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Hyster B160 (J25A, J30AS, J35A) Service Manual – PDF DOWNLOAD
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Description
Hyster B160 (J25A, J30AS, J35A) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster B160 (J25A, J30AS, J35A) Service Manual – PDF DOWNLOAD
Language : English
Pages : 276
Downloadable : Yes
File Type : PDF
Size: 7.25 MB
TABLE OF CONTENTS:
Hyster B160 (J25A, J30AS, J35A) Service Manual – PDF DOWNLOAD
Battery Discharge Indicators............................................................................ 1 INTRODUCTION........................................................................................ 1 GENERAL......................................................................................... 1 INDICATORS WITH METER MOVEMENTS................................................................. 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS..................................................... 3 Liquid Crystal Displays..................................................................... 3 Light Emitting Diode Displays............................................................... 7 CHECKS AND ADJUSTMENTS.............................................................................. 9 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS......................................... 9 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS............................................ 9 Reset Potentiometer......................................................................... 9 Specific Gravity Alarm...................................................................... 10 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS......................................... 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS............................................ 11 Reset Potentiometer......................................................................... 11 Discharge Potentiometer..................................................................... 11 LED DISPLAY WITH LIFT INTERRUPT................................................................. 12 CHECKING CURTIS 933-1 METER..................................................................... 12 Reset Check................................................................................. 12 Discharge Check............................................................................. 13 Lockout Check............................................................................... 13 LED's Do Not Illuminate..................................................................... 14 Hourmeter Check............................................................................. 14 Hour Glass Icon............................................................................. 14 ADJUSTMENT OF CURTIS 933-1 METER............................................................ 14 CHECKING CURTIS 1215 BATTERY INDICATOR...................................................... 14 ADJUSTING CURTIS 1215 BATTERY INDICATOR..................................................... 15 Voltage Selection....................................................................... 16 ADJUSTING BDI OF SEM DISPLAY PANEL.......................................................... 17 REPAIRS......................................................................................... 17 BATTERY INDICATORS.......................................................................... 17 Replacement............................................................................. 17 CONTROLLER FOR THE BATTERY INDICATOR........................................................ 17 Replacement............................................................................. 17 DISPLAY PANEL COMPONENTS.................................................................... 17 REPLACING SEM DISPLAY PANEL................................................................. 17 SEM Display Panel REMOVAL................................................................... 19 Removal And Replacement................................................................. 19 Brakes.................................................................................................. 21 INTRODUCTION........................................................................................ 21 General......................................................................................... 21 Description..................................................................................... 21 REPAIRS............................................................................................. 22 Service Brakes.................................................................................. 22 Parking Brake................................................................................... 24 Seat Brake...................................................................................... 26 CHECKS AND ADJUSTMENTS.............................................................................. 28 Removing Air From The Service Brakes ........................................................... 28 Brake Pedal Adjustment.......................................................................... 28 Adjustment Of The Parking Brake Linkage......................................................... 28 Adjustment Of The Seat Brake.................................................................... 28 Adjustment Of The Friction Pads................................................................. 29 TROUBLESHOOTING..................................................................................... 30 Capacities & Specification.............................................................................. 31 DC Motor Maintenance.................................................................................... 37 INTRODUCTION........................................................................................ 37 MAGNETISM........................................................................................... 37 MAGNETISM AND PERMANENT MAGNETS................................................................. 37 ELECTROMAGNETIC FIELDS.......................................................................... 37 ELECTROMAGNETS.................................................................................. 38 ELECTROMAGNETIC INDUCTION....................................................................... 39 MAGNETIC FORCE ON A CONDUCTOR................................................................... 39 BASIC MOTORS........................................................................................ 40 MOTOR OPERATION................................................................................. 40 COMMUTATION PRINCIPLE........................................................................... 41 DIRECTION OF MOTOR ROTATION..................................................................... 41 MOTOR SPEED..................................................................................... 41 MOTOR TORQUE.................................................................................... 42 COUNTER ELECTROMOTIVE FORCE..................................................................... 42 TYPICAL MOTOR................................................................................... 42 TYPES OF MOTORS................................................................................. 42 Permanent–Magnet............................................................................ 42 Series Wound................................................................................ 43 Parallel or Shunt Wound..................................................................... 44 Compound Wound.............................................................................. 44 MOTOR INSULATION CLASS.......................................................................... 45 STORAGE......................................................................................... 45 HANDLING........................................................................................ 45 BREAK–IN OPERATION.............................................................................. 45 CLEANING........................................................................................ 46 BASIC REPAIR GUIDELINES......................................................................... 46 BEARINGS, SEALS AND LUBRICATION................................................................. 47 BRUSHES AND BRUSH HOLDERS....................................................................... 47 ARMATURE........................................................................................ 48 COMMUTATOR...................................................................................... 