Hyster J1.5UT, J2.0UT, J2.5UT, J3.0UT Forklift Repair A3C4 Series Manual

Repair Manual for Hyster A3C4 Series, Models: J1.5UT, J2.0UT, J2.5UT, J3.0UT
Format: PDF
English

• Hyster J1.5UT, J2.0UT, J2.5UT, J3.0UT Forklift Repair A3C4 Series Manual: 94 Pages

Hyster A3C4 Series, Models: J1.5UT, J2.0UT, J2.5UT, J3.0UT Manual Table Of Content:

Forklift Truck Main Parts…………………………………………………………………………………………………………………….1
Battery……………………………………………………………………………………………………………………………………………..1
Battery And Installation…………………………………………………………………………………………………………………..1
Overview………………………………………………………………………………………………………………………………………1
Structure Of Battery………………………………………………………………………………………………………………………1
Storage Of Battery…………………………………………………………………………………………………………………………1
Use Of Battery……………………………………………………………………………………………………………………………… 2
Service Of Battery………………………………………………………………………………………………………………………….2
General Notices…………………………………………………………………………………………………………………………….3
Common Failures And Disposal Methods Of Battery……………………………………………………………………….. 4
Main Technical Specification Of Forklift Truck……………………………………………………………………………………… 5
Driving Motor And Driving System…………………………………………………………………………………………………….. 10
Overview…………………………………………………………………………………………………………………………………………10
Axle Box And Differential………………………………………………………………………………………………………………… 10
Notes For Installation And Use………………………………………………………………………………………………………..17
Front Tyre And Wheel Rim Models…………………………………………………………………………………………………… 17
Installation Of Wheel Hub………………………………………………………………………………………………………………17
Brake……………………………………………………………………………………………………………………………………………18
Parking Brake……………………………………………………………………………………………………………………………….24
Clearance Self-Adjusting Mechanism…………………………………………………………………………………………….. 24
Brake Disassembly And Assembly, Adjustment Essentials……………………………………………………………….26
Disassembly Of The Brake…………………………………………………………………………………………………………….26
Inspection Of Brake………………………………………………………………………………………………………………………28
Brake Assembly…………………………………………………………………………………………………………………………….30
Operation Steps For Brake Clearance Adjuster……………………………………………………………………………….. 33
Driving Motor………………………………………………………………………………………………………………………………. 33
Specification Of Driving Motor…………………………………………………………………………………………………….. 33
Operating Environment Conditions………………………………………………………………………………………………34
Pump Motor……………………………………………………………………………………………………………………………………… 34
Specification Of Pump Motor……………………………………………………………………………………………………………..34
Operating Environment Conditions……………………………………………………………………………………………….. 34
Electrical System………………………………………………………………………………………………………………………………. 34
Overview…………………………………………………………………………………………………………………………………………34
Characteristics Of AC Motor Controller…………………………………………………………………………………………….. 34
Steering Device And Installation………………………………………………………………………………………………………… 48
Overview…………………………………………………………………………………………………………………………………………48
Inspection Of Steering System After Reassembly………………………………………………………………………………48
Steering System Fault Diagnosis…………………………………………………………………………………………………… 49
Steering Axle And Installation…………………………………………………………………………………………………………….49
Overview Of Steering Axle……………………………………………………………………………………………………………….. 49
Essentials Of Adjustment And Maintenance……………………………………………………………………………………….55
Steering Wheel Bearing Preload Adjustment…………………………………………………………………………………..55
Parking Brake Operation……………………………………………………………………………………………………………………56
Overview…………………………………………………………………………………………………………………………………………56
Operating Device Of The Parking Brake……………………………………………………………………………………………..56
Brake Pedal Operation……………………………………………………………………………………………………………………….56
Overview…………………………………………………………………………………………………………………………………………56
Brake Pedal……………………………………………………………………………………………………………………………………. 56
Brake Master Cylinder……………………………………………………………………………………………………………………. 57
Brake Fault Diagnosis…………………………………………………………………………………………………………………….. 57
Hydraulic Oil Tank And Installation…………………………………………………………………………………………………… 59
Overview…………………………………………………………………………………………………………………………………………59

The Service Repair Manual are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from our website.

The Service Repair Manual provide general guidelines for maintenance and service  of the A3C4 Series, Models: J1.5UT, J2.0UT, J2.5UT, J3.0UT and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

• 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 from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

Caution:

• 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.