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

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hyster e160 j160 200xmt service manual 2

hyster e160 j160 200xmt service manual 3

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

$30.00

Type Of Manual: Service Manual
Number of Pages: 527
Size: 9.7MB
Format: PDF

Category: Hyster Service Manual PDF

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

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