Subido por Felipe Rodriguez

MANUAL MONTACARGAS HYSTER

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E25-40XMS, E25-40XMS 2 [D114],
E45-65XM, E45-65XM 2 [F108],
J40-65XM, J40-65XM 2 [A216]
PART NO. 897577
8000 SRM 552
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Periodic Maintenance
Table of Contents
TABLE OF CONTENTS
General .................................................................................................................................................................
Serial Number Data ........................................................................................................................................
How to Move Disabled Lift Truck ...................................................................................................................
How to Tow Lift Truck.................................................................................................................................
How to Put Lift Truck on Blocks.....................................................................................................................
How to Raise Drive Tires ............................................................................................................................
How to Raise Steering Tires .......................................................................................................................
Maintenance Schedule.........................................................................................................................................
Maintenance Procedures Every 8 Hours or Daily..............................................................................................
How to Make Checks with Key OFF ..............................................................................................................
Tires and Wheels .........................................................................................................................................
Forks ............................................................................................................................................................
Adjust.......................................................................................................................................................
Remove ....................................................................................................................................................
Install.....................................................................................................................................................
Forks, Mast, and Lift Chains, Inspect .....................................................................................................
Safety Labels .............................................................................................................................................
Steering Column Latch .............................................................................................................................
Operator Restraint System.......................................................................................................................
Battery Restraint System E25-65XM and E25-65XM 2 ...........................................................................
Battery Restraint System J40-65XM and J40-65XM 2 ............................................................................
Battery .......................................................................................................................................................
Hydraulic System ......................................................................................................................................
How to Make Checks with Key ON ..............................................................................................................
Gauges, Horn, and Fuses ..........................................................................................................................
Steering System ........................................................................................................................................
Service Brakes ...........................................................................................................................................
Parking Brake ...........................................................................................................................................
Control Levers and Pedals........................................................................................................................
Direction and Speed Control Pedals.........................................................................................................
Lift System Operation...............................................................................................................................
Maintenance Procedures Every 250 Hours or Six Weeks................................................................................
Steering Tie Rods...........................................................................................................................................
Maintenance Procedures Every 500 Hours or Three Months .........................................................................
Hydraulic Tank Breather ..............................................................................................................................
Differential and Speed Reducer ....................................................................................................................
Wheel Nut Torques ........................................................................................................................................
Steering Axle Spindles ..................................................................................................................................
Steering Tie Rods...........................................................................................................................................
Mast................................................................................................................................................................
Lift Chains .....................................................................................................................................................
Wear Check................................................................................................................................................
Forks...............................................................................................................................................................
Brake Fluid ....................................................................................................................................................
Other Lubrication ..........................................................................................................................................
Seat Brake (E25-65XM and E25-65XM 2 Only)............................................................................................
Electrical Inspection......................................................................................................................................
Contactors..................................................................................................................................................
Motor Brushes ...........................................................................................................................................
Motor Brushes, General............................................................................................................................
Maintenance Procedures Every 1000 Hours or Six Months............................................................................
Copyright © HYSTER COMPANY 2001
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i
Table of Contents
Periodic Maintenance
TABLE OF CONTENTS (Continued)
Lift Chains .....................................................................................................................................................
Forks...............................................................................................................................................................
Check Upper and Lower Bearings, Integral Sideshift Carriage.................................................................
Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................
Hydraulic System ..........................................................................................................................................
Change Filter for Hydraulic Oil ...............................................................................................................
Change Hydraulic Oil ...............................................................................................................................
Differential and Speed Reducer ....................................................................................................................
Service Brakes ...............................................................................................................................................
Contactors ......................................................................................................................................................
Wheel Bearings..............................................................................................................................................
Steer Wheels, Lubrication ........................................................................................................................
Drive Wheels, Lubrication ........................................................................................................................
Lift Chains .....................................................................................................................................................
Replace Upper and Lower Bearings, Integral Sideshift Carriage ..............................................................
Steering Axle..................................................................................................................................................
King Pins and Rod Ends (Steering Cylinders).........................................................................................
Other Lubrication ..........................................................................................................................................
Battery Maintenance .........................................................................................................................................
How to Charge Battery..................................................................................................................................
How to Change Battery .................................................................................................................................
General.......................................................................................................................................................
Change E25-65XM and E25-65XM 2 Battery ...........................................................................................
Change J40-65XM and J40-65XM 2 Battery ............................................................................................
Lift and Tilt System Leak Check ......................................................................................................................
Lift Cylinders Leak Check ............................................................................................................................
Tilt Cylinders Leak Check ............................................................................................................................
Safety Procedures When Working Near Mast..................................................................................................
Lift Chain Adjustments .....................................................................................................................................
PMT Circuit Check ............................................................................................................................................
Welding Repairs .................................................................................................................................................
Overhead Guard Changes .................................................................................................................................
Wheels and Tire Maintenance...........................................................................................................................
Tires and Wheels E25-65XM and E25-65XM 2 .............................................................................................
Remove Wheels from Lift Truck ...............................................................................................................
Remove and Install Tire on Wheel ...........................................................................................................
Pneumatic Tires and Wheels J40-65XM and J40-65XM 2 ...........................................................................
Remove Wheels from Lift Truck ...............................................................................................................
Remove Wheel from Pneumatic Tire........................................................................................................
Install Wheel in Pneumatic Tire ..............................................................................................................
Install Three- or Four-Piece Wheel in Pneumatic Tire ...........................................................................
Add Air to Tires .........................................................................................................................................
Wheels, Install...........................................................................................................................................
Solid Rubber Tires on Pneumatic Wheels ....................................................................................................
Remove Wheels from Lift Truck ...............................................................................................................
Remove Solid Rubber Tire from Pneumatic Wheel .................................................................................
Install Solid Rubber Tire on Pneumatic Wheel .......................................................................................
Wheels, Install...........................................................................................................................................
Adhesives and Sealants .....................................................................................................................................
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HYSTER COMPANY 2001
Periodic Maintenance
Table of Contents
TABLE OF CONTENTS (Continued)
This section is for the following models:
E25-40XMS, E25-40XMS 2 [D114],
E45-65XM, E45-65XM 2 [F108],
J40-65XM, J40-65XM 2 [A216]
Copyright © HYSTER COMPANY 2001
iii
8000 SRM 552
General
General
On lift trucks before XM 2 when turning the key
switch to the ON position the Brush Wear Indicator
and Motor Temperature Indicator will illuminate.
On XM 2 lift trucks, there is no brush wear indicator,
but the LCD screen will show a status code indicating that the brushes need replacing as described in
the Operating Manual. Contact your dealer if any
LED Indicators do not illuminate during the "check"
part of initial lift truck operation.
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection.
The Maintenance Schedule has time intervals for inspection, lubrication and maintenance. The time intervals are based on a normal operation. A normal
operation is considered to be one eight hour shift per
day in a relatively clean environment on an improved
surface. Multiple shifts, dirty operating conditions,
etc., will require a reduction in the recommended
time periods in the Maintenance Schedule.
Your dealer for Hyster lift trucks has the equipment
and trained service personnel to do a complete program of inspection, lubrication and maintenance. A
regular program of inspection, lubrication and maintenance will help your lift truck give more efficient
performance and operate for a longer period of time.
WARNING
Do not make repairs or adjustments unless you
have both authorization and training. Repairs
and adjustments that are not correct can make
a dangerous operating condition.
Do not operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair is necessary, put a "DO NOT OPERATE" tag
in the operator’s area. Remove the key from
the key switch. Disconnect the battery connector.
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
Disposal of batteries must meet local environmental regulations.
Some users have service personnel and equipment
to do the inspection, lubrication and maintenance
shown in the Maintenance Schedule. Service Manuals are available from your dealer for Hyster lift
trucks to help users who do their own maintenance.
SERIAL NUMBER DATA
The serial number code for the lift truck is on the
nameplate. The code is also stamped on top of the
rear bulkhead of the frame. It is on the bulkhead
inside the right rear leg of the overhead guard.
HOW TO MOVE DISABLED LIFT TRUCK
How to Tow Lift Truck
WARNING
Use extra caution when towing a lift truck if
any of the following conditions exist:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
• The lift truck must be moved on a steep
grade.
If the steering pump motor does not operate,
steering control of the lift truck can be slow
and difficult. Do NOT tow the lift truck if there
is no power. Poor traction can cause the disabled lift truck or towing vehicle to slide. Steep
grades will require additional brake force to
stop the lift truck.
Never carry a disabled lift truck unless the lift
truck MUST be moved and cannot be towed.
The lift truck used to carry the disabled lift
truck MUST have a rated capacity equal to
or greater than the weight of the disabled
lift truck. The capacity must be for a load
center equal to half the width of the disabled
lift truck. See the nameplate of the disabled
lift truck for the approximate total weight.
The forks must extend the full width of the
disabled lift truck. Put the weight center of
the disabled lift truck on the load center of the
forks. Do not damage the under side of the lift
truck.
1. The towed lift truck must have an operator.
2. Raise the carriage and forks approximately
300 mm (12 in.) from the surface. Install a chain
1
General
8000 SRM 552
to prevent the carriage and mast channels from
moving.
3. Tow with another lift truck of equal or greater capacity than the disabled lift truck. Install a load
of approximately half-capacity on the forks of the
lift truck that is being used to tow the disabled
lift truck. The half-capacity load will increase the
traction of the lift truck. Keep the load as low as
possible.
4. Use a towing link made of steel that fastens to
the tow pins in the counterweights of both lift
trucks.
5. Release the parking brake.
6. Tow the lift truck slowly.
HOW TO PUT LIFT TRUCK ON BLOCKS
a. Before removing the mast and drive axle,
put blocks under the counterweight so that
the lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the mast assembly so that the
lift truck cannot fall forward.
The surface must be solid, even and level when
the lift truck is put on blocks. Make sure that
any blocks used to support the lift truck are
solid, one piece units.
NOTE: Some lift trucks have lifting eyes. These lift
points can be used to raise the lift truck so that blocks
can be installed.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck. See Figure 1.
2. Put the mast in a vertical position. Put a block
under each outer mast channel.
How to Raise Drive Tires
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, battery or counterweight. When the lift
truck is put on blocks, put additional blocks in
the following positions to maintain stability:
3. Tilt the mast fully forward until the drive tires
are raised from the surface.
4. Put additional blocks under the frame behind the
drive tires.
NOTE: E45-65XM, E45-65XM 2 SHOWN. OTHERS SIMILAR.
1. DRIVE TIRES
2. STEERING TIRES
Figure 1. Put Lift Trucks on Blocks
2
8000 SRM 552
Maintenance Schedule
5. If the hydraulic system will not operate, use a
hydraulic jack under the side of the frame near
the front. Make sure that the jack has a capacity
equal to at least half the weight of the lift truck.
See the nameplate.
How to Raise Steering Tires
2. Use a hydraulic jack to raise the steering tires.
Make sure that the jack has a capacity of at least
2/3 of the total weight of the lift truck as shown
on the nameplate.
3. Put the jack under the steering axle or frame to
raise the lift truck. Put blocks under the frame
to support the lift truck.
1. Apply the parking brake. Put blocks on both
sides (front and back) of the drive tires to prevent movement of the lift truck. See Figure 1.
Maintenance Schedule
The MAINTENANCE SCHEDULE has two time
periods. If the lift truck is operated less than eight
hours each day, do maintenance at the 1 DAY, 6
WEEKS, 3 MONTHS, 6 MONTHS, and 1 YEAR
periods. If the lift truck is operated more than
eight hours each day, do maintenance at the periods
shown in hours (8, 250, 500, 1000, 2000). The
approximate locations of the items indicated in
the MAINTENANCE SCHEDULE are shown in
Figure 2, Figure 3, and Figure 4.
The MAINTENANCE SCHEDULE has the maximum service intervals for average conditions.
Inspect and lubricate more frequently if the lift
truck operates in dirty or difficult conditions.
Figure 2. E25-40XM, E25-40XM 2 Maintenance Points
3
Maintenance Schedule
8000 SRM 552
Figure 3. E45-65XM, E45-65XM 2 Maintenance Points
NOTE: *TOP OF COUNTERWEIGHT.
Figure 4. J40-60XM, J40-60XM 2 Maintenance Points
4
8000 SRM 552
Maintenance Schedule
Table 1. Maintenance Schedule
Item
No.
Item
Oil Leaks
8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ Procedure or
1 day 6 wks. 3 mo.
6 mo.
1 yr.
