Hyster G160 (J1.60-2.00XMT) Service Manual

Hyster G160 (J1.60-2.00XMT) Service Manual - Image 2

Hyster G160 (J1.60-2.00XMT) Service Manual - Image 3

Hyster G160 (J1.60-2.00XMT) Service Manual - Image 4

Hyster G160 (J1.60-2.00XMT) Service Manual - Image 5

hyster g160 j160 200xmt service manual 2

hyster g160 j160 200xmt service manual 3

Hyster G160 (J1.60-2.00XMT) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 863
Size: 30.7MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- G160 (J1.60-2.00XMT)

1. RM0460-(08-1995)-UK-EN
1.1. INTRODUCTION
1.2. DESCRIPTION
1.3. CHECKS AND ADJUSTMENTS
1.4. REPAIRS
1.5. TROUBLESHOOTING
2. RM0521-(03-2006)-UK-EN
2.1. Safety Precautions Maintenance and Repair
2.2. General
2.3. Description and Operation
2.4. Carriages
2.5. Mast Mounts
2.6. Two-Stage Mast, Limited Free-Lift (LFL)
2.7. Description and Operation
2.8. Two-Stage Mast, Full Free-Lift (FFL)
2.9. Description and Operation
2.10. Three-Stage Mast, Full Free-Lift (FFL)
2.11. Description and Operation
2.12. Four-Stage Mast
2.13. Description and Operation
2.14. Cylinder Cushion During Lifting Sequence
2.15. Cylinder Cushion During Lowering Sequence
3. RM0522-(07-2010)-UK-EN
3.1. Mast Repairs
3.2. Safety Precautions Maintenance and Repair
3.3. General
3.4. Safety Procedures When Working Near Mast
3.5. Fork Repair
3.6. Install
3.7. Carriages Repair
3.8. Standard Carriage, Remove
3.9. Hang-On Sideshift Carriage, Remove
3.10. Standard Carriage and Hang-On Sideshift Carriage, Repair
3.11. Standard Carriage, Install
3.12. Hang-On Sideshift Carriage, Install
3.13. Integral Sideshift Carriage
3.14. Clean and Inspect
3.15. Install
3.16. Mast Repair
3.17. Two-Stage LFL and Two-Stage FFL Masts, Disassemble
3.18. Three-Stage FFL Mast
3.19. Disassemble
3.20. Mast and Chains, Clean and Inspect
3.21. Two-Stage LFL and Two-Stage FFL Mast, Assemble
3.22. Three-Stage FFL Mast, Assemble
3.23. Install
3.24. Lift Cylinders Repair
3.25. Main Lift Cylinders, Remove
3.26. Free-Lift Cylinder, Remove
3.27. Cylinders, Disassemble
3.28. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
3.29. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
3.30. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
3.31. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
3.32. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
3.33. Clean and Inspect
3.34. Cylinders, Assemble
3.35. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
3.36. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
3.37. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
3.38. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
3.39. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
3.40. Main Lift Cylinders, Install
3.41. Free-Lift Cylinder, Install
3.42. Header Hose Arrangements
3.43. Two-Stage LFL Mast, New Hose Install
3.44. Two-Stage LFL Mast, Adjust Hoses After Installation
3.45. Two-Stage FFL Mast, New Hose Install
3.46. Two-Stage FFL Mast, Adjust Hoses After Installation
3.47. Three-Stage FFL Mast, New Hose Install
3.48. Three-Stage FFL Mast, Adjust Hoses After Installation
3.49. Header Hose Arrangement
3.50. Two-Stage LFL Mast, New Hose Install
3.51. Two-Stage LFL Mast, Adjust Hoses After Installation
3.52. Two-Stage FFL Mast, New Hose Install
3.53. Two-Stage FFL Mast, Adjust Hoses After Installation
3.54. Three-Stage FFL Mast, New Hose Install
3.55. Three-Stage FFL Mast, Adjust Hoses After Install
3.56. Lift and Tilt System Leak Check
3.57. Lift Cylinders Leak Check
3.58. Tilt Cylinders Leak Check
3.59. Tilt Cylinders Adjustment
3.60. Lift Chains Adjustment
3.61. Mast Adjustment
3.62. Carriage Adjustment
3.63. Troubleshooting
3.64. Table 1. Hook-Type Carriage Chain Adjustment
3.65. Table 2. Pin-Type Carriage Chain Adjustment
4. RM0568-(10-1999)-UK-EN
4.1. INTRODUCTION
4.2. REPAIRS
4.3. S2 SERIES TRANSAXLE
4.4. S1 SERIES TRANSAXLE
4.5. TROUBLESHOOTING
5. RM0570-(10-1999)-UK-EN
5.1. INTRODUCTION
5.2. REPAIRS
5.3. CHECKS AND ADJUSTMENTS
5.4. TROUBLESHOOTING
6. RM0576-(10-1999)-UK-EN
6.1. INTRODUCTION
6.2. REPAIRS
6.3. CHECKS AND ADJUSTMENTS
