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Hyster A935 (J1.5-2.0XNT J30-40XNT) Service Manual – PDF DOWNLOAD
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Hyster A935 (J1.5-2.0XNT J30-40XNT) Service Manual – PDF DOWNLOAD
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Hyster A935 (J1.5-2.0XNT J30-40XNT) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A935 (J1.5-2.0XNT J30-40XNT) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit fromrolling or falling. See HOWTO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed 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.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster A935 (J1.5-2.0XNT J30-40XNT) Service Manual – PDF DOWNLOAD
Hyster-J40xnt-Parts-and-Service-Cylinder-Repair-1688877-2100SRM1382-(05-2010)-US-EN......... 1 toc..................................................................................... 1 Cylinder Repair..................................................................... 1 Safety Precautions Maintenance and Repair........................................... 2 Safety Procedures When Working Near Mast............................................ 7 General............................................................................. 9 Description......................................................................... 10 Tilt Cylinder Repair for Lift Trucks E2.2-3.5XN (E45-70XN) (A268.................... 10 Remove.......................................................................... 10 Disassemble..................................................................... 10 Inspect......................................................................... 12 Clean........................................................................... 12 Assemble........................................................................ 12 Install......................................................................... 13 Tilt Cylinders, Adjust.......................................................... 13 Tilt Cylinder Leak Check........................................................ 14 Tilt Cylinder Repair for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K1.................... 15 Remove.......................................................................... 15 Disassemble..................................................................... 16 Inspect......................................................................... 17 Clean........................................................................... 18 Assemble........................................................................ 18 Install......................................................................... 18 Tilt Cylinders, Adjust.......................................................... 19 Tilt Cylinders Leak Check....................................................... 19 Lift Cylinder Repair for Lift Trucks E2.2-3.5XN (E45-70XN) (A268.................... 20 Main Lift Cylinders............................................................. 20 Remove...................................................................... 20 Two-Stage FFL........................................................... 20 Three-Stage FFL......................................................... 20 Four-Stage FFL.......................................................... 22 Two-Stage LFL........................................................... 22 Disassemble................................................................. 22 Two-Stage FFL........................................................... 22 Three-Stage FFL......................................................... 24 Four-Stage FFL.......................................................... 24 Two-Stage LFL........................................................... 26 Clean....................................................................... 27 Inspect..................................................................... 27 Assemble.................................................................... 27 Two-Stage FFL........................................................... 27 Three-Stage FFL......................................................... 28 Four-Stage FFL.......................................................... 28 Two-Stage LFL........................................................... 29 Install..................................................................... 29 Two-Stage FFL........................................................... 29 System Air Bleed Procedures............................................. 29 Three-Stage FFL......................................................... 30 Four-Stage FFL.......................................................... 30 Two-Stage LFL........................................................... 30 Lift Cylinder Repair for Lift Truck J1.5XNT (K160).................................. 31 Main Lift Cylinder.............................................................. 31 Remove...................................................................... 31 Main Lift Cylinders - Two-Stage FFL Mast................................ 31 Left-Hand Main Lift Cylinder - Three-Stage FFL Mast..................... 33 Right-Hand Main Lift Cylinder - Three-Stage FFL Mast.................... 37 Main Lift Cylinder - Two-Stage LFL Mast................................. 37 Disassemble................................................................. 39 Main Lift Cylinders - Two-Stage FFL Mast................................ 39 Main Lift Cylinder - Three-Stage FFL Mast............................... 41 Main Lift Cylinder - Two-Stage LFL Mast................................. 41 Clean....................................................................... 42 Inspect..................................................................... 42 Assemble.................................................................... 42 Main Lift Cylinder - Two-Stage FFL Mast................................. 42 Main Lift Cylinder - Three-Stage FFL Mast............................... 43 Main Lift Cylinder - Two-Stage LFL Mast................................. 43 Install..................................................................... 43 Main Lift Cylinder - Two-Stage FFL Mast................................. 44 Left-Hand Main Lift Cylinder - Three-Stage FFL Mast..................... 44 Right-Hand Main Lift Cylinder - Three-Stage FFL Mast.................... 45 Main Lift Cylinder - Two-Stage LFL Mast................................. 46 System Air Bleed Procedures............................................. 46 All Main Lift Cylinders................................................. 47 Lift Cylinder Repair for Lift Trucks J1.6-2.0XNT (J30-40XNT) (K1.................... 47 Main Lift Cylinder.............................................................. 47 Remove...................................................................... 47 Two-Stage FFL........................................................... 47 Three-Stage FFL......................................................... 48 Two-Stage LFL........................................................... 48 Four-Stage FFL.......................................................... 50 Disassemble................................................................. 50 Two-Stage FFL........................................................... 50 Three-Stage FFL......................................................... 53 Two-Stage LFL........................................................... 54 Four-Stage FFL.......................................................... 54 Clean....................................................................... 56 Inspect..................................................................... 56 Assemble.................................................................... 57 Two-Stage FFL........................................................... 57 Three-Stage FFL......................................................... 58 Two-Stage LFL........................................................... 58 Four-Stage FFL.......................................................... 58 Install..................................................................... 