Hyster J30UTT, J35UTT, J40UTT (A3C5) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 1060

File Size: 115.56 MB (Speed Download Link)

Brand: Hyster

Model: J30UTT, J35UTT, J40UTT (A3C5) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster J30UTT, J35UTT, J40UTT (A3C5) Forklift Service Manual

📘 Show Index

Hyster J30UTT, J35UTT, J40UTT (A3C5) Forklift Index:

Forklift Truck Main Parts
- Description of Forklift Truck Main Parts
- Service Menu
  - Service Menu
  - Internal Password Screen
  - Using Dashboard Like a Console
  - Smart Display Alarms
Main Technical Specification of Forklift Truck
Driving Motor and Driving System
- Overview
- Transmission
- Driving Motor
  - Specification of Driving Motor
  - Conditions of Operating Environment
Pump Motor and Installation
- Pump Motor Specification
- Operating Environment Conditions
- Pump Motor Components
Electrical System
- Overview
- AC Motor Controller
  - Remove and Install
- Instruments
  - Display
  - USB
  - Telemetry Wireless Asset Management System
- Electrical Schematic Diagram
- Trouble Shooting
  - Trouble Shooting
  - Fault Codes
Steering Device and Installation
- Overview
  - Examination of Steering System After Reassembly
  - Steering System Fault Diagnosis
Steering Axle and Installation
Hand Brake Operation
- Overview
- Parking Brake Operation Device
  - Adjustment of Braking Force
  - Fault Diagnosis
Electromagnetic Brake Operation
- Overview
- Maintenance
Foot Brake Operation
- Overview
- Foot Brake Pedal
  - Adjustment of Foot Pedal Brake
- Brake Master Cylinder
  - Brake Mast Cylinder Replacement
- Fault Diagnosis
Working Oil Tank and Installation
- Overview
- Hydraulic Oil Tank
Hydraulic System
- Overview
- Gear Pump
  - Maintenance of Gear Pump
  - Fault Diagnosis
- Multi-Way Valve
  - Fault Diagnosis
- Full Hydraulic Orbitrol
- Speed Limit Valve
- Hydraulic Lines
Lifting System
- Safety Procedures when Working Near Mast
- Overview
- Inner and Outer Mast
- Fork Carriage Assembly
  - Adjustment for Height of Fork Carriage
- Roller Positions
  - Replacement of Fork Backrest
- Lifting Cylinder
  - Working Status of Explosion Relieve Valve
  - Adjustment of Lifting Cylinder
- Tilting Cylinder
- Installation of Mast
- Disassembly of Mast
Daily Checks and Maintenance
- Periodic Maintenance Requirements
- Periodic Maintenance Items
- Periodic Maintenance
  - Tire
  - Forks
  - Replace the oil
- Periodic Maintenance Tables