6.4. TROUBLESHOOTING
7. RM0586-(03-2002)-UK-EN
7.1. Capacities and Specifications
7.2. Safety Precautions Maintenance and Repair
7.3. Wheels and Tires
7.4. Motors (Dual Voltage 36/48)
7.5. Mast Tilt Performance
7.6. Mast Speeds
7.7. c Pump One- and Two-Speed Contactor
7.8. c Pump Transistor Control
7.9. c Pump One- and Two-Speed Contactor
7.10. c Pump Transistor Control
7.11. Mast/Tilt Drift Speeds
7.12. Hydraulic System
7.13. Torque Specifications
7.14. Transaxle
7.15. Brake System
7.16. Steering System
7.17. Hydraulic System
7.18. Mast/Tilt/Attachment Systems
7.19. Accelerator Potentiometer Checks
7.20. Adjustments
7.21. EV 100 LX Traction Card
7.22. EV 100 LX Pump Card
7.23. Controller Settings
7.24. SR/SP Traction Controller Settings – Standard With Auto Regen
7.25. SR/SP Traction Controller Settings – Standard Without Auto Decel
7.26. SR/SP Lift Pump Controller Settings
7.27. SR/SP Traction Controller Settings – 36V Energy Option
7.28. Battery Size Specifications
7.29. Type Lead Acid Battery
8. RM0588-(05-1995)-UK-EN
8.1. INTRODUCTION
8.2. REPAIRS
9. RM0655-(03-2002)-UK-EN
9.1. Steering Housing and Steering Control Unit
9.2. Safety Precautions Maintenance and Repair
9.3. General
9.4. Description
9.5. Operation
9.6. Steering Housing Repair
9.7. Remove and Disassemble
9.8. Assemble and Install
9.9. Steering Control Unit Repair
9.10. Disassemble
9.11. Assemble
9.12. Install
9.13. System Air Removal
9.14. Troubleshooting
10. RM0103-(03-2007)-UK-EN
10.1. Tilt Cylinders
10.2. Safety Precautions Maintenance and Repair
10.3. General
10.4. Description
10.5. Tilt Cylinder Repair
10.6. Disassemble
10.7. Assemble
10.8. Tilt Cylinders With O-Ring or Single-Lip Seals
10.9. Tilt Cylinders for XM and XMS Models
10.10. Tilt Cylinders for XL, XLS, and XL 3 Models
10.11. Tilt Cylinders for H700-800A and Early Model H700-920B
10.12. Install
10.13. Tilt Cylinders Using Chevron Packing
10.14. Tilt Cylinder Leak Check
10.15. Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
10.16. Torque Specifications
10.17. Piston Rod Nut
10.18. Retainer
10.19. Troubleshooting
10.20. Table 1. Movement Rates (Maximum) for Tilt Cylinders
11. RM0231-(01-2016)-UK-EN
11.1. General
12. RM0687-(03-2002)-UK-EN
12.1. Steering System
12.2. Safety Precautions Maintenance and Repair
12.3. General
12.4. Operation
12.5. Steering Wheel and Column Assembly
12.6. Description
12.7. Install
12.8. Power Steering Pump and Motor
12.9. Description
12.10. Install
12.11. Disassemble
12.12. Assemble
12.13. Steering Axle Components
12.14. General
12.15. Wheel and Tire Assembly
12.16. Install
12.17. Wheel Hub Assembly
12.18. Install
12.19. Steering Axle Assembly
12.20. Install
12.21. Steering System Air Removal
12.22. Operation Check
12.23. Steering Pressure Check
12.24. Troubleshooting
13. RM0696-(03-2002)-UK-EN
13.1. Diagrams
13.2. Safety Precautions Maintenance and Repair
14. RM0697-(08-2005)-UK-EN
14.1. SX/SR Transistor Motor Controllers and Handset
14.2. Safety Precautions Maintenance and Repair
14.3. Introduction to SEM
14.4. Advantages of Transistorized SEM
14.5. Features of SEM
14.6. Solid-State Reversing
14.7. Performance and Efficiency
14.8. Field Weakening
14.9. Regenerative Braking
14.10. SX Transistor Motor Controllers
14.11. Introduction
14.12. Proportional Operation for Dual-Motor Trucks
14.13. General
14.14. Operation
14.15. Controller Features
14.16. General
14.17. Creep Speed
14.18. Controlled Acceleration
14.19. Current Limit
14.20. Braking
14.21. Regenerative Braking to Zero Speed
14.22. Pedal Position Braking
14.23. Auto Braking
14.24. Conventional Plug Braking
14.25. Auxiliary Speed Control
14.26. Field Weakening
14.27. Speed Limits
14.28. Ramp Operation
14.29. Ramp Start
14.30. Antirollback
14.31. Steer Pump Contactor Time Delay
14.32. On-Board Coil Drivers and Internal Coil Suppression
14.33. System Protective Override
14.34. SRO (Static Return to Off)
14.35. Accelerator Volts Hold Off
14.36. Pulse Monitor Trip (PMT)
14.37. Thermal Protector (TP)
14.38. Low Voltage
14.39. SR Lift Pump Controllers
14.40. Sensor Interface/Contactor Driver Module