48 Description................................................................................. 48 SATISFACTORY SURFACE............................................................................ 49 STREAKING AND THREADING SURFACE................................................................. 50 GROOVING ON SURFACE............................................................................. 51 COPPER DRAG ON SURFACE.......................................................................... 53 OVERHEATING..................................................................................... 53 FIELD ASSEMBLY.................................................................................. 55 INSPECTION CHECKLIST............................................................................ 55 CHECKING AND REPLACING MOTOR BRUSHES............................................................ 55 Inspecting Brushes.......................................................................... 55 INSPECT THE COMMUTATOR.......................................................................... 56 REPLACING BRUSHES............................................................................... 56 SEATING BRUSHES (STONING PROCEDURE)............................................................. 56 CHECK THE MOTORS FOR OPENS, GROUNDS AND SHORTS.................................................. 57 Check The Motor For Opens................................................................... 57 Check The Motor For Grounds................................................................. 57 Check The Motor For Shorts.................................................................. 57 COMMUTATOR INSPECTION........................................................................... 59 POLISHING COMMUTATOR............................................................................ 60 TURNING COMMUTATOR.............................................................................. 60 UNDERCUTTING COMMUTATOR......................................................................... 60 SLOT RAKING AND BRUSHING COMMUTATOR............................................................. 60 Diagrams Procontrol (EV-1B)............................................................................. 62 FIGURE 1. WIRING DIAGRAM............................................................................ 63 FIGURE 2. ELECTRICAL SCHEMATIC...................................................................... 67 Diagrams Procontrol-I (SEVCON).......................................................................... 68 FIGURE 1. ELECTRICAL SCHEMATIC...................................................................... 69 FIGURE 2. WIRING DIAGRAM - CHASSIS.................................................................. 71 FIGURE 3. WIRING DIAGRAM - CONTROL PANEL............................................................ 73 Diagrams-Procontrol-II (SEVCON)......................................................................... 74 FIGURE 1. ELECTRICAL SCHEMATIC...................................................................... 75 FIGURE 2. WIRING DIAGRAM - CONTROL PANEL............................................................ 77 FIGURE 3. WIRING DIAGRAM - CHASSIS.................................................................. 79 Electrical System for EV-1B Controller.................................................................. 80 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS.............................. 80 GENERAL......................................................................................... 80 CONTROL AND POWER FUSES......................................................................... 85 CONTROL CARD ADJUSTMENTS........................................................................ 86 Adjusting Creep Speed, "CREEP'.............................................................. 88 Adjusting Controlled Acceleration, "C/A" ................................................... 88 Adjusting Current Limit, "C/L".............................................................. 89 Adjust "1A TIME"............................................................................ 90 Adjust 1A Drop Out, "1A D.O"................................................................ 92 Adjust Plugging, "PLUG"..................................................................... 92 Ramp Start.................................................................................. 92 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."...................... 92 Adjust "REGEN C/L" (Current Limit).......................................................... 93 Adjust "REGEN D.O." (Drop Out).............................................................. 93 PROPORTIONAL CONTROL (J25-35A Only)............................................................. 96 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS......................................................... 97 SCR CONTROL, SINGLE PUMP MOTOR.................................................................. 97 Accelerator Card (E-20-100B, J40-60AS Only)................................................. 98 Circuit Description For Accelerator Card Used With A Seat Switch............................ 99 Accelerator "START" (IC3)...................................................................100 Accelertor "1A TIME" (IC2)..................................................................100 Circuit Description For Accelerator Card Used With A Seat Brake.............................100 Accelerator "START" (IC3)...................................................................101 Accelerator "1A TIME" (IC1 and IC2).........................................................101 CHECK THE ACCELERTOR CARD...................................................................101 ADJUSTING THE ACCELERATOR CARD..............................................................101 THE POTENTIOMETERS AND CONTOL SWITCHES..........................................................101 Steering Potentiometer (J25-35A Only).......................................................101 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only)....................103 Accelerator Potentiometer And Direction Switch..............................................104 Adjusting Start Switch......................................................................105 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks)..................105 Direction Switches (MONOTROL) (Later Production Lift Trucks)................................106 "FORWARD" And "REVERSE" Switch (Steering Column)............................................107 Hydraulic Pump Switch.......................................................................107 Replace The Key Switch......................................................................107 Adjust The Seat Switch......................................................................107 Adjust The Brake Switch.....................................................................108 Parking Brake Switch........................................................................108 Rocker Switch...............................................................................109 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only)....................................110 Frame...................................................................................................111 INTRODUCTION........................................................................................111 General.........................................................................................111 Description.....................................................................................111 DISASSEMBLY AND ASSEMBLY............................................................................112 Overhead Guard..................................................................................112 Hood and Seat Assembly..........................................................................112 Counterweight...................................................................................113 Hydraulic Tank Repairs..........................................................................113 Decal Replacement...............................................................................115 Hydraulic Gear Pumps....................................................................................117 INTRODUCTION........................................................................................117 DESCRIPTION.....................................................................................117 OPERATION.......................................................................................117 Flow Control Valve..........................................................................119 Relief Valve................................................................................119 