Hyster C160 (J35XMT) Forklift Service Repair Manual

General

Thissectionhasadescriptionandtheserviceproceduresforthepartsoftheframe.Thesepartsincludethe frame,counterweightassembly,overheadguard,hoodandseatassembly,accesspanels,andlabelpositions. Theprocedureforremovingthetractionmotorisalsodescribedinthissection.

Description

Theframeisasingleweldment.SeeFigure1.The framehasmountsforthefollowing:

• Counterweight

• Overheadguard

• Tiltcylinders

• Steeringaxle

• Driveaxleassembly

Thehydraulictankispartofthelifttruckframeand isaweldedsteelunit.Thelifttrucksmusthavea hoodoverthebattery,oracoveredbatteryifahood isnotinstalled.Thefloorplatescanberemovedfor accesstothehydraulicsystems.Apanelinthebottomofthebatterycompartmentcanberemovedfor accesstothetractionmotorandthehydraulicpump motor.Thepowersteeringpumpandmotorandmastercontrollerislocatedunderthefloorplateonthe leftsideofthelifttruck.TheE-hydrauliccontrol valvedrivermoduleislocatedunderthefloorplate nexttothehydraulicfilter.TheACelectroniccontrollersandcontactorsareinthecounterweight.A panelinthecounterweightcanberemovedforaccess totheACcontrollersandcontactors.

ThelifttruckmodelsE4.50XLandE4.50XLS(E100Z andE100ZS)canhaveashortorlongframe.SeeBatterySpecificationssectionforthebatterycompartmentsizeandbatteryspecifications.

WARNING

Thebatterymustfitthebatterycompartment sothatthebatteryrestraintwilloperatecorrectly.Aloosebatterycancauseseriousinjuryandpropertydamageifthelifttruckoverturns.Usespacerstopreventthebatteryfrom movingmorethan13mm(0.5in.)forwardor backward.

WARNING

Maximumclearancebetweenthebatteryand batterycompartmentwidthis13mm(0.5in.). Maximumclearancebetweenthebatteryand thespacerplateisalso13mm(0.5in.).TheBatterySpecificationschartshowstheminimum sizecompartmentallowed.

Thelifttrucksareequippedwithadjustablespacersinthebatterycompartment.SeeFigure2.Add orremoveshimsfromunderthefrontspacerbarto controlthemovementofthebatteryintheforward andbackwarddirections.Installanequalnumberof shimsateachcapscrew.Installtheadditionalshims underthenutsofthecapscrews(outsidebatterycompartment).Thespacersoneachsideofthebattery canbeadjustedtocontrolthemovementofthebatteryfromsidetoside.Accesstothenutsforthespacersforthesidesofthebatteryisundertheframenear thesteertiresonallunits.Tightenallcapscrews.It canbenecessarytoinstallthesidespacersfacingthe oppositedirectionforsomebatteries.Ifthespacers cannotbeadjustedforabatterythatisspecifiedfor thislifttruck,seeyourHysterlifttruckdealerfor thecorrectspacers.

Theweightofthebatteryisalargepartofthecounterweightsystemonanelectriclifttruck.Makesure thatthebatteryiswithintheweightlimitsindicated ontheNameplate.Eachmodeloflifttruckhasa cast-ironcounterweightthatprovidestheadditional weightnecessaryfortheindicatedcapacity.Aslotin theoverheadguardpermitsremovalofthebattery withoutremovingtheoverheadguard.

1.SIDESTEPANDFENDERWELDMENT

2.FRAME

3.ACCESSPANEL

4.COWL

5.FLOORMAT

6.FLOORPLATE

7.COVER(HYDRAULICLEVERS)

8.PLATE

Figure1.LiftTruckFrame,FloorPlates,andCovers

REMOVE

WARNING

Donotoperatethelifttruckwithouttheoverheadguardcorrectlyfastenedtothelifttruck.

WARNING

DONOTweldmountsforlightsoraccessories tolegsoftheoverheadguard.Changesthatare madebywelding,orbydrillingholesthatare toobigorinthewronglocation,canreducethe strengthoftheoverheadguard.

4.SPACERBAR

5.SHIM

6.STOREADDITIONALSHIMSINFRONTOF BULKHEAD

SeeyourdealerforHysterlifttrucksBEFORE performinganychangestotheoverhead guard.

