Manufacturing / Industrial • Maintenance

2015 HYSTER J35XNT Wheeled Electric Forklift Daily Maintenance Check

The 2015 HYSTER J35XNT Wheeled Electric Forklift Daily Maintenance Check inspects all components of your forklift to ensure that it is kept in quality working condition.

MaintainX

04/26/2021

2015 HYSTER J35XNT Wheeled Electric Forklift Daily Maintenance Check

The 2015 HYSTER J35XNT Wheeled Electric Forklift Daily Maintenance Check inspects all components of your forklift to ensure that it is kept in quality working condition.

Drive Tire and Wheel Assemblies

Tire and Wheel

Inspect the drive tires and wheel assemblies and the steer tire and wheel assemblies for damage.

Look for deep grooves or cuts in the tires.

Remove objects embedded in the tire, such as wire, rocks, glass, and pieces of metal that can cause damage. See Figure 25.

Remove any wire, strapping, or other material that is wrapped around the axle to prevent damage to the transaxle seals.

Inspect wheel rims for rust or cracks and check for loose or missing lug nuts and broken studs. DO NOT operate a lift truck with damage to any wheel rim, lug nuts, or studs.

Figure 25. Tire Check

CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM THE TREAD)
MAKE SMOOTH EDGES

Safety labels are installed on the lift truck to provide information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Check that all safety labels are installed in the correct loca- tions on the lift truck.

Check that the Operating Manual is not worn or damaged and replace it if necessary.

Frames, Covers, and Floor Plates

The overhead guard must be free from defects to ensure protection to the operator.

A variety of covers and floor plates provide protection and allow easy access to systems located inside and around the frame. See Figure 26.

Make certain that all covers and floor plates are present and secured in their proper locations.

Hydraulic System

WARNING: At operating temperature the hydraulic oil is HOT. DO NOT permit the oil to contact the skin and cause a burn.

WARNING: Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

CAUTION: DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed.

Never operate the pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

Some parts of the mast move at different speeds during raising and lowering.

Slowly raise and lower the mast several times without a load.

The mast components must raise and lower smoothly in the correct sequence.

The carriage raises first, then the inner weldment and intermediate weldment (three-stage masts only).

The inner and intermediate weldments and the carriage must lower completely.

Raise the forks 1 m (3 ft) with a capacity load.

The inner weldment and carriage must raise smoothly.

Lower the forks. All moving components must lower smoothly

With the load lowered, tilt the mast backward and forward.

The mast must tilt smoothly and both tilt cylinders must stop evenly.

Check that the controls for the attachment operate the functions of the attachment. See the symbols by each of the controls as shown in Table 4.

Make sure all of the hydraulic lines are connected correctly and do not leak.

Hydraulic Hoses, Hose Fittings, and Clamps

Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments

WARNING :Lower the lift mechanism completely. Never allow any person under a raised carriage.

DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the lift truck motor is OFF.

Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the cap screws and nuts are tight.

Inspect the channels for wear in the areas where the roll- ers travel. Inspect the rollers for wear or damage.

Check mast lubrication. If necessary, lubricate the sliding surfaces and the load roller surfaces along the full length of the channels as shown in Figure 32.

Only apply lubricant to surfaces that are clean and dry.

Only apply lubricant to the darker areas as indicated by (1) and (2) in Figure 32.

Inspect the load backrest extension for cracks and dam- age.

If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for cracks and wear.

Make sure the parts that fasten the side shift carriage or attachment to the carriage are in good condition.

WARNING : Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil.

Thoroughly wash oil from exposed areas of skin as soon as possible.

WARNING :Never check for leaks by putting hands on hydraulic lines or components under pressure.

Hydraulic oil under pressure can be injected into the skin.

Visually inspect hoses/fittings for hydraulic leaks

hose covers for cuts

Adjust
Repair
Replace Hose

cracks

Adjust
Repair
Replace hose

exposed reinforcement

Adjust
Repair
Replace hose

defective/broken clamping devices or sheaves

Adjust
Repair
Replace Hose

proper tracking during operation

Adjust
Repair
Replace Hose

Check that lift chains are correctly lubricated. Use SAE 30W engine oil to lubricate lift chains.

Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must be replaced as a set. See Figure 33.

NOTE: Chain anchor pins MUST be replaced any time chains are replaced.

Inspect the chain anchors and pins for cracks and dam- age.

