Hyster issued this 722-page service manual under its own document number, 620 SRM 294, for ten XL electric lift truck variants, E and J models from the E1.25XL to the E5.50XL. Wiring diagrams in this Hyster E1.25XL service manual PDF trace the EV-100 motor controller and its SCR control, while the hydraulic schematic maps the main control valve and solenoid valve circuit. Drive axle, differential, steering control unit and tilt cylinder repairs sit beside the DC motor work: brush replacement, stoning the commutator, and armature and field coil tests for open and short circuits. Torque GE motor power cables at M8 terminals to 18 to 22 Nm (159 to 195 lbf in), and bring the rear overhead guard fasteners on E1.25-3.00XL trucks to 435 Nm (320 lbf ft). Due for a brush and commutator inspection? Compare your commutator against the normal surface and commutator problems guidance. Pay once, and the bookmarked, text-searchable PDF stays yours for your trucks.
What's Inside This Hyster E1.25XL-E5.50XL, J2.00-3.00XL Series Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1 | Hydraulic Pump Motor and Traction Motor |
| Brush and Commutator Inspection | 1-7 | Hydraulic Pump Motor and Traction Motor, Steering Pump Motor, Normal Commutator Surface, Commutator Problems |
| Brush Replacement | 8-9 | Motor Brushes, Brush Springs, Brush Holders, Terminal Mounts |
| Stoning the Commutator | 10-11 | Commutator, Brush Seater Stone, Key Switch, Seat Switch, Battery |
| Motors Repair | 12-19 | Disassemble (Traction Motor and Hydraulic Pump Motor, Steering Pump Motor), Assemble (Traction Motor and Hydraulic Pump Motor |
| Brush Alignment, Traction and Hydraulic Motors | 20 | Brush Holder, Commutator, End Frame, Brush Mounting Plate |
| Tests for Damaged Field and Armature | 20-21 | 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 |
| DC Motor Maintenance | 22-51 | Brush Inspection, Commutator Maintenance, Motor Disassembly, Motor Assembly, Troubleshooting |
| Drive Axle and Differential | 52-67 | Drive Axle Removal, Differential Disassembly, Pinion Assembly, Torque Specifications, Troubleshooting |
| Steering Control Unit | 68-122 | Steering Control Unit Description, Seat Brake Assembly, Brake System Repairs, Troubleshooting, Torque Specifications |
| Hydraulic System | 123-148 | Hydraulic Schematic, Main Control Valve, Relief Valve Adjustments, Solenoid Valve, Troubleshooting |
| Tilt Cylinders | 149-188 | Tilt Cylinder Repair, Leak Checks, Troubleshooting, Meter Specifications, Battery Indicator Troubleshooting |
| Controller Description and Operation | 189-228 | Motor Controller Operation, SCR Control, Troubleshooting Fault Codes, Wiring Diagrams, Battery Maintenance |
| Controller Repairs and Adjustments | 229-256 | Control Card Adjustments, General Electrical System Adjustments, Shunt and Ammeter, Fuses, Component Locations |
| Controller Troubleshooting | 257-386 | SCR Control Card, Status Code Description, Troubleshooting, Function 2 Creep Speed, Regenerative Braking |
| SitDrive Electric Lift Trucks | 387-539 | Ev-100 Motor Controller Adjustments, Electrical Checks and Adjustments, Check the Accelerator Card, Armature Shunt Method, Electrolyte |
| Vista Mast Description | 540-650 | Vista Mast, Upright Speeds, Lift Cylinders, Carriage, Torque Specifications |
| Diagrams | 651-694 | Schematic Diagram, Battery Indicator, SCR Control Card, Wire Diagram, Steering Column |
| Electrical Diagrams | 695-722 | Pump Motor SCR Control Schematic, Battery Indicator W/Lift Interrupt, Field Weakening and SCR Pump Wiring Diagram, Power Steering |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| E1.25-3.00XL (E/J25-60XL) | ||
| Overhead Guard Front Torque | 86 Nm (64 lbf ft) | p. 7 |
| Overhead Guard Rear Torque | 435 Nm (320 lbf ft) | p. 7 |
| All Models | ||
| Torque for capscrews fastening the pump to the motor | 48 Nm (35 lbf ft) | p. 128 |
| Torque for power cables at M8 or 5/16-inch terminals on General Electric motors | 18 to 22 Nm (159 to 195 lbf in) | p. 126 |
| Diode D3 and D4 tightening torque | 3.4 N.m (30 lbf in) | p. 245 |
| Battery temperature rise limit | 14°C (25°F) during an eight hour charging period | p. 434 |
| Traction Motor to Transmission Bolt Torque | 38 N.m (28 lbf ft) | p. 67 |
| Pinion Nut Torque | 340 N.m (250 lbf ft) | p. 67 |
| Steer Axle Mount Bracket Hardware Torque | 88 N.m (65 lbf ft) | p. 100 |
| E20-30B/BS/BH | ||
| E20-30B/BS/BH Traction Fuse | 225A | p. 239 |
| E20-30B/BS/BH Hyd. pump Fuse | 175A | p. 239 |
| E/J1.25–1.75XL (E25–35XL) | ||
| Torque – Wheel Nuts, Drive Tires | 155 N.m (115 lbf ft) | p. 641 |
Hyster E1.25XL-E5.50XL, J2.00-3.00XL Series Common Problems This Manual Covers
Hyster XL electric forklift traction or hydraulic pump motor brushes worn unevenly or showing wear sensor wire
Raise the drive wheels so the traction motor commutator turns without moving the truck, then remove the brush covers following page 26. Vacuum out brush dust. If you use compressed air, keep the path away from everyone and wear goggles or a face shield (page 27). Replace all brushes if any brush is worn, cracked, or under half its original length. Inspect brushes and commutator every 350 hours.
