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Hyster E25-35XM2, E40XMS2 (D114) Forklift Service Manual

1,024 pages · Publication 1464842

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Models
E25-35XM2, E40XMS2 (D114)
Manual type
Service Manual
Pages
1,024
Publication
1464842
Condition
Brand new
Hyster E25-35XM2, E40XMS2 (D114) Forklift Service Manual, publication 1464842

What's inside

From the manual's own table of contents: 205 sections, 684 entries. See sample pages (PDF, 221 KB)

DC Motor Maintenance
Safety Precautions Maintenance and Repair
General
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 Repair6 topics
  • Disassemble
    • Traction Motor and Hydraulic Pump Motor
    • Steering Pump Motor
  • Assemble
    • 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
Troubleshooting
Table 1. Normal Commutator Surfaces
Table 2. Commutator Problems
Table 3. Brush Wear Replacement Guide
Steering System for Electric Lift Trucks
Description
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
Show all 205 sections
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 Repair2 topics
  • Remove
  • Install
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
Periodic Maintenance6 topics
  • 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 Daily17 topics
  • How to Make Checks With Key OFF
    • Tires and Wheels
    • Forks
    • Forks, Mast, and Lift Chains, Inspect
    • Safety Labels
    • Steering Column Latch
    • Operator Restraint System
    • 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 6 Weeks2 topics
  • Steering Tie Rods
  • Steering King Pins, Trucks Only
Maintenance Procedures Every 500 Hours or 3 Months14 topics
  • Hydraulic Tank Breather
  • Differential and Speed Reducer
  • Wheel Nut Torques
  • Steering Axle Spindles
  • Mast
  • Lift Chains
    • Wear Check
  • Forks
  • Brake Fluid
  • Other Lubrication
  • Electrical Inspection
    • Contactors
    • Motor Brushes
    • Motor Brushes, General
Maintenance Procedures Every 1000 Hours or 6 Months1 topic
  • Check Upper and Lower Bearings, Integral Sideshift Carriage
Maintenance Procedures Every 2000 Hours or Yearly11 topics
  • Hydraulic System
    • Change Filter for Hydraulic Oil
    • Change Hydraulic Oil
  • Service Brakes
  • Contactors
  • Wheel Bearings
    • Steer Wheels, Lubrication
    • Drive Wheels, Lubrication
  • Replace Upper and Lower Bearings, Integral Sideshift Carriage
  • Steering Axle
    • King Pins and Rod Ends (Steering Cylinders)
Battery Maintenance3 topics
  • How to Charge Battery
  • How to Change Battery
    • General
Lift Chain Adjustments
PMT Circuit Check
Welding Repairs
Overhead Guard Changes
Wheels and Tire Maintenance20 topics
  • Remove Wheels From Lift Truck
    • Remove and Install Tire on Wheel
    • 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
  • Solid Rubber Tire, Change
    • Remove and Install Tire on Wheel
    • Remove Wheel From Tire
    • Install Wheel in Tire
  • SIT Tire, Change
    • Remove SIT Solid Tire From Wheel
    • Install SIT Solid Tire on Wheel
Adhesives and Sealants
Table 1. Maintenance Schedule
Hydraulic System
Operation3 topics
  • Hydraulic Gear Pump
  • Rotator Actuator Valve
  • Steering Pump
Hydraulic Tank Repair7 topics
  • Inspect
  • Small Leaks, Repair
  • Large Leaks, Repair
  • Clean
    • Steam Method
    • Chemical Solution Method
  • Additional Methods for Tank Repair
Filter Replacement
Hydraulic Pump Repair2 topics
  • Pump Seal, Replace and Pump Assemble
  • Assemble Pump on Motor
Main Control Valve Repair
Steering Pump Repair1 topic
  • Pump, Assemble and Install
Rotary Actuator Valve Repair1 topic
  • Disassemble, Clean, and Inspect
Steering Control Unit Repair
Steering Cylinder Repair
Main Control Valve Check and Adjust
Steering Relief Valve Check and Adjust
Specifications5 topics
  • Relief Valve Pressures*
  • Hydraulic Tank Capacity (dipstick full mark)
  • Hydraulic Pump Capacities
  • Steering
  • Steering Housing and Steering Control Unit
