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Hyster E45-65XM (F108) Forklift Service Manual

1,104 pages · Publication 897654

$119.95
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Models
E45-65XM (F108)
Manual type
Service Manual
Pages
1,104
Publication
897654
Condition
Brand new
Hyster E45-65XM (F108) Forklift Service Manual, publication 897654

What's inside

From the manual's own table of contents: 195 sections, 681 entries. See sample pages (PDF, 294 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
Steering Axle
Steering Axle Assembly Repair2 topics
  • Remove
  • Install
Wheels and Hubs Repair2 topics
  • Remove and Disassemble
  • Assemble and Install
Spindles, Bearings, and Tie Rods Repair
Steering Cylinder Repair1 topic
  • Clean and Inspect
Show all 195 sections
Steering System for Electric Lift Trucks
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
Steering Housing and Control Unit
Operation3 topics
  • Steering Column Assembly, Remove
    • Steering Control Unit
  • Steering Column Assembly, Install
System Air Removal
Instrument Cluster7 topics
  • Display Panels on Steering Column, Internal Combustion
  • Display Panels on Steering Column, Electric Lift Trucks
    • Standard Display Panel
    • Enhanced Display Panel
  • Curtis 1215 Display Panel
    • Description and Features
    • Operation
Cluster-Type Display Panel (Internal Combustion) Replacement
Cluster Display Panel (Electric Lift Truck) Replacement7 topics
  • Display Panel Assembly, Replace
  • LED Indicators
  • Battery Indicators
  • Digital Display (Enhanced Display Panel Only)
  • Status Code or Performance Level Switches and LED indicators (En
  • Standard Display Panel Parts, Replace
  • Enhanced Display Panel Parts, Replace
Curtis 1215 Display Panel Replacement
Table 1. Instrument Cluster, Internal Combustion
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)
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Safety Procedures When Working Near Mast
Forks Repair
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
Electrical Diagrams
EV-100ZX™ SCR Motor Controller1 topic
  • Model Number Data For EV-100ZX Controller
Register Parameters2 topics
  • General
  • Function Numbers
Control Card, Checks and Adjustments
Handset7 topics
  • How to Check and Adjust Registers
  • How to Scroll through Fault Codes and Clear Them
  • Checks and Adjustments on Workbench
  • When Handset Is Connected to Control Card Installed In Lift Truc
  • Function Numbers 1 through 15
  • Function Numbers 16 through 30
  • Function Numbers 48 through 62
Control Cards68 topics
  • Function Number Descriptions
  • Traction Control Cards (Label Letters - ZH and ZY)
    • Function Number 1 STORED STATUS CODE
    • Function Number 2 CREEP SPEED
    • Function Number 3 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 4 CURRENT LIMIT
    • Function Number 5 PLUGGING DISTANCE (CURRENT)
    • Function Number 6 1A DROP OUT CURRENT
    • Function Number 7 FIELD WEAKENING PICK UP
    • Function Number 8 FIELD WEAKENING DROP OUT
    • Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT
    • Function Number 10 REGENERATIVE BRAKING START
    • Function Number 13 SPEED LIMIT 3 (SL3)
    • Function Number 14 INTERNAL RESISTANCE COMPENSATION
    • Function Number 15 BATTERY VOLTS
    • Function Numbers GREATER THAN 15
    • Function Number 16 PEDAL POSITION PLUG
    • Function Number 17 CARD TYPE SELECTION
    • Function Number 18 STEERING PUMP TIME DELAY
    • Function Number 19 MAINTENANCE ALERT (Tens/Units)
    • Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)
    • Function Number 21 MAINTENANCE SPEED LIMIT
    • Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS
    • Function Number 29 HOURMETER (Tens/Units)
    • Function Number 30 HOURMETER (Thousands/Hundreds)
    • Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE
    • Function Number 48 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 49 FIELD WEAKENING PICK UP
    • Function Number 50 SPEED LIMIT 1
    • Function Number 52 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 53 FIELD WEAKENING PICK UP
    • Function Number 54 SPEED LIMIT 1
    • Function Number 56 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 57 FIELD WEAKENING PICK UP
    • Function Number 58 SPEED LIMIT 1
    • Function Number 60 CONTROLLED ACCELERATION AND 1A TIME
    • Function Number 61 FIELD WEAKENING PICK UP
  • Pump Control Card (Label Letter ZP)
    • Function Number 1 STORED STATUS CODE
    • Function Number 2 INTERNAL RESISTANCE COMPENSATION START
    • Function Number 3 CONTROLLED ACCELERATION
    • Function Number 4 CURRENT LIMIT
    • Function Number 7 CONTROLLED ACCELERATION COMPENSATION
    • 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)
    • Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift
    • Function Numbers Greater Than 15
    • Function Number 16 INTERNAL RESISTANCE COMPENSATION
    • Function Number 17 CARD TYPE SELECTION
    • Function Numbers 18 through 28 TEMPORARY DATA REGISTERS
    • Function Number 29 HOURMETER (Tens/Units)
