Hyster E45-65XM2 (F108) Forklift Service Manual

Name: Hyster E45-65XM2 (F108) Forklift Service Manual
Brand: MidWestTech
SKU: 1464843
Price: 119.67 USD
Availability: InStock

1,180 pages · Publication 1464843

$119.67

Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.

Models: E45-65XM2 (F108)
Manual type: Service Manual
Pages: 1,180
Publication: 1464843
Condition: Brand new

Hyster E45-65XM2 (F108) Forklift Service Manual, publication 1464843

What's inside

From the manual's own table of contents: 215 sections, 527 entries. See sample pages (PDF, 289 KB)

Search the contents

Drive Axle, Speed Reducer, and Differential

Safety Precautions Maintenance and Repair

General

Description

Drive Axle, Speed Reducer, and Differential Repair5 topics

Drive Axle, Remove
Clean
Inspect
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 Repair1 topic

Disassemble

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 215 sections

Steering System for Electric Lift Trucks

Steering Wheel and Column Assembly Repair2 topics

Assembly Components, Remove
Assembly Components, Install

Power Steering Motor and Pump7 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

Hydraulic Steering Motor1 topic

Hydraulic Steering Motor Repairs

Steering System Air Removal

Steering Pressure Check

Steering Chain Tension Check (Unit With MDU Only)

Optical Encoder and Activator Circuits Check

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 Repair6 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

Mast Repair4 topics

Two-Stage LFL and Two-Stage FFL Masts, Disassemble
Three-Stage FFL Mast
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 Maintenance3 topics

Serial Number Data
How to Move Disabled Lift Truck
How to Put Lift Truck on Blocks

Maintenance Schedule

Maintenance Procedures Every 8 Hours or Daily2 topics

How to Make Checks With Key OFF
How to Make Checks With Key ON

Maintenance Procedures Every 250 Hours or 6 Weeks2 topics

Steering Tie Rods
Steering King Pins, Trucks Only

Maintenance Procedures Every 500 Hours or 3 Months10 topics

Hydraulic Tank Breather
Differential and Speed Reducer
Wheel Nut Torques
Steering Axle Spindles
Mast
Lift Chains
Forks
Brake Fluid
Other Lubrication
Electrical Inspection

Maintenance Procedures Every 1000 Hours or 6 Months1 topic

Check Upper and Lower Bearings, Integral Sideshift Carriage

Maintenance Procedures Every 2000 Hours or Yearly6 topics

Hydraulic System
Service Brakes
Contactors
Wheel Bearings
Replace Upper and Lower Bearings, Integral Sideshift Carriage
Steering Axle

Battery Maintenance2 topics

How to Charge Battery
How to Change Battery

Lift Chain Adjustments

PMT Circuit Check

Welding Repairs

Overhead Guard Changes

Wheels and Tire Maintenance3 topics

Solid Rubber Tires on Pneumatic Wheels
Solid Rubber Tire, Change
SIT Tire, Change

Adhesives and Sealants

Table 1. Maintenance Schedule

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 Repair3 topics

Small Leaks, Repair
Large Leaks, Repair
Additional Preparations for Repair

Painting Instructions

Safety Label Replacement

Battery Specifications

Table 1. Counterweights

Hydraulic System

Operation4 topics

Hydraulic Gear Pump
Rotator Actuator Valve
Steering Pump
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 System5 topics

ZX Series Display Panels
SEM Display Panels - Features
SEM Display Panel Indicators
Additional Components of Premium Display Panel
Other Control Components

Display Panel Components Replacement9 topics

ZX Panel Replacement
Display Panel Assembly
Key Switch, Replace
Indicator LEDs
Battery Indicators
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 Replacement17 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
Horn and Horn Button
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 Valve3 topics

Lift Section
Tilt Section
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 Mast

Carriage Repair2 topics

Repairs
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 Repair1 topic

Additional Preparations for Tank Repair

Spindles, Bearings, and Links Repair

Industrial Battery

Lead-Acid Batteries

Specific Gravity

Chemical Reaction in a Cell

Electrical Terms

Battery Selection

Battery Voltage

Battery as a Counterweight

Battery Ratings12 topics

Kilowatt-Hours
Safety Procedures
Maintenance Records
New Battery
Cleaning Battery
Adding Water to Battery
Hydrometer
Battery Temperature
Charging Battery
Where to Charge Batteries
Battery Connectors
Battery Care

Table 1. Battery Capacity Terms

Tilt Cylinders

Tilt Cylinder Repair

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 Repair

Steering Housing and Control Unit3 topics

Steering Control Unit, Disassemble
Steering Control Unit, Clean
Steering Control Unit, Assemble

System Air Removal

SR/SP Transistor Motor Controllers2 topics

General
Model Number Data for SR/SP Transistor Motor Controllers

Motor Controller Checks and Adjustments

Checks and Adjustments Using Handset6 topics

Connect Handset
Start Sequence
Check or Delete Stored Status Codes
Returning Lift Truck to Normal Operation
Workbench Checks and Adjustments
How to Check and Adjust Registers

