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Hyster H160 Service Manual – PDF DOWNLOAD
Original price was: $89.95.$28.95Current price is: $28.95.
Hyster H160 Service Manual – PDF DOWNLOAD
PART NO. 1454588
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Hyster H160 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster H160 Service Manual – PDF DOWNLOAD
PART NO. 1454588
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster H160 Service Manual – PDF DOWNLOAD
1454588-2200SRM0697-(09-2003)-US-EN......................................... 1 toc..................................................................... 1 SX/SR Transistor Motor Controllers and Handset...................... 1 Safety Precautions Maintenance and Repair........................... 2 Introduction to SEM................................................. 5 Advantages of Transistorized SEM................................ 5 Features of SEM................................................. 6 Solid-State Reversing....................................... 6 Performance and Efficiency.................................. 6 Field Weakening............................................. 6 Regenerative Braking........................................ 6 SX Transistor Motor Controllers..................................... 7 Introduction.................................................... 7 Proportional Operation for Dual-Motor Trucks.................... 7 General..................................................... 7 Operation................................................... 9 Controller Features............................................. 11 General..................................................... 11 Creep Speed................................................. 11 Controlled Acceleration..................................... 11 Current Limit............................................... 11 Braking......................................................... 11 Regenerative Braking to Zero Speed.......................... 11 Pedal Position Braking...................................... 12 Auto Braking................................................ 12 Conventional Plug Braking................................... 12 Auxiliary Speed Control......................................... 12 Field Weakening............................................. 12 Speed Limits................................................ 12 Ramp Operation.................................................. 12 Ramp Start.................................................. 12 Antirollback................................................ 13 Steer Pump Contactor Time Delay................................. 13 On-Board Coil Drivers and Internal Coil Suppression............. 13 System Protective Override...................................... 13 SRO (Static Return to Off).................................. 13 Accelerator Volts Hold Off.................................. 13 Pulse Monitor Trip (PMT).................................... 13 Thermal Protector (TP)...................................... 13 Low Voltage................................................. 13 SR Lift Pump Controllers............................................ 14 Sensor Interface/Contactor Driver Module............................ 18 Diagnostic Status Codes and Troubleshooting......................... 18 General Maintenance Instructions................................ 18 Special Precautions......................................... 18 Diagnostics..................................................... 19 Systems Diagnostics......................................... 19 Status Codes.................................................... 19 Standard Status Codes....................................... 19 Stored Status Codes......................................... 20 Other Features.................................................. 20 Hourmeter Readings.......................................... 20 Maintenance Alert and Speed Limit........................... 20 Battery Discharge Indication (BDI).......................... 20 Internal Resistance Compensation............................ 20 Handset Programmable........................................ 20 RS 232 Communication Ports.................................. 20 Circuit Board Coil Driver Modules........................... 21 Maintenance Management Capability........................... 21 Interactive Instrument Panel Modes.......................... 21 General Troubleshooting Instructions............................ 23 Status Code Troubleshooting Tables.................................. 25 SX/SR Handset Instructions.......................................... 63 General Features................................................ 63 Connecting the Handset.......................................... 65 Startup Sequence................................................ 65 Setup Mode...................................................... 66 Stored Status Code Mode......................................... 67 Clearing the Stored Status Codes................................ 67 Restarting Lift Truck........................................... 67 SX Traction Controller Function Descriptions........................ 68 Premium Instrument Panel Interactive Modes...................... 75 SR Pump Controller Function Descriptions............................ 78 Premium Instrument Panel Interactive Modes...................... 81 tables.................................................................. 1 Table 1. SX Traction Controller Connections/Descriptions............ 8 Table 2. SR Lift Pump Controller Connections/Descriptions/Status.... 15 Table 3. Instrument Panel Function Number Correlation............... 21 Table 4. Traction Function Settings Logic........................... 22 Table 5. Lift Pump Function Settings Logic.......................... 23 Table 6. Speed/Torque Compensation.................................. 80 Table 7. Traction Controller Settings - Standard With Auto Regen.... 83 Table 8. Traction Controller Settings - Standard Without Auto Re.... 85 Table 9. Traction Controller Settings - High Performance With Au.... 87 Table 10. Lift Pump Controller Settings............................. 89 1468297-1600SRM0769-(03-2002)-US-EN......................................... 93 toc..................................................................... 93 Steering System..................................................... 93 Safety Precautions Maintenance and Repair........................... 94 General............................................................. 97 Operation........................................................... 97 Steering Wheel and Column Assembly.................................. 98 Description..................................................... 98 Remove.......................................................... 