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Hyster A935 (J30-35-40XN) Forklift Service Manual

2,364 pages · Publication A935

$239.67
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Models
A935 (J30-35-40XN)
Manual type
Service Manual
Pages
2,364
Publication
A935
Condition
Brand new
Hyster A935 (J30-35-40XN) Forklift Service Manual, publication A935

What's inside

From the manual's own table of contents: 168 sections, 440 entries. See sample pages (PDF, 443 KB)

Frame
Safety Precautions Maintenance and Repair
Introduction4 topics
  • General
  • Description of Operation
  • Discharging the Capacitors
  • Rapid Charge
Covers and Floor Plates
Overhead Guard Replacement2 topics
  • Remove
  • Install
Hood and Seat Assembly1 topic
  • Ground Test
Counterweight Replacement
Safety Labels
Painting Instructions
Battery Specifications3 topics
  • J1.5-2.0XNT (K160) European Model Trucks
  • J30-40XNT (K160) US Model Trucks
  • J1.6-2.0XN (A935) European Model Trucks
Table 1. Counterweights for Lift Truck J1.5-2.0XNT (J30-40XNT) (
Table 2. Counterweights for Lift Truck J1.6-2.0XN (J30-40XN) (A9
Transaxle
General1 topic
  • Special Tools
Transaxle Assembly4 topics
  • Remove Transaxle From Frame
  • Remove the Parking Brake and Traction Motor
  • Install Parking Brake and Traction Motor
  • Install Transaxle to Frame
Maintenance and Repair10 topics
  • Speed Sensor Repair
  • Trunnion Cap Repair
  • Fluid Level Check
  • Fluid Change
  • Breather Repair
  • Stud Repair
  • Brake Cylinder Repair
  • Input Seal Repair
  • Cover to Housing Seal
  • Wet Brakes
Table 1. Hyster Special Tools
Brake System
Brake Pedal Assembly Repair2 topics
  • Disassemble
  • Assemble
Master Cylinder Repair2 topics
  • Clean and Inspect
  • Adjustments
Brake Lines1 topic
  • Brake Line Replacement
Parking Brake1 topic
  • Manual Release Lever
Hydraulic System
Hydraulic Pump Repair2 topics
  • Inspect
  • Clean
Show all 168 sections
Hydraulic Tank Assembly3 topics
  • Hydraulic Filter Replacement
  • Breather Clean and Inspect
  • Add Hydraulic Oil
Specifications
Steering Axle
Steering Axle Assembly Repair
Tie Rod Replacement
Spindle Repair
Steering Cylinder Repair
Steering System
Steering Control Unit (SCU) Repair
Steering Wheel and Fixed Steering Column Assembly Repair1 topic
  • Gear Replacement for Lift Trucks Built Prior to October, 2008
Steering Wheel and Telescopic Column Assembly Repair
Torque Specifications2 topics
  • Steering Control Unit
  • Steering Column
Main Control Valves
Manual Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT5 topics
  • Disassemble Handles and Levers
  • Disassemble Manual Control Valve
  • Spool Seal Replacement
  • Assemble Manual Control Valve
  • Assemble Handles and Levers
Manual Hydraulic Control Valve Repair E2.2-3.5XN (E45-70XN) (A26
Manual Hydraulic Control Valve Repair E4.0-5.5XN, E5.0XNS (E80-1
E-Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT (J301 topic
  • E-Hydraulic Controls
E-Hydraulic Control Valve Repair for Lift Truck E2.2-3.5XN (E45
E-Hydraulic Control Valve Repair for Lift Truck E4.0-5.5XN, E5.0
Checks and Adjustments for Lift Truck J1.5-2.0XNT (J30-40XNT) (K3 topics
  • Manual Control Valve
  • E-Hydraulic Control Valve
  • Hydraulic System Air Removal
Checks and Adjustments for Lift Truck E2.2-3.5XN (E45-70XN) (A26
Position Sensor and OPS Check and Adjustment3 topics
  • Position Sensor
  • (OPS) Operator Presence Solenoid
  • Manual Control Valve Re-Calibration
Calibration Procedure1 topic
  • Control Valve
Torque Specifications for Lift Truck J1.5-2.0XNT (J30-40XNT) (K12 topics
  • Manual Hydraulic Control Valve
  • Manual Control Valve Handles and Levers
Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A2681 topic
  • Manual Control Valve Covers
Table 1. Handle Options
Table 2. Position Sensor Connector Pin Layout
Table 3. Position Sensor Electrical Connector Pin Layout
Table 4. Handle Options
Table 5. Position Sensor Electrical Connector Pin Layout
Table 6. Handle Options
Table 7. Lower Solenoid Connector Pin Layout
Table 8. Upper Solenoid Connector Pin Layout
Table 9. Lower Solenoid Connector Pin Layout
