Hyster G160 (J1.60-1.80-2.00XMT) Service Manual

Hyster G160 (J1.60-1.80-2.00XMT) Service Manual - Image 2

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Hyster G160 (J1.60-1.80-2.00XMT) Service Manual - Image 4

Hyster G160 (J1.60-1.80-2.00XMT) Service Manual - Image 5

hyster g160 j160 180 200xmt service manual 2

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Hyster G160 (J1.60-1.80-2.00XMT) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 520
Size: 11.8MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- G160 (J1.60-1.80-2.00XMT)

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
78.2. REPAIRS
78.3. S2 SERIES TRANSAXLE
78.4. S1 SERIES TRANSAXLE
78.5. TROUBLESHOOTING
79.
79.1. INTRODUCTION
79.2. REPAIRS
79.3. CHECKS AND ADJUSTMENTS
79.4. TROUBLESHOOTING
80.
80.1. INTRODUCTION
80.2. STEERING WHEEL AND COLUMN ASSEMBLY
80.3. STEERING AXLE COMPONENTS
80.4. CHECKS AND ADJUSTMENTS
80.5. TROUBLESHOOTING
81.
81.1. INTRODUCTION
81.2. REPAIRS
81.3. CHECKS AND ADJUSTMENTS
81.4. TROUBLESHOOTING
82.
82.1. INTRODUCTION
82.2. REPAIRS
82.3. CHECKS AND ADJUSTMENTS
82.4. TROUBLESHOOTING
83.
83.1. INTRODUCTION
83.2. REPAIRS
84.
84.1. TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers
85.
85.1. INTRODUCTION TO SEM
85.2. SIX TRANSISTOR MOTOR CONTROLLERS
85.3. SR LIFT PUMP CONTROLLERS
85.4. SENSOR INTERFACE/CONTACTOR DRIVER MODULE
85.5. DIAGNOSTIC STATUS CODES AND TROUBLESHOOTING
85.6. SX/SR HAND SET INSTRUCTIONS
85.7. SIX TRACTION CONTROLLER FUNCTION DESCRIPTIONS
85.8. SR PUMP CONTROLLER FUNCTION DESCRIPTIONS
86.
86.1. GENERAL
86.2. INSTRUMENT PANELS
86.3. CONTROL AND POWER FUSES
86.4. STEER ANGLE POTENTIOMETER
86.5. POWER STEERING CONTROL ASSEMBLY
86.6. LIFT PUMP CONTROL BOARD
86.7. SENSOR INTERFACE/CONTACTOR DRIVER MODULE
86.8. OTHER CONTROL COMPONENTS
86.9. LIGHT ASSEMBLIES
87.
87.1. INTRODUCTION
87.2. CHECKS AND ADJUSTMENTS
87.3. REPAIRS
87.4. BATTERY INDICATORS
87.5. CONTROLLER FOR THE BATTERY INDICATOR
87.6. DISPLAY PANEL COMPONENTS
88.
88.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
88.2. LIFT CYLINDERS
88.3. REPAIRS
88.4. LIFT CYLINDERS FOR VISTA MASTS
88.5. CHECKS AND ADJUSTMENTS
88.6. TROUBLESHOOTING
88.7. SPECIFICATIONS
89.
89.1. INTRODUCTION
89.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
89.3. REPAIRS
89.4. CHECKS AND ADJUSTMENTS
89.5. TROUBLESHOOTING
90.
90.1. INTRODUCTION
90.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
90.3. REPAIRS
90.4. CHECKS AND ADJUSTMENTS
90.5. TROUBLESHOOTING
91.
91.1. INTRODUCTION
91.2. TABLE 1. BOLTS AND SCREWS
91.3. TABLE 2. STUDS AND NUTS
91.4. TABLE 3. TORQUE NUTS
91.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
91.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
91.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
92.
92.1. INTRODUCTION
92.2. MAINTENANCE SCHEDULE
92.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
92.4. EVERY 350 HOURS OR TWO MONTHS
92.5. HOURS OR YEARLY
92.6. GENERAL PROCEDURES
92.7. WHEELS AND TYRES
