Hyster E40ZS, Manual

Page 1: ...Hyster F114 E25Z E30Z E35Z E40ZS Forklift ...

Page 2: ...4 H1 6FT H1 8FT H2 0FTS H30FT H35FT H40FTS F001 S2 0 3 5FT S40 70FT S55FTS F187 J1 60 2 00XMT J30 40ZT J160 H2 0 3 5FT H40 70FT L177 S4 0 4 5 5 5FT S5 5FTS S80 100 120FT S80 100FTBCS S120FTS S120FTPRS G004 H004 J2 00 3 20XM J40 65Z B416 E2 00 3 20XM E45 65Z G108 H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 90 100 110 120FT N005 P005 R005 S005 E3 50 5 50XL E4 50XLS E70 120Z E100ZS E098 S50CT A267 H2...

Page 3: ...odic 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 ex ceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using ...

Page 4: ...9 Install 20 System Air Bleed Procedures 21 Two Stage FFL Left Side Main Lift Cylinder 22 Disassemble 22 Clean 22 Inspect 22 Assemble 23 Install 25 Free Lift Cylinder 25 Remove 25 Disassemble 28 Clean 28 Inspect 29 Assemble 29 Install 30 Torque Specifications 31 Lift Cylinder Leak Check 32 Fork Positioner Cylinder Repair 33 Remove 33 Disassemble 33 Clean 36 Inspect 37 Assemble 37 Install 37 Fork P...

Page 5: ...more information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions please write to me admin servicemanualperfect com ...

Page 6: ...MT J30 40ZT J160 H2 0 3 5FT H40 70FT L177 S4 0 4 5 5 5FT S5 5FTS S80 100 120FT S80 100FTBCS S120FTS S120FTPRS G004 H004 J2 00 3 20XM J40 65Z B416 E2 00 3 20XM E45 65Z G108 H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 90 100 110 120FT N005 P005 R005 S005 E3 50 5 50XL E4 50XLS E70 120Z E100ZS E098 S50CT A267 H2 0 2 5CT H50CT A274 Table of Contents Cylinder Repair Mast S N A551 A555 A559 A661 A662 A66...

Page 7: ...of each main lift cylinder rod fits into a guide on the top crossmember of the inner mast The free lift cylinder is installed in the inner mast Each of the lift cylinders has an inter nal lowering control valve A single external lower ing control valve is connected by tubing and hoses to all the lift cylinders NOTE On lift truck models listed below there are two free lift chains and chain sheaves ...

Page 8: ...arts are heavy and can move Distances be tween parts are small Serious injury or death can result if part of the body is hit by parts of the mast or the carriage Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is in stalled Also make sure that the power is OFF and the key is removed Put a DO NOT OPERATE tag in the operator...

Page 9: ... 3 8 inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower Put hook on back side of mast Make sure hook is completely engaged with a link in the chain Make sure safety chain does not touch lift chains or chain sheaves tubes hoses fittings or other parts on the mast 4 Lower mast until there is tension in safety chain and free lift cylinder two ...

Page 10: ...MAST 1 OUTER WELDMENT 2 INNER WELDMENT 3 INTERMEDIATE WELDMENT 4 HOOK 5 FREE LIFT CYLINDER 6 CARRIAGE BAR 7 CROSSMEMBER 8 FIRST INTERMEDIATE WELDMENT Figure 1 Two Stage LFL Two Stage FFL Three Stage FFL and Four Stage FFL Masts Safety Procedures When Working Near Mast 2100 SRM 1139 4 ...

Page 11: ... 2 Stroke cylinder to the full back tilt position 3 Disconnect the hydraulic lines at the tilt cylin der Install caps on the hydraulic lines and in the cylinder ports 4 Use a lifting device to move large tilt cylinders Remove the capscrew and retainer from the an chor pin Using a drift pin or similar tool push the anchor pin out of the frame 5 Using a lifting device remove the tilt cylinder from t...

Page 12: ...0 3 20XM J40 65Z B416 S30FT S35FT S40FTS E010 S2 0 3 5FT S40 70FT S55FTS F187 S4 0 4 5 5 5FT S5 5FTS S80 100 120FT S80 100FTBCS S120FTS S120FTPRS G004 H004 S50CT A267 See Figure 4 for lift truck models E1 50 2 00XM E25 35Z E40ZS E114 F114 J1 60 2 00XMT J30 40ZT J160 2 Using a pin type spanner wrench remove the gland from the tilt cylinder Remove the rod and piston assembly from the cylinder NOTE T...

Page 13: ...Figure 3 Tilt Cylinder 2100 SRM 1139 Tilt Cylinder Repair 7 ...

Page 14: ...100FTBCS S120FTS S120FTPRS G004 H004 H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 90 100 110 120FT N005 P005 R005 S005 AND E3 50 5 50XL E4 50XLS E70 120Z E100ZS E098 1 SHELL 2 GLAND 3 ROD 4 WIPER RING 5 SEAL 6 BACKUP RING 7 O RING 8 PISTON 9 PISTON SEAL 10 NUT 11 WEAR RING 12 BUSHING 1 CYLINDER SHELL 2 RETAINER 3 ROD 4 WIPER RING 5 SEAL 6 BACKUP RING 7 O RING 8 NUT 9 PISTON 10 PISTON SEAL Figure 4 ...

