Hyster E160 (J1.60-2.00XMT) Service Manual

Description

• Model List:
  • E160 (J1.60-2.00XMT)

• 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. AUXILIARY COUNTERWEIGHT
• 43. Removal
• 44. Installation
• 45. HYDRAULIC TANK
• 46. Inspection
• 47. Repairs, Small Leaks
• 48. Repairs, Large Leaks
• 49. Cleaning
• 50. Steam Method Of Cleaning
• 51. Chemical Solution Method Of Cleaning
• 52. Additional Preparations For Repair
• 53. SAFETY LABELS
• 54. INTRODUCTION
• 55. ELECTRIC MOTOR MAINTENANCE, GENERAL
• 56. BRUSH AND COMMUTATOR INSPECTION
• 57. Hydraulic Pump Motor And Traction Motor
• 58. Steering Pump Motor
• 59. TROUBLESHOOTING
• 60. TROUBLESHOOTING
• 61. Commutator Problems
• 62. BRUSH REPLACEMENT
• 63. DISASSEMBLY OF MOTORS
• 64. Traction Motor And Hydraulic Pump Motor
• 65. Steering Pump Motor
• 66. ASSEMBLY OF MOTORS
• 67. Traction Motor And Hydraulic Pump Motor
• 68. Steering Pump Motor
• 69. BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS
• 70. TESTS FOR A DAMAGED FIELD AND ARMATURE
• 71. Test For An Open Circuit In The Armature
• 72. Test For A ShortCircuit In One Armature Winding
• 73. Test For A ShortCircuit To Armature Shaft
• 74. Test For An Open Circuit In A Field Coil
• 75. Test For A ShortCircuit In A Field Coil
• 76. Test For A ShortCircuit Between The Field And The Motor Case
• 77. Brush Holder Test
• 78.
• 78.1. INTRODUCTION
• 78.1.1. GENERAL
• 78.1.2. LUBRICATION
• 78.2. REPAIRS
• 78.2.1. REMOVAL
• 78.2.2. INSPECTION
• 78.2.3. INSTALLATION
• 78.3. S2 SERIES TRANSAXLE
• 78.3.1. DISASSEMBLY
• 78.3.2. ASSEMBLY
• 78.4. S1 SERIES TRANSAXLE
• 78.4.1. DISASSEMBLY
• 78.4.2. ASSEMBLY
• 78.5. TROUBLESHOOTING
• 79.
• 79.1. INTRODUCTION
• 79.1.1. GENERAL
• 79.1.2. DESCRIPTION
• 79.1.3. OPERATION
• 79.2. REPAIRS
• 79.2.1. STEERING HOUSING
• 79.2.2. Removal And Disassembly
• 79.2.3. Cleaning
• 79.2.4. Assembly and Installation
• 79.2.5. STEERING CONTROL UNIT
• 79.3. CHECKS AND ADJUSTMENTS
• 79.3.1. REMOVE AIR FROM THE SYSTEM
• 79.4. TROUBLESHOOTING
• 80.
• 80.1. INTRODUCTION
• 80.1.1. GENERAL
• 80.1.2. OPERATION
• 80.2. STEERING WHEEL AND COLUMN ASSEMBLY
• 80.2.1. DESCRIPTION
• 80.2.2. POWER STEERING PUMP AND MOTOR
• 80.3. STEERING AXLE COMPONENTS
• 80.3.1. GENERAL
• 80.3.2. WHEEL AND TYRE ASSEMBLY
• 80.3.3. WHEEL HUB ASSEMBLY
• 80.3.4. STEERING AXLE ASSEMBLY
• 80.3.5. OLD STEERING SYSTEM
• 80.3.6. ROTARY ACTUATOR (OLD SYSTEM ONLY)
• 80.3.7. NEW STEERING SYSTEM
• 80.4. CHECKS AND ADJUSTMENTS
• 80.4.1. AIR IN THE SYSTEM
• 80.5. TROUBLESHOOTING
• 81.
