Hyster G160 Service & Repair Manual
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Hyster G160 Service & Repair Manual

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Hyster G160 (J1.60XMT, J1.80XMT, J2.00XMT) Forklift

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Summary of Contents for Hyster G160

  • Page 1 Hyster G160 (J1.60XMT, J1.80XMT, J2.00XMT) Forklift...
  • Page 2 MAST REPAIRS H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001]; E1.50-1.75XM (E25-35XM, E25-35XM ) [D114]; H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001]; E2.00XMS (E40XMS, E40XM S) [ D114]; H/S/2.00-3.20XM (H/S/40-65XM) [D177, D187]; E2.00-3.20XM (E40-65XM, E40-65XM ) [F108]; J2.00-3.20XM (J40-60XM, J40-60XM ) [A216]; J2.00-3.20XM (J40-65Z) [A416]; S/J2.00-3.00XL with Mast S/N C507, C508, C509, C562, C563, and C564 (S/E/J40-60XL) [A187, B187, C187, C108, B168];...
  • Page 3 • 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.

  • Page 4: Table Of Contents

    Three-Stage FFL Mast, New Hose Install ....................Three-Stage FFL Mast, Adjust Hoses After Install..................Lift and Tilt System Leak Check ........................Lift Cylinders Leak Check ..........................Tilt Cylinders Leak Check ..........................Tilt Cylinders Adjustment..........................Lift Chains Adjustment ............................. ©2004 HYSTER COMPANY...
  • Page 5 Table of Contents Mast TABLE OF CONTENTS (Continued) Mast Adjustment ............................... Carriage Adjustment ............................Troubleshooting..............................This section is for the following models: H/S/1.50-1.75XM (H/S/25-35XM) [D001, C010, D010, E001]; E1.50-1.75XM (E25-35XM, E25-35XM ) [D114]; H/S/2.00XMS (H/S/40XMS) [D001, C010, D010, E001]; E2.00XMS (E40XMS, E40XM S) [ D114];...

  • Page 6: General

    4000 SRM 522 Safety Procedures When Working Near Mast General 4000 SRM 521 for the description and operation of WARNING the masts. Before working on or near the mast, see Safety NOTE: Hoses have a service life that is determined Procedures When Working Near Mast in this by application and time.
  • Page 7 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 8 Safety Procedures When Working Near Mast 4000 SRM 522 A. TWO-STAGE LFL MAST B. TWO-STAGE FFL MAST C. THREE-STAGE FFL MAST 1. OUTER WELDMENT 4. HOOK 7. CROSSMEMBER 2. INNER WELDMENT 5. FREE-LIFT CYLINDER 3. INTERMEDIATE WELDMENT 6. CROSSMEMBER Figure 1. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts...

  • Page 9: Forks Repair

    4000 SRM 522 Forks Repair Forks Repair The forks are held on the carriage by hooks. The the fork removal notch. See Figure 3. Lower the car- forks are kept in position by latch pins that fit riage further so the top hook of the fork is disengaged through the top fork hooks and into slots in the top from the top carriage bar.

  • Page 10: Install

    Carriages Repair 4000 SRM 522 INSTALL removal notch. Slide the fork on the carriage so both upper and lower hooks engage the carriage bars. En- Move the fork and carriage so the top hook on the gage the latch pin with a notch in the upper carriage fork can engage the upper carriage bar.

  • Page 11: Hang-On Sideshift Carriage, Remove

    4000 SRM 522 Carriages Repair HANG-ON SIDESHIFT CARRIAGE, bracket and cylinder will stay on the standard carriage. Remove the bearings. REMOVE 1. Lower the carriage completely. Remove the forks WARNING and the load backrest extension. Hydraulic oil is hot after system operation and can cause burns.

  • Page 12: Standard Carriage And Hang-On Sideshift Carriage, Repair

    Carriages Repair 4000 SRM 522 STANDARD CARRIAGE AND HANG-ON d. Install the piston and rod in the shell. Ap- ® ply Loctite 242 to the threads of the retain- SIDESHIFT CARRIAGE, REPAIR ers. Install the retainers and tighten them to NOTE: The carriage can have four or six load rollers.

  • Page 13: Hang-On Sideshift Carriage, Install

    4000 SRM 522 Carriages Repair 2. Move the lift truck toward the carriage until the crane must be at least 908 kg (2002 lb)] to the inner mast weldment is aligned with the carriage lifting eye. Install the sideshift carriage on the rollers.
  • Page 14 Carriages Repair 4000 SRM 522 NOTE: TWO AND THREE-STAGE FFL IS SHOWN. 1. INNER CARRIAGE 12. LUBE FITTING 2. OUTER FRAME 13. PIN 3. SIDESHIFT CYLINDER 14. CHAIN ANCHOR 4. UPPER BEARING 15. SNAP RING 5. LOWER BEARING 16. PIN 6.

  • Page 15: Clean And Inspect

    4000 SRM 522 Carriages Repair 4. Use a crane with a capacity of at least 450 kg (992 lb) to lift the outer frame away from the in- ner frame. Lay the outer frame flat on a pallet or workbench. 5.

  • Page 16: Install

    Mast Repair 4000 SRM 522 e. Install the seals into the retainer grooves. 1. If necessary, install the lower sideshift bearings. Form the seals into a "kidney" shape to ease Then install the upper sideshift bearings. Lubri- placement into the groove. Note the direc- cate the upper and lower sideshift bearings with tion of the rod seals.
  • Page 17 4000 SRM 522 Mast Repair J2.00-3.20XM (J40-60XM, J40-60XM ) (A216), and J2.00-3.20XM (J40-65Z) (A416), see Fig- ure 9, remove the capscrews that hold the outer mast weldment to the pivot pins at the mounts. 5. On the H/S1.50-1.75XM, H/S2.00XMS (H/S25- 35XM, H/S40XMS), E1.50-1.75XM (E25-35XM, E25-35XM (D114),...
  • Page 18 Mast Repair 4000 SRM 522 cylinder. Remove the free-lift cylinder. Discon- nect the free-lift chains at the crossmember. 1. RETAINER CAP 5. BUSHING 2. SPACER 6. SHIMS 3. TILT CYLINDER 7. PIN 4. OUTER MAST 8. ROD END WELDMENT Figure 11. Mast Mounting S/E/J2.00-3.00XL (S/E/J40-60XL) 1.
  • Page 19 4000 SRM 522 Mast Repair 4. On H/S2.00-3.20XM (H/S40-65XM), 30 cm (12 in.). Remove the strip bearings and E2.00-3.20XM (E40-65XM, E40-65XM ) (F108), load rollers from the top of the outer mast weld- E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM ment. Remove the load rollers from the bottom (J40-60XM, J40-60XM ) (A216), J2.00-3.20XM of the inner mast weldment.
  • Page 20 Mast Repair 4000 SRM 522 Figure 13. Two-Stage, Limited Free-Lift Mast (Sheet 1 of 2)

This manual is also suitable for:

J1.60xmtJ1.80xmtJ2.00xmt

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