Hyster F160 (J30-40XMT) Forklift Service Manual
593 pages · Publication F160
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- Models
- F160 (J30-40XMT)
- Manual type
- Service Manual
- Pages
- 593
- Publication
- F160
- Condition
- Brand new
What's inside
From the manual's own table of contents: 106 sections, 377 entries. See sample pages (PDF, 201 KB)
INTRODUCTION2 topics
- GENERAL
- DESCRIPTION
REPAIRS18 topics
- OVERHEAD GUARD
- Removal
- Installation
- HOOD AND SEAT ASSEMBLY
- Removal
- Installation
- COUNTERWEIGHT
- Removal
- Installation
- HYDRAULIC TANK
- Inspection
- Repairs, Small Leaks
- Repairs. Large Leaks
- Cleaning
- Steam Method Of Cleaning
- Chemical Solution Method of Cleaning
- Additional Preparations For Repair
- SAFETY LABELS
BATTERY SIZE SPECIFICATIONS
STEERING WHEEL AND COLUMN ASSEMBLY1 topic
- Removal
POWER STEERING PUMP AND MOTOR5 topics
- Removal
- Installation
- REPAIRS
- Disassembly
- Assembly
STEERING TRUNNION ASSEMBLY15 topics
- STEER AXLE
- WHEEL ASSEMBLY
- Removal
- Installation
- WHEEL HUB
- Removal
- Installation
- STEER AXLE ASSEMBLY
- Removal
- Installation
- POWER STEERING CYLINDER
- Removal
- Installation
- Disassembly
- Assembly
CHECKS AND ADJUSTMENTS3 topics
- AIR IN THE STEERING SYSTEM
- Check the Operation
- Steering Pressure
TROUBLESHOOTING
DESCRIPTION6 topics
- INSTRUMENT PANELS
- Standard Display
- Preminum Display
- PRINTED CIRCUIT BOARDS
- Steering Angle Control Board
- Lift Pump Control Board
REPLACEMENT37 topics
- INSTRUMENT PANEL COMPONENTS
- Instrument Panel Assembly
- Key Switch
- Battery Indicators
- Hourmeter (Standard Panel Only)
- Indicator Lights
- Steering Angle Control Board
- Lift Pump Control Board
- OTHER CONTROL COMPONENTS
- Accelerator Switch Assembly
- Stop Light Switch
- Seat Switch
- Parking Brake Switch
- Direction Switches (Monotrol Pedal)
- Direction Control Switches (Steering Column)
- Hydraulic Cut Off Switch
- Brake Fluid Switch
- Motor Temperature Switches
- Rocker Switches for Lights
- Lights and Reverse Alarm
- Horn and Horn Button
- CONTROL AND POWER FUSES
- CHECK ACCELERATOR SWITCH ASSEMBLY
- ADJUSTING STOP LIGHT SWITCH
- CHECK SEAT SWITCH
- ADJUSTING PARKING BRAKE SWITCH
- DIRECTION SWITCHES (MONOTROL PEDAL)
- DIRECTION SWITCHES (STEERING COLUMN)
- HYDRAULIC CUT OFF SWITCH
- Steering Angle Control Board
- Lift Pump Control Board
- Bypassing the Lift Pump Control Board
- HOW TO MOVE A DISABLED LIFT TRUCK
- HOW TO TOW A LIFT TRUCK
- HOW TO PUT A LIFT TRUCK ONTO BLOCKS
- How to Raise the Load Wheels
- How to Raise the Steer Wheel
MAINTENANCE SCHEDULE
MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY20 topics
- CHECKS BEFORE OPERATION
- Hydraulic System
- Battery
- Operator Restraint System
- Battery Restraint System
- Tires and Wheels
- SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
- Forks
- Forks, Adjustment
- Forks, Removal
- Forks, Inspection
- Forks, Installation
- Mast and Lift Chains
- Lift Chain Adjustments
- CHECK THE OPERATION
- Gauges and Horn
- Control Levers and Pedals
- Service Brakes
- Parking Brake
- Steering System
EVERY 350 HOURS OR TWO MONTHS14 topics
- HYDRAULIC TANK BREATHER
- WHEEL NUT TORQUE
- STEERING TRUNNION MOUNTING CAPSCREW TORQUE
- TRANSAXLE
- LIFT SYSTEM OPERATION
- MAST
- LIFT CHAINS
- FORKS
- BRAKE FLUID
- OTHER LUBRICATION
- ELECTRICAL INSPECTION
- Contactors
- Motor Brushes