Quantity
X
Check for leaks
Specification
1 Tires
13 Forks
12 Mast and Carriage
X
X
Check operation
Safety Labels
X
Replace as
See Parts Manual
necessary
Check operation
Multipurpose
Lubricate as
Grease
necessary
See NOTE 2
Check operation
17 Direction and Speed
Control
Steering
4
7
X
Check condition
X
Check condition
X
X
Gauges, Horn, Lights, X
Reverse Alarm and
Fuses
Battery
X
Hood Latch or Battery X
Restraint
Seat Belt and Seat
X
Rails
CIL
Hydraulic Oil
("FULL" mark)
X
E25-40XM,
E25-40XM 2
X
E45-65XM,
E45-65XM 2
X
J40-60XM,
J40-60XM 2
Parking Brake
X
CIL
Check operation
Check condition
Check operation
Check condition
C
19 liter (20 qt)
C
23 liter (24 qt)
C
27 liter (29 qt)
Check operation
L
11 Lift Chains
X
L
X
15 Fork Pins And Guides
18 Hydraulic Filter
See NOTE 1
L
L
C
−180 to 38 C (0
to 100 F)
SAE 10W API
SC/CC
Silicone Spray
Hyster P/N 328388
Lubricate
linkage
Check condition 30W Motor oil
and lubrication or Hyster Chain
Check
and Cable
adjustment and Lubricant (P/N
length
171350)
As necessary
Motor oil
1
See Parts Manual
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
NOTE 1: Equalization charge is required approximately each month.
NOTE 2: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 3: Lubricate lower spindle bearings at 250 hours and upper bearings during assembly.
NOTE 4: Replace the contacts in the hydraulic pump contactor every 1000 hours of operation. Replace the other
contacts in the contactors when the thickness is 30% of a new contact. See the Service Manual for detailed
information.
NOTE: Never use steam to clean electrical parts.
5
Maintenance Schedule
8000 SRM 552
Table 1. Maintenance Schedule (Continued)
Item
Item
No.
3 Motor Brushes
6 Service Brakes
8
Brake Fluid
Seat Brake and
Parking Brake
Adjustment
16 Wheel Nut Torque
E25-40XM,
E25-40XM 2
Drive Wheels
(Wheel Bolts)
Steer Wheels
(Whl. Nuts Pneu.)
Steer Wheel Castle
Nuts (Cushion)
E45-65XM, E4565XM 2 J40-60XM,
J40-60XM 2
Drive Wheels
(Wheel Nuts)
Steer Wheels
(J40-60XM 2)
19 Steering Axle
Rod Ends (Steering
Cyl.)
King Pins
8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ Procedure or
Specification
1 day 6 wks. 3 mo.
6 mo.
1 yr.
Quantity
CIL
X
Check condition See Parts Manual
X
CIL
CIL
X
X
Check operation See Parts Manual
Check condition
0.24 liter (0.5 pt)
SAE J-1703
X
Adjust as
necessary
X
Check torque
Must hold a load
on a 15% grade
332 N•m
(245 lbf ft)
Check torque
156 N•m
(115 lbf ft)
Check grease
Multipurpose
and tighten to
Grease
correct torque
See NOTE 2
68 N•m (50 lbf ft)
Initial
3 N•m (2 lbf ft)
Final
X
X
X
237 to 305 N•m
(175 to 225 lbf ft)
237 to 305 N•m
Check torque
(175 to 225 lbf ft)
Check operation
Lubricate as
2 Fittings
required
2 Fittings
Multipurpose
See NOTE 3
grease
See NOTE 2
Check torque
X
L
L
Tie Rods
L
E25-40XMS
6 Fittings
L
J40-65XM
6 Fittings
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
NOTE 1: Equalization charge is required approximately each month.
NOTE 2: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 3: Lubricate lower spindle bearings at 250 hours and upper bearings during assembly.
NOTE 4: Replace the contacts in the hydraulic pump contactor every 1000 hours of operation. Replace the other
contacts in the contactors when the thickness is 30% of a new contact. See the Service Manual for detailed
information.
NOTE: Never use steam to clean electrical parts.
6
8000 SRM 552
Maintenance Schedule
Table 1. Maintenance Schedule (Continued)
Item
Item
8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ Procedure or
Specification
No.
1 day 6 wks. 3 mo.
6 mo.
1 yr.
Quantity
10 Mast
Check condition
See NOTE 2
9
L
Pivots
2 Fittings
Multipurpose
10
L
Sliding Surfaces
As required
grease
12
L
Sideshift Carriage
4 Fittings
12
X
C
Integral Sideshift
Check wear
2.5 mm (3/32 in.)
Carriage
or less
(Upper/Lower
4 Bearings
Bearings)
20 Contactors
X
C
Check condition See Parts Manual
See NOTE 4
Hinges, Levers,
L
L
As required
Multipurpose
Linkage, Pedals Seat
grease
Rails
See NOTE 2
or Silicone Spray
Hyster P/N 328388
14 Differential/Speed
Ultr Gear Lube
Reducer
SAE 80W or Gear
X
C
2.9 liter (3.1 qt) Oil SAE 80W-90
E25-40XM,
E25-40XM 2
(Chevron) or
X
C
4.2 liter (4.4 qt)
equivalent
E45-65XM,
E45-65XM 2
X
C
3.7 liter (3.9 qt)
J40-60XM,
J40-60XM 2
5 Hydraulic Tank
X
C
Clean or replace See Parts Manual
Breather
2 Wheel Bearings
L
As necessary
Multipurpose
grease
See NOTE 2
Seat Plate And Seat
L
Use Silicon Spray
Brake Pivots
Hyster P/N 328388
Brake Linkage And
L
Multipurpose
Shaft
grease
See NOTE 2
Hoist And Tilt
X
Lubricate as Use Silicon Spray
Controls
necessary
Hyster P/N 328388
Steering Column Tilt
X
Lubricate as Use Silicon Spray
Mechanism
necessary
Hyster P/N 328388
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
NOTE 1: Equalization charge is required approximately each month.
NOTE 2: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 3: Lubricate lower spindle bearings at 250 hours and upper bearings during assembly.
NOTE 4: Replace the contacts in the hydraulic pump contactor every 1000 hours of operation. Replace the other
contacts in the contactors when the thickness is 30% of a new contact. See the Service Manual for detailed
information.
NOTE: Never use steam to clean electrical parts.
7
Maintenance Procedures Every 8 Hours or Daily
8000 SRM 552
Maintenance Procedures Every 8 Hours or Daily
HOW TO MAKE CHECKS WITH KEY OFF
Tires and Wheels
WARNING
Air pressure in pneumatic tires can cause tire
and wheel parts to explode. The explosion of
wheel parts can cause serious injury or death.
Remove all of the air from the tires before the
tires are removed from the lift truck.
If the air pressure is less than 80% of the correct air pressure, the tire must be removed before air is added. Put the tire in a safety cage
when adding air pressure to the tire. Follow
the procedures described in Add Air to Tires.
When air is added to the tires, use a remote air
chuck. The person adding air must stand to the
side of the safety cage and not in front of it.
Inspect the tires for wire, rocks, glass, pieces of
metal, holes, cuts and other damage. See Figure 5.
Remove any object that will cause damage. Check
for loose or missing hardware. Remove any wire
strapping or other material that is wrapped around
the axle.
Make sure the wheel bolts or nuts are tight. Tighten
the wheel bolts or nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule table.
If the lift truck has pneumatic tire, keep the tires at
the correct air pressure. See the Nameplate. Check
the air pressure with a gauge when the tires are cold.
If it is necessary to add air to a tire that is warm,
check one of the other tires on the same axle and add
air to the tire that has low pressure so that the air
pressures are equal. The air pressure of the warm
tires must always be equal to or greater than the
specification for air pressure for cold tires. Check
pneumatic wheels for bent or damaged rims. Check
for loose or missing parts.
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 5. Tires Check
CAUTION
Check all wheel bolts or nuts after 2 to 5 hours
of operation: when new lift trucks begin operation and on all lift trucks when the wheels
have been removed and installed. Tighten the
bolts or nuts in a cross pattern to the correct
8
torque value shown in the Maintenance Schedule. When the bolts or nuts stay tight for eight
hours, the interval for checking the torque can
be extended to 500hours.
Tighten the castle nuts of the steer wheel spindles
of these units to 68 N•m (50 lbf ft) while rotating the
wheel in each direction at EACH installation. Loosen
the nuts 1/4 turn. Pull and push at top of wheel to
8000 SRM 552
Maintenance Procedures Every 8 Hours or Daily
check for movement (end play). If there is movement,
tighten the castle nuts to 3 N•m (2 lbf ft). Install
the cotter pins at the nearest alignment positions.
Install the hub cap. Additional torque checks are not
required.
Forks
The identification of a fork is determined by how it
is connected to the carriage. These lift trucks have
hook forks.
Adjust
Hook forks are connected to the carriage by hooks
and lock pins. See Figure 6. These lock pins are installed through the top fork hooks and fit into slots
in the top carriage bar. Adjust the forks as far apart
as possible for maximum support of the load. Raise
the lock pin in each fork to slide the fork on the carriage bar. Make sure the lock pin is engaged in the
carriage bar to lock the fork in position after making
adjustments.
4. LOCK PIN ASSEMBLY
5. CARRIAGE
1. FORK REMOVAL NOTCH
2. FORK
3. HOOK
Figure 6. Hook Fork
Remove
WARNING
Do not try to lift a fork without a lifting device.
The forks can weigh up to 400 lb each.
Slide a hook fork to the fork removal notch on the
carriage. See Figure 6 and Figure 7. Lower the fork
onto blocks so that the bottom hook of the fork moves
through the fork removal notch. Lower the carriage
further so that the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away
from the fork, or use a lifting device to move the fork
away from the carriage.
1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS
Figure 7. Hook Fork Removal
9
Maintenance Procedures Every 8 Hours or Daily
8000 SRM 552
Install
Move the fork and carriage so that the top hook on
the fork can engage the top carriage bar. Raise the
carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so that
both upper and lower hooks engage the carriage. Engage the lock pin with a notch in the top carriage bar.
Forks, Mast, and Lift Chains, Inspect
WARNING
NEVER work under a raised carriage or forks.
Lower the carriage or use chains on the mast
weldments and carriage so that they cannot
move. Make sure the moving parts are attached to a part that does not move.
Do not try to correct fork tip alignment by
bending the forks or adding shims. Replace
bent forks.
Never repair damaged forks by heating or
welding. Forks are made of special steel using
special procedures. Replace damaged forks.
1. Inspect the welds on the mast and carriage for
cracks. Make sure that the nuts and bolts are
tight.
2. Inspect the channel for excessive wear in the areas of roller contact. Check the rollers for wear
or damage.
3. Inspect the load backrest extension for cracks
and damage.
4. Inspect the forks for cracks and wear. Check that
the fork tips are aligned as shown in Figure 8.
Check that the bottom of the fork is not worn.
Fork Tip Alignment
Length of Forks
3% Dimension
915 mm (36 in.)
1220 mm (48 in.)
1830 mm (72 in.)
27 mm (1.10 in.)
37 mm (1.45 in.)
55 mm (2.15 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF DIMENSION
"X")
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93
Figure 8. Forks Check
5. Replace any damaged or broken parts that are
used to keep the forks locked in position.
6. Inspect the lift chains for the correct lubrication.
Use engine oil or Hyster Chain and Cable Lubricant available from your dealer for Hyster lift
trucks.
7. Inspect the lift chains for cracks or broken links
and pins. See Figure 9.
8. Inspect the chain anchors and pins for cracks and
damage.
10
9. Inspect the chain anchors and pins for cracks and
damage.
10. Make sure the lift chains are adjusted so that
they have equal tension. If the chains need repair or adjustment, it must be done by authorized
personnel. See Lift Chain Adjustments.
8000 SRM 552
Maintenance Procedures Every 8 Hours or Daily
the operator and battery restraint systems on the
E25-65XM, E25-65XM 2 models. The control lever assembly and latch are also part of the J40-65XM, J4065XM 2 operator restraint system. Each item must
be checked to make sure it is attached securely, functions correctly and is in good condition.
The seat belt must latch securely. Make sure the seat
belt extends and retracts smoothly and is not damaged nor torn. If the seat belt cannot be pulled from
the belt housing, the seat belt assembly must be replaced. Keep the belt straight so that it pulls out and
retracts smoothly.
Make sure the seat rails are not loose. The seat rails
must lock securely in position, but move freely when
unlocked. The seat rails must be securely attached
to the mounting surface.
1. WORN PIN
2. CRACKS
3. EDGE WEAR
(MAXIMUM 5% OF
NEW)
4.
5.
6.
7.
HOLE WEAR
LOOSE LEAVES
DAMAGED PIN
CORROSION
Figure 9. Lift Chains Check
Safety Labels
WARNING
Safety labels are installed on the lift truck to
give 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 Frame section of the Service Manual for
the correct locations of the safety labels.
Steering Column Latch
Make sure the latch for the steering column operates
correctly. The latch must NOT allow the column to
move unless the latch is released.
Operator Restraint System
There is an indicator light on the display panel for
the seat belt. The red light is ON as described in the
Operating Manual. The light can help the operator
remember to fasten the seat belt.
The seat belt, hip restraint brackets and the seat and
mounting are the parts of the operator restraint system. See Figure 10. The hood latch is also part of
1. HIP RESTRAINT
BRACKETS
2. SEAT BELT
3. HOOD LATCH
Figure 10. Operator Restraint System
Battery Restraint System E25-65XM and
E25-65XM 2
WARNING
The hood and battery restraint with its latch
mechanisms must operate correctly before a
lift truck is operated.
The battery restraint and hood frame is a heavy steel
weldment that has a hinge at the front of the battery
compartment. An adjustable spacer plate is used
inside the battery compartment to prevent forward
and backward movement of the battery. Side spacers
prevent side-to-side movement of the battery of E2535XM, E40XM, E25-35XM 2, and E40XMS 2 models.
