Hyster's 66-page service manual 8000 SRM 2354 takes apart the J1.6UTT, J1.8UTT and J2.0UTT 3-wheel battery forklift trucks system by system, from battery service to mast disassembly. Wiring diagrams in this Hyster J1.6UTT service manual PDF trace the AC motor controller and instrument circuits, and fault code tables let you decode what the display reports. Hydraulic schematics follow oil from the gear pump through the multi-way valve, speed limit valve and Orbitrol to the lifting and tilting cylinders, while the lifting system chapter covers fork carriage height adjustment, roller positions and the lifting cylinder's explosion relief valve. Set the J1.6UTT safety valve at 14.5 MPa. Check battery insulation resistance against 50 Ω/V. If you are tracing a steering fault after reassembly, the steering chapter pairs a post-reassembly examination with fault diagnosis. Bookmarked and text-searchable, the PDF goes with you to wherever the truck is parked, on a laptop or a phone.
What's Inside This Hyster J1.6UTT–J2.0UTT Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Forklift Truck Main Parts | 7-10 | Battery, Battery Installation, Battery Structure, Battery Storage, Battery Service |
| Main Technical Specification of Forklift Truck | 11-12 | Rated Capacity, Load Centre, Lifting Height, Fork Size, Mast Tilting Angle, Turning Radius |
| Driving Motor and Driving System | 13-17 | Overview, Transmission, Driving Motor (Specification of Driving Motor, Conditions of Operating Environment), Pump Motor and Installation |
| Electrical System | 18-28 | Overview, AC Motor Controller, Instruments, Fault Codes |
| Steering Device and Installation | 29-31 | Steering Wheel, Steering Column, Column Bracket, Orbitrol Control Unit, Locking Handle |
| Steering Axle and Installation | 32-33 | Steering Axle, Steer Potentiometer Shaft, Steer Potentiometer Bracket, Steering Axle Bolts, Steering Axle Washers |
| Hand Brake Operation | 34-35 | Hand Brake Assembly, Brake Stay, Brake Handle, Brake Cable, Brake Adjuster |
| Foot Brake Operation | 36-38 | Overview, Foot Brake Pedal (Brake Switch, Brake Master Cylinder, Fault Diagnosis) |
| Working Oil Tank and Installation | 39-54 | Overview, Hydraulic Oil Tank |
| Hydraulic Lines | 55 | Hydraulic Oil Pipeline, Multi-Way Valve, Speed Limit Valve, Lifting Cylinder, Tilting Cylinder |
| Lifting System | 56-62 | Safety Procedures When Working Near Mast, Overview, Inner and Outer Mast, Fork Carriage Assembly (Adjustment for Height of Fork Carriage, Roller Positions, Fork Backrest) |
| List of Wear Parts | 63-66 | Driving Wheel, Steering Wheel, Piston, Oil Seal, O-Ring, Combination Seal Ring |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Battery insulation resistance | 50Ω/V | p. 9 |
| Insulation resistance for entire battery (voltage to reach 20V) | 1000Ω | p. 9 |
| Thickness of lining plate | 4.94 mm (.19 in.) | p. 42 |
| Connecting bolts torque | 9-10 kg.m | p. 44 |
| J1.6UTT | ||
| Safety Valve Pressure Control Value | 14.5Mpa | p. 51 |
| Orbitrol Pressure Setting | 4.5Mpa | p. 51 |
| Rated Capacity | 1600 kg | p. 12 |
| Operating Pressure | 14.5 Mpa | p. 13 |
| J1.8UTT, J2.0UTT | ||
| Safety Valve Pressure Control Value | 17.5 Mpa | p. 51 |
| Orbitrol Pressure Setting | 6.3 Mpa | p. 51 |
| J1.8UTT | ||
| Rated Capacity | 1800 kg | p. 12 |
| J2.0UTT | ||
| Rated Capacity | 2000 kg | p. 12 |
Hyster J1.6UTT–J2.0UTT Series Common Problems This Manual Covers
Hyster J1.6UTT, J1.8UTT, J2.0UTT steering wheel fails to turn or steering operation feels strenuous
Check the oil pump, priority valve and hoses when the wheel will not turn (page 30). Replace a failed pump, and clean or replace a blocked priority valve, damaged hose or joint. For heavy steering, adjust bypass valve pressure, remove air from the oil circuit, replace a broken positioning spring and examine the steering cylinder piston sealing.
