Hyster E25-35XL (C114) Forklift Service Manual
950 pages · Publication 897131
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- Models
- E25-35XL (C114)
- Manual type
- Service Manual
- Pages
- 950
- Publication
- 897131
- Condition
- Brand new
What's inside
From the manual's own table of contents: 128 sections, 335 entries. See sample pages (PDF, 257 KB)
Frame
Safety Precautions Maintenance and Repair
General
Description
Overhead Guard Repair2 topics
- Remove
- Install
Battery Restraint and Seat Assembly Repair2 topics
- Seat Brake Assembly E/J1.25-3.00XL (E/J25-60XL), Adjust
- Seat Brake Assembly E3.50-5.50XL (E70-120XL), Adjust
Counterweight Repair
Traction Motor Repair
Hydraulic Tank Repair7 topics
- Inspect
- Small Leaks, Repair
- Large Leaks, Repair
- Clean
- Steam Method
- Chemical Solution Method
- Additional Preparations For Repair
Painting Instructions
Safety Label Replacement
Table 1. Battery Specifications (Battery without Cover)
Table 2. Battery Specifications (Battery with Flat Cover)
Table 3. Battery Specifications (Battery with Dome Cover)
Table 4. Battery Specifications*
Table 5. Seat Brake Adjustment
Table 6. Counterweights
Drive Axle, Speed Reducer, and Differential
Drive Axle, Speed Reducer, and Differential Repair7 topics
- Drive Axle, Remove
- Drive Axle, Disassemble
- Speed Reducer and Differential, Disassemble
- Assemble
- Speed Reducer and Differential, Assemble
- Drive Axle, Assemble
- Drive Axle Assembly, Install
Torque Specifications13 topics
- Wheel Nuts
- Axle Shaft Capscrews
- Axle Hangers to Frame
- Back Plate to Axle Mount Capscrews
- Wheel Cylinder Capscrews
- Ring Gear to Differential Case
- Differential Case Halves
- Bearing Cap Capscrews
- Retainer Capscrews
- Axle Housing to Differential Housing
- Pinion Nut
- Speed Reducer Housing to Differential Housing
- Traction Motor to Transmission
Troubleshooting
Table 1. Adjustment of Shims for Pinion Assembly
Table 2. Ring and Pinion Tooth Contact Adjustment
DC Motor Maintenance
Show all 128 sections
Brush and Commutator Inspection4 topics
- Hydraulic Pump Motor and Traction Motor
- Steering Pump Motor
- Normal Commutator Surface
- Commutator Problems
Brush Replacement
Stoning the Commutator
Motors Repair5 topics
- Disassemble
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
- Traction Motor and Hydraulic Pump Motor
- Steering Pump Motor
Brush Alignment, Traction and Hydraulic Motors
Tests for Damaged Field and Armature7 topics
- Test for an Open Circuit in Armature
- Test for Short Circuit in One Armature Winding
- Test for Short Circuit to Armature Shaft
- Test for Open Circuit in Field Coil
- Test for Short Circuit in Field Coil
- Test for Short Circuit between Field and Motor Case
- Brush Holder Test
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Steering Axle
Steering Axle Assembly Repair
Wheels and Hubs Repair2 topics
- Remove and Disassemble
- Assemble and Install
Spindles, Bearings, and Tie Rods Repair
Steering Cylinder Repair1 topic
- Clean and Inspect
Steering System for Electric Lift Trucks
Steering Wheel and Column Assembly Repair2 topics
- Assembly Components, Remove
- Assembly Components, Install
Power Steering Motor and Pump8 topics
- Description
- Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM
- Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)
- Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X
- Assemble and Install - All models with a vertical mount except J
- Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM
- Power Steering Pump, Repair
- Seal, Replace
Hydraulic Steering Motor6 topics
- Hydraulic Steering Motor Repairs
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
Steering System Air Removal
Steering Pressure Check
Steering Chain Tension Check (Unit With MDU Only)
Optical Encoder and Activator Circuits Check
Mast
Description and Operation2 topics
- Carriages
- Mast Mounts
Two-Stage Mast, Limited Free-Lift (LFL)1 topic
- Description and Operation
Two-Stage Mast, Full Free-Lift (FFL)
Three-Stage Mast, Full Free-Lift (FFL)
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Safety Procedures When Working Near Mast
Forks Repair
Carriages Repair10 topics
- Standard Carriage, Remove
- Hang-On Sideshift Carriage, Remove
- Standard Carriage and Hang-On Sideshift Carriage, Repair
- Standard Carriage, Install
- Hang-On Sideshift Carriage, Install
- Integral Sideshift Carriage
- Remove
- Clean and Inspect
- Repair
- Install
Mast Repair6 topics
- Two-Stage LFL and Two-Stage FFL Masts, Disassemble
- Three-Stage FFL Mast
- Disassemble
- Mast and Chains, Clean and Inspect
- Two-Stage LFL and Two-Stage FFL Mast, Assemble
- Three-Stage FFL Mast, Assemble
Lift Cylinders Repair6 topics
- Main Lift Cylinders, Remove
- Free-Lift Cylinder, Remove
- Lift Cylinders, Disassemble
- Lift Cylinders, Assemble
- Main Lift Cylinders, Install
- Free-Lift Cylinder, Install
Header Hose Arrangements6 topics
- Two-Stage LFL Mast, New Hose Install
- Two-Stage LFL Mast, Adjust Hoses After Installation
- Two-Stage FFL Mast, New Hose Install
- Two-Stage FFL Mast, Adjust Hoses After Installation
- Three-Stage FFL Mast, New Hose Install
- Three-Stage FFL Mast, Adjust Hoses After Installation
Header Hose Arrangement1 topic
- Three-Stage FFL Mast, Adjust Hoses After Install
Lift and Tilt System Leak Check2 topics
- Lift Cylinders Leak Check
- Tilt Cylinders Leak Check