14.41. Diagnostic Status Codes and Troubleshooting
14.42. General Maintenance Instructions
14.43. Special Precautions
14.44. Diagnostics
14.45. Systems Diagnostics
14.46. Status Codes
14.47. Standard Status Codes
14.48. Stored Status Codes
14.49. Other Features
14.50. Hourmeter Readings
14.51. Maintenance Alert and Speed Limit
14.52. Battery Discharge Indication (BDI)
14.53. Internal Resistance Compensation
14.54. Handset Programmable
14.55. RS 232 Communication Ports
14.56. Circuit Board Coil Driver Modules
14.57. Maintenance Management Capability
14.58. Interactive Instrument Panel Modes
14.59. General Troubleshooting Instructions
14.60. Status Code Troubleshooting Tables
14.61. SX/SR Handset Instructions
14.62. General Features
14.63. Connecting the Handset
14.64. Startup Sequence
14.65. Setup Mode
14.66. Stored Status Code Mode
14.67. Clearing the Stored Status Codes
14.68. Restarting Lift Truck
14.69. SX Traction Controller Function Descriptions
14.70. Premium Instrument Panel Interactive Modes
14.71. SR Pump Controller Function Descriptions
14.72. Premium Instrument Panel Interactive Modes
14.73. Table 1. SX Traction Controller Connections/Descriptions
14.74. Table 2. SR Lift Pump Controller Connections/Descriptions/Status
14.75. Table 3. Instrument Panel Function Number Correlation
14.76. Table 4. Traction Function Settings Logic
14.77. Table 5. Lift Pump Function Settings Logic
14.78. Table 6. Speed/Torque Compensation
14.79. Table 7. Traction Controller Settings – Standard With Auto Regen
14.80. Table 8. Traction Controller Settings – Standard Without Auto Re
14.81. Table 9. Traction Controller Settings – High Performance With Au
14.82. Table 10. Lift Pump Controller Settings
15. RM0698-(03-2002)-UK-EN
15.1. Electrical System
15.2. Safety Precautions Maintenance and Repair
15.3. General
15.4. Electrical Compartment
15.5. Instrument Panels
15.6. Standard Display (Previous Configuration)
15.7. Standard Display (Current Configuration)
15.8. Premium Display (Previous Configuration)
15.9. Replacement (Previous Configuration)
15.10. Premium Display (Current Configuration)
15.11. Replacement (Current Configuration)
15.12. Control and Power Fuses
15.13. Steer Angle Potentiometer
15.14. General
15.15. Operation
15.16. Example
15.17. Installation
15.18. Positioning Steer Tire for Straight Travel
15.19. Adjustment
15.20. Handset Method
15.21. Voltmeter Method
15.22. Testing
15.23. Power Steering Control Assembly
15.24. General
15.25. Operation
15.26. Testing
15.27. Removal and Replacement
15.28. Power Steering Control Assembly
15.29. Optical Encoder
15.30. Lift Pump Control Board
15.31. General
15.32. Testing
15.33. Bypassing Lift Pump Control Board
15.34. Sensor Interface/Contactor Driver Module
15.35. General
15.36. Troubleshooting
15.37. Other Control Components
15.38. Key Switch
15.39. Seat Switch
15.40. Replace
15.41. Parking Brake Switch
15.42. Replace
15.43. Accelerator Switch Assembly
15.44. Replace
15.45. Direction Switches (MONOTROL Pedal)
15.46. Replace
15.47. Direction Switches (Steering Column)
15.48. Replace
15.49. Brake Fluid Switch
15.50. Hydraulic Cutoff Switch
15.51. Replace
15.52. Stop Light Switch
15.53. Replace
15.54. Motor Temperature Switches
15.55. Rocker Switches for Lights
15.56. DC to DC Converter
15.57. Backup Light Relay Panel
15.58. Backup Light Switch Relay
15.59. Horn and Horn Button
15.60. Horn Switch and Cover (Button)
15.61. Lights and Reverse Alarm
15.62. Light Assemblies Replacement
15.63. Tail Light
15.64. Flashing Light Assembly
15.65. Front Driving Light and Rear Work Light Assemblies
15.66. Spot Light Assembly
15.67. Table 1. Potentiometer Specifications
15.68. Table 2. Power Steering Control Assembly Specifications
15.69. Table 3. Lift Pump Control Board Test Point/Function Relationshi
15.70. Table 4. Lift Pump Control Board Troubleshooting Guide
15.71. Table 5. Lift Pump Control Board Test Values
15.72. Table 6. Lift Pump Control Board Bypass Test
15.73. Table 7. SICDM Connections/Descriptions/Status Codes
16. RM0699-(10-2007)-UK-EN

Rate this product