Hyster D160 (J1.60-2.00XMT) Service Manual

Hyster D160 (J1.60-2.00XMT) Service Manual - Image 2

Hyster D160 (J1.60-2.00XMT) Service Manual - Image 3

Hyster D160 (J1.60-2.00XMT) Service Manual - Image 4

Hyster D160 (J1.60-2.00XMT) Service Manual - Image 5

hyster d160 j160 200xmt service manual 2

hyster d160 j160 200xmt service manual 3

Hyster D160 (J1.60-2.00XMT) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 472
Size: 7.1MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- D160 (J1.60-2.00XMT)

1. _2
1.1. INTRODUCTION
1.1.1. GENERAL
1.1.2. LEAD-ACID BATTERIES
1.1.3. SPECIFIC GRAVITY
1.1.4. THE CHEMICAL REACTION IN A CELL
1.2. ELECTRICAL TERMS
1.2.1. HOW TO SELECT THE BATTERY
1.2.2. VOLTAGE OF A BATTERY
1.2.3. THE BATTERY AS A COUNTERWEIGHT
1.2.4. BATTERY RATINGS
1.3. BATTERY MAINTENANCE
1.3.1. SAFETY PROCEDURES
1.3.2. MAINTENACE RECORDS
1.3.3. THE NEW BATTERY
1.3.4. HOW TO CLEAN THE BATTERY
1.3.5. HOW TO ADD WATER
1.3.6. THE HYDROMETER
1.3.7. BATTERY TEMPERATURE
1.3.8. CHARGING THE BATTERY
1.3.9. WHERE TO CHARGE THE BATTERIES
1.3.10. BATTERY CONNECTORS
1.3.11. BATTERY CARE
1.4. INTRODUCTION
1.4.1. GENERAL
1.4.2. DESCRIPTION
1.5. REPAIRS
1.5.1. OVERHEAD GUARD
1.5.2. HOOD AND SEAT ASSEMBLY
1.5.3. COUNTERWEIGHT
1.5.4. AUXILIARY COUNTERWEIGHT
1.5.5. HYDRAULIC TANK
1.5.6. SAFETY LABELS
2. _2
2.1. INTRODUCTION
2.1.1. ELECTRIC MOTOR MAINTENANCE, GENERAL
2.1.2. BRUSH AND COMMUTATOR INSPECTION
2.2. TROUBLESHOOTING
2.2.1. TROUBLESHOOTING
2.2.2. BRUSH REPLACEMENT
2.2.3. DISASSEMBLY OF MOTORS
2.2.4. ASSEMBLY OF MOTORS
2.2.5. BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS
2.2.6. TESTS FOR A DAMAGED FIELD AND ARMATURE
3.
3.1. INTRODUCTION
3.1.1. GENERAL
3.1.2. LUBRICATION
3.2. REPAIRS
3.2.1. REMOVAL
3.2.2. INSPECTION
3.2.3. INSTALLATION
3.3. S2 SERIES TRANSAXLE
3.3.1. DISASSEMBLY
3.3.2. ASSEMBLY
3.4. S1 SERIES TRANSAXLE
3.4.1. DISASSEMBLY
3.4.2. ASSEMBLY
3.5. TROUBLESHOOTING
4. _2
4.1. INTRODUCTION
4.1.1. GENERAL
4.1.2. DESCRIPTION
4.1.3. OPERATION
4.2. REPAIRS
4.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
4.3. CHECKS AND ADJUSTMENTS
4.3.1. REMOVE AIR FROM THE SYSTEM
4.4. TROUBLESHOOTING
5.
5.1. INTRODUCTION
5.1.1. GENERAL
5.2. STEERING WHEEL AND COLUMN ASSEMBLY
5.2.1. DESCRIPTION
5.3. POWER STEERING PUMP AND MOTOR
5.3.1. DESCRIPTION
5.3.2. REPAIRS
5.4. STEERING TRUNNION ASSEMBLY
5.4.1. STEERING AXLE WELDMENT
5.4.2. WHEEL AND TYRE ASSEMBLY
5.4.3. WHEEL HUB ASSEMBLY
5.4.4. STEERING AXLE ASSEMBLY
5.4.5. ROTARY ACTUATOR
5.5. CHECKS AND ADJUSTMENTS
5.5.1. AIR IN THE SYSTEM
5.6. TROUBLESHOOTING
6.
6.1. INTRODUCTION
6.1.1. GENERAL
6.1.2. DESCRIPTION
6.2. REPAIRS
6.2.1. SERVICE BRAKE PADS
6.2.2. SERVICE BRAKE CALIPER
6.2.3. PARK BRAKE CALIPER
6.2.4. MASTER CYLINDER
6.2.5. FOOT OPERATED PARK BRAKE LEVER
6.2.6. ELECTRICALLY RELEASED PARK BRAKE
6.2.7. ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS
6.3. CHECKS AND ADJUSTMENTS
6.3.1. PARK BRAKE ADJUSTMENT
6.3.2. SERVICE BRAKE ADJUSTMENT
6.3.3. REMOVE AIR FROM THE BRAKE SYSTEM
6.4. TROUBLESHOOTING
7.
7.1. INTRODUCTION
7.1.1. GENERAL
7.1.2. DESCRIPTION
7.1.3. OPERATION
7.2. REPAIRS
7.2.1. MAIN CONTROL VALVE
