Hyster E114 (E40ZS) Forklift Service Repair Manual

SERVICE REPAIR E25Z E30Z E35Z E40ZS [E114]

8000 SRM 1113

Counterweights

Wheels and Tires Item

Specification

Torque Value of Drive Wheel Bolts

330 N•m (243 lbf ft)

Torque Value of Steer Wheel Nuts (Pneumatic)

155 N•m (114 lbf ft)

Torque Value of Spindle Nut for Steer Wheels

68 N•m (50 lbf ft), loosen, then 3 N•m (2 lbf ft)

Size of Standard Drive Tires

18 × 5 × 12-1/8*

Size of Optional Drive Tires

18 × 5 × 12-1/8*

Size of Standard Steer Tires

14 × 4-1/2 × 8*

Size of Optional Steer Tires

15 × 5 × 11-1/4*

*Electric Compound Tires are available in smooth or lug tread. Polyurethane and nonmarking compounds are only available on smooth tread. NEVER mix types of tread or tire compound on the same truck.

Counterweights Model

Weight

+30 kg (66 lb) 0 kg (0 lb)

E25Z

337 kg (743 lb)

E1.50XM, (E30Z)

514 kg (1133 lb)

E1.75XM (E35Z)

626 kg (1380 lb)

E2.00XMS (E40ZS)

739 kg (1629 lb)

1

Capacities

8000 SRM 1113

Hydraulic System Table 1. Manual Control Valve Item

Specification

Relief Pressure, Lift System

17.9 ±0.7 MPa (2600 ±100 psi)

Relief Pressure, Tilt System

15.75 ±0.7 MPa (2250 ±100 psi)

Relief Pressure, Auxiliary

15.75 ±0.7 MPa (2250 ±100 psi)

Relief Pressure, Steering System

5709 ±248 kPa (828 ±36 psi)

*Oil temperature 54 to 66 C (130 to 150 F).

Table 2. E-Hydraulic Control Valve Item

Specification

Relief Pressure, Lift System (Primary Relief Valve)

17.9 ±0.7 MPa (2600 ±100 psi)

Relief Pressure, Tilt System and Auxiliary Functions (Secondary Relief Valve)

15.5 ±0.7 MPa (2250 ±100 psi)

Relief Pressure, Steering System

5709 ±248 kPa (828 ±36 psi)

Oil temperature 54 to 66 C (130 to 150 F).

Capacities Item Hydraulic System (Full Mark On Dipstick)*

Specification 11.3 liter (3.0 gal)

Differential/Speed Reducer

2.9 liter (3.1 qt)

Brake Fluid

0.24 liter (0.5 pt)

Hydraulic Pump Capacities** Large Lift Pump Steering Pump

19 cc/rev. (1.16 in 3/rev.)

4.23 cc/rev. (0.26 in 3/rev.)

*Check after all air is removed from the system and with the mast fully lowered. **Oil temperature at 54 to 66 C (130 to 150 F).

2

8000 SRM 1113

Battery Specifications

Battery Specifications Model

Min. Compartment Size Length × Width

Battery Size Minimum/ Maximum* Length

Width

Weight Minimum

E25Z

794 kg (1750 lb)

E1.50XM (E30Z)

839 kg (1850 lb)

E1.75XM (E35Z)

695 × 879 mm (27.4 × 34.6 in.)

784/876 mm (30.9/34.5 in.)

E2.00XM (E40ZS)

E1.50XM (E30Z) E1.75XM (E35Z) E2.00XM (E40ZS)

839 kg (1850 lb) 654/692 mm (25.8/ 27.2 in.)

E25Z

695 × 909 mm (27.4 × 35.8 in.)

784/907 mm (30.9/35.7 in.)

Maximum

839 kg (1850 lb) 794 kg (1750 lb)

1132 kg (2496 lb)

839 kg (1850 lb) 839 kg (1850 lb) 839 kg (1850 lb)

617 mm (24.3 in.) = maximum height for all batteries. This dimension is 31.75 mm (1.25 in.) less with optional battery rollers.

Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column shows the size range that will permit the battery to still fit into a battery compartment.

