Hyster C160 (J30-40XMT) Service Manual - Image 2

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Hyster C160 (J30-40XMT) Service Manual - Image 5

Hyster C160 (J30-40XMT) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 458
Size: 19.6MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C160 (J30-40XMT)

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. HYDRAULIC TANK
43. Inspection
44. Repairs, Small Leaks
45. Repairs. Large Leaks
46. Cleaning
47. Steam Method Of Cleaning
48. Chemical Solution Method of Cleaning
49. Additional Preparations For Repair
50. SAFETY LABELS
51. BATTERY SIZE SPECIFICATIONS
52. DC Motor Maintenance
53. Safety Precautions Maintenance and Repair
54. General
55. Brush and Commutator Inspection
56. Hydraulic Pump Motor and Traction Motor
57. Steering Pump Motor
58. Normal Commutator Surface
59. Commutator Problems
60. Brush Replacement
61. Stoning the Commutator
62. Motors Repair
63. Disassemble
64. Traction Motor and Hydraulic Pump Motor
65. Steering Pump Motor
66. Assemble
67. Traction Motor and Hydraulic Pump Motor
68. Steering Pump Motor
69. Brush Alignment, Traction and Hydraulic Motors
70. Tests for Damaged Field and Armature
71. Test for an Open Circuit in Armature
72. Test for Short Circuit in One Armature Winding
73. Test for Short Circuit to Armature Shaft
74. Test for Open Circuit in Field Coil
75. Test for Short Circuit in Field Coil
76. Test for Short Circuit between Field and Motor Case
77. Brush Holder Test
78. Troubleshooting
79. Table 1. Normal Commutator Surfaces
80. Table 2. Commutator Problems
81. Table 3. Brush Wear Replacement Guide
82.
82.1. INTRODUCTION
82.1.1. GENERAL
82.1.2. LUBRICATION
82.2. REPAIRS
82.2.1. REMOVAL
82.2.2. INSPECTION
82.2.3. INSTALLATION
82.3. S2 SERIES TRANSAXLE
82.3.1. DISASSEMBLY
82.3.2. ASSEMBLY
82.4. S1 SERIES TRANSAXLE
82.4.1. DISASSEMBLY
82.4.2. ASSEMBLY
82.5. TROUBLESHOOTING
83.
83.1. INTRODUCTION
83.1.1. GENERAL
83.1.2. DESCRIPTION
83.1.3. OPERATION
83.2. REPAIRS
83.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
83.3. CHECKS AND ADJUSTMENTS
83.3.1. REMOVE AIR FROM THE SYSTEM
83.4. TROUBLESHOOTING
84.
84.1. INTRODUCTION
84.1.1. General
84.2. STEERING WHEEL AND COLUMN ASSEMBLY
84.2.1. DESCRIPTION
84.3. POWER STEERING PUMP AND MOTOR
84.3.1. DESCRIPTION
84.3.2. REPAIRS
84.4. STEERING TRUNNION ASSEMBLY
84.4.1. STEER AXLE
84.4.2. WHEEL ASSEMBLY
84.4.3. WHEEL HUB
84.4.4. STEER AXLE ASSEMBLY
84.4.5. POWER STEERING CYLINDER
84.5. CHECKS AND ADJUSTMENTS
84.5.1. Air In The Steering System
84.6. TROUBLESHOOTING
85.
85.1. INTRODUCTION
85.1.1. GENERAL
85.1.2. DESCRIPTION
85.1.3. OPERATION
85.2. REPAIRS
85.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
85.3. CHECKS AND ADJUSTMENTS
85.3.1. REMOVE AIR FROM THE SYSTEM
85.4. TROUBLESHOOTING
86.
86.1. INTRODUCTION
86.1.1. GENERAL
86.1.2. DESCRIPTION
86.2. REPAIRS
86.2.1. SERVICE BRAKE PADS
86.2.2. SERVICE BRAKE CALIPER
86.2.3. PARK BRAKE CALIPER
86.2.4. MASTER CYLINDER
86.2.5. FOOT OPERATED PARK BRAKE LEVER ASSEMBLY
86.2.6. ELECTRICALLY RELEASED PARK BRAKE
86.2.7. ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS
86.3. CHECKS AND ADJUSTMENTS
86.3.1. PARK BRAKE ADJUSTMENT
86.3.2. SERVICE BRAKE ADJUSTMENT
86.3.3. REMOVE AIR FROM BRAKE SYSTEM
86.4. TROUBLESHOOTING
87.
87.1. INTRODUCTION
87.1.1. GENERAL
87.1.2. DESCRIPTION
87.1.3. OPERATION
87.2. REPAIRS
87.2.1. MAIN CONTROL VALVE
87.3. CHECKS AND ADJUSTMENTS
87.3.1. RELIEF VALVE
87.3.2. VANE SETTINGS
87.3.3. MAST TILT ADJUSTMENT