11
Maintenance Procedures Every 8 Hours or Daily
The batteries of E45-65XM 2 models must fit the battery compartment width with a maximum of 13 mm
(0.5 in.) clearance. Maximum movement allowed is
13 mm (0.5 in.) in any horizontal direction.
The hood must be locked in the down position during
operation. The battery must have the front spacer
plate and side spacers correctly adjusted to prevent
any horizontal movement of more than 13 mm
(0.5 in.). If the unit has a seat brake, raise the seat
and seat plate assembly. Use the latch handle at
the rear of the hood to release the hood frame and
battery restraint. See Figure 11. Raise the latch
handle and slide the handle toward the right side
of the truck. A spring moves the handle back to the
1.
2.
3.
4.
5.
6.
HOOD
SEAT
LATCH ASSEMBLY
BATTERY RESTRAINT AND HOOD FRAME
GAS SPRING
HINGE
8000 SRM 552
left. Use the lift handle by the seat to raise the hood.
A gas spring and stop rod will hold the assembly in
the up position. Make sure that the battery cannot
move more than a total of 13 mm (0.5 in.) in any one
horizontal direction. Release the stop rod by moving
it to the right before lowering hood. See the label
in Figure 11. Make sure the latch handle is fully
to the right when closing the hood so that the latch
can engage the latch piece. Make sure the hood is
locked securely. Try to raise the hood using only the
lift handle to make sure the hood is latched and will
not move.
If necessary, adjust the front and side spacer plates
for the battery as shown in Figure 37.
7.
8.
9.
10.
11.
12.
STOP ROD
RELEASE LABEL FOR STOP ROD
COUNTERWEIGHT
LATCH HANDLE
LIFT HANDLE
BATTERY RESTRAINT WARNING LABEL
Figure 11. Battery Restraint E25-65XM and E25-65XM 2
Battery Restraint System J40-65XM and
J40-65XM 2
must fit the battery compartment width with a maximum of 13 mm (0.5 in.) clearance.
The battery restraint is a heavy steel rod at the rear
of the battery compartment. See Figure 12. An adjustable spacer plate is used inside the battery compartment to prevent forward and backward movement of the battery. The batteries for these lift trucks
The hood cannot be closed unless the battery restraint is engaged. The battery restraint rod at the
top rear of the battery compartment must be aligned
over the edge of the battery. The handle of the
battery restraint must also be in the down position
to close the hood. Use the handle to move the battery
12
8000 SRM 552
Maintenance Procedures Every 8 Hours or Daily
restraint rod over the edge of the battery so that the
handle can be moved to the down position.
can cause personal injury when the battery is
connected.
Never put tools or other metal on the battery.
Metal on the battery can cause a short circuit
and possible damage or injury.
The acid in the electrolyte can cause injury. If
the electrolyte 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.
Make sure that the voltage and the weight of the battery are correct as shown on the nameplate.
A. RETRACTED
B. EXTENDED
1. BATTERY
RESTRAINT
WARNING LABEL
2. HOOD
3. BATTERY
RESTRAINT
4. BATTERY
Figure 12. Battery Restraint J40-65XM and
J40-65XM 2
Battery
NOTE: 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.
WARNING
On lift trucks other than the "XM 2" were operated with a low battery, inspect all contactors for welded contacts BEFORE you connect
a charged battery, The lift truck cannot be controlled if contacts are welded. This condition
Keep the battery case, top cover 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
voltage 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
electrolyte daily on a minimum of one cell. Add only
distilled water, as necessary, to all cells that do not
have the correct electrolyte level. The correct level is
halfway between the top of the plates and the bottom
of the fill hole.
13
Maintenance Procedures Every 8 Hours or Daily
8000 SRM 552
Hydraulic System
WARNING
At operating temperature the hydraulic oil is
HOT. Do not permit the oil to contact the skin
and cause a burn.
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.
Check the hydraulic oil level when the oil is at operating temperature, the carriage is lowered and the key
is in the OFF position. The fill/dipstick cap is under
the left side of the flat floor plate. Add hydraulic oil
only as needed. If more hydraulic oil is added than
the "FULL" level, the hydraulic oil will leak from the
breather during operation.
Figure 14. Hydraulic Oil Check E45-65XM and
E45-65XM 2
NOTE: The dipstick for the J40-65XM, J40-65XM 2
trucks is under the hood in front of the counterweight. See Figure 15.
Inspect the hydraulic system for leaks and damaged
or loose components.
NOTE: The dipstick/fill for the E25-35XM, E40XMS,
E25-35XM 2, and E40XMS 2 trucks is under the floor
plate near the left side. See Figure 13.
Figure 15. Hydraulic Tank Fill and Dipstick
J40-65XM and J40-65XM 2
HOW TO MAKE CHECKS WITH KEY ON
WARNING
1. FILL CAP AND DIPSTICK
2. BREATHER (AGAINST FRAME)
Figure 13. Hydraulic Tank Fill and Dipstick
E25-40XMS and E25-40XMS 2
NOTE: The dipstick/fill for the E45-65XM 2 trucks
is under the battery connector on the left side. See
Figure 14.
14
FASTEN YOUR SEAT BELT! The seat belt is installed to help the operator stay on the truck if
the lift truck tips over. IT CAN ONLY HELP IF
IT IS FASTENED.
Make sure the area around the lift truck is clear before moving the lift truck. Be careful when making
the checks. Proceed carefully.
8000 SRM 552
Gauges, Horn, and Fuses
1. Check the operation of the gauges and horn. The
horn will operate when the key is in any position.
On both the standard and enhanced or premium
display panels, the hourmeters record the hours
during operation. The hours are displayed on the
digital display or the LCD screen as described in
the Operating Manual.
2. The battery indicator will operate as described in
the Operating Manual.
3. Most fuses are located in the electrical compartment.
Steering System
WARNING
Because the lift truck has hydraulic power
steering, the steering can be difficult when the
power steering pump is not operating.
Make sure that the steering system operates
smoothly and gives good steering control.
Service Brakes
WARNING
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 light on the display panel for the
brake fluid level. The red light is ON as described
in the Operating Manual. If the light is ON 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. 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. The service brakes are automatically
adjusted as the brakes are applied when the lift truck
changes directions.
Maintenance Procedures Every 8 Hours or Daily
NOTE: Some lift trucks are used in operations where
the automatic adjusters can be slow to adjust the
brake shoes. If the brakes need adjustment, operate
the lift truck in forward and reverse 10 times. Apply
the brake pedal firmly, but do not cause the wheels
to slide. If the automatic adjusters do not adjust the
brake shoes, a qualified service person must check
the operation and condition of the brakes.
Parking Brake
There is an indicator light on the display panel for
the parking brake. The red light is ON as described
in the Operating Manual. If the light is ON after
approximately one second, the operator is not on the
seat or the key is in the OFF position. An alarm will
also make a noise. ALWAYS apply the parking brake
when leaving the seat.
Make sure the service brakes operate correctly
before checking the operation of the parking brake.
Check the operation of the parking brake. The
parking brake, when in good condition and correctly
adjusted, will hold a lift truck with a capacity load
on a 15% grade (1.5 ft rise in 10 ft). If necessary,
adjust the parking brake by first making sure the
lift truck cannot move (block wheels). Release the
parking brake and remove the floor plates for access
to the adjustment knob at the bottom of the pedal
linkage. Turn the knob clockwise to increase the
braking force.
Some lift trucks are equipped with an additional
linkage that automatically actuates a separate
brake when the operator leaves the seat (seat
brake). When correctly adjusted, this brake will also
hold the lift truck with a capacity load on a 15%
grade. If the brake does not hold the lift truck on the
grade, the seat brake must be adjusted by authorized
service personnel according to the procedure in the
Brake section of the Service Manual.
Control Levers and Pedals
Check that the levers for the mast and attachment
operate as described in the Operating Manual.
The brake pedals are checked in the previous Service Brakes and Parking Brake paragraphs with the
operation of the brakes.
15
Maintenance Procedures Every 250 Hours or Six Weeks
Direction and Speed Control Pedals
Check that the direction and speed control pedals operate as described in the Operating Manual. Lubricate the direction lever and accelerator pedal joints
as needed. See Maintenance Schedule.
8000 SRM 552
and lower smoothly in the correct sequence. The
carriage raises first, then the inner weldment
and intermediate weldment (three-stage masts
only).
NOTE: Some parts of the mast move at different
speeds during raising and lowering.
Lift System Operation
WARNING
NEVER work under a raised carriage or forks.
Lower the carriage or use chains on the mast
weldments and carriage so that they cannot
move. Make sure the moving parts are attached to a part that does not move.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
1. Check for leaks in the hydraulic system. Check
the condition of the hydraulic hoses and tubes.
3. The inner and intermediate weldments and the
carriage must lower completely.
4. Raise the forks three feet, with a capacity load.
The inner weldment and carriage must raise
smoothly. Lower the forks. All moving components must lower smoothly.
5. With the load lowered, tilt the mast backward
and forward. The mast must tilt smoothly and
both tilt cylinders must stop evenly.
6. Check that the controls for the attachment operate the functions of the attachment. See the
symbols by each of the controls. Make sure all of
the hydraulic lines are connected correctly and
do not leak.
2. Slowly raise and lower the mast several times
without a load. The mast components must raise
Maintenance Procedures Every 250 Hours or Six Weeks
NOTE: Do these procedures in addition to the 8-hour
checks.
STEERING TIE RODS
NOTE: Lubricate steering tie rods at 250 hours for
model E25-40XMS and E25-40XMS 2 only.
Lubricate the steering tie rods with multipurpose
grease (see Maintenance Schedule). More frequent
lubrication may be required if the lift truck operates
in dirty or difficult conditions. See Figure 16.
NOTE: MODEL J40-60XM SHOWN.
1. TIE ROD
2. LUBE FITTING (6)
Figure 16. Lubricate Steering Tie Rods
16
8000 SRM 552
Maintenance Procedures Every 500 Hours or Three Months
Maintenance Procedures Every 500 Hours or Three Months
NOTE: Do these procedures in addition to the 8-hour
checks.
DIFFERENTIAL AND SPEED REDUCER
WARNING
HYDRAULIC TANK BREATHER
Check and clean the hydraulic tank breather. Clean
the breather when it is dirty and will not permit the
easy passage of air. The breather for the E25-40XMS,
E25-40XMS 2 is fastened to the truck frame to the
left of the fill and dipstick cap. See Figure 13. The
breather for the E45-65XM and E45-65XM 2 is fastened to the truck frame to the right of the control
valve on a hose to the hydraulic tank. The breather
for the J40-65XM and J40-65XM 2 is part of the fill
cap and dipstick.
Do not work under a raised carriage. Lower
the carriage or use a chain to prevent the carriage and the inner or intermediate weldments
from lowering when doing maintenance. Make
sure that the moving parts are attached to
parts that can not move.
Check the oil level at fill plug. Add oil slowly at
the fill plug. See Figure 17 for E/J40-65XM and
E/J40-65XM 2. See Figure 18 for E25-40XMS and
E25-40XMS 2. Fill until oil just starts to flow out
the fill plug hole. Add oil only if the oil level is low.
The oil must flow through the bearings to the speed
reducer, so filling slowly is necessary to indicate the
correct level.
A. E45-65XM AND E45-65XM 2
B. J45-65XM AND J45-65XM 2
1.
2.
3.
4.
DRAIN PLUG (ON BOTTOM)
FILL PLUG
DIPSTICK (E45-65XM AND E45-65XM 2 ONLY) (NOT USED ON LATER PRODUCTION LIFT TRUCKS)
BREATHER
Figure 17. Differential
17
Maintenance Procedures Every 500 Hours or Three Months
8000 SRM 552
STEERING AXLE SPINDLES
Use multipurpose grease to lubricate the king pins in
the steering axle. See the section the Steering Axle
1600 SRM 619 XMS (E25-40XMS, E25-40XMS 2),
1600 SRM 258 (E45-65XM, E45-65XM 2), or 1600
SRM 316 (J40-65XM, J40-65XM 2) of the Service
Manual to disassemble and lubricate the king pin
bearings.
STEERING TIE RODS
NOTE: Lubricate the steering tie rods at 500 hours
for model J40-65XM only.
Lubricate the steering tie rods with multipurpose
grease. More frequent lubrication may be required if
the lift truck operates in dirty or difficult conditions.
See Lubricate Steering Tie Rods.
MAST
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recommendations of the manufacturer.
1. DRAIN PLUG (ON
BOTTOM)
2. FILL PLUG
3. DIPSTICK
4. BREATHER
Figure 18. Differential and Speed Reducer
E25-40XMS and E25-40XMS 2
WHEEL NUT TORQUES
WARNING
Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation
and on all lift trucks when the wheels have
been removed and installed. Tighten the nuts
in a cross pattern to the correct torque value
shown in the Maintenance Schedule. When
the nuts stay tight for eight hours, the interval
for checking the torque can be extended to 500
hours.
Tighten wheel nuts as required. See Wheels, Install
and tighten the nuts to the torque value shown in the
Maintenance Schedule.