10. Make sure the lift chains are adjusted so that they have equal tension. Adjustments or replacement of the lift chains must be done by authorized personnel.

Hydraulic Oil

WARNING :At operating temperature the hydraulic oil is HOT. DO NOT permit the oil to contact the skin and cause a burn.

WARNING: Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil.

Thoroughly wash oil from exposed areas of skin as soon as possible.

CAUTION: DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed.

Never operate the pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

Inspect the hydraulic system for leaks and damaged or loose components.

Heavy-duty or high-temperature opera- tions can require more frequent checks.

Hydraulic Oil Standard Truck (Total Capacity)

Change Oil. 22.0 liter (5.8 gal) See NOTE 8.

0 to 48 °C (32 to 118 °F) Hydraulic Oil ISO VG 46.

Hydraulic Oil Cooler/Freezer Truck (Total Capacity)

Change Oil. 22.0 liter (5.8 gal) See NOTE 8.

−29 to 48 °C (−20 to 118 °F) Hydraulic Oil ISO VG 32 - VI ≥ 140 (High Viscosity Index Oil per ISO 11158 L-HV)

Hydraulic Oil Sub-Zero Construction (Total Capacity)

Change Oil. 22.0 liter (5.8 gal) See NOTE 8.

−40 to 22 °C (−40 to 71.6 °F) Hydraulic Oil MIL-H-5606A

Steering Tire and Wheel Assemblies

Tire and Wheel

Inspect the drive tires and wheel assemblies and the steer tire and wheel assemblies for damage.

Look for deep grooves or cuts in the tires.

Remove objects embedded in the tire, such as wire, rocks, glass, and pieces of metal that can cause damage. See Figure 25.

Remove any wire, strapping, or other material that is wrapped around the axle to prevent damage to the transaxle seals.

Inspect wheel rims for rust or cracks and check for loose or missing lug nuts and broken studs.

DO NOT operate a lift truck with damage to any wheel rim, lug nuts, or studs.

Figure 25. Tire Check

CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM THE TREAD)
MAKE SMOOTH EDGES

Battery

WARNING: Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible dam- age or injury.

The acid in the electrolyte can cause injury. If the elec- trolyte is spilled, use water to flush the area.

Make the acid neutral with a solution of sodium bicarbonate (soda). Acid in the eyes must be flushed with water immediately.

Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open flames away from the battery area. DO NOT make a spark from the battery connections.

Disconnect the battery when doing maintenance.

There can be one of two types of batteries. One type has removable cell caps. The other type has sealed cells.

The sealed batteries require a different charger, the electrolyte level or specific gravity cannot be checked and water cannot be added to the electrolyte.

Make sure that the voltage and the weight of the battery are correct as shown on the Nameplate.

See Battery Specifications to check for correct battery dimensions.

Keep the battery case and the area for the battery clean and painted.

Leakage from the battery and corrosion can cause a malfunction in the electric controls of the lift truck.

Use a water and sodium bicarbonate (soda) solution to clean the battery and the battery area.

Keep the top of the battery clean, dry and free of corrosion.

Make sure the battery is charged and has the correct volt- age and ampere hour rating for the lift truck. See the Nameplate.

Inspect the battery case, connector and cables for damage, cracks or breaks.

See the battery dealer in the area to repair any damage

On batteries with cell caps, check the level of the electro- lyte daily on a minimum of one cell.

Add only distilled water, as necessary, to all cells that do not have the correct elec- trolyte level.

The correct level is halfway between the top of the plates and the bottom of the fill hole.

Battery Restraint

Steering System

The steering system should operate when a properly charged battery is connected

an operator is present in the seat, and the key or keyless switch is in the ON position

Move the steering tire and wheel assembly completely to the left by turning the steering wheel.

The assembly should turn smoothly to its stop.

The steering tire should stop approximately parallel to the battery.

Turn the steering tire and wheel assembly completely to its right hand stop using the steering wheel.

The steering system should move smoothly and make a full range of motion from its full left to full right position (approximately 180 degrees).

Automatic Parking Brake

There is an indicator icon on the display panel for the Auto- matic Parking Brake (APB).

The icon is illuminated as described in the Model Description section of this manual.

If the APB is not applied and the operator leaves the seat or turns the key or keyless switch to the OFF position, an alarm will sound for approximately 60 seconds.

This is only on manually applied parking brakes, not the Seat Activated parking brake option.

ALWAYS apply the parking brake when leaving the seat.

