Hyster B416 (J40-65Z) Forklift Service Manual
1,005 pages · Publication 1616862
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- Models
- B416 (J40-65Z)
- Manual type
- Service Manual
- Pages
- 1,005
- Publication
- 1616862
- Condition
- Brand new
What's inside
From the manual's own table of contents: 142 sections, 508 entries. See sample pages (PDF, 310 KB)
DC Motor Maintenance
Safety Precautions Maintenance and Repair
General
Brush and Commutator Inspection4 topics
- Hydraulic Pump Motor and Traction Motor
- Steering Pump Motor
- Normal Commutator Surface
- Commutator Problems
Brush Replacement
Stoning the Commutator
Motors Repair6 topics
- Disassemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
- Assemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
Brush Alignment, Traction and Hydraulic Motors
Tests for Damaged Field and Armature7 topics
- Test for an Open Circuit in One Armature Winding
- Test for Short Circuit in One Armature Winding
- Test for Short Circuit to Armature Shaft
- Test for Open Circuit in Field Coil
- Test for Short Circuit in Field Coil
- Test for Short Circuit Between Field and Motor Case
- Brush Holder Test
Troubleshooting
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Steering Axle
Description
Steering Axle Assembly Repair2 topics
- Remove
- Install
Wheels and Hubs Repair3 topics
- Remove and Disassemble
- Clean
- Assemble and Install
Spindles, Bearings, and Tie Rods Repair
Steering Cylinder Repair1 topic
- Clean and Inspect
Torque Specifications
Mast
Description and Operation2 topics
- Carriages
- Mast Mounts
Two-Stage Mast, Limited Free-Lift (LFL)1 topic
- Description and Operation
Two-Stage Mast, Full Free-Lift (FFL)
Show all 142 sections
Three-Stage Mast, Full Free-Lift (FFL)
Four-Stage Mast
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Hydraulic System
Operation3 topics
- Hydraulic Gear Pump
- Rotator Actuator Valve
- Steering Pump
Hydraulic Tank Repair6 topics
- Inspect
- Small Leaks, Repair
- Large Leaks, Repair
- Steam Method
- Chemical Solution Method
- Additional Methods for Tank Repair
Filter Replacement8 topics
- Remove
- Install
- Remove
- Install
- Remove
- Install
- Remove
- Install
Hydraulic Pump Repair2 topics
- Pump Seal Replace and Pump Assemble
- Assemble Pump on Motor
Main Control Valve Repair
Steering Pump Repair1 topic
- Pump, Assemble and Install
Rotary Actuator Valve Repair1 topic
- Disassemble, Clean, and Inspect
Steering Control Unit Replacement
Main Control Valve Check and Adjust
Steering Relief Valve Check and Adjust
Specifications6 topics
- Relief Valve Pressures*
- Hydraulic Tank Capacity (dipstick full mark)
- Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5
- Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1
- Steering
- Steering Housing and Steering Control Unit
Manual hydraulic Control Valve17 topics
- Lift Section
- Tilt Section
- Tilt Backward
- Tilt Forward
- Relief Valve
- Main Control Valve Without OPS Solenoid
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Main Control Valve With OPS Solenoid
- Remove
- Disassemble
- Clean and Inspect
- Relief Valve Repair
- Assemble
- Install
Control Lever Linkage Repair
Control Valve Linkage Repair
Pressure Relief Valve Check and Adjustment2 topics
- Primary Relief Valve
- Secondary Relief Valve
Steering Housing and Control Unit
Steering Wheel and Column Assembly Repair5 topics
- Assembly Components, Remove
- Steering Control Unit, Disassemble
- Steering Control Unit, Clean
- Steering Control Unit, Assemble
- Assembly Components, Install
System Air Removal
AC Motor Repair1 topic
- Drive End Bearing, Replace
Steering System for AC Electric Lift Trucks1 topic
- General
Power Steering Motor and Pump3 topics
