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Hyster J160 (J1.60-2.00XMT) Service Manual – PDF DOWNLOAD
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Hyster J160 (J1.60-2.00XMT) Service Manual – PDF DOWNLOAD
PART NO. 1554626
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Description
Hyster J160 (J1.60-2.00XMT) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster J160 (J1.60-2.00XMT) Service Manual – PDF DOWNLOAD
PART NO. 1554626
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 J160 (J1.60-2.00XMT) Service Manual – PDF DOWNLOAD
0100SRM1073-1554626(06-2004)-UK-EN.......................................... 1 toc..................................................................... 1 Frame............................................................... 1 Safety Precautions Maintenance and Repair........................... 2 Introduction........................................................ 5 General......................................................... 5 Description of Operation........................................ 5 Discharging the Capacitors...................................... 6 Covers and Floor Plates............................................. 7 Overhead Guard Repair............................................... 9 Remove.......................................................... 9 Install......................................................... 9 Hood and Seat Assembly.............................................. 10 Remove.......................................................... 11 Install......................................................... 11 Counterweight....................................................... 12 Remove.......................................................... 12 Install......................................................... 13 Safety Labels....................................................... 14 Painting Instructions............................................... 17 0620SRM1115-1566043(06-2004)-UK-EN.......................................... 21 toc..................................................................... 21 AC Traction Motor Repair............................................ 21 Safety Precautions Maintenance and Repair........................... 22 Introduction........................................................ 25 General......................................................... 25 Discharging the Capacitors...................................... 25 Description......................................................... 27 Traction Motor.................................................. 27 AC Motor Repair..................................................... 28 Remove.......................................................... 28 Disassemble..................................................... 28 Inspect......................................................... 28 Assemble........................................................ 28 Install......................................................... 30 Troubleshooting..................................................... 30 1300SRM1074-1554627(06-2004)-UK-EN.......................................... 35 toc..................................................................... 35 Transaxle........................................................... 35 Safety Precautions Maintenance and Repair........................... 36 Introduction........................................................ 39 General......................................................... 39 Discharging the Capacitors...................................... 39 Description......................................................... 41 Transmission.................................................... 41 Traction Motor.................................................. 41 Maintenance......................................................... 42 Oil Level Check................................................. 42 Oil Change...................................................... 42 Transaxle Assembly.................................................. 43 Remove.......................................................... 43 Disassemble..................................................... 44 Traction Motor and Covers................................... 44 Brake Assembly and Gears.................................... 45 Planetary Gears and Drive Axle.............................. 47 Clean and Inspect............................................... 48 Assemble........................................................ 49 Planetary Gears and Drive Axle.............................. 49 Brake Assembly and Gears.................................... 50 Traction Motor and Covers................................... 51 Install......................................................... 53 Troubleshooting..................................................... 54 tables.................................................................. 35 Table 1. Special Tools.............................................. 51 Table 2. Conventional Tools......................................... 52 1600SRM1075-1554628(03-2004)-UK-EN.......................................... 59 toc..................................................................... 59 Steering System..................................................... 59 Safety Precautions Maintenance and Repair........................... 60 Introduction........................................................ 63 General......................................................... 63 Discharging the Capacitors...................................... 63 Description of Operation............................................ 65 Steering Pressure Check............................................. 65 Operation Check..................................................... 67 Steering Wheel and Column........................................... 67 Steering Column Covers.......................................... 67 Remove...................................................... 67 Install..................................................... 67 Steering Column Components...................................... 68 Remove...................................................... 68 Install..................................................... 71 Steering Control Unit Assembly...................................... 72 Power Steering Pump and Motor....................................... 72 Description..................................................... 72 Remove.......................................................... 72 Install......................................................... 74 Disassemble..................................................... 74 Assemble........................................................ 74 Steering Actuator Components........................................ 76 Steer Tire and Wheel Assembly................................... 76 Remove...................................................... 76 Install..................................................... 76 Wheel Hub Assembly.............................................. 76 Remove...................................................... 