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

Description

• 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.