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Hyster E001 (S25-35XM S40XMS) Service Manual – PDF DOWNLOAD
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Hyster E001 (S25-35XM S40XMS) Service Manual – PDF DOWNLOAD
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Description
Hyster E001 (S25-35XM S40XMS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E001 (S25-35XM S40XMS) Service Manual – PDF DOWNLOAD
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 whenmaking 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.
TABLE OF CONTENTS:
Hyster E001 (S25-35XM S40XMS) Service Manual – PDF DOWNLOAD
Hyster-S25-35SM,S40XMS-897556,897557-(12-2003).................................. 1 897556-1400SRM0542-(12-2003)-US-EN.......................................... 1 toc..................................................................... 1 Drive Axle.......................................................... 1 Safety Precautions Maintenance and Repair........................... 2 General............................................................. 5 Description......................................................... 6 Drive Axle Repair................................................... 6 Remove and Disassemble.......................................... 6 Clean and Inspect............................................... 7 Assemble and Install............................................ 7 Torque Specifications............................................... 9 Troubleshooting..................................................... 9 897557-1300SRM0543-(12-2003)-US-EN.......................................... 13 toc..................................................................... 13 Single-Speed Powershift Transmission................................ 13 Safety Precautions Maintenance and Repair........................... 14 General............................................................. 17 Torque Converter Description and Operation.......................... 18 Description..................................................... 18 Operation....................................................... 18 Clutch Assemblies Description and Operation......................... 20 Description..................................................... 20 Operation....................................................... 21 Hydraulic System Operation.......................................... 22 Control Valve Operation............................................. 24 Regulator for Clutch Pressure................................... 24 Inching Spool Assembly.......................................... 24 Direction Spool................................................. 24 Modulator Circuit............................................... 24 Regulator for the Torque Converter.............................. 24 MONOTROL® Pedal Operation........................................... 25 Direction Control Lever Operation................................... 25 Differential Operation.............................................. 25 Torque Converter and Transmission Pump Repair....................... 25 Remove and Disassemble.......................................... 25 Inspect......................................................... 26 Assemble and Install............................................ 26 Clutch Assemblies Repair............................................ 27 Remove and Disassemble.......................................... 27 Inspect......................................................... 30 Assemble and Install............................................ 30 Differential Repair................................................. 31 Remove and Disassemble.......................................... 31 Inspect......................................................... 31 Assemble and Install............................................ 31 New Ring and Pinion Assembly, Install....................... 32 Pinion Assembly, Install.................................... 35 Differential and Ring Gear Assembly, Assemble............... 36 Control Valve Repair................................................ 37 Remove.......................................................... 37 Disassemble, Earlier Models..................................... 37 Disassemble, Later Models....................................... 38 Inspect......................................................... 38 Assemble, Earlier Models........................................ 38 Assemble, Later Models.......................................... 39 Install......................................................... 39 MONOTROL® Pedal Repair.............................................. 40 Remove and Disassemble.......................................... 40 Assemble and Install............................................ 40 Direction Control Lever Repair...................................... 43 Remove and Disassemble.......................................... 43 Assemble and Install............................................ 43 Torque Converter Stall Test......................................... 44 Transmission Pressure Tests......................................... 45 Transmission Pump Pressure Check, Test Port No. 1............... 46 Torque Converter Inlet Pressure Check, Test Port No. 2.......... 46 Clutch Pressure Check, Test Port No. 3.......................... 46 Inching/Brake Pedal Adjustment...................................... 46 Troubleshooting..................................................... 46 tables.................................................................. 13 Table 1. Pinion Assembly Shims Adjustment........................... 33 Table 2. Ring and Pinion Tooth Contact Adjustment................... 34 Table 3. Stall Speeds............................................... 45 Table 4. Pressure Test Ports........................................ 45 Hyster-S25-35XM,S40XMS-897590,897592-(02-2001).................................. 55 897590-8000SRM0546-(02-2001)-US-EN.......................................... 55 toc..................................................................... 55 Capacities and Specifications....................................... 55 Safety Precautions Maintenance and Repair........................... 56 Engine Specifications............................................... 59 Electrical System................................................... 59 Hydraulic System.................................................... 60 Lift Truck Weights.................................................. 60 Torque Converter Stall Speeds....................................... 60 Tire Pressure....................................................... 61 Capacities.......................................................... 61 Mast Speeds......................................................... 62 Mazda M4-1.5G Engine Mast Speeds................................ 62 Mazda M4-2.0G Engine Mast Speeds................................ 62 Mazda M4-2.5D Engine Mast Speeds................................ 63 Transmission Oil Pressures.......................................... 63 Torque Specifications............................................... 