76 Install..................................................... 77 Steering Axle Assembly.......................................... 77 Remove...................................................... 77 Clean....................................................... 79 Install..................................................... 79 Troubleshooting..................................................... 80 1800SRM1076-1554629(03-2004)-UK-EN.......................................... 85 toc..................................................................... 85 Brake System........................................................ 85 Safety Precautions Maintenance and Repair........................... 86 Introduction........................................................ 89 General......................................................... 89 Discharging the Capacitors...................................... 89 Brake Pedal Assembly................................................ 91 Remove.......................................................... 91 Disassemble..................................................... 92 Assemble........................................................ 92 Install......................................................... 92 Master Cylinder..................................................... 92 Remove.......................................................... 92 Install......................................................... 93 Adjustments..................................................... 94 Bleed the Brake System...................................... 94 Adjust Linkage.............................................. 94 Brake Lines......................................................... 94 Parking Brake....................................................... 95 Remove.......................................................... 95 Disassemble..................................................... 95 Assemble........................................................ 97 Install......................................................... 97 Troubleshooting..................................................... 97 1900SRM1077-1554630(06-2004)-UK-EN..........................................101 toc.....................................................................101 Hydraulic System....................................................101 Safety Precautions Maintenance and Repair...........................102 Introduction........................................................105 General.........................................................105 Discharging the Capacitors......................................105 Hydraulic System....................................................107 Hydraulic Oil...................................................107 Hydraulic Lines.................................................107 Cleaning........................................................107 Sound Level.....................................................107 Maintenance.....................................................107 Hydraulic Oil Filter, Change................................107 Hydraulic Oil Strainer, Check...............................108 Hydraulic Oil, Change.......................................108 Hydraulic Tank Assembly.............................................110 Remove..........................................................110 Clean...........................................................111 Trisodium Phosphate Method..................................111 Install.........................................................111 Lift Pump and Motor.................................................112 Remove..........................................................112 Disassemble.....................................................112 Assemble........................................................112 Install.........................................................113 Lift Pump...........................................................114 Disassemble.....................................................114 Assemble........................................................114 2000SRM1085-1554631(03-2004)-UK-EN..........................................119 toc.....................................................................119 HUSCO™ Main Control Valve...........................................119 Safety Precautions Maintenance and Repair...........................120 General.............................................................123 Description.........................................................123 Operation...........................................................123 Lift Section....................................................126 Tilt Section....................................................126 Tilt Backward...............................................126 Tilt Forward................................................126 Relief Valve....................................................128 Main Control Valve Repair...........................................129 Remove..........................................................129 Disassemble.....................................................131 Clean and Inspect...............................................131 Assemble........................................................131 Install.........................................................133 Pressure Relief Valve Check and Adjustment..........................136 Primary Relief Valve............................................136 Secondary Relief Valve..........................................136 Troubleshooting.....................................................137 2000SRM1086-1554632(06-2004)-UK-EN..........................................141 toc.....................................................................141 Electro-Hydraulic Control Valve.....................................141 Safety Precautions Maintenance and Repair...........................142 General.............................................................145 Description.........................................................145 Electro-Hydraulic Control System................................145 Electro-Hydraulic Control Valve.................................146 Valve Driver Module.............................................149 Manual Lowering Valve...........................................149 Hydraulic Lever Console.........................................149 Electro-Hydraulic Control Valve.....................................149 Remove..........................................................149 Disassemble.....................................................150 Clean and Inspect...............................................150 Assemble........................................................151 Lift Valve Section..........................................151 Tilt/Auxiliary Valve Sections...............................151 Valve Spool Coils...........................................152 Fittings....................................................152 Install.........................................................152 Check and