• 81.1. INTRODUCTION
• 81.1.1. GENERAL
• 81.1.2. DESCRIPTION
• 81.2. REPAIRS
• 81.2.1. SERVICE BRAKE PADS
• 81.2.2. SERVICE BRAKE CALIPER
• 81.2.3. PARK BRAKE CALIPER
• 81.2.4. MASTER CYLINDER
• 81.2.5. FOOT OPERATED PARK BRAKE LEVER
• 81.2.6. ELECTRICALLY RELEASED PARK BRAKE
• 81.2.7. ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS
• 81.3. CHECKS AND ADJUSTMENTS
• 81.3.1. PARK BRAKE ADJUSTMENT
• 81.3.2. SERVICE BRAKE ADJUSTMENT
• 81.3.3. REMOVE AIR FROM THE BRAKE SYSTEM
• 81.4. TROUBLESHOOTING
• 82.
• 82.1. INTRODUCTION
• 82.1.1. GENERAL
• 82.1.2. DESCRIPTION
• 82.1.3. OPERATION
• 82.2. REPAIRS
• 82.2.1. MAIN CONTROL VALVE
• 82.3. CHECKS AND ADJUSTMENTS
• 82.3.1. RELIEF VALVE
• 82.3.2. VANE SETTINGS
• 82.3.3. MAST TILT ADJUSTMENT
• 82.4. TROUBLESHOOTING
• 83.
• 83.1. INTRODUCTION
• 83.1.1. GENERAL
• 83.1.2. DESCRIPTION
• 83.2. REPAIRS
• 83.2.1. REMOVAL
• 83.2.2. DISASSEMBLY
• 83.2.3. CLEANING
• 83.2.4. ASSEMBLY
• 83.2.5. INSTALLATION
• 83.3. CHECKS AND ADJUSTMENTS
• 83.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
• 83.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
• 83.4. TROUBLESHOOTING
• 84.
• 84.1. ELECTRICAL WARNING DEVICES
• 84.1.1. GENERAL
• 84.1.2. DESCRIPTION
• 84.1.3. REPLACEMENT
• 85.
• 85.1. INTRODUCTION
• 85.1.1. General
• 85.2. DESCRIPTION
• 85.2.1. Diagnostic Control Card
• 85.2.2. Hand Set
• 85.2.3. Instrument Panel Display
• 85.2.4. Control Card Connections
• 85.3. CHECKS AND ADJUSTMENTS
• 85.3.1. General
• 85.3.2. Checking And Adjusting Function Settings
• 85.3.3. Function Tables
• 85.4. REPAIRS
• 85.4.1. General
• 85.4.2. Control Card Plugs
• 85.5. TROUBLESHOOTING
• 85.5.1. General
• 86.
• 86.1. INTRODUCTION
• 86.1.1. GENERAL
• 86.1.2. DESCRIPTION
• 86.2. REPAIRS
• 86.2.1. REMOVAL AND DISASSEMBLY
• 86.2.2. ASSEMBLY AND INSTALLATION
• 87.
• 87.1. INTRODUCTION
• 87.1.1. GENERAL
• 87.2. DESCRIPTION
• 87.2.1. INSTRUMENT PANEL
• 87.2.2. PRINTED CIRCUIT BOARDS
• 87.2.3. OTHER CONTROL COMPONENTS
• 87.3. REPLACEMENT
• 87.3.1. INSTRUMENT PANEL COMPONENTS
• 87.3.2. PRINTED CIRCUIT BOARDS
• 87.3.3. OTHER CONTROL COMPONENTS
• 87.4. CHECKS AND ADJUSTMENTS
• 87.4.1. CONTROL POWER FUSES
• 87.4.2. CHECK ACCELERATOR SWITCH ASSEMBLY
• 87.4.3. ADJUSTING STOP LIGHT SWITCH
• 87.4.4. CHECK SEAT SWITCH
• 87.4.5. ADJUSTING PARKING BRAKE SWITCH
• 87.4.6. DIRECTION SWITCHES (MONOTROL PEDAL)
• 87.4.7. DIRECTION SWITCHES (STEERING COLUMN)
• 87.4.8. HYDRAULIC CUT OFF SWITCH
• 87.4.9. PRINTED CIRCUIT BOARDS
• 88.
• 88.1. INTRODUCTION
• 88.1.1. GENERAL
• 88.1.2. INDICATORS WITH METER MOVEMENTS
• 88.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
• 88.2. CHECKS AND ADJUSTMENTS
• 88.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARYLY MODELS
• 88.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
• 88.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
• 88.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
• 88.2.5. LED DISPLAY WITH LIFT INTERRUPT
• 88.2.6. CHECKING CURTIS 933-1 METER
• 88.2.7. ADJUSTMENT OF CURTIS 933-1 METER
• 88.2.8. CHECKING CURTIS 1215 BATTERY INDICATOR
• 88.2.9. ADJUSTING CURTIS 1215 BATTERY INDICATOR
• 88.3. REPAIRS
• 88.4. BATTERY INDICATORS
• 88.4.1. Replacement
• 88.5. CONTROLLER FOR THE BATTERY INDICATOR
• 88.5.1. Replacement
• 88.6. DISPLAY PANEL COMPONENTS
• 89.