Make sure the service brakes operate correctly before checking the operation of the Automatic Parking Brake.

Check the operation of the APB.

The Automatic Parking Brake, when in good condition and correctly adjusted, will hold a lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft)].

If parking brake requires adjustment, notify service personnel.

Service Brake

Loss of fluid from the brake fluid reservoir indicates a leak.

Repair the brake system before using the lift truck.

Replace the brake fluid in the system if there is dirt, water, or oil in the system.

There is an indicator icon on the display panel for the brake fluid level.

The icon is illuminated as described in the Model Description section of this manual.

If the icon is illuminated during operation, the fluid in the reservoir for the brake master cylinder is too low.

Add brake fluid and check for leaks. The reservoir is under the brake pedal and floor plate. See Figure 24.

Clean the area around the fill cap so that no dirt enters the reservoir.

Check the operation of the service brakes. Push on the brake pedal.

The brakes must be applied before the pedal reaches the floor plate.

The brake pedal must stop firmly and must not move slowly down after the brakes are applied.

The brakes must apply equally to both drive wheels with no noticeable pull to either side.

Sliding Surfaces

Use Multipurpose Grease.

Carriage Assembly

Forks

Forks must be removed or installed by trained per- sonnel only.Forks must be removed or installed by trained personnel only.

The identification of a fork describes how the fork is connected to the carriage.

These lift trucks have hook forks.

Fork Tip Alignment

Fork Guides and Pins

WARNING: DO NOT try to move a fork without a lifting device. The forks can weigh 45 to 115 kg (99 to 254 lb).

Move the fork and carriage so that the top fork hook can engage the top carriage bar.

Raise the carriage to move the lower fork hook through the fork removal notch.

Slide the fork on the carriage so that both upper and lower fork hooks engage the carriage.

Engage the lock pin with a notch in the top carriage bar. See Figure 31.

If lift truck id equipped with a fork positioner, install inner fork carriers using four capscrews.

Tighten capscrews to 35 N•m (25 lbf ft). See Figure 27 and Figure 28.

Electric Circuits

Battery Disconnect Switch

Horn

Check the operation of the horn by pressing the horn button on the steering wheel.
The horn will operate when the key or key less switch is in any position.
If lift truck is equipped with E-Hydraulic controls, there is another horn button located on the armrest. See Figure 8, Figure 9, and Table 1.
There is also a handle with a horn button on the right over- head guard leg. See the Model Description section and Table 1.

Lights

Check the strobe light by turning the key or key less switch to the ON position and check the operation of the light.
The strobe light can also be operated with a rocker switch.

Alarms

Check the backup alarm on lift trucks equipped with a MONOTROL® pedal by sitting in the seat, turning the key or key less switch to the ON position, and pressing the reverse arrow on the MONOTROL® pedal.

Seat Switch

Check the seat switch.
Turn the key or key less switch to the OFF position and leave the seat.
Do not apply the parking brake.
If the seat switch is working correctly, an alarm will sound when the operator leaves the seat after turning the lift truck OFF, but does not apply the parking brake.
If lift truck is equipped with the Seat Activated parking brake option, the parking brake will be automatically applied when the operator leaves the seat after turning the lift truck OFF.
The parking brake will release when the operator returns to the seat and the accelerator or MONOTROL® pedal is applied.

Display Pannel

Direction and Speed Control Pedals

Check that the direction and speed control pedals operate as described in the Model Description section of this manual.

Lubricate the MONOTROL® pedal or accelerator pedal joints as needed. See the Maintenance Schedule.

Safety Labels and Operating Manual

Safety labels are installed on the lift truck to provide information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Check that all safety labels are installed in the correct locations on the lift truck. See the Parts Manual or the section Frame 100 SRM 1329 of the Service Manual for the cor- rect locations of the safety labels.

Check that the Operating Manual is not worn or damaged and replace it if necessary.

Steering Column Tilt Memory Lever

1. TILT POSITION LEVER
2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE

Seat Belt and Seat Rails

Operator Presence System Check

Check the operation of the Operator Presence System (OPS).

Turn the lift truck power ON while sitting in the seat.

Once lift truck power is ON, get up off the seat.

If the OPS is working correctly, a switch in the operator's seat willautomatically disable all hydraulic and electrical functions so that the lift truck cannot travel forward or backward when the operator is not on the seat.

If the lift truck can travel forward or backward, or the hydraulic functions oper- ate, when the operator is not on the seat, the OPS system is not working properly.