Functional Testing
- Functional Testing
List of Wear Parts
Lead-acid Battery Service
- Overview
- Battery Specification
- Safety Instructions and Precautions
- Routine Lead-acid Battery Charging Steps
- Service of Lead-Acid Battery
- Common Failures and Disposal Methods of Battery
EIKTO Lithium-ion Battery Service
- Battery Specification
- Safety Instructions and Precautions
- Notes When Lithim Battery Charging
- Service of Battery
  - Normal Charging
  - Weekly Service
  - Quarterly Service
Lithium-ion Battery Repair (250Ah/375Ah/500Ah)
- Battery Description
  - Battery Types and Options
  - Battery Working Environment Temperature
  - Battery Storage Environment Temperature
  - Glossary and Abbreviations
- Warnings and Cautions
  - Safety
  - Hazardous Overview
  - Composition and Ingredient Information
  - Hazard Identification
  - Fire Fighting Measures
  - Accidental Release Measures
  - Leak Emergency Measures
  - Handling and Storage
  - First Aid Measures
  - Handling and Storage
  - Exposure Controls and Personal Protection
  - Physical and Chemical Properties
  - Stability and Reactivity
  - Toxicological Information
  - Ecological information
  - Toxicological Information
  - Regulatory Information
  - Disposal Considerations
  - Transport Information
  - Charging and Labeling
- Component Description
  - Key Components
  - Top Cover Components
  - Connection Points
  - Module Connection
  - Module and BMS Connection
  - Module Structure
  - Connection Ports
  - Charger Specification
  - Charger Selection
- Software and User Interface
  - Description of Software Tools for Technicians
  - Truck Instrument
  - Battery Displayer
  - Charger Displayer
  - BMS Interface
- Maintenance
  - Battery Maintenance
- Battery Repair
  - Battery Removal
  - Battery Disassembly and Assembly
  - Module Maintenance
  - Module Replacement
- Battery Principles of Operation
  - Functional Descriptions
  - Schematics and Diagrams
- Troubleshooting
  - Charging Alarm Codes and Solutions
  - Charger Faults and Solutions
  - Discharge Alarm Codes and Solutions
  - Battery System Alarm Codes and Solutions
  - Other Battery Faults and Solutions
  - Discharge Fault Threshold
  - Charging Fault Threshold
  - Other Fault Threshold
Fault Codes and Troubleshooting
- Z86 Program Update with ZpCanConsole
- Parameter Import with ZAPI PC Can Console
- Fault Codes and Descriptions
- Troubleshooting

