Hyster J2.0XTLG J2.5XTLG J3.0XTLG J3.5XTLG Europe (A2A6) Service Manual 2025

Data Size: 25.98 MB
File Type: PDF
Language: English
Manufacturer: Hyster
Applicable Machine: Forklift
Document: Service Manual, Electric and Hydraulic Diagrams
Machine Model: Hyster J2.0XTLG J2.5XTLG J3.0XTLG J3.5XTLG Europe (A2A6) Class 1
Latest Publication Date: 2025

List Contents:

4387431 (08-2024) XTLG SERIES 2.0-3.5T COUNTERBALANCED BATTERY FORKLIFT TRUCK.pdf (146 Pages):
Overview
Structure of lithium battery
Specifications of the lithium battery and charger
Storage of lithium batteries
Application of lithium battery
Maintenance of lithium battery
General precautions
Definition of lithium battery profile and interface
Definition of discharge port pin
Definition of charge port pin (115.2V)
Definition of DC input connector pin
Air conditioning/blower pin definitions (153.6V)
Definition of low-voltage connector pin (115.2V)
Definition of communication port pin (153.6V)
Electrical diagram for battery system
Overview
Drive axle
Maintenance of drive axle
Front tire and rim models
Automatic clearance adjustor
Parking brake
Adjustment of brake pedal
Maintenance
Operational test for automatic clearance-adjustor
Troubleshooting of wheel brake
Propel motor
Reducer assembly (115.2V)
Transmission assembly (153.6V)
Model and specifications
Overview
Precautions for safe operation of high-voltage components
The matters needing attention for the maintenance of each high-voltage component
Electric control characteristics of permanent magnet motor
BMS common fault codes (115.2V)
Vehicle identification device (TSG81)
Overview
Check after the steering system is reinstalled
Troubleshooting
Overview
Steering knuckle and steering knuckle kingpin
External preload adjustment of steering wheel bearing
Braking system
Overview
Hydraulic oil tank
Overview
Main oil pump
Multi-way valve
Full hydraulic orbitrol
Speed limit valve
Hydraulic pipeline
Lifting cylinder
Tilting cylinder
Overview
Inner and outer masts
Fork carriage
Adjustment of lifting system
Adjustment of lifting cylinder
Some vulnerable parts
Combination seal ring
Transport
Storage
Pre-use preparation
Operation
Environmental requirements for use
Truck oil
Main load-bearing structural parts diagrams
4387455-8000SRM5039-(09-2024) PERIODIC MAINTENANCE.pdf (26 Pages):
Periodic maintenance
Periodic maintenance requirements
How to put a lift truck on blocks
Periodic Maintenance Items
Replace or repair tires
Periodic Maintenance Tables
Critical safety components for regular replacement
Some wear parts
Combination seal ring
81008842-2200SRM5093-(04-2025) LITHIUM-ION BATTERY.pdf (146 Pages):
Battery Description
Battery Types and Options
Battery Working Environment Temperature
Battery Storage Environment Temperature
Glossary and Abbreviations
Safety
Hazardous Overview
Composition and Ingredient Information
Hazard Identification
Responding to Fires
Accidental Release Measures
Leak Emergency Measures
Handling and Storage
First Aid Measures
Handling and Storage
Exposure Controls and Personal Protection
Physical and Chemical Properties
Stability and Reactivity
Toxicological Information
Ecological information
Toxicological Information
Regulatory Information
Disposal Considerations
Transport Information
Labeling
Key Components
Top Cover Components
Connection Points
Module Connection
Module and BMS Connection
Module Structure
Connection Ports
Charger Specification and Selection
Description of Software Tools for Technicians
Battery Displayer
Charger Displayer
iBMS PC Utility
General
Disconnect MSD
Battery High Voltage Disconnect Verification
Ending Steps
Battery Maintenance
Battery Removal and Installation
Battery Disassembly and Assembly
Module Maintenance
Module Replacement
Module Charging and Discharging
Functional Descriptions
Schematics and Diagrams
Troubleshooting
Standard Torque Chart