Battery compartment length is front to back. Width is side to side. The length dimension of the battery must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment front-to-back dimension.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

3

Battery Specifications

8000 SRM 1113

BATTERY HEIGHT SPECIFICATIONS (HOODS AND BATTERY TYPES) Maximum Height - Standard Hood Cell Connectors and Terminals Model

Battery Type

E1.50-1.75XM (E25-35Z), E2.00XMS (E40ZS)

I

E1.50-1.75XM (E25-35Z)), E2.00XMS (E40ZS)

II, III

With Battery Tray*

With Cell Cap**

Electrically Insulated***

Not Electrically Insulated**

594 mm (23.4 in.)

594 mm (23.4 in.)

574 mm (22.6 in.)

NA

NA

NA

607 mm (23.9 in.)

NA = Not Applicable BATTERY TYPES TYPE I - Battery without a cover as part of the battery.

TYPE II - Battery with a cover that is flat and is fastened to case of battery. Cover opens from FRONT OR REAR when installed in lift truck.

TYPE III - Battery with a cover that is flat and is fastened to case of battery. Cover opens from SIDE when installed in lift truck. *Battery Types II and III bottom of battery to highest point (top of cover or top of hinge). **Minimum height below top of battery tray is 4 mm (0.16 in.). ***Minimum height below top of battery tray is 0.5 mm (0.02 in.).

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use only batteries with the correct length shown in the table above. Adjust the spacer plate and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward, backward, or to the side.

4

8000 SRM 1113

Battery Specifications

Maximum Height - Raised Hood Cell Connectors and Terminals Model

Battery Type

E1.50-1.75XM (E25-35Z)), E2.00XMS (E40ZS)

I

E1.50-1.75XM (E25-35Z)), E2.00XMS (E40ZS)

II, III

With Battery Tray*

With Cell Cap**

Electrically Insulated***

Not Electrically Insulated**

625 mm (24.6 in.)

627 mm (24.7 in.)

607 mm (23.9 in.)

NA

NA

NA

640 mm (25.2 in.)

NA = Not Applicable BATTERY TYPES TYPE I - Battery without a cover as part of the battery.

TYPE II - Battery with a cover that is flat and is fastened to case of battery. Cover opens from FRONT OR REAR when installed in lift truck.

TYPE III - Battery with a cover that is flat and is fastened to case of battery. Cover opens from SIDE when installed in lift truck. *Battery Types II and III bottom of battery to highest point (top of cover or top of hinge). **Minimum height below top of battery tray is 4 mm (0.16 in.). ***Minimum height below top of battery tray is 0.5 mm (0.02 in.).

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use only batteries with the correct length shown in the table above. Adjust the spacer plate and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward, backward, or to the side.

5

Mast Speeds

8000 SRM 1113

Maximum Carriage and Tilt Creep Rates Vertical Creep at Carriage

Hydraulic Oil Temperature

Tilt Creep at Cylinder Rod

mm/Min

in./Min

/Min

mm/Min

in./Min

20 C (68 F)

2.2 mm

0.09 in.

0.10

0.63 mm

0.03 in.

30 C (86 F)

3.3 mm

0.13 in.

0.15

0.95 mm

0.04 in.

40 C (104 F)

6.3 mm

0.25 in.

0.29

1.83 mm

0.07 in.

50 C (122 F)

10.0 mm

0.39 in.

0.47

2.97 mm

0.12 in.

60 C (140 F)

14.6 mm

0.57 in.

0.68

4.30 mm

0.17 in.

Mast Speeds E25-35Z, E40ZS MAST SPEEDS (36 AND 48 VOLT) AMERICAS AC or DC Motor and 19 cc (1.16 in. 3 ) Lift Pump* Lifting Model

E25Z

E30Z

Mast

V

Rated Load

Lowering No Load

Rated Load

No Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

TwoStage LFL

36 48

0.396 0.508

78 100

0.544 0.681

107 134

0.508

100

0.472

93

TwoStage FFL

36 48

0.396 0.508

78 100

0.538 0.671

106 132

0.462

91

0.371

73

ThreeStage FFL

36 48

0.386 0.498

76 98

0.518 0.650

102 128

0.478

94

0.411

81

TwoStage LFL

36 48

0.381 0.488

75 96

0.544 0.681

107 134

0.508

100

0.472

93

TwoStage FFL

36 48

0.376 0.483

74 95

0.538 0.671

106 132

0.462

91

0.371

73

ThreeStage FFL

36 48

0.366 0.478

72 94

0.518 0.650

102 128

0.478

94

0.411

81

LFL = Limited Free Lift FFL = Full Free Lift *Oil temperature 54 to 66 C (130 to 150 F). Lifting speeds (valve fully open) ±10% acceptable. No Load lowering speeds are minimum values. Rated Load lowering speeds are maximum values. Load center is 610 mm (24 in.).

