Hyster E40-65Z (G108) Forklift Service Manual
766 pages · Publication 1551322
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- Models
- E40-65Z (G108)
- Manual type
- Service Manual
- Pages
- 766
- Publication
- 1551322
- Condition
- Brand new
What's inside
From the manual's own table of contents: 173 sections, 523 entries. See sample pages (PDF, 234 KB)
Drive Axle, Speed Reducer, and Differential
Safety Precautions Maintenance and Repair
General
Description
Drive Axle, Speed Reducer, and Differential Repair9 topics
- Drive Axle, Remove
- Drive Axle, Disassemble
- Speed Reducer and Differential, Disassemble
- Clean
- Inspect
- 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
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
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)
Show all 173 sections
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
Frame4 topics
- Main Frame
- Other Frame Weldments
- Battery Restraint/Hood Frame and Plate for Optional Seat Brake
- Overhead Guard
Overhead Guard Repair
Battery Restraint and Seat Assembly Repair
Counterweight Repair
Traction Motor Repair
Hydraulic Tank Repair5 topics
- Small Leaks, Repair
- Large Leaks, Repair
- Steam Method
- Chemical Solution
- Additional Preparations for Repair
Painting Instructions
Safety Label Replacement
Battery Specifications
Table 1. Counterweights
Hydraulic System
Operation6 topics
- Hydraulic Gear Pump
- Rotator Actuator Valve
- Steering Pump
- 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
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
Four-Stage Mast3 topics
- Mast
- Description
- Operation
Carriage Repair10 topics
- Standard Carriage
- Sideshift Carriage
- Repairs
- Standard Carriage
- Sideshift Carriage
- Main Lift Cylinders
- Free-Lift Cylinders
- Main Lift Cylinder
- Free-Lift Cylinder
- Header Hoses, Install
Lift and Tilt System Leaks Check2 topics
- Lift Cylinders Leaks Check
- Tilt Cylinders Leaks Check
Lift Chain Adjustments
Mast Adjustments
Carriage Adjustments
Table 1. Standard Four-Stage Hose Dimensions
Table 2. Hook type Carriage Chain Adjustment
Table 3. Pin-Type Carriage Chain Adjustment
Brake System3 topics
- Service Brakes
- Master Cylinder
- Parking Brake
Service Brakes Repair3 topics
- Remove and Disassemble
- Assemble and Install
- Adjust
Parking Brake Repair
Master Cylinder Repair
Seat Brake Assembly3 topics
- Seat Brake, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E
- Brake Switch, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM
- Electric Seat Brake, Adjust
Service Brakes Adjustment
Brake Pedal Adjustment
Master Cylinder Adjustment
Brake System Air Removal
Parking Brake Not Applied Switch Test
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
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 Axle
Steering Axle Assembly Repair
Wheels Repair
Spindles, Bearings, and Tie Rods Repair
Steering Housing and Control Unit
Steering Wheel and Column Assembly Repair5 topics
- Assembly Components, Remove
- Steering Control Unit, Disassemble
- Steering Control Unit, Clean
- Steering Control Unit, Assemble
- Assembly Components, Install
System Air Removal
Steering System for AC Electric Lift Trucks1 topic
- General
Power Steering Motor and Pump3 topics
- Description
- Power Steering Pump, Repair
- Seal, Replace
Steering System Air Removal
Steering Pressure Check
Steering Motor Circuits Check
Electrical System (Trucks With AC Controllers)2 topics
- Features of the Display Panels
- Other Control Components
Display Panel and Key Switch Replacement2 topics
- Display Panel, Replace
- Key Switch, Replace
Motor Controller Replacement
Control Components Replacement21 topics
- Start Switch, Replace
- Brake Light Switch, Replace
- Seat Switch, Replace
- Parking Brake Switch, Replace
- MONOTROL Pedal Direction Switches, Replace
- Steering Column Direction Control Switches, Replace
- Brake Fluid Switch, Replace
- Brush Wear and Overtemperature Sensors (Optional DC Pump Motor O
- Rocker Switches for Lights, Replace
- Accelerator Position Sensor, Replace
- On-Demand Steering Sensor, Replace
- Lights, Converter, Relay, and Reverse Alarm
- Brake, Tail, and Reverse Light Assembly, Replace
- Strobe Light Assembly, Replace
- Front, Rear Driving Light, or Spot Light Assemblies, Replace
- Converter, Replace
- Relay, Replace
- Backup Alarm, Replace
- Horn and Horn Button, Replace
- Horn Switch and Cover, Replace
- Hydraulic Pump Switches
Control and Power Fuse Check1 topic
- Fuse Locations
Brake Light Switch Adjustment
Seat Switch Check
Seat Brake Adjustment
Parking Brake Switch Adjustment
Direction Switches Check2 topics
- MONOTROL Pedal
- Steering Column
MONOTROL Pedal or Accelerator Pedal Adjustment
Accelerator Position Sensor Adjustment and Start Switch Adjustme2 topics
- Acceleration Position Sensor, Adjust
- Start Switch, Adjust
AC Motor Controllers/ Display Panel5 topics