59 Two-Stage FFL........................................................... 60 System Air Bleed Procedures............................................. 60 Three-Stage FFL Mast.................................................... 60 Two-Stage LFL........................................................... 61 Four-Stage FFL.......................................................... 61 Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, an........ 62 Mast and Carriage Installation for Four-Stage FFL....................... 62 Free-Lift Cylinder Repair for Lift Trucks E2.2-3.5XN (E40-70XN) .................... 62 Free-Lift Cylinder.............................................................. 62 Remove...................................................................... 62 Two and Three-Stage FFL Mast............................................ 62 Four-Stage FFL For Lift Truck E2.2-3.5XN (E45-70XN) (A268).............. 63 Disassemble................................................................. 65 Two and Three-Stage FFL Mast............................................ 65 Four-Stage FFL Mast for Lift Truck E2.2-3.5XN (E45-70XN) (A268)......... 66 Clean....................................................................... 66 Inspect..................................................................... 66 Assemble.................................................................... 67 Two and Three-Stage FFL Mast............................................ 67 Four-Stage FFL Mast for Lift Truck E2.2-3.5XN (E45-70XN) (A268)......... 67 Install..................................................................... 68 Two and Three-Stage FFL Mast............................................ 68 Four-Stage FFL Mast for Lift Truck E2.2-3.5XN (E45-70XN) (A268)......... 68 Free Lift Cylinder Repair for Lift Truck J1.5XNT (K160)............................. 69 Free-Lift Cylinder.............................................................. 69 Remove...................................................................... 69 Three-Stage FFL Mast.................................................... 69 Disassemble................................................................. 69 Clean....................................................................... 69 Inspect..................................................................... 71 Assemble.................................................................... 71 Install..................................................................... 72 Free Lift Cylinder Repair for Lift Trucks J1.6-2.0XNT (J30-40XNT.................... 72 Free-Lift Cylinder.............................................................. 72 Remove...................................................................... 72 Two and Three-Stage FFL Mast............................................ 72 Four-Stage FFL Mast..................................................... 74 Disassemble................................................................. 77 Two-Stage and Three-Stage FFL Masts..................................... 77 Four Stage FFL Mast..................................................... 77 Clean....................................................................... 78 Inspect..................................................................... 78 Assemble.................................................................... 79 Two-Stage and Three-Stage FFL Masts..................................... 79 Four-Stage FFL Mast..................................................... 79 Install..................................................................... 79 Two-Stage and Three-Stage FFL Masts..................................... 79 Four-Stage FFL Mast..................................................... 80 All Masts............................................................... 82 Torque Specifications for Lift Truck Models E2.2-3.5XN (E45-70XN.................... 82 Tilt Cylinders.................................................................. 82 Piston Rod Nut.............................................................. 82 Gland....................................................................... 82 Tilt Cylinder Mounting Capscrew............................................. 82 Tilt Cylinder Rod End Capscrew.............................................. 82 Main and Free-Lift Cylinder..................................................... 82 Torque Specifications for Lift Truck Model J1.5XNT (K160)........................... 83 Tilt Cylinders.................................................................. 83 Main and Free-Lift Cylinders.................................................... 83 Torque Specifications for Lift Truck Models J1.6-2.0XNT (J30-40X.................... 84 Tilt Cylinders.................................................................. 84 Main and Free-Lift Cylinders.................................................... 84 tables.................................................................................. 1 Table 1. Movement Rates (Maximum) for Tilt Cylinders, Lift Truck.................... 14 Hyster-J40xnt-Parts-and-Service-Diagrams-1688884-8000SRM1341-(07-2011)-US-EN................ 87 toc..................................................................................... 87 Diagrams............................................................................ 87 Safety Precautions Maintenance and Repair........................................... 88 Hyster-J40xnt-Parts-and-Service-Frame-1659445-0100SRM1329-(07-2011)-US-EN...................119 toc.....................................................................................119 Frame...............................................................................119 Safety Precautions Maintenance and Repair...........................................120 Introduction........................................................................123 General.........................................................................123 Description of Operation........................................................123 Discharging the Capacitors......................................................124 Covers and Floor Plates.............................................................126 Overhead Guard Replacement..........................................................128 Remove..........................................................................128 Install.........................................................................131 Hood and Seat Assembly..............................................................132 Remove..........................................................................134 Install.........................................................................135 Ground Test.....................................................................136 Counterweight Replacement...........................................................136 Remove..........................................................................138 Install.........................................................................140 Safety Labels.......................................................................142 Painting Instructions...............................................................145 Battery Specifications..............................................................146 J1.5-2.0XNT (K160) European Model Trucks........................................146 J30-40XNT (K160) US Model Trucks................................................147 J1.6-2.0XN (A935) European Model Trucks.........................................147 J30-40XN (A935) US Model Trucks.................................................148 tables..................................................................................119 Table 1. Counterweights for Lift Truck J1.5-2.0XNT (J30-40XNT) (....................137 Table 2. Counterweights