6

8000 SRM 1113

Mast Speeds

AC or DC Motor and 19 cc (1.16 in. 3 ) Lift Pump* Lifting Model

E35Z

E40ZS

Mast

V

Rated Load

Lowering No Load

Rated Load

No Load

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

TwoStage LFL

36 48

0.361 0.467

71 92

0.544 0.681

107 134

0.508

100

0.472

93

TwoStage FFL

36 48

0.356 0.467

70 92

0.538 0.671

106 132

0.462

91

0.371

73

ThreeStage FFL

36 48

0.351 0.457

69 90

0.518 0.650

102 128

0.478

94

0.411

81

TwoStage LFL

36 48

0.340 0.447

67 88

0.544 0.681

107 134

0.508

100

0.472

93

TwoStage FFL

36 48

0.335 0.447

66 88

0.538 0.671

106 132

0.462

91

0.371

73

ThreeStage FFL

36 48

0.330 0.437

65 86

0.518 0.650

102 128

0.478

94

0.411

81

LFL = Limited Free Lift FFL = Full Free Lift *Oil temperature 54 to 66 C (130 to 150 F). Lifting speeds (valve fully open) ±10% acceptable. No Load lowering speeds are minimum values. Rated Load lowering speeds are maximum values. Load center is 610 mm (24 in.).

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1600 SRM 720

Description

General This section has the description and repair procedures for the steering housing and the steering control unit.

Additional information on parts of the steering system can be found in the Steering Axle and Hydraulic System service manual sections for your lift truck.

Description The steering column assembly uses a steering control unit with hose connections on the bottom of the unit. The steering housing has mounts for the steering column and the steering control unit. The steering wheel is installed on the steering column. See Figure 1. The housing is adjustable and is held in position by a latch. The position of the housing can be changed for operator comfort. The steering housing is also the mount for control levers and some instrument clusters.

The steering system is a hydraulic system that does not have a mechanical connection between the steering wheel and the steering axle. The control of the steering is through a hydraulic circuit.

If the hydraulic pump for the steering system does not operate, steering is still possible. A check valve permits the steering control unit to control the steering cylinder. The lift truck is difficult to steer when the steering pump is not operating, but the steering control unit can operate the steering cylinder and make steering possible.

NOTE: INSTRUMENT CLUSTER NOT SHOWN. H2.00-3.20XM (H40-65XM) SHOWN. 1. STEERING WHEEL 2. STEERING COLUMN 3. STEERING CONTROL UNIT

4. COLUMN TILT LEVER 5. LATCH 6. COVER 7. COWL 8. MOUNT

Figure 1. Steering Housing Assembly

1

Operation

1600 SRM 720

Operation The steering control unit is a rotary valve operated by the steering wheel. See Figure 2. During the steering operation, the steering control unit controls the direction and amount of oil flow to the steering cylinder. The steering cylinder in the axle actuates the steering linkage to move the steer tires. Hydraulic oil returns from the steering cylinder to the steering control unit and then to the hydraulic tank.

Turning the steering wheel actuates three main parts of the steering control unit: the spool for the control section, the sleeve for the control section, and the rotor in the metering section. When the steering wheel is not moving, the spool and sleeve are held in the NEUTRAL (center) position by springs. During this time, oil flows freely through the steering control unit but none flows to the steering cylinder.

As the steering wheel is turned, the spool just begins to rotate. The springs try to move the sleeve to keep the NEUTRAL position between the spool and sleeve. However, the necessary force to turn the rotor is greater than the pressure of the springs. The springs begin to bend, letting the spool move a small

2

amount within the sleeve. The spool stops moving when it touches the center pin. In this position, the holes in the sleeve and the spool are aligned. Oil coming into the control unit flows to the metering section.

More rotation of the steering wheel causes the spool to rotate the pin. This action causes the rotation of the sleeve and the rotor in the metering section. The oil then flows to one side of the steering cylinder. Oil from the other side of the cylinder returns through the control section of the steering control unit.