98 Install.........................................................101 Power Steering Pump and Motor.......................................102 Description.....................................................102 Remove..........................................................102 Install.........................................................104 Disassemble.....................................................104 Assemble........................................................105 Steering Axle Components............................................106 General.........................................................106 Wheel and Tire Assembly.........................................106 Remove......................................................106 Install.....................................................106 Wheel Hub Assembly..............................................106 Remove......................................................106 Install.....................................................107 Steering Axle Assembly..........................................107 Remove......................................................107 Clean.......................................................108 Install.....................................................108 Steering System Air Removal.........................................110 Operation Check.....................................................110 Steering Pressure Check.............................................111 Troubleshooting.....................................................111 1468300-8000SRM0772-(08-2003)-US-EN.........................................119 toc.....................................................................119 Periodic Maintenance................................................119 Safety Precautions Maintenance and Repair...........................120 General.............................................................123 How to Move Disabled Lift Truck.................................123 How to Tow Lift Truck.......................................123 How to Put Lift Truck on Blocks.................................124 How to Raise Drive Tires....................................124 How to Raise Steer Tires....................................125 Maintenance Schedule................................................126 Maintenance Procedures Every 8 Hours or Daily.......................130 Before Operation Checks.........................................130 Hydraulic System............................................130 Battery.....................................................131 Battery Restraint System....................................131 Tires and Wheels............................................132 Safety Procedures When Working Near Mast........................133 Forks.......................................................135 Adjust..................................................135 Remove..................................................136 Inspect.................................................136 Install.................................................136 Mast and Lift Chains........................................137 Lift Chain, Adjustment......................................138 Operation Check.................................................139 Gauges and Horn.............................................139 Control Levers and Pedals...................................139 Service Brakes..............................................139 Parking Brake...............................................139 Steering System.............................................139 Maintenance Procedures Every 350 Hours or 3 Months..................140 Hydraulic Tank Breather.........................................140 Wheel Nut Torque................................................140 Steering Actuator Mounting Bolts................................140 Transaxle.......................................................140 Lift System Operation...........................................141 Mast............................................................141 Lift Chains.....................................................143 Forks...........................................................144 Safety Labels...................................................144 Brake Fluid.....................................................144 Other Lubrication...............................................144 Electrical Inspection...........................................144 Special Precautions.........................................144 Contactors..................................................145 Motor Brushes...............................................145 Parking Brake...............................................146 Maintenance Procedures Every 2000 Hours or Yearly...................152 Hydraulic System................................................152 Hydraulic Oil Filter, Change................................152 Hydraulic Oil Strainer, Check...............................152 Hydraulic Oil, Change.......................................152 Brakes..........................................................153 Parking Brake, Adjust.......................................153 Transaxle.......................................................153 Maintenance Procedures Every 4000 Hours.............................155 Transaxle.......................................................155 Lift and Tilt System Leak Check.....................................155 Lift System.....................................................155 Tilt System.....................................................156 Battery Maintenance.................................................156 How to Charge Battery...........................................156 How to Change Battery...........................................157 Battery Size Specifications.....................................158 Wheels and Tires Maintenance........................................160 General.........................................................160 How to Change Tires.............................................160 Steer and Drive Wheels..........................................160 Pneumatic Tires.................................................160 Remove Wheel From Lift Truck................................160 Tire Sizes and Pressures....................................161 Remove Tire From Wheel......................................162 Install Tire on Wheel.......................................163 Add Air to Tires............................................164 Pneumatic-Shaped Solid Tires....................................164 Remove Wheel From Lift Truck................................164 Press Tire From Wheel.......................................165 Install Tire on Wheel.......................................166 Install Wheel and Tire..........................................168 tables..................................................................119 Table 1. Maintenance Schedule.......................................127 Table 2. Transaxle Specifications...................................154 Table 3. Battery Size Specifications - Type: Lead-Acid Battery......158 1468301-8000SRM0771-(08-2003)-US-EN.........................................171 toc.....................................................................171 Diagrams............................................................171 Safety Precautions Maintenance and Repair...........................172
HYSTER H160 SERVICE MANUAL – PDF DOWNLOAD:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
