Battery, drive and pump motors, AC controller, steering, both brakes, hydraulics and mast: the Hyster J30UTT service manual PDF (OEM ID 4282423) works through each in 61 pages for the J30UTT, J35UTT and J40UTT counterbalanced 3-wheel battery forklift trucks. Wiring diagrams trace the 48V circuits through the AC motor controller and instruments, and the fault code listing tells you what the controller is reporting. Hydraulic schematics show the route from the gear pump through the multi-way valve, orbitrol and speed limit valve, with fault diagnosis for pump, valve, steering and brakes. Set the safety valve at 14.5 MPa on the J30UTT and 17.5 MPa on the J35UTT and J40UTT. Your job may be adjusting fork carriage height, setting the brake switch, or disassembling and reinstalling the mast. Bookmarks and a searchable text layer come with it. Save the file to a tablet and it goes wherever your truck is parked.
What's Inside This Hyster J30UTT, J35UTT, J40UTT Manual
| System | Pages | Key Topics |
|---|---|---|
| Forklift Truck Main Parts | 4-6 | Battery and Installation, Use of Battery, Service of Battery |
| Main Technical Specification of Forklift Truck | 7-8 | Rated Capacity, Load Centre, Lifting Height, Free Lifting Height, Fork Size, Mast Tilting Angle |
| Driving Motor and Driving System | 9-12 | Overview, Transmission, Driving Motor (Specification of Driving Motor, Conditions of Operating Environment), Pump Motor and Installation |
| Electrical System | 13-21 | Overview, AC Motor Controller, Instruments, Fault Codes |
| Steering Device and Installation | 22-26 | Overview (Examination of Steering System After Reassembly, Steering System Fault Diagnosis), Steering Axle and Installation |
| Hand Brake Operation | 27 | Parking Brake Operation Device, Adjustment of Braking Force, Hand Brake Assembly, Brake Wheel Cylinder |
| Foot Brake Operation | 28-31 | Foot Brake Pedal, Adjustment of Foot Pedal Brake, Adjustment of Brake Switch, Brake Master Cylinder |
| Working Oil Tank and Installation | 32-48 | Oil Tank, Oil Tank Cover Plate, Magnet, Filter Core, Breather, Drain Plug |
| Lifting System | 49-59 | Safety Procedures When Working Near Mast |
| List of Wear Parts | 60-61 | Driving Wheel, Steering Wheel, Piston, Instrument Cover Plate, Various Hoses, Oil Seal, O-Ring, Combination Seal Ring |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| J30UTT | ||
| Battery Capacity | 500Ah | p. 4 |
| Safety Valve Pressure Control Value | 14.5Mpa | p. 46 |
| Orbitrol Pressure Setting | 4.5Mpa | p. 46 |
| Rated Capacity | 1600 kg | p. 8 |
| All Models | ||
| Battery Voltage | 48V | p. 4 |
| Lifting Height | 3000 mm | p. 8 |
| Transmission Oil Rate | 0.55~0.65 L | p. 12 |
| Foot Brake Control Pressure | 60-80 bar | p. 12 |
| J35UTT, J40UTT | ||
| Safety Valve Pressure Control Value | 17.5 Mpa | p. 46 |
| J35UTT | ||
| Rated Capacity | 1800 kg | p. 8 |
| J40UTT | ||
| Rated Capacity | 2000 kg | p. 8 |
Hyster J30UTT, J35UTT, J40UTT Common Problems This Manual Covers
Hyster J30UTT battery capacity drops at normal discharge with quick voltage drop and low specific gravity
Check the electrolyte level first. An exposed plate top, insufficient initial or long-term charge, and long standing in a discharged state all cause pole plate salinization, according to the chart on page 7. Correct it with the overcharging, repeated charging, or hydropathy method listed there. Follow the page 7 warning: service the battery according to the Battery Use and Maintenance Manual, and contact a professional if unsure.
Manual Section: Battery Faults p. 7Display shows BATTERY LOW alarm code 66 and truck shuts down or loses output power
Verify the displayed charge level. Once it reads below 20, stop operation and charge the 48V battery, as page 18 instructs. Stop work at once whenever a fault code appears, and do not resume until the fault is cleared. An ALARM grade fault normally shuts the truck down, while a WARNING grade fault may only reduce output power (page 17).
Manual Section: Primary Controller Fault Codes p. 18Transmission on three-wheel drive unit makes constant gear noise during the running process
Check the gear oil level in the transmission first and top it up. Page 11 lists low gear oil as a cause of noise during running, and the transmission oil rate on page 12 is 0.55~0.65 L. If the noise persists with the oil level correct, adjust any excessive gear clearance and replace gears that show too much wear.
Manual Section: Transmission Faults p. 11Steering wheel operation strenuous and heavy to turn, with uneven left and right effort
Bleed air from the oil circuit first: jack up the rear wheel, then slowly turn the steering wheel left and right several times, following page 23. Next, adjust bypass valve pressure if it is too low. Replace a broken or weak positioning spring in the steering gear, and examine steering cylinder piston sealing for excessive internal leak.
Manual Section: Steering System Fault Diagnosis p. 23Brake system braking force insufficient when applying the hand brake or pressing the pedal
Inspect the brake pipeline for oil leaks, then correct them and re-add oil, following the chart on page 28. Remove any air from the brake pipeline and clean any blocked oil pipeline. Correct or replace the brake master cylinder if it functions abnormally. Check the result against the foot brake control pressure on page 12, which is 60-80 bar.
Manual Section: Hand Brake Fault Diagnosis p. 28Brake light does not turn on when the brake pedal is pushed down
Adjust the brake pedal height first. Then loosen the brake switch lock nut and pull off the plug to separate the lead wire, following page 31. Turn the switch until Clearance A measures 1 mm. Confirm the brake light comes on when the pedal is pushed down.
Manual Section: Foot Brake Operation p. 31Frequently Asked Questions
What are the Hyster J30UTT, J35UTT, J40UTT replacement specs for the lead-acid traction battery or individual modules?
The standard battery configuration for the J30UTT, J35UTT, and J40UTT models includes 24 cells. The J30UTT and J35UTT use a 48V4PZS460 or 48V4PZ460 battery with a 500Ah capacity, while the J40UTT uses a 625Ah capacity battery. p. 4
What are the replacement specifications for battery charging components on the Hyster J30UTT, J35UTT, J40UTT?
The standard charger specifications for the J30UTT and J35UTT are C2B3E-65A/48V, while the J40UTT requires a C2B3E-80A/48V charger. The standard plug specification for the J30UTT and J35UTT is REMA 160. p. 4
What is the specified torque for tightening the gear pump connecting bolts on the Hyster J30UTT, J35UTT, J40UTT?
After the gear pump has been properly assembled, the connecting bolts must be tightened to a specified torque of 9-10kg.m. p. 38
What is the specified thickness for the lining plate in the gear pump on the Hyster J30UTT, J35UTT, J40UTT?
The specified value for the thickness of the lining plate in the gear pump is 4.94 mm (0.19 in.). If the thickness is smaller than this value, the lining plate must be replaced. p. 36
What is the procedure for adjusting the foot pedal brake height?
To adjust the foot pedal brake, first adjust the push rod to be short, then adjust the catch bolt to set the pedal height. Push down the brake pedal and adjust the push rod to be long until the front end of the push rod contacts the master cylinder piston, then screw down the lock nut. p. 29
What do I get after purchasing this Hyster J30UTT manual?
Instant PDF download. You get the full 61-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Does this Hyster J30UTT manual allow printing?
Yes. Print the pages you need for the job in your own shop, and bin them when they get greasy.
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