When the steering wheel stops moving, the metering action in the metering section also stops. The NEUTRAL position springs return the sleeve to the NEUTRAL position, stopping oil flow to or from the cylinder. The pressure stays in the steering cylinder to keep the steer tires in position. Oil from the pump flows through the steering control unit to the tank or other parts of the system. To return the steer wheels to the straight position, the steering wheel must be rotated in the opposite direction. The steering control unit will operate as described, but all parts will rotate in the opposite direction.

1600 SRM 720

1.

2.

3.

4.

SPRING SET SPOOL SLEEVE CENTER PIN

Operation

5. GEAR SET 6. CONTROL SECTION 7. METERING SECTION Figure 2. Steering Control Unit

3

Steering Wheel and Column Assembly Repair

1600 SRM 720

Steering Wheel and Column Assembly Repair The upper end of the steering shaft has splines for the steering wheel. A large hex nut holds the steering wheel onto the steering column. The horn button is the cover for the center of the steering wheel. The lower end of the steering column has splines or a tang to engage the steering control unit. See Figure 5 and Figure 6.

3. On units with the Direction Control Handle, Remove the direction switch assembly from the housing of the steering column. Make an identification of the electric wires and disconnect them from the direction switch. See Figure 3.

The steering column assembly is adjustable and held in position by a latch. The position of the steering column assembly can be changed as needed for different operator requirements. An access cover on the steering column gives access to the steering control unit, key switch, horn switch, and if installed, the direction switch.

ASSEMBLY COMPONENTS, REMOVE NOTE: This procedure is for the removal of all components of the steering column assembly. All components are not often removed for a repair procedure.

Do only those steps of the procedure necessary to remove the required component. See Figure 5 and Figure 6.

WARNING The hydraulic hoses must be connected to the correct ports or the steering system will not operate as expected, which can cause damage or personal injury. Make sure the hoses are identified and connected correctly.

CAUTION Disconnect the negative battery cable on internal combustion trucks. Disconnect the battery connector on electric trucks. Disconnect the battery before removing any covers.

1. Attach a tag on the battery connector or negative cable stating DO NOT CONNECT BATTERY. Move the steering column to the most FORWARD position. Remove the column tilt lever.

Remove the upper and lower access covers from the steering column.

2. Remove the key switch and static strap from the housing of the steering column. Make an identification of the electric wires and disconnect them from the key switch.

4

NOTE: DIRECTION CONTROL HANDLE ASSEMBLY FOR MODELS J2.00-3.20XM [J40-65Z] (A416/B416), E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114), N30XMH, AND N30XMH 2 (C210), V30ZMD (D210/ E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098), AND E2.00-3.20XM [E45-65Z] (G108) IS SHOWN. OTHER TRUCK DIRECTION CONTROL HANDLE ASSEMBLIES ARE SIMILAR. 1.

2.

3.

4.

DIRECTION SWITCHES SHIFT LEVER ASSEMBLY SCREW ELECTRICAL CONNECTORS

Figure 3. Direction Control Handle Assembly 4. Remove the plastic rivets that fasten the bracket for the horn switch to the housing of the steering column. Move the horn switch and bracket away from the steering column. See Figure 5 and Figure 6.

1600 SRM 720

Steering Wheel and Column Assembly Repair

CAUTION If a puller tool is used to remove steering wheel from steering column, be careful not to damage the horn wires.

5. Remove the horn button assembly and electrical wires. Remove the large hex nut and the steering wheel from the shaft. A puller tool makes removal of the steering wheel easier, but not all steering wheels have puller holes.

6. On lift truck models J2.00-3.20XM (J4060XM 2) (A216), E1.50-1.75XM, E2.00XMS (E25-40XM 2S) (D114), N30XMH, N30XMH2 (C210), and E2.00-3.20XM (E45-65XM 2) (F108) units, remove the optical encoder housing and optical encoder from the steering column. Make an identification of the electrical wires and disconnect them from the assemblies. See Figure 5.

7. On lift truck models J2.00-3.20XM [J4065Z] (A416/B416), E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114), V30ZMD (D210/E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098), and E2.00-3.20XM [E45-65Z] (G108), disconnect the connector. Remove the two capscrews and steering sensor from the steering column. See Figure 6.