• 89.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 89.1.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 89.2. LIFT CYLINDERS
• 89.2.1. GENERAL
• 89.2.2. DESCRIPTION
• 89.3. REPAIRS
• 89.3.1. REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST
• 89.3.2. DISASSEMBLY
• 89.3.3. ASSEMBLY
• 89.3.4. INSTALLATION OF THE LIFT CYLINDER IN THE MAST
• 89.3.5. CHEVRON PACKING
• 89.4. LIFT CYLINDERS FOR VISTA MASTS
• 89.4.1. DESCRIPTION
• 89.4.2. REMOVAL
• 89.4.3. DISASSEMBLY
• 89.4.4. ASSEMBLY
• 89.4.5. INSTALLATION
• 89.5. CHECKS AND ADJUSTMENTS
• 89.5.1. CHECK FOR LEAKS IN LIFT SYSTEM
• 89.6. TROUBLESHOOTING
• 89.7. SPECIFICATIONS
• 90.
• 90.1. INTRODUCTION
• 90.1.1. GENERAL
• 90.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 90.3. REPAIRS
• 90.3.1. Removal
• 90.3.2. Installation
• 90.3.3. CARRIAGES
• 90.3.4. LIFT CYLINDERS
• 90.3.5. HEADER HOSE ARRANGEMENTS
• 90.4. CHECKS AND ADJUSTMENTS
• 90.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 90.4.2. ADJUST THE TILT CYLINDERS
• 90.4.3. ADJUST THE LIFT CHAINS
• 90.4.4. ADJUST THE MAST
• 90.4.5. ADJUST THE CARRIAGE
• 90.5. TROUBLESHOOTING
• 91.
• 91.1. INTRODUCTION
• 91.1.1. GENERAL
• 91.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 91.3. REPAIRS
• 91.3.1. Removal
• 91.3.2. Installation
• 91.3.3. CARRIAGES
• 91.3.4. LIFT CYLINDERS
• 91.3.5. HEADER HOSE ARRANGEMENTS
• 91.4. CHECKS AND ADJUSTMENTS
• 91.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 91.4.2. ADJUST THE TILT CYLINDERS
• 91.4.3. ADJUST THE LIFT CHAINS
• 91.4.4. ADJUST THE MAST
• 91.4.5. ADJUST THE CARRIAGE
• 91.5. TROUBLESHOOTING
• 92.
• 92.1. INTRODUCTION
• 92.1.1. NOMENCLATURE, THREADS
• 92.1.2. STRENGTH IDENTIFICATION
• 92.2. TABLE 1. BOLTS AND SCREWS
• 92.3. TABLE 2. STUDS AND NUTS
• 92.4. TABLE 3. TORQUE NUTS
• 92.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
• 92.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
• 92.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
• 93.
• 93.1. INTRODUCTION
• 93.1.1. GENERAL
• 93.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
• 93.1.3. HOW TO PUT A LIFT TRUCK ONTO BLOCKS
• 93.2. MAINTENANCE SCHEDULE
• 93.2.1. MAINTENANCE SCHEDULE
• 93.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 93.3.1. CHECKS BEFORE OPERATION
• 93.3.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 93.3.3. CHECK THE OPERATION
• 93.4. EVERY 350 HOURS OR TWO MONTHS
• 93.4.1. HYDRAULIC TANK BREATHER
• 93.4.2. WHEEL NUT TORQUE
• 93.4.3. TRANSAXLE
• 93.4.4. LIFT SYSTEM OPERATION
• 93.4.5. LIFT CHAINS
• 93.4.6. SAFETY LABELS
• 93.4.7. BRAKE FLUID
• 93.4.8. OTHER LUBRICATION
• 93.4.9. ELECTRICAL INSPECTION
• 93.5. HOURS OR YEARLY
• 93.5.1. HYDRAULIC SYSTEM
• 93.5.2. TRANSAXLE
• 93.6. GENERAL PROCEDURES
• 93.6.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 93.6.2. HOW TO CHECK THE PMT CIRCUIT
• 93.6.3. HOW TO CHARGE THE BATTERY
• 93.6.4. HOW TO CHANGE THE BATTERY
• 93.7. WHEELS AND TYRES
• 93.7.1. GENERAL
• 93.7.2. HOW TO CHANGE THE TYRES
• 93.7.3. STEER AND DRIVE WHEELS
• 93.7.4. TYRE SIZES AND PRESSURES
• 93.7.5. PNEUMATIC TYRES
• 93.7.6. PNEUMATIC SHAPED SOLID TYRES
• 93.7.7. INSTALL THE WHEEL AND TYRE
• 93.7.8. BATTERY SIZE SPECIFICATIONS
• 94.
