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Hyster J30-35-40XMT(C160/F160) Forklift Service Manual

622 pages · Publication 897666

$69.75
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Models
J30-35-40XMT(C160/F160)
Manual type
Service Manual
Pages
622
Publication
897666
Condition
Brand new
Hyster J30-35-40XMT(C160/F160) Forklift Service Manual, publication 897666

What's inside

From the manual's own table of contents: 94 sections, 217 entries. See sample pages (PDF, 110 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 Armature
  • 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 Housing and Control Unit
Description
Operation
Steering Wheel and Column Assembly Repair3 topics
  • Steering Column Assembly, Remove
    • Steering Control Unit
  • Steering Column Assembly, Install
System Air Removal1 topic
  • Remove
Instrument Cluster7 topics
  • Display Panels on Steering Column, Internal Combustion
  • Display Panels on Steering Column, Electric Lift Trucks
    • Standard Display Panel
    • Enhanced Display Panel
  • Curtis 1215 Display Panel
    • Description and Features
    • Operation
Cluster-Type Display Panel (Internal Combustion) Replacement2 topics
  • Remove and Disassemble
  • Assemble and Install
Cluster Display Panel (Electric Lift Truck) Replacement7 topics
  • Display Panel Assembly, Replace
  • LED Indicators
  • Battery Indicators
  • Digital Display (Enhanced Display Panel Only)
  • Status Code or Performance Level Switches and LED indicators (En
  • Standard Display Panel Parts, Replace
  • Enhanced Display Panel Parts, Replace
Curtis 1215 Display Panel Replacement1 topic
  • Install
Table 1. Instrument Cluster, Internal Combustion
Mast
Show all 94 sections
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)
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Safety Procedures When Working Near Mast
Forks Repair
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 Repair6 topics
  • Main Lift Cylinders, Remove
  • Free-Lift Cylinder, Remove
  • Lift Cylinders, Disassemble
  • Lift Cylinders, Assemble
  • 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 Valve5 topics
  • Lift Section
  • Tilt Section
    • Tilt Backward
    • Tilt Forward
  • Relief Valve
Main Control Valve Repair1 topic
  • Clean and Inspect
Relief Valve Check
Vane Settings Adjustment
Mast Tilt Adjustment
Industrial Battery
Lead-Acid Batteries
Specific Gravity
Chemical Reaction in a Cell
Electrical Terms
Battery Selection
Battery Voltage
Battery as a Counterweight
Battery Ratings1 topic
  • Kilowatt-Hours
Battery Maintenance16 topics
  • Safety Procedures
  • Maintenance Records
  • New Battery
  • Cleaning Battery
  • Adding Water to Battery
  • Hydrometer
  • Battery Temperature
  • Charging Battery
    • Types of Battery Charges
    • Methods of Charging
    • Troubleshooting Charger
    • Knowing When Battery Is Fully Charged
  • Where to Charge Batteries
    • Equipment Needed
  • Battery Connectors
  • Battery Care
Table 1. Battery Capacity Terms
Tilt Cylinders
Tilt Cylinder Repair5 topics
  • Clean
    • Tilt Cylinders With O-Ring or Single-Lip Seals
    • Tilt Cylinders for XM and XMS 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
Metric and Inch (SAE) Fasteners6 topics
  • Threaded Fasteners
  • Nomenclature, Threads
  • Strength Identification
  • Cotter (Split) Pins
  • Fastener Torque Tables
  • Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data

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, 622 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.

Other editions and similar models

Hyster F160 (J30-40XMT)Service Manual · F160 · $69.89

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).