MidWestTechService, Parts and Operator's Manuals, in stock and ready to ship!
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3+

Hyster J160 (J30-35-40ZT) Forklift Service Manual

949 pages · Publication 1554640

$99.57
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Models
J160 (J30-35-40ZT)
Manual type
Service Manual
Pages
949
Publication
1554640
Condition
Brand new
Hyster J160 (J30-35-40ZT) Forklift Service Manual, publication 1554640

What's inside

From the manual's own table of contents: 149 sections, 484 entries. See sample pages (PDF, 218 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
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
Show all 149 sections
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
Tilt Cylinders
Description
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
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 Menu3 topics
  • General
  • Technical Support
  • About Electric Truck AC Controls Program
Frame
Introduction2 topics
  • Description of Operation
  • Discharging the Capacitors
Covers and Floor Plates
Overhead Guard Repair
Hood and Seat Assembly
Counterweight
Safety Labels
Painting Instructions
Transaxle2 topics
  • Transmission
  • Traction Motor
Maintenance2 topics
  • Oil Level Check
  • Oil Change
Transaxle Assembly5 topics
  • Traction Motor and Covers
    • Brake Assembly and Gears
    • Planetary Gears and Drive Axle
    • Brake Assembly and Gears
    • Traction Motor and Covers
Table 1. Special Tools
Table 2. Conventional Tools
Steering System
Description of Operation
Steering Pressure Check
Operation Check
Steering Wheel and Column6 topics
  • Steering Column Covers
    • Remove
    • Install
  • Steering Column Components
    • Remove
    • Install
Steering Control Unit Assembly
Power Steering Pump and Motor1 topic
  • Description
Steering Actuator Components10 topics
  • Steer Tire and Wheel Assembly
    • Remove
    • Install
  • Wheel Hub Assembly
    • Remove
    • Install
  • Steering Axle Assembly
    • Remove
    • Clean
    • Install
Brake System
Brake Pedal Assembly
Master Cylinder3 topics
  • Adjustments
    • Bleed the Brake System
    • Adjust Linkage
Brake Lines
Parking Brake
Hydraulic System8 topics
  • Hydraulic Oil
  • Hydraulic Lines
  • Cleaning
  • Sound Level
  • Maintenance
    • Hydraulic Oil Filter, Change
    • Hydraulic Oil Strainer, Check
    • Hydraulic Oil, Change
Hydraulic Tank Assembly1 topic
  • Trisodium Phosphate Method
Lift Pump and Motor
Lift Pump
HUSCO™ Main Control Valve
Operation5 topics
  • Lift Section
  • Tilt Section
    • Tilt Backward
    • Tilt Forward
  • Relief Valve
Main Control Valve Repair1 topic
  • Switch Plate Adjustment
Pressure Relief Valve Check and Adjustment2 topics
  • Primary Relief Valve
  • Secondary Relief Valve
Electro-Hydraulic Control Valve13 topics
  • Electro-Hydraulic Control System
  • Electro-Hydraulic Control Valve
  • Valve Driver Module
  • Manual Lowering Valve
  • Hydraulic Lever Console
    • Lift Valve Section
    • Tilt/Auxiliary Valve Sections
    • Valve Spool Coils
    • Fittings
  • Check and Adjust
    • Tilt Counterbalance Valve
    • Main Relief Valve
    • Auxiliary Relief Valve
Valve Driver Module
Hydraulic Lever Console6 topics
  • Covers
    • Hydraulic Control Lever
    • Main PC Board
    • Hydraulic Control Lever
    • Covers
  • Troubleshooting Chart
Table 1. Error Codes
AC Motor Controllers/Display Panel5 topics
  • AC Motors
    • ZAPI™ AC Motor Controller
    • Principles of Operation
    • Controller Thermal Management
    • Controller Area Network (CANbus)
AC Motor Controller Repair3 topics
  • Special Precautions
  • Thermal Sensors
  • Motor Controller, Replace
Controller Checks and Adjustments
Function Parameters
Function Parameter Descriptions25 topics
  • Parameters
    • Top Speed Forward
    • Top Speed Reverse
    • Acceleration
    • Regen Braking
    • Auto Deceleration
    • Extended Shift
    • Pump Acceleration
    • Tilt/Auxiliary Pump Acceleration
    • Low Lift Speed
    • Maximum Lift Speed
    • Maximum Lowering Speed
    • Tilt Speed
    • 3rd Function
    • 3rd Function Speed
    • 4th Function
    • 4th Function Speed
    • Battery Voltage
    • Lift Interrupt
    • BDI Adjustment (Early Models)
    • BDI Adjustment (Later Models)
    • BDI Decrement Time
    • Service Reminder
    • Custom
    • Restore Defaults
Calibration Parameters2 topics
  • Throttle Calibration
  • Steering Calibration
Display Panel2 topics
  • Premium Display Panel
    • Standard Display Panel
Display Functions and Features10 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
  • Status Code List
Dash Display Service Menu Navigation2 topics
  • Moving Through Menu Selections
  • Editing and Adding Information