Electrical System24 topics
  • ZX Series Display Panels
    • Display Panel
    • Basic Display Panels
    • Performance Display
    • Brush Wear Indicators
  • SEM Display Panels - Features
    • Descriptions of Common Features
    • Additional Features of Premium Display Panel
    • Descriptions of Additional Features
  • SEM Display Panel Indicators
    • All Indicator Symbols
    • Hourmeter Indicator Symbol
    • Wrench Indicator Symbol
    • Battery Indicator Symbol
    • Battery State-of-Charge (BDI)
    • Brake Fluid Too Low Symbol
    • Parking Brake Symbol
    • Fasten Seat Belt Symbol
    • LCD Screen (Standard Display Panel)
  • Additional Components of Premium Display Panel
    • Alpha Numerical Screen
    • STAR Push Button
    • Push Buttons ##1 Through ##5 - SEM
  • Other Control Components
Display Panel Components Replacement9 topics
  • ZX Panel Replacement
  • Display Panel Assembly
  • Key Switch, 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
SEM Display Panel Replacement
Motor Controller (SR or SP) Replacement
Control Components Replacement25 topics
  • Start Switch, Replace
  • Brake Light Switch, Replace
  • Seat Switch, Replace
  • External Seat Switch, Adjust
  • Switch for Optional Seat Brake, Replace
  • Parking Brake Switch, Replace
  • Direction Switches (MONOTROL Pedal), Replace
  • Direction Control Switches (Steering Column), Replace
  • Direction Control Switches, E70-120XL 3 (Steering Column)
  • Brake Fluid Switch, Replace
  • Brush Wear and Overtemperature Sensors
  • Rocker Switches for Lights
  • Accelerator Position Sensor, Replace
  • On-Demand Steering Components
  • Lights, Converter, Relay, and Reverse Alarm
    • Brake, Tail, and Reverse Light Assembly, Replace
    • Flashing Light Assembly, Replace
    • Front, Rear Driving Light, or Spot Light Assemblies, Replace
    • Operator Compartment Light Assembly, Replace
    • Converter, Replace
    • Relay, Replace
    • Reverse Alarm, Replace
  • Horn and Horn Button
    • Horn Switch and Cover
  • Hydraulic Pump Switches
Control and Power Fuses Check
Brush Wear and Overtemperature Sensors Check - ZX
Thermal Sensors - SEM Check
Start Switch Adjustment2 topics
  • Accelerator Potentiometer and Start Switch E70-120XL, E70-120XL
  • Direction Switches (MONOTROL)
Brake Light Switch Adjustment
Seat Switch Check
Optional Seat Brake Switch Adjustment
Parking Brake Switch Adjustment
Direction Switches Check2 topics
  • Monotrol Pedal
  • Steering Column
Hydraulic Pump Switch Adjustment
MONOTROL or Accelerator Pedal Adjustment
Accelerator Position Sensor Adjustment
Main Control Valve6 topics
  • Lift Section
  • Tilt Section
    • Tilt Backward
    • Tilt Forward
  • Relief Valve
  • Clean and Inspect
Control Lever Linkage Repair
Control Valve Linkage Repair
Pressure Relief Valve Check and Adjustment2 topics
  • Primary Relief Valve
  • Secondary Relief Valve
Frame4 topics
  • Main Frame
  • Other Frame Weldments
  • Battery Restraint and Hood Frame
  • Overhead Guard
Overhead Guard Repair
Battery Restraint and Seat Assembly
Counterweight Repair
Traction Motor Repair3 topics
  • Steam Method
    • Chemical Solution Method
  • Additional Preparations for Repair
Painting Instructions
Safety Label Replacement
Battery Specifications
Table 1. Counterweights
Drive Axle, Speed Reducer, and Differential
Drive Unit Assembly Repair5 topics
  • Remove Complete Drive Unit Assembly as a Unit
  • Traction Motor, Remove
  • Drive Unit and Speed Reducer, Remove
  • Drive Axle, Disassemble
  • Differential and Speed Reducer, Disassemble
Assembly of Drive Unit5 topics
  • Find Correct Shim Set for Hypoid Gear
  • Pinion, Assemble and Install
  • Differential and Ring Gear, Assemble and Install
  • Input Gear for Speed Reducer, Assemble
  • Drive Axle and Hub Assembly, Assemble
Installation of Drive Unit2 topics
  • Drive Unit, Install
  • Traction Motor, Install
Torque Specifications
Table 1. Shims Adjustment for Pinion