Function Parameters Adjustments2 topics

Function Numbers
When Handset is Connected to Motor Controller in Lift Truck

Function Number Descriptions

Traction Motor Controller (Label Letter - SR)26 topics

Function Number 01 AUTO REGEN ENABLE SPEED
Function Number 02 CREEP SPEED
Function Number 03 CONTROLLED ACCELERATION
Function Number 04 ARMATURE CURRENT LIMIT
Function Number 05 REGEN RAMP RATE
Function Number 06 FIELD WEAKENING (FW) RATIO
Function Number 07 MINIMUM FIELD CURRENT
Function Number 08 MAXIMUM FIELD CURRENT
Function Number 09 REGENERATIVE BRAKING CURRENT LIMIT (C/L)
Function Number 10 FIELD CURRENT FOR REGENERATIVE BRAKING
Function Number 12 MAXIMUM ARMATURE % ON TIME (Travel Speed Limi
Function Number 13 SPEED LIMIT 3
Function Number 14 INTERNAL RESISTANCE COMPENSATION
Function Number 15 BATTERY VOLTAGE SELECTION
Function Number 16 STALL TRIP POINT % ON TIME
Function Number 17 CONTROL TYPE SELECTION
Function Number 18 STEERING PUMP TIME DELAY
Function Number 19 MAINTENANCE CODE TENS AND UNITS
Function Number 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS
Function Number 21 AUTO REGEN BRAKING CURRENT LIMIT
Function Number 23 FOR SPECIAL FUNCTIONS
Function Number 24 FIELD WEAKENING START
Function Number 25 MONITOR
Function Number 26 BASE RATIO
Function Number 28 STORED STATUS CODE COUNT POINTER
Functions with Premium Display Panel Only

Pump Motor Controller (Label Letter - SP)10 topics

Function Number 01 STORED STATUS CODE
Function Number 02 INTERNAL RESISTANCE COMPENSATION START
Function Number 04 CURRENT LIMIT
Function Number 07 INTERNAL RESISTANCE COMPENSATION RATE
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) Fast Lift
Function Number 16 SPEED/TORQUE COMPENSATION
Function Numbers 18 through 27 TEMPORARY DATA REGISTERS
Status Codes

SR (SEM) and SP Status Code Charts

SR/SP Transistor Motor Controller Repair7 topics

General Maintenance Instructions
Fuses
Contactor Driver Module
Motor Controller Plug
Brush Wear Indicators
Thermal Sensors
Motor Controller, Replace

Theory of Operation11 topics

SEM System Description
SEM System Operation (SR Motor Controller)
SEM System Operation (SP Motor Controller)
Braking
Auxiliary Speed Control
Ramp Operation
Steer Pump Contactor Time Delay
Coil Drivers and Internal Coil Suppression
System Protective Override
SP Pump Motor Controllers
Diagnostics

Table 1. List of Status Codes

Table 2. Speed/Torque Compensation

Table 3. Function Map for Motor Controllers SR (Traction)

Table 4. Function Map for Motor Controller SP (Lift Pump Motor)

Table 5. List of Status Codes

Table 6. Large (P) Plug (23-Pin) Connections/Descriptions for Mo

Table 7. Small Plug (12-Pin) Connections/Descriptions for Motor

Transistor Motor Controllers1 topic

Parameter Tables

Table 1. SR (SEM) Register Parameters for Traction Motor Control

Table 2. SR (SEM) Register Parameters for Traction Motor Control

Table 3. SP Register Parameters for Pump Motor Controller - E1.5

Table 4. SR (SEM) Register Parameters for Traction Motor Control

Table 5. SR (SEM) Register Parameters for Traction Motor Control

Table 6. SR (SEM) Register Parameters for Traction Motor Control

Table 7. SR (SEM) Register Parameters for Traction Motor Control

Table 8. SP Register Parameters for Pump Motor Controller - E45

Table 9. SP Register Parameters for Pump Motor Controller - E2.0

Table 10. SR (SEM) Register Parameters for Traction Motor Contro

Table 11. SR (SEM) Register Parameters for Traction Motor Contro

Table 12. SR (SEM) Register Parameters for Traction Motor Contro

Table 13. SP Register Parameters for Pump Motor Controller - J40

Table 14. SP Register Parameters for Pump Motor Controller - J2

Table 15. SR (SEM) Register Parameters for Traction Motor Contro

Table 16. SR (SEM) Register Parameters for Traction Motor Contro

Table 17. SP Register Parameters for Pump Motor Controller - N30

Electrical Diagrams

Display Panel for SEM Controls

SEM Display Panel Features3 topics

Descriptions of Common Features
Additional Features of Premium Display Panel
Descriptions of Additional Features (Available with Premium Disp

SEM Display Panel Indicators9 topics

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 Panel3 topics

Alphanumeric Screen
STAR Push Button
Push Buttons 1 Through 5

Adjustments With a Computer2 topics

Computer System
ITW Switches Windows Software Program (for SEM Display Panel)

Replacement1 topic

SEM Display Panel

Table 1. Adapter Pins (DB25F to DB9)

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 (1,180 pages). Open the sample pages (PDF, 289 KB)

Sample pages from the Hyster E45-65XM2 (F108) Forklift Service Manual: Specifications, Troubleshooting, Diagram

Specifications, page 320: Counterweight Repair
Troubleshooting, page 860: SR (SEM) and SP Status Code Charts
Diagram, page 1,040: 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, 1,180 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).