18
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
Metal particles can fall into the eyes during the
operation of the mast. Failure to remove these
particles can cause eye injury. Remove metal
particles that are attached to the edges of mast
parts with a grinder if necessary. Always wear
eye protection when using a grinder.
CAUTION
Do NOT use steam or high-pressure water to
clean the load rollers or the lift chains. Steam
and high- pressure water can remove the lubrication from the bearings in the load rollers.
Water in the bearings of the sheaves and the
link pins of chains can also shorten the service
life of these parts.
1. Clean the mast assembly. Inspect the mast channels in the areas where the rollers travel. If there
are loose particles or metal particles that are attached to the edges of mast parts, remove these
particles.
8000 SRM 552
Maintenance Procedures Every 500 Hours or Three Months
2. Lubricate the sliding surfaces and the load roller
surfaces along the full length of the channels as
shown in Figure 19. Only apply lubricant to surfaces that are clean and dry. Only apply lubricant
to the darker areas as indicated by (1) and (2).
LIFT CHAINS
Wear Check
WARNING
Do not repair a worn or damaged lift chain. Replace a worn or damaged lift chain with a new
chain. If a pair of lift chains is used in the mast,
both lift chains must be replaced.
If a section of chain is 3% longer than a similar section of new chain, the chain is worn and must be replaced. Check the chain at a section of chain that
goes over a chain sheave. If a chain scale is available, check the lift chains as shown in Figure 20. If
a chain scale is not available, measure 20 links of
chain. Measure from the center of a pin to the center of another pin 20 links away. Compare the length
with the chart in Figure 20. Replace the chain if the
length of 20 links of the worn section is more than
the WEAR LIMIT.
NOTE: MAST IS DIFFERENT, BUT LUBRICATION AREAS ARE THE SAME.
A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 19. Mast Lubrication
NOTE: Some applications will require more frequent
cleaning and lubrication of the mast assembly. Do
NOT use a lubricant-spray on the surfaces of the
mast channels where the load rollers make contact.
The use of the correct lubricant is important. Use
multipurpose grease (Hyster Part No. 3020381) or
an equivalent grease with 2% to 4% molybdenum
disulfide. The load rollers and sheaves have sealed
bearings that do not need additional lubrication.
3. Lubricate the pivots for the mast at the grease
fittings on the pivots or the pivot pins. Use multipurpose grease.
4. If a sideshift carriage is installed, lubricate the
fittings for the rollers or the sliding surfaces with
multipurpose grease.
Inspect the lift chains for edge wear. See Figure 9.
Make sure the edge wear of the chain is not greater
than 5% compared to a chain link that is not worn.
FORKS
WARNING
Never repair damaged forks. Do not heat, weld,
or bend the forks. Forks are made of special
steel using special methods. Replace damaged
forks.
1. Check the heel and attachment points of the
forks with a penetrant or magnetic particle
inspection.
2. Measure the thickness of the forks at a vertical
section where there is no wear. See Figure 8.
This is dimension X. Now measure the thickness
at the heel of the fork. If the thickness is not more
than 90% of dimension X, replace the fork.
3. Use clean engine oil as necessary to lubricate the
fork guides of the carriage and the locks for the
forks.
19
Maintenance Procedures Every 500 Hours or Three Months
8000 SRM 552
BRAKE FLUID
WARNING
Loss of fluid from the master cylinder indicates
a leak. This condition can cause brake failure.
The result can be material damage or personal
injury. Repair the brake system before the lift
truck is used. Replace the brake fluid in the
system if there is dirt, water, or oil in the system.
CHECK THE INDICATOR LIGHT DURING OPERATION. There is an indicator light on the display
panel for low brake fluid. The red light is ON for
approximately eight to ten seconds when the key is
first moved to the ON position. The light comes on
during operation when brake fluid is low.
Pitch
12.7 mm
(0.50 in.)
15.9 mm
(0.63 in.)
19.1 mm
(0.75 in.)
25.4 mm
(1.00 in.)
31.8 mm
(1.25 in.)
44.5 mm
(1.75 in.)
50.8 mm
(2.00 in.)
Total length of Wear Limit
20 links (pitch) The maximum
of new chain
length of 20
links.
254.0 mm
(10.0 in.)
317.5 mm
(12.5 in.)
381.0 mm
(15.0 in.)
508.0 mm
(20.0 in.)
635.0 mm
(25.0 in.)
889.0 mm
(35.0 in.)
1016.0 mm
(40.0 in.)
261.6 mm
(10.3 in.)
327.0 mm
(12.9 in.)
392.4 mm
(15.6 in.)
523.25 mm
(20.6 in.)
654.1 mm
(25.75 in.)
915.7 mm
(36.05 in.)
1046.5 mm
(41.2 in.)
NOTE: THE INSTRUCTIONS FOR MEASURING
CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE.
1. CHAIN WEAR SCALE
Figure 20. Lift Chains Check
20
Check the brake fluid in the reservoir for the master
cylinder. The reservoir is under the floor plate near
the brake pedal. Add brake fluid as necessary. Use
the brake fluid shown in the Maintenance Schedule.
OTHER LUBRICATION
Lubricate hinges, pins, linkages, cables, pedals, and
levers as necessary. Use SAE 30 oil, multipurpose
grease, or silicone lubricant-spray (Hyster Part No.
328388) as needed. See the Maintenance Schedule.
SEAT BRAKE (E25-65XM AND E25-65XM 2
ONLY)
Adjust the seat brake for parking as described
in the section the Brake System 1800 SRM 574
(E45-65XM and E45-65XM 2) or 1800 SRM 620
(E25-40XMS and E25-40XMS 2) (of the Service
Manual. Lubricate the linkage for the brake as
shown in Figure 21. See the Maintenance Schedule
for lubricants.
8000 SRM 552
Maintenance Procedures Every 500 Hours or Three Months
• Diagrams 8000 SRM 551, (E/J40-65XM)
• Diagrams 8000 SRM 622, (E25-40XMS)
Additional information for the EV-T100, SR (SEM)
or SP Transistor motor controllers is available in the
following sections of the Service Manual:
• EV-T100™ Transistor Motor Controller
Description, Checks, Adjustments, and Troubleshooting 2200 SRM 581
• Transistor Motor Controllers (SR and SP) Description & Operation and Repairs & Adjustments 2200 SRM 724
• Diagrams 8000 SRM 551, (E/J40-65XM)
• Diagrams 8000 SRM 622, (E25-40XMS)
• Electrical Diagrams Transistor Motor Controllers (SR and SP) (SEM) 8000 SRM 742,
(E25-65XM2, J40-65XM2, and N30XMH2)
Contactors
A. LUBRICATE
1. BEARING
2. ROD
3. BRACKET
Figure 21. Lubricate Linkage for Seat Brake
ELECTRICAL INSPECTION
WARNING
Disconnect the battery connector to prevent
injury from electric shock before you make
any inspections or repairs.
Discharge the capacitors when you make any
inspections or repairs inside of the electrical
compartment.
These lift trucks can have either the EV-100ZX SCR
motor controller (Figure 23, Figure 24, Figure 25,
and Figure 26) the EV-T100™, SR (SEM) or SP Transistor motor controllers (Figure 27, Figure 28, Figure 29, or Figure 30). These motor controllers are
made for Hyster Company by the General Electric
Company.
Additional information for the EV-100ZX SCR motor
controllers is available in the following sections of the
Service Manual:
• EV-100ZX™ Motor Controller Description &
Operation and Repairs & Adjustments 2200
SRM 557
The contactor contacts are made of a special silver
alloy. See Figure 22, Figure 23, Figure 24, Figure 27,
and Figure 28. The contacts will look black and
rough from normal operation. This condition does
not cause problems with the operation of the lift
truck. Cleaning is not necessary. DO NOT USE A
FILE ON THE CONTACTS. DO NOT LUBRICATE
THE CONTACTS. Always replace the contacts in
sets. Check for equal spring tension if the contacts
do not wear evenly.
Motor Brushes
CHECK THE INDICATOR LIGHT DURING OPERATION. There is an indicator light on the display
panel for motor brushes on some trucks. The red
light is ON for approximately eight to ten seconds
when the key is first moved to the ON position. The
light comes on during operation when motor brushes
are worn and need to be replaced.
NOTE: E25-40XMS and E25-40XMS 2: The traction motor, hydraulic pump motor, and the steering
pump motor are below the battery compartment. Remove the battery and the access panel to check the
motors.
NOTE: E45-65XM and E45-65XM 2: The traction
motor and the hydraulic pump motor are below the
battery compartment. Remove the battery and the
access panel to check the motors. The steering pump
motor is on a vertical mount below the floor plate. Remove the floor plates for access to the steering pump
motor.
21
Maintenance Procedures Every 500 Hours or Three Months
NOTE: J40-65XM and J40-65XM 2: The traction
motor is under the floor plate of the operator’s compartment. Remove the floor plate for access. The hydraulic pump motor and the steering pump motor are
behind the battery. Open the hood for access to the
motors. Many service people remove the four bolts
that hold the cowl to the overhead guard when doing service work under the floor plates. This action
permits the cowl and steering column to lean against
the mast and gives better access to the components
under the floor plate.
Motor Brushes, General
1. Visually inspect the commutator and brushes every 500 hours. Make sure the surface of the
commutator is good and the motor operates normally. Worn motor brushes must be replaced before they damage the surface of the commutator.
Move the brush spring and remove a brush from
the brush holder. When the brush wears within
approximately 1.5 mm (0.60 in.) of where the
brush wire joins the brush, the brush must be
replaced.
2. Some lift trucks are equipped with brush wear
indicators on the traction and hydraulic motors.
The brush wear indicators give a signal on the
LED display panel, or screen of the SEM display panel, on the instrument panel. The sensor
22
8000 SRM 552
wires for the brush wear indicators of units before the "XM 2" are an insert in the brush material
when it is made. When the brush wears within
1.5 mm (0.60 in.) of the brush wire, the insulation between the sensor wire and the brush material is destroyed. The connection between the
brush and the sensor wire causes the LED indicator to illuminate. The brush wear indicators
will not indicate a damaged commutator nor indicate a motor malfunction. On the "XM 2" units,
the brush spring makes a contact when the brush
is worn to the length where it must be replaced.
A status code will appear on the LCD screen as
an indication that the brushes must be replaced.
Visually inspect the commutator and brushes on
lift trucks with brush wear indicators also.
3. Inspect the brush holders for burns or damage.
Make sure the brush holder is fastened tightly to
the mounts at the end of the motor. Make sure
the brushes will move freely and smoothly in the
brush holders.
4. Check the brush springs for damage from heat
and corrosion. Replace a damaged brush spring.
See the section DC Motor Maintenance 620 SRM
294 of the Service Manual, for additional information to inspect the commutator and brushes.
8000 SRM 552
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Maintenance Procedures Every 500 Hours or Three Months
POWER STEERING CONTACTOR
FUSE 4 (40 AMP)
FUSE 6 (15 AMP)
FUSE 5 (15 AMP)
FUSE 3 (15 AMP)
FUSE 7 (3 AMP)
1A CONTACTOR
FUSE 1 (500 AMP)
REGENERATIVE BRAKING CONTACTOR
FIELD WEAKENING RESISTOR (SOME NORTH
AMERICAN TRUCKS ONLY)
11. REVERSE CONTACTOR
12. FORWARD CONTACTOR
13. FIELD WEAKENING CONTACTOR (SOME
NORTH AMERICAN TRUCKS ONLY)
14. LIFT PUMP CONTACTOR (WITHOUT SCR PUMP
CONTROL ONLY)
15. FUSE 2 (325 AMP) (ON SCR PANEL WITH SCR
PUMP CONTROL)
16. FUSE BLOCK
Figure 22. EV-100ZX Contactor Panel for E25-40XMS
23
Maintenance Procedures Every 500 Hours or Three Months
8000 SRM 552
NOTE: MOTOR CONTROLLER WITH REGENERATIVE BRAKING, 1A BYPASS, FIELD WEAKENING, AND SCR
CONTROLLER FOR HYDRAULIC PUMP MOTOR.
1. SCR CONTROL FOR HYDRAULIC PUMP
MOTOR CONTROL CARD
2. TRACTION WITH REGENERATIVE BRAKING
CONTROL CARD
3. POWER STEERING CONTACTOR
4.
5.
6.
7.
8.
1A CONTACTOR
REGENERATIVE BRAKING CONTACTOR
REVERSE DIRECTION CONTACTOR
FORWARD DIRECTION CONTACTOR
FIELD WEAKENING CONTACTOR
Figure 23. EV-100ZX SCR Motor Controller for E45-65XM
24
8000 SRM 552
Maintenance Procedures Every 500 Hours or Three Months
NOTE: MOTOR CONTROLLER WITH REGENERATIVE BRAKING, 1A BYPASS, FIELD WEAKENING, AND CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR.
1. TRACTION WITH REGENERATIVE BRAKING
AND FIELD WEAKENING CONTROL CARD
2. POWER STEERING CONTACTOR
3. 1A CONTACTOR
4. REGENERATIVE BRAKING CONTACTOR
5.
6.
7.
8.