Table 10. Upper Solenoid Connector Pin Layout
Table 11. Lower Solenoid Connector Pin Layout
Table 12. Upper Solenoid Connector Pin Layout
Table 13. Pressure Specifications
Table 14. Test Specifications
Table 15. Service Tools
Table 16. Position Sensor Wiring
Table 17. Sensor Power Check
Diagrams
Diagnostic Troubleshooting Manual
Safety Precautions TROUBLESHOOTING PROCEDURES1 topic
  • Service Manual Lookup
How To Use This Troubleshooting Manual5 topics
  • General Instructions and Safety Information
  • How to Use Diagnostic Troubleshooting Manual
  • General Instructions
  • Conventional Battery Box (CBB) Units
  • Drop Battery Box (DBB) Units
Operational Diagnostic Procedures1 topic
  • Operational Checkout Procedures
Traction Motor1 topic
  • Poor Tractive Performance
Electrical System9 topics
  • Troubleshooting Guidelines and Procedures
  • Wiring Reference Data
  • Harness Assembly Data
  • Electrical System
  • None
  • DTC None
  • Horn Failure
  • Lights Inoperative
  • Icon Glossary
Drive Axle/Unit5 topics
  • One Drive Wheel Will Not Move
  • Noise During Operation That Is Not Normal
  • Oil Leaks
  • Park Brake Does Not Operate Properly
  • Motion Inhibited
Hydraulic Systems59 topics
  • Manual Hydraulic Main Control Valve
  • E-Hydraulic Main Control Valve
  • Steering System
  • Abnormal Hydraulic Noise and/or Vibration
  • Abnormal Smell/Discoloration/Foaming of Oil
  • Cycle Times Too Fast - Fast Actuation (E-Valve)
  • Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve
  • Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-V
  • Jump/Delay In Tilt Forward or Back Actuation (E-Valve)
  • Forks Drop Slightly Before Lifting (E-Valve)
  • Forks Lower Without Command (E-Valve)
  • Forks Raise or Actuate Without Command (E-Valve)
  • Hydraulic Oil Cooler Not Functioning Correctly
  • Intermittent Activation (E-Valve) While Commanding Function
  • Forks Tilt Forward Without Command (E-Valve)
  • Lift/Lower Function Maximum Speed Too Slow (E-Valve)
  • Lift Function Will Not Move With MLM Movement (E-Valve)
  • Lift/Lower Continues To Move For Awhile After MLM Is Released (E
  • Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke
  • Lower Function Will Not Move With MLM Movement (E-Valve)
  • Poor Metering on Lift or Lower Functions (E-Valve)
  • Auxiliary Function Continues to Move for Awhile After MLM Is Rel
  • Auxiliary Function Maximum Speed Too Slow (E-Valve)
  • Auxiliary Function or Tilt Back Moves Without Command (E-Valve)
  • Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move
  • Tilt Forward or Tilt Back Function Continues to Move for Awhile
  • Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Val
  • Too Much MLM Movement (Deadband) to Start Function Moving (E-Val
  • Wrong Actuation Operates or Actuation is Backward (E-Valve)
  • Actuation Exhibits Slight Movement in Opposite Direction Before
  • Auxiliary Function is Slow or Does Not Function (Manual Valve)
  • Cycle Times Too Fast - Fast Actuation (Manual Valve)
  • Function Continues to Activate After Returning to Neutral
  • Lift Function Is Slow or Does Not Function (Manual Valve)
  • Tilt Back Function Will Not Operate (Manual Valve)
  • Tilt Forward or Tilt Back Will Not Function When Activated (Manu
  • No Steering (All Other Hydraulic Functions OK)
  • Steering Is Slow or Difficult
  • Steering Operation Is Not Smooth
  • Steering Wheel End Lock Position Cannot Be Felt by Operator
  • Steering Wheel Turns By Itself or Does Not Return To Neutral
  • Steering Wheel Turns the Tires in the Wrong Direction
  • Actuations Do Not Act Simultaneously
  • Oil Leaking/Component Life Too Short
  • Abnormal Steer Axle Noise
  • Abnormal Steering Wheel Vibration
  • Back Lash/Kick Back in Steering Wheel
  • Hydraulic Warm-up Procedure
  • Primary Relief Valve Test and Adjustment
  • Secondary Relief Valve Test and Adjustment
  • Hydraulic Pump Flow Test
  • Main Control Valve LS Leakage Test (E-Valve)
  • Main Control Valve Unloader Margin Test
  • E-Hydraulic Valve Leakage Test
  • Steering Relief Pressure Test and Adjustment
  • Steering Control Unit LS Pressure Test
  • Lift Cylinder Leakage Test