Tilt Cylinders Adjustment
Lift Chains Adjustment
Mast Adjustment
Carriage Adjustment
Table 1. Hook-Type Carriage Chain Adjustment
Table 2. Pin-Type Carriage Chain Adjustment
Industrial Battery
Lead-Acid Batteries
Specific Gravity
Chemical Reaction in a Cell
Electrical Terms
Battery Selection
Battery Voltage
Battery as a Counterweight
Battery Ratings1 topic
- Kilowatt-Hours
Battery Maintenance16 topics
- Safety Procedures
- Maintenance Records
- New Battery
- Cleaning Battery
- Adding Water to Battery
- Hydrometer
- Battery Temperature
- Charging Battery
- Types of Battery Charges
- Methods of Charging
- Troubleshooting Charger
- Knowing When Battery Is Fully Charged
- Where to Charge Batteries
- Equipment Needed
- Battery Connectors
- Battery Care
Table 1. Battery Capacity Terms
Tilt Cylinders
Tilt Cylinder Repair4 topics
- Tilt Cylinders With O-Ring or Single-Lip Seals
- Tilt Cylinders for XM and XMS Models
- Tilt Cylinders for H700-800A and Early Model H700-920B
- Tilt Cylinders Using Chevron Packing
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics
- Piston Rod Nut
- Retainer
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Instrument Panel Indicators and Senders14 topics
- Steering Column Gauges, Meters, and Indicators
- LED Display Panel
- Battery Discharge Indicators
- Brush Wear Indicators
- Motor Temperature Indicators
- LX Series Display Panel
- Hourmeter Functions
- Battery Indicator Function
- Status Code Function
- ZX Series Display Panels
- Display Panel
- Basic Display Panels
- Performance Display
- Brush Wear Indicators
Adjustments - General
Replacement - General Information
Meter Replacement
Sender Replacement2 topics
- Fuel Level Sender
- Pressure and Temperature Sender
ITW Display Panel Replacement
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics
- Display Panel Assembly, Replace
- Indicator LEDs
- Battery Indicators
- Digital Display (Performance Display Panel Only)
- Status Code or Performance Level Switches and Indicator LEDs (Pe
- Basic Display Panel, Replace Parts
- Performance Display Panel, Replace Parts
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace1 topic
- Remove and Replace
Specifications3 topics
- Meter Specifications
- Sender Specifications
- Meter
Battery Indicators8 topics
- Indicators With Meter Movements
- Battery Indicators With LCD or LED Displays
- Liquid Crystal Displays
- SEM Display Panels Description
- Light Emitting Diode Displays
- Description LX Series
- ZX Series Display Panels Description
- SEVCON POWERGAUGE—42 Battery Display Panel Description
Battery Indicators Without Lift Interrupt Adjustment (Early Mode
Battery Indicators With Lift Interrupt Adjustment (Early Models)2 topics
- Reset Potentiometer
- Specific Gravity Alarm
Battery Indicators Without Lift Interrupt Check (Later Models)
Battery Indicators With Lift Interrupt Adjustment (Later Models)1 topic
- Discharge Potentiometer
LED Display With Lift Interrupt
Curtis 933-1 Meter Check and Adjustment8 topics
- Check
- Reset Check
- Discharge Check
- Lockout Check
- LEDs Do Not Illuminate
- Hourmeter Check
- Hourglass Icon
- Adjust
SEVCON POWERGAUGE—42 Adjustment
Curtis Dash Display Assembly15 topics
- Description/Features
- Operation
- Testing
- Inoperative Dash Display Assembly
- Inoperative Drive Mode Selection
- Troubleshooting With a Programmer Handset
- Troubleshooting Without a Programmer Handset
- No Warnings or Faults Displayed
- MIB/Dash Display Communication
- Lift Interrupt
- Lost MIB Signal Displayed
- Lift Pump Hourmeter Input
- Forward/Reverse Hourmeter Inputs
- Adjust (Setup, Early Models)
- Adjust (Setup, Later Model)
Battery Indicators Replacement
Battery Indicator Controller Replacement
Display Panel Components Replacement
SEM Display Panel Replacement
Table 1. Battery Indicator (Later Models)
Table 2. SEVCON Discharge Curve Selector Positions
Table 3. Dash Display Drive Mode Inputs
Table 4. Dash Display Drive Mode Test Voltages
Table 5. Dash Display Status/Warning/Fault Test Voltages
Table 6. Testing Dash Display Status/Warning/Fault Inputs
Table 7. Battery Indicator Reset Adjustment
Lift Cylinders4 topics
- Lowering Control Valve
- Cylinders (General)
- Retainer, Install
- Cylinders (Two-Speed)
Lift Cylinder Repair10 topics
- Lift Cylinder Removal Without Removing Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
- Lift Cylinder Installation in Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Chevron-Style Packing
- Chevron-Style Packing Installation on Piston
- Chevron-Style Packing Installation in Packing Gland
Lift Cylinders for VISTA® Masts3 topics
- Lowering Control Valve
- Main Lift Cylinders
- Free-Lift Cylinder
Lift System Leak Check
Table 1. Lift Trucks with Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid
Metric and Inch (SAE) Fasteners6 topics
- Threaded Fasteners
- Nomenclature, Threads
- Strength Identification
- Cotter (Split) Pins
- Fastener Torque Tables
- Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Wheels Repair
Inside this manual
Real pages from this service manual (950 pages). Open the sample pages (PDF, 256 KB)
- Specifications, page 643: Header Hose Arrangement
- Troubleshooting, page 699: Battery Maintenance
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 950 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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