REVERSE DIRECTION CONTACTOR
FORWARD DIRECTION CONTACTOR
FIELD WEAKENING CONTACTOR
HYDRAULIC PUMP MOTOR CONTACTOR
Figure 24. EV-100ZX SCR Motor Controller for E45-65XM
25
Maintenance Procedures Every 500 Hours or Three Months
Figure 25. EV-100ZX SCR Motor Controller for J40-65XM
26
8000 SRM 552
8000 SRM 552
Maintenance Procedures Every 500 Hours or Three Months
Legend for Figure 25
NOTE: SCR MOTOR CONTROLLER WITH REGENERATIVE BRAKING, 1A BYPASS, FIELD WEAKENING, AND
SCR CONTROLLER FOR HYDRAULIC PUMP MOTOR.
1. SCR CONTROL FOR HYDRAULIC PUMP
MOTOR CONTROL CARD
2. POWER STEERING CONTACTOR
3. 1A CONTACTOR
4. REGENERATIVE BRAKING CONTACTOR
5.
6.
7.
8.
REVERSE DIRECTION CONTACTOR
FORWARD DIRECTION CONTACTOR
FIELD WEAKENING CONTACTOR
TRACTION WITH REGENERATIVE BRAKING
CONTROL CARD
27
Maintenance Procedures Every 500 Hours or Three Months
Figure 26. EV-100ZX SCR Motor Controller for J40-65XM
28
8000 SRM 552
8000 SRM 552
Maintenance Procedures Every 500 Hours or Three Months
Legend for Figure 26
NOTE: SCR MOTOR CONTROLLER WITH REGENERATIVE BRAKING, 1A BYPASS, FIELD WEAKENING, AND
CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR.
1. TRACTION WITH REGENERATIVE BRAKING
AND FIELD WEAKENING CONTROL CARD
2. POWER STEERING CONTACTOR
3. 1A CONTACTOR
4. REGENERATIVE BRAKING CONTACTOR
5.
6.
7.
8.
REVERSE DIRECTION CONTACTOR
FORWARD DIRECTION CONTACTOR
FIELD WEAKENING CONTACTOR
HYDRAULIC PUMP MOTOR CONTACTOR
29
Maintenance Procedures Every 500 Hours or Three Months
Figure 27. EV-T100 Transistor Motor Controller for J40-65XM
30
8000 SRM 552
8000 SRM 552
Maintenance Procedures Every 500 Hours or Three Months
Legend for Figure 27
NOTE: TRANSISTOR MOTOR CONTROLLER FOR HYDRAULIC PUMP MOTOR AND TRACTION MOTOR WITH
REGENERATIVE BRAKING, 1A BYPASS, AND FIELD WEAKENING.
1. TRANSISTOR CONTROL FOR HYDRAULIC
PUMP MOTOR CONTROL CARD
2. POWER STEERING PUMP CONTACTOR
3. 1A CONTACTOR
4. L CONTACTOR
5. REGENERATIVE BRAKING CONTACTOR
6.
7.
8.
9.
REVERSE CONTACTOR
FORWARD CONTACTOR
FIELD WEAKENING CONTACTOR
TRANSISTOR CONTROL FOR TRACTION
MOTOR CONTROL CARD
31
Maintenance Procedures Every 500 Hours or Three Months
8000 SRM 552
NOTE: CONTACTOR CONTROLLED HYDRAULIC PUMP MOTOR AND TRANSISTOR MOTOR CONTROLLER
FOR TRACTION MOTOR WITH REGENERATIVE BRAKING, 1A BYPASS, AND FIELD WEAKENING.
1.
2.
3.
4.
5.
CONTACTOR FOR HYDRAULIC PUMP MOTOR
POWER STEERING PUMP CONTACTOR
1A CONTACTOR
L CONTACTOR
REGENERATIVE BRAKING CONTACTOR
6.
7.
8.
9.
REVERSE CONTACTOR
FORWARD CONTACTOR
FIELD WEAKENING CONTACTOR
TRANSISTOR CONTROL FOR TRACTION
MOTOR CONTROL CARD
Figure 28. EV-T100 Transistor Motor Controller for J40-65XM
32
8000 SRM 552
1.
2.
3.
4.
5.
6.
FUSE 7 (15A)
FUSE 6 (15A)
FUSE 5 (15A)
FUSE 3 (15A)
POWER STEERING CONTACTOR
FUSE 4 (POWER STEERING) (40A)
Maintenance Procedures Every 500 Hours or Three Months
7.
8.
9.
10.
11.
12.
LINE CONTACTOR
OPENING IN COUNTERWEIGHT
TRACTION MOTOR CONTROLLER
FUSE 1 (TRACTION MOTOR) (500A)
FUSE 2 (LIFT PUMP MOTOR) (325A)
MOTOR CONTROLLER FOR LIFT PUMP MOTOR
Figure 29. SR (SEM) Transistor Traction and SP Pump Motor Controllers for E25-65XM 2,
J45-65XM 2, and N30XMH 2
33
Maintenance Procedures Every 500 Hours or Three Months
1.
2.
3.
4.
5.
6.
7.
FUSE 7 (15A)
FUSE 6 (15A)
FUSE 5 (15A)
FUSE 3 (15A)
POWER STEERING CONTACTOR
FUSE 4 (POWER STEERING) (40A)
LINE CONTACTOR
8.
9.
10.
11.
12.
13.
8000 SRM 552
OPENING IN COUNTERWEIGHT
TRACTION MOTOR CONTROLLER
FUSE 1 (TRACTION MOTOR) (500A)
CONTACTOR DRIVER MODULE
FUSE 2 (LIFT PUMP MOTOR) (325A)
CONTACTOR FOR LIFT PUMP MOTOR
Figure 30. SR (SEM) Transistor Traction Motor Controller and Contactor Control for Lift Pump
Motor for E25-65XM 2, J45-65XM 2, and N30XMH 2
34
8000 SRM 552
Maintenance Procedures Every 1000 Hours or Six Months
Maintenance Procedures Every 1000 Hours or Six Months
a. If either upper bearing is worn to less than
2.5 mm (3/32 in.) thickness, replace both upper bearings by driving the upper bearings
out of the carriage bar.
NOTE: Do these procedures in addition to the 500hour checks.
LIFT CHAINS
NOTE: Cleaning and lubrication can be needed more
frequently in very dirty applications. See .
b. If either lower bearing is worn to less than
2.5 mm (3/32 in.) thickness, replace both
lower bearings by prying the lower bearings
from the lower carriage bar.
NOTE: To check for chain wear, see Maintenance Procedures Every 500 Hours or Three Months.
Lubricate the lift chains with clean 30W engine oil or
Hyster Chain and Cable Lubricant (Hyster Part No.
171350).
FORKS
Lubricate the fork pins and guides with clean, 20W
motor oil. If the lift truck is used in dirty or difficult
conditions, lubrication of the fork pins and guides
may be required more frequently. Inspect the forks
for wear. See Maintenance Procedures Every 8
Hours or Daily for the procedure to inspect the forks.
CHECK UPPER AND LOWER BEARINGS,
INTEGRAL SIDESHIFT CARRIAGE
1. Lower the carriage completely and remove the
forks.
2. Remove the backrest and the lower mounting
hooks from the sideshift carriage.
NOTE: TWO AND THREE-STAGE FULL FREE-LIFT
CARRIAGE SHOWN.
3. Use a crane with a capacity of at least 450 kg
(1000 lb)to lift the outer frame away from the
inner carriage.
1.
2.
3.
4.
5.
4. Clean the bearing areas. Inspect the sideshift
bearings for wear as follows:
UPPER BEARING
LOWER HOOK
LOAD ROLLER
SNAP RING
SIDESHIFT
CYLINDER
6.
7.
8.
9.
10.
LOWER BEARING
SHIMS
INNER CARRIAGE
LUBE FITTING
OUTER FRAME
Figure 31. Integral Sideshift Carriage
35
Maintenance Procedures Every 2000 Hours or Yearly
8000 SRM 552
Maintenance Procedures Every 2000 Hours or Yearly
Do these procedures in addition to the 1000-hour
checks.
HYDRAULIC SYSTEM
Change Filter for Hydraulic Oil
WARNING
The hydraulic oil is HOT at operating temperature. Do not permit the hot oil to contact the
skin and cause a burn.
CAUTION
Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter
is changed. Dirt can cause damage to components of the hydraulic system.
Never operate the pump without oil in the hydraulic system. The operation of the hydraulic
pump without oil will damage the pump.
1. BREATHER
2. MAIN CONTROL
VALVE
3. RELIEF VALVE
4. FILTER
Figure 33. Hydraulic Filter E45-65XM and
E45-65XM 2
NOTE: Change the oil filter for the hydraulic system
after the first 100 hours on new lift trucks. See Figure 32, Figure 33, and Figure 34.
1. On the E25-65XM and E25-65XM 2 trucks, remove the floor plates. On the J40-65XM and
J40-65XM 2 trucks, open the hood for access to
the filter. Clean the hydraulic filter and hoses
at the filter.
Figure 34. Hydraulic Filter J40-65XM and
J40-65XM 2
Figure 32. Hydraulic Filter E25-40XMS and
E25-40XMS 2
36
2. Loosen the hose clamp at the filter for the hose
from the control valve. Lift the filter as high as
possible and remove the hose from the filter. Tip
the filter up to let the oil drain into the hydraulic
tank.
8000 SRM 552
3. After the oil has drained, loosen the other hose
clamp. On the J40-65XM and J40-65XM 2 units,
remove the two screws that fasten the filter. Remove the filter.
NOTE: The hydraulic oil filter has a bypass relief
valve that is part of the filter. Make sure the correct replacement filter with a bypass relief valve is
installed.
4. Install the new filter. Make sure the flow arrow
points toward the hydraulic tank hose. Tighten
the hose clamps and on the J40-65XM and J4065XM 2 units, install and tighten the two screws
that fasten the filter.
5. Operate the hydraulic system and check for
leaks.
Change Hydraulic Oil
Put the lift truck on a level surface. Lower the mast.
Put a drain pan with a capacity of approximately
27 liter (29 qt) under the hydraulic tank.
E25-65XM and E25-65XM 2 lift trucks. Disconnect
the hydraulic hose from the hydraulic tank to the
steering pump and drain the oil into the drain pan.
On the J40-65XM and J40-65XM 2 trucks, turn the
steering wheel for a full left turn. This action will
move the right steer tire and wheel for access to the
drain plug. The drain plug is in the bottom of the
tank directly below the dipstick/fill cap. Remove the
drain plug and drain the oil into the drain pan.
When the oil has drained, connect the hydraulic hose
or install the drain plug. Fill the hydraulic tank with
the correct oil after the filter is installed. See the
Maintenance Schedule.
Maintenance Procedures Every 2000 Hours or Yearly
DIFFERENTIAL AND SPEED REDUCER
Drain the oil at the drain plug on the left side (right
side facing the differential housing). See Figure 17
and Figure 18. The drain plug is in the differential
housing near the bottom. Make sure the drain pan
has a capacity of the differential and speed reducer
as specified in the Maintenance Schedule. The oil
drains slowly since it must flow through the bearings from the speed reducer to the differential housing. Install the drain plug after the oil has completely
drained. Clean the breather in solvent.
See the Maintenance Schedule for the correct lubricant. Add oil slowly at the fill plug. Fill until oil just
starts to flow out the fill plug hole. Add oil only if
the oil level is low. The oil must flow through the
bearings to the speed reducer, so filling slowly is necessary to indicate the correct level.
SERVICE BRAKES
WARNING
Brake linings contain fibers. Breathing the
dust from these brake linings can be a cancer
or lung disease hazard. Do not create dust! Do
not clean brake parts with compressed air or
by brushing. Use vacuum equipment approved
for asbestos dust or follow the cleaning procedure in this section. When the brake drums
are removed, do not create dust.
Do not sand, grind, chisel, hammer, or change
linings in any way that will create dust. Any
changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used.
Cleaning Procedures:
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recommendations of the manufacturer.
E25-65XM and E25-65XM 2 lift trucks. Remove the
breather from the breather hose. Wash the breather
in solvent and air dry, or replace the breather. Install
the clean breather on the breather hose or pipe.
J40-65XM and J40-65XM 2 lift trucks. Clean the dipstick and fill cap in solvent to clean the breather.
1. Do not release brake lining dust from the brake
linings into the air when the brake drum is removed.
2. Use a solvent approved for cleaning of brake
parts to wet the lining dust. Follow the instructions and cautions of the manufacturer for the
use of the solvent. If a solvent spray is used, do
not create brake lining dust with the spray.
3. When the brake lining dust is wet, clean the
parts. Put any cloth or towels in a plastic bag
or an airtight container while they are still wet.
Put a "DANGEROUS FIBERS" warning label on
the plastic bag or airtight container.
37
Maintenance Procedures Every 2000 Hours or Yearly
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the
air.
NOTE: Some lift trucks are used in operations where
the automatic adjusters can be slow to adjust the
brake shoes. If the brakes need adjustment, operate
the lift truck in forward and reverse 10 times. Apply
the brake pedal firmly, but do not cause the wheels
to slide. If the automatic adjusters do not adjust the
brake shoes, a qualified service person must check
the operation and condition of the brakes.