Noweldingordrillingonlegsofoverheadguardis permittedasperprevious WARNING

1. Removebatteryasdescribedinthesection PeriodicMaintenance 8000SRM1201.Seethe sectionBatterySpecificationsforinformationon batteryweightsandsizes.

Figure2.BatterySpacerandShims

2. Accesstocapscrewsthatholdrearsupportsof overheadguardtocounterweightisfromthebatterycompartment.Removecapscrews.

3. Removetwocapscrewsthatholdeachfrontsupportofoverheadguardtocowl.Disconnectany electricwiresfromundercowlthatgothrough supportsofoverheadguard.Whenoverhead guardisliftedfromtheframe,makesurethese electricwiresmovethroughtheholesinthecowl sotheyarenotdamaged.

4. Useliftingdeviceoranotherpersontohelplift overheadguardfromlifttruck.

INSTALL

1. Putoverheadguardonlifttruck.Installany electricwiresfromoverheadguardsupports throughholesincowl.

2. Installfourcapscrews,washers,andnutsthat holdfrontsupportstocowl.

3. Tightencapscrewstocorrecttorque.Install capscrewsandwashersthatholdrearsupports tocounterweight.Tightencapscrewstocorrect torque.Thecorrecttorquevaluesareshownin Figure3andTable1.Installbattery.

NOTE: OVERHEADGUARDWITHCURVEDLEGS SHOWN.OVERHEADGUARDMAYBEEQUIPPED WITHSTRAIGHTLEGS.

1.OVERHEAD

2.COUNTERWEIGHT

3.FRAME

4.CAPSCREWS(4)

5.CAPSCREWS(4)

6.CAPSCREWS(2)

7.CAPSCREWS(2)

WARNING

Thebatteryrestraintanditslatchmechanisms mustoperatecorrectlybeforealifttruckisoperated.Makesurethebatteryhasacoverifthe lifttruckdoesnothaveahood.

Abatteryrestraintsystemisinstalledasasafetydevice.SeeFigure4.Thefunctionofthebatteryrestraintsystem,whencorrectlylockedinthedownposition,istoholdthebatteryinthebatterycompartmentifanaccidentcausesthelifttrucktotipover. Thebatteryrestraintisasteelplatethatisconnected totheframewithahinge.Aslidinglatchmechanism locksthebatteryrestraintinthedownpositionfor operation.Aknobnearthehingeunlocksthebattery restraintfromtheframesothebatteryrestraintcan beraisedtotheuppositionforaccesstothebattery. Thebatteryrestraintisalsothesupportfortheseat. Aspringbraceholdstheseatandbatteryrestraintin theupposition.Abatteryretentionbarisfastened tothecounterweightwithahingeandispartofthe hood.Spacersareusedinsidethebatterycompartmenttopreventhorizontalmovementofthebattery. LegendforFigure4

Figure4.BatteryRestraintandSeatAssembly

NOTE: Thesteeringcolumnmustbeintheforward positionbeforeraisingtheseat.

Toraisethebatteryrestraintandhood,theoperator mustholdthehandleontherestraintplate(handle islocatednexttohiprestraintonseat)withonehand andwiththeotherhand,pulldownontheknobfor thelatchmechanismtoreleasethespringbrace,and thenraisetheseatassemblyandbatteryrestraint platetowardthesteeringcolumn.Aspringbracewill holdtheassemblyintheupposition.Withtheseat assemblyandbatteryrestraintplateintheraisedposition,pullonthehoodhandles,locatedtowardthe rearofthehood,toraisethehoodtowardthecounterweight.Thehingedsideplatesmustbeflippedto thecenterofthetruckbeforeraisingthehood.See Figure5andFigure6.

Makesurethatthebatterycannotmovemorethan atotalof13mm(0.5in.)inanyonehorizontaldirection.Makesurethecorrectspacersareinstalled

topreventthemovement.SeeyourHysterlifttruck dealertoreplacedamagedormissingspacers.Ifa smallerbatteryofthecorrectweight(seeNameplate) isinstalledandthespacerscannotpreventmovement,yourHysterlifttruckdealerhaslargerspacers.