- Description
- Power Steering Pump, Repair
- Seal, Replace
Steering System Air Removal
Steering Pressure Check
Steering Motor Circuits Check
Electrical System (Trucks With AC Controllers)2 topics
- Features of the Display Panels
- Other Control Components
Display Panel and Key Switch Replacement2 topics
- Display Panel, Replace
- Key Switch, Replace
Controller Replacement2 topics
- Traction and Pump Motor Controller Replacement
- Master Controller, Replace
Control Components Replacement26 topics
- Start Switch, Replace
- Brake Light Switch, Replace
- Seat Switch, Replace
- Parking Brake Switch, Replace
- MONOTROL Pedal Direction Switches, Replace
- Steering Column Direction Control Switches, Replace
- Remove
- Install
- Brake Fluid Switch, Replace
- Brush Wear and Over Temperature Sensors (DC Pump Motor Only)
- Rocker Switches for Lights, Replace
- Accelerator Position Sensor, Replace
- On-Demand Steering Sensor, Replace
- Lights, Converter, Relay, and Reverse Alarm
- Brake, Tail, and Reverse Light Assembly, Replace
- Strobe Light Assembly, Replace
- Wire Harness Repair
- Front, Rear Driving Light or Spot Light Assemblies, Replace
- Converter, Replace
- Reverse Relay, Replace
- Backup Alarm, Replace
- Horn and Horn Button, Replace
- Horn Replacement for Lift Trucks E3.50-5.50XL, E4.50XLS (E70-120
- Horn Switch and Cover, Replace
- Hydraulic Pump Switches
- Fan Power Supply, Replace
Control and Power Fuse Check1 topic
- Fuse Locations
Brake Light Switch Adjustment
Seat Switch Check
Seat Brake Adjustment
Parking Brake Switch Adjustment
Direction Switches Check2 topics
- MONOTROL Pedal
- Steering Column
MONOTROL Pedal or Accelerator Pedal Adjustment
Accelerator Position Sensor Adjustment and Start Switch Adjustme2 topics
- Acceleration Position Sensor, Adjust
- Start Switch, Adjust
Table 1. Wire Splice Size
AC Motor Controllers/Display Panel5 topics
- AC Motors
- Motor Controllers
- Master Controller
- Dash Display
- Controller Area Network Bus (CANbus)
Master Controller Checks and Adjustments
Function Settings1 topic
- Function Numbers
Function Descriptions20 topics
- Function Number 1 BATTERY VOLTAGE
- Function Number 2 EXTENDED SHIFT
- Function Number 3 ACCELERATION 1
- Function Number 4 ACCELERATION 2
- Function Number 5 TOP SPEED LIMIT
- Function Number 6 REGEN BRAKING
- Function Number 7 AUTO DECELERATION
- Function Number 8 BDI ADJUSTMENT
- Function Number 9 LIFT INTERRUPT
- Function Number 10 POWER STEERING TIME DELAY
- Function Number 11 SERVICE REMINDER
- Function Number 12 CUSTOM
- Function Number 13 PUMP SPEED 1
- Function Number 14 PUMP SPEED 2
- Function Number 15 PUMP SPEED 3
- Function Number 16 PUMP ACCELERATION
- Controller Status Light Emitting Diodes (LEDs)
- Master Controller
- AC Motor Controllers
- Status Codes
AC Motor Controllers Status Code Charts6 topics
- Troubleshooting When Dash and/or Lift Truck is not Operational
- Typical Symptoms
- Truck Runs but Dash Display is not Operational, or Only Displays
- Truck Does Not Run and Dash is Not Operational or Only Displays
- Hydraulics Operate Normally, Traction Does Not Operate Correctly
- Traction Operates Normally, Hydraulics do Not Operate Correctly
AC Transistor Motor Controller Replacement8 topics
- General Maintenance Instructions
- Special Precautions
- Fuses
- Fan Test
- Contactors
- Repair
- Thermal Sensors
- Motor Controller, Replace
Display Panel2 topics
- Premium Display Panel
- Standard Display Panel
Display Functions and Features9 topics
- Key-On Initialization
- Standard Display
- Premium Display
- Lift Truck Inspection Function
- Access to Service Functions
- Service Functions
- Performance Modes
- Battery Discharge Indicator (BDI)
- Hourmeter