REPAIRS.............................................................................................120 REMOVAL.........................................................................................120 DISASSEMBLY.....................................................................................120 CLEANING........................................................................................122 INSPECTION......................................................................................122 ASSEMBLY........................................................................................123 INSTALLATION....................................................................................124 CHECKS AND ADUSTMENTS...............................................................................125 CHECK THE OUTPUT OF THE PUMP....................................................................125 CHECK FOR AIR IN THE HYDRAULIC SYSTEM...........................................................125 TROUBLESHOOTING.....................................................................................127 Hydraulic Vane Pumps....................................................................................130 INTRODUCTION........................................................................................130 GENERAL.........................................................................................130 DESCRIPTION.....................................................................................130 OPERATION.......................................................................................130 Pump........................................................................................130 Relief Valve................................................................................131 REPAIRS.............................................................................................132 REMOVAL.........................................................................................132 DISASSEMBLY.....................................................................................132 ASSEMBLY........................................................................................133 INSTALLATION....................................................................................134 CHECKS AND ADJUSTMENTS..............................................................................134 CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE................................................134 Lift Trucks With Internal Combustion Engines................................................134 Electric Lift Trucks........................................................................134 Electric Lift Trucks With Adjustable Relief Valve...........................................135 SPECIFICATIONS......................................................................................136 TROUBLESHOOTING.....................................................................................136 Industrial Battery......................................................................................137 INTRODUCTION........................................................................................137 GENERAL.........................................................................................137 LEAD-ACID BATTERIES.............................................................................137 SPECIFIC GRAVITY................................................................................138 CHEMICAL REACTION IN A CELL.....................................................................138 ELECTRICAL TERMS................................................................................139 HOW TO SELECT THE BATTERY.......................................................................139 VOLTAGE OF A BATTERY............................................................................139 THE BATTERY AS A COUNTERWEIGHT..................................................................140 BATTERY RATINGS.................................................................................140 Kilowatt-Hours..............................................................................141 BATTERY MAINTENANCE.................................................................................141 SAFETY PROCEDURES...............................................................................141 MAINTENCE RECORDS...............................................................................142 THE NEW BATTERY.................................................................................142 HOW TO CLEAN THE BATTERY........................................................................143 HOW TO ADD WATER................................................................................143 THE HYDROMETER..................................................................................144 BATTERY TEMPERATURE.............................................................................144 CHARGING THE BATTERY............................................................................145 Types Of Battery Charges....................................................................146 Methods Of Charging.........................................................................147 Troubleshooting The Charger.................................................................147 How to Know When The Battery Is Fully Charged...............................................148 WHERE TO CHARGE THE BATTERIES...................................................................148 Equipment Needed............................................................................148 BATTERY CONNECTORS..............................................................................149 BATTERY CARE....................................................................................149 Lift Cylinders..........................................................................................151 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................151 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................151 LIFT CYLINDERS......................................................................................154 GENERAL.........................................................................................154 DESCRIPTION.....................................................................................154 Lowering Control Valve......................................................................154 Cylinders (General).........................................................................157 Cylinders (H520-620B,H700-800A).............................................................159 Cylinders (H360-460B).......................................................................160 Cylinders (Two-Speed).......................................................................160 REPAIRS.............................................................................................161 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..........................................161 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....161 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.....................165 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...............163 DISASSEMBLY.....................................................................................163 ASSEMBLY........................................................................................165 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...................................................165 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....165 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead............165 CHEVRON PACKING.................................................................................166 LIFT CYLINDERS FOR VISTA MASTS......................................................................169 DESCRIPTION.....................................................................................169 Lowering Control Valve......................................................................171 REMOVAL.........................................................................................172 DISASSEMBLY.....................................................................................172 ASSEMBLY........................................................................................172 INSTALLATION....................................................................................173 Main Lift Cylinders.........................................................................173 Free-Lift Cylinders.........................................................................173 CHECKS AND ADJUSTMENTS..............................................................................174 CHECK FOR LEAKS IN LIFT