Manual Section: Steering System Fault Diagnosis p. 30Hydraulic oil pump pressure low, oil delivery small and noise present during operation
Check the tank oil level and clean or replace a blocked oil pipe or filter (page 45). Fasten loose suction side fittings that pull air. If pressure stays low, adjust the overflow valve using a pressure gauge, and replace damaged bearings, seals or lining plates (thickness 4.94 mm, page 42). As pressure rises, watch oil temperature, pump surface temperature and running sound; reduce load until the oil cools before continuing the test (page 44).
Manual Section: Hydraulic System Fault Diagnosis p. 45Multi-way valve lifting oil circuit pressure fails to increase or rises slowly
Disassemble the multi-way valve and clean a blocked valve or oil hole, following the chart on page 52. For slow pressure rise, fully exhaust air from the circuit. If set pressure reads low, replace a broken spring and amend the valve seat surface or replace the overflow valve. Verify the safety valve setting for your model on page 51.
Manual Section: Multi-Way Valve Fault Diagnosis p. 52Transmission acting as the drive axle generates gear noise during the running process
Check the gear oil tank level first and fill gear oil if it is low, per the chart on page 15. Transmission oil quantity is 0.55~0.65 L on page 16. If noise continues with correct oil, adjust excessive gear clearance and replace gears showing too much wear.
Manual Section: Transmission Troubleshooting p. 15Foot brake gives poor braking or noise present with the brake pedal applied
Inspect the brake system for oil leaks and repair them, then adjust the brake clearance regulator, per page 38. Examine the brake fluid for contaminant and repair or replace hardened or contaminated friction plates. For noise, check for a distorted bottom plate, loose bolts, worn friction blocks or a loose wheel bearing, and adjust the brake pedal micro-valve.
Manual Section: Foot Brake Fault Diagnosis p. 38Battery capacity drops at normal discharge with quick voltage drop and early bubbling at charge
Measure the density and temperature of each battery unit after charging and compare against your previous records, per page 9; a large difference calls for a professional. Treat pole plate salinization by the overcharging, repeated charging or hydropathy method. Operate and maintain the battery according to the Battery Use and Maintenance Manual and contact a professional with any questions (page 10).
Manual Section: Battery Troubleshooting p. 9Frequently Asked Questions
What do the Hyster J1.6UTT–J2.0UTT error codes mean?
The error codes are listed in the Primary Controller Fault Codes tables (Tables 3 and 4). For example, code 0x6010 corresponds to a 'WATCHDOG' alarm, and code 0xFF42 corresponds to a 'BATTERY LOW' alarm. These codes help technicians identify the specific failure location to minimize downtime. p. 24
What are the torque specifications for the gear pump connecting bolts on the Hyster J1.6UTT-J2.0UTT Series?
The connecting bolts for the gear pump must be tightened to a torque of 9-10 kg.m after the pump has been properly assembled. p. 44
What is the procedure for adjusting safety valve pressure on the Hyster J1.6UTT to J2.0UTT Series multi-way valve?
To adjust the safety valve, mount a 20MPa pressure gauge to the inlet measurement hole. Operate the tilting handle to the end of the cylinder stroke, then loosen the lock nut on the overflow valve and adjust the screw until the pressure reaches the specified value (14.5Mpa for J1.6UTT or 17.5Mpa for J1.8UTT/J2.0UTT). p. 51
What is the specified thickness for the gear pump lining plate?
The lining plate must be replaced if its surface is damaged or if its thickness is less than the specified value of 4.94 mm (.19 in.). p. 42
What is the required side clearance adjustment for the composite roller on the Hyster J1.6UTT to J2.0UTT Series?
The side clearance of the composite roller must be adjusted to 0.5mm. Additionally, grease should be applied to the surface of the composite roller and the contact face of the mast. p. 58
Is this Hyster J1.6UTT manual a PDF I download?
Delivery is instant: a 66-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Am I free to print this Hyster J1.6UTT Service Manual?
Yes. Print the pages or sections you need for your own shop use. Any standard printer works.
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