Table 2. Ring and Pinion Tooth Contact Adjustment
Steering Axle
Steering Axle Assembly Repair
Wheels and Hubs Repair2 topics
  • Remove and Disassemble
  • Assemble and Install
Spindles, Bearings, and Links Repair
Capacities and Specifications
Wheels and Tires
Counterweights
Capacities1 topic
  • Battery Height Specifications (Hoods and Battery Types)
Maximum Carriage and Tilt Creep Rates
Mast Speeds7 topics
  • E25-40XM Mast Speeds (36 and 48 Volt) Americas
  • E1.50-2.00XM Mast Speeds (48 Volt) Europe
  • E25-40XM, E25-40XM 2 Mast Speeds Americas
  • E1.50-1.75XM E2.00XMS Mast Speeds Europe
  • Frame
  • Drive Axle, Speed Reducer, and Differential
  • Brake
EV-100ZX™ SCR Motor Controller
Register Parameters2 topics
  • General
  • Function Numbers
Control Card Checks and Adjustments
Register Parameter Tables
Table 1. EV-100ZX Parameters [Heavy Duty Motor ( Hyster Part Num
Table 2. EV-100ZX Parameters [Heavy Duty Motor ( Hyster Part Num
Table 3. EV-100ZX Parameters [Standard Motor ( Hyster Part Numbe
Table 4. EV-100ZX Parameters [Standard Motor ( Hyster Part Numbe
Table 5. EV-100ZX Parameters [Standard Motor ( Hyster Part Numbe
Table 6. EV-100ZX Parameters (Standard System) (Hydraulic Pump C
Table 7. EV-100ZX Parameters (Low Energy System) (Hydraulic Pump
Industrial Battery
Lead-Acid Batteries
Specific Gravity
Chemical Reaction in a Cell
Electrical Terms
Battery Selection
Battery Voltage
Battery as a Counterweight
Battery Ratings17 topics
  • Kilowatt-Hours
  • 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
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
Steering Housing and Control Unit3 topics
  • Steering Control Unit, Disassemble
  • Steering Control Unit, Clean
  • Steering Control Unit, Assemble
System Air Removal
SR/SP Transistor Motor Controllers1 topic
  • Model Number Data for SR/SP Transistor Motor Controllers
Motor Controller Checks and Adjustments
Checks and Adjustments Using Handset6 topics
  • Connect Handset
  • Start Sequence
  • Check or Delete Stored Status Codes
  • Returning Lift Truck to Normal Operation
  • Workbench Checks and Adjustments
  • How to Check and Adjust Registers
Function Parameters Adjustments4 topics
  • When Handset is Connected to Motor Controller in Lift Truck
    • Function Numbers 1 through 15
    • Function Numbers 16 through 30
    • Function Numbers 48 through 63
Function Number Descriptions
Traction Motor Controller (Label Letter - SR)42 topics
  • Function Number 01 AUTO REGEN ENABLE SPEED
  • Function Number 02 CREEP SPEED
  • Function Number 03 CONTROLLED ACCELERATION
  • Function Number 04 ARMATURE CURRENT LIMIT
  • Function Number 05 REGEN RAMP RATE
  • Function Number 06 FIELD WEAKENING (FW) RATIO
  • Function Number 07 MINIMUM FIELD CURRENT
  • Function Number 08 MAXIMUM FIELD CURRENT
  • Function Number 09 REGENERATIVE BRAKING CURRENT LIMIT (C/L)
  • Function Number 10 FIELD CURRENT FOR REGENERATIVE BRAKING
  • Function Number 12 MAXIMUM ARMATURE % ON TIME (Travel Speed Limi
  • Function Number 13 SPEED LIMIT 3
  • Function Number 14 INTERNAL RESISTANCE COMPENSATION
  • Function Number 15 BATTERY VOLTAGE SELECTION
  • Function Number 16 STALL TRIP POINT % ON TIME
  • Function Number 17 CONTROL TYPE SELECTION
  • Function Number 18 STEERING PUMP TIME DELAY
  • Function Number 19 MAINTENANCE CODE TENS AND UNITS
  • Function Number 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS
  • Function Number 21 AUTO REGEN BRAKING CURRENT LIMIT
  • Function Number 23 FOR SPECIAL FUNCTIONS
  • Function Number 24 FIELD WEAKENING START
  • Function Number 25 MONITOR
  • Function Number 26 BASE RATIO
  • Function Number 28 STORED STATUS CODE COUNT POINTER
  • Functions with Premium Display Panel Only
    • Function Number 48 MODE 1 - CONTROLLED ACCELERATION
    • Function Number 49 MODE 1 FIELD WEAKENING (FW) START
    • Function Number 50 MODE 1 - FIELD WEAKENING (FW) RATIO
    • Function 51 MODE 1 - MAXIMUM ARMATURE % ON TIME (MODE 1 - TRAVEL
    • Function 52 MODE 2 - CONTROLLED ACCELERATION