CAUTION
Do NOT use an oil solvent to clean the wheel
cylinder. Use a solvent approved for cleaning
of brake parts. Do not permit oil or grease in
the brake fluid or on the brake linings.
Check the brake lining and parts of the brake assembly for wear or damage. See the sections the Brake
System of the Service Manual, for the removal and
installation procedures of the drive wheels and hubs.
If the brake linings or brake shoes are worn or damaged, they must be replaced. Brake shoes must be
replaced in complete sets. Inspect the brake drums
for cracks or damage. Replace any damaged parts.
CONTACTORS
Always replace the contacts of a contactor as a complete set. See the motor controller sections of the
Service Manual for replacement and adjustment
procedures.
WHEEL BEARINGS
Steer Wheels, Lubrication
Lubricate the wheel bearings in the hubs for the
steer wheels with multipurpose grease as described
in the section the Steering Axle 1600 SRM 619
E25-40XMS, E25-40XMS 2, the section the Steering
Axle 1600 SRM 258 E45-65XM and E45-65XM 2
or the section the Steering Axle 1600 SRM 316
J40-65XM and J40-65XM 2 of the Service Manual.
Drive Wheels, Lubrication
Lubricate the inner wheel bearings in the hubs
for the drive wheels with multipurpose grease
as described in the section Drive Axle, Speed
Reducer and Differential 1400 SRM 618
E25-40XMS and E25-40XMS 2, the section Drive
Axle, Speed Reducer and Differential 1400 SRM
38
8000 SRM 552
285 E45-65XM and E45-65XM 2 or the section Drive
Axle, Speed Reducer and Differential 1400
SRM 575 J40-65XM and J40-65XM 2 of the Service
Manual.
LIFT CHAINS
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recommendations of the manufacturer.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Remove the lift chains. Clean the lift chains by soaking them in a solvent that has a petroleum base for at
least 30 minutes. Use compressed air to completely
dry the chains when they are clean.
Lubricate the lift chains by soaking them in 30W engine oil for at least 30 minutes. Remove the chains
from the oil. Hang the chains for one hour so that
excess oil will drain from the chains.
REPLACE UPPER AND LOWER
BEARINGS, INTEGRAL SIDESHIFT
CARRIAGE
Replace all four bearings regardless of wear. See
Check Upper and Lower Bearings, Integral Sideshift
Carriage for the procedure.
STEERING AXLE
King Pins and Rod Ends (Steering
Cylinders)
Lubricate the rod ends of the steering cylinder and
the king pins. Use multipurpose grease. See the
Maintenance Schedule for more information on lubricating these parts.
OTHER LUBRICATION
Lubricate hinges, levers, linkages cables and pedals
as necessary. Use SAE 30 oil, multipurpose grease
or silicone lubricant-spray (Hyster Part No. 328388)
as needed. See the Maintenance Schedule for more
lubricating information.
8000 SRM 552
Battery Maintenance
Battery Maintenance
HOW TO CHARGE BATTERY
WARNING
The acid in the electrolyte can cause injury.
If electrolyte is spilled, use water to flush the
area. Make the acid neutral with a solution of
sodium bicarbonate (soda) and water. Acid in
the eyes must be immediately flushed with water.
Batteries generate explosive fumes when
they are being charged. Keep fire, sparks,
and burning material away from the battery
charger area. Prevent sparks from the battery
connections.
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 of these sealed batteries.
Correct use of the hydrometer and proper operation
of the battery charger is important. See Figure 35.
Follow the instructions of the charger manufacturer.
Never let the battery discharge below the minimum
value given by the battery manufacturer. A fully
charged battery will have a specific gravity of 1.265
to 1.310 at 25 C (77 F). See Figure 35. Never charge
a battery at a rate that will raise the electrolyte temperature above 49 C (120 F). Never let a battery stay
discharged for long periods.
Charge batteries only in the special area for
charging batteries. When charging the batteries, keep the vent caps clean. The battery
charger area must have ventilation so that
explosive fumes are removed. Open the hood
over the battery or remove the cover if the
battery has a cover.
Disconnect the battery when doing cleaning
and maintenance.
If the lift truck has been operated with a low
battery, inspect all contactors for welded contacts BEFORE you connect a charged battery.
The circuit will not reset and lift truck operation cannot be controlled if the contacts are
welded.
CAUTION
Never connect the battery charger plug to
the plug of the lift truck. You can damage the
traction control circuit. Make sure the charger
voltage is the correct voltage and type for the
battery. Sealed batteries require a different
charger.
Use only battery chargers approved by the battery manufacturer or dealer.
CAUTION
Always make sure the color in the window of
the charger connector is the same as the color
in the window of the battery connector.
NOTE: There can be one of two types of batteries.
One type has removable cell caps. The other type
Specific
Gravity
Reading
Electrolyte
Temp.
Correction
Points
Correct
Value
1.210
31 C (87 F)
+0.003
1.213
1.210
27 C (80 F)
+0.001
1.211
1.210
25 C (77 F)
0.000
1.210
1.210
18 C (64 F)
−0.004
1.206
+0.001 or −0.001 for each 2 degree C from the 25
base value.
NOTE: CHECK ONLY BATTERIES THAT DO NOT
HAVE SEALED CELLS.
Figure 35. Check Specific Gravity
1. NORMAL CHARGE: This charge is normally
given to a battery that is discharged from normal
39
Battery Maintenance
8000 SRM 552
operation. Many customers charge the battery at
regular intervals that depend on use. This procedure
will keep the battery correctly charged if the battery
is not discharged below the limit. Always use a
hydrometer to check the battery if the battery is
charged at regular intervals. Frequent charging of a
battery that has a 2/3 or more charge can decrease
the life of the battery.
The replacement battery must fit the battery
area correctly. Adjust the spacer plate to prevent the battery from moving forward or backward in the battery compartment.
2. EQUALIZING CHARGE: This charge is at a low
rate and balances the charge in all of the cells. The
equalizing charge is normally given approximately
once a month. It is a charge at a slow rate for three
to six hours in addition to the regular charging
cycle. Do not give an equalizing charge more than
once a week. The most accurate specific gravity
measurements for a charged battery will be after an
equalizing charge. If the specific gravity difference
is more than 0.020 between cells of the battery after
and equalizing charge, there can be a defective cell.
Consult your battery dealer.
Make sure the battery restraint is locked in the
down position before the lift truck is operated.
NOTE: Many customers have battery chargers that
can follow a program to automatically charge a
battery according to recommendations of the battery
manufacturer. Use the recommendations of the
battery manufacturer for charging the battery.
Also see the section the Industrial Battery 2240
SRM 1 of the Service Manual, for additional information on the charging and maintenance of a battery.
HOW TO CHANGE BATTERY
General
WARNING
Batteries are heavy and can cause an injury.
Use care to avoid injury. Do NOT put hands,
arms, feet, and/or legs between the battery and
a solid object.
Make sure the capacity of the crane and
spreader bar is greater than the weight of the
battery. The weight of the battery is normally
shown on the battery case. The maximum
battery weight is shown on the lift truck nameplate. The spreader bar must NOT be made of
metal or it must have insulated straps.
40
Make sure that the battery voltage and weight
of the replacement battery is correct as shown
on the nameplate.
Before connecting the battery, make sure the
key is in the OFF position and the parking
brake is set.
CAUTION
Batteries must be discarded according to local
environmental regulations.
Observe previous WARNING and CAUTION before
changing batteries.
Change E25-65XM and E25-65XM 2 Battery
1. E25-65XMS and E25-65XMS 2. Disconnect the
battery. See Figure 36 and Figure 38. Move
the connector and cables so that they will not
be damaged when the battery is moved. Tilt the
steering column forward and make sure the detent engages to hold the steering column. Slide
the seat to the rear adjustment position. Open
the hood/battery restraint as shown in Figure 36.
Tilt the battery restraint and seat to the up position. Make sure the battery restraint is locked
in the up position. If the truck has optional side
covers, remove them. If the hood has a side door,
make sure it is open.
2. E25-40XMS and E25-40XMS 2. Use a spreader
bar and crane to lift the battery from the lift
truck. See Figure 38. When a replacement battery is installed, make sure the battery fits the
battery compartment. The battery must have
the front spacer plate and side spacers correctly
adjusted to prevent any horizontal movement of
more than 13 mm (0.5 in.). There must be enough
clearance for battery removal. See Figure 37.
8000 SRM 552
Battery Maintenance
Figure 36. Open Hood E25-65XM and E25-65XM 2
3. E45-65XM and E45-65XM 2. Use a spreader bar
and crane to lift the battery from the lift truck.
See Figure 38. When a replacement battery is
installed, make sure the battery fits the battery
compartment width with a maximum of 13 mm
(0.5 in.) clearance. Adjust the spacer plate to
prevent the battery from moving more than a total of 13 mm (0.5 in.) forward or backward. See
Figure 39. There must be enough clearance for
battery removal.
WARNING
Correct operation of the battery restraint system requires that the battery does not move
more than 13 mm (0.5 in.). Make sure the battery spacer plate is correctly adjusted.
4. If the truck has optional side covers, install them.
Release the stop rod by moving it to the right
before lowering hood. See the label Figure 11.
Lower the hood. Make sure the latch handle is
fully to the right when closing the hood so that
the latch can engage the latch piece. Make sure
the hood is locked securely. Try to raise the hood
using only the lift handle to make sure the hood
is latched and will not move. If the hood has a
side door, make sure it is closed.
5. Connect the battery connector. See Figure 40.
41
Battery Maintenance
8000 SRM 552
1. BATTERY
2. SPREADER BAR
3. CRANE CHAIN
Figure 38. Change Battery E25-65XM and
E25-65XM 2
1. BATTERY
COMPARTMENT
2. BATTERY
3. BULKHEAD
4. SPACER PLATE
5. ADJUSTMENT
CAPSCREW
6. JAM NUTS
A + B = 13 mm (0.5 in.) MAXIMUM
Figure 37. Battery Compartment Spacer Plates
E25-40XMS and E25-40XMS 2
1. BATTERY
COMPARTMENT
2. BATTERY
3. BULKHEAD
4. SPACER PLATE
5. ADJUSTMENT
CAPSCREW
6. JAM NUTS
Figure 39. Battery Compartment Spacer Plate
E/J45-65XM and E/J45-65XM 2
42
8000 SRM 552
Battery Maintenance
NOTE: INDICATOR INSERT - GREEN (FOR BATTERY WITH CELL CAPS) AND GRAY (FOR BATTERY WITH
SEALED CELLS).
A. DIN CONNECTOR
B. ANDERSON SBE CONNECTOR
1. BATTERY HALF OF CONNECTOR
2. INDICATOR INSERT FOR BATTERY VOLTAGE
AND BATTERY TYPE
3. LOCK FOR CABLE TERMINALS AND INDICATOR
4.
5.
6.
7.
WINDOW SHOWING BATTERY VOLTAGE
WIRE FOR 12-VOLT BATTERY TAP
CONNECTOR FOR 12-VOLT BATTERY TAP
LOCK PINS FOR 12-VOLT CONNECTOR
Figure 40. Battery Connectors for 12-Volt Battery Tap (Older Lift Trucks Only)
Change J40-65XM and J40-65XM 2 Battery
1. Move the steering column to the fully forward position and make sure it is latched. Release the
latch for the control lever assembly and move the
assembly to the forward position. Raise the hood
and seat to the fully raised position as shown in
Figure 41. Raise the handle of the battery restraint rod and move the rod to the rear position.
Disconnect the battery connector and move it to
a position so that it will not be damaged during
battery removal. Lift the side panels to remove
them.
2. Use a spreader bar and crane to lift the battery
from the lift truck. See Figure 41. When a replacement battery is installed, make sure the
battery fits the battery compartment width with
a maximum of 13 mm (0.5 in.) clearance. Adjust the spacer plate to prevent the battery from
moving more than a total of 13 mm (0.5 in.) forward or backward. See Figure 39. There must
be enough clearance for battery removal.
43
Battery Maintenance
8000 SRM 552
Correct operation of the battery restraint system requires that the battery does not move
more than 13 mm (0.5 in.). Make sure the battery spacer plate is correctly adjusted.
3. Connect the battery connector. Move the battery restraint rod to the forward position over the
edge of the battery. Move the handle to the down
position. Install the side covers. Lower the hood.
Move the control lever assembly fully to the rear
over the hood. Make sure the latch is completely
engaged. Try to raise the hood using only the lift
handle to make sure the hood will not raise.
A. LOCKED
B. OPEN
1.
2.
3.
4.
5. BATTERY RESTRAINT HANDLE
6. BATTERY RESTRAINT ROD
7. LATCH OF HAND LEVER ASSEMBLY
WARNING
BATTERY
CRANE CHAIN
SPREADER BAR
BATTERY CONNECTOR
Figure 41. Change Battery J40-65XM and J40-65XM 2
44
8000 SRM 552
Lift and Tilt System Leak Check
Lift and Tilt System Leak Check
LIFT CYLINDERS LEAK CHECK
WARNING
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, the key is in
the OFF position and the key is removed.
Before making any repairs, use chains on the
mast weldments and carriage so that they cannot move. Make sure the moving parts are attached to the parts that cannot move.
