Hyster C160 (J30-40XMT) Service Manual

Description

• Model List:
  • C160 (J30-40XMT)

• 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. REPAIRS
• 33. OVERHEAD GUARD
• 34. Removal
• 35. Installation
• 36. HOOD AND SEAT ASSEMBLY
• 37. Removal
• 38. Installation
• 39. COUNTERWEIGHT
• 40. Removal
• 41. Installation
• 42. HYDRAULIC TANK
• 43. Inspection
• 44. Repairs, Small Leaks
• 45. Repairs. Large Leaks
• 46. Cleaning
• 47. Steam Method Of Cleaning
• 48. Chemical Solution Method of Cleaning
• 49. Additional Preparations For Repair
• 50. SAFETY LABELS
• 51. BATTERY SIZE SPECIFICATIONS
• 52. DC Motor Maintenance
• 53. Safety Precautions Maintenance and Repair
• 54. General
• 55. Brush and Commutator Inspection
• 56. Hydraulic Pump Motor and Traction Motor
• 57. Steering Pump Motor
• 58. Normal Commutator Surface
• 59. Commutator Problems
• 60. Brush Replacement
• 61. Stoning the Commutator
• 62. Motors Repair
• 63. Disassemble
• 64. Traction Motor and Hydraulic Pump Motor
• 65. Steering Pump Motor
• 66. Assemble
• 67. Traction Motor and Hydraulic Pump Motor
• 68. Steering Pump Motor
• 69. Brush Alignment, Traction and Hydraulic Motors
• 70. Tests for Damaged Field and Armature
• 71. Test for an Open Circuit in Armature
• 72. Test for Short Circuit in One Armature Winding
• 73. Test for Short Circuit to Armature Shaft
• 74. Test for Open Circuit in Field Coil
• 75. Test for Short Circuit in Field Coil
• 76. Test for Short Circuit between Field and Motor Case
• 77. Brush Holder Test
• 78. Troubleshooting
• 79. Table 1. Normal Commutator Surfaces
• 80. Table 2. Commutator Problems
• 81. Table 3. Brush Wear Replacement Guide
• 82.
• 82.1. INTRODUCTION
• 82.1.1. GENERAL
• 82.1.2. LUBRICATION
• 82.2. REPAIRS
• 82.2.1. REMOVAL
• 82.2.2. INSPECTION
• 82.2.3. INSTALLATION
• 82.3. S2 SERIES TRANSAXLE
• 82.3.1. DISASSEMBLY
• 82.3.2. ASSEMBLY
• 82.4. S1 SERIES TRANSAXLE
• 82.4.1. DISASSEMBLY
• 82.4.2. ASSEMBLY
• 82.5. TROUBLESHOOTING
• 83.
• 83.1. INTRODUCTION
• 83.1.1. GENERAL
• 83.1.2. DESCRIPTION
• 83.1.3. OPERATION
• 83.2. REPAIRS
• 83.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 83.3. CHECKS AND ADJUSTMENTS
• 83.3.1. REMOVE AIR FROM THE SYSTEM
• 83.4. TROUBLESHOOTING
• 84.
• 84.1. INTRODUCTION
• 84.1.1. General
• 84.2. STEERING WHEEL AND COLUMN ASSEMBLY
• 84.2.1. DESCRIPTION
• 84.3. POWER STEERING PUMP AND MOTOR
• 84.3.1. DESCRIPTION
• 84.3.2. REPAIRS
• 84.4. STEERING TRUNNION ASSEMBLY
• 84.4.1. STEER AXLE
• 84.4.2. WHEEL ASSEMBLY
• 84.4.3. WHEEL HUB
• 84.4.4. STEER AXLE ASSEMBLY
• 84.4.5. POWER STEERING CYLINDER
• 84.5. CHECKS AND ADJUSTMENTS
• 84.5.1. Air In The Steering System
• 84.6. TROUBLESHOOTING
• 85.
