Hyster D114 (E25-40XM) Service Manual - Image 2

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Hyster D114 (E25-40XM) Service Manual - Image 5

Hyster D114 (E25-40XM) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 795
Size: 40.0MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- D114 (E25-40XM)

1. INTRODUCTION
2. GENERAL
3. LEAD-ACID BATTERIES
4. SPECIFIC GRAVITY
5. THE CHEMICAL REACTION IN A CELL
6. ELECTRICAL TERMS
7. HOW TO SELECT THE BATTERY
8. VOLTAGE OF A BATTERY
9. THE BATTERY AS A COUNTERWEIGHT
10. BATTERY RATINGS
11. Kilowatt-Hours
12. BATTERY MAINTENANCE
13. SAFETY PROCEDURES
14. MAINTENACE RECORDS
15. THE NEW BATTERY
16. HOW TO CLEAN THE BATTERY
17. HOW TO ADD WATER
18. THE HYDROMETER
19. BATTERY TEMPERATURE
20. CHARGING THE BATTERY
21. Types Of Battery Charges
22. Methods Of Charging
23. Troubleshooting The Charger
24. How To Know When The Battery Is Fully Charged
25. WHERE TO CHARGE THE BATTERIES
26. Equipment Needed
27. BATTERY CONNECTORS
28. BATTERY CARE
29. INTRODUCTION
30. GENERAL
31. DESCRIPTION
32. Main Frame
33. Other Frame Weldments
34. Battery Restraint And Hood Frame
35. Overhead Guard
36. REPAIRS
37. OVERHEAD GUARD
38. Removal
39. Installation
40. BATTERY RESTRAINT AND SEAT ASSEMBLY
41. COUNTERWEIGHT
42. Removal
43. Installation
44. TRACTION MOTOR
45. Removing Traction Motor
46. Installing Traction Motor
47. HYRAULIC TANK
48. Inspection
49. Repairs, Small Leaks
50. Repairs, Large Leaks
51. Cleaning
52. Steam Method of Cleaning
53. Chemical Solution Method Of Cleaning
54. Additional Preparations For Repair
55. PAINTING INSTRUCITONS
56. LABEL REPLACEMENT
57. DC Motor Maintenance
58. Safety Precautions Maintenance and Repair
59. General
60. Brush and Commutator Inspection
61. Hydraulic Pump Motor and Traction Motor
62. Steering Pump Motor
63. Normal Commutator Surface
64. Commutator Problems
65. Brush Replacement
66. Stoning the Commutator
67. Motors Repair
68. Disassemble
69. Traction Motor and Hydraulic Pump Motor
70. Steering Pump Motor
71. Assemble
72. Traction Motor and Hydraulic Pump Motor
73. Steering Pump Motor
74. Brush Alignment, Traction and Hydraulic Motors
75. Tests for Damaged Field and Armature
76. Test for an Open Circuit in Armature
77. Test for Short Circuit in One Armature Winding
78. Test for Short Circuit to Armature Shaft
79. Test for Open Circuit in Field Coil
80. Test for Short Circuit in Field Coil
81. Test for Short Circuit between Field and Motor Case
82. Brush Holder Test
83. Troubleshooting
84. Table 1. Normal Commutator Surfaces
85. Table 2. Commutator Problems
86. Table 3. Brush Wear Replacement Guide
87.
87.1. INTRODUCTION
87.2. REPAIRS
87.3. TORQUE SPECIFICATIONS
87.4. TROUBLESHOOTING
88.
88.1. STEERING SYSTEM
88.2. POWER STEERING MOTOR AND PUMP
88.3. HYDRAULIC STEERING MOTOR
88.4. CHECKS AND ADJUSTMENTS
88.5. TROUBLESHOOTING
89.
89.1. INTRODUCTION
89.2. REPAIRS
89.3. CHECKS AND ADJUSTMENTS
89.4. TROUBLESHOOTING
90.
90.1. INTRODUCTION
90.2. REPAIRS
90.3. TORQUE SPECIFICATIONS
90.4. TROUBLESHOOTING
91.
91.1. INTRODUCTION
91.2. TORQUE SPECIFICATIONS
91.3. TROUBLESHOOTING
92.
92.1. INTRODUCTION
92.2. REPAIRS
92.3. CHECKS AND ADJUSTMENTS
92.4. TROUBLESHOOTING CHART
92.5. SPECIFICATIONS
93.
93.1. INTRODUCTION
93.2. REPAIRS
93.3. CHECKS AND ADJUSTMENTS
93.4. TROUBLESHOOTING
94.