for Lift Truck J1.6-2.0XN (J30-40XN) (A9....................137 Hyster-J40xnt-Parts-and-Service-Periodic-Maintenance-1689720-8000SRM1339-(02-2012)-US-EN....151 toc.....................................................................................151 Periodic Maintenance................................................................151 Safety Precautions Maintenance and Repair...........................................152 Introduction........................................................................157 General.........................................................................157 Serial Number...................................................................157 Discharging the Capacitors......................................................158 How to Tow a Disabled Lift Truck................................................158 How to Put Lift Truck on Blocks.................................................160 How to Raise Drive Tires....................................................160 How to Raise Steer Tires....................................................160 How to Clean a Lift Truck.......................................................160 Safety Procedures When Working Near Mast............................................162 WHEN WORKING NEAR THE MAST ALWAYS:..............................................162 Maintenance Schedule................................................................164 Maintenance Procedures Every 8 Hours or Daily.......................................172 How to Make Checks With the Key or Keyless Switch OFF...........................172 Wheels and Tires............................................................172 Safety Labels...............................................................173 Frame and Covers............................................................173 Forks, General..............................................................174 Forks, Remove...............................................................174 Forks, Inspect..............................................................174 Fork Install................................................................175 Forks, Adjust...............................................................175 Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Att............175 Hydraulic Oil Level and Leaks...............................................177 Operator Restraint System...................................................177 Emergency Locking Retractor (ELR)...........................................178 Battery Restraint System....................................................178 Steering Column Adjustments.................................................183 Tilt Adjust Feature.....................................................183 Tilt Memory Feature.....................................................183 Telescopic Feature......................................................183 Battery Check...............................................................184 How to Make Checks With the Key or Keyless Switch ON............................184 Control Levers and Pedals...................................................184 Direction and Speed Controls................................................184 Electrical Components.......................................................184 Steering System.............................................................186 Hydraulic System............................................................186 Service Brakes..............................................................186 Automatic Parking Brake.....................................................186 Operator Presence System....................................................187 Oil Leaks...................................................................187 Maintenance Procedures After First 100 Hours or 2 Months of Serv....................187 Tire and Wheel Assemblies.......................................................187 Mast Sliding Surfaces...........................................................187 Mast Pivot Pins and Mounting Hardware...........................................188 Fork Guides and Pins............................................................188 Integral Sideshift Carriage.....................................................189 Check Upper and Lower Bearings..............................................189 Header Hoses, Hose Fittings, and Clamps.........................................189 Maintenance Procedures Every 500 Hours or Three Months..............................190 Tire and Wheel Assemblies.......................................................190 Mast and Carriage...............................................................190 Mast Sliding Surfaces.......................................................190 Mast Pivot Pins, Bushings, and Mounting Hardware............................191 Header Hoses................................................................191 Fourth Function Mini Rollers Lubrication....................................192 Lift Chain Lubrication......................................................193 Lift Chain Wear Check.......................................................193 Integral Sideshift Carriage.....................................................194 Check Upper and Lower Bearings..............................................194 Fork Guides and Pins........................................................194 Check Lower Mounting Hook...................................................194 Tilt Cylinder Rod End Pins......................................................195 Control Levers, Pedals, and Hinges..............................................196 Direction and Speed Control Pedals..............................................196 Hydraulic Hoses, Fittings, and Clamps...........................................196 Hydraulic Breather Cap..........................................................196 Service Brakes..................................................................197 Master Cylinder Oil Check...................................................197 Parking Brake...................................................................197 Manual Override Handle......................................................197 Electrical Inspection...........................................................198 Contactors..................................................................198 Maintenance Procedures Every 2000 Hours or Yearly...................................199 Hydraulic System................................................................199 Hydraulic Oil Filter, Change................................................199 Hydraulic Breather, Check...................................................201 Steering Axle...................................................................202 Steering Actuator and Steering Plate Torque Check...........................202 Transaxle Oil Level Check.......................................................202 Transaxle Breather Check........................................................203 Brake Oil Change................................................................203 Integral Sideshift Carriage.....................................................204 Lift Chains.....................................................................204 Maintenance Procedures Every 4000 Hours or Two Years................................204 Hydraulic Oil Change............................................................204 Steering Direction Sensor Inspection............................................206 Fixed Steering Column.......................................................206 Telescopic Steering Column..................................................207 Telescopic Steering Column Lubrication..........................................208 Welding Repairs.....................................................................209 Lift and Tilt System Leak Check.....................................................210 Lift Cylinders