SYSTEM..................................................................174 TROUBLESHOOTING.....................................................................................175 SPECIFICATIONS......................................................................................176 Mast Description........................................................................................177 INTRODUCTION........................................................................................177 GENERAL.........................................................................................177 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)...............................179 FULL FREE-LIFT MASTS............................................................................179 THREE-STAGE MASTS...............................................................................181 FOUR-STAGE MASTS................................................................................182 SEQUENCE VALVE..................................................................................182 Mast Repair.............................................................................................184 INTRODUCTION........................................................................................184 REPAIRS.............................................................................................184 Forks...........................................................................................184 Carriage........................................................................................184 Uprights........................................................................................186 CHECKS AND ADJUSTMENTS..............................................................................191 Checking For Leaks In The Lift System...........................................................191 Adjusting The Tilt Cylinder Stroke And Backward Tilt Angle......................................192 Upright Adjustments.............................................................................193 TROUBLESHOOTING.....................................................................................197 Master Cylinder.........................................................................................198 INTRODUCTION........................................................................................198 GENERAL.........................................................................................198 DESCRIPTION.....................................................................................198 REPAIRS.............................................................................................198 REMOVAL AND DISASSEMBLY.........................................................................198 CLEANING .......................................................................................199 ASSEMBLY........................................................................................199 CHECKS AND ADJUSTMENTS..............................................................................199 CHECKS..........................................................................................199 Periodic Maintenance....................................................................................200 INTRODUCTION........................................................................................200 GENERAL.........................................................................................200 SERIAL NUMBER DATA..............................................................................200 HOW TO MOVE A DISABLED LIFT TRUCK...............................................................200 How To Tow A Lift Truck.....................................................................200 RELEASE THE SEAT BRAKE ON A DISABLED LIFT TRUCK.................................................201 HOW TO PUT A LIFT TRUCK ON BLOCKS...............................................................202 HOW TO RAISE THE DRIVE TIRES....................................................................202 How to Raise the Steering Tires.............................................................202 MAINTENANCE SCHEDULE................................................................................203 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................205 CHECKS BEFORE OPERATION.........................................................................205 HOW TO MAKE CHECKS WITH THE KEY OFF.............................................................205 Tires And Wheels............................................................................205 Forks.......................................................................................206 Fork Adjustment.............................................................................206 Hook Fork, Removal..........................................................................206 Hook Fork, Installation.....................................................................207 Inspection Of Mast, Forks, And Lift Chains..................................................207 Safety Labels...............................................................................208 Operator Restraint System...................................................................209 Check The Operation.........................................................................209 Battery Restraint System....................................................................209 Battery.....................................................................................210 Hydraulic System............................................................................210 HOW TO MAKE CHECKS WITH THE KEY ON..............................................................211 Gauges And Horn.............................................................................211 Steering System.............................................................................211 Service Brakes..............................................................................211 Parking Brake...............................................................................211 Control Levers And Pedals...................................................................212 Lift System Operation.......................................................................212 EVERY 350 HOURS OR TWO MONTHS.......................................................................213 HYDRAULIC TANK BREATHER.........................................................................213 TRANSAXLE.......................................................................................213 WHEEL NUT TORQUE................................................................................213 MAST............................................................................................213 LIFT CHAINS.....................................................................................214 Check for Wear..............................................................................214 Lubrication.................................................................................215 FORKS...........................................................................................215 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................216 SEAT BRAKE......................................................................................217 BRAKE FLUID.....................................................................................217 OTHER LUBRICATION...............................................................................217 ELECTRICAL INSPECTION...........................................................................217 CONTACTORS......................................................................................217 MOTOR BRUSHES...................................................................................218 2000 HOURS OR YEARLY................................................................................219 HYDRAULIC SYSTEM................................................................................219 CHANGE THE OIL FILTER...........................................................................219 CHANGE THE HYDRAULIC OIL........................................................................219 TRANSAXLE.......................................................................................219 STEERING SYSTEM.................................................................................220 Manual Steering.............................................................................220 Power Steering..............................................................................220 BRAKES..........................................................................................220 CONTACTORS......................................................................................221 