64 Brake System.................................................... 64 Drive Axle...................................................... 64 Engine - Mazda M4-1.5G.......................................... 64 Engine - Mazda M4-2.0G.......................................... 64 Engine - Mazda M4-2.5D.......................................... 65 Frame........................................................... 66 Mast............................................................ 66 Steering System................................................. 66 Transmission and Differential................................... 66 897591-0900SRM0547-(02-2001)-US-EN.......................................... 69 toc..................................................................... 69 Gasoline Fuel System................................................ 69 Safety Precautions Maintenance and Repair........................... 70 Description......................................................... 73 Governor........................................................ 73 Carburetor Repair................................................... 74 Remove.......................................................... 74 Disassemble..................................................... 76 Clean........................................................... 78 Inspect......................................................... 78 Assemble........................................................ 79 Install......................................................... 82 Carburetor Checks and Adjustments................................... 82 Idle Speed and Mixture, Adjust.................................. 82 Throttle Linkage, Adjust........................................ 82 Governor Checks and Adjustments..................................... 84 Troubleshooting..................................................... 85 Hyster-S25-35XM,S40XMS-Instrument-Cluster-897495-2200SRM0514-(01-2004)-US-EN.... 91 toc......................................................................... 91 Instrument Cluster...................................................... 91 Safety Precautions Maintenance and Repair............................... 92 General................................................................. 95 Description............................................................. 95 Display Panels on Steering Column, Internal Combustion.............. 95 Display Panels on Steering Column, Electric Lift Trucks.............100 Standard Display Panel..........................................100 Enhanced Display Panel..........................................101 Curtis 1215 Display Panel...........................................105 Description and Features........................................105 Operation.......................................................105 Cluster-Type Display Panel (Internal Combustion) Replacement............106 Remove and Disassemble..............................................106 Assemble and Install................................................109 Cluster Display Panel (Electric Lift Truck) Replacement.................111 Display Panel Assembly, Replace.....................................111 LED Indicators......................................................111 Battery Indicators..................................................112 Digital Display (Enhanced Display Panel Only).......................112 Status Code or Performance Level Switches and LED indicators (En....112 Standard Display Panel Parts, Replace...............................112 Enhanced Display Panel Parts, Replace...............................113 Curtis 1215 Display Panel Replacement...................................113 Remove..............................................................113 Install.............................................................113 tables...................................................................... 91 Table 1. Instrument Cluster, Internal Combustion........................ 95 Hyster-S25-35XM,S40XMS-LPG-Fuel-System-1495954-0900SRM0948-(10-2006)-US-EN......117 toc.........................................................................117 LPG Fuel System.........................................................117 Safety Precautions Maintenance and Repair...............................118 General.................................................................121 Description and Operation...............................................121 Fuel Tank...........................................................121 Oxygen Sensor.......................................................121 Regulator...........................................................121 Start Mode......................................................124 Idle Mode.......................................................127 Run Mode........................................................127 Resonator...........................................................127 Carburetor..........................................................127 Start Mode......................................................127 Idle Mode.......................................................128 Run Mode........................................................128 Governor........................................................129 Hoses Replacement.......................................................129 LPG Tank Repair.........................................................130 Remove..............................................................130 Install.............................................................130 Relief Valve Repair.....................................................131 Remove and Install..................................................131 Carburetor Repair.......................................................131 Remove..............................................................131 Disassemble.........................................................131 Clean...............................................................132 Assemble............................................................132 Install.............................................................133 Fuel Injector Repair....................................................133 Remove..............................................................133 Clean and Inspect...................................................133 Install.............................................................133 Governor Repair.........................................................134 Remove..............................................................134 Inspect.............................................................134 Install.............................................................134 Regulator Repair........................................................134 Remove..............................................................134 Install.............................................................134 Oxygen Sensor Repair....................................................135 Remove and Install..................................................135 Vacuum Switches Repair..................................................135 Remove and