Hyster B160 (J25-35BS) Service Manual - Image 2

Hyster B160 (J25-35BS) Service Manual - Image 3

Hyster B160 (J25-35BS) Service Manual - Image 4

Hyster B160 (J25-35BS) Service Manual - Image 5

Hyster B160 (J25-35BS) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 574
Size: 27.5MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- B160 (J25-35BS)

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. DISASSEMBLY AND ASSEMBLY
33. Overhead Guard
34. Hood and Seat Assembly
35. Counterweight
36. Hydraulic Tank Repairs
37. Decal Replacement
38. INTRODUCTION
39. GENERAL
40. DESCRIPTION
41. OPERATION
42. REPAIRS
43. STEERING WHEEL AND COLUMN ASSEMBLY
44. TYPE A STEERING COLUMN ASSEMBLY
45. Removal And Disassembly
46. Assembly And Installation
47. TYPE A STEERING COLUMN
48. TYPE A STEERING COLUMN
49. TYPE B STEERING COLUMN
50. Removal And Disassembly
51. Assembly And Installation
52. TYPE B STEERING COLUMN
53. Disassembly of Steering Control Unit
54. Cleaning of Steering Control Unit
55. Assembly of Steering Control Unit
56. CHECKS AND ADJUSTMENTS
57. REMOVE AIR FROM THE SYSTEM
58. TROUBLESHOOTING
59. INTRODUCTION
60. GENERAL
61. DESCRIPTION
62. REPAIRS
63. REMOVAL AND DISASSEMBLY
64. CLEANING
65. ASSEMBLY
66. CHECKS AND ADJUSTMENTS
67. DC Motor Maintenance
68. Safety Precautions Maintenance and Repair
69. General
70. Brush and Commutator Inspection
71. Hydraulic Pump Motor and Traction Motor
72. Steering Pump Motor
73. Normal Commutator Surface
74. Commutator Problems
75. Brush Replacement
76. Stoning the Commutator
77. Motors Repair
78. Disassemble
79. Traction Motor and Hydraulic Pump Motor
80. Steering Pump Motor
81. Assemble
82. Traction Motor and Hydraulic Pump Motor
83. Steering Pump Motor
84. Brush Alignment, Traction and Hydraulic Motors
85. Tests for Damaged Field and Armature
86. Test for an Open Circuit in Armature
87. Test for Short Circuit in One Armature Winding
88. Test for Short Circuit to Armature Shaft
89. Test for Open Circuit in Field Coil
90. Test for Short Circuit in Field Coil
91. Test for Short Circuit between Field and Motor Case
92. Brush Holder Test
93. Troubleshooting
94. Table 1. Normal Commutator Surfaces
95. Table 2. Commutator Problems
96. Table 3. Brush Wear Replacement Guide
97. INTRODUCTION
98. GENERAL
99. SERIAL NUMBER DATA
100. HOW TO MOVE A DISABLED LIFT TRUCK
101. How To Tow A Lift Truck
102. RELEASE THE SEAT BRAKE ON A DISABLED LIFT TRUCK
103. HOW TO PUT A LIFT TRUCK ON BLOCKS
104. HOW TO RAISE THE DRIVE TIRES
105. How to Raise the Steering Tires
106. MAINTENANCE SCHEDULE
107. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
108. CHECKS BEFORE OPERATION
109. HOW TO MAKE CHECKS WITH THE KEY OFF
110. Tires And Wheels
111. Fork Adjustment
112. Hook Fork, Removal
113. Hook Fork, Installation
114. Inspection Of Mast, Forks, And Lift Chains
115. Safety Labels
116. Operator Restraint System
117. Check The Operation
118. Battery Restraint System
119. Battery
120. Hydraulic System
121. HOW TO MAKE CHECKS WITH THE KEY ON
122. Gauges And Horn
123. Steering System
124. Service Brakes
125. Parking Brake
126. Control Levers And Pedals
127. Lift System Operation
128. EVERY 350 HOURS OR TWO MONTHS
129. HYDRAULIC TANK BREATHER
130. TRANSAXLE
131. WHEEL NUT TORQUE
132. LIFT CHAINS
133. Check for Wear
134. Lubrication
135. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
136. SEAT BRAKE
137. BRAKE FLUID
138. OTHER LUBRICATION
139. ELECTRICAL INSPECTION
140. CONTACTORS
141. MOTOR BRUSHES
142. HOURS OR YEARLY
143. HYDRAULIC SYSTEM
144. CHANGE THE OIL FILTER
145. CHANGE THE HYDRAULIC OIL
146. TRANSAXLE
147. STEERING SYSTEM
148. Manual Steering
149. Power Steering
150. CONTACTORS
151. LIFT CHAINS
152. GENERAL PROCEDURES
153. HOW TO CHARGE THE BATTERY
154. HOW TO CHANGE THE BATTERY
155. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
156. Check the Lift Cylinders for Leaks
157. Check the Tilt Cylinders for Leaks
158. WELDING REPAIRS
159. CHANGES TO THE OVERHEAD GUARD
160. LIFT CHAIN ADJUSTMENTS
161. HOW TO CHECK THE PMT CIRCUIT
162. WHEELS AND TIRES
163. How To Change A Solid Rubber (Press-on) Tire
164. How To Repair A Pneumatic Tire
165. How To Remove A Wheel From The Lift Truck
166. How To Remove Tire From The Wheel
167. How To Install The Tire On The Wheel
168. Add Air To The Tires
169. How To Install The Wheel
170. Solid Rubber Tires That Look Like Pneumatic Tires
171. Remove The Wheels From The Lift Truck
172. Remove The Tire From The Wheel
173. Install The Tire On The Wheel
174. REFERENCE TABLE
175.
175.1. INTRODUCTION
175.1.1. General
175.1.2. Description
175.2. REPAIRS
175.2.1. Removal
175.2.2. Disassembly
175.2.3. Assembly
175.2.4. Installation
175.3. WHEELS AND TIRES
175.3.1. Description
175.4. TROUBLESHOOTING
176.
176.1. STEERING CONTROL UNIT
176.1.1. GENERAL
176.1.2. DESCRIPTION
176.1.3. DISASSEMBLY AND INSPECTION
176.1.4. ASSEMBLY
176.2. TROUBLESHOOTING
177.
177.1. INTRODUCTION
177.1.1. GENERAL
177.1.2. DESCRIPTION
177.2. STEERING WHEEL AND COLUMN ASSEMBLY
177.2.1. STEERING WHEEL AND HORN
177.2.2. STEERING CONTROL UNIT
177.3. POWER STEERING MOTOR AND PUMP
177.3.1. DESCRIPTION
177.3.2. REMOVAL AND DISASSEMBLY
177.3.3. ASSEMBLY AND INSTALLATION
177.3.4. REPAIRS, POWER STEERING PUMP
177.4. HYDRAULIC STEERING MOTOR
177.4.1. DESCRIPTION
177.4.2. REPAIRS, HYDRAULIC STEERING MOTOR
177.5. STEERING TRUNNION ASSEMBLY
177.5.1. TRUNNION AND WHEEL ASSEMBLY
177.6. CHECKS AND ADJUSTMENTS
177.6.1. Air In The Steering System
177.7. TROUBLESHOOTING
178.
178.1. INTRODUCTION
178.1.1. General
178.1.2. Description
178.2. REPAIRS
178.2.1. Service Brakes
178.2.2. Parking Brake
178.2.3. Seat Brake
178.3. CHECKS AND ADJUSTMENTS
178.3.1. Removing Air From The Service Brakes
178.3.2. Brake Pedal Adjustment
178.3.3. Adjustment Of The Parking Brake Linkage
178.3.4. Adjustment Of The Seat Brake
178.3.5. Adjustment Of The Friction Pads
178.4. TROUBLESHOOTING
179.
179.1. INTRODUCTION
179.1.1. General
179.2. HYDRAULIC SYSTEM
179.2.1. Hydraulic System (Early Production Lift Trucks)
179.2.2. Hydraulic System (Later Production Lift Trucks)
179.3. MAIN CONTROL VALVE
179.3.1. Main Control Valve (Early Production Lift Trucks)
179.3.2. Repairs
179.3.3. Main Control Valve (Later Production Lift Trucks)
179.3.4. Repairs
179.3.5. Checks and Adjustments
179.4. HYDRAULIC PUMP
179.4.1. Description
179.4.2. Repairs
179.5. TROUBLESHOOTING (HYDRAULIC PUMP)
179.6. TROUBLESHOOTING (MAIN CONTROL VALVE)
179.7. SPECIFICATIONS
180.
181.
182.
182.1. INTRODUCTION
182.1.1. General
182.2. CONTROL SWITCHES
182.2.1. Steering Switches
182.2.2. MONOTROL and Accelerator Pedal Adjustments
182.2.3. Later Production MONTROL