7.3. CHECKS AND ADJUSTMENTS
7.3.1. RELIEF VALVE
7.3.2. VANE SETTINGS
7.3.3. MAST TILT ADJUSTMENT
7.4. TROUBLESHOOTING
8. _2
8.1. INTRODUCTION
8.1.1. GENERAL
8.1.2. DESCRIPTION
8.2. REPAIRS
8.2.1. REMOVAL
8.2.2. DISASSEMBLY
8.2.3. CLEANING
8.2.4. ASSEMBLY
8.2.5. INSTALLATION
8.3. CHECKS AND ADJUSTMENTS
8.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
8.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
8.4. TROUBLESHOOTING
9.
9.1. ELECTRICAL WARNING DEVICES
9.1.1. GENERAL
9.1.2. DESCRIPTION
9.1.3. REPLACEMENT
10.
10.1. INTRODUCTION
10.1.1. General
10.2. DESCRIPTION
10.2.1. Diagnostic Control Card
10.2.2. Hand Set
10.2.3. Instrument Panel Display
10.2.4. Control Card Connections
10.3. CHECKS AND ADJUSTMENTS
10.3.1. General
10.3.2. Checking And Adjusting Function Settings
10.3.3. Function Tables
10.4. REPAIRS
10.4.1. General
10.4.2. Control Card Plugs
10.5. TROUBLESHOOTING
10.5.1. General
11.
11.1. INTRODUCTION
11.1.1. GENERAL
11.1.2. DESCRIPTION
11.2. REPAIRS
11.2.1. REMOVAL AND DISASSEMBLY
11.2.2. ASSEMBLY AND INSTALLATION
12.
12.1. INTRODUCTION
12.1.1. GENERAL
12.2. DESCRIPTION
12.2.1. INSTRUMENT PANEL
12.2.2. PRINTED CIRCUIT BOARDS
12.2.3. OTHER CONTROL COMPONENTS
12.3. REPLACEMENT
12.3.1. INSTRUMENT PANEL COMPONENTS
12.3.2. PRINTED CIRCUIT BOARDS
12.3.3. OTHER CONTROL COMPONENTS
12.4. CHECKS AND ADJUSTMENTS
12.4.1. CONTROL POWER FUSES
12.4.2. CHECK ACCELERATOR SWITCH ASSEMBLY
12.4.3. ADJUSTING STOP LIGHT SWITCH
12.4.4. CHECK SEAT SWITCH
12.4.5. ADJUSTING PARKING BRAKE SWITCH
12.4.6. DIRECTION SWITCHES (MONOTROL PEDAL)
12.4.7. DIRECTION SWITCHES (STEERING COLUMN)
12.4.8. HYDRAULIC CUT OFF SWITCH
12.4.9. PRINTED CIRCUIT BOARDS
13.
13.1. INTRODUCTION
13.1.1. GENERAL
13.1.2. INDICATORS WITH METER MOVEMENTS
13.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
13.2. CHECKS AND ADJUSTMENTS
13.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARYLY MODELS
13.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
13.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
13.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
13.2.5. LED DISPLAY WITH LIFT INTERRUPT
13.2.6. CHECKING CURTIS 933-1 METER
13.2.7. ADJUSTMENT OF CURTIS 933-1 METER
13.2.8. CHECKING CURTIS 1215 BATTERY INDICATOR
13.2.9. ADJUSTING CURTIS 1215 BATTERY INDICATOR
13.3. REPAIRS
13.4. BATTERY INDICATORS
13.4.1. Replacement
13.5. CONTROLLER FOR THE BATTERY INDICATOR
13.5.1. Replacement
13.6. DISPLAY PANEL COMPONENTS
14. _2
14.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
14.1.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
14.2. LIFT CYLINDERS
14.2.1. GENERAL
14.2.2. DESCRIPTION
14.3. REPAIRS
14.3.1. REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST
14.3.2. DISASSEMBLY
14.3.3. ASSEMBLY
14.3.4. INSTALLATION OF THE LIFT CYLINDER IN THE MAST
14.3.5. CHEVRON PACKING
14.4. LIFT CYLINDERS FOR VISTA MASTS
14.4.1. DESCRIPTION
14.4.2. REMOVAL
14.4.3. DISASSEMBLY
14.4.4. ASSEMBLY
14.4.5. INSTALLATION
14.5. CHECKS AND ADJUSTMENTS
14.5.1. CHECK FOR LEAKS IN LIFT SYSTEM
14.6. TROUBLESHOOTING
14.7. SPECIFICATIONS
15. _2
15.1. INTRODUCTION
15.1.1. GENERAL
15.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