  • Tilt Cylinder Leakage Test
  • Steering Cylinder Leakage Test
Operators Station8 topics
  • Operator Station General Description and Principles of Operation
  • Display Panel
  • Programming - Menus
  • Display Menu Flowchart
  • Manual Hydraulic Control Levers
  • E-Hydraulic System Interface
  • Lighting Control
  • Cab Panels
Front End (Mast) and Chassis35 topics
  • Front End, Mast
  • Carriages
  • Mast Mounts
  • Two-Stage Full Free-Lift (FFL) Mast
  • Two-Stage Limited Free-Lift (LFL) Mast
  • Three-Stage Full Free-Lift (FFL) Mast
  • Four-Stage Full Free-Lift (FFL) Mast
  • Cylinder Cushion During Lifting Sequence
  • Cylinder Cushion During Lowering Sequence
  • Tilt and Sideshift Cylinders
  • Lowering Control Valves
  • Chassis
  • Abnormal Channel Wear
  • Abnormal Hose Wear
  • Abnormal Mast Noise
  • Body Panels Making Noise
  • External Leakage From Free-Lift or Main Lift Cylinders
  • FFL Mast Banging During Phasing
  • High Tire Wear - Drive Axle
  • High Tire Wear - Steer Axle
  • Hoses Not Tracking Correctly
  • Integral Sideshift Moving Too Fast
  • Integral Sideshift Not Moving or Slow
  • Fork Positioner Not Moving or Slow
  • Mast is Loose
  • Mast Lift Chains Are Loose
  • Mast or Carriage Binding
  • Mast/Carriage Bounces or is Spongy
  • Misphasing of Full Free-Lift Mast
  • Overhead Guard Loose or Damaged
  • Racking During Lift
  • Racking During Tilt
  • Truck Feels Unstable
  • Truck Wanders, Does Not Track Straight or Steer Well
  • Wheel Studs Breaking
Supplementary Data1 topic
  • Abbreviations and Acronyms
Table 9030-03-1. Circuit Group Identification
Table 9030-03-2. Hyster Wiring Color Codes
Table 9030-10-1. VSM Connection
Table 9030-10-2. Motor Temperature Sensor
Table 9030-20-1. Main Schematic
Table 9030-20-2. Device Connectors
Table 9030-20-3. Main Schematic
Table 9030-20-4. Device Connectors
Table 9030-20-5. Main Schematic
Table 9030-20-6. Device Connectors
Table 9030-20-7. Main Schematic
Table 9030-20-8. Device Connectors
Table 9030-20-9. Display Internal Failure Fault DTCs
Table 9030-20-10. Motor Controller Temperature and Silicon Tempe
Table 9050-43-1. Test Specifications
Table 9050-43-2. Service Tools
Table 9050-43-3. Service Tools
Table 9050-43-4. Test Specifications
Table 9050-43-5. Test Specifications for Lift Trucks J1.5-2.0XNT
Table 9050-43-6. Test Specifications for Lift Trucks E2.2-3.5XN
Table 9050-43-7. Service Tools
Table 9050-43-8. Test Specifications
Table 9050-43-9. Service Tools
Table 9050-43-10. Test Specifications
Table 9050-43-11. Test Specifications
Table 9050-43-13. Test Specifications
Table 9050-43-14. Test Specifications
Table 9050-43-16. Test Specifications
Table 9050-43-18. Test Specifications
Table 9050-43-20. Test Specifications
Table 9050-43-22. Test Specifications
Table 9060-10-1. Display Panel
Table 9060-10-2. Activity Logs
Table 9060-10-3. Calibration
Table 9060-10-4. Diagnostics
Table 9060-10-6. Truck Status
Table 9060-10-7. Display Adjustments
Table 9080-50-1. Abbreviations and Acronyms
Display Panel and Key or Keyless Switch Replacement1 topic
  • Display Panel, Replace
Electronic and Manual Hydraulic Controls2 topics
  • Manual Hydraulic Controls
  • E-Hydraulic Controls - Test
Sensors and Switches17 topics
  • Synchronous Steering Valve
  • Steering Axle Sensor
  • Hydraulic Motor Speed Sensor
  • Hydraulic Motor Temperature Sensor
  • Transmission Speed Sensor
  • Traction Motor Temperature Sensor
  • Tilt Position Sensor
  • Low Level Brake Fluid Switch
  • Service Brake Pressure Sensor
  • Accelerator Pedal Position Sensor
  • Seat Sensor (Operator Presence System)
  • Steering Wheel Position Sensor
  • Load Weight Sensor
  • Battery Gate Switch
  • Horn Switch
  • Rear Horn Button Switch
  • Impact Sensor
Motor Controllers Replacement3 topics
  • Hydraulic Pump and Motor Controller
  • Traction Motor Controllers
  • Line Contactor
Vehicle Systems Manager2 topics
  • Programming a New VSM and/or Display Panel
  • PC Service Tool Software
Fuses
Audible Alarm
Battery Connection1 topic
  • Replacing Cables
Cab Heater
Lights5 topics
  • Work Lights (Front and Rear)
  • Strobe Light
  • LED Tail, Backup, and Brake Lights