See the section Electrical System 2200 SRM 1337 to repair or replace the seat switch that makes up the OPS system.

See the Operating Proce- dures section for more information on how the OPS works.

This lift truck may be equipped with an optional operator presence system which will not allow the truck to travel unless the seat belt is fastened.

When equipped, a seat belt interlock includes sequencing/logic for the seat pres- sure switch and seat belt switch.

The weight of the operator must be detected prior to the seat belt switch being engaged to enable operations.

Source: Hyster

Drive Tire and Wheel Assemblies

Tire and Wheel

Inspect the drive tires and wheel assemblies and the steer tire and wheel assemblies for damage.

Look for deep grooves or cuts in the tires.

Remove objects embedded in the tire, such as wire, rocks, glass, and pieces of metal that can cause damage. See Figure 25.

Remove any wire, strapping, or other material that is wrapped around the axle to prevent damage to the transaxle seals.

Inspect wheel rims for rust or cracks and check for loose or missing lug nuts and broken studs. DO NOT operate a lift truck with damage to any wheel rim, lug nuts, or studs.

Figure 25. Tire Check

CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM THE TREAD)

MAKE SMOOTH EDGES

Safety labels are installed on the lift truck to provide information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

Check that all safety labels are installed in the correct loca- tions on the lift truck.

Check that the Operating Manual is not worn or damaged and replace it if necessary.

Check Operation. Repair as Required.

Pedals

Seat Assembly

Hood

Hinges

Hood Latch

Frames, Covers, and Floor Plates

The frame is a single weldment with mounts for the

counterweight

overhead guard

mast

steering system

hydraulic system

trans axles

Check the condition of the

frames

especially around welds

rust

cracks

other damage

The overhead guard must be free from defects to ensure protection to the operator.

A variety of covers and floor plates provide protection and allow easy access to systems located inside and around the frame. See Figure 26.

Make certain that all covers and floor plates are present and secured in their proper locations.

Figure 26. Frame and Covers Check

OVERHEAD GUARD

Floor Plate

Frame

Hood Side Cover

Counter Weight Cover

STEERING COLUMN COVER

Hydraulic System

WARNING: At operating temperature the hydraulic oil is HOT. DO NOT permit the oil to contact the skin and cause a burn.

WARNING: Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil. Thoroughly wash oil from exposed areas of skin as soon as possible.

CAUTION: DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed.

Never operate the pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

Some parts of the mast move at different speeds during raising and lowering.

Slowly raise and lower the mast several times without a load.

The mast components must raise and lower smoothly in the correct sequence.

The carriage raises first, then the inner weldment and intermediate weldment (three-stage masts only).

The inner and intermediate weldments and the carriage must lower completely.

Raise the forks 1 m (3 ft) with a capacity load.

The inner weldment and carriage must raise smoothly.

Lower the forks. All moving components must lower smoothly

With the load lowered, tilt the mast backward and forward.

The mast must tilt smoothly and both tilt cylinders must stop evenly.

Check that the controls for the attachment operate the functions of the attachment. See the symbols by each of the controls as shown in Table 4.

Make sure all of the hydraulic lines are connected correctly and do not leak.

Hydraulic Hoses, Hose Fittings, and Clamps

Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments

WARNING :Lower the lift mechanism completely. Never allow any person under a raised carriage.

DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the lift truck motor is OFF.

Inspect the welds on the mast, cylinders, and carriage for cracks. Make sure that the cap screws and nuts are tight.

Inspect the channels for wear in the areas where the roll- ers travel. Inspect the rollers for wear or damage.

Check mast lubrication. If necessary, lubricate the sliding surfaces and the load roller surfaces along the full length of the channels as shown in Figure 32.

Only apply lubricant to surfaces that are clean and dry.

Only apply lubricant to the darker areas as indicated by (1) and (2) in Figure 32.

Inspect the load backrest extension for cracks and dam- age.

If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for cracks and wear.

Make sure the parts that fasten the side shift carriage or attachment to the carriage are in good condition.

WARNING : Always wear the proper protective equipment including eye protection and petroleum-resistant gloves when handling hydraulic oil.

Thoroughly wash oil from exposed areas of skin as soon as possible.

WARNING :Never check for leaks by putting hands on hydraulic lines or components under pressure.

Hydraulic oil under pressure can be injected into the skin.

Visually inspect hoses/fittings for hydraulic leaks

hose covers for cuts

Adjust

Repair