Leak Check.......................................................210 Tilt Cylinder Leak Check........................................................210 Battery Maintenance.................................................................211 How to Charge Battery...........................................................211 How to Change Battery...........................................................212 Remove the Battery..........................................................212 Install the Battery.........................................................214 Optional Side Removal of Battery............................................215 Battery Size Specifications.....................................................216 Wheel and Tires.....................................................................216 General.........................................................................216 Pneumatic Tires Repair..........................................................216 Remove Wheels From Lift Truck...............................................216 Remove Tire From Wheel......................................................216 Remove Tire From Two-Piece Wheel........................................217 Remove Tire From Three- and Four-Piece Wheels...........................218 Install Wheel in Tire.......................................................219 Install Two-Piece Wheel in Tire.........................................220 Install Three- or Four-Piece Wheel in Tire..............................221 Add Air to Tires............................................................222 Wheels, Install.............................................................222 Solid Rubber Tires on Pneumatic Wheels, Change..................................223 Remove Tire From Wheel......................................................223 Install Tire on Wheel.......................................................224 Install the Wheels..........................................................226 Solid Rubber (Cushioned) Tire Repair............................................226 Remove Wheels From Lift Truck...............................................226 Remove and Install Tire on Wheel............................................226 Lift Chain Adjustments..............................................................227 tables..................................................................................151 Table 1. Maintenance Schedule.......................................................165 Table 2. Hook-Type Carriage Chain Adjustment........................................228 Hyster-J40xnt-Parts-and-Service-Report-an-Error.............................................231 Hyster-J40xnt-Parts-and-Service-User-Interface-1688879-2200SRM1336-(12-2011)-US-EN..........232 toc.....................................................................................232 User Interface......................................................................232 Safety Precautions Maintenance and Repair...........................................233 General.............................................................................238 Description.....................................................................238 Display Panel Menu Access.......................................................238 Menu Flowchart......................................................................239 Technician Menu Flowchart.......................................................239 Menu Navigation.....................................................................245 Main Menu Structure.............................................................245 Screens and Title Screens.......................................................246 Submenus........................................................................246 Returning to the Main Menu......................................................247 Icons and Settings..............................................................247 Soft Keys.......................................................................247 Entering Numbers................................................................248 Icon Glossary.......................................................................248 Introduction....................................................................248 Soft Key Icons..................................................................248 Overlay Icons...................................................................250 System Off Screen and Alert Screens.............................................250 Main Menu Title Screens.........................................................253 Submenu Icons Grouped by Menu...................................................255 Operating Screen Icons......................................................255 Password Screen Icons.......................................................256 Activity Log Submenu Icons..................................................256 Calibration Submenu Icons...................................................258 Display Submenu Icons.......................................................261 Status Submenu Icons........................................................263 Truck Setup Submenu Icons...................................................266 Diagnostics Submenu Icons...................................................278 Operating Screen....................................................................286 Introduction....................................................................286 Performance Mode Controls.......................................................287 Status and Warning Icons........................................................287 Battery Discharge Indicator.....................................................288 Direction and Parking Brake Indicators..........................................289 Hazard Flashers and Lighting Controls...........................................289 Tire Angle Indicator............................................................289 System Time.....................................................................289 Load Weight Indicator...........................................................289 System Off/Alert Screens............................................................290 Introduction....................................................................290 System Off Screen...............................................................290 Alert Screens...................................................................290 Password Screen.....................................................................291 Introduction....................................................................291 Password Screen.................................................................291 Service Technician Password Setup...........................................292 Adding/Removing/Changing Passwords..............................................293 Password Log....................................................................296 Activity Log Menu...................................................................296 Introduction....................................................................296 Operator Checklist Log..........................................................297 Password Log....................................................................299 Impact Events Log...............................................................301 Calibration Menu....................................................................303 Introduction....................................................................303 Load Weight Calibration.........................................................303 Return to Set Tilt Stop Point Calibration.......................................303 E-Hydraulic and Manual Valve Threshold Calibration..............................304 Steering Wheel Knob Center Point Calibration....................................305 Steer Axle Position