ETACC Test8 topics
  • Manual Hydraulics
  • Electro-Hydraulics
  • Status Codes
  • Controller Connector Pin Outs
  • Valve Driver Module (Electro-Hydraulic Valve Option)
  • Hydraulic Lever Console (Electro-Hydraulic Option Only)
  • Dash Display
  • System Logic Diagrams
Table 1. Traction Parameters
Table 2. Transistor Lift With Manual Valve Parameters
Table 3. Transistor Lift With Electro-Hydraulic Valve Parameters
Table 4. List of Status Codes
Table 5. Connector A
Table 6. Connector C
Table 7. Connector D - Standard Model
Table 8. Connector D - Premium Model
Table 9. Connector B
Table 10. Connector C
Electrical System2 topics
  • Emissions
    • Electromagnetic Interference
Motor Controllers8 topics
  • Controllers
    • Remove
    • Install
  • Hydraulics Contactor
    • Remove
    • Disassemble
    • Assemble
    • Install
Contactor Panel8 topics
  • Main Contactor
    • Remove
    • Disassemble
    • Assemble
    • Install
    • Contactor Coil
    • Contactor Tips
  • Fuses
Display Units2 topics
  • Features
  • Replace
Key Switch
Directional Controls4 topics
  • Directional Control Switches
  • Accelerator Switches and Pedal Assembly
  • Calibrate
  • MONOTROL™ Directional Control
Brakes5 topics
  • Brake Switch
    • Adjust or Replace
  • Master Cylinder Indicator
  • Parking Brake Disengage
    • Override Mode
Horn Components and Steering Encoder4 topics
  • Horn Components
    • Horn
    • Horn Button and Contacts
  • Steering Encoder
Hood and Seat Switches2 topics
  • Hood Position Switches
  • Seat Switch
Steer Angle Potentiometer7 topics
  • Operation
    • Example
  • Position Steer Tire for Straight Travel
    • Set Potentiometer to Midpoint
    • Install to Steer Axle
    • Calibrate
  • Test
Wiring Harness
Table 1. Potentiometer Specifications
Periodic Maintenance5 topics
  • How to Move Disabled Lift Truck
    • How to Tow Lift Truck
  • How to Put Lift Truck on Blocks
    • How to Raise Drive Tires
    • How to Raise Steer Tires
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily14 topics
  • Checks With the Key Switch OFF
    • Safety Labels and Decals
    • Frame
    • Wheels and Tires
    • Mast, Carriage, and Forks
    • Hydraulic Oil Level and Leaks
    • Operator and Battery Restraints
    • Battery Check
  • Checks With the Key Switch ON
    • Electrical Components
    • Directional Speed Control
    • Steering System
    • Hydraulic System
    • Brakes
Maintenance Procedures Every 500 Hours or 3 Months7 topics
  • Tire and Wheel Assemblies
  • Mast and Carriage
  • Hydraulics
  • Battery
    • Hydraulic Motor Brushes
  • Parking Brakes
  • Transaxle
Maintenance Procedures Every 1000 Hours or 6 Months8 topics
  • Lift Chains
    • Check Upper and Lower Bearings
  • Hydraulic Breather Cap
  • Master Cylinder
  • Electrical Inspection
    • Contactors
    • Directional Speed Control
  • Transaxle, Oil Change
Maintenance Procedures Every 2000 Hours or Yearly6 topics
  • Steering
  • Hydraulic
    • Hydraulic Oil Filter, Change
    • Hydraulic Oil Strainer, Check
    • Hydraulic Oil, Change
    • Replace Upper and Lower Bearings
General Repairs4 topics
  • Welding Repairs
  • Painting Instructions
  • Lift System
  • Tilt System
Battery Maintenance3 topics
  • How to Charge Battery
  • How to Change Battery
  • Battery Size Specifications
Table 1. Maintenance Schedule
Capacities and Specifications
Lubrication Specifications
Tire Sizes4 topics
  • Electrical
  • Steering System
  • Hydraulic System
  • Manual Hydraulic Valve
Travel Speeds
Battery
Diagrams
AC Traction Motor Repair
AC Motor Repair1 topic
  • Inspect
Four-Stage (Quad) Mast2 topics
  • Mast
    • Operation
Forks1 topic
  • Checks
Carriage
Main Lift Cylinders Repair1 topic
  • Repair
Free-Lift Cylinder Repair
Lowering Control Valve1 topic
  • Valve Cartridge Service
Mast, Complete
Load rollers4 topics
  • Reach Assembly
    • Load Rollers and Wear Plugs
    • Thrust Rollers
  • Crosshead Assembly
Lift Chains1 topic
  • Clean and Lubricate
Mast Adjustments2 topics
  • Skewing
  • Shimming
Carriage Adjustments
Lift and Tilt System Leaks Check2 topics
  • Lift Cylinders Leaks Check
  • Tilt Cylinders Leaks Check
Table 1. Fork Tip Alignment Specifications

Inside this manual

Real pages from this service manual (949 pages). Open the sample pages (PDF, 218 KB)

Sample pages from the Hyster J160 (J30-35-40ZT) Forklift Service Manual: Troubleshooting, Diagram, Specifications
  • Troubleshooting, page 432: Troubleshooting
  • Diagram, page 698: Diagrams, Schematics, or Arrangements
  • Specifications, page 880: * Metric Formulas (All Dimensions are in Millimeters)

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, 949 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).