Install..................................................135 Inspect.............................................................135 Resistor Repair.........................................................135 Remove and Install..................................................135 Inspect.............................................................135 Carburetor and New Regulator Adjustment.................................136 Idle Speed and Fuel Mixture.........................................136 Idle Control Adjustment.............................................136 Governor Checks and Adjustments.........................................137 Checks..............................................................137 Adjustments.........................................................138 Throttle Linkage Adjustment.............................................138 MONOTROL Pedal Check....................................................140 Check Engine Light......................................................140 Inspect Warning Lamp................................................140 Check Feedback Operation............................................140 Check VAC1 and VAC2 Signals.........................................140 Check Resistor......................................................140 Check Fuel Injector.................................................141 Check Oxygen Sensor.................................................141 Check Vacuum Switch 1...............................................141 Check Vacuum Switch 2...............................................141 After Completing Checks.............................................141 Troubleshooting.........................................................142 tables......................................................................117 Table 1. Adjusting Screw................................................133 Hyster-S25-35XM,S40XMS-Mazda-Engine-897477-0600SRM0496-(02-2001)-US-EN..........151 toc.........................................................................151 Mazda Engine............................................................151 Safety Precautions Maintenance and Repair...............................152 General.................................................................155 Description.............................................................155 Engine Removal and Installation.........................................155 Cylinder Head, Camshaft, and Valve Mechanism Repair.....................156 Remove..............................................................156 Clean...............................................................157 Inspect and Repair..................................................158 Cylinder Head...................................................158 Rocker Shaft Assembly...........................................158 Camshaft........................................................158 Valve Guides....................................................159 Valve Seats.....................................................160 Valves..........................................................160 Valve Springs...................................................161 Install.............................................................161 Crankshaft and Main Bearings Repair.....................................164 Remove..............................................................164 Inspect and Repair..................................................164 Crankshaft......................................................164 Main Bearings...................................................164 Install.............................................................165 Pistons and Connecting Rods Repair......................................166 Remove and Disassemble..............................................166 Clean...............................................................166 Inspect and Repair..................................................166 Pistons.........................................................166 Piston Rings....................................................166 Connecting Rods and Bearings....................................167 Assemble and Install................................................167 Cylinder Block Repair...................................................169 Oil Pump Repair.........................................................169 Remove..............................................................169 Disassemble.........................................................170 Clean...............................................................170 Inspect.............................................................171 Assemble............................................................171 Install.............................................................172 Cooling System Repair...................................................172 Thermostat..........................................................172 Replace.........................................................172 Fan Assembly........................................................172 Remove and Disassemble..........................................172 Assemble and Install............................................173 Water Pump..........................................................173 Remove and Disassemble..........................................173 Assemble and Install............................................174 Distributor Repair......................................................175 Remove..............................................................175 Install.............................................................175 Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)...............176 Remove..............................................................176 Ring Gear, Replace..................................................176 Install.............................................................176 Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)............177 Remove..............................................................177 Install.............................................................177 Valve Adjustment........................................................178 Compression Pressure Check..............................................179 Engine Timing Adjustment................................................179 Throttle Linkage Adjustment.............................................180 Gasoline Engines....................................................180 LPG Engines (IMPCO).................................................180 LPG Engines (AISAN).................................................180 Engine Specifications...................................................180 Engine Data.........................................................180 Thermostat..........................................................180 Cylinder Head.......................................................180 Valve Mechanism.....................................................181 Camshaft............................................................181 Crankshaft..........................................................181 