Hyster J160 Manual
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Hyster J160 Manual

Hyster J160 Manual

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Hyster J160 (J30ZT J35ZT J40ZT) Forklift

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Summary of Contents for Hyster J160

  • Page 1 Hyster J160 (J30ZT J35ZT J40ZT) Forklift...
  • Page 2 2-, 3-, AND 4-STAGE MASTS S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; J1.60-2.00XMT (J30-40ZT) [J160]; J2.0-3.20XM (J40-65Z) [B416]; E2.00-3.20XM (E45-65Z) [G108] PART NO. 1580524 4000 SRM 1148...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 4: Table Of Contents

    Clean and Inspect ............................48 Two-Stage LFL and Two-Stage FFL Mast ...................... 50 Assemble ............................... 50 Three-Stage FFL Mast ............................51 Assemble ............................... 51 Four-Stage FFL Mast - Manufactured Before July, 2009 ................53 Disassemble ..............................53 Clean and Inspect ............................58 ©2015 HYSTER COMPANY...
  • Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 6 Mast Side Kicking Adjustment ........................139 This section is for the following models: (S30FT, S35FT, S40FTS) [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS) [F187]; H2.0-3.5FT (H40-70FT) [L177]; E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114]; J1.60-2.00XMT (J30-40ZT) [J160]; J2.0-3.20XM (J40-65Z) [B416]; E2.00-3.20XM (E45-65Z) [G108]...

  • Page 7: General

    General General NOTE: For models J1.60-2.00XMT (J30-40ZT) WARNING [J160], this section applies to only to Four-Stage masts. Refer to Mast Repairs 4000SRM0522 for Before working on or near the mast, see Safety Two-Stage and Three-Stage masts for these Procedures When Working Near Mast in this particular models.

  • Page 8: Safety Procedures When Working Near Mast

    Safety Procedures When Working Near Mast 4000 SRM 1148 Safety Procedures When Working Near Mast The following procedures MUST be used when in- • If parts of the mast must be in a raised posi- specting or working near the mast. Additional pre- tion, install a safety chain to restrain the cautions and procedures can be required when re- moving parts of the mast.
  • Page 9 4000 SRM 1148 Safety Procedures When Working Near Mast A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST 1. OUTER MAST 5. FREE-LIFT CYLINDER 2. INNER MAST 6. CARRIAGE BAR 3. INTERMEDIATE MAST 7.

  • Page 10: Fork Replacement

    Safety Procedures When Working Near Mast 4000 SRM 1148 Fork Replacement Forks are held on the carriage by hooks and kept in position by pins inserted through top fork hooks into slots in top carriage bar. If pin does not remain engaged in carriage slot, replace with new pin.
  • Page 11 4000 SRM 1148 Fork Replacement NOTE: If lift truck is equipped with a fork posi- tioner, see the section Carriages Repair for proce- dures to remove the forks. 1. Slide fork to fork removal notch in bottom bar of carriage. See Figure 3 and Figure 4Figure 5. 2.

  • Page 12: Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner

    Fork Replacement 4000 SRM 1148 A. EARLIER MODELS B. LATER MODELS 1. FORKS 6. LEVER 2. CARRIAGE 7. WASHER 3. LOAD BACKREST EXTENSION 8. SPRING 4. FORK REMOVAL NOTCH 9. PIN 5. LATCH PIN ASSEMBLY 10. KNOB Figure 5. Carriage and Forks NOTE: Forks are to be replaced in sets, not indi- REMOVE, LIFT TRUCKS vidually, by trained personnel only.

  • Page 13: Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012

    4000 SRM 1148 Fork Replacement 1. RETAINER CAPSCREWS 3. FORKS 2. FORK CARRIER BLOCKS 4. FORK CARRIER Figure 6. Forks Removal, Lift Trucks Equipped with Fork Positioner Manufactured After August, 2012 3. Slide fork on carriage so both upper and lower INSTALL, LIFT TRUCKS NOT EQUIPPED hooks engage carriage bars.

  • Page 14: Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012

    Fork Replacement 4000 SRM 1148 NOTE: Install fork carrier blocks and retainer cap- CAUTION screws in hole positions on fork carriers as noted during removal. Remove fork latch pins if adding a fork positioner attachment. Damage to forks and other carriage 3.