    • Function Number 53 MODE 2 - FIELD WEAKENING (FW) START
    • Function Number 54 MODE 2 - FIELD WEAKENING (FW) RATIO
    • Function Number 55 MODE 2 - MAXIMUM ARMATURE % ON TIME (MODE 2
    • Function Number 56 MODE 3 - CONTROLLED ACCELERATION
    • Function Number 57 MODE 3 - FIELD WEAKENING (FW) START
    • Function Number 58 MODE 3 - FIELD WEAKENING (FW) RATIO
    • Function Number 59 MODE 3 - MAXIMUM ARMATURE % ON TIME (MODE 3
    • Function Number 60 MODE 4 - CONTROLLED ACCELERATION
    • Function Number 61 MODE 4 - FIELD WEAKENING (FW) START
    • Function Number 62 MODE 4 - FIELD WEAKENING (FW) RATIO
    • Function Number 63 MODE 4 - MAXIMUM ARMATURE % ON TIME (MODE 4
Pump Motor Controller (Label Letter - SP)22 topics
  • Function Number 01 STORED STATUS CODE
  • Function Number 02 INTERNAL RESISTANCE COMPENSATION START
  • Function Number 04 CURRENT LIMIT
  • Function Number 07 INTERNAL RESISTANCE COMPENSATION RATE
  • Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S
  • Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif
  • Function Number 13 SPEED LIMIT 3 (SL3) Fast Lift
  • Function Number 16 SPEED/TORQUE COMPENSATION
  • Function Numbers 18 through 27 TEMPORARY DATA REGISTERS
    • Function Number 48 MODE 1 - CONTROLLED ACCELERATION
    • Function Number 49 MODE 1 - SPEED LIMIT 2
    • Function Number 50 MODE 1 - SPEED LIMIT 3
    • Function Number 52 MODE 2 - CONTROLLED ACCELERATION
    • Function Number 53 MODE 2 - SPEED LIMIT 2
    • Function Number 54 MODE 2 - SPEED LIMIT 3
    • Function Number 56 MODE 3 - CONTROLLED ACCELERATION
    • Function Number 57 MODE 3 - SPEED LIMIT 2
    • Function Number 58 MODE 3 - SPEED LIMIT 3
    • Function Number 60 MODE 4 - CONTROLLED ACCELERATION
    • Function Number 61 MODE 4 - SPEED LIMIT 2
    • Function Number 62 MODE 4 - SPEED LIMIT 3
  • Status Codes
SR (SEM) and SP Status Code Charts
SR/SP Transistor Motor Controller Repair10 topics
  • General Maintenance Instructions
    • Special Precautions
  • Fuses
    • Repair
  • Contactor Driver Module
    • Contactor Driver, Replace
  • Motor Controller Plug
  • Brush Wear Indicators
  • Thermal Sensors
  • Motor Controller, Replace
Theory of Operation35 topics
  • SEM System Description
  • SEM System Operation (SR Motor Controller)
    • Reverse Circuit
    • Performance and Efficiency
    • Field Weakening
    • Regenerative Braking
  • SEM System Operation (SP Motor Controller)
    • Creep Speed
    • Controlled Acceleration
    • Current Limit (CL)
  • Braking
    • Regenerative Braking to Zero Speed
    • Pedal Position Braking
    • Auto Braking
  • Auxiliary Speed Control
    • Field Weakening
    • Speed Limits
  • Ramp Operation
    • Ramp Start
    • Anti-rollback
  • Steer Pump Contactor Time Delay
  • Coil Drivers and Internal Coil Suppression
  • System Protective Override
    • Static Return to Off (SRO)
    • Accelerator Volts Hold Off
    • Pulse Monitor Trip (PMT)
    • Thermal Protector (TP)
    • Low Voltage
  • SP Pump Motor Controllers
  • Diagnostics
    • Systems Diagnostics
    • Standard Status Codes
    • Stored Status Codes
    • Hourmeter Readings
    • Maintenance Management Capability
Table 1. List of Status Codes
Table 2. Speed/Torque Compensation
Table 3. Function Map for Motor Controllers SR (Traction)
Table 4. Function Map for Motor Controller SP (Lift Pump Motor)
Table 5. List of Status Codes
Table 6. Large (P) Plug (23-Pin) Connections/Descriptions for Mo
Table 7. Small Plug (12-Pin) Connections/Descriptions for Motor
Transistor Motor Controllers1 topic
  • Parameter Tables
Table 1. SR (SEM) Register Parameters for Traction Motor Control
Table 2. SR (SEM) Register Parameters for Traction Motor Control
Table 3. SP Register Parameters for Pump Motor Controller - E1.5
Table 4. SR (SEM) Register Parameters for Traction Motor Control
Table 5. SR (SEM) Register Parameters for Traction Motor Control
Table 6. SR (SEM) Register Parameters for Traction Motor Control