182.2.4. FORWARD and REVERSE Switch (Steering Column)
182.2.5. Brake Switch
182.2.6. Seat Switch
182.2.7. Hydraulic Pump Switches
182.3. EV-100 DUAL MOTOR CONTROLLER
182.3.1. Control Card
182.3.2. Checking An SCR
182.3.3. The OFF Circuit For SCR 1
182.3.4. Diodes D3 and D4
182.3.5. Motor Current Sensor
182.3.6. The Electronic Driver Module
182.3.7. Contactors
182.3.8. Contactor Repair
182.3.9. Control Card Adjustments
183.
183.1. INTRODUCTION
183.1.1. General
183.2. SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)
183.2.1. Static Return To Off (SRO) Circuit
183.2.2. Pulse Monitor Trip (PMT)
183.2.3. Sequence of Operation
183.2.4. Checking For Correct Operation
183.3. TROUBLESHOOTING
183.3.1. General Procedures
183.3.2. Fault Guide
184.
185.
186.
186.1. INTRODUCTION
186.1.1. GENERAL
186.1.2. INDICATORS WITH METER MOVEMENT
186.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
186.2. CHECKS AND ADJUSTMENTS
186.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
186.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
186.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
186.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
186.2.5. LED DISPLAY WITH LIFT INTERRUPT
186.2.6. CHECKING CURTIS 933-1 METER
186.2.7. ADJUSTMENT OF CURTIS 933-1 METER
186.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
186.3. CURTIS DASH DISPLAY ASSEMBLY
186.3.1. Description/Features
186.3.2. Operation
186.3.3. Testing
186.4. REPAIRS
186.4.1. BATTERY INDICATORS
186.4.2. CONTROLLER FOR THE BATTERY INDICATOR
186.4.3. DISPLAY PANEL COMPONENTS
186.4.4. REPLACING SEM DISPLAY PANEL
186.4.5. SEM DISPLAY PANEL REMOVAL
187.
188.
188.1. INTRODUCTION
188.1.1. GENERAL
188.1.2. MAST WELDMENTS
188.1.3. CARRIAGE
188.1.4. MAST MOUNTS
188.2. VISTA TWO-STAGE MAST
188.2.1. DESCRIPTION AND OPERATION
188.3. VISTA FREE-LIFT MAST
188.3.1. DESCRIPTION
188.3.2. OPERATION
188.4. VISTA THREE-STAGE MAST
188.4.1. DESCRIPTION
188.4.2. OPERATION
188.5. VISTA FOUR-STAGE MAST
188.5.1. DESCRIPTION
188.5.2. OPERATION
189.
189.1. VISTA MAST, REPAIR
189.1.1. GENERAL
189.1.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
189.1.3. CARRIAGE
189.1.4. SIDE-SHIFT CARRIAGE (EARLIER DESIGN)
189.1.5. SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)
189.2. CHECKS AND ADJUSTMENTS
189.2.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
189.2.2. ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
189.2.3. LIFT CHAIN ADJUSTMENTS
189.2.4. MAST ADJUSTMENTS
189.2.5. CARRIAGE ADJUSTMENT
189.2.6. HEADER HOSE ARRANGEMENTS
189.3. TROUBLESHOOTING
190.
191.
192.
192.1. FIGURE 1. EV-100 SCHEMATIC DIAGRAM, DUAL MOTOR CONTROLLER
192.2. FIGURE 2. EV-100 WIRE DIAGRAM, DUAL MOTOR CONTROLLER
192.3. FIGURE 3. EV-100 WIRE DIAGRAM, CONTROL SWITCHES
192.4. FIGURE 4. EV-100 LX SCHEMATIC DIAGRAM, DUAL MOTOR CONTROLLER
192.5. FIGURE 5. EV-100 LX WIRE DIAGRAM, DUAL MOTOR CONTROLLER
192.6. FIGURE 6. EV-100 LX WIRE DIAGRAM, CONTROL SWITCHES
192.7. FIGURE 7. CABLE DIAGRAM
192.8. FIGURE 8. ARRANGEMENT, ELECTRIC CONTROL
192.9. FIGURE 9. HYDRAULIC SYSTEM (EARLY PRODUCTION LIFT TRUCKS)
192.10. FIGURE 10. HYDRAULIC SCHEMATIC (EARLY PRODUCTION LIFT TRUCKS)
192.11. FIGURE 11. HYDRAULIC SYSTEM (LATER PRODUCTION LIFT TRUCKS)
192.12. FIGURE 12. HYDRAULIC SCHEMATIC (LATER PRODUCTION LIFT TRUCKS)

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