• 85.1. INTRODUCTION
• 85.1.1. GENERAL
• 85.1.2. DESCRIPTION
• 85.1.3. OPERATION
• 85.2. REPAIRS
• 85.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 85.3. CHECKS AND ADJUSTMENTS
• 85.3.1. REMOVE AIR FROM THE SYSTEM
• 85.4. TROUBLESHOOTING
• 86.
• 86.1. INTRODUCTION
• 86.1.1. GENERAL
• 86.1.2. DESCRIPTION
• 86.2. REPAIRS
• 86.2.1. SERVICE BRAKE PADS
• 86.2.2. SERVICE BRAKE CALIPER
• 86.2.3. PARK BRAKE CALIPER
• 86.2.4. MASTER CYLINDER
• 86.2.5. FOOT OPERATED PARK BRAKE LEVER ASSEMBLY
• 86.2.6. ELECTRICALLY RELEASED PARK BRAKE
• 86.2.7. ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS
• 86.3. CHECKS AND ADJUSTMENTS
• 86.3.1. PARK BRAKE ADJUSTMENT
• 86.3.2. SERVICE BRAKE ADJUSTMENT
• 86.3.3. REMOVE AIR FROM BRAKE SYSTEM
• 86.4. TROUBLESHOOTING
• 87.
• 87.1. INTRODUCTION
• 87.1.1. GENERAL
• 87.1.2. DESCRIPTION
• 87.1.3. OPERATION
• 87.2. REPAIRS
• 87.2.1. MAIN CONTROL VALVE
• 87.3. CHECKS AND ADJUSTMENTS
• 87.3.1. RELIEF VALVE
• 87.3.2. VANE SETTINGS
• 87.3.3. MAST TILT ADJUSTMENT
• 87.4. TROUBLESHOOTING
• 88.
• 89.
• 89.1. ELECTRICAL WARNING DEVICES
• 89.1.1. GENERAL
• 89.1.2. DESCRIPTION
• 89.1.3. REPLACEMENT
• 90.
• 91.
• 91.1. INTRODUCTION
• 91.1.1. GENERAL
• 91.2. DESCRIPTION
• 91.2.1. INSTRUMENT PANELS
• 91.2.2. PRINTED CIRCUIT BOARDS
• 91.3. REPLACEMENT
• 91.3.1. INSTRUMENT PANEL COMPONENTS
• 91.3.2. PRINTED CIRCUIT BOARDS
• 91.3.3. OTHER CONTROL COMPONENTS
• 91.4. CHECKS AND ADJUSTMENTS
• 91.4.1. CONTROL AND POWER FUSES
• 91.4.2. CHECK ACCELERATOR SWITCH ASSEMBLY
• 91.4.3. ADJUSTING STOP LIGHT SWITCH
• 91.4.4. CHECK SEAT SWITCH
• 91.4.5. ADJUSTING PARKING BRAKE SWITCH
• 91.4.6. DIRECTION SWITCHES (MONOTROL PEDAL)
• 91.4.7. DIRECTION SWITCHES (STEERING COLUMN)
• 91.4.8. HYDRAULIC CUT OFF SWITCH
• 91.4.9. PRINTED CIRCUIT BOARDS
• 91.4.10. Steering Angle Control Board
• 91.4.11. Lift Pump Control Board
• 91.4.12. Bypassing the Lift Pump Control Board
• 92.
• 93.
• 93.1. INTRODUCTION
• 93.1.1. GENERAL
• 93.1.2. DESCRIPTION AND OPERATION
• 93.1.3. TWO-STAGE MAST, LIMITED FREE-LIFT
• 93.1.4. TWO-STAGE MAST, FULL FREE-LIFT
• 93.1.5. THREE-STAGE, FULL FREE-LIFT MAST
• 94.