Adjust................................................153 Tilt Counterbalance Valve...................................153 Main Relief Valve...........................................153 Auxiliary Relief Valve......................................153 Valve Driver Module.................................................153 Remove..........................................................153 Install.........................................................154 Hydraulic Lever Console.............................................154 Remove..........................................................154 Disassemble.....................................................154 Covers......................................................154 Hydraulic Control Lever.....................................154 Main PC Board...............................................154 Assemble........................................................155 Main PC Board...............................................155 Hydraulic Control Lever.....................................155 Covers......................................................155 Install.........................................................155 Troubleshooting.....................................................156 Troubleshooting Chart...........................................156 tables..................................................................141 Table 1. Error Codes................................................156 2100SRM0103-910102(10-2003)-UK-EN...........................................163 toc.....................................................................163 Tilt Cylinders......................................................163 Safety Precautions Maintenance and Repair...........................164 General.............................................................167 Description.........................................................167 Tilt Cylinder Repair................................................167 Remove..........................................................167 Disassemble.....................................................167 Clean...........................................................167 Assemble........................................................168 Tilt Cylinders With O-Ring or Single-Lip Seals..............168 Tilt Cylinders for XM and XMS Models........................169 Tilt Cylinders for H700-800A and Early Model H700-920B......170 Install.........................................................171 Tilt Cylinders Using Chevron Packing........................172 Install.................................................173 Tilt Cylinder Leak Check............................................175 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.................176 Torque Specifications...............................................177 Piston Rod Nut..................................................177 Retainer........................................................178 Troubleshooting.....................................................180 tables..................................................................163 Table 1. Movement Rates (Maximum) for Tilt Cylinders................176 2200SRM1078-1554634(06-2004)-UK-EN..........................................183 toc.....................................................................183 Electrical System...................................................183 Safety Precautions Maintenance and Repair...........................184 Introduction........................................................187 General.........................................................187 Discharging the Capacitors......................................187 Emissions.......................................................189 Electromagnetic Interference................................189 Motor Controllers...................................................189 Controllers.....................................................189 Remove......................................................189 Install.....................................................190 Hydraulics Contactor............................................191 Remove......................................................191 Disassemble.................................................191 Assemble....................................................191 Install.....................................................191 Contactor Panel.....................................................192 Main Contactor..................................................192 Remove......................................................192 Disassemble.................................................193 Assemble....................................................193 Install.....................................................194 Contactor Coil..............................................194 Contactor Tips..............................................194 Fuses...........................................................194 Display Units.......................................................195 Features........................................................195 Replace.........................................................196 Key Switch..........................................................196 Replace.........................................................196 Directional Controls................................................198 Directional Control Switches....................................198 Accelerator Switches and Pedal Assembly.........................199 Install.........................................................199 Calibrate.......................................................202 MONOTROL™ Directional Control...................................202 Brakes..............................................................204 Brake Switch....................................................204 Adjust or Replace...........................................204 Master Cylinder Indicator.......................................204 Parking Brake Disengage.........................................205 Override Mode...............................................205 Horn Components and Steering Encoder................................206 Horn Components.................................................206 Horn........................................................206 Horn Button and Contacts....................................207 Steering Encoder................................................207 Hood and Seat Switches..............................................208 Hood Position Switches..........................................208 Seat Switch.....................................................208 Steer Angle Potentiometer...........................................208 General.........................................................208 Operation.......................................................208 Example.....................................................209 Position Steer Tire for Straight Travel.........................209 Install.........................................................210 Set Potentiometer to