93.
93.1. WHEELS AND TYRES
93.2. MOTORS (DUAL VOLTAGE 36/48)
93.3. MAST TILT PERFORMANCE
93.4. MAST SPEEDS 19cc PUMP 1 and 2 SPEED CONTACTOR
93.5. MAST SPEEDS 19cc PUMP TRANSISTOR CONTROL
93.6. MAST SPEEDS 12cc PUMP 1 and 2 SPEED CONTACTOR
93.7. MAST SPEEDS 12cc PUMP TRANSISTOR CONTACTOR
93.8. MAST/TILT DRIFT SPEEDS
93.9. HYDRAULIC SYSTEM
93.10. TORQUE SPECIFICATIONS
93.11. ACCELERATOR POTENTIOMETER CHECKS
93.12. ADJUSTMENTS, EV 100 LX TRACTION CARD
93.13. SX/SR Traction Controller Settings – Standard
93.14. SX/SR Traction Controller Settings – Energy Option
93.15. SX/SR Traction Controller Settings – With or Without Auto Regen
93.16. ADJUSTMENTS, EV 100 LX PUMP CARD
93.17. SX/SR Lift Pump Controller Settings
93.18. BATTERY SIZE SPECIFICATIONS – TYPE LEAD ACID BATTERY
94.
94.1. FIGURE 1. TRACTION CONTROL WIRING SCHEMATIC
94.2. FIGURE 2. TRANSISTOR LIFT PUMP CONTROL WIRING SCHEMATIC
94.3. FIGURE 3. 1 SPEED LIFT PUMP CONTROL WIRING SCHEMATIC
94.4. FIGURE 4. 2 SPEED LIFT PUMP CONTROL WIRING SCHEMATIC
94.5. FIGURE 5. FRONT COMPARTMENT WIRING DIAGRAM WITH BDI
94.6. FIGURE 6. FRONT COMPARTMENT WIRING DIAGRAM WITH HOUR METER/VOLTMETER
94.7. FIGURE 7. REAR COMPARTMENT WIRING DIAGRAM WITH TRANSISTOR LIFT PUMP CONTROL
94.8. FIGURE 8. REAR COMPARTMENT WIRING DIAGRAM WITH 1 SPEED LIFT PUMP CONTROL
94.9. FIGURE 9. REAR COMPARTMENT WIRING DIAGRAM WITH 2 SPEED LIFT PUMP CONTROL
94.10. FIGURE 10. PLUG PIN CONNECTIONS
94.11. FIGURE 11 – TRACTION CONTROL WIRING SCHEMATIC
94.12. FIGURE 12 – TRANSISTOR LIFT PUMP CONTROL WIRING SCHEMATIC
94.13. FIGURE 13 – SPEED LIFT PUMP CONTROL WIRING SCHEMATIC
94.14. FIGURE 14 – SPEED LIFT PUMP CONTROL WIRING SCHEMATIC
94.15. FIGURE 15 – SEAT BRAKE WIRING DIAGRAM
94.16. FIGURE 16 – FRONT COMPARTMENT WIRING DIAGRAM WITH INSTRUMENT PANEL
94.17. FIGURE 17 – REAR COMPARTMENT WIRING DIAGRAM W/TRANSISTOR LIFT PUMP CONTROL
94.18. FIGURE 18 – REAR COMPARTMENT WIRING DIAGRAM WITH 1 SPEED LIFT PUMP CONTROL
94.19. FIGURE 11 – 12 VOLT LIGHTS WIRING DIAGRAM
94.20. FIGURE 12 – 12 VOLT LIGHTS WIRING DIAGRAM
94.21. FIGURE 13 – 12 VOLT LIGHTS WIRING DIAGRAM
94.22. FIGURE 12 – OPTIONS SCHEMATIC (LIGHTS)
94.23. FIGURE 13 – OPTIONS DIAGRAM (LIGHTS)
94.24. FIGURE 14 – PLUG / SPLICE DETAILS (LIGHTS)
94.25. FIGURE 15 – HYDRAULIC SCHEMATIC WITH 3 SPOOL VALVE ARRANGEMENT
94.26. FIGURE 16 – HYDRAULIC SCHEMATIC WITH 4 SPOOL VALVE ARRANGEMENT
95.
95.1. INTRODUCTION
95.2. MAINTENANCE SCHEDULE
95.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
95.4. EVERY 500 HOURS OR THREE MONTHS
95.5. HOURS OR YEARLY
95.6. EVERY 4000 HOURS
95.7. GENERAL PROCEDURES
95.8. WHEELS AND TYRES
95.9. BATTERY SIZE SPECIFICATIONS
96.
96.1. INTRODUCTION
96.2. MAINTENANCE SCHEDULE
96.3. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY
96.4. EVERY 350 HOURS OR TWO MONTHS
96.5. HOURS OR YEARLY
96.6. EVERY 4000 HOURS
96.7. GENERAL PROCEDURES
96.8. WHEELS AND TYRES
96.9. BATTERY SIZE SPECIFICATIONS

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