95.
96.
96.1. Electrical System
96.2. Safety Precautions Maintenance and Repair
96.3. General
96.4. Description
96.5. ZX Series Display Panels
96.6. Display Panel
96.7. Basic Display Panels
96.8. Performance Display
96.9. Brush Wear Indicators
96.10. SEM Display Panels – Features
96.11. Descriptions of Common Features
96.12. Additional Features of Premium Display Panel
96.13. Descriptions of Additional Features
96.14. SEM Display Panel Indicators
96.15. All Indicator Symbols
96.16. Hourmeter Indicator Symbol
96.17. Wrench Indicator Symbol
96.18. Battery Indicator Symbol
96.19. Battery State-of-Charge (BDI)
96.20. Brake Fluid Too Low Symbol
96.21. Parking Brake Symbol
96.22. Fasten Seat Belt Symbol
96.23. LCD Screen (Standard Display Panel)
96.24. Additional Components of Premium Display Panel
96.25. Alpha Numerical Screen
96.26. STAR Push Button
96.27. Push Buttons 1 Through 5 – SEM
96.28. Other Control Components
96.29. Display Panel Components Replacement
96.30. ZX Panel Replacement
96.31. Display Panel Assembly
96.32. Key Switch, Replace
96.33. Indicator LEDs
96.34. Battery Indicators
96.35. Digital Display (Performance Display Panel Only)
96.36. Status Code or Performance Level Switches and Indicator LEDs (Pe
96.37. Basic Display Panel, Replace Parts
96.38. Performance Display Panel, Replace Parts
96.39. SEM Display Panel Replacement
96.40. Motor Controller (SR or SP) Replacement
96.41. Control Components Replacement
96.42. Start Switch, Replace
96.43. Brake Light Switch, Replace
96.44. Seat Switch, Replace
96.45. External Seat Switch, Adjust
96.46. Switch for Optional Seat Brake, Replace
96.47. Parking Brake Switch, Replace
96.48. Direction Switches (MONOTROL Pedal), Replace
96.49. Direction Control Switches (Steering Column), Replace
96.50. Direction Control Switches, E70-120XL 3 (Steering Column)
96.51. Brake Fluid Switch, Replace
96.52. Brush Wear and Overtemperature Sensors
96.53. Rocker Switches for Lights
96.54. Accelerator Position Sensor, Replace
96.55. On-Demand Steering Components
96.56. Lights, Converter, Relay, and Reverse Alarm
96.57. Brake, Tail, and Reverse Light Assembly, Replace
96.58. Flashing Light Assembly, Replace
96.59. Front, Rear Driving Light, or Spot Light Assemblies, Replace
96.60. Operator Compartment Light Assembly, Replace
96.61. Converter, Replace
96.62. Relay, Replace
96.63. Reverse Alarm, Replace
96.64. Horn and Horn Button
96.65. Horn Switch and Cover
96.66. Hydraulic Pump Switches
96.67. Control and Power Fuses Check
96.68. Brush Wear and Overtemperature Sensors Check – ZX
96.69. Thermal Sensors – SEM Check
96.70. Start Switch Adjustment
96.71. Accelerator Potentiometer and Start Switch E70-120XL, E70-120XL
96.72. E70-120XL
96.73. E70-120XL 3
96.74. Direction Switches (MONOTROL)
96.75. Brake Light Switch Adjustment
96.76. Seat Switch Check
96.77. Optional Seat Brake Switch Adjustment
96.78. Parking Brake Switch Adjustment
96.79. Direction Switches Check
96.80. Monotrol Pedal
96.81. Steering Column
96.82. Hydraulic Pump Switch Adjustment
96.83. MONOTROL or Accelerator Pedal Adjustment
96.84. Accelerator Position Sensor Adjustment
97.
98.
98.1. TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers
99.
99.1. EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables
99.2. TABLE 1. EV-100ZX Parameters (Heavey Duty Motor (8702303) Traction Card Type ZH or Zy With Regenerative Braking
99.3. TABLE 2. EV-100ZX Parameters (Heavy Duty Motor (8702303) Traction Card Type ZH or ZY No Regenerative Braking
99.4. TABLE 3. EV-100ZX Parameters (Standard Motor (P/N 8702301 or 8702302) Traction Card Type ZH or ZY With Regen. Braking
99.5. TABLE 4. EV-100ZX Parameters (Standard Motor (P/N 8702301 or 8702302) Traction Card Type ZH or ZY No Regen. Braking
99.6. TABLE 5. EV-100ZX Parameters-(Standard Motor (P/N 8702301 or 8702302) (Low Energy System)(Traction Card Type ZH and ZY
99.7. TABLE 6. EV-100ZX Parameters (Standard System) (Hydraulic Pump Card Type ZP With or Without Lift Interrupt)
99.8. TABLE 7. EV-100ZX Parameters (Low Energy System) (Hydraulic Pump Card Type ZP With or Without Lift Interrupt)
100.