LIFT CHAINS.....................................................................................221 GENERAL PROCEDURES..................................................................................222 HOW TO CHARGE THE BATTERY.......................................................................222 HOW TO CHANGE THE BATTERY.......................................................................223 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................224 Check the Lift Cylinders for Leaks..........................................................224 Check the Tilt Cylinders for Leaks..........................................................224 WELDING REPAIRS.................................................................................225 CHANGES TO THE OVERHEAD GUARD...................................................................225 LIFT CHAIN ADJUSTMENTS..........................................................................225 HOW TO CHECK THE PMT CIRCUIT....................................................................226 WHEELS AND TIRES................................................................................226 How To Change A Solid Rubber (Press-on) Tire................................................227 How To Repair A Pneumatic Tire..............................................................227 How To Remove A Wheel From The Lift Truck...................................................228 How To Remove Tire From The Wheel...........................................................228 How To Install The Tire On The Wheel........................................................229 Add Air To The Tires........................................................................230 How To Install The Wheel....................................................................230 Solid Rubber Tires That Look Like Pneumatic Tires...........................................230 Remove The Wheels From The Lift Truck.......................................................230 Remove The Tire From The Wheel..............................................................230 Install The Tire On The Wheel...............................................................230 REFERENCE TABLE.....................................................................................233 SAE & Metric Fasteners..................................................................................234 INTRODUCTION........................................................................................234 NOMENCLATURE, THREADS...........................................................................234 STRENGTH IDENTIFICATION.........................................................................235 TABLE 1. BOLTS AND SCREWS...........................................................................235 TABLE 2. STUDS AND NUTS.............................................................................236 TABLE 3. TORQUE NUTS................................................................................237 TABLE 4. TORQUE NUTS WITH NYLON INSERT..............................................................238 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...........................................................239 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.........................................................240 Steering Control Unit...................................................................................243 INTRODUCTION........................................................................................243 GENERAL.........................................................................................243 DESCRIPTION.....................................................................................243 OPERATION.......................................................................................243 REPAIRS.............................................................................................243 STEERING WHEEL AND COLUMN ASSEMBLY..............................................................243 TYPE "A" STEERING COLUMN ASSEMBLY...............................................................245 Removal And Disassembly.....................................................................245 Assembly And Installation...................................................................245 TYPE "A" STEERING COLUMN........................................................................246 TYPE "A" STEERING COLUMN........................................................................247 TYPE "B" STEERING COLUMN........................................................................248 Removal And Disassembly.....................................................................248 Assembly And Installation...................................................................248 TYPE "B" STEERING COLUMN........................................................................249 Disassembly of Steering Control Unit........................................................250 Cleaning of Steering Control Unit...........................................................250 Assembly of Steering Control Unit...........................................................252 CHECKS AND ADJUSTMENTS..............................................................................255 REMOVE AIR FROM THE SYSTEM......................................................................255 TROUBLESHOOTING.....................................................................................256 Tilt Cylinders..........................................................................................257 INTRODUCTION........................................................................................257 GENERAL.........................................................................................257 DESCRIPTION.....................................................................................257 REPAIRS.............................................................................................257 REMOVAL.........................................................................................257 DISASSEMBLY.....................................................................................257 CLEANING........................................................................................257 ASSEMBLY........................................................................................257 Tilt Cylinders with O-Rings or Single Lip Seals.............................................257 Tilt Cylinders for the XM and XMS Models....................................................258 Tilt Cylinders for H700 800A and Early Model H700 920B......................................260 INSTALLATION....................................................................................260 Tilt Cylinders Using Chevron Packing........................................................261 CHECKS AND ADJUSTMENTS..............................................................................263 CHECK THE TILT CYLINDERS FOR LEAKS..............................................................263 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.........................................263 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS............................................264 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...........................................265 TROUBLESHOOTING.....................................................................................267 Transaxle Assembly......................................................................................268 INTRODUCTION........................................................................................268 General.........................................................................................268 Description.....................................................................................268 REPAIRS.............................................................................................271 Removal.........................................................................................271 Disassembly.....................................................................................272 Assembly........................................................................................272 Installation....................................................................................273 WHEELS AND TIRES....................................................................................274 Description.....................................................................................274 TROUBLESHOOTING.....................................................................................276
HYSTER B160 (J25A, J30AS, J35A) SERVICE MANUAL – PDF DOWNLOAD:
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