Dash Display Service Menu Navigation2 topics
- Moving Through Menu Selections
- Editing and Adding Information
Table 5. List of Status Codes
Table 6. 42-Pin Connections/Descriptions for Master Controller
Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo
Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen
Troubleshooting and Adjustments Using the AC Controls Program (E6 topics
- Computer Requirements
- Software, Install
- Language Selection
- Demo Mode
- Connect PC to Lift Truck
- Starting AC Controls Program
Lift Truck Control Setup6 topics
- Change Lift Truck Serial Number or Hourmeter
- Setting Factory Default Values or Changing Lift Truck Parameters
- Create New Custom Lift Truck Configuration
- Lift Truck Configuration Properties
- Import New Lift Truck Configuration From Disk
- Delete Custom Lift Truck Configuration or Password File
Dash Display3 topics
- Custom Display Languages
- Download Display Language
- Clear Operator Log
Password Functions7 topics
- Enable/Disable Password and Lift Truck Inspection Functions
- Truck Inspection Checklist
- Password
- Password Properties
- Create New Password File
- Download Passwords
- Upload Passwords
Reports Menu8 topics
- Devices Report
- Custom Report
- Password Report
- Operator Report
- Current Settings Report
- Status Code Report
- Status Codes Log
- Diagnostics
Help Menu2 topics
- Technical Support
- About Electric Truck AC Controls Program
Frame9 topics
- Main Frame
- Other Frame Weldments
- Overhead Guard
- Battery Restraint, Hood, and Seat Assembly
- Hood With Manual Hydraulic Levers
- Hood With E-Hydraulics
- Operator Restraint System and Seat Assembly
- Operator Restraint System
- Hood and Seat Latches
Overhead Guard Replacement
Hood, Seat Assembly, and Operator Restraint Replacement3 topics
- Hood and Seat Assembly
- Remove
- Install
Counterweight Replacement
Hydraulic Tank Replacement4 topics
- Steam Method
- Chemical Solution Method
- Additional Preparations for Tank Repair
- Preparations for Usage After Repair
Painting Instructions
Safety Label Replacement
Battery Specifications
Table 1. Counterweights
Drive Unit Assembly
Wet Disc Brake Repair4 topics
- Wet Disc Brakes
- Remove
- Inspect
- Install
Gearbox Replacement5 topics
- Gearbox Removal
- Intermediate Flange Removal
- Intermediate Flange
- Intermediate Flange Installation
- Gearbox Installation
Drive Unit Removal
Main Housing Repair12 topics
- Main Housing, Right-Hand Side
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
- Main Housing, Left-Hand Side
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
Differential Assembly Replacement
Traction Motor Repair
Drive Unit Installation
Electro-Hydraulic Control Valve5 topics
- Electro-Hydraulic Control System
- Electro-Hydraulic Control Valve
- Electro-Hydraulic Valve Driver Module
- Mini-Lever Module (MLM)
- Joystick
Electro-Hydraulic Control Valve Repair9 topics
- Solenoid Coil Replacement
- Cartridge Replacement
- Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement
- Lift Circuit Check Valve Replacement
- Compensator Cartridge Replacement
- Primary and Secondary Relief Valves Replacement
- Tilt Counterbalance Valve Replacement
- Flow Regulator Valve Replacement
- E-Hydraulics Calibration
Mini-Lever Module17 topics
- Remove
- Install
- Mini-Lever Replacement
- Remove
- Clean and Inspect
- Install
- Push Button Switch Replacement
- Remove
- Install
- Test
- Mini-levers
- Full Stroke Test
- Function Returns to Neutral Test
- Push Button Switch
- Remove and Disassemble
- Inspect
- Assemble and Install
Table 1. Primary and Secondary Relief Valve Values
Table 2. Solenoid Resistance Values
Table 3. Cartridge and Solenoid Coil Nut Torque for Lift truck M