Midpoint...............................210 Install to Steer Axle.......................................210 Calibrate...................................................211 Test............................................................211 Wiring Harness......................................................212 tables..................................................................183 Table 1. Potentiometer Specifications...............................211 2200SRM1087-1554633(06-2004)-UK-EN..........................................219 toc.....................................................................219 AC Motor Controllers/ Display Panel.................................219 Safety Precautions Maintenance and Repair...........................220 Description.........................................................223 General.........................................................223 Description.....................................................223 AC Motors...................................................223 ZAPI™ AC Motor Controller...................................223 Principles of Operation.....................................224 Controller Thermal Management...............................225 Controller Area Network (CAN Bus)...........................225 Discharging the Capacitors......................................225 AC Motor Controller Repair..........................................226 General.........................................................226 Special Precautions.........................................226 Thermal Sensors.................................................227 Motor Controller, Replace.......................................227 Controller Checks and Adjustments...................................227 Function Parameters.................................................228 General.........................................................228 Function Parameter Description......................................229 Parameters......................................................229 Top Speed Forward...........................................229 Top Speed Reverse...........................................229 Acceleration................................................229 Regen Braking...............................................230 Auto Deceleration...........................................230 Extended Shift..............................................230 Pump Acceleration...........................................230 Tilt/Auxiliary Pump Acceleration............................230 Low Lift Speed..............................................230 Maximum Lift Speed..........................................230 Tilt Speed..................................................230 3rd Function Speed..........................................231 4th Function Installed......................................231 4th Function Speed..........................................231 3rd Function Interlock......................................231 4th Function Interlock......................................231 Battery Voltage.............................................231 Lift Interrupt..............................................231 BDI Adjustment..............................................231 BDI Decrement Time..........................................231 Service Reminder............................................232 Custom......................................................232 Restore Defaults............................................232 Calibration Parameters..............................................232 Throttle Calibration............................................232 Steering Calibration............................................232 Display Panel.......................................................232 General.........................................................232 Premium Display Panel.......................................232 Standard Display Panel......................................232 Display Functions and Features......................................233 Key-ON Initialization...........................................233 Standard Display................................................233 Premium Display.................................................235 Lift Truck Inspection Function..................................235 Access to Service Functions.....................................236 Service Functions...............................................236 Performance Modes...............................................237 Battery Discharge Indication (BDI)..............................238 Hourmeter.......................................................238 Status Code List................................................238 Dash Display Service Menu Navigation................................239 General.........................................................239 Moving Through Menu Selections..................................239 Editing and Adding Information..................................239 Troubleshooting.....................................................240 General.........................................................240 Status Codes....................................................240 Controller Connector Pin Outs...................................299 Valve Driver Module (Electro-Hydraulic Valve Option)............301 Hydraulic Lever Console (Electro-Hydraulic Option Only).........302 Dash Display....................................................302 System Logic Diagrams...........................................303 tables..................................................................219 Table 1. Traction Parameters........................................228 Table 2. Transistor Lift With Manual Valve Parameters...............228 Table 3. Transistor Lift With Electro-Hydraulic Valve Parameters....229 Table 4. List of Status Codes.......................................241 Table 5. Connector A................................................299 Table 6. Connector C................................................300 Table 7. Connector D - Standard Model...............................300 Table 8. Connector D - Premium Model................................301 Table 9. Connector B................................................301 Table 10. Connector C...............................................301 2240SRM001-899648(11-2003)-UK-EN............................................309 toc.....................................................................309 Industrial Battery..................................................309 Safety Precautions Maintenance and Repair...........................310 General.............................................................313 Lead-Acid Batteries.................................................313 Specific Gravity....................................................314 Chemical Reaction in a Cell.........................................314 Electrical Terms....................................................315 Battery Selection...................................................316 Battery Voltage.....................................................317 Battery as