Hyster F160 (J30-40XMT) Service Manual - Image 2

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Hyster F160 (J30-40XMT) Service Manual - Image 5

Hyster F160 (J30-40XMT) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 443
Size: 24.7MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- F160 (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
83.2. STEERING WHEEL AND COLUMN ASSEMBLY
83.2.1. DESCRIPTION
83.3. POWER STEERING PUMP AND MOTOR
83.3.1. DESCRIPTION
83.3.2. REPAIRS
83.4. STEERING TRUNNION ASSEMBLY
83.4.1. STEER AXLE
83.4.2. WHEEL ASSEMBLY
83.4.3. WHEEL HUB
83.4.4. STEER AXLE ASSEMBLY
83.4.5. POWER STEERING CYLINDER
83.5. CHECKS AND ADJUSTMENTS
83.5.1. AIR IN THE STEERING SYSTEM
83.6. TROUBLESHOOTING
84.
84.1. INTRODUCTION
84.1.1. GENERAL
84.1.2. DESCRIPTION
84.1.3. OPERATION
84.2. REPAIRS
84.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
84.3. CHECKS AND ADJUSTMENTS
84.3.1. REMOVE AIR FROM THE SYSTEM
84.4. TROUBLESHOOTING
85.
85.1. INTRODUCTION
85.1.1. GENERAL
85.1.2. DESCRIPTION
85.2. REPAIRS
85.2.1. SERVICE BRAKE PADS
85.2.2. SERVICE BRAKE CALIPER
85.2.3. PARK BRAKE CALIPER
85.2.4. MASTER CYLINDER
85.2.5. FOOT OPERATED PARK BRAKE LEVER ASSEMBLY
85.2.6. ELECTRICALLY RELEASED PARK BRAKE
85.2.7. ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS
85.3. CHECKS AND ADJUSTMENTS
85.3.1. PARK BRAKE ADJUSTMENT
85.3.2. SERVICE BRAKE ADJUSTMENT
85.3.3. REMOVE AIR FROM BRAKE SYSTEM
85.4. TROUBLESHOOTING
86.
86.1. INTRODUCTION
86.1.1. GENERAL
86.1.2. DESCRIPTION
86.1.3. OPERATION
86.2. REPAIRS
86.2.1. MAIN CONTROL VALVE
86.3. CHECKS AND ADJUSTMENTS
86.3.1. RELIEF VALVE
86.3.2. VANE SETTINGS
86.3.3. MAST TILT ADJUSTMENT
86.4. TROUBLESHOOTING
87.
88.
88.1. ELECTRICAL WARNING DEVICES
88.1.1. GENERAL
88.1.2. DESCRIPTION
88.1.3. REPLACEMENT
89.
90.
90.1. INTRODUCTION
90.1.1. GENERAL
90.2. DESCRIPTION
90.2.1. INSTRUMENT PANELS
90.2.2. PRINTED CIRCUIT BOARDS
90.3. REPLACEMENT
90.3.1. INSTRUMENT PANEL COMPONENTS
90.3.2. PRINTED CIRCUIT BOARDS
90.3.3. OTHER CONTROL COMPONENTS
90.4. CHECKS AND ADJUSTMENTS
90.4.1. CONTROL AND POWER FUSES
90.4.2. CHECK ACCELERATOR SWITCH ASSEMBLY
90.4.3. ADJUSTING STOP LIGHT SWITCH
90.4.4. CHECK SEAT SWITCH
90.4.5. ADJUSTING PARKING BRAKE SWITCH
90.4.6. DIRECTION SWITCHES (MONOTROL PEDAL)
90.4.7. DIRECTION SWITCHES (STEERING COLUMN)
90.4.8. HYDRAULIC CUT OFF SWITCH
90.4.9. PRINTED CIRCUIT BOARDS
90.4.10. Steering Angle Control Board
90.4.11. Lift Pump Control Board
90.4.12. Bypassing the Lift Pump Control Board
91.
92.
92.1. INTRODUCTION
92.1.1. GENERAL
92.1.2. DESCRIPTION AND OPERATION
92.1.3. TWO-STAGE MAST, LIMITED FREE-LIFT
92.1.4. TWO-STAGE MAST, FULL FREE-LIFT
92.1.5. THREE-STAGE, FULL FREE-LIFT MAST
93.
93.1. INTRODUCTION
93.1.1. GENERAL
93.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
93.3. REPAIRS
93.3.1. Removal
93.3.2. Installation
93.3.3. CARRIAGES
93.3.4. LIFT CYLINDERS
93.3.5. HEADER HOSE ARRANGEMENTS H/S/E/J2.003.20XM (H/S/E/J4065XM) S/E/J2.003.00XL (S/E/J4060XL)
93.3.6. HEADER HOSE ARRANGEMENTS H/E1.501.75XM, H/S2.00XMS (H/S/E2535XM, H/S/E40XMS) and J1.602.00XMT (J3040XMT)
93.4. CHECKS AND ADJUSTMENTS
93.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
93.4.2. ADJUST THE TILT CYLINDERS
93.4.3. ADJUST THE LIFT CHAINS
93.4.4. ADJUST THE MAST
93.4.5. ADJUST THE CARRIAGE
93.5. TROUBLESHOOTING
94.
95.
95.1. INTRODUCTION
95.1.1. GENERAL
95.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
95.1.3. HOW TO TOW A LIFT TRUCK
95.1.4. HOW TO PUT A LIFT TRUCK ONTO BLOCKS
95.2. 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 350 HOURS OR TWO MONTHS
95.4.1. HYDRAULIC TANK BREATHER
95.4.2. WHEEL NUT TORQUE
95.4.3. STEERING TRUNNION MOUNTING CAPSCREW TORQUE
95.4.4. TRANSAXLE
95.4.5. LIFT SYSTEM OPERATION
95.4.6. LIFT CHAINS
95.4.7. SAFETY LABELS
95.4.8. BRAKE FLUID
95.4.9. OTHER LUBRICATION
95.4.10. 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. LIFT SYSTEM
95.7.3. TILT SYSTEM
95.7.4. HOW TO CHECK THE PMT CIRCUIT
95.7.5. HOW TO CHARGE THE BATTERY
95.7.6. HOW TO CHANGE THE BATTERY
95.8. WHEELS AND TIRES
95.8.1. GENERAL
95.8.2. HOW TO CHANGE THE TIRES
95.8.3. STEER AND DRIVE WHEELS
95.8.4. PNEUMATIC TIRES
95.8.5. PNEUMATIC SHAPED SOLID TIRES
95.8.6. SOLID TIRES
95.8.7. INSTALL THE WHEEL AND TIRE
95.8.8. BATTERY SIZE SPECIFICATIONS
96.
97.
97.1. WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP
97.2. WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP
97.3. OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP
97.4. WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP
97.5. WIRING DIAGRAM WITH CONTACTOR CONTROLLED LIFT PUMP
97.6. OPTIONAL WIRING WITH CONTACTOR CONTROLLED LIFT PUMP
97.7. OPTIONAL MAIN LIGHTS WIRING
97.8. CABLE DETAILS
97.9. ELECTRICAL ARRANGEMENT WITH SCR CONTROLLED LIFT PUMP
97.10. ELECTRICAL ARRANGEMENT WITH CONTACTOR CONTROLLED LIFT PUMP
97.11. HYDRAULIC SYSTEM ARRANGEMENT
97.12. HYDRAULIC SCHEMATIC

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