    • Function Number 30 HOURMETER (Thousands/Hundreds)
    • Function Number 48 CONTROLLED ACCELERATION
    • Function Number 49 SPEED LIMIT 2
    • Function Number 50 SPEED LIMIT 3
    • Function Number 52 CONTROLLED ACCELERATION
    • Function Number 53 SPEED LIMIT 2
    • Function Number 54 SPEED LIMIT 3
    • Function Number 56 CONTROLLED ACCELERATION
    • Function Number 57 SPEED LIMIT 2
    • Function Number 58 SPEED LIMIT 3
    • Function Number 60 CONTROLLED ACCELERATION
    • Function Number 61 SPEED LIMIT 2
    • Function Number 62 SPEED LIMIT 3
  • Register Parameters
  • Status Codes
  • Register Maps
Status Code Charts
EV-100ZX SCR Motor Controller Repair19 topics
  • Fuses
  • SCR, Check
  • SCR Assembly
  • Thermal Protector
  • SCR 1 Assembly, Replace
  • OFF Circuit for SCR 1
    • Reactor Assembly, Check
    • Suppressors for SCR 2 and SCR 5, Check
    • SCR 2 and SCR 5, Check
    • SCR 2 and SCR 5, Replace
    • Capacitor C1, Check
  • Diodes D3 and D4
    • Diodes D3 and D4, Check
    • Diodes D3 and D4, Replace
  • Motor Current Sensor
    • Contactor, Repair
  • Control Card
  • Control Card Plugs
    • Brush Wear Indicators
Theory of Operation25 topics
  • Electronic Speed Controls
    • Silicon Controlled Rectifier (SCR)
    • Motor Circuit That Operates With Pulses
    • Traction Circuit
    • Hydraulic Pump Motor
    • SCR 1 OFF Circuit
  • Induction Current from Motor
  • Control Cards
    • Pulse Monitor Trip (PMT) (Traction Circuit Only)
    • SRO Circuit (Traction Circuit Only)
  • Sequence of Operation
    • Control Card Adjustments (Traction Circuit)
    • Accelerator Control
  • SCR Control (Hydraulic Pump Motor)
  • Circuit Protection
    • Traction Circuit Fuse
    • Current Limit
    • Thermal Protection
    • Suppressors
  • Truck Management Module (TMM1)
  • Display Panels
    • Display Panel
    • Basic Display
    • Performance Display
    • Brush Wear Indicators
Table 1. Terminal and Plug Wire Connections for Control Card ZY
Table 2. Terminal and Plug Wire Connections for Control Card ZH
Table 3. Terminal and Plug Wire Connections for Control Card ZH
Table 4. Terminal and Plug Wire Connections for Controller with
Table 5. Status Codes List
Table 6. Register Map for Control Cards ZH and ZY (Traction)
Table 7. Register Map for Control Card ZP (Hydraulic Pump)
Table 8. Terminal and Plug Wire Connections for TMM1 Module
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 System6 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
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 Replacement8 topics
  • ZX Panel Replacement
  • Display Panel Assembly
  • Key Switch, Replace
  • Indicator LEDs
  • 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
Capacities and Specifications
Counterweights
Wheels and Tires
Capacities
Movement Rates (Maximum) for Tilt Cylinders
Mast Speeds7 topics
  • E45-65XM Mast Speeds (36 or 48 Volt) Americas
  • J40-65XM Mast Speeds (36 or 48 Volt) Americas
  • Frame
  • Drive Axle, Speed Reducer, and Differential E.200-3.20XM (E45-65
  • Drive Axle, Speed Reducer, and Differential J2.00-3.20XM (J40-65
  • Masts
  • Seat Brake
Main Control Valve5 topics
  • Lift Section
  • Tilt Section
    • Tilt Backward
    • Tilt Forward
  • Relief Valve
Control Lever Linkage Repair
Control Valve Linkage Repair
Pressure Relief Valve Check and Adjustment2 topics
  • Primary Relief Valve
  • Secondary Relief Valve
Four-Stage Mast2 topics
  • 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
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 System2 topics
  • Master Cylinder
  • Parking Brake
Service Brake Repairs1 topic
  • Adjust
Parking Brake Repair
Master Cylinder Repair1 topic
  • Repair
Service Brakes Adjustment
Brake Pedal Adjustment
Master Cylinder Adjustment
Brake System Air Removal
Parking Brake Not Applied Switch Test
Service Brakes Repair
Seat Brake Assembly4 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
  • Battery Restraint, Hood, and Seat Assembly
Replacement - General
Hood and Seat Assembly Repair3 topics
  • Steam Method
    • Chemical Solution Method
  • Additional Preparations for Tank Repair
Control Card Checks and Adjustments
Register Parameter Tables
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
Wheels Repair3 topics
  • Steering Control Unit, Disassemble
  • Steering Control Unit, Clean
  • Steering Control Unit, Assemble
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 (1,104 pages). Open the sample pages (PDF, 294 KB)

Sample pages from the Hyster E45-65XM (F108) Forklift Service Manual: Specifications, Diagram, Troubleshooting
  • Specifications, page 64: Steering Axle Assembly Repair
  • Diagram, page 404: Diagrams, Schematics, or Arrangements
  • Troubleshooting, page 880: Troubleshooting

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, 1,104 pages

Quantity one is the manual described above.

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Other editions and similar models

Hyster E45-65XM2 (F108)Service Manual · 1464843 · $119.67

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