Connecting Rods.....................................................182 Cylinder Block......................................................182 Pistons.............................................................182 Oil Pump............................................................182 Torque Specifications...................................................183 Troubleshooting.........................................................184 Hyster-S25-35XM,S40XMS-Metric-and-Inch-910442-8000SRM0231-(12-2004)-US-EN.......189 toc.........................................................................189 Metric and Inch (SAE) Fasteners.........................................189 Safety Precautions Maintenance and Repair...............................190 General.................................................................193 Threaded Fasteners..................................................193 Nomenclature, Threads...............................................193 Strength Identification.............................................194 Cotter (Split) Pins.................................................194 Fastener Torque Tables..............................................199 Conversion Table....................................................201 tables......................................................................189 Table 1. Bolts and Screws...............................................195 Table 2. Studs and Nuts.................................................196 Table 3. Torque Nuts....................................................197 Table 4. Torque Nuts With Nylon Insert..................................198 Table 5. Torque Values for Metric Fasteners*............................199 Table 6. Torque Values for Inch Fasteners*..............................200 Table 7. Conversion Table for Metric and English Units..................201 Table 8. Cotter Pin Dimensional Data....................................202 Table 9. Cotter Pin Dimensional Data....................................203 Table 10. Cotter Pin Dimensional Data...................................204 Table 11. Cotter Pin Dimensional Data...................................206 Hyster-S25-35XM,S40XMS-Steering-Axle-897545-1600SRM0532-(10-2004)-US-EN.........211 toc.........................................................................211 Steering Axle...........................................................211 Safety Precautions Maintenance and Repair...............................212 General.................................................................215 Description.............................................................215 Steering Axle Assembly Repair...........................................216 Remove..............................................................216 Install.............................................................216 Wheels and Hubs Repair..................................................216 Pneumatic Tires, Remove and Disassemble.............................216 Cushion Tires, Remove and Disassemble...............................218 Pneumatic Tires, Assemble and Install...............................218 Cushion Tires, Assemble and Install.................................218 Spindles, Bearings, and Tie Rods Repair.................................219 Pneumatic Tires, Remove.............................................219 Cushion Tires, Remove...............................................219 Pneumatic Tires, Install............................................219 Cushion Tires, Install..............................................220 Steering Cylinder Repair................................................220 Remove and Disassemble..............................................220 Clean and Inspect...................................................220 Assemble and Install................................................220 Torque Specifications...................................................221 Troubleshooting.........................................................222 Hyster-S25-35XM,S40XMS-Steering-Housing-1459370-1600SRM0720-(11-2006)-US-EN.....225 toc.........................................................................225 Steering Housing and Control Unit.......................................225 Safety Precautions Maintenance and Repair...............................226 General.................................................................229 Description.............................................................229 Operation...............................................................230 Steering Wheel and Column Assembly Repair...............................232 Assembly Components, Remove.........................................232 Steering Control Unit, Disassemble..................................235 Steering Control Unit, Clean........................................237 Steering Control Unit, Assemble.....................................237 Assembly Components, Install........................................239 System Air Removal......................................................240 Troubleshooting.........................................................241 Hyster-S25-35XM,S40XMS-Tilt-Cylinders-910102-2100SRM0103-(03-2007)-US-EN........245 toc.........................................................................245 Tilt Cylinders..........................................................245 Safety Precautions Maintenance and Repair...............................246 General.................................................................249 Description.............................................................249 Tilt Cylinder Repair....................................................249 Remove..............................................................249 Disassemble.........................................................249 Clean...............................................................249 Assemble............................................................249 Tilt Cylinders With O-Ring or Single-Lip Seals..................249 Tilt Cylinders for XM and XMS Models............................251 Tilt Cylinders for XL, XLS, and XL 3 Models.....................252 Tilt Cylinders for H700-800A and Early Model H700-920B..........254 Install.............................................................255 Tilt Cylinders Using Chevron Packing............................255 Install.....................................................256 Tilt Cylinder Leak Check................................................258 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.....................260 Torque Specifications...................................................260 Piston Rod Nut......................................................260 Retainer............................................................261 Troubleshooting.........................................................263 tables......................................................................245 Table 1. Movement Rates (Maximum) for Tilt Cylinders....................259
HYSTER E001 (S25-35XM S40XMS) SERVICE MANUAL – PDF DOWNLOAD:
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