ADJUSTMENTS
• 186.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
• 186.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
• 186.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
• 186.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
• 186.2.5. LED DISPLAY WITH LIFT INTERRUPT
• 186.2.6. CHECKING CURTIS 933-1 METER
• 186.2.7. ADJUSTMENT OF CURTIS 933-1 METER
• 186.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
• 186.3. CURTIS DASH DISPLAY ASSEMBLY
• 186.3.1. Description/Features
• 186.3.2. Operation
• 186.3.3. Testing
• 186.4. REPAIRS
• 186.4.1. BATTERY INDICATORS
• 186.4.2. CONTROLLER FOR THE BATTERY INDICATOR
• 186.4.3. DISPLAY PANEL COMPONENTS
• 186.4.4. REPLACING SEM DISPLAY PANEL
• 186.4.5. SEM DISPLAY PANEL REMOVAL
• 187.
• 188.
• 188.1. INTRODUCTION
• 188.1.1. GENERAL
• 188.1.2. MAST WELDMENTS
• 188.1.3. CARRIAGE
• 188.1.4. MAST MOUNTS
• 188.2. VISTA TWO-STAGE MAST
• 188.2.1. DESCRIPTION AND OPERATION
• 188.3. VISTA FREE-LIFT MAST
• 188.3.1. DESCRIPTION
• 188.3.2. OPERATION
• 188.4. VISTA THREE-STAGE MAST
• 188.4.1. DESCRIPTION
• 188.4.2. OPERATION
• 188.5. VISTA FOUR-STAGE MAST
• 188.5.1. DESCRIPTION
• 188.5.2. OPERATION
• 189.
• 189.1. VISTA MAST, REPAIR
• 189.1.1. GENERAL
• 189.1.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 189.1.3. CARRIAGE
• 189.1.4. SIDE-SHIFT CARRIAGE (EARLIER DESIGN)
• 189.1.5. SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)
• 189.2. CHECKS AND ADJUSTMENTS
• 189.2.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 189.2.2. ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
• 189.2.3. LIFT CHAIN ADJUSTMENTS
• 189.2.4. MAST ADJUSTMENTS
• 189.2.5. CARRIAGE ADJUSTMENT
• 189.2.6. HEADER HOSE ARRANGEMENTS
• 189.3. TROUBLESHOOTING
• 190.
• 191.
• 192.
• 192.1. FIGURE 1. EV-100 SCHEMATIC DIAGRAM, DUAL MOTOR CONTROLLER
• 192.2. FIGURE 2. EV-100 WIRE DIAGRAM, DUAL MOTOR CONTROLLER
• 192.3. FIGURE 3. EV-100 WIRE DIAGRAM, CONTROL SWITCHES
• 192.4. FIGURE 4. EV-100 LX SCHEMATIC DIAGRAM, DUAL MOTOR CONTROLLER
• 192.5. FIGURE 5. EV-100 LX WIRE DIAGRAM, DUAL MOTOR CONTROLLER
• 192.6. FIGURE 6. EV-100 LX WIRE DIAGRAM, CONTROL SWITCHES
• 192.7. FIGURE 7. CABLE DIAGRAM
• 192.8. FIGURE 8. ARRANGEMENT, ELECTRIC CONTROL
• 192.9. FIGURE 9. HYDRAULIC SYSTEM (EARLY PRODUCTION LIFT TRUCKS)
• 192.10. FIGURE 10. HYDRAULIC SCHEMATIC (EARLY PRODUCTION LIFT TRUCKS)
• 192.11. FIGURE 11. HYDRAULIC SYSTEM (LATER PRODUCTION LIFT TRUCKS)
• 192.12. FIGURE 12. HYDRAULIC SCHEMATIC (LATER PRODUCTION LIFT TRUCKS)