HYSTER E25XM2, E30XM2, E35XM2, E40XMS2 Electric Forklift Service Repair Manual & Parts Manual (D114)

1 INTRODUCTION GENERAL This section contains a MAINTENANCE SCHEDULE and the instructions for maintenance and inspection. The MAINTENANCE SCHEDULE has time intervals for inspection, lubrication and maintenance for your lift truck. The service intervals are given in both operating hours recorded on the lift truck hour meter, and in calen- dar time. Use the interval that occurs first. The recommendation for the time intervals are for eight hours of operation per day. The time intervals must be decreased from the recommendations in the MAINTE- NANCE SCHEDULE for the following conditions: a. If the lift truck is used more than eight hours per day. b. If the lift truck must work in dirty operating conditions. 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. 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. 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. Dis- connect the battery connector. 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 cannot move. CAUTION Disposal of lubricants and fluids must meet local environmental regulations. CAUTION Disposal of batteries must meet local environmental regulations. SERIAL NUMBER DATA The serial number code for the lift truck is on the nameplate. The code is also stamped on the right side of the front face of the rear bulkhead (battery compartment) near the top. HOW TO MOVE A DISABLED LIFT TRUCK WARNING Use extra caution when towing a lift truck if there is a problem with any of the following: • 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. This can make the control of the lift truck difficult. If there is no electrical power, there is no power steering. Do NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehi- cle 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. 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.

2 How To Tow A Lift Truck 1. The towed lift truck must have an operator. 2. Raise the carriage and forks approximately 30 cm (12 inches) from the surface. Install a chain 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 A LIFT TRUCK ON BLOCKS 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 and drive assembly, battery or the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: a. Before removing the mast and drive assembly, put blocks under the counterweight so that the lift truck can not fall backward. b. Before removing the counterweight, put blocks under the mast assembly so that the lift truck can not fall forward. Put the lift truck on blocks only if the surface is solid, even and level. 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. How To Raise The Drive Tires (See FIGURE 1.) 1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck. 2. Put the mast in a vertical position. Put a block under each outer mast channel. 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. 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 The Steering Tires (See FIGURE 1.) 1. Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck. 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.

3 FIGURE 1. PUT THE LIFT TRUCK ON BLOCKS DRIVE TIRES STEERING TIRES 12911 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, 2 MONTH 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, 350, 2000). The approximate loca- tions of the items indicated in the MAINTENANCE SCHEDULE are shown in FIGURE 2. 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. E1.50–1.75XM, E2.00XMS (E25–35XM, E40XMS) MAINTENANCE POINTS 19 8 9 2 17 12858 1 2 3 3 4 5 6 7 6 14 13 10 15 1 16 9 18 3 20 19 21 10 11 12 19