87.4. TROUBLESHOOTING
88.
89.
89.1. ELECTRICAL WARNING DEVICES
89.1.1. GENERAL
89.1.2. DESCRIPTION
89.1.3. REPLACEMENT
90.
91.
91.1. INTRODUCTION
91.1.1. GENERAL
91.2. DESCRIPTION
91.2.1. INSTRUMENT PANELS
91.2.2. PRINTED CIRCUIT BOARDS
91.3. REPLACEMENT
91.3.1. INSTRUMENT PANEL COMPONENTS
91.3.2. PRINTED CIRCUIT BOARDS
91.3.3. OTHER CONTROL COMPONENTS
91.4. CHECKS AND ADJUSTMENTS
91.4.1. CONTROL AND POWER FUSES
91.4.2. CHECK ACCELERATOR SWITCH ASSEMBLY
91.4.3. ADJUSTING STOP LIGHT SWITCH
91.4.4. CHECK SEAT SWITCH
91.4.5. ADJUSTING PARKING BRAKE SWITCH
91.4.6. DIRECTION SWITCHES (MONOTROL PEDAL)
91.4.7. DIRECTION SWITCHES (STEERING COLUMN)
91.4.8. HYDRAULIC CUT OFF SWITCH
91.4.9. PRINTED CIRCUIT BOARDS
91.4.10. Steering Angle Control Board
91.4.11. Lift Pump Control Board
91.4.12. Bypassing the Lift Pump Control Board
92.
93.
93.1. INTRODUCTION
93.1.1. GENERAL
93.1.2. DESCRIPTION AND OPERATION
93.1.3. TWO-STAGE MAST, LIMITED FREE-LIFT
93.1.4. TWO-STAGE MAST, FULL FREE-LIFT
93.1.5. THREE-STAGE, FULL FREE-LIFT MAST
94.
94.1. INTRODUCTION
94.1.1. GENERAL
94.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
94.3. REPAIRS
94.3.1. Removal
94.3.2. Installation
94.3.3. CARRIAGES
94.3.4. LIFT CYLINDERS
94.3.5. HEADER HOSE ARRANGEMENTS H/S/E/J2.003.20XM (H/S/E/J4065XM) S/E/J2.003.00XL (S/E/J4060XL)
94.3.6. HEADER HOSE ARRANGEMENTS H/E1.501.75XM, H/S2.00XMS (H/S/E2535XM, H/S/E40XMS) and J1.602.00XMT (J3040XMT)
94.4. CHECKS AND ADJUSTMENTS
94.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
94.4.2. ADJUST THE TILT CYLINDERS
94.4.3. ADJUST THE LIFT CHAINS
94.4.4. ADJUST THE MAST
94.4.5. ADJUST THE CARRIAGE
94.5. TROUBLESHOOTING
95.
96.
96.1. INTRODUCTION
96.1.1. GENERAL
96.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
96.1.3. HOW TO TOW A LIFT TRUCK
96.1.4. HOW TO PUT A LIFT TRUCK ONTO BLOCKS
96.2. MAINTENANCE SCHEDULE
96.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
96.3.1. CHECKS BEFORE OPERATION
96.3.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
96.3.3. CHECK THE OPERATION
96.4. EVERY 350 HOURS OR TWO MONTHS
96.4.1. HYDRAULIC TANK BREATHER
96.4.2. WHEEL NUT TORQUE
96.4.3. STEERING TRUNNION MOUNTING CAPSCREW TORQUE
96.4.4. TRANSAXLE
96.4.5. LIFT SYSTEM OPERATION
96.4.6. LIFT CHAINS
96.4.7. SAFETY LABELS
96.4.8. BRAKE FLUID
96.4.9. OTHER LUBRICATION
96.4.10. ELECTRICAL INSPECTION
96.5. HOURS OR YEARLY
96.5.1. HYDRAULIC SYSTEM
96.5.2. TRANSAXLE
96.6. EVERY 4000 HOURS
96.6.1. TRANSAXLE (S2 SERIES ONLY)
96.7. GENERAL PROCEDURES
96.7.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
96.7.2. LIFT SYSTEM
96.7.3. TILT SYSTEM
96.7.4. HOW TO CHECK THE PMT CIRCUIT
96.7.5. HOW TO CHARGE THE BATTERY
96.7.6. HOW TO CHANGE THE BATTERY
96.8. WHEELS AND TIRES
96.8.1. GENERAL
96.8.2. HOW TO CHANGE THE TIRES
96.8.3. STEER AND DRIVE WHEELS
96.8.4. PNEUMATIC TIRES
96.8.5. PNEUMATIC SHAPED SOLID TIRES
96.8.6. SOLID TIRES
96.8.7. INSTALL THE WHEEL AND TIRE
96.8.8. BATTERY SIZE SPECIFICATIONS
97.
97.1. FIGURE 1. WIRING SCHEMATIC
97.2. FIGURE 2. WIRING DIAGRAM
97.3. FIGURE 3. WIRING SCHEMATIC WITH SCR HYDRAULICS
97.4. FIGURE 4. WIRING DIAGRAM WITH SCR HYDRAULICS
97.5. FIGURE 5. OPTIONAL WIRING
97.6. FIGURE 6. CABLE DETAILS
97.7. FIGURE 7. ARRANGEMENT ELECTRICAL CONTROL WITH SCR HYDRAULICS
97.8. FIGURE 8. ARRANGEMENT ELECTRICAL CONTROL WITH CONTACTOR HYDRAULICS
97.9. FIGURE 9. ARRANGEMENT, HYDRAULIC SYSTEM
97.10. FIGURE 10. HYDRAULIC SCHEMATIC
98.

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