  • Page 15: Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner

    4000 SRM 1148 Fork Replacement 3. Check that the bottom of each fork is not exces- Table 1. Fork Tip Alignment sively worn. Fork Tip Alignment Specifications 4. Check for smooth and proper operation of the Standard Fork Maximum Fork Tip fork lock pins.

  • Page 16: Carriages Repair

    Fork Replacement 4000 SRM 1148 A. HEEL OF FORK (MUST BE 90% OF DIMEN- B. ORIGINAL FORK THICKNESS (DIMENSION B) SION B) 1. TIP ALIGNMENT (MUST BE WITHIN 3% OF 5. WASHER FORK LENGTH) 6. CAPSCREW 2. CRACKS 7. PIN 3.

  • Page 17: Repair

    5. CHAIN ANCHOR 6. CHAIN PIN structure of the mast or cause incorrect function 7. COTTER PIN ® of the mast. Consult your Hyster lift truck dealer 8. ANCHOR PIN for more information before welding on the mast. 9. SPACER 2.

  • Page 18: Standard Carriage, Remove

    Carriages Repair 4000 SRM 1148 2. Move the lift truck toward the carriage until the ends of the lift chains to a part of the mast. the inner mast is aligned with the carriage roll- Make sure the chains can move freely when the ers.

  • Page 19: Hang-On Sideshift Carriage, Remove

    4000 SRM 1148 Carriages Repair 6. Move the lift truck away from the carriage. HANG-ON SIDESHIFT CARRIAGE, Completely lower the inner mast so it cannot REMOVE move. 1. Lower the carriage completely. Remove the 7. Connect a lifting device to the carriage. Remove forks and the load backrest extension.

  • Page 20: Standard Carriage And Hang-On Sideshift Carriage, Repair

    Carriages Repair 4000 SRM 1148 2. Connect a crane [the capacity of the crane must 1. If any of the load rollers must be replaced, be at least 681 kg (1501 lb)] to the lifting eye on make a note of the location and number of the the sideshift carriage.

  • Page 21: Standard Carriage, Install

    4000 SRM 1148 Carriages Repair 4. Replace the cylinder rod seals as follows: 2. Move the lift truck toward the carriage until the inner mast is aligned with the carriage roll- a. Clamp the cylinder in a soft-jawed vise. DO ers.

  • Page 22: Remove

    S30FT, S35FT, S40FTS (E010) E1.50-2.00XM (E25-35Z, E40ZS) [E114], • E1.50-2.00XM (E25-35Z, E40ZS) (E114/ H/S2.00-2.75XM (H/S40-55XM), S/E/ F114) J2.00-2.50XL (S/E/J40-50XL), J1.60-2.00XMT (J30-40XMT), • J1.60-2.00XMT (J30-40ZT) (J160) J2.00-2.50XM (J40-50XM) [A216], and • H1.6FT, H1.8FT, H2.0FTS (H30FT, J2.00-2.50XM (J40-50Z) [A416] units, H35FT, H40FTS) (F001) tighten capscrews 435 N•m (321 lbf ft).
  • Page 23 4000 SRM 1148 Carriages Repair NOTE: TWO- AND THREE-STAGE FFL IS SHOWN. 1. INNER CARRIAGE 13. PIN 2. OUTER FRAME 14. CHAIN ANCHOR 3. SIDESHIFT CYLINDER 15. SNAP RING 4. UPPER BEARING 16. PIN 5. LOWER BEARING 17. COTTER PIN 6.
  • Page 24 10. HAIRPIN 22. SPACER 11. PIN 23. FORK REMOVAL NOTCH 12. LUBE FITTING Figure 15. Integral Sideshift Carriage for Lift Truck Models S30FT, S35FT, S40FTS (E010); E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114); J1.60-2.00XMT (J30-40ZT) (J160); and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
  • Page 25 S30FT, S35FT, S40FTS (E010) • E1.50-2.00XM (E25-35Z, E40ZS) (E114/ 3. Clean the bearing areas. Inspect the sideshift F114) bearings for wear as follows: • J1.60-2.00XMT (J30-40ZT) (J160) a. Remove the upper bearings from the upper • H1.6FT, H1.8FT, H2.0FTS (H30FT, apron.

This manual is also suitable for:

J30ztJ35ztJ40zt

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