Forklift Truck Main Parts
- Description of Forklift Truck Main Parts
- Service Menu
  - Service Menu
  - Internal Password Screen
  - Using Dashboard Like a Console
  - Smart Display Alarms
Main Technical Specification of Forklift Truck
Driving Motor and Driving System
- Overview
- Transmission
- Driving Motor
  - Specification of Driving Motor
  - Conditions of Operating Environment
Pump Motor and Installation
- Pump Motor Specification
- Operating Environment Conditions
- Pump Motor Components
Electrical System
- Overview
- AC Motor Controller
  - Remove and Install
- Instruments
  - Display
  - USB
  - Telemetry Wireless Asset Management System
- Electrical Schematic Diagram
- Trouble Shooting
  - Trouble Shooting
  - Fault Codes
Steering Device and Installation
- Overview
  - Examination of Steering System After Reassembly
  - Steering System Fault Diagnosis
Steering Axle and Installation
Hand Brake Operation
- Overview
- Parking Brake Operation Device
  - Adjustment of Braking Force
  - Fault Diagnosis
Electromagnetic Brake Operation
- Overview
- Maintenance
Foot Brake Operation
- Overview
- Foot Brake Pedal
  - Adjustment of Foot Pedal Brake
- Brake Master Cylinder
  - Brake Mast Cylinder Replacement
- Fault Diagnosis
Working Oil Tank and Installation
- Overview
- Hydraulic Oil Tank
Hydraulic System
- Overview
- Gear Pump
  - Maintenance of Gear Pump
  - Fault Diagnosis
- Multi-Way Valve
  - Fault Diagnosis
- Full Hydraulic Orbitrol
- Speed Limit Valve
- Hydraulic Lines
Lifting System
- Safety Procedures when Working Near Mast
- Overview
- Inner and Outer Mast
- Fork Carriage Assembly
  - Adjustment for Height of Fork Carriage
- Roller Positions
  - Replacement of Fork Backrest
- Lifting Cylinder
  - Working Status of Explosion Relieve Valve
  - Adjustment of Lifting Cylinder
- Tilting Cylinder
- Installation of Mast
- Disassembly of Mast
Daily Checks and Maintenance
- Periodic Maintenance Requirements
- Periodic Maintenance Items
- Periodic Maintenance
  - Tire
  - Forks
  - Replace the oil
- Periodic Maintenance Tables
Functional Testing
- Functional Testing
List of Wear Parts
Lead-acid Battery Service
- Overview
- Battery Specification
- Safety Instructions and Precautions
- Routine Lead-acid Battery Charging Steps
- Service of Lead-Acid Battery
- Common Failures and Disposal Methods of Battery
EIKTO Lithium-ion Battery Service
- Battery Specification
- Safety Instructions and Precautions
- Notes When Lithim Battery Charging
- Service of Battery
  - Normal Charging
  - Weekly Service
  - Quarterly Service
Lithium-ion Battery Repair (250Ah/375Ah/500Ah)
- Battery Description
  - Battery Types and Options
  - Battery Working Environment Temperature
  - Battery Storage Environment Temperature
  - Glossary and Abbreviations
- Warnings and Cautions
  - Safety
  - Hazardous Overview
  - Composition and Ingredient Information
  - Hazard Identification
  - Fire Fighting Measures
  - Accidental Release Measures
  - Leak Emergency Measures
  - Handling and Storage
  - First Aid Measures
  - Handling and Storage
  - Exposure Controls and Personal Protection
  - Physical and Chemical Properties
  - Stability and Reactivity
  - Toxicological Information
  - Ecological information
  - Toxicological Information
  - Regulatory Information
  - Disposal Considerations
  - Transport Information
  - Charging and Labeling
- Component Description
  - Key Components
  - Top Cover Components
  - Connection Points
  - Module Connection
  - Module and BMS Connection
  - Module Structure
  - Connection Ports
  - Charger Specification
  - Charger Selection
- Software and User Interface
  - Description of Software Tools for Technicians
  - Truck Instrument
  - Battery Displayer
  - Charger Displayer
  - BMS Interface
- Maintenance
  - Battery Maintenance
- Battery Repair
  - Battery Removal
  - Battery Disassembly and Assembly
  - Module Maintenance
  - Module Replacement
- Battery Principles of Operation
  - Functional Descriptions
  - Schematics and Diagrams
- Troubleshooting
  - Charging Alarm Codes and Solutions
  - Charger Faults and Solutions
  - Discharge Alarm Codes and Solutions
  - Battery System Alarm Codes and Solutions
  - Other Battery Faults and Solutions
  - Discharge Fault Threshold
  - Charging Fault Threshold
  - Other Fault Threshold
Fault Codes and Troubleshooting
- Z86 Program Update with ZpCanConsole
- Parameter Import with ZAPI PC Can Console
- Fault Codes and Descriptions
- Troubleshooting