Manual Section: Brush and Commutator Inspection p. 27Traction or hydraulic pump motor commutator showing heavy streaks and fine grooves under the brushes
Check for the causes on page 47: dirty or abrasive operation, continuous light-load running, low brush pressure, or worn brushes. Clean the commutator more often, increase motor load from time to time, increase brush pressure, and replace worn brushes. If grooves and lines have followed the streaks, remove the armature for repair or replacement, or the brushes will wear rapidly.
Manual Section: Motors Repair Troubleshooting p. 47Copper drag pulling commutator bar copper into the slots between bars, with rapid brush wear
Clean the commutator more frequently if the truck works in dirty or abrasive conditions. Adjust the brush holder so it is set electrically correct for the motor, replace brushes with the correct type, and adjust brush pressure, since pressure that is too high or too low both cause drag (page 48). Fix it early, because copper drag will short circuit the commutator bars.
Manual Section: Motors Repair Troubleshooting p. 48Motor commutator bars burned at the ends or on opposite sides, with damaged varnish insulation
Test for an open armature winding or open field coil using the tests on page 20, and replace whichever is open. Replace the armature or resurface the commutator in a lathe for flashover burns. Check for high or loose commutator bars. If the motor was stalled or ran too hot, correct operating technique and confirm the truck suits the application (page 49).
Manual Section: Motors Repair Troubleshooting p. 49New motor brushes not seating fully against the commutator after brush replacement
Raise the drive wheels and stone the commutator following page 10. Wear eye protection, run the motor at low speed, and keep your fingers clear of moving parts (page 35). Use a brush seater stone at least 60 mm (2.4 in) long and do not hold it on longer than needed. Turn the key switch OFF, disconnect the battery, and confirm 85 percent of each brush face contacts the commutator.
Manual Section: Stoning the Commutator p. 10Mast tilt cylinders drifting when a capacity load is held on the forks
Test the tilt cylinders following the leak check on page 159, with a capacity load on the forks. Never let anyone under a raised carriage, and never feel for leaks with your hand on pressurized components, because oil can be injected into the body. If the main control valve needs repair, lower the upright before disconnecting lines (page 139), then replace all seals and O-rings and lubricate parts with clean hydraulic oil (page 140).
Manual Section: Tilt Cylinders p. 159Frequently Asked Questions
How do you clear an Hyster E2.00-2.50XL or E2.00-3.00XL fault?
Status codes can be cleared from memory by adjusting the setting number to zero using the hand set. The setting number must be stored by pushing the STORE key for one second. Adjustment of this function does not change the operation of the lift truck. p. 319
What are the replacement specifications for traction-motor brushes on the Hyster E1.25-5.50XL, J2.00-3.00XL Series?
Motor brushes must be replaced before they are worn enough to damage the commutator surface. Replace all brushes as a set if any brush is worn to a minimum length. For example, if the original brush height is 32 mm (1.26 in.), it should be replaced when the worn brush height reaches 16 mm (0.63 in.). p. 33
What is the torque specification for the drive wheel nuts on an E2.00-3.00XL lift truck?
The torque specification for the drive wheel nuts on the E2.00-3.00XL (E40-60XL) lift truck is 237 to 305 N.m (175 to 225 lbf ft). p. 67
What is the correct hydraulic oil capacity for an E2.00-3.00XL lift truck?
The hydraulic system capacity for the E/J2.00-3.00XL (E/J40-60XL) lift truck is 19.30 litres (20.4 qt) to the FULL mark. p. 643
How do you adjust the service brakes on an E/J2.00-3.00XL lift truck?
Put the lift truck on blocks so the drive wheels can be rotated. Use a brake adjuster tool to adjust the brake shoes until the brake drum will not rotate. Push the adjuster wheel actuator away from the adjuster wheel with a small screwdriver and loosen the adjuster wheel approximately 25 teeth. p. 114
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