- Parking Brake
HOURS OR YEARLY6 topics
- HYDRAULIC SYSTEM
- Change the Hydraulic Oil Filter
- Check the Hydraulic Oil Strainer
- Change the Hydraulic Oil
- BRAKES
- Adjust the Parking Brake
EVERY 4000 HOURS1 topic
- TRANSAXLE (S2 SERIES ONLY)
GENERAL PROCEDURES6 topics
- CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
- LIFT SYSTEM
- TILT SYSTEM
- HOW TO CHECK THE PMT CIRCUIT
- HOW TO CHARGE THE BATTERY
- HOW TO CHANGE THE BATTERY
WHEELS AND TIRES16 topics
- HOW TO CHANGE THE TIRES
- STEER AND DRIVE WHEELS
- PNEUMATIC TIRES
- Remove the Wheel from the lift truck
- Remove the Tire from the Wheel
- Install The Tire On The Wheel
- Add Air to the Tires
- PNEUMATIC SHAPED SOLID TIRES
- Remove the Wheel from the lift truck
- Remove the Tire from the Wheel
- Install the Tire on the Wheel
- SOLID TIRES
- Remove the One Piece Wheel and Tire
- Install the Tire on the One Piece Wheel
- INSTALL THE WHEEL AND TIRE
- BATTERY SIZE SPECIFICATIONS
WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP
WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP
OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP
WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP
WIRING DIAGRAM WITH CONTACTOR CONTROLLED LIFT PUMP
OPTIONAL WIRING WITH CONTACTOR CONTROLLED LIFT PUMP
OPTIONAL MAIN LIGHTS WIRING
Show all 106 sections
CABLE DETAILS
ELECTRICAL ARRANGEMENT WITH SCR CONTROLLED LIFT PUMP
ELECTRICAL ARRANGEMENT WITH CONTACTOR CONTROLLED LIFT PUMP
HYDRAULIC SYSTEM ARRANGEMENT
HYDRAULIC SCHEMATIC
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
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
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)
Three-Stage Mast, Full Free-Lift (FFL)
Four-Stage Mast
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Mast Repairs
Safety Procedures When Working Near Mast
Fork Repair2 topics
- Remove
- Install
Carriages Repair10 topics
- Standard Carriage, Remove
- Hang-On Sideshift Carriage, Remove
- Standard Carriage and Hang-On Sideshift Carriage, Repair
- Standard Carriage, Install
- Hang-On Sideshift Carriage, Install
- Integral Sideshift Carriage
- Remove
- Clean and Inspect
- Repair
- Install
Mast Repair6 topics
- Two-Stage LFL and Two-Stage FFL Masts, Disassemble
- Three-Stage FFL Mast
- Disassemble
- Mast and Chains, Clean and Inspect
- Two-Stage LFL and Two-Stage FFL Mast, Assemble
- Three-Stage FFL Mast, Assemble
Lift Cylinders Repair15 topics
- Main Lift Cylinders, Remove
- Free-Lift Cylinder, Remove
- Cylinders, Disassemble
- Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
- Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
- Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
- Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
- Clean and Inspect
- Cylinders, Assemble
- Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
- Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
- Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
- Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
- Main Lift Cylinders, Install
- Free-Lift Cylinder, Install
Header Hose Arrangements6 topics
- Two-Stage LFL Mast, New Hose Install
- Two-Stage LFL Mast, Adjust Hoses After Installation
- Two-Stage FFL Mast, New Hose Install
- Two-Stage FFL Mast, Adjust Hoses After Installation
- Three-Stage FFL Mast, New Hose Install
- Three-Stage FFL Mast, Adjust Hoses After Installation