Table 4. Cartridge and Solenoid Coil Nut Torque for Lift truck M
Electrical Diagrams
Periodic Maintenance6 topics
- Serial Number Data
- How to Move A Disabled Lift Truck
- How to Tow a Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily21 topics
- How to Make Checks With Key Switch OFF
- Tires and Wheels
- Forks
- Mast, Carriage, Header Hoses, and Lift Chains, Inspect
- Safety Labels
- Steering Column Latch
- Operator Restraint System
- Seat Rails
- Battery Restraint System
- Battery
- Hydraulic System
- How to Make Checks With Key Switch ON
- Horn, Lights, and Alarm
- Steering System
- Service Brakes
- Parking Brake
- Hydraulic Control Levers
- Direction and Speed Control Pedals
- Lift System Operation
- Oil Leaks
- Seat Switch
First Service After First 100 Hours of Operation3 topics
- Change Filter for Hydraulic Oil
- Remove
- Install
Maintenance Procedures Every 500 Hours or 3 Months9 topics
- Wheel Nut Torque
- Header Hose Checks
- Mast
- Forks
- Remove
- Inspect
- Install
- Adjust
- Parking Brake Adjustment
Maintenance Procedures Every 1000 Hours or 6 Months13 topics
- Lift Chains
- Wear Check
- Lift Chain Lubrication
- Check Upper and Lower Bearings, Integral Sideshift Carriage
- Steering Tie Rods
- Steering Axle Spindles
- King Pins
- Gearbox and Brake Chamber
- Brake Oil
- Electrical Inspection
- AC and DC Hydraulic Pump Motor
- Contactors
- Other Lubrication
Maintenance Procedures Every 2000 Hours or Yearly13 topics
- Remove
- Install
- Change Hydraulic Oil
- Hydraulic Tank Breather
- Remove
- Install
- Gearbox and Brake Oil Replacement
- Remove
- Install
- Brake Oil Replacement
- Wheel Bearings
- Steer Wheels, Lubrication
- Replace Upper and Lower Bearings, Integral Sideshift Carriage
Battery Maintenance3 topics
- How to Charge Battery
- How to Change Battery
- General
Lift and System Leak Check2 topics
- Lift Cylinders Leak Check
- Tilt Cylinders Leak Check
Safety Procedures When Working Near Mast1 topic
- WHEN WORKING NEAR THE MAST ALWAYS
Lift Chain Adjustment
Welding Repairs
Overhead Guard Changes
Wheels and Tire Maintenance14 topics
- Pneumatic Tires and Wheels
- Remove Wheels From Lift Truck
- Remove Wheel From Pneumatic Tire
- Install Three- or Four-Piece Wheel in Pneumatic Tire
- Add Air to Tires
- Wheels, Install
- Solid Rubber Tires on Pneumatic Wheels
- Remove Wheels From Lift Truck
- Remove Solid Rubber Tire From Pneumatic Wheel
- Install Solid Rubber Tire on Pneumatic Wheel
- Wheels, Install
- Snap-On Tire, Change
- Remove Snap-On Solid Tire From Wheel
- Install Snap-On Solid Tire on Wheel
Adhesives and Sealants
Table 1. Maintenance Schedule
Capacities and Specifications
Counterweight
Steering System
Wheels and Tires
Capacities
Movement Rates (Maximum) for Tilt Cylinders
Mast Speeds5 topics
- Mast Speeds - J40-65Z (72 or 80 Volt) Americas
- Frame
- Drive Axle, Speed Reducer, and Differential
- Masts
- E-Hydraulic Control Valve
Table 1. Manual Control Valve
Table 2. E-Hydraulic Control Valve
Brake Pedal and Linkage
Brake Pedal Replacement
Master Cylinder Repair1 topic
- Install and Adjust
Parking Brake Replacement1 topic
- Adjust
Brake Pedal Adjustment
Master Cylinder Adjustment
Brake System Air Removal2 topics
- Using Power Pressure Bleed System
- Using Brake Pedal Bleed System
Inside this manual
Real pages from this service manual (1,005 pages). Open the sample pages (PDF, 309 KB)
- Specifications, page 148: Specifications
- Troubleshooting, page 403: AC Motor Controllers Status Code Charts
- Diagram, page 883: Diagrams, Schematics, or Arrangements
- Color page, page 856: Mini-Lever Module
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,005 pages
Quantity one is the manual described above.
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