- AC Motors
- Motor Controllers
- Master Controller
- Dash Display
- Controller Area Network Bus (CANbus)
Master Controller Checks and Adjustments
Function Parameters1 topic
- Function Numbers
Function Parameter Descriptions20 topics
- Function Number 1 BATTERY VOLTAGE
- Function Number 2 EXTENDED SHIFT
- Function Number 3 ACCELERATION 1
- Function Number 4 ACCELERATION 2
- Function Number 5 TOP SPEED LIMIT
- Function Number 6 REGEN BRAKING
- Function Number 7 AUTO DECELERATION
- Function Number 8 BDI ADJUSTMENT
- Function Number 9 LIFT INTERRUPT
- Function Number 10 POWER STEERING TIME DELAY
- Function Number 11 SERVICE REMINDER
- Function Number 12 CUSTOM
- Function Number 13 PUMP SPEED 1
- Function Number 14 PUMP SPEED 2
- Function Number 15 PUMP SPEED 3
- Function Number 16 PUMP ACCELERATION
- Controller Status Light Emitting Diodes (LEDs)
- AC Master Controller
- AC Motor Controllers
- Status Codes
AC Motor Controllers Status Code Charts
AC Transistor Motor Controller Repair8 topics
- General Maintenance Instructions
- Special Precautions
- Fuses
- Fan Test
- Contactors
- Repair
- Thermal Sensors
- Motor Controller, Replace
Display Panel2 topics
- Premium Display Panel
- Standard Display Panel
Display Functions and Features9 topics
- Key-ON Initialization
- Standard Display
- Premium Display
- Lift Truck Inspection Function
- Access to Service Functions
- Service Functions
- Performance Modes
- Battery Discharge Indication (BDI)
- Hourmeter
Dash Display Service Menu Navigation2 topics
- Moving Through Menu Selections
- Editing and Adding Information
Table 4. List of Status Codes
Table 5. 42-Pin Connections/Descriptions for Master Controller
Table 6. Pin Connections/Descriptions for 72/80 Volt Motor Contr
Table 7. Pin Connections/Descriptions for 36/48 Volt Motor Contr
Troubleshooting and Adjustments Using The AC Controls Program6 topics
- Computer Requirements
- Software, Install
- Language Selection
- Demo Mode
- Connect PC to Lift Truck
- Starting AC Controls Program
Lift Truck Control Setup6 topics
- Change Lift Truck Serial Number or Hourmeter
- Setting Factory Default Values or Changing Lift Truck Parameters
- Create New Custom Lift Truck Configuration
- Lift Truck Configuration Properties
- Import New Lift Truck Configuration From Disk
- Delete Custom Lift Truck Configuration or Password File
Dash Display4 topics
- Custom Display Languages
- Download Display Language
- Clear Operator Log
- Clear Status Log
Password Functions7 topics
- Enable/Disable Password and Lift Truck Inspection Functions
- Truck Inspection Checklist
- Password
- Password Properties
- Create New Password File
- Download Passwords
- Upload Passwords
Reports Menu4 topics
- Passwords
- Operators
- Current Settings
- Diagnostics
Help Menu2 topics
- Technical Support
- About Electric Truck AC Controls Program
Electrical Diagrams
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 Daily18 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 Restraint System J2.00-3.20XM (J40-60Z) (A416) Lift Truc
- 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, E1.50-2.00XM (E114) Trucks Only
Maintenance Procedures Every 500 Hours or 3 Months4 topics
- Differential and Speed Reducer, V30ZD (D210), E2.00-3.20XM (E45
- Wheel Nut Torques
- Forks
- Parking Brake Adjustment
Maintenance Procedures Every 1000 Hours or 6 Months12 topics
- Lift Chains
- Wear Check
- Check Upper and Lower Bearings, Integral Sideshift Carriage
- Steering Tie Rods, All Models Except E1.50-2.00XM (E114)
- Steering Axle Spindles
- King Pins, All Models Except E1.50-2.00XM (E114)
- Hydraulic Tank Breather
- Differential and Speed Reducer J2.00-3.20XM (J40-60Z) (A416) Lif
- Electrical Inspection
- Contactors
- Motor Brushes (Optional DC Pump)
- Other Lubrication
Maintenance Procedures Every 2000 Hours or Yearly9 topics
- Change Filter for Hydraulic Oil
- Change Hydraulic Oil
- Differential and Speed Reducer
- Wheel Bearings
- Steer Wheels, Lubrication
- Drive Wheels, Lubrication
- Replace Upper and Lower Bearings, Integral Sideshift Carriage
- How to Charge Battery
- General
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
Capacities and Specifications
Counterweights
Wheels and Tires
Capacities
Movement Rates (Maximum) for Tilt Cylinders
Mast Speeds5 topics
- E45-65Z, and V30ZD Mast Speeds (36 or 48 Volt) Americas
- Frame
- Drive Axle, Speed Reducer, and Differential E.200-3.20XM (E45-65
- Masts
- Seat Brake
AC Motor Repair
Inside this manual
Real pages from this service manual (766 pages). Open the sample pages (PDF, 234 KB)
- Specifications, page 143: Header Hose Arrangement
- Troubleshooting, page 319: Troubleshooting
- Diagram, page 649: Diagrams, Schematics, or Arrangements
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, 766 pages
Quantity one is the manual described above.
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