100.1. EV-T100 TRANSISTOR MOTOR CONTROLLER, Parameter Tables
101.
102.
103.
103.1. INTRODUCTION
104.
104.1. INTRODUCTION
104.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
104.3. REPAIRS
104.4. CHECKS AND ADJUSTMENTS
104.5. TROUBLESHOOTING
105.
106.
106.1. FIGURE 1. J2.00-3.200XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
106.2. FIGURE 2. E1.50-3.20XMS TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
106.3. FIGURE 3. SCHEMATIC DIAGRAM, TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
106.4. FIGURE 4. WIRING DIAGRAM, J2.00-3.20XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
106.5. FIGURE 5. WIRING DIAGRAM, J2.00-3.20XM TRANSISTOR CONTROLLER FOR TRACTION MOTOR, CONTACTOR CONTROLLER FOR HYDRAULIC PUMP
106.6. FIGURE 6. WIRING DIAGRAM, E1.50-3.20XMS TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
106.7. FIGURE 7. WIRING DIAGRAM, E1.50-3.20XMS TRANSISTOR CONTROLLER FOR TRACTION MOTOR, CONTACTOR CONTROL FOR HYDRAULIC PUMP
106.8. FIGURE 8. WIRE HARNESS, J2.00-3.20XM
106.9. FIGURE 9. POWER CABLES AND BATTERY CONNECTOR, J2.00-3.20XM
106.10. FIGURE 10. E1.50-3.20XM TRUCK WIRING
106.11. FIGURE 11. TRUCK POWER CABLES
106.12. FIGURE 12. TRUCK POWER CABLES
106.13. FIGURE 13. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS
106.14. FIGURE 14. WIRING SCHEMATIC FOR THE INSTRUMENT PANEL, E/J2.00-3.20XM
106.15. FIGURE 15. DISPLAY PANELS AND PLUG CONNECTIONS
106.16. FIGURE 16. CONFIGURATION OF THE EV-T100 MOTOR CONTROLLER MODULE
106.17. FIGURE 17. CONTROL CARD CONNECTIONS
106.18. FIGURE 18. TRUCK MANAGEMENT MODULE (TMM1)
106.19. FIGURE 19. WIRING SCHEMATIC, E2.00-3.20XM TRANSISTOR CONTROLLERS FOR TRACTION MOTOR AND HYDRAULIC PUMP MOTORS
106.20. FIGURE 20. DETAIL OF BATTERY CONNECTOR WITH 12 VOLT TAP
106.21. FIGURE 21. HYDRAULIC SCHEMATIC, E/J2.00-3.20XM E1.50-2.00XMS
106.22. FIGURE 22. WIRING DIAGRAM FOR LIGHTS
107.
107.1. WHEELS AND TIRES
107.2. COUNTERWEIGHTS
107.3. HYDRAULIC SYSTEM
107.4. CAPACITIES
107.5. BATTERY SPECIFICATIONS
107.6. BATTERY HEIGHT SPECIFICATIONS (Hoods and Battery Types)
107.7. MAXIMUM CARRIAGE AND TILT CREEP RATES
107.8. E25-40XM MAST SPEEDS (36 48 VOLT) Americas
107.9. E1.50-2.00XM MAST SPEEDS (48 VOLT) Europe
107.10. E25-40XM, E25-40XM2 MAST SPEEDS (3/99) Americas
107.11. E1.50-1.75XM E2.00XMS MAST SPEEDS (3/99) Europe
107.12. TORQUE SPECIFICATIONS
107.13. REFERENCE TABLE
108.
109.
109.1. INTRODUCTION
109.2. MAINTENANCE SCHEDULE
109.3. MAINTENANCE PROCEDURES
109.4. EVERY 8 HOURS OR DAILY
109.5. EVERY 350 HOURS OR TWO MONTHS
109.6. EVERY 2000 HOURS OR YEARLY
109.7. GENERAL PROCEDURES
109.8. REFERENCE TABLE

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