Toclosethebatteryrestraintandhoodandtooperate correctly,thebatteryrestraintplatemustbelocked inthedownposition.Lowerthebatteryretention barfirst,thenpullthereleaseknobtoreleasetheup latchontheseatandlowerthehood.Pushtheseat andthebatteryrestraintdownuntilthelatchlocksto lockthebatteryrestraintplateinthedownposition overthebar.Liftonbatteryrestrainttomakesure itislatchedsecurelytotheframeandwillnotmove.

Figure5.OpenHood

1.HINGED SIDEPLATES

2.CAPSCREW

3.HOODHANDLE(2)

4.WASHER

5.LOCKWASHER

6.NUT

7.ADHESIVETRIM(SEAL)

8.RETAININGRING

9.PLATE(FORBATTERYRESTRAINTBAR)

10.PIN

11.HINGE

12.BRACKET

13.HOOD

Figure6.HoodAssembly

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OPERATORRESTRAINTSYSTEMAND SEATASSEMBLY

Theseatbelt,hiprestraintbrackets,seatandmounting,hood,andlatchesareallpartoftheoperatorrestraintsystem.Eachitemmustbecheckedtomake sureitisattachedsecurely,functionscorrectly,and isingoodcondition.SeeFigure7.

AutomaticLockingRetractor(ALR)

NOTE: LifttrucksproducedbeforeNovember2005 areequippedwiththeALRtypeseatbelts.

Theseatbeltmustfastensecurely.Makesurethe seatbeltextendsandretractssmoothlyandisnot frayedortorn.Iftheseatbeltisdamagedordoesnot operateproperly,itmustbereplaced.SeeFigure7.

Aseatbeltthatisdamagedwornordoesnotoperate properlywillnotgiveprotectionwhenitisneeded. Theendofthebeltmustfastencorrectlyinthelatch. Theseatbeltmustbeingoodcondition.Replacethe seatbeltifdamageorwearisseen.SeeFigure8.

NOTE: LifttrucksproducedafterNovember2005 areequippedwiththeEmergencyLockingRetractor (ELR)styleseatbelt.

WhentheELRstyleseatbeltisproperlybuckled acrosstheoperator,thebeltwillpermitslightoperatorrepositioningwithoutactivatingthelocking mechanism.Ifthetrucktips,travelsoffadock,or comestoasuddenstop,thelockingmechanismwill beactivatedandholdtheoperator’slowertorsoin theseat.

Thefollowingseatbeltoperationchecksmustbeperformed:

• Withthehoodclosedandinthelockedposition, pulltheseatbeltslowlyfromtheretractorassembly.Makesuretheseatbeltpullsoutandretracts smoothly.iftheseatbeltcannotbepulledfromthe retractorassemblyorthebeltwillnotretract,replacetheseatbeltassembly.

• Withthehoodclosedandinthelockedposition, pulltheseatbeltwithasuddenjerk.Makesurethe seatbeltwillnotpullfromtheretractorassembly. Iftheseatbeltcanbepulledfromtheretractor, whenitispulledwithasuddenjerk,replacethe seatbeltassembly.

• Withthehoodintheopenposition,makesurethe seatbeltwillnotpullfromtheretractorassembly. Iftheseatbeltcanbepulledfromtheretractor, withthehoodintheopenposition,replacetheseat beltassembly.

Makesuretheseatrailsandlatchstrikerarenot loose.Theseatrailsmustlocksecurelyinposition

Figure7.OperatorRestraintSystem EmergencyLockingRetractor(ELR)

Figure8.HoodandSeatCheck

100SRM1200CounterweightReplacement

butmovefreelywhenunlocked.Theseatrailsmust besecurelyattachedtothemountingsurface.The hoodmustbefullyclosed.Liftthehoodtomakesure itisclosedandwillnotmove.

SEATBRAKEREPAIR

Seethesection BrakeSystem 1800SRM338forthe proceduresfortheseatbrake.

CounterweightReplacement

NOTE: Ifthelifttruckmustbeputonblocksfor maintenanceandrepair,seethesection HowtoPut aLiftTruckonBlocks inthe OperatingManual orinthesection PeriodicMaintenance 8000SRM 1201.

WARNING

Thecounterweightisveryheavy.Makesure thatthecraneandliftingdeviceshaveenough liftingcapacitytosafelyliftthecounterweight. Theweightsofthecounterweightsareshown inTable2.