4 TABLE 1. MAINTENANCE SCHEDULE (Item No. Reference FIGURE 2.) ITEM NO. ITEM 8 hr or 1 day 350 hr or 2 mo. 2000 hr or 1 yr. PROCEDURE OR QUANTITY SPECIFICATIONS OIL LEAKS X Check for leaks 1 TIRES X Check condition 13 FORKS X Check condition 12 MAST AND CARRIAGE X Check operation SAFETY LABELS X Replace as necessary See Parts Manual 17 DIRECTION AND SPEED CONTROL X Check operation STEERING X Check operation GUAGES, HORN, LIGHTS, REVERSE ALARM AND FUSES X Check operation BATTERY HOOD LATCH OR BATTERY RESTRAINT X 1 X Check condition Check operation SEAT BELT AND SEAT RAILS X CIL Check condition 4 HYDRAULIC OIL (“FULL” mark) X C 11.3 litre (3 gal) 54°C to 66°C (130°F to 150°F) SAE 10W API SC/CC 7 PARKING BRAKE X CIL L Check operation Lubricate linkage Silicone Spray (P/N Hyster 328388) 11 LIFT CHAINS X L X L Check condition and lubricate Check adjustment and length. Clean and soak. 30W Motor Oil 30W Motor Oil 15 FORK GUIDES AND LOCKS X L As necessary Motor oil 18 HYDRAULIC FILTER C 2 C 1 See Parts Manual 3 MOTOR BRUSHES CIL X Check condition See Parts Manual 6 SERVICE BRAKES X X Check operation Check condition See Parts Manual 8 BRAKE FLUID CIL X 0.24 litre (0.5 pint) SAE J–1703 SEAT AND PARKING BRAKE ADJUSTMENT X Adjust as necessary Must hold a load on a 15% grade 16 20 WHEEL TORQUES Drive Wheels (Wheel Bolts) Steer Wheels (Spindle Nut) X X Check Torque Check Grease & Tighten to Correct Torque 330 Nm (244 lb f ft) Multi–Purpose Grease 3 200 Nm (144 lb f ft), loosen, then 34 Nm (25 lb f ft) X = Check C= Change L = Lubricate CIL = Check Indicator Light during operation 1 Equalization charge is required approximately each month. 2 Change filters on NEW lift trucks at the first 100 hours on the Hourmeter. NOTE: Never use steam to clean electrical parts. REFER TO SERVICE MANUAL FOR DETAILED INFORMATION.

5 ITEM NO. ITEM 8 hr or 1 day 350 hr or 2 mo. 2000 hr or 1 yr. PROCEDURE OR QUANTITY SPECIFICATIONS 19 STEERING SPINDLE AND LINKAGE L* As required* Multi–Purpose Grease 3 21 CONTACTORS X C 4 Check condition See Parts Manual HINGES, LEVERS, LINKAGE, PEDALS SEAT RAILS L L As required Multi–Purpose grease 3 or Sili- cone Spray (P/N Hyster 328388) 14 DIFFERENTIAL/SPEED REDUCER X C 2.9 liters (3.1 quarts) Ultr Gear Lube SAE 80W or Gear oil SAE 80W–90 (Chevron) or equivalent 5 HYDRAULIC TANK BREATHER C Clean or replace See Parts Manual 2 WHEEL BEARINGS L As necessary Multi–Purpose grease 3 X = Check C= Change L = Lubricate CIL = Check Indicator Light during operation 3 Multi–Purpose Grease with 2–4% Molybdenum Disulfide 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 *8 fittings at 200 hr. NOTE: Never use steam to clean electrical parts. REFER TO SERVICE MANUAL FOR DETAILED INFORMATION. MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY Do all safety and operational checks as shown in the MAINTENANCE SCHEDULE. WARNING 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. HOW TO MAKE CHECKS WITH THE KEY SWITCH “OFF” Inspect the lift truck every eight hours or daily before use. Put the lift truck on a level surface. Lower the carriage and forks and turn the key to the OFF position. Ap- ply the parking brake. Remove the floor plates and inspect for leaks and conditions that are not normal. Clean any oil spills. Make sure that lint, dust, paper and other materials are removed from the compartments. Make the additional checks as described in the following para- graphs of HOW TO MAKE CHECKS WITH THE KEY SWITCH “OFF” and HOW TO MAKE CHECKS WITH THE KEY SWITCH “ON”. Tires And Wheels (See FIGURE 3.) Inspect the tires for wire, rocks, glass, pieces of metal, holes, cuts and other damage. Remove any object that will cause damage. Check for loose or missing hard- ware. Remove any wire strapping or other material that is wrapped around the axle. Make sure the wheel bolts are tight. Tighten the wheel bolts in a cross pattern to the correct torque value shown in the MAINTENANCE SCHEDULE table. CAUTION Check all wheel bolts 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 shown in the MAINTENANCE SCHEDULE. When the nuts stay tight for eight hours, the interval for checking the torque can be ex- tended to 350 hours.

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HYSTER E25XM2, E30XM2, E35XM2, E40XMS2 Electric Forklift Service Repair Manual & Parts Manual (D114)

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