Do not try to find hydraulic leaks by putting
your hand on hydraulic components under
pressure. Hydraulic oil can be injected into
the body by pressure.
During test procedures for the hydraulic system, fasten the load to the carriage with chains
to prevent it from falling. Keep all personnel
away from the lift truck during the tests.
1. Operate the hydraulic system. Put a capacity
load on the forks and raise and lower the load
several times. Lower the load and tilt the mast
forward and backward several times. Check for
leaks.
2. Raise the carriage and load so that the rods of the
main lift cylinders extend at least 60 cm (2 ft). If
the carriage lowers slowly with the control valve
in the NEUTRAL position, there are leaks inside
the hydraulic system. The maximum speed that
the carriage is allowed to lower is 50 mm (2 in.)
per 10 minutes when the hydraulic oil is 30 C
(90 F). If the oil temperature is 70 C (160 F), the
maximum speed that the carriage can lower is
150 mm (6 in.) per 10 minutes.
3. Check the lift cylinders for internal leaks. Remove the load from the forks. Install a gate valve
in the supply line between the main control valve
and the mast. Put a capacity load on the forks
again. Raise the carriage and load so that the
rods of the main lift cylinders extend at least 2
feet. Close the gate valve. If the carriage or mast
weldments lower slowly, the seals in the lift cylinders have leaks.
4. If the carriage and mast weldments do not move,
open the gate valve and check for movement
again. If the carriage lowers when the valve is
open, check for leaks in the hydraulic lines or
fittings. If no leaks are found, the main control
valve can have a defect. Remove the load from
the forks.
TILT CYLINDERS LEAK CHECK
1. Put a capacity load on the forks. If the mast
slowly tilts forward when the control valve is in
the NEUTRAL position, there are leaks inside
the hydraulic system. The maximum speed that
the mast is allowed to tilt forward when there are
internal leaks in the lift system is 13 mm (0.5 in.)
per 10 minutes (measured at the tilt cylinder).
The maximum speed is measured when the hydraulic oil is 30 C (90 F). If the oil temperature
is 70 C (160 F), the maximum speed is 38 mm
(1.5 in.) per 10 minutes.
2. If the leak rate is greater than these specifications, remove the load from the mast. Install
a valve between the port at the front of the tilt
cylinder and the hydraulic line. Put the load on
the forks again. Close the valve. If the mast tilts
slowly forward, the cylinder seals are leaking. Be
sure to check both tilt cylinders.
3. If the mast does not move, open the gate valve
and check for movement again. If the mast
moves forward when the gate valve is open,
check for leaks in the hydraulic lines or fittings.
If no leaks are found, the main control valve can
have a defect. Remove the load from the forks.
45
Safety Procedures When Working Near Mast
8000 SRM 552
Safety Procedures When Working Near Mast
The following procedures must be used when inspecting or working near the mast. Additional precautions
and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are completely lowered or a safety chain is installed.
Also make sure that the power is off and the
key is removed. Put a "DO NOT OPERATE"
tag in the operator’s compartment.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• Do NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• Do NOT use blocks to support the mast weldments nor to restrain their movement.
• Mast repairs require disassembly and removal of parts and can require removal
of the mast or carriage. Follow the repair
procedures in the correct Service Manual
section for the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push
the lift/lower control lever forward and make
sure there is no movement in the mast. Make
sure that all parts of the mast that move are
fully lowered.
OR
2. If parts of the mast must be in raised position,
install a safety chain to restrain the moving parts
46
of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom crossmember of the weldment that moves in the
outer weldment with a crossmember on the
outer weldment. On the two-stage and freelift mast, the moving part is the inner weldment. On the three-stage mast it is the intermediate weldment. On the four-stage mast it
is the first intermediate weldment. See Figure 42.
c. Use a 9.4 mm (3/8 in.) minimum safety chain
with a hook to fasten the crossmembers together so that the movable member cannot
lower. Put the hook on the back side of the
mast. Make sure the hook is completely engaged with a link in the chain. Make sure
the safety chain does not touch lift chains or
chain sheaves, tubes, hoses, fittings or other
parts on the mast.
d. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (freelift and three-stage masts only) is completely
retracted. If running, stop the engine. Apply
the parking brake. Install a "DO NOT REMOVE" tag on the safety chain(s).
e. Install another safety chain [9.4 mm (3/8 in.)
minimum] between the top or bottom crossmember of the carriage and a crossmember
on the outer weldment.
3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a "DO NOT OPERATE" tag
in the operator’s compartment.
8000 SRM 552
Safety Procedures When Working Near Mast
Figure 42. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
47
Lift Chain Adjustments
8000 SRM 552
Legend for Figure 42
A. TWO-STAGE MAST
B. FREE-LIFT MAST
C. THREE-STAGE MAST
D. FOUR-STAGE MAST
1.
2.
3.
4.
5.
6.
7.
8.
OUTER WELDMENT
INNER WELDMENT
INTERMEDIATE WELDMENT
FIRST INTERMEDIATE WELDMENT
HOOK
FREE-LIFT CYLINDER
CROSSMEMBER
CROSSMEMBER
Lift Chain Adjustments
WARNING
When working on or near the mast, see in this
section. Never allow anyone 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 engine is STOPPED. Do not try to find hydraulic
leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be
injected into the body by the pressure. During
test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away
from the lift truck during the tests.
2. Adjust the chain anchors which support the carriage until the bottom of the fork heel is 6 ±3 mm
(0.25 ±0.12 in.) above the floor level. See Figure 43.
3. See Figure 44. Adjust the chain anchors which
support the carriage until the bottom of the lower
carriage bar is above the floor level as shown in
Table 2.
Table 2. Hook Type Carriage Chain Adjustment
Class II and III
82.5 ± 3 mm (3.25 ± 0.12 in.)
Class IV
133.5 ± 3 mm (5.25 ± 0.12 in.)
When the lift chains are correctly adjusted:
• The tension will be the same on each chain of the
chain set. Check tension by pushing on both chains
at the same time.
• The chain length will be correct.
• The chains must travel freely through the complete
cycle.
NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain
anchors are completely engaged. Make sure that all
of the adjustment is not removed from the chain anchors. The chain anchors must be able to move on
their mounting.
1. When adjusting the lift chains on forklift trucks
equipped with either pin or hook forks installed,
go to Step 2 . If the forklift truck is normally
equipped with a hook type carriage and has an
attachment without forks, go to Step 3. If the
forklift truck is normally equipped with a pin
type carriage and has an attachment without
forks go to Step 4.
NOTE: Prior to performing adjustment procedures
make sure that the forklift truck is parked on a level
surface and that the mast is in the vertical position.
48
1.
2.
3.
4.
TILT MAST FULLY BACKWARD
CARRIAGE ROLLER
FORK
CARRIAGE ROLLER MUST NOT EXTEND
MORE THAN 34 mm (1.3 in.)BELOW INNER
MAST CHANNEL
Figure 43. Lift Chain Adjustment, Hook or Pin
Type Forks
8000 SRM 552
PMT Circuit Check
1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR
Figure 44. Lift Chain Adjustment, Hook Type
Carriage
4. See Lift Chain Adjustment, Pin Type Carriage.
Adjust the chain anchors which support the carriage until the center line of the fork pin is above
the floor level as shown in Table 3.
Table 3. Pin Type Carriage Chain Adjustment
H70/80, 90 XLS
545 ± 3 mm (21.5 ± 0.12 in.)
H90-110 XL
708 ± 3 mm (27.88 ± 0.12 in.)
H135-155XL
907 ± 3 mm (35.75 ± 0.12 in.)
1. LOAD BACKREST
2. FORK PIN
3. DISTANCE FROM FORK PIN TO FLOOR
Figure 45. Lift Chain Adjustment, Pin Type
Carriage
PMT Circuit Check
WARNING
Some malfunctions can make the traction motor run at high speed with no control by the
speed controller. The PMT circuit prevents operation if these malfunctions occur. Do not operate the lift truck if the PMT circuit does not
operate correctly.
The Pulse Monitor Trip (PMT) circuit only functions
if a fault occurs. To check the circuit, we must cause
a temporary malfunction. Check the PMT circuit for
correct operation as follows:
1. Raise the drive wheels and put the lift truck on
blocks. See How to Raise Drive Tires in this section. Release the parking brake.
49
PMT Circuit Check
WARNING
Disconnect the battery connector before making any inspections or repairs. Personal injury
or equipment and tool damage can occur if the
battery is not disconnected.
On unit before "XM 2" units, do not touch the
terminals of capacitor C1 of the traction or lift
control circuits. The charge on the capacitors
can cause electrical shock and personal injury.
Use an insulated screwdriver or jumper wire to
make a short-circuit across the capacitor terminals to discharge each capacitor. This will
discharge the capacitors to prevent electrical
shocks.
On "XM 2" units, do not touch the power terminals of the motor controllers. The charge on
the capacitors can cause electrical shock and
personal injury. Disconnect the battery connector and push the horn button until the horn
stops making a noise to discharge the capacitors.
2. Disconnect the battery and discharge capacitor(s) C1 as previously described in the WARNING.
3. EV-100ZX Motor Controller. Disconnect the
gate lead from the SCR 5 (SCR panel) for the traction circuit. The gate lead has a push-on connector on the SCR panel. Make sure that the end
of the gate lead does not touch any other surface.
See the section Diagrams that came with the lift
truck for the location of the gate lead.
EV-T100 Transistor Controller. Connect a
jumper wire across the bus bars for the Contactor 1A. The logic circuit will sense a short-circuit
and prevent the operation of the motor controller.
8000 SRM 552
6. Listen for the direction contactor to open. The
traction system will not operate. The traction
motor controller will allow two power pulses before opening the contactor.
7. When the PMT circuit disables the traction control, turn the key to the "OFF" position. If the
PMT circuit does not disable the traction control,
replace the control card. See the sections:
• EV-100ZX™ Motor Controller Description
& Operation and Repairs & Adjustments
2200 SRM 557
• EV-T100™ Transistor Motor Controller
Description & Operation and Repairs &
Adjustments 2200 SRM 581
8. SR (SEM) Transistor motor controller: Disconnect the battery and discharge capacitor(s) C1
as previously described in the WARNING. Disconnect one of the power leads for the motor field
(F1 or F2) at the top of the SR motor controller.
Make sure that the end of the F1 or F2 lead does
not touch any other surface. Connect the battery. Apply the service brakes and actuate the
Monotrol control pedal or the direction control
lever and accelerator for slow movement in the
FORWARD or REVERSE direction. The traction
motor will try to run for approximately one second and then not operate. A status code 49 will
appear on the LCD screen of the SEM Display
Panel.
9. When the PMT circuit disables the traction control, turn the key to the OFF position. If the PMT
circuit does not disable the traction control, replace the motor controller. See the sections:
• Transistor Motor Controllers (SR and SP)
Description & Operation and Repairs &
Adjustments 2200 SRM 724
4. Connect the battery.
10. Disconnect the battery, open the electrical
compartment, and discharge capacitors C1 as
described in the earlier WARNING.
5. Sit on the seat to close the seat switch and turn
the key to the ON position. Actuate the Monotrol
control pedal or the direction control lever and
accelerator for slow movement in the FORWARD
or REVERSE direction.
11. Connect the gate lead, disconnect any jumper
wires or connect the F1 or F2 leads. Connect the
battery. Raise the drive wheels and remove the
blocks. Check for normal operation of the traction motor.
50
8000 SRM 552
Wheels and Tire Maintenance
Welding Repairs
WARNING
CAUTION
Welding can cause a fire or an explosion. Always follow the instructions in the Frame section of the Service Manual if a fuel or hydraulic
tank must be welded. Make sure there is no
fuel, oil, or grease near the weld area. Make
sure there is good ventilation in the area where
the welding must be done.
Do not heat, weld, or bend forks. Forks are
made of special steel using special methods.
Get information from your dealer for Hyster
lift trucks before welding on a mast.
When an arc welder is used, always disconnect
the battery connector on the lift truck. This
action will prevent damage to the SCR control.
Connect the ground clamp for the arc welder as
close as possible to the weld area. This action
will prevent damage to a bearing from the large
current from the welder.
Some repairs require welding. If an acetylene or arc
welder is used, do the procedures in the following
WARNING and CAUTION.
Overhead Guard Changes
Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.
that are too big in the wrong location, can reduce the strength of the overhead guard. See
your dealer for Hyster lift trucks before making any changes to the overhead guard.
Do not make changes to the overhead guard by
welding or drilling. Welding, or drilling holes
Observe previous WARNING before doing any
changes to overhead guard.
WARNING
Wheels and Tire Maintenance
TIRES AND WHEELS E25-65XM AND
E25-65XM 2
WARNING
The type of tire is shown on the nameplate.
Make sure the nameplate is correct for the
type of tires on the lift truck.
Wheels must be changed and tires repaired by
trained personnel only.
Always wear safety glasses.
This series of lift trucks use solid rubber tires. See
Figure 46. Solid rubber tires made from softer or
harder material can be installed as optional equipment. The tread on the solid rubber tires can be either smooth or it can have lugs. Electric compound
tires are recommended. Do not mix types of tires or
tread on the lift truck.