Page 15: ... surfaces use brass tools when installing seals and O rings 1 Install a new piston seal and O ring on the pis ton See Figure 3 NOTE Perform Step 2 only if the piston was re moved from the rod 2 Place the rod in a soft jaw vise and lube the threads of the nut with hydraulic oil Install the piston on the rod and tighten the nut to a 170 to 220 N m 125 to 162 lbf ft on lift truck models S2 0 2 5FT S4...

Page 16: ...nd on rod as noted during removal Lubricate threads on capscrew with lubricant Hyster P N 186061 Install cap screw in rod end so that capscrew head is on the inboard side of rod end Install washer and nut on capscrew Washer and nut must be on the outboard side of rod end See Figure 5 Tighten nut to 90 N m 66 lbf ft 6 Repeat the above steps for the other tilt cylin der NOTE LEFT TILT CYLINDER SHOWN...

Page 17: ...r 5 Remove chain holding the mast to the frame WARNING DO NOT put hands between the cylinder rod end and the mast Serious injury can occur 6 Operate the tilt cylinders Check for correct op eration and leakage Adjust the tilt cylinders TILT CYLINDERS ADJUST WARNING When the tilt cylinders have tilt limit spacers make sure they are installed during installation procedures Without the tilt limit spac...

Page 18: ... then stop Repeat this procedure until both cylinder rods stop at the same position within 1 1 mm 0 04 in for lift truck models S30FT S35FT S40FTS E010 H1 6FT H1 8FT H2 0FTS H30FT H35FT H40FTS F001 S2 0 3 5FT S40 S70FT S55FTS F187 H2 0 3 5FT H40 70FT L177 E1 50 2 00XM E25 35Z E40ZS E114 F114 E2 00 3 20XM E45 65Z G108 J2 00 3 20XM J40 65Z B416 J1 60 2 00XMT J30 40ZT J160 H4 0FT5 FT6 H4 5FTS5 H4 5FT...

Page 19: ... both rod ends contact the spacers within 0 5 mm 0 02 in d After the adjustments are complete tighten the nuts on the rod ends to 90 N m 66 lbf ft e Tilt the mast fully backward and measure the tilt angle See the nameplate for tilt an gles If necessary add an equal number of shims to both rods for the correct angle TILT CYLINDER LEAK CHECK WARNING Never allow anyone under a raised carriage DO NOT ...

Page 20: ...etween the port at the front of the tilt cylinder and the hydraulic line The valve must be able to completely shut off the flow of hydraulic oil Put the load on the forks again Close the valve Tilt the mast for ward just past the vertical position If the mast continues to tilt SLOWLY forward the seals on the piston are leaking 4 If the mast does not move open the valve and check the movement again...

Page 21: ...CT A274 38 N m 28 lbf ft For lift truck models S4 0 4 5 5 5FT S5 5FTS S80 100 120FT S80 100FTBCS S120FTS S120FTPRS G004 H004 and H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 90 100 110 120FT N005 P005 R005 S005 68 N m 50 lbf ft For lift truck models E3 50 5 50XL E4 50XLS E70 120Z E100ZS E098 77 N m 57 lbf ft Tilt Cylinder Rod End Nut 90 N m 66 lbf ft Lift Cylinder Repair MAIN LIFT CYLINDERS Remove ...

Page 22: ...fety chain to connect middle crossmem ber of first intermediate mast section to top crossmember on outer mast section Lower mast so safety chain holds weight of the mast sections WARNING Be careful when removing or install snap rings These snap rings can come loose during removal or installation with enough force to cause an in jury Always use the correct snap ring pliers and wear eye and face pro...

Page 23: ...NG 3 SHIM 4 FITTING AND O RING 5 LEFT MAIN LIFT CYLINDER 6 LOWERING CONTROL VALVE FITTING 7 HOUSING 8 HOSE 9 LOWERING CONTROL VALVE 10 RIGHT MAIN LIFT CYLINDER 11 SPACER 12 RETAINER 13 NUT 14 BOLT 15 WASHER Figure 8 Main Lift Cylinders Remove 2100 SRM 1139 Lift Cylinder Repair 17 ...

Page 24: ... snap rings These snap rings can come loose during removal or installation with enough force to cause an in jury Always use the correct snap ring pliers and wear eye and face protection during removal or installation NOTE Step 2 does not apply to lift trucks equip ped with a two stage FFL mast or to lift trucks shown below H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 120FT N005 P005 R005 S005 S4 0 ...

Page 25: ... compressed air Inspect Inspect the gland for damage to the threads and the seal surfaces If damaged replace gland Inspect the piston for any damage to the seal surfa ces If damaged replace piston Inspect the rod for damage to the rod surface and ensure that the rod is not bent If damaged replace rod Inspect the inner surface of the cylinder tube for damage If damaged replace cylinder assembly Ass...