a Counterweight..........................................317 Battery Ratings.....................................................317 Kilowatt-Hours..................................................317 Battery Maintenance.................................................318 Safety Procedures...............................................318 Maintenance Records.............................................318 New Battery.....................................................318 Cleaning Battery................................................319 Adding Water to Battery.........................................320 Hydrometer......................................................321 Battery Temperature.............................................321 Charging Battery................................................322 Types of Battery Charges....................................323 Methods of Charging.........................................324 Troubleshooting Charger.....................................325 Knowing When Battery Is Fully Charged.......................325 Where to Charge Batteries.......................................325 Equipment Needed............................................325 Battery Connectors..............................................326 Battery Care....................................................326 tables..................................................................309 Table 1. Battery Capacity Terms.....................................317 4000SRM521-897506(05-2004)-UK-EN............................................331 toc.....................................................................331 Mast................................................................331 Safety Precautions Maintenance and Repair...........................332 General.............................................................335 Description and Operation...........................................335 Carriages.......................................................335 Mast Mounts.....................................................337 Two-Stage Mast, Limited Free-Lift (LFL).............................339 Description and Operation.......................................339 Two-Stage Mast, Full Free-Lift (FFL)................................340 Description and Operation.......................................340 Three-Stage Mast, Full Free-Lift (FFL)..............................342 Description and Operation.......................................342 Cylinder Cushion During Lifting Sequence............................345 Cylinder Cushion During Lowering Sequence...........................346 4000SRM522-897507(05-2004)-UK-EN............................................349 toc.....................................................................349 Mast................................................................349 Safety Precautions Maintenance and Repair...........................350 General.............................................................353 Safety Procedures When Working Near Mast............................353 Forks Repair........................................................355 Remove..........................................................355 Install.........................................................356 Carriages Repair....................................................356 Standard Carriage, Remove.......................................356 Hang-On Sideshift Carriage, Remove..............................357 Standard Carriage and Hang-On Sideshift Carriage, Repair........358 Standard Carriage, Install......................................358 Hang-On Sideshift Carriage, Install.............................359 Integral Sideshift Carriage.....................................359 Remove......................................................359 Clean and Inspect...........................................361 Repair......................................................361 Install.....................................................362 Mast Repair.........................................................362 Remove..........................................................362 Two-Stage LFL and Two-Stage FFL Masts, Disassemble..............364 Three-Stage FFL Mast............................................371 Disassemble.................................................371 Mast and Chains, Clean and Inspect..........................374 Two-Stage LFL and Two-Stage FFL Mast, Assemble..................375 Three-Stage FFL Mast, Assemble..................................376 Install.........................................................378 Lift Cylinders Repair...............................................379 Main Lift Cylinders, Remove.....................................379 Free-Lift Cylinder, Remove......................................379 Lift Cylinders, Disassemble.....................................380 Lift Cylinders, Assemble........................................380 Main Lift Cylinders, Install....................................383 Free-Lift Cylinder, Install.....................................384 Header Hose Arrangements............................................384 Two-Stage LFL Mast, New Hose Install............................384 Two-Stage LFL Mast, Adjust Hoses After Installation.............390 Two-Stage FFL Mast, New Hose Install............................390 Two-Stage FFL Mast, Adjust Hoses After Installation.............395 Three-Stage FFL Mast, New Hose Install..........................397 Three-Stage FFL Mast, Adjust Hoses After Installation...........407 Header Hose Arrangement.............................................408 Two-Stage LFL Mast, New Hose Install............................408 Two-Stage LFL Mast, Adjust Hoses After Installation.............408 Two-Stage FFL Mast, New Hose Install............................412 Two-Stage FFL Mast, Adjust Hoses After Installation.............417 Three-Stage FFL Mast, New Hose Install..........................419 Three-Stage FFL Mast, Adjust Hoses After Install................424 Lift and Tilt System Leak Check.....................................428 Lift Cylinders Leak Check.......................................428 Tilt Cylinders Leak Check.......................................428 Tilt Cylinders Adjustment...........................................429 Lift Chains Adjustment..............................................430 Mast Adjustment.....................................................432 Carriage Adjustment.................................................434 Troubleshooting.....................................................434 tables..................................................................349 Table 1. Hook-Type Carriage Chain Adjustment........................431 Table 2. Pin-Type Carriage Chain Adjustment.........................431 8000SRM0231-910442(03-2004)-UK-EN...........................................439 toc.....................................................................439 Metric and Inch (SAE) Fasteners.....................................439 Safety Precautions Maintenance and Repair...........................440 