  • Front Marker/Turn Signal Lights
  • Converter
Capacities and Specifications
Lubrication Specifications
Tire Sizes4 topics
  • Frame
  • Electrical
  • Hydraulic System
  • Transaxle
Mast Speeds
Maximum Carriage and Tilt Creep Rates
Tilt Angles
Travel Speeds
Battery1 topic
  • Battery Discharge Rate
Table 1. Tilt Angles
AC Motor Repair2 topics
  • Discharging the Capacitors for Lift Truck Models E30-40HSD 2 (B2
  • Discharging the Capacitors (All Other Models)
Traction Motor Repair
Hydraulic Motor Repair8 topics
  • Traction Motor for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) an
  • Traction Motor for Lift Truck E30-40HSD 2 (B219)
  • Hydraulic Motor for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) a
  • Hydraulic Motor for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
  • Hydraulic Motor for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
  • Hydraulic Motor for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
  • Hydraulic Motor for Lift Truck E30-40HSD 2 (B219)
  • Hydraulic Motor for Lift Truck J4.0-5.0XN (J80-100XN) (A970) and
Table 1. Speed Sensor Connector
Table 2. Thermal Sensor Connector
Periodic Maintenance4 topics
  • Serial Number
  • How to Tow a Disabled Lift Truck
  • How to Put Lift Truck on Blocks
  • How to Clean a Lift Truck
Safety Procedures When Working Near Mast1 topic
  • WHEN WORKING NEAR THE MAST ALWAYS
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily2 topics
  • How to Make Checks With the Key or Keyless Switch OFF
  • How to Make Checks With the Key or Keyless Switch ON
Maintenance Procedures After First 100 Hours or 2 Months of Serv6 topics
  • Tire and Wheel Assemblies
  • Mast Sliding Surfaces
  • Mast Pivot Pins and Mounting Hardware
  • Fork Guides and Pins
  • Integral Sideshift Carriage
  • Header Hoses, Hose Fittings, and Clamps
Maintenance Procedures Every 500 Hours or Three Months10 topics
  • Mast and Carriage
  • Tilt Cylinder Rod End Pins
  • Control Levers, Pedals, and Hinges
  • Direction and Speed Control Pedals
  • Hydraulic Hoses, Fittings, and Clamps
  • Hydraulic Breather Cap
  • Service Brakes
  • Parking Brake
  • Electrical Inspection
  • Cab Heater
Maintenance Procedures Every 2000 Hours or Yearly5 topics
  • Transaxle Oil Level Check
  • Transaxle Breather Check
  • Brake Oil Change
  • Steer Wheel Bearings
  • Lift Chains
Maintenance Procedures Every 4000 Hours or Two Years3 topics
  • Hydraulic Oil Change
  • Steering Direction Sensor Inspection
  • Telescopic Steering Column Lubrication
Welding Repairs
Lift and Tilt System Leak Check2 topics
  • Lift Cylinders Leak Check
  • Tilt Cylinder Leak Check
Battery Maintenance3 topics
  • How to Charge Battery
  • How to Change Battery
  • Battery Size Specifications
Wheels and Tires3 topics
  • Pneumatic Tires Repair
  • Solid Rubber Tires on Pneumatic Wheels, Change
  • Solid Rubber (Cushioned) Tire Repair
Lift Chain Adjustments
Table 1. Maintenance Schedule
Table 2. Hook-Type Carriage Chain Adjustment
Operator's Cab
Window Replacement3 topics
  • Front Panel
  • Rear Panel
  • Door Window
Window Wipers Replacement1 topic
  • Front Wiper Assembly
Cab Component Repair2 topics
  • Roof Liner
  • Top Panel
Cab Door Assembly1 topic
  • Door Assembly
Weather Panel Replacement for Lift Truck Model E2.2-3.5XN (E45-7
Table 1. Connector C1
Table 2. Connector C2
Table 3. Connector C3
Table 4. Connector C4
Table 5. Connector C5
Table 6. Connector C6
Table 7. Connector C7

Inside this manual

Real pages from this service manual (2,364 pages). Open the sample pages (PDF, 442 KB)

Sample pages from the Hyster A935 (J30-35-40XN) Forklift Service Manual: Troubleshooting, Diagram, Specifications, Color page, Color page
  • Troubleshooting, page 1,105: General Maintenance and Diagnostic Data
  • Diagram, page 1,609: Observed Symptoms
  • Specifications, page 2,005: Battery
  • Color page, page 1,204: Diagnostic Trouble Codes
  • Color page, page 1,868: Observed Symptoms

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 2,364 pages

Quantity one is the manual described above.

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