Table 7. SR (SEM) Register Parameters for Traction Motor Control
Table 8. SP Register Parameters for Pump Motor Controller - E45
Table 9. SP Register Parameters for Pump Motor Controller - E2.0
Table 10. SR (SEM) Register Parameters for Traction Motor Contro
Table 11. SR (SEM) Register Parameters for Traction Motor Contro
Table 12. SR (SEM) Register Parameters for Traction Motor Contro
Table 13. SP Register Parameters for Pump Motor Controller - J40
Table 14. SP Register Parameters for Pump Motor Controller - J2
Table 15. SR (SEM) Register Parameters for Traction Motor Contro
Table 16. SR (SEM) Register Parameters for Traction Motor Contro
Table 17. SP Register Parameters for Pump Motor Controller - N30
Electrical Diagrams
Display Panel for SEM Controls
SEM Display Panel Features15 topics
  • Descriptions of Common Features
    • LED Symbol Indicators
    • LCD Screen
    • Battery Discharge Indicator (BDI)
    • Service Reminder
    • Status Codes
    • Hourmeter
  • Additional Features of Premium Display Panel
  • Descriptions of Additional Features (Available with Premium Disp
    • LCD Screen
    • Operator Passwords
    • Daily Check List and Service Items
    • Performance Modes
    • Status Code Lists
    • Adjustment of BDI
SEM Display Panel Indicators9 topics
  • All Indicator Symbols
  • Hourmeter Indicator Symbol
  • Wrench Indicator Symbol
  • Battery Indicator Symbol
  • Battery State-of-Charge (BDI)
  • Brake Fluid Too Low Symbol
  • Parking Brake Symbol
  • Fasten Seat Belt Symbol
  • LCD Screen (Standard Display Panel)
Additional Components of Premium Display Panel3 topics
  • Alphanumeric Screen
  • STAR Push Button
  • Push Buttons 1 Through 5
Adjustments With a Computer10 topics
  • Computer System
    • Connect PC to SEM Display Panel
  • ITW Switches Windows Software Program (for SEM Display Panel)
    • Description
    • Where to Get Help
    • Hardware and Software Requirements
    • Install
    • How to Start ITW SWITCHES Program
    • Menus
    • Sample Sessions
Replacement2 topics
  • SEM Display Panel
    • Remove and Replace
Table 1. Adapter Pins (DB25F to DB9)
Troubleshooting and Adjustments With a Computer
Computer System2 topics
  • Connect a PC to a Control Card
  • Installation
HYTECH™ Windows Software Program18 topics
  • How to Start the Program
  • DEMO Mode
  • Selecting the Communications Port
  • Verification of Controller and Lift Truck
  • Select Lift Truck Series
  • Controller Card Register Parameter List
  • How to Change a Parameter
  • How to Save a Changed Parameter File
  • How to Load a Saved Parameter File
  • How to Show and Remove Saved Parameter Files
  • How to Return to Factory Default Settings
  • How to Save Changes to Control Card
  • How to View Status Codes
  • Saving Status Codes
  • How to Show and Remove Saved Status Code Files
  • Closing and Clearing Status Code List
  • How to View Saved Register Data and Saved Status Data
  • How to Save Register Data and Status Code Data In and
GE Sentry™ Software Program4 topics
  • How to Start GE SENTRY Program
  • How to Reset MIN and MAX Display
  • Graphing Mode
  • How to Exit GE SENTRY Program
Table 1. Cable Connections - Computer to Control
Table 2. Adapter Pins (DB25F to DB9)
Table 3. Plug-Z Connection

Inside this manual

Real pages from this service manual (1,024 pages). Open the sample pages (PDF, 221 KB)

Sample pages from the Hyster E25-35XM2, E40XMS2 (D114) Forklift Service Manual: Specifications, Troubleshooting, Diagram
  • Specifications, page 133: Header Hose Arrangements
  • Troubleshooting, page 493: Troubleshooting
  • Diagram, page 898: Diagrams, Schematics, or Arrangements

This is a service manual

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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, 1,024 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hyster E25-35XM, E40XMS (D114)Service Manual · 897887 · $89.75

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).