Hyster J30-35-40XMT2 (H160) Forklift Service Manual
726 pages · Publication 1468296
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- Models
- J30-35-40XMT2 (H160)
- Manual type
- Service Manual
- Pages
- 726
- Publication
- 1468296
- Condition
- Brand new
What's inside
From the manual's own table of contents: 161 sections, 484 entries. See sample pages (PDF, 278 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
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)
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Safety Procedures When Working Near Mast
Forks 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
Show all 161 sections
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
Description
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 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
SX/SR Transistor Motor Controllers and Handset
Introduction to SEM6 topics
- Advantages of Transistorized SEM
- Features of SEM
- Solid-State Reversing
- Performance and Efficiency
- Field Weakening
- Regenerative Braking
SX Transistor Motor Controllers28 topics
- Introduction
- Proportional Operation for Dual-Motor Trucks
- General
- Operation
- Controller Features
- General
- Creep Speed
- Controlled Acceleration
- Current Limit
- Braking
- Regenerative Braking to Zero Speed
- Pedal Position Braking
- Auto Braking
- Conventional Plug Braking
- Auxiliary Speed Control
- Field Weakening
- Speed Limits
- Ramp Operation
- Ramp Start
- Antirollback
- Steer Pump Contactor Time Delay
- On-Board Coil Drivers and Internal Coil Suppression
- System Protective Override
- SRO (Static Return to Off)
- Accelerator Volts Hold Off
- Pulse Monitor Trip (PMT)
- Thermal Protector (TP)
- Low Voltage
SR Lift Pump Controllers
Sensor Interface/Contactor Driver Module
Diagnostic Status Codes and Troubleshooting18 topics
- General Maintenance Instructions
- Special Precautions
- Diagnostics
- Systems Diagnostics
- Status Codes
- Standard Status Codes
- Stored Status Codes
- Other Features
- Hourmeter Readings
- Maintenance Alert and Speed Limit
- Battery Discharge Indication (BDI)
- Internal Resistance Compensation
- Handset Programmable
- RS 232 Communication Ports
- Circuit Board Coil Driver Modules
- Maintenance Management Capability
- Interactive Instrument Panel Modes
- General Troubleshooting Instructions
Status Code Troubleshooting Tables
SX/SR Handset Instructions7 topics
- General Features
- Connecting the Handset
- Startup Sequence
- Setup Mode
- Stored Status Code Mode
- Clearing the Stored Status Codes
- Restarting Lift Truck
SX Traction Controller Function Descriptions1 topic
- Premium Instrument Panel Interactive Modes
SR Pump Controller Function Descriptions
Table 1. SX Traction Controller Connections/Descriptions
Table 2. SR Lift Pump Controller Connections/Descriptions/Status
Table 3. Instrument Panel Function Number Correlation
Table 4. Traction Function Settings Logic
Table 5. Lift Pump Function Settings Logic
Table 6. Speed/Torque Compensation
Table 7. Traction Controller Settings - Standard With Auto Regen
Table 8. Traction Controller Settings - Standard Without Auto Re
Table 9. Traction Controller Settings - High Performance With Au
Table 10. Lift Pump Controller Settings
Steering System
Steering Wheel and Column Assembly1 topic
- Description
Power Steering Pump and Motor
Steering Axle Components11 topics
- General
- Wheel and Tire Assembly
- Remove
- Install
- Wheel Hub Assembly
- Remove
- Install
- Steering Axle Assembly
- Remove
- Clean
- Install
Steering System Air Removal
Operation Check
Steering Pressure Check
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 Daily15 topics
- Before Operation Checks
- Hydraulic System
- Battery
- Battery Restraint System
- Tires and Wheels
- Safety Procedures When Working Near Mast
- Forks
- Mast and Lift Chains
- Lift Chain, Adjustment
- Operation Check
- Gauges and Horn
- Control Levers and Pedals
- Service Brakes
- Parking Brake
- Steering System
Maintenance Procedures Every 350 Hours or 3 Months16 topics
- Hydraulic Tank Breather
- Wheel Nut Torque
- Steering Actuator Mounting Bolts
- Transaxle
- Lift System Operation
- Mast
- Lift Chains
- Forks
- Safety Labels
- Brake Fluid
- Other Lubrication
- Electrical Inspection
- Special Precautions
- Contactors
- Motor Brushes
- Parking Brake
Maintenance Procedures Every 2000 Hours or Yearly6 topics
- Hydraulic System
- Hydraulic Oil Filter, Change
- Hydraulic Oil Strainer, Check
- Hydraulic Oil, Change
- Brakes
- Parking Brake, Adjust
Maintenance Procedures Every 4000 Hours5 topics
- Lift System
- Tilt System
- How to Charge Battery
- How to Change Battery
- Battery Size Specifications
Wheels and Tires Maintenance13 topics
- How to Change Tires
- Steer and Drive Wheels
- Pneumatic Tires
- Remove Wheel From Lift Truck
- Tire Sizes and Pressures
- Remove Tire From Wheel
- Install Tire on Wheel
- Add Air to Tires
- Pneumatic-Shaped Solid Tires
- Remove Wheel From Lift Truck
- Press Tire From Wheel
- Install Tire on Wheel
- Install Wheel and Tire
Table 1. Maintenance Schedule
Table 3. Battery Size Specifications - Type: Lead-Acid Battery
Diagrams
Capacities and Specifications
Wheels and Tires
Motors (Dual Voltage 36/48)
Mast Tilt Performance
Mast Speeds5 topics
- Contactor Controlled 19cc/rev Displacement Pump
- Transistor Controlled 19cc/rev Displacement Pump
- Contactor Controlled 12cc Displacement Pump
- Transistor Controlled 12cc/rev Displacement Pump
- Mast/Tilt Drift Speeds
Hydraulic System
Transaxle Specifications5 topics
- Frame
- Brake System
- Wheels
- Steering System
- Mast/Tilt/Attachment Systems
Accelerator Potentiometer Checks
Controller Settings5 topics
- SR/SP Traction Controller Settings - Standard
- SR/SP Traction Controller Settings - 36 V Energy Saver Option
- SR/SP Traction Controller Settings - With or Without Auto Decele
- SR/SP Traction Controller Settings - With or Without Lift Limit
- SR/SP Lift Pump Controller Settings
Battery Size Specifications1 topic
- Type: Lead Acid Battery
Frame
Overhead Guard Repair
Hood and Seat Assembly Repair
Counterweight Repair
Hydraulic Tank Repair5 topics
- Small Leaks, Repair
- Large Leaks, Repair
- Steam Method
- Chemical Solution Method
- Additional Preparations for Repair
Safety Labels
Battery Specifications
Table 1. Battery Platform Weights
Table 2. J30XMT2 Truck Capacity 1600 kg ( 3500 lb) - Wheel Base
Table 3. J35XMT2 Truck Capacity 1800 kg ( 4000 lb) - Wheel Base
Table 4. J40XMT2 Truck Capacity 2000 kg ( 4400 lb) - Wheel Base
SR/SP Transistor Motor Controller and Handset4 topics
- Solid-State Reversing
- Performance and Efficiency
- Field Weakening
- Regenerative Braking
SR Transistor Traction Motor Controllers19 topics
- General
- Operation
- General
- Creep Speed
- Controlled Acceleration
- Current Limit
- Regenerative Braking to Zero Speed
- Pedal Position Braking
- Auto Regenerative Braking
- Conventional Plug Braking
- Field Weakening
- Speed Limits
- Ramp Start
- Antirollback
- SRO (Static Return to Off)
- Accelerator Volts Hold Off
- Pulse Monitor Trip (PMT)
- Thermal Protector (TP)
- Low Voltage
SP Lift Pump Controllers13 topics
- Special Precautions
- Systems Diagnostics
- Standard Status Codes
- Stored Status Codes
- Hourmeter Readings
- Maintenance Alert and Speed Limit
- Battery Discharge Indication (BDI)
- Internal Resistance Compensation
- Handset Programmable
- RS 232 Communication Ports
- Circuit Board Coil Driver Modules
- Maintenance Management Capability
- Interactive Instrument Panel Modes (Premium Only)
SR/SP Handset Instructions2 topics
- Connecting Handset
- Clearing Stored Status Codes
SR Traction Controller Function Descriptions
SP Pump Controller Function Descriptions
Table 1. SR Traction Controller Connections/Descriptions
Table 2. SP Lift Pump Controller Connections/Descriptions/Status
Troubleshooting and Adjustments With a Computer
Computer System2 topics
- Connect a PC to a Control Card
- Installation
HYTECH™ Windows Software Program18 topics
- How to Start the Program
- DEMO Mode
- Selecting the Communications Port
- Verification of Controller and Lift Truck
- Select Lift Truck Series
- Controller Card Register Parameter List
- How to Change a Parameter
- How to Save a Changed Parameter File
- How to Load a Saved Parameter File
- How to Show and Remove Saved Parameter Files
- How to Return to Factory Default Settings
- How to Save Changes to Control Card
- How to View Status Codes
- Saving Status Codes
- How to Show and Remove Saved Status Code Files
- Closing and Clearing Status Code List
- How to View Saved Register Data and Saved Status Data
- How to Save Register Data and Status Code Data In and
GE Sentry™ Software Program4 topics
- How to Start GE SENTRY Program
- How to Reset MIN and MAX Display
- Graphing Mode
- How to Exit GE SENTRY Program
Table 1. Cable Connections - Computer to Control
Table 2. Adapter Pins (DB25F to DB9)
Table 3. Plug-Z Connection
HUSCO™ Main Control Valve2 topics
- Tilt Backward
- Tilt Forward
Pressure Relief Valve Check and Adjustment2 topics
- Primary Relief Valve
- Secondary Relief Valve
Inside this manual
Real pages from this service manual (726 pages). Open the sample pages (PDF, 277 KB)
- Diagram, page 527: J30-40XMT2 (After 8/01)
- Specifications, page 560: Battery Size Specifications
- Troubleshooting, page 604: Status Code Troubleshooting Tables
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, 726 pages
Quantity one is the manual described above.
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