1. SOLID RUBBER TIRE
2. WHEEL
Figure 46. Tire and Wheel
Remove Wheels from Lift Truck
1. Raise the lift truck as described in How to Put
Lift Truck on Blocks in this manual.
2. Remove the wheel nuts or spindle nut and remove the wheel from the lift truck. Lift truck
wheels are heavy.
51
Wheels and Tire Maintenance
Remove and Install Tire on Wheel
NOTE: Make sure the tires are installed on the
wheels so that the outside edges of the tire and
wheel are as shown in Figure 46. Also check the
nameplate of the lift truck for the correct tire size
and tread width.
1. The correct tools, equipment and a press ring
must be used for each size of wheel. Use a press
to push the wheel from the rim and tire. The capacity of the press must be approximately 18 to
89 kN (80,000 to 400,000 lb). For the tire sizes,
see the nameplate.
WARNING
Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation
and on all lift trucks when the wheels have
been removed and installed. Tighten the nuts
in a cross pattern to the correct torque value
shown in the Maintenance Schedule. When
the nuts stay tight for eight hours, the interval
for checking the torque can be extended to 500
hours.
2. When the drive wheels are installed on the lift
truck, tighten the wheel nuts to the value shown
in the Maintenance Schedule.
3. The steering wheels are fastened to the spindle of
the steering axle with a large castle nut. Make
sure the inner and outer bearings are correctly
lubricated with grease. Install the inner bearing
assembly and wheel on the spindle. Install the
outer bearing cone and castle nut. Tighten the
castle nuts of the steer wheel spindles of these
units to 68 N•m (50 lbf ft) while rotating the
wheel in each direction at EACH installation.
Loosen the nuts 1/4 turn. Pull and push at top of
wheel to check for movement (end play). If there
is movement, tighten the castle nuts to 3 N•m
(2 lbf ft). Install the cotter pins at the nearest
alignment positions. Install the hub cap. Additional torque checks are not required.
52
8000 SRM 552
PNEUMATIC TIRES AND WHEELS
J40-65XM AND J40-65XM 2
Remove Wheels from Lift Truck
WARNING
A solid rubber tire that is the same shape as
a pneumatic tire can be installed on a wheel
for a pneumatic tire. DO NOT make changes
in the parts of the rim if this type of solid rubber tire is installed instead of a pneumatic tire.
Changes to the parts of the rim can cause a failure of the wheel and cause an accident.
The type of tire and the tire pressure (pneumatic tires) are shown on the nameplate. Make
sure the nameplate is correct for the type of
tires on the lift truck.
WARNING
Wheels must be changed and tires repaired by
trained personnel only.
Deflate tire completely before removing the
wheel from the lift truck. If dual wheels are
used, deflate both tires. Air pressure in the
tires can cause the tire and rim parts to explode causing serious injury or death.
Always wear safety glasses.
1. Put the lift truck on blocks as described in How
to Put Lift Truck on Blocks at the beginning of
this section.
2. Remove the air from the tire. Remove the valve
core to make sure that all of the air is out of the
inner tube. Push a wire through the valve stem
to make sure that the valve stem does not have a
restriction.
3. Remove the wheel nuts and remove the wheel
and tire from the lift truck. Lift truck tires and
wheels are heavy. See Figure 47.
8000 SRM 552
Wheels and Tire Maintenance
A. OPTIONAL RIM ASSEMBLY
B. THREE-PIECE WHEEL
C. FOUR-PIECE WHEEL
1. WHEEL RIM
2. SIDE FLANGE
3. LOCK RING
4. FLANGE SEAT
Figure 47. Types of Wheels for Pneumatic and Solid Pneumatic Tires
Remove Wheel from Pneumatic Tire
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air
pressure in the tires can cause the tire and rim parts to explode causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force
to cause an injury.
STEP 1.
Loosen the tire bead from the side flange.
STEP 2.
Put the tire tool into the slot between the lock ring
and wheel rim. Remove the lock ring and side flange.
If there is a flange seat, remove it.
53
Wheels and Tire Maintenance
8000 SRM 552
STEP 3.
Loosen the bead from the other side of the wheel rim.
Remove the valve stem from the wheel. If there is a
washer, keep it for installation during assembly.
STEP 4.
Remove the wheel rim from the tire.
Install Wheel in Pneumatic Tire
NOTE: There are two types of wheels used on this
series of lift trucks. See Figure 47.
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the following procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• Do NOT use any damaged or repaired wheel
parts.
• Make sure that all parts of the wheel are the
correct parts for that wheel assembly.
• Do NOT mix parts between different types or
manufacturers of wheels.
• Do NOT mix types of tires, type of tire tread,
or wheel assemblies of different manufacturers on any one lift truck.
Do not use a steel hammer on the wheel. Use
a rubber, lead, plastic or brass hammer to put
parts together. Make sure that the lock ring is
in the correct position. The ends of the lock
ring must not touch. The clearance at the ends
of the lock ring will be approximately 13 to
54
25 mm (0.5 to 1.0 in.) after it is installed. If the
clearance is wrong, the wrong part has been
used.
1. Clean and inspect all parts of the wheel. Paint
any parts that have rust or corrosion.
2. Install a new inner tube in the tire. Used tubes
and flaps can cause tire failure.
3. Apply a rubber lubricant or a soap solution to the
tire bead and tube.
WARNING
Do not lubricate the tire bead with antifreeze
or petroleum based liquid. Vapors from these
liquids can cause an explosion during inflation
or use.
4. Install a new tire flap.
5. Make sure the rim is the correct size for the tire.
Lubricate the part of the wheel that contacts the
bead and flap.
6. Install the three-piece or four-piece wheel in the
tire as shown in Install Three- or Four-Piece
Wheel in Pneumatic Tire.
8000 SRM 552
Wheels and Tire Maintenance
Install Three- or Four-Piece Wheel in Pneumatic Tire
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• Do NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• Do NOT mix parts between different types or manufacturers of wheels.
• Do NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on
any one lift truck.
Do not use a steel hammer on the wheel. Use a rubber, lead, plastic or brass hammer to put parts
together. Make sure that the lock ring is in the correct position. The ends of the lock ring must not
touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.)
after it is installed. If the clearance is wrong, the wrong part has been used.
STEP 1.
Install the inner tube and the rubber flap in the tire.
STEP 2.
Install the wheel rim in the tire. Install the washer
on the stem (if removed during disassembly). Make
sure the stem of the inner tube is aligned with the
slot in the rim.
STEP 3.
Turn over the rim and tire. Put blocks under the rim
so that the rim is 8 to 10 cm (3 to 4 in.) above the floor.
Install the flange seat (if used) and the side flange.
Hold them in the correct position.
55
Wheels and Tire Maintenance
8000 SRM 552
STEP 4.
Put the lock ring in the correct position on the rim.
Add air pressure to the tire as described in Add Air
to Tires.
Add Air to Tires
WARNING
Add air pressure to the tires only in a safety
cage. Inspect the safety cage for damage before
use. When air pressure is added, use a chuck
that fastens onto the valve stem of the inner
tube. Make sure there is enough hose to permit
the operator to stand away from the safety cage
when air pressure is added to the tire.
Do not sit or stand by the safety cage. Do not
use a hammer to try and correct the position of
the side flange or lock ring when the tire has
air pressure greater than 20 kPa (3 psi).
1. Put the tire in a safety cage. See Figure 48.
2. Add 3 psi of air pressure to the tire.
3. Check that all wheel parts are correctly installed.
Hit the lock ring lightly to make sure that it is in
the seat.
4. If installation is correct, add air pressure to the
tire to the specified pressure.
5. Check that all wheel parts are correctly installed.
If installation is not correct, remove all of the air
pressure from the tire. Remove the valve core
to make sure all of the air pressure has been removed and then make adjustments. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire
has the correct air pressure.
56
Figure 48. Add Air to Tires
Wheels, Install
WARNING
Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation
and on all lift trucks when the wheels have
been removed and installed. Tighten the nuts
in a cross pattern to the correct torque value
shown in the Maintenance Schedule. When
the nuts stay tight for eight hours, the interval
for checking the torque can be extended to 500
hours.
Install the wheel on the hub. Tighten the nuts as
shown in the Maintenance Schedule.
8000 SRM 552
SOLID RUBBER TIRES ON PNEUMATIC
WHEELS
Remove Wheels from Lift Truck
WARNING
Wheels must be changed and tires repaired by
trained personnel only.
Wheels and Tire Maintenance
Always wear safety glasses.
1. Put the lift truck on blocks as described in How
to Put Lift Truck on Blocks at the beginning of
this section.
2. Remove the wheel nuts and remove the wheel
and tire from the lift truck. Lift truck tires and
wheels are heavy.
Remove Solid Rubber Tire from Pneumatic Wheel
NOTE: There are two types of pneumatic wheels used on these trucks. See Figure 47.
WARNING
Wheels must be changed and tires repaired by trained personnel only.
Always wear safety glasses.
WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to
cause serious injury.
STEP 1.
Put the wheel rim on the bed of the press. Put the
cage in position on the tire. Use the press to push
the tire away from the side flange.
STEP 2.
Put the tire tool into the slot between the lock ring
and the wheel rim. Remove the lock ring and side
flange. If there is a flange seat, remove it.
57
Wheels and Tire Maintenance
STEP 3.
Turn the tire over. Put a support under the wheel
rim. Make sure the wheel rim is at least 150 to
200 mm (6 to 8 in.) from the bed of the press.
STEP 4.
Put the cage in position on the tire. Use the press to
push the tire from the wheel rim.
58
8000 SRM 552
8000 SRM 552
Wheels and Tire Maintenance
Install Solid Rubber Tire on Pneumatic Wheel
NOTE: There are two types of pneumatic wheels used on these trucks. See Figure 47.
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• Do NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for the wheel assembly.
• Do NOT mix parts between different types or manufacturers of wheels.
• Do NOT mix type of tires, type of tire tread or wheel assemblies of different manufacturers on
any one lift truck.
Do NOT use a steel hammer on the wheel. Use a rubber, lead, plastic or a brass hammer to put
parts together. Make sure that the lock ring is in the correct position. The ends of the lock ring
must not touch. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.05
to 1.0 in.) after it is installed. If the clearance is wrong, the wrong part has been used.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
STEP 1.
Lubricate the wheel rim and the inner surface of the
tire with tire lubricant or soap.
STEP 2.
Put the wheel rim on the bed of the press. Put the
tire over the wheel rim. Put the cage in position on
the tire. Use the press to install the tire on the wheel
rim.
59
Wheels and Tire Maintenance
8000 SRM 552
STEP 3.
Remove the cage and put the flange seat (if used),
the side flange and the lock ring in position on the
wheel rim. Install the cage on the tire. Use the press
to push the tire onto the wheel rim so that the side
flange and lock ring can be installed.
STEP 4.
While the cage is holding the tire on the wheel rim,
install the lock ring. Use a tire tool to make sure the
lock ring is in the correct position.
Wheels, Install
WARNING
Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation
and on all lift trucks when the wheels have
been removed and installed. Tighten the nuts
60
in a cross pattern to the correct torque value
shown in the Maintenance Schedule. When
the nuts stay tight for eight hours, the interval
for checking the torque can be extended to 500
hours.
Install the wheel on the hub. Tighten the nuts as
shown in the Maintenance Schedule.
8000 SRM 552
Adhesives and Sealants
Adhesives and Sealants
Hyster Part
No.
Loctite®
Part No.
360387
222
Small Screw Threadlock (Purple)
50 ml (1.7 oz)
318702*
242
Removable Threadlock (Blue)
10 ml (0.34 oz)
226414*
271
High Strength Threadlock (Red)
10 ml (0.34 oz)
318996
277
High Viscosity Threadlock (Red)
50 ml (1.7 oz)
318650
290
Low Viscosity Threadlock (Green)
0.6 ml (0.02 oz)
251099
290
Low Viscosity Threadlock (Green)
50 ml (1.7 oz)
355844*
422
SuperBonder® Adhesive
3 ml (0.1 oz)
350830
515
Gasket Eliminator (Purple)
6 ml (0.2 oz)
313022*
515
Gasket Eliminator (Purple)
50 ml (1.7 oz)
273338*
567
Pipe Sealant with Teflon® (White)
50 ml (1.7 oz)
318705
595
Super Flex® Silicone
100 ml (3.5 oz)
318701*
609
Retaining Compound
10 ml (0.34 oz)
341959
680
Retaining Compound
50 ml (1.7 oz)
226415
Primer T - Aerosol
177 ml (6 oz)
316865
Anti-Seize Compound
476 ml (1 lb)
360053-10
Chisel Gasket Remover (10 Aerosol cans per case)
318700*
Loctite®,
Teflon®
Description
Size
536 ml (18 oz)
Adhesive & Sealant Kit (Contains one each of * items)
Flex®,
Super
and SuperBonder® are registered trademarks of the Loctite Corporation.
is a registered trademark of Du Pont de Nemours Co. Inc.
61
NOTES
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62
TECHNICAL PUBLICATIONS
8000 SRM 552
5/01 (10/99)(3/99)(9/96)(3/95)(7/94) Printed in United Kingdom
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