Hyster J40-60Z (A416) Forklift Service Manual

Name: Hyster J40-60Z (A416) Forklift Service Manual
Brand: MidWestTech
SKU: 1534731
Price: 79.83 USD
Availability: InStock

708 pages · Publication 1534731

$79.83

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Models: J40-60Z (A416)
Manual type: Service Manual
Pages: 708
Publication: 1534731
Condition: Brand new

Hyster J40-60Z (A416) Forklift Service Manual, publication 1534731

What's inside

From the manual's own table of contents: 163 sections, 478 entries. See sample pages (PDF, 246 KB)

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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 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 163 sections

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

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 Replacement

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 Repair

Main Control Valve Check and Adjust

Steering Relief Valve Check and Adjust

Specifications5 topics

Relief Valve Pressures*
Hydraulic Tank Capacity (dipstick full mark)
Hydraulic Pump Capacities
Steering
Steering Housing and Steering Control Unit

Main Control Valve5 topics

Lift Section
Tilt Section
- Tilt Backward
- Tilt Forward
Relief Valve

Control Lever Linkage Repair

Control Valve Linkage Repair

Pressure Relief Valve Check and Adjustment2 topics

Primary Relief Valve
Secondary Relief Valve

Brake System3 topics

Service Brakes
Master Cylinder
Parking Brake

Service Brake Repairs1 topic

Adjust

Parking Brake Repair

Master Cylinder Repair1 topic

Repair

Service Brakes Adjustment

Brake Pedal Adjustment

Master Cylinder Adjustment

Brake System Air Removal

Parking Brake Not Applied Switch Test

Drive Axle, Speed Reducer, and Differential

Drive Axle, Speed Reducer, and Differential Repair

Frame4 topics

Main Frame
Other Frame Weldments
Overhead Guard
Battery Restraint, Hood, and Seat Assembly

Replacement - General

Overhead Guard Repair

Hood and Seat Assembly Repair

Counterweight Repair

Traction Motor Repair3 topics

Steam Method
- Chemical Solution Method
Additional Preparations for Tank Repair

Painting Instructions

Safety Label Replacement

Battery Specifications

Table 1. Counterweights

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 Repair4 topics

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 Adjustment2 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

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

Motor Controller Replacement

Control Components Replacement21 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
Brake Fluid Switch, Replace
Brush Wear and Overtemperature Sensors (Optional DC Pump Motor O
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
- Front, Rear Driving Light, or Spot Light Assemblies, Replace
- Converter, Replace
- Relay, Replace
- Backup Alarm, Replace
Horn and Horn Button, Replace
- Horn Switch and Cover, Replace
Hydraulic Pump Switches

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

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 Parameters1 topic

Function Numbers

Function Parameter 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)
- AC Master Controller
- AC Motor Controllers
Status Codes

AC Motor Controllers Status Code Charts

AC Transistor Motor Controller Repair8 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 Indication (BDI)
Hourmeter

Dash Display Service Menu Navigation2 topics

Moving Through Menu Selections
Editing and Adding Information

Table 4. List of Status Codes

Table 5. 42-Pin Connections/Descriptions for Master Controller

Table 6. Pin Connections/Descriptions for 72/80 Volt Motor Contr

Table 7. Pin Connections/Descriptions for 36/48 Volt Motor Contr

Troubleshooting and Adjustments Using The AC Controls Program6 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 Display4 topics

Custom Display Languages
Download Display Language
Clear Operator Log
Clear Status 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 Menu4 topics

Passwords
Operators
Current Settings
Diagnostics

Help Menu2 topics

Technical Support
About Electric Truck AC Controls Program

Electrical Diagrams

Periodic Maintenance6 topics

Serial Number Data
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 Steering Tires

Maintenance Schedule

Maintenance Procedures Every 8 Hours or Daily18 topics

How to Make Checks With Key OFF
- Tires and Wheels
- Forks
- Forks, Mast, and Lift Chains, Inspect
- Safety Labels
- Steering Column Latch
- Operator Restraint System
- Battery Restraint System J2.00-3.20XM (J40-60Z) (A416) Lift Truc
- Battery
- Hydraulic System
How to Make Checks With Key ON
- Gauges, Horn, and Fuses
- Steering System
- Service Brakes
- Parking Brake
- Control Levers and Pedals
- Direction and Speed Control Pedals
- Lift System Operation

Maintenance Procedures Every 250 Hours or 6 Weeks2 topics

Steering Tie Rods
Steering King Pins, E1.50-2.00XM (E114) Trucks Only

Maintenance Procedures Every 500 Hours or 3 Months5 topics

Differential and Speed Reducer, V30ZD (D210), E2.00-3.20XM (E45
Wheel Nut Torques
Mast
Forks
Parking Brake Adjustment

Maintenance Procedures Every 1000 Hours or 6 Months12 topics

Lift Chains
- Wear Check
Check Upper and Lower Bearings, Integral Sideshift Carriage
Steering Tie Rods, All Models Except E1.50-2.00XM (E114)
Steering Axle Spindles
- King Pins, All Models Except E1.50-2.00XM (E114)
Hydraulic Tank Breather
Differential and Speed Reducer J2.00-3.20XM (J40-60Z) (A416) Lif
Electrical Inspection
- Contactors
- Motor Brushes (Optional DC Pump)
Other Lubrication

Maintenance Procedures Every 2000 Hours or Yearly9 topics

Change Filter for Hydraulic Oil
- Change Hydraulic Oil
Differential and Speed Reducer
Wheel Bearings
- Steer Wheels, Lubrication
- Drive Wheels, Lubrication
Replace Upper and Lower Bearings, Integral Sideshift Carriage
How to Charge Battery
- General

Lift Chain Adjustments

Welding Repairs

Overhead Guard Changes

Wheels and Tire Maintenance20 topics

Remove Wheels From Lift Truck
- Remove and Install Tire on Wheel
- Remove Wheels From Lift Truck
- Remove Wheel From Pneumatic Tire
- Install Wheel in 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
Solid Rubber Tire, Change
- Remove and Install Tire on Wheel
- Remove Wheel From Tire
- Install Wheel in Tire
SIT Tire, Change
- Remove SIT Solid Tire From Wheel
- Install SIT Solid Tire on Wheel

Adhesives and Sealants

Table 1. Maintenance Schedule

Capacities and Specifications

Counterweights

Wheels and Tires

Capacities

Movement Rates (Maximum) for Tilt Cylinders

Mast Speeds4 topics

Mast Speeds - J40-60Z (72 or 80 Volt) Americas
Frame
Drive Axle, Speed Reducer, and Differential
Masts

Inside this manual

Real pages from this service manual (708 pages). Open the sample pages (PDF, 246 KB)

Sample pages from the Hyster J40-60Z (A416) Forklift Service Manual: Specifications, Troubleshooting, Diagram

Specifications, page 111: Header Hose Arrangements
Troubleshooting, page 491: AC Motor Controllers Status Code Charts
Diagram, page 581: Diagrams, Schematics, or Arrangements

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, 708 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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