• 94.1. WHEELS AND TYRES
• 94.2. MOTORS (DUAL VOLTAGE 36/48)
• 94.3. MAST TILT PERFORMANCE
• 94.4. MAST SPEEDS 19cc PUMP 1 and 2 SPEED CONTACTOR
• 94.5. MAST SPEEDS 19cc PUMP TRANSISTOR CONTROL
• 94.6. MAST SPEEDS 12cc PUMP 1 and 2 SPEED CONTACTOR
• 94.7. MAST SPEEDS 12cc PUMP TRANSISTOR CONTACTOR
• 94.8. MAST/TILT DRIFT SPEEDS
• 94.9. HYDRAULIC SYSTEM
• 94.10. TORQUE SPECIFICATIONS
• 94.11. ACCELERATOR POTENTIOMETER CHECKS
• 94.12. ADJUSTMENTS, EV 100 LX TRACTION CARD
• 94.13. SX/SR Traction Controller Settings – Standard
• 94.14. SX/SR Traction Controller Settings – Energy Option
• 94.15. SX/SR Traction Controller Settings – With or Without Auto Regen
• 94.16. ADJUSTMENTS, EV 100 LX PUMP CARD
• 94.17. SX/SR Lift Pump Controller Settings
• 94.18. BATTERY SIZE SPECIFICATIONS – TYPE LEAD ACID BATTERY
• 95.
• 95.1. INTRODUCTION
• 95.1.1. GENERAL
• 95.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
• 95.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
• 95.2. MAINTENANCE SCHEDULE
• 95.2.1. MAINTENANCE POINTS
• 95.2.2. MAINTENANCE SCHEDULE
• 95.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
• 95.3.1. CHECKS BEFORE OPERATION
• 95.3.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 95.3.3. CHECK THE OPERATION
• 95.4. EVERY 500 HOURS OR THREE MONTHS
• 95.4.1. HYDRAULIC TANK BREATHER
• 95.4.2. WHEEL NUT TORQUE
• 95.4.3. TRANSAXLE
• 95.4.4. LIFT SYSTEM OPERATION
• 95.4.5. LIFT CHAINS
• 95.4.6. SAFETY LABELS
• 95.4.7. BRAKE FLUID
• 95.4.8. OTHER LUBRICATION
• 95.4.9. ELECTRICAL INSPECTION
• 95.5. HOURS OR YEARLY
• 95.5.1. HYDRAULIC SYSTEM
• 95.5.2. TRANSAXLE
• 95.6. EVERY 4000 HOURS
• 95.6.1. TRANSAXLE (S2 SERIES ONLY)
• 95.7. GENERAL PROCEDURES
• 95.7.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 95.7.2. HOW TO CHECK THE PMT CIRCUIT
• 95.7.3. HOW TO CHARGE THE BATTERY
• 95.7.4. HOW TO CHANGE THE BATTERY
• 95.8. WHEELS AND TYRES
• 95.8.1. GENERAL
• 95.8.2. HOW TO CHANGE THE TYRES
• 95.8.3. STEER AND DRIVE WHEELS
• 95.8.4. PNEUMATIC TYRES
• 95.8.5. PNEUMATIC SHAPED SOLID TYRES
• 95.8.6. INSTALL THE WHEEL AND TYRE
• 95.9. BATTERY SIZE SPECIFICATIONS
• 96.
• 96.1. WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP
• 96.2. WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP
• 96.3. OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP
• 96.4. WIRING SCHEMATIC WITH TMM MODULE
• 96.5. WIRING DIAGRAM WITH TMM MODULE
• 96.6. OPTIONAL WIRING WITH TMM MODULE
• 96.7. WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP