service repair manual

1. SERVICE REPAIR
E25Z E30Z E35Z E40ZS [E114]

2. 8000 SRM 1113 Counterweights
Wheels and Tires
Item Specification
Torque Value of Drive Wheel Bolts 330 N•m (243 lbf ft)
Torque Value of Steer Wheel Nuts (Pneumatic) 155 N•m (114 lbf ft)
Torque Value of Spindle Nut for Steer Wheels 68 N•m (50 lbf ft), loosen, then
3 N•m (2 lbf ft)
Size of Standard Drive Tires 18 × 5 × 12-1/8*
Size of Optional Drive Tires 18 × 5 × 12-1/8*
Size of Standard Steer Tires 14 × 4-1/2 × 8*
Size of Optional Steer Tires 15 × 5 × 11-1/4*
*Electric Compound Tires are available in smooth or lug tread. Polyurethane and nonmarking compounds
are only available on smooth tread. NEVER mix types of tread or tire compound on the same truck.
Counterweights
Model Weight
+30 kg (66 lb)
0 kg (0 lb)
E25Z 337 kg (743 lb)
E1.50XM, (E30Z) 514 kg (1133 lb)
E1.75XM (E35Z) 626 kg (1380 lb)
E2.00XMS (E40ZS) 739 kg (1629 lb)
1

3. Capacities 8000 SRM 1113
Hydraulic System
Table 1. Manual Control Valve
Item Specification
Relief Pressure, Lift System 17.9 ±0.7 MPa (2600 ±100 psi)
Relief Pressure, Tilt System 15.75 ±0.7 MPa (2250 ±100 psi)
Relief Pressure, Auxiliary 15.75 ±0.7 MPa (2250 ±100 psi)
Relief Pressure, Steering System 5709 ±248 kPa (828 ±36 psi)
*Oil temperature 54 to 66 C (130 to 150 F).
Table 2. E-Hydraulic Control Valve
Item Specification
Relief Pressure, Lift System (Primary Relief Valve) 17.9 ±0.7 MPa (2600 ±100 psi)
Relief Pressure, Tilt System and Auxiliary Functions
(Secondary Relief Valve)
15.5 ±0.7 MPa (2250 ±100 psi)
Relief Pressure, Steering System 5709 ±248 kPa (828 ±36 psi)
Oil temperature 54 to 66 C (130 to 150 F).
Capacities
Item Specification
Hydraulic System (Full Mark On Dipstick)* 11.3 liter (3.0 gal)
Differential/Speed Reducer 2.9 liter (3.1 qt)
Brake Fluid 0.24 liter (0.5 pt)
Hydraulic Pump Capacities**
Large Lift Pump 19 cc/rev. (1.16 in3
/rev.)
Steering Pump 4.23 cc/rev. (0.26 in3
/rev.)
*Check after all air is removed from the system and with the mast fully lowered.
**Oil temperature at 54 to 66 C (130 to 150 F).
2

4. 8000 SRM 1113 Battery Specifications
Battery Specifications
Battery Size Minimum/
Maximum*
Weight
Model
Min.
Compartment
Size
Length × Width Length Width
Mini-
mum
Maxi-
mum
E25Z 794 kg
(1750 lb)
E1.50XM
(E30Z)
839 kg
(1850 lb)
E1.75XM
(E35Z)
839 kg
(1850 lb)
E2.00XM
(E40ZS)
695 × 879 mm
(27.4 × 34.6 in.)
784/876 mm
(30.9/34.5 in.)
839 kg
(1850 lb)
E25Z 794 kg
(1750 lb)
E1.50XM
(E30Z)
839 kg
(1850 lb)
E1.75XM
(E35Z)
839 kg
(1850 lb)
E2.00XM
(E40ZS)
695 × 909 mm
(27.4 × 35.8 in.)
784/907 mm
(30.9/35.7 in.)
654/692 mm
(25.8/
27.2 in.)
839 kg
(1850 lb)
1132 kg
(2496 lb)
617 mm (24.3 in.) = maximum height for all batteries. This dimension is 31.75 mm (1.25 in.) less with
optional battery rollers.
Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column
shows the size range that will permit the battery to still fit into a battery compartment.
Battery compartment length is front to back. Width is side to side. The length dimension of the battery
must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.)
maximum. Battery width must fit within the battery compartment front-to-back dimension.
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate
and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward or back-
ward.
3

5. Battery Specifications 8000 SRM 1113
BATTERY HEIGHT SPECIFICATIONS (HOODS AND BATTERY TYPES)
Maximum Height - Standard Hood
Cell Connectors and Terminals
Model Battery Type With Battery
Tray*
With Cell
Cap** Electrically
Insulated***
Not
Electrically
Insulated**
E1.50-1.75XM
(E25-35Z),
E2.00XMS
(E40ZS)
I
594 mm
(23.4 in.)
594 mm
(23.4 in.)
574 mm
(22.6 in.)
E1.50-1.75XM
(E25-35Z)),
E2.00XMS
(E40ZS)
II, III
607 mm
(23.9 in.)
NA NA NA
NA = Not Applicable
BATTERY TYPES
TYPE I - Battery without a cover as part of the battery.
TYPE II - Battery with a cover that is flat and is fastened to case of battery. Cover opens from FRONT
OR REAR when installed in lift truck.
TYPE III - Battery with a cover that is flat and is fastened to case of battery. Cover opens from SIDE
when installed in lift truck.
*Battery Types II and III bottom of battery to highest point (top of cover or top of hinge).
**Minimum height below top of battery tray is 4 mm (0.16 in.).
***Minimum height below top of battery tray is 0.5 mm (0.02 in.).
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in the table above. Adjust the spacer
plate and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward,
backward, or to the side.
4

6. 8000 SRM 1113 Battery Specifications
Maximum Height - Raised Hood
Cell Connectors and Terminals
Model Battery Type With Battery
Tray*
With Cell
Cap** Electrically
Insulated***
Not
Electrically
Insulated**
E1.50-1.75XM
(E25-35Z)),
E2.00XMS
(E40ZS)
I
625 mm
(24.6 in.)
627 mm
(24.7 in.)
607 mm
(23.9 in.)
E1.50-1.75XM
(E25-35Z)),
E2.00XMS
(E40ZS)
II, III
640 mm
(25.2 in.)
NA NA NA
NA = Not Applicable
BATTERY TYPES
TYPE I - Battery without a cover as part of the battery.
TYPE II - Battery with a cover that is flat and is fastened to case of battery. Cover opens from FRONT
OR REAR when installed in lift truck.
TYPE III - Battery with a cover that is flat and is fastened to case of battery. Cover opens from SIDE
when installed in lift truck.
*Battery Types II and III bottom of battery to highest point (top of cover or top of hinge).
**Minimum height below top of battery tray is 4 mm (0.16 in.).
***Minimum height below top of battery tray is 0.5 mm (0.02 in.).
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in the table above. Adjust the spacer
plate and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward,
backward, or to the side.
5

7. Mast Speeds 8000 SRM 1113
Maximum Carriage and Tilt Creep Rates
Vertical Creep at Carriage Tilt Creep at Cylinder RodHydraulic Oil
Temperature mm/Min in./Min /Min mm/Min in./Min
20 C (68 F) 2.2 mm 0.09 in. 0.10 0.63 mm 0.03 in.
30 C (86 F) 3.3 mm 0.13 in. 0.15 0.95 mm 0.04 in.
40 C (104 F) 6.3 mm 0.25 in. 0.29 1.83 mm 0.07 in.
50 C (122 F) 10.0 mm 0.39 in. 0.47 2.97 mm 0.12 in.
60 C (140 F) 14.6 mm 0.57 in. 0.68 4.30 mm 0.17 in.
Mast Speeds
E25-35Z, E40ZS MAST SPEEDS (36 AND 48 VOLT) AMERICAS
AC or DC Motor and 19 cc (1.16 in.3
) Lift Pump*
Lifting Lowering
Rated Load No Load Rated Load No LoadModel Mast V
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
Two-
Stage
LFL
36
48
0.396
0.508
78
100
0.544
0.681
107
134
0.508 100 0.472 93
Two-
Stage
FFL
36
48
0.396
0.508
78
100
0.538
0.671
106
132
0.462 91 0.371 73E25Z
Three-
Stage
FFL
36
48
0.386
0.498
76
98
0.518
0.650
102
128
0.478 94 0.411 81
Two-
Stage
LFL
36
48
0.381
0.488
75
96
0.544
0.681
107
134
0.508 100 0.472 93
Two-
Stage
FFL
36
48
0.376
0.483
74
95
0.538
0.671
106
132
0.462 91 0.371 73E30Z
Three-
Stage
FFL
36
48
0.366
0.478
72
94
0.518
0.650
102
128
0.478 94 0.411 81
LFL = Limited Free Lift
FFL = Full Free Lift
*Oil temperature 54 to 66 C (130 to 150 F). Lifting speeds (valve fully open) ±10% acceptable. No Load
lowering speeds are minimum values. Rated Load lowering speeds are maximum values. Load center is
610 mm (24 in.).
6

8. 8000 SRM 1113 Mast Speeds
AC or DC Motor and 19 cc (1.16 in.3
) Lift Pump*
Lifting Lowering
Rated Load No Load Rated Load No LoadModel Mast V
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
Two-
Stage
LFL
36
48
0.361
0.467
71
92
0.544
0.681
107
134
0.508 100 0.472 93
Two-
Stage
FFL
36
48
0.356
0.467
70
92
0.538
0.671
106
132
0.462 91 0.371 73E35Z
Three-
Stage
FFL
36
48
0.351
0.457
69
90
0.518
0.650
102
128
0.478 94 0.411 81
Two-
Stage
LFL
36
48
0.340
0.447
67
88
0.544
0.681
107
134
0.508 100 0.472 93
Two-
Stage
FFL
36
48
0.335
0.447
66
88
0.538
0.671
106
132
0.462 91 0.371 73E40ZS
Three-
Stage
FFL
36
48
0.330
0.437
65
86
0.518
0.650
102
128
0.478 94 0.411 81
LFL = Limited Free Lift
FFL = Full Free Lift
*Oil temperature 54 to 66 C (130 to 150 F). Lifting speeds (valve fully open) ±10% acceptable. No Load
lowering speeds are minimum values. Rated Load lowering speeds are maximum values. Load center is
610 mm (24 in.).
7

9. Thank you very much
for your reading. Please
Click Here Then Get
More Information.
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

10. 1600 SRM 720 Description
General
This section has the description and repair procedures for the steering housing and the steering control unit.
Additional information on parts of the steering system can be found in the Steering Axle and Hydraulic
System service manual sections for your lift truck.
Description
The steering column assembly uses a steering con-
trol unit with hose connections on the bottom of the
unit. The steering housing has mounts for the steer-
ing column and the steering control unit. The steer-
ing wheel is installed on the steering column. See
Figure 1. The housing is adjustable and is held in po-
sition by a latch. The position of the housing can be
changed for operator comfort. The steering housing
is also the mount for control levers and some instru-
ment clusters.
The steering system is a hydraulic system that does
not have a mechanical connection between the steer-
ing wheel and the steering axle. The control of the
steering is through a hydraulic circuit.
If the hydraulic pump for the steering system does
not operate, steering is still possible. A check valve
permits the steering control unit to control the steer-
ing cylinder. The lift truck is difficult to steer when
the steering pump is not operating, but the steer-
ing control unit can operate the steering cylinder and
make steering possible.
NOTE: INSTRUMENT CLUSTER NOT SHOWN.
H2.00-3.20XM (H40-65XM) SHOWN.
1. STEERING WHEEL
2. STEERING
COLUMN
3. STEERING
CONTROL UNIT
4. COLUMN TILT
LEVER
5. LATCH
6. COVER
7. COWL
8. MOUNT
Figure 1. Steering Housing Assembly
1

11. Operation 1600 SRM 720
Operation
The steering control unit is a rotary valve operated by
the steering wheel. See Figure 2. During the steer-
ing operation, the steering control unit controls the
direction and amount of oil flow to the steering cylin-
der. The steering cylinder in the axle actuates the
steering linkage to move the steer tires. Hydraulic
oil returns from the steering cylinder to the steering
control unit and then to the hydraulic tank.
Turning the steering wheel actuates three main
parts of the steering control unit: the spool for the
control section, the sleeve for the control section, and
the rotor in the metering section. When the steering
wheel is not moving, the spool and sleeve are held
in the NEUTRAL (center) position by springs. Dur-
ing this time, oil flows freely through the steering
control unit but none flows to the steering cylinder.
As the steering wheel is turned, the spool just be-
gins to rotate. The springs try to move the sleeve to
keep the NEUTRAL position between the spool and
sleeve. However, the necessary force to turn the ro-
tor is greater than the pressure of the springs. The
springs begin to bend, letting the spool move a small
amount within the sleeve. The spool stops moving
when it touches the center pin. In this position, the
holes in the sleeve and the spool are aligned. Oil com-
ing into the control unit flows to the metering section.
More rotation of the steering wheel causes the spool
to rotate the pin. This action causes the rotation of
the sleeve and the rotor in the metering section. The
oil then flows to one side of the steering cylinder. Oil
from the other side of the cylinder returns through
the control section of the steering control unit.
When the steering wheel stops moving, the meter-
ing action in the metering section also stops. The
NEUTRAL position springs return the sleeve to the
NEUTRAL position, stopping oil flow to or from the
cylinder. The pressure stays in the steering cylinder
to keep the steer tires in position. Oil from the pump
flows through the steering control unit to the tank or
other parts of the system. To return the steer wheels
to the straight position, the steering wheel must be
rotated in the opposite direction. The steering con-
trol unit will operate as described, but all parts will
rotate in the opposite direction.
2

12. 1600 SRM 720 Operation
1. SPRING SET
2. SPOOL
3. SLEEVE
4. CENTER PIN
5. GEAR SET
6. CONTROL SECTION
7. METERING SECTION
Figure 2. Steering Control Unit
3

13. Steering Wheel and Column Assembly Repair 1600 SRM 720
Steering Wheel and Column Assembly Repair
The upper end of the steering shaft has splines for the
steering wheel. A large hex nut holds the steering
wheel onto the steering column. The horn button is
the cover for the center of the steering wheel. The
lower end of the steering column has splines or a tang
to engage the steering control unit. See Figure 5 and
Figure 6.
The steering column assembly is adjustable and held
in position by a latch. The position of the steering col-
umn assembly can be changed as needed for different
operator requirements. An access cover on the steer-
ing column gives access to the steering control unit,
key switch, horn switch, and if installed, the direc-
tion switch.
ASSEMBLY COMPONENTS, REMOVE
NOTE: This procedure is for the removal of all com-
ponents of the steering column assembly. All compo-
nents are not often removed for a repair procedure.
Do only those steps of the procedure necessary to re-
move the required component. See Figure 5 and Fig-
ure 6.
WARNING
The hydraulic hoses must be connected to the
correct ports or the steering system will not op-
erate as expected, which can cause damage or
personal injury. Make sure the hoses are iden-
tified and connected correctly.
CAUTION
Disconnect the negative battery cable on inter-
nal combustion trucks. Disconnect the battery
connector on electric trucks. Disconnect the
battery before removing any covers.
1. Attach a tag on the battery connector or negative
cable stating DO NOT CONNECT BATTERY.
Move the steering column to the most FOR-
WARD position. Remove the column tilt lever.
Remove the upper and lower access covers from
the steering column.
2. Remove the key switch and static strap from the
housing of the steering column. Make an identi-
fication of the electric wires and disconnect them
from the key switch.
3. On units with the Direction Control Handle,
Remove the direction switch assembly from the
housing of the steering column. Make an identi-
fication of the electric wires and disconnect them
from the direction switch. See Figure 3.
NOTE: DIRECTION CONTROL HANDLE ASSEMBLY
FOR MODELS J2.00-3.20XM [J40-65Z] (A416/B416),
E1.50-2.00XM [E25-35Z, E40ZS] (E114/F114),
N30XMH, AND N30XMH2 (C210), V30ZMD (D210/
E210), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), AND E2.00-3.20XM [E45-65Z] (G108)
IS SHOWN. OTHER TRUCK DIRECTION CONTROL
HANDLE ASSEMBLIES ARE SIMILAR.
1. DIRECTION SWITCHES
2. SHIFT LEVER ASSEMBLY
3. SCREW
4. ELECTRICAL CONNECTORS
Figure 3. Direction Control Handle Assembly
4. Remove the plastic rivets that fasten the bracket
for the horn switch to the housing of the steering
column. Move the horn switch and bracket away
from the steering column. See Figure 5 and Fig-
ure 6.
4

14. 1600 SRM 720 Steering Wheel and Column Assembly Repair
CAUTION
If a puller tool is used to remove steering wheel
from steering column, be careful not to damage
the horn wires.
5. Remove the horn button assembly and electrical
wires. Remove the large hex nut and the steer-
ing wheel from the shaft. A puller tool makes
removal of the steering wheel easier, but not all
steering wheels have puller holes.
6. On lift truck models J2.00-3.20XM (J40-
60XM2) (A216), E1.50-1.75XM, E2.00XMS
(E25-40XM2S) (D114), N30XMH, N30XMH2
(C210), and E2.00-3.20XM (E45-65XM2) (F108)
units, remove the optical encoder housing and
optical encoder from the steering column. Make
an identification of the electrical wires and dis-
connect them from the assemblies. See Figure 5.
7. On lift truck models J2.00-3.20XM [J40-
65Z] (A416/B416), E1.50-2.00XM [E25-35Z,
E40ZS] (E114/F114), V30ZMD (D210/E210),
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(D098/E098), and E2.00-3.20XM [E45-65Z]
(G108), disconnect the connector. Remove the
two capscrews and steering sensor from the
steering column. See Figure 6.
8. Make an identification of the hydraulic hoses
at the steering control unit so they can be con-
nected correctly during assembly. See Figure 4,
Figure 5, Figure 6, and the WARNING in the
beginning of this section. Some hydraulic hoses
have fittings that will permit disconnection at
the steering control unit. Disconnect the other
hydraulic hoses at the base of the cowl, the
control valve, or the steering pump. Remove
all mount clamps so that the hoses will turn
freely and not become twisted. Disconnect the
hydraulic hoses at the bottom of the steering
control unit. Install plugs at all hoses and ports
to prevent dirt from entering the steering hy-
draulic system.
1. HYDRAULIC HOSE ENDS
2. HOSE PORTS
3. STEERING CONTROL UNIT
4. SCREWS
5. HORN SWITCH
Figure 4. Hydraulic Hose Connections
9. If your model of lift truck has an instrument
cluster that wraps around the steering col-
umn, remove the instrument cluster. The
removal procedures for the instrument clus-
ter can be found in the service manual sec-
tions Instrument Cluster 2200 SRM 514 for
models H2.00-3.20XM (H40-65XM) (H177),
S1.50-1.75XM, S2.00XMS (S25-40XM) (D010)
and H1.50-1.75XM, H2.00XMS (H25-35XM,
H40XMS) (E001), or Electrical System,
Replacement, Checks, and Adjustments
Trucks with EV-100/200ZX or SR (SEM)
and SP Motor Controllers 2200 SRM
560 for models E1.50-1.75XM (E25-35XM2)
(D114), E2.00XMS (E40XM2S), E2.00-3.20XM
(E45-65XM2) (F108), and J2.00-3.20XM
(J40-60XM2) (A216).
10. If there is a instrument cluster on the steering
column housing, disconnect all plugs connected
to the display panel.
5

15. Steering Wheel and Column Assembly Repair 1600 SRM 720
Figure 5. Steering Column Assembly, For Models J2.00-3.20XM (J40-60XM2) (A216), E1.50-1.75XM,
E2.00XMS (E25-40XM2S,(D114), N30XMH, N30XMH2 (C210), and E2.00-3.20XM (E45-65XM2) (F108)
6

16. 1600 SRM 720 Steering Wheel and Column Assembly Repair
Legend for Figure 5
NOTE: * NOT INCLUDED ON LIFT TRUCK MODELS H2.00-3.20XM (H40-65XM) (H177), S1.50-1.75XM,
S2.00XMS (S25-40XM) (D010), AND H1.50-1.75XM, H2.00XMS (H25-35XM, H40XMS (E001)
1. ON-DEMAND STEERING COMPONENTS
2. UPPER ACCESS COVER
3. BRACKET
4. PIVOT (STEERING) SHAFT
5. PLATE
6. LOCKWASHER
7. CAPSCREW
8. LOCK NUT
9. SCREW
10. STATIC GROUND PATCH
11. LOWER ACCESS COVER
12. COLUMN TILT LEVER
13. PUSH ROD
14. LATCH
15. SPRING
16. WASHER
17. COTTER PIN
18. PIN
19. STEERING CONTROL UNIT
20. PLUG (WITHOUT TURN SIGNAL)
21. OPTICAL ENCODER HOUSING*
22. GEAR*
23. OPTICAL ENCODER*
24. HORN BUTTON ASSEMBLY
25. STEERING WHEEL
26. STEERING COLUMN
27. RETURN SPRING
28. LARGE HEX NUT
29. INPUT
30. RIGHT TURN
31. LEFT TURN
32. RETURN
33. PLASTIC RIVET
11. Remove the tilt stop screw located at the bottom
left side of the steering column bracket.
12. Remove the capscrews, lockwashers, and lock
plates that fasten the steering column to the
pivots on the lift truck. Remove the steering col-
umn from the lift truck. Make sure the electric
wires and the hydraulic hoses are not damaged
as the steering column is removed.
13. Remove the four capscrews that hold the steer-
ing column to the bracket. Remove the four cap-
screws or nuts that fasten the steering control
unit to the steering column.
STEERING CONTROL UNIT,
DISASSEMBLE
1. Place the steering pump into a soft jaw vise with
the splined shaft facing down.
2. Remove the hydraulic fittings and the special
screws, and rotate the steering pump 90 degrees
sideways in the vise. Discard the O-rings. See
Figure 7.
3. Remove the end cover, spacer, gear housing,
and gear from the steering pump. Discard the
O-rings.
4. Remove the cardan shaft from the spool assem-
bly.
5. Remove the check ball, ball stop, and emergency
steering ball from the pump housing.
6. Remove the spool assembly from the pump hous-
ing.
NOTE: To help with installation of the thrust bearing
assembly, note the positions of the thrust washers
on either side of the thrust bearing while performing
Step 7.
7. Remove the thrust bearing assembly from the
shaft end of the spool assembly.
8. Remove the retaining ring from the spool assem-
bly.
9. Press the cross pin out of the spool assembly.
10. Press the spool from the sleeve and remove the
springs from the spool. Press the spool from the
sleeve and remove the springs from the spool.
11. Remove the shaft seals from the pump housing.
Discard the seals.
7