15.3. REPAIRS
15.3.1. Removal
15.3.2. Installation
15.3.3. CARRIAGES
15.3.4. LIFT CYLINDERS
15.3.5. HEADER HOSE ARRANGEMENTS
15.4. CHECKS AND ADJUSTMENTS
15.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
15.4.2. ADJUST THE TILT CYLINDERS
15.4.3. ADJUST THE LIFT CHAINS
15.4.4. ADJUST THE MAST
15.4.5. ADJUST THE CARRIAGE
15.5. TROUBLESHOOTING
16. _2
16.1. INTRODUCTION
16.1.1. GENERAL
16.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
16.3. REPAIRS
16.3.1. Removal
16.3.2. Installation
16.3.3. CARRIAGES
16.3.4. LIFT CYLINDERS
16.3.5. HEADER HOSE ARRANGEMENTS
16.4. CHECKS AND ADJUSTMENTS
16.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
16.4.2. ADJUST THE TILT CYLINDERS
16.4.3. ADJUST THE LIFT CHAINS
16.4.4. ADJUST THE MAST
16.4.5. ADJUST THE CARRIAGE
16.5. TROUBLESHOOTING
17. _2
17.1. INTRODUCTION
17.1.1. NOMENCLATURE, THREADS
17.1.2. STRENGTH IDENTIFICATION
17.2. TABLE 1. BOLTS AND SCREWS
17.3. TABLE 2. STUDS AND NUTS
17.4. TABLE 3. TORQUE NUTS
17.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
17.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
17.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
18.
18.1. INTRODUCTION
18.1.1. GENERAL
18.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
18.1.3. HOW TO PUT A LIFT TRUCK ONTO BLOCKS
18.2. MAINTENANCE SCHEDULE
18.2.1. MAINTENANCE SCHEDULE
18.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
18.3.1. CHECKS BEFORE OPERATION
18.3.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
18.3.3. CHECK THE OPERATION
18.4. EVERY 350 HOURS OR TWO MONTHS
18.4.1. HYDRAULIC TANK BREATHER
18.4.2. WHEEL NUT TORQUE
18.4.3. TRANSAXLE
18.4.4. LIFT SYSTEM OPERATION
18.4.5. LIFT CHAINS
18.4.6. SAFETY LABELS
18.4.7. BRAKE FLUID
18.4.8. OTHER LUBRICATION
18.4.9. ELECTRICAL INSPECTION
18.5. HOURS OR YEARLY
18.5.1. HYDRAULIC SYSTEM
18.5.2. TRANSAXLE
18.6. GENERAL PROCEDURES
18.6.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
18.6.2. HOW TO CHECK THE PMT CIRCUIT
18.6.3. HOW TO CHARGE THE BATTERY
18.6.4. HOW TO CHANGE THE BATTERY
18.7. WHEELS AND TYRES
18.7.1. GENERAL
18.7.2. HOW TO CHANGE THE TYRES
18.7.3. STEER AND DRIVE WHEELS
18.7.4. TYRE SIZES AND PRESSURES
18.7.5. PNEUMATIC TYRES
18.7.6. PNEUMATIC SHAPED SOLID TYRES
18.7.7. INSTALL THE WHEEL AND TYRE
18.7.8. BATTERY SIZE SPECIFICATIONS
19.
19.1. WHEELS AND TYRES
19.2. MOTORS (DUAL VOLTAGE 36/48)
19.3. MAST TILT PERFORMANCE
19.4. MAST SPEEDS 19cc PUMP 1 and 2 SPEED CONTACTOR
19.5. MAST SPEEDS 19cc PUMP TRANSISTOR CONTROL
19.6. MAST SPEEDS 12cc PUMP 1 and 2 SPEED CONTACTOR
19.7. MAST SPEEDS 12cc PUMP TRANSISTOR CONTACTOR
19.8. MAST/TILT DRIFT SPEEDS
19.9. HYDRAULIC SYSTEM
19.10. TORQUE SPECIFICATIONS
19.11. ACCELERATOR POTENTIOMETER CHECKS
19.12. ADJUSTMENTS, EV 100 LX TRACTION CARD
19.13. SX/SR Traction Controller Settings – Standard
19.14. SX/SR Traction Controller Settings – Energy Option
19.15. SX/SR Traction Controller Settings – With or Without Auto Regen
19.16. ADJUSTMENTS, EV 100 LX PUMP CARD
19.17. SX/SR Lift Pump Controller Settings
19.18. BATTERY SIZE SPECIFICATIONS – TYPE LEAD ACID BATTERY
20.

Rate this product