Header Hose Arrangement1 topic
- Three-Stage FFL Mast, Adjust Hoses After Install
Lift and Tilt System Leak Check2 topics
- Lift Cylinders Leak Check
- Tilt Cylinders Leak Check
Tilt Cylinders Adjustment
Lift Chains Adjustment
Mast Adjustment
Carriage Adjustment
Table 1. Hook-Type Carriage Chain Adjustment
Table 2. Pin-Type Carriage Chain Adjustment
Transaxle
Lubrication
Transaxle Repair1 topic
- Inspect
S2 Series Transaxle7 topics
- Inspection
- General
- Ring Gear, Install
- Intermediate Shaft, Install
- Axle Shaft, Install
- Pinion Gear, Install
- Final Assembly
S1 Series Transaxle
Table 1. Transaxle Identification
Table 2. Transaxle Specifications
Table 3. Gear Teeth Contact Pattern
Brake System
Service Brake Pads Repair
Service Brake Caliper Repair
Park Brake Caliper Repair
Master Cylinder Repair
Foot-Operated Park Brake Lever Assembly Repair
Electrically Released Park Brake Repair1 topic
- Mechanical Operation
Electrically Released Park Brake - Electrical Components Repair6 topics
- Control Box
- Remove
- Install
- Terminal Block
- Remove
- Install
Park Brake Adjustment
Service Brake Adjustment
Brake System Air Removal
Main Control Valve
Operation5 topics
- Lift Section
- Tilt Section
- Tilt Backward
- Tilt Forward
- Relief Valve
Main Control Valve Repair
Relief Valve Check
Vane Settings Adjustment
Mast Tilt Adjustment
Tilt Cylinders
Tilt Cylinder Repair6 topics
- Clean
- Tilt Cylinders With O-Ring or Single-Lip Seals
- Tilt Cylinders for XM and XMS Models
- Tilt Cylinders for XL, XLS, and XL 3 Models
- Tilt Cylinders for H700-800A and Early Model H700-920B
- Tilt Cylinders Using Chevron Packing
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
Torque Specifications2 topics
- Piston Rod Nut
- Retainer
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Electrical Warning Devices9 topics
- Operator-Controlled Horns
- System Warning Lights, Buzzers, and Bells
- Reverse Warning Horns
- Warning Lights
- Horns or Bells, Replace
- Horn Relay or Buzzer, Replace
- Warning Lights/Bulbs, Replace
- Light Assemblies, Replace
- Flashing Units, Replace
Lift Cylinders4 topics
- Lowering Control Valve
- Cylinders (General)
- Retainer, Install
- Cylinders (Two-Speed)
Lift Cylinder Repair10 topics
- Lift Cylinder Removal Without Removing Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
- Lift Cylinder Installation in Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Chevron-Style Packing
- Chevron-Style Packing Installation on Piston
- Chevron-Style Packing Installation in Packing Gland
Lift Cylinders for VISTA® Masts3 topics
- Lowering Control Valve
- Main Lift Cylinders
- Free-Lift Cylinder
Lift System Leak Check
Specifications
Table 1. Lift Trucks With Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid
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
Inside this manual
Real pages from this service manual (593 pages). Open the sample pages (PDF, 200 KB)
- Diagram, page 125: FIGURE 1 – WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP
- Specifications, page 368: Header Hose Arrangement
- Troubleshooting, page 548: Troubleshooting
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, 593 pages
Quantity one is the manual described above.
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Other editions and similar models
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