Forklift Truck Main Parts
- Battery
  - Battery and Installation
Main Technical Specification of Forklift Truck
Driving Motor and Driving System
- Overview
- Transmission
- Driving Motor
  - Specification of Driving Motor
  - Conditions of Operating Environment
Pump Motor and Installation
Electrical System
- Overview
- AC Motor Controller
- Instruments
- Fault Codes
Steering Device and Installation
- Overview
  - Examination of Steering System After Reassembly
  - Steering System Fault Diagnosis
Steering Axle and Installation
Hand Brake Operation
- Overview
- Parking Brake Operation Device
  - Adjustment of Braking Force
  - Fault Diagnosis
Foot Brake Operation
- Overview
- Foot Brake Pedal
  - Adjustment of Foot Pedal Brake
- Brake Master Cylinder
- Fault Diagnosis
Working Oil Tank and Installation
- Overview
- Hydraulic Oil Tank
Hydraulic System
- Overview
- Gear Pump
  - Maintenance of Gear Pump
  - Fault Diagnosis
- Multi-Way Valve
  - Fault Diagnosis
- Full Hydraulic Orbitrol
- Speed Limit Valve
- Hydraulic Lines
Lifting System
- Safety Procedures when Working Near Mast
- Overview
- Inner and Outer Mast
- Fork Carriage Assembly
  - Adjustment for Height of Fork Carriage
- Roller Positions
  - Replacement of Fork Backrest
- Lifting Cylinder
  - Working Status of Explosion Relieve Valve
  - Adjustment of Lifting Cylinder
- Tilting Cylinder
- Installation of Mast
- Disassembly of Mast
General (CATL-based Lithium-ion Battery)
- Description of Batteries
- Battery Types and Options
- Battery Working Environment Temperature
- Glossary and Abbreviations
Warnings and Cautions (CATL-based Lithium-ion Battery)
- Safety
- Hazardous Overview
  - Hazard Pictograms
  - Signal Word
  - Hazard Statements
  - Precautionary Statements
  - Other Hazards
- Composition and Ingredient Information
- Hazard Identification
- Fire Fighting Measures
  - Hazard Analysis (electrical shock, fire, explode, population)
  - Material Preparation and Personnel Trainings
  - Fire Extinguisher Instruction
  - Unusual Fire and Explosion Hazards
- Accidental Release Measures
- Leak Emergency Measures
- Handling and Storage
  - Handling
  - Storage
- First Aid Measures
- Handling and Storage
- Exposure Controls and Personal Protection
- Physical and Chemical Properties
- Stability and Reactivity
- Toxicological Information
- Ecological information
- Toxicological Information
- Regulatory Information
  - USA
  - International
  - Air Transportation
  - Ocean Shipping
  - Land Transportation
  - Avoid Electrical Shock
- Disposal Considerations
- Transport Information
  - Transport Information
- Charging and Labling
  - Charging
  - Charging Voltages and Currents:
  - Labling
  - Disposal
Component Description (CATL-based Lithium-ion Battery)
- Key Components
- Top Cover Components
- Connection Points
- Module Connection
- Module Structure
- Connection Ports
- Charger Specification
- Charger Selection
Software and User Interface (CATL-based Lithium-ion Battery)
- Description of Software Tools for Technicians
- Truck Instrument
- Battery Displayer
- Charger Displayer
- BMS Interface
  - System Overview
  - Real-time Information
  - Parameter Calibration
  - Force Control
  - Fireware Upgrading
  - History Data
  - Real-time Information
Maintenance (CATL-based Lithium-ion Battery)
- Battery Maintenance
Battery Repair (CATL-based Lithium-ion Battery)
- Battery Disassembly
- Module Replacement
  - Module Failure
  - Module Aging
Principles of Operation (CATL-based Lithium-ion Battery)
- Functional Descriptions
  - Discharge Power-on Process
  - Discharge Power-off Process
  - Charging Power-on Proecss
  - Charging Power-off Proecss
  - Module Heating Process
  - Signal Detection Process
  - CAN Communication
  - Other Functions
- Schematics and Diagrams
  - System Electrical Schematic
  - Discharge Schematic Part (I)
  - Discharge Schematic Part (II)
  - Charging Schematic
  - Module Heating Schematic
  - Single Detection Schematic
  - CAN Communication Schematic
  - Other Functions Schemetic
  - Main Wire Harness Connection
  - Link Wire and H Port Wire Connection
  - CAN Wire Connection
  - Power Cable Connection
  - Heating Cable Connection
  - CSC Wire Connection
  - Wire Sequence Detector
Troubleshooting (CATL-based Lithium-ion Battery)
- Troubleshooting
  - Charging Alarm Codes and Solutions
  - Charger Faults and Solutions
  - Discharge Alarm Codes and Solutions
  - Battery System Alarm Codes and Solutions
  - Other Battery Faults and Solutions
  - Discharge Fault Threshold
  - Charging Fault Threshold
  - Other Fault Threshold
List of Wear Parts