Calibration.................................................305 Manual Hydraulics Calibration...................................................306 Display Menu........................................................................307 Introduction....................................................................307 Set Date and Time Format Menu...................................................307 Set Daylight Saving Time Menu...................................................309 Procedure for Setting Up Automatic Daylight Savings Time....................309 Set Time and Date Menu..........................................................311 Procedure for Setting Time and Date.........................................312 Set Units Menu..................................................................312 Status Menu.........................................................................313 Introduction....................................................................313 VSM Versions....................................................................313 Display Versions................................................................314 Truck Serial Number.............................................................314 Hour Meters.....................................................................314 E-Hydraulic Controller Versions.................................................314 Pump Motor Controller Versions..................................................314 Traction Motor Controller 1 Versions............................................315 Traction Motor Controller 2 Versions............................................315 Light Controller Versions.......................................................315 Impact Sensor Versions..........................................................315 Truck Setup Menu....................................................................315 Introduction....................................................................315 Add/Remove Password.............................................................316 Motor Braking...................................................................316 Changing the Motor Braking Settings.........................................317 Battery Setup...................................................................317 BDI Adjustment Setting..........................................................319 Acceleration Rates..............................................................319 Hour Meter Initialization.......................................................320 Impact Monitor Shutdown.........................................................320 Operator Checklist..............................................................321 Minimum Pump Standby Flow Rate..................................................321 Scheduled Maintenance Reminder..................................................322 Traction Speed Limit............................................................323 Return to Set Tilt..............................................................323 Auto Power-Off Time Delay.......................................................324 Impact Monitor Settings.........................................................324 Impact Detection............................................................325 Setting Adjustments.........................................................325 Initial Adjustment of Soft and Hard Impact Settings.........................325 Readjustment of Soft and Hard Impact Settings...............................325 Motion Alarm....................................................................325 Lift Hydraulic Function Maximum Speed and Ramp Times............................326 Lower Hydraulic Function Maximum Speed and Ramp Times...........................327 Tilt Forward Hydraulic Function Maximum Speed and Ramp Times....................327 Tilt Backward Hydraulic Function Maximum Speed and Ramp Times...................327 Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times....................327 Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times....................327 Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times....................327 Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times....................328 Optional Hydraulic Functions....................................................328 Rear Lights Control.............................................................328 Restore Default Settings........................................................329 Diagnostics Menu....................................................................329 Introduction....................................................................329 Fault Code Log..................................................................330 Fault Log Details...........................................................330 Speedometer.....................................................................331 Direction Switch................................................................331 Traction Motor 1 Status.........................................................331 Traction Motor 2 Status.........................................................332 Occupancy Sensor................................................................332 Brake System Sensors............................................................332 Pump Status.....................................................................333 Hydraulic Control Inputs........................................................333 E-Hydraulic Valves..............................................................333 Hydraulic Sensors...............................................................334 System Voltages.................................................................335 Steering Position Sensors.......................................................335 tables..................................................................................232 Table 1. Technician Menu Flowchart..................................................244 Table 2. Soft Key Icons.............................................................249 Table 3. Overlay Icons..............................................................250 Table 4. Alert Screen Icons.........................................................250 Table 5. Main Menu Title Screens....................................................253 Table 6. Operating Screen Icons.....................................................255 Table 7. Password Screen Icons......................................................256 Table 8. Activity Log Submenus and Icons............................................256 Table 9. Calibration Submenus and Icons.............................................258 Table 10. Display Submenus and Icons................................................261 Table 11. Status Submenus and Icons.................................................263 Table 12. Truck Setup Submenu Icons.................................................266 Table 13. Diagnostic Submenu Icons..................................................278 Table 14. BSOC in Relation to BDI...................................................288 Table 15. Add Password..............................................................293 Table 16. Change or Remove Password.................................................295 Table 17. Access Operator Checklist Log Screens.....................................298 Table 18. Access Password Log Screens...............................................300 Table 19. Access Impact Events Log Screens..........................................302 Table 20. Accessing the Set Date and Time Format Screen.............................308 Table 21. Set Daylight Saving Time Menu.............................................310 Table 22. Battery Setup Factory Defaults............................................318
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HYSTER A935 (J1.5-2.0XNT J30-40XNT) SERVICE MANUAL – PDF DOWNLOAD:
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