8. Make an identification of the hydraulic hoses at the steering control unit so they can be connected correctly during assembly. See Figure 4, Figure 5, Figure 6, and the WARNING in the beginning of this section. Some hydraulic hoses have fittings that will permit disconnection at the steering control unit. Disconnect the other hydraulic hoses at the base of the cowl, the control valve, or the steering pump. Remove all mount clamps so that the hoses will turn freely and not become twisted. Disconnect the hydraulic hoses at the bottom of the steering control unit. Install plugs at all hoses and ports to prevent dirt from entering the steering hydraulic system.

1.

2.

3.

4.

5.

HYDRAULIC HOSE ENDS HOSE PORTS STEERING CONTROL UNIT SCREWS HORN SWITCH Figure 4. Hydraulic Hose Connections

9. If your model of lift truck has an instrument cluster that wraps around the steering column, remove the instrument cluster.

The removal procedures for the instrument cluster can be found in the service manual sections Instrument Cluster 2200 SRM 514 for models H2.00-3.20XM (H40-65XM) (H177), S1.50-1.75XM, S2.00XMS (S25-40XM) (D010) and H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS) (E001), or Electrical System, Replacement, Checks, and Adjustments Trucks with EV-100/200ZX or SR (SEM) and SP Motor Controllers 2200 SRM 560 for models E1.50-1.75XM (E25-35XM 2) (D114), E2.00XMS (E40XM 2S), E2.00-3.20XM (E45-65XM 2) (F108), and J2.00-3.20XM (J40-60XM 2) (A216).

10. If there is a instrument cluster on the steering column housing, disconnect all plugs connected to the display panel.

5

Steering Wheel and Column Assembly Repair

1600 SRM 720

Figure 5. Steering Column Assembly, For Models J2.00-3.20XM (J40-60XM 2) (A216), E1.50-1.75XM, E2.00XMS (E25-40XM 2S,(D114), N30XMH, N30XMH 2 (C210), and E2.00-3.20XM (E45-65XM 2) (F108)

6

1600 SRM 720

Steering Wheel and Column Assembly Repair Legend for Figure 5

NOTE: * NOT INCLUDED ON LIFT TRUCK MODELS H2.00-3.20XM (H40-65XM) (H177), S1.50-1.75XM, S2.00XMS (S25-40XM) (D010), AND H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS (E001) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

ON-DEMAND STEERING COMPONENTS UPPER ACCESS COVER BRACKET PIVOT (STEERING) SHAFT PLATE LOCKWASHER CAPSCREW LOCK NUT SCREW STATIC GROUND PATCH LOWER ACCESS COVER COLUMN TILT LEVER PUSH ROD LATCH SPRING WASHER COTTER PIN

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

PIN STEERING CONTROL UNIT PLUG (WITHOUT TURN SIGNAL) OPTICAL ENCODER HOUSING* GEAR* OPTICAL ENCODER* HORN BUTTON ASSEMBLY STEERING WHEEL STEERING COLUMN RETURN SPRING LARGE HEX NUT INPUT RIGHT TURN LEFT TURN RETURN PLASTIC RIVET

11. Remove the tilt stop screw located at the bottom left side of the steering column bracket.

4. Remove the cardan shaft from the spool assembly.

12. Remove the capscrews, lockwashers, and lock plates that fasten the steering column to the pivots on the lift truck. Remove the steering column from the lift truck. Make sure the electric wires and the hydraulic hoses are not damaged as the steering column is removed.

5. Remove the check ball, ball stop, and emergency steering ball from the pump housing.

13. Remove the four capscrews that hold the steering column to the bracket. Remove the four capscrews or nuts that fasten the steering control unit to the steering column.

STEERING CONTROL UNIT, DISASSEMBLE 1. Place the steering pump into a soft jaw vise with the splined shaft facing down.

2. Remove the hydraulic fittings and the special screws, and rotate the steering pump 90 degrees sideways in the vise. Discard the O-rings. See Figure 7.

3. Remove the end cover, spacer, gear housing, and gear from the steering pump. Discard the O-rings.

6. Remove the spool assembly from the pump housing.

NOTE: To help with installation of the thrust bearing assembly, note the positions of the thrust washers on either side of the thrust bearing while performing Step 7.

7. Remove the thrust bearing assembly from the shaft end of the spool assembly.

8. Remove the retaining ring from the spool assembly.

9. Press the cross pin out of the spool assembly.

10. Press the spool from the sleeve and remove the springs from the spool. Press the spool from the sleeve and remove the springs from the spool.

11. Remove the shaft seals from the pump housing.

Discard the seals.

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