Forklift Truck Main Parts
- Battery
  - Battery and Installation
Main Technical Specification of Forklift Truck
Driving Motor and Driving System
- Overview
- Transmission
- Driving Motor
  - Specification of Driving Motor
  - Conditions of Operating Environment
Pump Motor and Installation
Electrical System
- Overview
- AC Motor Controller
- Instruments
- Fault Codes
Steering Device and Installation
- Overview
  - Examination of Steering System After Reassembly
  - Steering System Fault Diagnosis
Steering Axle and Installation
Hand Brake Operation
- Overview
- Parking Brake Operation Device
  - Adjustment of Braking Force
  - Fault Diagnosis
Foot Brake Operation
- Overview
- Foot Brake Pedal
  - Adjustment of Foot Pedal Brake
- Brake Master Cylinder
- Fault Diagnosis
Working Oil Tank and Installation
- Overview
- Hydraulic Oil Tank
Hydraulic System
- Overview
- Gear Pump
  - Maintenance of Gear Pump
  - Fault Diagnosis
- Multi-Way Valve
  - Fault Diagnosis
- Full Hydraulic Orbitrol
- Speed Limit Valve
- Hydraulic Lines
Lifting System
- Safety Procedures when Working Near Mast
- Overview
- Inner and Outer Mast
- Fork Carriage Assembly
  - Adjustment for Height of Fork Carriage
- Roller Positions
  - Replacement of Fork Backrest
- Lifting Cylinder
  - Working Status of Explosion Relieve Valve
  - Adjustment of Lifting Cylinder
- Tilting Cylinder
- Installation of Mast
- Disassembly of Mast
General (CATL-based Lithium-ion Battery)
- Description of Batteries
- Battery Types and Options
- Battery Working Environment Temperature
- Glossary and Abbreviations
Warnings and Cautions (CATL-based Lithium-ion Battery)
- Safety
- Hazardous Overview
  - Hazard Pictograms
  - Signal Word
  - Hazard Statements
  - Precautionary Statements
  - Other Hazards
- Composition and Ingredient Information
- Hazard Identification
- Fire Fighting Measures
  - Hazard Analysis (electrical shock, fire, explode, population)
  - Material Preparation and Personnel Trainings
  - Fire Extinguisher Instruction
  - Unusual Fire and Explosion Hazards
- Accidental Release Measures
- Leak Emergency Measures
- Handling and Storage
  - Handling
  - Storage
- First Aid Measures
- Handling and Storage
- Exposure Controls and Personal Protection
- Physical and Chemical Properties
- Stability and Reactivity
- Toxicological Information
- Ecological information
- Toxicological Information
- Regulatory Information
  - USA
  - International
  - Air Transportation
  - Ocean Shipping
  - Land Transportation
  - Avoid Electrical Shock
- Disposal Considerations
- Transport Information
  - Transport Information
- Charging and Labling
  - Charging
  - Charging Voltages and Currents:
  - Labling
  - Disposal
Component Description (CATL-based Lithium-ion Battery)
- Key Components
- Top Cover Components
- Connection Points
- Module Connection
- Module Structure
- Connection Ports
- Charger Specification
- Charger Selection
Software and User Interface (CATL-based Lithium-ion Battery)
- Description of Software Tools for Technicians
- Truck Instrument
- Battery Displayer
- Charger Displayer
- BMS Interface
  - System Overview
  - Real-time Information
  - Parameter Calibration
  - Force Control
  - Fireware Upgrading
  - History Data
  - Real-time Information
Maintenance (CATL-based Lithium-ion Battery)
- Battery Maintenance
Battery Repair (CATL-based Lithium-ion Battery)
- Battery Disassembly
- Module Replacement
  - Module Failure
  - Module Aging
Principles of Operation (CATL-based Lithium-ion Battery)
- Functional Descriptions
  - Discharge Power-on Process
  - Discharge Power-off Process
  - Charging Power-on Proecss
  - Charging Power-off Proecss
  - Module Heating Process
  - Signal Detection Process
  - CAN Communication
  - Other Functions
- Schematics and Diagrams
  - System Electrical Schematic
  - Discharge Schematic Part (I)
  - Discharge Schematic Part (II)
  - Charging Schematic
  - Module Heating Schematic
  - Single Detection Schematic
  - CAN Communication Schematic
  - Other Functions Schemetic
  - Main Wire Harness Connection
  - Link Wire and H Port Wire Connection
  - CAN Wire Connection
  - Power Cable Connection
  - Heating Cable Connection
  - CSC Wire Connection
  - Wire Sequence Detector
Troubleshooting (CATL-based Lithium-ion Battery)
- Troubleshooting
  - Charging Alarm Codes and Solutions
  - Charger Faults and Solutions
  - Discharge Alarm Codes and Solutions
  - Battery System Alarm Codes and Solutions
  - Other Battery Faults and Solutions
  - Discharge Fault Threshold
  - Charging Fault Threshold
  - Other Fault Threshold
List of Wear Parts