General.............................................................443 Threaded Fasteners..............................................443 Nomenclature, Threads...........................................443 Strength Identification.........................................444 Cotter (Split) Pins.............................................444 Fastener Torque Tables..........................................449 Conversion Table................................................451 tables..................................................................439 Table 1. Bolts and Screws...........................................445 Table 2. Studs and Nuts.............................................446 Table 3. Torque Nuts................................................447 Table 4. Torque Nuts With Nylon Insert..............................448 Table 5. Torque Values for Metric Fasteners*........................449 Table 6. Torque Values for Inch Fasteners*..........................450 Table 7. Conversion Table for Metric and English Units..............451 Table 8. Cotter Pin Dimensional Data................................452 Table 9. Cotter Pin Dimensional Data................................453 Table 10. Cotter Pin Dimensional Data...............................454 Table 11. Cotter Pin Dimensional Data...............................456 8000SRM1079-1554635(06-2004)-UK-EN..........................................459 toc.....................................................................459 Periodic Maintenance................................................459 Safety Precautions Maintenance and Repair...........................460 Introduction........................................................463 General.........................................................463 Discharging the Capacitors......................................463 How to Move Disabled Lift Truck.................................465 How to Tow Lift Truck.......................................465 How to Put Lift Truck on Blocks.................................466 How to Raise Drive Tires....................................466 How to Raise Steer Tires....................................467 Safety Procedures When Working Near Mast............................467 Maintenance Schedule................................................469 Maintenance Procedures Every 8 Hours or Daily.......................474 Checks With the Key Switch OFF..................................474 Safety Labels and Decals....................................474 Frame.......................................................474 Wheels and Tires............................................474 Mast, Carriage, and Forks...................................474 Hydraulic Oil Level and Leaks...............................475 Operator and Battery Restraints.............................476 Battery Check...............................................476 Checks With the Key Switch ON...................................477 Electrical Components.......................................477 Directional Speed Control...................................477 Steering System.............................................477 Hydraulic System............................................477 Brakes......................................................478 Maintenance Procedures Every 500 Hours or 3 Months..................478 Tire and Wheel Assemblies.......................................478 Mast and Carriage...............................................478 Battery.........................................................479 Parking Brakes..................................................480 Transaxle.......................................................481 Maintenance Procedures Every 1000 Hours or 6 Months.................482 Lift Chains.....................................................482 Hydraulic Breather Cap..........................................482 Master Cylinder.................................................483 Electrical Inspection...........................................483 Hydraulic Motor Brushes.....................................483 Contactors..................................................483 Directional Speed Control...................................484 Transaxle, Oil Change...........................................484 Maintenance Procedures Every 2000 Hours or Yearly...................485 Steering........................................................485 Hydraulic.......................................................486 Hydraulic Oil Filter, Change................................486 Hydraulic Oil Strainer, Check...............................486 Hydraulic Oil, Change.......................................486 General Repairs.....................................................487 Welding Repairs.................................................487 Painting Instructions...........................................488 Lift and Tilt System Leak Check.....................................488 Lift System.....................................................488 Tilt System.....................................................489 Battery Maintenance.................................................490 How to Charge Battery...........................................490 How to Change Battery...........................................491 Battery Size Specifications.....................................491 tables..................................................................459 Table 1. Maintenance Schedule.......................................470 8000SRM1080-1554636(05-2004)-UK-EN..........................................495 toc.....................................................................495 Capacities and Specifications.......................................495 Safety Precautions Maintenance and Repair...........................496 General.............................................................499 Hydraulic System....................................................500 Steering System.....................................................501 Tire Sizes..........................................................502 Torque Specifications...............................................503 Electrical......................................................503 Steering System.................................................503 Hydraulic System................................................503 Manual Hydraulic Valve..........................................503 Transaxle.......................................................503 Transaxle Assembly..................................................504 Travel Speeds.......................................................505 Battery.............................................................506 8000SRM1081-1554637(06-2004)-UK-EN..........................................513 toc.....................................................................513 Diagrams............................................................513 Safety Precautions Maintenance and Repair...........................514
HYSTER J160 (J1.60-2.00XMT) SERVICE MANUAL – PDF DOWNLOAD:
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