Thecounterweightnormallyisnotremovedformost repairs.ReplacementoftheACcontrollersisaccomplishedbyremovingthecoverfromthecounterweight.SeeFigure9.Thecounterweightisfastened totheframewithfourcapscrews.Theweightsfor thecounterweightsareshowninTable2.

Table2.WeightofCounterweights Model Weight*

E3.50XL(E70Z) 822kg(1812lb)

E4.00-4.50XL (E80-100Z) 1253kg(2762lb)

E4.50XLS(E100ZS) 1912kg(4215lb)

E5.50XL(E120Z) 1912kg(4215lb)

*±50kg(110lb)

REMOVE

1. Removebattery.See HowtoChangetheBattery inthesection PeriodicMaintenance 8000 SRM1201.SeeBatterySpecificationssectionfor informationonbatteryweightsandsizes.

2. RemoveoverheadguardasdescribedintheparagraphsunderOverheadGuardReplacement.

3. Installliftingeyeboltinholeontopofcounterweight.SeeFigure9.Attachchainorslingto

eyebolt.Usecranetoholdtheweightofthecounterweight.

CAUTION

Topreventdamagetothecontrollerwhenremovingthecounterweight,carefullyliftcounterweightupwarduntilitisofftheframe,then straightbackfromthelifttruck.

4. Frominsidethebatterycompartment,remove twocapscrewsthatholdcounterweighttoframe. Removetwocapscrewsfromtowpinareaofcounterweight.Usecranetoliftcounterweightaway fromframe.Makesureyoudonotdamagethe electroniccontrols.

Figure9.CounterweightAssembly

INSTALL CAUTION

Topreventdamagetothecontrollerwheninstallingthecounterweight,carefullymovethe counterweighttothelifttruckslightlyabove theframe,thenlowerthecounterweighttothe frame.

NOTE: Theaccesspaneltothecontrollercanbe removedfromthecounterweighttomakechecks andadjustmentsonthecontroller.Makesurelugs arecorrectlyengagedwhenaccesspanelisinstalled againorpanelwillfallfromcounterweightduring operation.

1. Usecranetoliftcounterweightintoposition. Makesureyoudonotdamagecontroller.Installtwouppercapscrewsfrominsidebattery compartmentthatholdcounterweighttoframe. Installtwolowercapscrewsintowpinareaof counterweight.Tightencapscrewstocorrect torque.Thecorrecttorquevaluesforcapscrews areshowninTable1.

2. Disconnectslingorchain.Removeeyeboltsfrom counterweight.

3. InstalloverheadguardasdescribedintheparagraphsforOverheadGuardReplacement.

4. Installbattery.See HowtoChangetheBattery inthesection PeriodicMaintenance 8000 SRM1201.SeeBatterySpecificationssectionfor informationonbatteryweightsandsizes.

TractionMotorRepair REMOVE

Thisprocedurewillshowtheremovalofthetractionmotorthroughthebatterycompartment.The lifttruckscoveredinthismanualcanhaveanoptionalseatbrakethatactuatesthebrakeonthearmatureshaftofthetractionmotor.SeeFigure10. Theguidepipeconnectionandelectricalconnections fortheseatbrakemustbedisconnectedfromthe tractionmotorbeforethemotorisremoved.Seethe section BrakeSystem 1800SRM338forseatbrake adjustmentprocedures.

NOTE: Thetractionmotorcanalsoberemovedfrom underthelifttruckwiththeuseofafloorjack,butis moredifficult.Thelifttruckmustbeonblockswith clearanceforthejackandtractionmotorifthetractionmotorisremovedfromunderthelifttruck.See thesection HowtoPutaLiftTruckonBlocks in the OperatingManual orinthesection Periodic Maintenance 8000SRM1201.Thehydrauliclines fromthehydraulictankmustalsobedisconnected ifthetractionmotorisremovedfromunderthelift truck.

LegendforFigure10

NOTE: TRACTIONMOTORWITHOPTIONALSEAT BRAKESHOWN.

1.GUIDE PIPECONNECTION

2.ELECTRICALCONNECTION

3.SEATBRAKE

1. Removebatteryasdescribedinthesection PeriodicMaintenance 8000SRM1201.Remove

Figure10.TractionMotorandSeatBrake

floorplatesandaccesspanelinbottomofbattery compartment.SeeFigure1.