• 94.1. INTRODUCTION
• 94.1.1. GENERAL
• 94.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 94.3. REPAIRS
• 94.3.1. Removal
• 94.3.2. Installation
• 94.3.3. CARRIAGES
• 94.3.4. LIFT CYLINDERS
• 94.3.5. HEADER HOSE ARRANGEMENTS H/S/E/J2.003.20XM (H/S/E/J4065XM) S/E/J2.003.00XL (S/E/J4060XL)
• 94.3.6. HEADER HOSE ARRANGEMENTS H/E1.501.75XM, H/S2.00XMS (H/S/E2535XM, H/S/E40XMS) and J1.602.00XMT (J3040XMT)
• 94.4. CHECKS AND ADJUSTMENTS
• 94.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 94.4.2. ADJUST THE TILT CYLINDERS
• 94.4.3. ADJUST THE LIFT CHAINS
• 94.4.4. ADJUST THE MAST
• 94.4.5. ADJUST THE CARRIAGE
• 94.5. TROUBLESHOOTING
• 95.
• 96.
• 96.1. INTRODUCTION
• 96.1.1. GENERAL
• 96.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
• 96.1.3. HOW TO TOW A LIFT TRUCK
• 96.1.4. HOW TO PUT A LIFT TRUCK ONTO BLOCKS
• 96.2. MAINTENANCE SCHEDULE
• 96.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 96.3.1. CHECKS BEFORE OPERATION
• 96.3.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 96.3.3. CHECK THE OPERATION
• 96.4. EVERY 350 HOURS OR TWO MONTHS
• 96.4.1. HYDRAULIC TANK BREATHER
• 96.4.2. WHEEL NUT TORQUE
• 96.4.3. STEERING TRUNNION MOUNTING CAPSCREW TORQUE
• 96.4.4. TRANSAXLE
• 96.4.5. LIFT SYSTEM OPERATION
• 96.4.6. LIFT CHAINS
• 96.4.7. SAFETY LABELS
• 96.4.8. BRAKE FLUID
• 96.4.9. OTHER LUBRICATION
• 96.4.10. ELECTRICAL INSPECTION
• 96.5. HOURS OR YEARLY
• 96.5.1. HYDRAULIC SYSTEM
• 96.5.2. TRANSAXLE
• 96.6. EVERY 4000 HOURS
• 96.6.1. TRANSAXLE (S2 SERIES ONLY)
• 96.7. GENERAL PROCEDURES
• 96.7.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 96.7.2. LIFT SYSTEM
• 96.7.3. TILT SYSTEM
• 96.7.4. HOW TO CHECK THE PMT CIRCUIT
• 96.7.5. HOW TO CHARGE THE BATTERY
• 96.7.6. HOW TO CHANGE THE BATTERY
• 96.8. WHEELS AND TIRES
• 96.8.1. GENERAL
• 96.8.2. HOW TO CHANGE THE TIRES
• 96.8.3. STEER AND DRIVE WHEELS
• 96.8.4. PNEUMATIC TIRES
• 96.8.5. PNEUMATIC SHAPED SOLID TIRES
• 96.8.6. SOLID TIRES
• 96.8.7. INSTALL THE WHEEL AND TIRE
• 96.8.8. BATTERY SIZE SPECIFICATIONS
• 97.
• 97.1. FIGURE 1. WIRING SCHEMATIC
• 97.2. FIGURE 2. WIRING DIAGRAM
• 97.3. FIGURE 3. WIRING SCHEMATIC WITH SCR HYDRAULICS
• 97.4. FIGURE 4. WIRING DIAGRAM WITH SCR HYDRAULICS
• 97.5. FIGURE 5. OPTIONAL WIRING
• 97.6. FIGURE 6. CABLE DETAILS
• 97.7. FIGURE 7. ARRANGEMENT ELECTRICAL CONTROL WITH SCR HYDRAULICS
• 97.8. FIGURE 8. ARRANGEMENT ELECTRICAL CONTROL WITH CONTACTOR HYDRAULICS
• 97.9. FIGURE 9. ARRANGEMENT, HYDRAULIC SYSTEM
• 97.10. FIGURE 10. HYDRAULIC SCHEMATIC
• 98.