2. Iflifttruckisequippedwithaseatbrake,disconnectseatbrakeguidepipeandelectricalconnections(seeFigure10).Disconnecthydraulicline tomaincontrolvalvesomotormountcanbedisconnected.Putcapsonopenhydraulicfittings.

3. Disconnectpowercablesfromtractionmotor. Markthecablesandterminalsforeaseofreconnecting.

4. Putlifttruckonblocksforeasieraccesstobottom boltsbetweentractionmotorandspeedreducer. Removeboltsbetweenspeedreducerandmotor.

WARNING

Makesuretheslingandcranecansupportthe weightofthetractionmotor.Thetractionmotorontheselifttrucksweighsapproximately 204kg(450lb).Makesuretheslingcannotslide andpermittractionmotortofallandcauseinjury.

5. Installslingtoholdtractionmotor.SeeFigure11.Usewoodblockandboardunderslingas showninFigure11.Usecranetoholdweightof tractionmotor.SeeFigure12.

6. Removemotormountthatholdstractionmotor toframe.Pulltractionmotorfromspeedreducer.

7. Usecranetomovetractionmotortoaspaceto makerepairs.

INSTALL

1. Installslingtolifttractionmotor.Usewoodblock andboardunderslingasshowninFigure11to controltractionmotorduringinstallation.

2. Lowertractionmotorintopositioninlifttruck. Aligntractionmotorwithspeedreducer.SeeFigure11.

3. Useboardorprybarasnecessarytopushtractionmotorintospeedreducer.

4. Alignboltholesinspeedreducerandmotor housing.Installboltsthatholdtractionmotortospeedreducer.Tightenboltsto38N•m (28lbfft).

NOTE: TRACTIONMOTORWITHOPTIONALSEAT BRAKESHOWN.

1.SLING

2.USEWOODBLOCKANDBOARDUNDERSLING FORALEVER

3.TRACTIONMOTOR

Figure11.SlingInstallationtoLiftTraction Motor

NOTE: TRACTIONMOTORWITHOPTIONALSEAT BRAKESHOWN.

Figure12.UseCranetoLiftTractionMotor

5. Removeslingandinstalltractionmotormount.

6. Connectinlethydrauliclinetomaincontrol valve.Installpowercables.

7. Ifseatbrakewasremoved,connectseatbrake guidepipeandelectricalconnections.SeeFigure10.

INSPECT

8. Installfloorplatesandaccesspanelinbottomof batterycompartment.SeeFigure1.Installbatteryasdescribedinthesection PeriodicMaintenance 8000SRM1201.

HydraulicTankRepair

WARNING

Makeavisualinspectionofallsidesofthetank.Inspectweldsforcracksandleakage.Checkforwetareas,accumulationofdirt,andlooseormissingpaint causedbyleakage.Areasofthetankthatarenoteasilyseencanbecheckedwithaninspectionmirrorand alightthatisapprovedforlocationswithflammable vapors.

Thehydraulictankispartoftheframeweldmentand cannotberemovedfromthelifttruck.SeeFigure13. Repairsforleaksinthehydraulictankcanrequire specialproceduresdescribedinthenextparagraphs.

Donotusetoolsthatcanmakesparks,heat,or staticelectricity.Thevaporsinthetankcan causeanexplosion.

2. ApplyLoctite® 290toleak.Followinstructions ofmanufacturer.

LARGELEAKS,REPAIR

1. UseoneoftheproceduresdescribedunderClean inthissectiontocleanandpreparethetankfor repairs.

2. Useacceptableweldingpracticestorepairtank. SeetheAmericanNationalStandard SafetyIn WeldingandCutting AWSZ49.1-1999.

CLEAN

WARNING

Specialproceduresmustbefollowedwhen largeleaksorotherrepairsneedweldingor cutting. Allworkmustbedonebyauthorized personnel.Ifthetankiscleanedinsideofa building,makesurethereisenoughventilation.See thefollowingmanualsforadditional information:

•SafePracticesforWeldingandCuttingContainersThatHaveHeldCombustiblesbythe AmericanWeldingSociety,F4.1-1999.

1.HYDRAULICTANK 2.OUTERFRAME 3.INNERFRAME 4.SUCTIONPIPE

Figure13.HydraulicTank

SMALLLEAKS,REPAIR

Usethefollowingproceduretosealsmallleaks:

1. Usesteamtocleanareaaroundleak.Removeall paintanddirtaroundleak.

•SafetyIn WeldingandCutting,AmericanNationalStandard,AWSZ49.1-1999.

Whencleaningtank,donotusesolutionsthatmake dangerousgasesatnormaltemperaturesorwhen heated. Weareyeandfaceprotection.Protectthe bodyfromburns.

Whencleaningwithsteam,useahosewithaminimumdiameterof19mm(0.75in.).Controlthepressureof thesteambyavalveinstalledatthenozzleof thehose.Ifametalnozzleisused,itmustbemadeof

amaterialthatdoesnotmakesparks.Makeanelectricalconnectionbetweennozzleandtank.Connect groundwiretotanktopreventstaticelectricity.

SteamMethod

Usethefollowingproceduretocleanthetankwith steam:

1. Removeallpartsfromtank.Installdrainplug.

2. Filltank1/4fullwithasolutionofwaterand sodiumbicarbonateorsodiumcarbonate.Mix 0.5kg(1lb)per4liter(1gal)ofwater.

WARNING

Compressedaircanmoveparticlessothatthey causeinjurytotheuserortootherpersonnel. Makesurethatthepathofthecompressedair isawayfromallpersonnel.Wearprotective gogglesorafaceshieldtopreventinjurytothe eyes.

3. Mixsolutionintankusingairpressure.Make sureallsurfacesoninsideoftankareflushed withsolution.Draintank.

4. Putsteamintotankuntiltankdoesnothave odorsandmetalishot.Steamvaporsmustcome fromallopenings.

5. Flushinsideoftankwithboilingwater.Make sureallloosematerialisremovedfrominsideof tank.

6. Makeinspectionofinsideoftank.Ifitisnot clean,repeatStep4andStep5andmakeanother inspection.Whenmakinginspections,usealight thatisapprovedforlocationswithflammablevapors.

7. Putplugsinallopeningsintank.Wait15minutes,thenremoveinletandoutletplugs.Testa sampleofthevaporwithaspecialindicatorfor gasvapors.Iftheamountofflammablevapors isabovethelowerflammablelimit,repeatthe cleaningprocedures.

ChemicalSolutionMethod

Ifthetankcannotbecleanedwithsteam,usethe followingprocedure:

1. Mixasolutionofwaterandtrisodiumphosphate oracleaningcompoundwithanalkalibase.Followtheinstructionsgivenbythemanufacturer.

WARNING

Compressedaircanmoveparticlessothatthey causeinjurytotheuserortootherpersonnel. Makesurethatthepathofthecompressedair isawayfromallpersonnel.Wearprotective gogglesorafaceshieldtopreventinjurytothe eyes.

2. Filltankwithcleaningsolution.Usecompressed airtomixsolutionintank.

3. Draintank.Flushinsideoftankwithhot(boiling)water.Makesureallcleaningcompoundis removed.

4. Makeaninspectionofinsideoftank.Iftankis notclean,repeatStep1throughStep3.Make anotherinspectionoftank.Whenmakinginspections,usealightthatisapprovedforlocations withflammablevapors.

5. Checktankforflammablevaporsusingaspecialindicatorforgasvapors.Iftheamountof flammablevaporsisabovethelowerflammable limit,repeatthecleaningprocedures.

ADDITIONALPREPARATIONSFOR REPAIR

Ifnitrogengasorcarbondioxidegasisavailable,preparethetankforweldingusingthesegases.Seethe manual SafePracticesForWeldingandCuttingContainersThatHaveHeldCombustibles bytheAmericanWeldingSociety,F4.1-1999.Ifthesegasesare notavailable,anothermethodusingwatercanbe usedasfollows:

1. Filltankwithwatertojustbelowthepointwhere theworkwillbedone.Makesurethespaceabove thelevelofthewaterhasavent.

2. Useacceptableweldingpracticestorepairtank. SeetheAmericanNationalStandard"Safetyin WeldingandCutting,"AWSZ49.1-1999.